Documente Academic
Documente Profesional
Documente Cultură
PN 9918066
Printed in USA
UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
Throughout these instructions, important information is brought to your attention by the following symbols:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
DANGER
Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person
inspecting or servicing the ATV.
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or
person inspecting or servicing the ATV.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property
damage.
NOTE:
A NOTE provides key information to clarify instructions.
Trademarks
This manual includes procedures for maintenance operations, component identification and unit repair, along
with service specifications for 2003 Polaris Sportsman 600/700 ATVs. Comments or suggestions about this
manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota
55340.
ECopyright 2002 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the
time of publication. Due to constant improvements in the design and quality of production components, some minor descrepancies
may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this
publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of
the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
CHAPTER INDEX
CHAPTER 1 GENERAL
CHAPTER 2 MAINTENANCE
CHAPTER 3 ENGINE
CHAPTER 5 BODY/SUSPENSION
CHAPTER 8 TRANSMISSION
CHAPTER 9 BRAKES
CHAPTER 10 ELECTRICAL
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
1
Model Identification . . . . . . . . . . . . . . . . . . . . . . . 1.2
Serial Number Location . . . . . . . . . . . . . . . . . . . 1.2
2003 Sportsman Models . . . . . . . . . . . . . . . . . . 1.3
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . 1.4-1.5
Specifications - 2002 Sportsman 700 . . . . . . . 1.6-1.7
Specifications - 2003 Sportsman 600 . . . . . . . 1.8-1.9
Specifications - 2003 Sportsman 700 . . . . . . . 1.10-1.11
Publication Numbers . . . . . . . . . . . . . . . . . . . . . 1.12
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Replacement Keys . . . . . . . . . . . . . . . . . . . . . . . 1.12
Standard Torque Specifications . . . . . . . . . . . . 1.13
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . 1.14
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . 1.15
Tap Drill Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . 1.17-1.18
1.1
GENERAL INFORMATION
MODEL IDENTIFICATION
The machine model number must be used with any correspondence regarding warranty or service.
VIN IDENTIFICATION
World Mfg. ID Vehicle Description Vehicle Identifier
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A C H 6 8 A * 2 P 0 0 0 0 0 0
1.2
GENERAL INFORMATION
SPORTSMAN 600
SPORTSMAN 700
NOTE: MODELS WILL VARY IN COLOR.
1.3
GENERAL INFORMATION
MACHINE DIMENSIONS
FRONT
46 in
116.84 cm
85 in
215.90 cm
SIDE
50.75 in
128.90 cm
1.4
GENERAL INFORMATION
MACHINE DIMENSIONS
46 in
116.84 cm
47 in
119.38 cm
11 in
REAR 27.94 cm
46 in
116.84 cm
1.5
GENERAL INFORMATION
JETTING CHART
AMBIENT TEMPERATURE
Altitude
ltitude
CARBURETION Below 40
40°F
F
Below +5°C
+40 F and above
+40_F
+5_C and above
Type . . . . . . . . . . . . . . . . BST 34 Mikuni Meters 0-1800
(Feet) (0-6000) 167 5
167.5 162 5
162.5
Main Jet . . . . . . . . . . . . 162.5
Above 1800
Pilot Jet . . . . . . . . . . . . . 45 Above (6000) 160 155
Jet Needle . . . . . . . . . . . 4BH41--4
Needle Jet . . . . . . . . . . . P-6
Throttle Valve . . . . . . . . #100
Pilot Screw . . . . . . . . . . 1.5 Turns Out
Pilot Air Jet . . . . . . . . . . 160
Valve Seat . . . . . . . . . . . 1.5 CLUTCH CHART
Float Height . . . . . . . . . 14.7mm (.58I)±1mm
*EBS require no helix/spring adjustment
Fuel Octane (R+M/2) . 87 Non-Oxygenated or
89 Oxygenated
Shift Drive Clutch Driven Clutch Driven
Altitude Weight Spring Spring Helix
CLUTCH Meters 0-1800
20 -56
20- 56 Blue/Green White/Yellow EBS
(Feet) (0-6000) (5631215)
Type . . . . . . . . . . . . . . . . . . . . PVT 1800-3700 Blue/Green
20 -54
20- 54 White/Yellow EBS
Belt . . . . . . . . . . . . . . . . . . . . . 3211091 (6000-12000) (5631214)
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Twin Cyl.
Displacement . . . . . . . . . . . . . . . 683 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.149I (80 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.677I (68 mm)
Valve Clearance In/Ex . . . . . . . 0.006/0.006I@ TDC on compression
Compression Ratio . . . . . . . . . . 9.78/1 Full Stroke
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Pressurized Wet Sump
Operating RPM±200 . . . . . . . . . 6000 RPM
Idle RPM±200 (lights off) . . . . . 1100 RPM
Compression Pressure . . . . . . . (Std) ±15%
1.6
GENERAL INFORMATION
1.7
GENERAL INFORMATION
JETTING CHART
AMBIENT TEMPERATURE
Altitude
CARBURETION Below 40
40qF
F
Below +5qC
+40 F and above
+40_F
+5_C and above
Type . . . . . . . . . . . . . . . . BST 34 Mikuni Meters 0-1800
(0-6000) 162 5
162.5 155
Main Jet . . . . . . . . . . . . 155 (Feet)
Above 1800
Pilot Jet . . . . . . . . . . . . . 45 Above (6000) 150 145
Jet Needle . . . . . . . . . . . J8--4FA01--3
Needle Jet . . . . . . . . . . . P-4
Throttle Valve . . . . . . . . #100
Pilot Screw . . . . . . . . . . 1.5 Turns Out
Pilot Air Jet . . . . . . . . . . 160
Valve Seat . . . . . . . . . . . 1.5 CLUTCH CHART
Float Height . . . . . . . . . 14.7mm (.58I)r1mm
Fuel Octane (R+M/2) . 87 Non-Oxygenated or *EBS require no helix/spring adjustment
89 Oxygenated
Shift Drive Clutch Driven Clutch Driven
Altitude Weight Spring Spring Helix
CLUTCH Meters 0-1800
10 MH Blue/Green White/Yellow EBS
(Feet) (0-6000) (5631215)
Type . . . . . . . . . . . . . . . . . . . . PVT 1800-3700 Blue/Green
10 WH White/Yellow EBS
Belt . . . . . . . . . . . . . . . . . . . . . 3211091 (6000-12000) (5631214)
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Twin Cyl.
Displacement . . . . . . . . . . . . . . . 597 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.012I (76.5 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.559I (65 mm)
Compression Ratio . . . . . . . . . . 9.35/1 Full Stroke
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Pressurized Wet Sump
Operating RPMr200 . . . . . . . . . 6000 RPM
Idle RPM r 100 (lights off) . . . . 1100 RPM
Compression Pressure . . . . . . . 150--170psi r15%
1.8
GENERAL INFORMATION
1.9
GENERAL INFORMATION
JETTING CHART
AMBIENT TEMPERATURE
Altitude
CARBURETION Below 40
40qF
F
Below +5qC
+40 F and above
+40_F
+5_C and above
Type . . . . . . . . . . . . . . . . BST 34 Mikuni Meters 0-1800
(0-6000) 160 155
Main Jet . . . . . . . . . . . . 155 (Feet)
Above 1800
Pilot Jet . . . . . . . . . . . . . 47.5 Above (6000) 147 5
147.5 142 5
142.5
Jet Needle . . . . . . . . . . . J8--4FA01--3
Needle Jet . . . . . . . . . . . P-6M (829)
Throttle Valve . . . . . . . . #100
Pilot Screw . . . . . . . . . . 1.5 Turns Out
Pilot Air Jet . . . . . . . . . . 160
Valve Seat . . . . . . . . . . . 1.5 CLUTCH CHART
Float Height . . . . . . . . . 14.7mm (.58I)r1mm
Fuel Octane (R+M/2) . 87 Non-Oxygenated or *EBS require no helix/spring adjustment
89 Oxygenated
Shift Drive Clutch Driven Clutch Driven
Altitude Weight Spring Spring Helix
CLUTCH Meters 0-1800
20 -56
20- 56 Blue/Green White/Yellow EBS
(Feet) (0-6000) (5631215)
Type . . . . . . . . . . . . . . . . . . . . PVT 1800-3700 Blue/Green
20 -54
20- 54 White/Yellow EBS
Belt . . . . . . . . . . . . . . . . . . . . . 3211091 (6000-12000) (5631214)
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Twin Cyl.
Displacement . . . . . . . . . . . . . . . 683 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.149I (80 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.677I (68 mm)
Compression Ratio . . . . . . . . . . 9.78/1 Full Stroke
Cooling . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication Type . . . . . . . . . . . . Pressurized Wet Sump
Operating RPMr200 . . . . . . . . . 6000 RPM
Idle RPMr100 (lights off) . . . . . 1100 RPM
Compression Pressure . . . . . . . 150--170psi r15%
1.10
GENERAL INFORMATION
1.11
GENERAL INFORMATION
PUBLICATION NUMBERS
Year Model Model No. Owner’s Parts Parts
Manual Manual PN Micro Fiche
PN PN
2003 Sportsman 600/700 A03CH59 / A03CH68 9918213 9917718 9917719
When ordering service parts be sure to use the correct parts manual.
PAINT CODES
PAINTED PART COLOR DITZLER POLARIS
DESCRIPTION NUMBER NUMBER
Springs Black 9440 P-067
REPLACEMENT KEYS
Replacement keys can be made from the original
key. To identify which series the key is, take the
first two digits on the original key and refer to the
chart to the right for the proper part number.
Should both keys become lost, ignition switch
replacement is required.
1.12
GENERAL INFORMATION
1.13
GENERAL INFORMATION
DECIMAL EQUIVALENTS
1/64 . . . . . . . . . . . . . . . . . . . . . . . . . .0156
1/32 . . . . . . . . . . . . . . . . . . . .0312 . . . . . . . . . . . . . . . . 1 mm = .0394²
3/64 . . . . . . . . . . . . . . . . . . . . . . . . . .0469
1/16 . . . . . . . . . . . . . . .0625
5/64 . . . . . . . . . . . . . . . . . . . . . . . . . .0781 . . . . . . . . . . . . . . . . 2 mm = .0787²
3/32 . . . . . . . . . . . . . . . . . . . .0938
7/64 . . . . . . . . . . . . . . . . . . . . . . . .1094 . . . . . . . . . . . . . . . . 3 mm = .1181²
1/8 . . . . . . . . . 1250
9/64 . . . . . . . . . . . . . . . . . . . . . . . . . .1406
5/32 . . . . . . . . . . . . . . . . . . . .1563 . . . . . . . . . . . . . . . . 4 mm = .1575²
11/64 . . . . . . . . . . . . . . . . . . . . . . . . .1719
3/16 . . . . . . . . . . . . . . .1875 . . . . . . . . . . . . . . . . 5 mm = .1969²
13/64 . . . . . . . . . . . . . . . . . . . . . . . . .2031
7/32 . . . . . . . . . . . . . . . . . . . .2188
15/64 . . . . . . . . . . . . . . . . . . . . . . . . .2344 . . . . . . . . . . . . . . . . 6 mm = .2362²
1/4 . . . . . . . . . . .25
17/64 . . . . . . . . . . . . . . . . . . . . . . . . .2656 . . . . . . . . . . . . . . . . 7 mm = .2756²
9/32 . . . . . . . . . . . . . . . . . . . .2813
19/64 . . . . . . . . . . . . . . . . . . . . . . . . .2969
5/16 . . . . . . . . . . . . . . .3125 . . . . . . . . . . . . . . . . 8 mm = .3150²
21/64 . . . . . . . . . . . . . . . . . . . . . . . . .3281
11/32 . . . . . . . . . . . . . . . . . . .3438 . . . . . . . . . . . . . . . . 9 mm = .3543²
23/64 . . . . . . . . . . . . . . . . . . . . . . . . .3594
3/8 . . . . . . . . . . .375
25/64 . . . . . . . . . . . . . . . . . . . . . . . . .3906 . . . . . . . . . . . . . . . . 10 mm = .3937²
13/32 . . . . . . . . . . . . . . . . . . .4063
27/64 . . . . . . . . . . . . . . . . . . . . . . . . .4219 . . . . . . . . . . . . . . . . 11 mm = .4331²
7/16 . . . . . . . . . . . . . . .4375
29/64 . . . . . . . . . . . . . . . . . . . . . . . . .4531
15/32 . . . . . . . . . . . . . . . . . . .4688 . . . . . . . . . . . . . . . . 12 mm = .4724²
31/64 . . . . . . . . . . . . . . . . . . . . . . . . .4844
1/2 . . . . . . . . . . .5 . . . . . . . . . . . . . . . . . . . 13 mm = .5118
33/64 . . . . . . . . . . . . . . . . . . . . . . . . .5156
17/32 . . . . . . . . . . . . . . . . . . .5313
35/64 . . . . . . . . . . . . . . . . . . . . . . . . .5469 . . . . . . . . . . . . . . . . 14 mm = .5512²
9/16 . . . . . . . . . . . . . . .5625
37/64 . . . . . . . . . . . . . . . . . . . . . . . . .5781 . . . . . . . . . . . . . . . . 15 mm = .5906²
19/32 . . . . . . . . . . . . . . . . . . .5938
39/64 . . . . . . . . . . . . . . . . . . . . . . . . .6094
5/8 . . . . . . . . . . .625 . . . . . . . . . . . . . . . . . 16 mm = .6299²
41/64 . . . . . . . . . . . . . . . . . . . . . . . . .6406
21/32 . . . . . . . . . . . . . . . . . . .6563 . . . . . . . . . . . . . . . . 17 mm = .6693²
43/64 . . . . . . . . . . . . . . . . . . . . . . . .6719
11/16 . . . . . . . . . . . . . .6875
45/64 . . . . . . . . . . . . . . . . . . . . . . . . .7031 . . . . . . . . . . . . . . . . 18 mm = .7087²
23/32 . . . . . . . . . . . . . . . . . . .7188
47/64 . . . . . . . . . . . . . . . . . . . . . . . . .7344 . . . . . . . . . . . . . . . . 19 mm = .7480²
3/4 . . . . . . . . . . .75
49/64 . . . . . . . . . . . . . . . . . . . . . . . . .7656
25/32 . . . . . . . . . . . . . . . . . . .7813 . . . . . . . . . . . . . . . . 20 mm = .7874²
51/64 . . . . . . . . . . . . . . . . . . . . . . . . .7969
13/16 . . . . . . . . . . . . . .8125 . . . . . . . . . . . . . . . . 21 mm = .8268²
53/64 . . . . . . . . . . . . . . . . . . . . . . . . .8281
27/32 . . . . . . . . . . . . . . . . . . .8438
55/64 . . . . . . . . . . . . . . . . . . . . . . . . .8594 . . . . . . . . . . . . . . . . 22 mm = .8661²
7/8 . . . . . . . . . . .875
57/64 . . . . . . . . . . . . . . . . . . . . . . . . .8906 . . . . . . . . . . . . . . . . 23 mm = .9055²
29/32 . . . . . . . . . . . . . . . . . . .9063
59/64 . . . . . . . . . . . . . . . . . . . . . . . .9219
15/16 . . . . . . . . . . . . . .9375 . . . . . . . . . . . . . . . . 24 mm = .9449²
61/64 . . . . . . . . . . . . . . . . . . . . . . . . .9531
31/32 . . . . . . . . . . . . . . . . . . .9688 . . . . . . . . . . . . . . . . 25 mm = .9843
63/64 . . . . . . . . . . . . . . . . . . . . . . . . .9844
1 ............ 1.0
1.14
GENERAL INFORMATION
CONVERSION TABLE
Unit of Measure Multiplied by Converts to
ft. lbs. x 12 = in. lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.356 = Nm
in. lbs. x .0115 = kg-m
Nm x .7376 = ft.lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 = in. lbs.
kg-m x 10 = Nm
in. x 25.4 =mm
mm x .03937 = in.
in. x 2.54 = cm
mile (mi.) x 1.6 = km
km x .6214 = mile (mi.)
Ounces (oz) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x 0.035 = Ounces (oz)
lb. x .454 = kg
kg x 2.2046 = lb.
Cubic inches (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 = Liters (l)
Liters (l) x 0.88 = Imperial quarts (Imp qt)
Imperial quarts (Imp qt) x 1.201 = US quarts (US qt)
US quarts (US qt) x 0.833 = Imperial quarts (Imp qt)
US quarts (US qt) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt)
US gallons (US gal) x 3.785 =Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x 0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)
p (3.14) x R2 x H (height) = Cylinder Volume
1.15
GENERAL INFORMATION
1.16
GENERAL INFORMATION
GLOSSARY OF TERMS
1.17
GENERAL INFORMATION
GLOSSARY OF TERMS
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the
windings. Mechanical energy is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040².
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch System)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM
increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy conversion to
heat.
Right Side: Always referred to based on normal operating position of the driver.
RPM: Revolutions per minute.
Secondary Clutch: Driven clutch on chaincase or jackshaft.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder
wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck
piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery and ignition charging coils.
TDC: Top dead center. Piston’s most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the
circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
1.18
MAINTENANCE
CHAPTER 2
MAINTENANCE
2.1
MAINTENANCE
E Oil Filter 100 hrs 6 months 1000 (1600) Replace with oil change
E" Air Filter - Screen Pre-Cleaner Daily Daily -- Inspect-Clean & oil more often in dirty conditions
E" Air Filter - Main Element Weekly Weekly -- Inspect - Replace if necessary
" Air Box Sediment Tube -- Daily -- Drain deposits whenever visible
" Engine Breather Filter 20 hrs Monthly 200 (320) Inspect and replace if necessary
E Idle Speed As required As required -- Adjust as required
H Throttle Cable / ETC Switch 50 hrs 6 months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary
Choke (Enricher) Cable 50 hrs 6 months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary
Carburetor Float Bowl 50 hrs 6 months 500 (800) Drain bowl periodically and prior to storage
Carburetor Air Intake Ducts/Flange 50 hrs 6 months 500 (800) Inspect all ducts for proper sealing/air leaks
EH Fuel System 100 hrs 12 months 1000 (1600) Check for leaks at tank cap, lines, fuel valve, filter,
pump & carburetor. Replace lines every 2 years.
EH Fuel Filter 100 hrs 12 months 1000 (1600) Replace filter annually
Coolant/Level Inspection Daily Daily Replace engine coolant every 2 years
Coolant Strength / Pressure Test 100 hrs 6 months 1000 (1600) Inspect strength seasonally;
System Pressure test system annually
Radiator 100 hrs 12 months 1000 (1600) Inspect / Clean external surface
Cooling System Hoses 100 hrs 12 months 1000 (1600) Inspect
Engine Mounts 100 hrs 12 months 1000 (1600) Inspect
Exhaust Muffler / Pipe 100 hrs 12 months 1000 (1600) Inspect
ELECTRICAL
E Spark Plug 100 hrs 12 months 1000 (1600) Inspect - Replace if necessary
Wiring 100 hrs 12 months 1000 (1600) Inspect for abrasion, routing, security
Ignition Timing 100 hrs 12 months 1000 (1600) Inspect
Battery 20 hrs Monthly 200 (320) Check terminals; Clean; Check fluid level
Headlight Aim As required As required -- Adjust if Necessary
Headlamp Inspection Daily Daily -- Check operation daily; Apply Nyogelt
Grease to connector when lamp is replaced
Tail Lamp Inspection Daily Daily -- Check Operation Daily; Apply Nyogelt
Grease to socket when lamp is replaced
2.2
MAINTENANCE
2.3
MAINTENANCE
RECOMMENDED LUBRICANTS -
Item Type Notes See
Pages
Engine Oil Polaris Premium 4 Add to proper level on dipstick. 2.21
Synthetic 0W--40
Transmission Polaris Synthetic Refer to procedures outlined in this chapter. 2.10
Gear Case Lubricant
Front Gear Case Polaris Premium Demand Refer to procedures outlined in this chapter. 2.9
Drive Hub Fluid
Coolant Level Polaris Premium 60/40 Allow engine and cooling system to 2.18
Pre-mixed Antifreeze/ cool completely and check level in ra-
Coolant or a 50/50 mixture diator. Fill to top of filler neck. If reser-
high quality antifreeze/ voir was empty or extremely low, fill
coolant and distilled water reservoir tank to full line if necessary.
Brake Fluid Polaris DOT 3 Brake Fluid Fill to indicated level inside reservoir. 2.26
NOTE: Quick Reference Lubricants and maintenance product part numbers are listed on page 2.5
2.4
MAINTENANCE
2.5
MAINTENANCE
SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN
PV--43527 Oil Filter Wrench 2,3
2870872 Shock Spanner Wrench 2, 5
8712100 or 8712500 Tachometer 2,10
2200634 Valve Seat Reconditioning Kit 3
PU--45257 Valve Spring Compressor 3
PU--45652 Valve Pressure Hose 3
2871043 Flywheel Puller 3
PU--44693 Valve Train Table 3
2870390 Piston Support Block 3
PU--45497--2 Cam Gear Tooth Alignment Tool 3
PU--45497--1 Cam Gear Spring Installation Kit (3 Tapered Pins) 3
PU--45498 Cam Spanner Wrench 3
PU--45838 Gear Holder 3
PA--44995 Water Pump Mechanical Seal Installer 3
PU--45543 Universal Drive Handle 3
PU--45483 Main Seal Installer 3
PU--45658 Main Crankshaft Seal Saver 3
PA--45401 Water Pump Seal Saver 3
PU--45778 OIl System Priming Tool 3
2870975 Mity Vact Pressure Test Tool 3, 4, 9
2872314 Carburetor Float Adjustment Tool 4
2870871 Ball Joint Replacement Tool 5
2870623 Shock Absorber Spring Compression Tool 5
2871572 Strut Rod Wrench 5
2871573 LH Strut Spring Compressor 5
2871574 RH Strut Spring Compressor 5
7052069 Charging Needle 5
2200421 Gas Shock Recharging Kit 5
2871352 Shock Rod Holding Tool 5
2871351 Foxt Shock IFP Depth Tool 5
2870506 Clutch Puller 6
9314177 Clutch Holding Wrench 6
2871358 Clutch Holding Fixture 6
2870341 Drive Clutch Spider Removal and Install Tool 6
2870913 Driven Clutch Puller 6
2870910 Roller Pin Tool 6
2871226 Clutch Bushing Replacement Tool Kit 6
2870386 Piston Pin Puller 6
2872292 EBS Clutch Alignment Tool 6
2201379 EBS Bushing Replacement Kit 6
8700220 Clutch Compression Tool 6
2871025 Clutch Bushing Replacement Tool Kit 6
2872608 Roller Pin Removal Tool 7
8700226 CV Boot Clamp Pliers 7
PV--43568 Fluket77 Digital Multimeter 10
2870630 Timing Light 10
2870836 Battery Hydrometer 10
*Special Tools Can be ordered through SPX Corporation (1--800--328--6657).
2.6
MAINTENANCE
LUBRICATION
Dipstick
Transmission
Plug
1. Engine Oil and Filter 2. Transmission
Fill Plug
Fill plug
3. Front Gear Case Fill Plug 4. Rear Gear Case Fill Plug
Master Cylinder
Reservoir
* More often under severe use, such as operated in water or under severe loads.
© Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
More often under severe conditions (operating in water or hauling heavy loads)
¢ Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or
Mobilegrease Special
Ill. Item Lube Rec. Method Frequency*
#
1. Engine OIl Polaris 0W--40 Check dipstick and add to Change after 1st month, 6 months or 100
Synthetic proper level. hours thereafter; Change more often
(25-50 hours) in extremely dirty condi-
tions, or short trip cold weather operation.
2. Transmis- Polaris Synthetic Add lube to bottom of fill hole. Change annually ©
sion Gear Case Lubricant
3. Front Gear Premium Demand Drain completely. Add lube to spe- Change annually ©
Case Drive Hub Fluid cified quantity.
4. Rear Gear Polaris Gear Drive Drain completely. Add lube to spe- Change annually ©
Case Fluid cified quantity.
5. Brake Fluid Polaris Dot 3 Brake Fill master cylinder reservoir to in- As required. Change fluid every 2 years
Fluid dicated level inside reservoir.
2.7
MAINTENANCE
LUBRICATION, CONT.
6. Front Drive
Axle U-Joint
* More often under severe use, such as operated in water or under severe loads.
© Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
More often under severe conditions (operating in water or hauling heavy loads)
¢ Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or
Mobilegrease Special
2.8
MAINTENANCE
GEARCASE LUBRICATION
The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.
G Be sure vehicle is level before proceeding.
G Check vent hose to be sure it is routed properly and unobstructed.
G The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid.
G The correct rear gearcase lubricant to use is Polaris Premium Gear Drive Fluid.
ILL. 1
Rear Gearcase: Fill with the recommended fluid
amount or fill to the bottom of the fill plug hole threads. Drain plug
(See ILL.3) ILL. 3
2.9
MAINTENANCE
TRANSMISSION
LUBRICATION
The transmission lubricant level should be checked
and changed in accordance with the maintenance TRANSMISSION SPECIFICATIONS
schedule.
G Be sure the vehicle is level before proceeding. Specified Lubricant:
G Check vent hose to be sure it is not kinked or Premium Synthetic Gearcase Lubricant
obstructed. PN 2871477 (gal.) PN 2871478 (12oz.)
G Follow instructions to check / change transmission Capacity: 13.5 oz. (400 ml.)
lubricant. Drain Plug / Fill Plug Torque:
To check the level:
1. Remove propshaft shield from the right side of the 14 ft. lbs. (19.4 Nm)
vehicle.
2. Remove fill plug and visually inspect the oil level.
Level is correct when it reaches the bottom of the
fill hole as shown at right.
To change lubricant:
1. Remove propshaft shield from the right side of the
vehicle .
2. Remove transmission drain plug to drain the oil. Oil Level 1 5/8²
Catch and discard used oil properly.
3. Clean and reinstall the drain plug with a new
sealing washer. Torque to specification.
4. Remove fill plug.
5. Add Polaris Premium Synthetic Gearcase
Lubricant to proper level as described above. View From Front
6. Check for leaks.
7. Reinstall propshaft shield.
2.10
MAINTENANCE
SHIFT LINKAGE INPSECTION 4. Turn handlebars from full right to full left. If idle
speed increases at any point in the turning range,
NOTE: Shift rod is preset at time of manufacture. inspect throttle cable routing and condition.
Adjust cable tension as needed until lock--to--lock
turning can be accomplished with no rise in
Shift Linkage Rod engine rpm.
5. Replace the throttle cable if worn, kinked, or
damaged.
To remove the ETC cover:
1. Use a medium flat blade screwdriver and insert
blade into the pocket of the cover starting on the
#1 position.
2. Twist screwdriver slightly while lifting on the cover
to release snap.
3. Repeat procedure at the other five locations as
shown.
NOTE: Do not attempt to remove cover until all
latch points are released.
6
2. Note orientation of tie rod end studs with the ends 5 4
that are up down (vertical). Remove both rod end
bolts from transmission bell crank.
ETC Cover
Ill. 1 Removal Sequence
Shifter Mount
CHOKE (ENRICHER)
ADJUSTMENT
If the choke knob does not stay out when pulled,
adjust the choke tension by tightening (clockwise) the
jam nut under the rubber boot between the choke
knob and nut. Firmly grasp the rubber boot and
Shifter
tighten until the choke slides freely but stays out when
Shift Linkage Rod pulled.
THROTTLE INSPECTION
Check for smooth throttle opening and closing in all
handlebar positions. Throttle lever operation should
be smooth and lever must return freely without
binding.
1. Place the gear selector in neutral.
2. Set parking brake.
3. Start the engine and let it idle.
2.11
MAINTENANCE
Verify free play of 1/16--3/16” (1.6--4.76 mm) and 4. Set idle speed to 1100 RPM. Always check
smooth operation of choke cable. throttle cable freeplay after adjusting idle speed
and adjust if necessary.
If smooth choke operation is not obtainable, inspect
choke cable for kinks or sharp bends in routing. 5. Slowly turn mixture screw clockwise using the
pilot screw wrench until engine begins to miss.
Illustration of choke may vary with models.
6. Slowly turn mixture screw counterclockwise until
idle speed increases to maximum RPM.
Continue turning counterclockwise until idle RPM
begins to drop.
7. Center the pilot screw between the points in Step
5 and 6.
8. Re adjust idle speed to specification.
2.12
MAINTENANCE
FUEL LINES
Fuel Lines
Direction
of travel
1/16² - 1/8²
Ill. 2 Freeplay
2.13
MAINTENANCE
VENT LINES 3. Turn drain screw out two turns and allow fuel in
the float bowl and fuel line to drain completely.
Check fuel tank, oil tank, carburetor, battery and 4. Inspect the drained fuel for water or sediment.
transmission vent lines for signs of wear, 5. Tighten drain screw.
deterioration, damage or leakage. Replace every two
6. Turn fuel valve to “ON”.
years.
7. Start machine and check for leaks.
Be sure vent lines are routed properly and secured
with cable ties. CAUTION: Make sure lines are not NOTE: All tubes attached to the carburetor must be
kinked or pinched. check for pinching or blockage, as this will effect
engine performance.
FUEL FILTER
The fuel filter should be replaced in accordance with
the Periodic Maintenance Chart or whenever
sediment is visible in the filter.
Drain tube
attached
here
Arrow Indicates Direction
of Flow Drain Screw
Ill. 1
RES
To Carburetor
OFF
Ill. 2
2.14
MAINTENANCE
Ill. 3 Maintain
between upper
and lower level
marks
Ill. 1
2.15
MAINTENANCE
Use only distilled water. Tap water contains Spark Plug Gap
minerals which are harmful to a battery.
SPARK PLUG
1. Remove spark plug high tension lead. Clean plug
area so no dirt and debris can fall into engine
when plug is removed.
2. Remove spark plug.
3. Inspect electrodes for wear and carbon buildup.
Look for a sharp outer edge with no rounding or
erosion of the electrodes.
4. Clean with electrical contact cleaner or a glass
bead spark plug cleaner only. CAUTION: A wire
brush or coated abrasive should not be used. Ground Cable
2.16
MAINTENANCE
Antifreeze Hydrometer
COOLING SYSTEM
G A 50/50 or 60/40 mixture of
PRESSURE TEST
antifreeze and distilled water will Refer to Chapter 3 for pressure test procedures.
provide the optimum cooling,
corrosion protection, and antifreeze
protection.
G Do not use tap water. Tap water
contains minerals and impurities
which build up in the system. Do not
add straight antifreeze or straight
water to the system. Straight water
or antifreeze may cause the system
to freeze, corrode, or overheat.
2.17
MAINTENANCE
Ill.1
2.18
MAINTENANCE
Filter Support
Pre-filter
Main Element
Air Box
Ill.1
Cleaning:
5. Slip the pre-filter element off of main element.
Ill.3 Front
Clean the pre filter with high flash point solvent,
followed by hot soapy water.
6. Rinse and dry thoroughly. NOTE: The air filter should rest on the filter support.
7. Inspect element for tears or damage. Proper placement of the air filter is important to
8. Apply foam filter oil or clean engine oil and prevent rattles and air leaks. See Illustration above.
squeeze until excess oil is removed. 12. Install air box cover and secure with clips.
9. Inspect main filter and replace if necessary. If the
filter has been soaked with fuel or oil it must be
replaced. AIR BOX SEDIMENT TUBE
Installation:
Periodically check the air box drain tube located
10. Reinstall pre-filter element over main filter. Be toward the rear of the machine. Drain whenever
sure the element covers entire surface of main deposits are visible in the clear tube.
filter without folds, creases, or gaps.
1. Remove drain plug from end of sediment tube.
11. Reinstall filter on main filter mount. Place filter
clamp over the assembly and tighten. 2. Drain tube.
2.19
MAINTENANCE
BREATHER FILTER
INSPECTION
Four cycle ATV engines are equipped with a breather
filter. The in-line filter is similar in appearance to a fuel
filter, and is visible on the left side (Location A).
In-line breather filters should be installed with the
arrow pointing toward the engine (away from the air
box).
2.20
MAINTENANCE
Dipstick
Dipstick
Ill.1
SAFE
Ill.2 Crankcase Drain
2.21
MAINTENANCE
2.22
MAINTENANCE
2.23
MAINTENANCE
WHEEL ALIGNMENT
METHOD 1:
STRAIGHTEDGE OR STRING
Be sure to keep handlebars centered. See notes
below.
Rear rim
Measure measure-
from string ment should
to rim at be 1/16² to
front and 1/8² (.2 to .3
rear of rim. cm) more
than front rim
measure-
ment.
2.24
MAINTENANCE
2.25
MAINTENANCE
2.26
MAINTENANCE
Floor
Board Surface
3/64²
(.1cm)
Minimum
Thickness AUXILIARY BRAKE
ADJUSTMENT (HYDRAULIC)
Use the following procedure to inspect the hydraulic
HOSE/FITTING INSPECTION auxiliary (foot) brake system and adjust or bleed if
necessary:
Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose First, check foot brake effectiveness by applying 50 lb.
fittings and replace any worn or damaged parts. (approx.) downward force on the pedal. The top of the
pedal should be at least 1 inch, (25.4mm) above the
surface of the footrest.
AUXILIARY BRAKE TESTING
The auxiliary brake should be checked for proper
function. 1/8, to 1/4,
Free Play
1² or greater
50 lbs
Auxiliary Brake
Floorboard
2.27
MAINTENANCE
(PN 2870872)
2.28
MAINTENANCE
4. Remove the wheel nuts and remove the wheel. G The use of non-standard size or type
tires may affect ATV handling.
CAUTION:
Improperly installed wheels could affect vehicle
handling and tire wear. On vehicles with tapered rear
wheel nuts, make sure tapered end of nut goes into
taper on wheel.
WARNING
Operating an ATV with worn tires will increase
the possibility of the vehicle skidding and pos-
Flange Nuts: sible loss of control.
Flat side against wheel Worn tires can cause an accident.
Always replace tires when the tread depth
measures 1/8² (.3 cm) or less.
TIRE PRESSURE
CAUTION: FRAME, NUTS, BOLTS,
Maintain proper tire pressure. Refer to the warning FASTENERS
tire pressure decal applied to the vehicle.
Periodically inspect the torque of all fasteners in
Tire Pressure Inspection (PSI - Cold) accordance with the maintenance schedule. Check
that all cotter pins are in place. Refer to specific
Front Rear fastener torques listed in each chapter.
5 5
TIRE INSPECTION
G Improper tire inflation may affect ATV
maneuverability.
G When replacing a tire always use
original equipment size and type.
2.29
MAINTENANCE
2.30
ENGINE
CHAPTER 3
ENGINE
3.1
ENGINE
271
(27-33 Nm)
Oil Dipstick
Crankcase
Bearing Assembly
Seal
Bushing
4.5-5.5 ft. lbs.
271
Bearing
(6-7 Nm)
O--Ring
Gasket
4.5-5.5 ft. lbs.
(6-7 Nm)
Journal Seals
271
Oil Pickup
Bearings
262
Magnetic Plug
(12-13 Nm)
3.2
ENGINE
271
Breather Cover (12-13 Nm)
Rocker Cover
(3--4 Nm)
271
(81--87 Nm) (27-33 Nm)
Thermostat
(12-13 Nm)
Cover
Thermostat Temperature
Switch
Exhaust Exhaust
Gasket Manifold
16-20 ft. lbs.
(22-27 Nm)
Cylinder Head
Head Gasket
(15-18 Nm)
Frost Plug
3.3
ENGINE
242
(35-41 Nm)
Camshaft
Piston Assembly Gears
Thrust Plate
271
(6--7 Nm)
20-24 ft. lbs.
(27-33 Nm)
Rocker Arms
Crankshaft
Pushrods
Valve
Woodruff Key Springs
Valve
Seals
Gears
Cylinder Head
Balance Shaft
3.4
ENGINE
Oil Filter
Nipple
242
(12-13 Nm) Water/Oil
Bearing Pump Gear
Gerotor
Oil Pressure 9-11 ft. lbs.
Relief Oil Pump
Housing (12-15 Nm)
Water/Oil
Shaft
Gasket
Impeller
O--Ring
Water Pump Seal
Gear/Stator Housing
Apply Loctitet 242 to
242
3.5
ENGINE
242
(11.5--13 Nm)
242
(109-136 Nm)
Stator
Bolts
Flywheel
Flywheel Nut
Stator Housing
Sound Cover
Outer Cover
O--rings
Timing Plug
Washers 7-9 ft. lbs.
(10-12 Nm)
(12-13 Nm)
242
Bendix
(12-13 Nm)
3.6
ENGINE
SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION
PV--43527 Oil Filter Wrench
2200634 Valve Seat Reconditioning Kit
PU--45257 Valve Spring Compressor
PU--45652 Valve Pressure Hose
2871043 Flywheel Puller
PU--44693 Valve Train Table
2870390 Piston Support Block
PU--45497--2 Cam Gear Tooth Alignment Tool
PU--45497--1 Cam Gear Spring Installation Kit (Tapered Pins)
PU--45498 Cam Spanner Wrench
PU--45648 Gear Holder
PA--44995 Water Pump Mechanical Seal Installer
PU--45543 Universal Driver Handle
PU--45483 Main Seal Installer
PU--45658 Main Crankshaft Seal Saver
PA--45401 Water Pump Seal Saver
2870975 Mity Vact Pressure Test Tool
PU--45778 Oil System Priming Tool
ACCESSIBLE COMPONENTS
The following components can be serviced or The following components require engine
removed with the engine installed in the frame: removal for service:
G Cylinder G Crankcase
G Piston/RIngs
G Camshaft
G Rocker Arms
G Oil pump/Water Pump and Oil
Pump Drive Gear
G Gear Train Components
3.7
ENGINE
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Fastener Size 600/700
Ft. Lbs. (Nm)
Camshaft Gear 8 mm 26-30 (35-41 Nm)
Camshaft Thrust Plate 6 mm 4.5-5.5 (6-7 Nm)
Carburetor Adaptor 8 mm 11-13 (15-18 Nm)
Counterbalance Gear 8 mm 26-30 (35-41 Nm)
Crankcase 8 mm 20-24 (27-33 Nm)
Crankcase Breather 5 mm 27--33 in.lbs.(3--4 Nm)
Cylinder Head Bolts 12 mm 60-64 (68-73 Nm)
Exhaust Manifold 8 mm 20-24 (27-33 Nm)
Flywheel 14 mm 80-100 (109-136 Nm)
Magneto Cover 6 mm 8.5-9.5 (12-13 Nm)
Oil Baffle Weldment 5 mm 4.5-5.5 (6-7 Nm)
Oil Drain Bolt (Crankcase) 12 mm 20--22 (27-30 Nm)
Oil Fill Tube Bolt 5 mm 4.5-5.5 (6-7 Nm)
Oil Filter Pipe Fitting 20 mm 33-37 (45-50 Nm)
Oil Pick Up 5 mm 4.5-5.5 (6-7 Nm)
Oil Pressure Relief Plug 10 mm 20-24 (27-33 Nm)
Oil Pressure Switch 1/4-18 8.5-9.5 (12-13 Nm)
Oil Pump Housing Screw 6 mm 8.5-9.5 (12-13 Nm)
Rocker Arm 8 mm 20-24 (27-33 Nm)
Rocker Cover 6 mm 8.5-9.5 (12-13 Nm)
Spark Plug 14 mm 16-20 (22-27 Nm)
Starter Motor 6 mm 8.5-9.5 (12-13 Nm)
Stator Assembly 6 mm 9-10 (12-14 Nm)
Stator Housing 6 mm 8.5-9.5 (12-13 Nm)
Temperature Switch 3/8 PT 16-20 (22-27 Nm)
Thermostat Housing 6 mm 8.5-9.5 (12-13 Nm)
Timing Plug 3/4-16 7-9 (10-12 Nm)
Trigger Coil/Stator Wire Holddown 5 mm 4.5-5.5 (6-7 Nm)
Water Pump Housing Cover 6 mm 8.5-9.5 (12-13 Nm)
Water Pump Impeller Nut 8 mm 9-11 (12-15 Nm)
3.8
ENGINE
Tighten cylinder head/cylinder base, and crankcase fasteners in the following sequence outlined below.
10 15 11
14
13
12
2 6
4
3 1 5
3
1 5
6 2 4 9
7 8
Cylinder Head Crankcase
PISTON IDENTIFICATION
Four stroke engine rings have a rectangular profile. See text on Page 3.27 for ring installation. Use the information
below to identify pistons and rings.
NOTE: The pistons have no directional identification marks. New pistons are non--directional.
3.9
ENGINE
j
Camshaft journal OD Mag 1.654” r 0.00039” (42 r 0.010 mm)
Center 1.634” r 0.00039” (41.50 r 0.010 mm)
PTO 1.614” r 0.00039” (41 r 0.010 mm)
j
Camshaft journal bore Mag 1.656” r 0.00039” (42.07 r 0.010 mm)
ID Center 1.637” r 0.00039” (41.58 r 0.010 mm)
PTO 1.617” r 0.00039” (41.07 r 0.010 mm)
Camshaft Oil clear- Std 0.00118” r 0.00079” (0.03 r 0.02 mm)
ance
End Play 0.0135” r 0.0111” (0.3450 r 0.2825 mm)
g
Overall length In 4.51” r 0.01476” (114.5550 r 0.375 mm)
Ex 4.5453” r .01496” (115.45 r 0.38 mm)
Valve Overall length Free 1.8267” (46.40 mm)
Spring
p g Length
Installed 1.47” (37.34 mm)
Height
3.10
ENGINE
3.11
ENGINE
j
Camshaft journal OD Mag 1.654” r 0.00039” (42 r 0.010 mm)
Center 1.634” r 0.00039” (41.50 r 0.010 mm)
PTO 1.614” r 0.00039” (41 r 0.010 mm)
j
Camshaft journal bore Mag 1.656” r 0.00039” (42.07 r 0.010 mm)
ID Center 1.637” r 0.00039” (41.58 r 0.010 mm)
PTO 1.617” r 0.00039” (41.07 r 0.010 mm)
Camshaft Oil clear- Std 0.00118” r 0.00079” (0.03 r 0.02 mm)
ance
End Play 0.0167” r 0.0098” (0.425 r 0.25 mm)
g
Overall length In 4.51” r 0.01476” (114.5550 r 0.375 mm)
Ex 4.5453” r .01496” (115.45 r 0.38 mm)
Valve Overall length Free 1.8267” (46.40 mm)
Spring
p g Length
Installed 1.47” (37.34 mm)
Height
3.12
ENGINE
3.13
ENGINE
FLOW
Radiator
Thermal
Hose Sensor
Water
Thermostat Lower Engine
Pump
Hose
Fan
Shroud
Cylinder Cylinder
Head Exploded View Radiator
Top
Radiator
Front
View
Bottom
Radiator
Left Side
View
3.14
ENGINE
ENGINE REMOVE & INSTALL 12. Disconnect the coolant hoses. Properly dispose
of any antifreeze from the engine or hoses.
1. Clean work area. 13. Refer to PVT System Chapter 6 to remove outer
2. Thoroughly clean the ATV engine and chassis. clutch cover, drive belt, drive clutch, driven clutch,
and inner cover (D).
3. Disconnect battery negative (-) cable.
14. When removing starter cables, note and mark
4. Remove the following parts as required:
ground cable and positive(+) cable mounting
G Seat angle and locations . Remove cables.
G Left and Right Side Covers (Refer to 15. Remove transmission linkage rod from gear
Chapter 5) selector and secure out of the way.
G Fuel Tank Cover / Front Cab (Refer to 16. Disconnect coolant temperature sensor wire.
Chapter 5)
17. Remove engine to chassis ground cable.
G Fuel Tank (Refer to Chapter 4)
18. Remove all engine mount nuts and / or engine
5. Remove springs from exhaust pipe and remove mount plates. Remove the frame brace (E) from
pipe. the front left side of the frame.
6. Drain coolant and engine oil.
7. Remove air pre-cleaner and duct.
8. Remove airbox.
E
C
A
19. Remove the engine from the left side of the frame.
3.15
ENGINE
3.16
ENGINE
3.17
ENGINE
OIL FLOW
This chart describes the flow of oil through the EH68 and the EH059 engine. Beginning in the crankcase sump,
the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter.
If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. At this
point, the oil is supplied to the main oil galley through a crankcase passage. Oil is then diverted three ways from
the main oil galley, with the first path entering the camshaft bores, onto the rear balance shaft journal and then
draining back into the crankcase sump. The second oil path from the main oil galley feeds the lifter bores and
then drains back to the crankcase sump. The third oil path flows through a crankcase galley to the MAG side
crankshaft journal and also to the front balance shaft journal and onto the crankcase sump. The oil pressure
switch is fed off the main oil galley.
Crankshaft Crankcase
Main Bearing Sump
Rod
Crankshaft
Bearings Main Bearing
Counterbalance Counterbalance
Bore Bore
PTO MAGNETO
SIDE SIDE
Lifter Bores
Oil Pressure
Relief
Pump
Filter
Crankcase
Sump
3.18
ENGINE
ROCKER ARM INSPECTION 5. If the push rod (A) is visibly bent, it should be
replaced.
1. Mark or tag rocker arms in order of disassembly to
keep them in order for reassembly.
A
WARNING
3.19
ENGINE
PU--45257
B
3.20
ENGINE
D C
Valve Spring
Free Length
3.21
ENGINE
Valve Guide
A
3.22
ENGINE
WARNING
3.23
ENGINE
VALVE SEAT RECONDITIONING CONT’D G If the seat is too narrow, widen using
the 45° cutter and re-check contact
G If the contact area of the cutter is in
point on the valve face and seat width
the same place, the valve guide is
after each cut.
distorted from improper installation
and must be replaced. Be sure the
cylinder head is at the proper NOTE: When using an interference angle, the seat
temperature and replace the guide. contact point on the valve will be very narrow, and is
a normal condition. Look for an even and continuous
G If the contact area of the initial cut is
contact point all the way around the valve face. (B)
greater than 75%, continue to cut the
seat until all pits are removed and a
new seat surface is evident. NOTE: (B)
Remove only the amount of material
necessary to repair the seat surface.
5. To check the contact area of the seat on the valve
face, apply a thin coating of Prussian Bluet paste
to the valve seat. If using an interference angle (A)
(46°) apply black permanent marker to the entire
valve face (A).
3.24
ENGINE
WARNING
CYLINDER HEAD
REASSEMBLY
NOTE: Assemble the valves one at a time to maintain
proper order.
1. Apply engine oil to valve guides and seats.
2. Install new valve seals on valve guides.
3. Coat valve stem with molybdenum disulfide
grease or 0W--40 Synthetic oil.
4. Install valve carefully with a rotating motion to
avoid damaging valve seal. 7. Repeat procedure for remaining valves. When all
valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the split
keepers. NOTE: To prevent damage to the valve
seals, do not compress the valve spring more
than necessary to install the keepers.
3.25
ENGINE
PUSH RODS
SPRINGS
GUIDE SEALS
HEAD
HYDRAULIC LIFTERS
VALVES
3.26
ENGINE
ENGINE HEAD REASSEMBLY 4. Lubricate push rods (D) and install into lifters.
B E
3.27
ENGINE
ENGINE HEAD REASSEMBLY CONT’D 11. Install thermostat (J). Apply Loctitet 271 (PN
2871954) to the bolts of the cover. Torque bolts to
8. Install breather reed (G) into rocker cover (H).
8.5-9.5 ft. lbs. (12-13 Nm).
Lightly apply black RTV sealant to the outer
edges of the breather reed. The reed has a tab
and will assemble one way only. Apply Loctitet
271 (PN 2871954) to the bolts. Torque the
breather bolts to 27--33 in. lbs. (3--4 Nm).
J
NOTE: When applying RTV, do not get any RTV
inside the reed assembly.
9. Place a new seal (I) into the bottom of the cover.
Be sure the seal is seated into the cover properly.
8.5-9.5 ft. lbs.
27--33 in.lbs. (12-13 Nm)
(3--4 Nm)
H
Thermostat Housing Bolt Torque:
I
G
12. Apply pipe dope or Teflon tape to pipe threads of
temperature sender (K). Install and torque to
16-20 ft. lbs. (22-27 Nm).
REMINDER: Before assembly, clean the bolts and
bolt holes with Primer N (PN 2870585) to remove any
debris. This will ensure proper sealing when installing
bolts and new Loctitet.
10. Install rocker cover. Apply Loctitet 271 (PN
2871954) to the bolts. Torque bolts to 8.5-9.5 ft.
lbs.12-13 Nm).
3.28
ENGINE
PISTON REMOVAL
VALVE LIFTER
1. Remove circlip (A). Mark the piston with a white
REMOVAL/INSPECTION pen to ensure proper orientation (if reused) during
assembly.
1. Remove the valve lifter’s by reaching into the
crankcase and pushing the lifter up through the
lifter bore by hand. Mark the piston
2. Thoroughly clean the lifters in cleaning solvent
and wipe them with a clean lint-free cloth.
3. Mark the lifters with a white pen if using the lifters
for reassembly. This will ensure that the lifters are
properly placed during engine reassembly.
3.29
ENGINE
apply heat to the piston rings. The ring may lose b) Remove the expander.
radial tension.
3. Remove top compression ring:
*Using a piston ring pliers: Carefully expand ring
and lift it off the piston. CAUTION: Do not expand the Compression B
ring more than the amount necessary to remove it Rings
from the piston, or the ring may break.
*By hand: Placing both thumbs as shown, spread the
ring open and push up on the opposite side. Do not
scratch the ring lands.
Oil Ring
CYLINDER INSPECTION
1. Remove all gasket material from the cylinder
sealing surfaces.
2. Inspect the top of the cylinder (B) for warpage
using a straight edge (A) and feeler gauge (C).
Refer to Ill. 1 and Ill. 2.
3.30
ENGINE
A
Y
X
Y
X
C
Y
Ill.2
X
Cylinder Warpage.
1/2s Up From Bottom
.004s (0.1 mm) Max.
5. Record measurements. If cylinder is tapered or
out of round beyond .002, the cylinder must be
3. Inspect cylinder for wear, scratches, or damage. replaced.
Cylinder Taper
Limit: .002I (.05mm)Max.
Cylinder Out of Round
Limit: .002I (.05mm)Max.
PISTON-TO-CYLINDER
CLEARANCE
4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure Measure piston outside diameter at a point 5 mm up
in two different directions, front to back and side to from the bottom of the piston at a right angle to the
side, on three different levels (1/2s down from top, direction of the piston pin.
in the middle, and 1/2s up from bottom). Subtract this measurement from the maximum
cylinder measurement obtained in Step 5.
3.31
ENGINE
5 mm
Piston
Piston Pin
600: 3.0096” r .00035I (76.445 .009 mm) 3. Measure connecting rod small end ID.
PISTON/ROD INSPECTION
1. Measure piston pin bore.
3.32
ENGINE
Piston Ring-to-Ring Groove Clearance NOTE: Ring should be installed with the mark on the
ring facing upward.
Top Ring Limit: 0.0019” r 0.00069”
2. Measure installed gap with a feeler gauge (C) at
(0.0475 r 0.0175 mm)
Second Ring Limit : 0.0017” r 0.00049” both the top and bottom of the cylinder.
(0.0425 r .0125 mm) REMINDER: A difference in end gap indicates
cylinder taper. The cylinder should be measured
for excessive taper and out of round.
3. If the bottom installed gap measurement exceeds
the service limit, replace the rings. If ring gap is
PISTON RING INSTALLED GAP smaller than the specified limit, file ring ends until
gap is within specified range.
1. Place each piston ring (A) inside cylinder (B) NOTE: Always check piston ring installed gap after
using piston to push ring squarely into place as re-boring a cylinder or when installing new rings. A
shown. (See next page) re-bored cylinder should always be scrubbed
thoroughly with hot soapy water, rinsed, and dried
C completely. Wipe cylinder bore with oil immediately to
remove residue and prevent rust.
B 25-50mm
STARTER DRIVE/BENDIX
REMOVAL/INSPECTION
1. Remove stator housing bolts and remove
A housing.
2. Remove the flywheel nut and washer. Install
Flywheel Puller (PN 2871043) and remove
flywheel. CAUTION: Do not thread the puller
bolts into the flywheel more than 1/4s or stator
coils may be damaged.
3. Remove starter bendix assembly (A). Note the
thrust washers located on both sides of the
bendix.
3.33
ENGINE
B
C
3.34
ENGINE
3.35
ENGINE
C D
2871043
ENGINE LOWER
DISASSEMBLY/INSPECTION
1. Remove the stator cover (A) and water pump
cover (B).
I
B
G H
3.36
ENGINE
ENGINE DISASSEMBLY CONT’D camshaft gear (K), water/oil pump gear (L),
crankshaft gear (M), or counterbalance gear (N).
6. Remove the gear/stator housing bolts and
remove the gear/stator housing cover (J) and Cam Gear Removal
gasket from the crankcase. Be sure to catch the
excess oil from the crankcase. 9. Use the Cam Gear Tooth Alignment Tool
(PU--45497--2) (O) to align the cam split gear
assembly. With the split gear aligned, remove the
J bolt and cam gear assembly.
PU--45497--2 O
Water/oil pump Gear NOTE: Install the Cam Gear Tooth Alignment Tool
Camshaft Gear (PU--45497--2) into the assembly hole counter
clockwise from the timing mark as shown.
(PU--45497--2)
Timing Marks K L
3 Loaded Spring
M
NOTE: It is recommended to replace all of the gears 11. The cam gear assembly contains three loaded
if any of the following gears are to be replaced: springs. To open the cam gear assembly:
3.37
ENGINE
Insert Springs
PU--45497--1
Accent the Timing Marks 16. Insert the pointed dowels from the Tapered Pins
(PU--45497--1) into the cam gear.
14. Inspect the gear teeth and the three tabs on the
gears for wear. It is recommended to replace the
springs whenever the gear is taken apart. PU--45497--1
3.38
ENGINE
PU--45497--1
3.39
ENGINE
2871043
PU--45497--2
PU--45498
24. Install the two puller bolts (R). Tighten the puller
bolts up so that the bolts are at equal length.
R
P
3.40
ENGINE
2871043
Mark Rotors
27. Inspect the oil pump rotors for wear. Mark the 29. Reinstall the valve (dowel tapered end first).
rotors with a white pen to ensure upon Install the spring, washer, and bolt. Torque the
reassembly that the correct sides of the rotors are bolt to 20--24 ft. lbs. (27--33 Nm).
installed and mesh with the same edges as
previously installed.
20--24 ft.lbs.
(27--33 Nm)
3.41
ENGINE
Heat Housing 33. Press bearing from shaft. Replace the old
bearing with a new bearing during assembly.
Bearing
3.42
ENGINE
Gear Boss
Separate the
crankcase
halves
WARNING
Wear appropriate safety gear
during this procedure. Heat resistant gloves,
3.43
ENGINE
V CAMSHAFT INSPECTION
1. Thoroughly clean the cam shaft.
40. Remove balance shaft and crankshaft. 2. Visually inspect each cam lobe for wear, chafing
or damage.
Lobe height
3.44
ENGINE
B
5. Measure ID of camshaft journal bores.
3.45
ENGINE
5. Install crankshaft assembly and apply engine oil Crankcase Bolt Torque:
to crank pins and rods (D). Apply Starter Drive
Grease (PN 2871460) to the main journals and 20-24 ft. lbs. (27-33 Nm)
bearings.
3.46
ENGINE
Grease Lifters
Cylinder Installation
3.47
ENGINE
14. Install the piston pin keepers (F). The pin keeper
ends should be installed at the 12 O’clock 16. Assemble rotors as marked when disassembled.
position. Use a cleaner to remove the marks previously
made on the rotors.
Line Up Marks
Lubricate Rotors
3.48
ENGINE
19. Install oil pump housing bolts (H). The new bolts
contain patch lock, so Loctitet is not needed on
I J
the new bolts. Torque bolts to 8.5--9.5 ft. lbs.
(11.5--13 Nm).
3.49
ENGINE
CAUTION: I J
The crankshaft gear is extremely hot! Severe
burns or injury can occur if the gear is not
handled with extreme care and caution. Follow
the procedure below to help ensure safety.
22. Use extreme caution when removing the
crankshaft gear from the hot plate. Use a pair of
pliers and leather gloves when handling the
crankshaft gear.
23. Install the crankshaft gear (I) onto the crankshaft.
NOTE: For assembly of the gears, the cam gear and PU--45648
the crankshaft gear are stamped with “This Side Out.”
This indicates the side of the gear that faces outward
or away from the Gear Holder:
case.
(PU--45648)
24. Install counter balance shaft gear (J) with new PU--45497--2
key, aligning timing marks with crankshaft gear
(I). Apply LocTitet242 (PN 2871949) to the bolt
threads. Install washer and bolt. Use the Gear
NOTE: If the timing mark on the camshaft gear does
Holder (PU--45648). Torque to 26-30 ft.
not align properly, remove the camshaft gear and tool.
lbs.(35-41 Nm).
Use the Cam Spanner Wrench (PU--45498) to rotate
the cam to the proper position.
NOTE: Cam Spanner Wrench (PU--45498) is only
needed to rotate the camshaft when the entire valve
train is assembled.
3.50
ENGINE
PA--44995 O
N
26. Reinstall the camshaft gear; so the timing marks
are properly aligned. Apply Loctitet 242 (PN
2871949) to the bolt threads. Install the washer
and bolt. Torque to 26-30 ft. lbs.(35-41 Nm).
NOTE: Be sure all of the timing marks are properly
aligned.
Timing Marks
NOTE: To remove the water pump seal, the
gear/stator housing must be removed. The water
pump seal cannot be removed or installed with the
gear/stator housing attached to the engine. Shaft
damage will occur.
NOTE: Install the waterpump seal (N) with the seal
lip facing out (towards the crankcase). Use of a
hydraulic press is recommended for this procedure.
28. Install a new crankshaft seal (P) into the
gear/stator housing cover (O). Use the Universal
Driver Handle (PU--45543) and the Main Seal
Timing Marks Installer (PU--45483) to seat the crankshaft seal
into place.
Counterbalance Gear and Camshaft
Gear Bolt Torque:
PU--45543
26-30 ft. lbs. (35-41 Nm)
O
GEAR/STATOR HOUSING SEAL REPLACEMENT P
IMPORTANT: Due to seal design and
construction, these seals MUST be installed dry
(no lubricant) during assembly. Use of lubricants
(oil, soapy water, etc.) will not allow the seal to
wear--in and seal properly. Do not touch seal
surface or allow seal surface to come in contact
with contaminates during installation. PU--45483
Thoroughly clean parts, tools and hands before
installation.
3.51
ENGINE
NOTE: Install the crankshaft seal (P) with the seal lip
facing out (towards the crankcase).
PA--45658
32. Install the new gasket to the gear/stator housing
30. Carefully install the tapered end of the cover and crankcase. With the tools installed,
Crankshaft Seal Protection Tool (PA--45658) carefully place the gear/stator housing cover over
the protection tools. NOTE: New gasket is not
through the paper side of the crankshaft seal.
shown in the picture.
(Back to Front) Leave the seal protector installed
in the crankshaft seal. Check the crankshaft seal
lips to verify they have not been rolled or
damaged.
3.52
ENGINE
3.53
ENGINE
S
Water Pump Housing Bolt Torque: T U
3.54
ENGINE
Nm).
PU--45778
(PU--45778)
Stator Housing Bolt Torque:
3.55
ENGINE
TROUBLESHOOTING
Spark Plug Fouling
G Spark plug cap loose or faulty G Engine flooded
G Choke cable adjustment or G Low compression (high cylinder
plunger/cable sticking leakage)
G No spark (Spark plug fouled)
G Foreign material on choke plunger ignition component failure
seat or plunger
Engine Does Not Turn Over
G Incorrect spark plug heat range or
gap G Dead battery
G Starter motor does not turn
G Carburetor inlet needle and seat
worn G Engine seized, rusted, or
mechanical failure
G Jet needle and/or needle jet worn
or improperly adjusted Engine Runs But Will Not Idle
G Excessive carburetor vibration G Restricted carburetor pilot system
(loose or missing needle jet locating G Carburetor misadjusted
clips) G Choke not adjusted properly
G Loose jets in carburetor or G Low compression
calibration incorrect for G Crankcase breather restricted
altitude/temperature Engine Idles But Will Not Rev Up
G Incorrect float level setting G Spark plug fouled/weak spark
G PVT system calibrated incorrectly/ G Broken throttle cable
components worn or mis-adjusted G Obstruction in air intake
G Fuel quality poor (old) or octane too G Air box removed (reinstall all intake
high components)
G Incorrect or restricted carburetor
G Low compression jetting
G Restricted exhaust G ETC switch limiting speed
G Weak ignition (loose coil ground, G Reverse speed limiter limiting
faulty coil, stator, or ETC switch) speed
G Carburetor vacuum slide
G ETC switch mis-adjusted sticking/diaphragm damaged
G Restricted air filter (main or G Incorrect ignition timing
pre-cleaner) or breather system G Restricted exhaust system
G Improperly assembled air intake G Cam worn excessively
system
Engine Has Low Power
G Restricted engine breather system G Spark plug fouled
G Oil contaminated with fuel G Cylinder, piston, ring, or valve wear
or damage (check compression)
Engine Turns Over But Fails to Start G PVT not operating properly
G Restricted exhaust muffler
G No fuel
G Carburetor vacuum slide
G Dirt in fuel line or filter sticking/diaphragm damaged
G Fuel will not pass through fuel valve G Dirty carburetor
G Fuel pump inoperative/restricted G Cam worn excessively
G Tank vent plugged or pinched
G Carb starter circuit plugged
3.56
ENGINE
3.58
FUEL SYSTEM/CARBURETION
CHAPTER 4
FUEL SYSTEM/CARBURETION
4.1
FUEL SYSTEM/CARBURETION
1. Carburetor Assembly
BST 34 CARBURETOR 2. Screw
3. Throttle Valve
EXPLODED VIEW 4. Cover, Diaphragm
5. Jet Block Assembly
6. Spring
7. Diaphragm Assembly
8. Ring
9. “E” Ring
10. Ring
11. Needle Jet
12. Cover
13. O-Ring
14. Throttle Shaft Assembly
15. Ring
16. Seal
17. Spring
18. Packing
19. “E” Ring
20. Cap
21. Screw
22. Drain Screw
23. O-Ring
24. Washer
25. Adjuster
26. Spring
27. Pilot Jet
28. Main Jet
29. Washer
30. Jet Needle
31. Float Assembly
32. Float Body Assembly
33. Float Pin
34. Needle Valve
35. O-Ring
36. O-Ring
37. Filter
38. Screw
39. Screw
22
40. Screw
1 41. Guide Holder
2
42. Spring
3
4 43. Plunger Assembly
5 44. Spring Washer
45. Screw
46. Air Jet
47. Cable Guide
Jet Needle
Refer to Page 4.4 for Jet Part Numbers “E” Clip Position 48. Spring
49. Ring
50. Adjust Screw
51. Screw and Washer Assy.
4.2
FUEL SYSTEM/CARBURETION
Fuel Cap
Tank Vent
Forward
Tank
Foam Seal
Fuel Tank Foil
Fuel Tank Foil
Fuel Knob
FUEL FLOW
Fitting Screens
Carburetor Vent
Carburetor Engine
4.3
FUEL SYSTEM/CARBURETION
4.4
FUEL SYSTEM/CARBURETION
Venturi
4.5
FUEL SYSTEM/CARBURETION
8
5
Throttle 1
Plate
Venturi
6
7
= Low Pressure
4
= Air Flow
Note: Diagrams are for explanation of theory only, and are not true 2
representations of Mikuni BST carburetor.
PILOT (IDLE AND SLOW) Fuel is drawn into the starter circuit from the float
chamber (2) through the starter jet (3). Starter jet
SYSTEM meters this fuel, which then flows into starter pipe (4)
and mixes with the air (7) coming from the float
This system supplies fuel during engine operation
chamber. The mixture, rich in fuel content, reaches
with throttle valve closed (1) or slightly opened. The
starter plunger and mixes again with the air coming
fuel from float chamber (2) is metered by pilot jet (3)
through a passage (8) extending from underneath the
where it mixes with air coming in through pilot air jet
diaphragm. The rich fuel/air mixture for starting is
(4). The mixture then goes up through pilot passage
discharged through starter outlet (6) in the the main
to pilot screw (5). A part of the mixture is discharged
bore.
into the main bore out of bypass ports (6). The
remainder is then metered by pilot screw and
discharged into the main bore through pilot outlet (7).
4.6
FUEL SYSTEM/CARBURETION
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 needle seat (4), and around the inlet needle (2).
As the fuel fills the float chamber, the float (1) rises and 1
forces the inlet needle against the seat, shutting off 2
the orifice in the seat. When fuel level is up in float
chamber, floats are up and needle valve remains
pushed up against valve seat. Under this condition,
no fuel enters the float chamber. As the fuel level falls, 7
floats go down and needle valve unseats itself to
admit fuel into the chamber. In this manner, the
needle valve admits and shuts off fuel alternately to A
6
maintain a practically constant fuel level inside the
float chamber.
3
5
Inlet CARBURETOR
Pipe
DISASSEMBLY - MIKUNI CV
Use the following disassembly, assembly, and
inspection techniques to service a CV carburetor.
1. Remove carburetor diaphragm chamber cover
with a ratchet style screwdriver. DO NOT use an
1 3 impact driver to remove the screws or carburetor
may be permanently damaged.
4
2
MAIN SYSTEM
As throttle valve (1) is opened, engine speed rises,
and this increases negative pressure in the venturi.
Consequently the vacuum slide (2) moves upward.
The fuel in float chamber (3) is metered by main jet (4),
and the metered fuel enters needle jet (5), in which it
mixes with the air admitted through main air jet (6) to
form an emulsion. The emulsified fuel then passes
through the clearance between needle jet (5) and jet
needle (7), and is discharged into the venturi (A).
Mixture proportioning is accomplished in needle jet
(5); the clearance through which the emulsified fuel
must flow is determined ultimately by throttle position
and vacuum slide height.
4.7
FUEL SYSTEM/CARBURETION
CARBURETOR DISASSEMBLY CONT’D NOTE: The starter jet is not removeable. Upon
disassembly, place the parts in a container for safe
2. Remove float bowl and carefully remove the
keeping.
pressed float pin.
Support Here
Pilot Screw
Starter Jet
4.8
FUEL SYSTEM/CARBURETION
Inspect this C
area B
D
A
E
Seat
Wear areas
Needle
Pilot Screw
4.9
FUEL SYSTEM/CARBURETION
Float Height:
2. Measure the height from the float bowl mating Mity Vact (PN 2870975)
surface to the top of step in float as shown. Both
sides of float should be parallel to each other. The
measurement should be made at the mid-point on
the top of the float using Float Adjustment Tool
(PN 2872314) or a vernier caliper. When
measuring the height be sure the inlet needle
valve spring is not compressed.
4.10
FUEL SYSTEM/CARBURETION
1.5 mm
FUEL PUMP DISASSEMBLY
.060² 1. Remove the screws from the pump diaphragm
Bowl Mating cover. Note the location of the two longer screws.
Surface
2. Remove the diaphragm cover gasket,
diaphragm, and valve body gasket.
3. Remove the outlet check valve cover, diaphragm,
2. Open bowl drain screw by turning and gasket.
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 FUEL PUMP
specification, remove carburetor and inspect inlet
needle and seat, float height, passages, etc. INSPECTION/ASSEMBLY
NOTE: If a line was removed to perform this 1. Inspect inlet and outlet check valves for cracks,
procedure, it must be replaced.
warpage or damage. Inspect the diaphragms for
cracks, holes or swelling.
2. To clean the valves or pump body, remove the set
FUEL PUMP screw and washer. Remove the valve and wash
The Polaris Sportsman 600/700 is equipped with a with soap and water. Carburetor cleaner may be
pressure regulated fuel pump (1-3 PSI). The pump is used to clean the pump body when the check
located under the left front fender of the machine. valves are removed. CAUTION: Some
carburetor cleaners are very caustic and should
To test the fuel pump: not be used to clean the non-metal parts of the
1. Turn fuel off. fuel pump.
2. Disconnect impulse line from pump. 3. Check the sealing surfaces of the pump body and
covers. Carefully remove all traces of old gasket
3. Connect Mity-Vact (PN 2870975) to the impulse
and check the surfaces for damage. Replace
line fitting on the pump.
diaphragms and gaskets as a set.
4. Apply 5 inches (Hg) vacuum to the pump fitting.
4. Reassemble the pump in the reverse order of
The diaphragm should hold vacuum indefinitely.
disassembly. Tighten all screws evenly.
4.11
FUEL SYSTEM/CARBURETION
4.12
BODY / STEERING / SUSPENSION
CHAPTER 5
BODY / STEERING / SUSPENSION
5.1
BODY / STEERING / SUSPENSION
BODY ASSEMBLY Rear Cab Assembly Pull UP on rear of seat and back
to disengage tabs at front of seat
EXPLODED VIEW Seat Latch
Seat Latch
Release
Storage
Rear Cab
Clutch Guard
Frame Brace
Footrest
Front Cover
Side Cover
Front Cab
Footrest
Front Mud
Guard
Frame
Splash Deflector
Guard Shield
NOTE: All warning information labels must be in place when body parts are assembled.
5.2
BODY / STEERING / SUSPENSION
Rear Rack
Reflector .
Frame
Front Rack
Bumper
Panel
Frame
Brush Guard
Lower Bumper
Radiator Cover
Grill
Side Shield
5.3
BODY / STEERING / SUSPENSION
B A
Assembly
G Install bottom of pod onto handlebar and secure to brackets.
Handlebar clamp torque:
G Install key switch, choke cable, and headlight.
11-13 ft. lbs. (15-18 Nm)
G Connect 12V power outlet (where applicable)
G Connect headlight.
G Connect speedometer connectors to speedometer.
G Install top of pod onto bottom half, making sure interlocking tabs mate properly.
G Install two side Phillips screws.
G Install one rear Phillips screw.
G To adjust headlight, refer to procedure outlined in Maintenance chapter.
G To apply decals, refer to Page 5.12.
5.4
BODY / STEERING / SUSPENSION
STEERING/A--ARM NOTE:
To avoid damage to tie rods and other steering
EXPLODED VIEW components, be sure to install tie rod end bolts in the
proper direction. The steering post arm bolt (B) points up;
the rod end bolts (A) point down. Be sure inner rod ends
are placed between the steering post arms.
Steering Post
Steering Post
Arm (Frog) 12-14 ft. lbs.
(17-19 Nm)
30 ft. lbs.
(41 Nm)
2
25 ft. lbs. 8 ft. lbs. (11 Nm)
242
(35 Nm)
Always use new bolts Always use new cotter pins upon
1 upon reassembly
2 reassembly. Install with open end Apply Loctitet 242 to
242
5.5
BODY / STEERING / SUSPENSION
REAR SUSPENSION
EXPLODED VIEW 17 ft. lbs.
(24 Nm)
17 ft. lbs. Stabilizer Support
(24 Nm)
35 ft. lbs.
(48 Nm)
Forward
1 Upper
Control
Arm Skid Plate Strap
Stabilizer
Bar Arm
35 ft. lbs.
(48 Nm) 30 ft. lbs.
(41 Nm)
Lower
Control A--Arm Bushing
Arm
Rear Front
Bushing Orientation
5.6
BODY / STEERING / SUSPENSION
Nut
15 ft. lbs.
(21 Nm) Strut Bumper
Washer
Clamp
Spring Retainer
Lubrication Fitting
Spring
Hubstrut Bearing
Brake Caliper
Retaining Ring
NOTE: Grease fitting location. Check lubrication guide for recommended service intervals.
5.7
BODY / STEERING / SUSPENSION
5.8
BODY / STEERING / SUSPENSION
Step 1.
A-ARM REPLACEMENT
1. Elevate and safely support vehicle with weight
removed from front wheel(s). Remove wheels.
2. Remove cotter pin from ball joint stud at wheel
Pull forward and out to disengage end of A-arm and loosen nut until it is flush with
two rear tabs. end of stud.
2. Place hand on top of side panel behind the fuel
3. Using a soft face hammer, tap nut to loosen A-arm
tank. With a quick and firm motion, push down on from bolt. Remove nut and A-arm from hub strut
the side panel to disengage the top rear two tabs. assembly.
Then pull up on side panel to disengage front
upper and lower tab. 4. Loosen two bolts on A-arm tube by alternating
each about 1/3 of the way until A-arm can be
Step 2. removed.
5. Examine A-arm shaft. Replace if worn. Discard
hardware.
6. Insert A-arm shaft into new A-arm.
7. Install CV joint shields.
8. Install new A-arm assembly onto vehicle frame.
Torque new bolts to 30 ft. lbs. (41.4 Nm).
WARNING
5.9
BODY / STEERING / SUSPENSION
242
(41 Nm) the bolt threads.
Long Bushing
242
(11 Nm)
A-Arm Shaft Cotter Pin
CV Joint Shield
1. Hand tighten.
2. Align cotter pin hole.
3. Install cotter pin.
Bend both ends of cot-
ter pin around nut in op-
posite directions.
4. Check steering,
must move freely and
easily from full left to
full right without bind-
ing.
5.10
BODY / STEERING / SUSPENSION
5.11
BODY / STEERING / SUSPENSION
5.12
CLUTCH
CHAPTER 6
PVT SYSTEM
Drive Clutch Exploded View . . . . . . . . . . . . . . . 6.2
PVT Sealing and Ducting Components . . . . . . 6.2
EBS System Exploded View . . . . . . . . . . . . . . . 6.3
Special Tools, Supplies & Torques . . . . . . . . . . 6.4
PVT Operation Overview . . . . . . . . . . . . . . . . . . 6.4
PVT Maintenance/Inspection/Drying . . . . . . . . 6.5
PVT Overheating/Diagnosis . . . . . . . . . . . . . . . 6.6
PVT Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6.7
PVT Assembly/Inspection . . . . . . . . . . . . . . . . . 6.8
Drive Clutch Spring Specifications . . . . . . . . . . 6.9
Shift Weights /Inspection . . . . . . . . . . . . . . . . . . 6.10--6.11
Drive Clutch Disassembly/Inspection . . . . . . . 6.11--6.13
Drive Clutch Reassembly . . . . . . . . . . . . . . . . . 6.13--6.14
Drive Belt Removal/Inspection . . . . . . . . . . . . . 6.14--6.15
Drive Belt Installation . . . . . . . . . . . . . . . . . . . . . 6.16
Clutch Alignment/Offset . . . . . . . . . . . . . . . . . . . 6.16--6.17
Drive One--way Clutch Inspection . . . . . . . . . . 6.17--6.18
Driven One--way Clutch Inspection . . . . . . . . . 6.18--6.20
Drive Clutch Bushing Service . . . . . . . . . . . . . . 6.20--6.21
Driven Clutch Bushing Service . . . . . . . . . . . . . 6.22--6.23
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24--6.25
6
6.1
CLUTCH
Transmission Cover
Seal Inner Clutch
Cover Clamps
Boot Duct
Inner Cover
Seal
Seal Retainer
Bracket
Clutch Cover
6.2
CLUTCH
Washer
Brass Washer
Shift Weights
Compression
Coil Torque to
Spring
Spring 200 Ft. Lbs.
(271 Nm) Bushing
Roller/Bushing
One Way Clutch Bushing
Assembly
(Driven)
6.3
CLUTCH
TORQUES At lower RPM, the drive belt rotates low in the drive
clutch sheaves. As engine RPM increases,
Drive Clutch Retaining Bolt . . . 40 ft. lbs. (54 Nm) centrifugal force causes the drive belt to be forced
upward on drive clutch sheaves.
Driven Clutch Retaining Bolt . . 17 ft. lbs. (23 Nm)
PVT Inner Cover Bolts . . . . . . . 12 ft. lbs. (16 Nm) DRIVEN CLUTCH OPERATION
Drive Clutch Spider EBS Clutch) . . . . . 200 ft. lbs.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (271 Nm) Driven clutches primarily sense torque, opening and
closing according to the forces applied to it from the
Drive Clutch Spider Lock Nut (Plastic) . 15 ft. lbs. . drive belt and the transmission input shaft. If the
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (20.3 Nm) torque resistance at the transmission input shaft is
Drive Clutch Cover Plate . . . . . 90 in. lbs. (10 Nm) greater than the load from the drive belt, the drive belt
is kept at the outer diameter of the driven clutch
sheaves.
6.4
CLUTCH
DRIVEN CLUTCH OPERATION CONT’D air ducts, as well as the inner and outer covers,
must be properly sealed to ensure clean air is
As engine RPM and horsepower increase, the load being used for cooling the PVT system. This also
from the drive belt increases, resulting in the belt will prevent water and other contaminants from
rotating up toward the outer diameter of the drive entering the PVT area. A sealed PVT is
clutch sheaves and downward into the sheaves of the especially critical on units subjected to frequent
driven clutch. This action, which increases the driven water forging.
clutch speed, is called upshifting.
Should the throttle setting remain the same and the PVT DRYING
vehicle is subjected to a heavier load, the drive belt
rotates back up toward the outer diameter of the NOTE: If operating the ATV through water, be sure
driven clutch and downward into the sheaves of the to check the PVT cover and other ATV components
drive clutch. This action, which decreases the driven for water ingestion. The ATV should be checked
clutch speed, is called backshifting. immediately. Refer to Owner’s Manual for Safe
In situations where loads vary (such as uphill and Riding Tips.
downhill) and throttle settings are constant, the drive
and driven clutches are continually shifting to maintain
optimum engine RPM. At full throttle a perfectly PVT Drain Plug
matched PVT system should hold engine RPM at the
peak of the power curve. This RPM should be
maintained during clutch upshift and backshift. In this
respect, the PVT system is similar to a power
governor. Rather than vary throttle position, as a
conventional governor does, the PVT system
changes engine load requirements by either
upshifting or backshifting.
PVT
MAINTENANCE/INSPECTION
To drain any water that may be trapped inside the PVT
Under normal operation the PVT system will provide cover, simply remove the PVT drain plug and O--ring
years of trouble free operation. Periodic inspection located on the bottom of the PVT cover and let the
and maintenance is required to keep the system water drain out. The PVT drain plug is shown below.
operating at peak performance. The following list of
items should be inspected and maintained to ensure To further expel water in the PVT cover and to dry out
maximum performance and service life of PVT the PVT system, shift the transmission to neutral and
components. Refer to the troubleshooting checklist at rev engine slightly to expel the moisture. This will also
the end of this chapter for more information. air-dry the belt and clutches. Allow engine RPM to
settle to idle speed, shift transmission to lowest
1. Drive to Driven Clutch Offset, Belt Width. See available range and test for belt slippage. Repeat as
Page-6.16--6.18 needed. Operate ATV in lowest available range for a
2. Drive and Driven Clutch Buttons and short period of time until PVT system is dry.
Bushings, Drive Clutch Shift Weights and
Pins, Drive Clutch Spider Rollers and Roller
Pins, Drive and Driven Clutch Springs. See
Pages 6.11-6.12
3. Sheave Faces. Clean and inspect for wear.
4. PVT System Sealing. Refer to appropriate
illustrations and photos. The PVT system is air
cooled by fins on the drive clutch stationary
sheave. The fins create a low pressure area in the
crankcase casting, drawing air into the system
through an intake duct. The opening for this
intake duct is located at a high point on the vehicle
(location varies by model). The intake duct draws PVT Drain Plug & O--ring
fresh air through a vented cover. All connecting
6.5
CLUTCH
PVT OVERHEATING/DIANOSIS
During routine maintenance or whenever PVT system overheating is evident, it’s important to check the inlet
and outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase PVT
system operating temperatures. The ATV should be operated in LOW RANGE when pulling or plowing heavy
loads, or if extended low speed operation is anticipated.
GENERAL RANGE OPERATION Low Range: Heavy pulling, basic operational speeds less
GUIDELINES: than 7 MPH, riding through rough terrain (swamps, mountains,
etc.), low ground speeds.
High Range: High ground speeds, speeds above 7 MPH.
6.6
CLUTCH
PVT DISASSEMBLY
NOTE: Some fasteners and procedures will vary.
Driven Clutch Puller (PN 2870913)
Refer to the appropriate parts manual for proper
fasteners and fastener placement.
1. Remove seat.
2. Remove or loosen rear cab fasteners as 8. Remove driven clutch offset spacers from the
necessary to gain access to PVT outer cover. transmission input shaft. NOTE: Remember to
3. Remove PVT air outlet duct hose. keep spacers in order for proper clutch offset on
4. Remove outer cover screws. Refer to Page 6.2. reassembly.
5. Mark the drive belt direction of rotation and
remove drive belt. See Page 6.16 for drive belt Keep Spacers In Order
removal.
6. Remove drive clutch retaining bolt and remove
drive clutch using puller.
Inner cover
Retainer Seal
6.7
CLUTCH
Offset
Spacer
6.8
CLUTCH
FORCE (POUNDS)
1. Controls clutch engagement 280
RPM. The springs which have a
260
higher rate when the clutch is in
neutral will increase clutch 240
engagement RPM.
220
2. Controls the rate at which the
drive belt moves upward in the 200
drive clutch sheaves. This is
referred to as drive clutch upshift. 180
The drive clutch spring is one of the Green
7041168
160
most critical components of the PVT Purple
7041063
system. It is also one of the easiest to 140 White
7041132
service. Due to the severe stress the Plain
coil spring is subject to during 120 7041021
Blue/Green
operation, it should always be 7041157
6.9
CLUTCH
SHIFT WEIGHTS
Shown below are optional shift weights which may be used in the PVT system. These 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 understanding the effects they have on belt to sheave
clearance, clutch balance, engagement and shifting characteristics.
16
55
53
10 10
10
RH WH
BH
20 20 20
54 56 58
6.10
CLUTCH
6.11
CLUTCH
6.12
CLUTCH
Moveable Sheave Bushing Inspection button is positioned toward the solid roller pin. It is
recommended to switch all buttons to the rubber
2. Inspect the Teflont coating on the moveable version during service (if needed).
sheave bushing.
6.13
CLUTCH
DRIVE CLUTCH REASSEMBLY CONT’D 8. Reinstall cover, aligning “X” mark with other
marks. Torque cover bolts evenly to specification.
2. Install moveable sheave onto fixed 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, on spider aligns with “X”,
or the marks that were made earlier on the
moveable sheave.
5. Torque spider to specification using the holding
fixture and spider tool. Torque with smooth
motion to avoid damage to the stationary sheave.
Refer to Page 6.3 for torque specification.
CAUTION:
DRIVE BELT
REMOVAL/INSPECTION
1. Remove outer PVT cover as described in PVT
Spacer washers Disassembly.
2. Mark drive belt direction of rotation so that it can
6. Install limiter nut on top of spider using the Clutch be installed in the same direction. NOTE:
Spider Nut Socket (PN 2870338). Torque to 15 ft. Normally positioned so part numbers are easily
lbs. Reinstall shift weights using new lock nuts on read.
the bolts. 3. To remove drive belt, apply brake, pull upward
7. Reinstall clutch spring. and rearward on belt to open driven clutch
sheaves, pull out and down on belt to slip over the
driven clutch outer sheave.
Engine
Rotation
6.14
CLUTCH
Belt Width:
6.15
CLUTCH
DRIVE BELT INSTALLATION 2. With tool touching rear of driven clutch inner
sheave, the distance at point “A” should be 1/8².
1. Loop belt over drive and over top of driven NOTE:If the distance is greater than 1/8² or less than
sheave. 1/16², clutch alignment must be adjusted as follows:
2. While pushing down on top of belt, turn the back 3. Remove drive and driven clutch. See PVT
or moveable driven sheave clockwise. Disassembly, Pages 6.7--6.8.
4. Remove PVT inner cover.
5. Loosen all engine mounts. Move front of engine
to the right or left slightly until alignment is correct.
6. Tighten engine mounts and verify alignment is
correct.
7. Measure belt deflection and measure offset both
above and below shaft centerlines. Adjust if
necessary.
Center line
B
CLUTCH OFFSET
Important: Inspect clutch alignment and center
A distance before adjusting offset.
Offset is correct when rear of tool contacts rear of
inner sheave with driven clutch pushed completely
1/8I +0 / -- 1/16
inward on shaft and bolt torqued. Adjust offset by
3.2mm +0 / -- 1.6 mm)
adding or removing spacer washers between back of
driven clutch and spacer.
6.16
CLUTCH
ONE-WAY CLUTCH
INSPECTION (DRIVE
CLUTCH) Brass Washer Thickness
1. Rotate one-way clutch clockwise (as viewed from Standard: .030² (.76mm)
the cover plate side). The clutch should rotate on Service Limit: .025² (.64mm)
the shaft with only slight amount of drag. Verify
there is no binding or rough spots. When rotated
counterclockwise, the clutch should lock to the 2. Lift one-way clutch off shaft. Replace as an
shaft without slipping. If problems are noted in assembly if worn, damaged, or if problems were
either direction, continue with disassembly. noted.
6.17
CLUTCH
Move Freely
MOVEABLE SHEAVE
BUSHING INSPECTION
1. Inspect the Teflont coating on the moveable
sheave bushing. Inspect BOTH sheaves for signs
of wear, grooving or cracking. Clean surfaces with
a 3Mt pad if needed
6.18
CLUTCH
2. When rotated clockwise, the outer sheave should NOTE: Rotating the moveable sheave so that the
lock to the shaft and inner sheave without rollers are not in contact with either helix ramp
slipping. surfaces will lessen the effort needed to push the helix
inward.
5. Remove spring seat washer and inspect for wear
Lock to Shaft and Outer Sheave
or damage. Replace if worn.
6. Inspect surface of rollers for flat spots and wear.
Rollers must rotate freely on pins without
excessive clearance. Check the roller pin and
roller bore for wear and replace if necessary.
Rollers
Heat Area
Roller
Lightly Apply Loctitet
680 To Tapered
Portion Of Screw
Dry Locking
Agent Applied
To New Screws
6.19
CLUTCH
6.20
CLUTCH
6. With towers pointing toward the vise, slide sheave EBS Drive Clutch Cover Bushing Removal
onto puller rod.
1. Install main adapter (Item 8) on puller.
7. Install removal tool (Item A/B) into center of
sheave with “A side” toward sheave.
8. Install nut (C) onto end of puller rod and hand Nut (C)
Removal Tool (3)
tighten. Turn puller barrel to increase tension on
sheave if needed. Using a hand held propane
torch, apply heat around outside of bushing until
tiny smoke tailings appear.
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 Adapter
rod. Remove bushing from tool and discard. Reducer (9)
Main Adapter
EBS Drive Moveable Bushing Installation (8) Piston Pin
Puller
1. Place main adapter (Item 8) on puller.
EBS Drive Clutch Cover Bushing Removal
Puller Tool (A/B)
Nut (C) 2. Install adapter reducer (Item 9).
Side “A” toward
sheave 3. From outside of clutch cover, insert removal tool
(Item 3) into cover bushing.
4. With inside of cover toward vise, slide cover onto
puller.
5. Install nut onto puller rod and hand tighten. Turn
puller barrel to increase tension as needed.
Bushing 6. Turn clutch cover counterclockwise on puller rod
until bushing is removed and cover comes free.
7. Remove nut from puller rod and set aside.
Main Adapter Piston Pin
(8) 8. Remove bushing and bushing removal tool from
Puller puller. Discard bushing.
EBS Drive Clutch Moveable Sheave EBS Drive Clutch Cover Bushing Installation
Bushing Installation
1. Apply Loctitet 609 evenly to bushing bore in
2. Apply Loctitet 609 evenly to bushing bore inside cover.
moveable sheave. 2. Working from inside of cover, insert new bushing
3. Set bushing in place on sheave. and bushing installation tool into center of clutch
4. Insert installation puller tool (Item A/B) with “A” cover.
side down, into center of bushing. 3. With main adapter on puller, insert cover onto
5. With towers pointing upward, slide sheave, puller rod, placing outside of cover toward vise.
bushing and tool onto puller rod. 4. Install nut on rod and hand tighten. Turn puller
6. Install nut on puller rod and hand tighten. Turn barrel to apply more tension if needed.
barrel to apply additional tension if needed. 5. Turn clutch cover counterclockwise on puller rod
7. Turn sheave counterclockwise, making sure until bushing is seated.
bushing is drawn straight into bore. Continue until 6. Remove nut from puller rod. Take installation tool
bushing is seated. and clutch cover off rod.
8. Remove nut from puller rod and set aside.
9. Remove sheave from puller.
10. Remove installation tool.
6.21
CLUTCH
EBS DRIVEN BUSHING 8. Remove nut (C) (left hand thread) from puller rod
and set aside.
SERVICE 9. Remove adapters from puller.
10. Remove bushing and removal tool from adapters.
EBS Driven - Bushing Removal
Discard bushing.
1. Install puller adapter (Item 10) onto puller. EBS Driven - Bushing Installation
1. Slide adapter (Item 10) onto puller.
Bushing
Ill. 1
2. Insert EBS main adapter (Item D) onto puller. See Puller Adapter (10)
Ill. 1.
2. Apply Loctitet 609 evenly to bushing bore inside
3. Install bushing removal tool (Item E) into center of
moveable sheave.
clutch sheave. See Ill. 2.
3. Install sheave onto puller (belt surface up).
4. Place new bushing on side B of installation tool
(Item A/B) and slide both over puller rod.
5. Install nut (C) onto puller rod and hand tighten
against installation tool.
6. Turn clutch sheave counterclockwise until
bushing is seated.
7. Remove nut (C) (left hand thread) from puller rod
and set aside.
8. Remove installation tool and clutch sheave from
puller.
Bushing
EBS Driven - Backside (Outer) Bushing Removal
Removal Tool (E)
Ill. 2 1. Install main puller adapter (Item 8) onto puller.
2. Install adapter reducer (Item 9).
4. Install sheave onto puller.
3. Using a hand held propane torch, apply heat
5. Install left hand nut onto puller rod and tighten by around outside of bushing until tiny smoke tailings
hand. Turn puller barrel for further tension if appear.
needed.
CAUTION: Clutch components will be hot! In
6. Using a hand held propane torch, apply heat order to avoid serious burns, wear insulated
evenly around outside of bushing until tiny smoke gloves during the removal process.
tailings appear.
CAUTION: Clutch components will be hot! In 4. Flip sheave over onto puller.
order to avoid serious burns, wear insulated 5. Install bushing tool (Item 2).
gloves during the removal process. 6. Install left hand nut (C) and spacer onto puller rod
7. Turn clutch sheave counterclockwise until and tighten by hand. Turn puller barrel for further
bushing is removed and sheave comes free. tension if needed.
6.22
CLUTCH
7. Turn clutch sheave counterclockwise until 8. Remove nut (C) (left hand thread) from puller rod
bushing is removed and sheave comes free. and set aside.
8. Remove nut (C) (left hand thread) from puller rod 9. Remove installation tool and clutch sheave from
and set aside. puller.
9. Remove adapters from puller.
Adapter
Reducer (9)
Main Adapter
(8)
Nut (C)
Bushing Bushing
Tool (2)
Bushing
Tool (2)
Puller Adapter Adapter
(10) (9)
6.23
CLUTCH
TROUBLESHOOTING
Erratic engine -Drive clutch binding. a. Disassemble drive clutch; inspect shift weights for wear
operating RPM and free operation.
during accelera- b. Clean and polish stationary shaft hub; reassemble clutch
tion or load vari- without spring to determine problem area.
ations.
-Belt worn unevenly - thin/burnt spots Replace belt
-Driven clutch binding. -Disassemble, clean, and inspect driven clutch, noting worn
sheave bushing and ramp buttons and helix spring location.
-Converter sheaves greasy; belt slippage. -Clean sheaves with denatured alcohol or brake cleaner,
install new belt.
Harsh drive -Drive belt worn too narrow. -Replace belt.
clutch engage-
ment. -Excessive belt/sheave clearance with new -Perform belt/sheave clearance adjustment with shim wash-
belt. ers beneath spider.
Drive belt turns -Wrong belt for application. -Replace with correct belt.
over
-Clutch alignment out of spec. -Adjust alignment offset.
-Use of High vs. low range -Instruct operator on guidelines for operation in proper driving
range for different terrain as outlined in Owner’s Safety and
Maintenance Manual.
Water ingestion -Cover seals or ducts leaking -Find leak and repair as necessary.
6.24
CLUTCH
TROUBLESHOOTING
-Slow, easy clutch engagement -Instruct firm, effective use of throttle for efficient engage-
ment.
PVT noise -Belt worn or separated, thin spots, loose -Replace belt.
belt
6.25
CLUTCH
NOTES
6.26
FINAL DRIVE
CHAPTER 7
FINAL DRIVE
7.1
FINAL DRIVE
Drive Axle
Clamps
Propshaft Assembly
Prop Shaft O-Ring
Cross and Bearing Kit
Spring Pin
7.2
FINAL DRIVE
CAUTION:
11. With short, sharp jerks, remove drive shaft from Front Hub Retaining Nut Torque
front gearcase.
70 ft. lbs. (95 Nm)
7.4
FINAL DRIVE
4. Slide strut off end of drive shaft and tie it up out of Boot replacement with complete CV
the way of the shaft. joint cleaning requires an additional
30g. (Total 60g)
5. Remove clamps from rubber boot using the
proper boot clamp pliers.
6. Remove the large end of the boot from the CV 9. Slide the new clamp and boot (small end first)
joint, slide the boot back and separate the wheel over the splined shaft, then slide (tap) the CV joint
spindle and CV joint assembly from the axle shaft into the splines of the axle. Install small boot
by pulling the shaft sharply outward, away from clamp.
the CV joint. It may be necessary to tap the CV
10. Add grease through large end of boot.
joint assembly outward with a soft faced hammer.
11. Position large end of boot on CV joint, purge
excess air by partially compressing axle into CV
7.5
FINAL DRIVE
bell, lift one edge of boot to let out excess air NOTE: Drive bearing out evenly by tapping on outer
Secure with clamp. race only. Once bearing is at bottom of casting,
support casting on outer edges so bearing can be
removed.
FRONT SHAFT Joint Capacity 3. Inspect the bearing.
30 Grams
Boot Capacity NOTE: Due to extremely close tolerances and
30 Grams minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by hand,
inspect for rough spots, discoloration, or corrosion.
The bearings should turn smoothly and quietly, with
no detectable up and down movement and minimal
movement sideways between inner and outer race.
Front outboard joint capacity: 4. Inspect bearing housing for scratches, wear or
30g if boot is replaced only. damage. Replace housing if damaged.
Another 30g (60g total) if joint is
cleaned.
FRONT HUB ASSEMBLY
1. Support bottom of hubstrut housing.
FRONT HUB DISASSEMBLY 2. Start bearing in housing.
1. Remove outer snap ring. 3. Press bearing into place until outer race bottoms
on housing.
CAUTION:
7.6
FINAL DRIVE
U-JOINT DISASSEMBLY
CAUTION: Wear eye protection at all times.
1. Remove internal or external snap ring from all
bearing caps.
4. Force U-joint cross to one side and lift out of inner
yoke.
7.7
FINAL DRIVE
7.8
FINAL DRIVE
Front Gearcase
FRONT GEARCASE
OPERATION -- CENTRALIZED
HILLIARD)
8. Pull the hub and strut assembly out and pull the
drive--shaft out of the hub. Normal Operation: With the AWD switch off the
9. Pull both driveshafts from the front gearcase. vehicle is only driving the rear wheels (2 wheel
Replace the circlip on the driveshaft end for drive).When the AWD switch is activated it engages
reassembly. the Hilliard and locks both front wheels and we then
have, True All Wheel Drive.
Coil
Cover
Output
Hub
Armature
Plate
7.9
FINAL DRIVE
CAUTION: If the rear wheels are spinning, release 2. Remove bolts and output shaft cover.
the throttle before turning the AWD switch on. If AWD
is engaged while the wheels are spinning, severe
drive shaft and clutch damage could result.
Output
Hub
Roller Cage
& Bearings
Armature
Plate
Roller
Cage
Output Hub
Roller Cam
Rollers
7.10
FINAL DRIVE
H--spring
9. Remove the ring gear (C), the output hub (D), the
shim (E), and the armature plate (F) from the
6. Thoroughly clean all parts. Inspect the rollers (A) output cover.
for nicks and scratches. The rollers must slide up
and down freely within the roller cage surfaces
(B). C D
B
Coils
E
A
F
7.11
FINAL DRIVE
12. Remove the other output hub from the main FRONT GEARCASE
gearcase.
REASSEMBLY/INSPECTION
1. Replace all O--rings, seals, and worn
components.
2. Press the pinion shaft seal into the pinion cover,
until the seal is flush with the sealing surface.
3. Inspect bearings on output and pinion shafts. To
replace, press new bearing on to shaft.
NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by hand,
inspect for rough spots, discoloration, or corrosion.
The bearings should turn smoothly and quietly, with
no detectable up and down movement and minimal
movement side to side.
4. Install pinion shaft, bearing, and input cover with
13. Remove the O--ring and seal from the output new o-ring and torque bolts to 14 ft. lbs (19 Nm).
cover.
7.12
FINAL DRIVE
6. Install the ring gear into the gearcase housing. 9. Install the armature plate onto the ring gear.
7. Slide the roll cage into the ring gear. Insert the NOTE: Be sure armature plate tabs are placed into
rollers as the roll cage is installed. the slots on roll cage.
10. Apply grease to the thrust bearing. Insert the
thrust bearing onto the output hub. Insert the
output hub, dowel, and thrust bearing into the ring
gear.
7.13
FINAL DRIVE
ILL. 1 Possible
Wear Ring on
FRONT GEARCASE Armature Plate
DIAGNOSIS
Symptom: AWD Will Not Engage.
1. Check the gearcase coil resistance. To test the OK Condition
gearcase coil resistance, use the coil harness
(Grey & Brown/White). The gearcase coils should
measure between 22.8 ohms and 25.2 ohms.
2. Check the minimum battery voltage at the wire
(Grey & Brown/White) that feeds the hub coil wire.
There should be a minimum of 11.80--12.0 Volts
present for proper operation.
Bad Condition
(Wear from Coil
On Armature Plate)
7.14
FINAL DRIVE
New spring
Pin
Gearcase Cover
Coil
U--shaped insert
Side Cutaway View of Centralized Hilliard Cover 2. Add the proper lubricant to the front gearcase.
Check drain plug for proper torque. Refer to Page
5. Inspect the rollers for nics and scratches. The 2.10 in the maintenance chapter for fill capacities.
rollers must slide up and down and in and out
freely within the roll cage sliding surfaces.
Premium Front Housing Fluid
(PN 2871654)
Rollers
FRONT HOUSING
INSTALLATION
1. To install gearcase, reverse removal procedure.
Use new spring pin in front prop shaft.
7.15
FINAL DRIVE
1
2
3
4 5
6 18
28 7 9 21
8 10
22 11
12 17 20
36
13
14 22
15 19
16 23
13 24
35 25
34 26
6 27
28
29
33
32 30
31
7.16
FINAL DRIVE
REAR HUB REMOVAL 8. Remove hub nut, domed washer and flat washer.
9. Remove hub.
CAUTION:
7.17
FINAL DRIVE
11. Remove both lower control arm bolts. Lower Control Arm Bolt Torque:
40 ft. lbs. (54 Nm)
7.18
FINAL DRIVE
7.19
FINAL DRIVE
Lock ring
7.20
FINAL DRIVE
7.21
FINAL DRIVE
Tap CV Housing
Off Shaft
Snap ring
7.22
FINAL DRIVE
7.23
FINAL DRIVE
D
30 ft. lbs Fill Plug
. (41 Nm) B
(5 bolts)
C A
30 ft. lbs. (41 2. Torque the installation bolts and nuts to the
30 ft. lbs. (41 Nm) Nm) (4 bolts) torques specified in Ill. 1.
Ill.1
3. Refill the rear gearcase with 5 oz. (150 ml) of
Polaris Premium Gearcase Lubricant (PN
2871653). Torque the fill plug to 14 ft. lbs. (19
Nm).
7.24
FINAL DRIVE
REAR GEARCASE
DISASSEMBLY
Thrust Button Shims
1. Drain and properly dispose of used oil.
2. Remove the gearcase housing cover bolts and
the gearcase housing cover.
7.25
FINAL DRIVE
REAR GEARCASE
REASSEMBLY
1. Inspect the pinion shaft bushing for wear.
7.26
FINAL DRIVE
7.27
FINAL DRIVE
5
4
2 3
1
19
17 7
18 8
17
16
10
11 12 13
6 14
15
4
2
5
7.28
TRANSMISSION
CHAPTER 8
TRANSMISSION SERVICE
8.1
TRANSMISSION
19
18
17
16
15
17
14
13 22
20 21
23
13
22 36
31 35
21 34
3 26 25
29 27
12
31 33 28
11 32
8 31
9 10 13
6 7 28 30
26 29
5 27 37
4 13 25 38
2 3 17 16 40 39
1 43 41
44 42
45
66 61
65 59
69 64 62 48
17 46 47
63 60 57 49
58 56 50
67 51
55
68
54 8
16
53 52
8.2
TRANSMISSION
8.3
TRANSMISSION
LUBRICATION
Refer to maintenance section for transmission
lubricant type and capacity.
TRANSMISSION REMOVAL
1. Remove seat, rear rack, rear cab, air box, and
exhaust system, and right footwell (if required for
access).
Transmission
8.4
TRANSMISSION
TRANSMISSION REMOVAL CONT’D 6. Loosely install left side and rear mounting brackets.
7. Loosely install lower right bracket bolt.
9. Loosen or remove the bolts that secure the rear
8. Loosely install front mounting bolts.
gearcase. Move the rear gearcase back just
enough to slide the rear propshaft from the 9. Tighten mounting fasteners in order A-F as shown.
transmission shaft. NOTE: Align clutches as outlined in Clutch Chapter 6.
Transmission Mounting
Bolts Torque
D
B
Remove or Loosen
Rear Gearcase Bolts C
F E
Tighten Bolts In Sequence A through F
TRANSMISSION DISASSEMBLY
1. Place the bellcrank in neutral position.
TRANSMISSION INSTALLATION
1. Install transmission from right side of vehicle.
2. Align rear output shaft to rear propshaft yoke and Detent Pawl Case
roll pin hole. Bellcrank
3. Slide rear output shaft into propshaft yoke.
4. Position transmission in frame. 2. Remove the nut, and washer that secure the bell
crank. Remove the bellcrank.
5. Install front propshaft and roll pin.
8.5
TRANSMISSION
TRANSMISSION DISASSEMBLY CONT’D 6. Mark the shift lockout disc, this will indicate which
sideof the disc faces outward during assembly.
3. Remove the e--clip and then remove the
Remove the shift lockout disc.
transmission switch.
Transmission
Switch
Spring
8.6
TRANSMISSION
TRANSMISSION DISASSEMBLY CONT’D NOTE: You may have to tap the shift drum from the
backside of the case to aid in removal.
NOTE: It may be helpful to accent the timing marks
using a white marking pen. 12. Remove the upper gear cluster and shift forks.
You may need to move the assembly back and
9. Remove the bolts on the LH transmission case. forth to aid in removal.
Tap the cover off with a soft face hammer if
necessary.
8.7
TRANSMISSION
TRANSMISSION DISASSEMBLY CONT’D 18. Remove the snap ring and washer from the
reverse shaft.
15. Remove the bearing from the reverse shaft using
a puller.
Engagement
Dogs
8.8
TRANSMISSION
8.9
TRANSMISSION
8.10
TRANSMISSION
TRANSMISSION REASSEMBLY
1. Reinstall the chain onto the front output shaft and
rear output shaft. Crankcase Sealant
(PN 2871557)
8.11
TRANSMISSION
TRANSMISSION REASSEMBLY CONT’D NOTE: Install a new snap ring at this time. When
installing the new snap ring, open the the snap ring
just far enough to go over the shaft, to avoid stressing
the snap ring. If the snap ring is over--stressed, it
could come off the shaft and cause internal damage
to the transmission.
10. Slide the reverse shaft assembly through the
silent chain.
13. Install the ball bearing onto the end of the input
shaft.
14. As the engagement dogs are installed onto the
shaft, place the wave springs into the spring
groove. Keep the spring in place while the fork is
being installed on the shaft and while placing the
shafts into the case.
8.12
TRANSMISSION
TRANSMISSION REASSEMBLY CONT’D 17. Replace and grease the O--rings on the shift drum
before installation.
NOTE: Installing the shift rail will aid in keeping the 18. Install the shift drum into the case.
shift forks, shift dogs, and the springs in place.
15. Carefully install the shaft assembly and gear
cluster as a unit into their respective bearing case
recesses. Tap with a soft face hammer to seat
shaft assemblies.
16. Position the shift forks up and so the the pins point
toward the 9 o’clock position, before installing the
shift drum assembly.
8.13
TRANSMISSION
Detent Star
22. Grease the seal lips of the input shaft seal. Apply
electricians tape or somehow cover the splines of Keyed Spline
the shaft to protect the seal lips during installation.
Install new input shaft seal. 27. Install the detent pawl and spring. Install a new
23. Install drain plug with a new sealing washer. o--ring onto the shift shaft after the detent pawl is
Torque drain plug to 14--18 ft. lbs. (19--24 Nm). assembled to the shaft. Place a small amount of
grease on the small O--ring on the shift shaft and
on the detent star. Grease the o--ring on the end
Drain Plug Torque: of the shift drum.
14-- 18 ft. lbs. (19-- 24 Nm)
8.14
TRANSMISSION
28. Install the park lockout assembly. Torque park Bellcrank Nut Torque:
lockout to 12 -- 14 ft. lbs. (16--19 Nm).
12-- 18 ft. lbs. (16-- 24 Nm)
29. Apply Crankcase Sealant (PN 2871557) onto the
cover and case mating surfaces. Install the cover 31. Install the shift switch. Install the retaining clip.
and torque the cover bolts to 6--12 ft. lbs. (12--16 Hook up the switch harness and reconnect the
Nm). lockout plunger spring.
8.15
TRANSMISSION
NOTES
8.16
BRAKES
CHAPTER 9
BRAKES
9.1
BRAKES
SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION
2870975 Mity Vact Pressure Test Tool
SPECIFICATIONS
Front Brake Caliper
TORQUE SPECIFICATIONS
Item Torque Torque
(ft. lbs. except where noted*) (Nm)
Front Caliper Mounting Bolts 16.0 22
Output Shaft Caliper Mounting Bolts 15.0 21
Master Cylinder Mounting Bolts *25 in. lbs. 3.0
Master Cylinder Reservoir *5 in. lbs. 0.56
Cover Bolt
Brake Line Banjo Bolt 15.0 21
Front Brake Disc 18.0 25
Front Wheel Mounting Nuts 20.0 28
NOTE:Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures are
used when torquing certain bolts and fasteners.
9.2
BRAKES
9.3
BRAKES
HYDRAULIC BRAKE SYSTEM when the lever is released and the master cylinder
piston is outward. As the temperature within the
OPERATION OVERVIEW hydraulic system changes, this port compensates for
fluid expansion (heated fluid) or contraction (cooled
Typical Hydraulic Brake System fluid). During system service, be sure this port is
Compensating port open. Due to the high temperatures created within the
Must be clear E compensates system during heavy braking, it is very important that
to allow for temperature the master cylinder reservoir have adequate space to
proper dia- changes by allow- allow for fluid expansion. Never overfill the
phragm move- ing fluid back to
C master cylinder reservoir! Fill to 1/4² - 5/16² (.64 - .80 cm) from top
ment of the cylinder.
F
This system also incorporates a diaphragm (E) as part
of the cover gasket; and a vent port (F) located
between the gasket and the cover. The combination
diaphragm and vent allow for the air above the fluid to
B
equalize pressure as the fluid expands or contracts.
A Make sure the vent is open and allowed to function.
If the reservoir is over filled or the diaphragm vent is
plugged the expanding fluid may build pressure in the
Move-
brake system leading to brake failure.
able D When servicing Polaris ATV brake systems, use only
Brake Polaris DOT 3 Brake Fluid (PN 2870990).
Pad G
WARNING: Once a bottle is opened, use what is
necessary and discard the rest in accordance with
local laws. Do not store or use a partial bottle of brake
The Polaris disc brake system consists of the fluid. Brake fluid is hygroscopic, meaning it rapidly
following components or assemblies: brake lever; absorbs moisture. This causes the boiling
master cylinder; hydraulic hose; brake calipers (slave temperature of the brake fluid to drop, which can lead
cylinder); brake pads; and brake discs, which are to brake fade and the possible loss of control.
secured to the drive line.
When the hand activated brake lever (A) is applied it HYDRAULIC
contacts piston (B) within the master cylinder. As the
master cylinder piston moves inward it closes a small CALIPER BLEEDING
opening (compensating port C) within the cylinder and
This caliper is a single piston design. The caliper
starts to build pressure within the brake system. As
pistons are “T”-shaped, which allows both hand and
the pressure within the system is increased, the piston
foot brake to use the same caliper piston, but remain
(D) located in the brake caliper moves outward and
separated by seals. The hand brake system applies
applies pressure to the brake pad. This pad contacts
hydraulic pressure to both front calipers and only the
the brake disc and moves the caliper in its floating
outer diameter of the rear caliper pistons. The
bracket, pulling the stationary side pad into the brake
auxiliary (foot) brake applies pressure to the inner
disc. The resulting friction reduces brake disc and
portion of the rear caliper pistons. Because the hand
vehicle speed. As the lever pressure is increased, the
and foot brake hydraulic systems are separate, there
braking affect is also increased.
are also two bleed screws -- one for the outer fluid
The friction applied to the brake pads will cause the chamber (hand brake), and one for the inner fluid
pads to wear. As these pads wear, the piston within chamber (foot brake). The basic procedure for
the caliper moves further outward and becomes self bleeding the brake system is the same as outlined on
adjusting. Fluid from the reservoir fills the additional page 9.4 - 9.5, however, each system must be bled
area created when the caliper piston moves outward. separately.
Brake fluid level is critical to proper system operation. Hydraulic Auxiliary Brake inspection and adjustment
Too little fluid will allow air to enter the system and is outlined in Chapter 2 beginning on Page 2.27.
cause the brakes to feel spongy. Too much fluid could
cause brakes to drag due to fluid expansion.
Located within the master cylinder is the
compensating port (C) which is opened and closed by
the master cylinder piston assembly. The port is open
9.4
BRAKES
NOTE: Uppermost (inner) bleed screw and brake line 4. If changing fluid, remove old fluid from reservoir
(A) is for hand brake system. Lower (outer) bleed screw with a Mity Vact pump or similar tool.
and brake line (B) is for auxiliary (foot) brake system.
MAX
BB A
C Sight
Glass
B
A
EB F
D
9.5
BRAKES
BRAKE BLEEDING CONT’D 13. Install diaphragm, cover and screws. Tighten
screws to 5 in. lbs. (0.56 Nm).
NOTE: Fluid may be forced from supply port (B) when
brake lever is pumped. Place diaphragm (C) in
reservoir to prevent spills. Do not install cover. See
Illustration above.
7. Slowly pump brake lever (D) until pressure builds
and holds.
8. While maintaining lever pressure, open bleeder
screw. Close bleeder screw and release brake
lever. NOTE: Do not release lever before bleeder
screw is tight or air may be drawn into caliper.
Maintain at least 1/2² (1.27 cm) of brake fluid in the 14. Field test machine at low speed before putting
reservoir to prevent air from entering the master into service. Check for proper braking action and
cylinder. lever reserve. With lever firmly applied, lever
10. Tighten bleeder screw securely and remove reserve should be no less than 1/2² (1.3 cm) from
bleeder hose. Torque the bleeder screw to 25--30 handlebar.
in.lbs. (2.80 --3.40 Nm). 15. Check brake system for fluid leaks and inspect all
11. Repeat procedure Steps 5-9 for the remaining hoses and lines for wear or abrasion. Replace
caliper(s). hose if wear or abrasion is found.
12. Add Polaris Dot 3 Brake Fluid (PN 2870990) to
MAX level inside reservoir. MASTER CYLINDER
REMOVAL
1. Clean master cylinder and reservoir assembly.
Make sure you have a clean work area to
disassemble brake components.
9.6
BRAKES
2. Place a shop towel under brake line connection at 2. Place new sealing washers on each side of banjo
master cylinder. Loosen banjo bolt; remove bolt line and torque banjo bolt to specification.
and sealing washers.
MASTER CYLINDER
INSTALLATION Master Cylinder Mounting Bolt
Torque 25 in. lbs. (3 Nm)
Notice: When replacing the brake master cylinder
assembly or master cylinder parts, use the correct Brake Line Banjo Bolt Torque
parts. There are different brake master cylinders for 15 ft. lbs. (21 Nm)
the different Polaris ATV models. Refer to your parts
manual or guide for the correct parts. This master 3. Fill reservoir with DOT3 Brake Fluid (PN
cylinder is not servicable and is replaced as a 2870990).
unit.
1. Install master cylinder on handlebars. Torque
mounting bolts to 25 in. lbs. (3 Nm). Torque the
inside bolt first as indicated in the illustration to the
right.
NOTE: To speed up the brake bleeding procedure, 4. Follow bleeding procedure on Pages 9.7-9.8.
the master cylinder can be purged of air before brake Check all connections for leaks and repair if
line is attached. Fill with DOT3 Brake Fluid (PN necessary.
2870990) and pump lever slowly two to three times
with finger over the outlet end to purge master cylinder
of air.
9.7
BRAKES
CAUTION:
9.8
BRAKES
BRAKE BURNISHING
PROCEDURE
18 ft. lbs. It is required that a burnishing procedure be
(25 Nm) performed after installation of new brake pads to
extend service life and reduce noise.
Start machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Allow pads
Front Caliper Mounting Bolts
and disc to cool sufficiently during the procedure. Do
Torque: 18 ft. lbs. (25Nm) not allow pads or disc to become hot or warpage may
result. Repeat this procedure 10 times.
4. Slowly pump the brake lever until pressure has FRONT DISC INSPECTION
been built up. Maintain at least 1/2² (12.7 mm) of
brake fluid in the reservoir to prevent air from 1. Visually inspect the brake disc for nicks,
entering the brake system. scratches, or damage.
5. Install the adjuster screw and turn clockwise until 2. Measure the disc thickness at eight different
stationary pad contacts disc, then back off 1/2 points around the pad contact surface using a
turn (counterclockwise). 0-1² micrometer. Replace disc if worn beyond
service limit.
9.9
BRAKES
3. Mount dial indicator as shown to measure disc CAUTION: Always use new brake disc mounting
runout. Slowly rotate the disc and read total bolts. The bolts have a pre-applied locking agent
runout on the dial indicator. Replace the disc if which is destroyed upon removal.
runout exceeds specifications.
FRONT CALIPER REMOVAL
CAUTION:
9.10
BRAKES
FRONT CALIPER
DISASSEMBLY Remove
Mounting Bracket
1. Remove brake pad adjuster screw.
9.11
BRAKES
(PN 2871423)
3. Inspect the brake disc and pads as outlined for 4. Compress the mounting bracket and make sure
brake pad replacement this section. See Pages the dust seals are fully seated. Install the pads as
9.10--9.11. shown on Page 9.10. Clean the disc and pads
with brake parts cleaner or denatured alcohol to
remove any dirt, oil or grease.
9.12
BRAKES
9.13
BRAKES
Square
3 O--Rings 3 Piston
Bleeder Screw
35--60 IN. LBS. Brake Pads
(4--6.5 NM)
Caliper Assembly
Boot Bushing
Caliper Mount
9.14
BRAKES
PROCEDURE
It is required that a burnishing procedure be
performed after installation of new brake pads to
extend service life and reduce noise.
Start machine and slowly increase speed to 30 mph. Clip
Gradually apply brakes to stop machine. Allow pads
and disc to cool sufficiently during the procedure. Do
not allow pads or disc to become hot or warpage may
result. Repeat this procedure 10 times.
9.15
BRAKES
Measure
Thickness
Install Pads
9.16
BRAKES
Seal
Caliper
C
Bushing
D
9. Inspect caliper piston bore for scratches, severe
corrosion, or galling and replace if necessary.
B
Inspect
9.17
BRAKES
Seals
O-Rings
4. Install caliper and torque mounting bolts to 18
ft.lbs (25 Nm).
2. Carefully assemble caliper body, making sure
O-rings are properly positioned in groove.
Tighten the caliper anvil bolts and then torque the
anvil bolts evenly to 16--18 ft. lbs. (22--25 Nm).
Torque Mounting
Bolts
9.18
BRAKES
TROUBLESHOOTING
Banjo Bolt Torque
Brakes Squeal
15 ft. lbs. (21 Nm)
G Dirty/contaminated friction pads
G Improper alignment
6. Follow bleeding procedure outlined on Pages
G Worn disc
9.6-9.7 of this section and refer to system
overview and illustrations on Pages 9.2--9.3. G Worn disc splines
7. Field test unit for proper braking action before Poor Brake Performance
putting into service. Inspect for fluid leaks and G Air in system
firm brakes. Make sure the brake is not dragging G Water in system (brake fluid contaminated)
when lever is released. If the brake drags,
G Caliper/disc misaligned
re-check assembly and installation.
G Caliper dirty or damaged
REAR BRAKE DISC G Brake line damaged or lining ruptured
G Worn disc and/or friction pads
INSPECTION G Incorrectly adjusted lever
1. Visually inspect disc for scoring, scratches, or G Incorrectly adjusted stationary pad
gouges. Replace the disc if any deep scratches G Worn or damaged master cylinder or components
are evident. G Improper clearance between lever and switch
2. Use a 0-1² micrometer and measure disc
Lever Vibration
thickness at 8 different points around perimeter of
disc. Replace disc if worn beyond service limit. G Disc damaged
G Disc worn (runout or thickness variance exceeds
service limit)
Caliper Overheats (Brakes Drag)
Rear Brake
G Compensating port plugged
Disc
G Pad clearance set incorrectly
G Auxiliary brake pedal incorrectly adjusted
Measure G Brake lever or pedal binding or unable to return
Thickness fully
G Parking brake left on
G Residue build up under caliper seals
Brake Disc Thickness
G Operator riding brakes
New .177-.187² (4.496-4.750 mm) Brakes Lock
Service Limit .167² (4.242 mm) G Alignment of caliper to disc.
9.19
BRAKES
Bleed
3 Piston Screws
Torque
25--30 in. lbs.
Bracket O--rings (2.80--3.40) Nm
Seals
Pads 3
Slide Pins
Torque
Bushings
30--35 ft.lbs.
Seal (41--48 Nm)
Front Caliper
Snap Ring
Reservoir Hose
Bolt
Seal
Rear Brake
Master Cylinder
Screw Brake Mount
Spring
Washer
Screw
Bushing
Washer
Bushing
9.20
ELECTRICAL
CHAPTER 10
ELECTRICAL
10.1
ELECTRICAL
Cap
Spark
Plug
LR390
Wire
Ignition Controller
Magnetic Switch
Bumper
Area
Refer to wiring diagrams for
COMPONENT LOCATION specified stator coil resistance
FLYWHEEL IDENTIFICATION
The flywheel can be identified by the tag located on the flywheel. The tag indicates the Polaris Part Number,
the production date, direction of rotation, and has timing marks to time the engine.
Polaris
Part Number
Production
Date Direction of Rotation
10.2
ELECTRICAL
ELECTRICAL SERVICE
NOTES
Keep the following notes in mind when diagnosing an
electrical problem.
10.3
ELECTRICAL
30
A B C D E F
28
26
IGNITION TIMING (DEGREES) B.T.D.C.
24
22
A B C D E F
20
High Range F
18
Low Range F
16
Neutral F F
Reverse F
12
Park F
8
Measure Trigger
Coil Gap
10.4
ELECTRICAL
10.5
ELECTRICAL
PROGRAM SERVICE INTERVAL CONT’D NOTE: If the gauge will not indicate what gear it is in
and will not allow AWD operation, AWD can still be
2. Begin entering the next service hour total by
enabled by holding in the mode/override button.
releasing and pressing the mode/reverse override
button. Each time the mode/reverse override button To enter the diagnostics mode:
is pressed and released the service interval time is 1. Turn the key switch off and wait 10 seconds.
increased by an hour. NOTE: Continuing to hold
2. Set the park brake and shift the transmission to
down the mode button will add to the hour total faster.
neutral.
3. When the desired hour total has been reached, 3. Hold the mode/reverse override button as you
stop pressing the mode/reverse override button and turn the key switch on.
wait for the wrench icon to quit flashing. Once the
The initial screen displayed looks similar to Ill. 1 and
wrench icon quits flashing the service hours are set.
is referring to the software version currently installed
If you scroll past the intended number, hold the button
in your instrument cluster. This information is only
down until the count turns over to “0”. At this point you
briefly displayed.
can re--attempt to set the number.
4. The P.S.I. then counts down from this total per
hours of engine operation.
5. When the number reaches “0”, the wrench icon will
flash for five seconds during vehicle start up to remind
the driver that the next scheduled service is due. To
turn the P.S.I. off, toggle to the service interval mode
and press the mode/reverse override button for
approximately seven seconds until the word “OFF” Ill. 1
appears in the Rider Information Center.
Diagnostic Mode Use the mode/reverse override button to toggle
through the diagnostic screens.
Warning Indications Displayed on Rider
Information Center The first screen indicates battery voltage. Refer to Ill.
2.
Warning Indication Warning Explanation
“E” Most of the time this error
message indicates that you
are between gears. It can
also indicate that the trans-
mission switch is broken.
“StAtr” “Stator” -- is displayed when
the gauge senses ground
speed but no engine rpm for Ill. 2
at least 10 seconds. May in-
dicate a failing stator or wir- Screen three (Ill. 4) is the tachometer for setting idle
ing problem.
speed. This mode is not operational while in motion.
“hdLbr” “Handlebar” -- is displayed
when the mode/override but-
ton is stuck in for more than
ten seconds in any mode ex-
cept Programmable Service
Interval or Diagnostic
modes.
10.6
ELECTRICAL
SPEEDOMETER REMOVAL
1. Remove the headlight pod cover and disconnect
the wire connectors from the instrument cluster.
Bezel
Instrument Cluster
Pod
Push Instrument
Cluster Outward
NOTE: Be sure the key on the instrument cluster
NOTE: Do not remove the rubber grommet in the pod. housing is aligned with the keyway in the rubber
Only remove the rubber grommet if necessary. grommet, to ensure proper alignment.
10.7
ELECTRICAL
SPEEDOMETER TROUBLESHOOTING
10.8
ELECTRICAL
SPEEDOMETER TROUBLESHOOTING
16PIN MEA-
SURE 12VDC N REPAIR
ON PINS 1 WIRING
N
&8 AND 2 & 8 REPLACE
N SPEEDO REPLACE
SPEEDO
N
N Y
ODOMETER TEST ODOMETER Y Y SPEEDO
DISPLAY DRIVE POINTER OK
CHANGE? MOVE?
INSPECT WIRING
Y AND CDI
N
TEST TRANSMISSION
SHIFT INTO REVERSE: N (SHIFT) SWITCH AND
H Measure Harness Side
IS REVERSE INDICA- WIRING
TOR ON? RESTART ATV
H
TURN KEY SWITCH OFF JUMPER TO PIN 4 Y REPLACE
(BLACK) TO PIN 8 SPEEDO
Y REMOVE 16 PIN PLUG (BROWN). DOES
FROM BACK OF ENGINE STOP?
SPEEDOMETER HEAD
10.9
ELECTRICAL
SPEEDOMETER TROUBLESHOOTING
IS
TURN ATV SPEEDO
Y FUNCTIONING N CHECK
ON IN DIAGNOSTIC SPEEDO
CORRECTLY?
MODE. TOGGLE TO TACH--
OMETER SETTING & REV ENGINE. (TEST NO. 2)
HOLD UNTIL DISPLAY STABILIZES.
DOES IT APPEAR
ACCURATE?
RESTART ATV
N
ENGINE IDLING
MEASURE AC VOLTAGE
Y REPLACE
TURN KEY SWITCH OFF SPEEDOMETER
BETWEEN PIN 7 AND
1. RAISE ATV WHEELS OFF GROUND AND REMOVE 16 PIN PIN 8.
SUPPORT IN A SAFE MANNER. CONNECTOR FROM OVER 3 VAC?
BACK OF
2. MONITOR VOLTAGE AT HUB COIL INSTRUMENT
CONNECTOR, BETWEEN BROWN/WHITE CLUSTER.
AND GROUND
NOTE: IF THE AWD
LIGHT IS FLICKERING N
RATHER THAN ON
CONTINUOUSLY,
THERE IS AN OPEN IN CHECK CHARGING SYSTEM
THE HUB COIL. (STATOR, REGULATOR,
AND WIRING)
TURN
AWD OFF.
START THE ENGINE
REV AND HOLD THE N
16 Pin Connector
RPM’S ABOVE 3100. NO PROBLEM 1. Red-- 12V Constant
TURN AWD ON. 9. Blue White-- Engine Overheat Switch
2. Red/White-- 12V Switched 10. Purple/Yellow-- OIl Pressure Switch
DOES FRONT
3. Grey/Orange-- Mode/Override button 11. Orange/Red-- Park Gear
DRIVE
ENGAGE? 4. Black-- Ignition Kill 12. Purple-- Reverse Gear
5. N/C 13. Green/White-- Neutral
6. N/C 14. White/Blue-- Low Gear
7. Yellow/Red-- RPM Input 15. Blue/Red-- High Gear
8. Brown-- Ground 16. Brown/White-- AWD Control
Y
INSPECT
HUB COIL WIRING
Y FOR SHORT CIRCUITS N
IS THE TO GROUND. (DISCONNECT REPLACE
AWD LIGHT ON? CONNECTOR & MEASURE SPEEDOMETER
BETWEEN HUB COIL
BROWN/WHT
& GROUND.)
N Y
10.10
ELECTRICAL
SPEEDOMETER TROUBLESHOOTING
10.11
ELECTRICAL
10.12
ELECTRICAL
5. If the fan motor draws more than 13 Amps, ETC OPERATION TEST
replace the motor.
Remove throttle block cover by carefully releasing all
Fan Motor Current Draw: tabs around edge of cover.
Place transmission in neutral and apply parking
Should Be Less Than 15 Amps brake.
NOTE: This fan motor current draw specification only Start engine and open throttle lever slightly until
applies to Sportsman 600/700. engine RPM is just above idle speed.
Hold throttle cable with fingers at point “A” as shown
below and release throttle lever. If the ETC system is
FAN CONTROL SWITCH functioning properly, the engine will lose spark and
stop.
OPERATION TEST
Electronic Throttle Control (ETC) Switch
1. Place switch in a water bath and submerse it to
(Composite Throttle Housing)
the base of the threads. Do not allow threads to
contact container or inaccurate reading will result. ETC switch contacts
2. Heat the coolant slowly and monitor the are closed in a fault
temperature with a thermometer or Fluket meter condition (throttle cable
pyrometer. The switch should be closed slack).
Switch contacts are
(conductive) at the “ON” temperature indicated in open during normal op-
the chart, and stay conductive until the “OFF” eration
temperature is reached.
A
ELECTRONIC THROTTLE
CONTROL (ETC) SWITCH
The Electronic Throttle Control (ETC) system is Blk
designed to stop the engine of an ATV in the event of Brn Brn
a mechanical problem with the throttle mechanism.
The ETC switch is mounted independently of the
throttle actuator lever inside the throttle block
assembly. This is a normally closed switch, and is
held in the open position (contacts are separated (as
shown below) by throttle cable tension. The contacts
are “open” during normal operation regardless of
throttle lever position. In the event of a mechanical
problem in the throttle mechanism (cable tension is
lost), the switch contacts close, connecting the CDI
black wire to ground, which prevents ignition spark. CDI UNIT
10.13
ELECTRICAL
Disconnect the black wire at the CDI module -Test the ignition switch, engine stop
to isolate the ignition from the kill system. switch, and speed limiter circuit for
Yes shorts to ground.
Does it have spark? -Check connectors for moisture,
wire color matching or corrosion.
No
Yes
Check coil ground connection between engine and coil Clean coil mounting area.
mount using an ohmmeter. The coil mount should No
Repair ground wire connections.
have good continuity to ground on the engine (0-.2 W).
Yes
Yes
If all of the above tests are within specifications, and all grounds, connections, and wire color coding
have been inspected, perform voltage output tests on following page or replace the CDI module.
10.14
ELECTRICAL
10.15
ELECTRICAL
10.16
ELECTRICAL
10.17
ELECTRICAL
10.18
ELECTRICAL
2. Disconnect battery negative (-) (black) cable first, OCV - OPEN CIRCUIT
followed by the positive (+) (red) cable.
VOLTAGE TEST
CAUTION
Battery voltage should be checked with a digital
Whenever removing or reinstalling the battery, multitester. Readings of 12.6 volts or less require
disconnect the negative (black) cable first and further battery testing and charging. See charts and
reinstall the negative cable last! Load Test on below.
3. Remove the battery.
NOTE: Lead-acid batteries should be kept at or near
4. Remove the filler caps and add distilled water
a full charge as possible. Electrolyte level should be
only as needed to bring each cell to the proper
kept between the low and full marks. If the battery is
level. Do not overfill the battery.
stored or used in a partially charged condition, or with
low electrolyte levels, hard crystal sulfation will form
Refill using only distilled water. Tap water
on the plates, reducing the efficiency and service life
contains minerals which are harmful to a battery. of the battery.
10.19
ELECTRICAL
10.20
ELECTRICAL
6. Install clear battery vent tube from vehicle to HIGH BEAM HEADLIGHT
battery vent. WARNING: Vent tube must be free
from obstructions and kinks and securely LAMP REPLACEMENT
installed. If not, battery gases could accumulate
and cause an explosion. Vent should be routed CAUTION: Do not service while headlight is hot.
away from frame and body to prevent contact with Serious burns may result. Protect lamp during install.
electrolyte. Avoid skin contact with electrolyte, as
severe burns could result. If electrolyte contacts Position Snap pins
the vehicle frame, corrosion will occur. knob in into tabs
7. Route cables so they are tucked away in front and slot and
secure Slip O-Ring
behind battery.
in lock- over pin
ing tabs
HIGH BEAM HEADLIGHT
Route
ADJUSTMENT Adjustment plug over
Knob Stop handlebar
The headlight beam can be adjusted to any position
desired by turning the adjusting knob located on the
bottom right side of the headlight pod.
1. Place the vehicle on a level surface with the
headlight approximately 25’ (7.6 m) from a wall. 1. Remove three Phillips screws on the headlight
pod.
25’ (7.6 m) 2. Lift pod cover up.
3. Unplug headlamp from wiring harness.
Lamp Center Height 4. Remove rubber shield from headlamp housing.
5. Push in and turn plastic retainer counter
clockwise and remove.
2² (5.1 cm)
6. Carefully remove headlamp bulb from housing.
7. Reverse procedure to install new headlamp bulb.
HEADLIGHT HOUSING
REPLACEMENT
2. Measure the distance from the floor to the center 1. Remove three Phillips screws on the headlight
of the headlight and make a mark on the wall at pod.
the same height. 2. Lift pod cover up. Unplug speedometer from
3. Start the engine and turn the headlight switch to harness. Unplug indicator lights from harness
high beam. and remove pod cover.
4. Observe headlight aim. The most intense part of 3. Unplug headlamp from wiring harness.
the headlight beam should be aimed 2² (5.1 cm) 4. Remove O-Ring from headlight pivot pins.
below the mark placed on the wall in Step 2
NOTE: Rider weight must be included on the
seat. On machines with separate low beam O-Ring
lights, the drop should be 8² (20.3 cm) in 25’ from
the center of the low beam lamp.
5. Adjust beam to desired position .
10.21
ELECTRICAL
LOWER HEADLAMP
REMOVAL/INSTALLATION
Lens Cover
Lower Headlamp
10.22
ELECTRICAL
switch if there is no continuity or greater than .5 the meter when testing connections should not
ohms resistance when the brake is applied with exceed .1 VDC per connection or component.
slight pressure.
To perform the test, place the meter on DC volts and
place the meter leads across the connection to be
STARTER SYSTEM tested. Refer to the chart on 10.27 to perform voltage
drop tests on the starter system.
TROUBLESHOOTING
Starter Motor Does Not Turn Voltage should not exceed
.1 DC volts per connection
GBattery discharged. Low specific
gravity
GLoose or faulty battery cables or STARTER MOTOR
corroded connections (see Voltage
Drop Tests)
DISASSEMBLY
GRelated wiring loose, disconnected, or
NOTE: Use electrical contact cleaner to clean starter
corroded
motor parts. Some solvents may leave a residue or
GPoor ground connections at battery damage internal parts and insulation.
cable, starter motor or starter
solenoid (see Voltage Drop Tests)
GFaulty key switch
GFaulty kill switch
GFaulty starter solenoid or starter motor.
GEngine problem - seized or binding (Can
engine be rotated easily with recoil
starter?)
Starter Motor Turns Over Slowly
GBattery discharged - low specific
gravity
GExcessive circuit resistance - poor
connections (see Voltage Drop Test
below)
1. Remove the starter from the engine.
GEngine problem - seized or binding
(Can engine be rotated easily?) 2. Remove the two bolts, washers, and sealing
O-Rings. Inspect O-Rings and replace if
GFaulty or worn brushes in starter
damaged.
motor
GAutomatic compression release
inoperative
Starter Motor Turns - Engine Does Not Rotate
GFaulty starter drive
GFaulty starter drive gears or starter
motor gear
GFaulty flywheel gear or loose flywheel
10.23
ELECTRICAL
O--rings
BRUSH
INSPECTION/REPLACEMENT
1. Measure resistance between starter input
terminal and insulated brushes. The reading
should be .3 ohms or less. Remember to subtract
meter lead resistance.
Inspection
1. Measure length of each carbon brush. Replace
brush assembly when worn to 5/16² (8 mm) or
less. The brushes must slide freely in their
holders.
Brush Length
Brush Replacement
10.24
ELECTRICAL
ARMATURE TESTING Use care when handling starter housing. Do not drop
or strike the housing as magnet damage is possible.
1. Remove armature from starter casing. Note If magnets are damaged, starter must be replaced.
order of shims on drive end for reassembly.
10.25
ELECTRICAL
Roller Bearing
Seal
10.26
ELECTRICAL
STARTER DRIVE
Pinion Gear - Anti Kick-out Shoe, Garter
Spring Replacement
If the garter spring is damaged, the overrun clutch
may fail to return properly. Use either of the following
methods to remove and install a new garter spring.
Spring
Cover
Stopper
Gear Assembly
Thrust Washer
Bushing Retaining
Ring Thrust
Washer
(PN 2871460)
10.27
ELECTRICAL
STARTER ASSEMBLY
11
16
7*
1*
8
3
1*
15
10 5*
12
17
4 18 13
14
15
10.28
ELECTRICAL
Yes
Yes
Yes
Yes
If all of these indicate a good condition, yet the starter still fails to turn, the
starter must be removed for static testing and inspection.
10.29
ELECTRICAL
NOTES
10.30
ELECTRICAL
10.31
ELECTRICAL
10.32
Brake Pad Removal, Rear, 9.15, 9.16
Numbers
Brake System Inspection, 2.26
2003 Sportsman 600/700 Models, 1.3
Brake System Operation, 9.4
Brake, Auxiliary, Hydraulic, 2.27
A Brake, Auxiliary, Testing, 2.27
Brakelight Lamp Replacement, 10.22
A--Arm Replacement, 5.9
Breather Filter Maintenance, 2.20
Air Filter Service, 2.19
Breather Hose Inspection, 2.20
Alternator Output Test, 10.16
Brush Replacement, Starter Motor, 10.24
B C
Battery Charging, 10.20
Cam Gear Assembly, 3.38
Battery Installation, 10.19
Cam Gear Disassembly , 3.37
Battery Maintenance, 2.15
Cam Gear Removal, 3.37
Battery Service, 10.18, 10.19, 10.20
Camber & Caster, 2.23
Battery Terminal Bolts, 10.18
Camshaft Inspection, 3.44
Battery Testing, 10.19
Carburetor Assembly, 4.9
Battery, Off Season Storage, 10.20
Carburetor Disassembly, 4.7
Body Assembly Exploded View, 5.3
Carburetor Exploded View, BST34, 4.2
Brake Bleeding/Fluid Change, 9.5, 9.6, 9.9, 9.15 Carburetor Float Bowl Draining, 2.14
Brake Caliper Disassembly, Front, 9.11 Carburetor Float Height Adjustment, 4.10
Brake Caliper Exploded View, Front, 9.14 Carburetor Float System, 4.7
Brake Caliper Exploded View, Rear, 9.20 Carburetor Fuel Level Testing, 4.11
Brake Caliper Inspection, Front, 9.12 Carburetor Inspection, 4.8, 4.9
Brake Caliper Installation, Front, 9.13 Carburetor Main System, 4.7
Brake Caliper Removal, Front, 9.10 Carburetor Needle and Seat Testing, 4.10
Brake Caliper Removal/Inspection, Rear, 9.17 Carburetor Operation, 4.5
Brake Disc Inspection, Front, 9.9 Carburetor Pilot System, 4.6
Brake Disc Inspection, Rear, 9.19 Carburetor Starter System, 4.6
Brake Disc Removal/Replacement, Front, 9.10 Carburetor System Function, 4.5
Brake Fluid Level, 2.26 CDI Output Test, 10.15
Brake Hose/Fitting Inspection, 2.27 Charging System Break Even Test, 10.16
Brake Light Switch Testing, 10.22 Charging System Testing, 10.17
Brake Master Cylinder Exploded View, Rear, 9.20 Choke Adjustment, 2.11
Brake Noise, 9.3 Clutch Alignment, 6.16
Brake Pad Assembly, Front, 9.8 Clutch Offset, 6.16
Brake Pad Inspection, 2.27 Combustion Chamber, 3.23
Brake Pad Installation, Rear, 9.16 Compression Test, 2.14
Brake Pad Removal, Front, 9.8 Controls Inspection, 2.28
Coolant Level Inspection , 2.18 EBS Driven Clutch Bushing Service, 6.22
Coolant Strength, 2.17 EBS Driven Clutch Disassembly, 6.18, 6.20
Coolant Temperature Sensor, 10.12 EBS Exploded View, 6.3
Cooling System Hoses, 2.17 EBS Moveable Sheave Bushing Inspection, 6.18
Cooling System Overview , 2.17 EBS One Way Drive Clutch Inspection, 6.17, 6.18
Cooling System Test, 2.17 EBS One Way Driven Clutch Inspection, 6.18
Cover/Panel Removal, 5.8 Electrical Service Notes, 10.3
Cranking Output Test, 10.15 Electrical Special tools, 10.3
Current Draw, 10.15 Engine Accessible Components, 3.7
CV Joint Handling Tips, 7.4, 7.21 Engine Bottom End Disassembly, 3.29, 3.30, 3.32
Cylinder Head Assembly, 3.25 Engine Bottom End Disassembly/Inspection, 3.44
Cylinder Head Disassembly, 3.20, 3.21 Engine Break in Period, 3.16
Cylinder Head Inspection, 3.20 Engine Designation Numbers, 1.2
Cylinder Head Reconditioning, 3.23 Engine Exploded View, 3.2, 3.3, 3.4, 3.5, 3.6
Cylinder Head Removal, 3.19, 3.26 Engine Eploded View, 2002, Sportsman 700, 3.58
Cylinder Head Warpage, 3.20 Engine Fastener Torque Patterns, 3.9
Cylinder Honing, 3.17 Engine Head Assembly, 3.27, 3.28
Cylinder Inspection, 3.30 Engine Lower Disassembly/Inspection, 3.36, 3.37
Cylinder Removal/Inspection, 3.29 Engine Lower Reassembly, 3.45
Engine Lubrication, 3.17
Engine Removal, 3.15
D Engine Serial Number Location, 1.2
Decal Replacement, 5.12 Engine Service Data, 600 Engine, 3.10, 3.11
Decimal Equivalent Chart, 1.14 Engine Service Data, 700 Engine, 3.12, 3.13
Diagnostic Mode, 10.5, 10.6 Engine to Frame Ground, 2.16
Drive Belt Installation, 6.16 Engine Top End Disassembly, 3.19, 3.22, 3.26
Drive Belt Removal/Inspection, 6.14 ETC Operation Test, 10.13
Drive Clutch Assembly, 6.13, 6.14 ETC Switch Adjustment, 2.12
Drive Clutch Disassembly, 6.11, 6.12, 6.13 ETC Switch Testing, 10.13
Drive Clutch Exploded View, 6.2 Exhaust System, Maintenance, 2.26
Drive Clutch Inspection, 6.11
Drive Clutch Operation, 6.4
F
Drive Shaft Boot Replacement, 7.5
Driven Clutch Operation, 6.4, 6.5 Fan Control Circuit Testing, 10.12
Dual Hydraulic Caliper Bleeding, 9.4 Fan Control Switch Bypass Test, 10.12
Fan Control Switch Testing, 10.13
Fan Motor Current Draw Test, 10.12
E Flywheel Identification, 10.2
EBS Drive Clutch Bushing Service, 6.20 Frame, Nuts, Bolts, Fasteners, 2.29
EBS Drive Clutch Inspection, 6.17 Front Axle Exploded View, 7.2
Front Axle Installation, 7.4 High/Low Battery Voltage, 10.5
Front Axle Removal, 7.3 Honing to Oversize, 3.17
Front Hub Assembly, 7.6 Hour Meter, 10.5
Front Hub Disassembly, 7.6 Hub Installation, Rear, 7.18
Front Hub Inspection, 7.3 Hub Removal, Rear, 7.17
G J
Jetting Guidelines, 4.4
Gear Position Switch Test, 10.4
Gear Shift Selector Removal, 8.4
Gearcase Assembly, Rear , 7.26 K
Gearcase Assembly/Inspection, Front, 7.12 Keys, Replacement, 1.12
Gearcase Coil Resistance, Front, 7.10
Gearcase Diagnosis -- Centralized Hilliard, Front, L
7.14
Load Test, 10.20
Gearcase Disassembly, Front, 7.10
Low Oil Pressure, 10.5
Gearcase Disassembly, Rear , 7.25
Lubricants, 2.5
Gearcase Exploded View, Front, 7.16
Lubricants, Recommended, 2.4
Gearcase Exploded View, Rear , 7.28
Lubrication Charts, 2.7, 2.8
Gearcase Installation, Front, 7.15
Lubrication, Transmission, 2.10, 8.4
Gearcase Installation, Rear , 7.24
Gearcase Lubrication, Front/Rear, 2.9
Gearcase Operation (4X4), Front, 7.9
M
Machine Dimensions, 1.4, 1.5
Gearcase Removal, Front, 7.8
Mag Cover Seal Replacement, 3.51
Gearcase Removal, Rear , 7.24
Maintenance Chart, Periodic, 2.2, 2.3
Glossary of Terms, 1.17, 1.18
Master Cylinder Installation, 9.7
Master Cylinder Removal, 9.6
H Model & Serial Number Location, 1.2
Model Identification, 1.2
Headlamp Service, 10.21, 10.22
Headlamp Switch Testing, 10.22
Headlight Adjustment, 10.21 O
High Engine Coolant Temperature, 10.5 Oil Check , Engine, 2.21
Oil Filter Change, 2.21 Rocker Arm Inspection, 3.19
Oil Flow, 3.18
Oil Pressure Test, 3.17 S
Sediment Tube, Maintenance, 2.19
P Shift Linkage Adjustment, 2.11
PN 9918066
Printed in USA