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7.2

FINAL DRIVE

SPECIFICATIONS

Torque Table

IMPORTANT: Verify which type of wheel ATV is

equipped with (aluminum or steel) when torquing
wheel nuts.

Special Tools

Gearcase Fluid / Capacity

FRONT DRIVE AXLE

Removal

Set the ATV in park. Remove hub dust cap.

Remove cotter pin.

Loosen the hub retaining nut.

Loosen - but do not remove - the wheel nuts.

Safely lift and support the front of the ATV.

Remove wheel.

Remove the two brake caliper attaching bolts.

OMPONENT

LBS

(

LBS

F/R

Steel

Wheel Nuts

F/R

Aluminum

Wheel Nuts

122

Front Hub Nut

Rear Hub Nut

109

Front Gearcase Mount Bolts

Standard Gearcase Screws

Lower Hub Carrier Bolts

Upper Hub Carrier Bolts

ADC Pump Screws

(17-23)

1.9 - 2.5

ADC Cover Screws

7 - 11

9.4 - 14.9

ADC Bleed Valves

(80)

ART

UMBER

OOL

ESCRIPTION

2872608

Roller Pin Removal Tool

8700226

CV Boot Clamp Pliers

2870772

1 3/4” Straight Wrench

PA-48542

ADC Gearcase Piston

Installation Tool

EARCASE

ESCRIPTION

Centralized Hilliard

(Standard Models)

Demand Drive LT

Premium Hub Fluid

8.97 oz. (265 ml)

Centralized Hilliard

w/ ADC

(Deluxe Models)

Demand Drive LT

Premium Hub Fluid

9.3 oz. (275 ml)

ADC Gearcase

Pump Reservoir

Polaris ADC or AW ISO 10

Hydraulic Fluid

CAUTION

Serious injury could occur if machine tips or falls.

CAUTION

Do not hang the caliper by the brake line. Use wire

to hang the caliper to prevent possible damage to

the brake line.

Содержание 2007 Sportsman 450 EFI

Страница 1: ...ols Use only the proper tools as specified Comments or suggestions about this manual may be directed to Service Publications Dept Polaris Sales Inc 2100 Hwy 55 Medina Minnesota 55340 2007 Sportsman 45...

Страница 2: ...E NOTE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLO...

Страница 3: ...1 GENERAL 2 MAINTENENCE 3 ENGINE 4 FUEL SYSTEM 5 BODY SUSPENSION 6 CLUTCH 7 TRANSMISSION 8 FINAL DRIVE 9 BRAKES 10 ELECTRICAL 11 INTERNATIONAL...

Страница 4: ...NOTES...

Страница 5: ...ND STANDARD MODEL COMPONENT COMPARISON 1 4 SPORTSMAN X2 DELUXE AND STANDARD MODEL COMPONENT COMPARISON1 5 2007 SPORTSMAN 450 1 6 MODEL NUMBER A07MH46AA AZ 1 6 2007 SPORTSMAN 500 EFI 1 8 MODEL NUMBER A...

Страница 6: ...ber whenever corresponding about an engine This information can be found on the sticker applied to the top side of the crankcase A An additional number is stamped on the side of the crankcase beneath...

Страница 7: ...Manual PN Parts Micro Fiche PN 2007 Sportsman 500 EFI A07MN50A Deluxe A07MH50A Standard A07MH50F Standard Intl 9920364 9920365 N A 2007 Sportsman X2 500 EFI A07TN50A Deluxe A07TH50A Standard 9920632 9...

Страница 8: ...2 Titan Tires PVT w EBS 3 Non EBS X2 excluded Rear Work Lights 4 No Work Lights Front Drive w Active Descent Control ADC 5 No Active Descent Control ADC Speed Sensor Wiring for ADC 6 No Sensor Wiring...

Страница 9: ...eluxe and Standard model were offered Use the following table as a guide X2 DELUXE MODEL Item Location X2 STANDARD MODEL Winch 1 No Winch Rear Work Lights 2 No Work Lights Front Drive w Active Descent...

Страница 10: ...on Capacity Length 83 in 211 cm Width 48 in 122 cm Height 48 in 122 cm Wheel Base 50 5 in 128 3 cm Ground Clearance 11 in 27 94 cm Dry Weight 715 lbs 324 kg Gross Vehicle Weight 1210 lbs 549 kg Front...

Страница 11: ...Circuit Protection Solid State PDM Starting Electric Recoil Instrument Cluster Analog Speedo w LCD Table 1 6 Sportsman 450 Drivetrain Transmission Type Drumshift H L N R P Transmission Capacity 32 oz...

Страница 12: ...General Specifications Category Dimension Capacity Length 83 in 211 cm Width 48 in 122 cm Height 48 in 122 cm Wheel Base 50 5 in 128 3 cm Ground Clearance 11 25 in 28 6 cm Dry Weight 715 lbs 324 kg G...

Страница 13: ...amp Switched Power 10 amp Fuel Pump 10 amp ECU 15 amp Ignition Coil 10 amp Accessory Power 10 amp Lights 20 Amp Starting Electric Recoil Instrument Cluster Analog Speedo w LCD Table 1 11 Sportsman 500...

Страница 14: ...ategory Dimension Capacity Length 93 in 236 cm Width 48 in 122 cm Height 48 in 122 cm Wheel Base 57 in 145 cm Ground Clearance 11 in 28 cm Dry Weight 798 lbs 362 kg Gross Vehicle Weight 1500 lbs 680 k...

Страница 15: ...Hr Circuit Breakers Fan 12 amp Switched Power 10 amp Fuel Pump 10 amp ECU 15 amp Ignition Coil 10 amp Accessory Power 10 amp Lights 20 Amp Starting Electric Recoil Instrument Cluster Analog Speedo w L...

Страница 16: ...fications The following torque specifications are to be used as a general guideline There are exceptions in the steering suspension and engine areas Always consult the exploded views in each manual se...

Страница 17: ...mm 9449 61 64 9531 31 32 9688 25 mm 9843 63 64 9844 1 1 0 Thread Size Drill Size Thread Size Drill Size 0 80 3 64 1 2 13 27 64 1 64 53 1 2 20 29 64 1 72 53 9 16 12 31 64 2 56 51 9 16 18 33 64 2 64 50...

Страница 18: ...nches cu in x 16 387 Cubic centimeters cc Cubic centimeters cc x 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters l Liters l x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Li...

Страница 19: ...r in length applied in a rotational direction l or ltr Liter Left Side Always referred to based on normal operating position of the driver m Meter meters Mag Magneto Magnetic Induction As a conductor...

Страница 20: ...NOTES GENERAL INFORMATION 1 16...

Страница 21: ...L FILTER 2 17 COMPRESSION TEST 2 17 ENGINE MOUNTS 2 17 SPARK PLUG 2 18 ACTIVE DESCENT CONTROL ADC RESERVOIR LEVEL 2 18 BATTERY MAINTENANCE 2 18 LIQUID COOLING SYSTEM OVERVIEW 2 19 COOLANT STRENGTH TYP...

Страница 22: ...ON 2 31 CV SHAFT BOOT INSPECTION 2 31 CONTROLS 2 31 WHEELS 2 31 WHEEL HUB AND SPINDLE TORQUE TABLE 2 32 WHEEL REMOVAL FRONT OR REAR 2 32 WHEEL INSTALLATION 2 32 TIRE PRESSURE 2 32 TIRE INSPECTION 2 33...

Страница 23: ...f the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Maintenance Chart Key The following symbols denote potential...

Страница 24: ...Pre Ride Verify Box is latched E Air filter pre filter Daily Inspect clean often E Air box sediment tube Daily Drain deposits when visible Coolant Daily Check level daily change coolant every 2 years...

Страница 25: ...M 310 500 Inspect lubricate adjust Steering 50 H 6 M 310 500 Lubricate Front suspension 50 H 6 M 310 500 Lubricate Rear suspension 50 H 6 M 310 500 Lubricate E Throttle Cable ETC Switch 50 H 6 M 310...

Страница 26: ...ses if applicable 100 H 12M 620 1000 Inspect for leaks Engine mounts 100 H 12M 620 1000 Inspect Exhaust muffler pipe 100 H 12M 620 1000 Inspect E Spark plug 100 H 12M 620 1000 Inspect replace as neede...

Страница 27: ...2 7 MAINTENANCE 2 LUBRICATION FLUIDS SPORTSMAN Component Locations Sportsman Only Deluxe...

Страница 28: ...ntrol Run Switch Speedometer Override Rear Dump Box Passenger Area PVT Cover Oil Dipstick Front Demand Behind Radiator Front Storage Compartment Rack Gas Cap Gear Shifter Front Drive CV Shafts Front P...

Страница 29: ...mium All Season Grease 3 oz cartridge 24 count 2871423 Premium All Season Grease 14 oz cartridge 10 count 2871460 Starter Drive Grease 12 count 2871515 PremiumU JointLube 3 oz 24 Count 2871551 Premium...

Страница 30: ...t Taillight Brakelight check operation of all indicator lights and switches Engine stop switch check for proper function Wheels check for loose wheel nuts and axle nuts check to be sure axle nuts are...

Страница 31: ...urs in extremely dirty conditions or short trip cold weather operation 2 Transmission Polaris AGL Synthetic Gearcase Lube Add lube to bottom fill hole Change annually o 3A 3B Front Gearcase ADC Fluid...

Страница 32: ...ubricant 1 Remove gearcase drain plug A located on the bottom of the gearcase and drain oil The drain plug is accessible through the skid plate Catch and discard used oil properly 2 Clean and reinstal...

Страница 33: ...n oil drain plug area 2 Clean around the drain plug and remove the drain plug and wipe the magnetic end clean to remove all accumulated metallic filings 3 After the oil has drained completely install...

Страница 34: ...to loosen Loosen bleeder screw slowly allowing oil and any trapped air to flow out of fitting IMPORTANT Do not allow hydraulic fluid in reservoir to drain below minimum fill line Close bleeder valve...

Страница 35: ...snap 3 Repeat procedure at the other five locations as shown NOTE Do not attempt to remove cover until all latch points are released Throttle Cable Electronic Throttle Control ETC Switch Adjustment 1...

Страница 36: ...or signs of wear deterioration damage or leakage Replace every two years Be sure vent lines are routed properly and secured with cable ties WARNING Gasoline is extremely flammable and explosive under...

Страница 37: ...n test Smooth idle generally indicates good compression Low engine compression is rarely a factor in running condition problems above idle speed Abnormally high compression can be caused by a decompre...

Страница 38: ...Polaris ADC fluid when required Battery Maintenance Complete battery servicing information for both conventinoal and sealed batteries can be found in Chapter 10 of this manual NOTE Expected battery sh...

Страница 39: ...ating of engine could occur if air is not fully purged from system Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water Coolant Strength Type Test the strength of the co...

Страница 40: ...e and or repair However if the recovery bottle has run dry or if overheating is evident the level in the radiator should be inspected and coolant added if necessary NOTE Use of a non standard pressure...

Страница 41: ...the assembly and tighten NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling NOTE The air filter should rest on the filter support Proper placem...

Страница 42: ...should also be done before storing the ATV The drain screw is located at the bottom of the recoil housing Remove the screw with a 10 mm wrench Reinstall screw once housing has been drained CAUTION Ma...

Страница 43: ...icate moisture collecting in the oil reservoir If the oil level is over the full mark change the oil Oil and Filter Change NOTICE Care must be taken to ensure that the fluids are contained Be prepared...

Страница 44: ...Place shop towels beneath oil filter Use Oil Filter Wrench PV 43527 turn filter counterclockwise to remove 16 Using a clean dry cloth clean filter sealing surface on the crankcase 17 Lubricate the o r...

Страница 45: ...positioned at Top Dead Center TDC on compression stroke 1 Remove the seat 2 Remove body panels and fuel tank as necessary to gain access to valve cover 3 Remove the spark plug high tension lead and re...

Страница 46: ...the engines valves NOTE Both feeler gauges should remain inserted during adjustment of each valve 3 When clearance is correct hold adjuster screw and tighten locknut securely 4 Re check the valve cle...

Страница 47: ...andlebars in this position NOTE The steering arm center section can be used as an indicator of whether the handlebars are straight The center section should always point straight back from the steerin...

Страница 48: ...ission in Park and start the engine Purge accumulated carbon from the system by momentarily revving the engine several times CAUTION During tie rod adjustment it is very important that the following p...

Страница 49: ...e the machine is in Park and repeat Steps 2 and 3 SEE WARNING 6 Repeat steps 2 through 5 until no more particles are expelled when the engine is revved 7 Stop the engine and allow the arrestor to cool...

Страница 50: ...raulic auxiliary foot brake system and adjust or bleed if necessary First check foot brake effectiveness by applying 50 lb approx downward force on the pedal The top of the pedal should be at least 1...

Страница 51: ...ntrols Check controls for proper operation positioning and adjustment Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body...

Страница 52: ...ground 4 Securely tighten the wheel nuts to the proper torque listed in the table Tire Pressure Item Specification Steel Front Wheel Nuts 27 Ft Lbs 37 Nm Steel Rear Wheel Nuts 27 Ft Lbs 37Nm Aluminum...

Страница 53: ...ins are in place Refer to specific fastener torques listed in each chapter Storage Compartments The storage compartments are easily accessible To open the front compartment turn the latch handle to th...

Страница 54: ...winch control located on the side of the winch gives the operator easy access to switch between ENGAGED and FREESPOOL When the winch is ENGAGED the winch only allows the cable to be pulled IN or relea...

Страница 55: ...ow crimp cover is located in the rear fender area The red wire connects to the battery The Orange White wires are located under the front cover under headlight pod The Orange White wires supply the co...

Страница 56: ...uel in the tank and EFI sytem carburetor Turn the fuel valve off and drain the carburetor bowl 450 only Oil and Filter Warm the engine and change the oil and filter Follow the procedure in this chapte...

Страница 57: ...ions Engine Anti Freeze Test engine coolant strength and change if necessary Coolant should be replaced every two years Storage Area Covers Set the tire pressure and safely support the ATV with the ti...

Страница 58: ...2 38 MAINTENANCE Maintenance Schedule Service Date Hours Miles Service Performed Serviced By...

Страница 59: ...KER ARM CAMSHAFT REMOVAL 3 14 CAM CHAIN TENSIONER INSPECTION 3 14 ROCKER ARM SHAFT INSPECTION 3 15 CAMSHAFT REMOVAL 3 16 AUTOMATIC COMPRESSION RELEASE REMOVAL INSPECTION 3 17 AUTOMATIC COMPRESSION REL...

Страница 60: ...3 40 CRANKCASE ASSEMBLY 3 41 WATER PUMP MECHANICAL SEAL INSTALLATION 3 41 WATER PUMP MECHANICAL SEAL REMOVAL ENGINE INSTALLED 3 41 ONE WAY VALVE INSTALLATION 3 42 CAM CHAIN DRIVE SPROCKET INSTALLATIO...

Страница 61: ...2mm 11 15 15 21 Nm Oil Drain Bolt Crankcase 14mm 14 17 19 23 Nm Oil Filter Pipe Fitting 20mm 36 43 49 59 Nm Oil Hose Fitting 1 8 Pipe Thread 6 5 11 9 15 Nm Hard Metal Oil Line Banjo Fitting N A 11 16...

Страница 62: ...8 005 38 025 mm Camshaft Oil clearance Std 022 0035 055 090 mm Limit 0039 10 mm Cylinder Head Surface warpage limit 0020 05 mm Standard Height 3 870 98 3 mm Valve Seat Contacting width In Std 028 7 mm...

Страница 63: ...9053 9055 22 994 23 0 mm Standard clearance piston pin to pin bore 0002 0003 004 008 mm Degree of fit Piston Pin must be a push by hand fit at68o F 20o Piston Ring Piston Ring Installed gap Top ring S...

Страница 64: ...ine The other numbers are used for identification as to diameter length and design Four stroke engine rings are rectangular profile See text for oil control ring upper rail installation Use the inform...

Страница 65: ...cooling system hoses and clamps or water pump seal Radiator Cap Pressure Test 1 Remove radiator cap and test using a cap tester commercially available 2 The radiator cap relief pressure is 13 lbs 89...

Страница 66: ...r Front Cab Refer to Chapter 5 Fuel Tank Refer to Chapter 4 5 Disconnect spark plug high tension lead 6 Remove springs from exhaust pipe and remove pipe 7 Drain coolant and engine oil 8 Remove air pre...

Страница 67: ...In Period 4 Cycle Engine Break In Period is defined as the first 10 hours of engine operation or 2 full tanks of fuel 1 Use only Polaris Premium 4 All Season synthetic oil or API certified SH oil Neve...

Страница 68: ...to the corners of the intake and exhaust ports Cleaning the Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material Wash the cylind...

Страница 69: ...l is diverted in two directions Oil is supplied to the camshaft through the left front cylinder stud and an oil passage in the head Oil enters the camshaft through the PTO L journal The camshaft journ...

Страница 70: ...Oil Pump Scavenging Oil Hose Oil Strainer Crankcase Oil Gallery Oil Pump Feed One Way Valve Bypass Oil Filter Delivery Pipe Crankshaft Prevents oil from draining into crankcase with engine off Top of...

Страница 71: ...3 13 ENGINE 3 EH50PL Engine Exploded Views Crankshaft Cylinder and Piston Cylinder Head Crankcase Valvetrain...

Страница 72: ...on hole and the cam sprocket pin facing upward aligned with the camshaft to crankshaft center line NOTE The cam lobe should be pointing down and valves should have clearance at this point 5 Remove cam...

Страница 73: ...ner assembly if any part is worn or damaged Rocker Arm Shaft Inspection 1 Mark or tag rocker arms to keep them in order for assembly 2 Inspect each rocker arm cam follower surface If there is any dama...

Страница 74: ...or damaged parts NOTE The end of the adjuster screw is hardened and cannot be ground or re faced Camshaft Removal 1 Remove thermostat housing 2 Remove camshaft sprocket inspection cover 3 Loosen three...

Страница 75: ...s not replaceable Replace the camshaft as an assembly if the actuator ball is worn or damaged 1 Check release lever shaft A for smooth operation throughout the entire range of rotation The spring B sh...

Страница 76: ...ttom of illustration at right 6 Place arm of spring under stop pin as shown and push release lever inward until fully seated Do not pre wind the spring one full turn or the compression release will no...

Страница 77: ...emoval 1 Remove the two 6mm flange bolts A from cylinder head See next exploded view on next page 2 Loosen each of the four cylinder head bolts B evenly 1 8 turn each time in a criss cross pattern unt...

Страница 78: ...3 20 ENGINE Cylinder Head Exploded View EH50PL EH50PL A...

Страница 79: ...in order with respect to their location in the cylinder head 1 Using a valve spring compressor A compress the valve springs and remove the split keeper NOTE To prevent loss of tension do not compress...

Страница 80: ...TE The valves cannot be re faced or end ground Valves 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 me...

Страница 81: ...valves in order with their respective seat NOTE Valve seat width and point of contact on the valve face is very important for proper sealing The valve must contact the valve seat over the entire circu...

Страница 82: ...ce 46o cutter on the pilot and make a light cut 10 Inspect the cut area of the seat If the contact area is less than 75 of the circumference of the seat rotate the pilot 180o and make another light cu...

Страница 83: ...all filings from the area with hot soapy water rinse and dry with compressed air 15 Lubricate the valve guides with clean engine oil and apply oil or water based lapping compound to the face of the va...

Страница 84: ...Clean and dry the combustion chamber area 2 Pour a small amount of clean high flash point solvent into the intake port and check for leakage around each intake valve The valve seats should hold fluid...

Страница 85: ...e clamps and remove coolant inlet hose 4 Remove the two 6 mm cylinder base bolts 5 Loosen each of the four large cylinder base bolts 1 4 turn at a time in a criss cross pattern until loose and remove...

Страница 86: ...second ring The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section The top rail has a locating tab on the end which fits into a notch A in...

Страница 87: ...diameter at a point 40 mm down from the top 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 abov...

Страница 88: ...place the rings If ring gap is below specified limit file ring ends until gap is within specified range NOTE Always check piston ring installed gap after re boring a cylinder or when installing new ri...

Страница 89: ...rance exceeds the service limit 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...

Страница 90: ...chain drive sprocket and woodruff key from crankshaft 6 Inspect sprocket teeth for wear or damage 7 Inspect woodruff key for wear 8 Replace any worn or damaged parts One Way Valve Removal The one way...

Страница 91: ...parate the crankcase 4 Remove the Mag RH crankcase from the PTO case Oil Pump Removal Inspection 1 Remove pump shaft bearing A and thrust washer B from pump shaft 2 Remove 2 bolts holding pump drive g...

Страница 92: ...ecome plugged 2 Install pump shaft and scavenge rotor drive pin 3 Install outer scavenge rotor inner scavenge rotor and scavenge casing 4 Install outer feed rotor and inner feed rotor drive pin 5 Inst...

Страница 93: ...case The inner race should be firm with minimal side to side movement and no detectable up and down movement Crankshaft Removal Inspection 7 Remove the shim washer A from the crankshaft 8 Support the...

Страница 94: ...e removal process and should not be re used Pump Shaft Oil Seal Water Pump Mechanical Seal Removal Engine Disassembled NOTE The water pump mechanical seal can be removed without removing the engine Re...

Страница 95: ...performed to determine the amount of crankshaft counter balancer shaft and pump shaft end play Excessive end play may cause engine noise at idle and slow speeds Too little play will side load the bea...

Страница 96: ...r dial caliper and record Crankshaft Width____________ 10 Subtract the Crankshaft Width measured in Step 7 from the Total Case Width recorded in Step 6 and record below Total End Play_____________ 11...

Страница 97: ...ne if a different shim is needed The result must be within the specified range listed at below Oil Pump Shaft End Play Adjustment 1 Make sure the pump shaft bearing is firmly seated in the Magneto sid...

Страница 98: ...shaft and tighten the nut to draw the crankshaft into the main bearings until fully seated Loosen the nut and remove the threaded rod from the crankshaft If removal is difficult install two nuts on th...

Страница 99: ...the pump shaft 7 Screw the guide onto the end of the pump shaft 8 Install the washer and nut and tighten to draw seal into place until fully seated 9 Remove the guide adaptor using the additional nut...

Страница 100: ...echanical seal Ill 5 6 Turn the puller T Handle clockwise until it contacts the water pump shaft Continue rotating until the remaining portion of mechanical seal has been removed from the cases Ill 6...

Страница 101: ...marking and can be installed either way The ends should butt squarely together and must not overlap 2 Install the oil ring top rail NOTE The top rail has a locating tab to prevent rotation The tab mus...

Страница 102: ...ang outward See Caution with Step 3 above Push the piston pin in both directions to make sure the clips are properly seated in the groove Cylinder Installation 7 Place the dowel pins in the crankcase...

Страница 103: ...d cylinder Remove all traces of old gasket material Refer to disassembly photos 1 Install the cam chain tensioner guide Be sure bottom end of guide is located properly in crankcase 2 Install the two d...

Страница 104: ...rom the cam chain and rotate the engine to align the single TDC timing mark Top Dead Center on the flywheel with the notch in the timing inspection window Be sure to use the single TDC mark when insta...

Страница 105: ...crankshaft to camshaft centerline Refer to illustration 8 Apply Crankcase Sealant PN 2871557 to the camshaft end cap and install using a new O Ring 9 Check all cam timing marks to verify proper cam ti...

Страница 106: ...3 48 ENGINE CAMSHAFT TIMING Dots Crankshaft to Camshaft Centreline Sprocket Alignment Pin Single TDC Mark Aligned TDC Mark Rotation Do Not Use Advance Marks...

Страница 107: ...new O Ring in the oil passage recess in the crankcase 3 Apply 3 Bond 1215 PN 2871557 or an equivalent sealer to the stator plate outer surface and install a new O Ring 4 Install the stator plate bein...

Страница 108: ...il to the threads of the bolts and tighten evenly 7 Adjust valves according to the valve adjustment procedure found in Chapter 2 Maintenance 8 Apply clean engine oil liberally to the valve springs cam...

Страница 109: ...spring and inspect Replace spring or ratchet pawl if worn broken or damaged NOTE Long arm of spring engages reel Short end against pawl 7 Hold reel firmly in housing Pull rope handle until 12 18 30 4...

Страница 110: ...o the center post of the housing and the bushing 5 Install reel into housing making sure the spring drive tab on the reel engages the spring and the reel is fully seated in the housing 6 Apply downwar...

Страница 111: ...intake system Restricted engine breather system Oil contaminated with fuel Restricted oil tank vent Engine Engine Turns Over But Fails to Start No fuel Dirt in fuel line or filter Fuel will not pass...

Страница 112: ...r incorrect plug or plug gap Carburetion faulty lean condition Exhaust system air leaks Ignition system faulty Spark plug cap cracked broken Ignition coil faulty Ignition or kill switch circuit faulty...

Страница 113: ...FUEL SYSTEM 4 1 CHAPTER 4 FUEL SYSTEM 4 ELECTRONIC FUEL INJECTION 4 3 4 30 CARBURETOR SPORTSMAN 450 4 31 4 47...

Страница 114: ...4 2 FUEL SYSTEM...

Страница 115: ...ENT 4 14 FUEL PRESSURE REGULATOR 4 15 GENERAL INFORMATION 4 15 FUEL FILTERS 4 16 GENERAL INFORMATION 4 16 FUEL INJECTOR 4 16 GENERAL INFORMATION 4 16 CRANKSHAFT POSITION SENSOR CPS 4 17 GENERAL INFORM...

Страница 116: ...6 EFI CIRCUIT POWER ON 4 26 EFI CIRCUIT CRANK POSITION SENSOR 4 26 EFI CIRCUIT FUEL PUMP 4 27 EFI CIRCUIT IGNITION COIL 4 27 EFI CIRCUIT IDLE AIR CONTROL 4 28 EFI CIRCUIT THROTTLE POSITION SENSOR 4 28...

Страница 117: ...ure Test Valve Kit 2201519 Throttle Position Sensor Tester PU 47471 Digital Wrench SmartLink Kit WARNING Gasoline is extremely flammable and explosive under certain conditions EFI components are under...

Страница 118: ...l Wrench diagnostic software Polaris dealers can also order separately SmartLink Module PU 47468 Vehicle Interface Cable PU 47469 and PC Interface Cable PU 47470 For use on all 15 pin connector based...

Страница 119: ...omponents Do not use dielectric grease on sealed connectors connectors with a rubber grommet as it may displace the rubber seal and allow contaminants to enter the connector Never attempt to service a...

Страница 120: ...3 Intake Air Temperature Sensor IAT 4 Idle Air Control IAC 5 Crankshaft Position Sensor CPS inside cover 6 Fuel Injector 7 Fuel Rail 8 Fuel Filter s 9 Fuel Pump Tank Assy 10 Engine Coolant Temperatur...

Страница 121: ...r Control IAC 5 Crankshaft Position Sensor CPS inside recoil cover 6 Fuel Injector 7 Fuel Rail 8 Fuel Filters 1 located in tank 1 under front cab 9 Fuel Pump Regulator Gauge Sender Assembly located In...

Страница 122: ...s fed through the fuel rail and into the injector which injects into the intake port The ECM controls the amount of fuel by varying the length of time that the injectors are on This can range from 1 5...

Страница 123: ...engine If the engine fails to start a problem may still exist and should be diagnosed NOTE Accurate testing of EFI components is recommended utilizing the Polaris Diagnostic Software dealer only FUEL...

Страница 124: ...into the ECM If the maximum RPM limit 7000 is exceeded the ECM will suppress the ignition signal or injection signal This process repeats itself in rapid succession limiting operation to the preset m...

Страница 125: ...o be faulty If a fuel delivery problem is suspected make certain the filters are not plugged that the pump is being activated through the ECM all electrical connections are properly secured the fuses...

Страница 126: ...ation by plugging in a known good ECM NOTE If the pump still does not operate replace the pump tank assembly Fuel Pump Tank Assembly Replacement NOTE All EFI units utilize quick connect fuel lines NOT...

Страница 127: ...tion The fuel pressure regulator maintains the required operating system pressure of 39 psi 3psi A rubber fiber diaphragm divides the regulator into two separate sections the fuel chamber and the pres...

Страница 128: ...ant the ECM completes the ground circuit energizing the injector The valve needle in the injector is opened electromagnetically and the pressure in the fuel rail forces fuel down through the inside Th...

Страница 129: ...aid installation The lower O ring should remain dry Torque the fuel rail mounting screws to 5 7 ft lbs 6 9 Nm Then install the doubler plate and torque to 8 9 5 ft lbs 11 13 Nm CRANKSHAFT POSITION SE...

Страница 130: ...s the ECM to adjust the fueling according to actual engine load as well as identify which stroke is the intake stroke The MAP sensor also provides the ECM with the ability to compensate for high altit...

Страница 131: ...w sensor using a twisting motion to properly seat the sensor in the grommet 4 Re connect the harness IDLE AIR CONTROL IAC General Information The Idle Air Control IAC is used to stabilize the idle qua...

Страница 132: ...set to the ohms scale observe the reading at the following pin locations of the TPS Using TPS Test Adapter Harness 2201519 Set up the TPS Test Harness 2201519 according to the instructions Verify that...

Страница 133: ...S setting This step is crucial as it sets the TPS position using the fixed physical stop Open and close throttle plate a couple of times to ensure full throttle closing Do not snap closed as this coul...

Страница 134: ...for any reason the engine temperature sensor circuit is interrupted the fan will default to ON Engine Temperature Sensor Test Polaris dealers can test the sensor by using the Polaris Digital Wrench S...

Страница 135: ...Sensor or disconnected wiring Throttle stop screw tampering replace throttle body POOR IDLE Symptom Idle Too High If greater than 1300 RPM when engine is warm Throttle stop screw tampering replace th...

Страница 136: ...will appear on the LCD display and the Malfunction Indicator Light MIL or Check Engine light will begin to flash Read and record the number of flashes of the MIL light A code 12 indicates the beginnin...

Страница 137: ...igh Voltage Yes 44 CPS Circuit Fault Yes 45 Barometric Pressure Sensor MAP Circuit Low Input Yes 46 Barometric Pressure Sensor MAP Circuit High Input Yes 47 IAC Open Load Yes 47 IAC Short to Ground Ye...

Страница 138: ...4 26 FUEL INJECTION TROUBLESHOOTING DIAGRAMS EFI CIRCUIT Power On EFI CIRCUIT Crank Position Sensor...

Страница 139: ...4 27 FUEL INJECTION 4 EFI CIRCUIT Fuel Pump EFI CIRCUIT Ignition Coil...

Страница 140: ...4 28 FUEL INJECTION EFI CIRCUIT Idle Air Control EFI CIRCUIT Throttle Position Sensor...

Страница 141: ...4 29 FUEL INJECTION 4 EFI CIRCUIT Manifold Absolute Pressure Sensor EFI CIRCUIT Engine Coolant Temperature...

Страница 142: ...4 30 FUEL INJECTION EFI CIRCUIT Air Temperature Sensor EFI CIRCUIT Malfunction Indicator Light...

Страница 143: ...4 37 FLOAT SYSTEM 4 37 PILOT SCREW 4 38 AIR FUEL MIXTURE RATIO 4 38 JET NEEDLE 4 39 NEEDLE JET 4 39 THROTTLE OPENING VS FUEL FLOW 4 39 CARBURETOR DISASSEMBLY MIKUNI CV 4 39 CARBURETOR CLEANING 4 40 C...

Страница 144: ...tment Tool WARNING Gasoline is extremely flammable and explosive under certain conditions Always stop the engine and refuel outdoors or in a well ventilated area Do not overfill the tank The tank is a...

Страница 145: ...mponents REFERENCE DESCRIPTION REFERENCE DESCRIPTION A Jet Needle J Throttle Control Cover Plate B Diaphragm Assembly K Carburetor Body C Needle Jet L Enrichment Plunger D Jet Block Assembly M Enrichm...

Страница 146: ...ENCE DESCRIPTION A Throttle Plate Shaft Retaining Components J Float Bowl O Ring B Pilot Jet K Float Bowl C Needle Valve Assembly L Float Bowl Drain Screw D Throttle Plate M Throttle Shaft E Idle RPM...

Страница 147: ...n the venturi and therefore in the chamber above the diaphragm becomes significantly lower than atmospheric Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward raising...

Страница 148: ...the float chamber The mixture rich in fuel content reaches starter plunger and mixes again with the air coming through a passage 8 extending from underneath the diaphragm The rich fuel air mixture for...

Страница 149: ...w is determined ultimately by throttle position and vacuum slide height Float System Fuel enters the float chamber 3 by means of the inlet pipe and passage through a screen on the back of the inlet ne...

Страница 150: ...tapers off at one end and the clearance between the jet needle and the needle jet increases as the throttle valve opening gets wider The air fuel mixture ratio is controlled by the height of the E cl...

Страница 151: ...y be significantly affected Needle Jet The needle jet works in conjunction with the jet needle to regulate fuel flow rate An air bleed opening in the side of the needle jet brings in air measured by t...

Страница 152: ...t be removed Even a small amount of residue will reduce the flow characteristics of the jet 4 Verify all passages and jets are unobstructed by spraying electrical contact cleaner through the passages...

Страница 153: ...ested after assembly Carburetor Assembly Inspect the diaphragm A for holes deterioration or damage Make sure the diaphragm is pliable but not swollen The diaphragm should fit properly in the carbureto...

Страница 154: ...pressing the needle valve pin 3 Measure the height from the float bowl mating surface to the top of step of the float as shown in Illustration 2 Both sides of float should be parallel to each other Th...

Страница 155: ...or shut off however engine must run briefly to allow fuel level to stabilize 1 Attach a clear line to drain fitting Be sure line fits tightly on fitting Position hose along side of carburetor as shown...

Страница 156: ...4 44 CARBURETOR SPORTSMAN 450 FUEL TANK FUEL DELIVERY SYSTEM Fuel System Exploded View...

Страница 157: ...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...

Страница 158: ...ssembly Tighten all screws evenly Fuel Filter Replacement 1 Loosen the filter clamps and remove filter 2 Install new filter onto fuel lines and install clamps FUEL GAUGE SENDING UNIT Sending Unit Remo...

Страница 159: ...ow power spark plug erosion engine runs hot surging high idle idle speed erratic No fuel in tank Restricted tank vent or routed improperly Fuel lines or fuel valve restricted Fuel filter plugged Carbu...

Страница 160: ...et incorrectly Idle mixture screw misadjusted or damaged Belt dragging Ignition timing incorrect Worn jet needle needle jet Plugged or restricted idle jet Erratic Idle Choke cable bending or incorrect...

Страница 161: ...11 RADIATOR SCREEN REMOVAL 5 11 SPORTSMAN BODY ASSEMBLY EXPLODED VIEW 5 12 X2 BODY ASSEMBLY EXPLODED VIEW 5 13 BODY RACK EXPLODED VIEWS 5 14 HEADLIGHT POD EXPLODED VIEW 5 15 STEERING 5 16 HANDLEBAR B...

Страница 162: ...Block 11 13 15 18 Master Cylinder Clamp Bolt 45 55 5 2 6 3 Rear Shock Bolt Upper 30 41 Rear Shock Bolt Lower 30 41 Rear Wheel Hub Nut 80 108 Upper Stabilizer Support Nuts 17 27 Upper Control Arm Moun...

Страница 163: ...p on the insert DO NOT apply too much pressure on the side cutters or damage to the insert will occur 2 Next use the diagonal side cutters under outside insert B to completely remove the assembly NOTE...

Страница 164: ...ward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it from the ATV 3 Reinstall the side panel by reversing the removal procedure Front Cover Removal Insta...

Страница 165: ...res to install the foot well Be sure to properly align the cab ends into the foot wells upon reassembly X2 Foot Well Removal Installation 1 Remove the four plastic inserts A that secure the wheel well...

Страница 166: ...move the four bolts that secure the storage rack to the frame 3 Remove the two T25 screws that secure the storage box to the front fender well areas each side 4 Remove the two T25 screws that secure t...

Страница 167: ...up on the cover piece To install the front cover place top lip of the cover into and lift up to remove 6 Remove the front headlights C or simply disconnect the electric connector D before removing the...

Страница 168: ...area of the cab if removed 6 Install the two plastic inserts E into the front cab if removed 7 Torque all bolts and screws according to the illustration 8 Install the front radiator cap cover E Sports...

Страница 169: ...wo screws B that secure the front cab to the frame in the fuel tank mount area 4 Remove the side panels D refer to the SIDE PANEL REMOVAL section 5 Remove the plastic inserts E that secure the front o...

Страница 170: ...ulling the locks on each side and removing the connectors Lift the rear cab from the frame 5 Reverse the removal steps for installation X2 Rear Quarter Panel Removal Installation 1 Remove the seat 2 R...

Страница 171: ...r storage compartment in place 3 For installation reverse the removal steps 4 Torque the three T 25 screws that hold the rear storage to the rear cab to specification Radiator Screen Removal 1 Pull ou...

Страница 172: ...embly Exploded View Rear Cab Assembly Pull UP on rear of seat and back to disengage tabs at front of seat Seat Latch Rear Cab Storage Frame Wheelwell Frame Front Brush Guard Support Side Cover Splash...

Страница 173: ...EERING SUSPENSION 5 X2 Body Assembly Exploded View Rear Cab Assembly Frame Front Brush Guard Support Side Cover Splash Shields Front Cab Front Cover Front Cab Assembly Footwell Frame RH Rear Cab Footw...

Страница 174: ...STEERING SUSPENSION Body Rack Exploded Views Rack Rails Rear Rack Rear Rack Support Frame Front Brush Guard Radiator Shield Radiator Screen Grill Front Bumper Panel Rack Rails Box Assembly Cover Sport...

Страница 175: ...d E Assembly Install bottom of pod onto handlebar and secure to brackets Install key switch choke cable and headlight Connect 12Vdc power outlet where applicable Connect headlight Connect instrument c...

Страница 176: ...h the middle hole B in the bottom block for proper installation The pin A and middle hole B should face the front of the ATV 4 Install the pin side bolts first and evenly tighten the bolts down Evenly...

Страница 177: ...od end bolts A point down Verify inner rod ends are placed between the steering post arms Apply Loctite 242 to bolt threads 8 ft lbs 11 Nm 25 ft lbs 35 Nm 2 2 2 Always use new cotter pins upon reassem...

Страница 178: ...to specification 9 Attach A arm to hub strut assembly Tighten ball joint nut to specification If cotter pin holes are not aligned tighten nut slightly to align Install a new cotter pin with open ends...

Страница 179: ...urn nut I clockwise until ball joint is removed from strut housing 13 To install a new ball joint Remove extension cap and attach puller guide using short bolts provided in the kit 14 Remove extension...

Страница 180: ...nd easily from full left to full right without binding SUSPENSION Front Strut Cartridge Replacement NOTE Refer to illustration on following page 1 Hold strut rod and remove top nut 2 Remove upper stru...

Страница 181: ...t Assembly Nut 15 ft lbs 21 Nm Washer Spacer Rubber Upper Pivot Ball Spacer Nut Lower Pivot Ball Spring Retainer Spring Strut Bumper Strut Washer Bolts Hubstrut Bearing Retaining Ring Brake Caliper 18...

Страница 182: ...ssembly 17 ft lbs 24 Nm Stabilizer Bar 35 ft lbs 48 Nm 30 ft lbs 41 Nm Rear Shock Lower Control Arm Bushings 35 ft lbs 48 Nm Upper Control Arm 30 ft lbs 41 Nm Rear Front 1 Orientate Bushings Correctly...

Страница 183: ...ION 5 X2 Rear Suspension Exploded View Upper Control Arm Lower Control Arm Rear Shock Bushings Rear Compression Spring Preload Adjustment Cam A Arm Shaft Wheel Bearing Carrier Grease Zerk Boot Shield...

Страница 184: ...5 24 BODY STEERING SUSPENSION X2 Torsion Bar Exploded View Linkage Bushing Stabilizer Bar Torsion Mount Linkage Asm Bushing Stabilizer Bushing...

Страница 185: ...5 25 BODY STEERING SUSPENSION 5 X2 CARGO BOX Exploded View...

Страница 186: ...e rear taillights on each side of the cargo box as illustrated below 2 Remove the taillight assembly from the cargo box 3 Disconnect the two wire harnesses connected to each of the taillights 4 Carefu...

Страница 187: ...to the frame There are two on each side 8 Support the cargo box and remove the clip and pin holding the gas shock to the cargo box 9 Carefully remove the cargo box from the ATV 10 Reverse the removal...

Страница 188: ...5 28 BODY STEERING SUSPENSION X2 SEAT ASSEMBLY Exploded Views...

Страница 189: ...up on the passenger backrest loop that is face down in the cargo box 3 Lift the passenger backrest up and into place then lay the driver seat backrest down into place 4 Fold the driver seat backrest...

Страница 190: ...ps Passenger Seat Backrest Removal Installation 1 Configure the seating for 2 UP riding Lift up on the latch for the passenger backrest and lift the backrest to the full up position 2 Lift up on the l...

Страница 191: ...CLUTCH OFFSET 6 14 EBS DRIVE CLUTCH SERVICE 6 15 DRIVE CLUTCH DISASSEMBLY 6 15 SPIDER REMOVAL 6 15 BUTTON TO TOWER CLEARANCE INSPECTION 6 17 SHIFT WEIGHT INSPECTION 6 17 DRIVE CLUTCH INSPECTION 6 17...

Страница 192: ...ler Pin Tool 2870910 Clutch Bushing Replacement Tool Kit 2871226 Piston Pin Puller 2870386 EBS Clutch Alignment Tool 2872292 EBS Bushing Replacement Kit 2201379 Clutch Compression Tool 8700220 Clutch...

Страница 193: ...Components Drive Clutch Exploded Views Standard and Deluxe Clutch Inlet Duct Clamps Boot Duct Clutch Cover Clutch Cover Seal Seal Retainer Bracket Inner Seal Cover Inner Clutch Cover Transmission Cove...

Страница 194: ...ew 2 Cam Assembly 3 Retaining Ring 4 E clip 5 Washer 6 Roller 7 Outer Spider 8 Spring 9 Shaft 10 Thrust Washer 11 Moveable Sheave 12 Roller Pin 13 Spring Pin 14 Stationary Sheave 15 Bearing 16 Retaini...

Страница 195: ...Clutch Drive Washer Spacer Shift Weights Roller Bushing Assembly Torque 200 ft lbs Spider Lock Nut Coil Spring Bushing Cover Drive Belt Cam Assembly Retaining Ring Spider Assembly Compression Spring...

Страница 196: ...ive belt and the transmission input shaft If the torque resistance at the transmission input shaft is greater than the load from the drive belt the drive belt is kept at the outer diameter of the driv...

Страница 197: ...to ensure maximum performance and service life of PVT components Refer to the troubleshooting checklist at the end of this chapter for more information 1 Drive to Driven Clutch Offset Belt Width See C...

Страница 198: ...onents in insuring optimum performance It is very important that the spring is of correct design and is in good condition Measuring Spring Length With the spring resting on a flat surface measure its...

Страница 199: ...shift weights have many different factors designed into them for controlling engagement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough underst...

Страница 200: ...ion to lowest available range and test for belt slippage Repeat as needed Operate ATV in lowest available range for a short period of time until PVT system is dry PVT Disassembly NOTE Some fasteners a...

Страница 201: ...gine seal 2 Place a new seal on transmission input shaft 3 Apply RTV silicone sealant to outside edge of inner cover to engine seal to ensure a water tight fit between the seal and the cover on engine...

Страница 202: ...Removal Inspection 1 Remove outer PVT cover as described in PVT Disassembly 2 Mark drive belt direction of rotation so that it can be installed in the same direction The belt is normally positioned so...

Страница 203: ...not a specific center distance 10 Replace belt if worn past the service limit Belts with thin spots burn marks etc should be replaced to eliminate noise vibration or erratic PVT operation See Troubles...

Страница 204: ...s Adjust if necessary NOTE On some models minor adjustments can be made by adding shims between the frame and front lower left engine mount to increase the distance at point A If a shim is present it...

Страница 205: ...the bushing 4 Inspect area on shaft where bushing rides for wear galling nicks or scratches Replace clutch assembly if worn or damaged 5 Remove and inspect spring See Drive Clutch Spring Specification...

Страница 206: ...st fit tightly in roller Use the Roller Pin Tool PN 2870910 to replace rollers and pins Take care not to damage roller bushing or bearing surface of the new pin during installation 4 Rubber backed but...

Страница 207: ...ection see Roller Pin and Thrust Washer Inspection Drive Clutch Inspection NOTE Remove cover spring and spider following instructions for drive clutch removal then proceed as follows 1 Remove moveable...

Страница 208: ...ct BOTH sheaves for signs of wear grooving or cracking De glaze surfaces with a 3M pad if needed Drive Clutch Bushing Service NOTE Special Tool Required EBS CLUTCH BUSHING REMOVAL AND INSTALLATION In...

Страница 209: ...ear 9 Turn sheave counterclockwise on puller rod until it comes free Lift sheave off puller 10 Remove nut from puller rod and set aside 11 Pull bushing removal tool and adapter from puller rod Remove...

Страница 210: ...5 Turn clutch cover counterclockwise on puller rod until bushing is seated 6 Remove nut from puller rod Take installation tool and clutch cover off rod One Way Clutch Inspection Drive Clutch 1 Rotate...

Страница 211: ...ge to the stationary sheave 6 Install limiter nut on top of spider using the Clutch Spider Nut Socket PN 2870338 Torque to specification Reinstall shift weights using new lock nuts on the bolts 7 Rein...

Страница 212: ...s for reference This will aid in reassembly and helps to maintain clutch balance after reassembly 3 Remove the four torx screws that secure the cam assembly helix using a T25 torx 4 Place the clutch i...

Страница 213: ...nspect the rollers for wear replace if worn 8 Remove the clutch assembly from the holding tool Remove the large outer retaining ring I and the inner retaining ring J 9 Press out the spring pins K in t...

Страница 214: ...talling new bushing Driven Clutch Bushing Removal 1 Install main puller adapter Item 8 onto puller 2 Install adapter reducer Item 9 3 Using a hand held propane torch apply heat around outside of bushi...

Страница 215: ...m 2 and install assembly into sheave 6 Install left hand thread nut C onto puller rod and hand tighten against installation tool 7 Turn clutch sheave counterclockwise making sure bushing is drawn stra...

Страница 216: ...the marks previously used Put the sheaves together 5 Install the roller A onto the roller pin B Both Sides 6 Install the roller pin into the sheave assembly Both sides The flat side of the roller pin...

Страница 217: ...Use the marks previously made to align the skip tooth spider or use the X on top of the spider and align it with the skip tooth on the shaft 13 Place the clutch into Clutch Compression Tool PN 870022...

Страница 218: ...rker mark the cover spider and moveable and stationary sheaves for reference as the previous X s may not have been in alignment before disassembly 2 Remove cover bolts evenly in a cross pattern and re...

Страница 219: ...Turn roller with your finger If you notice resistance galling or flat spots replace rollers pins and thrust washers in sets of three Also inspect to see if roller and bushing are separating Bushing m...

Страница 220: ...ooth and free of dents or gall marks Remove shift weight bolts and weights 2 Inspect the weight pivot bore and pivot bolts for wear or galling If weights or bolts are worn or broken replace in sets of...

Страница 221: ...d set aside 4 Install puller adapter Item 10 from kit PN 2871226 5 Install main adapter onto puller 6 With towers pointing toward the vise slide sheave onto puller rod 7 Install removal tool into cent...

Страница 222: ...ver insert new bushing and bushing installation tool into center of clutch cover 3 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 4 Install nut on rod an...

Страница 223: ...he tower and cover Torque cover bolts evenly to specification T Spider Torque 200 ft lbs 271 Nm CAUTION Verify spider spacer washers are fully seated in the recessed area of the spider Any misalignmen...

Страница 224: ...Separate the clutch sheaves by pulling upward while rotating the inner sheave Inspection 1 Inspect both the inner and outer sheave surfaces Replace the entire clutch assembly if worn damaged or cracke...

Страница 225: ...all inner spring retainer if removed 2 Install the inner sheave onto the outer sheave NOTE Verify X marks on each side of the sheaves are aligned upon reassembly of sheaves 3 Install the compression s...

Страница 226: ...ed to low ambient temperatures Warm engine at least 5 min then with transmission in neutral advance throttle to 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent...

Страница 227: ...n clutch binding Disassemble clean and inspect driven clutch noting worn sheave bushing and ramp buttons and helix Converter sheaves greasy belt slippage Clean sheaves with denatured alcohol or brake...

Страница 228: ...Instruct firm effective use of throttle for efficient engagement PVT noise Belt worn or separated thin spots loose belt Replace belt Broken or worn clutch components cover hitting clutches Inspect and...

Страница 229: ...ED VIEW STANDARD MODELS 7 11 OPERATION 7 12 GEARCASE REMOVAL 7 12 DISASSEMBLY INSPECTION 7 13 REASSEMBLY INSPECTION 7 17 SETTING RING GEAR BACKLASH 7 18 FRONT GEARCASE DIAGNOSIS 7 19 GEARCASE INSTALLA...

Страница 230: ...Bolts 30 41 Standard Gearcase Screws 14 19 Lower Hub Carrier Bolts 50 68 Upper Hub Carrier Bolts 35 48 ADC Pump Screws 17 23 1 9 2 5 ADC Cover Screws 7 11 9 4 14 9 ADC Bleed Valves 80 9 PART NUMBER T...

Страница 231: ...om lower A arm ball joint Remove lower A arm from ball joint 10 Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly 11 Pull strut assembly out while pivoti...

Страница 232: ...tter pin 4 Install hub and tighten hub nut to specification FRONT DRIVE SHAFT CV BOOT Inspection Check the front and rear driveshaft CV boots for any tears or leaking grease If the driveshaft boot los...

Страница 233: ...pe and quantity of grease Use only the grease contained in the boot kit DO NOT use a substitute grease and DO NOT overfill or under fill the CV joint 9 Slide the new clamp and boot small end first ove...

Страница 234: ...arings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and...

Страница 235: ...ear propshaft loosening and or removal of rear gearcase mounting bolts may be required to gain necessary clearance for propshaft removal U JOINT Disassembly 1 Remove internal or external snap ring fro...

Страница 236: ...d center of shaft Take care not to dislodge needle bearings upon installation of cross joint Tighten vise to force bearing caps in 2 Using a suitable arbor fully seat bearing cap in one side Continual...

Страница 237: ...t installed Repeat procedure for other side 6 Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown 7 When installation is complete yokes must pivot fr...

Страница 238: ...lip Inner CV Joint Circlip Inner Boot Outer Boot Circlip Outer CV Joint Drive Axle Components Drive Boot Replacement Kits Prop Shaft Components Clamps Outer Clamp Boot Clamp 3 5 oz grease Propshaft As...

Страница 239: ...Plate Asm 1 14 Gearcase Sub Asm 1 4 O Ring 1 15 Ring Gear Clutch Housing 1 5 Retaining Ring 1 16 Output Hub Asm 2 6 Bearing 3 17 Roll Cage Asm 1 7 Pinion Gear Asm 1 18 Armature Plate 1 8 Pinion Bushin...

Страница 240: ...ear and output hubs that link both front axles resulting in true all wheel drive Disengagement As the front and rear wheels gain equal traction rotating very close to the same speed the transmission s...

Страница 241: ...uring the bottom of housing to the skid plate frame Bolts and fluid drain plug are accessible through the skid plate 9 Remove vent line 10 Remove the front gearcase from left side of frame pulling bot...

Страница 242: ...utput hubs is pressed into assembly 4 Remove the armature plate and RH output hub assembly from the outer cover plate Inspect the bearing and contact surfaces of the output hub for signs of wear or da...

Страница 243: ...st slide up and down freely within the roller cage surfaces 8 Inspect the ring gear C for consistent wear patterns The surfaces should be free of nicks or burrs 9 Inspect roll cage B sliding surface T...

Страница 244: ...d screw is removed See the FRONT GEARCASE ASSEMBLY procedure later in this chapter for details on backlash setting 12 Remove the bolts retaining the input shaft cover and pinion gear assembly 13 Remov...

Страница 245: ...y hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement side to side 4 Install input shaft...

Страница 246: ...in gearcase NOTE Verify the square O ring arrow is placed flat on the cover surface If the O ring is twisted fluid leakage may occur 11 Torque the cover plate bolts to specification 12 Laythegearcaseo...

Страница 247: ...t the gearcase coil resistance use the coil harness Grey Brown White NOTE To test the gearcase coil resistance use the coil harness The gearcase coil should measure between 22 8 ohms and 25 2 ohms 2 C...

Страница 248: ...over Plate Assembly 5 Inspect the rollers for nicks scratches and flat spots Also inspect the roll cage for cracks and ensure the rollers are able to slide up and down and in and out freely within the...

Страница 249: ...Clutch Assy LH Exploded View 1 21 Wire Connector 1 6 Vent 1 22 O ring Outer 2 7 Cap Bleed Screw 2 23 O ring Inner 2 8 Spacer Clutch Basket 1 24 Bleeder Valve 2 9 Cover Assembly 1 25 Cam Assembly 1 10...

Страница 250: ...shaft coil 1 Operation is controlled by the ECU grounding and ungrounding the coil The coil s magnetic field attracts a splined armature plate 2 on the pinion input shaft 4 The energized splined armat...

Страница 251: ...unter clockwise to loosen Loosen bleeder screw slowly allowing oil and any trapped air to flow out of fitting IMPORTANT Do not allow hydraulic fluid in reservoir to drain below minimum fill line Close...

Страница 252: ...ates are steel on steel or if the friction material is worn the assembly should be replaced NOTE Excessive debris in the oil and or noise coming from the front drive on deceleration with ADC active ar...

Страница 253: ...oller cage surfaces Inspect the ring gear 3 for consistent wear patterns Surfaces should be free of nicks or burrs 12 Inspect roll cage sliding surface 2 This surface must be clean and free of nicks b...

Страница 254: ...replaced or the back lash pad screw is removed See the FRONT GEARCASE ASSEMBLY in this chapter for details on backlash setting 15 Remove the bolts retaining the input shaft cover and pinion gear assem...

Страница 255: ...nt Procedure 1 Place ADC Piston Tool PA 48542 on top of the piston Using moderate hand pressure hold the tool on top of the piston while using compressed air at the gearcase passage circled to force p...

Страница 256: ...nment 6 Place ADC Piston Tool PA 48542 on top of the piston and verify alignment of the sight hole circled and piston mark with the casting marks Support the case and press the piston down evenly The...

Страница 257: ...l the pinion gear bearing assembly 1 Install a new seal and o ring the input shaft cover 2 prior to reassembly 4 Install the snap ring retaining the input shaft assembly 5 Install the eccentric cam as...

Страница 258: ...s replaced or the back lash pad screw is removed 9 Install the roll cage and rollers into the ring gear Insert the rollers as the roll cage is installed 10 Install the clutch pack 1 spacer 2 and ring...

Страница 259: ...mbly on Install bolts arrows retaining the outer cover plate assembly and torque to specification 15 Install a new passage o ring dotted circle on the gearcase and install the piston pump assembly Tor...

Страница 260: ...Loosen the hub retaining nut B 4 Loosen the wheel nuts C 5 Safely support the rear of the ATV 6 Remove wheel nuts and wheel 7 Remove the rear brake caliper and safely suspend the caliper from the fram...

Страница 261: ...bearing is at bottom of casting support casting on outer edges so bearing can be removed 3 Inspect bearing NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visua...

Страница 262: ...ing into groove Installation 1 Insert bearing carrier on drive shaft 2 Align bottom of carrier housing and lower control arm Grease and slide lower control arm bushings into place securing corner hous...

Страница 263: ...ue axle nut and wheel nuts to specification 9 Install a new cotter pin Tighten nut slightly to align holes if required REAR DRIVE CV SHAFT Removal 1 Remove rear hub see REAR HUB REMOVAL 2 Remove upper...

Страница 264: ...ocate snap ring 3 Open the snap ring using a snap ring pliers or small needle nose pliers Tap CV housing off shaft with a soft faced hammer while holding snap ring open 4 Place a new snap ring in the...

Страница 265: ...fingers A gritty feeling indicates contamination If the grease is not contaminated the boot can be replaced without cleaning the CV joint Use the recommended amount of grease for boot replacement only...

Страница 266: ...boot kit NOTE CV Joint Grease Capacity Outboard Joint 30g if boot is replaced only Another 50g 80 total if joint is cleaned Inboard Joint 50g if boot is replaced only Another 50g 100 total if joint i...

Страница 267: ...potential damage to the driveshaft joints Over angling of joints beyond their capacity could result in boot or joint damage Make sure surface ground areas and splines of shaft are protected during ha...

Страница 268: ...NOTES FINAL DRIVE 7 40...

Страница 269: ...ECIFICATIONS 8 3 SPECIAL TOOLS 8 3 LUBRICATION 8 3 GEAR SELECTOR REMOVAL 8 3 TRANSMISSION REMOVAL 8 3 TRANSMISSION INSTALLATION 8 5 TROUBLESHOOTING CHECKLIST 8 6 TRANSMISSION SERVICE 8 7 EXPLODED VIEW...

Страница 270: ...8 2 GENERAL INFORMATION TRANSMISSION GENERAL Mounting Exploded View x2 x3 x4 x4 x2 x1 x1 x1...

Страница 271: ...lcrank C 7 Remove PVT outer cover drive and driven clutches and the inner PVT cover refer to Clutch Removal in Chapter 6 8 Remove both rear drive shafts Brake caliper removal is required Do not let ca...

Страница 272: ...r 7 for more details 13 Remove all lower transmission mounting fasteners J from each side 14 Remove the middle transmission support bracket K completely from the ATV 15 Remove the rear transmission su...

Страница 273: ...7Nm Torque all upper rear and middle support bracket bolts circled to 17 ft lbs 24 Nm 5 Install the upper control arms Refer to Chapter 5 for procedures and torque specifications 6 Reconnect the torsi...

Страница 274: ...s to the transmission 15 Reconnect the shift rod Torque to standard specification 16 Install the rear wheel nuts and torque to specification 17 With the ATV on level ground add Polaris AGL Gearcase Lu...

Страница 275: ...8 7 GENERAL INFORMATION 8 TRANSMISSION SERVICE Exploded View 262 242 THREAD LOCKING AGENT FOR ALL FT LBS FASTENERS THREAD LOCKING AGENT FOR INCH LBS FASTENERS...

Страница 276: ...8 8 GENERAL INFORMATION 242 262 262 262 262 262...

Страница 277: ...tor cover bolts 5 and remove the sector cover 6 Removal can be aided by using your thumbs to press down on the shafts and pulling up the cover with your fingers 6 Remove the compression spring 7 7 Rem...

Страница 278: ...de the cam chain tensioner shoe 15 pins 16 and cam chain tensioner cam 17 from the assembly 13 Remove the differential gear 18 and chain by gently prying underneath or tapping the differential gear fr...

Страница 279: ...Place the gear cluster assembly on a clean surface for inspection Gear Cluster Disassembly 18 Remove the bearing from the reverse shaft using a bearing puller Slide the engagement dog 1 off of the re...

Страница 280: ...assemble the shift fork rail remove the snap ring 10 from the end of the shift rail on either side Transmission Snorkel Shaft Removal 27 Remove the snorkel lock screw located inside the gearcase Use a...

Страница 281: ...snap ring 13 and spacer 14 from the snorkel shaft NOTE Shim may or may not be present Depending on input shaft tolerance 32 To remove the snorkel shaft from the snorkel tube use a press to press the s...

Страница 282: ...for replacement 2 Reverse the disassembly procedure for the assembly of the snorkel shaft assembly 3 Inspect the output gear assembly 1 replace bearings if needed Inspect the 91T gear for nics chips...

Страница 283: ...make sure the snorkel gear and output bevel gear are lightly seated or meshing so there is zero lash Do not overtighten Gears should rotate freely without binding Before turning the snorkel tube look...

Страница 284: ...ly Remove the output shaft assembly 4 Assemble the input shaft assembly if previously disassembled 5 Assemble the reverse shaft assembly if previously disassembled Screw Fits in Slots of Snorkel Tube...

Страница 285: ...be installed at the same time to properly align all components NOTE To ease assembly use a plastic tie strap to hold the shift forks D and the shift drum C together during assembly 9 With the gearcase...

Страница 286: ...tial gear bearing may be lightly tapped into place The case half seal can be installed once the assembly is in place 13 Tensioner Installation NOTE Case halve mating may be difficult due to tensioner...

Страница 287: ...nstall the shift gear 16T G on the shift drum shaft Install the sector gear F in the bushing pocket on the left side Aligning the timing marks on the gears 18 Install the O ring if not yet done and lo...

Страница 288: ...Install the bellcrank onto the shift shaft Note the key splined on the bellcrank and shaft Install the nut Torque the nut to 12 18 ft lbs 16 26 Nm 23 Install the transmission switch and secure the swi...

Страница 289: ...9 12 INSPECTION 9 12 REMOVAL REPLACEMENT 9 13 FRONT CALIPER 9 14 REMOVAL 9 14 INSPECTION 9 15 REASSEMBLY 9 15 INSTALLATION 9 16 REAR BRAKE PAD 9 17 X2 PAD REMOVAL 9 17 X2 PAD INSTALLATION 9 18 SPORTS...

Страница 290: ...Sportsman Caliper Slide Pins 30 35 41 48 Rear Master Cylinder to Frame Bolts 8 11 FRONT BRAKE CALIPER Sportsman and X2 ITEM STANDARD SERVICE LIMIT Brake Pad Thickness 298 7 6 mm 180 4 6 mm Brake Disc...

Страница 291: ...Fitting 15 ft lbs 21 Nm 3 Flare Style Fittings 12 15 ft lbs 16 21 Nm 4 Brake Switch 12 15 ft lbs 16 21 Nm Apply Pipe Sealant to Threads 2 2 1 2 2 3 3 2 2 3 4 All Bleed Screws 25 30 in lbs 2 80 3 40 Nm...

Страница 292: ...n System Component Exploded View All Banjo Style Fittings 15 ft lbs 21 Nm All Flare Style Fittings 12 15 ft lbs 16 21 Nm All Bleed Screws 25 30 in lbs 2 80 3 40 Nm Apply Pipe Sealant To Threads 2 Scre...

Страница 293: ...Asm D Boot E Square O rings F Piston G Caliper Mount H Brake PAds A B C D E F G H Apply Polaris All Purpose Grease 3 3 Apply Polaris DOT approved Brake Fluid to Component A Socket Set Screw B Bleeder...

Страница 294: ...the caliper piston moves outward Brake fluid level is critical to proper system operation Too little fluid will allow air to enter the system and cause the brakes to feel spongy Too much fluid could...

Страница 295: ...ecessary and discard the rest in accordance with local laws Do not store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture This causes the boiling t...

Страница 296: ...he brake lever until pressure builds and holds 7 While maintaining lever pressure open bleeder screw Close bleeder screw and release brake lever NOTE Do not release lever before bleeder screw is tight...

Страница 297: ...a clean work area to disassemble brake components 2 Remove master cylinder from handlebars 3 While holding upright continue to remove master cylinder Cover the brake line to avoid spillage when remov...

Страница 298: ...er slowly two to three times with finger over the outlet end to purge master cylinder of air 4 Follow proper bleeding procedures Check all connections for leaks and repair if necessary FRONT BRAKES Pa...

Страница 299: ...to caliper Remove excess fluid from reservoir as required 6 Push mounting bracket inward and slip outer brake pad past edge Remove inner pad 7 Measure the thickness of the pad material Replace pads if...

Страница 300: ...reservoir and install reservoir cap 7 Install wheels and torque wheel nuts It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and redu...

Страница 301: ...before applying heat to the bolts 1 Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent 2 Remove bolts and disc 3 Clean mating surface of disc and hub 4...

Страница 302: ...lip brake pads past edge Loosen pad adjuster 3 Remove mounting bracket pin assembly and dust boot 4 Remove piston dust seals and piston seals 5 Clean the caliper body piston and retaining bracket with...

Страница 303: ...ection See BRAKE PAD INSPECTION earlier in this chapter Reassembly 1 Install new caliper seals A in the caliper body B Be sure groove is clean and free of residue or brakes may drag upon assembly 2 Co...

Страница 304: ...mounting bolts to specification 6 Install brake line and torque the banjo bolt to specification 7 Install the adjuster screw and turn until stationary pad contacts disc then back off 1 2 turn 8 Perfo...

Страница 305: ...liper so as not to kink or bend brake line 5 Push caliper piston into the caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating...

Страница 306: ...2 7 mm of brake fluid in the reservoir to prevent air from entering the brake system 5 Install the adjuster screw and turn clockwise until the stationary pad contacts the disc then back off 1 2 turn c...

Страница 307: ...be careful not to damage brake line Support caliper so as not to kink or bend brake line 5 Push caliper pistons into caliper bore slowly with pads installed 6 Remove the caliper slide pins and remove...

Страница 308: ...ommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Brake Burnishing Procedure Start machine and slowly increase speed to 30...

Страница 309: ...nting bolts and the caliper 4 Loosen the adjuster screw and remove the brake pads 5 Remove mounting bracket pin assembly and dust boot 6 Remove piston dust seals and piston seals 7 Clean the caliper b...

Страница 310: ...ection See BRAKE PAD INSPECTION earlier in this chapter Reassembly 1 Install new caliper seals A in the caliper body B Be sure groove is clean and free of residue or brakes may drag upon assembly 2 Co...

Страница 311: ...s Place a container to catch brake fluid draining from brake lines 3 Remove the two caliper mounting bolts and the caliper 4 Remove the slide bolt snap rings A the slide pins B the bracket pad C and t...

Страница 312: ...in bore Apply brake fluid to piston seals and install carefully with a twisting motion to ease assembly until fully seated 2 Carefully assemble caliper body making sure O rings are properly positioned...

Страница 313: ...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 2 Use a micrometer and measure...

Страница 314: ...R MASTER CYLINDER X2 Exploded View A B D E F G I H C D E J A Master Cylinder Bolts B Rear Brake Line C Rear Master Cylinder D Bushing s E Washer s F Cotter Pin G FootPedal H Spring I Front Brake Line...

Страница 315: ...re applicable Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely X2 Rear Master Cylinder Removal and Installation 1 Remove the RH footwell to ga...

Страница 316: ...der mount the master cylinder to the mount plate and torque bolts to specification 5 Reinstall the brake line and torque the banjo bolt to specification depending on the style of fitting 6 Perform bra...

Страница 317: ...misaligned Caliper dirty or damaged Brake line damaged or lining ruptured Worn disc and or friction pads Incorrectly adjusted lever Incorrectly adjusted stationary pad Worn or damaged master cylinder...

Страница 318: ...NOTES BRAKES 9 30...

Страница 319: ...RKING 10 23 TEST 8 SHIFT INDICATOR NOT WORKING 10 23 ACTIVE DESCENT CONTROL ADC COIL 10 24 OPERATION OVERVIEW 10 24 DIAGNOSING SYSTEM FAILURES 10 24 ALL WHEEL DRIVE AWD COIL 10 24 OPERATION OVERVIEW 1...

Страница 320: ...R EXPLODED VIEW 10 48 STARTER DRIVE 10 49 PINION GEAR ANTI KICK OUT SHOE GARTER SPRING REPLACEMENT 10 49 STARTER SYSTEM TESTING FLOW CHART 10 50 BASIC WINCH WIRING 10 51 PRE WIRED MODELS 10 51 TROUBLE...

Страница 321: ...Tools Ignition System Basic Electrical Components Table 10 1 PART NUMBER TOOL DESCRIPTION PV 43568 Fluke 77 Digital Multimeter 2870630 Timing Light 2870836 Battery Hydrometer 2460761 Hall Sensor Prob...

Страница 322: ...7 Digital Multimeter PV 43568 This meter is used for when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multimeter reading K M etc an...

Страница 323: ...s and how they function Regulator The rectifier converts the output of the 3 phase alternator and applies it to the battery and the PDM loads The regulator monitors the battery voltage and shuts off t...

Страница 324: ...tays activated until the KAP_EFI input goes high The ECM_RELAY output current is monitored by the micro controller If the over current threshold is exceeded for the pre programmed delay time the outpu...

Страница 325: ...Battery Ground J1 P Unused J1 R Unused J1 S ECM_RELAY IPS to the power the ECM relay output CONNECTOR 2 PIN SIGNAL NAME DESCRIPTION IPS Intelligent Power Switch J2 A COIL 1 Input from stator coil win...

Страница 326: ...use turn off after delay Time Delay 0 6 Sec Time above limit until SSCB trips Voltage 6 2 Vdc Min Battery voltage for BAT_PROT to remain on ECM RELAY OUTPUT Current Output 20 Amp Nominal continuous ou...

Страница 327: ...ent 9 A Max pull in current when solenoid is energized Hold Current 2 A Max holding current when solenoid is energized TURF MODE Input 0 16 V Input voltage range TURF MODE Input Pull Down 5K Ohm Resis...

Страница 328: ...tage The regulator shuts off current on the BAT pin if the batter exceeds the over voltage threshold A high voltage transient will cause the regulator to turn off for a short period of time If there t...

Страница 329: ...ed on thermal recovery Once tripped this output will remain off until the key switch is cycled on and off again Lights Output The LIGHTS output uses a smart high side power switch The LIGHTS relay out...

Страница 330: ...attery voltage for BAT_PROT to remain on ACC_PWR OUTPUT Output Current 10 25 Amp Max continuous current Nominal Current 26 Amp Current above which the output will shut off after 15 25 seconds Overload...

Страница 331: ...uctuations from day to day are normal because of changes in humidity temperature and elevation Trip meter records the miles traveled by the ATV if reset before each trip or total miles to 999 To reset...

Страница 332: ...fuel immediately Instrument Cluster Diagnostic Mode NOTE This gauge features auto shut off protection if the voltage on the DC bus is excessive This is usually the result of an open battery condition...

Страница 333: ...nt is flowing through the AWD coil on models with switchable AWD Screen 4 Gear Circuit Diagnostic This screen displays the resistance value in ohms being read at the gear switch input of the gauge NOT...

Страница 334: ...he wrench stops blinking your service hours are set NOTE If you scroll past the intended number hold the button down until the count turns over to 0 You can then reset the number Turn Service Interval...

Страница 335: ...e proper diagnostic tools to further diagnose the blink codes To recall blink codes fail codes from the ECM 1 Verify the ATV key switch is off and the transmission is in park 2 Turn the key switch ON...

Страница 336: ...rea of the instrument cluster This will help the instrument cluster slide into the pod assembly more easily 2 Be sure the rubber grommet inside the pod is fully installed and that the indexing key is...

Страница 337: ...10 19 ELECTRICAL 10 ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING TEST 1 No All Wheel Drive...

Страница 338: ...10 20 ELECTRICAL TEST 2 No Speedometer Display TEST 3 No Reverse Speed Limit...

Страница 339: ...10 21 ELECTRICAL 10 TEST 4 No AWD Hub Safety Limit...

Страница 340: ...10 22 ELECTRICAL TEST 5 Reverse Speed Limiter Activated In Forward Gear TEST 6 Wheel Speed Sensor...

Страница 341: ...10 23 ELECTRICAL 10 TEST 7 Fuel Gauge Display Not Working TEST 8 Shift Indicator Not Working...

Страница 342: ...olt ohm meter IMPORTANT Verify all wires and wiring connections have been tested properly with a known good volt ohm meter before suspecting a component failure 80 of all electrical issues are caused...

Страница 343: ...n refer to FAN MOTOR CURRENT DRAW in this section Repair or replace as necessary If the fan runs with the sensor harness disconnected but will not turn on when the engine is hot check the coolant temp...

Страница 344: ...perature Resistance table to determine if the sensor needs to be replaced NOTE If the coolant temperature sensor or circuit malfunctions the radiator fan will default to ON NOTE The fan may not functi...

Страница 345: ...nnecting the black wire to ground which prevents ignition spark This is the same as turning the key or engine stop switch OFF NOTE Test the ETC switch at the harness connector ETC will not activate un...

Страница 346: ...e electrical charge collapsing the coil field for ignition based on the ECM timing map CDI A 12 volt DC current is supplied directly from the battery to the CDI At the CDI a current is supplied to the...

Страница 347: ...10 29 ELECTRICAL 10 Components of EFI Alternator and DC CDI Ignition System...

Страница 348: ...10 30 ELECTRICAL EFI Ignition System Testing Flow Chart...

Страница 349: ...l mount loose or corroded Incorrect wiring inspect color coding in connectors etc Faulty ignition coil winding measure resistance of primary and secondary Sheared flywheel key Flywheel loose or damage...

Страница 350: ...into Park and start the engine With the engine running at idle observe meter readings 5 Increase engine RPM while observing ammeter and tachometer 6 Note RPM at which the battery starts to charge amme...

Страница 351: ...g RPM 1 Set the selector dial to measure AC Voltage 2 Start the engine and let it idle 3 While holding the ATV at a specified RPM separately measure the voltage across each leg of the stator by connec...

Страница 352: ...Testing Diagrams Whenever charging system problems are suspected proceed with the following system check after verifying that all wires are in good condition connected and not kinked or pinched SPORTS...

Страница 353: ...10 35 ELECTRICAL 10 PDM...

Страница 354: ...olenoid using a suitable tool 2 Coat threads of new solenoid with anti seize compound or sealant 3 Thread new solenoid into gearcase housing Tighten to specification LIGHTING High Beam Headlight Bulb...

Страница 355: ...p and harness assembly into the headlight assembly Turn the headlight harness clockwise to secure the head lamp into place Headlight Housing Relacement 1 Remove three Phillips screws on the headlight...

Страница 356: ...h the headlight approximately 25 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the h...

Страница 357: ...ired 5 Remove the screw that secures the lower head lamp 6 Pull the head lamp out of the locking tab Low Beam Headlight Adjustment 1 The low beam can be adjusted slightly upward or downward 2 Loosen t...

Страница 358: ...ower at the blue wire Brake Light Work Light Replacement The brake light A and the work light B are both located in the rear tail lamp housing 1 X2 Open the tailgate and remove the 2 torx head screws...

Страница 359: ...st bulb housing to remove from lamp assembly and replace bulb Brake Light Switch Test 1 Remove the front cover 2 Disconnect wire harness from switch 3 Connect an ohmmeter across switch contacts Readin...

Страница 360: ...he fuel sender harness wire B and wire C 4 With the sender float in the empty position the meter should read 5 ohms 5 Slowly tilt invert the tank so that gravity moves the sender float to the full pos...

Страница 361: ...sories are located under the front cover The wires are 12 Volt wires and are Orange White in color To locate the wires remove the front cover The wires will be located in the main wire loom on the rig...

Страница 362: ...ansmission signal and determines if the switch is in Neutral or Park When the conditions are met the PDM will activate SSCB 2 Pin N to ground the starter solenoid Pin G on SSCB 2 of the PDM senses whe...

Страница 363: ...10 45 ELECTRICAL 10 Starter Lockout Diagram EFI Starter Lockout Diagram Sportsman 450...

Страница 364: ...nspection Replacement 1 Measure resistance between starter input terminal and insulated brushes The reading should be 3 ohms or less Measure the resistance between the cable terminal and brush housing...

Страница 365: ...stall the two small phenolic washers the large phenolic washer flat washer and nut Armature Testing 1 Remove armature from starter casing NOTE Note order of shims on drive end for reassembly 2 Inspect...

Страница 366: ...condition and not twisted on the case 5 Align casing marks and install housing pushing back brushes while installing shaft in bushing 6 Reinstall starter motor housing bolts Make sure O Rings are in g...

Страница 367: ...r the overrun clutch and into the spring groove Make sure that the spring is positioned between the shoe alignment pins and the back flange of the anti kick out shoes 2 Remove the retaining ring thrus...

Страница 368: ...rter solenoid coil by connecting an ohmmeter between the solenoid wire and the solenoid mounting plate Check solenoid ground path by measuring resistance between mounting plate and battery negative te...

Страница 369: ...10 51 ELECTRICAL 10 BASIC WINCH WIRING Pre wired Models...

Страница 370: ...10 52 ELECTRICAL TROUBLESHOOTING DIAGRAMS Power On EFI Start Circuit EFI To ECU Pin 12...

Страница 371: ...10 53 ELECTRICAL 10 Ignition Coil EFI Fuel Pump EFI...

Страница 372: ...10 54 ELECTRICAL Fan EFI Charging System EFI...

Страница 373: ...10 55 ELECTRICAL 10 All Wheel Drive EFI Transmission Switch EFI...

Страница 374: ...10 56 ELECTRICAL Reverse Override EFI Differential Solenoid X2...

Страница 375: ...vent plug from vent fitting Remove cell caps 2 Fill battery with electrolyte to upper level marks on case 3 Set battery aside to allow for acid absorption and stabilization for 30 minutes Removable C...

Страница 376: ...level remove the battery and fill with distilled water only to the upper level line To remove the battery 1 Disconnect holder strap and remove covers 2 Disconnect battery negative black cable first fo...

Страница 377: ...in the machine with the cables disconnected or store in a cool place NOTE Stored batteries lose their charge at the rate of 1 per day Recharge to full capacity every 30 to 60 days during a non use pe...

Страница 378: ...d the cranking voltage drops below 9 5 volts during the test replace the battery Charging Procedure 1 Remove the battery from the ATV to prevent damage from leaking or spilled acid during charging 2 C...

Страница 379: ...Batteries Batteries must be fully charged before use or battery life will 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...

Страница 380: ...nking the observed voltage should not drop below 9 5 volts 4 If the beginning voltage is 12 8 volts or higher and the cranking voltage drops below 9 5 volts during the test replace the battery Low Mai...

Страница 381: ...PLODED VIEW 11 4 500 EFI QUADRICYCLE EMISSIONS SYSTEM 11 5 OVERVIEW 11 5 500 QUADRICYCLE ELECTRICAL 11 6 TURN HAZARD SIGNAL DIAGRAM 11 6 NOTE This chapter illustrates components that are unique to the...

Страница 382: ...brake is applied all brake calipers are active as braking pressure is routed from the foot brake master cylinder through the proportioning valve and distribution block exiting one line to the front ca...

Страница 383: ...11 3 500 EFI INTERNATIONAL QUADRICYCLE 11 Exploded View Foot Brake Supply Hand Brake Supply...

Страница 384: ...View The 500 EFI International Quadricycle Sportsman is equipped with a steering locking mechanism to prevent theft or unauthorized use Steering post removal may be required for lock service or repai...

Страница 385: ...ir valve closes During idle through mid range RPM the air valve is open and air is drawn into the from the PVT intake duct The air valve assembly B opens and closes based on the vacuum pressure connec...

Страница 386: ...11 6 500 EFI INTERNATIONAL QUADRICYCLE 500 INTERNATIONAL QUADRICYCLE ELECTRICAL Turn Hazard Signal Diagram...

Страница 387: ...ystem Exploded View International 11 3 Brake System Exploded Views 9 3 Brake System Overview International 11 2 Brake Master Cylinder Removal 9 9 Brake Rear Auxiliary Brake 9 28 Brake Rear Auxiliary M...

Страница 388: ...25 Engine Torque Specifications 3 3 Engine Valve Clearance Adjustment 2 25 ETC Operation Test 10 27 ETC Switch Operation 10 27 F Fan Control Circuit Operation 10 25 Fan Control Circuit Operation Testi...

Страница 389: ...6 Piston Removal 3 28 Piston Ring Installation 3 30 3 43 Plastic Inserts 5 3 Power Distribution Module 10 5 Pre ride Checklist 2 10 Propshaft Removal 7 7 Publication Numbers 1 3 PVT Assembly 6 11 PVT...

Страница 390: ...pecifications Engine Fastener Torque 3 3 Specifications Engine Service Data 3 4 Specifications Final Drive Torque Values 7 2 Specifications Front Gearcase Lubrication Type Capacity 7 2 Specifications...

Страница 391: ...IX 5 IX Wheels Removal 2 32 Wheels Tire Pressure 2 32 Wheels Torque Table 2 32 Wire Diagram Winch Basic 10 51 Wire Diagrams Electrical 10 52 Work Light Switch 10 40 X X2 Seat Disassembly 5 30...

Страница 392: ...IX 6...

Страница 393: ...WD 1 WIRE DIAGRAM 2007 SPORTSMAN ACTIVE DESCENT CONTROL ADC WIRE DIAGRAM...

Страница 394: ...WD 2 WIRE DIAGRAM INTENTIONAL BLANK PAGE...

Страница 395: ...WD 3 WIRE DIAGRAM 2007 SPORTSMAN 450 WIRE DIAGRAM...

Страница 396: ...WD 4 WIRE DIAGRAM...

Страница 397: ...WD 5 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI STANDARD WIRE DIAGRAM...

Страница 398: ...WD 6 WIRE DIAGRAM...

Страница 399: ...WD 7 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI DELUXE WIRE DIAGRAM...

Страница 400: ...WD 8 WIRE DIAGRAM...

Страница 401: ...WD 9 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI INTERNATIONAL WIRE DIAGRAM...

Страница 402: ...WD 10 WIRE DIAGRAM...

Страница 403: ...WD 11 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI X2 WIRE DIAGRAM...

Страница 404: ...WD 12 WIRE DIAGRAM...

Страница 405: ...WD 13 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI X2 QUADRICYCLE WIRE DIAGRAM...

Страница 406: ...WD 14 WIRE DIAGRAM...

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