Polaris TRAIL BOSS 325 2001 Manual Download Page 1

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CHAPTER 1
GENERAL INFORMATION

Model Identification

1.1

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Serial Number Location

1.1

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Machine Dimensions

1.2-1.3

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Specifications

1.4-1.5

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Publication Numbers

1.6

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Paint Codes

1.6

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Replacement Keys

1.6

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Standard Torque Specifications

1.7

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Torque Conversion Table

1.8-1.9

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Decimal Equivalent Chart

1.10

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Conversion Table

1.11

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Tap Drill Charts

1.12

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Glossary of Terms

1.13-1.14

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Summary of Contents for TRAIL BOSS 325 2001

Page 1: ...1 Machine Dimensions 1 2 1 3 Specifications 1 4 1 5 Publication Numbers 1 6 Paint Codes 1 6 Replacement Keys 1 6 Standard Torque Specifications 1 7 Torque Conversion Table 1 8 1 9 Decimal Equivalent C...

Page 2: ......

Page 3: ...ividual Serial No Body Style Check Digit World Mfg ID This could be either a number or a letter ENGINE SERIAL NUMBER LOCATION Whenever corresponding about an engine be sure to refer to the engine mode...

Page 4: ...36 25 in 92 cm 45 5 in 115 6 cm 72 in 182 8 cm 13 5 in 34 2 cm 48 75 in 123 8 cm 9 75 in 23 5 cm 13 in 33 02 cm 35 5 in 90 1 cm FRONT SIDE GENERAL INFORMATION 1 2 MACHINE DIMENSIONS...

Page 5: ...Hitch 10 5 in 26 67 cm Rock Guard 5 5 in 13 9 cm 40 6 in 103 1 cm 45 5 in 115 6 cm 34 75 in 88 27 cm 44 6 in 113 3 cm REAR GENERAL INFORMATION 1 3 MACHINE DIMENSIONS...

Page 6: ...00 0 6000 10RH Blue 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 07...

Page 7: ...SIS 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...

Page 8: ...185 P 133 Rack s Fire Red 72060 P 093 Fenders Tank Tool Box Covers Bright White 2185 P 133 Bumper Caps Front Cover Headlight Pod Seat and Side Panel Porsche Red N A P 136 FRAME COLOR P067 Medium Gloss...

Page 9: ...27 3 1 43 5 0 60 6 9 10 32 31 3 6 49 5 6 68 7 8 Torque ft lbs Nm 1 4 20 5 7 8 11 12 16 1 4 28 6 8 10 14 14 19 5 16 18 11 15 17 23 25 35 5 16 24 12 16 19 26 29 40 3 8 16 20 27 30 40 45 62 3 8 24 23 32...

Page 10: ...Newton Metre to Pound Foot and Pound Inch GENERAL INFORMATION 1 8 TORQUE CONVERSIONS...

Page 11: ...Newton Metre to Pound Foot and Pound Inch GENERAL INFORMATION 1 9 TORQUE CONVERSIONS...

Page 12: ...10 mm 3937s 13 32 4063 27 64 4219 11 mm 4331s 7 16 4375 29 64 4531 15 32 4688 12 mm 4724s 31 64 4844 1 2 5 13 mm 5118 33 64 5156 17 32 5313 35 64 5469 14 mm 5512s 9 16 5625 37 64 5781 15 mm 5906s 19 3...

Page 13: ...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 I...

Page 14: ...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...

Page 15: ...icator while crankshaft is supported between centers on V blocks or resting in crankcase Measure at various points especially at PTO DCV Direct current voltage Dial Bore Gauge A cylinder measuring ins...

Page 16: ...engine RPM increases Reservoir Tank The fill tank in the liquid cooling system Resistance Inthemechanical sense frictionor load Inthe electrical sense ohms Bothresult inenergy conversionto heat Right...

Page 17: ...ection 2 8 Carburetor Adjustments 2 8 2 11 Fuel System 2 12 2 13 Compression Test 2 14 Battery Maintenance 2 15 Electrical 2 16 Air Filter Service 2 17 Air Box Sediment Tube Service 2 17 Recoil Housin...

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Page 19: ...eplace if necessary Air Box Sediment Tube Daily Drain deposits whenever visible EH Valve Clearance 100 hrs 12 months 1000 1600 Inspect Adjust E Idle Speed As required As required Adjust H Throttle Cab...

Page 20: ...Years Brake Fluid Level Pre ride Pre ride Inspect Daily Pre Ride Inspection Item Brake Lever Pedal Travel Pre ride Pre ride Inspect Daily Pre Ride Inspection Item H Brake Pad Wear 10 hrs Monthly 100 1...

Page 21: ...Y INFORMATION Item Type Notes See Page Engine Oil Polaris Premium 4 Synthetic 0W 40 Add to proper level on dipstick 2 21 Transmission Polaris Synthetic Gear Case Lubricant Refer to procedures outlined...

Page 22: ...Grease 2871312 Grease Gun Kit 2871329 Dielectric Grease Nyogelt Additives Sealants Thread Locking Agents Misc 2870585 Loctitet Primer N Aerosol 25g 2871949 Loctitet Threadlock 242 50ml 2871950 Loctite...

Page 23: ...lube to full level on dipstick Change annually 3 Brake Fluid Polaris DOT 3 Brake Fluid Fill master cylinder reservoir to in dicated level inside reservoir See page 2 29 As required Change fluid every...

Page 24: ...se Apply fresh grease by hand and reassemble Semi annually 9 Steering Post Bush ings All Season Grease Locate fittings on upper and lower steering post and grease with grease gun Semi annually 10 Rear...

Page 25: ...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 magnetic end clean to remove accumulated metallic filings 6 After the oil has drai...

Page 26: ...poor performance 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 w...

Page 27: ...ing temperature about 10 minutes This is a very important step PILOT SCREW ADJUSTMENT IMPORTANT NOTE Idle speed is specified with the lights OFF On the idle speed will drop between 100 150 RPM when th...

Page 28: ...Start engine and set idle to specified RPM NOTE Be sure the engine is at operating temperature See Idle Speed Adjustment 4 Loosen lock nut on in line cable adjuster Ill 1 5 Turn cable adjuster out un...

Page 29: ...rs from left to right through the entire turning range If idle speed increases check for proper cable routing If cable is routed properly and in good condition repeat adjustment procedure ETC switch c...

Page 30: ...s 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 Replac...

Page 31: ...t bowl 1 Turn fuel valve to the off position 2 Place a clean container beneath the bowl drain spigot or bowl drain hose 3 Turn drain screw out two turns and allow fuel in the float bowl and fuel line...

Page 32: ...ed 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 indi...

Page 33: ...ever 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 a...

Page 34: ...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...

Page 35: ...r new main filter and reinstall AIR BOX SEDIMENT TUBE Periodically check the air box drain tube located toward the rear of the machine Drain whenever deposits are visible in the clear tube NOTE The se...

Page 36: ...ON Make sure the manual start handle is ful ly seated on the recoil housing especially when trav elling in wet areas If it is not sealed properly water may enter the recoil housing and damage compo ne...

Page 37: ...il level is over the full mark change the oil OIL AND FILTER CHANGE 1 Place vehicle on a level surface 2 Run engine two to three minutes until warm Stop engine 3 Clean area around drain plug 4 Place a...

Page 38: ...d additional 1 2 turn 12 Remove dipstick and fill sump with 2 quarts 1 9 l of Polaris Premium 4 synthetic oil 13 Place gear selector in neutral and set parking brake 14 Start the engine and let it idl...

Page 39: ...Remove plastic valve plugs 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 Rotat...

Page 40: ...LEARANCE ADJUSTMENT NOTE The exhaust valve is adjusted the same as the in take valve 1 Insert 006s feeler gauge between end of exhaust valve stem and adjuster screw 2 Loosen locknut and turn adjuster...

Page 41: ...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...

Page 42: ...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...

Page 43: ...e out This means the measurement at the front of the tire A is 1 8s to 1 4s 3 to 6 cm wider than the measurement at the rear B TOE ALIGNMENT ADJUSTMENT 7 If toe alignment is incorrect measure the dist...

Page 44: ...drive the 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 neutral and repeat steps 2 and 3...

Page 45: ...ake 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...

Page 46: ...e Ill 1 If less than one inch two things must be examined Free Play Free play of the brake pedal should be 1 8 1 4 inch 3 2 6 35 mm If free play is excessive inspect pedal linkage and master cylinder...

Page 47: ...SPECTION 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 4s 6 cm DRIVE CHAIN INSPECTION The chain...

Page 48: ...during inspection Measure the chain deflection as shown in the diagram Delfection should be approximately 3 8 10 mm After inspection again slowly move the ATV forward until all the chain slack is on...

Page 49: ...he eccentric housing and adjust to the proper tension approx 3 8s or 10 mm 6 Tighten the eccentric clamp bolts to specification WITH TRAILER HITCH 45 ft lbs 61 Nm CAUTION DO NOT OVER TIGHTEN ECCENTRIC...

Page 50: ...ward checking chain tension at the same point in several places around the chain The chain is adjusted correctly when the tightest portion of the chain has approximately 3 8 10 mm of deflection 10 Pos...

Page 51: ...or dam age Inspect 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...

Page 52: ...and remove the 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 the valve stem is toward the outs...

Page 53: ...affect ATV handling Tire Tread Depth Alwaysreplacetireswhentreaddepthiswornto1 8s 3 mm or less WARNING Operating an ATV with worn tires will increase the possibility of the vehicle skidding easily wit...

Page 54: ...NOTES...

Page 55: ...ure Test 3 8 Lubrication Oil Flow 3 9 3 10 Engine Exploded View 3 11 Engine Top End Disassembly 3 12 3 24 Valve Seat Service 3 25 3 30 Engine Bottom End Disassembly 3 31 3 46 Crankcase Bearing Assembl...

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Page 57: ...7 7 9 Nm Cylinder 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 Fittings 1 2 9 16 20 27 Nm Oil Delivery Pipe...

Page 58: ...d the flywheel side of the engine The other numbers are used for identification as to diameter length and design Four stroke engine rings are rectangular profile The numbers or letters on all rings ex...

Page 59: ...amshaft Oil clearance Std 0022 0035s 055 090 mm Limit 0039s 10 mm Cylinder Head Surface warpage limit 0020s 05 mm y Standard height 2 908s 73 8 mm Valve Seat Contacting width In Std 039s 1 0 mm g Limi...

Page 60: ...iston ring installed gap Top ring Std 0079 0138s 0 20 0 35 mm g g g p p g Limit 039s 1 0 mm Second i Std 0138 0197s 0 35 0 50 mm ring Limit 039s 1 0 mm Oil ring Std 0079 0276s 0 20 0 70 mm g Limit 059...

Page 61: ...uel Tank Cover Front Cab Refer to Chapter 5 SFuel Tank Refer to Chapter 4 5 Disconnect spark plug high tension lead 6 Remove springs from exhaust pipe and remove pipe 7 Drain engine oil 8 Remove airbo...

Page 62: ...t deflection Chapter 6 3 Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing Chapter 6 Transmission 1 Inspect transmission operation and adjust linkage if...

Page 63: ...ons on page 3 4 before honing Complete the siz ing with fine grit stones to provide the proper cross hatch finish and required piston clearance A finished cylinder should have a cross hatch pattern to...

Page 64: ...ification ES32PF 71 99 PSI 3000 RPM Polaris 0W 40 Synthetic Oil temp at 122_F 50_C OIL PRESSURE TEST ES32PF 1 Remove lower blind plug behind oil filter on crankcase 2 Insert a 1 8 NPT oil pressure gau...

Page 65: ...il is diverted in two directions Oil is supplied to the camshaft through the right front cylinder head bolt passage and into the camshaft through the camshaft journal The camshaft journals cam lobes a...

Page 66: ...r 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 Fi...

Page 67: ...Crankcase Cylinder Cylinder Head Crankshaft and Piston Valve Train ES32PFE06 07 08 EARLY ES32PFE06 ENGINE 3 11 ES32PFE ENGINE EXPLODED VIEW...

Page 68: ...C 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 sprocket marks align with gasket surface and t...

Page 69: ...l 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...

Page 70: ...face If there is any damage or uneven wear replace the rocker arm NOTE Always inspect camshaft lobe if rocker arms are worn or damaged 5 Remove cylinder block plug using a 14mm hex head wrench 6 Measu...

Page 71: ...nspect surface Compare to specifications 9 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 adjuste...

Page 72: ...end plug 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 cam chain with a wire t...

Page 73: ...NE 3 17 CAMSHAFT REMOVAL CONT 6 Inspect cam sprocket teeth for wear or damage Replace if necessary 7 Remove camshaft Inspect for Areas of Tooth Wear or Damage Return spring spacer Dowel pin Release le...

Page 74: ...nder head 1 Check release lever shaft for smooth operation throughout the entire range of rotation 2 Remove release lever shaft and return spring spacer 3 Inspect shaft for wear or galling 4 Inspect l...

Page 75: ...e by subtracting journal OD from journal bore ID Compare to specifications Replace camshaft if damaged or if any part is worn past the service limit Replace cylinder head if camshaft journal bore is d...

Page 76: ...linder head lightly with a plastic hammer until loose CAUTION Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging casting 9 Remove cylinder head and head gasket C...

Page 77: ...inder head disassembly and reassembly NOTE Keep all parts in order with respect to their location in the cylinder head 1 Using a valve spring compressor compress the valve spring and remove the split...

Page 78: ...ace 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...

Page 79: ...ting 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 Measu...

Page 80: ...tem 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 NOTE If valve guides are r...

Page 81: ...e protection when performing cylinder head service Valve guide replacement will require heating of the cylinder head Wear gloves to prevent burns Valve Guide Removal Installation 1 Remove all carbon d...

Page 82: ...ing 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 h...

Page 83: ...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 SIf the c...

Page 84: ...to narrow the seat SIf the seat is too narrow widen using the 45q cutter and re check contact point on the valve face and seat width after each cut NOTE When using an interference angle the seat conta...

Page 85: ...valve is fully seated and repeat process for the other valve 12 Clean cylinder head valves and camshaft oil supply passage A thoroughly 13 Spray electrical contact cleaner into oil passage and dry usi...

Page 86: ...eepers 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 VALV...

Page 87: ...Remove cam chain guide at front of cylinder 2 Remove the two 6 mm cylinder base bolts 3 Tap cylinder lightly with a plastic hammer in the reinforced areas only until loose 4 Rock cylinder forward and...

Page 88: ...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 Pl...

Page 89: ...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 t...

Page 90: ...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 Ma...

Page 91: ...pin O D Replace piston and or piston pin if out of tolerance 5 Measure connecting rod small end ID Piston Pin Bore 7095 7097I 18 007 18 013 mm Piston Pin Measurement Locations Piston Pin O D 7092 709...

Page 92: ...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 scru...

Page 93: ...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 directio...

Page 94: ...ot thread the puller bolts into the flywheel more than 1 4s or stator coils may be damaged 3 Mark or note position of stator plate on crankcase 4 Remove bolts and carefully remove stator assembly bein...

Page 95: ...spect 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...

Page 96: ...lief valve opens to relieve any excess pressure from the oil pump if oil pressure reaches approxi mately 71 psi It must be clean and have adequate spring pressure in order to seal properly 1 Remove ca...

Page 97: ...easure pump end clearance using a feeler gauge and straight edge 4 Measure clearance between outer feed rotor and crankcase pocket with a feeler gauge 5 Measure rotor tip clearance with a feeler gauge...

Page 98: ...ner feed rotor and feed chamber cover with screw 4 Tighten screw securely 5 Install oil pump on crankcase and torque bolts to 6 ft lbs 8 Nm CRANKCASE SEPARATION 1 Remove flange bolts 11 from magneto s...

Page 99: ...termine which part s are outside of specifications NOTE Markings on connecting rod and cap that must be aligned for assembly If marks are not clearly visible mark the rod and cap with a permanent mark...

Page 100: ...CRANKSHAFT MAIN BEARING INSPECTION 1 Inspect the crankshaft main bearings NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel Look for signs of...

Page 101: ...careful not to disturb the Plastigauge 6 Use the measuring scale on the Plastigauge wrapper to measure the thickness of the Plastigauge The rod must not turn during this procedure NOTE Use the widest...

Page 102: ...signs of discoloration scoring or galling Turn the inner race of bearing The bearing should turn smoothly and quietly The outer race should fit tightly in the crankcase The inner race should be firm...

Page 103: ...ss only on outer race of bearing to prevent bearing damage S70mm 2 755s driver For crankshaft main bearings END PLAY INSPECTION ADJUSTMENT Before reassembling the crankcase the following steps should...

Page 104: ...idth from MAG side bearing seat to the outside race of the PTO bearings with a micrometer or dial caliper and record NOTE If PTO bearings are not installed measure the width of the bearings and add to...

Page 105: ...he crankshaft Ensure that I D marks are aligned NOTE Procedure during disassembly called for mark ing of connecting rod and cap Ensure that each part is installed in its original location by noting th...

Page 106: ...Set the crankcase in position carefully Mate the crankcase halves by tapping lightlywith asoft facedhammer Continually check alignment of the cases during installation closing the gap equally until t...

Page 107: ...STALLATION 1 Install the tensioner blade and tighten the mounting bolt to specified torque OIL FILTER INSTALLATION 1 Apply clean engine oil to oil filter gasket Install filter until gasket lightly tou...

Page 108: ...oove when compressed PISTON INSTALLATION 1 Clean the gasket surfaces on the cylinder and crankcase Remove all traces of old gasket material 2 Make sure the cylinder mounting bolt holes are clean and f...

Page 109: ...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 rings are captive...

Page 110: ...inder 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 4 Tighten 6mm cylind...

Page 111: ...e gasket surface the alignment pin faces to the intake side and camshaft lobes are point ing down Camshaft Installation Timing Method 1 Refer to Illustration Page 3 57 If the stator assembly is remove...

Page 112: ...242 to the cam sprocket bolt and torque to specifications 8 Check all cam timing marks to verify proper cam timing and install the cam chain tensioner See Cam Chain Tensioner Installation page 3 60 N...

Page 113: ...d 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...

Page 114: ...use the single TDC mark when installing the cam Do not use the advance marks See Ill on next page 4 Loop the cam chain on the cam sprocket with the dot on the sprocket facing outward and the alignmen...

Page 115: ...ion 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 stro...

Page 116: ...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 Apply 3 B...

Page 117: ...ation STARTER DRIVE 1 Be sure the washer is positioned on the back of the drive gear 2 Apply starter drive grease P N 2871460 to the drive bushing in the crankcase and all moving surfaces of the start...

Page 118: ...557 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 9 Install rocker cover blo...

Page 119: ...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 b...

Page 120: ...pring 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...

Page 121: ...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 en...

Page 122: ...g needle jet locating pins SLoose jets in carburetor or calibration incorrect for altitude temperature SIncorrect float level setting SPVT system calibrated incorrectly or components worn or mis adjus...

Page 123: ...sadjusted SChoke not adjusted properly SLow compression SCrankcase breather restricted Engine Idles But Will Not Rev Up SSpark plug fouled weak spark SBroken throttle cable SObstruction in air intake...

Page 124: ...y adjusted SCylinder or piston worn SPiston rings worn leaking broken or sticking SBent valve or stuck valve SValve spring broken or weak SValve not seating properly bent or carbon accumulated on seal...

Page 125: ...nts 4 4 Mikuni CV Carburetor Operation 4 5 4 7 Mikuni BST Carburetor Exploded View 4 8 Mikuni CV Carburetor Disassembly 4 9 4 10 Mikuni CV Carburetor Cleaning 4 11 Mikuni CV Carburetor Assembly Inspec...

Page 126: ......

Page 127: ...idle to 1 4 throttle setting Refer to Mainte nance Chapter 2 for complete adjustment procedure and the following guidelines for minor altitude adjustments Pilot Screw Turn the fuel screw in clockwise...

Page 128: ...steering post Forward 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 FUEL...

Page 129: ...tor 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 5 3130566 145...

Page 130: ...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 P...

Page 131: ...nt 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 signif...

Page 132: ...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 ci...

Page 133: ...r 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 in...

Page 134: ...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...

Page 135: ...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 floa...

Page 136: ...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...

Page 137: ...lutions 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 o...

Page 138: ...e 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...

Page 139: ...nstalled 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 spri...

Page 140: ...ting 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 to...

Page 141: ...Open bowl drain screw by turning counterclockwise approximately two turns Start and run engine for 3 to 5 seconds to allow fuel level to stabilize in the line If level is out of specification remove c...

Page 142: ...3 Remove the screws from the pump diaphragm cover Note the location of the two longer screws 4 Remove the diaphragm cover gasket diaphragm and valve body gasket 5 Remove the outlet check valve cover d...

Page 143: ...4 17 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 In...

Page 144: ...r air cleaner cover S Ruptured vacuum slide diaphragm or poor seal between diaphragm and slide vacuum slide stuck closed or sticky S Improper spring S Jet needle position incorrect S Incorrect pilot s...

Page 145: ...ed S Idle speed set incorrectly S Idle mixture screw misadjusted or damaged S Belt dragging S Ignition timing incorrect S Worn jet needle needle jet ERRATIC IDLE S Choke cable bending or incorrectly a...

Page 146: ...NOTES...

Page 147: ...moval 5 3 Steering Assembly Exploded View 5 4 A Arm Replacement 5 5 Concentric Swingarm Removal Disassembly 5 6 Concentric Swingarm Assembly Installation 5 7 Strut Assembly Exploded View 5 8 Front Str...

Page 148: ......

Page 149: ...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...

Page 150: ...USPENSION 5 2 BODY ASSEMBLY EXPLODED VIEW 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...

Page 151: ...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...

Page 152: ...bly Install w open end to ward rear of machine B 1 2 1 30 ft lbs 41 Nm A 2 12 14 ft lbs 17 17 Nm 40 45 ft lbs 54 61 Nm Steering Post Steering Post Arm Frog 1 2 NOTE To avoid damage to tie rods and oth...

Page 153: ...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...

Page 154: ...then remove both 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...

Page 155: ...o 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 flat...

Page 156: ...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 F...

Page 157: ...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...

Page 158: ...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...

Page 159: ...minate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged WARNING The following procedure involves the use of an open flame Perform this procedure in a we...

Page 160: ...NOTES...

Page 161: ...6 10 Shift Weights 6 11 Drive Clutch Inspection 6 12 Drive Clutch Exploded View 6 13 Drive Clutch Disassembly Inspection 6 14 6 16 Drive Clutch Assembly 6 17 6 18 Drive Belt Tension 6 18 Drive Belt R...

Page 162: ......

Page 163: ...Tool 2870910 Clutch Bushing Removal Installation 2871226 Piston Pin Puller Used with 2871226 2870386 Loctitet 680 2870584 RTV Silicone Sealer 2870661 Loctite Gasket Remover 2870601 PVT SYSTEM FASTENE...

Page 164: ...he 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...

Page 165: ...ation below and on the following pages The PVT system is air cooled by fins on the drive clutch stationary sheave The fins create a low pressure area in the crankcase casting drawing air into the syst...

Page 166: ...ng Slow and easy clutch engagement Fast effective use of the throttle for efficient engagement Towing Pushing at low RPM low ground speed Use Low Range only Plowing snow dirt etc utility use Use Low R...

Page 167: ...Remove or loosen rear cab fasteners as necessary to gain access to PVT outer cover 3 Remove PVT air outlet duct hose 4 Remove outer cover screws and clamps Refer topage 6 8 5 Mark the drive belt dire...

Page 168: ...et 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...

Page 169: ...mission input shaft 9 Apply a light film of grease to the splines on the shaft 10 Install the driven clutch washer lock washer and retaining bolt Torque to specification 11 Clean end of taper on crank...

Page 170: ...CLUTCH 6 8 PVT SEALING AND DUCTING COMPONENTS Inlet Duct Exhaust Duct Outer Cover Outer Cover Seal Retainer Inner Cover Seal Inner Cover Shield Clutch Cover Bracket...

Page 171: ...s 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 w...

Page 172: ...air 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...

Page 173: ...ights 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...

Page 174: ...ring or washer where applicable and inspect surface of towers See spider removal page 6 15 2 Inspect sheave surfaces Replace the entire service clutch if worn damaged or cracked WARNING The clutch as...

Page 175: ...CLUTCH 6 13 DRIVE CLUTCH EXPLODED VIEW Drive Clutch Mark with permanent marker before disassembly Teflon coated brass bushing Teflon coated brass bushing...

Page 176: ...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 r...

Page 177: ...and thickness of these washers To maintain proper clutch balance and belt to sheave clearance be sure to reinstall original quantity and thickness washers Moveable Sheave Bushing Inspection 2 Inspect...

Page 178: ...rs in sets of three Also inspect to see if roller and bushing are separating Bushing must fit tightly in roller Use pin removal tool PN 2870910 to replace rollers and pins Take care not to damage roll...

Page 179: ...ixed sheave 3 Install spider spacers Use same quantity and thickness as were removed 4 Compress spider buttons for each tower and install spider making sure that X or the marks that were made earlier...

Page 180: ...out of specification adjust by removing or adding shims between the driven clutch sheaves S Remove shims to decrease belt deflection S Add shims to increase belt deflection See Driven Clutch Disassemb...

Page 181: ...deflection S The top edges have been trimmed on some drive belts It will be necessary to project the side profiles and measure from corner to corner S Place a straight edge on each side of the drive...

Page 182: ...belt if worn past the service limit Belts with thin spots burn marks etc should be replaced to eliminate noise vibration or erratic PVT operation See Troubleshooting Chart at the end of this chapter...

Page 183: ...an 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 OF...

Page 184: ...apter 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 asi...

Page 185: ...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 wi...

Page 186: ...de 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...

Page 187: ...utch 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 Tu...

Page 188: ...oving 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 s...

Page 189: ...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 T20 7 Remove moveable sheave and note the number of sp...

Page 190: ...es for wear or damage 10 Clean and inspect splines on helix and transmission input shaft 11 Lube splines with a light film of grease Do not lubricate the bushings Inspect bushings for wear Moveable Sh...

Page 191: ...test 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 crea...

Page 192: ...lose as possible to the bushing bore when using a press 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 f...

Page 193: ...lustration 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...

Page 194: ...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...

Page 195: ...t 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 clu...

Page 196: ...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...

Page 197: ...lutch 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 w...

Page 198: ...NOTES...

Page 199: ...ncentric Swingarm Rear Axle Removal 7 7 7 8 Concentric Swingarm Rear Axle Disassembly 7 9 Concentric Swingarm Rear Axle Assembly 7 10 7 11 Concentric Swingarm Rear Axle Installation 7 12 Concentric Sw...

Page 200: ......

Page 201: ...Ft Lbs Front Spindle Nut 40 Ft Lbs Rear Hub Retaining Nut 80 Ft Lbs Refer to exploded views and text for torque values of other fasteners CAUTION Locking nuts and bolts with preapplied locking agent s...

Page 202: ...oving 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 n...

Page 203: ...e 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 spac...

Page 204: ...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 number...

Page 205: ...mooth 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 9 Install hub cap 10 Rotate hub It should rotate smoothl...

Page 206: ...trut 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 6...

Page 207: ...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...

Page 208: ...FINAL DRIVE 7 8 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 209: ...CONCENTRIC SWINGARM REAR AXLE DISASSEMBLY 1 Remove rear axle See page 7 7 2 Remove snap ring collar and foam seal 3 Remove nut brake disc assembly and stop ring Stop Ring Disc Hub Groove in spline Nut...

Page 210: ...line 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 tightenin...

Page 211: ...11 CONCENTRIC SWINGARM REAR AXLE ASSEMBLY CONT 4 Install foam seal and axle nut lock sleeve with taper toward nut Install snap ring to retain the lock sleeve Foam Seal Lock Sleeve Tapered side toward...

Page 212: ...am 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 procedu...

Page 213: ...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...

Page 214: ...R HOUSING REMOVAL 1 Remove rear axle See page 7 7 2 Remove sprocket hub Note sealing O ring between sprocket hub and bearing 3 Remove brake caliper mounting bracket 4 Remove brake caliper pivot bushin...

Page 215: ...FINAL DRIVE 7 15 CONCENTRIC SWINGARM REAR HOUSING REMOVAL CONT 5 Remove rear housing...

Page 216: ...ve in new bearing race with brass drift 2 Lubricate and install new tapered bearings 3 Lubricate and install new seals CONCENTRIC SWINGARM REAR HOUSING INSTALLATION 1 Place brake caliper pivot bushing...

Page 217: ...APTER 8 TRANSMISSION SERVICE Torque Specifications 8 1 Transmission Remove Install 8 2 Transmission Disassembly 8 3 8 8 Transmission Assembly 8 9 8 10 Transmission Exploded View 8 11 Troubleshooting 8...

Page 218: ......

Page 219: ...6 Nm Bell Crank Nut 12 ft lbs 16 6 Nm Transmission Drain Plug 14 ft lbs 19 3 Nm Transmission Mounting Bolts 25 ft lbs 34 5 Nm Swing Arm Pivot Bolts Concentric Swingarm 150 ft lbs 207 5 Nm LUBRICATION...

Page 220: ...nect harness from gear position switch 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 rig...

Page 221: ...sprocket 4 Remove the transmission cover bolts 5 With a soft face hammer tap on the 3 cover bosses and carefully remove the cover 6 Remove detent plug washer spring and shifting bullet NOTE Shifting...

Page 222: ...8 4 TRANSMISSION DISASSEMBLY CONT 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 for...

Page 223: ...SION DISASSEMBLY CONT 11 Mark orientation of bellcrank to the shift fork shaft 12 Remove bellcrank Use a small puller if necessary 13 Remove snap ring and washer Pull down and rotate shift fork shaft...

Page 224: ...Inspect 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 o...

Page 225: ...7 Remove bearing from other end of input shaft Remove two snap rings and gear 18 Inspect gear bushing Replace if 50 of teflon surface is gone 19 Inspect output shaft gear sprocket and bearing Replace...

Page 226: ...CONT 20 Stretch chain tight on a flat surface and measure the length of 8 pitches in a minimum of three places on chain Replace chain if measurement is longer than 3 0904I Measure 8 pitches Chain Str...

Page 227: ...the dog gear NOTE Input gear cogs face inward on input shaft 2 Assemble output shaft with sprocket gear and bearing if they were disassembled 3 Assemble output shaft assembly with chain to the input s...

Page 228: ...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 trans...

Page 229: ...Input Shaft High Reverse Dog Position Switch Silent Chain Output Shaft Drain Plug Shift Fork Dipstick TRANSMISSION 8 11 TRANSMISSION EXPLODED VIEW...

Page 230: ...ment and rod end positioning S Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the tra...

Page 231: ...embly 9 10 9 11 Master Cylinder Installation 9 12 Front Pad Removal 9 13 Front Pad Assembly 9 14 9 15 Front Disc Inspection 9 15 Front Disc Removal Replacement 9 16 Front Caliper Removal 9 17 Front Ca...

Page 232: ......

Page 233: ...3 81mm Brake Disc Thickness 177 187s 4 496 4 750mm 167s 4 242mm Brake Disc Thickness Variance Between Measurements 002s 051mm Brake Disc Runout 010s 25mm Master Cylinder I D Front 750s Master Cylinde...

Page 234: ...for brake drag after any brake system service and investigate cause if brake drag is evident S Make sure caliper moves freely on guide pins where applicable S Inspect caliper piston seals for foreign...

Page 235: ...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 restri...

Page 236: ...ause 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 c...

Page 237: ...the hand and foot brake hydraulic systems are separate there are also two bleed screws one for the outer fluid chamber hand brake and one for the inner fluid chamber foot brake The basic procedure fo...

Page 238: ...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 indicated MAX level insid...

Page 239: ...cylinder 10 Tighten bleeder screw securely and remove bleeder hose 11 Repeat procedure steps 5 9 for the remaining caliper s 12 Add brake fluid to MAX level inside reservoir 13 Install diaphragm cover...

Page 240: ...ke line connection at master cylinder Loosen brake line 1 4 to 1 2 turn CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 3 Remove ma...

Page 241: ...lever 4 Clean surfaces of the reservoir and master cylinder body Be sure supply port is clean before reassembly 5 Remove outer dust seal Be ready to catch piston assembly NOTE The return spring may fo...

Page 242: ...orn replace lever MASTER CYLINDER 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 bor...

Page 243: ...Push the piston assembly through the installation tool using the plunger handle Continue pushing until plunger is solid against installation tool 5 Hold piston assembly inward while removing both too...

Page 244: ...outlet end 1 Install master cylinder on brake line hand tight 2 Install master cylinder on handlebars Tighten outer pinch bolt first Torque mounting bolts to 55 in lbs 6 Nm 3 Using a line wrench tigh...

Page 245: ...o 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 int...

Page 246: ...nting bolts 4 Slowly pump the brake lever until pressure has been built up Maintain at least 1 2s 12 7 mm of brake fluid in the reservoir to prevent air from entering the brake system PAD ADJUSTMENT 5...

Page 247: ...cks scratches or damage 2 Measure the disc thickness at 8 different points around the pad contact surface using a 0 1s micrometer Replace disc if worn beyond service limit 3 Mount dial indicator as sh...

Page 248: ...ts 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 appli...

Page 249: ...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 FRONT CALIPER...

Page 250: ...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 wor...

Page 251: ...on 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 mou...

Page 252: ...llow brake bleeding procedure outlined on pages 9 6 9 7 5 Install wheels and torque wheel nuts to specification NOTE If new brake pads are installed it is recommended that a burnishing procedure be pe...

Page 253: ...BRAKES 9 21 FRONT BRAKE CALIPER EXPLODED VIEW Pads Caliper Mount Piston Pin Boot Square O Rings Adjuster Screw...

Page 254: ...to 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 n...

Page 255: ...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...

Page 256: ...ng 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 an...

Page 257: ...ngs 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 tw...

Page 258: ...lines and tighten to specified torque 7 Follow bleeding procedure outlined on pages 9 6 9 7 of this section and refer to system overview and illustration on page 9 4 8 Field test unit for proper brak...

Page 259: ...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 Measure Thickness Rear Brake...

Page 260: ...18 ft lbs 24 8 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...

Page 261: ...ed lever S Incorrectly adjusted stationary pad S Worn or damaged master cylinder or components S Improper clearance between lever and switch Lever Vibration S Disc damaged S Disc worn runout or thickn...

Page 262: ...NOTES...

Page 263: ...0 9 Ignition System Troubleshooting 10 10 Battery Service 10 11 10 14 Charging System Testing 10 15 10 17 Starter System Troubleshooting 10 18 Starter System Testing 10 19 Starter Motor Service 10 20...

Page 264: ......

Page 265: ...e 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 f...

Page 266: ...ity 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 Remov...

Page 267: ...rten the life of the lamp Hold the lamp by the base TAILLIGHT BRAKELIGHT LAMP REPLACEMENT If the taillight brakelight does not work the lamp may need to be replaced 1 From the rear of the taillight re...

Page 268: ...the ignition timing check hole and check the ignition timing NOTE Do not allow the engine to warm up The timing will retard approximately 2q when the engine is warm If the ignition timing is not withi...

Page 269: ...several hundred RPM either above or below the specified timing RPM 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 MAX...

Page 270: ...p Location The flywheel can be identified by the stamp mark in location A Refer to I D location in chart below Do not use the cast mark to determine flywheel application Engine Application Type Cast S...

Page 271: ...er Air Gap 016 030s 4 75 mm Meter Meter Meter Ignition Coil Primary Winding 3 Exciter Coils NOTE CDI boxes may look the same but have different internal circuitry Be sure to always use the correct CDI...

Page 272: ...e 10 7 or the wiring schematic for meter connections and specifications Compare results to the specifica tions on the exploded views Are all within speci fications Inspect connectors wiring and ground...

Page 273: ...module Test output from exciter coil pulse trigger coil and compare to the chart The following measurements are obtained when cranking the engine with the electric start er spark plug installed The st...

Page 274: ...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 c...

Page 275: ...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 e...

Page 276: ...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 ro...

Page 277: ...5 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 NOT...

Page 278: ...is 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...

Page 279: ...esent 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 rep...

Page 280: ...s lights etc and begins to charge the 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 SCon...

Page 281: ...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...

Page 282: ...oblem seized or binding Can engine be rotated easily with recoil starter SFaulty or worn brushes in starter motor or starter motor problem SAutomatic compression release inoperative Starter Motor Turn...

Page 283: ...enoid 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 b...

Page 284: ...ue 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 Ri...

Page 285: ...e 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 pas...

Page 286: ...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 reinsta...

Page 287: ...ss 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 indic...

Page 288: ...housing aligning marks 4 Install O Ring on other end of field magnet casing Make sure it is in good condition and not twisted on the case 5 Align casing marks and install housing pushing back brushes...

Page 289: ...e 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 ne...

Page 290: ...y the module Modules may have same LR I D number with different part numbers terminals and internal function LIMIT SPECIFICATIONS Always refer to current parts manual or micro fiche for part number an...

Page 291: ...ar 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 reverse ELEC...

Page 292: ...AT IDLE N TEST WIRING N TEST VOLTAGE REGULATOR AND CHARGING SYSTEM MEASURE DC VOLTS ON GRY OR WIRE TO GROUND AT LR44 3 MODULE MEASURE AC VOLTS ON Y R WIRE AT LR44 3 MOD ULE TO GROUND Y DISCONNECT BLA...

Page 293: ...127q C 2 5K Fan ON Temp Rising 290q F 143q C 1 6K 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 h...

Page 294: ...e 4 Apply brake 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 pre...

Page 295: ...High Range Neutral Reverse F F F F D C B A F F High Neutral Reverse Switch ELECTRICAL 10 31 GEAR POSITION INDICATOR SWITCH TEST Switch Continuity Table Switch Schematic...

Page 296: ...e 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 i...

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