Polaris Trail Blazer Service Manual Download

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3.45

Polaris Sales Inc.

4/99

ENGINE

Oil Flow Diagram - ES33PF

Oil Tank

Crankcase

Oil Gallery

Oil Pump

(Scavenging)

Oil Pickup

Screen

Oil Hose

Crankcase

Oil Passage

Oil Pump

(Feed)

One Way Valve

Delivery Pipe

Bypass

Oil Filter

Chain Room

Cam Shaft

Journal

Sprocket

Chain

Rocker Arm

Rocker Shaft

Cam Lobe

Cam Shaft

Journal

Delivery Pipe

Oil Passage

In Cylinder

Crankcase

Oil Gallery

Crankcase

Small End

Bearing

Cylinder Sleeve

Main Bearing

(PTO)

Large End

Bearing

Crank Pin

Crankshaft

Screen Fitting

(Bottom of Tank)

335 (ES33PFE) Oil Flow Chart

Top of Oil Tank

Hose Fitting (Lower hose fitting on engine)

Oil Jet

(Fixed)

Hose Fitting

(Upper on engine)

Through Front Left

Cylinder Head Bolt

Passage

Indirect

Lubrication

Prevents oil

from draining

into crankcase

with engine off

Bottom fitting is oil

outlet or return to

tank

Top fitting is oil

feed or intake from

bottom of tank

One way valve

From filter

to crankshaft

Oil feed to

filter

Oil filter

Oil passes through

cylinder head bolt

passage, to camshaft

335 (ES33PFE) Engine

Stator Plate

Bushing

= Filtered Oil

Oil Cooler

Hot Oil

Thermo valve allows oil to

by-pass cooler when cold

Ther

Cooler to thermo valve

Thermo valve to cooler

Cooled Oil

Hot Oil

Path

Oil bypasses

cooler at valve

when cold

Balance Gears

Also refer to thermo valve flow diagram

Indirect

Lubrication

Summary of Contents for Trail Blazer

Page 1: ......

Page 2: ...ss 300 1 18 1 19 Xplorer 300 1 20 1 21 Sportsman 335 1 22 1 23 Sport 400 1 24 1 25 Scrambler 400 1 26 1 27 Xplorer 400 1 28 1 29 Scrambler 500 1 30 1 31 Magnum 500 1 32 1 33 Sportsman 500 1 34 1 35 Big Boss 500 6x6 1 36 1 37 Model Specifications 2000 Trail Blazer 1 38 1 39 Xplorer 4x4 1 40 1 41 Trail Boss 325 1 42 1 43 Magnum 325 01 Engine 1 44 1 45 Magnum 325 04 05 Engine 1 46 1 47 Xpedition 325 ...

Page 3: ......

Page 4: ...l Number and VIN Number Location The machine Model Number and Vehicle Identification Number VIN are important for vehicle identification The VIN number will be stamped into the frame in one of the following locations S 1998 Current On the left hand lower frame rail A near the rear A arm mount Transmission I D Number Location Transmission model and serial numbers are located on top of the transmiss...

Page 5: ...cle Identification Number Model Number Key Body Style Powertrain Engine Emissions Options A Gen II A 2x4 chain 25 EC25PF 250cc A Approved by CARB A Option 1 B Gen III C 4x4 chain 28 EC28PF 300 cc B England B Option 2 C Gen IV D 4x4 shaft 33 ES33PF 335 cc C Non CARB Approved R RANGER E 6x6 chain 38 EC38PL 400 cc D Norway F 6x6 shaft 42 EH42PL 425 cc E Sweden G 4x4 chain rear shaft front 50 EH50PL 5...

Page 6: ...cs 9913278 Describes all current Polaris charging systems Provides work ing knowledge of charging system theory and diagnostics Polaris Variable Transmissions PVT 9913987 Theory disassembly assembly and troubleshooting of the Polaris PVT system Fuels and Fuel Delivery 9914393 Describes fuel properties including octane and vapor pres sure fuel mixture and burn characteristics VM and CV car buretor ...

Page 7: ...400 Springs Burnished Brown P218 Rims Aluminum P117 Scrambler 400 Springs Fire Red 8520149 P093 72060 Rims Bright White 8520153 P133 2185 Sport 400L Springs Fire Red 8520149 P093 72060 Rims Bright White 8520153 P133 2185 Sportsman 335 Opt A Springs Rims Black 8520147 P067 9440 Sportsman 335 Opt B Springs Black 8520147 P067 9440 Rims Aluminum P117 Xplorer 300 Springs Fire Red 8520149 P093 72060 Rim...

Page 8: ...dard torque Bolt Size Threads In Grade 2 Grade 5 Grade 8 Torque in lbs N m 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 N m 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 1...

Page 9: ...375 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 ...

Page 10: ...81 Fluid Ounces fl oz Fluid Ounces fl oz x 29 57 Cubic centimeters cc or milliliters ml 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...

Page 11: ...12 59 64 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 ...

Page 12: ...r holes and hand tighten Then following the method and sequence indicated in this manual tighten evenly to the specified torque value When removing nuts bolts or screws from a part with several fasteners loosen them all about 1 4 turn before removing them If the condition of any gasket or O Ring is in question replace it with a new one Be sure the mating surfaces around the gasket are clean and sm...

Page 13: ...onation The spontaneous ignition of the unburned fuel air mixture after normal spark ignition Piston looks hammered through rough appearance around hole Possible causes 1 too high a compression ratio for the fuel octane 2 low octane fuel 3 over advanced ignition timing Dial Bore Gauge A cylinder measuring instrument which uses a dial indicator Good for showing taper and out of round in the cylinde...

Page 14: ...rqued 3 glowing piece of head gasket metal burr or carbon in the combustion chamber 4 lean fuel air mixture Primary Circuit This circuit is responsible for the voltage build up in the CDI capacitor In the CDI system the parts include the exciter coil the trigger coil pulse coil the wires from stator plate to CDI box and to the low resistance primary windings in the ignition coil Primary Clutch Dri...

Page 15: ...ns Prevents over charging of battery or damage to electrical components as engine RPM increases Venturi Anareaofair constriction A venturi isused incarburetors tospeed upair flow which lowerspressure inventuri to below atmospheric pressure causing fuel to be pushed through jets etc and into the venturi to be mixed with air and form a combustible air fuel mixture Volt The unit of measure for electr...

Page 16: ...cial Tool w e b s i t e U S dealers can obtain a current price list or get tool information by contacting the SPX Company at the address phone or FAX number listed below Dealers serviced by a distributor should follow tool ordering procedures established by their respective distributor parts department SPX Service Solutions 28635 Mound Road Warren MI 48092 5509 TO PLACE AN ORDER Tool Order FAX Num...

Page 17: ...800 G Blue Green 2 1 900 1800 3000 6000 G Blue Green 2 1 1800 2700 16 Blue Green 2 2 1800 2700 6000 9000 16 Blue Green 2 2 2700 3700 16 Blue Green 2 1 2700 3700 9000 12000 16 Blue Green 2 1 ENGINE Type 2 Cycle Single Cyl Displacement 244 cc Bore 2 8346 72mm Stroke 2 3622 60mm Compression Ratio 6 1 1 Effective Cooling Air Lubrication Type Oil Injected Piston Cylinder Clearance 0 0011 0 0021 0 03 0 ...

Page 18: ... III Chain Type 520 O Ring Front Suspension MacPherson Strut Gear Reduction Low N A Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 3 05 1 Turning Radius 60 152 4cm Gear Reduction High 2 68 1 Toe Out 1 8 1 4 3 6 35mm Front Drive Ratio N A Ground Clearance 6 15 24cm Center Drive Ratio N A Front Vertical Travel 6 7 17 02cm Final Drive Ratio 11 38 78P Rear Suspension Progressive Rate Swing Arm Brake ...

Page 19: ...3000 6000 16 Blue Green 2 1 1800 2700 16 Mod Blue Green 2 2 1800 2700 6000 9000 16 Mod Blue Green 2 2 2700 3700 16 Mod Blue Green 2 2 2700 3700 9000 12000 16 Mod Blue Green 2 2 ENGINE Type 2 Cycle Single Cyl Displacement 244 cc Bore 2 8346 72mm Stroke 2 3622 60mm Compression Ratio 6 1 1 Effective Cooling Air Lubrication Type Oil Injected Piston Cylinder Clearance 0 0011 0 0021 0 03 0 05mm Service ...

Page 20: ...Chain Type 520 O Ring Front Suspension MacPherson Strut Gear Reduction Low N A Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 3 42 1 Turning Radius 60 152 4cm Gear Reduction High 2 68 1 Toe Out 1 8 1 4 3 6 35mm Front Drive Ratio N A Ground Clearance 5 5 13 97cm Center Drive Ratio N A Front Vertical Travel 6 25 15 88cm Final Drive Ratio 12 42 88P Rear Suspension Progressive Rate Swing Arm Brake Ha...

Page 21: ...2 or 2 1 900 1800 3000 6000 G 48GR Blue Green 2 2 or 2 1 1800 2700 F Blue Green 2 2 1800 2700 6000 9000 F 45GR Blue Green 2 2 2700 3700 F Blue Green 2 1 2700 3700 9000 12000 F 45GR Blue Green 2 1 ENGINE Type 2 Cycle Single Cyl Displacement 283 cc Bore 2 9331 74 5mm Stroke 2 5591 65mm Compression Ratio 6 1 1 Effective Cooling Air Lubrication Type Oil Injected Piston Cylinder Clearance 0 0012 0 0026...

Page 22: ...in Type 520 O Ring Front Suspension MacPherson Strut Gear Reduction Low 6 64 1 Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 5 13 1 Turning Radius 60 152 4cm Gear Reduction High 3 29 1 Toe Out 1 8 1 4 3 6 35mm Front Drive Ratio N A Ground Clearance 6 5 16 51cm Center Drive Ratio N A Front Vertical Travel 6 25 15 88cm Final Drive Ratio 13 38 86P Rear Suspension Progressive Rate Swing Arm Brake Ha...

Page 23: ... 2 or 2 1 900 1800 3000 6000 G 48GR Blue Green 2 2 or 2 1 1800 2700 F Blue Green 2 2 1800 2700 6000 9000 F 45GR Blue Green 2 2 2700 3700 F Blue Green 2 1 2700 3700 9000 12000 F 45GR Blue Green 2 1 ENGINE Type 2 Cycle Single Cyl Displacement 283 cc Bore 2 9331 74 5mm Stroke 2 5591 65mm Compression Ratio 6 1 1 Effective Cooling Air Lubrication Type Oil Injected Piston Cylinder Clearance 0 0012 0 002...

Page 24: ...Hub Fluid SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen IV Chain Type 520 O Ring Front Suspension MacPherson Strut Gear Reduction Low 6 64 1 Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 5 13 1 Turning Radius 57 144 78cm Gear Reduction High 3 39 1 Toe Out 1 8 1 4 3 6 35mm Front Drive Ratio 12 22 64P Ground Clearance 6 15 24cm Center Drive Ratio 11 22 70P Front Vertical Travel 6 25 15 88cm Final ...

Page 25: ...2 1 1800 2700 16 Mod Blue Green 2 2 1800 2700 6000 9000 16 Mod Blue Green 2 2 2700 3700 16 Mod Blue Green 2 2 2700 3700 9000 12000 16 Mod Blue Green 2 2 ENGINE Type 4 Cycle Single Cyl Displacement 334 cc Bore 3 0732 78mm Stroke 2 758 70mm Compression Ratio 9 2 1 Full Stroke Cooling Air W Oil Cooler Assist Lubrication Type Dry Sump Piston Cylinder Clearance 0 0012 0 0035 0 03 0 09mm Service Limit 0...

Page 26: ...SSIS DRIVE TRAIN Body Style Gen IV Chain Type Shaft Drive Front Suspension MacPherson Strut Gear Reduction Low 6 89 1 Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 5 17 1 Turning Radius 65 165 1cm Gear Reduction High 3 56 1 Toe Out 1 8 1 4 3 6 35mm Front Drive Ratio 2 1 Ground Clearance 10 25 26 04cm Center Drive Ratio N A Front Vertical Travel 6 25 15 88cm Final Drive Ratio 3 16 1 Rear Suspensi...

Page 27: ... Weight Spring Helix Meters 0 900 S 55 White 2 2 Meters Feet 0 900 0 3000 S 55 White 2 2 Feet 900 1800 S 55 White 2 2 or 2 1 900 1800 3000 6000 S 55 White 2 2 or 2 1 1800 2700 S White 2 1 1800 2700 6000 9000 S White 2 1 2700 3700 S or White 2 1 2700 3700 9000 12000 S or 10MH White 2 1 ENGINE Type 2 Cycle Single Cyl Displacement 378 cc Bore 3 2677 83mm Stroke 2 7559 70mm Compression Ratio 6 9 1 Eff...

Page 28: ...IN Body Style Gen III Chain Type 520 O Ring Front Suspension MacPherson Strut Gear Reduction Low N A Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 3 05 1 Turning Radius 60 152 4cm Gear Reduction High 2 68 1 Toe Out 1 8 1 4 3 6 35mm Front Drive Ratio N A Ground Clearance 6 15 24cm Center Drive Ratio N A Front Vertical Travel 8 2 20 83cm Final Drive Ratio 13 36 76P Rear Suspension Progressive Rate...

Page 29: ...itude Weight Spring Helix Meters 0 900 S 55 White 2 2 Meters Feet 0 900 0 3000 S 55 White 2 2 Feet 900 1800 S 55 White 2 2 or 2 1 900 1800 3000 6000 S 55 White 2 2 or 2 1 1800 2700 S White 2 1 1800 2700 6000 9000 S White 2 1 2700 3700 S or White 2 1 2700 3700 9000 12000 S or 10MH White 2 1 ENGINE Type 2 Cycle Single Cyl Displacement 378 cc Bore 3 2677 83mm Stroke 2 7559 70mm Compression Ratio 6 9 ...

Page 30: ...PENSION CHASSIS DRIVE TRAIN Body Style Gen III Chain Type 520 O Ring Front Suspension MacPherson Strut Gear Reduction Low N A Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 4 36 1 Turning Radius 60 152 4cm Gear Reduction High 2 82 1 Toe Out 1 8 1 4 3 6 35mm Front Drive Ratio 2 1 Ground Clearance 6 5 16 51cm Center Drive Ratio N A Front Vertical Travel 8 2 20 83cm Final Drive Ratio 13 36 76P Rear ...

Page 31: ... Green 2 2 or 2 1 900 1800 3000 6000 S 55 Blue Green 2 2 or 2 1 1800 2700 S Blue Green 2 1 1800 2700 6000 9000 S Blue Green 2 1 2700 3700 S Blue Green 2 1 2700 3700 9000 12000 S Blue Green 2 1 ENGINE Type 2 Cycle Single Cyl Displacement 378 cc Bore 3 2677 83mm Stroke 2 7559 70mm Compression Ratio 6 9 1 Effective Cooling Liquid Lubrication Type Oil Injected Piston Cylinder Clearance 0 0023 0 0037 0...

Page 32: ...s 0W 40 Synthetic Engine Lubricant PDD Premium Demand Drive Hub Fluid SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen IV Chain Type 520 O Ring Front Suspension MacPherson Strut Gear Reduction Low 6 14 1 Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 4 74 1 Turning Radius 65 165 1cm Gear Reduction High 3 06 1 Toe Out 1 8 1 4 3 6 35mm Front Drive Ratio 2 1 Ground Clearance 7 5 19 05cm Center Drive Ra...

Page 33: ...900 1800 3000 6000 10WH Blue Green 2 1 1800 2700 10RH Blue Green 1 1 1800 2700 6000 9000 10RH Blue Green 1 1 2700 3700 10RH Blue Green 2 1 2700 3700 9000 12000 10RH Blue Green 2 1 ENGINE Type 4 Cycle Single Cyl Displacement 499 cc Bore 3 6248 92mm Stroke 2 955 75mm Compression Ratio 10 2 Full Stroke Cooling Liquid Lubrication Type Dry Sump Piston Cylinder Clearance 0 0006 0 0018 0 015 0 046mm Serv...

Page 34: ...IN Body Style Gen III Chain Type 520 O Ring Front Suspension MacPherson Strut Gear Reduction Low N A Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 4 74 1 Turning Radius 60 152 4cm Gear Reduction High 3 06 1 Toe Out 1 8 1 4 3 6 35mm Front Drive Ratio 2 1 Ground Clearance 6 5 16 51cm Center Drive Ratio N A Front Vertical Travel 8 2 20 83cm Final Drive Ratio 13 36 76P Rear Suspension Progressive Ra...

Page 35: ...ue Green EBS 1800 2700 6000 9000 10WH Blue Green EBS 2700 3700 10RH Blue Green EBS 2700 3700 9000 12000 10RH Blue Green EBS EBS requires no helix adjustment ENGINE Type 4 Cycle Single Cyl Displacement 498 cc Bore 3 6248 92mm Stroke 2 955 75mm Compression Ratio 10 2 Full Stroke Cooling Liquid Lubrication Type Dry Sump Piston Cylinder Clearance 0 0006 0 0018 0 015 0 046mm Service Limit 0 0024 0 061m...

Page 36: ... 40 Synthetic Engine Lubricant PDD Premium Demand Drive Hub Fluid SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen IV Chain Type N A Front Suspension MacPherson Strut Gear Reduction Low 7 46 1 Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 5 12 1 Turning Radius 65 165 1cm Gear Reduction High 3 3 1 Toe Out 1 8 1 4 3 6 35mm Front Drive Ratio 3 7 1 Shaft Ground Clearance 7 25 18 42cm Center Drive Ratio...

Page 37: ... 2700 10WH Blue Green EBS 1800 2700 6000 9000 10WH Blue Green EBS 2700 3700 10RH Blue Green EBS 2700 3700 9000 12000 10RH Blue Green EBS EBS requires no helix adjustment ENGINE Type 4 Cycle Single Cyl Displacement 498 cc Bore 3 625 92mm Stroke 2 955 75mm Compression Ratio 10 2 Full Stroke Cooling Liquid Lubrication Type Dry Sump Piston Cylinder Clearance 0 0006 0 0018 0 015 0 046mm Service Limit 0...

Page 38: ...ium Demand Drive Hub Fluid SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen IV Chain Type Shaft Drive Front Suspension MacPherson Strut Gear Reduction Low 6 69 1 Tow Capacity 1225 lbs 556 2kg Gear Reduction Rev 5 17 1 Turning Radius 65 165 1cm Gear Reduction High 3 34 1 Toe Out 1 8 1 4 3 6 35mm Front Drive Ratio 2 1 Ground Clearance 11 27 94cm Center Drive Ratio N A Front Vertical Travel 6 25 15 88cm...

Page 39: ... 10BH Blue Green 2 2 1800 2700 10WH Blue Green 2 1 1800 2700 6000 9000 10WH Blue Green 2 1 2700 3700 10RH Blue Green 2 1 2700 3700 9000 12000 10RH Blue Green 2 1 ENGINE Type 4 Cycle Single Cyl Displacement 498 cc Bore 3 625 92mm Stroke 2 955 75mm Compression Ratio 10 2 Full Stroke Cooling Liquid Lubrication Type Dry Sump Piston Cylinder Clearance 0 0006 0 0018 0 015 0 046mm Service Limit 0 0024 0 ...

Page 40: ...520 O Ring Front Suspension MacPherson Strut Gear Reduction Low 6 64 1 Tow Capacity 1225 lbs 556 2kg Gear Reduction Rev 5 13 1 Turning Radius 98 248 9cm Gear Reduction High 3 29 1 Toe Out 1 8 1 4 3 6 35mm Front Drive Ratio 11 22 68P Ground Clearance 5 5 13 97cm Center Drive Ratio 11 24 72P Front Vertical Travel 6 25 15 88cm Final Drive Ratio 12 42 88P Rear Suspension Swing Arm w Scissor Stabilizer...

Page 41: ...tch Driven Altitude Shift Weight Clutch Spring Driven Helix Altitude Weight Spring Helix Meters 0 1800 G Blue Green 2 2 Meters Feet 0 1800 0 6000 G Blue Green 2 2 Feet 1800 3700 16 Blue Green 2 2 1800 3700 6000 12000 16 Blue Green 2 2 ENGINE Type 2 Cycle Single Cyl Displacement 244 cc Bore 2 8346I 72mm Stroke 2 3622I 60mm Compression Ratio 6 1 1 Effective Cooling Air Lubrication Type Oil Injected ...

Page 42: ...Gen III Chain Type 520 O Ring Front Suspension MacPherson Strut Gear Reduction Low N A Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 3 05 1 Turning Radius 60I 152 4cm Gear Reduction High 2 68 1 Toe Out 1 8I 1 4I 3 6 35mm Front Drive Ratio N A Ground Clearance 6I 15 24cm Center Drive Ratio N A Front Vertical Travel 6 7I 17 02cm Final Drive Ratio 11 38 78P Rear Suspension Progressive Rate Swing Ar...

Page 43: ...HART Shift Clutch Driven Altitude Shift Weight Clutch Spring Driven Helix Altitude Weight Spring Helix Meters 0 1800 G Blue Green 2 2 Meters Feet 0 1800 0 6000 G Blue Green 2 2 Feet 1800 3700 16 Blue Green 2 2 1800 3700 6000 12000 16 Blue Green 2 2 ENGINE Type 2 Cycle Single Cyl Displacement 244 cc Bore 2 8346I 72mm Stroke 2 3622I 60mm Compression Ratio 6 1 1 Effective Cooling Air Lubrication Type...

Page 44: ... Style Gen II Chain Type 520 O Ring Front Suspension MacPherson Strut Gear Reduction Low N A Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 3 05 1 Turning Radius 60I 152 4cm Gear Reduction High 3 34 1 Toe Out 1 8I 1 4I 3 6 35mm Front Drive Ratio 2 01 Ground Clearance 6I 15 24cm Center Drive Ratio N A Front Vertical Travel 6 7I 17 02cm Final Drive Ratio 12 42 82P Rear Suspension Progressive Rate S...

Page 45: ...lue Green 2 2 Feet 1800 3700 16 Mod Blue Green 2 2 1800 3700 6000 12000 16 Mod Blue Green 2 2 40_ helix black driven spring ENGINE Type 4 Cycle Single Cyl Displacement 324 cc Bore 3 073I 78mm Stroke 2 679I 68mm Valve Clearance In Ex 0 006 0 006I BTDC on compression Cooling Air w fan assisted oil cooler Lubrication Type Dry Sump Piston Marking None Operating RPM 200 6000 RPM Idle RPM 200 lights off...

Page 46: ...luid SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen II Chain Type 520 O Ring Front Suspension MacPherson Strut Gear Reduction Low N A Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 3 05 1 Turning Radius 60I 152 4cm Gear Reduction High 2 68 1 Toe Out 1 8I 1 4I 3 6 35mm Front Drive Ratio N A Ground Clearance 5 5I 13 97cm Center Drive Ratio N A Front Vertical Travel 6 7I 17 02cm Final Drive Ratio 11 ...

Page 47: ...black driven spring ENGINE Type 4 Cycle Single Cyl Displacement 324 cc Bore 3 073I 78mm Stroke 2 679I 68mm Valve Clearance In Ex 0 006 0 006I TDC on compression Cooling Air w fan assisted oil cooler Lubrication Type Dry Sump Operating RPM 200 6000 RPM Idle RPM 200 lights off 1300 RPM Compression Ratio 9 2 1 Compression Pressure Std 15 CARBURETION Type BST 31 Mikuni Main Jet 142 5 Pilot Jet 50 Jet ...

Page 48: ...luid SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen IV Chain Type N A Front Suspension MacPherson Strut Gear Reduction Low 7 46 1 Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 5 12 1 Turning Radius 65I 165 1cm Gear Reduction High 3 3 1 Toe Out 1 8I 1 4I 3 6 35mm Front Drive Ratio 3 7 1 Shaft Ground Clearance 7 25I 18 42cm Center Drive Ratio N A Front Vertical Travel 6 7I 17 02cm Final Drive Ratio...

Page 49: ...2 2 compound helix black driven spring ENGINE Type 4 Cycle Single Cyl Displacement 324 cc Bore 3 073I 78mm Stroke 2 679I 68mm Valve Clearance In Ex 0 006 0 006I TDC on compression Cooling Air w fan assisted oil cooler Lubrication Type Dry Sump Operating RPM 200 6000 RPM Idle RPM 200 lights off 1300 RPM Compression Ratio 9 2 1 Compression Pressure Std 15 CARBURETION Type BST 31 Mikuni Main Jet 145 ...

Page 50: ...and Drive Hub Fluid SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen IV Chain Type N A Front Suspension MacPherson Strut Gear Reduction Low 7 46 1 Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 5 12 1 Turning Radius 65I 165 1cm Gear Reduction High 3 3 1 Toe Out 1 8I 1 4I 3 6 35mm Front Drive Ratio 3 7 1 Shaft Ground Clearance 7 25I 18 42cm Center Drive Ratio N A Front Vertical Travel 6 7I 17 02cm Fi...

Page 51: ...ssure Std 15 SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen IV Gear 1 Ratio 4 182 Front Suspension MacPherson Strut Gear 2 Ratio 2 562 Tow Capacity 850 lbs 385 9kg Gear 3 Ratio 1 522 Turning Radius 65I 165 1cm Gear 4 Ratio 1 111 Toe Out Total 1 8I 1 4I 3 6 35mm Gear 5 Ratio 0 813 Ground Clearance 7 25I 18 42cm Reverse 4 128 Front Vertical Travel 6 7I 17 02cm Primary 2 655 Rear Suspension Progressiv...

Page 52: ...Start Standard Brake Hand Dot 3 Electronic Speedo Accessory Brake Foot Dot 3 Front Hubs AWD 2 5 oz 75 ml PDD Shift Selector Box N A PP6 Polaris Premium 60 40 Antifreeze Coolant PPS Polaris Premium Synthetic Gear Case Oil PP4 Polaris 0W 40 Synthetic Engine Lubricant PDD Premium Demand Drive Hub Fluid TIRES Tire Size Front 24 x 8 12 Tire Size Rear 24 x 11 5 10 Tire Size Center N A Tire Pressure F R ...

Page 53: ...00 1800 16 Blue Green 2 1 900 1800 3000 6000 16 Blue Green 2 1 1800 2700 16 Mod Blue Green 2 2 1800 2700 6000 9000 16 Mod Blue Green 2 2 2700 3700 16 Mod Blue Green 2 2 2700 3700 9000 12000 16 Mod Blue Green 2 2 ENGINE Type 4 Cycle Single Cyl Displacement 334 cc Bore 3 0732I 78mm Stroke 2 758I 70mm Valve Clearance In Ex 0 006 0 006I TDC on compression Compression Ratio 9 2 1 Full Stroke Cooling Ai...

Page 54: ...IVE TRAIN Body Style Gen IV Drive Type Shaft Drive Front Suspension MacPherson Strut Gear Reduction Low 6 89 1 Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 5 17 1 Turning Radius 65I 165 1cm Gear Reduction High 3 56 1 Toe Out 1 8I 1 4I 3 6 35mm Front Drive Ratio 2 1 Ground Clearance 10 25I 26 04cm Center Drive Ratio N A Front Vertical Travel 6 25I 15 88cm Final Drive Ratio 3 16 1 Rear Suspension...

Page 55: ...RT Shift Clutch Driven Altitude Shift Weight Clutch Spring Driven Helix Altitude Weight Spring Helix Meters 0 1800 S55 Blue Green 2 2 Meters Feet 0 1800 0 6000 S55 Blue Green 2 2 Feet 1800 3700 6000 12000 S Blue Green 2 1 ENGINE Type 2 Cycle Single Cyl Displacement 378 cc Bore 3 2677I 83mm Stroke 2 7559I 70mm Compression Ratio 6 9 1 Effective Cooling Liquid Lubrication Type Oil Injected Operating ...

Page 56: ...nthetic Engine Lubricant PDD Premium Demand Drive Hub Fluid SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen IV Chain Type 520 O Ring Front Suspension MacPherson Strut Gear Reduction Low 6 14 1 Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 4 74 1 Turning Radius 65I 165 1cm Gear Reduction High 3 06 1 Toe Out 1 8I 1 4I 3 6 35mm Front Drive Ratio 2 1 Ground Clearance 7 5I 19 05cm Center Drive Ratio N ...

Page 57: ... Out For 87 Octane Oxygenated Fuel Refer to jetting recommendation in Fuel System Carburetion section CLUTCH CHART Shift Clutch Driven Altitude Shift Weight Clutch Spring Driven Helix Altitude Weight Spring Helix Meters 0 1800 S55 White 2 2 Meters Feet 0 1800 0 6000 S55 White 2 2 Feet 1800 3700 S White 2 1 1800 3700 6000 12000 S White 2 1 40 Helix Red Driven ENGINE Type 2 Cycle Single Cyl Displace...

Page 58: ...mand Drive Hub Fluid SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen III Chain Type 520 O Ring Front Suspension MacPherson Strut Gear Reduction Low N A Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 3 05 1 Turning Radius 60I 152 4cm Gear Reduction High 2 68 1 Toe Out 1 8I 1 4I 3 6 35mm Front Drive Ratio N A Ground Clearance 5 5I 13 97cm Center Drive Ratio N A Front Vertical Travel 8 2I 20 83cm Fina...

Page 59: ... Out For 87 Octane Oxygenated Fuel Refer to jetting recommendation in Fuel System Carburetion section CLUTCH CHART Shift Clutch Driven Altitude Shift Weight Clutch Spring Driven Helix Altitude Weight Spring Helix Meters 0 1800 S55 White 2 2 Meters Feet 0 1800 0 6000 S55 White 2 2 Feet 1800 3700 S White 2 1 1800 3700 6000 12000 S White 2 1 40 Helix Red Driven ENGINE Type 2 Cycle Single Cyl Displace...

Page 60: ...Hub Fluid SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen III Chain Type 520 O Ring Front Suspension MacPherson Strut Gear Reduction Low N A Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 4 36 1 Turning Radius 60I 152 4cm Gear Reduction High 2 82 1 Toe Out 1 8I 1 4I 3 6 35mm Front Drive Ratio 2 1 Ground Clearance 5 5I 13 97cm Center Drive Ratio N A Front Vertical Travel 8 2I 20 83cm Final Drive Rat...

Page 61: ...ssion Pressure 60 90 lbs SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen IV Gear 1 Ratio 4 182 Front Suspension MacPherson Strut Gear 2 Ratio 2 562 Tow Capacity 850 lbs 385 9kg Gear 3 Ratio 1 522 Turning Radius 65I 165 1cm Gear 4 Ratio 1 036 Toe Out Total 1 8I 1 4I 3 6 35mm Gear 5 Ratio 0 758 Ground Clearance 7 25I 18 42cm Reverse 4 484 Front Vertical Travel 6 7I 17 02cm Primary 2 406 Rear Suspensio...

Page 62: ...ctric Start Standard Brake Hand Dot 3 Electronic Speedo Standard Brake Foot Dot 3 Front Hubs AWD 2 5 oz 75 ml PDD Shift Selector Box N A PP6 Polaris Premium 60 40 Antifreeze Coolant PPS Polaris Premium Synthetic Gear Case Oil PP4 Polaris 0W 40 Synthetic Engine Lubricant PDD Premium Demand Drive Hub Fluid TIRES Tire Size Front 25 x 8 12 Tire Size Rear 25 x 11 10 Tire Size Center N A Tire Pressure F...

Page 63: ...E Type 4 Cycle Single Cyl Displacement 498 cc Bore 3 6248I 92mm Stroke 2 955I 75mm Valve Clearance In Ex 0 006 0 006I TDC on compression Cooling Liquid Lubrication Type Dry Sump Piston Marking Arrow to MAG side Operating RPM 200 6000 RPM Idle RPM 200 lights off 1200 RPM Compression Ratio 10 2 Full Stroke Compression Pressure Std 15 CARBURETION Type BST 34 Mikuni Main Jet 157 5 Pilot Jet 40 Jet Nee...

Page 64: ...Hub Fluid SUSPENSION CHASSIS DRIVE TRAIN Body Style Gen IV Chain Type N A Front Suspension MacPherson Strut Gear Reduction Low 7 46 1 Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 5 12 1 Turning Radius 65I 165 1cm Gear Reduction High 3 3 1 Toe Out 1 8I 1 4I 3 6 35mm Front Drive Ratio 3 7 1 Shaft Ground Clearance 7 25I 18 42cm Center Drive Ratio N A Front Vertical Travel 6 7I 17 02cm Final Drive ...

Page 65: ...1 40_ helix silver driven ENGINE Type 4 Cycle Single Cyl Displacement 499 cc Bore 3 6248I 92mm Stroke 2 955I 75mm Valve Clearance In Ex 0 006 0 006I TDC on compression Compression Ratio 10 2 Full Stroke Cooling Liquid Lubrication Type Dry Sump Operating RPM 200 6500 RPM Idle RPM 200 lights off 1200 RPM Compression Pressure Std 15 CARBURETION Type BST 40 Mikuni Main Jet 155 Pilot Jet 40 Jet Needle ...

Page 66: ...HASSIS DRIVE TRAIN Body Style Gen III Chain Type 520 O Ring Front Suspension MacPherson Strut Gear Reduction Low N A Tow Capacity 850 lbs 385 9kg Gear Reduction Rev 4 74 1 Turning Radius 60I 152 4cm Gear Reduction High 3 06 1 Toe Out 1 8I 1 4I 3 6 35mm Front Drive Ratio 2 1 Ground Clearance 5 5I 13 97cm Center Drive Ratio N A Front Vertical Travel 8 2I 20 83cm Final Drive Ratio 13 36 76P Rear Susp...

Page 67: ... adjustment ENGINE Type 4 Cycle Single Cyl Displacement 498 cc Bore 3 625I 92mm Stroke 2 955I 75mm Valve Clearance In Ex 0 006 0 006I TDC on compression Compression Ratio 10 2 Full Stroke Cooling Liquid Lubrication Type Dry Sump Operating RPM 200 6000 RPM Idle RPM 200 lights off 1200 RPM Compression Pressure Std 15 Remingtont Special Edition CARBURETION Type BST 34 Mikuni Main Jet 155 Pilot Jet 40...

Page 68: ...le Gen IV Chain Type Shaft Drive Front Suspension MacPherson Strut Gear Reduction Low 6 69 1 Tow Capacity 1225 lbs 556 2kg Gear Reduction Rev 5 17 1 Turning Radius 65I 165 1cm Gear Reduction High 3 34 1 Toe Out 1 8I 1 4I 3 6 35mm Front Drive Ratio 2 1 Ground Clearance 11I 27 94cm Center Drive Ratio N A Front Vertical Travel 6 7I 17 02cm Final Drive Ratio 3 16 1 Rear Suspension Progressive Rate Ind...

Page 69: ... 40_ helix red driven ENGINE Type 4 Cycle Single Cyl Displacement 498 cc Bore 3 625I 92mm Stroke 2 955I 75mm Valve Clearance In Ex 0 006 0 006I TDC on compression Compression Ratio 10 2 Full Stroke Cooling Liquid Lubrication Type Dry Sump Operating RPM 200 6000 RPM Idle RPM 200 lights off 1200 RPM Compression Pressure Std 15 CARBURETION Type BST 34 Mikuni Main Jet 142 5 Pilot Jet 40 Jet Needle 4HB...

Page 70: ... Reduction Low 6 691 Tow Capacity 1225 lbs 556 2kg Gear Reduction Rev 5 17 1 Turning Radius 98I 248 9cm Gear Reduction High 3 34 1 Toe Out 1 8I 1 4I 3 6 35mm Front Drive Ratio 2 1 Ground Clearance 5 5I 13 97cm Center Drive Ratio N A Front Vertical Travel 6 7I 17 02cm Final Drive Ratio 12 38 80P Rear Suspension Swing Arm w Scissor Stabilizer Axle to Axle 30 30 116P Rear Travel 7 5I 19 06cm Brake Ha...

Page 71: ...NOTES ...

Page 72: ...e Trans LInkage Adjustment HLR 2 18 2 20 Carburetor Adjustments 2 21 2 26 Oil Pump Adjustment Filter 2 stroke 2 27 2 30 Fuel System 2 31 2 32 Compression Tests 2 33 Battery Maintenance 2 34 Electrical 2 35 Coolant System Maintenance 2 36 2 38 Air Filter Service 2 Stroke 2 39 2 42 Air Filter Service 4 Stroke 2 43 Air Box Sediment Tube Service 2 44 Breather Filter 2 45 Recoil Housing 2 46 Oil Change...

Page 73: ......

Page 74: ...and replace if necessary Oil Tank Vent Hose 100 hrs 12 months 1000 1600 Inspect hose routing hose condition EH Valve Clearance 4 strokes 100 hrs 12 months 1000 1600 Inspect Adjust Counter Balancer Fluid 400s 100 hrs 12 months 1000 1600 Check Monthly Change Annually E Idle Speed As required As required Adjust H Throttle Cable ETC Switch 50 hrs 6 months 500 800 Inspect Adjust Lubricate Replace if ne...

Page 75: ...de Inspection Item H Brake Fluid 200 hrs 24 months 2000 3200 Change Every Two Years Brake Fluid Level Pre ride Pre ride Inspect Daily Pre Ride Inspection Item Brake Lever Travel Pre ride Pre ride Inspect Daily Pre Ride Inspection Item H Brake Pad Wear 10 hrs Monthly 100 160 Inspect Periodically Auxiliary Brake Adjustment As required As required Inspect Deflection Daily Adjust Output Shaft Bearing ...

Page 76: ... procedures outlined later in this chapter 2 Gear Shift Selector Box Polaris 0W 40 Synthetic Engine Lubricant or 10W Motor Oil Oil in selector box should be at the center line of the shift selector plungers Do not overfill or the selector may hydro lock 8 Coolant Level Polaris Premium 60 40 Pre mixed Antifreeze Coolant or a 50 50 mixture high quality antifreeze coolant and distilled water Fill res...

Page 77: ...idge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871312 Grease Gun Kit 1350046 CV Joint Grease Pack 30g 1350047 CV Joint Grease Pack 50g 2871329 Dielectric Grease Nyogelt 2871654 Premium Demand Drive Hub Fluid 12 oz Coolant 2871323 60 40 Coolant Gallon 2871534 60 40 Coolant Quart Additives Seal...

Page 78: ...Brake Fluid Polaris DOT 3 Brake Fluid Fill master cylinder reservoir to 1 4 6 4mm from top or between indicated lines See page 2 57 As required Change fluid every 2 years 4 Drive Chain Polaris Chain Lube or O Ring Apply to chain link plates and rollers As required 5 Middle Chain Lube or O Ring chain lube rollers 6 Front Chain chain lube 4 Rear Drive Chain 5 Middle Drive Chain Full Operating Range ...

Page 79: ...els Sealed Replace Inspect and replace bearings if necessary Annually 9 Front Drive Axle U Joints Polaris U Joint Grease Locate grease fitting and grease with grease gun Semi annually 10 Ball Joint Polaris All Season Grease Locate grease fitting on back side of struts and grease with grease gun Semi annually 11 Front A Arm Pivot Shaft Polaris All Season Grease Locate grease fitting on pivot shaft ...

Page 80: ...nter Swing Arm Housing 6x6 Polaris All Season Grease Locate grease fitting on swing arm and grease with grease gun Semi annually 18 Chain Adjusters Center and Front Eccentrics Polaris All Season Grease Locate grease fitting on center eccentric and grease Locate grease fitting on front eccentric side opposite chain and grease Semi annually 19 Rear Strut 6x6 Polaris All Season Grease Locate fitting ...

Page 81: ...ease Semi annually 3 Yoke Rear Prop Shaft Shaft Ride Models Premium U Joint Grease Locate Fittings and Grease Semi annually 4 U Joints Front Prop Shaft Premium U Joint Grease Locate Fittings and Grease Semi annually 5 Propshaft Yoke Premium U Joint Grease Locate fittings and grease 3 pumps maximum Annually 6 Transmission Synthetic Transmission Lubricant Add to proper level on dipstick Approx 20 oz...

Page 82: ...8 Lower Control Arms Polaris All Season Grease Locate fittings and grease Semi annually 9 Rear Wheel Hub Bearing Carrier Polaris All Season Grease Locate fittings and grease Semi annually 10 Rear Anti Roll Bar Polaris All Season Grease Locate fittings and grease Semi annually More often under severe use such as wet or dusty conditions Semi annually or 50 hours of operation refer to Maintenance Sch...

Page 83: ...ront 4 oz 118 ml 80 90 GL 5 Drain Refill w proper amount Sport 400 A99BA38CA Trans 11 3 oz 335 ml PPS Dipstick Scrambler 500 A99BG50AA Trans 32 oz 948 ml PPS Bottom of fill hole Front Type ll Front 4 oz 118 ml 80 90 GL 5 Drain Refill w proper amount Magnum 500 A99CD50AA Trans 13 5 oz 400 ml PPS Bottom of fill hole Front Type lll Front 5 oz 150 ml 80 90 GL 5 Drain Refill w proper amount Rear 10 oz ...

Page 84: ... l To check the level 1 Remove fill check plug 2 Add proper lubricant if necessary until level with bottom of fill hole threads 3 Install fill check plug To change lubricant 1 Remove gearcase drain plug located on the bottom and drain oil Catch and discard used oil properly 2 Clean and reinstall drain plug using a new sealing washer 3 Remove fill plug 4 Add proper lubricant to bottom of fill hole ...

Page 85: ...roper amount of lubricant Refer to page 2 10 5 Install fill plug 6 Check for leaks TYPE lll To check the level 1 The Type lll front gearcase lubricant level cannot be checked with a dipstick or by visual reference The gearcase must be drained and re filled with the proper amount of lubricant Refer to procedure below To change lubricant 1 Remove gearcase drain plug located on the bottom and drain o...

Page 86: ...plug threads Tighten securely 14 ft lbs 1 93 kgm 4 Reinstall fill plug 5 Check for leaks To change the lubricant 1 Remove gearcase drain plug located on the bottom and drain the oil Catch and discard used oil properly 2 Clean and reinstall the drain plug with a new sealing washer and tighten securely 14 ft lbs 1 93 kgm 3 Remove fill plug 4 Add 300 ml of GL5 80 90 Weight Gear Lube and in spect leve...

Page 87: ...d to bring level into operating range as shown in Ill 1 and Ill 2 To change lubricant 1 Remove skid plate if necessary 2 Place a drain pan beneath the transmission oil drain plug area 3 Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings 4 After the oil has drained completely install a new sealing washer and install the drain plug Torque to 14 ft lbs 1 93 k...

Page 88: ...ally inspect the oil level Lev el is correct when it reaches the bottom of the 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 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 S...

Page 89: ...ck in fully and remove to check 4 Read level shown on stick 5 Add SAE 10W30 oil with a transmission fluid funnel The recommended oil level is indicated by the knurled area on the dipstick 6 Reinstall dipstick with new sealing o ring Do not over tighten 7 Inspect counter balancer vent line for kinks or obstructions Counter Balance Oil Changing Procedure 1 Remove seat Locate and remove dipstick 2 Re...

Page 90: ...s play from shift linkage S Perform torque stop adjustment on models so equipped before adjusting shift linkage S Refer to Transmission chapter for more information Torque Stop Adjustment Adjust the torque stop S Prior to shift linkage adjustment S When shifting difficulties are encountered S If transmission has been removed from the frame NOTE The torque stop is located on the bottom left hand si...

Page 91: ...nspect shift linkage tie rod ends clevis pins and pivot bushings and replace if worn or damaged Lubricate the tie rod ends with a light aerosol lubricant or grease 3 Loosen all rod end adjuster jam nuts see Ill 1 4 Note orientation of tie rod end studs with stud up or down Remove both rod end studs from transmission bell cranks 5 Be sure idle speed is adjusted properly NOTE It is important to disc...

Page 92: ...clockwise until the same resistance is felt counting the revolutions as the rod is turned 10 Turn the rod clockwise again one half of the revolutions counted in Step 9 11 Tighten the rod end jam nuts securely while holding the rod end The jam nuts must be tightened with both front and rear rod ends parallel to each other If jam nuts are properly tightened the rod should rotate freely 1 4 turn with...

Page 93: ...osen rod end adjuster jam nuts A on both ends of linkage rod 5 Note orientation of tie rod end studs which way the stud goes through the transmission bell crank and gear selector arm 6 Remove rod end from gear selector arm Ill 1 7 Place gear selector lever in center of travel range as shown at right Be sure the lever does not move from this position 8 Turn linkage rod A to shorten or lengthen rod ...

Page 94: ...ng and poor performance Ill 1 If cable slack is excessive the choke fuel passage will not open far enough which may cause cold starting difficulty Also the half choke position used for intermittent applica tions will not function properly 1 Flip choke toggle to full off position 2 Slide boots C off choke cable adjuster and lock nut Ill 2 3 Loosen adjustment locknut A on cable sleeve in line adjust...

Page 95: ...bout 10 minutes 3 Set idle speed to 600 800 RPM NOTE Adjusting the air screw may affect idle speed Always check throttle cable freeplay after adjusting idle speed and adjust if necessary 4 Turn the screw in to richen or out to lean the mixture Adjust air screw for best throttle response and smooth idle 5 Re adjust idle speed if necessary Air Screw Adjustment 2 Stroke engines Refer to Specification...

Page 96: ... and cover all openings to prevent metal shavings from entering 3 Invert the carburetor and carefully drill out the center of the plug with a 1 8 or 5 32 3 or 4mm drill bit Before drilling set a drill stop on the shank of the drill bit to prevent drilling beyond 3 16 CAUTION Be careful not to drill into the pilot screw 4 Drill the plug at slow drill speeds Use a self tapping metal screw and a plie...

Page 97: ... screw counterclockwise until idle speed increases to maximum RPM Continue turning counterclockwise until idle RPM begins to drop 6 Center the pilot screw between the points in step 5 and 6 7 Re adjust idle speed if not within specification Pilot Screw Adjustment 335 4 Stroke Models IMPORTANT NOTE Idle speed is specified with the lights OFF On the idle speed will drop between 100 150 RPM when the ...

Page 98: ...wise to increase or out counterclockwise to decrease RPM Refer to Ill at right NOTE Adjusting the idle speed affects throttle cable freeplay and electronic throttle control ETC adjustment Always check throttle cable freeplay after adjusting idle speed and adjust if necessary Idle Speed Refer to Specifications Idle Screw CV Carburetor 4 Cycle Engines VM Carburetor 2 Cycle Engines Idle Screw ...

Page 99: ...TE On models with aluminum throttle block cover is held on by 3 screws see Ill 4 be sure ETC switch plunger is held inward by throttle cable tension 7 Tighten lock nut securely and slide boot completely in place to ensure a water tight seal NOTE On 2 stroke models whenever throttle cable ad justments are made always check oil pump adjustment and re adjust if necessary 8 Turn handlebars from left t...

Page 100: ... Place very slight pressure on the throttle lever until all freeplay is removed from throttle cable to carburetor to the point where the carb slide is just starting to rise and engine RPM begins to increase 6 Loosen locknut A 7 Turn adjuster B in or out until all freeplay is removed from oil pump cable the point where the oil pump arm C is just starting to move off of its stop NOTE The pump stop k...

Page 101: ... Lift boot A up off adjuster sleeve on cable Remove the oil pump cover Loosen the cable adjuster locknut B Adjust oil pump cable until marks align C when the throttle slide just begins to raise 6 Adjust oil pump cable until marks align when throttle slide just begins to raise and engine speed just begins to increase 7 Tighten jam nuts 8 Reinstall the ETC cover removed in step 1 making sure cover g...

Page 102: ...re all air is out of the system Oil Pump Troubleshooting Procedure To verify oil delivery to engine proceed as follows 1 Premix fuel in tank at a 40 1 fuel oil ratio 2 With the oil reservoir full and the pump bled remove the oil delivery line from the intake manifold 3 Test the oil delivery check valve with a low pressure pump and gauge See Page 3 22 4 Start engine and lift oil pump lever to full ...

Page 103: ...st not be substituted Replace the oil filter in accordance with the Maintenance Schedule or whenever water or debris has entered the oil tank Do not attempt to clean this filter 1 Remove clamps securing lines to filter 2 Remove lines and replace filter with arrow pointing in direction of oil flow towards pump 3 Reinstall clamps on each line and check for leaks Oil Filter Arrow Indicates Direction ...

Page 104: ...ck fuel lines for signs of wear deterioration damage or leakage Replace if necessary 2 Be sure fuel lines are routed properly and secured with cable ties CAUTION Make sure lines are not kinked or pinched 3 Replace all fuel lines every two years Vent Lines 1 Check fuel tank oil tank carburetor battery and transmission vent lines for signs of wear deterioration damage or leakage Replace every two ye...

Page 105: ...iment trap islocated onthe bottom of the float bowl on 400cc 2 stroke models 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 remove drain plug for 2 Strokes 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 ...

Page 106: ...tion problems above idle speed Abnormally high compression can be caused by a decompressor malfunction or worn or damaged exhaust cam lobes Inspect camshaft and automatic decompression mechanism if compres sion is abnormally high A cylinder leakage test is the best indication of engine condition on models with automatic decompression Follow manufacturer s instructions to perform a cylinder leakage...

Page 107: ...ect battery negative black cable first followed by the positive red cable CAUTION Whenever removing or reinstalling the battery disconnect the negative black cable first and reinstall the negative cable last 3 Disconnect the vent hose 4 Remove the battery 5 Remove the filler caps and add distilled water only as needed to bring each cell to the proper level Do not overfill the battery To refill use...

Page 108: ...gap with a wire gauge Refer to specifications for proper spark plug type and gap Adjust gap if necessary by bending the side electrode carefully 6 If necessary replace spark plug with proper type CAUTION Severe engine damage may occur if the incorrect spark plug is used 7 Apply a small amount of anti seize compound to the spark plug threads 8 Install spark plug and torque to 14 ft lbs Ignition Tim...

Page 109: ...lant using an antifreeze hydrometer S A 50 50 or 60 40 mixture of antifreeze and distilled wa ter will provide the optimum cooling corrosion protec tion and antifreeze protection S Do not use tap water straight antifreeze or straight wa ter in the system Tap water contains minerals and im purities which build up in the system S Straight water or antifreeze may cause the system to freeze corrode or...

Page 110: ...upper and lower marks on the coolant reservoir If not 1 Remove reservoir cap Inner splash cap vent hole must be clear and open 2 Fill reservoir to upper mark with Polaris Premium 60 40 Anti Freeze Coolant or 50 50 or 60 40 mixture of antifreeze and distilled water as required for freeze protection in your area 3 Reinstall cap NOTE If overheating is evident allow system to cool completely and check...

Page 111: ...on standard pressure cap will not allow the recovery system to function properly To access the radiator pressure cap Gen II To access the pressure cap remove the access cover on the front of the ATV just below the oil cap Using a flat stubby screwdriver loosen the screw 1 4 turn and pull the cover forward and up to remove Gen III To access the pressure cap clean the area around the oil cap and rem...

Page 112: ...ection oil 1 to 2 teaspoons Squeeze out the excess into an ab sorbant cloth 7 Reinstall the yellow foam boot onto the air filter box 8 Reinstall the primary air filter box removed in step 2 NOTE There will be some resistance Be sure the black rubber sealing ring is securely positioned over the main filter neck CAUTION When installing the primary air filter box be sure the gray foam collar B is bel...

Page 113: ...place the pre filter if the element is torn or damaged 5 Apply 1 to 2 teaspoons 2 cycle injection oil to the foam pre filter Squeeze filter gently to distribute oil evenly over entire filter Squeeze out the excess into an absorbant cloth 6 Reinstall the foam boot onto the air filter box 7 Reinstall the primary air filter box removed in step 2 NOTE There will be some resistance Be sure the black ru...

Page 114: ...rbox Be sure filter element seats securely 9 Check cover gasket and replace if required Be sure cover is seated properly and wing nuts are fin ger tightened securely 10 Reinstall primary air filter box as per instructions found on previous page 11 Reinstall seat Cleaning the Main Filter Important It is advisable to replace the filter when it is dirty How ever in a new filter is not immediately ava...

Page 115: ...if the element is torn or damaged 8 Install dry pre filter over new main filter and install NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing Cleaning the Main Filter Important It is advisable to replace the filter when it is dirty How ever in a new filter is not immediately available it is permissible to clean the main filter if you observe t...

Page 116: ...Style 1 Remove seat 2 Remove spring clamps securing the airbox lid and remove lid 3 Pull foam breather filter out 4 Loosen clamp and remove filter 5 Remove foam pre cleaner from main filter 6 Carefully wash the pre filter in soapy water and dry it thoroughly Replace the pre filter if the element is torn or damaged 7 Install dry pre filter over new mainfilter andreinstall 8 Push foam breather filte...

Page 117: ...the rear of the machine Drain whenever deposits are visible in the clear tube NOTE The sediment tube will require more frequent ser vice if the vehicle is operated in wet conditions or at high throttle openings for extended periods 1 Remove drain plug from end of sediment tube 2 Drain tube 3 Reinstall drain plug Sediment Tube Sediment Tube ...

Page 118: ...ters 1 Inspect the breather filter s for obstruction Replace if necessary In line breather filters should be installed with the arrow pointing toward the engine away from the air box NOTE In line breather filter service life is extended when the foam air box pre filter is in place and maintained prop erly Never operate the engine without the pre filter s Breather Hose 1 Be sure breather line is ro...

Page 119: ...d damage compo nents S Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water S After travelling in wet areas the recoil housing and starter should always be drained completely by re moving the recoil S Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some en gine oil will be lost if crankcase drain is ope...

Page 120: ...un engine two to three minutes until warm Stop engine 3 Clean area around drain plug B at bottom of oil tank 4 Place a drain pan beneath oil tank and remove drain plug CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as serious burns may result 5 Allow oil to drain completely 6 Replace sealing washer A on drain plug NOTE The sealing surfaces on drain plug and oil tank sho...

Page 121: ... drain plug and crankcase should be clean and free of burrs nicks or scratches 20 Reinstall drain plug 21 Remove dipstick and fill tank with 2 quarts 1 9 l of Polaris Premium 4 synthetic oil 22 Place gear selector in neutral and set parking brake 23 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 24 Re check the oil level on the dipstick and add oil as...

Page 122: ...t faced hammer to loosen it from the cylinder head 5 Remove timing inspection plug from recoil housing CAUTION Failure to position the crankshaft at TDC on compression stroke will result in improper valve adjust ment 6 Rotate engine slowly with recoil rope watching the intake valve s open and close NOTE At this point watch the camshaft sprocket locating pin and slowly rotate engine until locating ...

Page 123: ...e models Exhaust Valve Clearance Adjustment NOTE The exhaust valves on 425 and 500cc share a common rocker arm and must be adjusted using two feel er gauges 1 Insert 006 feeler gauge s between end of exhaust valve stem and adjuster screw s 2 Loosen locknut s and turn adjuster screw s until there is a slight drag on feeler gauge s NOTE Both feeler gauges should remain inserted during adjustment of ...

Page 124: ... the cover or cylinder head 7 Reinstall the cover using a new gasket 8 Torque cover bolts to 78 in lbs 9 Remove the shop towel from the spark plug cavity 10 Reinstall the spark plug Torque to 14 ft lbs 19 Nm 11 Reinstall the spark plug high tension lead 12 Reinstall the fuel tank 13 Reinstall the fuel tank shroud 14 Reinstall the left and right body panels Sealant UP Cover Bolt Torque 72 in lbs Sp...

Page 125: ...g parts Use only genuine Polaris replacement parts One of two methods can be used to measure toe alignment The string method and the chalk method If adjust ment is required refer to following pages for procedure Tie Rod End Steering Inspection S To check for play in the tie rod end grasp the steering tie rod pull in all directions feeling for movement S Repeat inspection for inner tie rod end on s...

Page 126: ... to rim at front and rear of rim NOTE String should just touch side surface 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 ...

Page 127: ...icle toe tolerance 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 Toe Alignment Adjustment 7 If toe alignment is incorrect measure the distance between vehicle center and each wheel This will tell you which tie rod needs adjusting NOTE Be sure handlebars are straight ahead before determining whi...

Page 128: ...ront Hub Fluid Change AWD Models 1 Place a drain pan beneath the hub 2 Remove 3 screws and hub cap Pry equally in notches provided until cap is removed 3 Allow fluid to drain completely 4 Inspect hub cap O rings for nicks cuts or abrasions Replace if necessary 5 Remove check fill plug 6 Reinstall the hub cap NOTE The check fill plug must be removed before reinstalling the hub cap 7 Turn wheel unti...

Page 129: ...machine onto the incline so the front of the machine is one foot higher than the rear Set the parking brake and block the wheels Make sure the machine is in neu tral and repeat steps 2 and 3 WARNING SEE BELOW 6 Repeat steps 2 through 5 until no more particles are ex pelled when the engine is revved 7 Stop the engine and allow the arrestor to cool 8 Reinstall the clean out plugs WARNING S Do not pe...

Page 130: ...DOT 3 brake fluid PN 2870990 S Check brake system for fluid leaks S Check brake for excessive travel or spongy feel S Check friction pads for wear damage and looseness S Check surface condition of the disc S Inspect thickness of brake pad friction material Brake Pad Inspection S Pads should be changed when friction material is worn to 3 64 1 cm or about the thickness of a dime Hose Fitting Inspect...

Page 131: ...is Other models are non adjustable type right If free play is excessive on a non adjustable brake inspect pedal linkage and master cylinder for wear or damage and replace any worn parts To adjust the linkage S Remove right hand drive cover to gain access to brake pushrod S Hold clevis A and loosen clevis adjuster lock nut B S To increase free play shorten the pushrod C S To decrease free play leng...

Page 132: ...e 2 Type I If adjustment is necessary turn adjuster bolt A clockwise until disc rotation becomes difficult Turn adjuster bolt counterclockwise until brake en gagement starts at approximately 1 2 of the total pedal travel See Illustration 1 and 2 Type II If adjustment is necessary loosen jam nut A and turn adjuster bolt B clockwise until disc rotation becomes difficult Turn adjuster bolt counterclo...

Page 133: ...ve chain Sprocket Inspection Inspect the sprocket for worn broken or bent teeth To check for wear pull outward on the chain as shown Re place sprocket if chain movement exceeds 1 4 6 cm Drive Chain Inspection The chain must be replaced when it reaches 3 elonga tion 1 Stretch the chain tightly in a straight line 2 Measure a length of twenty pitches pins from pin center to pin center and compare to ...

Page 134: ...ound the axle and rear bumper tube Tighten until a straight line A can be drawn from the axle to the transmission output shaft intersecting the swing arm pivot S If the chain needs adjustment use the following procedure Rear Drive Chain Tension Adjustment Standard Swingarm 1 Loosen chain guard 2 Loosen two eccentric locking bolts 3 Insert a pin punch through the sprocket hub and into the eccentric...

Page 135: ...ward to gain slack at the top side of the rear chain At this point the chain should have 3 16 3 8 5 10 mm deflection If the chain needs adjustment use the following procedure Adjustment Procedure Concentric Swin garm Rear Axles Tapered Roller Bearings 1 Loosen chain guard 2 Loosen two eccentric clamp bolts 3 Loosen caliper mounting bracket bolts 3 16 3 8 48 cm 95 cm Deflection Pin Punch Step 2 Loo...

Page 136: ...o adjust chain slack to the proper dimension and then pro ceed to Step 7 or follow Steps 5 and 6 for alternate method if 2 1 2 wrench is not available 5 Insert a pin punch through the sprocket hub and into the eccentric axle housing 6 Roll the vehicle ahead or back to adjust chain slack to the proper dimension Tighten Loosen Alternate Adjustment Method Pin Punch Step 5 and 6 ...

Page 137: ...T TRAILER HITCH 30 ft lbs 41 Nm 8 Verify chain adjustment is correct after tightening eccentric clamp bolts to specification 9 Tighten caliper mounting bracket bolts 10 12 ft lbs 14 17 Nm 10 Reinstall chain guard where applicable NOTE Reposition chain guide to allow 1 8 3 cm clearance between sprocket and guide Torque the nut Eccentric Clamp With Hitch Torque the nut Eccentric Clamp Without Hitch ...

Page 138: ...entric hole Rotate vehicle rearward to tight en chain Chain deflection should be 1 4 1 2 6 13 mm with 18 lbs 8 18 kg of force at center of chain 6 Tighten eccentric clamp bolts to 45 ft lbs 62 Nm NOTE This does not include nut rolling torque Check chain tension 7 Loosen forward chain eccentric clamp bolt B Install punch as was done previously and adjust chain to 1 4 1 2 6 13 mm with 18 lbs 8 18 kg...

Page 139: ...ts 3 Insert a pin punch through the sprocket hub and into the eccen tric axle housing 4 Roll the vehicle ahead or back to adjust chain slack to the proper dimension Correct chain slack adjustment is 1 1 4 to 1 1 2 30 38 mm total at the midpoint 5 Tighten the eccentric locking bolts to 60 ft lbs 6 Reinstall chain guard NOTE Reposition chain guide to allow 1 8 3 cm clearance be tween sprocket and gu...

Page 140: ...pect front strut cartridges for leakage Rear Suspension Compress and release rear suspension Damping should be smooth throughout the range of travel Check all rear suspension components for wear or dam age Inspect shock for leakage Controls Checkcontrolsforproperoperation positioningandad justment Brake control and switch must be positioned to allow brake lever to travel throughout entire range wi...

Page 141: ...taining Nut 100 Ft Lbs Wheel Removal Front or Rear 1 Stop the engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel nuts and remove the wheel Wheel Installation 1 With the transmission in gear and the parking brake locked place the wheel in the corre...

Page 142: ...al equipment size and type S The use of non standard size or type tires may affect ATV handling Tire Tread Depth Alwaysreplacetireswhentreaddepthiswornto1 8 3 mm or less WARNING Operating an ATV with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control Worn tires can cause an accident Always replace tires when the tread depth measures 1 8 3 cm or le...

Page 143: ...NOTES ...

Page 144: ...Stroke 3 36 3 37 Cylinder Honing 3 38 Connecting Rod Inspection 2 Stroke 3 39 Crankshaft Runout Inspection 2 Stroke 3 40 ES33PF EH50PL Engine Lubrication 3 43 ES33PF Lubrication Oil Flow 3 44 3 45 ES50PL Lubrication Oil Flow 3 46 3 47 ES33PF Engine Exploded View 3 48 EH50PL Engine Exploded View 3 49 ES33PF EH50PL Engine Removal 3 50 ES33PF EH50PL Engine Top End Disassembly 3 50 3 65 ES33PF EH50PL ...

Page 145: ......

Page 146: ...ase 8mm 17 18 23 24 17 18 23 24 17 18 23 24 Crankcase 6mm 6 8 8 11 6 8 8 11 6 8 8 11 Crankshaft Slotted Nut 16mm 29 44 40 60 Water Pump Impeller Nut 6mm 5 6 5 7 9 Stator Plate 6mm 5 6 5 7 9 5 6 5 7 9 5 6 5 7 9 Flywheel 16mm 44 62 60 85 44 62 60 85 29 44 40 60 Starter Motor 6mm 5 6 5 7 9 5 6 5 7 9 5 6 5 7 9 Recoil Housing 6mm 5 6 5 7 9 5 6 5 7 9 5 6 5 7 9 Spark Plug New 14mm 9 11 12 15 9 11 12 15 9...

Page 147: ...fer to Engine Assembly for torque procedure Drive Clutch Bolt 7 16 20 40 55 Nm 40 55 Nm 40 55 Nm Flywheel 16mm 58 72 78 98 Nm 58 72 78 98 Nm 58 72 78 98 Nm Oil Delivery Pipe 12mm 11 15 15 21 Nm 11 15 15 21 Nm 11 15 15 21 Nm Oil Drain Bolt Crankcase 14mm 14 17 19 23 Nm 14 17 19 23 Nm 14 17 19 23 Nm Oil Filter Pipe Fitting 20mm 36 43 49 59 Nm 36 43 49 59 Nm 36 43 49 59 Nm Oil Hose Fitting 1 8 Pipe T...

Page 148: ...se fasteners in 3 steps following the sequence outlined below 1 2 3 4 5 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 Crankcase 400L 6mm 1 2 3 4 6 5 Cylinder Base 250 300 400 Cylinder Head 250 300 Crankcase 250 300 Cylinder Head Cylinder Base 335 425 500 1 2 3 4 5 6 Cylinder Head 400 Crankcase 335 425 500 1 2 3 4 9 7 6 8 5 10 ...

Page 149: ...5 50 1 00 68 mm 3W 4W EC28PFE 01 02 25 50 70 mm 28 ES33PFE01 02 25 50 52 5 mm None EC38PLE 04 05 25 50 78mm 38A EC38PLE 06 07 08 09 25 50 78mm 38B EH42PL 02 25 50 66mm B EH50PLE04 06 08 09 25 50 72mm C Pistons and rings marked 25 equal 25mm 010I oversized Pistons and rings marked 50 equal 50mm 020I oversized Pistons and rings marked 10 equal 1 0mm 040I oversized 250 engines only Piston Clearance S...

Page 150: ...025 mm j PTO 1 4963 1 4970 38 005 38 025 mm Camshaft Oil clearance Std 0022 0035 055 090 mm Limit 0039 10 mm Cylinder Head Surface warpage limit 0020 05 mm y Standard height 3 870 98 3 mm Valve Seat Contacting width In Std 028 7 mm g Limit 055 1 4 mm Ex Std 039 1 0 mm Limit 071 1 8 mm Valve Guide Inner diameter 2362 2367 6 0 6 012 mm Protrusion above head 689 709 17 5 18 0 mm Valve Margin thicknes...

Page 151: ...in must be fitted into position with thumb at 68 F 20 C Piston Ring Piston ring installed gap Top ring Std 0079 0138 20 36 mm g g g p p g Limit 039 1 0 mm Second i Std 0138 0197 35 50 mm ring Limit 039 1 0 mm Oil ring Std 0079 0276 20 70 mm g Limit 059 1 5 mm Piston Ring Standard clearance i i i Top ring Std 0014 0030 035 075 mm g piston ring to ring groove p g Limit 0059 15 mm Second i Std 0010 0...

Page 152: ...63 1 4970 38 005 38 025 mm Camshaft Oil clearance Std 0022 0035 055 090 mm 0022 0035 055 090 mm Limit 0039 10 mm 0039 10 mm Cylinder Head Surface warpage limit 0020 05 mm 0020 05 mm y Standard height 3 870 98 3 mm 3 870 98 3 mm Valve Seat Contacting width In Std 028 7 mm 028 7 mm g Limit 055 1 4 mm 055 1 4 mm Ex Std 039 1 0 mm 039 1 0 mm Limit 071 1 8 mm 071 1 8 mm Valve Guide Inner diameter 2362 ...

Page 153: ...it Piston pin must be a push by hand fit at 68 F 20 C Piston Ring Piston ring installed gap Top ring Std 0079 0138 20 36 mm 0079 0138 20 36 mm g g g p p g Limit 039 1 0 mm 039 1 0 mm Second i Std 0079 0138 20 36 mm 0079 0138 20 36 mm ring Limit 039 1 0 mm 039 1 0 mm Oil ring Std 0079 0276 20 70 mm 0079 0276 20 70 mm g Limit 059 1 5 mm 059 1 5 mm Piston Ring Standard clearance i i i Top ring Std 00...

Page 154: ...rged through a bleed hole at the top between the two halves see illustration above If there is difficulty bleeding the cooling system or if overheating problems are encountered remove the radiator cap and inspect to see if the bleed hole is clear System Pressure Test 1 Remove radiator cap access panel from front of headlamp housing 2 Remove recovery bottle hose from radiator 3 Connect a Mity Vac P...

Page 155: ...m Specifications 250 300 Scrambler and Sport Liquid Cooled Except Scrambler and Sport Fan Switch Off Fan Switch On 210 F 99 C 10 235 F 113 C 154 F 68 C 5 174 F 79 C 175 F 79 C 5 190 F 88 C Hot Light On 4 Strokes 221 F 105 C Hot Light On 2 Strokes 205 F 96 C 205 F 96 C System Capacity 2 25 Quarts 2 25 Quarts Radiator Cap Relief Pressure 13 PSI 13 PSI Raised side of reinforcement rib faces engine on...

Page 156: ...ines S Camshaft 4 Strokes S Rocker Arms S Cam Chain and Sprockets 4 Strokes S Water Pump Water Pump Mechanical Seal The following components require engine removal for service S Oil pump Oil Pump Drive Gear 300 335 425 500 S Counterbalance Shaft or Bearing s 4 Cycle engines S Connecting Rod S Crankshaft S Crankshaft Main Bearings S Crankcase It may be necessary to loosen engine mounts and move eng...

Page 157: ...Insert a shop towel into the carburetor flange to prevent dirt from entering the intake port 12 Loosen auxiliary brake master cylinder mount if necessary for clearance 13 Remove center chain guard on chain drive AWD models 14 Remove center drive and driven sprocket bolts and remove chain and sprockets as an assembly 15 Refer to PVT System to remove outer clutch cover drive belt drive clutch driven...

Page 158: ...t to top of fill neck 6 Start engine and observe coolant level in the radiator Allow air to purge and top off as necessary Reinstall radiator cap and bring engine to operating temp Check level in reservoir tank after engine is cool and add coolant if necessary Engine Break In Period 2 Cycle 2 Cycle Engine Break In Period is defined as the first 3 hours of engine operation or one full tank of fuel ...

Page 159: ...om piston 3 Refer to Top End Component Parts Inspection on page 3 36 3 39 to inspect cylinder piston rings and connecting rod small end bearing 4 Remove the crankcase half attaching bolts Heat crankcase in the bearing support areas After applying heat tap on PTO end and magneto end to separate case half from crankshaft 5 After removing the crankshaft thoroughly clean the bearings and lubricate Che...

Page 160: ...nd connecting rod bearings with Polaris Premium 2 engine oil Carefully check each main bearing on the shaft NOTE Due to extremely close tolerances the bearings must be inspected visually and by feel Look for signs of discoloration scoring or galling Turn the outer race of each bearing The bearings should turn smoothly and quietly The inner race of each bearing should fit tightly on the crankshaft ...

Page 161: ...ngs which may cause premature bearing failure Measure Crankshaft Width Bearings Installed 1 Measure distance from outer edge of PTO end bearing race to outer edge of mag side bearing race Record measurement If bearings and spacers are already installed measure distance as shown in photo at right then proceed to Step 5 or If PTO end bearings have not yet been installed mea sure distance as shown in...

Page 162: ...he bearing seating surface Subtract thickness of flat stock and record the measurement on line B below 6 Measure magneto side case half using the same procedure Record measurement on line C below Remember to subtract thickness of flat stock 7 Add the readings from steps 5 and 6 and record on line D Subtract line A from line D The result is the amount of crankshaft end play 8 If adjustment is requi...

Page 163: ...ket eliminator on one of the case halves 14 Reinstall the mag side half 15 Torque case half attaching bolts in three steps to torque specified on page 3 1 Follow the torque pattern shown on page 3 3 NOTE Before proceeding check piston to cylinder clearance ring end gap and cylinder honing procedures on page 3 36 3 38 16 Install piston rings beveled side up onto piston Keystone rings are beveled to...

Page 164: ...roove 19 Rotate driver to complete engagement of clip 20 Visually inspect the C clip to be sure it is fully seated in the groove 21 Reinstall piston onto rod with F mark or toward the magneto side of the engine Support with support block 22 Lubricate piston pin and pin bearing with 2 Stroke oil 23 Reinstall piston pin Warm piston crown lightly with heat gun to ease pin installation CAUTION Do not ...

Page 165: ...0 for dynamic ignition timing 2 Reinstall flywheel 3 Reinstall magneto housing 4 Torque flywheel bolt to specification found on page 3 1 5 Reinstall recoil starter assembly 6 Seal wire harness grommet to crankcase using RTV silicone sealant 7 Refer to electrical section of this manual for starter motor inspection Reinstall starter motor When installing base gasket use gasket eliminator no 518 on b...

Page 166: ...e thrust washer you will not be able to achieve the proper drive gear end play as outlined below Refer to the Illustration on page 3 22 250 300 Models Refer to Illustration on following page 1 Lubricate and install pump drive gear thrust washer pump drive gear and bushing into crankcase Make sure parts are completely seated 2 Measure the distance from the pump bushing to the crankcase pump mountin...

Page 167: ...ure to the line spigot of the check valve Use a Mity Vac PN2870975 or similar tester The valve should release between 2 and 7 PSI The check valve is located on the cylinder Oil Check Valve Testing EC28PF The oil pump check valve on the EC28PF engine must be tested by applying 3 7 inches of mercury VACUUM to the line spigot of the check valve The valve should release be tween 3 and 7 inches of merc...

Page 168: ...edge of the reel unscrew the reel counterclockwise to remove it from the ratchet pawl bracket shaft 6 Remove the ratchet pawl bracket spring hook ratchet friction ring and friction spring NOTE It is not necessary to remove the spring retainer plate and spring unless it is damaged 7 Clean and inspect all parts Repair or replace as required 1 Flywheel Housing 2 Reel 3 Recoil Spring 4 Spring Retainin...

Page 169: ... square drive on the bracket shaft should properly align in the spring hook 8 While holding the bracket tight against the spring hook flip the flywheel housing over and thread the reel onto the pawl bracket shaft 9 Clamp the ratchet pawl bracket in the corner of the jaws of a vise Firmly hand tighten the reel 10 If the rope was removed or if a new rope is being installed attach one end of the rope...

Page 170: ...reel clockwise until the rope is completely re wound 3 Rotate the housing three more turns and install the pawl return spring with the large end of the spring going into rope housing reinstall retainer plate lock washer and bolt 4 Check recoil and ratchet operation 5 When reinstalling assembly onto engine use Loctite 518 Gasket Eliminator between the flywheel housing and crankcase ...

Page 171: ...ly and flywheel cover 2 Remove starter pulley and flywheel nut 3 Hold flywheel with holder tool and remove flywheel nut 4 For starter removal remove bolts retaining starter bracket on PTO side and two bolts A on mag side 5 Remove flywheel using puller Holder Flywheel Holder PN 8700229 A Flywheel Puller PN 2871043 ...

Page 172: ...bly be sure to seal rubber grommet A completely with silicone sealer to avoid water or dirt ingestion into stator as sembly 150 Watt alternator shown at right 200 Watt alternator shown at right 7 Remove six cylinder head bolts using a 12 mm socket Note the position of the bleeder plug for the coolant system A Bleeder plug ...

Page 173: ... and remove the four cylinder nuts NOTE Use a 14 mm socket on the exhaust side A 14 mm wrench will be necessary on the intake side 10 Remove cylinder 11 Refer to page 3 35 3 40 to inspect parts Reassembly Note Due to limited clearance atorque adaptor must be used to apply specified torque to base nuts upon reassembly 12 Install piston support block and remove C clips Reassembly Note When reinstall...

Page 174: ...ight with a 12 mm socket 17 Remove four nuts and two bolts B indicated in the photo at right with a 10 mm socket 18 Remove cover tapping lightly with a soft face hammer if necessary 19 Using a 10 mm socket remove the impeller nut C 20 Slide water pump assembly from counterbalance assembly Reassembly Note Watch for adjuster shims which may be between the impeller and pump housing Make sure to reins...

Page 175: ...n both gears must be across from each other dur ing reassembly See photo three at right 25 Heat counter balance bearing areas D and E on the crankcase with a heat gun for approximately one to two minutes WARNING Oil and gasoline are highly flammable and explosive under certain conditions Use extreme caution when using a heat gun or propane torch in this environment 26 Once these areas are thorough...

Page 176: ...case bolts 28 Tap cases apart with a soft faced hammer Inspect oil pump drive gear and bearing Replace shaft as an assembly Shims used to adjust crankshaft end play Follow procedure on page 3 16 3 17 Inspect crankshaft runout and components See page 3 40 Align marks upon reassembly ...

Page 177: ... 036 9mm Connecting Radial Clearance 31 Measure the total movement of the connecting rodbig end bearing Movement should not exceed 0013 033mm 32 Remove seals from crankcase 33 Clean crankcase thoroughly and install new seals until flush with edge of seal bore Reassembly Notes 1 Before assembling the crankcase calculate crankshaft end play and place shims between as required Follow procedure on pag...

Page 178: ...e failure may be hard starting and poor low end performance 3 Check each reed valve petal for white stress marks or missing material Replace if necessary Water Pump Impeller Clearance Whenever the counterbalance assembly is removed it will be necessary to verify impeller clearance Fol lowing is a recommended procedure for measuring water pump impeller clearance 1 Apply a small amount of putty or c...

Page 179: ...B C C Counterbalance Water Seal Lip Spring Toward Counterbalance Bearing Closed Side Toward Each Other Oil Seal Lip Spring Toward Impeller Impeller 3084184 3084185 Oil Hole Bearing Weep Hole Press Oil Seal Past Weep Hole Press Water Seal Flush The illustration depicts correct positioning of the seals The water seal is identified by counting the number of sealing lips It is a triple lip seal and ha...

Page 180: ...gine must be tested by applying 2 7 PSI of pressure to the line spigot of the check valve Use a Mity Vac PN2870975 or similar tester The valve should release between 2 and 7 PSI The check valve is located on the cylinder NOTE Refer to page 3 22 for check valve testing on 250 and 300cc engines To engine 400 Check Valve EC38PL Apply 2 7 PSI pres sure to the line fitting ...

Page 181: ...o determine taper or out of round Record all measurements Piston Inspection Measurement 2 Stroke 1 Check piston for scoring or cracks in piston crown or pin area Excessive carbon buildup below the ring lands is an indication of piston ring or cylinder wear 2 Measure piston outside diameter at a point 10 mm 3 8 up from bottom of skirt at a 90 angle to the direction of the piston pin Record the meas...

Page 182: ... the cylinder NOTE A difference in end gap between the bottom and top of the cylinder indicates cylinder taper The cylinder should be measured for excessive taper and out of round Replace rings if the installed end gap exceeds the service limit Refer to page 3 4 for specifications NOTE Always check piston ring installed gap after re boring a cylinder or when installing new rings NOTE Install rings...

Page 183: ...ross hatch pattern to ensure piston ring seating and to aid in the retention of the fuel oil mixture during initial break in Hone cylinder according to hone manufacturer s instructions or these guidelines S Use a motor speed of approximately 300 500 RPM run the hone in and out of the cylinder rapidly until cutting tension decreases Remember to keep the hone drive shaft centered or cylinder centere...

Page 184: ...s occurred 5 Visually inspect piston pin for damage discoloration or wear Feel along the length of the pin and replace it if any rough spots galling or wear is detected 6 Oil and install needle bearing and pin in connecting rod Rotate pin slowly and check for rough spots or any resistance to movement Slide pin back and forth through bearing while rotating and check for rough spots 7 With pin and b...

Page 185: ...rrect a situation like the one shown in the illustration at right squeeze the crankshaft at point A Use tool from alignment kit 10 If the crank rod pin location is 180_ from the dial indicator opposite that shown above it will be necessary to spread the crankshaft at position A as shown in the illustration at right When rebuilding and straightening a crankshaft runout must be as close to zero as p...

Page 186: ...3 41 Polaris Sales Inc 4 99 ENGINE 4 Stroke Engine Service ...

Page 187: ...3 42 Polaris Sales Inc 4 99 ENGINE Notes ...

Page 188: ...n Fitting 14 ft lbs 19 Nm Oil Pressure Specification 20 PSI 5500 RPM Polaris 0W 40 Synthetic Engine Hot Oil Pressure Test ES33PF EH50PL 1 Remove blind plug on front left cylinder head 2 Insert a 1 8 NPT oil pressure gauge adaptor into the cylinder head and attach the gauge 3 Start engine and allow it to reach operating temperature monitoring gauge indicator NOTE Use Polaris Premium 4 Synthetic Eng...

Page 189: ...he PTO L journal The camshaft journals cam lobes and rocker arms are lubricated through holes in the camshaft The oil lubricatesthe camchain andsprocket and drains to the sump The other oil path from the filter leads through a delivery pipe to the crankcase main oil gallery which leads to the stator plate oil passage Here it passes through the slotted friction bearing located in the stator plate i...

Page 190: ...Fitting Lower hose fitting on engine Oil Jet Fixed Hose Fitting Upper on engine Through Front Left Cylinder Head Bolt Passage Indirect Lubrication Prevents oil from draining into crankcase with engine off Bottom fitting is oil outlet or return to tank Top fitting is oil feed or intake from bottom of tank One way valve From filter to crankshaft Oil feed to filter Oil filter Oil passes through cylin...

Page 191: ... plate oil passage Here it passes through the slotted friction bearing located in the stator plate into the crankshaft An oil seal on the stator plate prevents oil from entering the stator flywheel area Oil travels through the crankshaft to the crank pin lubricating the connecting rod large end bearing directly Oil also passes through an oil jet drilled orifice in the end of the crank pin to the P...

Page 192: ...llery Crankcase Small End Bearing Cylinder Sleeve Main Bearing PTO Large End Bearing Crank Pin Crankshaft Screen Fitting Bottom of Tank EH50PL Oil Flow Chart Top of Oil Tank Union Fitting Lower Oil Jet Union Fitting Upper Through Cylinder Stud Front Left Indirect Lubrication Prevents oil from draining into crankcase with engine off Bottom fitting is oil exhaust or return to tank Top fitting is oil...

Page 193: ...Crankcase Cylinder Cylinder Head Crankshaft and Piston Valve Train 3 48 Polaris Sales Inc 4 99 ENGINE ES33PFEngine Exploded View ...

Page 194: ...3 49 Polaris Sales Inc 4 99 ENGINE EH50PL Engine Exploded View Crankcase Cylinder Cylinder Head Crankshaft and Piston Valve Train A ...

Page 195: ...g intake valves open and start to close 3 Continue to rotate engine slowly watching camshaft sprocket marks and the mark in the timing inspection hole 4 Align single TDC mark on flywheel with projection in inspection hole and the cam sprocket pin facing upward aligned with the camshaft to crankshaft center line NOTE The cam lobe should be pointing down and valves should have clearance at this poin...

Page 196: ...r teeth B for wear or damage 2 Push ratchet pawl and hold it The plunger should move smoothly in and out of the tensioner body 3 Release ratchet pawl and push inward on plunger It should remain locked in position and not move inward 4 Measure free length of tensioner spring Replace spring if excessively worn Compare to specifications on page 3 5 3 8 5 Replace entire tensioner assembly if any part ...

Page 197: ...s in order Note position of spring washer on rocker shaft Flats face out toward the shaft support 1 Loosen rocker shaft retaining bolt A to remove shaft 2 Remove the four bolts securing rocker shaft supports and remove the supports rocker shaft and rocker arms as an assembly being careful not to drop the dowel pins into the engine ES33PF A ...

Page 198: ...ly 2 Inspect each rocker arm cam follower surface If there is any damage or uneven wear replace the rocker arm NOTE Always inspect camshaft lobe if rocker arms are worn or damaged 3 Measure O D of rocker shaft Inspect it for wear or damage Compare to specifications on page 3 5 3 8 Forward Wave washer Inspect surface of follower ES33PF EH50PL ...

Page 199: ...page 3 5 3 8 5 Measure I D of both rocker arm shaft supports and visually inspect surface Compare to specifications on page 3 5 3 8 6 Inspect rocker adjuster screws for wear pitting or damage to threads of the adjuster or locknut Replace all worn or damaged parts NOTE The end of the adjuster screw is hardened and cannot be ground or re faced ES33PF EH50PL ...

Page 200: ...E ES33PF EH50PL Engine Camshaft Removal 1 Remove camshaft sprocket inspection cover 2 Loosen three camshaft sprocket bolts 3 Remove camshaft end cap and O Ring 4 Inspect camshaft end cap thrust face for wear Replace if worn or damaged ...

Page 201: ...ft inward to allow removal of cam sprocket and remove sprocket from camshaft and chain 7 Secure cam chain with a wire to prevent it from falling into the crankcase 8 Inspect cam sprocket teeth for wear or damage Replace if necessary 9 Slide camshaft out the PTO side of the cylinder head ES33PF EH50PL Inspect for Areas of Tooth Wear or Damage Decompressor Ball Retainer Sleeve Decompressor Shaft ...

Page 202: ...de spring onto shaft 2 Apply engine oil to release lever shaft The actuator ball must be held outward to allow instal lation of the release lever shaft If Camshaft Is Removed From Engine 3 Turn the camshaft until the actuator ball is in the lowest position and install the release lever shaft pre winding the spring approximately 1 4 6 5mm If Camshaft Is Installed In The Engine 4 Use a small magnet ...

Page 203: ...am lobe using a micrometer Compare to specifications on page 3 5 3 8 4 Measure camshaft journal outside diameter O D 5 Measure ID of camshaft journal bore 6 Calculate oil clearance by subtracting journal OD from journal bore ID Compare to specifications on page 3 5 3 8 Replace camshaft if damaged or if any part is worn past the service limit Replace cylinder head if camshaft journal bore is damage...

Page 204: ...3 59 Polaris Sales Inc 4 99 ENGINE ES33PF EH50PL Engine Engine Disassembly Cont Cylinder Head Exploded View ES33PF ES33PF 1 Remove the two 6mm flange bolts from cylinder head ES33PF ...

Page 205: ...3 60 Polaris Sales Inc 4 99 ENGINE ES33PF EH50PL Engine Cylinder Head Exploded View EH50PL 1 Remove the two 6mm flange bolts A from cylinder head A EH50PL ...

Page 206: ... with a plastic hammer until loose CAUTION Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging casting 4 Remove cylinder head and head gasket ES33PF New head gasket must be installed with sealant facing upward Cylinder Head Inspection 1 Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon CAUTION Use care not to damage seal...

Page 207: ...eassembly NOTE Keep all parts in order with respect to their location in the cylinder head The EH50 cylinder head is shown in examples throughout cylinder head service section The ES33 cylinder head is similar to EH50 1 Using a valve spring compressor compress the valve spring and remove the split keeper NOTE To prevent loss of tension do not compress the valve spring more than necessary 2 Remove ...

Page 208: ...g for squareness Compare to specifications on page 3 5 3 8 Replace spring if either measurement is out of specification 5 Remove valve seals CAUTION Replace seals whenever the cylinder head is disassembled Hardened cracked or worn valve seals will cause excessive oil consumption and carbon buildup Valve Spring Free Length Coil Fatigue Squareness ...

Page 209: ... blocks and a dial indicator 3 Check end of valve stem for flaring pitting wear or damage A 4 Inspect split keeper groove for wear or flaring of the keeper seat area B NOTE The valves cannot be re faced or end ground They must be replaced if worn bent or damaged 5 Measure diameter of valve stem with a micrometer in three places and in two different directions six measurements total Compare to spec...

Page 210: ...t valve stem measurement to obtain stem to guide clearance NOTE Be sure to measure each guide and valve combination individually 8 Replace valve and or guide if clearance is excessive Compare to specifications on page 3 5 3 8 NOTE If valve guides are replaced valve seats must be reconditioned Refer to Valve Seat Reconditioning for pro cedure Combustion Chamber Clean all accumulated carbon deposits...

Page 211: ... Wear eye protection when performing cylinder head service Valve guide replacement will require heating of the cylinder head Wear gloves to prevent burns Valve Guide Removal Installation 1 Remove all carbon deposits from the combustion chamber valve seat and valve guide area before attempting to remove valve guides CAUTION Carbon deposits are extremely abrasive and may damage the valve guide bore ...

Page 212: ...low the old guides to be removed 2 Using valve guide driver drive guides out of the cylinder head from the combustion chamber side Be careful not to damage guide bore or valve seat when removing guides 3 Place cylinder head on cylinder head table NOTE Be sure cylinder head is still at 212 F 100 C before installing new guides 4 Place a new guide in the valve guide installation tool and press guide ...

Page 213: ...ed S If the contact area of the cutter is in the same place the valve guide is distorted from im proper installation and must be replaced Be sure the cylinder head is at the proper temper ature and replace the guide S If the contact area of the initial cut is greater than 75 continue to cut the seat until all pits are removed and a new seat surface is evi dent NOTE Remove only the amount of materi...

Page 214: ...oth top and bottom cutters to narrow the seat S If the seat is too narrow widen using the 45 cutter and re check contact point on the valve face and seat width after each cut NOTE When using an interference angle the seat contact point on the valve will be very narrow and is a normal condition Look for an even and continuous contact point on the black marker all the way around the valve face 8 Cle...

Page 215: ...an cylinder head valves and camshaft oil supply passage A thoroughly 13 If oil passage blind plug was removed apply 3 Bond 1215 or equivalent sealer to the threads and install torquing to 8 ft lbs 1 1 kg m CAUTION Do not allow sealant to enter oil passage 14 Spray electrical contact cleaner into oil passage and dry using compressed air Cylinder Head Assembly CAUTION Wear eye protection during asse...

Page 216: ...g tension Install split keepers with the gap even on both sides 7 Repeat procedure for remaining valve 8 When all valves are installed tap lightly with soft faced hammer on the end of the valves to seat the split keepers Valve Sealing Test 1 Clean and dry the combustion chamber area 2 Pour a small amount of clean high flash point solvent into the intake port and check for leakage around each intak...

Page 217: ...ine disassembly procedures to remove valve cover camshaft and rocker arms and cylinder head 1 Remove cam chain guide at front of cylinder 2 Loosen all four oil pipe banjo bolts and then remove the bolts and eight sealing washers Remove the pipes EH50PL 3 Loosen hose clamps and remove coolant inlet hose EH50PL Shown EH50PL Shown EH50PL ...

Page 218: ...cross pattern until loose and remove bolts EH50PL The bolts are inside the water jacket 6 Tap cylinder lightly with a plastic hammer in the reinforced areas only until loose 7 Rock cylinder forward and backward and lift it from the crankcase supporting piston and connecting rod Support piston with piston support block PN 2870390 8 Remove dowel pins from crankcase EH50PL ES33PF EH50PL Shown EH50PL ...

Page 219: ...y with a propane torch CAUTION Do not apply heat to the piston rings The ring may lose radial tension 3 Remove top compression ring Using a piston ring pliers Carefully expand ring and lift it off the piston CAUTION Do not expand the ring more than the amount necessary to remove it from the piston or the ring may break By hand Placing both thumbs as shown spread the ring open and push up on the op...

Page 220: ...ght edge and feeler gauge 3 Inspect cylinder for wear scratches or damage 4 Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge Measure in two different directions front to back and side to side on three different levels 1 2 down from top in the middle and 1 2 up from bottom Cylinder Warpage 002 05 mm 1 2 Down From Top of Cylinder 1 2 Up From Bottom X X Y Y X ...

Page 221: ...Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin 2 Subtract this measurement from the maximum cylinder measurement obtained in step 5 above Cylinder Taper Limit 002 Max Cylinder Out of Round Limit 002 Max Standard Bore Size Refer to Page 3 5 3 8 5 mm Piston Piston Pin Piston to Cylinder Clearance Refer to Page 3 5 ...

Page 222: ...roove clearance by placing the ring in the ring land and measuring with a thickness gauge Replace piston and rings if ring to groove clearance exceeds service limits Piston Pin Bore Refer to Specifications on Page 3 5 3 8 Piston Pin Measurement Locations Piston Pin O D Refer to Specifications on Page 3 5 3 8 Connecting Rod Small End I D Refer to Specifications on Page 3 5 3 8 Piston Ring to Groove...

Page 223: ...asured for excessive taper and out of round 3 If the bottom installed gap measurement exceeds the service limit replace the rings NOTE Always check piston ring installedgap afterre boring a cylinder or when installing new rings A re bored cylinder should always be scrubbed thoroughly with hot soapy water rinsed and dried completely Wipe cylinder bore with an oil rag immediately to re move residue ...

Page 224: ...ted at the rear of the drive mechanism 3 Inspect the thrust washer for wear or damage and replace if necessary 4 Measure the OD of the starter drive shaft on both ends and record 5 Measure the ID of the bushing in the recoil housing A and in the crankcase and record Measure in two directions 90 apart to determine if bushing is out of round Calculate bushing clearance Replace bushing if clearance e...

Page 225: ...er 2 Install flywheel puller PN 2870159 and remove flywheel CAUTION Do not thread the puller bolts into the flywheel more than 1 4 or stator coils may be damaged 3 Mark or note position of stator plate on crankcase 4 Remove bolts and carefully remove stator assembly being careful not to damage crankshaft bushing on stator plate 5 Replace crankshaft seal 6 Remove oil passage O Ring 7 Remove large s...

Page 226: ...o crankcase A 2 Remove blade and inspect for cracks wear or damage 3 Remove cam chain Inspect chain for worn or missing rollers or damage Stretch chain tight on a flat surface and apply a 10 lb 4 53 kg load Measure length of a 20 pitch section of chain Replace if worn past service limit A Chain Service Limit 5 407 13 7 cm ...

Page 227: ...parts One Way Valve The one way valve prevents oil from draining out of the oil tank and into the crankcase when the engine is off It must be clean and have adequate spring pressure in order to seal properly 1 Remove cap bolt sealing washer spring and one way valve from PTO side crankcase 2 Inspect free length of spring and check coils for distortion 3 Inspect valve for wear 4 Check seat area for ...

Page 228: ...ss drift through the hole in the crankcase if necessary to ensure the balancer shaft stays in the PTO side crankcase Watch the gap along the crankcase mating surface and separate the crankcase evenly It may also be necessary to tap the oil pump shaft lightly to separate the crankcase CAUTION Do not strike the oil pump shaft at an angle or the shaft may bend causing irreparable damage Tap only ligh...

Page 229: ...1 Remove pump shaft bearing A and thrust washer B from pump shaft 2 Remove pump drive gear C 3 Inspect drive gear teeth for cracks damage or excessive wear 4 Remove three oil pump retaining bolts and pump 5 Inspect mating surface of crankcase and oil pump Check for nicks burrs or surface irregularities A B C ...

Page 230: ...bly Cont 6 Remove the three screws and strainer screen from pump 7 Clean screen thoroughly 8 Remove pump body screw and feed chamber cover 9 Measure pump end clearance using a feeler gauge and straight edge Pump End Clearance Std 001 003 0254 0762 mm Wear Limit 004 1016 mm ...

Page 231: ...o all parts Do not use gasket sealer on the pump body mating surfaces or oil passages will become plugged 2 Install pump shaft and scavenge rotor drive pin 3 Install outer scavenge rotor inner scavenge rotor and scavenge casing 4 Install outer feed rotor and inner feed rotor drive pin 5 Install inner feed rotor and feed chamber cover with screw 6 Tighten screw securely 7 Install screen on pump bod...

Page 232: ...ase 4 Inspect the balancer drive gear and pump shaft drive gear 5 Replace the shaft if gear teeth are abnormally worn or damaged 6 Inspect the balancer shaft bearings NOTE Due to extremely close tolerances and minimal wear the balancer shaft ball bearings must be inspected visually and by feel Look for signs of discoloration scor ing or galling Turn the inner race of each bearing The bearings shou...

Page 233: ... or connecting rod 3 Use a feeler gauge to measure the connecting rod big end side clearance 4 Place the crankshaft in a truing stand or V blocks and measure the runout on both ends with a dial indicator Refer to page 3 40 5 Measure the connecting rod big end radial clearance 6 Inspect the crankshaft main bearing journals for scoring and abnormal wear Connecting Rod Big End Side Clearance Refer to...

Page 234: ...earings out of each crankcase 4 To remove balancer shaft bearings and pump shaft bearing use a blind hole bearing puller NOTE Bearings are stressed during the removal pro cess and should not be re used Pump Shaft Oil Seal Water Pump Mechani cal Seal Removal Engine Disassembled NOTE The water pump mechanical seal can be re moved without removing the engine Refer to Water Pump Mechanical Seal Instal...

Page 235: ...y are clean and not damaged Bearing Installation NOTE To ease bearing installation warm the crank case until hot to the touch Place the bearings in a freez er 1 Install the bearings so the numbers are visible 2 Drive or press new bearings into the crankcases using the proper driver CAUTION Press only on outer race of bearing to prevent bearing damage S 70mm 2 755 driver For crankshaft main bearing...

Page 236: ...ay may cause engine noise at idle and slow speeds Too little play will side load the bearings which may lead to premature bearing failure Crankshaft End Play Adjustment 1 Make sure all bearings are firmly seated in the both Mag and PTO crankcase 2 Measure the distance from the PTO crankcase mating surface to the main bearing using a dial caliper and a straight edge 3 Subtract the thickness of the ...

Page 237: ...readings recorded in Step 3 and Step 5 and record below Total Case Width 7 Measure the width of the crankshaft at the bearing seats with a micrometer or dial caliper and record Crankshaft Width 8 Subtract the Crankshaft Width measured in Step 7 from the Total Case Width recorded in Step 6 and record below Total End Play 9 Subtract the thickness of the existing shim from the result of step 8 to det...

Page 238: ...dial caliper and a straight edge Subtract the thickness of the straightedge and record 4 Measure the distance from the PTO crankcase mating surface to the bearing using the same method outlined in Step 1 2 and 3 5 Add the readings obtained in Step 3 and Step 4 6 Subtract the counter balancer shaft width measured in step 2 from the figure obtained in step 5 7 Subtract the thickness of the existing ...

Page 239: ... measure the width of the pump and gear Subtract this measurement from the measurement recorded in Step 2 4 Subtract the thickness of the existing shim from the result of Step 3 to determine if a different shim is needed Pump Shaft Oil Seal Installation 1 Install the seal from the outside of the crankcase water pump side with the spring facing inward toward the pump shaft bearing 2 Drive or press ...

Page 240: ...the proper shim washer on the shaft 5 Inspect the oil pump sealing surface on the crankcase Apply a light film of engine oil to the surface and install the oil pump NOTE Do not use gasket sealer on the pump mating surfaces 6 Align the drive gear with the drive pin on the pump shaft and install the gear Be sure the gear is fully seated and properly engaged 7 Install the proper shim washer on the pu...

Page 241: ...n EH42PL EH50PL engines without removing the engine and splitting the cases CAUTION Improper or careless use of this tool or procedure can result in a bent water pump shaft Pump shaft replacement requires engine removal and crankcase separation Use caution while performing this proce dure Make sure that the puller is parallel to the shaft at all times Do not place side loads on the water pump shaf...

Page 242: ...the split between the puller legs is fully sup ported by the main body of the tool Ill 4 5 Tighten the hex socket screws on the puller legs suffi ciently so the lip of the puller legs will grasp the me chanical seal Ill 5 6 Turn the puller T Handle clockwise until it contacts the water pump shaft Continue rotating until the remaining portion of mechanical seal has been removed from the cases Ill 6...

Page 243: ...n Drive Sprocket Installation 1 Install the Woodruff key drive sprocket and slotted nut Tighten the nut tothe specifiedtorque Tensioner Blade Installation 1 Install the tensioner blade and tighten the mounting bolt to specified torque One Way Valve Plug Torque 16 ft lbs 2 2 kg m A B Slotted Nut Torque 35 51 ft lbs 4 71 6 86 kg m Tensioner Blade Mounting Bolt Torque 6 ft lbs 828 kg m ...

Page 244: ...lean any accumulated carbon from the ring grooves and oil control ring holes 1 Place the oil control ring expander in oil ring groove with the end gap facing forward The expander has no up or down marking and can be installed either way The ends should butt squarely together and must not overlap 2 Install the oil ring top rail NOTE The top rail has a locating tab to prevent rota tion The tab must ...

Page 245: ...the piston with the end gap facing up or down and tang outward CAUTION Circlips become deformed during the removal process Do not re use old circlips Do not compress the new clip more than necessary upon installation to prevent loss of radial tension Severe engine damage may result if circlips are re used or deformed during installation 4 Apply clean engine oil to the piston rings ring lands pisto...

Page 246: ...he ring compressor Snap On PN RCL30 and install the compressor following manufacturers instructions CAUTION Make sure the oil control ring upper rail tab is positioned properly in the notch of the piston Verify all ring end gaps are correctly located 3 Apply clean engine oil liberally to the cylinder bore and tapered area of the sleeve Install the cylinder with a slight rocking motion until the ri...

Page 247: ...finger tight Rotate the engine and position the piston at BDC NOTE If cam chain is installed hold it up while rotating the engine to avoid damage to the chain drive sprocket teeth or tensioner blade 8 Tighten the cylinder bolts in three steps ina crisscross pattern and torque to specifications 9 Install the two 6mm bolts Cylinder Bolt Torque 10mm 46 ft lbs 6 348 kg m 6mm 6 ft lbs 828 kg m ...

Page 248: ...ead gasket 3 Place the cylinder head on the cylinder Apply a film of engine oil to the cylinder head bolt threads and washers and hand tighten the bolts The following procedure must be used to torque the cylinder head properly Torque all bolts evenly in a criss cross pattern Torque bolts to 22 ft lbs 3 04 kg m Torque bolts to 51 ft lbs 7 04 kg m Loosen bolts evenly 180 1 2 turn Loosen bolts again ...

Page 249: ...Starter Drive grease to the camshaft main journals and cam lobes Lubricate automatic compression release mechanism with clean engine oil To install the compression release mechanism refer to page 3 57 2 Install the camshaft with the lobes facing downward and the sprocket alignment pin facing upward 3 Disconnect the wire from the cam chain and rotate the engine to align the single TDC timing mark T...

Page 250: ...ocket on the camshaft Apply Loctite 242 to the cam sprocket bolts and torque to specifications 7 Verify TDC mark in timing inspection hole and alignment pin is directly in line with crankshaft to camshaft centerline Refer to Ill on following page 8 Apply Loctite 515 or 518 Gasket Eliminator or 3 Bond 1215 to the camshaft end cap and install using a new O Ring 9 Check all cam timing marks to verify...

Page 251: ...6 Polaris Sales Inc 4 99 ENGINE ES33PF EH50PL Engine Assembly Camshaft Timing Single TDC Mark Aligned Crankshaft to Camshaft Centerline Sprocket Alignment Pin Do Not Use Advance Marks Rotation TDC Mark Dots ...

Page 252: ... can be assembled with the engine in the frame Stator 1 Apply a light film of grease to the crankshaft seal Apply molybdenum disulfide grease or assembly lubricant to the crankshaft bushing 2 Install a new O Ring in the oil passage recess in the crankcase 3 Apply 3 Bond 1215 Loctite 515 or 518 or an equivalent sealer to the stator plate outer surface and install a new O Ring 4 Install the stator p...

Page 253: ...que flywheel to specification Starter Drive 1 Be sure the washer is positioned on the back of the drive gear 2 Apply grease to the drive bushing in thecrankcase and all moving surfaces of the starter drive mechanism Install the starter drive 3 Install recoil housing gasket and recoil housing Stator Plate Bolt Torque 5 1 6 5 ft lbs 68 88 kg m Flywheel Nut Torque 58 72 ft lbs 7 85 9 81 kg m Starter ...

Page 254: ... evenly 7 Adjust valves according to the valve adjustment procedure found in Chapter 2 Maintenance 8 Apply clean engine oil liberally to the valve springs cam chain rocker arms and camshaft 9 Place a new rocker cover gasket on the cylinder head and install the cover and bolts Thermostat Installation Install the thermostat with one of the air bleed holes positioned next to the upper thermostat cove...

Page 255: ...proper tension and the handle for cracks or damage which may allow water or dirt to enter the recoil housing through the rope NOTE The handle must seal tightly on the recoil housing to prevent water from entering 3 Remove center bolt from recoil friction plate A 4 Inspect plate for wear or damage Inspect plate friction spring for wear damage and proper tension The spring should fit tightly on fric...

Page 256: ...pproximately 6 7 turns until spring tension is released 8 Slowly and carefully remove reel from recoil housing making sure the spring remains in the housing Inspect the reel hub and bushing A for wear 9 Unwind rope and inspect for cuts or abrasions 10 Inspect drive tab on hub return spring for damage To remove hub return spring hold outer coils in place with one hand and slowly remove spring one c...

Page 257: ... side of reel 3 Lock rope into notch on outer edge of reel 4 Apply a small amount of grease or equivalent to the center post of the housing and the bushing 5 Install reel into housing making sure the spring drive tab on the reel engages the spring and the reel is fully seated in the housing 6 Apply downward pressure on the reel and rotate counterclockwise approximately 6 7 turns to pre wind the sp...

Page 258: ...poor old or octane too high S Low compression S Restricted exhaust S Weak ignition loose coil ground faulty coil stator or ETC switch S ETC switch mis adjusted S Oil line check valve leaking Spark Plug Fouling 4 Stroke Engines S Spark plug cap loose or faulty S Choke cable adjustment or plunger cable sticking S Foreign material on choke plunger seat or plunger S Incorrect spark plug heat range or ...

Page 259: ...rrect ignition timing Restricted exhaust system Replace cable Clean or repair air intake Jet as per jetting chart Repair ETC refer to ETC troubleshooting Repair reverse speed limiter refer to reverse speed limiter troubleshooting chart Check and adjust ignition timing Repair or replace exhaust system Engine has low power Cylinder piston and ring wear or damage check compression PVT not operating p...

Page 260: ...ting for altitude temperature S Inoperative fan or low fan RPM check fan motor amp draw should be less than 6 5 amps low bat tery fan switch or connections wiring S Cooling system cooling fins radiator fins restricted air flow obstructed S Incorrect piston to cylinder clearance S Air leaks in intake tract air intake ducts mounting flange damaged or loose S Foreign material ingestion S Air in oil p...

Page 261: ...n S Crankcase breather restricted Engine Idles But Will Not Rev Up S Spark plug fouled weak spark S Broken throttle cable S Obstruction in air intake S Air box removed reinstall all intake components S Incorrect or restricted carburetor jetting S ETC switch limiting speed S Reverse speed limiter limiting speed S Carburetor vacuum slide sticking diaphragm damaged S Incorrect ignition timing S Restr...

Page 262: ...n leaking broken or sticking S Bent valve or stuck valve S Valve spring broken or weak S Valve not seating properly bent or carbon accumulated on sealing surface S Rocker arm sticking Backfiring S ETC or speed limiter system malfunction S Fouled spark plug or incorrect plug or plug gap S Carburetion faulty lean condition S Exhaust system air leaks S Ignition system faulty Spark plug cap cracked br...

Page 263: ...ixture restricted jets vents fuel pump or fuel valve S Fuel pump output weak S Restricted radiator internally or cooling fins S Water pump failure S Cooling system restriction S Cooling fan inoperative or turning too slowly perform current draw test S Ignition timing misadjusted S Low oil level S Spark plug incorrect heat range S Faulty hot light circuit S Thermostat stuck closed or not opening co...

Page 264: ...2 Cycle 4 16 Needle and Seat Leakage Test 2 Cycle 4 16 Exploded View Mikuni VM 30 34 SS Carburetor 4 17 4 Cycle Section CV Carburetor System Function 4 Cycle 4 18 CV Carburetor Vent System 4 Cycle 4 18 CV Carburetor Operation 4 19 4 21 Exploded View Mikuni BST 34 Carburetor 4 22 Exploded View Mikuni BST 40 Carburetor 4 23 Disassembly Notes CV Carburetor 4 24 4 25 Cleaning CV Carburetor 4 26 Inspec...

Page 265: ......

Page 266: ...ng charts should be used as a guideline for selecting optimum jetting for varying temperature and altitude conditions Air screw or fuel screw adjustment will affect mixture from approximately idle to 1 4 throttle setting Refer to Maintenance Chapter 2 for complete adjustment procedure and the following guidelines for minor altitude adjust ments Air Screw 2 stroke models Turn the air screw in clock...

Page 267: ...or Oil Filter Typical 2 Cycle model with tank mounted fuel valve Details vary by model Refer to parts manual Fuel tank mounted valve Forward Forward 4 Polaris Sales Inc 4 99 FUEL SYSTEM CARBURETION Fuel Tank Assembly Oil Tank Assembly ...

Page 268: ...steering post Forward 2 Res 1 ON Outlet 1 ON Reserve Silver fitting short stand pipe to Res marked 2 on fuel valve 2 Reserve Tank to fuel valve connection Gold fitting tall stand pipe to ON marked 1 on fuel valve Typical 2 Cycle or 4 Cycle model with frame mounted fuel valve Details vary by model 4 3 Polaris Sales Inc 4 99 FUEL SYSTEM CARBURETION Fuel Tank Assembly ...

Page 269: ...uel Filter Carburetor Fuel System Diagram 2 Stroke Models Fuel Tank Vent Carburetor Vent Fitting Screens Fuel Tank Fuel Valve Engine Filter Fuel Pump Carburetor Fuel System Diagram 4 Stroke Models Fuel Tank Vent Carburetor Vent Fitting Screens L L 325 425 Under Headlamp Cover 335 500 Above Oil Tank ...

Page 270: ...5 3130122 200 3130123 210 3130124 220 3130125 230 3130126 240 3130127 250 3130128 260 3130129 270 3130130 280 3130131 290 3130132 300 3130133 310 3130134 320 3130135 Main Jet Part Numbers 4 Cycle Mikuni BST Carburetor Jet Number Part Number 112 5 3130554 115 3130555 117 5 3130556 120 3130557 122 5 3130558 125 3130559 127 5 3130560 130 3130561 132 5 3130562 135 3130563 137 5 3130564 140 3130527 142...

Page 271: ...r Oil Filter Typical 2 Cycle model with tank mounted fuel valve Details vary by model Refer to parts manual Fuel tank mounted valve Forward Forward 4 6 Polaris Sales Inc 4 99 FUEL SYSTEM CARBURETION Fuel Tank Assembly Oil Tank Assembly ...

Page 272: ...supply and changing the mixture ratio Air Fuel Mixture Ratio A carburetor with a piston type throttle valve is also called a variable venturi type carburetor In this type of carburetor the needle jet and jet needle serve to control a proper air fuel mixture ratio at the medium throttle valve opening be tween 1 4 and 3 4 opening Having the proper needle jet and jet needle has a major impact on engi...

Page 273: ...mixture Moving the clip higher pro duces a leaner mixture If the taper is worn due to vibration fuel flow may be significantly affected Needle Jet The needle jet works in conjunction with the jet needle to regulate fuel flow rate An air bleed opening in the side of the needle jet brings in air measured by the air jet This air initiates the mixing and atomizing process inside the needle jet Mixing ...

Page 274: ...according to the size of the cutaway The higher the number the leaner the gasoline air mixture Main Jet When the throttle opening becomes greater and the area between the needle jet and jet needle increases fuel flow is metered by the main jet The number on the jet indicates the amount of fuel CCs which will pass through it in one minute under controlled conditions Larger numbers give a greater fl...

Page 275: ...ows into the plunger area mixes again with air coming from the air intake port for starting and is delivered to the engine through the fuel discharge nozzle in the optimum air fuel ratio The starter is opened and closed by means of the starter plunger The starter type carburetor is constructed to utilize the negative pressure of the inlet pipe so it is important that the throttle valve is closed w...

Page 276: ...nge Fuel for the pilot jet is drawn from the float bowl mixed with air regulated by the air screw and delivered to the engine through the pilot outlet The mixture is regulated to some degree by adjusting the air screw When the air screw is closed the fuel mixture is made richer as the amount of air is reduced When the air screw is opened the mixture is made more lean as the amount of air is increa...

Page 277: ... less resistance to air flow A flat angle would provide a much richer mixture because there is more resistance to air flow The venturi shape can be adjusted for each engine s breathing characteristics by using a different valve cutaway angle A number will be stamped into the bottom of the valve e g 2 5 indicating the size of the cutaway The higher the number the steeper the angle Air Jet Throttle ...

Page 278: ...tion of the E clip on the needle Moving the clip down raises the needle in the jet passage and richens the mixture Moving the clip up lowers the needle in the jet passage and leans the mixture Letter and number codes are stamped into the needle and the jet indicating sizes and tapers of each Air Jet Throttle Valve Jet Needle By pass Pilot Outlet Pilot Jet Needle Jet Main Jet Clip Position Shown in...

Page 279: ...edle jet system During low speed driving there is very little clearance between the jet needle and the needle jet therefore very little fuel from the main jet can pass between the jet needle and the needle jet As the throttle valve opening is increased the tapered jet needle is raised farther out of the needle jet allowing greater fuel flow Under full throttle opening the cross sectioned area of c...

Page 280: ...n jet affects fuel delivery at 1 4 throttle and consistently increases to full throttle opening Carburetor Component Function 2 Cycle System Main Components Main Function Main Affect Float System Fuel Level Control Inlet Pipe Needle and Seat Floats Float Pins Maintains specified fuel lev el in float chamber carbure tor float bowl All systems All throttle ranges Venting Vent Passages in Carbure tor...

Page 281: ...tongue lightly on the inlet needle valve pin without compressing the spring 3 Measure height from float bowl mating surface to float arm as shown Both sides of float arm must be parallel to each other Use float adjustment tool PN 2872314 or a vernier caliper When measuring height be sure inlet needle valve spring is not compressed If adjustment is necessary bend the tongue slightly Needle and Seat...

Page 282: ...sher Assy 17 Main Jet 18 O Ring 19 Drain Plug 20 Float Bowl 21 Float 22 Cap 23 Gasket 24 Valve Inlet Needle 25 Arm Float 26 Pin Float 27 Gasket Inlet Valve 28 Carb Body Assy 1 30 29 Needle Jet 30 E Clip 2 Cycle Mikuni VM30SS VM34SS Carburetor Exploded View Refer to Page 4 8 for Jet Part Numbers 1 2 3 4 5 Jet Needle E Clip Position 4 6 5 3 2 1 7 8 9 10 11 12 13 15 27 28 29 30 No Flow Flow To Carbur...

Page 283: ...mixture necessary for cold starting All throttle ranges Greatest effect at low throttle settings and idle Pilot Idle System Pilot Jet Passageways Pilot Mixture Screw with Spring Washer and Sealing O Ring Bypass Ports Behind Throttle Plate Pilot Air Jet Pilot Outlet Throttle Plate Primarily supplies fuel at idle and low throttle settings Mainly idle to 1 4 throttle Minimal effect after 1 2 throttle...

Page 284: ...m slide dampens the slide movement and assists the return of the slide When the throttle plate is opened and engine speed begins to increase the pressure in the venturi and therefore in the chamber above the diaphragm becomes significantly lower than atmospheric Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward raising the slide against spring pressure When the pr...

Page 285: ...ed by pilot screw and dis charged into the main bore through pilot outlet 7 Starter System Choke or Enrichment When the choke cable 1 is activated the starter plunger 5 is lifted off the seat Fuel is drawn into the starter circuit from the float chamber 2 through the starter jet 3 Starter jet meters this fuel which then flows into starter pipe 4 and mixes with the air 7 coming from the float chamb...

Page 286: ... the chamber In this manner the needle valve admits and shuts off fuel alternately to maintain a practically constant fuel level inside the float chamber 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 ...

Page 287: ...crew 22 Drain Screw 23 O Ring 24 Washer 25 Adjuster 26 Spring 27 Pilot Jet 28 Main Jet 29 Washer 30 Jet Needle 31 Float Assembly 32 Float Body Assembly 33 Float Pin 34 Needle Valve 35 O Ring 36 O Ring 37 Filter 38 Screw 39 Screw 40 Screw 41 Guide Holder 42 Spring 43 Plunger Assembly 44 Spring Washer 45 Screw 46 Air Jet 47 Cable Guide 48 Spring 49 Ring 50 Adjust Screw 51 Screw and Washer Assy Mikun...

Page 288: ... E Clip 5 Spacer 6 Jet Needle 7 Diaphragm Assembly 8 Throttle Valve 9 Cable Guide 10 Spring 11 Adjuster Cable 12 Drain Plug 13 O Ring 14 Jet Main 15 Spacer Ring 16 Drain Screw 17 O Ring 18 Float Assembly 19 Plug 20 Pilot Screw 21 Spring 22 Washer 23 O Ring 24 Pilot Jet 25 Valve Inlet Needle 26 Shaft Seal 27 O Ring 28 Air Jet 29 Choke Plunger Guide 30 Spring 31 Choke Plunger 32 Cap 33 O Ring 34 Jet...

Page 289: ...carburetor diaphragm chamber cover with a ratchet style screwdriver DO NOT use an impact driver to remove the screws or carburetor may be permanently damaged 2 Use a small spring loaded center punch to remove pressed float pin 3 Remove inlet needle seat retaining screw along with plate and carefully remove needle seat NOTE Do not use a pliers to remove the seat or permanent damage may occur ...

Page 290: ... Mikuni CV 4 Do not misplace the pilot mixture screw spring flat washer or O Ring If anti tamper plug is installed in pilot screw cavity refer to Maintenance chapter 2 for removal procedure 5 NOTE The starter jet is not removeable O Ring Washer Spring Pilot Screw Starter Jet ...

Page 291: ...Rings in caustic cleaning solutions Irreparable damage may occur Do not use agitator type carburetor cleaning equipment Rubber parts must be cleaned with mild detergent and hot water only 2 If the carburetor is extremely dirty or contaminated with fuel residue and varnish soak for short periods only in carburetor cleaner and rinse in hot water 3 Replace the jets if they are extremely dirty or have...

Page 292: ...le to upper portion of the needle where it contacts the needle jet is the most likely wear point If jet needle shows signs of wear replace both needle and needle jet to prevent a rich condition 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 afte...

Page 293: ...e installed below the E Clip Refer to parts manual for more information 3 Be sure the tab E on outer edge of diaphragm is positioned properly in the carburetor body 4 Install the pilot mixture screw spring washer and O ring as an assembly Lubricate the O Ring with oil or light grease before installation CAUTION Do not damage the O ring during installation Turn the screw in until it lightly contact...

Page 294: ...m 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 the height be sure the inlet needle valve spring is not compressed 3 If adjustment is necessary bend the tongue slightly Be sure fl...

Page 295: ...lows you to observe the height of the fuel in the float bowl without removing the carburetor The fuel level can be ob served with the engine either running or shut off however engine must run briefly to allow fuel level to stabilize Be sure to review all fuel warnings on page 4 41 and 4 44 1 Attach a clear line to drain fitting Be sure line fits tightly on fitting Position hose along side of carbu...

Page 296: ...ation on following 2 Remove the screws from the pump diaphragm cover Note the location of the two longer screws 3 Remove the diaphragm cover gasket diaphragm and valve body gasket 4 Remove the outlet check valve cover diaphragm and gasket Fuel Pump Inspection Assembly 1 Inspect inlet and outlet check valves for cracks warpage or damage Inspect the diaphragms for cracks holes or swelling 2 To clean...

Page 297: ... CARBURETION Fuel Pump Fuel Pump Exploded View 3 2 1 5 5 4 1 Fuel Pump Assembly 2 Diaphragm Gasket Set 3 Screw and Washer Assembly 4 Screw and Washer Assembly 5 Screw and Washer Assembly 6 Pressure Regulator 7 Fuel Inlet 8 Fuel Outlet 6 8 7 ...

Page 298: ...d or sticky 4 Strokes S Improper spring 4 Strokes S Jet needle position incorrect S Incorrect pilot screw adjustment Rich Mixture Symptoms Fouls spark plugs black sooty exhaust smoke rough idle poor fuel economy engine runs rough misses poor performance bog engine loads up backfire S Air intake restricted inspect intake duct S Air filter dirty plugged S Choke plunger sticking incorrectly adjusted ...

Page 299: ...ming incorrect S Worn jet needle needle jet Erratic Idle S Choke cable bending or incorrectly adjusted S Throttle cable incorrectly adjusted S Air leaks dirty carburetor passages pilot circuit S Pilot mixture screw damaged or adjusted incorrectly S Tight valves S Ignition timing incorrect S Belt dragging S Dirty air cleaner S Engine worn S Spark plug fouled S Idle speed set incorrectly speed limit...

Page 300: ... Exploded View 4x4 6x6 Models 5 12 A Arm Replacement 5 13 Concentric Swingarm Removal 5 14 Concentric Swingarm Assembly Installation 5 15 Swing Arm and Rear Suspension Exploded View 5 16 Shaft Ride Rear Suspension Exploded View 5 17 Shaft Ride Swingarm Removal Installation 5 18 Independent Rear Suspension Exploded View 5 19 Rear Strut Stabilizer Exploded View 6x6 5 20 Rear Swing Arm Weldment Explo...

Page 301: ......

Page 302: ... Wheel Nuts Shaft Drive Models 15 ft lbs 21 Nm Strut Rod Retaining Nut Top 15 ft lbs 21 Nm Strut Casting Pinch Bolt 15 ft lbs 21 Nm Swing Arm Pivot Bolt standard swingarm 55 ft lbs 76 Nm Swing Arm Pivot Bolt concentric swingarm 150 ft lbs 207 Nm Tie Rod End Jam Nut 12 14 ft lbs 17 19 Nm Tie Rod End Castle Nut 23 24 ft lbs 32 33 Nm Tie Rod End Attaching Bolt 25 30 ft lbs 35 41 Nm NOTE Refer to expl...

Page 303: ...TEERING SUSPENSION Body Assembly Exploded View Gen ll Typical Rear Cab Assembly Front Cab Assembly Headlight Cover Fuel Tank Cover Seat Side Cover Front Cab All warning information labels must be in place when body parts are assembled ...

Page 304: ... at rear of cover 1 screw on left front 1 screw on right front Disconnect headlamp wiring harness Radiator cap access panel Turn fastener at front 1 4 turn Rear rack Remove Seat 2 bolts nuts and washers at rear of rack 2 bolts nuts and washers at front of rack Rear cab assembly Remove Seat Rear rack 3 screws nuts and washer plate at rear of left footrest 2 screws nuts and washer plate at rear of r...

Page 305: ...aris Sales Inc 4 99 BODY STEERING SUSPENSION Body Assembly Exploded View Gen lll Typical Rear Cab Assembly Front Cab Assembly Seat Release Latch Mud Flap Front Cab Front Cover Panel or Headlight Cover Mud Flap ...

Page 306: ...Seat 3 screws nuts and washer plate at rear of left footrest 2 screws nuts and washer plate at rear of right footrest 4 bolts and flat washers from top of cab assembly 2 screws at rear of muffler guard 2 screws at rear of front cab on each side Disconnect taillight harness Front cab assembly Remove Seat Fuel tank cap Headlight cover 3 screws nuts and washers from left footrest 2 screws nuts and wa...

Page 307: ...ody Assembly Exploded View Gen lV Typical 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 ...

Page 308: ...sembly Remove Seat Rear rack 1 screw nut and washer at rear of inner left footrest 4 screws at bottom of left rear mudflap 1 screw nut and washer at rear of inner right footrest 4 screws at bottom of right rear mudflap 4 bolts and flat washers from top of cab assembly under seat 2 screws at rear bottom of cab assembly near tail light Disconnect taillight harness Front rack Remove 4 screws lock was...

Page 309: ...rews securing bottom half of pod Assembly S Install bottom of pod onto handlebar and secure to brackets S Install key switch choke cable and headlight S Connect indicator light wire coupler to indicator lights in top half of pod S Connect speedometer cable to speedometer where applicable S Install top of pod onto bottom half making sure interlocking tabs mate properly S Install two front Phillips ...

Page 310: ...ce hand on top of side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two tabs Then pull up on side panel to disengage front upper and lower tab 3 To reinstall side panel align panel tabs with slots on front cab Push panel upward and forward until tabs lock Bend rear of side panel and insert the two tabs into the rear cab Pull forward ...

Page 311: ...d other steering components be sure to install stud ends correctly Both sides must be installed as shown with inner rod end stud pointing DOWN on the steering post and the outer rod end pointing UP through the strut casting Always use new patch lock bolts upon reassembly Always use new cotter pins upon reassembly 23 24 ft lbs 32 33 Nm 30 ft lbs 41 Nm 25 ft lbs 35 Nm Loctite 242 8 ft lbs 11 Nm ...

Page 312: ...m 30 ft lbs 41 Nm NOTE 2x4 Models Except 1999 Trail Boss250 To avoid damage to tie rods and other steering components be sure to install tie rod end stud in the proper direction Both sides must be installed as shown with inner rod end positioned beneath the lower steering post arm and outer rod end stud pointing DOWN through the strut casting Steering Post Arm Steering Post Bolt pointing UP Rod en...

Page 313: ...nner rod end must be placed between the steering post arms The Left inner rod end must be below the lower arm as shown Both outer rod end studs must point DOWN through the strut casting Always use new bolts upon reassembly Always use new cotter pins upon reassembly B A Steering Post Steering Post Arm 25 30 ft lbs 35 41 Nm 23 24 ft lbs 32 33 Nm Loctite 242 8 ft lbs 11 Nm 25 ft lbs 35 Nm 30 ft lbs 4...

Page 314: ...g m WARNING The locking features on the existing bolts were destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during opera tion 8 Attach A arm to hub strut assembly Tighten ball joint nut to 25 ft lbs 35 Nm If cotter pin holes are not aligned tighten nut slightly to align Installa newcotter pin with open ends toward rear of machine Bend bo...

Page 315: ...h bolts while supporting swingarm 7 Remove swingarm 8 Remove LH pivot bushing 7 and swingarm bushing 6 from swingarm 9 Place flats of right side pivot bushing 4 in a vise to hold while removing nut 1 10 Remove two piece bushing 3 and RH pivot bushing 4 from swingarm 11 Clean and inspect parts for wear Replace worn parts 5 Pivot Bolt 4 Pivot Bushing Right Place flats of pivot bushing in vise to hol...

Page 316: ... and torque nut 1 to 150 ft lbs 207 Nm 5 Install left pivot bushing 7 Note There are stop plates attached to the inside of the frame to prevent the pivot bushings from turning when the pivot bolts are tightened The flats of the pivot bushings must be oriented correctly to align with the frame plate or the pivot bolt holes will not be aligned The top flat on the nut should be approximately parallel...

Page 317: ...5 16 Polaris Sales Inc 4 99 BODY STEERING SUSPENSION Standard Swing Arm and Rear Suspension Exploded View 25 ft lbs 35 Nm 60 ft lbs 83 Nm 55 ft lbs 76 Nm 25 ft lbs 35 Nm 55 ft lbs 76 Nm ...

Page 318: ...5 17 Polaris Sales Inc 4 99 BODY STEERING SUSPENSION Shaft Ride Swingarm Exploded View ...

Page 319: ... firmly seated against bearing S With tool in place torque left side pivot bolt to 14 ft lbs 19 Nm S Torque right side pivot bolt to 14 ft lbs 19 Nm Try to remove spacer tool If tool cannot be removed tighten right side pivot bolt an additional 1 4 turn Remove tool If tool cannot be removed repeat process S Apply Loctite 242 Blue to exposed threads of pivot bolts and lock nuts S Torque lock nuts t...

Page 320: ... check model number for correct replacement parts Be sure fasteners are properly torqued Forward 17 ft lbs 24 Nm 35 ft lbs 48 Nm Upper Control Arm Index Bushings Correctly 30 ft lbs 41 Nm 30 ft lbs 41 Nm Lower Control Arm 35 ft lbs 48 Nm 100 ft lbs 48 Nm 15 ft lbs 21 Nm 17 ft lbs 24 Nm 35 ft lbs 48 Nm 30 ft lbs 41 Nm ...

Page 321: ...5 20 Polaris Sales Inc 4 99 BODY STEERING SUSPENSION Rear Strut Stabilizer 6x6 Models 30 ft lbs 41 Nm 30 ft lbs 41 Nm 30 ft lbs 41 Nm Grease Fittings ...

Page 322: ... Models S Rear strut 1 and weldment 2 can only be replaced as an assembly They are pressed and welded together at the factory and cannot be disassembled S Grease fittings 3 and 4 Check lubrication guide for service intervals 1 2 18 ft lbs 25 Nm 60 ft lbs 83 Nm Guide 16 ft lbs 22 Nm ...

Page 323: ...5 22 Polaris Sales Inc 4 99 BODY STEERING SUSPENSION Front Swing Arm Weldment 6x6 Models 55 ft lbs 76 Nm 55 ft lbs 76 Nm 17 ft lbs 24 Nm ...

Page 324: ...View 2x4 Models Nut 15 ft lbs 21 Nm Washer Spacer Rubber Upper Pivot Ball Lower Pivot Ball Spacer Nut Spring Retainer Spring Strut Bumper Strut Cartridge Spring Retainer Washer Strut Housing Clamp Ball Joint Grease Fitting Washer Lock Nut Bolt Washer Spindle 15 ft lbs 21 Nm 2x4 ...

Page 325: ...o not match strut replacement will be necessary Grease fitting 2 location Check lubrication guide for recommended service intervals Specified pole gap is 0 001 0 0254mm 1 2 15 ft lbs 21 Nm Nut 15 ft lbs 21 Nm 18 ft lbs 25 Nm Seal Sleeve Install Using tool PN 2871199 Washer Upper Pivot Ball Lower Pivot Ball Washer Spacer Rubber Spring Retainer Spring Bolt Spacer Washer Clamp Wire retainer Hub Coil ...

Page 326: ...pring and collapse strut cartridge 5 Remove two pinch bolts from strut casting 6 Remove strut cartridge 7 Install cartridge until bottomed in strut casting 8 Install pinch bolts with wire clamp s Torque pinch bolts to 15 ft lbs 21 Nm 9 Reassemble spring and top pivot assembly Be sure all parts are installed properly and seated fully 10 Torque strut rod nut to specification Do not over torque nut S...

Page 327: ...ut housing Refer to photos at right S Install puller guide A with extension cap B S Apply grease to extension cap and threads of puller bolt to ease removal S Thread bolt D with nut C ontoball joint stud as shown S Hold bolt D and turn nut C clockwise until ball joint is removed from strut housing 8 To install new ball joint S Remove extension cap and attach puller guide using short bolts provided...

Page 328: ...plorer 400 Springs Burnished Brown Rims Brushed Aluminum N A N A Scrambler 400 Springs Fire Red 72060 8520149 Rims Bright White 2185 8520153 S bl 500 S i Fi R d 72060 8520149 Scrambler 500 Springs Fire Red 72060 8520149 Scrambler 500 Springs Fire Red 72060 8520149 p g Magnum 500 Springs Black 9440 8520147 Rims Brushed Aluminum N A N A Sportsman 500 Springs Front AA Black 9440 8520147 Springs Front...

Page 329: ...20147 Rims AB Aluminum N A N A Xplorer 400 Springs Burnished Brown Rims Aluminum N A N A Scrambler 400 Springs Fire Red 72060 8520149 Rims Bright White 2185 8520153 Xpedition 425 Springs Black 9440 8520147 Rims Black 9440 8520147 Magnum 500 Springs Black 9440 8520147 Rims Aluminum N A N A Scrambler 500 Springs Fire Red 72060 8520149 Scrambler 500 Springs Fire Red 72060 8520149 Rims Aluminum N A N ...

Page 330: ...owing procedure involves the use of an open flame Perform this procedure in a well ventilated area away from gasoline or other flammable materials Be sure the area to be flame treated is clean and free of gasoline or flammable residue To flame treat the decal area 1 Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appears sli...

Page 331: ...NOTES ...

Page 332: ...iew 6 14 Drive Clutch Disassembly Inspection 6 15 6 17 Drive Clutch Assembly 6 18 6 19 Drive Belt Tension 6 22 Drive Belt Removal Inspection 6 23 Clutch Alignment Offset 6 24 Drive Clutch Bushing Service 6 26 6 29 Driven Clutch Disassembly Inspection 6 30 6 32 Driven Clutch Assembly 6 33 Driven Clutch Bushing Service 6 34 6 37 EBS Introduction 6 40 EBS Operation Guidelines 6 41 EBS Exploded View 6...

Page 333: ......

Page 334: ...ushing Removal Installation 2871226 Piston Pin Puller Also used with 2871226 2870386 Loctitet 680 2870584 RTV Silicone Sealer 2870661 Loctite Gasket Remover 2870601 PVT System Fastener Torques Drive Clutch Retaining Bolt 40 ft lbs Driven Clutch Retaining Bolt 17 ft lbs PVT Inner Cover Bolts 12 ft lbs Drive Clutch Spider Standard Clutch 200 ft lbs Drive Clutch Spider EBS Clutch 185 ft lbs Drive Clu...

Page 335: ... spinning sheaves and cause the drive belt to move This movement in turn rotates the driven clutch At light throttle settings the drive belt will stay low in the drive clutch and high in the driven clutch As engine RPM increases so does the centrifugal force on the shift weights causing the drive belt to be forced upward in the drive clutch and downward into the driven clutch The forces in the dri...

Page 336: ...catedat ahigh point on the vehicle location varies by model The intake duct draws fresh air through a vented cover All connecting air ducts as well as the inner and outer covers must be properly sealed to ensure clean air is being used for cooling the PVT system and also to prevent water and other contaminants from entering the PVT area This is especially critical on units subjected to frequent wa...

Page 337: ...3 Remove PVT air outlet duct hose 4 Remove outer cover screws and clamps Refer to pages 6 7 6 9 5 Mark the drive belt direction of rotation and remove drive belt The belt is normally installed so the numbers can be easily read To remove drive belt apply brake pull upward and rearward on belt to open driven clutch sheaves push down on belt to hold sheaves open and slip belt over driven clutch outer...

Page 338: ... clutch offset spacers from the transmission input shaft 9 Bend back retainer tabs on three screws at the front of the inner cover where applicable Remove screws and retainer plate 10 Remove inner cover retaining bolts at rear of cover 11 Remove cover along with foam seal on back of coveror shaft Driven Clutch Puller PN 2870913 Keep Spacers In Order ...

Page 339: ...of grease to the splines on the shaft 11 Install the driven clutch washer lock washer and retaining bolt Torque to specification 12 Clean end of taper on crankshaft and the taper bore inside drive clutch 13 Install drive clutch and torque retaining bolt to specification 14 Reinstall drive belt noting direction of rotation If a new belt is installed install so numbers can be easily read 15 Replace ...

Page 340: ...Sales Inc 4 99 CLUTCH Sealing and Ducting Components PVT Sealing and Ducting Components Inlet Duct Outer Cover Seal Outer Cover Exhaust Duct Inner Cover Inner Cover Seal Retainer Typical of Gen ll 4 strokes Type ll ...

Page 341: ...Ducting Components PVT Sealing and Ducting Components Type lll Type lV Typical of Gen lll Liquid Cooled Scrambler Sport Typical of Gen lV Air Cooled Xpress Xplorer 300 Gen ll and Gen lll Air Cooled Trail Boss Trail Blazer Trail Boss 1996 Trail Boss ...

Page 342: ...6 9 Polaris Sales Inc 4 99 CLUTCH Sealing and Ducting Components Type lV To Engine Typical of Gen lV 4 Strokes Sportsman 500 Xplorer 500 ...

Page 343: ...ifugal force pushes the weights against the rollers the moveable sheave will force the belt to climb up the drive clutch sheave and increase vehicle speed If the weights and spring are matched properly the engine RPM will go to the desired range and remain there on both the upshift and backshift If the weights are too light or the spring rate too high the maximum RPM will be too great and the driv...

Page 344: ...g any clutch operation diagnosis or repair 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 Distortion of the spring indicates stress fatigue requiring replacement PART NUMBER COLOR CODE W...

Page 345: ...g engagement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance clutch balance and shifting pattern PN 5630513 50 5 gr PN 5630509 55 gr 55 58 PN 5630581 58 gr PN 5630418 50 gr High Alt 350L PN 5630095 53 gr 53 PN 5630709 44 gr PN 5630710 46 gr PN 563071...

Page 346: ...eplace all buttons and O ring or washer where applicable and inspect surface of towers See spider removal page 6 16 3 Inspect sheave surfaces Replace the entire service clutch if worn damaged or cracked WARNING The clutch assembly is a precisely balancedunit Never replace parts with used parts from another clutch as sembly All PVT system maintenance repairs must be per formed only by an authorized...

Page 347: ... Exploded View Drive Clutch Mark with permanent marker before disassembly Teflon coated brass bushing Teflon coated brass bushing EBS Drive Clutch Spacer Sleeve PTFE Washer One Way Clutch Spider Lock Nut Mark with permanent marker before disassembly ...

Page 348: ...3 Inspect cover bushing A Theouter coverbushing is manufactured with a Teflon coating Bushing wear is determined by the amount of Teflon remaining on the bushing 4 Inspect area on shaft where bushing rides for wear galling nicks or scratches Replace clutch assembly if worn or damaged 5 Remove and inspect spring See page 6 11 A Cover Bushing Inspection Replace the cover bushing if more brass than T...

Page 349: ...shers To maintain proper clutch balance and belt to sheave clearance be sure to reinstall original quantity and thickness washers Refer to appropriate parts manual for spider button type and placement of damping device Moveable Sheave Bushing Inspection 2 Inspect the Teflon coating on the moveable sheave bushing Clutch Holding Fixture PN 2870547 or 2871358 Spider Removal Tool PN 2870341 Moveable S...

Page 350: ... at right is a pin style spider button used on some models This arrangement uses a hollow roller pin Other models have a solid roller pin and rubber backed buttons below NOTE Some models use an O ring on the drivingside of the spider and a flat rubber washer on the trailing side of the spider Pre mature wear will result if the heat resistant O rings are substituted with another type Use only genui...

Page 351: ...c X mark under weight 2 Install moveable sheave 3 Install spider making sure spacers installed are the same quantity and thickness and that X mark on spider aligns with X mark in moveable sheave 4 Torque spider to specification using the holding fixture and spider tool Torque with smooth motion to avoid damage to the stationary sheave CAUTION Be sure the spider spacer washers are fully seated in t...

Page 352: ... CLUTCH Spider Removal 7 Reinstall cover aligning X mark with other marks Torque cover bolts evenly to specification Spider Torque 200 ft lbs 27 6 kg m Spider Torque EBS 180 ft lbs 25 5 kg m Cover Screw Torque 90 in lbs 1 04 kg m ...

Page 353: ...6 20 Polaris Sales Inc 4 99 CLUTCH Standard P 90 Non EBS Clutch ...

Page 354: ...6 21 Polaris Sales Inc 4 99 CLUTCH NOTES ...

Page 355: ...en the driven clutch sheaves S Remove shims to decrease belt deflection S Add shims to increase belt deflection See Driven Clutch Disassembly Inspection pages 6 30 6 32 NOTE At least one shim must remain between the inner and outer sheave of the driven clutch If proper belt deflection cannot be obtained measure drive belt width length and center distance of drive and driven clutch outlined in this...

Page 356: ...e of the belt Belts which measure longer than nominal length may require driven shimming or engine adjustment for a longer center distance to obtain proper belt deflection Belts which measure shorter than nominal length may require driven shimming or a shorter center distance Remember proper belt deflection is the desired goal not a specific center distance 6 Replace belt if worn past the service ...

Page 357: ...inor adjustments can be made by adding shims between the frame and front lower left engine mount to increase the distance at point A If a shim is pres ent it can be removed to decrease the distance at point A Clutch Offset Important Inspect clutch alignment and center distance be fore adjusting offset 1 Install offset alignment tool as shown Offset is correct when rear of tool contacts rear of inn...

Page 358: ...6 25 Polaris Sales Inc 4 99 CLUTCH This Page Blank ...

Page 359: ...Two Puller Adapter 5020633 Drive Clutch Moveable Sheave Bushing Removal 1 Install handle end of piston pin puller securely into bench vise and lightly grease puller threads 2 Remove nut from puller rod and set aside 3 Install main adapter Item 8 onto puller 4 Insert adaptor 2 into bushing from belt side as shown With towers pointing toward vise slide sheave and bushing onto puller rod 5 Install nu...

Page 360: ...8 on puller 2 Apply Loctite 680 retaining compound to the back side of new bushing Push bushing into center of sheave on tower side by hand 3 Insert installation tool Item 2 into center of sheave and with towers pointing away from vise slide sheave onto puller rod 4 Install nut on puller rod and hand tighten Turn barrel to apply additional tension if needed 5 Turn sheave and barrel together counte...

Page 361: ...o cover bushing 3 With inside of cover toward vise slide cover onto puller 4 Install nut onto puller rod and hand tighten Turn puller barrel to increase tension as needed 5 Turn clutch cover counterclockwise on puller rod until bushing is removed 6 Remove nut from puller rod and set aside 7 Remove bushing and bushing removal tool from puller Discard bushing Main Adaptor Piston Pin Puller PN 287038...

Page 362: ...tion tool into center of clutch cover 2 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 3 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 4 Turn clutch cover and barrel together counterclockwise on puller rod until bushing is seated 5 Remove nut from puller rod and take installation tool and clutch cover off rod B...

Page 363: ...tion when removing snap ring to prevent serious personal injury 1 Apply and hold downward pressure on the helix or place driven clutch in compressor tool PN 8700220 2 Remove snap ring retainer 3 Note location of spring and remove helix 4 Note location of spring in themoveable sheave and remove the spring Note hole location of spring in helix and sheave ...

Page 364: ... if tabs are misaligned or the spring coils are distorted 6 Inspect ramp buttons in the moveable sheave and replace if worn NOTE The ramp buttons are secured by Torx screws 7 Remove moveable sheave and note the number of spacer washers One spacer must remain between the sheaves when adjusting belt deflection Tabs Aligned Belt deflection adjustment washers ...

Page 365: ...ble sheave bushing 9 Inspect driven clutch faces for wear or damage 10 Clean and inspect splines on helix and transmission input shaft 11 Lube splines with a light film of grease Inspect bushings for wear Moveable Sheave Bushing Inspection Replace the bushing if more brass than Teflon is visible on the bushing Re fer to bushing replacement in this chapter ...

Page 366: ... RPMs The greatest amount of spring tension will raise engine RPMs during clutch upshift and allow quicker backshift or downshift when pulling or negotiating a hill for example The least amount of tension will create a slower downshift and a harder upshift 4 Line up boss spline and push helix down until it engages the splines 1 2 to 3 4 5 While holding downward pressure on helix wind moveable shea...

Page 367: ...at 1 Install main adapter Item 8 onto puller 2 Insert adapter reducer Item 9 onto puller sliding it inside the main adapter 3 Remove ramp buttons from moveable sheave 4 Using a hand held propane torch apply heat directly on bushing until tiny smoke tailings appear CAUTION Clutch components will be hot In order to avoid serious burns wear some type of insulated gloves for the rest of the removal pr...

Page 368: ...illustration at right 6 Install sheave onto puller 7 Install nut onto puller rod and tighten by hand Turn puller barrel for further tension if needed 8 Turn clutch sheave counterclockwise until bushing is removed Repeat steps 5 8 for other bushing 9 Remove nut from puller rod and set aside 10 Remove adapters from puller 11 Remove bushing and removal tool from adapters Discard bushing Bushing Remov...

Page 369: ...ion 1 Working from the top insert adapter number ten onto puller See illustration at right 2 Start new bushing evenly in moveable sheave Apply Loctite 680 retaining compound to the back side of new bushing 3 Install sheave onto puller with new bushing upward as shown Install adaptor number two Adapter Number Ten ...

Page 370: ... onto puller rod and hand tighten against installation tool 5 Turn clutch sheave counterclockwise until bushing is seated 6 Remove nut from puller rod and set aside 7 Remove installation tool and clutch sheave from puller 8 Repeat installation procedure for other moveable bushing ...

Page 371: ...6 38 Polaris Sales Inc 4 99 CLUTCH This Page Blank ...

Page 372: ...6 39 Polaris Sales Inc 4 99 CLUTCH ENGINE BRAKING SYSTEM EBS Clutch ...

Page 373: ... drive train turns the driven clutch belt and one way clutch in the direction of engine rotation When the one way clutch rotational speed exceeds drive clutch rotational speed the one way clutch locks to the drive clutch shaft and engine braking occurs Essentially the driven clutch has becomethe driving clutch Engine braking will continue until drive clutch speed exceeds one way clutch speed or un...

Page 374: ...ide to the deceleration side An audible engagement noise may be heard during this transition and is a normal condition S Changes to drive clutch calibration are recommended if the vehicle will be oper ated at elevations above 3000 ft 900 meters Refer to the model specific clutch ing chart for type of drive clutch weight and or drive clutch spring to install for high elevation WARNING All PVT syste...

Page 375: ...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 185 Ft Lbs Roller EBS Exploded View One Way Clutch Driven 6 42 Polaris Sales Inc 4 99 CLUTCH Engine Braking System EBS ...

Page 376: ... only slight amount of drag There should not be any 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 1 Remove moveable sheave spacer sleeve and the 2 PTFE washer Visually inspect the washer for damage Measure the thickness and compare to specification...

Page 377: ...shaft is worn or damaged 5 Remove 2 1 2 PTFE washer from shaft Visually inspect the washer for damage Measure the thickness and compare to specification Replace if worn or damaged Moveable Sheave Bushing Inspection 1 Inspect the Teflon coating on the moveable sheave bushing Shaft Diameter Standard 1 3745 1 375 Service Limit 1 3730 PTFE Washer Thickness Standard 030 76mm Service Limit 025 64mm Move...

Page 378: ...6 45 Polaris Sales Inc 4 99 CLUTCH This Page Blank ...

Page 379: ...er sheave of the driven clutch moveable in a counterclockwise direction as shown at right The sheave should rotate on the shaft with only a slight amount of drag There should not be any binding or rough spots 2 When rotated clockwise the inner moveable sheave should lock to the shaft and outer sheave without slipping 3 Remove driven clutch from the transmission input shaft Do not disassemble the d...

Page 380: ...aining 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 torch Use a high quality hexagonal wrench Allent in good con dition to avoid screw damage A small amount of valve grinding compound can be applied to the tip of the hex wrench to ensure a tight fit Always use new bolts if they are removed for inspec...

Page 381: ... the driven clutch shaft in the one way clutch If the shaft can be moved laterally or if the one way clutch does not function properly as described in Step 1 and 2 on page 6 46 replace driven clutch assembly Moveable Sheave Bushing Inspection Replace the bushing if more brass than Teflon is visible on the surface of the bushing ...

Page 382: ...6 49 Polaris Sales Inc 4 99 CLUTCH This Page Blank ...

Page 383: ... Clutch Moveable Sheave Bushing Removal 1 Remove clutch as outlined previously in this chapter 2 Install handle end of piston pin puller PN 2870386 securely into bench vise and lightly grease puller threads 3 Remove nut from puller rod and set aside 4 Install puller adapter Item 10 from kit 2871226 5 Install main adapter Item D onto puller 6 With towers pointing toward the vise slide sheave onto p...

Page 384: ...vise slide cover onto puller 5 Install nut onto puller rod and hand tighten Turn puller barrel to increase tension as needed 6 Turn clutch cover counterclockwise on puller rod until bushing is removed and cover comes free 7 Remove nut from puller rod and set aside 8 Remove bushing and bushing removal tool from puller Discard bushing EBS Clutch Cover Bushing Installation 1 Apply Loctitet 609 evenly...

Page 385: ...lockwise until bushing is removed and sheave comes free 8 Remove nut C left hand thread from puller rod and set aside 9 Remove adapters from puller 10 Remove bushing and removal tool from adapters Discard bushing EBS Driven Bushing Installation 1 Slide adapter Item 10 onto puller 2 Apply Loctitet 609 evenly to bushing bore inside moveable sheave 3 Install sheave onto puller belt surface up 4 Place...

Page 386: ...ller 10 Remove bushing and removal tool from adapters Discard bushing EBS Driven Backside Outer Bushing Installation 1 Install puller adapter Item 10 onto puller 2 Install adapter Item 9 onto puller 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...

Page 387: ...h binding Install correct recommended spring Install correct recommended shift weights Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Disassemble clean and inspect driven clutch noting worn sheave bushing and ramp buttons and helix spring location Harsh drive clutch engage men...

Page 388: ...NOTES ...

Page 389: ...agement Caution operator to use low gear when pulling heavy loads and operate machine within guidelines Vehicle operated with park brake on Inspect brake system Fast effective use of throttle for efficient engagement 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 stabb...

Page 390: ...ing Exploded View 7 37 Rear Axle Exploded View Xpress Xplorer 7 39 Rear Axle Removal Xpress Xplorer 7 40 Rear Axle Installation Xpress Xplorer 7 40 Rear Axle Removal Concentric Swingarm 7 41 7 42 Rear Axle Installation Concentric Swingarm 7 43 Rear Axle Exploded View Concentric Swingarm 7 44 Rear Axle Disassembly Concentric Swingarm 7 45 Rear Axle Assembly Concentric Swingarm 7 46 7 47 Rear Housin...

Page 391: ......

Page 392: ...and Front Hub Nut Refer to text for procedure Pg 7 11 and Chain Shaft Models Rear Hub Retaining Nut 80 Ft Lbs Front Wheel Nuts 15 Ft Lbs 4 x 4 Rear Wheel Nuts 15 Ft Lbs 4 x 4 Shaft Drive Front Hub Nut Refer to text for procedure Pg 7 11 Rear Hub Retaining Nut 100 Ft Lbs Refer to exploded views and text for torque values of other fasteners CAUTION Locking nuts and bolts with preapplied locking agen...

Page 393: ...eye protec tion when removing bearings and seals 2 Check bearings for side play by grasping tire wheel firmly and checking for movement It should rotate smoothly without binding or rough spots 3 Remove wheel nuts and wheel 4 Remove brake caliper 5 Remove hub cap cotter pin front spindle nut and washer 6 Rotate each bearing by hand and check for smooth rotation Visually inspect bearing for moisture...

Page 394: ...pacer to one side to expose inner bearing race Drive bearing out using a drift through opposite side of hub and discard 9 Remove spacer and drive other bearing out and discard 10 Clean hub and spacer thoroughly 11 Inspect spacer for wear or damage Measure length of spacer and replace if worn beyond service limit or if ends are rounded Tap spacer to side Bearing Spacer Length Service Limit 2 1850 5...

Page 395: ... 1 180 46 mm bearing driver CAUTION Do not drive on the inner race of the bearing 2 Coat bearing spacer with grease and install into hub Drive or press the other bearing into hub until seated against spacer 3 Install seal into hub with numbers facing out until flush with end of seal bore Seal Premium All Season Grease PN 2871322 3 oz Tube PN 2871423 14 oz Tube Seal ...

Page 396: ...th ends of cotter pin around end of spindle in different directions 8 Lightly grease a new O ring and install on hub cap 9 Install hub cap 10 Rotate hub It should rotate smoothly without binding or rough spots or side play 11 Install brake caliper using new bolts Tighten bolts to specified torque CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brak...

Page 397: ...rut Housing Seal Bearing Bearing Wheel Nut Spacer Washer domed side out Nut 40 ft lbs 55 3 Nm Cotter Pin O Ring Hub Cap 18 ft lbs 24 9 Nm Use new bolts with pre applied locking agent 7 6 Polaris Sales Inc 4 99 FINAL DRIVE 2x4 Front Hub Exploded View ...

Page 398: ...This Page Blank 7 7 Polaris Sales Inc 4 99 FINAL DRIVE ...

Page 399: ...he correct spring refer to appropriate parts manual and use installation tool PN 2870888 WARNING It is important that the front and rear axle drive ratio and tire size are not changed Changing this ratio will cause erratic engagement which could result in a loss of vehicle control and serious injury or death Electric Hub Engagement AWD When AWD is selected in a forward gear current flows through a...

Page 400: ...d of the foot rests CAUTION Make sure the machine is solidly supported before proceeding Serious injury could occur if the machinetips orfalls 2 Remove the front wheels and thoroughly clean the area around the hub strut casting brake caliperand brake disc 3 Remove the two brake caliper attaching bolts CAUTION Do not hang the caliper by the brake hose Use wire to hang the caliper to prevent possibl...

Page 401: ...hub it should be flush with the outside surface of the hub 2 Grease hub seal to allow it to slideover rollerclutch components 3 Install wheel hub inner bearing NOTE All bearings must slide freely onto the spindle If bearings do not slide freely wheel bearing torque will be affected 4 Install wheel hub outer bearing washer and attaching nut NOTE It is very important that the hub is not moved outwar...

Page 402: ...fferent directions NOTE If cotter pin hole does not align tighten slightly to align and install pin Do not exceed 144 in lbs 6 Reinstall hub cap 7 Remove fill check plug and rotate hole to either 4 00 or 8 00 position 8 Fill with Polaris Premium Demand Drive Hub Fluid or Type F Automatic Transmission Fluid until fluid trickles out NOTE Do not force the oil into the hub under pressure This can caus...

Page 403: ...Seal Armature Plate Brake Disc Bearing Race Bearing 1 000 I D Garter Spring Spacer Cotter Pin Washer Wheel Nut Refer to text on page 7 11 for more information Detail Front Hub Clutch Bearing 1 000 I D 7 12 Polaris Sales Inc 4 99 FINAL DRIVE AWD Front Hub Exploded View ...

Page 404: ...This Page Blank 7 13 Polaris Sales Inc 4 99 FINAL DRIVE ...

Page 405: ...comes too hot to touch pry out the old seal as shown Do not damage the surface of the seal cavity Clean the hub in the seal mating area 4 With spring side of new seal facing toward hub casting press it in until flush with brake disc mating surface CAUTION Do not use a hammer as damage to the seal will result 5 Thoroughly clean the brake disc with brake cleaner It is very important that the brake d...

Page 406: ...l even with the inner pole See page 7 24 for additional information Once the seal sleeve is properly positioned a 1 16I 16 cm bead of silicone should remain around the inner edge Clean off all excess silicone The seal sleeve area must be free of silicone or the hub seal may leak NOTE Always install a new seal sleeve when replacing the coil It may be necessary to apply more silicone or an equivalen...

Page 407: ...ed tool PN 2870888 and into the groove of the rollers and cage WARNING If this procedure is not followed the spring will be over stressed and lose its tension Springs with incorrect tension may allow rollers to move outward at high vehicle speeds If the rollers move outward the front hub s will engage and cause vehicle instability which could result in serious injury or death WARNING Be sure to us...

Page 408: ...ing on the armature plate however the wear rings should be even 2 Install the roller clutch Hilliard Clutch assembly and be sure the armature plate A is positioned properly Also when installing the hub assembly be sure the armature plate tabs remain engaged with the roller clutch cage CAUTION After the hub is installed the slightest movement outward with the hub may cause the armature plate tabs t...

Page 409: ...ecure before beginning this service procedure Wear eye protection when remov ing and installing drive axles or component parts 3 Remove wheel nuts and wheels 4 Remove hub cap 5 Remove the two brake caliper attaching bolts CAUTION Do not hang the caliper by the brake hose Use wire to hang the caliper to prevent possible damage to the brake line 6 Place a catch pan beneath the front hub andremove th...

Page 410: ...to damage the tapered roller bearing Install the new seal until it bottoms against the shoulder in the strut casting AWD Front Drive Axle Installation 1 Install spring washer and drive shaft Align hole in U joint yoke with hole in eccentric shaft and install new roll pin 2 Install new seal in strut casting Refer to page7 10 3 Install drive shaft in strut 4 Install lower ball joint torque nut to 25...

Page 411: ...mage S Do not allow boots to come into contact with sharp edges or hot engine and exhaust components S The driveshaft is not to be used as a lever arm to position other suspension components S Never use a hammer or sharp tools to remove or to install boot clamps S Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and w...

Page 412: ...arefully 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 below 8 Before installing the new boot remove all grease from the boot area and shaft NOTE It is very important to use the correct type and quantity of grease by using the grease contai...

Page 413: ...y 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 7 22 Polaris Sales Inc 4 99 FINAL DRIVE AWD Front Drive Axle Exploded View ...

Page 414: ...eal until it bottoms against the shoulder in the strut casting 4 Apply grease to the seal inner lip reinstall the spindle and axle assembly 5 Reinstall the A arm to the ball joint Torque to 25 ft lbs 3 5 kg m NOTE If the cotter pin hole does not align at the above torque tighten slightly until the cotter pin hole aligns and install the pin with open ends toward rear of machine Bearing Replacement ...

Page 415: ...driven onto the strut casting until flush with the inner magnet pole Use the flat side no step of tool PN 2871199 4 To check the gap between the inner and outer poles place a straight edge on the outer pole so that it just intersects with the inner pole The gap between the straight edge and inner pole should be 0 to 001I 0 025mm This measurement should be checked in three different positions aroun...

Page 416: ... Removal 1 Using a drift punch remove the roll pin from prop shaft at rear of housing Slide prop shaft back and away from front housing Pull sharply forward to remove from transmission shaft NOTE If removing front housing use a drift punch to remove the roll pins from both front drive axles ...

Page 417: ...g caps NOTE If yoke or bearing is removed cross bearing must be replaced Note orientation of grease fitting and mark inner and outer yoke for correct re positioning dur ing 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 ...

Page 418: ...int cross with grease fitting properly positioned inward toward center of shaft Take care not to dislodge needle bearings upon installation of cross joint Tighten vise to force bearing caps in 2 Using a suitable arbor fully seat bearing cap in one side Continually check for free movement of bearing cross as bearing caps are assembled 3 Install snap ring to contain bearing cap just installed Repeat...

Page 419: ...s 1 3 to install bearing caps on outer yoke 6 Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown 7 When installation is complete Yokes must pivot freely in all directions without binding If the joint is stiff or binding tap the yoke lightly to center the joint until it pivots freely in all directions ...

Page 420: ... cotter pin lower ball joint nut and A arm from ball joint 6 Remove bolts securing bottom of housing to frame Remove vent line and remove housing from right side of frame Front Housing Disassembly NOTE Type l front gear case shown Type ll and Type lll differences noted REFER TO EXPLODED VIEWS ON PAGE 7 37 1 Drain and properly dispose of used housing oil Loosen both Allen set screws on input side o...

Page 421: ...y which is used on your machine and follow procedures that are unique to the type Refer to the appropriate parts manual for parts infor mation Primary difference between Type II and Type III is the drain plug location Fill plug on top Type lll Drain plug Case Bolts Bolted Case Drain Plug Fill plug Type l Threaded Spanner Fill plug on side Drain Plug Type lI Case Bolts Bolted Case ...

Page 422: ...r ring gear assembly and shaft On Type ll and lll remove output shaft assembly large shim and thrust button with its small shim 6 Clean all parts and inspect spacers for wear Inspect ring gear for chipped broken or missing teeth NOTE Due to extremely close tolerances and mini mal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discol...

Page 423: ...wrench and turn spanner socket counter clockwise as viewed from end of pinion shaft to remove retainer Type l On Type ll and Type lll remove pinion cover O ring and pinion shaft 9 Remove pinion shaft assembly Inspect pinion gear for chipped broken or missing teeth Remove cover brass spacer steel spacer ring gear assembly and shaft Clean all parts and inspect spacers for wear Inspect ring gear for ...

Page 424: ...ent and minimal movement side ways between inner and outer race 1 Replace all O rings seals and worn components 2 Install needle bearing snap ring and left side seal 3 Press bearing on pinion shaft install both snap rings and slide outer bearing into place NOTE On Type l thoroughly lubricate cover O ring and cover threads before installation Do not install seal in pinion cover until after backlash...

Page 425: ...nt both ring gear and pinion gear should be free of oil and grease when installed 5 Install ring gear assembly steel spacer brass spacer and side cover Make sure lock bolt on holding fixture is backed out of the way Rotate pinion shaft while slowly turning side cover inward until gears mesh As gear backlash is reduced to zero the shaft will begin to bind At this point back off 1 4 turn On Type II ...

Page 426: ...acklash S To reduce backlash loosen output shaft lock bolt on holding fixture Rotate output cover clockwise as viewed from cover side On Type II remove cover and add a slightly thicker shim behind ring gear and thrust button Rein stall cover and torque bolts to specifications S To increase backlash loosen output shaft lock bolt on holding fixture Rotate side cover counterclockwise as viewed from c...

Page 427: ...1 Remove front housing from holding fixture and tighten bottom pinion shaft retaining nut set screw Type I Front Housing Installation 1 To install housing reverse removal procedure Use new roll pins in drive shafts 2 Add Polaris Premium Front Housing Lubricant or GL5 80 90 gear lube to front housing Check drain plug for proper torque Type l Fill Plug Type l Premium Front Housing Fluid PN 2871653 1...

Page 428: ... Seal O Ring Bearing Pinion Shaft Output Shaft Bearing Shim O Ring Output Cover Thrust Button Shim Seal Vent Bushing Seal Retaining Ring Retaining Ring Pinion Cover Seal O Ring Bearing Pinion Shaft Bushing Washer Retaining Ring Vent Seal Seal O Ring Output Cover Needle Bearing Bearing Thrust Washer Output Shaft Output Gear ...

Page 429: ...7 38 Polaris Sales Inc 4 99 FINAL DRIVE Rear Drive ...

Page 430: ...o outside 80 ft lbs 110 Nm Flat Washer Bearing 50 ft lbs 69 Nm Lubricate hub splines with light film of grease Hub Rear Axle Bend The rear axle shaft is hardened to approximately 3 to 4 7 6 to 10 cm from the outer ends This allows the shaft to bend in case of impact or accident Small amounts of axle runout can be straightened using V blocks a hydrau lic press and a dial indicator CAUTION Do not us...

Page 431: ... Axle Installation 1 Slide locating collar on left end of axle with recess facing outward 2 Install a new circlip 3 Tap locating collar back towards left end of axle until it captivates circlip 4 Apply a light coat of grease to axle and install a new O Ring 5 Insert axle from left to right 6 Install O Ring sprocket hub and washer 7 Clean axle nut threads with a wire brush Apply Loctite 242 to thre...

Page 432: ...Swingarm Rear Axle Removal 1 Securely support rear of machine with rear wheels off the floor Remove rear wheels and hubs 2 Remove drive chain 3 Remove snap ring A lock sleeve B and foam seal C from axle 4 Remove sprocket hub nut 5 Remove rear brake caliper A B C Remove caliper bolts ...

Page 433: ...ales Inc 4 99 FINAL DRIVE Concentric Swingarm Rear Axle Concentric Swingarm Rear Axle Removal Cont 6 Support rear caliper with wire or a tie strap Do not hang caliper by brake line 7 Slide axle assembly out left side ...

Page 434: ...to side is detected axle is too loose 4 Install foam seal and slide lock sleeve onto hub and install lock sleeve with taper inward Install snap ring 5 Install brake caliper and drive chain Adjust drive chain refer to Maintenance Chapter 2 for procedure Torque eccentric pinch bolts to 30 ft lbs 41 Nm on models without a trailer hitch or 40 ft lbs 55 Nm on models with a trailer hitch Verify proper c...

Page 435: ...l Sleeve O Ring Seal Bearing Bearing Race Eccentric Housing Grease Fitting Axle Bearing Race Bearing Seal O Ring Sprocket Hub Foam Seal Axle Nut Lock Collar Snap Ring Caliper Mount Upper Caliper Mount Lower Caliper Left side of axle identified by groove in spline 10 12 ft lbs 1 38 1 65kg m 18 ft lbs 2 49 kg m Torque 80 ft lbs 11 06 kg m Torque 50 ft lbs 6 91 kg m Foam Seal ...

Page 436: ... Concentric Swingarm Rear Axle Concentric Swingarm Rear Axle Disassembly 1 Remove rear axle See page 7 39 2 Remove snap ring collar foam seal and disc hub 3 Remove nut disc assembly and stop ring Stop Ring Disc Hub Groove Nut Threads Splines ...

Page 437: ...oove on left side of axle 2 Install disc hub assembly on axle Be sure hub covers stop ring Install disc in soft jawed vise Apply Loctite 272 to threads install left axle nut and tighten to 120 ft lbs 166 Nm 3 Lubricate spacer and new O ring Install on axle Stop Ring Disc Hub Groove Stop ring Axle Nut Disc Side Torque 120 ft lbs 166 Nm ...

Page 438: ...and axle nut lock sleeve with taper toward nut Install snap ring to retain the lock sleeve Concentric Swingarm Rear Housing Removal 1 Remove rear axle See page 7 39 2 Remove sprocket hub Note sealing O ring between sprocket hub and bearing 3 Remove brake caliper mounting bracket Foam Seal Lock Sleeve Tapered side toward nut Snap Ring ...

Page 439: ...Polaris Sales Inc 4 99 FINAL DRIVE Concentric Swingarm Rear Axle Concentric Swingarm Rear Housing Removal Cont 4 Remove brake caliper pivot bushing from stud NOTE Flange inward as shown 5 Remove rear housing ...

Page 440: ...acks or wear Replace if damaged Rear Housing Assembly Bearing Service 1 Drive in new bearing race with brass drift Use heat 2 Lubricate and install new tapered bearings 3 Lubricate and install new seals Concentric Swingarm Rear Housing Installation 1 Place brake caliper pivot bushing on stud with flange inward as shown 2 Loosely assemble upper and lower brake caliper mount Do not tighten at this t...

Page 441: ...g condition and correct as necessary Rear Axle Removal 1 Lock the parking brake Remove left rear hub cap 2 Remove cotter pin 3 Loosen the hub retaining nut 4 Loosen but do not remove the wheel nuts 5 Safely support the rear of the ATV CAUTION Serious injury could occur if machine tips or falls 6 Remove left wheel 7 Remove hub 8 Remove brake line shield Clip tie wrap from brake line tubes Carefully...

Page 442: ...ear brake caliper and support it from machine frame 10 Remove rear brake disc 11 Remove skid plate 12 Remove 3 left swing arm bolts 13 Remove 4 axle tube bolts from rear gearcase 14 Slide axle through rear gearcase to the right enough to allow the axle tube to slip off between axle and and swingarm ...

Page 443: ...ing and collar NOTE Collar should enclose hog ring See previous photo on removal step 15 4 Slide axle tube assembly over axle shaft until it engages the swingarm 5 Install 4 new axle tube bolts loosely 6 Install 3 left swing arm bolts and torque to 85 ft lbs 7 Torque 4 axle tube bolts in a cross pattern to 60 ft lbs 8 Re install skid plate and torque bolts to 25 ft lbs 9 Install new greased o ring...

Page 444: ...emove jackstand and torque axle nut and wheel nuts 16 Install a new cotter pin Tighten nut slightly to align holes if required 17 Install hub cap Rear Axle Bearing Removal 1 Remove left wheel and hub See page 7 20 of rear axle removal steps 1 7 2 Remove rear brake caliper and support it from machine frame 3 Remove rear brake disc 4 Remove and discard o ring from axle shaft Tie Wrap T clip Rear Hub...

Page 445: ...AL DRIVE Shaft Ride Rear Axle Service Rear Axle Bearing Removal 5 Slide axle through rear gearcase to the right as far as it will go 6 Remove outer axle seal and discard 7 Remove outer bearing and spacer Bearing Spacer Outer Bearing ...

Page 446: ...r Axle Bearing Installation 1 Clean bearing service of axle tube and install new bearings retaining ring and seals reversing steps 1 8 of rear axle bearing removal 2 Torque brake caliper rear hub nut and rear wheel nuts to specifications Brake Caliper Torque 18 ft lbs 2 48 kg m Rear Hub Nut Torque 80 ft lbs 11 06 kg m Rear Wheel Nut Torque 15 ft lbs 2 07 kg m ...

Page 447: ...l 1 Lock the parking brake Remove rear hub cap 2 Remove cotter pin 3 Loosen the hub retaining nut 4 Loosen the wheel nuts 5 Safely support the rear of the ATV CAUTION Serious injury could occur if machine tips or falls 6 Remove hub nut domed washer and flat washer 7 Remove wheel nuts and wheel ...

Page 448: ...Polaris Sales Inc 4 99 FINAL DRIVE Independent Rear Hub Rear Hub Bearing Carrier Removal 8 Remove hub 9 Remove upper control arm bolt as shown 10 Remove both lower control arm bolts 11 Remove bearing carrier ...

Page 449: ...rm Install and torque upper control arm bolt and torque to specification 5 Pull drive shaft outward and install hub onto driveshaft splines 6 Install cone washers with domed side facing outward 7 Install retainer nut wheel and wheel nuts 8 Remove jackstand and torque axle nut and wheel nuts 9 Install a new cotter pin Tighten nut slightly to align holes if required 10 Install hub cap Lower Control ...

Page 450: ...ng support casting on outer edges so bearing can be removed 3 Inspect bearing NOTE Due to extremely close tolerances and mini mal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement side ways between inner...

Page 451: ...ar Hub Assembly 1 Support bottom of bearing carrier housing 2 Start bearing in housing 3 Press bearing into place until outer race bottoms on housing CAUTION Use an arbor and press only on the outer race as bear ing damage may occur 4 Install snap ring into groove ...

Page 452: ...and a normal service life S The complete driveshaft and joint should be handled by getting hold of the interconnecting shaft to avoid disassembly or potential damage to the driveshaft joints S Over angling of joints beyond their capacity could result in boot or joint damage S Make sure surface ground areas and splines of shaft are protected during handling to avoid damage S Do not allow boots to c...

Page 453: ...7 62 Polaris Sales Inc 4 99 joints and CV joint boots ...

Page 454: ... lock ring and install the shaft 4 Lift bearing carrier into place and installbolt toupper control arm Torque bolt to 35 ft lbs 48 Nm 5 Install hub flat washer domed washer domed side out and nut Torque center nut to 100 ft lbs Install new cotter pin and hub cap 6 Install rear wheel and torque wheel nuts to specification 7 Grease all fittings thoroughly with Premium U Joint Lubricant Rear Hub Nut ...

Page 455: ...bling U Joint the yoke bore alignment must be inspected as outlined below U Joint Inspection Rear Drive Shafts NOTE When rebuilding rear drive shaft U Joints it is necessary to inspect the yoke cap bores for alignment or warpage If a yoke cap bore is warped or twisted the yoke must be replaced 1 Make sure yoke bores are free of nicks or burrs from disassembly 2 Slide the appropriate tool through b...

Page 456: ...ht is shown without shaft for clarity Wipe grease away from recess in CV joint inner hub to locate snap ring 3 Open the snap ring using a snap ring pliers or small needle nose pliers Tap CV housing off shaft with a soft faced hammer while holding snap ring open CV Boot Clamp Pliers Earless Type 8700226 Snap ring located in recessed area Snap ring Tap CV Housing Off Shaft Spread ends of snap ring t...

Page 457: ...n the interconnecting shaft 6 Install and tighten large boot clamp with boot clamp pliers 7 Remove excess grease from the CV joint s external surfaces and position joint boot over housing making sure boot is seated in groove Position clamp over boot end and make sure clamp tabs are located in slots Note Before tightening boot clamp on inboard joint make sure any air pressure which may have built u...

Page 458: ...t of grease for CV joint cleaning to the joint as shown below Be sure grease penetrates all parts of the joint Boot Installation 5 Fit joint boot and clamps on interconnecting shaft Make sure small end of boot is fully seated in groove 6 Position small clamp over small end of boot Be sure it is seated all the way around in the clamp recess on the boot 7 Tighten boot clamp using boot clamp pliers 8...

Page 459: ...7 68 Polaris Sales Inc 4 99 FINAL DRIVE Independent Rear Suspension Exploded View Dual CV Shaft Dual U Joint or ...

Page 460: ...ss bearing races into housing S Lubricate and install bearings and seals S Install shaft S Install O ring spacer sprocket and washer on outer end of shaft S Loosely install nut on outer end of shaft S Loosen front eccentric pich bolt and rotate eccentric to provide maximum chain slack S Install front drive sprocket inner washer and lock washer on inner end of shaft S Install eccentric assembly in ...

Page 461: ...centric Removal Installation Procedure Grease Fitting S Remove spacers and O rings from both ends of shaft S Tap on end of shaft with a soft faced hammer to drive seal and bearing out opposite end of housing S Remove bearing from shaft and re install shaft to drive other bearing and seal from housing S Inspect shaft for wear in the bearing area S Inspect housing for wear cracks or damage S Warm th...

Page 462: ...7 71 Polaris Sales Inc 4 99 FINAL DRIVE Center Front Chain Tightener Exploded View ...

Page 463: ...NOTES ...

Page 464: ...on Removal 8 15 8 18 Type IV Shaft Drive Transmission Installation 8 19 8 22 Type IV Shaft Drive Transmission Disassembly 8 23 8 31 Type IV Shaft Drive Transmission Assembly 8 32 8 43 Type IV Shaft Drive Transmission Exploded View 8 44 Type V Shaft Chain Transmission Remove Install 8 45 Type V Shaft Chain Transmission Disassembly 8 46 8 48 Type V Shaft Chain Transmission Assembly 8 49 8 51 Type V ...

Page 465: ......

Page 466: ...ing Arm Pivot Bolts Concentric Swingarm 150 ft lbs 20 75 kg m Lubrication Refer to maintenance section for transmission lubricant type and capacity Transmission Type Identification TRANSMISSION TYPE DESCRIPTION Type lll EZ Shift High Reverse High Low Reverse Chain drive front where applicable Chain drive rear Type lV Shaft Drive High Low Reverse Used on independent rear suspension models i e Sport...

Page 467: ... side of machine 4 Disconnect the two linkage rods from gear shift selector slides 5 Remove three bolts attaching gear shift selector to the mounting bracket 6 Lift gear selector out of mounting bracket and away from frame Gear Shift Selector Disassembly CAUTION Wear eye protection during this procedure Read each step completely before proceeding Essential parts may be lost or damaged if you do no...

Page 468: ...t closely if moisture is present in selector box 7 Tap gear shift selector body top down against a hard smooth flat surface to jar the stop pin and two detent bullets loose Pull the detent bullets and the stop pin out of the gear shift selector body 8 Hold the interlock butterfly out of the way and remove the two slides one at a time 9 Remove interlock butterfly and inspect for wear or damage NOTE...

Page 469: ...elector box is level when adding oil 6 Carefully reinstall the gear shift selector switch The hook on the switch faces downward toward shift slides This hook catches on the selector body to prevent the switch from moving out of place NOTE Switch must be positioned properly or AWD may not function 7 Wipe gear selector dry clean surfaces of cover and selector box with Loctite Primer T and place a be...

Page 470: ... 1 Using a slotted screwdriver remove cap from gear shift knob 2 Remove torx screw securing knob to selector rod 3 Pull selector knob off selector rod 4 Remove band clamps on rubber boot 5 Slide boot off selector rod and replace with a new one 6 Apply RTV silicone to selector rod to seal top of boot 7 Place band clamps in position and tighten using CV boot clamp pliers 8 Replace shift knob securin...

Page 471: ...e cover bosses and carefully remove the cover See Ill 1 4 Using the battery cable clamp puller remove the bearing from the sliding gear shaft See Ill 2 5 Remove outer thrust washer 6 To remove the needle bearing from the low gear tip transmission to point end of shaft downward Work gear back and forth as shown until bearing is exposed and slide bearing out See Ill 3 Ill 1 Tap with soft face hammer...

Page 472: ...s to aid in moving the shift fork shaft 9 Remove the low range shift fork shaft with engagement dog by rotating the low gear shift arm clockwise and pulling outward on shift fork shaft NOTE High Reverse bell crank must be in neutral to re move Low gear shift fork shaft 10 Remove output shaft and gear assembly by tapping on shaft with a soft faced hammer from the back side of the gear case assembly...

Page 473: ...E Make sure input shaft gear clears oil deflector but do not remove the oil deflector 12 Clean all components in a parts washer and inspect for wear 13 Inspect engagement dogs of gears and replace if edges are rounded 14 Inspect gear teeth for wear cracks chips or broken teeth 15 Remove seals from transmission case NOTE New seals should be installed after the transmis sion is completely assembled ...

Page 474: ...embly into neutral position NOTE After installation the High Reverse shift arm must be placed in the neutral position to complete reas sembly 3 Install the output shaft and gear assembly into the gear case 4 Install engagement dog on low range shift shaft NOTE Dogs should face toward the mating gear 5 Install low shift shaft assembly aligning pin on shift shaft between ends of return spring the en...

Page 475: ...ver make sure the mating cover surfaces are clean and dry Apply Loctitet 518 or 3 Bond 1215 to mating surfaces 11 Reinstall cover and torque bolts in 3 steps to 12 ft lbs 17 Nm using a criss cross pattern 12 Install transmission and add Polaris Premium Synthetic Gear Case Lubricant in the recommended amount Refer to Maintenance Chapter 2 13 Reinstall transmission switch es Apply Loctitet 242 blue ...

Page 476: ...place 6 Loosely install left side 3 8 16 x 3 4 top mounting bolt 7 Install washer and nut on the left side swing arm bolt 8 Align transmission case bushing with bolt and torque nut to 55 ft lbs 76 Nm Bend the tab washer to lock the bolt in place 9 Align transmission with engine See Clutch Section for center distance and alignment procedure Torque lower mounting bolt to 25 ft lbs 35 Nm Torque right...

Page 477: ...intain proper alignment when mounting nuts are tightened Torque to specification 18 Apply silicone to splines of brake disk and reinstall disk 19 Install brake caliper on disk and bolt to frame with the rear caliper shield Torque to specification Swing Arm Bolt Torque 55 ft lbs 76 Nm Transmission Mounting Bolt Torque 25 ft lbs 35 Nm Skid Plate Bolt Torque 5 ft lbs 7 Nm Inner Cover Bolt Torque 12 f...

Page 478: ...aner assembly making sure carb boot seals on air box correctly Tighten hose clamp 26 Reinstall pre cleaner duct work and pre cleaner 27 Proceed with linkage rod adjustment found in the Maintenance Chapter 2 Speedometer Service 1 Remove speedometer cable from the speedometer head and lubricate it periodically with Polaris cable lube PN 2870510 2 Use a generous bend radius when installing cable Do n...

Page 479: ...r Gear Shaft Input Shaft Output Gear Output Shaft Reverse Gear Drain Plug Output Shaft Seal Bushing Vent O Ring Dipstick High Gear High Reverse Engagement Dog High Reverse Shift Shaft Lower Forward most on Transmission Bell Crank Low Shift Shaft Upper Rearmost on Transmission Low Engagement Dog Reverse Chain Detent Spring O Ring Washer Large I D Needle Bearing Washer Small I D Oil Deflector ...

Page 480: ...t frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure Wear eye protection when re moving and installing bearings and seals 5 Remove wheel nuts and wheels 6 Apply hand and auxiliary brake and remove brake disc retaining nut and washer NOTE Domed side of washer faces nut 7 Remove rear auxiliary brake caliper and disc...

Page 481: ...Cont 10 Remove left side upper control arm attaching bolts at transmission Pivot upper control arm away from transmission as shown 11 Remove both lower transmission mounting bolts from each side 12 Remove all 8 bolts attaching the stabilizer support bracket and remove support Lower Mounting Bolts ...

Page 482: ...rive shafts to transmission and remove drive shafts Dual CV Joint Shafts On models with CV joint shafts pull the shaft sharply outward to dislodge locking ring from transmission below 15 Lift right side drive shaft and hub up and out of the way This will provide access to remove transmission out right side of frame Front Transmission Support Bracket Forward Pull outward to remove form transmission...

Page 483: ...ales Inc 4 99 TRANSMISSION Type IV Shaft Drive Transmission Transmission Removal Cont 16 Remove bottom transmission bolts as shown in illustration 17 Lift and remove transmission out right side of frame Remove bolts ...

Page 484: ...aft Drive Transmission Transmission Installation 1 Apply anti seize compound to splines of front output shaft and insert into prop shaft 2 Rotate transmission into place from right side of frame 3 Loosely install bottom transmission bolts Install bolts ...

Page 485: ...t upper and lower S Bottom transmission bolts S Lower left and right transmission mounting bolts 5 Apply Loctite 272 to right hand drive shaft bolt and install internally threaded spacer onto bolt Torque to specification 6 Apply anti seize to splines of drive shaft and install right side drive shaft in transmission with opening in U joint upward Support right hand hub and install right hand upper ...

Page 486: ... bolt before installing driveshaft completely into splined hub Torque left drive shaft bolt to specification 8 Attach speedometer cable Rear Drive Shaft Retaining Bolt Torque 35 ft lbs 4 85 kg m Apply Loctite 272 Whenever the drive shafts are disassembled the inner and outer U joint yokes on each shaft must be aligned as shown to prevent excessive driveline vibration It is not necessary to align t...

Page 487: ...45 ft lbs 12 Install PVT system Refer to PVT section for procedure 13 Install airbox assembly and transmission vent line Be sure vent line is not kinked or pinched 14 Add Polaris Premium Synthetic Gearcase Lubricant to the proper level on dipstick Approximately 1 quart Do not overfill 15 Install rear wheel nuts and torque to specification 16 Refer to Maintenance Section to adjust transmission link...

Page 488: ...cover with soft face hammer to remove Note 2 bolts in center of cover CAUTION Remove gear indicator switch es if equipped BEFORE disassembly Do not pry on case half sealing surfaces 3 Mark chain rotation direction for assembly Note location of chain tensioner cam If fully extended chain is worn beyond service limit Replace chain and chain tensioner shoe Drain Remove all bolts ...

Page 489: ...e Transmission Transmission Disassembly Cont 4 Remove chain tensioner along with mounting pins and spacers Note position of spacers for assembly 5 Remove rear output gear and chain as an assembly by lifting straight outward 6 Remove oil deflector Remove Screws ...

Page 490: ...le in oil deflector is clear and unobstructed 8 Using a puller remove Hi Lo Reverse HLR shaft bearing and bearing thrust washer 9 Turn transmission so shafts are pointing down Slide the Low gear in and out until needle bearing slides out of gear and can be removed Remove needle bearing low gear and inner thrust washer ...

Page 491: ... Transmission Disassembly Cont 10 Inspect shift dogs for excessive rounding on the leading edges Replace if worn 11 Remove low range shift fork and dog Replace along with mating gear if wear is evident 12 Inspect face of shift fork for excessive wear discoloration or bending ...

Page 492: ...r shaft assembly by tapping on opposite side with a soft face hammer NOTE Be sure drain plug is removed or magnet will in terfere with gear 14 Remove the remaining gears and shafts as an assembly Rotate the shift bellcrank with a 1 2 wrench to aid in removal 15 Remove pinion gear retaining plate and pinion gear assembly ...

Page 493: ...ransmission Transmission Disassembly Cont 16 Inspect pinion gear for broken chipped or worn teeth Check bearing condition and snap ring location 17 Loosen front output housing pinch bolts 18 Mark housing and casting for reference upon reassembly Loosen Pinch Bolts ...

Page 494: ...ransmission casting until O ring is exposed 1 2 13mm NOTE Do not attempt to unscrew the front drive housing completely at this time 20 Remove bottom access plate 21 Bend the lock plate tab away from ring gearretaining bolt 22 Using a strap wrench on splines to hold shaft remove front output ring gear retaining bolt lock tab washer and flat washer Lock Plate Flat Washer Ring Gear ...

Page 495: ... gear Inspect for broken chipped or worn teeth 24 Unscrew front drive housing and remove it from case Apply electrical tape to threads of housing to prevent damage 25 Using a brass hammer or a press drive the shaft bearing retaining ring and seal out of the housing from rear to front Bearing Shim s Seal Retaining Ring Shaft Housing ...

Page 496: ...seal off shaft and remove snap ring and shims Record of shims and thickness of each for reference 27 Inspect center shaft bushing for wear If necessary remove with the large end of bushing drive tool 28 Remove all remaining seals from transmission cases and clean all parts thoroughly Bushing Drive Tool PN 2871697 ...

Page 497: ...243 blue to threads of screws and install center shaft cover Tighten screws securely Front Output Housing Snorkel Assembly 1 Bearing is a light press fit on ring gear end of front output shaft Heat inner bearing on a hot plate or with a heat gun to ease installation Install bearing on shaft until inner race bottoms on flange of shaft CAUTION Do not use a torch bearing damage may re sult Bushing Dr...

Page 498: ...g shaft and bearing assembly over and install front bearing until fully seated 4 Front output shaft end play must be measured and adjusted if shaft or housing was replaced To measure end play Install snap ring on shaft without shims in place Clamp housing lightly in soft jawed vise 5 Set up a dial indicator to measure shaft end play Bearing Shaft Transmission End of Housing ...

Page 499: ...as required to obtain specified end play 000 003 Remove snap ring install shims reinstall snap ring It may be necessary to tap snap ring into place NOTE Shaft should rotate freely when finished Confirm end play measurement with dial indicator Do not install front housing seal until backlash is adjusted 7 Remove electrical tape and liberally apply anti seize compound to the threads of the front out...

Page 500: ...ning plate Use Loctite Primer N on threads and housing Apply Loctite 242 to bolts and torque to specification Front Output Housing Snorkel Backlash Adjustment 11 Lubricate front housing O ring thoroughly with Polaris All Season grease Continue to screw front housing in making sure O ring enters housing without damage Be sure ring and pinion gear teeth mesh properly 12 Rotate front shaft while slow...

Page 501: ...75 98 43mm from shaft centerline S Set backlash at 008 014 20 36mm S Check backlash in several locations of ring gear 14 Install special tool PN 2871695 on shaft as shown With pinion gear held stationary rotate output shaft back and forth reading the total movement of dial indicator The dial indicator must be positioned as shown at the proper distance aligned with outermost mark on tool and 90 to ...

Page 502: ...shaft installation tool lubricate and carefully install the front seal until flush with housing 18 Assemble Hi Low Reverse shaft as shown Machined flat side of circlip should face direction of thrust Sliding high reverse engagement dog is symmetrical and can be installed either way The outer gear dogs must face each other Access Plate Screws 8 10 ft lbs 1 10 1 38 kg m Low Gear Reverse Gear High Ge...

Page 503: ...tral shaft has 2 detents and Hi Neutral Reverse has 3 detents 21 Install Hi Reverse cluster in transmission as an assembly If necessary use a soft face hammer to install shafts until fully seated Make sure the hi reverse shift pin is located between the spring tail ends Place the Hi Reverse shift assembly in neutral position If it is not located in neutral the interlock mechanism will prevent inst...

Page 504: ...3 Install Low shift fork with sliding dog in place Dogs must be positioned outward toward you Slide the shift dog over the spline and the low range shift shaft into the detent lock Make sure the shift shaft pin is located between the tail ends of the return spring 24 Lubricate and install inner thrust washer low gear and needle bearing ...

Page 505: ...thrust washer and bearing 26 Install plastic oil deflector Apply Loctite 242 or 243 blue to all screw threads NOTE Do not over tighten deflector screws or deflector may crack 27 Install drive gear with chain 28 Install chain tensioner Refer to Illustration on following page Oil Deflector Screws Loctite 242 or 243 Blue ...

Page 506: ...Leg Under Cam Forward Forward Lift Spring Over Rear Mounting Pin With chain and sprockets installed 2 Place tensioner cam on front spacer and tensioner shoe on rear spacer 1 Place spacers in case 3 Insert pins through cam and spacer and through shoe and spacer 4 Place spring over front pin and hook spring leg under cam 5 Lift leg of spring up and over the rear pin Tensioner cam will lift shoe and ...

Page 507: ...surface of case and install cover bolts Torque to specification in three steps following a criss cross pattern Start with the center 2 bolts 31 Install seal installation tool in drive gear as shown Lubricate new seal with grease and slide onto tool Drive seal into place using large end of slide hammer Repeat procedure for other side Torque 5 16 bolts 2 17 20 ft lbs 2 35 2 77 kg m Torque 1 4 bolts ...

Page 508: ...sing installation tool Install the seal flush with transmission housing 33 Apply grease to the lip of a new center drive shaft seal Install seal being careful to work the lip of the seal over the step in the shaft Install seal to a depth of 1 8 below the transmission housing Refer to photo 34 Install gear indicator switch es Apply Loctitet 242 blue to threads of switch screws and torque to 13 16 i...

Page 509: ...t Fork HR Shift Fork Interlock Pins Reverse Gear High Gear Oil Deflector Pinion Gear Retainer Plate Output Sprocket Bearings Drive Chain Center Drive Shaft Tensioner Assembly Dipstick Vent Tube Seals Bottom Access Plate Bushing Seal Front Output Ring Gear Bearing Front Output Shaft Front Output Housing Shims Snap Ring Tensioner Assembly Shoe Pins Cam Spacers Spring Forward ...

Page 510: ... allow pin to clear skid plate 6 Remove carburetor 7 Disconnect gear indicator switch es 8 Remove drive chain and sprocket 9 Remove mounting bolts and brackets as shown in Ill 1 10 Remove through bolt from bottom of transmission 11 Loosen left side swingarm bolt until clear of transmission case 12 Remove recoil 13 Remove transmission from right side of frame Transmission Installation 1 Reverse rem...

Page 511: ...e hammer tap on the cover bosses and carefully remove the cover See Ill 1 5 Using the battery cable clamp puller remove the bearing from the sliding gear shaft See Ill 2 6 Remove outer thrust washer 7 To remove the needle bearing from the low gear tip transmission to point end of shaft downward Work gear back and forth as shown until bearing is exposed and slide bearing out See Ill 3 Ill 1 Tap wit...

Page 512: ...low range shift fork with dog gear NOTE High Reverse bell crank must be in neutral to re move low gear shift fork shaft 10 Remove snap ring from front drive input shaft 11 Remove output shaft and gear assembly along with sprocket and chain by tapping on shaft with a soft faced hammer from the back side of the gear case 12 Use a 1 2 wrench to rotate high reverse bell crank and remove shift fork alo...

Page 513: ...nd ring gear assembly 16 Clean all components in a parts washer and inspect for wear 17 Inspect engagement dogs of gears and replace if edges are rounded 18 Inspect gear teeth for wear cracks chips or broken teeth 19 Remove seals from transmission case NOTE New seals should be installed after the transmis sion is completely assembled 20 Inspect bearings for smooth operation Check for excessive pla...

Page 514: ...h flat side toward bearing 5 Apply Loctitet 242 Blue to bolts and torque to 18 ft lbs 25 Nm 6 Carefully install high reverse shaft assembly and gear cluster as a unit into their respective bearing case areas Tap with a soft face hammer to seat shaft assemblies NOTE Make sure high reverse shift shaft pin is properly positioned within legs of shift fork shaft return spring NOTE After installation th...

Page 515: ...haft into case aligning splines of gear with shaft while engaging shift shaft pin in legs of shift fork shaft return spring Push the assembly into case until seated 10 Install thrust washer with larger inside diameter on shaft against splines of shaft 11 Install low gear with slots facing dog gear 12 Lubricate and install needle bearing in low gear 13 Install washer small inside diameter on shaft ...

Page 516: ...Reinstall cover and torque bolts in a criss cross pattern in 3 steps to 18 ft lbs 25 Nm 17 Install drain plug with a new sealing washer Torque drain plug to 14 ft lbs 19 Nm 18 Install transmission and add Polaris Premium Synthetic Gear Case Lubricant in the recommended amount Refer to Maintenance Chapter 2 19 Install gear indicator switch es Apply Loctitet 242 blue to threads of switch screws and ...

Page 517: ...8 52 Polaris Sales Inc 4 99 TRANSMISSION Type V Shaft Chain Transmission Transmission Exploded View ...

Page 518: ...utch and inner PVT cover refer to Clutch Chapter 6 6 Remove rear PVT bracket 7 Remove pin from front prop shaft at front housing and remove prop shaft 8 Drive roll pin from rear driveshaft yoke 9 Disconnect gear position indicator switch es 10 Remove left side transmission bracket rear bracket and lower right bracket bolt 11 Remove through bolt from bottom of transmission 12 Remove front transmiss...

Page 519: ... output shaft and 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 Install transmission alignment tool PN 2872315 as shown 10 Tighten mounting fasteners in order A F as shown NOTE Align clutches as outlined in Clutch C...

Page 520: ...bly 1 Place both bellcranks in neutral position 2 Remove gear position indicator switch es 3 Remove case cover screws 4 Remove the transmission cover bolts 5 With a soft face hammer tap on the cover bosses and carefully remove the cover 6 Remove bearing and 41 tooth helical gear High Reverse Low ...

Page 521: ... Type Vl Shaft Ride Transmission Transmission Disassembly cont 7 Remove input shaft reverse shaft and both shift for shafts as an assembly 8 Remove pinion shaft retainer plate and pinion shaft 9 Remove front drive output housing cover screws ...

Page 522: ...ll components in a parts washer and inspect for wear 13 Inspect engagement dogs of gears and replace if edges are rounded 14 Inspect gear teeth for wear cracks chips or broken teeth 15 Remove seals from transmission case NOTE New seals should be installed after the transmis sion is completely assembled 16 Inspect bearings for smooth operation Check for excessive play between inner and outer race ...

Page 523: ...ocket on front output shaft with sprocket boss side inward as shown 2 Assemble front and rear output shafts 3 Install front and rear output shafts with chain as an assembly 4 Reinstall cover and torque bolts in a criss cross pattern in 3 steps to 18 ft lbs 25 Nm 5 Install new front and rear output shaft seals ...

Page 524: ...g surfaces are clean and dry and shafts are fully seated in the transmission case Apply Loctitet 518 or 3 Bond 1215 to mating surfaces 7 Install pinion shaft with bearing 8 Install retainer plate with flat side toward bearing 9 Apply Loctitet 242 Blue to screw threads and torque screws to 18 ft lbs 25 Nm 10 Assemble shafts with chain and shift forks ...

Page 525: ...long with sprocket and chain 13 Prior to reinstalling the cover make sure the mating cover surfaces are clean and dry and shafts are fully seated in transmission case Apply Loctitet 518 or 3 Bond 1215 to mating surfaces 14 Reinstall cover and torque bolts in a criss cross pattern in 3 steps to 18 ft lbs 25 Nm 15 Install new input shaft seal 16 Install drain plug with a new sealing washer Torque dr...

Page 526: ...in Spring Bearing 16 in lbs 1 5 Nm 16 in lbs 1 5 Nm Gear Indicator Switch Pinion Shaft 10T Bearing Snap Ring Bearing Retainer Plate 14 ft lbs 19 Nm Loctitet 242 Gear Helical 44T Needle Bearing Gear Thrust Washer Snap Ring Engagement Dog Low Thrust Washer Bearing 14 ft lbs 19 Nm Sealing Washer O ring Low H R Gearcase RH Snap Ring Thrust Washer Bearing Sprocket 12T Gear 31T Shaft Rear Output Bearing...

Page 527: ...ings S Linkage rod adjustment and rod end positioning S Shift selector rail travel S Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the transmission by disconnecting linkage rods from transmission bellcranks Manually select each gear range at the transmission bellcrank and test ride v...

Page 528: ...nt Caliper Removal 9 19 Front Caliper Disassembly 9 19 9 20 Front Caliper Inspection 9 20 Front Caliper Assembly 9 21 Front Caliper Installation 9 22 Front Caliper Exploded View 9 23 DH Pad Removal 9 24 DH Pad Installation 9 25 DH Caliper Removal Inspection 9 26 9 27 DH Caliper Assembly 9 27 9 28 DH Disc Inspection 9 29 DH Caliper Master Cylinder Trans Mounted 9 30 DH Caliper Master Cylinder Rear ...

Page 529: ......

Page 530: ...mm Output Shaft Brake Caliper Item Standard Service Limit Brake Pad Thickness 275 7 0mm 150 3 81mm Brake Disc Thickness 177 187 4 496 4 750mm 167 4 242mm Brake Disc Thickness Variance Between Measurements 002 051mm Brake Disc Runout 010 25mm Rear Axle Brake Caliper Item Standard Service Limit Brake Pad Thickness 490 12 45mm 150 3 81mm Brake Disc Thickness 177 187 4 496 4 750mm 167 4 242mm Brake Di...

Page 531: ...nt Caliper Mounting Bolts 18 0 25 Output Shaft Caliper Mounting Bolts 15 0 21 Rear Axle Caliper Mounting Bolts 18 0 25 Master Cylinder Mounting Bolts 55 in lbs 6 0 Master Cylinder Reservoir Cover Bolt 45 in lbs 5 0 Brake Line Banjo Bolt 15 0 21 Front Brake Disc 18 0 25 Rear Brake Disc 6x6 24 0 33 Front Wheel Mounting Nuts 15 0 21 ...

Page 532: ... cannot be ordered it is included in the chart for reference only Part numbers on the following chart may change or supercede to a new number Always refer to the current parts manual for part numbers Part No Type Description Application FRONT BRAKE PAD KITS 2201149 Kit Soft Front brake pad kit Contains 4 pads PN 1930731 For dry dusty conditions 1930731 Pad Pad contained in kit PN 2201149 For dry d...

Page 533: ... from disc or pads Pad s dragging on disc noise or premature pad wear Improper adjustment Insufficient lever or pedal clearance Master cylinder reservoir overfilled Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston s not returning Operator error riding the brake park brake applied Adjust pad stop front calipers or adjust auxiliary brake Che...

Page 534: ...m and cause the brakes to feel spongy Too much fluid could cause brakes to drag due to fluid expansion Located within the master cylinder is the compensating port C which is opened and closed by the master cylinder piston assembly The port is open when the lever is released and the master cylinder piston is outward As the temperature within the hydraulic system changes this port compensates for fl...

Page 535: ...one for the inner fluid chamber foot brake The basic procedure for bleeding the brake system is the same as outlined on page 9 8 9 9 howev er each system must be bled separately Hydraulic Auxiliary Brake inspection and adjustment is outlined on page 9 7 Upper bleed screw and brake line A is for hand brake system Lower bleed screw and brake line B is for auxiliary foot brake system Ill 1 NOTE Calip...

Page 536: ... fully extended position If freeplay is less than 1 8 3 2mm be sure dust seal is fully seated in groove on master cylinder body See photo on page 9 11 Bleeding If the free play is correct but pedal travel is excessive or spongy then air is trapped somewhere in the system Bleeding the auxiliary brake system is accomplished in a conventional manner except that there are two brake lines and bleeder s...

Page 537: ...ckage 4 If changing fluid remove old fluid from reservoir with a Mity Vac pump or similar tool NOTE Do not remove brake lever when reservoir fluid level is low 5 Add brake fluid to the upper level mark on reservoir 6 Begin bleeding procedure with the caliper that is farthest from the master cylinder Install a box end wrench on caliper bleeder screw fitting Attach a clean clear hose to fitting and ...

Page 538: ...ir to prevent air from entering the master cylinder 10 Tighten bleeder screw securely and remove bleeder hose 11 Repeat procedure steps 5 9 for the front right caliper 12 Repeat procedure steps 5 9 for the front left caliper 13 Add brake fluid to the proper level 14 Install diaphragm cover and screws Tighten screws to specification 15 Field test machine at low speed before putting into service Che...

Page 539: ...linder Loosen banjo bolt remove bolt and sealing washers CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 3 Remove master cylinder from handlebars 4 Remove cover and diaphragm from master cylinder and dispose of the fluid properly 5 Be sure vents in cover are clean and unobstructed 6 Remove brake lever Banjo Bolt Master Cylinder P...

Page 540: ... of the reservoir and master cylinder body Be sure compensating A and supply B ports are clean before reassembly 9 Remove outer dust seal Be ready to catch piston assembly NOTE The return spring may force piston out when dust seal has been removed 10 Remove piston assembly and return spring from master cylinder Replace piston assembly and spring Reservoir Bolts Outer Dust Seal ...

Page 541: ...if worn 2 Inspect parking brake for wear If teeth or locking cam are worn replace lever Assembly 1 Install new primary and secondary seals on the piston 2 Select the appropriate master cylinder piston installation tool and insert into master cylinder bore A typical installation tool is shown at right Outer Dust Seal Primary Seal Secondary Seal Return Spring 2201190 2201191 Components of Kit 220087...

Page 542: ...ool sleeve using the plunger handle included with installation tool kit Continue pushing until plunger is solid against installation tool Both tools can now be removed 5 Hold piston assembly inward and install a new dust seal Be sure dust seal is completely seated in the groove NOTE The Piston assembly should spring back against the seal when compressed 6 Install reservoir with new seal Be careful...

Page 543: ...ly two to three times with finger over the outlet end to purge master cylinder of air 2 Place new sealing washers on each side of banjo line and torque banjo bolt to specification 3 Fill reservoir with DOT 3 fluid 4 Follow bleeding procedure on pages 9 8 9 9 Check all connections for leaks and repair if necessary Brake Line Banjo Bolt Sealing Washers Torque to 15 ft lbs 2 07 kg m Master Cylinder M...

Page 544: ...er piston into caliper bore slowly usinga C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 5 Push upper pad retainer pin inward and slip outer brake pad past edge Remove inner pad 6 Measure the thickness of the pad materi...

Page 545: ...re free of dirt or grease 3 Install caliper on hub strut and torque mounting bolts 4 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 brake system Pad Adjustment 5 Install the adjuster screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn counterclockwise Polaris ...

Page 546: ...he brake disc for nicks scratches or damage 2 Measure the disc thickness at 8 different points around the pad contact surface using a 0 1 micrometer Replace disc if worn beyond service limit 3 Mount dial indicator as shown to measure disc runout Slowly rotate the disc and read total runout on the dial indicator Replace the disc if runout exceeds specifications Front Wheel Nut Torque 15 ft lbs 2 07...

Page 547: ...king 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 CAUTION Always use new brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal 18 ft lbs 24 9 Nm Use new bolts with pre applied locking agent Front Brake Disc Mounting Bolt Torque 18 ft lbs 24 9 Nm ...

Page 548: ...pads See page 9 15 2 Using a line wrench loosen and remove brake line to caliper Place a container under caliper to catch fluid draining from brake line 3 Remove brake caliper and drain fluid into container Caliper Disassembly 1 Remove brake pad adjuster screw 2 Push upper pad retainer pin inward and slip brake pads past edge 3 Remove mounting bracket pin assembly and dust boot Remove Mounting Bra...

Page 549: ... Measure bore size and compare to specifications Replace if damage is evident or if worn beyond service limit 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 page 9 17 Front Caliper Piston Bore I D Std 1 191 1 192 30 25 30 28 mm Service L...

Page 550: ... 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 4 Compress the mounting bracket and make sure the dust seals are fully seated Install the pads as shown on page 9 16 Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt ...

Page 551: ...turn 4 Follow brake bleeding procedure outlined on pages 9 8 9 9 5 Install wheels and torque wheel nuts to specification NOTE If new brake pads are installed it is recommended that a burnishing procedure be performed toextend padser vice life and reduce noise Start machine and slowly in crease speed to 30 mph Gradually apply brakes to stopma chine Repeat procedure 10 times Front Caliper Mounting B...

Page 552: ...9 23 Polaris Sales Inc 4 99 BRAKES Front Brake Caliper Exploded View Pads Caliper Mount Piston Pin Boot Square O Rings Adjuster Screw ...

Page 553: ...forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 3 Remove brake pad retaining pin and pad spacer NOTE This is a spring pin do not spread apart farther than necessary to remove it 4 Clean pad retainer pins with a wire brush 5 Clean the caliper w brake cleaner or alcohol 6 Measure the thicknes...

Page 554: ...tain at least 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the master cylinder 4 It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes tostop machine Repeat procedure 10 times Spacer DH Brake Caliper Torque 18 ft lbs ...

Page 555: ... container to catch brake fluid draining from brake lines 3 Remove caliper 4 Remove brake pad retaining pin pads and pad spacer NOTE This is a spring pin Do not spread apart farther than necessary to remove it 5 Remove Allen head screw and separate caliper halves and remove pistons with piston pliers 6 Remove O rings and clean O ring grooves 7 Clean disc caliper body and pistons with brake cleaner...

Page 556: ...all new O rings in caliper body 2 piston seals per caliper half Be sure O ring grooves are thoroughly cleaned of all residue or piston may bind in bore Apply brake fluid to pistons and install carefully with a twisting motion to ease assembly until fully seated 2 Install new O rings between caliper halves 3 Carefully assemble caliper body making sure O rings are properly positioned in groove Torqu...

Page 557: ...aliper and torque mounting bolts 6 Install brake lines and tighten with a flare nut wrench 7 Follow bleeding procedure outlined on pages 9 8 9 9 of this section and refer to system overview and illustration on page 9 6 8 Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when lever is released If the bra...

Page 558: ...asure disc thickness at 8 different points around perimeter of disc Replace disc if worn beyond service limit 3 Mount dial indicator and measure disc runout Replace the disc if runout exceeds specifications Brake Disc Thickness Service Limit 167 4 242 mm New 177 187 4 496 4 750 mm Brake Disc Thickness Variance Service Limit 002 051 mm difference between measurements Brake Disc Runout Service Limit...

Page 559: ...inder Return Spring Auxiliary Brake Disc Auxiliary Master Cylinder Hand Brake Line Auxiliary Brake Line Auxiliary Brake Pads DH Caliper Auxiliary Reservoir Hand Brake Bleed Auxiliary Brake Bleed Torque 8 ft lbs 1 1 Kg m Torque 18 ft lbs 2 48 Kg m Torque 45 ft lbs 6 2 Kg m ...

Page 560: ...r Torque 18 ft lbs 2 48 Kg m DH Caliper Auxiliary Brake Pads Hand Brake Line Auxiliary Brake Line Auxiliary Brake Bleed Hand Brake Bleed Torque 15 ft lbs 2 07 Kg m Torque 18 ft lbs 2 48 Kg m Return Spring Auxiliary Brake Reservoir Auxiliary Brake Master Cylinder Torque 8 ft lbs 1 1 Kg m ...

Page 561: ...Brake Pads Torque 18 ft lbs 2 48 Kg m Hand Brake Line Auxiliary Brake Line Torque 15 ft lbs 2 07 Kg m Auxiliary Brake Bleed Hand Brake Bleed Auxiliary Reservoir Return Spring Auxiliary Master Cylinder Torque 15 ft lbs 2 07 Kg m Torque 8 ft lbs 1 1 Kg m Torque 8 ft lbs 1 1 Kg m Torque 8 ft lbs 1 1 Kg m ...

Page 562: ...iston See Ill 3 8 By hand walk caliper piston back and forth until it can be pulled out of caliper or remove with a caliper piston pliers internal expanding 9 Straighten a large paper clip and form a small hook on one end Polish the end of the clip so there are no sharp edges CAUTION Extreme care must be used to avoid scratching the cylinder bore seal ring groove surfaces 10 Position clip in cylin...

Page 563: ...can be covered with your finger Close bleeder fitting and add approximately 1 4 ounce of brake fluid to piston bore CAUTION Brake fluid will cause damage to painted surfaces Wipe up any spills at once 8 Lubricate piston with brake fluid and install in caliper piston bore flat beveled end first 9 Compress piston until seated in caliper and wipe off excess brake fluid from piston area 10 Attach brak...

Page 564: ... forward end of chain guard to the mounting brackets with hardware C 7 Reinstall right front and rear mud flap bolt in footrest 8 Refill master cylinder with DOT 3 brake fluid and reinstall cover and diaphragm 9 Refer to brake bleeding instructions in this chapter and bleed system 10 Field test unit for proper brakingaction beforeputting into service Inspect for fluid leaks and firm brakes Make su...

Page 565: ... Caliper Mechanical Auxiliary Brake Pads Brake Caliper Ramp Moveable Ramp Stationary Torque Seat then tighten an additional 1 2 turn See step 5 page 9 34 Auxiliary Caliper Arm Detail A Torque 5 6 ft lbs 69 83 Kg m Detail A Trail Boss Xpress Xplorer 300 ...

Page 566: ...9 37 Polaris Sales Inc 4 99 BRAKES Auxiliary Brake Caliper Mounting Mechanical Spacer Auxiliary Caliper Torque 12 ft lbs 1 65 Kg m ...

Page 567: ...rectly adjusted lever S Incorrectly adjusted stationary pad S Worn or damaged master cylinder or components S Improper clearance between lever and switch Lever Vibration S Disc damaged S Disc worn runout or thickness variance exceeds service limit Caliper Overheats Brakes Drag S Compensating port plugged S Pad clearance set incorrectly S Auxiliary brake pedal incorrectly adjusted S Brake lever or ...

Page 568: ...ion System Testing 10 16 10 17 Ignition System Troubleshooting 10 18 Battery Service 10 19 10 22 Charging System Testing 10 23 10 25 Starter System Troubleshooting 10 26 Starter System Testing 10 27 Starter Motor Service 10 28 10 32 Starter Drive 10 33 Speed Limiter System Troubleshooting 10 34 10 40 All Wheel Drive System 10 41 10 43 Electronic Speedometer Overview 10 44 10 45 Electronic Speedome...

Page 569: ......

Page 570: ...record the resistance The resistance of the component is equal to tested value minus the lead resistance SBecome familiar with the operation of your meter Be sure leads are in the 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 SVoltage amperage and resistance values included in this manual are obt...

Page 571: ...ssary to maintain lighting quality Riding with poor lighting can result in severe injury or death 1 Remove the seat 2 Remove the plastic panel surrounding the upper portion of the gas tank by first removing the gas tank cap 3 Remove the Phillips screws on either side of the panel at the junction of this panel the lower panels and the rear of the front fenders 4 Remove the Phillips screws on either...

Page 572: ...ing the headlight assembly on end to allow access to the back of the headlight assem bly 12 Disengage the wire bail holding the headlight lamp in place and move it out of the way 13 Grasp the base of the lamp and lift it out 14 Reverse the previous steps to replace the lamp and reassemble the panels NOTE Do not touch a halogen lamp with bare fingers Oil from your skin leaves a residue causing a ho...

Page 573: ... headlight cover Turning right screw clockwise moves the intense spot of light up to the left Turning the left screw clockwise moves intense spot of light up to the right Turning the bottom screw clockwise adjusts thelight upwards Headlight Lamp Replacement Gen III NOTE Do not touch a halogen lamp with bare fingers Oil from your skin leaves a residue causing a hot spot which will shorten the life ...

Page 574: ...bulb at back of housing and twist Carefully remove bulb from housing 4 Gently pull back locking tabs on wire harness terminal un til base of bulb is released Unplug bulb from harness 5 Plug new bulb into wire harness making sure it snaps into place 6 Carefully insert bulb into back of housing Twist to lock in place 7 Reinstall plastic lens retaining bracket 8 Reinstall Phillips screw in bottom of ...

Page 575: ...g and twist Carefully remove bulb from housing 4 Gently pull back locking tabs on wire harness terminal until base of bulb is released Un plug bulb from harness Headlight Housing Replacement Gen IV 1 Remove three Phillips screws at back of headlight pod 2 Remove Phillips screws from bottom of headlight pod at each front corner NOTE To aid in accessing these screws it may be helpful to turn handleb...

Page 576: ...that it s working Indicator Lamp Replacement Gen II 1 With a small flat screwdriver gently pry loose the indi cator light cover 2 Using a small flexible tube such as an oil delivery hose grasp the burned out lamp and remove it 3 Replace the removed lamp with a Polaris PN 4030042 4 Replace the indicator light cover NOTE Check all lights daily for proper operation replace or repair if necessary Indi...

Page 577: ...ing check hole and check the ignition timing NOTE Do not allow the engine to warm up The timing will retard approximately 2 when the engine is warm If the ignition timing is not within the specified range adjust the stator plate position as described below Flywheel Rotation EC38 PL 25 5 Timing Pointer 23 5 21 5 Flywheel Rotation 32 Timing Pointer 30 28 ES33PF EH42PL EH50PL Flywheel Rotation 27 25 ...

Page 578: ...troke 4 6 8 10 12 14 16 18 20 22 24 26 IGNITION TIMING DEGREES B T D C MAXIMUM ADVANCE POINT 0 1000 2000 3000 4000 5000 6000 7000 Typical 4 Stroke Actual advance point may vary by several hundred RPM either above or below 3500 Use the point of maximum advance when checking ignition timing 8 10 12 14 16 18 20 22 24 26 28 30 IGNITION TIMING DEGREES B T D C MAXIMUM ADVANCE POINT 0 1000 2500 3000 3500...

Page 579: ...0 546 0220 10 569 0220 626 0247 674 0270 11 688 0270 757 0298 815 0320 12 818 0320 900 0355 969 0380 13 959 0380 1 055 0416 1 136 0450 14 1 111 0440 1 223 0482 1 316 0520 15 1 274 0500 1 402 0552 1 509 0590 16 1 447 0570 1 593 0627 1 714 0680 17 1 632 0640 1 796 0707 1 933 0760 18 1 827 0720 2 011 0792 2 164 0850 19 2 033 0800 2 238 0881 2 407 0950 20 2 249 0890 2 476 0975 2 663 1050 21 2 475 0970...

Page 580: ...p Comment Flywheel I D Stamp Trail Boss Trail Blazer EC25PFE10 EC25PFE13 FF4564 FF45 64 With Ring Gear B 300 Xplorer Xpress EC28PFE02 FF4574 FF95 4574 150W A Sportsman 335 ES33PFE01 ES33PFE02 FF9502 FF95 02 200W A Xplorer 400 EC38PLE08 FF9504 FF95 04 200W A Scrambler 400 Sport 400 EC38PLE09 FF4576 FF95 4576 150W A Magnum EH50PLE08 FF9706 FF97 06 250W A Sportsman 500 and RSE EH50PLE09 FF9706 FF97 0...

Page 581: ...TE When replacing exciter coil position the numbers to the outside toward flywheel CDI Plug Meter Ω Ignition Coil Primary Winding 3 Ω Meter Ω 5000 Ω Meter Ω 6300Ω Ω Flywheel and Ring Gear Casting Refer to Specifications for identification NOTE CDI boxes may look the same but have different internal circuitry Be sure to always use the correct CDI box part number Refer to wiring diagrams for stator ...

Page 582: ...DI box part number CDI Box NOTE When replacing exciter coil position the numbers to the outside toward flywheel Ignition Kill Wire Black CDI Plug Coil Lead Meter Ω Meter Ω Ignition Coil Primary Winding 3 Ω Ignition Coil Secondary Winding 6 300Ω Meter Ω 5000 Ω Flywheel and Ring Gear Casting Refer to page 10 3b for identification Secondary Coil Check coil mount for good ground to engine 0 2 Ω Refer ...

Page 583: ...Pulse Coil Trigger Air Gap 016 040 4 1 0 mm Meter Ω 5000 Ω Meter Ω 6300 Ω Meter Ω Ignition Coil Primary Winding 3 Ω Exciter Coils NOTE CDI boxes may look the same but have different internal circuitry Be sure to always use the correct CDI box part number Ignition Kill Wire Black Coil Lead Secondary Coil Check coil mount for good ground to engine 0 2 Ω Refer to wiring diagrams for specified stator ...

Page 584: ...nding Meter 5k Ω NOTE CDI boxes may look the same but have different internal circuitry Be sure to always use the correct CDI box part number Battery Charging Coils Ignition Kill Wire Black Coil Lead 3 Ω 6300 Ω Pulse Coil Trigger Air Gap 016 040 4 1 0 mm Flywheel and Ring Gear Casting Refer to page 10 3b for identification Refer to wiring diagrams for specified stator coil resistance 200 W 3 wires...

Page 585: ...ble Refer to the chart on page 10 3 or the wiring schematic for meter connections and specifica tions Compare results to the specifications on the chart Are all within specifications Inspect connectors wiring and grounds to the component in question Replace the compo nent if a wiring problem cannot be found Yes No Yes Yes No Check coil ground connection between engine and coil mount using an ohmme...

Page 586: ...e electric start er spark plug installed The starter system must be in good condition and the battery fully charged 200 250 Watt 4 Stroke Coil Connect Meter Wires To Reading With Peak Reading Volt meter Exciter 1 Black Red and Red 140 DCV Exciter 2 Black Red and Green 140 DCV Exciter 3 Green and Red 5 DCV Pulse Trigger White Red and White 2 5 DCV 200 Watt 2 Stroke Coil Connect Meter Wires To Readi...

Page 587: ...d or connections wet corroded SPoor ignition coil ground e g coil mount loose or corroded SFaulty stator measure resistance of all ignition related windings SIncorrect wiring inspect color coding in connectors etc SFaulty ignition coil winding measure resistance of primary and secondary SWorn magneto RH end Crankshaft bearings SSheared flywheel key SFlywheel loose or damaged STrigger coil air gap ...

Page 588: ...k immediate medical attention To ensure maximum service life and performance from a new battery perform the following steps NOTE Do not service the battery unless it will be put into regular service within 30 days After initial service add only distilled water to the battery Never add electrolyte after a battery has been in service 1 Remove vent plug from vent fitting 2 Fill battery with electroly...

Page 589: ...27 3 Install clear battery vent tube from vehicle to battery vent WARNING Vent tube must be free from obstructions and kinks and securely installed If not battery gases could accumulate and cause an explosion Vent should be routed away from frame and body to prevent contact with electrolyte Avoid skin contact with battery electrolyte severe burns could result If electrolyte contacts the vehicle fr...

Page 590: ... 275 1 225 1 175 1 135 less than 1 115 At 80_F NOTE Subtract 01 from the specific gravity reading at 40_ F Load Test CAUTION Remove spark plug high tension leads and connect securely to engine ground before proceeding NOTE This test can only be performed on machines with electric starters This test cannot be performed with an engine or starting system that is not working properly A battery may ind...

Page 591: ...re as the battery dis charges The chart at right indicates freezing points by specific gravity Charging Procedure Charge the battery with a charger no larger than 1 10 of the battery s amp hr rating for as many hours as needed to raise the specific gravity to 1 270 or greater Electrolyte Freezing Points Specific Gravity of Electrolyte Freezing Point 1 265 75 F 1 225 35 F 1 200 17 F 1 150 5 F 1 100...

Page 592: ...y voltage must be present on red wire terminal on harness side of voltage 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 terminal bo...

Page 593: ... battery Depending on battery condition and system load the break even point may vary slightly The battery should be fully charged before performing this test SConnect an ammeter set to DC amps in series be tween the negative battery cable and terminal SConnect a tachometer according to manufacturer s in structions SWith engine off and the key and kill switch in the ON position the ammeter should ...

Page 594: ...meter leads to the Yellow and Yellow Red wires leading from the alternator SStart the engine and let it idle Reading should be a minimum of 7A at idle CAUTION This test simulates a full load on the alter nator Do not perform this test longer than required to obtain a reading or the alternator stator windings may overheat 10 15 seconds is acceptable Alternator Current Output Minimum of 7 AC Amps To...

Page 595: ...Test below SEngine problem seized or binding Can engine be rotated easily with recoil starter SFaulty or worn brushes in starter motor SAutomatic compression release inoperative Starter Motor Turns Engine Does Not Rotate SFaulty starter drive SFaulty starter drive gears or starter motor gear SFaulty flywheel gear or loose flywheel Voltage Drop Test The Voltage Drop Test is used to test for bad con...

Page 596: ...ect 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 starter ...

Page 597: ... Some solvents may leave a residue or damage inter nal parts and insulation 1 Note the alignment marks on both ends of the starter motor casing These marks must align during reassembly 2 Remove the two bolts washers and sealing O Rings Inspect O Rings and replace if damaged 3 Remove brush terminal end of housing while holding other two sections together ...

Page 598: ...emove nut flat washer large phenolic washer two small phenolic washers and O Ring from brush terminal Inspect the O Ring and replace if damaged 3 Remove brush plate and brushes Measure length of brushes and replace if worn past the service limit Replace springs if they are discolored or have inadequate tension 4 Inspect surface of commutator for wear or discoloration See steps 3 6 of armature test...

Page 599: ...rap of electrical tape on the threads of the terminal bolt to prevent O Ring damage during reinstallation 7 Install the O Ring over the bolt Make sure the O ring is fully seated 8 Remove the electrical tape and reinstall the two small phenolic washers the large phenolic washer flat washer and nut ...

Page 600: ...hould 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 replacement of the starter motor 6 Place armature in a growler Turn growler on and position a hacksaw blade or feeler gauge lengthwise 1 8 3 cm above a...

Page 601: ...n good condition and seated in groove EC38PL EC28PF EC25PF Install new gasket on starter flange 7 Inspect permanent magnets in starter housing Make sure they are not cracked or separated from housing CAUTION Use care when handling starter housing Do not drop or strike the housing as magnet damage is possible If magnets are damaged starter must be replaced Starter Motor Installation EC38PL 1 Loosel...

Page 602: ...ange of the anti kick out shoes 2 Remove the lock ring end washer spring retainers and clutch return spring Screw the overrun clutch off the end of the pinion shaft Remove the old spring and install a new one Lightly grease the pinion shaft and reinstall the clutch spring retainers end washer and lock ring in the reverse order Make sure the end washer is positioned properly so that it will hold th...

Page 603: ... Refer to parts manual or microfiche for part number and application PART NO TYPE FUNCTION LIMIT RPM COMMENTS 4060085 LR44 Reverse Limit 3500 ETC Limit 1900 Trail Boss Xpress Xplorer 4060186 LR49 1 Reverse Limit ETC Limit Trail Blazer Sport 400 4060199 LR83 1 Scrambler 400 4060201 LR83 2 Reverse Limit 3100 ETC Limit 1400 Scrambler 500 4060205 LR83 Reverse Limit 3100 ETC Limit 1400 Sportsman 335 40...

Page 604: ...tem will limit Below the reverse limit RPM the ignition system will operate normally Electronic Throttle Control ETC Theory of Operation Sportsman 335 Xplorer Xpress 300 Trail Boss LR44 The limiter also incorporates a throttle safety feature called the Electronic Throttle Control ETC When there is a mechanical problem in the throttle mechanism throttle plate throttle shaft or cable and the throttl...

Page 605: ...10 36 Polaris Sales Inc 4 99 ...

Page 606: ...adjusted incorrectly Adjust ETC switch until switch plunger is completely Engine miss at idle or rough idle ETC switch adjusted incorrectly Idle speed adjusted incorrectly Adjust ETC switch until switch plunger is completely depressed No plunger Clearance 1 16 1 8 throttle idle Idle speed adjusted incorrectly depressed No plunger Clearance 1 16 1 8 throttle lever free play Readjust Idle Backfire o...

Page 607: ...erse Limit System Scrambler 400 Scrambler 500 RPM Signal Gray Orange Reverse Gear Signal AWD Circuit Ground Y R Blk Gry Or Brn Wht LR83 2 Engine Stop Signal 10 38 Polaris Sales Inc 4 99 ELECTRICAL Reverse Limit System ...

Page 608: ... 9V AC AT IDLE N TEST GEAR POSITION INDICATOR SWITCH N TEST REGULATOR AND CHARGING SYSTEM MEASURE DC VOLTS ON GRY OR WIRE AT LR83 2 MODULE TO GROUND MEASURE AC VOLTS ON Y R WIRE AT LR83 2 MOD ULE TO GROUND Y DISCONNECT BLACK WIRE FROM LR83 2 MOD ULE AND CONNECT TO GROUND ENGINE STOP Y REPLACE LIMITER MODULE N TEST WIRING TEST CDI BLACK WIRE 1999 Scrambler 400 500 10 39 Polaris Sales Inc 4 99 ELECT...

Page 609: ...RPM Signal Gray Orange Reverse Gear Signal Y R Blk Gry Or LR83 1 Gry Or Blk Y R Engine Stop Signal RPM Signal 10 40 Polaris Sales Inc 4 99 ELECTRICAL Reverse Limit System ...

Page 610: ...nctioning properly Refer to AWD and Transmission Switch Testing this section No AWD in Reverse If AWD functions properly in forward but not in reverse perform the following tests NOTE Override button must be pushed for AWD in reverse 1 Turn ignition key on and shift transmission to reverse 2 If reverse lamp is on the gear selector switch is functioning properly If reverse lamp is off not illuminat...

Page 611: ...isabled or left in the testing mode Return all wires to the proper terminal on the terminal board according to color and verify proper neutral light operation after testing CAUTION The speed limiter control module may be permanently damaged if the machine is operated with the voltage regulator damaged and or the battery disconnected Hub Engagement Limiter RPM Test Perform this test to check hub en...

Page 612: ...tral before starting 11 Place the All Wheel Drive AWD switch in the OFF position button out no AWD 12 Slowly increase RPM above 4000 13 Push the AWD button to select All Wheel Drive The neutral light should light up indicating an interrupted ground path through the LR83 power on the Brown White terminal is finding ground through the neutral light bulb 14 Slowly let RPM drop back to idle The neutra...

Page 613: ...ngine is running the hour meter is recording the run time The hour meter RPM signal comes from the stator to the speedometer on pin D typically the yellow red wire Reverse Speed Limit PVT models only The transmission gear signal is sent tothe speedometeron pin F The operating speed of the ATV is limited when the transmission is shifted into reverse gear The ignition spark to the engine is turned o...

Page 614: ... If the engine is running the hour meter is recording the run time The hour meter RPM signal comes from the stator to the speedometer on pin D typically the yellow red wire Reverse Speed Limit PVT models only The transmission gear signal is sent tothe speedometeron pin F The operating speed of the ATV is limited when the transmission is shifted into reverse gear The ignition spark to the engine is...

Page 615: ... ORANGE Reverse signal With transmission in reverse around 12 V DC Should go to 0 V DC when the override button is pushed WARNING All tests done with key and engine stop switch ON All voltages are with reference to pin B ground Polaris probe kit 2201209 will help in measurements but is not necessary if care is used when probing the connectors ELECTRONIC SPEEDOMETER HARNESS WIRE LOCATION AND FUNCTI...

Page 616: ...EEDOMETER AND OR ODOMETER DISPLAY N N N Y Y Y Y N N Y Y Y Y N N N Y N N TEST 1 NO ALL WHEEL DRIVE Note If AWD light comes on speedometer is O K Proceed to AWD system tests in Service Manual Check hub coils related wiring and mechanical system for fault and repair as necessary REMOVE 6 PIN PLUG FROM BACK OF SPEEDOMETER HEAD PROCEED WITH HARNESS TEST PERFORM TEST 2 MEASURE PIN E TO PIN B IS BATTERY ...

Page 617: ...4 NO HIGH SPEED ENGAGEMENT LIMIT 1 RAISE VEHICLE WHEELS OFF GROUND AND SUPPORT IN A SAFE MANNER 2 REASSEMBLE SPEEDO MONITOR VOLTAGE BETWEEN BROWN WHITE WIRE OF HUB COIL AND VEHICLE GROUND OR WATCH AWD LAMP 3 TURN AWD OFF START ENGINE REV ABOVE 3000 RPM AND TURN AWD ON HUBS SHOULD NOT ENGAGE VOLTAGE SHOULD REMAIN AT 12 VDC AWD LAMP OFF 4 LOWER RPM AT APPROXIMATELY 2600 RPM VOLTAGE SHOULD GO TO 1 VD...

Page 618: ...WHEEL SPEED SENSOR Tools Required SL E D Test Light tool P N 2871745 SAdaptor Harness P N 2460761 or equivalent jumper wires To test wheel speed sensor 1 Disconnect 3 Pin connector from speedometer 2 Connect wires from test light to sensor 3 Pin connector as shown at right using adaptor harness P N 2460761 or jumper leads 3 Elevate front right side of vehicle until tire is off the ground 4 Slowly ...

Page 619: ...eter lost powr For example If the ATV was traveling 30 mph when the engine stop switch is turned off speedo may indicate 30 mph until reset 1 Operate vehicle at a speed greater than indicated on speedometer past point where needle is stuck Needle will return to normal operation 2 In the above example the ATV speed would have to exceed 30 mph to reset 10 50 Polaris Sales Inc 4 99 ELECTRICAL Speedom...

Page 620: ...ELECTRONIC SPEEDOMETER WIRING DIAGRAM PVT MODELS 10 51 Polaris Sales Inc 4 99 ...

Page 621: ...n Black and Brown wires No continuity between Red White and Red wires On Continuity between Red White and Red wires No continuity between Black and Brown wires Starter Switch Check starter switch at terminal board or at the harness connector Terminal boards Disconnect the White Red wire from the switch at the panel Turn key and engine stop switch ON The wire should show battery voltage when the st...

Page 622: ...or Turn ignition switch and en gine stop switch to On position Shift transmission and check for battery voltage on each of the wires when the specific range is selected NOTE Make sure transmission linkage is adjusted correctly or disconnect linkage rods before testing switch Inspect wiring between switch and terminal board and repair or replace if damaged Replace the switch if battery voltage is n...

Page 623: ...f the light socket is connected to the coolant temperature sensoron thecylinder head In normal operating conditions the temperature sensor is non conductive open If engine coolant reach es the specified temperature the sensor becomes conductive completing the ground path for the light With engine cold disconnect lead and measure resistance of sensor between connector terminal and ground There shou...

Page 624: ...77 F 25 C 100KΩ Fan OFF 240 F 116 C 3 5KΩ Fan ON 260 F 127 C 2 5KΩ Fan ON 290 F 143 C 1 6KΩ Fan ON Hot Light ON OFF Thermistor LR60 Fan Control Test STurn ON and engine stop switch to RUN STest voltage on R W wire to ground R W wire should have 12 Volts DC battery voltage SShort thermistor leads together fan and hot light ON If not test hot light fan motor and circuit SDisconnect thermistor wires ...

Page 625: ...ke at handlebar lever and check for continuity between switch contacts Replace switch if there is no continuity or greater than 5 ohms resistance when the brake is applied with slight pressure Headlamp Switch Remove the fuel tank and top cover Disconnect the headlamp switch wires Red White Green and Yellow at the panel or connector R W and from the headlamp high beam harness Y and low beam harness...

Page 626: ... C B A D F F F F F F F F F F F F High Neutral Reverse Switch Low Neutral Switch H N R Switch L N Switch 10 57 Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Switch Testing Gear Position Indicator Switch Test Switch Continuity Table Switch Schematic ...

Page 627: ... on the white wire will cause the ignition system to misfire at the ETC Limit listed on page 10 37 Test the ETC switch at the terminal board or harness connector NOTE Adjust throttle cable freeplay ETC switch and make sure throttle mechanism is functioning properly before testing the switch Refer to Maintenance Chapter 2 for cable adjustment procedure Terminal board models Disconnect White wire on...

Page 628: ...osition con tacts are separated as shown in Ill 1 by throttle cable tension The contacts are open in normal operation re gardless 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 preventing ignition spark This is the same as turning the key or engine stop switch OFF Test...

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Page 630: ... Polaris Industries Inc 4 99 ELECTRICAL Wiring Diagram 1999 Trail Blazer ...

Page 631: ... Polaris Industries Inc 4 99 ELECTRICAL Wiring Diagram 1999 Trail Boss ...

Page 632: ... Polaris Industries Inc 4 99 ELECTRICAL Wiring Diagram 1999 Xplorer 300 Xpress 300 ...

Page 633: ... Polaris Industries Inc 4 99 ELECTRICAL Wiring Diagram 1999 Sportsman 335 ...

Page 634: ... Polaris Industries Inc 4 99 ELECTRICAL Wiring Diagram 1999 Sport 400 ...

Page 635: ... Polaris Industries Inc 4 99 ELECTRICAL Wiring Diagram 1999 Scrambler 400 Early ...

Page 636: ... Polaris Industries Inc 4 99 ELECTRICAL Wiring Diagram 1999 Scrambler 400 Late ...

Page 637: ... Polaris Industries Inc 4 99 ELECTRICAL Wiring Diagram 1999 Xplorer 400 ...

Page 638: ... Polaris Industries Inc 4 99 ELECTRICAL Wiring Diagram 1999 Scrambler 500 ...

Page 639: ... Polaris Industries Inc 4 99 ELECTRICAL Wiring Diagram 1999 Magnum 500 ...

Page 640: ... Polaris Industries Inc 4 99 ELECTRICAL Wiring Diagram 1999 Sportsman 500 Sportsman 500 RSE ...

Page 641: ... Polaris Industries Inc 4 99 ELECTRICAL Wiring Diagram 1999 Worker 500 International ...

Page 642: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 1999 Big Boss 500 6x6 ...

Page 643: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Trail Blazer ...

Page 644: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Xplorer 4x4 ...

Page 645: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Trail Boss 325 ...

Page 646: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Magnum 325 2x4 ...

Page 647: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Magnum 325 4x4 ...

Page 648: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Xpedition 325 ...

Page 649: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Sportsman 335 Early ...

Page 650: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Sportsman 335 Late RU WKH IROORZLQJ PRGHOV DQG ...

Page 651: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Xplorer 400 ...

Page 652: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Scrambler 400 2x4 ...

Page 653: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Scrambler 400 4x4 ...

Page 654: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Xpedition 425 ...

Page 655: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Magnum 500 Early ...

Page 656: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Magnum 500 Late ...

Page 657: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Scrambler 500 Early ...

Page 658: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Scrambler 500 Late ...

Page 659: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Sportsman 500 Early ...

Page 660: ... Polaris Sales Inc 99 00 ATV Update 12 99 ELECTRICAL Wiring Diagram 2000 Sportsman 500 Late ...

Page 661: ...on tacts are separated as shown in Ill 1 by throttle cable tension The contacts are open in normal operation re gardless 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 preventing ignition spark This is the same as turning the key or engine stop switch OFF Test the ETC ...

Page 662: ...or Function 4 12 Carburetor Inspection 4 33 Carburetor Installation CV 4 39 Carburetor Main System 4 27 Carburetor Operation 4 25 Carburetor Pilot System 4 26 Carburetor Removal 4 29 Carburetor Starter System 4 26 CDI Output Test 10 18 Center Drive Chain Inspection Adjustment 2 37 Center Eccentric Assembly 7 34 7 36 Center Eccentric Disassembly 7 34 Center Eccentric Installation 7 36 7 37 Center E...

Page 663: ...e Installation 7 51 Front Gearcase Lubricant Change 2 10 Front Gearcase Lubrication Level 2 10 Front Gearcase Removal 7 44 7 45 Front Hub Bearing Adjustment AWD Models 7 13 Front Hub Disassembly 7 4 7 8 Front Hub Fluid Change 2 31 Front Hubs 4x4 Maintenance 2 31 Front Strut Ball Joint Replacement 5 25 Front Strut Rod Holding Tool 1 24 Front Strut Spring Compressor 1 24 Front Strut Weldment Replace...

Page 664: ...8 Piston Ring Installed Gap 3 65 Piston to Cylinder Clearance 3 63 Piston Cylinder Clearance 2 Stroke 3 34 Pliers CV Boot Clamp 1 25 Pre Ride Inspection 2 2 Prop Shaft Removal 7 44 Publication Numbers 1 2 Puller Drive Clutch 1 19 Puller Driven Clutch 1 19 Puller Flywheel 1 15 Puller Piston Pin 1 14 Puller Shaft 1 14 Pump Kit Vacuum 1 25 Pump Shaft End Play 3 76 Pump Shaft Oil Seal Installation 3 7...

Page 665: ...on 3 89 Throttle Cable Adjustment 2 11 2 12 Throttle Cable Lubrication 2 29 Throttle Lever Stop Adjustment 2 12 Throttle Opening vs Fuel Flow 4 14 Throttle Operation 2 11 Throttle Valve 4 15 Tie Rod Inspection 2 31 Tightening Tool Drive Clutch Spider 1 19 Timing Check Procedures 10 10 Timing Light 1 13 Tire Inspection 2 42 Tire Tread Depth 2 42 Toe Alignment 2 30 5 8 5 9 Tool Fox Shock IFP Removal...

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