Polaris TRAIL BOSS 2003 Service Manual Download | Manualshive

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ENGINE

3.37

The following procedure must be used to torque the
cylinder head properly:

Torque

5-6.5 ft. lbs.

(7--9 Nm)

Torque in cross

pattern per procedure

Torque all bolts evenly in a cross

pattern. Apply oil to bolt threads

*Torque bolts to 18 ft. lbs. (24.5 Nm)

*Loosen bolts evenly 180

°

(1/2 turn)

*Torque bolts to 11 ft. lbs. (14.7 Nm)

*From this point, tighten bolts evenly

90

°

(1/4 turn)

*Finally, tighten another 60

°

(1/6 turn)

Torque 6mm case bolts to 5--6.5 ft. lbs.

( 7--9 Nm )

CAM CHAIN/CAMSHAFT

INSTALLATION

CAUTION: Serious engine damage may result if
the camshaft is not properly timed to the
crankshaft.

Install the cam chain over the crankshaft.

Sprocket

Mark

Plated

Link

Crankcase

Projection

IMPORTANT CAMSHAFT TIMING NOTE:

In order

to time the camshaft to the crankshaft, the piston must
be precisely located at Top Dead Center (TDC). This
can be accomplished using one of two methods.

When the stator assembly is removed, follow the
procedure outlined in Method 1. This method uses
the cam chain plate links to time the camshaft and the
dot on the cam chain drive sprocket to establish TDC
(see below, Method 1). It is important to note that this
method can only be used when the stator is removed
and the cam chain drive sprocket is in view. The plate
links

are not

used to time the camshaft when the

flywheel is installed.

When the stator assembly is installed, use Method 2.
This method establishes accurate Top Dead Center
(TDC) by aligning the single mark on the flywheel with
the notch in the timing inspection hole (see Method 2,
Page 3.40). The camshaft sprocket alignment marks
are parallel to the gasket surface, the alignment pin
faces to the intake side, and camshaft lobes are
pointing down.

Camshaft Installation - Timing Method 1
Refer to Illustration Page 3.39

If the stator assembly is removed:

NOTE:

Use this

method only when the stator is removed and cam
chain drive sprocket is in view.

1.

Rotate the crankshaft until the mark on the cam
chain drive sprocket is aligned with the crankcase
projection (mark facing downward).

2.

Align the single plated link on the cam chain with
the marked tooth of the cam chain drive sprocket.
Use a wire to pull the chain up through the cylinder
and cylinder head, and secure it to hold the chain
in place.

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Summary of Contents for TRAIL BOSS 2003

Page 1: ...PN 9918061 Printed in USA 2003 TRAIL BOSS SERVICE MANUAL PN 9918061 2003 TRAIL BOSS SERVICE MANUAL PN 9918061 59173 03 TrailBoss Cover 8 23 02 8 47 PM Page 1 ...

Page 2: ...e operations component identification and unit repair along with service specifications for 2003 Polaris Trail Boss ATVs Comments or suggestions about this manualmay be directed to Service Publications Dept Polaris Sales Inc 2100 Hwy 55 Medina Minnesota 55340 2003 Trail Boss 330 ATV Service Manual PN 9918061 ECopyright 2002 Polaris Sales Inc All information contained within this publication is bas...

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

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

Page 5: ......

Page 6: ...r Location 1 2 2003 Trailboss Model 1 3 Replacement Keys 1 4 Machine Dimensions 1 5 Specifications 2003 Trail Boss 330 1 6 1 7 Publication Numbers 1 8 Paint Codes 1 8 Standard Torque Specifications 1 8 Tap Drill Charts 1 9 Decimal Equivalent Chart 1 9 Unit of Measure Conversion Table 1 10 Glossary of Terms 1 11 ...

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

Page 8: ...GENERAL INFORMATION 1 3 2003 TRAILBOSS MODEL 2003 TRAILBOSS 330 ...

Page 9: ...take the first two digits on the original key and refer to the chart to the right for the proper part number Should both keys become lost ignition switch replacement is required Series Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 31XX Key Series Number ...

Page 10: ...46 in 117 cm 46 in 117 cm 75 in 191 cm 49 5 in 126 cm 34 in 86 cm FRONT SIDE GENERAL INFORMATION 1 5 MACHINE DIMENSIONS ...

Page 11: ...Grey Black 2 2 40E helix black driven spring ENGINE Type 4 Cycle Single Cyl Displacement 329 cc Bore 3 0912 78 5mm Stroke 2 6792 68mm Valve Clearance In Ex 0 006 0 00082 0 15 0 02 mm BTDC on compression Cooling Air with fan assisted oil cooler Lubrication Type Wet Sump Piston Marking None Operating RPM 200 6300 RPM Idle RPM 50 lights off 1300 RPM Compression Ratio 9 2 1 Compression Pressure 70 90 ...

Page 12: ...ing Front Suspension MacPherson Strut Gear Reduction Rev 3 05 1 Tow Capacity 850 lbs 385 9 kg Gear Reduction High 2 68 1 Turning Radius 752 191 cm Final Drive Ratio 11 40 78P Toe Out 1 82 1 42 3 6 35 mm Brake Hand Single Lever Hyd Disc Ground Clearance 5 52 13 97 cm Brake Auxiliary Foot Hydraulic Front Vertical Travel 6 72 17 02 cm Rear Suspension Progressive Rate Swing Arm Rear Travel 9 02 22 86 ...

Page 13: ... See Quick Reference Manual for ordering info STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline FOR SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section There are exceptions in the steering suspension and engine sections Bolt Size Threads In Grade 2 Grade 5 Grade 8 Torque in lbs Nm 10 24 27 3 1 43 5 0 60 6 9 1...

Page 14: ...6 11 32 R 3 8 13 32 13 32 0 0995 0 0937 0 1285 0 125 0 166 0 161 0 196 0 234 0 277 0 265 0 3125 0 3125 0 3437 0 339 0 375 0 406 0 406 3 32 3 32 1 8 1 8 11 64 5 32 13 64 15 64 9 32 17 64 5 16 5 16 11 32 11 32 3 8 13 32 13 32 DECIMAL EQUIVALENTS 1 64 0156 1 32 0312 1 mm 0394 3 64 0469 1 16 0625 5 64 0781 2 mm 0787 3 32 0938 7 64 1094 3 mm 1181 1 8 1250 9 64 1406 5 32 1563 4 mm 1575 11 64 1719 3 16 1...

Page 15: ...ubic centimeters cc x 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters l Liters l x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Liters l Liters l x 0 88 Imperial quarts Imp qt Imperial quarts Imp qt x 1 201 US quarts US qt US quarts US qt x 0 833 Imperial quarts Imp qt US quarts US qt x 0 946 Liters l Liters l x 1 057 US quarts US qt US gallons US gal x 3 785 Liters l Li...

Page 16: ...n a rotational direction g Gram Unit of weight in the metric system gal Gallon ID Inside diameter in Inch inches Inch Pound In lb 12 in lbs 1 ft lb kg cm 2 Kilograms per square centimeter kg m Kilogram meters Kilogram meter A force of one kilogram at the end of a lever one meter in length applied in a rotational direction l or ltr Liter lbs in 2 Pounds per square inch Left or Right Side Always ref...

Page 17: ...GENERAL INFORMATION 1 12 NOTES ...

Page 18: ...witch Adjustment 2 11 Fuel System 2 12 Compression Test 2 13 Battery Maintenance 2 13 2 14 Electrical 2 14 2 15 Oil Cooler Maintenance 2 15 Air Filter Service 2 15 Air Box Sediment Tube Service 2 16 Breather Filter 2 16 Recoil Housing PVT Drying 2 16 2 17 Oil Level Change Filter 2 17 2 18 Valve Clearance 2 19 2 20 Steering and Toe Alignment 2 20 2 22 Exhaust System Maintenance 2 22 Brake System Se...

Page 19: ... routing hose condition EH Valve Clearance 100 hrs 12 months 1000 1600 Inspect Adjust E Idle Speed As required As required Adjust H Throttle Cable ETC Switch 50 hrs 6 months 500 800 Inspect Adjust Lubricate Replace if necessary Choke Enricher Cable 50 hrs 6 months 500 800 Inspect Adjust Lubricate Replace if necessary Carburetor Float Bowl 50 hrs 6 months 500 800 Drain bowl periodically and prior t...

Page 20: ...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 Monthly Monthly Grease Monthly Brake Syst...

Page 21: ...se Gun Kit 2871329 Dielectric Grease Nyogel Coolant 2871323 60 40 Coolant Gallon 6 Count 2871534 60 40 Coolant Quart 12 Count Additives Sealants Thread Locking Agents Misc 2870585 Loctite Primer N Aerosol 25 g 2871956 Loctite Thread Sealant 565 50 ml 6 Count 2871949 Loctite Threadlock 242 50 ml 10 Count 2871950 Loctite Threadlock 242 6 ml 12 Count 2871951 Loctite Threadlock 262 50 ml 10 Count 2871...

Page 22: ...proper level Change after 1st month 6 months or 100 hours thereafter Change more often 25 50 hours in extremely dirty conditions or short trip cold weather operation 2 Transmission Polaris Synthet ic Gear Case Lubricant Add lube to FULL level on dip stick Change annually 3 Brake Fluid Polaris DOT 3 Brake Fluid Fill master cylinder reservoir to in dicated level inside reservoir See Page 2 23 As req...

Page 23: ... fresh grease by hand and reassemble Semi annually 8 Rear Axle Bearings Polaris All Season Grease Locate grease fitting on eccentric and grease with grease gun Semi annually 9 Swing Arm Bush ings Polaris All Season Grease Locate grease fitting on swing arm and grease with grease gun Semi annually More often under severe use such as operated in water or under severe loads Semi annually or 50 hours ...

Page 24: ...l 5 2871572 Strut Rod Wrench 5 2871573 LH Strut Spring Compressor 5 2871574 RH Strut Spring Compressor 5 2870506 Clutch Puller 6 9314177 Clutch Holding Wrench 6 2871358 Clutch Holding Fixture 6 2870341 Drive Clutch Spider Removal and Install Tool 6 2870654 Clutch Offset Alignment Tool 6 2870913 Driven Clutch Puller 6 2870910 Roller Pin Tool 6 2871226 Clutch Bushing Replacement Tool Kit 6 2870386 P...

Page 25: ...t as required to bring level into operating range as shown Full Operating Range TRANSMISSION FLUID CHANGE TORQUE STOP ADJUSTMENT 1 Remove skid plate if necessary 2 Place a drain pan beneath the transmission oil drain plug area 3 Loosen jam nut A 4 Turn adjuster bolt B in to allow the removal of drain plug 5 Remove the drain plug and wipe the magneticend clean to remove accumulated metallic filings...

Page 26: ...r both jam nuts are tight G The transmission shift linkage should be periodically inspected for wear and parts replaced as required to remove excess play from shift linkage G Refer to Transmission chapter for more information NOTE The rod end must be held when tightening the jam nut to prevent damage to the rod end SHIFT LINKAGE ADJUSTMENT 1 Inspect shift linkage tie rod ends clevis and pivot bush...

Page 27: ... inspect choke cable for kinks or sharp bends in routing PILOT SCREW IDLE MIXTURE ADJUSTMENT NOTE These procedures are intended as reference only Actual final settings may be different depending on the atmospheric conditions in your area 1 Turn pilot screw in clockwise until lightly seated Turn screw out the specified number of turns NOTE Do not tighten the pilot screw forcefully against the seat ...

Page 28: ...play Direction of travel Boot Adjuster Sleeve Lock nut Boot 3 Tighten locknut and slide boots over cable adjuster until they touch at the middle point of the adjuster 4 With engine running turn the handlebars from full left to full right with transmission in neutral Engine RPM should not change and the engine should not die If either of these occur return to the first step THROTTLE OPERATION To re...

Page 29: ...amage 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 years 2 Be sure vent lines are routed properly an...

Page 30: ...tion on models with automatic decompression Follow tester manufacturer s instructions to perform a cylinder leakage test Never use high pressure leakage testers as crankshaft seals may dislodge and leak Cylinder Compression Standard 70 90 PSI Cylinder Leakage Service Limit 10 Inspect for cause if leakage exceeds 10 ENGINE MOUNTS Inspect rubber engine mounts for cracks or damage ENGINE FASTENER TOR...

Page 31: ...tion of one cup water and one tablespoon baking soda Rinse well with clean water and dry thoroughly 5 Reinstall battery attaching positive red cable first and then the negative black cable 6 Coat terminals and bolt threads with Dielectric Grease PN 2871329 7 Reinstall battery cover and holder strap SPARK PLUG 1 Remove spark plug high tension lead Clean plug area so no dirt and debris can fall into...

Page 32: ...hould be cleaned before each ride using the following procedure 1 Lift up on the rear of the seat 2 Pull the seat back and free of the tabs NOTE When reinstalling seat make sure the slots in the seat engage the tabs in the fuel tank 3 Remove clips from air box cover A and remove cover Inspect the gasket E It should adhere tightly to the cover and seal all the way around 4 Loosen clamp and remove a...

Page 33: ...e sediment tube will require more frequent service if the vehicle is operated in wet conditions or at high throttle openings for extended periods 1 Remove drain plug from end of sediment tube 2 Drain tube 3 Reinstall drain plug RECOIL HOUSING 0 Drain the housing periodically to remove moisture Recoil Drain Crankcase Drain 0 Drain the recoil housing after operating the ATV in very wet conditions Th...

Page 34: ...utches Allow engine RPM to settle to idle speed shift transmission to lowest available range and test for belt slippage Operate ATV in lowest available range for a short period of time until PVT system is dry ENGINE OIL LEVEL To check the oil level 1 Set machine on a level surface 2 Start and run engine for 20 30 seconds This will return oil to its true level in the engine sump 3 Stop engine remov...

Page 35: ...beneath oil filter Using an oil filter wrench turn filter counterclockwise to remove Filter 9 Using a clean dry cloth clean filter sealing surface on crankcase 10 Lubricate O ring on new filter with a film of engine oil Check to make sure the O ring is in good condition 11 Install new filter and turn by hand until filter gasket contacts the sealing surface then turn and additional 1 2 turn NOTE Th...

Page 36: ...ke valve closing and then start to open continue to rotate until the T aligns with pointer The camshaft lobes should be pointing downward 7 Verify accurate TDC positioning by observing the T mark aligned with the pointer in the timing inspection hole In this position there should be clearance on all valves 0 006 0 0008I 0 15 0 02 mm BTDC on compression INTAKE VALVE CLEARANCE INTAKE VALVE CLEARANCE...

Page 37: ... be sure the steering mechanism is not restricted or limited NOTE Whenever steering components are replaced check front end alignment Use only genuine Polaris parts WARNING NOTE Due to the critical nature of the procedures outlined in this chapter Polaris recommends steering component repair and adjustment be performed by an authorized Polaris Dealer Only a qualified technician should replace worn...

Page 38: ...sition NOTE The steering arm frog can be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible NOTE It is important that the height of both marks be equally positioned in order ...

Page 39: ...y hot Serious burns could result from contact with ex haust components G To reduce fire hazard make sure that there are no combustible materials in the area when purging the spark arrestor G Wear eye protection G Do not stand behind or in front of the ve hicle while purging the carbon from the spark arrestor G Never run the engine in an enclosed area Exhaust contains poisonous car bon monoxide gas...

Page 40: ... G Use Polaris DOT 3 Brake Fluid PN 2870990 Parking Brake Lock Sight Glass Min Max Rear Master Cylinder Reservoir G Check brake system for fluid leaks excessive travel or spongy feel G Check friction pads for wear damage or looseness G Check surface condition of the disc G Inspect thickness of brake pad friction material BRAKE PAD INSPECTION 3 64 1cm Minimum Thickness Pads should be changed when f...

Page 41: ...ard on the chain as shown Replace sprocket if chain movement exceeds 1 4 6 cm DRIVE CHAIN INSPECTION The chain must be replaced when it reaches 3 elongation 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 the specification Replace the chain if the length exceeds the wear limit 3 When replacing or reinstalling dri...

Page 42: ... of the chain to ensure deflection is correct at the tightest point 3 8 10 mm Deflection ADJUSTMENT PROCEDURE CONCENTRIC SWINGARM 1 Loosen chain guide 2 Loosen the two 2 eccentric clamp bolts 3 Loosen caliper mounting bracket bolts located under the axle See illustration for bolt locations Loosen 2 caliper mounting bracket bolts Step 3 Loosen Eccentric clamp bolts Step 2 4 Insert a pin punch throu...

Page 43: ...y loosening the rear eccentric housing as described previously and using a 2 1 2 63 5 mm wrench on the flats of the eccentric Turn the eccentric with the wrench until chain tension is to specification Tighten Loosen SUSPENSION SPRING PRELOAD ADJUSTMENT Operator weight and vehicle loading affect suspensionspringpreloadrequirements Adjustas necessary to avoid bottoming of the shocks FRONT SUSPENSION...

Page 44: ... 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 Tapered nuts install with tapered side against wheel Flange Nuts Flat side against wheel WHEEL INSTALLATION 1 With the transmission in gear and the parking brake locked place the wheel in the correct position on the wheel hub Be sure th...

Page 45: ...he warning tire pressure decal applied to the vehicle G Improper tire inflation may affect ATV maneuverability G When replacing a tire always use original equipment size and type G The use of non standard size or type tires may affect ATV handling Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Tread Depth 1 8I 3 mm FRAME NUTS BOLTS FASTENERS Periodically inspect...

Page 46: ...Lubrication 3 7 Oil Pressure Test 3 7 3 8 Lubrication Oil Flow 3 8 3 9 Engine Exploded View 3 10 Engine Top End Disassembly 3 11 3 18 Valve Valve Seat Service 3 18 3 22 Engine Bottom End Disassembly 3 22 3 32 Crankcase Bearing Assembly 3 32 Crankshaft End Play Inspection 3 32 3 33 Engine Assembly Inspection 3 33 3 42 Recoil Disassembly Inspection Reassembly 3 42 3 44 Spark Plug Fouling Checklist 3...

Page 47: ...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 2 908 73 8 mm Valve Seat Contacting width In Std 039 1 0 mm g Limit 055 1 4 mm Ex Std 059 1 5 mm Limit 071 1 8 mm Valve Guide Inner diameter 2362 2367 6 000 6 012 mm Protrusion above head 681 689 17 3 17 5 mm Valve Margin thickness In Std 039 1 0 mm g Limi...

Page 48: ...g Piston ring installed gap Top ring Std 0079 0118 0 20 0 30 mm g g g p p g Limit 039 1 0 mm Second i Std 0138 0197 0 35 0 50 mm ring Limit 039 1 0 mm Oil ring Std 0079 0236 0 20 0 60 mm g Limit 059 1 5 mm Piston Ring Standard clearance i i i Top ring Std 0014 0030 0 035 0 075 mm g piston ring to ring groove p g Limit 0059 0 15 mm Second i Std 0010 0026 0 025 0 065 mm ring Limit 0059 0 15 mm Conne...

Page 49: ...nder Head Bolts 10mm Refer to Engine Assembly for torque pro cedure Drive Clutch Bolt 7 16 20 40 55 Nm Flywheel 16mm 58 72 78 98 Nm Oil Hose Fit tings 1 2 9 16 20 27 Nm Oil Delivery Pi pe 12mm 11 15 15 21 Nm Oil Drain Bolt Crankcase 14mm 14 17 19 23 Nm Oil Filter Pipe Fitting Con nector 20mm 36 43 49 59 Nm Oil Line Fitting 20 27 Nm Oil Pump Cov er 6mm 4 5 5 7 Nm Oil Relief Valve Plug 14mm 14 5 16 ...

Page 50: ...or G Starter Motor Starter Drive G Cylinder Head G Cylinder G Piston RIngs G Oil pump G Rocker Arms G Cam Chain and Sprockets The following components require engine removal for service G Camshaft G Connecting Rod G Crankshaft G Crankshaft Main Bearings G Crankcase ENGINE REMOVAL 1 Clean work area 2 Thoroughly clean the ATV engine and chassis 3 Disconnect battery negative cable 4 Remove the follow...

Page 51: ...tant Using a common spring loaded glaze breaker for honing is not advised for nicasil cylinders Polaris recommends using a rigid hone or arbor honing machine Cylinders may be wet or dry honed depending upon the hone manufacturer s recommendations Wet honing removes more material faster and leaves a more distinct pattern in the bore HONING TO DEGLAZE A finished cylinder should have a cross hatch pa...

Page 52: ...ately 1 2 1 3 cm beyond the bore at the end of each stroke G Release the hone at regular intervals and inspect the bore to determine if it has been cleared and to check piston fit NOTE Do not allow cylinder to heat up during honing The thinner areas of the liner around the ports will expand causing an uneven bore G After honing has been completed inspect all port opening areas for rough or sharp e...

Page 53: ... Oil Pressure at 3000 RPM Engine Hot Standard 71 99 PSI Minimum 20 PSI at idle ES32PF10 NOTE Use Polaris Premium 0 40W Synthetic Engine Lubricant PN 2871281 OIL COOLER ASSEMBLY Inlet Hose Top Bracket Lower Bracket Fan Motor Shroud Thermistor Oil Cooler U Clips Rubber Mounts Screws Hose Clamps To Engine ...

Page 54: ...l Rocker Arm Rocker Shaft Sprocket Chain Cam Lobe Cam Shaft Journal Indirect Lubrication Crankcase Oil Passage Crankshaft Small End Bearing Cylinder Sleeve Main Bearing Large End Bearing Crank Pin Oil Jet Fixed Crankcase Oil Passage Pressure Relief Connecting Rod Piston Through Front Right Cylinder Head Bolt Passage Oil Cooler Oil Hoses Out Crankcase Oil Passage In ...

Page 55: ...ENGINE 3 10 ES32PFE ENGINE EXPLODED VIEW Crankcase Cylinder Cylinder Head Crankshaft and Piston Valve Train ES32PF ...

Page 56: ... crankshaft center line NOTE The sprocket marks align with gasket surface and the cam lobes should be pointing down and valves should have clearance at this point Sprocket marks align with gasket surface 5 Remove cam chain tensioner plug sealing washer spring and pin CAUTION The plug is under spring tension Maintain inward pressure while removing 6 Remove the two 6x25 mm cam chain tensioner flange...

Page 57: ...n order for assembly Inspect surface of followers Wave washer PTO 3 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 4 Remove cylinder block plug using a 14 mm hex head wrench Cylinder block plug 5 Measure O D of rocker shaft Inspect it for wear or damage Compare to specifi...

Page 58: ... screws for wear pitting or damage to threads of the adjuster or locknut Replace all worn or damaged parts NOTE The end of the adjuster screw is hardened and cannot be ground or re faced CAMSHAFT REMOVAL 1 Remove cam shaft end plug A A 2 Remove camshaft sprocket flange bolt and washer 3 Place a clean shop towel in the area below cam chain sprocket 4 Remove sprocket from camshaft and chain 5 Secure...

Page 59: ... shaft for smooth operation throughout the entire range of rotation Lobe 2 Remove release lever shaft and return spring spacer 3 Inspect shaft for wear or galling 4 Inspect lobe on end of release lever shaft for wear and replace if necessary AUTOMATIC COMPRESSION RELEASE INSTALLATION 1 Slide spring onto shaft 2 Apply engine oil to release lever shaft CAMSHAFT INSPECTION 1 Visually inspect each cam...

Page 60: ... Clearance Std 0022 0035I 055 090 mm Limit 0039I 10 mm Replace camshaft if damaged or if any part is worn past the service limit Replace cylinder head if camshaft journal bore is damaged or worn excessively CYLINDER HEAD REMOVAL 1 Loosen each of the four cylinder head bolts evenly 1 8 turn each time in a cross pattern until loose A 2 Remove bolts A and tap cylinder head lightly with a plastic hamm...

Page 61: ...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 spring retainer and spring A NOTE The valve springs should be positioned with the tightly wound coils against the cylinder head on progressively wound springs A 3 Push valve out keeping it in order for reassembly in th...

Page 62: ...itting wear or damage A A B 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 specifications Measure valve stem in several places Valve Stem Diame...

Page 63: ...en Good Too Narrow Cylinder Head Reconditioning NOTE Servicing the valve guides and valve seats requires special tools and a thorough knowledge of reconditioning techniques Follow the instructions provided in the Valve Seat Reconditioning Kit PN 2200634 CAUTION Wear eye protection when performing cylinder head service Valve guide replacement will require heating of the cylinder head Wear gloves to...

Page 64: ... head from the combustion chamber side Be careful not to damage guide bore or valve seat when removing guides 7 Place cylinder head on cylinder head table NOTE Be sure cylinder head is still at 212 F 100 C before installing new guides 8 Place a new guide in the valve guide installation tool and press guide in to proper depth Check height of each guide above the cylinder head A Refer to specificati...

Page 65: ...ct area of the seat on the valve face apply a thin coating of Prussian Bluetpaste to the valve seat If using an interference angle 46 apply black marker to the entire valve face A A 6 Insert valve into guide and tap valve lightly into place a few times 7 Remove valve and check where the Prussian Bluet or black marker indicates seat contact on the valve face The valve seat should contact the middle...

Page 66: ...ide and lap using a lapping tool or a section of fuel line connected to the valve stem 11 Rotate the valve rapidly back and forth until the cut sounds smooth Lift the valve slightly off of the seat rotate 1 4 turn and repeat the lapping process Do this four to five times until the valve is fully seated and repeat process for the other valve 12 Clean cylinder head valves and camshaft oil supply pas...

Page 67: ...NG TEST 1 Clean and dry the combustion chamber area 2 Pour a small amount of clean solvent into the intake port and check for leakage around each intake valve The valve seats should hold fluid with no seepage 3 Repeat for exhaust valves by pouring fluid into exhaust port ENGINE BOTTOM END DISASSEMBLY Cylinder Removal Follow engine disassembly procedures to remove valve cover camshaft and rocker ar...

Page 68: ...e side Do not scratch the ring lands 4 Repeat procedure for second ring The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section 5 Remove the top rail first followed by the bottom rail 6 Remove the expander CYLINDER INSPECTION 1 Remove all gasket material from the cylinder sealing surfaces 2 Inspect the top of the cylinder for warpage usi...

Page 69: ... 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin 5 mm Piston Piston Pin 2 Subtract this measurement from the maximum cylinder measurement obtained in Step 5 Piston to Cylinder Clearance Std 0015 0032I 038 082 mm Limit 004I 11 mm Piston O D Std 3 0881 3 0891I 78 438 77 462 mm 3 Measure piston pin bore Piston Pin Bore 7095 7097I 18 007 18 013 mm 4 Measure pi...

Page 70: ... gap with a feeler gauge at both the top and bottom of the cylinder NOTE A difference in end gap indicates cylinder taper The cylinder should be measured for excessive taper and out of round 3 If the bottom installed gap measurement exceeds the service limit replace the rings NOTE Always check piston ring installed gap after re boring a cylinder or when installing new rings A re bored cylinder sho...

Page 71: ...tions 90 apart to determine if bushing is out of round Calculate bushing clearance Replace bushing if clearance exceeds the service limit A Starter Drive Bushing Clearance Std 0015 004 038 102 mm Service Limit 008 203 mm 6 Inspect gear teeth on starter drive Replace starter drive if gear teeth are cracked worn or broken FLYWHEEL STATOR REMOVAL INSPECTION 1 Remove flywheel nut and washer A 2 Instal...

Page 72: ...3 kg load Measure length of a 20 pitch section of chain Replace if worn past service limit Measure 20 Pitch Length Chain Service Limit 5 407 13 7 cm DRIVE SPROCKET REMOVAL INSPECTION 1 Using the Slotted Nut Socket PN 2871293 remove the crankshaft slotted nut A NOTE The slotted nut is a left hand thread A B Remove 2 Remove cam chain drive sprocket B and Woodruff key from crankshaft 3 Inspect sprock...

Page 73: ...52 cm 3 Inspect valve for wear 4 Check seat area for nicks or foreign material that may prevent proper sealing of valve OIL PUMP REMOVAL INSPECTION 1 Remove the five screws on the oil pump cover with an impact driver 2 Inspect rotors and mating surface of oil pump cover Check for nicks burrs or surface irregularities 3 Measure pump end clearance using a feeler gauge and straight edge Outer Feed Ro...

Page 74: ...over with screw 4 Tighten screw securely 5 Install oil pump on crankcase and torque bolts to 6 ft lbs 8 Nm Oil Pump Attaching Bolt Torque 6 ft lbs 8 Nm CRANKCASE SEPARATION 1 Remove flange bolts 11 from magneto side crankcase evenly in a criss cross pattern 2 Separate crankcase by tapping with a soft faced hammer in reinforced areas 3 Watch the gap along the crankcase mating surface and separate t...

Page 75: ... rod nuts and connecting rod bearing cap NOTE It may be necessary to lightly tap on the side of the cap with a plastic mallet to loosen it CRANKSHAFT INSPECTION 1 Measure the width of the rod bearing journal 2 Measure the width of the connecting rod at the big end Connecting Rod Width Std 8233 8252I 20 88 20 93 mm 3 Visually inspect bearing journal for scoring damage or excessive wear Replace cran...

Page 76: ...t to disturb the PlastigaugeÒ 6 Use the measuring scale on the PlastigaugeÒ wrapper to measure the thickness of the PlastigaugeÒ The rod must not turn during this procedure NOTE Use the widest part of the PlastigaugeÒ to determine the oil clearance Connecting Rod To Crankshaft Clearance Std 0007 0021 019 053 mm Limit 0026 065 mm 7 If oil clearance is not within specification install new rod bearin...

Page 77: ...embling the crankcase the following steps should be performed to determine the amount of crankshaft end play Excessive end play may cause engine noise at idle and slow speeds Too little play will side load the bearings which may lead to premature bearing failure Crankshaft End Play Adjustment 1 Make sure crankshaft bearing is firmly seated in the MAG side crankcase 2 Measure the distance from the ...

Page 78: ...ckness as required to bring end play within range Crankshaft End Play 008 016 02 04 cm ENGINE ASSEMBLY CONNECTING ROD INSTALLATION 1 Clean all oil off connecting rod connecting rod cap and bearing inserts 2 Install bearing inserts onto connecting rod and cap NOTE First install bearing tab into groove then press the rest of the bearing into place 3 Apply assembly lube onto the connecting rod bearin...

Page 79: ...the gap equally until the surfaces are tightly sealed 3 Install the crankcase flange bolts and tighten to specified torque in 3 steps according to the torque pattern See Page 3 4 Crankcase Bolt Torque 14 15 ft lbs 19 21 Nm Crankcase Sealant PN 2871557 OIL PUMP INSTALLATION 1 Inspect the oil pump sealing surface on the crankcase Apply a light film of engine oil to the surfaces Install outer and inn...

Page 80: ...Install the oil ring top rail with the end gap at least 30 from the end of the expander 3 Install the bottom rail with the gap at least 30 from the end of the expander on the side opposite the top rail gap Ring Profile Top R1 Mark up R Mark up Second 4 Install the second ring with the R mark facing up Position the end gap toward the rear intake side of the piston 5 Install the top ring chrome face...

Page 81: ...Position the Piston Support Block PN 2870390 A beneath the piston skirt to support the piston during cylinder installation A 2 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 rings are captive in the sleeve 3 Remove the ring compressor and support block 4 Push the cylinder downward until fully seated o...

Page 82: ...and the dot on the cam chain drive sprocket to establish TDC see below Method 1 It is important to note that this method can only be used when the stator is removed and the cam chain drive sprocket is in view The plate links are not used to time the camshaft when the flywheel is installed When the stator assembly is installed use Method 2 This method establishes accurate Top Dead Center TDC by ali...

Page 83: ...disulfide 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 18 2 Install the camshaft with the lobes facing downward and the sprocket alignment pin facing toward intake 3 Disconnect the wire from the cam chain and rotate the engine to align the single TDC timing mar...

Page 84: ...nd Rectangular Mark on Cam Chain Drive Sprocket Crankcase Projection NOTE Plated links will not align after engine is rotated Sprocket marks aligned with gasket surface at TDC on compression stroke cam lobes facing downward Crankshaft to Camshaft Centerline Method 1 Camshaft Timing with Stator Removed ...

Page 85: ...dvance Marks Rotation TDC Mark Decompressor arm stop pin UP Cam lobes DOWN Cam Timing View through timing inspection hole Position crankshaft at TDC Sprocket marks aligned with gasket surface at TDC on compression stroke cam lobes facing downward de compressor arm stop pin UP Do not use dot on sprocket for cam timing Do Not Use Advance Marks For Cam Timing ...

Page 86: ...TE The stator flywheel starter drive and recoil 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 Timing Marks 2 Apply Crankcase Sealant PN 2871557 to the stator plate outer surface and install a new O Ring 3 Install the stator plate being careful not to damage...

Page 87: ...haft 6 Apply Crankcase Sealant PN 2871557 to the rocker cover mating surfaces Be sure the alignment pins are in place 7 Install the rocker cover assembly 8 Install rocker cover bolts and torque to specifications Rocker Cover Bolt Torque 7 8 ft lbs 9 11 Nm 9 Adjust valves according to the valve adjustment procedure found in Chapter 2 Maintenance 10 Install rocker cover block plug Rocker Cover Block...

Page 88: ...8 of rope is exposed and hold reel in place 7 Place rope in notch on outer edge of reel Release tension on hub and allow reel to unwind approximately 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 A 9 Unwind rope and inspect for cuts or abrasions 10 Inspect d...

Page 89: ...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 Open end here 6 Apply downward pressure on the reel and rotate counterclockwise approximately 6 7 turns to pre wind the spring Continue rotating counterclockwi...

Page 90: ...n fuel line or filter G Fuel will not pass through fuel valve G Fuel pump inoperative restricted G Tank vent plugged G Carb starter circuit G Engine flooded G Low compression high cylinder leakage G No spark Spark plug fouled Engine Does Not Turn Over G Dead battery G Starter motor does not turn G Engine seized rusted or mechanical failure G Recoil components damaged Engine Runs But Will Not Idle ...

Page 91: ...d G Cylinder or piston worn G Piston rings worn leaking broken or sticking G Bent valve or stuck valve G Valve spring broken or weak G Valve not seating properly bent or carbon accumulated on valve area G Rocker arm sticking Backfiring G ETC or speed limiter system malfunction G Fouled spark plug or incorrect plug or plug gap G Carburetion faulty lean condition G Intake Exhaust system air leaks G ...

Page 92: ... Carburetor Jetting 4 5 Main Jet Pilot Jet Part Numbers 4 5 CV Carburetor System Function 4 Cycle 4 6 CV Carburetor Vent System 4 Cycle 4 6 CV Carburetor Operation 4 6 4 7 Disassembly Notes CV Carburetor 4 8 4 9 Cleaning CV Carburetor 4 9 Inspection CV Carburetor 4 10 Assembly CV Carburetor 4 10 4 11 Float Adjustment CV Carburetor 4 11 Needle Seat Leakage Test 4 11 Fuel Level 4 12 Fuel Pump Servic...

Page 93: ... 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 Plug 38 Screw 39 Screw 40 Guide Holder 41 Spring 42 Plunger Assembly 43 Spring Washer 44 Screw 45 Air Jet 46 Cable Guide 47 Spring 48 Ring 49 Adjust Screw 50 Screw and Washer Assy 51 Plate 52 Screw Refer to Page 4 5 for Jet Part Numbers 1 2 3 4 5 Jet...

Page 94: ...N 4 3 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 95: ... Vent line routed smoothly into center of steering post Forward 1 ON 2 Reserve Tank to fuel valve connection Gold fitting tall stand pipe to ON Gas Tank Mounting Hardware Fuel Valve 90 Degree Fuel Outlet Fitting 90 Degree Fuel Reserve Outlet Fitting Fuel Filter Fuel Line Marked 2 on fuel valve Marked 1 on fuel valve L Located Above Coolant Reservoir Above LH Front Tire ...

Page 96: ...eters and ambient temperatures between 40 and 80 F 5 to 26 C Carburetors must be re calibrated if operated outside this temperature and or altitude range The jetting installed in production is not intended for all altitudes and or temperatures In addition air screw pilot screw adjustments and PVT adjustments may be required to suit operating conditions CARBURETOR JETTING CAUTION A main jet that is...

Page 97: ...d range and high throttle settings 1 4 to full throttle VENT SYSTEMS CV CARBURETOR The carburetor float bowl vent lines supply atmospheric pressure to the float bowl The lines must be free of kinks restrictions and be properly routed This allows fuel to flow in the proper amount and prevents contaminants from entering the carburetor MIKUNI CV CARB OPERATION The constant velocity carburetor incorpo...

Page 98: ...Mikuni BST carburetor PILOT IDLE AND SLOW SYSTEM This system supplies fuel during engine operation with throttle valve closed 1 or slightly opened The fuel from float chamber 2 is metered by pilot jet 3 where it mixes with air coming in through pilot air jet 4 The mixture then goes up through pilot passage to pilot screw 5 A part of the mixture is discharged into the main bore out of bypass ports ...

Page 99: ...3 MAIN SYSTEM As throttle valve 1 is opened engine speed rises and this increases negative pressure in the venturi Consequently the vacuum slide 2 moves upward The fuel in float chamber 3 is metered by main jet 4 and the metered fuel enters needle jet 5 in which it mixes with the air admitted through main air jet 6 to form an emulsion The emulsified fuel then passes through the clearance between n...

Page 100: ... cleaner in your eyes or if you swallow cleaner seek medical attention immediately Carburetor cleaners can be extremely caustic Extended periods of soaking can loosen the adhesive sealer on the passage drill way plugs Do not soak rubber or plastic components such as the vacuum slide diaphragm needle seat screen or O Rings in caustic cleaning solutions Irreparable damage may occur Do not use agitat...

Page 101: ... Needle Jet 2 Inspect the inlet needle tapered surface for any sign of wear or damage Be sure the spring loaded pin is free moving and returns freely when pushed The inlet needle and seat should be pressure tested after assembly Good Condition Worn Deposits Wear areas Seat Needle CARBURETOR ASSEMBLY Inspect the diaphragm A for holes deterioration or damage Make sure the diaphragm is pliable but no...

Page 102: ...et needle valve pin without compressing the spring Float Height BST 34 13 14 mm 51 55 inches 2 Measure the height from the float bowl mating surface to the top of step in float as shown Both sides of float should be parallel to each other The measurement should be made at the mid point on the top of the float using Float Adjustment Tool PN 2872314 or a vernier caliper When measuring the height be ...

Page 103: ...mp 3 Connect Mity Vact PN 2870975 to the impulse line fitting on the pump 4 Apply 5 inches Hg vacuum to the pump fitting The diaphragm should hold vacuum indefinitely If fuel is present in the impulse line or vacuum chamber of the pump the diaphragm is ruptured The pump diaphragms must be replaced Fuel Filter Fuel Pump Impulse line FUEL PUMP DISASSEMBLY 1 Remove the screws from the pump diaphragm ...

Page 104: ...G Choke plunger sticking incorrectly adjusted choke G Choke cable binding or improperly routed G Incorrect pilot air fuel screw adjustment G Faulty inlet needle and seat G Faulty inlet needle seat O Ring G Float level too high G Poor fuel quality old fuel G Loose jets G Worn jet needle needle jet or other carburetor parts G Dirty carburetor air bleed passages or jets G Weak or damaged vacuum pisto...

Page 105: ...FUEL SYSTEM CARBURETION 4 14 NOTES ...

Page 106: ...ifications and Special Tools 5 4 Cover Panel Removal 5 5 Side Panel Removal 5 5 A Arm Replacement 5 6 Concentric Swing Arm Removal 5 7 Concentric Swing Arm Assembly Installation 5 8 Front Strut Exploded View 5 9 Strut Assembly and Service 5 10 Front Strut Ball Joint Replacement 5 10 5 11 Steering Post Assembly 5 12 Decal Replacement 5 12 ...

Page 107: ... ASSEMBLY EXPLODED VIEW Rear Cab Assembly Front Cab Assembly Front Cover Fuel Tank Cover Seat Side Cover Front Cab Rock Gaurd Clutch Gaurd Frame Footwell Rear Cab Seat Latch Retainer Tool Box Seat Latch Footwell Frame Deflector Shield ...

Page 108: ...t Arm Frog Left Hand Tie Rod End Positioned Below Steer ing Post Arms 1 2 Right Hand Tie Rod End Positioned Between Steering Post Arms NOTE To avoid damage to tie rods and other steering components be sure to install tie rod end bolts in the proper direction The steering post arm bolt B points up the rod end bolts A point down Be sure inner rod ends are positioned properly The right inner rod end ...

Page 109: ... Rear Wheel Nut 50 ft lbs 69 Nm Strut Rod Retaining Nut Top 15 ft lbs 21 Nm Strut Casting Pinch Bolt 15 ft lbs 21 Nm Swing Arm Pivot Bolt 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 exploded views throughout this chapter for identification and location of components SPECIAL T...

Page 110: ...ve 4 screws lock washers and flat washers Front Cab Assembly G Remove Seat G Side panels G 2 screws at rear of cab at fuel tank mount bracket G Front rack G Front bumper G Front cover panel G 3 screws from bottom left mudflap G 3 screws from bottom right mudflap G 1 inner screw from front cab to foot rest on each side G 2 screws under front panel SIDE PANEL REMOVAL 1 Remove seat Grasp rear of pane...

Page 111: ... existing bolts were destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation 5 Examine A arm shaft Replace if worn Discard hardware 6 Insert A arm shaft into new A arm NOTE On AWD models install CV joint shields See Ill 7 Install new A arm assembly onto vehicle frame Torque new bolts to 30 ft lbs 41 Nm 8 Attach A arm to hub stru...

Page 112: ...support securely with wheels off the floor 2 Remove drive chain 3 Remove rear caliper CAUTION Do not allow the caliper to hang by the brake line Brake line damage may result 4 Remove rear wheels and or hubs 5 Remove lower shock bolt 6 Loosen both swingarm pivot bolts 5 and 8 and then remove both bolts while supporting swingarm heat bolts with propane torch to soften Loctitet 7 Remove swingarm 8 Re...

Page 113: ...g 4 through the two piece bushing 3 4 Install washer 2 and nut 1 Hold pivot bushing 4 in vise and torque nut 1 to 120 ft lbs 163 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 ...

Page 114: ... 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 ...

Page 115: ...rut Rod Nut Torque 15 ft lbs 21 Nm BALL JOINT REPLACEMENT REFER TO ILLUSTRATION ON PAGES 5 9 1 Loosen front wheel nuts slightly 2 Elevate and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure 3 Remove wheel nuts and wheels 4 Remove cotter pin A from ball joint castle nut A B ...

Page 116: ...ve new joint into strut housing until fully seated 9 Apply Loctitet 242 PN 2871949 to threads of retaining plate screws or install new screws with pre applied locking agent Torque screws to 8 ft lbs 11 Nm 10 Install A arm on ball joint and torque castle nut to 25 ft lbs 35 Nm 11 Reinstall cotter pin with open ends toward rear of machine SAFETY REMINDER Remember to use safety glasses and other prot...

Page 117: ...yethylene material Therefore they must be flame treated prior to installing a decal to ensure good adhesion A bonus of the flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged To flame treat the decal area 1 Pass the flame of a propane torch back and forth quickly over the area where the d...

Page 118: ...ploded View 6 7 Drive Clutch Spring Specifications 6 8 Shift Weights 6 9 Drive Clutch Inspection 6 10 Drive Clutch Disassembly Inspection 6 10 6 12 Drive Clutch Assembly 6 12 6 13 Drive Belt Tension 6 13 Drive Belt Removal Inspection 6 14 6 15 Drive Belt Installation 6 15 Clutch Alignment Offset 6 15 6 16 Drive Clutch Bushing Service 6 16 6 18 Driven Clutch Disassembly Inspection 6 19 6 20 Driven ...

Page 119: ...ents of the drive clutch and driven clutch control engagement initial vehicle movement clutch upshift and backshift During the development of a Polaris ATV the PVT system is matched first to the engine power curve then to average riding conditions and the vehicle s intended usage Therefore modifications or variations of components at random are never recommended Proper clutch setup and careful ins...

Page 120: ...fset Belt Width See Page 6 16 6 18 2 Drive and Driven Clutch Buttons and Bushings Drive Clutch Shift Weights and Pins Drive Clutch Spider Rollers and Roller Pins Drive and Driven Clutch Springs See Pages 6 11 6 12 3 Sheave Faces Clean and inspect for wear 4 PVT System Sealing Refer to appropriate illustrations and photos The PVT system is air cooled by fins on the drive clutch stationary sheave Th...

Page 121: ... at least 5 min then with transmission in neutral advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow and easy clutch engagement Fast effective use of the throttle for efficient engagement Continuous operation at the point of engagement initial vehicle movement increases PVT temperatures and component wear Towing Pus...

Page 122: ...for drive belt removal A B 6 Install the Drive Clutch Holder PN 9314177 A 7 Remove drive clutch retaining bolt and remove drive clutch using the Drive Clutch Holder PN 9314177 B Drive Clutch Puller PN 2870506 Drive Clutch Holder PN 9314177 8 Remove driven clutch retaining bolt and driven clutch Use the Driven Clutch Puller PN 2870913 if necessary Driven Clutch Puller PN 2870913 Keep Spacers In Ord...

Page 123: ...ear 12 ft lbs 16 6 Nm Driven Clutch Retaining Bolt Torque 17 ft lbs 23 5 Nm Drive Clutch Retaining Bolt Torque 40 ft lbs 55 Nm Offset Spacer Offset Spacer 7 Install clutch offset spacers on transmission input shaft 8 Clean splines inside driven clutch and on the transmission input shaft 9 Apply a light film of grease to the splines on the shaft 10 Install the driven clutch washer lock washer and r...

Page 124: ...NTS DRIVE CLUTCH EXPLODED VIEW Outer Cover Exhaust Duct Inner Cover Seal Inlet duct Retainer Clip Inner Cover Outer Cover Seal Drive Clutch Mark with permanent marker before disassembly Teflont coated brass bushing Teflont coated brass bushing ...

Page 125: ... subject to during operation it should always be inspected for tolerance limits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure its free length from 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 ...

Page 126: ...agement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance clutch balance and shifting pattern PN 5630513 50 5 gr PN 5630509 55 gr 55 16 PN 5630279 43 gr PN 5630418 50 gr PN 5630095 53 gr 53 PN 5630709 44 gr PN 5630710 46 gr PN 5630711 47gr RH BH WH 10 ...

Page 127: ...ould be smooth and free of dents or gall marks Inspect the weight pivot bore and pivot bolts for wear or galling If weights or bolts are worn or broken replace in sets of three with new bolts NOTE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly See ROLLER PIN AND THRUST WASHER INSPECTION Page 6 12 Broken Worn Good BUTTON TO TOWER CLEARANCE INSPECTION 1 ...

Page 128: ...ace clutch assembly if worn or damaged 5 Remove and inspect spring See Page 6 8 SPIDER REMOVAL Clutch Holding Fixture PN 2871358 Spider Removal Tool PN 2870341 1 Install clutch in holding fixture and loosen the spider counterclockwise using spider removal tool NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly Be sure to note the n...

Page 129: ...roller pin DRIVE CLUTCH ASSEMBLY NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly The Teflont bushings are self lubricating Do not apply oil or grease to the bushings 1 Reassemble drive clutch in the following sequence Be sure the X or the marks thatwere made earlier are aligned during each phase of assembly a X or the marks that...

Page 130: ...LT TENSION 1 1 8 28 5 mm Straight Edge Belt Deflection Tension 1 1 8 2 9 cm 1 1 4 3 2 cm NOTE Pinch the sheaves lightly together with clamp to prevent the belt from being pushed into the driven sheave 1 Place a straight edge on top of the belt between drive and driven clutch 2 Push down on drive belt until it is lightly tensioned 3 Measure belt deflection as shown in photo NOTE If belt deflection ...

Page 131: ...h side of the drive belt G Place another straight edge on top of belt G Measure the distance where the side straight edges intersect the top as shown in the illustration below 5 Inspect belt for loose cords missing cogs cracks abrasions thin spots or excessive wear Replace if necessary 6 Inspect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt Hour gl...

Page 132: ...d the driven clutch 1 Remove belt and install the Clutch Offset Alignment Tool PN 2870654 as shown 2 With tool touching rear of driven clutch inner sheave the distance at point A should be 1 8 If the distance is greater than 1 8 or less than 1 16 clutch alignment must be adjusted as follows 3 Remove drive and driven clutch See PVT Disassembly Pages 6 5 4 Remove PVT inner cover 5 Loosen all engine ...

Page 133: ... BUSHING SERVICE Clutch Bushing Replacement Tool Kit PN 2871226 Stamp Qty Part Description Part 2 1 P 90 Drive Driven Clutch Bushing Install Tool 5020628 3 1 Drive Clutch Cover Bushing Removal Installation Tool all clutches 5020629 5 1 P 90 Driven Clutch Cover Bushing Re moval Tool 5020631 8 1 Main Puller Adapter 5020632 9 1 Adapter Reducer 5010279 10 1 Number Two Puller Adapter 5020633 DRIVE CLUT...

Page 134: ...Remove bushing from tool and discard DRIVE CLUTCH MOVEABLE SHEAVE BUSHING INSTALLATION 1 Place the Main Puller Adapter 8 PN 5020632 onto the puller 2 Apply Loctitet 680 PN 2870584 to the back side of new bushing Push bushing into center of sheave on tower side by hand Bushing PN 3576504 Loctitet 680 PN 2870584 3 Insert the Clutch Bushing Installation Tool 2 PN 5020628 into center of sheave and wit...

Page 135: ... and bushing removal tool from puller Discard bushing DRIVE CLUTCH COVER BUSHING INSTALLATION 1 Apply Loctitet 680 PN 2870584 to the back side of new bushing Working from inside of cover insert bushing and bushing installation tool into center of clutch cover Bushing PN 3576510 Loctitet 680 PN 2870584 2 With the Main Puller Adapter 8 PN 5020632 on the puller insert cover onto puller rod placing ou...

Page 136: ...n Tool PN 8700220 2 Remove snap ring retainer Note hole location of spring in helix and sheave 3 Note the location of the spring and remove helix 4 Note the location of the spring in the moveable sheave and remove the spring 5 Check alignment of tabs on spring Replace the spring if tabs are misaligned or the spring coils are distorted 6 Inspect ramp buttons in the moveable sheaveand replace if wor...

Page 137: ...stall moveable sheave with spacer washers Important At least one spacer washer must be installed Teflont bushings are self lubricating Do not apply oil or grease to the bushings 2 Install spring inserting spring tab into proper hole in moveable sheave 3 Insert spring tab into proper hole in helix See specifications at the beginning of this section The driven clutch helix moveable assembly has seve...

Page 138: ...nside the main adapter 3 Remove ramp buttons from moveable sheave 4 Using an electric or 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 process Clutch Bushing Removal Tool 5 5 Working from the top install Driven Clutch Bushing...

Page 139: ...er See illustration at above 2 Start new bushing evenly in moveable sheave Apply Loctitet 680 PN 2870584 to the back side of new bushing 3 Install sheave onto puller with new bushing upward as shown Install the Number Two Puller Adapter 10 PN 5020633 4 Install nut onto puller rod and hand tighten against installation tool 5 Turn clutch sheave counterclockwise until bushing is seated 6 Remove nut f...

Page 140: ...hts Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Disassemble clean and inspect driven clutch noting worn sheave bushing and ramp buttons and helix spring location Clean sheaves with denatured alcohol or brake cleaner install new belt Harsh drive clutch engage ment Drive belt...

Page 141: ...tch engagement Caution operator to operate machine within guidelines Vehicle operated with park brake on Inspect brake system Fast effective use of throttle for efficient engagement PVT noise Belt worn or separated thin spots loose belt Broken or worn clutch components cover hitting clutches Replace belt Inspect and repair as necessary Engagement erratic or stabby Thin spots on belt worn belt Driv...

Page 142: ... 2 7 3 Front Hub Assembly 7 3 7 4 Front Hub Installation 7 4 Front Hub Exploded View 7 5 Rear Axle Removal 7 6 Rear Axle Disassembly 7 7 Rear Axle Assembly 7 7 7 8 Rear Axle Installation 7 8 Rear Axle Exploded View 7 9 Rear Housing Removal 7 10 Rear Housing Service 7 10 Rear Housing Installation 7 11 ...

Page 143: ...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 removing bearings and seals 2 Check bearings for side play by grasping tire wheel firmly top and bottom and checking for movement It should rotate smoothly without binding or rough spots 3 Remove wheel nuts and wheel 4 Remove the two bra...

Page 144: ... damage Measure length of spacer and replace if worn beyond service limit or if ends are rounded Bearing Spacer Length Service Limit 2 1850 5 55 cm FRONT HUB ASSEMBLY Seal Hub assembly view 1 Drive or press one new bearing into hub using a 1 180 46 mm bearing driver CAUTION Do not drive on the inner race of the bearing Premium All Season Grease PN 2871322 3 oz Tube PN 2871423 14 oz Tube 2 Coat bea...

Page 145: ...tall a new cotter pin Tighten nut slightly if necessary to align cotter pin holes 7 Rotate wheel and check for smooth operation Bend both ends of cotter pin around end of spindle in different directions 8 Lightly grease a new O ring and install on hub cap Install hub cap 9 Rotate hub It should rotate smoothly without binding or rough spots or side play 10 Install brake caliper using new bolts Tigh...

Page 146: ...Strut 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 FINAL DRIVE 7 5 FRONT HUB EXPLODED VIEW ...

Page 147: ...Remove drive chain 3 Remove snap ring A lock sleeve B and foam seal C from axle A B C 4 Remove sprocket hub nut D D 5 Remove the two rear brake caliper bolts Remove the rear brake caliper Remove Rear Caliper 6 Support rear caliper with wire or a tie strap Donot hang caliper by brake line Support Caliper from Frame 7 Slide axle assembly out left side ...

Page 148: ... groove on left side of axle Stop Ring Disc Hub Groove in spline NOTE Left side of axle is identified by the small groove in the middle of the spline 2 Install disc hub assembly on axle Be sure hub covers stop ring Install disc in soft jawed vise Apply Never Seize to threads install left axle nut and tighten to 120 ft lbs 166 Nm Keep tightening nut until flat aligns with flat on brake hub Stop rin...

Page 149: ...g If axle binds the nut is too tight If axle movement up and down or side to side is detected axle is too loose Axle Nut Sprocket Side Torque 8 10 ft lbs 11 14 Nm 4 Install foam seal C and slide lock sleeve B onto hub and install lock sleeve with taper inward Install snap ring A A B C 5 Install brake caliper and drive chain Adjust drive chain refer to Maintenance Chapter 2 for procedure Torque ecc...

Page 150: ...eve 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 14 17 Nm 18 ft lbs 25 Nm Torque 80 ft lbs 110 Nm Torque 50 ft lbs 69 Nm Foam Seal ...

Page 151: ...ing from the upper mounting bracket NOTE Flange inward as shown Upper Mounting Bracket Rear Housing Caliper Mount Bushing 5 Remove the rear housing from the swingarm REAR HOUSING DISASSEMBLY BEARING SERVICE 1 Remove seals from housing Seal Bearing Bearing Race Seal 2 Remove bearings 3 Drive bearing race out from opposite sides 4 Inspect housing for cracks or wear Replace if damaged REAR HOUSING AS...

Page 152: ...s shown Upper Mounting Bracket Rear Housing Caliper Mount Bushing 2 Loosely assemble upper and lower brake caliper mount Do not tighten at this time Lower Mount Bracket Upper Mounting Bracket Brake Disc Guard Rear Housing Mount Bolts 3 Install rear axle See Page 7 8 4 Fill housing with grease until grease purges from both seals ...

Page 153: ...FINAL DRIVE 7 12 NOTES ...

Page 154: ...APTER 8 TRANSMISSION SERVICE Special Tools 8 2 Torque Specifications 8 2 Transmission Remove Install 8 2 Transmission Disassembly 8 2 8 5 Transmission Assembly 8 6 8 7 Troubleshooting 8 7 Transmission Exploded View 8 7 8 8 ...

Page 155: ...7 Remove drive chain and sprocket 8 Remove mounting bolts and brackets as shown 9 Remove through bolt from bottom of transmission 10 Remove transmission from right side of frame TRANSMISSION INSTALLATION 1 Reverse removal steps to install transmission NOTE Install the Center Distance Tool PN2871710 on engine and transmission input shaft before tightening transmission mounting bolts Align clutches ...

Page 156: ...f shift assembly and drive gear 8 Remove shift assembly and gear as an assembly NOTE Direction of shift fork 9 Inspect shift fork surface for wear or damage Replace if necessary 10 Remove shift fork guide pin 11 Mark orientation of bellcrank to the shift fork shaft 12 Remove bellcrank Use a small puller if necessary ...

Page 157: ...ct shift fork shaft O ring Replace if necessary Lubricate O ring to ease in reassembly and to protect O ring during assembly 15 Remove input shaft bearing 16 Inspect gears for galling and wear on teeth and bearing surface Replace if necessary 17 Remove bearing from other end of input shaft Remove two snap rings and gear ...

Page 158: ...Stretch Limit 8 pitch length 3 0904I Maximum Measure 8 pitches TRANSMISSION ASSEMBLY 1 Assemble input shaft assembly NOTE Install bearings with numbers and letters facing out so they can be read after assembly Sprocket cogs face the dog gear NOTE Input gear cogs face inward on input shaft Input Shaft Bushing Sprocket Dog Gear Input Gear Thrust Washer 2 Assemble output shaft with sprocket gear and ...

Page 159: ... ft lbs 25 Nm 9 Install drain plug with a new sealing washer Torque drain plug to 14 ft lbs 19 Nm 10 Insert shifting bullet with tip in position as shown Insert spring and plug Torque plug to 14 ft lbs 19 Nm 11 Install transmission and add Polaris Premium Synthetic Gear Case Lubricant PN 2871477 in the recommended amount Refer to Maintenance Chapter 2 12 Install gear indicator switch Apply Loctite...

Page 160: ...ansmission problem remains disassemble transmission and inspect all gear dogs for wear rounding damage Inspect all bearings for wear TRANSMISSION EXPLODED VIEW NOTE See next page for exploded view of transmission Ref Qty Description Ref Qty Description 1 Asm Gearcase 24 1 Washer 1 2 Bearing 25 1 Plug Detent Extension 2 1 Ring Retaining 26 1 Dipstick 3 1 Washer Thrust 27 2 Seal 4 1 Sprocket 19T 28 ...

Page 161: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 27 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 1 12 TRANSMISSION 8 8 TRANSMISSION EXPLODED VIEW ...

Page 162: ...Installation 9 8 Front Pad Removal 9 9 9 10 Front Pad Assembly 9 10 9 11 Front Disc Inspection 9 11 Front Disc Removal Replacement 9 11 9 12 Front Caliper Removal 9 12 Front Caliper Disassembly 9 12 9 13 Front Caliper Inspection 9 13 9 14 Front Caliper Assembly 9 14 Front Caliper Installation 9 15 Front Caliper Exploded View 9 16 Rear Pad Removal 9 17 Rear Pad Installation 9 17 9 18 Rear Caliper R...

Page 163: ...77 mm 167 4 242 mm Brake Disc Thickness Variance Between Measurements 002 051 mm Brake Disc Runout 010 25 mm Master Cylinder I D 750 TORQUE SPECIFICATIONS Item Torque ft lbs except where noted Torque Nm Front Caliper Mounting Bolts 18 0 25 Rear Caliper Mounting Bolts 28 38 Master Cylinder Mounting Bolts 25 in lbs 3 0 Master Cylinder Reservoir Cover Bolt 5 in lbs 56 Brake Line Banjo Bolt 15 0 21 Fr...

Page 164: ...ildup on the brake pads and disc is the most common cause of brake noise squeal caused by vibration If cleaning does not reduce the occurrence of brake noise Permatext Disc Brake Quiet PN 2872113 can be applied to the back of the pads Follow directions on the package This will keep pads in contact with caliper piston s to reduce the chance of squeaks caused by dirt or dust See table below Brake No...

Page 165: ... 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 fluid e...

Page 166: ...left and right hand brake to use the same caliper piston but remain separated by seals The left hand brake system applies hydraulic pressure to both front calipers and only the outer diameter of the rear caliper piston The right hand brake applies pressure to the inner portion of the rear caliper piston Because the left and right hand brake hydraulic systems are separate there are also two bleed s...

Page 167: ... reservoir with a Mity Vact PN 2870975 or similar tool NOTE Do not remove brake lever when reservoir fluid level is low MAX 5 Add brake fluid to the upper level mark on reservoir Polaris DOT 3 Brake Fluid PN 2870990 Hand brake bleeder screw Auxiliary brake bleeder screw Hand Brake Line Aux Brake Line Forward DH Caliper 6 Begin bleeding procedure with the caliper that is farthest from the master cy...

Page 168: ...ws Torque the screws to 5 in lbs 0 56 Nm Reservoir Cover Torque 5 in lbs 0 56 Nm 14 Field test machine at low speed before putting into service Check for proper braking action and lever reserve With lever firmly applied lever reserve should be no less than 1 2 1 3 cm from handlebar 15 Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasion Replace hose if wear or ab...

Page 169: ... mounting bolts to 25 in lbs 3 Nm Torque the inside bolt first as indicated in the illustration 25 in lbs 3 Nm Torque Outer Bolt First 5 in lbs 0 56 Nm NOTE To speed up the brake bleeding procedure the master cylinder can be purged of air before brake line is attached Fill with DOT3 Brake Fluid PN 2870990 and pump lever slowly two to three times with finger over the outlet end to purge master cyli...

Page 170: ... occur if machine tips or falls 2 Remove the front wheel Loosen pad adjuster screw 2 3 turns 3 Remove caliper from mounting bracket 4 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservo...

Page 171: ... boots Polaris Premium All Season Grease PN 2871423 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other Be sure pads and disc are free of dirt or grease 3 Install caliper on hub strut and torque mounting bolts 18 ft lbs 25 Nm Front Caliper Mounting Bolts Torque 18 ft lbs 25Nm 4 Slowly pump the brake lever until pressure has be...

Page 172: ...ocedure Do not allow pads or disc to become hot or warpage may result Repeat this procedure 10 times FRONT DISC INSPECTION 1 Visually inspect the brake disc for nicks scratches or damage 2 Measure the disc thickness at eight different points around the pad contact surface using a 0 1 micrometer Replace disc if worn beyond service limit Brake Disc Thickness Service Limit 140 3 556 mm New 150 165 3 ...

Page 173: ...ting bolts The bolts have a pre applied locking agent which is destroyed upon removal FRONT CALIPER REMOVAL CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 1 Remove brake pads See Page 9 9 2 Using a line wrench loosen and remove brake line to caliper Place a container under caliper to catch fluid draining from brake line 3 R...

Page 174: ...eal grooves in caliper body Clean Components FRONT CALIPER INSPECTION 1 Inspect caliper body for nicks scratches or wear Measure bore size and compare tospecifications Replace if damage is evident or if worn beyond service limit Front Caliper Piston Bore I D Std 1 191 1 192 30 25 30 28 mm Service Limit 1 193 30 30 mm 2 Inspect piston for nicks scratches wear or damage Measure diameter and replace ...

Page 175: ...Fluid C Install piston D with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 3 Lubricate the mounting bracket pins with Polaris Premium All Season Grease and install the rubber dust seal boots Polaris Premium All Season Grease PN 2871423 4 Compress the mounting bracket and make sure the dust seals are fully seated Install the pads as sh...

Page 176: ...olt Torque 18 ft lbs 25 Nm 2 Install brake line and tighten securely with a line wrench 3 Install the adjuster screw and turn until stationary pad contacts disc then back off 1 2 turn 4 Follow brake bleeding procedure outlined on Pages 9 6 9 7 5 Install wheels and torque wheel nuts to specification Front Wheel Nut Torque 20 ft lbs 27 Nm ...

Page 177: ...LODED VIEW Caliper Mount Piston Bushing Boot Square O Rings Socket Set Screw Boot Bushing Brake Pads Caliper Assembly Bleeder Screw 35 60 IN LBS 4 6 5 NM APPLY POLARIS ALL PURPOSE GREASE APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT 3 3 3 ...

Page 178: ...e pad retaining pin and pad spacer NOTE This is a spring pin do not spread apart farther than necessary to remove it 4 Measure the thickness of the pad material Replace pads if worn beyond the service limit Measure Thickness Rear Brake Pad Thickness New 298 005 6 85 127 mm 0 Service Limit 150 3 81 mm REAR BRAKE PAD INSTALLATION Spacer Retaining Pin 1 Install new pads in caliper body Be sure to put...

Page 179: ... lines 2 Using a wrench remove left hand brake outer and right hand brake inner lines Place a container to catch brake fluid draining from brake lines 3 Remove the caliper and pads from the caliper Spacer Retaining Pin 4 Remove Allen head screw and separate caliper halves and remove pistons with piston pliers 5 Remove O rings and clean O ring grooves 6 Clean disc caliper body and pistons with brak...

Page 180: ...ully seating piston 2 Install new O rings in caliper halves 3 Carefully assemble caliper body making sure O rings are properly positioned in groove Apply LocTitet242 PN 2871949 to the allen head screw and torque body screw evenly to 18 ft lbs 25 Nm Caliper Halves Bolt Torque 18 ft lbs 25 Nm 4 Install brake pads in caliper body with friction material facing each other If equipped with a pad spacer ...

Page 181: ... drags re check assembly and installation REAR BRAKE DISC INSPECTION 1 Visually inspect disc for scoring scratches or gouges Replace the disc if any deep scratches are evident Measure Thickness Rear Brake Disc 2 Use a 0 1 micrometer and measure disc thickness at 8 different points around perimeter of disc Replace disc if worn beyond service limit Brake Disc Thickness Service Limit 167 4 242 mm New...

Page 182: ...ed lever G Incorrectly adjusted stationary pad G Worn or damaged master cylinder or components G Improper clearance between lever and switch Lever Vibration G Disc damaged G Disc worn runout or thickness variance exceeds service limit G Caliper Overheats Brakes Drag G Compensating port plugged G Pad clearance set incorrectly G Auxiliary brake pedal incorrectly adjusted G Brake lever or pedal bindi...

Page 183: ...lbs 38 Nm DH Caliper Auxiliary Brake Pads Hand Brake Line Auxiliary Brake Line Auxiliary Brake Bleed Hand Brake Bleed Torque 15 ft lbs 20 7 Nm Torque 18 ft lbs 24 8 Nm Torsion Spring Auxiliary Brake Reservoir Auxiliary Brake Master Cylinder Torque 8 ft lbs 11 Nm 15 ft lbs 20 Nm ...

Page 184: ...nt Draw Test 10 6 Electronic Throttle Control System Operation 10 7 Flywheel Identification DC CDI Operation 10 8 ES32PF 200 Watt Alternator Exploded View 10 9 Ignition System Testing 10 10 Ignition System Troubleshooting 10 11 Cranking Output Tests 10 11 Charging System Testing 10 12 10 14 Battery Service 10 14 10 17 Headlight Tail Light Service 10 18 10 19 Starter System Testing 10 20 Starter Sy...

Page 185: ... obtained with other meters may differ GPay attention to the prefix on the multimeter reading K M etc and the position of the decimal point GFor resistance readings isolate the component to be tested Disconnect it from the wiring harness or power supply TIMING CHECK PROCEDURES 1 The ignition timing check hole is in the starter recoil magneto housing Remove the check plug NOTE The ignition timing m...

Page 186: ...inted on some late model LR modules Whenever possible use part number to identify the module Modules may have same LR I D number with different part numbers terminals and internal function Speed Limiter Module LR ID Number Part number is printed on module LIMITER SPECIFICATIONS Refer to parts manual or microfiche for part num ber and application PART NO TYPE FUNCTION LIMIT RPM 4010137 LR44 3 Rever...

Page 187: ...Signal Gray Orange Reverse Gear Signal Y R Blk Gry Or LR44 3 Gry Or Blk Y R Engine Stop Signal RPM Signal Transmission Switch Reverse speed limit module sends signal ground to CDI to eliminate spark at 3500 approx in re verse Under Front cover ...

Page 188: ...P Y 3V 9V AC AT IDLE N TEST WIRING N TEST VOLTAGE REGULATOR AND CHARGING SYSTEM MEASURE DC VOLTS ON GRY OR WIRE TO GROUND AT LR MODULE MEASURE AC VOLTS ON Y R WIRE AT LR MODULE TO GROUND Y DISCONNECT BLACK WIRE FROM LR MOD ULE AND CONNECT TO GROUND ENGINE STOP N TEST WIRING TEST CDI BLACK WIRE Y REPLACE LIMITER MODULE 12 VOLTS DC ELECTRICAL 10 5 REVERSE SPEED LIMIT SYSTEM ...

Page 189: ...her fan and hot light ON If not test hot light fan motor and circuit GDisconnect thermistor wires and test the resistance of the thermistor refer to temperature resistance table Replace thermistor if out of specified range GReplace the module and test system FAN MOTOR CURRENT DRAW TEST Connect ammeter leads between exposed Orange Black terminals at fan connection Connect only the Red White termina...

Page 190: ...park This is the same as turning the key or engine stop switch OFF Test the ETC switch at the harness connector NOTE Adjust throttle cable freeplay ETC switch and make sure throttle mechanism is functioning properly before testing the switch Refer to Maintenance Chapter 2 for cable adjustment procedure ETC OPERATION TEST 1 Remove throttle block cover by carefully releasing all tabs around edge of ...

Page 191: ...e trouble shooting and maintenence Operation Overview The DC CDI system relies on battery power for ignition Instead of generating DC voltage via magnetic induction a 12 volt DC current is supplied directly to the CDI unit from the battery At the CDI 12 volt DC current charges an internal capacitor to build up the initial ignition charge A small A C signal from the Trigger Pulse coil closes a thyr...

Page 192: ...e Coil Trigger Air Gap 016 030 4 75mm Meter W Ignition Coil Primary Winding 3 W Ignition Kill Wire Black Coil Lead Secondary Coil Check coil mount to verify ground to engine 0 2 W Refer To Wiring Diagrams For Specified Stator Coil Resistance Magnetic Switch Meter 10 5KW W Note DC CDI components are not compatible with any other type of ignition 12 Volt DC Supply Wire Red 520W W Meter ...

Page 193: ...wiring schematic for meter con nections and specifications Compare results to the specifications on the exploded views Is it within specification Inspect connectors wiring and grounds to the component in ques tion Replace the component if a wiring problem cannot be found Yes No Yes Yes No Check coil ground connection between engine and coil mount using an ohmmeter The coil mount should have good c...

Page 194: ...ading adaptors are commercially available for use with the FlukeZ 77 Digital Multimeter PV 43568 which will allow peak voltage tests to be performed accurately Follow the directions provided with the adaptor All measurements are indicated in DC Volts Readings obtained without a peak reading adaptor will be significantly different Test output from the CDI and pulse trigger coil and compare to the t...

Page 195: ...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 board replace the voltage regul...

Page 196: ...y cable and terminal Do not use electric start YB14A Current Drain Inspection Key Off Less Than 9 mA GConnect a tachometer according to manufacturer s instructions GWith engine off and the key and kill switch in the ON position the ammeter should read negative amps battery discharge Reverse meter leads if a positive reading is indicated GShift transmission into neutral Start engine with recoil onl...

Page 197: ...conditions As a general rule before placing the battery into service check the battery condition and charge accordingly New Batteries Batteries must be fully charged before use or battery life can be reduced by 10 30 of full potential Charge battery for 3 5 hours at a current equivalent of 1 10 of the battery s rated amp hour capacity i e 12amp hr x 10 1 2 amp charging Do not use the alternator to...

Page 198: ...e will with clean water and dry thoroughly 2 Reinstall battery attaching positive red cable first and then the negative black cable Coat terminals and bolt threads with Dielectric Grease PN 2871329 3 Conventional Lead Acid Batteries Only 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 gase...

Page 199: ...full charge condition in the OCV test and the specific gravity test but still may not have the storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is encountered To perform this test hook a multitester to the battery in the same manner as was done in the OCV test The reading s...

Page 200: ...electrolyte Avoid skin contact with battery electrolyte severe burns could result If electrolyte contacts the vehicle frame corrosion will occur 5 Route cables so they are tucked away in front and behind battery HEADLIGHT ADJUSTMENT The headlight beam can be adjusted up and down and side to side 1 Place the vehicle on a level surface with the headlight approximately 25 7 6 m from a wall 25 7 6 m L...

Page 201: ...ecommended lamp Apply Dielectric Grease PN 2871329 3 Reinstall the lens cover removed in Step 1 4 Test the taillight brakelight to see that it s working POD ASSEMBLY REMOVAL INDICATOR LAMP REPLACEMENT 1 Remove the two screw covers A and screws from the pod assembly B A B C 2 Disconnect indicator light panel from harness by lifting the retaining latch from the wire connector NOTE The indicator pane...

Page 202: ...n the key and engine stop switch are on When neutral is selected power flows through the switch to the Green White wire through the lamp and to ground via the Brown wire If the light is not on when neutral is selected check the bulb If the bulb is good check the wiring transmission switches and lamp socket ground path BRAKE LIGHT SWITCH 1 Remove front cover 2 Disconnect wire harness from switch 3 ...

Page 203: ...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 cabl...

Page 204: ...ine Does Not Rotate GFaulty starter drive GFaulty starter drive gears or starter motor gear GFaulty flywheel gear or loose flywheel VOLTAGE DROP TEST The Voltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection will appear as a high voltage reading Voltage shown on the meter when t...

Page 205: ... Length 5 16 8 cm Brush Length Service Limit 5 16 8 cm 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 testing on Page 10 23 5 Install a new carbon brush assembly in the brush housing NOTE Be sure...

Page 206: ...be replaced STARTER ASSEMBLY 1 Place armature in field magnet casing 2 Place shims on drive end of armature shaft with phenolic washer outermost on shaft Engage tabs of stationary washer in drive end housing holding it in place with a light film of grease 3 Install case sealing O Ring Make sure O Ring is in good condition and not twisted on the case Lubricate needle bearing and oil seal with a lig...

Page 207: ...with the end bent in a hook and pick the old spring out of its channel Slide it off the end of the shaft Slide the new spring over the overrun clutch and into the spring groove Make sure that the spring is positioned between the shoe alignment pins and the back flange of the anti kick out shoes 2 Remove the lock ring end washer spring retainers and clutch return spring Screw the overrun clutch off...

Page 208: ... Inspection 2 23 Brake Pad Installation Rear 9 17 Brake Pad Removal Front 9 9 Brake Pad Removal Rear 9 17 Brake System Inspection 2 23 Brake System Main Components 9 5 Brake System Operation 9 4 Brake System Service Notes 9 3 Brake Auxiliary Hydraulic 2 23 Brakelight Lamp Replacement 10 18 C Cam Chain Drive Sprocket Installation 3 34 Cam Chain Tensioner Inspection 3 11 Cam Chain Tensioner Installa...

Page 209: ... 15 Cylinder Head Warpage 3 16 Cylinder Honing 3 6 Cylinder Inspection 3 23 3 24 Cylinder Installation 3 36 Cylinder Removal 3 22 D Decal Replacement 5 12 Decimal Equivalents 1 9 Draining Recoil Housing 2 16 Drive Belt Removal Inspection 6 14 Drive Belt Tension 6 13 Drive Chain Adjustment 2 24 Drive Chain Inspection 2 24 Drive Clutch Assembly 6 12 Drive Clutch Bushing Service 6 16 6 17 6 18 Drive ...

Page 210: ...2 12 Fuel Tank Assembly Exploded View 4 4 G Gear Position Switch Test 10 3 Glossary of Terms 1 11 H Headlamp Replacement 10 18 Headlamp Switch Testing 10 19 Headlight Adjustment 10 17 Headlight Assembly Removal 10 17 Headlight Lamp Replacement 10 17 Honing to Oversize 3 6 3 7 I Idle Speed Adjustment 2 11 Ignition System Testing 10 10 Ignition Timing 2 14 Indicator Lamp Replacement 10 18 Intake Val...

Page 211: ...sing Installation 7 11 Rear Housing Removal 7 10 Recoil Assembly 3 44 Recoil Disassembly Inspection 3 42 Recoil Draining 2 16 Reverse Limit System 10 4 10 5 Rocker Arm Shaft Inspection 3 12 Rocker Shaft Rocker Arm Assembly Installation 3 42 Troubleshooting Transmission 8 7 S Sediment Tube Maintenance 2 16 Shift Linkage Adjustment 2 9 Shift Weights 6 9 Side Panel Removal 5 5 Spark Plug Maintenance ...

Page 212: ... Torque Stop Adjustment 2 8 Trailboss 2003 Model 1 3 Transmission Assembly 8 5 Transmission Disassembly 8 2 Transmission Exploded View 8 7 8 8 Transmission I D Location 1 2 Transmission Installation 8 2 Transmission Linkage Adjustment 2 9 Transmission Removal 8 2 Troubleshooting Brakes 9 21 Troubleshooting Engine 3 45 3 46 Troubleshooting Fuel System Carb 4 13 Troubleshooting Ignition System 10 11...

Page 213: ...ELECTRICAL 10 25 WIRING DIAGRAM 2003 TRAILBOSS 330 ...

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