2003 SPORTSMAN 600 2002 - 2003 SPORTSMAN 700

SERVICE MANUAL
PN 9918066

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
Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity Vac, Registered Trademark of Neward Enterprises, Inc. Ammco, Registered Trademark of Ammco Tools, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation

2003 SPORTSMAN 600/700 SERVICE MANUAL
Foreword
This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified. 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.

2002 Sportsman 600/700 ATV Service Manual (PN 9918066)
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 CHAPTER 2 CHAPTER 3 CHAPTER 4 CHAPTER 5 CHAPTER 6 CHAPTER 7 CHAPTER 8 CHAPTER 9 CHAPTER 10 GENERAL MAINTENANCE ENGINE FUEL SYSTEM BODY/SUSPENSION PVT SYSTEM FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL

GENERAL INFORMATION

CHAPTER 1 GENERAL INFORMATION
Model Identification . . . . . . . . . . . . . . . . . . . . . . . Serial Number Location . . . . . . . . . . . . . . . . . . . 2003 Sportsman Models . . . . . . . . . . . . . . . . . . Machine Dimensions . . . . . . . . . . . . . . . . . . . . . Specifications - 2002 Sportsman 700 . . . . . . . Specifications - 2003 Sportsman 600 . . . . . . . Specifications - 2003 Sportsman 700 . . . . . . . Publication Numbers . . . . . . . . . . . . . . . . . . . . . Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Keys . . . . . . . . . . . . . . . . . . . . . . . Standard Torque Specifications . . . . . . . . . . . . Decimal Equivalent Chart . . . . . . . . . . . . . . . . . Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . Tap Drill Charts . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . 1.2 1.2 1.3 1.4-1.5 1.6-1.7 1.8-1.9 1.10-1.11 1.12 1.12 1.12 1.13 1.14 1.15 1.16 1.17-1.18

1

1.1

A MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION The machine model number and serial number are important for vehicle identification. Electric Start EH059OLE11 . . . . . . . . The machine serial number is stamped on the lower left side of the frame tube. Twin cylinder. number is located on the right side of machine. .D. . Liquid Cooled. . . Twin cylinder. . . 1. ID Vehicle Description Vehicle Identifier 1 4 2 X 3 A 4 C 5 H 6 6 7 8 8 A 9 10 11 12 * 2 P 0 13 14 15 16 17 0 0 0 0 0 Individual Serial No.GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service.(B) Front B TRANSMISSION I. 4 Stroke. .2 . . . Powertrain ENGINE SERIAL NUMBER LOCATION Whenever corresponding about an engine. . . Electric Start VIN IDENTIFICATION World Mfg. . NUMBER LOCATION The transmission I. Liquid Cooled. be sure to refer to the engine model number and serial number.D. . An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow. . . . * This could be either a number or a letter Body Style Model Emissions Year Engine Check Digit Plant No. 4 Stroke. . . This information can be found on the sticker applied to the top side of the crankcase (A). Machine Model Number Identification A 03 CH 68 AA Year Designation Basic Chassis Designation Emissions & Model Option Engine Designation ENGINE DESIGNATION NUMBERS EH068OLE11 . . . .

GENERAL INFORMATION 2003 SPRORTSMAN 600 & 700 MODELS SPORTSMAN 600 SPORTSMAN 700 NOTE: MODELS WILL VARY IN COLOR. 1.3 .

GENERAL INFORMATION MACHINE DIMENSIONS FRONT 46 in 116.4 .90 cm SIDE 50.90 cm 1.75 in 128.84 cm 85 in 215.

84 cm 47 in 119.38 cm REAR 11 in 27.GENERAL INFORMATION MACHINE DIMENSIONS 46 in 116.84 cm 1.5 .94 cm 46 in 116.

. . . . . . Pilot Jet . . .56 20 -56 20. . . . . . . . . . . . . . . . . Jet Needle . . . Secondary Spring . . . Needle Jet . . . . Belt Width (Projected) . . . Clutch Offset . . . Operating RPM±200 . . . . . . . Fuel Octane (R+M/2) . . Driven Helix . . . . . . .5 167 5 160 162. Cooling . Belt . . . . . .5 14. . . . . . . . . . . . . Twin Cyl. . . Idle RPM±200 (lights off) . Pilot Air Jet . . Pilot Screw . . . . . . . . . 2002 SPORTSMAN MODEL NUMBER: . Spring Position (Helix) . .5 Turns Out 160 1.188I 10±. . . . . .78/1 Full Stroke Liquid Pressurized Wet Sump 6000 RPM 1100 RPM (Std) ±15% 1. . . . . . . . . . . . . . . . . .006I@ TDC on compression 9. .5I (12. . . Compression Pressure . . . . . Outside Circumference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Jet . . . . .7mm) White/Yellow Compound (EBS) N/A N/A Meters (Feet) 20. . . . . . . . Side Angle (Overall) . . . . . . .188I (30. . . . . . . . . . . . . . . . . . . . . . . . . .149I (80 mm) 2. . . . . . BST 34 Mikuni 162. . . . . . . . . . . . . . . . . . Bore . . . . . . . . . . Valve Seat . . . . Stroke .18mm) 28° ± 2° 40. . Lubrication Type . . . .677I (68 mm) 0. . . . . . . . . . . . . . . . . . . . . . . . PVT 3211091 1. . . . .12I (254. . . . . . . .006/0. . . . . . . . . . . . . . . .6 . . . . . Compression Ratio . . . . Displacement . . . . Float Height . . . EH68ALOE1 700 JETTING CHART AMBIENT TEMPERATURE CARBURETION Type . . .54 20 -54 Blue/Green (5631215) Blue/Green (5631214) White/Yellow White/Yellow EBS EBS ENGINE Type . . . . . . . . . . A02CH68AA/CA ENGINE MODEL: . . . . . . . .58I)±1mm 87 Non-Oxygenated or 89 Oxygenated Altitude ltitude Meters (Feet) 0-1800 (0-6000) Above 1800 Above (6000) Below 40°F 40 F Below +5°C +40 F +40_F and above +5_C and above 167. . . . . . . . . Valve Clearance In/Ex . .875 ±. . . . . . . Throttle Valve . . . Center Distance . .5 45 4BH41--4 P-6 #100 1. . . . . . 4 Cycle. Spring Position (Sheave) . . . . . . . . . . 683 cc 3.7mm (.GENERAL INFORMATION MODEL: . .5 162 5 155 CLUTCH CHART *EBS require no helix/spring adjustment Altitude Shift Weight 0-1800 (0-6000) 1800-3700 (6000-12000) Drive Clutch Spring Driven Clutch Spring Driven Helix CLUTCH Type . . . . . . . . . . . . . . . .5mm) 0. . .

. . .F/R . . . . . . Alternator Output . . . . . . Tow Capacity . Rear Shock . 3.11/1 Gear Reduction-High 3. .26 watts 26. Hyd. . . Wheel Base . . EH68ALOE1 700 FLUID Capacity Type ELECTRICAL Flywheel I. . . . . . . . . . . . . . . . Electric Start . 3. . . 4060152 4010364 300 Watts 25° BTDC@3000±500RPM RC7YC -. .90 cm) 740 lbs. . . . .9 watts LR39 Standard LCD Fuel Tank . .82/1 Final Drive Ratio . Brake . . Lights: Head . . 25 x 8 .09/1 Front Drive Ratio . . Ignition Timing . . . . . . .9L) . . . . . . . . .6 kg) 76I (181. . . 5.12 5/5 lbs 46I (116. . . .10/1 Brake (Hand) . Voltage Regulator . . . .. .38 cm) 50. 4. . 2002 SPORTSMAN MODEL NUMBER: . Turning Radius . . . .02 cm) Progressive Rate Independent 9.0. Front Vertical Travel Rear Suspension . . .036I (0.9 L) Coolant . (3 L) . . . . . . 5oz. . . . *PP6 Transmission . . . 80--90 GL5 Engine Oil . .1500 lbs. . . . . . . 13. .5I (24. . . . . . Shock Adjustment . Rear Travel . Tire Pressure . . . .13 cm) 2I Twin Tube Cam DRIVE TRAIN 4 Wheel Independent Shaft Drive Gear Reduction-Low . . . . . . . . . . . . 7. . . . . . . . .75 gals. . . . . .75I (128. . . . . . 150 lbs. Ground Clearance . . . . Total Length . . Total Height . . . Hitch Towing Capacity.2 qts. . . 5 oz. . . . . Gen IV MacPherson Strut 1225 lbs. . .84 cm) 85I (215. . . . . . . *PPS Gearcase Oil (Front). A02CH68AA/CA ENGINE MODEL: . . Grill (2) . . .5/1 Gear Reduction-Rev . . . . 3. . . . .60 kg) LOAD CAPACITY Front Rack (Std) . . Tire Size . .Rear . . . . Single Lever. . (335. 90 lbs. . . (555. . . .*PDD Gearcase Oil (Rear) . . . . Total Width . .94 cm) 6. . . . . . . . Tail . . .61 cm) 1/8I-1/4I (3-6. . . Dot 3 Lubricant Key *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oi *PP4 Polaris 0W--40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS Body Style . . .12 25 x 11 . . 2 qts. . (150 ml). . Dot 3 Brake (Foot) . . *PP4 Brake (Hand) . .7I (17. . .D. . . . . Rear Rack (Std) . . 180 lbs. . Disc Brake (Auxiliary Foot) Hydraulic Transmission Park Lock TIRES Tire Size . . . . Tongue Weight . . Weight . . ..Dry . . . 1. CDI Marking . .Front . .9mm) 50 Watt Quartz 27 Watts Quartz 8. .90 cm) 47I (119. . . . . . .. .GENERAL INFORMATION MODEL: . .50 oz.35 mm) 11I (27. Instrument Cluster . . . . Spark Plug / Gap .7 . Toe Out . .. (150 ml) . (1. Front Suspension . . . . . (17.

Jet Needle . . .GENERAL INFORMATION MODEL: .58I) 1mm 87 Non-Oxygenated or 89 Oxygenated Altitude Meters (Feet) 0-1800 (0-6000) Above 1800 Above (6000) AMBIENT TEMPERATURE Below 40 F Below +5 C +40 F +40_F and above +5_C and above 162. . . . . . . . . . . . . . . A03CH59 ENGINE MODEL: . .5 mm) 2. . . . . . 2003 SPORTSMAN MODEL NUMBER: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .875 . . Outside Circumference . . . . . Stroke . .35/1 Full Stroke Liquid Pressurized Wet Sump 6000 RPM 1100 RPM 150--170psi 15% 1. . . Operating RPM 200 .7mm) White/Yellow Compound (EBS) N/A N/A Altitude Meters (Feet) 0-1800 (0-6000) 1800-3700 (6000-12000) Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix 10 MH 10 WH Blue/Green (5631215) Blue/Green (5631214) White/Yellow White/Yellow EBS EBS ENGINE Type . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . .7mm (. . . . . . . . . . . Compression Ratio . . . . Valve Seat .188I 10 . . . . . . . . . Needle Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5I (12.559I (65 mm) 9.188I (30. . . . . . . . . Belt Width (Projected) . . . . . . . . . . . . . . . 4 Cycle. Compression Pressure . Clutch Offset .012I (76. . . . . . Pilot Air Jet . . . . . Driven Helix . . . . . . .12I (254. . PVT 3211091 1. . . BST 34 Mikuni 155 45 J8--4FA01--3 P-4 #100 1. . . . . . . . . . . . Fuel Octane (R+M/2) . . . . Belt . Side Angle (Overall) . . . . . . . .18mm) 28 2 40. . . . . . . . . .5 162 5 150 155 145 CLUTCH CHART *EBS require no helix/spring adjustment CLUTCH Type . . . . .5 14. . . . . Throttle Valve . . . Cooling . . . . . . . . . . . . . . . . . . . . . . . Twin Cyl. . Secondary Spring . . . Lubrication Type . . . . . . . . . . .8 . . . . . . . . . . 597 cc 3. . . . . EH059OLE 600 JETTING CHART CARBURETION Type . . . . . . . . . . . . . . . . . .5mm) 0. . . . . . . . . . Main Jet . . . . . . . . . . . . . . . Float Height . . Pilot Screw . . . . . Idle RPM 100 (lights off) . Spring Position (Sheave) .5 Turns Out 160 1. . . . . . . . Center Distance . . . . . . . Spring Position (Helix) . . . . . . . . Pilot Jet . . . . Bore . . . . . . . . . . .

9L) . Dot 3 Brake (Foot) . . . . . . . . .*PDD Gearcase Oil (Rear) . . . .02 cm) Progressive Rate Independent 9. . . . . . .90 cm) 740 lbs. . . . . . . . . 200 lbs. . . *PP4 Brake (Hand) . . . . .. .82:1 Final Drive Ratio . . Tail . .9 L) Coolant . *PPS Gearcase Oil (Front).35 mm) 11I (27. Tow Capacity . . . Front Vertical Travel Rear Suspension . . .F/R . . . . (68 kg) Hitch Towing Capacity. . (681) 1. Tire Pressure . . .61 cm) 1/8I-1/4I (3-6. . .10:1 Brake (Hand) ..84 cm) 85I (215. . . . . . . 2003 SPORTSMAN MODEL NUMBER: . . . . . (91 kg) Tongue Weight . Single Lever. . .13 cm) 2I Twin Tube Cam DRIVE TRAIN 4 Wheel Independent Shaft Drive Gear Reduction-Low . . . Total Height . .7I (17.Rear . . . . . Instrument Cluster . . 13. . . . (150 ml) . .1500 lbs. 5 oz.. . ..26 watts 26. . . A03CH59 ENGINE MODEL: . . . Voltage Regulator . .49:1 Gear Reduction-Rev . Front Suspension . . . . Dot 3 Lubricant Key *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Lube *PP4 Polaris 0W--40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS Body Style .50 oz. . . . Grill (2) .D.6 kg) 76I (181. *PP6 Transmission . .0.94 cm) 6.60 kg) LOAD CAPACITY Front Rack (Std) . . . . EH059OLE 600 FLUID Capacity Type ELECTRICAL Flywheel I. . Hyd. . . . (17. . 5. Electric Start . . . . .11:1 Gear Reduction-High 2. . 90 lbs. . . .9 . (555. Alternator Output . . . . . . . . . 4. . . . . . . . . . .Dry . . . . . . . Total Width . . . . Shock Adjustment . .75 gals. 80--90 GL5 Engine Oil . . . . . . . .9mm) 50 Watt Quartz 27 Watts Quartz 8. . . . . Lights: Head . . . . Brake . . . Ignition Timing . Wheel Base . . Ground Clearance . . .5I (24.. . .38 cm) 50. . .GENERAL INFORMATION MODEL: .12 5/5 lbs 46I (116. . . 150 lbs. . . . . Turning Radius . . (1. (335. . . 5oz. . . . . . . . . . . . . (3 L) . . . . . . . . Gen IV MacPherson Strut 1225 lbs. . 7. . . . 3.89:1 Front Drive Ratio . . . 3. (41 kg) Rear Rack (Std) . . . . . (150 ml). . Tire Size . . Rear Travel . . .12 25 x 11 . Disc Brake (Auxiliary Foot) Hydraulic Transmission Park Lock Tire Size . . Total Length .75I (128. . . . . . Spark Plug / Gap .035I (0. . . . Rear Shock . Weight . Toe Out . . . . . . .Front . . . TIRES 25 x 8 . 4060152 4010785 300Watts 25 BTDC@3000RPM 500 RC7YC -. . .90 cm) 47I (119. CDI Marking . 3. . .2 qts. . 2 qts. .9 watts LR39 Standard LCD Fuel Tank . . . . . . . . .

Clutch Offset . . . Pilot Jet . . . . . . . . . Pilot Screw . . . . . .7mm (. . Compression Pressure . Belt Width (Projected) . Main Jet . . . . . . . . .54 20 -54 Blue/Green (5631215) Blue/Green (5631214) White/Yellow White/Yellow EBS EBS ENGINE Type . .677I (68 mm) 9. . . . . . . . . . . . . . . . . . . . . . . . . . Jet Needle . . . . . . . . . . Side Angle (Overall) . . .58I) 1mm 87 Non-Oxygenated or 89 Oxygenated Altitude Meters (Feet) 0-1800 (0-6000) Above 1800 Above (6000) AMBIENT TEMPERATURE Below 40 F Below +5 C +40 F +40_F and above +5_C and above 160 147. . . . . . . Bore . Compression Ratio . Spring Position (Helix) .10 . . Cooling .5 14. Throttle Valve . . Spring Position (Sheave) . . Driven Helix .188I (30. 2003 SPORTSMAN MODEL NUMBER: . Needle Jet . . . . . . . . . Secondary Spring . . . . . . . . . . . . . . . . . . . . . . . . .GENERAL INFORMATION MODEL: . . . . . . . . . . . . . . . . . .56 20 -56 20. . . . . Twin Cyl. . . . . . . . . . Idle RPM 100 (lights off) . . . . . . . . BST 34 Mikuni 155 47. . . . . . . . . . . . . . . . . . Outside Circumference . . . . . . . . . . Valve Seat . . . . . . . . . . . .149I (80 mm) 2. . . . . . . . . . . . . Lubrication Type . . . . . . . . . . . . . . . . . . . . . . . .188I 10 . . . Stroke . . . .5 142 5 CLUTCH CHART *EBS require no helix/spring adjustment CLUTCH Type . .5 147 5 155 142. . .5 Turns Out 160 1. . .875 . 683 cc 3. . . . . . . Pilot Air Jet . . . Float Height . Fuel Octane (R+M/2) . . . . Displacement . . . . . . Operating RPM 200 . . . . . . . 4 Cycle. . . . . . . . . . . . . . . . . A03CH68 ENGINE MODEL: . .78/1 Full Stroke Liquid Pressurized Wet Sump 6000 RPM 1100 RPM 150--170psi 15% 1. . .5I (12. .18mm) 28 2 40. . . . . . . . . . . . . Center Distance . .5mm) 0. .7mm) White/Yellow Compound (EBS) N/A N/A Altitude Meters (Feet) 0-1800 (0-6000) 1800-3700 (6000-12000) Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12I (254. . . EH068OLE 700 JETTING CHART CARBURETION Type . . . . . PVT 3211091 1. .5 J8--4FA01--3 P-6M (829) #100 1. . Belt . . . . . . . . . . . . . .

. . . Turning Radius . . . . . . . Spark Plug / Gap . . Grill (2) . Tire Pressure . . . . Lights: Head .. . . . . . Total Height . . . Single Lever. . TIRES 25 x 8 . .75 gals. .11 . Gen IV MacPherson Strut 1225 lbs. .84 cm) 85I (215. . 3. . Tow Capacity . . . . Hitch Towing Capacity. . . Rear Travel . . . . .GENERAL INFORMATION MODEL: . . . . . . . Total Width . . 2 qts. .*PDD Gearcase Oil (Rear) . . . . . . . . Front Vertical Travel Rear Suspension . . *PP4 Brake (Hand) .Dry . . 80--90 GL5 Engine Oil . . . . . 5oz. 13. . 90 lbs.9 L) Coolant .61 cm) 1/8I-1/4I (3-6. . . . Front Suspension . .90 cm) 740 lbs. . . Rear Rack (Std) . . . . . . 4060152 4010364 300 Watts 32 BTDC@5760RPM 200 RC7YC -. 3. . Disc Brake (Auxiliary Foot) Hydraulic Transmission Park Lock Tire Size . .12 25 x 11 . . .Front . . *PP6 Transmission . Weight .89:1 Front Drive Ratio . . 4. . . . . .02 cm) Progressive Rate Independent 9. . . .2 qts. .60 kg) LOAD CAPACITY Front Rack (Std) . . . . 1.Rear . .D. . . . Ignition Timing . . Electric Start . Wheel Base . . . . (335. EH068OLE 700 FLUID Capacity Type ELECTRICAL Flywheel I. .50 oz. . . (150 ml) . . . . . . . . . . . . . . . 2003 SPORTSMAN MODEL NUMBER: . . . 7. .94 cm) 6. (555. Hyd. . CDI Marking . .. . .49:1 Gear Reduction-Rev . . . . . . . Shock Adjustment . . . .9 cm) 47I (119. .. . Dot 3 Brake (Foot) . .12 5/5 lbs 46I (116.0. . Ground Clearance . . .1:1 Gear Reduction-High 2.82:1 Final Drive Ratio . . .036I (0. . . 5 oz.F/R . .35 mm) 11I (27. Rear Shock . . . .9mm) 50 Watt Quartz 27 Watts Quartz 8. . . Dot 3 Lubricant Key *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Lube *PP4 Polaris 0W--40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS Body Style . . . Tail . . Tire Size . . . . . .75I (128.1500 lbs. .9L) . Brake . . . . . . . Instrument Cluster . (17. . . . . 3. . . . (1. . . . 150 lbs. . . . . . .. . . . Total Length . . . . Toe Out . .7I (17. Alternator Output . . 5. .9 watts LR39 Standard LCD Fuel Tank . . . . . . .26 watts 26. . .5I (24. . .10:1 Brake (Hand) . . .38 cm) 50. . Voltage Regulator . . .13 cm) 2I Twin Tube Cam DRIVE TRAIN 4 Wheel Independent Shaft Drive Gear Reduction-Low . .. . *PPS Gearcase Oil (Front). . . . . . . (3 L) . . . . 180 lbs. .6 kg) 76I (181. . . . A03CH68 ENGINE MODEL: . . . . . . . . Tongue Weight . (150 ml). . . . .

take the first two digits on the original key and refer to the chart to the right for the proper part number. Owner’s Manual PN 9918213 Parts Manual PN 9917718 Parts Micro Fiche PN 9917719 2003 Sportsman 600/700 A03CH59 / A03CH68 When ordering service parts be sure to use the correct parts manual. PAINT CODES PAINTED PART Springs COLOR DESCRIPTION Black DITZLER NUMBER 9440 POLARIS NUMBER P-067 FRAME COLOR . Mix as directed. Series # 20 21 31XX Key Series Number 22 23 27 28 31 32 67 68 Part Number 4010278 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 4010278 1.(All) P067 Medium Gloss Black 9440 / 8520147.12 . To identify which series the key is. REPLACEMENT KEYS Replacement keys can be made from the original key. ignition switch replacement is required.GENERAL INFORMATION PUBLICATION NUMBERS Year Model Model No. Should both keys become lost. Order direct from Midwest Industrial Coatings (952-942-1840).

12 (16) 14 (19) 25 (35) 29 (40) 45 (62) 50 (69) 70 (97) 80 (110) 110 (152) 120 (166) Metric 6 x 1. . . 14 . . . .0 8 x 1. . . . . . . . . lbs. . . . . .9) 49 (5. . . . . . 14-18 ft. . . . . . . . . . . . . . . 1. . . . . 55 (76) . . 12 (16) . . . . . . . . . . . . . . . . . . .1) . . . . . lbs. . . . .13 . . . . . . . . . . . . . . . 68 (7. . . . . . . . Bolt Size #10 #10 1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 - Threads/In 24 . . . 19 (26) . . . . . . . . multiply Nm by . . . 30 (40) . . . . . . . . . . . . . . . . 72-78 In. . . . . . . . . . . . . There are exceptions in the steering. . . 50 (69) . . . . . . . . . . (Nm) 27 (3. . 30 (40) . . . . . . . 23 (32) . . . . 75 (104) . .0) . . . . . . . Grade 2 Torque in. . 16 . . . . . . . . . . 20 . . . . 20 (27) . . . . . . . . . . . . . . . . 31 (3. . . . . 10 (14) . . . . . . . . . . . . . . .25 *To convert ft. . . . . . . . . . . . . . . . . . . lbs. . . . . . . . . . Grade 5 Grade 8 43 (5. . . . . . . . . . . . . . . . . . . . . . . . . . . .25 10 x 1. 55 (76) . . . . . SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section. . . . . . . . 35 (48) . 20 . lbs. . . . 35 (48) . . . . . . . .6) . . . . . . . lbs. . . . . . . 24 . . . . . . . lbs. . . . . . . . . . . . . . .6) . . . . . to Nm multiply foot pounds by . . suspension. . . . . . . and engine areas. . . . . . . 28 . . . . . . . . . . . . . . . . . . . . . . . .8) 8 (11) . . . .1. . . 6 (8) . . . . . . . 90 (124) . . . . . . . . . . . . . . . . . . . . 60 (6. (Nm)* 5 (7) . . . . . 11 (15) . Torque ft. . . . . 26-30 ft.7376. . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . .GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline. . . . . . . . . 32 . . . . . . . . . . . Always consult the exploded views in each manual section for torque values of fasteners before using standard torque. 13 . . . . . . . . . . . . . . . . . . 50 (69) .382 *To convert Nm to ft. . . 17 (23) . . . . . . . . . 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . lbs. . . . . . . . . . .

. . . . . . . . . . . . .. . . . . . . . . .3150² 9 mm = . . . . . . . . . . . . . . . . . .0625 . . . . . .4331² 12 mm = . . . . . . . . . . . . . . . . . . . .4844 . . . . . . . . . . . . . . . . . . .1181² 4 mm = . . . . . . . . . 5/32 . . . . . . . . . . . . .3125 . . . . . . .5156 . . . . . . . . . . . . . . . . . . . . . . . . . . .3594 . . . . . . . . . . . . . . . . . . . . . 17/64 . . . . . . . . . . . . . . . . .5313 . 15/32 . . . . . . .4688 . . . . . . . . . . . . . . . . . . . . .8661² 23 mm = . . . . . . . . . . . . . . . . . . . . . . .6875 . . . .3937² 11 mm = .4063 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9/64 . . . . . . . . . . . .2656 . . . . . . . . . . . . . . . . . 13/64 . . . . . . . . . . . . . . . 3/64 . . . . . . . . . . . . . .4531 . . . . . 27/64 . . . . 15/16 . . . 47/64 . 43/64 . . . . . 55/64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/64 . .0394² 2 mm = . . . . . . . 39/64 . . . . . . . 9/32 . . . 63/64 . . . . . 23/64 . . . . . . . . . . . . . . .. . . . . . .0787² 3 mm = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0469 . . . . . 1/4 . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . .0938 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6299² 17 mm = . . .1406 . . . . . . . . . . . . 11/16 . . . .. . . . . . . . . . . . . 53/64 . . . .875 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5512² 15 mm = . . . . . . .7188 . . . . . .. . . . . . . 7/8 . . . . . .6406 . . 11/64 . . 15/64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29/64 . . . . . . . . . .7813 . . . . . . . . . . . . . . . .6563 . . . . . .2344 . . . . . . . .0312 . . . . . . . . . . . . . . . . . . . .5781 .3438 . . . .625 . . . . . . . . . . .25 . 9/16 . . . . .6693² 18 mm = . . . . . . . . . . . . . . . . . . . 11/32 . . . . . . . . . . . . . . . . . . 5/64 . . . . . . . . . . . . . . .9449² 25 mm = . . .7874² 21 mm = . . 61/64 . . .1575² 5 mm = . . . .5938 . . . . . . . . . . . . . . . . . . . . 1/2 . . 5/16 . . 41/64 . . . . . . . . . . . . . .8906 . . . . . . . . .9375 . . . . . . . . . . 3/8 . . . . . . . . . . . . . . . . . . 3/32 . . . . . . . .. . 29/32 . . . . .9843 1. . 21/32 . .9844 1. . . 33/64 . . . . . . 19/32 . . . . . . .1875 . . 25/64 . . . 37/64 . . . .375 . . .0156 . . . . . . . . . . . . . . . . . . . . . . . 13/32 . . . . . . . . . . . .2188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9531 . . . . . . . . . 45/64 . . .GENERAL INFORMATION DECIMAL EQUIVALENTS 1/64 . . . . . . .9063 . . . .4219 . . . . . . . . . . . .6719 . . . . . . . . . . . . . . . . . . .9219 .3543² 10 mm = . . . . . . . . . . . . . . . 27/32 . . . . . . . 23/32 . . .9055² 24 mm = . . . . .8281 .8438 . 17/32 . . . . . . . .3281 . . . . . . . . . . . . . . .0781 . . . . . 21/64 . . . . . . . . . . . . . .5 .4375 . . . . . . . . . . . . . . . . . 13/16 .1094 . . . 1/8 . . . 35/64 . . . . . . . . . . . 5/8 . . . . . . . . . 31/32 . . . . . . . . . . 59/64 . . . . . .5469 . . . . . . .8268² 22 mm = . 49/64 . . . . . . . . . . . . . . . . . . . . . . 25/32 . . . . 7/32 . . . . . . . . . . . . . . . . .. .7969 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7656 . . . . . . . . . . . . . . . . . . . . . . . . .14 . . . . . . . . . . . .75 . . . . . . . . . . .2362² 7 mm = . . .8594 . . . . . . . . . .2969 . . . . . . . . . . . . . . . . .6094 . . . . . . .. . . . .1969² 6 mm = . . . . . . . . . . . . . . . . . . . .4724² 13 mm = . . . . . 3/4 .2813 . .7087² 19 mm = . . . . . . . .. . . . . . . . . . . . . . . . . . . . 1250 . . . . . . . .. . 57/64 . . . . . . .2756² 8 mm = . . . . .9688 . . .8125 . . . . . . . . . . . . . . . . . . .1719 . . . . . . . . . . . 7/16 . . . . . . . . . . . . . . . . . . . . . . . . . .1563 . . . . . . .5906² 16 mm = . . . . . . . . .7480² 20 mm = . . . . . . . . . . . . . . . . . . . ..3906 . . . . . .7344 . . . . . . . . 31/64 . . . . . . . 3/16 . . . . . . . . . . . . . .5625 . . . . . . . . . . .7031 . . . . . 51/64 .2031 . . . . . . . . . . . . . . . . . . . 19/64 . . . . . . . . . . . . .0 1 mm = . .. . . . . . . . . . . . . . . . . . .5118 14 mm = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/16 . . . . .

= Nm = kg-m = ft.) Cubic Centimeters (cc) Grams (g) lb.force per square inch (psi) Kilopascals (kPa) Kilopascals (kPa) Kilograms .895 x 0. = ft.785 x 0.GENERAL INFORMATION CONVERSION TABLE Unit of Measure ft. lbs.03937 x 2.force per square cm = Kilopascals (kPa) = Cylinder Volume Converts to °C to °F: 9 (°C + 40) ¸ 5 .01 x 98.264 x 6.387 x 0.6214 x 28.201 x 0. = in. Nm kg-m kg-m kg-m in.35 x 29. kg Cubic inches (cu in) Cubic centimeters (cc) Imperial pints (Imp pt) Liters (l) Imperial quarts (Imp qt) Liters (l) Imperial quarts (Imp qt) US quarts (US qt) US quarts (US qt) Liters (l) US gallons (US gal) Liters (l) Pounds .233 x 86.796 x 10 x 25.0115 x .) km Ounces (oz) Fluid Ounces (fl. lbs. lbs.145 x 0. lbs.88 x 1.454 x 2.57 x .137 x 0.7376 x 7. in. oz.2046 x 16. mile (mi.833 x 0. = Cubic centimeters (cc) = Cubic inches (cu in) = Liters (l) = Imperial pints (Imp pt) = Liters (l) = Imperial quarts (Imp qt) = US quarts (US qt) = Imperial quarts (Imp qt) = Liters (l) = US quarts (US qt) =Liters (l) = US gallons (US gal) = Kilopascals (kPa) = Pounds .356 x .force per square inch (psi) = Kilograms .6 x .40 = °C 1.061 x 0.03381 x 0.) = Grams (g) = Cubic Centimeters (cc) = Fluid Ounces (fl.4 x .035 x . = Nm =mm = in.14) x R2 x H (height) x 12 x .1 Multiplied by = in. lbs. oz.40 = °F °F to °C: 5 (°F + 40) ¸ 9 . in. lbs. ft. = cm = km = mile (mi.) = Ounces (oz) = kg = lb.force per square cm p (3.057 x 3.lbs.76 x 1.54 x 1. lbs. lbs. mm in.946 x 1.568 x 1. = ft.0833 x 1.15 .

00 9 x 1.196 0.00 7 x 1.90 6 x 1.3125 0.00 8 x 1.1285 0.50 12 x 1.25 10 x 1.166 0.3125 0.6mm 7 3 F I O Q U 25/64 Thread Size 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 7/8-9 7/8-14 1-8 1-12 1 1/8-7 1 1/8-12 1 1/4-7 1 1/4-12 1 1/2-6 1 1/2-12 1 3/4-5 1 3/4-12 2-4 1/2 2-12 2 1/4-4 1/2 2 1/2-4 2 3/4-4 3-4 Drill Size 27/64 29/64 31/64 33/64 17/32 37/64 21/32 11/16 49/64 13/16 7/8 59/64 63/64 1 3/64 1 7/64 1 11/64 1 11/32 1 27/64 1 9/16 1 43/64 1 25/32 1 59/64 2 1/32 2 1/4 2 1/2 2 3/4 METRIC TAP DRILL SIZES Tap Size 3 x .406 Nearest Fraction 3/32 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32 1.265 0.16 .339 0.0995 0.3437 0.75 #39 3/32 #30 1/8 #19 #20 #9 16/64 J 17/64 5/16 5/16 11/32 R 3/8 13/32 13/32 Drill Size Decimal Equivalent 0.60 4 x .125 0.50 11 x 1.00 8 x 1.75 5 x .406 0.277 0.70 4 x .25 9 x 1.161 0.50 3 x .80 5 x .50 12 x 1.375 0.0937 0.25 10 x 1.GENERAL INFORMATION SAE TAP DRILL SIZES Thread Size #0-80 #1-64 #1-72 #2-56 #2-64 #3-48 #3-56 #4-40 #4-48 #5-40 #5-44 #6-32 #6-40 #8-32 #8-36 #10-24 #10-32 #12-24 #12-28 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 Drill Size 3/64 53 53 51 50 5/64 45 43 42 38 37 36 33 29 29 24 21 17 4.234 0.

BTDC: Before top dead center. 35 = 3/8² or 1 cm). CI: Cubic inches. A force of one pound at the end of a lever one foot in length. in. 2 2 1. l or ltr: Liter. Condenser/Capacitor: A storage reservoir for DC voltage. = 1 ft. gal. g: Gram. Foot Pound: Ft. Good for showing taper and out-of-round in the cylinder bore. ft. kg/cm : Kilograms per square centimeter. Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. applied in a rotational direction. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. ACV: Alternating current voltage. lbs/in : Pounds per square inch. DCV: Direct current voltage. applied in a rotational direction. Polaris measures chain length in number of pitches. 12 in. Unit of weight in the metric system. An electrical circuit which is completed before the current reaches the intended load. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. Alternator: Electrical generator producing alternating current voltage.: Foot/feet.e. CC: Cubic centimeters. profile and engine RPM cause the drive clutch to close. lbs. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Electrical Short: Short circuit. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch faces. Measure at various points especially at PTO end. Clutch Weights: Three levers in the drive clutch which relative to their weight. End Seals: Rubber seals at each end of the crankshaft. An electrical circuit which isn’t complete. Inch Pound: In. a bare wire touching the chassis). Chain Pitch: Distance between chain link pins (No.GENERAL INFORMATION GLOSSARY OF TERMS ABDC: After bottom dead center. lb. ID: Inside diameter.: Inch/inches. Electrical Open: Open circuit. BDC: Bottom dead center. lb.: Gallon. BBDC: Before bottom dead center.17 . Kilogram/meter: A force of one kilogram at the end of a lever one meter in length. kg-m: Kilogram meters. (i. HP: Horsepower. Clutch Buttons: Plastic bushings which transmit rotation of the clutch to the movable sheave in the drive and driven clutch. Left Side: Always referred to based on normal operating position of the driver. ATDC: After top dead center. lb.

18 . 1. Watt: Unit of electrical power. psi. Piston Clearance: Total distance between piston and cylinder wall. Regulator: Voltage regulator. TDC: Top dead center. oz. Regulates battery charging system output at approx. 4) stuck piston rings. mi. RPM: Revolutions per minute. a voltage will be generated in the windings. 14.: Pounds per square inch. Secondary Clutch: Driven clutch on chaincase or jackshaft. Nm: Newton meters. Mechanical energy is converted to electrical energy in the stator. Unit of length in the metric system. Reservoir Tank: The fill tank in the liquid cooling system. 3) insufficient piston clearance. Measured by a voltmeter in parallel with the circuit. OD: Outside diameter. Mag: Magneto. WOT: Wide open throttle. Stator Plate: The plate mounted under the flywheel supporting the battery and ignition charging coils. Seized Piston: Galling of the sides of a piston.: Quart/quarts. 2) excessive temperatures.GENERAL INFORMATION GLOSSARY OF TERMS m: Meter/meters. Magnetic Induction: As a conductor (coil) is moved through a magnetic field. Watts = amperes x volts. PVT: Polaris Variable Transmission (Drive Clutch System) qt. mm: Millimeter.: Mile/miles. Piston’s most outward travel from crankshaft. Both result in energy conversion to heat. Ohm: The unit of electrical resistance opposing current flow. Volt: The unit of measure for electrical pressure of electromotive force. PTO: Power take off. ohms.5 DCV as engine RPM increases. Resistance: In the mechanical sense. Possible causes: 1) improper lubrication. Right Side: Always referred to based on normal operating position of the driver.: Ounce/ounces. In the electrical sense. friction or load. 1mm = approximately . Usually there is a transfer of aluminum from the piston onto the cylinder wall.040².

. . . . . . . . Lubrication Charts . . . . Wheel Removal/Installation . . . . . . . . . .14 2. . . . 2. Battery Maintenance . Transmission Lubrication . . . . . .28 2. . . . . . . . . . . . . . . . . . . . .12-2. . . . . . . . . . . . . . .19 2. . . . . . . . . . . . . . . . . . Lubricant and Maintenance Product Numbers Special Tools . . Air Box Sediment Tube Service . . . . . . . . . . . . . . . . . Steering and Toe Alignment .13-2. . . . . .19 2. . .10 2. . . . .8 2. . . . . Front & Rear Gearcase Lubrication .20 2. . . . . . . . . . . . . . .29 2 2. . . . . Suspension Service . .4 2.3 2. . . . . . . .16 2. . . . . . . . . .17-2. . . . . Recommended Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAINTENANCE CHAPTER 2 MAINTENANCE Periodic Maintenance Chart . .26 2. . . . . . .6 2. .5 2. . . . . .1 . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . Oil Change/Filter . . . . PVT Drying & PVT Drain Plug . .9 2. .13 2. . . . . . . . Brake System Service . . . .28 2. . . . . . . . . . . . . . . . . . . . . . . .2-2. . . . . . . . Pre-Ride Inspection . . . . . . . . . .14--2. . . . . . . . . . . . . . Controls .3 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Inspection . . .15 2. . . . . . . . Breather Filter . . . . . .26-2.16 2. . . . . . . . . . . . . . . . . . Transmission Linkage Inspection . . . . . . . . . . . .29 2. . . . . . . . . Coolant System Maintenance . . . .7-2. . .22 2. . . . . . .22-2. . .15--2. . . . . . . . . . . . . . . . . . Air Filter Service . . . . . . . . Carburetor Adjustments . . . . . . . . . . . . . . Compression Test . . . . . . . . . . . . .20 2. . .21-2.25 2. . . . . . . . . . . .11 2. . . . . . . . . . .27 2. . . Exhaust System Maintenance . . . . . . . . . . Fuel System . . . . . . . . . Radiator Screen Removal . .18 2. . . . . . .18 2. .

Change oil immediately if oil level begins to rise. Check fluid level Adjust if Necessary Check operation daily. lines. A rise in oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Always use genuine Polaris parts. Apply Nyogelt Grease to socket when lamp is replaced 2. Pressure test system annually Inspect / Clean external surface Inspect Inspect Inspect E" E E" E" " " Engine Oil . Inspect. The following symbols denote potential items to be aware of during maintenance: H= CAUTION: Due to the nature of these adjustments. Lubricate. clean. Replace filter annually Replace engine coolant every 2 years 1000 (1600) 1000 (1600) 1000 (1600) 1000 (1600) 1000 (1600) Inspect strength seasonally. Replace lines every 2 years. Item PERIODIC MAINTENANCE . prolonged idle) should be inspected and serviced more frequently.service at 1 month -In Replace with oil change Inspect-Clean & oil more often in dirty conditions Inspect . filter. Break. routing. Pay special attention to oil level.Level/Change Oil Filter Air Filter . security Inspect Check terminals. E= Emission Control System Service (California). Apply Nyogelt Grease to connector when lamp is replaced Check Operation Daily.2 . it is recommended this service be performed by an authorized Polaris dealer. Clean.MAINTENANCE PERIODIC MAINTENANCE CHART Inspection. Lubricate. Replace if necessary Inspect -Adjust. For engine oil. low speed heavy load operation.Main Element Air Box Sediment Tube Engine Breather Filter Idle Speed Throttle Cable / ETC Switch Choke (Enricher) Cable Carburetor Float Bowl Carburetor Air Intake Ducts/Flange 100 hrs 100 hrs Daily Weekly 20 hrs As required 50 hrs 50 hrs 50 hrs 50 hrs 100 hrs 100 hrs Daily 100 hrs 100 hrs 100 hrs 100 hrs 100 hrs E H EH EH Fuel System Fuel Filter Coolant/Level Inspection Coolant Strength / Pressure Test System Radiator Cooling System Hoses Engine Mounts Exhaust Muffler / Pipe ELECTRICAL E Spark Plug Wiring Ignition Timing Battery Headlight Aim Headlamp Inspection Tail Lamp Inspection 100 hrs 100 hrs 100 hrs 20 hrs As required Daily Daily 12 months 12 months 12 months Monthly As required Daily Daily 1000 (1600) 1000 (1600) 1000 (1600) 200 (320) Inspect . "= Vehicles subjected to severe use (operation in wet or dusty areas. pump & carburetor. short trip cold weather riding also constitutes severe use. fuel valve. adjust or replace parts as necessary.ENGINE Maintenance Interval (Whichever comes first) Remarks Hours Calendar 6 months 6 months Daily Weekly Daily Monthly As required 6 months 6 months 6 months 6 months 12 months 12 months Daily 6 months 12 months 12 months 12 months 12 months Miles (Km) 1000 (1600) 1000 (1600) 200 (320) 500 (800) 500 (800) 500 (800) 500 (800) 1000 (1600) 1000 (1600) Check Level Daily.Replace if necessary Drain deposits whenever visible Inspect and replace if necessary Adjust as required Inspect -Adjust. lubricate.Replace if necessary Inspect for abrasion. Replace if necessary Drain bowl periodically and prior to storage Inspect all ducts for proper sealing/air leaks Check for leaks at tank cap.Screen Pre-Cleaner Air Filter . adjustment and lubrication intervals of important components is listed in the following chart. NOTE: Inspection may reveal the need for replacement parts. Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 mph.

check to be sure axle nuts are secured by cotter pins G Air cleaner element . Replace if Necessary Inspect. CHASSIS Item Maintenance Interval (Whichever comes first) Remarks Hours " " General Lubrication Front Gearcase Lubricant Drive Belt Clutches (Drive And Driven) Check/Drain PVT Housing " Transmission Oil Level Shift Linkage H H " " Steering Toe Adjustment Front Suspension Rear Suspension Tires H " " H Brake Fluid Brake Fluid Level Brake Lever Travel Brake Pad Wear Auxiliary Brake Adjustment Brake System Wheels Frame Nuts. Bolts.check condition and pressures G Fuel and oil tanks .check for free operation noting any unusual looseness in any area G Loose parts .visually inspect vehicle for any damaged or loose nuts.check operation and adjustment (includes auxiliary brake) G Throttle . Cables. Adjust Pre-Ride Inspection Item Pre-Ride Inspection Item Pre-Ride Inspection Item PRE-RIDE / DAILY INSPECTION Perform the following pre-ride inspection daily. CONT.MAINTENANCE PERIODIC MAINTENANCE CHART. clean or replace G Steering .3 . G Tires . Adjust When Parts are Replaced Inspect .check for loose wheel nuts and axle nuts. Pre-Ride Inspection Item Inspect Daily. Fasteners 50 hrs 100 hrs 50 hrs 100 hrs Weekly 25 hrs 50 hrs 50 hrs As required 50 hrs 50 hrs Pre-ride 200 hrs Pre-ride Pre-ride 10 hrs As required Pre-ride Pre-ride Pre-ride Calendar 3 months 12 months 6 months 12 months Weekly Monthly 6 months 6 months As required 6 months 6 months Pre-ride 24 months Pre-ride Pre-ride Monthly As required Pre-ride Pre-ride Pre-ride Miles (Km) 500 (800) 1000 (1600) 500 (800) 1000 (1600) Lubricate All Fittings.fill both tanks to their proper level. Lubricate Periodic Inspection.check operation of all indicator lights and switches G Engine stop switch . bolts or fasteners G Engine coolant . Pivots. Do not overfill oil tank G All brakes .check for proper function G Wheels .Lubricate Inspect . Etc. Pre-Ride Inspection Item Inspect Periodically Inspect Deflection Daily.check for free operation G Headlight/Taillight/Brakelight .Lubricate Inspect Daily. Clean More often if operating in wet environment 250 (400) 500 (800) 500 (800) 500 (800) 500 (800) 2000 (3200) 100 (160) Inspect Monthly. Change Annually Inspect .Adjust.check for dirt. Pre-Ride Inspection Item Change Every Two Years Inspect Daily. Inspect Monthly.check for proper level at the recovery bottle 2. Lubricate. and when servicing the vehicle at each scheduled maintenance. Adjust Inspect Daily. Change Annually Inspect.

Refer to procedures outlined in this chapter.9 2. fill reservoir tank to full line if necessary.26 NOTE: Quick Reference Lubricants and maintenance product part numbers are listed on page 2. Fill to top of filler neck. Allow engine and cooling system to cool completely and check level in radiator.21 2. If reservoir was empty or extremely low.18 Brake Fluid 2. Fill to indicated level inside reservoir.5 2. Refer to procedures outlined in this chapter.4 . See Pages 2.10 2.MAINTENANCE RECOMMENDED LUBRICANTS Item Engine Oil Transmission Front Gear Case Coolant Level Type Polaris Premium 4 Synthetic 0W--40 Polaris Synthetic Gear Case Lubricant Polaris Premium Demand Drive Hub Fluid Polaris Premium 60/40 Pre-mixed Antifreeze/ Coolant or a 50/50 mixture high quality antifreeze/ coolant and distilled water Polaris DOT 3 Brake Fluid Notes Add to proper level on dipstick.

5 .) (12 Count) Premium Drive Hub Fluid (2.) (12 Count) NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order. Aerosol) 2870584 2870587 2872113 2871326 2870652 2871957 2871958 2870990 2872113 2871557 2872893 Premium 2 Cycle Engine Oil (Quart) (12 Count) 2871281 Engine Oil (Quart) Premium 4 Synthetic 0W--40 (4--Cycle) (12 Count) 2871844 Engine Oil (Gallon) Premium 4 Synthetic 0W--40 (4--Cycle) (4 Count) 2871567 Engine Oil (16 Gallon) Premium 4 Synthetic 0W--40 (4--Cycle) Gearcase / Transmission Lubricants 2873603 2873602 2871653 2871653 2870465 2871654 2872277 2871653 2871322 2871423 2871460 2871515 2871551 2871312 2871329 2871323 2871534 Premium Synthetic Gearcase Lubricant (1 Gal. 2870791 2871098 Description Engine Lubricant Fogging Oil (12 oz.) (12 Count) Loctitet Threadlock 271 (6 ml.) (10 Count) Loctitet Threadlock 262 (6 ml. (9 oz.) Grease / Specialized Lubricants Premium All Season Grease (3 oz. 25 g Loctitet Thread Sealant 565 (50 ml.) Engine Degreaser (12oz.) (10 Count) Loctitet Threadlock 242 (6 ml. NOTE: Each item can be purchased separately at your local Polaris dealer.) Loctitet 518 Gasket Eliminator / Flange Sealant (50 ml.) (12 Count) Fuel Stabilizer (16 oz.) (12 Count) Black RTV Silicone Sealer (3 oz. Aerosol.) (6 Count) Loctitet Threadlock 242 (50 ml. cartridge) (10 Count) Starter Drive Grease (12 Count) Premium U-Joint Lube (3 oz. cartridge) (12 Count) DOT3 Brake Fluid (12 Count) Disc Brake Quiet. Additives / Sealants / Thread Locking Agents / Misc. tube) (12 Count) Black RTV Silicone Sealer (11 oz. 3-Bond 1215 (5oz. bottle) (12 Count) Premium Front Gearcase Fluid (8 oz.) (10 Count) Disk Brake Quiet (12 oz.) (12 Count) Loctitet Threadlock 262 (50 ml.) (12 Count) 2.) (12 Count) Crankcase Sealant.) (6 Count) Loctitet 680-Retaining Compound (10 ml.MAINTENANCE AND SERVICE PRODUCTS Part No.5 gal.) (12 Count) Premium Carbon Clean (12 oz.) (12 Count) Premium Gear Drive Fluid (2. 2870585 2871956 2871949 2871950 2871951 2871952 2871953 Loctitet Primer N. cartridge) (24 Count) Premium All Season Grease (14 oz. Aerosol.) (4 Count) Premium Synthetic Gearcase Lubricant (12 oz.5 Gal) (2 Count) Oil Pump for 1 Gallon Jug Premium Drive Hub Fluid (8 oz.) (10 Count) Grease Gun Kit Dielectric Grease (Nyogelt) Coolant 60/40 Coolant (Gallon) (6 Count) 60/40 Coolant (Quart) (12 Count) 2871954 Loctitet Threadlock 271 (36 ml.MAINTENANCE POLARIS LUBRICANTS.) (24 Count) Premium U-Joint Lube (14 oz.) (2 Count) Angle Drive Fluid (8 oz.

6 .3 2. 4. 9 4 5 5 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 6 6 7 7 10 10 10 *Special Tools Can be ordered through SPX Corporation (1--800--328--6657).MAINTENANCE SPECIAL TOOLS PART NUMBER PV-43527 2870872 8712100 or 8712500 2200634 PU-45257 PU-45652 2871043 PU-44693 2870390 PU-45497-2 PU-45497-1 PU-45498 PU-45838 PA-44995 PU-45543 PU-45483 PU-45658 PA-45401 PU-45778 2870975 2872314 2870871 2870623 2871572 2871573 2871574 7052069 2200421 2871352 2871351 2870506 9314177 2871358 2870341 2870913 2870910 2871226 2870386 2872292 2201379 8700220 2871025 2872608 8700226 PV-43568 2870630 2870836 TOOL DESCRIPTION Oil Filter Wrench Shock Spanner Wrench Tachometer Valve Seat Reconditioning Kit Valve Spring Compressor Valve Pressure Hose Flywheel Puller Valve Train Table Piston Support Block Cam Gear Tooth Alignment Tool Cam Gear Spring Installation Kit (3 Tapered Pins) Cam Spanner Wrench Gear Holder Water Pump Mechanical Seal Installer Universal Drive Handle Main Seal Installer Main Crankshaft Seal Saver Water Pump Seal Saver OIl System Priming Tool Mity Vact Pressure Test Tool Carburetor Float Adjustment Tool Ball Joint Replacement Tool Shock Absorber Spring Compression Tool Strut Rod Wrench LH Strut Spring Compressor RH Strut Spring Compressor Charging Needle Gas Shock Recharging Kit Shock Rod Holding Tool Foxt Shock IFP Depth Tool Clutch Puller Clutch Holding Wrench Clutch Holding Fixture Drive Clutch Spider Removal and Install Tool Driven Clutch Puller Roller Pin Tool Clutch Bushing Replacement Tool Kit Piston Pin Puller EBS Clutch Alignment Tool EBS Bushing Replacement Kit Clutch Compression Tool Clutch Bushing Replacement Tool Kit Roller Pin Removal Tool CV Boot Clamp Pliers Fluket77 Digital Multimeter Timing Light Battery Hydrometer CHAPTER TOOL USED IN 2.10 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3. 2. 5 2.

Transmission Front Gear Case Rear Gear Case Brake Fluid Polaris Synthetic Gear Case Lubricant Add lube to bottom of fill hole. 3. ¡ Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) More often under severe conditions (operating in water or hauling heavy 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) Mobilegrease Special © ¢ Grease conforming to NLGI No. 5.MAINTENANCE LUBRICATION Dipstick Transmission Plug 1. Polaris 0W--40 Synthetic Method Check dipstick and add to proper level. such as operated in water or under severe loads. Frequency* Change after 1st month. or short trip cold weather operation. Item Engine OIl Lube Rec. Change more often (25-50 hours) in extremely dirty conditions. Add lube to specified quantity. such as Polaris Premium All Season Grease. 2. Change fluid every 2 years 2. Change annually © Change annually © Change annually © As required. 2. 6 months or 100 hours thereafter. Premium Demand Drain completely. Front Gear Case Fill Plug 4. Brake Fluid (Left hand Master Cylinder) * More often under severe use.7 . Fill master cylinder reservoir to indicated level inside reservoir. Transmission Fill plug 3. # 1. Engine Oil and Filter Fill Plug 2. Add lube to speDrive Hub Fluid cified quantity. Polaris Gear Drive Fluid Polaris Dot 3 Brake Fluid Drain completely. Rear Gear Case Fill Plug Master Cylinder Reservoir 5. 4. Conoco Superlube M or Ill.

CONT. Item Front Drive Axle “U” Joints Front Prop Shaft Rear Wheel Hub Bearing Carrier Front Hub strut Lube Rec. Locate grease fitting and grease with grease gun. Polaris U-Joint Grease¢ Polaris U-Joint Grease¢ Polaris All Season Grease¢ Polaris All Season Grease¢ Method Locate grease fitting and grease with grease gun. 8. ¡ Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) More often under severe conditions (operating in water or hauling heavy 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) Mobilegrease Special © ¢ Grease conforming to NLGI No. 7. # 6.MAINTENANCE LUBRICATION. 7. Front Drive Axle U-Joint 8. Locate fittings and grease Locate fittings and grease Frequency* Semi-annually ¡ Semi-annually ¡ Semi-annually ¡ Semi-annually ¡ * More often under severe use. 2. Front Prop Shaft U-Joint 6. 9. such as operated in water or under severe loads.8 . such as Polaris Premium All Season Grease. Conoco Superlube M or 2. Rear Wheel Hub Bearing Carrier 9. Front Hub strut Ill.

The gearcase must be drained and re-filled with the proper amount of lubricant.3) 5.4 Nm) 14 ft. 2. Clean and reinstall drain plug using a new sealing washer. .below threads or fill with 5 oz.75 in. 3 2. . 3. Remove fill plug. (See ILL. lbs. G The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid. . (The drain plug is accessible through the skid plate.5. (19. (150 ml. (150 ml. . Install fill plug and check for leaks. . (See ILL. FRONT GEARCASE SPECIFICATIONS Specified Lubricant: Premium Demand Drive Hub Fluid (PN 2871654) Capacity: . Remove gearcase drain plug located on the bottom of the gearcase and drain oil.MAINTENANCE GEARCASE LUBRICATION The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule. lbs. G The correct rear gearcase lubricant to use is Polaris Premium Gear Drive Fluid. Refer to procedure below. Drain plug ILL. Add proper amount of lubricant: Front Gearcase: Fill with the recommended fluid amount or fill to 0. lubricant. G Check vent hose to be sure it is routed properly and unobstructed. REAR GEARCASE SPECIFICATIONS Specified Lubricant: Polaris Gear Drive Fluid (PN 2871653) Capacity: 5 Oz.4 Nm) To check the lubricant level: The front and rear gearcases lubricant level cannot be checked with a dipstick or by visual reference.) Catch and discard used oil properly. G Be sure vehicle is level before proceeding. 2 REAR GEARCASE Make sure vent is unobstructed Fill plug Fill Plug ILL.) Drain Plug / Fill Plug Torque: 14 ft.0 Oz. To change gearcase lubricant: 1. (19 mm) below the threads of the fill plug. . 2) Front Gearcase Fill Plug Threads Fill to 3/4 in. . 1 Rear Gearcase: Fill with the recommended fluid amount or fill to the bottom of the fill plug hole threads. (19.9 . . 4.) Drain Plug / Fill Plug Torque: FRONT GEARCASE Make sure vent is unobstructed Drain plug ILL. 1 & ILL.

2. 7. Level is correct when it reaches the bottom of the fill hole as shown at right.5 oz. G Follow instructions to check / change transmission lubricant. Check for leaks. 6. To check the level: 1. Remove fill plug and visually inspect the oil level. G Be sure the vehicle is level before proceeding. Remove fill plug.) Capacity: 13. 4.) Drain Plug / Fill Plug Torque: 14 ft. 2. Catch and discard used oil properly. Reinstall propshaft shield. TRANSMISSION SPECIFICATIONS Specified Lubricant: Premium Synthetic Gearcase Lubricant PN 2871477 (gal. 3. Remove propshaft shield from the right side of the vehicle . 5. lbs.) PN 2871478 (12oz. To change lubricant: 1. Torque to specification. G Check vent hose to be sure it is not kinked or obstructed.MAINTENANCE TRANSMISSION LUBRICATION The transmission lubricant level should be checked and changed in accordance with the maintenance schedule. Clean and reinstall the drain plug with a new sealing washer. (19.10 .4 Nm) Oil Level 1 5/8² View From Front Do not fill to bottom of fill plug threads Transmission Fill Plug 2. Add Polaris Premium Synthetic Gearcase Lubricant to proper level as described above. Remove transmission drain plug to drain the oil. (400 ml. Remove propshaft shield from the right side of the vehicle.

1. Shift Linkage Rod 4. clevis pins. Throttle lever operation should be smooth and lever must return freely without binding. Shifter Shift Linkage Rod THROTTLE INSPECTION Check for smooth throttle opening and closing in all handlebar positions. or damaged. Turn handlebars from full right to full left. 3. Note orientation of tie rod end studs with the ends that are up down (vertical). 1 Shifter Mount Removal Sequence CHOKE (ENRICHER) ADJUSTMENT If the choke knob does not stay out when pulled. 5. and pivot bushings and replace if worn or damaged. 1. If idle speed increases at any point in the turning range. Inspect shift linkage tie rod ends. kinked. 3. adjust the choke tension by tightening (clockwise) the jam nut under the rubber boot between the choke knob and nut.MAINTENANCE SHIFT LINKAGE INPSECTION NOTE: Shift rod is preset at time of manufacture. 2. 2. Adjust cable tension as needed until lock--to--lock turning can be accomplished with no rise in engine rpm. Remove both rod end bolts from transmission bell crank. inspect throttle cable routing and condition. Replace the throttle cable if worn. Use a medium flat blade screwdriver and insert blade into the pocket of the cover starting on the #1 position.11 . Place the gear selector in neutral. To remove the ETC cover: 1. Set parking brake. Twist screwdriver slightly while lifting on the cover to release snap. 2. 6 3 2 1 5 4 ETC Cover Ill. Start the engine and let it idle. Repeat procedure at the other five locations as shown. NOTE: Do not attempt to remove cover until all latch points are released. Lubricate the tie rod ends with a light aerosol lubricant or grease. Firmly grasp the rubber boot and tighten until the choke slides freely but stays out when pulled. 2.

2 Pilot Screw 1. Start engine and warm it up to operating temperature (about 10 minutes). 2. (Ill. 6. Start engine and warm it up thoroughly. NOTE: Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be permanently damaged. Connect an accurate tachometer that will read in increments of + or -. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary. 7.3 Idle Screw FRONT (Engine) Ill. inspect choke cable for kinks or sharp bends in routing.12 . Set idle speed to 1100 RPM.200 RPM - 1. Turn screw out the specified number of turns. Illustration of choke may vary with models. IDLE SPEED ADJUSTMENT CV Carburetor Ill. If smooth choke operation is not obtainable. Continue turning counterclockwise until idle RPM begins to drop.MAINTENANCE Verify free play of 1/16--3/16” (1. 5. Slide boot off throttle cable adjuster and jam nut. Place shift selector in neutral and set parking brake. 2.50 RPM such as the PET 2100DX (PN 8712100DX) or the PET 2500 (PN 8712500).1 Boot CARBURETOR PILOT SCREW ADJUSTMENT Ill. Idle Speed: 1100 +/.3) NOTE: Adjusting the idle speed affects throttle cable freeplay and electronic throttle control (ETC) adjustment. Adjust idle speed by turning the idle adjustment screw in (clockwise) to increase or out (counterclockwise) to decrease RPM. 2) Pilot Screw Adjustment Refer to Specifications in Chapter 1 3. (Ill. 4. Center the pilot screw between the points in Step 5 and 6. Turn pilot screw in (clockwise) until lightly seated. Slowly turn mixture screw clockwise using the pilot screw wrench until engine begins to miss. Slowly turn mixture screw counterclockwise until idle speed increases to maximum RPM. 2.76 mm) and smooth operation of choke cable. 8. Re adjust idle speed to specification. 2.6--4. THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL (ETC SWITCH) ADJUSTMENT 1.

1 Fuel Filter 1. immediately wash it off with soap and water and change clothing. See Idle Speed Adjustment. Turn handlebars from left to right through the entire turning range. (Ill. Never start the engine or let it run in an enclosed area. 1).MAINTENANCE THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL (ETC SWITCH) ADJUSTMENT CONT’D 3. Fuel Pump Ill. Start engine and set idle to specified RPM. Tighten lock nut securely and slide boot completely in place to ensure a water-tight seal. Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time. Do not overfill the tank. Be sure fuel lines are routed properly and secured with cable ties. 7. 2). check for proper cable routing. If cable is routed properly and in good condition. 2. If you get gasoline in your eyes or if you swallow gasoline. After making adjustments. 2 1/16² . Loosen lock nut on in-line cable adjuster (Ill. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Replace if necessary. 1 NOTE: Be sure the engine is at operating temperature. CAUTION: Make sure lines are not kinked or pinched. Boot Adjuster Sleeve Locknut Boot G G G G Ill. 2. quickly actuate the thumb lever several times and reverify freeplay. 4. If idle speed increases. 3. G G G Always stop the engine and refuel outdoors or in a well ventilated area. Replace all fuel lines every two years.1/8² Freeplay 6. 5. Severe burns may result.13 . deterioration. Turn adjuster until 1/16² to 1/8² freeplay is achieved at thumb lever. Check fuel lines for signs of wear. repeat adjustment procedure. FUEL LINES Fuel Lines Direction of travel Ill. Do not fill the tank neck. FUEL SYSTEM WARNING Gasoline is extremely flammable and explosive under certain conditions. seek medical attention immediately. damage or leakage. If you spill gasoline on your skin or clothing. Never drain the float bowl when the engine is hot.

battery and transmission vent lines for signs of wear. Start machine and check for leaks. 6. 3. CARBURETOR DRAINING The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl. damage or leakage. NOTE: All tubes attached to the carburetor must be check for pinching or blockage. 2 1. Replace every two years. 7. Shut off fuel supply at fuel valve. Be sure vent lines are routed properly and secured with cable ties. 2. oil tank. 3. Place a clean container beneath the bowl drain spigot or bowl drain hose. A smooth idle generally indicates good compression. Tighten drain screw. Start engine and inspect for leaks. Install new filter and clamps onto fuel lines with arrow pointed in direction of fuel flow. Low engine compression is rarely a factor in running condition problems above idle speed. 1 Drain Screw RES To Carburetor OFF Ill. Inspect the drained fuel for water or sediment. as this will effect engine performance. Turn drain screw out two turns and allow fuel in the float bowl and fuel line to drain completely. 2. 7. NOTE: The bowl drain screw is located on the bottom left side of the float bowl. 4. deterioration. damaged exhaust cam lobes. Turn fuel valve to the off position. 2 COMPRESSION TEST NOTE: This engine does NOT have decompression components. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about 150-170 psi during a compression test. or before extended periods of storage. carburetor.MAINTENANCE VENT LINES Check fuel tank. 2. ON Ill. Abnormally high compression can be caused by carbon deposits in the combustion chamber or worn. Turn fuel valve “ON”. Turn fuel valve to “ON”.14 . CAUTION: Make sure lines are not kinked or pinched. Inspect camshaft and combustion chamber if compression is abnormally high. Install clamps on fuel line. 5. Remove line clamps at both ends of the filter. Remove fuel lines from filter. Drain tube attached here Arrow Indicates Direction of Flow Ill. 4. 5. 6. FUEL FILTER The fuel filter should be replaced in accordance with the Periodic Maintenance Chart or whenever sediment is visible in the filter. 1.

15 .MAINTENANCE COMPRESSION TEST CONT’D A cylinder leakdown test is the best indication of engine condition. Internal: Drink large quantities of water or milk. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN. Antidote: External: Flush with water. (Never use high pressure leakage testers.1) A Ill. Keep sparks. (Ill. or vegetable oil. Ventilate when charging or using in an enclosed space. Batteries produce explosive gases. Do not use the alternator to charge a new battery. 3 Maintain between upper and lower level marks Ill. Charge battery for 3-5 hours at a current equivalent of 1/10 of the battery’s rated amp/hour capacity. 1 2. Cylinder Compression Standard: 150-170 PSI Cylinder Leakdown Service Limit 10 % (Inspect for cause if leakage exceeds 10%) ENGINE MOUNTS Inspect rubber engine mounts (A) for cracks or damage. cigarettes.3) Check engine fasteners and ensure they are tight. Serious burns can result from contact with skin. away. Follow manufacturer’s instructions to perform a cylinder leakage test. A A NOTE: New Batteries: Batteries must be fully charged before use or battery life will be reduced by 10-30% of full potential. (Refer to battery video PN 9917987) The battery is located under the left rear fender. eyes or clothing. (Ill. When the electrolyte nears the lower level. Inspect the battery fluid level. as crankshaft seals may dislodge and leak). etc. Call physician immediately. beaten egg. It contains sulfuric acid. BATTERY MAINTENANCE WARNING Battery electrolyte is poisonous. remove the battery and add distilled water only to the upper level line. flame. Eyes: Flush with water for 15 minutes and get prompt medical attention. Follow with milk of magnesia.

6. Adjust gap if necessary by bending the side electrode carefully. Reinstall battery. SPARK PLUG 1.MAINTENANCE To remove the battery: 1. Remove the battery. Use only distilled water. Disconnect holder strap and remove cover. Measure gap with a wire gauge. Apply a small amount of anti-seize compound to the spark plug threads. install the negative cable last. 3. 2.9 mm) 5. 7. disconnect the negative (black) cable first. Install spark plug and torque to specification. Reinstall battery cover and holder strap. 10. Reattach vent hose making sure it is properly routed and not kinked or pinched. CAUTION To reduce the chance of sparks: Whenever removing the battery. CAUTION: Severe engine damage may occur if the incorrect spark plug is used. Lbs. CAUTION: A wire brush or coated abrasive should not be used. Corrosion can be removed using a solution of one cup water and one tablespoon baking soda. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. . Recommended Spark Plug: Refer to Specifications Chapter 1 Spark Plug Torque: 14 Ft. Look for a sharp outer edge with no rounding or erosion of the electrodes. Be sure it is clean and tight. If necessary. (Illustration below) 6. 9.036² (0. 8. Do not allow cleaning solution or tap water to enter the battery. as it will shorten the life of the battery. 2.16 . Do not overfill the battery. Coat terminals and bolt threads with Dielectric Grease (PN 2871329). 7. (19 Nm) Spark Plug Gap IGNITION TIMING Refer to Chapter 10 for ignition timing procedures. Fully recharge after filling. Clean battery cables and terminals with a stiff wire brush. Disconnect the vent hose. attaching positive (+) (red) cable first and then the negative (-) (black) cable. replace spark plug with proper type. ENGINE-TO-FRAME GROUND Inspect engine-to-frame ground cable connection. Remove spark plug. 8. 4. Remove the filler caps and add distilled water only as needed to bring each cell to the proper level. Refer to specifications for proper spark plug type and gap. Inspect electrodes for wear and carbon buildup. followed by the positive (+) (red) cable. When reinstalling the battery. Rinse well with clean water and dry thoroughly. Reinstall the battery caps. Disconnect battery negative (-) (black) cable first. 5. Remove spark plug high tension lead. 4. Tap water contains minerals which are harmful to a battery. 3. 11. Ground Cable 2. Clean plug area so no dirt and debris can fall into engine when plug is removed.

Replace if necessary. Check tightness of all hose clamps. Do not add straight antifreeze or straight water to the system. 3. Straight water or antifreeze may cause the system to freeze. abrasion or leaks.MAINTENANCE LIQUID COOLING SYSTEM OVERVIEW The engine coolant level is controlled or maintained by the recovery system. Do not use tap water. corrosion protection. Remove any obstructions with compressed air or low pressure water. and antifreeze protection. causing a restriction or leak. radiator filler neck. Carefully straighten any bent radiator fins. 2. (4 Nm). Observe coolant levels often during the break-in period. COOLING SYSTEM HOSES Inspect all hoses for cracks. COOLANT STRENGTH / TYPE Test the strength of the coolant using an antifreeze hydrometer. Polaris 60/40 Anti-Freeze / Coolant (PN 2871323) COOLING SYSTEM PRESSURE TEST Refer to Chapter 3 for pressure test procedures. Overheating of engine could occur if air is not fully purged from system. G Some coolant level drop on new machines is normal as the system is purgingitself of trappedair. Tap water contains minerals and impurities which build up in the system. lbs. radiator pressure cap and connecting hose. deterioration. RADIATOR 1. Check radiator external air flow passages for restrictions or damage. Radiator hose clamp torque is 36 in. or overheat. Do not dilute with water. the expanding(heated)excesscoolantisforcedoutofthe radiator past the pressure cap and into the recovery bottle. corrode. Antifreeze Hydrometer G G A 50/50 or 60/40 mixture of antifreeze and distilled water will provide the optimum cooling. Do not over-tighten hose clamps at radiator or radiator fitting may distort. As coolant operating temperature increases. Asenginecoolant temperature decreasesthe contracting(cooled)coolantisdrawnbackupfromthe tank past the pressure cap and into the radiator. G G 1. 2.17 . The recovery system components are the recovery bottle. PolarisPremium60/40anti--freezeis premixed and ready to use. 2.

Inspect for signs of trapped air in system. must be maintained between the minimum and maximum levels indicated. Ill.2 RADIATOR SCREEN REMOVAL 1. NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair.1 RADIATOR COOLANT LEVEL INSPECTION WARNING Never remove the radiator pressure cap when the engine is warm or hot. Front Cover Rack Ill. located on the left side of the machine.1) With the engine at operating temperature. Escaping steam and fluid can cause severe burns. Recovery Bottle Accessible Under Side Panel Ill.3 2. If it is not: 1. To install the screen. Remove reservoir cap. pull out on the bottom of the screen to remove the screen. 2. Fill reservoir to upper mark with Polaris Premium 60/40 Anti Freeze / Coolant (PN 2871323) or a mixture of antifreeze and distilled water as required for freeze protection in your area. With the top free. 3. NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. Escaping steam and fluid can cause severe burns.18 . Reinstall cap. Remove front cover by placing your fingers under the front of the cover and pulling upward. simply press the tabs on the screen back into the mounting grommets. (Ill. The engine must be allowed to cool before removing the pressure cap. Verify the inner splash cap vent hole is clear and open. Be sure the screen is securely in place. the level in the radiator should be inspected via the radiator cap first and coolant added if necessary. However.MAINTENANCE COOLANT LEVEL INSPECTION WARNING Never remove the radiator pressure cap when the engine is warm or hot. Pull out slightly on the top of the radiator screen. To access the radiator pressure cap: Remove the four screws securing front rack. allow system to cool completely and check coolant level in the radiator. the coolant level should be between the upper and lower marks on the coolant reservoir. Turn handle bars full left or right to provide more clearance. 3. or if overheating is evident. The recovery bottle. 2. NOTE: If overheating is evident. if the recovery bottle has run dry. The engine must be allowed to cool before removing the pressure cap.

Remove drain plug from end of sediment tube. 12. or gaps. The pre filter should be cleaned before each ride using the following procedure: 1.2 Cover Gasket Proper Filter Placement Main Filter Pre-filter Main Element Ill. 7. Loosen clamp and remove air filter assembly. 4. Inspect the gasket. Drain tube. When riding in extremely dusty conditions.3 Front NOTE: The air filter should rest on the filter support.19 . Clean the pre filter with high flash point solvent. 6. creases. It should adhere tightly to the cover and seal all the way around. 9. NOTE: When reinstalling seat. NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling. See Illustration above. Filter Support Air Box Ill. Reinstall pre-filter element over main filter. replacement is required more often. Remove clips (6) from air box cover and remove cover.MAINTENANCE AIR FILTER/PRE-FILTER SERVICE It is recommended that the air filter and pre filter be replaced annually. Inspect main filter and replace if necessary. Lift up on the rear of the seat. make sure the slots in the seat engage the tabs in the fuel tank.1 Cleaning: 5. Apply foam filter oil or clean engine oil and squeeze until excess oil is removed. Inspect element for tears or damage. followed by hot soapy water. 2. Pull the seat back and free of the tabs. Rinse and dry thoroughly. Proper placement of the air filter is important to prevent rattles and air leaks. 8. If the filter has been soaked with fuel or oil it must be replaced. 3. Place filter clamp over the assembly and tighten. 2. Installation: 10. Install air box cover and secure with clips. 2. AIR BOX SEDIMENT TUBE Periodically check the air box drain tube located toward the rear of the machine. Filter Clamp Ill. Reinstall filter on main filter mount. 11. Slip the pre-filter element off of main element. Drain whenever deposits are visible in the clear tube. Be sure the element covers entire surface of main filter without folds. 1.

1 NOTE: The sediment tube will require more frequent service if the vehicle is operated in wet conditions or at high throttle openings for extended periods. be sure to check the PVT cover and other components for water ingestion. Typical Breather Filter Location In-Line Breather Filter Location A PVT Drain Plug & O--ring Ill. 1. Allow engine RPM to settle to idle speed. Sediment Tube Ill. To further expel water from the cover and to dry out the PVT system. Operate ATV in lowest available range for a short period of time until PVT system is dry.MAINTENANCE 3. shift the transmission to neutral and rev engine slightly to expel the moisture and air-dry the belt and clutches. and is visible on the left side (Location A). Never operate the engine without the pre-filter.3 2. In-line breather filters should be installed with the arrow pointing toward the engine (away from the air box).2 View -. 2. The PVT drain plug is shown below. simply remove the PVT drain plug and O--ring located on the bottom of the PVT cover and let the water drain out. BREATHER HOSE 1. Reinstall drain plug. To release any water that maybe trapped in the PVT cover. PVT DRYING & PVT DRAIN PLUG NOTE: If operating the ATV in or through water. Ill. shift transmission to lowest available range and test for belt slippage. Be sure breather line is routed properly and secured in place. BREATHER FILTER INSPECTION Four cycle ATV engines are equipped with a breather filter. CAUTION: Make sure lines are not kinked or pinched.20 .Under Left Front Fender NOTE: In-line breather filter service life is extended when the foam air box pre-filter is in place and maintained properly. The in-line filter is similar in appearance to a fuel filter. The ATV should be checked immediately.

2) Remove dipstick and wipe dry with a clean cloth. 2. 5. Do not lock the dipstick. change the oil immediately.(Ill. Do not allow hot oil to come into contact with skin. regardless of the level marks being on top or on bottom. (See the next illustration) Dipstick Always read top side of dipstick to properly check oil level in crankcase Dipstick Ill. Remove dipstick and check to see that the oil level is in the normal range. the oil level will read higher on the bottom Engine Oil Drain Plug . NOTE: Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of stick consistent. Place vehicle on a level surface. Stop engine.MAINTENANCE ENGINE OIL LEVEL The 600/700 engine is a wet--sump engine. Set machine on a level surface.2 SAFE Crankcase Drain 4. Proper level indication is determined on the upper surface of the dipstick as it is being removed. 3. 4. 2. Ill. Reinstall dipstick and push it into place.Bottom View CAUTION: Oil may be hot. When reinstalling the dipstick. OIL AND FILTER CHANGE 1. meaning the oil is contained in the bottom of the crankcase. Place a drain pan beneath crankcase and remove drain plug.1 1. Run engine two to three minutes until warm. Add oil as indicated by the level on the dipstick. make certain to seat the lever lock. 2. Stop engine and unlock the lever lock. (See NOTE below!) NOTE: Due to the dipstick entry angle into the crankcase. Do not overfill. If the oil level is over the full mark. Start and run engine for 20-30 seconds. Clean area around drain plug at bottom of oil engine. 3. as serious burns may result. Lever Lock Dipstick NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase.21 . To check the oil level: side of the dipstick.

clean filter sealing surface on crankcase. Place shop towels beneath oil filter. nicks or scratches. Check to make sure the O-ring is in good condition. Dispose of used filter and oil properly. Lubricate O-ring on new filter with a film of fresh engine oil. NOTE: Whenever steering components are replaced. Using a clean dry cloth. Use only genuine Polaris parts. 14. 15. hoses. Replace the sealing washer on drain plug. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.MAINTENANCE Recommended Engine Oil Polaris Premium 4 All Season Synthetic. Steering should move freely through entire range of travel without binding. Allow oil to drain completely. they must not be re-used. Reinstall drain plug and torque to 14 ft. Replace any worn or damaged steering components. 12. 0W-40 (PN 2871281) Ambient Temperature Range: -40 F to 120 F Oil Filter (PN 2540006) Crankcase Drain Plug Torque: 20-22 ft. NOTE: The sealing surfaces on drain plug and oil tank should be clean and free of burrs. and damage. lbs. worn tie rod ends. 6. Stop the engine and inspect for leaks. and wiring to be sure the steering mechanism is not restricted or limited. 10. lbs. 9. 13. 7. Also check to make sure all cotter pins are in place. then turn an additional 1/2 turn. 11. 8. 16.22 . Place gear selector in neutral and set parking brake. (19 Nm). Check routing of all cables. turn filter counterclockwise to remove. 2. Install new filter and turn by hand until filter gasket contacts the sealing surface. (27-30 Nm) Oil Filter Torque: Turn by hand until filter gasket contacts sealing surface. Using Oil Filter Wrench (PV-43527). STEERING The steering components should be checked periodically for loose fasteners. Start the engine and let it idle for one to two minutes. Always use new cotter pins. If cotter pins are removed. then turn an additional 1/2 turn Oil Filter Wrench: (PV-43527) 5.9 l) of Polaris Premium 4 Synthetic Oil (PN 2871281). check front end alignment. Remove dipstick and fill sump with 2 quarts (1.

Check for any looseness in front hub / wheel assembly by grasping the tire firmly at top and bottom first. Steering should move freely through entire range of travel without binding. CAMBER AND CASTER The camber and caster are non-adjustable. If adjustment is required. One of two methods can be used to measure toe alignment. pull in all directions feeling for movement. WARNING Due to the critical nature of the procedures outlined in this chapter. TIE ROD END / STEERING INSPECTION G To check for play in the tie rod end. refer to following pages for procedure. inspect the hub and wheel assembly to determine the cause ( possible loose wheel nuts or loose front hub components). The string method and the chalk method. 2. Try to move the wheel and hub by pushing inward and pulling outward.23 . grasp the steering tie rod. G G Replace any worn steering components. Use only genuine Polaris replacement parts. Repeat inspection for inner tie rod end on steering post. Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD-certified technician when replacing worn or damaged steering parts. and then at front and rear.MAINTENANCE TIE ROD END/STEERING INSPECTION CONT’D G If abnormal movement is detected. G Check for Loose Wheel or Hub G Refer to the Body/Steering Chapter 5 or Final Drive Chapter 7 for service procedures. Elevate front end of machine so front wheels are off the ground.

Rear rim measurement should be 1/16² to 1/8² (.MAINTENANCE WHEEL ALIGNMENT METHOD 1: STRAIGHTEDGE OR STRING Be sure to keep handlebars centered.3 cm) more than front rim measurement. NOTE: The steering post arm “frog” can be used as an indicator of whether the handlebars are straight. See notes below.2 to . Measure from string to rim at front and rear of rim.24 . The frog should always point straight back from the steering post. 2. NOTE: String should just touch side surface of rear tire on each side of machine.

3 to . Call this measurement “A”. CAUTION: During tie rod adjustment. G Loosen jam nuts at both end of the tie rod. This will tell you which tie rod needs adjusting. TOE ALIGNMENT ADJUSTMENT If toe alignment is incorrect. Rotate the tires 180° by moving vehicle forward or backward. 2.MAINTENANCE WHEEL ALIGNMENT METHOD 2: CHALK 1. even with the hub/axle centerline. measure the distance between vehicle center and each wheel. lbs. Measurement “B” 2. 4. If the rod end is positioned incorrectly it will not pivot. Call this measurement “B”.4 cm) from the floor or as close to the hub/axle center line as possible. Damage may not be immediately apparent if done incorrectly.1 Chalk Line Measurement “A” To adjust toe alignment: G Hold tie rod end to keep it from rotating. Hold Rod End Ill.2 Ill. it is very important that the following precautions be taken when tightening tie rod end jam nuts.25 . Place a chalk mark on the center line of the front tires approximately 10² (25. The difference between measurements “A” and “B” is the vehicle toe alignment. (16-19 Nm). G After alignment is complete. Place machine on a smooth level surface. Again measure the distance between the marks and record.6 cm) toe out. NOTE: It is important that the height of both marks be equally positioned in order to get an accurate measurement. torque jam nuts to 12-14 ft.3 to . G IMPORTANT: When tightening the tie rod end jam nuts. Set handlebars in a straight ahead position and secure handlebars in this position. the rod ends must be held parallel to prevent rod end damage and premature wear. This means the measurement at the front of the tire (A) is 1/8² to 1/4² (. 3. G Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in Method 1 or Method 2. NOTE: Be sure handlebars are straight ahead before determining which tie rod(s) need adjustment. The frog should always point straight back from the steering post.6 cm) wider than the measurement at the rear (B). 6. Measure the distance between the marks and record the measurement. See illustration 2. NOTE: The steering arm “frog” can be used as an indicator of whether the handlebars are straight. and may break. The recommended vehicle toe tolerance is 1/8² to 1/4² (.2 Correctly Tightened Jam Nut Incorrectly Tightened Jam Nut Ill. Subtract measurement “B” from measurement “A”. Position chalk marks facing rearward. 5.

Remove the clean out plugs located on the bottom of the muffler as shown in illustration 1. BRAKE SYSTEM INSPECTION The following checks are recommended to keep the brake system in good operating condition. SEE WARNING G G G G G Check brake system for fluid leaks. Inspect brakes in accordance with the maintenance schedule and before each ride. G Wear eye protection. Set the hand brake and block the wheels. Failure to heed these warnings could result in serious personal injury or death. Serious burns could result from contact with exhaust components. If some carbon is expelled. G Never run the engine in an enclosed area. Check surface condition of the disc. Place the transmission in neutral and start the engine. Set the hand brake and block the wheels to prevent roll back. back the machine onto an incline so the rear of the machine is one foot higher than the front. G Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor. Purge accumulated carbon from the system by momentarily revving the engine several times. G To reduce fire hazard. Exhaust contains poisonous carbon monoxide gas. Make sure the machine is in neutral and repeat Steps 2 and 3. 8. 3. Rear Master Cylinder Reservoir Ill. damage or looseness.1 Clean Out Plug Max Min 2. Service life of brake system components depends on operating conditions. 5. Repeat Steps 2 through 5 until no more particles are expelled when the engine is revved. SEE WARNING 6. Reinstall the clean out plugs. drive the machine onto the incline so the front of the machine is one foot higher than the rear. Check brake for excessive travel or spongy feel. 4. If particles are still suspected to be in the muffler. Inspect thickness of brake pad friction material.26 . as the exhaust system becomes very hot. cover the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times. 2. make sure that there are no combustible materials in the area when purging the spark arrestor. Set the hand brake and block the wheels. Check friction pads for wear. If particles are still suspected to be in the muffler. G Do not go under the machine while it is inclined. G Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir.MAINTENANCE EXHAUST PIPE WARNING G Do not perform clean out immediately after the engine has been run. Make sure the machine is in neutral and repeat Steps 2 and 3. Stop the engine and allow the arrestor to cool. 7. Use Polaris DOT 3 Brake Fluid (PN 2870990). Parking Brake Lock G Sight Glass The exhaust pipe must be periodically purged of accumulated carbon as follows: 1.

The top of the pedal should be at least 1 inch. check foot brake effectiveness by applying 50 lb. HOSE/FITTING INSPECTION Check brake system hoses and fittings for cracks.MAINTENANCE BRAKE PAD INSPECTION Pads should be changed when the friction material is worn to 3/64² (. abrasion. (25. Bleed the hydraulic auxiliary brake system in 2. to 1/4. Auxiliary Foot Brake Pedal Full Full Height Engagement Floor Board Surface 3/64² (.1/4 inch (3. apply the auxiliary foot brake.27 . Support the rear wheels off the ground.2 . While turning the rear wheels by hand.1cm) Minimum Thickness AUXILIARY BRAKE ADJUSTMENT (HYDRAULIC) Use the following procedure to inspect the hydraulic auxiliary (foot) brake system and adjust or bleed if necessary: First. If free play is excessive. Tighten any loose fittings and replace any worn or damaged parts. or about the thickness of a dime. This brake should not stop the wheels from turning until the lever is half way between its rest position and bottoming on the footrest. deterioration.35 mm). (approx. two things must be examined: Free Play: Free play of the brake pedal should be 1/8 . AUXILIARY BRAKE TESTING The auxiliary brake should be checked for proper function. Free Play 50 lbs 1² or greater Auxiliary Brake Floorboard If less than one inch. and leaks.6. and master cylinder for wear or damage and replace any parts as needed. air may be trapped somewhere in the system. Bleeding: If free play is correct and brake pedal travel is still excessive.1 cm). 1/8.) downward force on the pedal. linkage.4mm) above the surface of the footrest. inspect pedal.

Damping should be smooth throughout the range of travel. (108 Nm) G Compress and release rear suspension. CONTROLS Check controls for proper operation. Check all front suspension components for wear or damage. Stop the engine. Shock Spanner Wrench (PN 2870872) FRONT SUSPENSION G Compress and release front suspension. following the procedure outlined in Brake Chapter 9. HUB. 3. Lbs. Damping should be smooth throughout the range of travel. G G WHEELS Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight. Inspect front strut cartridges for leakage. Lbs. 2. REAR SUSPENSION WHEEL. WHEEL REMOVAL: FRONT OR REAR 1. Do not over tighten the wheel nuts.28 . Check all rear suspension components for wear or damage. Inspect shock for leakage. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. place the transmission in gear and lock the parking brake. Adjustas necessary.MAINTENANCE a conventional manner. positioning and adjustment. Lbs. (41 Nm) 30 Ft. (41Nm) Refer to procedure listed in Chapter 7 80 Ft. AND SPINDLE TORQUE TABLE Rear Spring Adjustment Cam Item Front Wheel Nuts Rear Wheel Nuts Front Spindle Nut Rear Hub Retaining Nut Specification 30 Ft. Loosen the wheel nuts slightly. Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body. G G 2. Apply Loctitet 271 (PN 2871954) to the wheel studs whenever reinstalling the wheel nuts. SUSPENSION: SPRING PRELOAD ADJUSTMENT Operator weight and vehicle loading affect suspensionspringpreloadrequirements.

make sure tapered end of nut goes into taper on wheel. WHEEL INSTALLATION 1. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. 3. FASTENERS Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Securely tighten the wheel nuts to the proper torque listed in the table. 2.MAINTENANCE 4. With the transmission in gear and the parking brake locked. Tread Depth 1/8I (3 mm) WARNING Flange Nuts: Flat side against wheel Operating an ATV with worn tires will increase the possibility of the vehicle skidding and possible loss of control. BOLTS. Remove the wheel nuts and remove the wheel. 2. Attach the wheel nuts and finger tighten them. Worn tires can cause an accident. NUTS. Refer to specific fastener torques listed in each chapter. Check that all cotter pins are in place. G The use of non-standard size or type tires may affect ATV handling. When replacing a tire always use original equipment size and type.29 . Refer to the warning tire pressure decal applied to the vehicle. Tire Tread Depth Always replace tires when tread depth is worn to 1/8² (3 mm) or less. Always replace tires when the tread depth measures 1/8² (. TIRE INSPECTION G G Improper tire inflation may affect ATV maneuverability. Tire Pressure Inspection (PSI . Lower the vehicle to the ground. On vehicles with tapered rear wheel nuts.3 cm) or less. place the wheel in the correct position on the wheel hub.Cold) Front 5 Rear 5 FRAME. TIRE PRESSURE CAUTION: Maintain proper tire pressure. CAUTION: Improperly installed wheels could affect vehicle handling and tire wear. 4.

MAINTENANCE

2.30

ENGINE

CHAPTER 3 ENGINE
Engine Exploded Views . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . Engine Fastener Torque Patterns . . . . . . . . . . . . . Piston Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Service Data . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System Specifications . . . . . . . . . . . . . . . . Cooling System Pressure Tests . . . . . . . . . . . . . . . Engine Removal/Installation . . . . . . . . . . . . . . . . . . Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm/Pushrod Inspection . . . . . . . . . . . . . . . Cylinder Head Disassembly/Inspection . . . . . . . . . Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . Valve Sealing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Train Exploded View. . . . . . . . . . . . . . . . . . . . Engine Head Reassembly . . . . . . . . . . . . . . . . . . . . Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Lifter Removal/Inspection . . . . . . . . . . . . . . . Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . Piston/Rod/Ring Service . . . . . . . . . . . . . . . . . . . . . Starter Bendix Removal/Inspection . . . . . . . . . . . . Flywheel/Stator Removal/Inspection . . . . . . . . . . . Flywheel/Stator Installation . . . . . . . . . . . . . . . . . . . Engine Lower Disassembly/Inspection . . . . . . . . . Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lower Assembly . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 Engine Exploded View (Back Book) . . . . . . . . 3.2--3.6 3.7 3.8 3.9 3.9 3.10--3.13 3.14 3.14 3.15 3.16 3.17 3.18 3.19 3.19--3.21 3.22 3.22 3.23--3.25 3.25 3.26 3.26 3.27--3.29 3.29 3.29 3.29--3.30 3.30--3.31 3.31--3.33 3.33--3.34 3.34--3.35 3.35--3.36 3.36--3.44 3.44--3.45 3.45--3.55 3.56--3.57 3.58

3

3.1

ENGINE

ENGINE EXPLODED VIEW
Crankcase 20-24 ft. lbs. (27-33 Nm)
Oil Dipstick Seal Bearing Bushing Bearing Crankcase Assembly
271

4.5-5.5 ft. lbs. (6-7 Nm)

271

O--Ring

4.5-5.5 ft. lbs. (6-7 Nm)
Oil Pickup Journal Bearings
271

Gasket Seals

262

Magnetic Plug

Baffle
NOTE: Heat the oil baffle bolts with a heat gun to remove.

Gear/Stator Housing Cover

Crankcase Screws Apply Loctitet 262 to the bolt threads. Apply Loctitet 242 to the bolt threads. Apply Loctitet 271 to the bolt threads.
262

3.2

271

20-24 ft. lbs. (27-33 Nm)

242

242

242

20--22 ft. lbs. (27-30 Nm)

8.5-9.5 ft. lbs. (12-13 Nm)

ENGINE

ENGINE EXPLODED VIEW
Cylinder/ Cylinder Head
Breather Cover Reed

8.5-9.5 ft. lbs. (12-13 Nm)

Rocker Cover

27--33 in. lbs. (3--4 Nm)

271

60--64 ft. lbs. (81--87 Nm) 16--20 ft. lbs. (22--27 Nm)

20-24 ft. lbs. (27-33 Nm)

8.5-9.5 ft. lbs. Thermostat (12-13 Nm)
Cover Thermostat Temperature Switch

271

271

16-20 ft. lbs. (22-27 Nm)

Exhaust Gasket Cylinder Head

Exhaust Manifold

Head Gasket

11-13 ft. lbs. (15-18 Nm)
Frost Plug

271

Cylinder

Base Gasket Carburetor
242

Apply Loctitet 242 to the bolt threads. Apply Loctitet 271 to the bolt threads.

271

271

3.3

ENGINE

ENGINE EXPLODED VIEW
Crankshaft and Pistons Valve Train
Camshaft 26-30 ft. lbs. (35-41 Nm)
242

Piston Assembly Thrust Plate

Camshaft Gears

4.5-5.5 ft. lbs. (6--7 Nm) 20-24 ft. lbs. (27-33 Nm)
Rocker Arms

Crankshaft Pushrods

Woodruff Key

Valve Springs

271

Valve Seals Gears Cylinder Head

Balance Shaft

Apply Loctitet 242 to the bolt threads. Apply Loctitet 271 to the bolt threads.

26-30 ft. lbs. (35-41 Nm)

242

242

Lifter Valve Valves

3.4

271

lbs. Apply Loctitet 271 to the bolt threads.5-9. (12-15 Nm) Water/Oil Shaft Gasket Impeller O--Ring Water Pump Seal Water Pump Cover Gear/Stator Housing Apply Loctitet 242 to the bolt threads.5-9.ENGINE ENGINE EXPLODED VIEW Water Pump / Oil Pump 20-24 ft.5-9.5 . lbs. lbs. lbs.5 ft. lbs. (12-13 Nm) 3. 271 242 271 8. (12-13 Nm) Oil Filter 33-37 ft. lbs. (27-33 Nm) Oil Plug 8. (12-13 Nm) 242 Bearing Gerotor Oil Pressure Relief Oil Pump Housing Water/Oil Pump Gear 9-11 ft. (45-50 Nm) Oil Filter Nipple 8.5 ft.5 ft.

(12-13 Nm) 271 Starter 8.5--9.6 271 242 . lbs. (10-12 Nm) Bendix 242 8. (11. lbs.5 ft.5 ft.5-5. lbs. lbs. 3. lbs.5--13 Nm) 80-100 ft. (109-136 Nm) 242 Stator Bolts Flywheel Flywheel Nut Stator Housing Sound Cover Outer Cover O--rings Timing Plug Washers 7-9 ft.ENGINE ENGINE EXPLODED VIEW Stator/Starter Stator Wire Holddown 242 4. Apply Loctitet 271 to the bolt threads.5 ft. (12-13 Nm) Apply Loctitet 242 to the bolt threads.5 ft. (6-7 Nm) 242 8.5-9.5-9. lbs.

7 .ENGINE SPECIAL TOOLS PART NUMBER PV-43527 2200634 PU-45257 PU-45652 2871043 PU-44693 2870390 PU-45497-2 PU-45497-1 PU-45498 PU-45648 PA-44995 PU-45543 PU-45483 PU-45658 PA-45401 2870975 PU-45778 TOOL DESCRIPTION Oil Filter Wrench Valve Seat Reconditioning Kit Valve Spring Compressor Valve Pressure Hose Flywheel Puller Valve Train Table Piston Support Block Cam Gear Tooth Alignment Tool Cam Gear Spring Installation Kit (Tapered Pins) Cam Spanner Wrench Gear Holder Water Pump Mechanical Seal Installer Universal Driver Handle Main Seal Installer Main Crankshaft Seal Saver Water Pump Seal Saver Mity Vact Pressure Test Tool Oil System Priming Tool ACCESSIBLE COMPONENTS The following components can be serviced or removed with the engine installed in the frame: G G G G G G G G G G Flywheel Alternator/Stator Starter Motor/Starter Drive Cylinder Head Cylinder Piston/RIngs Camshaft Rocker Arms Oil pump/Water Pump and Oil Pump Drive Gear Gear Train Components The following components removal for service: G G G G G require engine Counterbalance Shaft or Bearing(s) Connecting Rod Crankshaft Crankshaft Main Bearings Crankcase 3.

(Nm) 26-30 (35-41 Nm) 4.5-9.5 (6-7 Nm) 8.5-5.5-5.5 (6-7 Nm) 20-24 (27-33 Nm) 8.5-9.5 (12-13 Nm) 9-11 (12-15 Nm) 3.5-5.5 (6-7 Nm) 33-37 (45-50 Nm) 4.5-9.ENGINE TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Camshaft Gear Camshaft Thrust Plate Carburetor Adaptor Counterbalance Gear Crankcase Crankcase Breather Cylinder Head Bolts Exhaust Manifold Flywheel Magneto Cover Oil Baffle Weldment Oil Drain Bolt (Crankcase) Oil Fill Tube Bolt Oil Filter Pipe Fitting Oil Pick Up Oil Pressure Relief Plug Oil Pressure Switch Oil Pump Housing Screw Rocker Arm Rocker Cover Spark Plug Starter Motor Stator Assembly Stator Housing Temperature Switch Thermostat Housing Timing Plug Trigger Coil/Stator Wire Holddown Water Pump Housing Cover Water Pump Impeller Nut Size 8 mm 6 mm 8 mm 8 mm 8 mm 5 mm 12 mm 8 mm 14 mm 6 mm 5 mm 12 mm 5 mm 20 mm 5 mm 10 mm 1/4-18 6 mm 8 mm 6 mm 14 mm 6 mm 6 mm 6 mm 3/8 PT 6 mm 3/4-16 5 mm 6 mm 8 mm 600/700 Ft.5-9.5 (12-13 Nm) 7-9 (10-12 Nm) 4.5-9.5 (12-13 Nm) 20-24 (27-33 Nm) 8.5 (12-13 Nm) 16-20 (22-27 Nm) 8.5-9. Lbs.5 (12-13 Nm) 8.lbs.5 (12-13 Nm) 16-20 (22-27 Nm) 8.8 .5 (12-13 Nm) 9-10 (12-14 Nm) 8.5-5.5 (12-13 Nm) 4.5 (6-7 Nm) 11-13 (15-18 Nm) 26-30 (35-41 Nm) 20-24 (27-33 Nm) 27--33 in.(3--4 Nm) 60-64 (68-73 Nm) 20-24 (27-33 Nm) 80-100 (109-136 Nm) 8.5-9.5-5.5-9.5 (6-7 Nm) 20--22 (27-30 Nm) 4.

10 15 11 14 13 12 2 6 3 1 5 4 3 6 2 Cylinder Head 1 7 Crankcase 5 4 9 8 PISTON IDENTIFICATION Four stroke engine rings have a rectangular profile. NOTE: The pistons have no directional identification marks. See text on Page 3.27 for ring installation.9 .ENGINE ENGINE FASTENER TORQUE PATTERNS Tighten cylinder head/cylinder base. EH680ALE EH590ALE Piston Length 80 mm 76.50 mm Standard Piston Identification None None 3. Use the information below to identify pistons and rings. New pistons are non--directional. and crankcase fasteners in the following sequence outlined below. Engine Model No.

010 mm) 1.0065”(3.20 -.20 + 0. .015 mm) 0.38 mm) 1.0039” (1.2825 mm) 0.07 0.2346” 0.00039” (41.40 mm) 1.0.EH059OLE 0.010 mm) 1.060 mm) 0.5118 0.010 mm) 1.10 mm) 0.51” 0.00039” (0.010 mm) 4.5550 0.010 mm) 1.34 mm) Valve Spring p g Overall length 3.00236” (5.07 0.0591” + 0.478” (88.2374” 0.00787” -.5610” 0.00394” (0.00098” (0.58 0.045 0.01476” (114.1 mm) 3.8267” (46.617” 0.50 + 0.2356” 0.637” 0.0.00039” (41.030 0.01 mm) 0.01 mm) 0.03 0.654” 0.0039” (1.375 mm) 4.25 0.656” 0.060 mm) Mag Center PTO j Camshaft journal bore Mag ID Center PTO Camshaft Oil clearStd ance End Play Counter Balance Cylinder y Head H d End Play 1.2170” 0 .3450 0.00787” -.00039” (41.025 mm) 0.0135” 0.127 mm) 0.00039” (5.10 .0.085 0.47” (37.50 0.985 0.010 mm) 1.00059” (6.01496” (115.45 0.ENGINE 600 ENGINE SERVICE DATA Camshaft Cylinder Head / Valve Cam lobe height In g Std Ex j Camshaft journal OD Std 0 .634” 0.00334” 0.488 0.0065” (3.00039” (5.20 -.5118 0.10 mm) 0.005” (0.541 0.00039” (42.25 0.75 0.010 mm) 0.00177” 0.35 mm) 0.00079” (0.00394” (14.1373” 0.00039” (42 0.00118” 0.614” 0.1394” 0.10 mm) 44.5453” .165 mm) Surface warpage limit Standard height Valve Seat Contacting width In Std Ex Std Valve G id Guide Valve Seat Angle Std Inner diameter Protrusion above head g Margin thickIn Std ness Ex Stem diameter Stem oil clearance g Overall length Std In Ex Std In Ex In Ex Free Length Installed Height 0.0472” + 0.96 0.02 mm) 0.00039” (41 0.0.00236” (5.2170” Engine No.0111” (0.165 mm) 0.

OS: Oversize. (20.00492” (0.0118” (76.00098I (20.00069” (0. .30 0.8438” 0.00006” (0.00015” 0.0125 mm) 0.017 mm) N/A 0.00031” (0.00027” 0.007 0.0175 mm) 0.01181” 0.00025” (21.39 8 0.10 mm) Limit 0.EH590ALOE 0.00098” 0.01476” 0.00062”(21.01181” 0.0015 mm) 0.00635 mm) 0.15 mm) 0.789” 0.25 0.00984” .0025 mm) 0.0075 mm) .009 mm) 0..5mm) 0.005 mm) Piston pin must be a push (by hand) fit at 68 F (20 C) Piston Pin Piston Ring g Connecting rod small end ID g Connecting rod small end radial l di l clearance Connecting rod big end side clearance Connecting rod big end radial clearance 0.01 mm) 0. OD: Outer Diameter.445 .4322 0.0002” (20 -.025 0.00393” (0.00039” (0.7874” -.008 mm) 0.0038 Crankshaft Crankshaft runout limit 0.Std: Standard.0022” .00591” (0.00049I (0.055 .0045 0.0017” 0.30 0.0157 mm) 3.78757” .060 mm) KEY .00030” (0.ENGINE 600 ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod Cylinder Surface warpage limit (mating with cylinder head) Cylinder bore Std Taper limit Out of round limit Piston clearance Limit Boring limit Lifter Outer Diameter Std Block Bore Std Piston Std Standard inner diameter of piston pin bore Outer diameter Standard clearance-piston pin to pin bore Degree of fit Piston ring installed g gap Top ring Limit Second ring Oil ring Limit Standard clearance piston ring to ring i t i t i groove Connecti R d ing Rod Top ring Limit Second ring Limit Std 0.005 mm) 0.0019” 0.00019” (0. PTO: Power Take Off Side 3.00067” (.010 mm) Limit Limit 0.00059”.0475 0.00039” (0. ID: Inner Diameter.84245” 0..00035I (76.015 mm) 0.0425 0.375 0.0096” .125 mm) Engine No. Mag: Magneto Side.00236” (0.030 0.004” (0.10 mm) 3.11 .

47” (37.00065” (5.5118 0.010 mm) 0.010 mm) 1.0472” + 0.5118 0.010 mm) 1.00118” 0.010 mm) 1.00039” (41 0.2170” 0.0515 0.0.0315 mm) 0.0065”(3.00039” (42.2170” 0.010 mm) 1.656” 0.0098” (0.165 mm) Surface warpage limit Standard height Valve Seat Contacting width In Std Ex Std Valve G id Guide Valve Seat Angle Std Inner diameter Protrusion above head g Margin thickIn Std ness Ex Stem diameter Stem oil clearance g Overall length Std In Ex Std In Ex In Ex Free Length Installed Height 0.01476” (114.1394” 0.0165 mm) 0.5453” .0591” + 0.9535 0.0.488 0.00236” (5.00079” (0.00039” (41.00394” (14.5550 0.2344” 0.010 mm) 1.0.10 mm) 0.5610” 0.060 mm) Mag Center PTO j Camshaft journal bore Mag ID Center PTO Camshaft Oil clearStd ance End Play Counter Balance Cylinder y Head H d End Play 1.00039” (41.00065” (5.20 -.00203” 0.0039” (1.25 mm) 0.01496” (115.00039” (42 0.614” 0.50 + 0.25 0.00236” (5.654” 0.2354” 0.00124” (0.58 0.50 0. .07 0.00787” -.75 0.07 0.541 0.10 mm) 0.165 mm) 0.9785 0.030 0.0167” 0.0165 mm) 0.03 0.0.20 -.40 mm) 1.127 mm) 0.00124” (0.02 mm) 0.0030” 0.0039” (1.375 mm) 4.0065” (3.34 mm) Valve Spring p g Overall length 3.ENGINE 700 ENGINE SERVICE DATA Camshaft Cylinder Head / Valve Cam lobe height In g Std Ex j Camshaft journal OD Std Engine No.1 mm) 3.00787” -.005” (0.20 + 0.478” (88.0315 mm) 4.38 mm) 1.12 .0765 0.35 mm) 0.060 mm) 0 .637” 0.51” 0.10 mm) 44.617” 0.00039” (41.2374” 0.EH68ALOE / EH068OLE 0 .015 mm) 0.1373” 0.25 0.00059” (6.8267” (46.425 0.45 0.634” 0.00394” (0.

0038 Crankshaft Crankshaft runout limit 0.00031” (0. (20.EH68ALOE / EH068OLE 0.0177” .00635 mm) 0.0.075 mm) 0.0002” (0.00394” (0.10 mm) 3.78789” .0125 mm) 0.0015 mm) 0.004” (0.0177” 0.1495” (80 mm) 0.00006” (0.00015” 0.0.0175 mm) 0.016 mm) N/A 0.008 mm) 0.0475 0.060 mm) KEY .00063” (.0000098I (20.0075 mm) .ENGINE 700 ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod Cylinder Surface warpage limit (mating with cylinder head) Cylinder bore Std Taper limit Out of round limit Piston clearance Limit Boring limit Lifter Outer Diameter Std Block Bore Std Piston Std Standard inner diameter of piston pin bore Outer diameter Standard clearance-piston pin to pin bore Degree of fit Piston ring installed g gap Top ring Limit Second ring Oil ring Limit Standard clearance piston ring to ring i t i t i groove Connecti Rod ing R d Top ring Limit Second ring Limit Std 0.0425 0.030 -.0017” 0.789” -.010 mm) Limit Limit 0.01181” 0. Mag: Magneto Side. .0025 mm) 0.00062”(21.003 mm) 0.25 mm) Limit 0.0157 mm) 3.0016” .275 0.00039” (0.01083” 0.0019” 0.041 . ID: Inner Diameter.0125 0.005 mm) 0.00059” 0.025 0.00591” (0.8438” 0. OS: Oversize. OD: Outer Diameter.00059”.00295” (0.00069” (0. PTO: Power Take Off Side 3.1477” .015 mm) 0.00098” 0.84245” 0.00236” (0.10 mm) Engine No.005 mm) Piston pin must be a push (by hand) fit at 68 F (20 C) Piston Pin Piston Ring g Connecting rod small end ID g Connecting rod small end radial l di l clearance Connecting rod big end side clearance Connecting rod big end radial clearance 0.00025” (21.00012I (79.39 8 0.015 0.4322 0.30 0.Std: Standard.13 .954 .45 0.0002” (20 .15 mm) 0.45 0.00984” (0.00049I (0.00030” (0.787” .

ENGINE COOLING SYSTEM SPECIFICATIONS Fan Switch (Off) Fan Switch (On) Hot Light On System Capacity Radiator Cap Relief Pressure Thermostat 149° F (65° C) ± 8° 180° F (82° C) ± 3° 221° F (105° C) 2. 2. The system must retain 10 psi for five minutes or longer.14 . If pressure loss is evident within five minutes. resulting in possible engine damage. Connect a Mity Vact (PN 2870975) to the filler neck nipple and pressurize system to 10 psi. The cooling system is under pressure and serious burns may result.25 Quarts 13 PSI Starts opening 176° F (80° C) Open 8mm @ 205° F (96° C) COOLING SYSTEM WARNING Never remove radiator cap when engine is warm or hot. Radiator Cap Pressure Test 1. Replace cap if it does not meet this specification. Allow the engine and cooling system to cool before servicing. clamps and water pump seals for leakage. 1. Surge Tank Filler Neck Assy. Remove radiator cap and test cap using a commercially available cap tester. depending on freeze protection required in your area. check the radiator. Upper Engine Hose Recommended Coolant Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio. FLOW Radiator Thermal Sensor Hose Thermostat Water Pump Lower Engine Hose Fan Cylinder Head Coolant Flow Diagram Top Cylinder Exploded View To Water Pump Shroud Radiator Radiator Front View Bottom Radiator Left Side View 3. Remove front cover. CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation. hoses. ready to use. The radiator cap relief pressure is 13 lbs. 2. Remove recovery bottle hose from coolant filler neck. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed. 3.

D NOTE: Use caution when lifting the engine out of frame.ENGINE ENGINE REMOVE & INSTALL 1. Disconnect battery negative (-) cable. 9. Remove cables. and inner cover (D). Clean work area. B 5. E C A 19. 2. Remove the frame brace (E) from the front left side of the frame. 20.15 . Drain coolant and engine oil. Remove air pre-cleaner and duct. For engine procedures. Remove engine to chassis ground cable. Insert a shop towel into the carburetor flange to prevent dirt from entering the intake port. 11. 16. 7. 4. Disconnect coolant temperature sensor wire. drive belt. Remove the air breather line (C). 6. 18. 15. Properly dispose of any antifreeze from the engine or hoses. Thoroughly clean the ATV engine and chassis. installation. 17. 10. Remove the engine from the left side of the frame. Remove the following parts as required: G Seat G Left and Right Side Covers (Refer to Chapter 5) G Fuel Tank Cover / Front Cab (Refer to Chapter 5) G Fuel Tank (Refer to Chapter 4) Remove springs from exhaust pipe and remove pipe. drive clutch. Use an engine lift or other means if the engine is too heavy to be lifted manually. 14. reverse these 3. Remove all engine mount nuts and / or engine mount plates. Refer to PVT System Chapter 6 to remove outer clutch cover. Remove airbox. 13. Disconnect spark plug high tension lead (B). When removing starter cables. Disconnect the coolant hoses. driven clutch. Remove transmission linkage rod from gear selector and secure out of the way. 12. 3. note and mark ground cable and positive(+) cable mounting angle and locations . 8. Remove carburetor (A).

2. Refer to Chapter 2 and Chapter 8. 2. PVT System 1. Exhaust 1. Serious engine damage and voiding of warranty can result. Install previously removed components using new gaskets. Remove radiator cap and slowly add coolant to the bottom of filler neck. Install radiator cap and gently squeeze coolant hoses to force any trapped air out of system. 4. Perform regular checks on fluid levels. 5. 2.16 . alignment. 3. Do not operate at sustained idle or sustained high speed. Bleeding generally should not be necessary. Start engine and observe coolant level in the radiator. Fill fuel tank with unleaded or leaded fuel which has a minimum pump octane number of 87= (R+ M)/2. 7. After engine is cool. seals. Check to be sure all springs are in good condition. Vary throttle positions. (Chapter 6) Transmission 1. or the time it takes to use two full tanks of gasoline. and belt deflection. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully. 3. Adjust center distance of drive and driven clutch. Add oil if necessary. Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing. 4. NOTE: Should the reservoir tank become empty. 1. Excessive heat can build up and cause damage to close fitted engine parts. (Chapter 6) 3. 6. Again.ENGINE ENGINE INSTALLATION NOTES After the engine is installed in the frame. review this checklist and perform all steps that apply: General Items 1. Pull only light loads during initial break in. No single action on your part is as important as a proper break in period. Inspect transmission operation and adjust linkage if necessary. Reinstall radiator cap and bring engine to operating temperature. Do not operate at full throttle or high speeds for extended periods during the first three hours of use. 2. Seal connections with high temp silicone sealant. Fill coolant reservoir tank to full mark. (Chapter 6) 2. Change break in oil and filter at 20 hours or 200 miles. Engine Break In Period The break in period for a Polaris ATV engine is defined as the first ten hours of operation. 1. Adjust clutch offset. check level in reservoir tank and add coolant if necessary. Drive slowly at first to gradually bring engine up to operating temperature. controls. Perform regular checks on fluid levels. Replace exhaust gaskets. controls and all important areas on the vehicle. Allow air to purge and top off as necessary. and fasteners where applicable. remove radiator cap and slowly add coolant to the bottom of fill neck if needed. Bleed Cooling System NOTE: This cooling system contains vent lines to help purge trapped air during filling.6 for hose routing. Refer to page 3. it will be necessary to refill at the radiator and repeat the bleeding procedure. and all important areas on the vehicle as outlined in the daily pre-ride inspection checklist (refer to Chapter 2 or the Owner’s Manual). 5. SAFE ADD 8 OZ 3. CAUTION Use only Polaris Premium 0--40W All Season synthetic oil or equivalent. Never substitute or mix oil brands. Check oil reservoir level indicated on dipstick.

Wet honing removes more material faster and leaves a more distinct pattern in the bore. Engine at operating temperature. Hone cylinder according to hone manufacturer’s instructions. NOTE: Use only Polaris Premium 0--40W Synthetic Engine Lubricant. HONING TO DEGLAZE A finished cylinder should have a cross-hatch pattern to ensure piston ring seating and to aid in the retention of the fuel/oil mixture during initial break in.17 . Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations.9 l) Filter . 2. Remove blind plug/sender from left side of crankcase. Polaris recommends using a rigid hone or arbor honing machine. Start engine and allow it to reach operating temperature. then in hot. Using a common spring loaded glaze breaker for honing is not advised for nicasil cylinders.ENGINE CYLINDER HONE SELECTION AND HONING PROCEDURE CAUTION: A hone which will straighten as well as remove material from the cylinder is very important. If cylinder wear or damage is excessive. 3.3 cm) above and below the bore at the end of each stroke. it will be necessary to replace the cylinder. OIL PRESSURE TEST 1. NOTE: Do not allow cylinder to heat up during honing. G Release the hone at regular intervals and inspect the bore to determine if it has been sufficiently deglazed. inspect cylinder for thinning or peeling.Polaris Premium 4 Synthetic (PN 2871281) or API certified “SH” 5W30 oil Capacity .25--34 PSI @ 5500 RPM. G ENGINE LUBRICATION Oil Type . or these guidelines: Use a motor speed of approximately 300-500 RPM.(PN 2540006) Filter Wrench . Wash the cylinder in a solvent. Rinse thoroughly. and oil the bore immediately with Polaris 4 Cycle Lubricant to prevent the formation of surface rust.Approximately 2 U. Oil Pressure at 5500 RPM (Engine Hot): Standard: 34 PSI Minimum: 25 PSI 3. Use electrical contact cleaner if necessary to clean these areas. Hone only enough to deglaze the outer layer of the cylinder bore. Polaris 0W--40 Synthetic . soapy water. G After honing has been completed. dry with compressed air. monitoring gauge indicator.PV-43527 or equivalent Oil Pressure Specification .S. EXAMPLE OF CROSS HATCH PATTERN IMPORTANT: Clean the Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Remember to keep the hone drive shaft centered (or cylinder centered on arbor) and to bring the stones approximately 1/2² (1. and to check for correct cross--hatch. run the hone in and out of the cylinder rapidly until cutting tension decreases. The cylinders are lined with a nicasil coating and are not repairable. Insert a 1/8 NPT oil pressure gauge adaptor into the crankcase and attach the gauge. Quarts (1.

Beginning in the crankcase sump. The oil pressure switch is fed off the main oil galley. 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.18 . the oil is drawn through an oil galley to the feed side of the oil pump. onto the rear balance shaft journal and then draining back into the crankcase sump. with the first path entering the camshaft bores. If the oil filter is obstructed. The oil is then pumped through the oil filter. 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.ENGINE OIL FLOW This chart describes the flow of oil through the EH68 and the EH059 engine. Oil is then diverted three ways from the main oil galley. Crankshaft Main Bearing Crankcase Sump Rod Bearings Crankshaft Main Bearing Counterbalance Bore Counterbalance Bore Camshaft Bore Camshaft Bore Camshaft Bore PTO SIDE Lifter Bores Oil Pressure Relief Main Oil Gallery Pump Filter MAGNETO SIDE Crankcase Sump 3.

nicks or burrs. The push rods (A) can be visually checked for straightness while they are installed in the engine by rotating them with the valve closed. Loosen the six cylinder head bolts evenly 1/8 turn each in a criss--cross pattern until loose. If the pad is grooved. cracks. replace the rocker arm. WARNING Always wear safety glasses when working with compressed air to prevent personal injury. Blow dry push rods with compressed air. 4. PUSH ROD INSPECTION 1. Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness. A 2. grooves. B C D 3. A 3. Use compressed air to confirm the oil passage is clear in the center of the push rod. Inspect the wear pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. roughness or excessive wear. 3. CAUTION: Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging the head or cylinder. 2. Remove cylinder head (B) and head gasket (C) from the cylinder (D).ENGINE ROCKER ARM INSPECTION 1. 3. If the push rod (A) is visibly bent. it should be replaced. Clean push rods (A) in a suitable solvent. 5. Remove bolts (A) and tap cylinder head (B) lightly with a soft face hammer until loose.19 . NOTE: Do not attempt to true this surface by grinding. 2. Check the rocker arm pad and fulcrum seat for excessive wear. CYLINDER HEAD REMOVAL 1. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. Check the ends of the push rods (A) for nicks.

ENGINE CYLINDER HEAD INSPECTION 1. CAUTION: Use care not to damage sealing surface.20 . Valve Spring Compressor: (PU-45257) Valve Pressure Hose: (PU-45652) NOTE: To prevent damage to the valve seals. Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon. WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly. do not compress the valve spring more than is needed to remove the valve keepers. rocker arms and pushrods. Valve Train Servicing In some cases the valve train can be serviced while the cylinder head is still on the engine. 3. 2. Keep all parts in order with respect to their location in the cylinder head. align the cylinder to be worked on at top dead center. If warpage exceeds the service limit. Install the Valve Pressure Hose (PU-45652) into the spark plug hole. This will seat the valves during valve spring removal. replace the cylinder head. PU-45257 Bottom Side View A Cylinder Head Warpage Limit: 004² (. Remove spring retainer and spring. NOTE: A small parts magnet (A) can aid in the removal of the retainers (B).1016 mm) Max. A 1. 4. B B Measure at different points on the surface. 3. compress the valve spring and remove the valve keepers. Hook the hose to an air compressor and supply 50 to100 psi to the hose. The valve seals are now serviceable. Lay a straight edge (A) across the surface of the cylinder head (B) at several different points and measure warpage by inserting a feeler gauge between the straight edge and the cylinder head surface. CYLINDER HEAD WARPAGE 1. CYLINDER HEAD DISASSEMBLY NOTE: The following procedure is only for servicing the top end of the valve train when replacing valve springs or replacing valve seals. Having already removed the valve cover. Do not remove air from the hose at anytime until reassembly is completed. Using the Valve Spring Compressor (PU-45257).

Replace spring if measurement is out of specification. NOTE: If working on the cylinder head while removed from the engine assembly. clean area. Mark the valves with a white pen. This will ensure that the valves are properly placed during engine reassembly.21 . Remove valve guide seals. Place the hydraulic lifters (C). use the Valve Train Table (PU-44693) to perform cylinder head work. Remove the valves from the cylinder head. Valve Spring Free Length 3.34 mm) 6.40 mm) Installed Height: 1. D C 7. Measure free length of spring with a Vernier caliper. Compare to specifications.827I (46. The cylinder head attaches simply to the table. Hardened.ENGINE CYLINDER HEAD DISASSEMBLY. PU-44693 Valve Spring Length: Std: 1. E Mark the valves 5. pushrods (D). cracked or worn valve seals will cause excessive oil consumption and carbon buildup. IMPORTANT: It is recommended to replace seals whenever the cylinder head is disassembled.47” (37. CONT. and rocker arms (E) in a safe.

00059” (6. To check for bent valve stems.22 . 3. Remove all carbon from valves with a soft wire wheel or brush. Rotate the valve 90 degrees and measure for wear. 2.2346” 0.96 0. Measure diameter of valve stem with a micrometer in three places. Measure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer. if necessary. or damaged. Compare to specifications.985 0.01 mm) Measure valve stem in several places. 5. Valve Guide I. NOTE: The valve guides cannot be replaced. burnt. Be sure to measure each guide and valve combination individually. Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance. Valve Stem Diameter: Intake: 0.015 mm) 7.: 0. wear or damage (A). pitting.2374” 0.030 0.ENGINE VALVE INSPECTION 1. 6. then rotate 90 degrees and measure again (six measurements total).00039” (5. and burnt spots.2356” 0. Measure in two directions.00039” (5. Check end of valve stem for flaring. mount valve in a drill or use “V” blocks and a dial indicator. NOTE: The valves can be re-faced or end ground. Check valve face for runout.D. Inspect split keeper groove for wear or flaring of the keeper seat area (B). pitting. 3. They must be replaced if extensively worn.01 mm) Exhaust: 0. Valve Guide A B 4. bent.

Wear safety glasses during cleaning. roughness. heat transfer from valve to seat is reduced. Place 46° cutter on the pilot and make a light cut. burnt spots. 1. Follow the manufacturers instructions provided with the valve seat cutters in the Cylinder Head Reconditioning Kit (PN 2200634). IMPORTANT: Do not use a wire brush. Combustion Area seat reconditioning equipment can also be used. and uneven surface. Clean all accumulated carbon deposits from combustion chamber and valve seat area with carbon cleaner and a soft plastic scraper. If the seat is too wide. Too Wide Uneven Good Too Narrow VALVE SEAT RECONDITIONING Cylinder Head Reconditioning NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area. the valve seat must be reconditioned. If the valve seat is cracked the cylinder head must be replaced. 4. resulting in burnt valves. The valve may overheat and warp. G If the cutter now contacts the uncut portion of the seat. compression leakage will result. If the pilot is bent it must be replaced. Inspect the cut area of the seat: G If the contact area is less than 75% of the circumference of the seat. 3. Keep all valves in order with their respective seat. NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing.23 . Install pilot into valve guide. Abrasive stone 3. rotate the pilot 180° and make another light cut. or runout. and the seat must be the proper width all the way around. The valve must contact the valve seat over the entire circumference of the seat. causing carbon accumulation and possible compression loss. Look for burrs. metal scraper. seat pressure is reduced. check the pilot. If any of the above conditions exist. If the seat is uneven. WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly.ENGINE COMBUSTION CHAMBER 1. nicks. 2. If the seat is too narrow. or abrasive cleaners to clean the bottom of the cylinder head. Extensive damage to the cylinder head may result. NOTE: The cylinder head valve guides cannot be replaced. Apply cutting oil to valve seat and cutter. Valve Seat Inspection Inspect valve seat in cylinder head for pitting.

apply a thin coating of Prussian Bluet paste to the valve seat. The valve seat should contact the middle of the valve face or slightly above.8 mm) 3. NOTE: Remove only the amount of material necessary to repair the seat surface.0 mm) Limit: . measure seat width. use both top and bottom cutters to narrow the seat. Remove valve and check where the Prussian Bluet indicates seat contact on the valve face. Seat Width Valve Seat Width: Intake Std: . When contact area is centered on the valve face.071I (1. If using an interference angle (46°) apply black permanent marker to the entire valve face (A). continue to cut the seat until all pits are removed and a new seat surface is evident. and is a normal condition. (B) (B) (A) Proper Seat Contact On Valve Face Bottom .028I (. the valve guide is distorted from improper installation and must be replaced. G G If the seat is too narrow.7 mm) Limit: . Use the 30° cutter to lower the valve seat.039I (1. To check the contact area of the seat on the valve face.60° (A) Seat . 7. use the 60° cutter to raise the seat. and must be the proper width. widen using the 45° cutter and re-check contact point on the valve face and seat width after each cut.45° Top .ENGINE VALVE SEAT RECONDITIONING CONT’D If the contact area of the cutter is in the same place. NOTE: When using an interference angle. Look for an even and continuous contact point all the way around the valve face. Be sure the cylinder head is at the proper temperature and replace the guide.055I (1.24 . G If too low.30° 6. G If the indicated seat contact is at the top edge of the valve face and contacts the margin area(B) it is too high on the valve face. G If the seat is too wide or uneven.4 mm) Exhaust Std: . the seat contact point on the valve will be very narrow. Insert valve into guide and tap valve lightly into place a few times. 5. G If the contact area of the initial cut is greater than 75%.

2. NOTE: A small parts magnet can aid in installation of the keepers. and repeat process for the other valve(s). Install valve carefully with a rotating motion to avoid damaging valve seal. rotate 1/4 turn. 10. 1. do not compress the valve spring more than necessary to install the keepers. and repeat the lapping process. 5. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem. 6. NOTE: To prevent damage to the valve seals. When all valves are installed. Install new valve seals on valve guides. (PU-45257) CYLINDER HEAD REASSEMBLY NOTE: Assemble the valves one at a time to maintain proper order. Lift the valve slightly off of the seat. tap lightly with soft faced hammer on the end of the valves to seat the split keepers.ENGINE VALVE SEAT RECONDITIONING CONT”D 8. Install split keepers with the gap even on both sides. 12. Do this four to five times until the valve is fully seated.25 . Rotate the valve rapidly back and forth until the cut sounds smooth. Repeat procedure for remaining valves. Coat valve stem with molybdenum disulfide grease or 0W--40 Synthetic oil. 3. Dip valve spring and retainer in clean engine oil and install. Clean all filings from the area with hot soapy water. 9. 7. and dry with compressed air. 11. WARNING Wear eye protection or a face shield when working with compressed air during cylinder head disassembly and reassembly. rinse. Apply engine oil to valve guides and seats. Lubricate the valve guides with clean engine oil. and apply oil or water based lapping compound to the face of the valve. Thoroughly clean cylinder head and valves. 3. Place retainer on spring and install Valve Spring Compressor (PU-45257). NOTE: Lapping is not required with an interference angle valve job. 4.

23 for cleaning tips. Refer to Page 3. LBS. Pour a small amount of clean solvent onto the intake port and check for leakage around each intake valve. 3. The valve seats should hold fluid with no seepage.26 .ENGINE VALVE SEALING TEST 1. 2.50 NM) SPRING RETAINERS RETAINER LOCKS PUSH RODS SPRINGS GUIDE SEALS HEAD HYDRAULIC LIFTERS VALVES 3. Repeat for exhaust valves by pouring fluid into exhaust port. Clean and dry the combustion chamber area (A). (27-32. A VALVE TRAIN EXPLODED VIEW ROCKER ARMS 20-24 FT.

7. Verify pushrods are engaged in lifters.27 . F Cylinder Head Bolt Torque: 60-64 ft. Lubricate rockers (E) with engine oil. Lubricate push rods (D) and install into lifters.9. C 6. lbs. This will ensure proper sealing when installing bolts and new Loctitet. 4. Torque bolts to 20-24 ft. following torque pattern on Page 3. Install the head gasket (A) on the cylinder (B). Install rockers. lbs. Install head bolts (C). 1. D A 5.ENGINE ENGINE HEAD REASSEMBLY Before reassembly. Install cylinder head on cylinder. lbs. (81-87 Nm). clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. (81-87 Nm) Rocker Arm Bolt Torque: 20-24 ft. (27-33 Nm). 3. lbs. (27-33 Nm) 3. Be sure that tab of fulcrum (F) is seated in head stand-off. Torque bolts to 60-64 ft. E B 2.

This will ensure proper sealing when installing bolts and new Loctitet. lbs. (22-27 Nm) Rocker Cover Bolt Torque: 8. Torque bolts to 8.5-9.lbs. lbs.5 ft. lbs.5-9. Apply Loctitet 271 (PN 2871954) to the bolts.5-9.28 . NOTE: When applying RTV. (3--4 Nm). (12-13 Nm) I G 12. Torque bolts to 8.5 ft.5-9. Install and torque to 16-20 ft. clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris.5 ft. (22-27 Nm). Install breather reed (G) into rocker cover (H). REMINDER: Before assembly.ENGINE ENGINE HEAD REASSEMBLY CONT’D 8. The reed has a tab and will assemble one way only. 27--33 in. Be sure the seal is seated into the cover properly. (12-13 Nm) 3. 10.5 ft. Install thermostat (J). K Apply pipe dope or Teflon tape to threads. (12-13 Nm) 11. lbs. Install rocker cover. Lightly apply black RTV sealant to the outer edges of the breather reed. Apply pipe dope or Teflon tape to pipe threads of temperature sender (K). Place a new seal (I) into the bottom of the cover. Torque the breather bolts to 27--33 in. lbs. J H Thermostat Housing Bolt Torque: 8. 9.5 ft. Apply Loctitet 271 (PN 2871954) to the bolts of the cover. do not get any RTV inside the reed assembly. (12-13 Nm). lbs. Temperature Sender Torque: 16-20 ft. (3--4 Nm) 8.5-9. lbs. Apply Loctitet 271 (PN 2871954) to the bolts. lbs.12-13 Nm).

2. Rock cylinder forward and backward while lifting it from the crankcase. 4. heat the crown of the piston slightly with a propane torch. Mark the piston A NOTE: If the pistons are to be reused. 6. If necessary. Mark the lifters with a white pen if using the lifters for reassembly. A Inspect Hydraulic Lifter NOTE: Lifters that are scored. Remove the valve lifter’s by reaching into the crankcase and pushing the lifter up through the lifter bore by hand. 5. reassemble the pistons in the same cylinder and direction from which they were removed. Mark the Hydraulic Lifter PISTON REMOVAL 1. 2. Check the bottom end of lifter to make sure that it has a slight convex. Support pistons with Piston Support Block (PN 2870390).29 . the camshaft should also be replaced. 2. it may be used with the original camshaft only. NOTE: New pistons are non--directional and can be placed in either cylinder. 3. worn. This will ensure that the lifters are properly placed during engine reassembly. Remove circlip (A). Tap cylinder (A) lightly with a rubber mallet in the reinforced areas only until loose. If the bottom surface has worn flat. Remove piston circlip and push piston pin out of piston. Follow engine disassembly procedures to remove rocker cover and cylinder head. If replacing the lifters. Thoroughly clean the lifters in cleaning solvent and wipe them with a clean lint-free cloth. Check the lifters for wear or scores. supporting pistons and connecting rods. or if the bottom is not smooth should be replaced with new lifters and cam as an assembly. VALVE LIFTER REMOVAL/INSPECTION 1. 3. CAUTION: Do not 3.ENGINE CYLINDER REMOVAL 1. Mark the piston with a white pen to ensure proper orientation (if reused) during assembly.

Refer to Ill. A B Measure at different points on the surface. *By hand: Placing both thumbs as shown. 5.30 . spread the ring open and push up on the opposite side. The ring may lose radial tension. 1 and Ill. Remove the oil control ring. To Remove: a) Remove the top rail first followed by the bottom rail. Inspect the top of the cylinder (B) for warpage using a straight edge (A) and feeler gauge (C). CAUTION: Do not expand the ring more than the amount necessary to remove it from the piston.ENGINE apply heat to the piston rings. Compression Rings B Oil Ring CYLINDER INSPECTION 1. Do not scratch the ring lands. The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section. Remove all gasket material from the cylinder sealing surfaces. Repeat procedure for second ring. or the ring may break. b) Remove the expander. 2. Remove top compression ring: *Using a piston ring pliers: Carefully expand ring and lift it off the piston. 2. 3. The top rail has a locating tab on the end which fits into a notch (B) in the upper oil ring land of the piston. 4.1 Top View 3. Ill.

002I (. the cylinder must be replaced. front to back and side to side.004 (0.05mm)Max. .2 X Cylinder Warpage.ENGINE B A 1/2 Down From Top of Cylinder X Y Y X C Y Ill. in the middle.05mm)Max.31 . 3. Inspect cylinder for wear. Cylinder Out of Round Limit: . Record measurements. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin.002.1 mm) Max. Subtract this measurement from the maximum cylinder measurement obtained in Step 5.002I (. scratches. Measure in two different directions. or damage. If cylinder is tapered or out of round beyond . and 1/2 up from bottom).50 mm) PISTON-TO-CYLINDER CLEARANCE 4.0018” (76. on three different levels (1/2 down from top. Cylinder Taper Limit: . 1/2 Up From Bottom 3. 5.1496I (80 mm) Sportsman 600: 3. Standard Bore Size (Both Cylinders): Sportsman 700 : 3.

015 mm) Piston Pin Bore: 600: 0.0002” (0.030 . 5 mm Piston Piston Pin Piston Pin Measurement Locations Piston to Cylinder Clearance 600: . .00035I (76.D.ENGINE 2.32 .005 mm) 4. Measure piston pin bore. PISTON/ROD INSPECTION 1.D.003 mm) .445 .0018” .20.78841”.007 0. 0.954 . 3.00063” (.995 mm) 3. Replace piston and rings if ring-to-groove clearance exceeds service limits.00019” (0.016 mm) Piston Pin O.789” .. Measure piston pin O.D.005 mm) 700: 0. Replace piston and/or piston pin if out of tolerance.0096” 700: 3.1477” .D.015 0.00059” 0. 600: 3.009 mm) . Connecting Rod Small End I. Measure connecting rod small end ID.00012I (79.00067” (.19.7872” (20 .7874” ..017 mm) .041 Piston O.0022” 700: . Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. (20.055 .00027” 0.

ENGINE

Piston Ring Installed Gap 600 Piston Ring Top Ring: 0.01181” 0.00393” (0.30 0.10 mm) Second Ring Limit: 0.01476” 0.00492” (0.375 0.125 mm) Oil Ring Limit: 0.00984” .00393” (0.25 0.10 mm) 700 Feeler Gauge Top Ring Limit: 0.01083” 0.00295” (0.275 0.075 mm) Second Ring Limit: 0.0177” 0.00394” (0.45 0.10 mm) Oil Ring Limit: 0.0177” .00984” (0.45 0.25 mm) NOTE: Ring should be installed with the mark on the ring facing upward. 2. Measure installed gap with a feeler gauge (C) at both the top and bottom of the cylinder. 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 smaller than the specified limit, file ring ends until gap is within specified range. NOTE: Always check piston ring installed gap after re-boring a cylinder or when installing new rings. A re-bored cylinder should always be scrubbed thoroughly with hot soapy water, rinsed, and dried completely. Wipe cylinder bore with oil immediately to remove residue and prevent rust.

Piston Ring-to-Ring Groove Clearance Top Ring Limit: 0.0019” 0.00069” (0.0475 0.0175 mm) Second Ring Limit : 0.0017” 0.00049” (0.0425 .0125 mm)

PISTON RING INSTALLED GAP
1. Place each piston ring (A) inside cylinder (B) using piston to push ring squarely into place as shown. (See next page)

C
B 25-50mm

STARTER DRIVE/BENDIX REMOVAL/INSPECTION
1. Remove stator housing bolts and remove 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 1/4 or stator coils may be damaged. 3. Remove starter bendix assembly (A). Note the thrust washers located on both sides of the bendix.

A

3.33

ENGINE

B C

4. Inspect the thrust washer for wear or damage and replace if necessary. 5. After the bendix is removed, tap on the starter assembly with a soft faced mallet to loosen the starter from the crankcase.

FLYWHEEL/STATOR REMOVAL/INSPECTION
1. Remove stator housing bolts and remove housing.

B

6. Inspect gear teeth on starter drive (B). Replace starter drive if gear teeth are cracked, worn, or broken. 7. Inspect the bendix bushing (C) in the mag cover for wear. Replace as needed.

2. Remove flywheel nut and washer. 3. Install Flywheel Puller (PN 2871043) and remove flywheel (A). CAUTION: Do not thread the puller bolts into the flywheel more than 1/4² or stator coils may be damaged. See next page.

3.34

ENGINE
lock, so Loctitet is not needed on the new bolts. Torque bolts to 9--10 ft. lbs. (12--14 Nm). 2871043

A 4. Use caution when removing the wire holddown (B), trigger coil (C), and the stator assembly (D). Do not tap or bump the gear /stator housing cover or the stator. This could cause the seal around the gear/stator housing cover and the crankcase to break, causing a leak. E C B Flywheel Nut Torque: 80-100 ft. lbs. (108.50-135.60 Nm) 5. Inspect the mating surface around the gear/stator housing cover and the crankcase for oil seepage. If there is seepage between the mating surfaces, then the gear/stator housing cover must be resealed. Clean the gearcase surfaces and reseal with a new gasket. Refer to the Lower Engine Disassembly section and the Lower Engine Assembly section for details. lnspect the areas pointed out in the photograph for possible oil seepage.

3. Install the starter bendix if removed. 4. Install woodruff key. Install the flywheel. Install the flywheel washer and nut. Apply Loctitet 242 (PN 2871949) onto the threads. Torque the flywheel nut to 80--100 ft.lbs. (109--136 Nm)

D 5. Remove the bendix (E) if necessary.

FLYWHEEL/STATOR INSTALLATION
NOTE: 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. 1. Carefully install the stator and trigger coil to the gear/stator housing cover. Do not tap on the stator or the gear stator housing cover. This may cause a leak in between the gear/stator housing cover and the crankcase. 2. Properly place the stator wires under the wire holddown and install the bolts. Apply LocTitet242 (PN 2871949) onto the bolts. Inspect the bolts, if new bolts are needed, replace them with new bolts. The new bolts contain patch

FLYWHEEL/STATOR INSTALLATION 6. Install stator housing with new O-rings. Apply LocTitet271 (PN 2871954) onto the bolts.

3.35

ENGINE
Torque the bolts to 8.50--9.50 ft. lbs. (12--13 Nm). E

C

D

Stator Housing Bolt Torque: 8.50-9.50 ft. lbs. (12-13 Nm)

3. Remove flywheel nut and washer. 4. Install Flywheel Puller (PN 2871043) and remove flywheel (F). CAUTION: Do not thread the puller bolts into the flywheel more than 1/4² or stator coils may be damaged.

2871043

ENGINE LOWER DISASSEMBLY/INSPECTION
1. Remove the stator cover (A) and water pump cover (B). A F 5. Remove the starter bendix (G), wire holddown plate (H), and the woodruff key (I) from the crankshaft. The stator does not have to be removed at this point.

I B 2. Remove the nylok nut (C), washer (D), and water pump impeller (E). Remove part of the water pump seal behind the impeller.

G

H

3.36

ENGINE
ENGINE DISASSEMBLY CONT’D 6. Remove the gear/stator housing bolts and remove the gear/stator housing cover (J) and gasket from the crankcase. Be sure to catch the excess oil from the crankcase. camshaft gear (K), water/oil pump gear (L), crankshaft gear (M), or counterbalance gear (N).

Cam Gear Removal
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 bolt and cam gear assembly. PU-45497-2

J

O

7. Note the positions of the gears in the photo. Water/oil pump Gear Camshaft Gear NOTE: Install the Cam Gear Tooth Alignment Tool (PU-45497-2) into the assembly hole counter clockwise from the timing mark as shown.

Cam Gear Alignment Tool: (PU-45497-2)

Cam Gear Disassembly
Crank Gear Counterbalance Gear 10. Inspect the cam gear teeth and check to make sure there is spring tension offsetting the teeth between the two gears. If there is no tension, check the springs inside of the cam gear assembly.

8. Use a white pen to accent the timing marks on the gears. This will ensure proper gear alignment and timing during reassembly of the gears. Timing Marks K L

3 Loaded Spring

N M NOTE: It is recommended to replace all of the gears if any of the following gears are to be replaced: 11. The cam gear assembly contains three loaded springs. To open the cam gear assembly:

3.37

38 . Remove the top gear. Install the new springs into the grooves of the cam gear. USE CAUTION WHEN WORKING WITH THE TOP GEAR.ENGINE G G Place the cam gear on a flat surface with the timing mark side facing up. Inspect Teeth & Tabs G CAUTION: WEAR SAFETY GLASSES AT ALL TIMES. 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. With a white marking pen. Insert Springs PU-45497-1 13. PU-45497-1 3. 12. Insert the pointed dowels from the Tapered Pins (PU-45497. Remove all three springs using one of the tapered pins from the Tapered Pins (PU-45497-1). While holding both gears together.into the cam gear. lightly work a small flathead screwdriver between the two gears. -1) 14. accent the timing mark on the gear that contains the springs. Accent the Timing Marks 16. Replace Three Springs Cam Gear Reassembly 15. THE SPRINGS COULD CAUSE INJURY OR BECOME LOST SHOULD THEY POP OUT. The springs should stay in place.

PU-45497-1 20. NOTE: Install the Cam Gear Alignment Tool (PU-45497-2) into one assembly hole counter clockwise from the timing mark.are below flush with end of the -1) springs. After the tapered pins are removed. NOTE: Do not remove the tapered pins at this time. Use the Cam Gear Tooth Alignment Tool (PU-45497-2) (R) to align the teeth of the cam gears. be sure the cam gear assembly is held together tightly. G G Align Timing Marks 19.ENGINE CAM GEAR REASSEMBLY CONT’D To assemble: Hold the spring with one finger. firmly hold the gears together with one hand. using both hands and hold securely. Place the cam gear assembly on a flat surface. Once the gears are pressed together. G Perform this procedure with all three tapered pins. Cam Gear Spring Installation Tool Kit: (PU-45497) Tapered Pins: (PU-45497-1) Cam Gear Tooth Align Tool: (PU-45497-2) 18. Push the gears back together. Line up the two gears using the timing marks and the three gear tabs that were referenced earlier. 17. Note in the photograph that the Tapered Pins (PU-45497. 3. This helps to align the three gear tabs during the next step. as shown in the picture.39 . G Do not push the pins too far through or the springs will pop out. Carefully remove the Tapered Pins (PU-45497-1) by pulling them out one at a time with the other hand. Start the pointed end of the tapered pin into the cam gear hole and slowly push the dowel through the hole until the end of the dowel is almost flush with the spring.

ENGINE

2871043

PU-45497-2

NOTE: For ease of installing the Cam Gear Alignment Tool (PU-45497-2) (R), use a twisting motion when pushing down on the tool. ENGINE DISASSEMBLY CONT’D 21. To remove the balance shaft gear, the flat side of the camshaft (P) must face the balance shaft gear. To rotate the camshaft, use the Cam Spanner Wrench (PU-45498) to rotate the camshaft so the flat side of the camshaft faces the balance shaft gear. PU-45498

23. Inspect the crankshaft gear (Q) for broken or worn teeth. If the crankshaft gear does not need to be replaced, it does not need to be removed. If the crankshaft gear is damaged, remove the crankshaft gear with the Flywheel Puller (PN 2871043).

Q

24. Install the two puller bolts (R). Tighten the puller bolts up so that the bolts are at equal length. R P

NOTE: This Cam Spanner Wrench (PU-45498) is only needed to rotate the camshaft when the entire valve train is assembled. If the rocker arms are removed, the cam--shaft can be turned by hand. 22. Remove the bolt and nut from the balance shaft gear. Try to remove the balance shaft gear. If the gear does not come off manually, use the Flywheel Puller (PN 2871043) to remove the balance shaft gear.

25. Install the Flywheel Puller (PN 2871043) and remove the flywheel, if needed.

3.40

ENGINE

2871043 Mark Rotors

NOTE: If replacing the old rotors, new replacement rotors will fit into the old oil/water pump housing.

Water/Oil Pump Removal/Disassembly

26. Rotate the water/oil pump gear (S), so that all four bolts are visible though the gear. Remove the four bolts with a hex wrench. Pull out the pump. S

28. Remove the oil pressure relief. The oil pressure relief consists of a bolt, washer, spring, and valve (dowel). Inspect the the valve (dowel) for signs of possible obstructions. Use compressed air to blow out any debris.

27. Inspect the oil pump rotors for wear. Mark the rotors with a white pen to ensure upon reassembly that the correct sides of the rotors are installed and mesh with the same edges as previously installed.

29. Reinstall the valve (dowel tapered end first). Install the spring, washer, and bolt. Torque the bolt to 20--24 ft. lbs. (27--33 Nm).

20--24 ft.lbs. (27--33 Nm)

3.41

ENGINE
NOTE: Be sure to place the tapered end of the valve (dowel) in first. If the valve is installed incorrectly, oil pressure and oil priming problems will occur.

Press out gear

DISASSEMBLY OF WATER/OIL PUMP SHAFT
Wear appropriate safety gear during this procedure. Heat resistant gloves, clothing and eyewear are required. 30. Heat oil/water pump drive housing (T). Remove from shaft using a soft hammer. T
WARNING

Heat Housing

33. Press bearing from shaft. Replace the old bearing with a new bearing during assembly.

Bearing

31. Remove the gear shaft from the water/oil pump housing.

WATER/OIL PUMP REASSEMBLY 34. Press shaft into new gear. NOTE: Boss side of gear faces out.

32. Press gear from shaft.

3.42

ENGINE
clothing and eyewear are required. 37. Remove thrust plate (U).

U Gear Boss

35. Apply Loctitet 609 to the pump shaft to help secure the bearing. Press on a new bearing. 38. Remove PTO end engine mount. Remove crankcase bolts. Tap on the reinforced areas on the cases using soft hammer. Carefully separate the two crankcase halves.

Separate the crankcase halves 36. Warm the housing. Apply Loctitet to bearing outer race. Slide housing securely onto shaft and bearing.

NOTE: Only remove the oil baffle if the baffle is damaged. When removing the oil baffle bolts, use a heat gun to heat the bolts and loosen the Loctitet. This will prevent any possible damage to the bolts or to the crankcase casting.

Warm the Housing

Wear appropriate safety gear during this procedure. Heat resistant gloves,

WARNING

3.43

ENGINE
ENGINE LOWER DISASSEMBLY/INSPECTION CONT’D 39. Remove and clean oil pick up (V) and oil baffle weldment (W).

W

V 40. Remove balance shaft and crankshaft.

CAMSHAFT INSPECTION
1. Thoroughly clean the cam shaft. 2. Visually inspect each cam lobe for wear, chafing or damage.

Lobe height 41. Remove and inspect crankshaft main journal bearings for abnormal wear. It is recommended to replace the bearings anytime the engine is disassembled.

3. Measure height of each cam lobe using a micrometer. Compare to specifications. Cam Lobe Height (Intake & Exhaust): Std: 0 .2170” ± 0.00236” (5.5118 ± 0.060 mm) 4. Measure camshaft journal outside diameters (O.D.)

3.44

Apply LocTitet 271 (PN 2871954).58 ± 0.010 mm) C.’s.5 ft. (6-7 Nm).D.654” ± .010 mm) B 5. NOTE: Before assembly.00039” (42 ± . Torque bolts to 4. (6-7 Nm). : A.00039” (41 ± . Follow Steps 44. Camshaft Journal Bore I. 4.D.617” ± 0.D. NOTE: Replace engine block if camshaft journal bores are damaged or worn excessively.010 mm) (Ctr. (6-7 Nm) A 2.010 mm) B. Oil Baffle Weldment Bolt Torque: 4.5-5.00039” (41. lbs.0299mm) Limit: .’s ENGINE LOWER REASSEMBLY WARNING: After any reassembly or rebuild.614” ± .50 ± .00039” (41.5-5.07 ± 0.656” ± 0. lbs. Apply LocTitet 262 (PN 2871952). Calculate oil clearance by subtracting journal O.D. lbs.00039” (41. if removed.5-5.ENGINE Journal O. Install oil pick up (A).D. 1.45 in this section to properly prime the engine and to help aid proper engine break in. (Mag): 1. Measure ID of camshaft journal bores.5 ft. Compare to specifications. lbs. Camshaft Oil Clearance: Std: 0. Install oil baffle weldment (B). (PTO): 1. Torque bolt to 4.010 mm) 6. (Ctr. Rotate 3.07 ± 0. (6-7 Nm) 3.45 . clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris.5 ft.010 mm) (PTO) 1.’s from journal bore I.637” ± 0.00118” (.45778) and a 3/4-full oil filter before initial start-up. Inspect balance shaft clearance (C) in both gearcase halves. the engine must be primed using the Oil Priming Adapter (PU.5-5.634” ± .: (Mag): 1.0039” (.): 1.10 mm) Oil Pick Up Bolt Torque: NOTE: Replace camshaft if damaged or if any part is worn past the service limit. Install the balance shaft.00039” (42. C B A Camshaft Journal O.) 1.5 ft. This will ensure proper sealing when installing bolts and new Loctitet.

Grease cam lobes and valve lifters with Polaris Starter Drive Grease (PN 2871460). Torque bolts to 20-24 ft. NOTE: Always install new balance shaft bearings. (27--33 Nm) following torque pattern on Page 3. Apply Starter Drive Grease (PN 2871460) to cam journals and balance shaft bearing surfaces of the MAG case halve. 4. Apply LocTitet 242 (PN 2871949). 5. 7. Apply Starter Drive Grease (PN 2871460) to the main journals and bearings. Assemble the crankcase halves. (27-33 Nm) 8.ENGINE balance shaft to ensure that there is clearance between it and oil baffle weldment. Install cam and balance shafts.2. Apply Crankcase Sealant (PN 2871557) to PTO gearcase halve. lbs. E NOTE: Do not apply sealant to cam relief hole (E). C D 6.46 . lbs. 3. Crankcase Bolt Torque: 20-24 ft. Install crankshaft assembly and apply engine oil to crank pins and rods (D).

47 . slide a rod that is close to the same diameter as the wrist pin holes to properly align them in the cylinder. Position cylinder and piston assemblies onto the connecting rods and push the piston pins through the piston and pushrod. 11. to ensure proper alignment of the pistons to the connecting rods upon assembly. NOTE: To help align the pistons. DO NOT USE SILICONE. Lubricate lifters with engine oil and install in the original order as removed in disassembly.ENGINE NOTE: Apply a small amount of grease to the cylinder gasket to help hold it in place during cylinder assembly. NOTE: Always replace the camshaft and lifters as a set. Grease Cam Lobes Grease Lifters 9. Partially install the piston pins into the pistons. Cylinder Installation 10. Install piston assemblies into cylinder aligning the piston pin holes. 13. 12. Install new cylinder gasket on cylinder. Apply Lubriplate to the ends of the lifters. Lubricate connecting rods with engine oil. 3.

Apply starter grease . Align the bolt holes and install oil pump assembly into crankcase. Line Up Marks Place Pin Keeper (F) in 12 O’clock position NOTE: While installing in piston pins. cover all engine passages. G Push in Piston Pins 14.5 ft. Assemble rotors as marked when disassembled. lbs. 3. lubriplate. Lubricate Rotors F 15. or oil to the rotors on the oil pump shaft. The pin keeper ends should be installed at the 12 O’clock position. as this checks for binding if new rotors are used. Rotate the rotors in the housing during installation. The clip could fall into the engine during installation.ENGINE NOTE: New bolts have patch lock on the threads and do not require Loctitet. Torque bolts to 4. 18. Install the piston pin keepers (F). (6-7 Nm). NOTE: The application of oil or lubriplate aids in priming the oil pump during initial engine start up. Use a cleaner to remove the marks previously made on the rotors. Install camshaft thrust plate (G) with new bolts. 16.5-5. 17.48 .

5--9. (11. NOTICE: If you replace one gear. to ensure all of the gears are replaced. Install oil pump housing bolts (H). The new bolts contain patch lock. Apply Loctitet 242 (PN crankshaft. H This Side Out NOTE: Before assembly. NOTE: Occasionally spin the oil pump when installing bolts to check for binding of the rotors.49 .5-9.5 ft. so Loctitet is not needed on the new bolts.ENGINE NOTE: For assembly of the gears. 19. all of the gears will be shipped automatically.5 ft. lbs. All Gears Replaced As A Set Oil Pump Bolt Torque: 8. the cam gear and the crankshaft gear are stamped with “This Side Out.5-13 Nm) 20.5--13 Nm). 2871949) to the 21. I J 3. all of the gears must be replaced as a set. lbs. 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. (11. Before installing the crankshaft gear (I). This helps to ensure proper gear mesh and helps to prevent abnormal gear wear. heat the crankshaft gear to 250° F (121°C) on a hot plate (J). When ordering a replacement gear.” This indicates the side of the gear that faces outward or away from the case. Torque bolts to 8.

3. 23. NOTE: Cam Spanner Wrench (PU-45498) is only needed to rotate the camshaft when the entire valve train is assembled. PU-45497-2 NOTE: If the timing mark on the camshaft gear does not align properly. Use a pair of pliers and leather gloves when handling the crankshaft gear. Use the Cam Spanner Wrench (PU-45498) to rotate the cam to the proper position.(35-41 Nm).50 . Apply LocTitet242 (PN 2871949) to the bolt threads. Follow the procedure below to help ensure safety. aligning timing marks with crankshaft gear (I). remove the camshaft gear and tool. I M This Side Out 24. 22.ENGINE CAUTION: The crankshaft gear is extremely hot! Severe burns or injury can occur if the gear is not handled with extreme care and caution. Torque to 26-30 ft.” This indicates the side of the gear that faces outward or away from the case. Use the Cam Gear Alignment Tool (PU-45497-2) to align the teeth of the cam gear (M). Install counter balance shaft gear (J) with new key. Install the crankshaft gear (I) onto the crankshaft. NOTE: For assembly of the gears. lbs. Install the cam gear (M) (with the Cam Gear Alignment Tool still in place) onto the camshaft. Install washer and bolt. Use extreme caution when removing the crankshaft gear from the hot plate. I J PU-45648 Gear Holder: (PU-45648) 25. The timing marks on the camshaft gear should align with the keyway on the balance shaft gear. the cam gear and the crankshaft gear are stamped with “This Side Out. Use the Gear Holder (PU-45648).

tools and hands before installation. Use the Universal Driver Handle (PU-45543) and the Main Seal Installer (PU-45483) to seat the crankshaft seal into place. etc. Shaft damage will occur. Torque to 26-30 ft. Install a new water pump seal (N) into the gear/stator housing (O). 28.51 . soapy water. PU-45498 PA-44995 O N 26. the gear/stator housing must be removed. Reinstall the camshaft gear. Do not touch seal surface or allow seal surface to come in contact with contaminates during installation. Use the Water Pump Mechanical Seal Installer (PA-44995) to properly install the seal to the correct depth in the cover.) will not allow the seal to wear-in and seal properly. PU-45543 Timing Marks Counterbalance Gear and Camshaft Gear Bolt Torque: 26-30 ft. Use of lubricants (oil. these seals MUST be installed dry (no lubricant) during assembly. NOTE: Be sure all of the timing marks are properly aligned. NOTE: Install the waterpump seal (N) with the seal lip facing out (towards the crankcase). Install a new crankshaft seal (P) into the gear/stator housing cover (O). (35-41 Nm) O GEAR/STATOR HOUSING SEAL REPLACEMENT IMPORTANT: Due to seal design and construction. lbs. Install the washer and bolt. so the timing marks are properly aligned. Thoroughly clean parts. lbs. Apply Loctitet 242 (PN 2871949) to the bolt threads. Use of a hydraulic press is recommended for this procedure.(35-41 Nm). replace the seals in the cover. Before installing the gear/stator housing. The water pump seal cannot be removed or installed with the gear/stator housing attached to the engine. Timing Marks NOTE: To remove the water pump seal. P PU-45483 3.ENGINE 27.

Install the new gasket to the gear/stator housing cover and crankcase. Carefully install the tapered end of the Crankshaft Seal Protection Tool (PA-45658) through the paper side of the crankshaft seal.ENGINE NOTE: Install the crankshaft seal (P) with the seal lip facing out (towards the crankcase). Important: Set the direction of the paper seal lip (PA-45658) 31.52 .(Back to Front) Remove the tool. 3. carefully place the gear/stator housing cover over the protection tools. PA-45401 PA-45658 30. install the Water Pump Seal Saver (PA-45401) onto the water pump shaft. Check the crankshaft seal lips to verify they have not been rolled or damaged. NOTE: New gasket is not shown in the picture. P Seal lip goes towards the crankcase. With the tools installed. 32. Once the crankshaft seal is installed into the gear/ stator housing cover. Before installing the gear/stator housing cover. (Back to Front) Leave the seal protector installed in the crankshaft seal. set the direction of the paper lip by sliding the Main Crankshaft Seal Saver (PA-45658) into the crankshaft seal from the rubber lipped side to the paper lip side. 29.

33. lbs. (12-13 Nm). 34.lbs. Gear/Stator Housing Cover Bolt Torque: 8. 3. Install the gear/stator housing gasket onto he crankcase. lbs. (12-13 Nm) 36. Remove seal protectors from the shaft ends once secure.5-9. Apply Loctitet 242 (PN 2871949) to the bolts. clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. 37.5-9.53 . (See photos below. Install shaft seal with ceramic surface facing inward.5 ft. Torque the nut to 8.5 ft. Secure the gear/stator housing cover (O) to the crankcase with the cover bolts. This will ensure proper sealing when installing bolts and new Loctitet.5 ft. Secure the impeller with the washer and a new nylok nut (Q).5-9. Apply Crankcase Sealant (PN 2871557) to the outside edges of the crankcase halves (See arrows). (12-13 Nm) in a criss--cross pattern. (PA-45401) O (PA-45658) NOTE: Before assembly.) This helps to prevent coolant leakage. where the crankcases mate. Install water pump impeller (P).ENGINE 35. Torque bolts to 8.

9-10 ft. lbs. 41. lbs.5 ft. Sparingly apply Starter Drive Grease (PN 2871423) to the starter drive. (12-15 Nm) 38. (12-14 Nm). Install the flywheel.5 ft. (12-13 Nm). and key.5-9. Coat the stator wire grommet (U) with Nyogelt Grease (PN 2871329). nut. 40. lbs. (12-14 Nm) 42. lbs. NOTE: Be sure the stator wires are routed properly under the wire hold down bracket. Install water pump cover (R) with new O-ring seal. washer. Install two new wire hold down bolts. Apply Loctitet 271 (PN 2871954) to the bolts. Torque flywheel nut to 80-100 ft. Install the the wire hold down bracket (T). NOTE: There are thrust washers on both sides of starter drive.5-9. (109-136 3. Replace 2 bolts with new bolts R Water Pump Housing Bolt Torque: 8. Apply Loctitet 242 (PN 2871949) to the nut threads.ENGINE P Q Water Pump Impeller Nut Torque: 9-11 ft. Install the starter bendix. lbs. (12-14 Nm). Torque bolts to 8. Install stator assembly (S) and bolts. Torque bolts to 9-10 ft. (12-13 Nm) T U S Stator Assembly Bolt Torque: 39. Apply Loctitet 242 (PN 2871949) to the bolts. lbs. New bolts contain patch--lock. lbs. Torque bolts to 9-10 ft. so Loctitet is not needed on the new bolts.54 .

(9. the engine must be properly primed with Polaris 0W--40 Synthetic Oil (PN 2871281). Install the plug and torque to 7--9 ft. Install the Oil System Priming Adapter (PU-45778) into the oil plug hole. Follow the steps in this section to properly prime the engine and aid proper engine break in.) of Polaris 0W--40 into the adapter until resistance is felt. Remove the adapter.55 . (109-136 Nm) 43.5--9. (approx. Install the filter onto the engine. Failure to perform this procedure may cause internal engine damage on initial start. Torque the bolts to 8. Push 3--5 oz. (12--13 Nm). Fill 3/4 full with 0W--40 oil Flywheel Nut Torque: 80-100 ft. Let the oil soak into the filter for 8--10 minutes. lbs.5-9. Install stator housing with new O-rings.50--12 Nm).lbs. the engine must be primed using the Oil Priming Adapter (PU.ENGINE Nm).5 ft.45778) and a 3/4-full oil filter before initial start-up. - 3. (12-13 Nm) 44. Apply pipe dope or Teflon tape to the plug threads. lbs. WARNING: After any reassembly or rebuild.lbs. PU-45778 Oil System Priming Adapter: (PU-45778) Stator Housing Bolt Torque: 8.up. Apply Loctitet 242 (PN 2871949) to the bolts. Remove primer plug from the engine. Fill the oil filter three--quarters full with Polaris 0W--40 Synthetic Oil (PN 2871281). After the engine is completely assembled and ready for installation.5 ft. 45.

or ETC switch) ETC switch mis-adjusted Restricted air filter (main or pre-cleaner) or breather system Improperly assembled air intake system Restricted engine breather system Oil contaminated with fuel G G G Engine flooded Low compression (high cylinder leakage) No spark (Spark plug fouled) ignition component failure Engine Does Not Turn Over G G G Dead battery Starter motor does not turn Engine seized. piston.ENGINE TROUBLESHOOTING Spark Plug Fouling G Spark plug cap loose or faulty G G G G G G Choke cable adjustment or plunger/cable sticking Foreign material on choke plunger seat or plunger Incorrect spark plug heat range or gap Carburetor inlet needle and seat worn Jet needle and/or needle jet worn or improperly adjusted Excessive carburetor vibration (loose or missing needle jet locating clips) Loose jets in carburetor or calibration incorrect for altitude/temperature Incorrect float level setting PVT system calibrated incorrectly/ components worn or mis-adjusted Fuel quality poor (old) or octane too high Low compression Restricted exhaust Weak ignition (loose coil ground. or mechanical failure Engine Runs But Will Not Idle G G G G G G G G G G G G G G G G Restricted carburetor pilot system Carburetor misadjusted Choke not adjusted properly Low compression Crankcase breather restricted Spark plug fouled/weak spark Broken throttle cable Obstruction in air intake Air box removed (reinstall all intake components) Incorrect or restricted carburetor jetting ETC switch limiting speed Reverse speed limiter limiting speed Carburetor vacuum slide sticking/diaphragm damaged Incorrect ignition timing Restricted exhaust system Cam worn excessively G Engine Idles But Will Not Rev Up G G G G G G G G G G G Engine Has Low Power G G G G G G G Spark plug fouled Cylinder. or valve wear or damage (check compression) PVT not operating properly Restricted exhaust muffler Carburetor vacuum slide sticking/diaphragm damaged Dirty carburetor Cam worn excessively Engine Turns Over But Fails to Start G G G G G G No fuel Dirt in fuel line or filter Fuel will not pass through fuel valve Fuel pump inoperative/restricted Tank vent plugged or pinched Carb starter circuit plugged 3. ring. stator.56 . faulty coil. rusted.

57 .lean condition Exhaust system air leaks Ignition system faulty: Spark plug cap cracked/broken Ignition coil faulty Ignition or kill switch circuit faulty Ignition timing incorrect Sheared flywheel key Poor connections in ignition system Temperature Too Low G Thermostat stuck open Leak at Water Pump Weep Hole G G Faulty water pump mechanical seal (coolant leak) Faulty pump shaft oil seal (oil leak) G 3. vents. piston. accident damage) Lean mixture (restricted jets. pump. broken. CONT Piston Failure . fuel pump or fuel valve) Fuel pump output weak Electrical malfunction Water pump failure/ Loose impeller Thermistor failure Cooling fan inoperative or turning too slowly (perform current draw test) Ignition timing misadjusted Low oil level Spark plug incorrect heat range Faulty hot light circuit Thermostat stuck closed or not opening completely Excessive Smoke and Carbon Buildup G G G G G G Excessive piston-to-cylinder clearance Wet sumping Worn rings. or cylinder Worn valve guides or seals Restricted breather Air filter dirty or contaminated Low Compression G G G G G G G Cylinder head gasket leak No valve clearance ( cam wear ) Cylinder or piston worn Piston rings worn.ENGINE TROUBLESHOOTING. lines.Scoring G G G Lack of lubrication Dirt entering engine through cracks in air filter or ducts Engine oil dirty or contaminated G G G Valve sticking Air leaks in intake Lean condition COOLING SYSTEM TROUBLESHOOTING Overheating G G G G G Low coolant level Air in cooling system Wrong type/mix of coolant Faulty pressure cap or system leaks Restricted system (mud or debris in radiator fins causing restriction to air flow. passages blocked in radiator. or sticking Bent valve or stuck valve Valve spring broken or weak Valve not seating properly (bent or carbon accumulated on sealing surface) Rocker arm sticking G G G G G G G G G G G G Backfiring G G G G G ETC or speed limiter system malfunction Fouled spark plug or incorrect plug or plug gap Carburetion faulty . leaking. or water jacket.

install the radiator cap and idle machine until fan comes on. Repeat Steps 1 and 2 four or five times or until no more coolant is pulled into the system. 3. the coolant system will not draw coolant from the reservoir tank. Remove radiator cap and top off coolant. 6. 5.ENGINE BLEEDING PROCEDURE FOR 4-STROKE COOLING SYSTEMS Use this procedure when a unit overheats and no apparent leaks in the cooling system are found. Always add coolant to the radiator first. Stop the engine and let cool for a few minutes or until a “glug” is seen at the filler neck or there is a dropping of the coolant level. Steps 1 and 2 may have to be performed with the radiator cap on to prevent coolant loss. indicating that coolant has been pulled into the system. Start and idle machine for 5-10 minutes until steam is visible in the radiator cap area. To test. Make sure the fan comes on before the hot light. 4. Pump hose by hand to help purge system Squeeze Hose Here to Help Purge Air From System Temperature Sensor Remote Filler Cooling System Polaris Premium Antifreeze 2871534 Quart 2871323 Gallon 3. Leave the cap off of the radiator. Elevating the rear of the ATV with a floor jack (rear tires 4-6. Important Tips: Slowly squeezing the hose after the bend below the filler neck will aid in purging the system of air. Pump the hose using your hand several times as shown in the diagram. Fill the reservoir only after you have completely filled the cooling system at the radiator filler neck. or if there are leaks in the system. 2. off the ground) also aids the purging of air from the system.58 . 1. In some instances. Park Machine on a flat surface. Note: If the coolant level is LOW in the radiator. filling to the top of the neck to replace air that has been purged from the system.

. . . Assembly. . .2 4. . . CV Carburetor Vent System (4 Cycle) . . . . . . . CV Carburetor Operation . . . . 4. . . . .8 4. . . . . . . . . . CV Carburetor . . . . . . . . . . . . . . .11 4. . . . . . . . . . Mikuni BST 40 Carburetor . . . . . . .10 4. CV Carburetor . . .4 4. . .5 4. . .8 4. . .5 4. . . . . . . . . . Main Jet / Pilot Jet Part Numbers . . Carburetor Jetting . . . . . . . . . . . . . . . . Disassembly Notes.5-4. . . . . . . . . . . . . . . . . . . . . . . . .3 4. . . . . . Inspection. . . . . . Float Adjustment. . . . . . . . . . . . . Needle & Seat Leakage Test . . . .4 4. Cleaning. .11 4. . . Fuel Pump Service . . . . . . . . .3 4. . . . Troubleshooting . . . . . Special Tool & Jetting Guidelines . .9 4. . . . . . . . . Fuel Tank Asm. . Fuel Level . . . CV Carburetor . . . . . . CV Carburetor . . . . . . . .7 4.4 4. . . . . . . . . . . . . . . . . . .10 4. . .9 4.12 4 4. . . Fuel Flow Diagram . . . . . . . . . . . . . . . .1 . . . . . . . . . . . . . . Exploded View . . . . . . CV Carburetor . . . . . . . . . . . . . . . . .7-4. . . . . .FUEL SYSTEM/CARBURETION CHAPTER 4 FUEL SYSTEM/CARBURETION Exploded View. CV Carburetor System Function (4 Cycle) . . .

Float Assembly 32. O-Ring 14. Ring 11. Cable Guide 48. Needle Jet 12. Screw 40. Cover 13. Main Jet 29. Air Jet 47. Throttle Valve 4. Filter 38. Needle Valve 35.2 . Washer 25.4 for Jet Part Numbers Jet Needle “E” Clip Position 4. Ring 16. Spring 7. Jet Needle 31. Screw 22. O-Ring 24. Ring 9. Diaphragm Assembly 8. Packing 19. Washer 30. Spring Washer 45. Spring 18. Screw 22 1 3 5 2 39. Screw and Washer Assy. Spring 49. Jet Block Assembly 6. Ring 50. Float Pin 34. Screw 41. Spring 27. “E” Ring 20. Screw 46. Seal 17. Spring 4 43. Pilot Jet 28. Drain Screw 23. Cap 21. Adjust Screw 51. O-Ring 36. Diaphragm 5. Cover.FUEL SYSTEM/CARBURETION BST 34 CARBURETOR EXPLODED VIEW 1. Plunger Assembly 44. O-Ring 37. Throttle Shaft Assembly 15. Screw 3. Carburetor Assembly 2. “E” Ring 10. Guide Holder 42. Adjuster 26. Float Body Assembly 33. Refer to Page 4.

FUEL SYSTEM/CARBURETION FUEL TANK ASSEMBLY Fuel Cap Tank Vent Forward Tank Foam Seal Fuel Tank Foil Fuel Tank Foil 3--Way Fuel Valve Main Fuel Outlet Fuel Knob FUEL FLOW Fuel Tank Vent Fuel Tank Fitting Screens L Fuel Pump Filter Carburetor Vent Carburetor Fuel Valve Engine L Located Above Oil Tank 4.3 .

Clutching changes may also be required for changes in elevation.0 3130624 115 3130555 42.5 3131142 165 3131143 167. seek medical attention immediately. (0-1800 meters) and ambient temperatures between +40 and +80 F (+5 to +26 C).5 3130566 145 3130567 147. Always stop the engine and refuel outdoors or in a well ventilated area. IMPORTANT: The following guidelines must be followed when establishing a main jet setting: 1.5 3130554 40. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.5 3130568 150 3130569 152.5 3130570 155 3130571 157. Polaris ATV Carburetors are calibrated for an altitude of 0-6000 ft.5 3130526 117.4. 2. WARNING Gasoline is extremely flammable and explosive under certain conditions. Never start the engine or let it run in an enclosed area.FUEL SYSTEM/CARBURETION SPECIAL TOOLS PART NUMBER 2870975 2872314 TOOL DESCRIPTION Mity Vact Pressure Test Tool Carburetor Float Adjustment Tool outside this temperature and/or altitude range. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.5 3130560 130 3130561 132. The tank is at full capacity when the fuel reaches the bottom of the filler neck.5 3131144 170 3131145 JETTING GUIDELINES Changes in altitude and temperature affect air density.5 3130562 135 3130563 137.5 3130558 125 3130559 127. Select the correct main jet from the chart on Page 1. In higher elevations and higher temperatures. 4. Refer to clutching chart in the specifications section for recommendations.5 3130564 140 3130527 142. the air is more dense and has more oxygen. CARBURETOR JETTING CAUTION: A main jet that is too small will cause a lean operating condition resulting in serious engine damage. air screw / pilot screw adjustments and PVT adjustments may be required to suit operating conditions. Leave room for expansion of fuel. In addition.4 . immediately wash with soap and water and change clothing.5 3130556 120 3130557 122. Determine the lowest approximate altitude at which the machine will be operated. which is essentially the amount of oxygen available for combustion. Do not overfill the tank. Select the lowest anticipated temperature at which the machine will be operated. If you spill gasoline on your skin or clothing. MIKUNI JET PART NUMBERS Main Jets Pilot Jets Jet Number Part Number Jet Number Part Number 112. Carburetors must be re-calibrated if operated 4. In low elevations and cold temperatures. Severe burns may result. 3. If you get gasoline in your eyes or if you should swallow gasoline.5 3130572 160 3131141 162. the air is less dense with reduced oxygen. Never drain the float bowl when the engine is hot. The jetting installed in production is not intended for all altitudes and/or temperatures. Select the correct main jet carefully for elevation and temperature according to the charts in the specifications section or in the Owner’s Safety and Maintenance Manual for each particular model.

Float. Main Air Passage. Float Pin Float System Maintains specified fuel level in float chamber (carburetor float bowl) All systems All throttle ranges MIKUNI CV CARB OPERATION The constant velocity carburetor incorporates a mechanically operated throttle plate and a vacuum controlled slide valve (vacuum slide). The chamber below the diaphragm is vented to atmospheric pressure by a passage on the air box side of the carburetor. Throttle Plate Main Jet. Cable. Vacuum Slide.5 . Vent lines to frame Choke Lever. PilotMixture Screw with Spring Washer and Sealing ORing. 1/4 to full throttle Throttle Plate Vacuum Slide Venturi = Air Flow = Low Pressure 4.CV CARBURETOR The carburetor float bowl vent lines supply atmospheric pressure to the float bowl. Throttle Plate Supplies All systems atmospheric All throttle pressure to ranges float chamber Supplies additional fuel air mixture necessary for cold starting All throttle ranges Greatest effect at low throttle settings and idle Mainly idle to 1/4 throttle Minimal effect after 1/2 throttle Starter (Choke/Enrichment) Pilot (Idle System) Primarily supplies fuel at idle and low throttle positions From Air Box Main System Supplies fuel at midrange and high throttle settings. Starter Bleed Pipe) Pilot Jet/ Passageways. The lines must be free of kinks. Inlet Pipe. Main Air Jet. Carb Passages (Starter Jet.FUEL SYSTEM/CARBURETION CV CARBURETOR SYSTEM FUNCTION Carburetor Component Function System Main Components Main Function Main Affect VENT SYSTEMS . restrictions and be properly routed. Jet Needle. The venturi cross-sectional area in the carburetor bore is increased or decreased automatically by the vacuum slide. A spring. Diaphragm Low Pressure From Venturi Air Box Pressure Venting Passages in Carburetor. This allows fuel to flow in the proper amount and prevents contaminants from entering the carburetor. Pilot Outlet. which moves according to the amount of negative pressure (less than atmospheric) present in the venturi. Needle Jet. A diaphragm attached to the top of the vacuum slide is sealed to the slide and to the carburetor body forming two chambers. Plunger. Needle and (Level Control) Seat. Bypass Ports (Behind Throttle Plate). dampens the slide movement and assists the return of the slide. The chamber above the diaphragm is connected to the venturi area by a drilled orifice in the center of the vacuum slide. installed in the center of the vacuum slide. Pilot Air Jet. Return Spring.

4. The fuel from float chamber (2) is metered by pilot jet (3) where it mixes with air coming in through pilot air jet (4). rich in fuel content.6 . This provides improved fuel atomization and optimum fuel/air ratio. 4 1 6 7 5 2 Diaphragm Low Pressure From Venturi Vacuum Slide 3 From Air Box STARTER SYSTEM (CHOKE OR ENRICHMENT) When the choke cable (1) is activated. which then flows into starter pipe (4) and mixes with the air (7) coming from the float chamber. When the pressure above and below the diaphragm are nearly equal. Starter jet meters this fuel. reaches starter plunger and mixes again with the air coming through a passage (8) extending from underneath the diaphragm. 8 5 1 Throttle Plate Venturi 6 7 = Air Flow = Low Pressure 4 Note: Diagrams are for explanation of theory only. The mixture. the pressure in the venturi (and therefore in the chamber above the diaphragm) becomes significantly lower than atmospheric. Fuel is drawn into the starter circuit from the float chamber (2) through the starter jet (3).FUEL SYSTEM/CARBURETION CARBURETOR OPERATION CONT’D When the throttle plate is opened and engine speed begins to increase. The rich fuel/air mixture for starting is discharged through starter outlet (6) in the the main bore. raising the slide against spring pressure. The mixture then goes up through pilot passage to pilot screw (5). Raising or lowering the slide increases or decreases the cross sectional area in the venturi. A part of the mixture is discharged 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). Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward. the starter plunger (5) is lifted off the seat. and therefore the air velocity in the venturi is kept relatively constant. and are not true representations of Mikuni BST carburetor. the slide moves downward under spring pressure. 2 3 PILOT (IDLE AND SLOW) SYSTEM This system supplies fuel during engine operation with throttle valve closed (1) or slightly opened.

floats are up and needle valve remains pushed up against valve seat. no fuel enters the float chamber. The emulsified fuel then passes through the clearance between needle jet (5) and jet needle (7). 1 4 2 3 MAIN SYSTEM As throttle valve (1) is opened. assembly. Mixture proportioning is accomplished in needle jet (5). and inspection techniques to service a CV carburetor. Under this condition. and is discharged into the venturi (A). The fuel in float chamber (3) is metered by main jet (4). and around the inlet needle (2). and this increases negative pressure in the venturi. As the fuel level falls. 4. the clearance through which the emulsified fuel must flow is determined ultimately by throttle position and vacuum slide height. As the fuel fills the float chamber. In this manner. 1. shutting off the orifice in the seat. the needle valve admits and shuts off fuel alternately to maintain a practically constant fuel level inside the float chamber.FUEL SYSTEM/CARBURETION FLOAT SYSTEM Fuel enters the float chamber (3) by means of the inlet pipe and passage. When fuel level is up in float chamber. floats go down and needle valve unseats itself to admit fuel into the chamber. and the metered fuel enters needle jet (5). the float (1) rises and forces the inlet needle against the seat. engine speed rises. through a screen on the back of the inlet needle seat (4). in which it mixes with the air admitted through main air jet (6) to form an emulsion.MIKUNI CV Use the following disassembly. Remove carburetor diaphragm chamber cover with a ratchet style screwdriver. Consequently the vacuum slide (2) moves upward. 1 2 7 A 6 5 4 3 Inlet Pipe CARBURETOR DISASSEMBLY .7 . DO NOT use an impact driver to remove the screws or carburetor may be permanently damaged.

Even a small amount of residue will reduce the flow characteristics of the jet. Remove the pilot mixture screw. 5. Carburetor cleaners can be extremely caustic. Pilot Screw Starter Jet NOTE: Be careful not to damage the float pin tower during the float pin removal. If the carburetor is extremely dirty or contaminated with fuel residue and varnish. Replace the jets if they have a buildup of fuel residue or bacterial growth that cannot be removed. O-Ring Washer Spring Pilot Screw Protect eyes from contact with cleaner. and all passages with carburetor cleaner or electrical contact cleaner. Take appropriate safety measures during these procedures. CARBURETOR CLEANING WARNING 4. soak for short periods only in carburetor cleaner. Extended periods of soaking can loosen the adhesive sealer on the passage drill-way plugs. Support the float pin tower while removing the float pin. This helps to prevent the float pin towers from breaking off. and rinse in hot water. If an anti-tamper plug is installed over the pilot screw cavity. Remove inlet needle seat retaining screw along with plate. jets. NOTE: Do not use a pliers to remove the seat or permanent damage may occur. Upon disassembly. Use low pressure air to dry carburetor body and all components. place the parts in a container for safe keeping. CAUTION: Do not use wire or welding tip cleaners as the orifice size may be altered.FUEL SYSTEM/CARBURETION CARBURETOR DISASSEMBLY CONT’D 2. Rubber parts must be cleaned with mild detergent and hot water only. 4. Do not soak rubber or plastic components (such as the vacuum slide diaphragm. Should you get cleaner in your eyes or if you swallow cleaner. needle seat screen. and O-Ring. 3.8 . Thoroughly clean the carburetor body. 4. Remove float bowl and carefully remove the pressed float pin. and carefully remove needle seat. Irreparable damage may occur. or O-Rings in caustic cleaning solutions. spring. 1. seek medical attention immediately. Do not use agitator--type carburetor cleaning equipment. Verify all passages and jets are unobstructed by spraying electrical contact cleaner through the passages. 2. it must be removed for access. Support Here NOTE: The starter jet is not removeable. flat washer. Safety glasses and chemical resistant gloves are required. 3.

TIP: A worn needle jet is difficult to spot.9 . 4. The middle to upper portion of the needle contacts the needle jet and is the most likely wear point. Deposits 3. Be sure the spring loaded pin is free moving and returns freely when pushed. Refer to parts manual for more information. Be sure the tab (E) on outer edge of diaphragm is positioned properly in the carburetor body. Replace parts in proper order. or damage. or an area that looks different than the rest of the needle. Spacer washer (D) must be installed below the E-Clip. The spring seat washer (B) is stepped and must be placed on TOP of “E” Clip (C). Jet Needle Needle Jet Inspect this area D E B C A 2. Look for discoloration. Light will be visible between the needle and needle jet if it is worn. shiny spots. slide a slightly larger new jet needle into the needle jet and hold it to a light source. If jet needle shows signs of wear replace both the needle and needle jet to prevent a rich condition. Replace diaphragm assembly if diaphragm is damaged. Make sure the diaphragm is pliable but not swollen. Seat Wear areas Needle Pilot Screw 4. The diaphragm should fit properly in the carburetor body.FUEL SYSTEM/CARBURETION CARBURETOR INSPECTION 1. CARBURETOR ASSEMBLY Inspect the diaphragm (A) for holes. Inspect jet needle and needle jet for wear. The inlet needle and seat should be pressure tested after assembly. deterioration. Inspect the inlet needle tapered surface for any sign of wear or damage. To check. Good Condition Worn.

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. Install the float bowl. Turn the screw in until it lightly contacts the seat. the float tongue will rest lightly on the inlet needle valve pin without compressing the spring. inspect needle and seat and seat O-ring. NOTE: The final pilot (idle) mixture must be adjusted with the engine running.FUEL SYSTEM/CARBURETION CARBURETOR ASSEMBLY CONT’D 5.10 . NEEDLE AND SEAT LEAKAGE TEST 1. Lubricate the O-Ring with oil or light grease before installation.51-. In this position. When measuring the height be sure the inlet needle valve spring is not compressed. spring. The needle and seat should hold pressure indefinitely. Float Height: Std: BST 34 13-14 mm (. and O-ring as an assembly. Float arms even FLOAT HEIGHT ADJUSTMENT 1.55 inches) 2. bend the tongue slightly. If not. Mity Vact (PN 2870975) 4.4 Bend to adjust float 3. Both sides of float should be parallel to each other. Back out the specified number of turns. CAUTION: Do not damage the O-ring during installation. Be sure float measurement is even on left and right side. Pilot Mixture Screw Base Setting (Set at Factory) Refer to Specifications Page 1. Place the carburetor on a level surface as shown at right to remove weight from float arm. Apply 5 PSI pressure to inlet fitting. Refer to Page 2. Measure the height from the float bowl mating surface to the top of step in float as shown. Invert the carburetor and install a Mity-Vact (PN 2870975) to the fuel inlet fitting. Install the pilot mixture screw. If adjustment is necessary.13. washer.

FUEL PUMP The Polaris Sportsman 600/700 is equipped with a pressure regulated fuel pump (1-3 PSI). Remove the diaphragm cover gasket. Inspect the diaphragms for cracks. CAUTION: Some carburetor cleaners are very caustic and should not be used to clean the non-metal parts of the fuel pump. Remove the valve and wash with soap and water. Attach a clear line to drain fitting. remove carburetor and inspect inlet needle and seat. engine must run briefly to allow fuel level to stabilize. passages. 3. and valve body gasket.FUEL SYSTEM/CARBURETION FUEL LEVEL A fuel level test can be performed on some models if the drain hose fitting is accessible. Turn fuel off. 4. Start and run engine for 3 to 5 seconds to allow fuel level to stabilize in the line.060² Bowl Mating Surface FUEL PUMP DISASSEMBLY 1. float height. The fuel level can be observed with the engine either running or shut off. Inspect inlet and outlet check valves for cracks. The pump diaphragms must be replaced. Remove the screws from the pump diaphragm cover. Carburetor cleaner may be used to clean the pump body when the check valves are removed. 3. 2. If level is out of specification. If fuel is present in the impulse line or vacuum chamber of the pump. The pump is located under the left front fender of the machine. The diaphragm should hold vacuum indefinitely. Connect Mity-Vact (PN 2870975) to the impulse line fitting on the pump.5 mm . diaphragm. remove the set screw and washer.. however. Carefully remove all traces of old gasket and check the surfaces for damage. and gasket. 4. Position hose along side of carburetor as shown. A fuel level test allows you to observe the height of the fuel in the float bowl without removing the carburetor. Replace diaphragms and gaskets as a set. To clean the valves or pump body.11 . Note the location of the two longer screws. Open bowl drain screw by turning counterclockwise approximately two turns. Be sure line fits tightly on fitting. 1. Fuel Pump Fuel Filter Impulse line 1. NOTE: If a line was removed to perform this procedure. holes or swelling. warpage or damage. etc. 2. Tighten all screws evenly. Reassemble the pump in the reverse order of disassembly. To test the fuel pump: 1. 4. 3. the diaphragm is ruptured. Disconnect impulse line from pump. diaphragm. 2. 2. Check the sealing surfaces of the pump body and covers. FUEL PUMP INSPECTION/ASSEMBLY 1. Be sure to re-attach the bowl drain hose after performing the test. Apply 5 inches (Hg) vacuum to the pump fitting. Remove the outlet check valve cover. it must be replaced.

airbox or air cleaner cover) G Ruptured vacuum slide diaphragm. routed incorrectly G Choke cable sticking. improperly adjusted. sooty exhaust smoke. black. spark plug erosion. engine runs rough/ misses. G Air intake restricted (inspect intake duct) G Air filter dirty/plugged G Choke plunger sticking. bog. bog.12 . poor performance. popping through intake / exhaust. surging. Vacuum slide stuck closed or sticky G Improper spring G Jet needle position incorrect G Incorrect pilot screw adjustment RICH MIXTURE Symptoms: Fouls spark plugs. backfire. high idle. hesitation. intake ducts.FUEL SYSTEM/CARBURETION TROUBLESHOOTING FUEL STARVATION/LEAN MIXTURE Symptoms: Hard start or no start. idle speed erratic. backfire. pinched) G Intake air leak (throttle shaft. improperly adjusted. detonation. G No fuel in tank G Restricted tank vent. rough idle. holding inlet needle closed or inlet needle stuck G Float level too low G Fuel pump inoperative G Air leak at impulse line G Restricted impulse line (kinked. incorrectly adjusted choke G Choke cable binding or improperly routed G Incorrect pilot air/fuel screw adjustment G Faulty inlet needle and seat G Faulty inlet needle seat O-Ring G Float level too high G Poor fuel quality (old fuel) G G G G G Loose jets Worn jet needle/needle jet or other carburetor parts Dirty carburetor (air bleed passages or jets) Weak or damaged vacuum piston return spring Fouled spark plug POOR IDLE Idle Too High G Idle adjusted improperly/idle mixture screw damaged G Sticky vacuum slide G Throttle cable sticking. low power. engine loads up. routed incorrectly G Plugged or restricted idle jet Idle Too Low G G G G G G G Choke cable bending or incorrectly adjusted Idle speed set incorrectly Idle mixture screw misadjusted or damaged Belt dragging Ignition timing incorrect Worn jet needle/needle jet Plugged or restricted idle jet Erratic Idle G G G G G G G G G G G G G Choke cable bending or incorrectly adjusted Throttle cable incorrectly adjusted Air leaks. poor fuel economy. dirty carburetor passages (pilot circuit) Pilot mixture screw damaged or adjusted incorrectly Tight valves Ignition timing incorrect Belt dragging Dirty air cleaner Engine worn Spark plug fouled Idle speed set incorrectly (speed limiter) Worn jet needle/needle jet Plugged or restricted idle jet 4. engine runs hot. or routed improperly G Fuel lines or fuel valve restricted G Fuel filter plugged G Carburetor vent line(s) restricted G Plugged or restricted inlet needle and seat screen or inlet passage G Clogged jets or passages G Float stuck.

. . . . . . . . . . . . . . . . . . . . . .8 5. . . . . . . . . .5 5. . . . .12 5. . . . . . . . Front Strut Ball Joint Replacement . . . . . . Front Strut Cartridge Replacement . . Side Panel Removal . . . .10 5. . . . . . . . .9--5. . . Front Strut Assembly Exploded View . . . . . . . . . . . . . . . . . . . . . . Cover/Panel Removal .10 5. . . . . . . . . . . . A-Arm Replacement . .BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION Body Assembly. . . .11--5. . . . . . . . . . . . . . . . . . . . . Steering/A--Arm Exploded View . . . . . . 5. .7 5.3 5. .9 5. . . . . . . . . . . . Headlight Pod Exploded View . . . . . . . . . . . . . . . .1 . . . Decal Replacement . . . Exploded View . . . Rear Suspension Exploded View . . . . . . . . Steering Post Assembly . . . . . . . . . . . .8 5. . . . . .12 5 5.11 5. . . . .2--5. . . . . . . . Special Tools & Torque Specifications . . . . . . . . . . . . . .4 5. . . . . . .6 5. . . .

BODY / STEERING / SUSPENSION BODY ASSEMBLY EXPLODED VIEW Rear Cab Assembly Seat Latch Pull UP on rear of seat and back to disengage tabs at front of seat Seat Latch Release Storage Rear Cab Clutch Guard Frame Brace Rear Mud Guard Frame Footrest Front Cab Assembly Front Cover Side Cover Front Cab Footrest Front Mud Guard Frame Splash Guard Deflector Shield NOTE: All warning information labels must be in place when body parts are assembled.2 . 5.

Frame Front Rack Extender Front Rack Front Support Rack Bumper Panel Frame Brush Guard Radiator Cover Grill Lower Bumper Side Shield 5.3 .BODY / STEERING / SUSPENSION Rear Rack Extender Rear Support Rack Rear Rack Reflector .

(15-18 Nm) Connect 12V power outlet (where applicable) Connect headlight. Lift top half of pod. Disconnect oil indicator light wires and gear position indicator connector. choke cable. To apply decals. Remove two screws securing bottom half of pod (E). and headlight. (15-18 Nm) B A A Disassembly G G G G G G G G G G Remove two side Phillips screws (A). 5.4 . refer to procedure outlined in Maintenance chapter. Remove headlight with adjuster. refer to Page 5. 11-13 ft. Disconnect speedometer wire connectors. Remove one rear Phillips screw (B). Handlebar clamp torque: Install key switch. making sure interlocking tabs mate properly. Install one rear Phillips screw. Install two side Phillips screws.12. Connect speedometer connectors to speedometer.BODY / STEERING / SUSPENSION HEADLIGHT POD EXPLODED VIEW Torque bolts evenly so gap is equal at front and rear of handlebar block 11-13 ft. To adjust headlight. Disconnect headlight harness. lbs. Remove ignition switch (C) and choke cable (D). E Clean knurling when repositioning handlebars Adjuster D C Assembly G G G G G G G G G G Install bottom of pod onto handlebar and secure to brackets. Disconnect 12V power plug (where applicable). Install top of pod onto bottom half. lbs.

5 . (35-41 Nm) Steering Post Steering Post Arm (Frog) 12-14 ft. (17-19 Nm) A B 40-45 ft. 242 242 8 ft. (54-61 Nm) 30 ft. (11 Nm) 1 Always use new bolts upon reassembly 2 Apply Loctitet 242 to the bolt threads. (35 Nm) Always use new cotter pins upon reassembly.BODY / STEERING / SUSPENSION STEERING/A-ARM EXPLODED VIEW NOTE: To avoid damage to tie rods and other steering components. lbs. be sure to install tie rod end bolts in the proper direction. (41 Nm) 1 2 25 ft. Install with open end toward rear of machine. 25-30 ft. the rod end bolts (A) point down. Be sure inner rod ends are placed between the steering post arms. lbs. lbs. lbs. lbs. The steering post arm bolt (B) points up. 5. (41 Nm) 1 2 30 ft. lbs. lbs.

(41 Nm) Rear Shock 1 Orientate Bushings Correctly Rear Front Bushing Orientation 5. (24 Nm) 35 ft. lbs. lbs. (48 Nm) 30 ft. (48 Nm) Forward 1 Upper Control Arm Skid Plate Strap Stabilizer Bar Arm 35 ft.BODY / STEERING / SUSPENSION REAR SUSPENSION EXPLODED VIEW 17 ft. (41 Nm) Lower Control Arm A--Arm Bushing Lower Control Bushing Wheel Bearing Carrier 30 ft. lbs.6 . (24 Nm) Stabilizer Support 17 ft. lbs. lbs. lbs.

5. lbs.BODY / STEERING / SUSPENSION FRONT STRUT ASSEMBLY EXPLODED VIEW Nut 15 ft. lbs.7 . lbs. (25 Nm) Lower Pivot Ball Bolt Spring Retainer Lubrication Fitting Spring Hubstrut Bearing Retaining Ring Brake Caliper NOTE: Grease fitting location. (21 Nm) 18 ft. (21 Nm) Washer Upper Pivot Ball Spacer Rubber Strut Bumper Strut Washer Clamp Spacer Nut 15 ft. Check lubrication guide for recommended service intervals.

Remove fuel tank cap (reinstall on tank after cab is removed) Radiator Cover Pull out slightly on the top of the radiator screen. then pull out on the bottom of the screen To Remove: 2871572 2871573 2871574 7052069 2200421 2871352 2871351 To Remove: To Remove: To Remove: To Remove: TORQUE SPECIFICATIONS Front A-Arm Attaching Bolt... (21 Nm) Tie Rod End Jam Nut... (21 Nm) Strut Casting Pinch Bolt.....1 screw-nut and washer at rear of inner left footrest.BODY / STEERING / SUSPENSION SPECIAL TOOLS TOOL DESCRIPTION Ball Joint Replacement Tool Shock Spanner Wrench Shock Absorber Spring Compression Tool Strut Rod Wrench LH Strut Spring Compressor RH Strut Spring Compressor Charging Needle Gas Shock Recharging Kit Shock Rod Holding Tool Foxt Shock IFP Depth Tool PART NUMBER 2870871 2870872 2870623 COVER/PANEL REMOVAL To Remove: Seat Pull release lever at the rear of the seat Lift and pull seat rearward.... lbs.25-30 ft.... Front cover panel. lbs..Disengage cover and lift out Rear Rack Remove Seat. (48 Nm) Lower Control Arm Mounting Bolt........30 ft. lbs. (41 Nm) Upper Wheel Bearing Carrier Bolt...35 ft.30 ft.. lbs..30 ft... 1 inner screw from front cab to foot rest on each side........ lbs.17 ft..2-6.35 ft...... 2 bolts at rear of rack and 2 bolts at front of rack Rear Cab Assembly Remove Seat. (17-19 Nm) Tie Rod End Castle Nut. lbs. lbs...... Side panels. (54-61 Nm) Tie Rod End Attaching Bolt............ (136 Nm) Wheel Nuts..30 ft.... 4 screws at bottom of left rear mud flap....... lift off Front Cab Assembly Remove Seat....... nut and washer at rear of inner right footrest....15 ft.......... (35 Nm) Handlebar Adjuster Block.. lbs. Front bumper (4 screws).... (41 Nm) Rear Wheel Hub Nut.. 2 screws at rear of cab at fuel tank mount bracket........ (35-41 Nm) NOTE: Refer to exploded views for identification and location of components. lbs.100 ft.. lbs.. 3 screws from bottom left mud flap....4) Front Cover Remove Front rack. 4 bolts and flat washers from top of cab assembly under seat...25 ft....6 Nm) Upper Stabilizer Support Nut.. 3 screws from bottom right mud flap.......30 ft.. lbs........... (24 Nm) Upper Control Arm Mounting Bolt.... Front rack.. lbs.... (41 Nm) Strut Rod Retaining Nut (Top)....3 Nm) Rear Shock Bolt (upper). (41 Nm) Rear Shock Bolt (lower).. To Remove: To Remove: To Remove: 5...... (14-17 Nm) Master Cylinder ... lbs..40-45 ft.. lbs.. disengaging seat from tabs at the rear of the fuel tank Side panels (See Page 5.15 ft...45-55 in.. lbs........... lbs..... lbs. 4 screws at bottom of right rear mud flap.... 2 screws at rear bottom of cab assembly near tail light. (41 Nm) Front A-Arm Ball Joint Stud Nut... (48 Nm) Lower Wheel Bearing Carrier Bolt....9) Remove Seat Disengage tabs at front and rear and pull away Headlight pod (See Page 5... 1 screw.12-14 ft...10-12 ft.8 .. (40.. lbs.. Rear rack.30 ft. 2 screws under front panel... Disconnect taillight harness Front rack Remove 4 screws.. (5....

push down on the side panel to disengage the top rear two tabs. Torque new bolts to 30 ft. Place hand on top of side panel behind the fuel tank. align panel tabs with slots. WARNING Push down to disengage top rear two tabs. pull the panel forward and outward to disengage the two rear tabs. Push upward and forward until tabs lock. (41. A-arm Attaching Bolt Torque: 30 ft. Remove wheels. Examine A-arm shaft. Push panel upward and forward until tabs lock. 8. align panel tabs with slots on front cab.9 . A-ARM REPLACEMENT 1. Bend rear of side panel and insert the two tabs into the rear cab. Discard hardware. Pull forward and out to disengage two rear tabs. lbs. lbs. Replace if worn. Step 3. (35 Nm) 5. Serious injury or death could result if fasteners come loose during operation. 4. 5. Install new A-arm assembly onto vehicle frame. 7. With a quick and firm motion. lbs. Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud. Install CV joint shields. 2. Using a soft face hammer. 1. Then pull up on side panel to disengage front upper and lower tab. DO NOT reuse old bolts. Step 1. 3. With a quick and firm motion. Remove nut and A-arm from hub strut assembly. Loosen two bolts on A-arm tube by alternating each about 1/3 of the way until A-arm can be removed. Grasp rear of side panel near rear cab. To reinstall side panel. tap nut to loosen A-arm from bolt. The locking features on the existing bolts were destroyed during removal. Step 2. Insert A-arm shaft into new A-arm. To reinstall. (41 Nm) Ball Joint Stud Nut Torque: 25 ft.BODY / STEERING / SUSPENSION SIDE PANEL REMOVAL NOTE:Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 3. Remove seat. 2.4 Nm). Elevate and safely support vehicle with weight removed from front wheel(s). 6.

Attach A-arm to hub strut assembly. 4. Check steering. 3. test vehicle at low speeds before putting into regular service. Apply Loctitet 242 to the bolt threads.BODY / STEERING / SUSPENSION A-ARM REPLACEMENT CONT’D 9. Tighten ball joint nut to 25 ft. lbs. Align cotter pin hole. Install cotter pin. If cotter pin holes are not aligned. lbs. (41 Nm) Washer A-Arm Tube Ball Joint Stud 242 Nut A-Arm Shaft Cotter Pin CV Joint Shield 8 ft. lbs. 5. lbs (35 Nm). must move freely and easily from full left to full right without binding. (11 Nm) STEERING POST ASSEMBLY 1. Bend both ends in opposite directions around nut. Vehicle Frame WARNING Upon A-arm installation completion. Bolt 30 ft. 2. tighten nut slightly to align. Hand tighten. Bolt 30 ft. (41 Nm) Long Bushing Grease Fitting Bushing 25 ft.10 242 . Install a new cotter pin with open ends toward rear of machine. Bend both ends of cotter pin around nut in opposite directions. (35 Nm). lbs.

2. 8. G Thread bolt (D) with nut (C) onto ball joint stud as shown. 5. 3. Remove wheel nuts and wheels. (21 Nm). 1 7. Do not over torque nut. 10.BODY / STEERING / SUSPENSION FRONT STRUT CARTRIDGE REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5. 7. Remove coil spring and collapse strut cartridge. CAUTION: Serious injury may result if machine tips or falls. G Apply grease to extension cap and threads of puller bolt to ease removal. 6. Torque strut rod nut to specification. Install cartridge until bottomed in strut casting. 4. Using the Ball Joint Replacement Tool (PN 2870871).11 . 5. Remove strut cartridge. lbs. 3. Torque pinch bolts to 15 ft. Compress spring using strut spring compressor tools. Strut Spring Compressor Tools (PN 2871573) and (PN 2871574) B A 2. 4. Remove two pinch bolts from strut casting. Elevate and safely support machine under footrest/frame area. lbs. Remove cotter pin (A) from ball joint castle nut. (Refer to Illustration 1 on this page. remove ball joint (F) from strut housing. Loosen front wheel nuts slightly. G Hold bolt (D) and turn nut (C) clockwise until ball joint is removed from strut housing.) 2 D C B 5. Remove castle nut (B) and separate A-arm (C) from ball joint stud. 6. Refer to photo 2. Hold strut rod and remove top nut. Be sure all parts are installed properly and seated fully. Remove upper strut pivot assembly. (21 Nm) A BALL JOINT REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5. C F E D Strut Rod Nut Torque 15 ft. Reassemble spring and top pivot assembly.7 1. Remove screws (D) and ball joint retaining plate plate (E). G Install puller guide (A) with extension cap (B). 9. G Applying heat will ease removal. Install pinch bolts with wire clamp(s).7 1. Be sure machine is secure before beginning this service procedure.

(2--3 inches from the flame tip is recommended) Keep the torch moving to prevent damage. To flame treat the decal area: 1. Reinstall cotter pin with open ends toward rear of machine. front and rear fender cabs are plastic polyethylene material. 2. Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appears slightly glossy. A B C D E E F 9. Be sure the area to be flame treated is clean and free of gasoline or flammable residue. Install A-arm on ball joint and torque castle nut to 25 ft. flexed. (11 Nm). DECAL REPLACEMENT WARNING The following procedure involves the use of an open flame. G Drive new joint into strut housing until fully seated. 11. Perform this procedure in a well ventilated area. they must be “flame treated” prior to installing a decal to ensure good adhesion. or damaged. Apply Loctitet 242 (PN 2871949) to threads of retaining plate screws or install new screws with pre-applied locking agent. This should occur after just a few seconds of flame treating. Do not hold the torch too close to the surface. (35 Nm). The side panels. Therefore. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. lbs. Apply the decal on one edge first.12 . away from gasoline or other flammable materials.BODY / STEERING / SUSPENSION BALL JOINT REPLACEMENT CONT’D 8. Torque screws to 8 ft. G Applying heat will ease installation. A bonus of the flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent. To install new ball joint: G Remove extension cap and attach puller guide using short bolts provided in the kit. 5. 10. G Insert new ball joint (E) into driver (F). G Slide ball joint/driver assembly into guide. lbs.

. . . . . Clutch Alignment/Offset . . . . . .CLUTCH CHAPTER 6 PVT SYSTEM Drive Clutch Exploded View . . . . .13--6. . . . . . . . . . . . . . . .18 6. . . . . Drive One--way Clutch Inspection . . . . . . . . . . . .7 6. . . . .22--6. . . . .20 6. . . . . . . . . . . . . . .4 6. . . . PVT Overheating/Diagnosis . . . Troubleshooting . . Supplies & Torques . . . . . .2 6. . .6 6. . . . . . . . . . . . . . PVT Maintenance/Inspection/Drying . . .25 6 6. . .20--6. . . . . Drive Clutch Bushing Service . . . Shift Weights /Inspection .8 6. . EBS System Exploded View . . . . . . . . Special Tools. . .17 6. .3 6. .14--6. . Drive Clutch Spring Specifications . . . . . . . . . . . . . . . . . Driven Clutch Bushing Service . . Drive Clutch Disassembly/Inspection . . . . . . . . .9 6. . .5 6. . . . . . .16 6. . . . . . . . . . . . . . PVT Assembly/Inspection .1 .17--6.16--6. . . . . . Drive Belt Removal/Inspection . . .10--6. . . . . . . . . . Driven One--way Clutch Inspection . . .18--6. . . . . Drive Belt Installation . . . . . . . PVT Operation Overview . PVT Disassembly .4 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11--6. . . . . . . . 6. . . .2 6. . . .13 6. PVT Sealing and Ducting Components .11 6.23 6. . . . . .21 6. . . . . . . . . Drive Clutch Reassembly . . . .24--6. . . . . . . .14 6. . . .15 6. . . . . . . . .

CLUTCH DRIVE CLUTCH EXPLODED VIEW Mark with permanent marker before disassembly One way clutch EBS Drive Clutch PVT SEALING AND DUCTING COMPONENTS Clutch Inlet Duct Transmission Cover Seal Inner Clutch Cover Boot Duct Clutch Cover Seal Clamps Inner Cover Seal Seal Retainer Bracket Clutch Cover 6.2 .

Lbs.25² PTFE Washer Ramp Bushing Washer Coil Spring Torque to 200 Ft. (271 Nm) Compression Spring Bushing Spacer Sleeve Cover Bushing Screw Roller Roller/Bushing Assembly One Way Clutch (Driven) Flat Washer PTFE Washer Retaining Ring Bushing Spider Lock Nut Bolts. Lock Washers Drive Belt Driven Clutch Assembly 6.3 .CLUTCH ENGINE BRAKING SYSTEM (EBS) EXPLODED VIEW Drive Clutch Assembly Flat Spacer Ramp Retaining Ring One Way Clutch Drive Brass Washer Shift Weights 2.

. lbs. . . . and 3) The Drive Belt. . . . . . . 90 in. . . 6. . . . . . . . . . causing the shift weights to push against rollers on the moveable sheave. . . . . . . Therefore. . 2870584 RTV Silicone Sealer . (271 Nm) Drive Clutch Spider Lock Nut (Plastic) . lbs. . . Proper clutch setup and careful inspection of existing components must be the primary objective when troubleshooting and tuning. 2870661 Loctite Gasket Remover . 15 ft. (23 Nm) PVT Inner Cover Bolts . modifications or variations of components at random are never recommended. . lbs. . . . . . . . (20. . . . . The two major components which control its shifting function are the shift weights and the coil spring. . . centrifugal force is created. Because of the critical nature and precision balance incorporated into the PVT components. . . then to average riding conditions and the vehicle’s intended usage. . the drive belt is kept at the outer diameter of the driven clutch sheaves. (16 Nm) Drive Clutch Spider EBS Clutch) . 40 ft. . SPECIAL SUPPLIES PART NUMBER Loctitet 680 . (54 Nm) Driven Clutch Retaining Bolt . centrifugal force causes the drive belt to be forced upward on drive clutch sheaves. lbs. . . . . . . . . . . . . . When this force becomes higher than the preload in the spring. . . 17 ft. the PVT system is matched first to the engine power curve. . . . . . . . . . . . 2870913 2870910 2871226 2870386 2872292 2201379 8700220 2871025 DRIVE CLUTCH OPERATION Drive clutches primarily sense engine RPM. . . . . . . . which is held open by coil spring preload. . The internal components of the drive clutch and driven clutch control engagement (initial vehicle movement). . . the outer sheave moves inward and contacts the drive belt. . . . . . 200 ft. . . . which in turn rotates the driven clutch. . . . . . . . . . . As engine RPM increases. . If the torque resistance at the transmission input shaft is greater than the load from the drive belt. . . .3 Nm) Drive Clutch Cover Plate . . . Whenever engine RPM is increased. lbs. the drive belt rotates low in the drive clutch sheaves. . . . . . At lower RPM. . . opening and closing according to the forces applied to it from the drive belt and the transmission input shaft.4 . . (10 Nm) DRIVEN CLUTCH OPERATION Driven clutches primarily sense torque. . . clutch upshift and backshift. This motion pinches the drive belt between the spinning sheaves and causes it to rotate. . During the development of a Polaris ATV. lbs.CLUTCH SPECIAL SERVICE TOOLS AND SUPPLIES TOOL DESCRIPTION Clutch Puller Clutch Holding Wrench Clutch Holding Fixture Spider Nut Socket Drive Clutch Spider Removal and Install Tool Driven Clutch Puller Roller Pin Tool Clutch Bushing Replacement Tool Kit Piston Pin Puller EBS Clutch Alignment Tool EBS Bushing Replacement Kit Clutch Compression Tool Clutch Bushing Replacement Tool Kit PART NUMBER 2870506 9314177 2871358 2870338 2870341 PVT OPERATION OVERVIEW WARNING All PVT maintenance or repairs should be performed only by a certified Polaris Master Service Dealer (MSD) technician who has received the proper training and understands the procedures outlined in this manual. . 2) The Driven Clutch. it is absolutely essential that no disassembly or repair be made without factory authorized special tools and service procedures. . 2870601 PVT SYSTEM FASTENER TORQUES Drive Clutch Retaining Bolt . . . 12 ft. . . . The Polaris Variable Transmission (PVT) consists of three major assemblies: 1) The Drive Clutch. . .

the drive and driven clutches are continually shifting to maintain optimum engine RPM.16--6. See Page-6. the PVT system is similar to a power governor. Clean and inspect for wear. The intake duct draws fresh air through a vented cover. simply remove the PVT drain plug and O--ring located on the bottom of the PVT cover and let the water drain out. Operate ATV in lowest available range for a short period of time until PVT system is dry. which increases the driven clutch speed. be sure to check the PVT cover and other ATV components for water ingestion. the load from the drive belt increases. This also will prevent water and other contaminants from entering the PVT area. See Pages 6. must be properly sealed to ensure clean air is being used for cooling the PVT system. Periodic inspection and maintenance is required to keep the system operating at peak performance. is called upshifting. This action. Belt Width. In situations where loads vary (such as uphill and downhill) and throttle settings are constant. Drive and Driven Clutch Buttons and Bushings. 4.11-6. PVT System Sealing. Allow engine RPM to settle to idle speed. Drive to Driven Clutch Offset. air ducts. as a conventional governor does. The fins create a low pressure area in the crankcase casting. 1. A sealed PVT is especially critical on units subjected to frequent water forging. Refer to appropriate illustrations and photos. At full throttle a perfectly matched PVT system should hold engine RPM at the peak of the power curve. This action. Drive and Driven Clutch Springs. PVT Drain Plug & O--ring 6. The following list of items should be inspected and maintained to ensure maximum performance and service life of PVT components. PVT DRYING NOTE: If operating the ATV through water. Should the throttle setting remain the same and the vehicle is subjected to a heavier load. shift transmission to lowest available range and test for belt slippage. Refer to the troubleshooting checklist at the end of this chapter for more information. which decreases the driven clutch speed. shift the transmission to neutral and rev engine slightly to expel the moisture. Refer to Owner’s Manual for Safe Riding Tips. This RPM should be maintained during clutch upshift and backshift. In this respect.CLUTCH DRIVEN CLUTCH OPERATION CONT’D As engine RPM and horsepower increase. the PVT system changes engine load requirements by either upshifting or backshifting.5 .18 2. resulting in the belt rotating up toward the outer diameter of the drive clutch sheaves and downward into the sheaves of the driven clutch. This will also air-dry the belt and clutches. the drive belt rotates back up toward the outer diameter of the driven clutch and downward into the sheaves of the drive clutch. To further expel water in the PVT cover and to dry out the PVT system. is called backshifting. The ATV should be checked immediately. Sheave Faces. The opening for this intake duct is located at a high point on the vehicle (location varies by model). drawing air into the system through an intake duct.12 3. Drive Clutch Spider Rollers and Roller Pins. as well as the inner and outer covers. All connecting To drain any water that may be trapped inside the PVT cover. PVT Drain Plug PVT MAINTENANCE/INSPECTION Under normal operation the PVT system will provide years of trouble free operation. Drive Clutch Shift Weights and Pins. Repeat as needed. Rather than vary throttle position. The PVT system is air cooled by fins on the drive clutch stationary sheave. The PVT drain plug is shown below.

Use Low Range only. riding through rough terrain (swamps. carefully use fast. Fast. 6. Shift the transmission to Low Range. Continuous operation at the point of engagement (initial vehicle movement) increases PVT temperatures and component wear. or if extended low speed operation is anticipated. Using the throttle. Slow and easy clutch engagement. During this procedure. engine rpm from idle to 3/4 throttle. GENERAL RANGE OPERATION GUIDELINES: Low Range: Heavy pulling. The ATV should be operated in LOW RANGE when pulling or plowing heavy loads. prevent belt burning. Plowing snow. vary the into the PVT system.). Warning: Excessive throttle may cause loss of control and vehicle overturn. Inspection/repair of clutch components should be performed by a certified Polaris MSD techinician. aggressive throttle application to engage clutch. etc. then with transmission in neutral./utility use. low ground speeds. effective use of the throttle for efficient engagement. Climbing over large objects from a Shift the transmission to Low Range. Engage transmission in the lowest possible range and test for belt slippage Repeat several times as required. advance throttle to approx. etc. aggressive. or dismount the ATV after first applying the park brake and perform the “K” turn. PVT seals should be inspected for damage if repeated leaking occurs. Stuck in mud or snow. The use of Low (at approximately 3--7 MPH). Belt slippage from water or snow ingestion Shift the transmission to neutral. the throttle should not be held at the full position for more than 10 seconds. Driving at low RPM or low ground speed Drive at higher speed or use Low Range. 1/8 throttle in short bursts. basic operational speeds less than 7 MPH. High Range: High ground speeds. dirt. 5 to 7 times. Starting out going up a steep incline.6 . Towing/Pushing at low RPM/low ground Use Low Range only. mountains. throttle application to engage clutch. stopped position. low ambient temperatures. carefully use fast. it’s important to check the inlet and outlet ducting for obstructions. Diagnosis of Clutch Drive Belt & Cover Related Issues: Possible Causes Solutions/What to do Loading the ATV into a pickup or tall trailer Shift transmission to low range during loading of the ATV to when in high range. Clutch malfunction. Insufficient warm--up of ATVs exposed to Warm engine at least 5 min. Obstructions to air flow through the ducts will significantly increase PVT system operating temperatures. use low range. The belt will become more flexible and prevent belt burning.. Range is highly recommended for cooler PVT operating temperatures and longer component life. Warning: Excessive throttle may cause loss of control and vehicle overturn. speeds above 7 MPH. speed.CLUTCH PVT OVERHEATING/DIANOSIS During routine maintenance or whenever PVT system overheating is evident. When starting out on an incline.

Mark the drive belt direction of rotation and remove drive belt. Foam Seal 10. 6. Refer to the appropriate parts manual for proper fasteners and fastener placement. Remove driven clutch offset spacers from the transmission input shaft. 3. 1.16 for drive belt removal. Inner cover Retainer Seal Drive Clutch Puller (PN 2870506) Clutch Holding Wrench (PN 9314177) 7. Keep Spacers In Order 9. See Page 6. Remove outer cover screws. NOTE: Remember to keep spacers in order for proper clutch offset on reassembly. Use puller if necessary.7 . Remove inner cover retaining bolts at rear of cover. Remove driven clutch retaining bolt and driven clutch. 5. 4. Remove cover along with foam seal on back of cover or shaft. 11. Refer to Page 6. 2. Remove or loosen rear cab fasteners as necessary to gain access to PVT outer cover.2.CLUTCH PVT DISASSEMBLY NOTE: Some fasteners and procedures will vary. Remove PVT air outlet duct hose. Driven Clutch Puller (PN 2870913) 8. 6. Remove cover screws and retainer plate. Remove seat. Remove drive clutch retaining bolt and remove drive clutch using puller.

5 Nm) Drive Clutch Retaining Bolt Torque: 40 ft. Install drive clutch and torque retaining bolt to specification. If a new belt is installed. Inner Cover Bolt Torque (Rear): 12 ft. 14. Apply RTV silicone sealant to outside edge of inner cover-to-engine seal. 5. Surfaces must be clean to ensure adhesion of silicone sealant. lbs. Fit lip of inner cover seal (A)to engine.CLUTCH PVT ASSEMBLY/INSPECTION 1. 3. Reinstall drive belt noting direction of rotation. Install the driven clutch. to ensure a water tight fit between the seal and the cover on engine side. Torque rear inner cover bolts (B) to specification. washer. lbs. Install clutch offset spacer(s) on transmission input shaft. Reinstall rear cab assembly. 11. (16. 10. lbs. Align the alignment mark on the cover with the mark on the engine seal. Apply a light film of grease to the splines on the shaft. Place a new seal on transmission input shaft. Clean end of taper on crankshaft and the taper bore inside drive clutch. B 8. 9. Reinstall cover and tighten rear cover bolts just enough to hold it in place.6 Nm) Driven Clutch Retaining Bolt Torque: 17 ft. Seal this edge to cover on engine side 7. Offset Spacer 2. Inspect PVT inner cover-to-engine seal. install so numbers can be easily read. Clean splines inside driven clutch and on the transmission input shaft. Only replace PVT outer cover rubber gasket if it is damaged. and retaining bolt. Reinstall PVT outer cover and secure with screws. 13. 4. panel and seat. lock washer. (55 Nm) 6. Place the gasket with the narrow side out (C). Install seal retainer plate and tighten screws securely. 12. Toward outer cover C A Seal outer edge to cover with RTV silicone sealant PVT Cover Gasket 15. (23. 16. Torque to specification. 6. Replace if cracked or damaged.8 .

177I . Distortion of the spring indicates stress fatigue.19 COMPRESSED SPRING LENGTH (INCHES) Measuring Spring Length: With the spring resting on a flat surface. it should always be inspected for tolerance limits during any clutch diagnosis or repair. 2.168I . It is also one of the easiest to service.157I .25I 4. requiring replacement.CLUTCH DRIVE CLUTCH SPRING SPECIFICATIONS The drive clutch spring has two primary functions: 1. CAUTION: Never shim a drive clutch spring to increase its compression rate.00 1. Refer to the spring specification chart for specific free length measurements and tolerances. It is very important that the spring is of correct design and is in good condition.140I . There are other components which control upshift.125I 4. Also check to see that spring coils are parallel to one another. Primary Clutch Springs PART NUMBER 7041021 7041022 7041063 7041132 7041168 7041157 COLOR CODE Plain Black Purple White Green Blue/Green WIRE DIAMETER .50 1.37I 2. This may result in complete stacking of the coils and subsequent clutch component failure.177I FREE LENGTH ¦. Due to the severe stress the coil spring is subject to during operation.25 1.92I 3. but the spring is one of the primary components in insuring optimum performance.05I 2.38I 4.53I Secondary Clutch Springs PART NUMBER 7041198 7041782 7041501 7041499 7041296 7041646 DESCRIPTION Red Black 5-coil Gold 6-coil Silver Blue Silver/Blue 6. The drive clutch spring is one of the most critical components of the PVT system.75 1. Controls the rate at which the drive belt moves upward in the drive clutch sheaves. The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM. NEUTRAL 300 ATV TRAVEL FULL UPSHIFT 280 260 240 220 200 180 160 140 120 100 80 60 40 20 0 2.5 FORCE (POUNDS) Green 7041168 Purple 7041063 White 7041132 Plain 7041021 Blue/Green 7041157 Black 7041022 2. This is referred to as drive clutch upshift.25 2.9 .177I . measure its free length from the outer coil surfaces as shown. Controls clutch engagement RPM.

engagement and shifting characteristics. 16 53 PN 5630418 50 gr PN 5630279 43 gr PN 5630095 53 gr 55 PN 5630509 55 gr 10 RH 10 WH 10 BH PN 5630709 44 gr PN 5630513 50.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.5 gr PN 5630710 46 gr PN 5630711 47gr 20 54 20 56 20 58 PN 5631214 54 gr PN 5631215 56 gr PN 5631216 58 gr 6. clutch balance.10 . Shift weights should not be changed or altered without first having a thorough understanding the effects they have on belt to sheave clearance.

mark the cover. replace all buttons and inspect surface of towers.11 . Inspect for any clearance between spider button to tower. If clearance exists. Broken Worn Good Inspect the weight pivot bore and pivot bolts for wear or galling. See Spider Removal Page 6. WARNING DRIVE CLUTCH DISASSEMBLY 1. Never replace parts with used parts from another clutch assembly! All PVT maintenance or repairs should be performed only by a certified Polaris Master Service Dealer (MSD) technician who has received the proper training and understands the procedures outlined in this manual.CLUTCH SHIFT WEIGHT INSPECTION 1. See roller inspection. If weights or bolts are worn or broken. Replace the entire clutch as an assembly if worn. Inspect as shown. Page 6. replace in sets of three with new bolts. as the previous X’s may not have been in alignment before disassembly. damaged or cracked. BUTTON TO TOWER CLEARANCE INSPECTION 1. Inspect sheave surfaces. The contact surface of the weight should be smooth and free of dents or gall marks.000 . Mark The clutch assembly is a precisely balanced unit.001I 2. Because of the critical nature and precision balance incorporated into the PVT system. “X” Mark 6.. Using a permanent marker.12. it is absolutely essential that no attempt at disassembly or repair be made without factory authorized special tools and service procedures. NOTE: A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly.12. Remove shift weight bolts and weights. and moveable and stationary sheaves for reference. Button to Tower Clearance: . using a clutch holding tool to compress the moveable sheave. spider.

Install clutch in holding fixture and loosen the spider (counterclockwise) using Clutch Spider Install Tool (PN 2870341). Refer to bushing replacement in this chapter. The outer cover bushing is manufactured with a Teflont coating. galling. Cover Bushing inspection A SPIDER REMOVAL 1.CLUTCH DRIVE CLUTCH DISASSEMBLY CONT’D 2. Remove the limiter nut using the Clutch Spider Nut Socket (PN 2870338).12 . Inspect cover bushing (A). Inspect area on shaft where bushing rides for wear. nicks. Be sure to note the number and thickness of these washers. 6. 3. 5. 4. Remove and inspect spring. Cover Bushing Inspection: Replace the cover bushing if more brass than Teflont is visible on the bushing. be sure to reinstall original quantity and thickness washers Clutch Holding Fixture: (PN 2871358) Spider Removal Tool: (PN 2870341) NOTE: It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly. or scratches. Replace clutch assembly if worn or damaged. (See Page 6. Wear is determined by the amount of Teflon remaining on the bushing. Remove cover bolts evenly in a cross pattern and remove cover plate.9) Inspect shaft To maintain proper clutch balance and belt-to-sheave clearance.

13 . The Teflon bushings are self-lubricating. making sure spacer washers are installed underneath spider and positioned properly in recess. galling. It is recommended to switch all buttons to the rubber version during service (if needed). Bushing must fit tightly in roller. Reassemble drive clutch in the following sequence. or flat spots. or the marks that were made earlier under weight Roller. a) “X”. If you notice resistance. Turn roller with your finger. Pin and Thrust Washer Inspection 3. or the marks that were made earlier. 4. Inspect the Teflont coating on the moveable sheave bushing. Inspect all rollers. replace rollers. DRIVE CLUTCH REASSEMBLY NOTE: It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly. are aligned during each phase of assembly. Rubber backed buttons can and should be used in all ATV clutches if the hollow roller pin is changed to a solid roller pin. Be sure the “X”.CLUTCH Moveable Sheave Bushing Inspection 2. Do not apply oil or grease to the bushings. c) “X”. bushings and roller pins by pulling a flat metal rod across the roller. 1. Use the Roller Pin Tool (PN 2870910) to replace rollers and pins. NOTE: The rubber side of the 6. pins and thrust washers in sets of three. Also inspect to see if roller and bushing are separating. button is positioned toward the solid roller pin. Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflont is visible on the bushing. or the marks that were made earlier on cover b) X on spider. Refer to bushing replacement in this chapter. Take care not to damage roller bushing or bearing surface of the new pin during installation.

14 . Reinstall cover. Torque spider to specification using the holding fixture and spider tool. Mark drive belt direction of rotation so that it can be installed in the same direction. 7. (10. or the marks that were made earlier on the moveable sheave. Install limiter nut on top of spider using the Clutch Spider Nut Socket (PN 2870338). NOTE: Normally positioned so part numbers are easily read.4 Nm) DRIVE BELT REMOVAL/INSPECTION Spacer washers 6. 4. lbs. Spider Torque: 200 ft. (271 Nm) Cover Screw Torque: 90 in. To remove drive belt. 8. Remove outer PVT cover as described in PVT Disassembly. making sure that “X”. 2. apply brake. Any misalignment will alter clutch balance. Inverting the clutch while initially tightening the spider will help position the washers. pull out and down on belt to slip over the driven clutch outer sheave. aligning “X” mark with other marks. lbs. lbs. Reinstall clutch spring. Install spider spacers.CLUTCH DRIVE CLUTCH REASSEMBLY CONT’D 2. 3. 1. CAUTION: Be sure the spider spacer washers are fully seated in the recessed area of the spider.3 for torque specification. or the marks that were made earlier. on spider aligns with “X”. 5. Torque to 15 ft. Reinstall shift weights using new lock nuts on the bolts. 3. Compress spider buttons for each tower and install spider. Refer to Page 6. Torque with smooth motion to avoid damage to the stationary sheave. Install moveable sheave onto fixed sheave. Use same quantity and thickness as were removed. pull upward and rearward on belt to open driven clutch sheaves. Torque cover bolts evenly to specification. Engine Rotation Nut on trailing side 6.

98-3.875²± 3/16 (103. thin spots. G Install the drive clutch onto the crankshaft. etc.5 / -1.05 (254 +2.1. Belts which measure longer than nominal length may require driven shimming or engine adjustment for a longer center distance to obtain proper belt deflection. Hour glassing occurs when the drive train does not move and the drive clutch engages the belt continuously in one spot.174 . Belts with thin spots..02 cm) Wear Limit 1. Install the belt onto the driven clutch. Belts which measure shorter than nominal length may require driven shimming or a shorter center distance. G Place another straight edge on top of belt. Remember. 8. or erratic PVT operation.CLUTCH Belt Width: New 1. burn marks. belts should be replaced if clutches can no longer be adjusted to provide proper belt deflection. Measure belt width and replace if worn.15 .188² (2. cracks.1 / -. 4. G The top edges have been trimmed on some drive belts. Inspect belt for hour glassing (extreme circular wear in at least one spot and on both sides of the belt).not a specific center distance. See Troubleshooting Chart at the end of this chapter for possible causes. G Place a straight edge on each side of the drive belt. 6. Measure belt length with a tape measure around the outer circumference of the belt. abrasions.125² (2. proper belt deflection is the desired goal . Replace belt if worn past the service limit. or excessive wear. 7.40. Inspect belt for loose cords. as shown in the illustration.48 cm) 6.3mm) Belt Nominal Length . It will be necessary to project the side profiles and measure from corner to corner. vibration. G Measure the distance where the side straight edges intersect the top. missing cogs.86 cm) NOTE:When reinstalling the belt with the drive clutch and driven clutch already removed follow these steps: Install the driven clutch. Center Distance Projected Belt Width Clutch Center Distance 10² +.8 cm ± . Replace if necessary. Loop the drive clutch through the belt. Generally. should be replaced to eliminate noise. G G G 5.

clutch alignment must be adjusted as follows: 3.1. turn the back or moveable driven sheave clockwise. Adjust if necessary. NOTE:If the distance is greater than 1/8² or less than 1/16². the distance at point “A” should be 1/8². CLUTCH ALIGNMENT 1.EBS B Shim Kit (PN 2200126) CLUTCH OFFSET Important: Inspect clutch alignment and center distance before adjusting offset. Loop belt over drive and over top of driven sheave. With tool touching rear of driven clutch inner sheave. Tighten engine mounts and verify alignment is correct. Offset Alignment Tool (PN 2872292) . 2.7--6. If a shim is present. Offset is correct when rear of tool contacts rear of inner sheave with driven clutch pushed completely inward on shaft and bolt torqued. 6. Remove belt and install the Clutch Offset Alignment Tool (PN 2872292) as shown.6 mm) Spacer Washer (PN 7556401) 6. it can be removed to decrease the distance at point “A”. Measure belt deflection and measure offset both above and below shaft centerlines.16 . Pages 6. See PVT Disassembly. 5. Center line 3. 4.8. Loosen all engine mounts. A 1/8I +0 / -.2mm +0 / -. minor adjustments can be made by adding shims between the frame and front lower left engine mount to increase the distance at point “A”. NOTE:Be sure to position belt so part number is easily read. 7. While pushing down on top of belt. Measure offset above and below centerline NOTE: On some models.CLUTCH DRIVE BELT INSTALLATION 1.1/16 3. Adjust offset by adding or removing spacer washers between back of driven clutch and spacer. Remove PVT inner cover. The belt then should be able to be pushed down into and between the sheaves. Remove drive and driven clutch. Move front of engine to the right or left slightly until alignment is correct. 2.

Remember to measure above and below the shaft centerlines. Remove moveable sheave spacer sleeve and the brass washer.64mm) 2.CLUTCH 1. Install offset alignment tool as shown. then proceed as follows: 1. Brass Washer Thickness Standard: . the clutch should lock to the shaft without slipping. continue with disassembly. 6. Measure the thickness and compare to specification. Visually inspect the washer for damage. Driven Clutch Offset To adjust. The clutch should rotate on the shaft with only slight amount of drag. Replace if worn or damaged. spring. Lift one-way clutch off shaft. If problems are noted in either direction.17 . When rotated counterclockwise. Replace as an assembly if worn.76mm) Service Limit: . Verify there is no binding or rough spots. Rotate one-way clutch clockwise (as viewed from the cover plate side). add or remove washers from behind the driven clutch ONE-WAY CLUTCH INSPECTION (DRIVE CLUTCH) 1. and spider following instructions for drive clutch removal.030² (. or if problems were noted. damaged.025² (. Offset Alignment Tool should contact rear edge of driven clutch sheave DRIVE CLUTCH INSPECTION NOTE: Remove cover.

grooving or cracking.18 . Visually inspect the washer for damage. Replace if worn or damaged.030 (. Measure the outside diameter and compare to specifications. grooves.76mm) Service Limit: . Inspect surface of shaft for pitting. Inspect BOTH sheaves for signs of wear. Replace the drive clutch assembly if shaft is worn or damaged. or damage. Clean surfaces with a 3Mt pad if needed Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflont is visible on the bushing. EBS DRIVEN CLUTCH DISASSEMBLY/INSPECTION CAUTION: The driven clutch must be disassembled from the helix end to lessen the chance of damage to seals in the one-way clutch. Review all information below before proceeding. The sheave should rotate with only a slight amount of drag. Refer to bushing replacement in this chapter.3730 4. hold the inner sheave and rotate the outer sheave of the driven clutch in a counterclockwise direction as shown at right. Move Freely MOVEABLE SHEAVE BUSHING INSPECTION 1. 6. There should not be any binding or rough spots.64mm) ONE-WAY CLUTCH PRELIMINARY INSPECTION (DRIVEN) 1.025 (. Remove 2 1/2 PTFE washer from shaft. Shaft Diameter Standard: 1. Measure the thickness and compare to specification.1. With drive belt removed and transmission in gear.CLUTCH ONE-WAY CLUTCH INSPECTION (DRIVE CLUTCH) CONT’D 3. PTFE Washer Thickness Standard: . Inspect the Teflont coating on the moveable sheave bushing.375 Service Limit: 1.3745 .

Do not attempt disassembly of the driven clutch from the outside snap ring. Apply Loctitet 680 retaining compound sparingly to the tapered head portion of the roller retaining screws. the outer sheave should lock to the shaft and inner sheave without slipping. Remove spring seat washer and inspect for wear or damage. ROLLER PIN DISASSEMBLY New roller retaining bolts have a dry locking agent applied to the threads. When rotated clockwise. Remove driven clutch from the transmission input shaft. 6. Rollers must rotate freely on pins without excessive clearance. Always use new bolts if they are removed for inspection. Do not allow locking agent to contact the inside of the rollers.19 . The driven clutch must be disassembled from the helix side or the one-way clutch seals may be damaged. Heat Area Lightly Roller Apply Loctitet 680 To Tapered Portion Of Screw Dry Locking Agent Applied To New Screws 6. Before attempting to remove the roller pins. Do not lubricate the roller or roller pin.CLUTCH 2. Push helix inward. Inspect surface of rollers for flat spots and wear. Lock to Shaft and Outer Sheave NOTE: Rotating the moveable sheave so that the rollers are not in contact with either helix ramp surfaces will lessen the effort needed to push the helix inward. A small amount of valve grinding compound can be applied to the tip of the hex wrench to ensure a tight fit. Place the driven assembly into the clutch holder. and spring. 5. Rollers 3. Wear heat resistant gloves during this procedure. washer. helix. NOTE: The spring is a compression spring only and has no torsional wind. heat the threaded area lightly with a propane torch. Do not disassemble from this side 4. Use a high quality hexagonal wrench in good condition to avoid screw damage. Replace if worn. Remove snap ring. Check the roller pin and roller bore for wear and replace if necessary.

If the shaft can be moved laterally. grooving or cracking. Check for movement of the shaft in the one-way clutch. Install puller adapter (Item 10 from kit PN 2871226). NOTE: Bushings are installed at the factory using Loctitet 609.20 . 5. 3. 2. or if the one-way clutch does not function properly as described in Step 1 and 2 on Page 6. Remove clutch as outlined previously in this chapter. 4. In order to remove bushings it will be necessary to apply heat evenly to the area around each bushing. Clean surfaces with a 3Mt pad if needed EBS DRIVE BUSHING SERVICE EBS CLUTCH BUSHING REMOVAL AND INSTALLATION (Use Tool Kit PN 2201379) The contents of this kit include: Item A/B C D E Qty 1 1 1 1 1 Part Description EBS Puller Tool EBS Puller Nut EBS Main Adapter EBS Bushing Removal Tool Instructions Part No 5132027 5132501 5132029 5132028 9915111 Also required:Clutch Bushing Replacement Tool Kit (PN 2871226) (ATV Clutch Kit) or (PN 2871025) (For all clutches) Piston Pin Puller (PN 2870386) REMOVAL AND INSTALLATION INSTRUCTIONS Moveable Sheave Bushing Inspection: Replace the bushing if more brass than Teflont is visible on the surface of the bushing. EBS Drive Clutch Moveable Sheave Bushing Removal 8. replace driven clutch assembly. Inspect moveable sheave bushing for wear. Inspect BOTH sheaves for signs of wear. Install main adapter (Item D) onto puller. Install handle end of Piston Pin Puller (PN 2870386) securely into bench vise and lightly grease puller threads.18. Clean all residual Loctite from bushing bore prior to installing new bushing. 1. Remove nut from puller rod and set aside. Puller Tool (A/B) Side “A” toward sheave Nut (C) Main Adapter (D) Puller Adapter (10) Piston Pin Puller 6.CLUTCH DRIVEN CLUTCH DISASSEMBLY/ INSPECTION CONT’D 7.

Discard bushing. Bushing Main Adapter (8) Piston Pin Puller EBS Drive Clutch Moveable Sheave Bushing Installation 2. 9. 5. Set bushing in place on sheave. 8. 5. 4. 2. With main adapter on puller. insert cover onto puller rod. 7.21 . apply heat around outside of bushing until tiny smoke tailings appear. Apply Loctitet 609 evenly to bushing bore in cover. Install nut onto puller rod and hand tighten. Turn puller barrel to increase tension as needed. 8. slide sheave onto puller rod. Continue until bushing is seated. slide sheave. insert new bushing and bushing installation tool into center of clutch cover. 10. 9.CLUTCH 6. Install main adapter (Item 8) on puller. slide cover onto puller. Lift sheave off puller. making sure bushing is drawn straight into bore. Turn sheave counterclockwise on puller rod until it comes free. 6. Turn barrel to apply additional tension if needed. From outside of clutch cover. insert removal tool (Item 3) into cover bushing. into center of bushing. 11. 10. Apply Loctitet 609 evenly to bushing bore inside moveable sheave. Remove nut from puller rod and set aside. bushing and tool onto puller rod. Remove bushing from tool and discard. Turn clutch cover counterclockwise on puller rod until bushing is seated. Turn puller barrel to increase tension on sheave if needed. EBS Drive Moveable Bushing Installation 1. Pull bushing removal tool and adapter from puller rod. EBS Drive Clutch Cover Bushing Installation 1. 5. 6. With towers pointing toward the vise. 6. Install adapter reducer (Item 9). Install nut on puller rod and hand tighten. 4. Install nut on rod and hand tighten. Remove bushing and bushing removal tool from puller. 7. Place main adapter (Item 8) on puller. 3. placing outside of cover toward vise. 3. Install nut (C) onto end of puller rod and hand tighten. Remove nut from puller rod and set aside. Install removal tool (Item A/B) into center of sheave with “A side” toward sheave. 6. Turn sheave counterclockwise. 3. 8. With inside of cover toward vise. Turn puller barrel to apply more tension if needed. Remove installation tool. Take installation tool and clutch cover off rod. 4. Puller Tool (A/B) Side “A” toward sheave EBS Drive Clutch Cover Bushing Removal 1. Turn clutch cover counterclockwise on puller rod until bushing is removed and cover comes free. Insert installation puller tool (Item A/B) with “A” side down. With towers pointing upward. Using a hand held propane torch. Working from inside of cover. Remove nut from puller rod. Removal Tool (3) Nut (C) Adapter Reducer (9) Main Adapter (8) Piston Pin Puller EBS Drive Clutch Cover Bushing Removal Nut (C) 2. Remove nut from puller rod and set aside. Remove sheave from puller. 7.

6. 8. 9. Install adapter reducer (Item 9). Bushing Removal Tool (E) Ill. Apply Loctitet 609 evenly to bushing bore inside moveable sheave. Install sheave onto puller. 6. Turn puller barrel for further tension if needed. 6. Turn puller barrel for further tension if needed.Bushing Removal 1. Remove installation tool and clutch sheave from puller.CLUTCH EBS DRIVEN BUSHING SERVICE EBS Driven . CAUTION: Clutch components will be hot! In order to avoid serious burns.Backside (Outer) Bushing Removal 1. 4. 2. 3. 5. apply heat around outside of bushing until tiny smoke tailings appear. Flip sheave over onto puller. Puller Adapter (10) 2. 8. wear insulated gloves during the removal process. 7. apply heat evenly around outside of bushing until tiny smoke tailings appear. 1. 10. Install bushing removal tool (Item E) into center of clutch sheave. Remove bushing and removal tool from adapters. 2 4. 3. See Ill. Using a hand held propane torch. Install left hand nut onto puller rod and tighten by hand. Install left hand nut (C) and spacer onto puller rod and tighten by hand. CAUTION: Clutch components will be hot! In order to avoid serious burns. Install bushing tool (Item 2). 7. wear insulated gloves during the removal process. Slide adapter (Item 10) onto puller. 3.Bushing Installation 1. Discard bushing. 5. Turn clutch sheave counterclockwise until bushing is removed and sheave comes free. Turn clutch sheave counterclockwise until bushing is seated. Install puller adapter (Item 10) onto puller. EBS Driven . See Ill. EBS Driven . 6. EBS Driven Clutch Bushing Installation D Puller Tool (A/B) Side “B” toward sheave Nut (C) Bushing Ill. Install sheave onto puller (belt surface up). 5. 4. Place new bushing on side B of installation tool (Item A/B) and slide both over puller rod. 2. Install main puller adapter (Item 8) onto puller. Using a hand held propane torch. 1 2. Remove nut (C) (left hand thread) from puller rod and set aside. Remove adapters from puller.22 . Install nut (C) onto puller rod and hand tighten against installation tool. Insert EBS main adapter (Item D) onto puller. Remove nut (C) (left hand thread) from puller rod and set aside.

23 . Turn clutch sheave counterclockwise until bushing is removed and sheave comes free. Install new bushing on installation tool (Item 2) and install assembly into sheave. Install adapter (Item 9) onto puller. 5. 4. Install sheave face down on puller. 6. Remove bushing and removal tool from adapters. Discard bushing. 2. Install puller adapter (Item 10) onto puller. Remove nut (C) (left hand thread) from puller rod and set aside. 6. Apply Loctitet 609 evenly to bushing bore inside moveable sheave. 8. 9. EBS Driven . Remove nut (C) (left hand thread) from puller rod and set aside. Continue until bushing is seated. EBS Driven Clutch Outer Bushing Removal 8. making sure bushing is drawn straight into bore. 9.CLUTCH 7. Remove adapters from puller. Bushing Tool (2) Nut (C) Adapter Reducer (9) Main Adapter (8) 10. Remove installation tool and clutch sheave from puller.Backside (Outer) Bushing Installation 1. 7. Turn clutch sheave counterclockwise. Install left hand thread nut (C) onto puller rod and hand tighten against installation tool. EBS Driven Clutch OuterBushing Installation Nut (C) Bushing Tool (2) Bushing Bushing Tool (2) Puller Adapter (10) Adapter (9) 3.

belt slippage. -Replace spring. inspecting shift weights and rollers. Inform operator. -Driven clutch spring broken or installed wrong . Remedy -Replace with recommended spring. and inspect driven clutch. -Sheave face grooved. rubbing on cover -Clutches or weight being applied to cover while in operation -Use of High vs. Water ingestion -Cover seals or ducts leaking -Operator error 6. -Inspect/adjust or replace. grease. -Drive clutch binding. Reassemble without the spring and move sheaves through entire range to further determine probable cause. Harsh drive clutch engagement. -Plugged air intake or outlet -Belt slippage due to water. -Disassemble. Erratic engine -Drive clutch binding. Disassemble drive clutch. Seal PVT system ducts. refer to proper installation location. Replace belt a. -Drive clutch shift weights incorrect for application (too light). operating RPM during acceleration or load variations. -Install correct recommended shift weights. -Remove weight. -Adjust alignment offset. -Drive clutch shift weight too heavy.CLUTCH TROUBLESHOOTING Situation Engine RPM below specified operating range although engine is properly tuned. b. -Incorrect drive clutch spring (too high spring rate).thin/burnt spots -Driven clutch malfunction. Clean . Replace ramp buttons. -Engine mount broken or loose. noting worn sheave bushing and ramp buttons and helix spring location. b. Inspect movable sheave for excessive bushing clearance/ replace. -Driven clutch binding. -Replace the clutch.. reassemble clutch without spring to determine problem area. a. -Instruct operator on guidelines for operation in proper driving range for different terrain as outlined in Owner’s Safety and Maintenance Manual.24 . inspect shift weights for wear and free operation. Clean and polish stationary shaft hub. -Perform belt/sheave clearance adjustment with shim washers beneath spider. -Install correct recommended spring. etc. Drive belt turns over -Drive belt worn too narrow. -Instruct operator on guidelines for operation in wet terrain as outlined in Owner’s Safety and Maintenance Manual. oil. -Belt worn unevenly . -Replace belt. install new belt. -Converter sheaves greasy. clean. -Find leak and repair as necessary. Engine RPM above specified operating range. -Clutch alignment out of spec. Probable Cause -Wrong or broken drive clutch spring. -Install correct shift weight kit to match engine application. low range PVT cover overheating (melting) -Inspect system. repair or replace as necessary. -Clean sheaves with denatured alcohol or brake cleaner. -Excessive belt/sheave clearance with new belt. -Replace with correct belt. -Disassemble and clean clutch. -Wrong belt for application. -Clear obstruction.

excess load) -Dragging brake -Slow. thin spots -Belt contaminated with oil or grease -Inspect and clean. loose belt -Broken or worn clutch components. vehicle is stationary. -Instruct firm. -Abuse (continued throttle application when -Caution operator to operate machine within guidelines. easy clutch engagement -Vehicle operated with park brake on. Remedy Belt burnt. -Replace belt. -Inspect and repair as necessary. PVT noise -Belt worn or separated. -Replace belt. effective use of throttle for efficient engagement.25 . Refer to belt burnt troubleshooting and instruct operator.CLUTCH TROUBLESHOOTING Situation Belt slippage Probable Cause -Belt worn out -Water ingestion -Replace belt. worn belt -Drive clutch bushings stick Engagement erratic or stabby 6. Inspect brake system. cover hitting clutches -Thin spots on belt. thin spots. -Inspect and repair clutches. -Inspect and seal PVT system.

CLUTCH NOTES 6.26 .

. .6 7.24 7. . . . . . .15 7. . . .12 7.24 7. . . .10 7. .12--7. . . . . . . 7. . . . . . . Rear Hub Removal . . . . . . . . . . . . . . Rear Driveshaft Installation . . . . . . . Rear Hub Installation . . . . .14--7. . . Front Drive Axle Removal . . . . . . . . Front Gearcase Assembly & Inspection . .4 7. . . . . . . . . . . . . . .20 7. . . . . U--Joint Assembly . . .1 . . . . . . . . . . .9 7. . . . . Front Gearcase Operation . . Front Hub Inspection . . .17--7. . . . . . . . . . . . . . . . . . . . . . .8 7. . . Front Hub Disassembly & Assembly . Rear Gearcase Installation . . . . . . . . . . . Rear Hub Disassembly . . . . . . . .2 7. . .7 7. . . . . . . . . . . . . . . . . . . . Front Gearcase Diagnosis . . . . . . .4 7. . . . . . Rear Hub Assembly . Front Gearcase Removal . . . . Front Drive Axle Installation . AWD Front Prop Shaft Removal . . . . . . . . .19 7. . . . .7-7. . . . . . . . . .3 7. . Rear Driveshaft Service . Rear Gearcase Removal . . . . . .4 7. . . . . . . . .28 7 7. . . . . . . .FINAL DRIVE CHAPTER 7 FINAL DRIVE AWD Axle/Propshaft Exploded Views . . . . . . . . .10-7. . Driveshaft and CV Joint Tips .21 7. . . . .3--7. . . . .20 7. . . .3 7. . .18 7. . . .26--7. .6 7.18--7. Front Gearcase Disassembly & Inspection . . . . . . . . . . . .9--7. . . . . . . . . . . . . .20 7. . . . . . . . . . . . . . . . . . U-Joint Disassembly .21 7. . . . . . Rear Gearcase Exploded View . .14 7. Front Gearcase Exploded View . . . Driveshaft & CV Joint Handling Tips . . . . . Special Tools & Torque Specifications . . . . . .25--7. . . . . . . Front Gearcase Installation . . . . . . . . .19--7. . . . . . Rear Driveshaft Removal . . . .6--7. .8--7. . . . . . .15 7. Front Driveshaft CV Boot Replacement .22--7. . . . . . .5--7. . . . . . . . . . .24 7. . . . . . . . . .7 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 7. . . . Rear Gearcase Disassembly . . Rear Gearcase Assembly . . . . . . .26 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 7. . . . . . .

FINAL DRIVE AWD FRONT DRIVE AXLE EXPLODED VIEW Front Drive Axle Components Circlip Boot Drive Axle CV Joint Assy U--Joint and Yoke Clamps Front Prop Shaft Components Propshaft Assembly Prop Shaft Cross and Bearing Kit O-Ring Yoke. Propshaft to Transmission Yoke. Front Gearcase Spring Pin 7.2 .

Lbs. Remove cotter pin and nut from lower A-arm ball joint. Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly. 5.3 . Remove wheel. 4. Remove cotter pin. Set the ATV in park. 3. CAUTION: Do not hang the caliper by the brake line. FRONT DRIVE AXLE REMOVAL 1. hub nut torque and bearing condition and correct as necessary. Serious injury could occur if machine tips or falls.but do not remove . Remove hub. Grasp wheel/hub and check for movement. (41 Nm) 70 Ft. 8. (95 Nm) 80 Ft. Lbs.the wheel nuts. 10. Remove hub dust cap.FINAL DRIVE SPECIAL TOOLS PART NUMBER 2872608 8700226 TOOL DESCRIPTION Roller Pin Removal Tool CV Boot Clamp Pliers 7. Support machine securely with front wheels elevated. CAUTION: 9. Loosen the hub retaining nut. Use wire to hang the caliper to prevent possible damage to the brake line. The self-locking properties of the nut or bolt are reduced or destroyed during removal. lbs. If movement is detected. (41 Nm) 30 Ft. 2. inspect hub. 3. (109 Nm) CAUTION: Locking nuts and bolts with preapplied locking agent should be replaced if removed. Loosen . WHEEL AND HUB TORQUE TABLE Item Front Wheel Nuts Rear Wheel Nuts Front Hub Nut Rear Hub Retaining Nut Specification 30 Ft. Lbs. Remove the two brake caliper attaching bolts. Remove lower A-arm from ball joint. 6. FRONT HUB INSPECTION 1. 2. Safely lift and support the front of the ATV. 7.

Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft with rubber faced hammer.4 . G Do not allow boots to come into contact with sharp edges or hot engine and exhaust components. 4. torque nut to 25 ft. With short. Install hub and tighten hub nut to 70 ft. Install lower ball joint. 2.5 Nm) and install new cotter pin. Driveshaft components are precision parts. G The complete driveshaft and joint should be handled by getting hold of the interconnecting shaft to avoid disassembly or potential damage to the driveshaft joints. remove drive shaft from front gearcase. Refer to text for grease capacity of CV joints and CV joint boots. lbs. G Never use a hammer or sharp tools to remove or to install boot clamps. G The driveshaft is not to be used as a lever arm to position other suspension components. sharp jerks. 7. Install new spring ring on drive shaft. FRONT DRIVE AXLE INSTALLATION 1. Install drive shaft in strut. lbs. (95 Nm). Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life. 3. (95 Nm) DRIVESHAFT AND CV JOINT HANDLING TIPS Care should be exercised during driveshaft removal or when servicing CV joints. lbs. G Make sure surface-ground areas and splines of shaft are protected during handling to avoid damage. G Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned. (34. Front Hub Retaining Nut Torque 70 ft. Apply an anti--seize compound to splines. G Over-angling of joints beyond their capacity could result in boot or joint damage.FINAL DRIVE New Cotter Key 11.

(Total 60g) 9. Add grease through large end of boot. the CV joint grease may be contaminated. away from the CV joint. Use only the grease contained in the boot kit. Slide the new clamp and boot (small end first) over the splined shaft. Slide strut off end of drive shaft and tie it up out of the way of the shaft. Remove the large end of the boot from the CV joint.3 for procedure. Position large end of boot on CV joint. If CV joint is cleaned. purge excess air by partially compressing axle into CV 7. Refer to information following. Remove wheel.5 . 2. then slide (tap) the CV joint into the splines of the axle. Retaining ring Pull shaft to remove from CV joint 7. 5.FINAL DRIVE FRONT DRIVE SHAFT CV JOINT BOOT REPLACEMENT 1. Refer to Front Drive Axle Removal Page 7. 10. 6. Front drive axle CV boot replacement requires 30g of grease. slide the boot back and separate the wheel spindle and CV joint assembly from the axle shaft by pulling the shaft sharply outward. 8. and clean the joint thoroughly if necessary. 3. Boot replacement with complete CV joint cleaning requires an additional 30g. Before installing the new boot. Inspect the grease carefully for contamination. brake caliper and wheel hub. NOTE: It is very important to use the correct type and quantity of grease. Disconnect A-arm from ball joint using a tie rod fork. 11. CV Joint Grease -30g (PN 1350046) CV Boot Clamp Pliers: Earless Type (PN 8700226) Boot Replacement requires 30g 4. an additional 30g of grease is required. remove all grease from the boot area and shaft. NOTE:If the ATV has been operated with a damaged boot. Remove cotter pin and castle nut from A-arm ball joint. Remove small clamp and boot from driveshaft. DO NOT use a substitute grease and DO NOT overfill or underfill the CV joint. Install small boot clamp. Remove clamps from rubber boot using the proper boot clamp pliers. It may be necessary to tap the CV joint assembly outward with a soft faced hammer.

with no detectable up and down movement and minimal movement sideways between inner and outer race. wear or damage. NOTE: Due to extremely close tolerances and minimal wear. Once bearing is at bottom of casting. discoloration. From the back side. Start bearing in housing. Inspect bearing housing for scratches. as bearing damage may occur. 3. and by feel.FINAL DRIVE bell. FRONT SHAFT Joint Capacity Boot Capacity 30 Grams 30 Grams Front outboard joint capacity: 30g if boot is replaced only. or corrosion. tap on the outer bearing race with a drift punch in the reliefs as shown. 1. FRONT PROP SHAFT REMOVAL 2. Replace housing if damaged. FRONT HUB DISASSEMBLY 1. 2. Slide prop shaft back and away from front housing. The bearings should turn smoothly and quietly. While rotating bearings by hand. 4. Remove outer snap ring. 3. Inspect the bearing. remove the roll pin from prop shaft at rear of housing. Using Roll Pin Removal Tool (PN 2872608). Another 30g (60g total) if joint is cleaned. support casting on outer edges so bearing can be removed. inspect for rough spots. 4. Press bearing into place until outer race bottoms on housing. Support bottom of hubstrut housing. the bearings must be inspected visually. CAUTION: When using an arbor press be sure to press only on the outer race. FRONT HUB ASSEMBLY 1. 7. lift one edge of boot to let out excess air Secure with clamp. NOTE: Drive bearing out evenly by tapping on outer race only. Pull sharply forward to remove from transmission shaft.6 . Install snap ring into groove.

7 . Tighten vise to force bearing caps inward. Support inner yoke as shown and drive outer yoke down (bearing cap out) with a soft face hammer. U-JOINT REASSEMBLY 1.FINAL DRIVE Roll Pin Remover Tool (PN 2872608) NOTE: If removing front housing. cross bearing must be replaced. 3. U-JOINT DISASSEMBLY CAUTION: Wear eye protection at all times. Remove internal or external snap ring from all bearing caps. 4. Take care not to dislodge needle bearings upon installation of cross joint. 2. 1. 7. use roll pin removal tool to remove the pins from both front drive axles. NOTE: If yoke or bearing is removed. Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing caps. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft. Install new bearing caps in yoke by hand. Force U-joint cross to one side and lift out of inner yoke. Note orientation of grease fitting and mark inner and outer yoke for correct re-positioning during installation.

6. CAUTION: Serious injury may result if machine tips or falls. Loosen right front wheel nuts slightly. Continually check for free movement of bearing cross as bearing caps are assembled. Repeat procedure for other side. 2. Install outer yoke. When installation is complete. 4.FINAL DRIVE 2. Using a suitable arbor or vise. Wear eye protection when removing and installing bearings and seals. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown. fully seat bearing cap in one side. place machine in Park and set parking brake. Remove the front brake caliper and safely suspend the brake caliper from the frame with a piece of wire. 3. tap the yoke lightly to center the joint until it pivots freely in all directions. Remove right wheel nuts and wheel. 4. Be sure machine is secure before beginning this service procedure. 5. aligning marks made before disassembly. Install snap ring to contain bearing cap just installed. Repeat Steps 1-3 to install bearing caps on outer yoke. Elevate and support machine under footrest/frame area. If the joint is stiff or binding. 7. Yokes must pivot freely in all directions without binding. FRONT GEARCASE REMOVAL 1. 7.8 . 3. Stop engine. 5.

CENTRALIZED HILLIARD) 8. Frame Front Gearcase FRONT GEARCASE OPERATION . 6. Remove bolts securing bottom of housing to frame. Coil Cover Output Hub Armature Plate 10. Normal Operation: With the AWD switch off the vehicle is only driving the rear wheels (2 wheel drive). 9. The vehicle now has True All Wheel Drive. lower ball joint nut and A-arm from ball joint. Remove cotter pin. Remove vent line. Replace the circlip on the driveshaft end for reassembly. The 14 rollers engage themselves to the output hubs that link both front axles. Remove the front hub from the drive shaft.FINAL DRIVE CAUTION: Do not hang the caliper by the brake line. 7. True All Wheel Drive. Remove the front gearcase from right side of frame. Pull both driveshafts from the front gearcase.9 . Pull the hub and strut assembly out and pull the drive--shaft out of the hub. Engagement: When the AWD switch is activated it charges the coil. It then charges an armature plate that is keyed to a roller cage that contains 14 rollers which are forced in by an external cam. Use wire to hang the caliper to prevent possible damage to the brake line.When the AWD switch is activated it engages the Hilliard and locks both front wheels and we then have. 7.

FINAL DRIVE CAUTION: If the rear wheels are spinning. disengaging AWD. 4. 7. Remove output shaft assembly. Roller Cage and Bearing’s Rotate Inward and Grip the Output Hub for AWD Engagement Roller Cage Front Gearcase Coil Resistance: 22. The vehicle is now back to rear wheel drive.10 .2 ohms. Output Hub Rollers Roller Cam FRONT GEARCASE DISASSEMBLY/INSPECTION 1. NOTE: Be careful not to misplace the thrust bearing located between the two output shafts. The gearcase coils should measure between 22. Clean all parts and inspect spacers for wear.2 Ohms Gearcase Coil Resistance NOTE: To test the gearcase coils resistance. Inspect ring gear for chipped. 3. Remove bolts and output shaft cover. release the throttle before turning the AWD switch on. Remove any metal particles from the drain plug magnet. If AWD is engaged while the wheels are spinning.8-25. broken. severe drive shaft and clutch damage could result.8 ohms and 25. Output Hub Roller Cage & Bearings Armature Plate Disengagement: As soon as the front and rear wheels gain traction and are rotating at very close to the same speed the front wheels will overdrive the output hubs and the rollers are forced outward. use the coil harness. Drain and properly dispose of used oil. 2. or missing teeth.

G 7. Inspect roll cage (B) sliding surface. Inspect the armature plate (F) for a consistent wear pattern. Remove the ring gear (C). the shim (E). The rollers must slide up and down freely within the roller cage surfaces (B). B 9. This surface must be clean and free of nicks. H D 7. and the armature plate (F) from the output cover. C D Coils E A F C 10. Thoroughly clean all parts.11 . Inspect the ring gear (C) for consistent wear patterns. burrs or scratches.FINAL DRIVE 5. 8. Inspect the thrust bearing (G) and the dowel (H). and H--springs. Remove the thrust bearing (G) from the output hub (D). which may cause intermittent operation. Inspect the rollers (A) for nicks and scratches. B H--spring 6. 11. The surfaces should be free of nicks and scratches. rollers. Remove the roll cage assembly. Remove and inspect the H--springs. Uneven wear of the armature plate (F) indicates a warped plate. the output hub (D).

Install the output hub into the gearcase housing. Remove the O--ring and seal from the output cover. NOTE: Due to extremely close tolerances and minimal wear. Remove the other output hub from the main gearcase. Cover Bolts Torque 14. discoloration. with no detectable up and down movement and minimal movement side to side. or corrosion. Inspect bearings on output and pinion shafts.12 . Inspect the pinion gear for chipped. and worn components. or missing teeth. Replace as needed. until the seal is flush with the sealing surface. To replace. FRONT GEARCASE REASSEMBLY/INSPECTION 1. and the pinion gear. press new bearing on to shaft. 7. 4. The output hub should spin freely.FINAL DRIVE 12. inspect for rough spots. bearing. broken. bearing. Install pinion shaft. the bearings must be inspected visually. 13. lbs (19 Nm). Replace all O--rings. While rotating bearings by hand. 3. (19 Nm) 5. 14 ft. Inspect the output shaft bushing. Press the pinion shaft seal into the pinion cover. 2. and by feel. seals. and input cover with new o-ring and torque bolts to 14 ft. lbs. The bearings should turn smoothly and quietly. Clean the inside surfaces of both gearcase halves. Remove the input cover.

Slide the roll cage into the ring gear. NOTE: Be sure armature plate tabs are placed into the slots on roll cage. Apply grease to the thrust bearing.13 . 10. 7. lbs. Install the armature plate onto the ring gear. (19 Nm).FINAL DRIVE 6. Install the shim onto the ring gear. Insert the output hub. Insert the rollers as the roll cage is installed. 8. Install the ring gear into the gearcase housing. 11. dowel. Insert the thrust bearing onto the output hub. and thrust bearing into the ring gear. 9. 7. Install output cover with new o-ring and torque bolts to 14 ft.

The top of the coil should be seated below the U--shaped insert.14 . If this is the cause order a new Plate Cover Assembly (PN 3233952). The gearcase coils should measure between 22. which may cause intermittent operation. 1. If the top of the coil is above the surface of the U--shaped insert it raises the armature plate. Check the minimum battery voltage at the wire (Grey & Brown/White) that feeds the hub coil wire.8 ohms and 25. 1 FRONT GEARCASE DIAGNOSIS Symptom: AWD Will Not Engage. Armature Plate Cover Bolts Torque 14 ft. 7. The U--shaped insert controls the pole gap.0 Volts present for proper operation. If the pole gap increases the coil will not be strong enough to engage the AWD system. Check to make sure the coil is seated in the U--shaped insert that is pressed into the gearcase cover. lbs. inspect the coil area as indicated in Step 4. (19 Nm) 12. Bad Condition (Wear from Coil On Armature Plate) Possible Wear Ring on Armature Plate OK Condition 3. use the coil harness (Grey & Brown/White). Check for wear bands ILL. There should be a minimum of 11. If only one band of wear is present (or if there is wear between the two bands. thereby increasing pole gap.80-12. Check the gearcase coil resistance. There should one or two distinct wear 4. A band with an interrupted wear mark may indicate a warped plate. Inspect the armature plate for a consistent wear pattern. To test the gearcase coil resistance.2 ohms. See Illustration 1. Install new seals into the gearcase housing and gearcase housing cover. 2.FINAL DRIVE bands (one band inside the other).

Premium Front Housing Fluid (PN 2871654) Front Housing Capacity 5.0 fl.FINAL DRIVE New spring Pin Gearcase Cover Coil U--shaped insert Side Cutaway View of Centralized Hilliard Cover 5. (148 ml) Rollers FRONT HOUSING INSTALLATION 1. 7. Refer to Page 2. The rollers must slide up and down and in and out freely within the roll cage sliding surfaces. Use new spring pin in front prop shaft.15 . To install gearcase. Add the proper lubricant to the front gearcase. 2.10 in the maintenance chapter for fill capacities. reverse removal procedure. Check drain plug for proper torque. Inspect the rollers for nics and scratches. oz.

Input Bearing.Ring Seal Kit.. Fuel Clip Clamp. Roller Ball Hub. 33. 24. LH Seal. 10. 29. Female Bushing Line. Oil Drain Washer Bearing. 16. 9. 4. 32. 8. Qty. 28. Oil Fill Washer.FINAL DRIVE FRONT GEARCASE EXPLODED VIEW 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 18 17 19 23 26 6 33 32 30 31 29 27 28 25 24 20 22 21 28 22 36 16 13 35 34 Ref. 5. 36. 23. Qty. 7. Needle. 15. 20. 18. Race/Output. Dowel Bearing. 21. Roller Ball Shaft. Male Pin. 11. Race/Output. Roller Ball Clutch Housing/Ring Gear Spring Kit. 22. 34. Roll Ring. 12. 6. 14. Bolt Cover. Shim Set (Incl. 19. 25. Spring Lock Screw Plug. 27. 1. Mid Gearcase Cover. 17. Oil Plug. 2 3. 1 1 11 1 1 1 1 1 2 1 4 4 1 1 1 1 1 Description O-. Hose Ref. 26. Pinion. Output O-.16 . Aluminum Plate Armature 7. 30. Shims) Bearing.Ring Insert Coil Kit. Roller Thrust Roll Cage. 13. 35. 11T Bushing Gearcase. 1 1 1 1 1 1 2 1 1 1 1 1 14 2 1 1 1 AR 1 1 Description Asm. 31. Retaining Bushing Hub.

Remove hub. Remove the rear brake caliper and safely suspend the caliper from the frame with a piece of wire. Loosen the hub retaining nut.FINAL DRIVE REAR HUB REMOVAL 1. 8. 4. 2. 9. 7. Remove wheel nuts and wheel. 5. domed washer and flat washer. 7. Place the ATV in Park and lock the parking brake. Remove hub nut.17 . CAUTION: Secure the machine. Safely support the rear of the ATV. 3. Serious injury could occur if machine tips or falls. Remove rear hub cap. Remove cotter pin. 6. Loosen the wheel nuts.

Lower Control Arm Bolt Torque: 40 ft. (48 Nm) 3. Remove bearing carrier. 12. Rear Hub Nut Torque: 80 ft. 2. Align bottom of carrier housing and lower control arm. lbs.18 . 4. (109 Nm) Rear Wheel Nut Torque 30 ft. Install and torque upper control arm bolt and torque to specification. REAR HUB INSTALLATION 1. Remove both lower control arm bolts.FINAL DRIVE 10. Lift bearing carrier until top aligns with upper control arm. lbs. (54 Nm) Upper Control Arm Bolt Torque: 35 ft. Remove upper control arm bolt as shown. Install upper and lower bolts 11. (41 Nm) 7. Insert bearing carrier on drive shaft. lbs. Install and torque both lower control arm bolts. Grease and slide lower control arm bushings into place. lbs. securing corner housing.

Install cone washers with domed side facing outward. From the back side. 8. Once bearing is at bottom of casting. Pull drive shaft outward and install hub onto driveshaft splines. 6. 7. 10. wear or damage. While rotating bearings by hand. 2. inspect for rough spots. or corrosion. 7. 9. NOTE: Drive bearing out evenly by tapping on outer race only. Replace housing if damaged.FINAL DRIVE 5. Inspect bearing. 4. tap on the outer bearing race with a drift punch in the reliefs as shown. Tighten nut slightly to align holes if required. The bearings should turn smoothly and quietly. 3.19 . Remove outer snap ring. with no detectable up and down movement and minimal movement sideways between inner and outer race. REAR HUB DISASSEMBLY 1. the bearings must be inspected visually. wheel and wheel nuts. support casting on outer edges so bearing can be removed. and by feel. NOTE: Due to extremely close tolerances and minimal wear. Inspect bearing housing for scratches. Install hub cap. Install retainer nut. discoloration. Install a new cotter pin. Remove jackstand and torque axle nut and wheel nuts.

Tip hub outward and remove shaft from hub. Install a new lock ring upon assembly. 3.FINAL DRIVE REAR HUB ASSEMBLY 1. as bearing damage may occur. CAUTION: Use an arbor press only on the outer race. 3. Press bearing into place until outer race bottoms on housing.17 . REAR DRIVE SHAFT REMOVAL 1. Pull outward sharply to remove from transmission Lock ring 7. Support bottom of bearing carrier housing. Pull sharply outward to remove shaft from transmission. 2. 2. Start bearing in housing.18).7. (See Pages 7. Remove rear hub and bearing carrier. Install snap ring into groove. 4.20 .

Install rear wheel and torque wheel nuts to specification. 80 ft.21 . Never use a hammer or sharp tools to remove or to install boot clamps. lbs. Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life. G G G 5. G The complete driveshaft and joint should be handled by getting hold of the interconnecting shaft to avoid disassembly or potential damage to the driveshaft joints. Install hub. Lift bearing carrier into place and install bolt to upper control arm. lbs. Torque center hub nut to 80 ft. Install new cotter pin and hub cap. Grease all fittings thoroughly with Premium U-Joint Lubricant (PN 2871551). lbs. The driveshaft is not to be used as a lever arm to position other suspension components. (109 Nm) Flat Washer G G REAR DRIVE SHAFT INSTALLATION 1. Torque bolt to 35 ft. 4. Install a new lock ring and install the shaft. lbs. G Rear Hub Nut Torque: 80 ft. 7. Do not allow boots to come into contact with sharp edges or hot engine and exhaust components. 2. (109 Nm) 6. Make sure surface-ground areas and splines of shaft are protected during handling to avoid damage. Slide shaft assembly into bearing carrier hub. 3.FINAL DRIVE DRIVESHAFT AND CV JOINT HANDLING TIPS Care should be exercised during driveshaft removal or when servicing CV joints. Over-angling of joints beyond their capacity could result in boot or joint damage. Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned. lbs. domed washer (domed side out) and nut. Refer to text for grease capacity of CV joints and CV joint boots. (109 Nm). Out Cone Washer Cone washer dome to outside Rear Wheel Nut Torque: 30 ft. (41 Nm) 7. (48 Nm). Driveshaft components are precision parts. flat washer. Apply anti-seize compound to splines of shaft.

FINAL DRIVE REAR DRIVE SHAFT SERVICE 1. 7. Place a new snap ring in the groove of the CV joint inner hub. CV Boot Clamp Pliers: Earless Type (PN 8700226) 2. Wipe grease away from recess in CV joint inner hub to locate snap ring. Snap ring located in recessed area Tabs face shaft Snap ring 3. Open the snap ring using a snap ring pliers or small needle nose pliers. Remove clamps from rubber boot(s) using the proper boot clamp pliers. Tap CV housing off shaft with a soft faced hammer while holding snap ring open. Spread ends of snap ring to remove joint from shaft Tap CV Housing Off Shaft 4. NOTE: Photo at right is shown without shaft for clarity.22 . with tabs facing the shaft as shown.

If the grease is not contaminated. 8. Position clamp over boot end and make sure clamp tabs are located in slots. Remove CV joint from end of shaft. The joint is fully assembled when the snap ring is located in the groove on the interconnecting shaft. making sure boot is seated in groove. 4. NOTE: IF CV JOINT WAS CLEANED. Be sure it is seated all the way around in the clamp recess on the boot. Fit joint boot and clamps on interconnecting shaft. the boot can be replaced without cleaning the CV joint. 6. Replace CV joint only if components are cracked. Proceed to Boot Installation. Remove boot from shaft. NOTE: Before tightening boot clamp on inboard joint. Open snap ring and pull CV joint away from shaft Boot Replacement 1.23 . Tap joint onto shaft 2. 6. Fill boot with grease supplied from boot service kit and spread evenly inside CV joint.20) 7. cracks or other damage. Remove any excess grease from the CV joint external surfaces and position joint boot over housing. 7. A gritty feeling indicates contamination. Refit CV joint on interconnecting shaft by tapping with a plastic hammer on the joint housing. Be sure grease penetrates all parts of the joint. add the recommended amount of grease to the joint in addition to the grease pack supplied with boot kit. Thoroughly clean and dry the CV joint and inspect ball tracks and cages for wear. Take care not to damage threads on the outboard CV joint. Do not replace CV joints because parts have polished surfaces. 7. The air should be released after the plunging joint has been centered properly. make sure any air pressure which may have built up in joint boot has been released. Tighten small boot clamp using boot clamp pliers. NOTE: When replacing a damaged boot. CV Joint Cleaning / Replacement NOTE:Shiny areas in ball tracks and on the cage spheres are normal.FINAL DRIVE 5. Install and tighten large boot clamp with boot clamp pliers. (See Page 7. Tighten boot clamp using boot clamp pliers. check the grease for contamination by rubbing it between two fingers. worn or otherwise unserviceable. Add the recommended amount of grease for CV joint cleaning to the joint as shown below. Make sure small end of boot is fully seated in groove. Boot Installation 5. Position small clamp over small end of boot. broken. Use the recommended amount of grease for boot replacement only (see below). Be sure to use only the Constant Velocity Joint grease supplied with boot service kit. 3.

Remove the five bolts. reverse the removal procedures. Torque the installation bolts and nuts to the torques specified in Ill. Remove the upper shock mounting bolt. 10. (41 Nm) (2 bolts) REAR GEARCASE INSTALLATION 1. 1. and washers. Another 50g (80 total) if joint is cleaned. (150 ml) of Polaris Premium Gearcase Lubricant (PN 2871653). nuts. 7. Torque the fill plug to 14 ft. (19 Nm). 4. Refer to the “Rear Drive Shaft Removal” section. REAR GEARCASE REMOVAL C B 30 ft. Jack up the rear of the ATV and safely support the ATV with jackstands. lbs. 7. Remove the two mounting bolts and washers (B) from the front of the rear gearcase. Inboard joint . Be sure the machine is secure before beginning this service procedure. Place the ATV in park and set the parking brake. 3. Remove the four mounting bolts and washers (A) on the underside of the rear gearcase. lbs. (C) and (D).50g if boot is replaced only. (41 Nm) (4 bolts) Ill. (41 Nm) 2. 2.FINAL DRIVE Joint Capacity 50 Grams Joint Capacity 50 Grams CAUTION: Serious injury may result if the machine tips or falls. 8.30g if boot is replaced only. 9. C D 30 ft. Remove the rear prop shaft from the rear gearcase. Remove the rear drive shafts. lbs. NOTE: To remove the bottom bolts (C) from the rear gearcase the lower control may have to be removed. 1. 6.24 .1 30 ft. Remove the two rear tires. lbs . Refill the rear gearcase with 5 oz. (41 Nm) B (5 bolts) Fill Plug C A 30 ft. Another 50g (100total) if joint is cleaned. 5. Pull the gearcase from the frame. lbs. OUTBOARD 80g Total INBOARD 100g Total Boot Capacity 30 Grams Boot Capacity 50 Grams NOTE: CV Joint Grease Capacity: CV Joint Grease . 3. To install the rear gearcase. that hold the gearcase to the frame.30g (PN 1350046) 50g (PN 1350047) Outboard joint .

FINAL DRIVE REAR GEARCASE DISASSEMBLY 1. or chipped teeth. Remove the shim. Inspect the ring gear for abnormal wear. Remove rear bevel gear from the gearcase housing. cover. thrust button. 3. 6. Remove the gearcase housing cover bolts and the gearcase housing cover. and thrust button shim from the gearcase. broken. Replace the bearing if needed. Thrust Button Shims 4. 7. See next page. Spin the bearing to check the ball bearings for smoothness. 2. Remove the input shaft cover and the pinion shaft from the gearcase housing. 5. Drain and properly dispose of used oil.25 .

Spin the bearing to check the ball bearings for smoothness.FINAL DRIVE REAR GEARCASE REASSEMBLY 1. Inspect the ring gear for abnormal wear. 7. 2. (34 Nm). O--rings. seals.26 . or chipped teeth. Install the pinion shaft cover and torque the cover bolts to 25 ft. Inspect the pinion shaft bushing for wear. broken. lbs. 7. Replace the bearing if needed. Replace all components. Install the pinion shaft into the gearcase housing. and worn 3.

27 . lbs. Install the drain plugs. Install the gearcase cover onto the gearcase housing. (34 Nm) 25 ft. lbs. Apply Crankcase Sealant (PN 2871557) to surface of case and install cover bolts. (34 Nm) 6. in a criss cross pattern. thrust button. lbs. 7. Replace the drain plug washers to ensure proper sealing after filling. Torque the cover bolts to 25 ft.FINAL DRIVE Gearcase Cover Bolt Torque: Pinion Shaft Cover Bolt Torque: 25 ft. Install the original shim(s). 4. and thrust button shims into the gearcase cover. 5.

1. 14. 18. Rear Gearcase Cover. 4. 9.. LH Screw Tube Vent Washer Plug Bearing. 1 1 8 1 2 2 2 AR 1 2 1 Description Asm. 6. Qty. 16. 2. 15. 12. 10.ring Cover. 5. 13. 3. 11. 8. 17.28 .FINAL DRIVE REAR GEARCASE EXPLODED VIEW 4 2 1 6 3 5 19 17 18 9 17 8 7 16 10 6 11 12 13 14 15 4 5 2 Ref. 7. Input Seall Rear Gearcase Housing Ball Bearing 31T Gear Shim 7. Roller Ball Shim Thrust Button Knock Pipe Bushing Ref. Qty. 19. Output. 1 1 1 1 1 1 2 1 AR Description 10T Pinion Shaft Ball Bearing O-.

. . .4--8. .11 8. .4 8.4 8. . . . . . . . .15 8 8. . . . . . . . . . .5-8. . Exploded View . . . . . . . . . . . . . 8. . .3 8. . . . . . . Transmission Disassembly . .5 8. . . .TRANSMISSION CHAPTER 8 TRANSMISSION SERVICE Transmission. . . . . . . . . . . . . . . Transmission Reassembly . . . . . . . . . Torque Specifications/Lubrication . . . . . . . . .5 8. . Transmission Removal . . . . . . . . . . . . . . Transmission Installation . . . . .11-8. . . Gear Shift Selector Removal . .1 . . . .2--8. . .

2 .TRANSMISSION TRANSMISSION EXPLODED VIEW 19 17 18 16 15 17 14 13 20 23 22 21 36 31 35 34 25 21 13 22 3 12 11 8 6 3 4 5 7 9 10 26 29 27 31 33 28 32 31 28 26 30 29 38 40 39 41 42 45 13 37 2 1 17 16 43 61 65 64 63 67 62 59 60 17 58 57 44 13 25 27 66 69 46 56 55 54 16 48 47 49 50 51 68 8 53 52 8.

13. 56. 33. 53. 49. 1 1 1 8 1 1 1 1 2 1 1 1 1 4 1 1 4 4 1 1 1 2 2 1 1 1 2 3 2 2 1 2 1 1 1 Description Asm. 35. 51. 37. 29.. 24. 4x4 Transmission Nut Washer Screw Cover Detent Pawl O-.TRANSMISSION TRANSMISSION EXPLODED VIEW. 22. 31T Oil.ring Shaft. Qty. 59. 3. 11. 30. 2. Qty. 58. 52. 57. 55. 1. 64. Shift Seal Gear. 40. 65. 12.3 . 7. 36. 32.Ring 16T Gear Lockout Disc Star Detent O-. 6. 15. 19. 28. 67. 10. 26. 16. 38. 1 1 1 4 1 1 1 1 1 1 1 1 1 AR AR 1 17 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description 28T Gear 40T Gear 44T Gear Screw Cover Bearing Ring Ball Bearing 10T Pinion Shaft Thrust Washer 22T/18T Sprocket 31T Gear Main Rear Output Shaft Thrust Button Shim Shim Front Output Cover Screw Plug Washer Front Output Shaft Silent Chain 22/22T Sprocket Bushing Park Lockout Main Gearcase Washer O-. 39. Plug Fill Vent Tube Cap Vent Tube Bearing Silent Chain Input Shaft Bearing Knock Pipe LH Cover Seal Shift Drum Shift Fork Dowel Pin Shift Shaft Rail Park Plate Engagement Dog Wave Spring Engagement Dog Retaining Ring Washer 33T Gear Needle Bearing Reverse Shaft 24T Sprocket Washer Ref. 48. 69. 21. 41. 47. 8. 68. 31. 5. 44. 43. 54. 20. 50. 14. 27. Ref. 23. 4. 18. 9. 45. 25. 66. 17. 34. 61. 62. 46. 42. CONT. 60.ring Compression Spring Switch Retaining Ring Bellcrank 8. 63.

5 Nm) Park Lockout Plunger . Transmission Front 6.TRANSMISSION TORQUE SPECIFICATIONS Transmission Case Bolts 27--34 ft. 7. lbs. 2. lbs. lbs. . air box. TRANSMISSION REMOVAL 1. rear rack. 6--12 ft. . Drain transmission lubricant. Disconnect gear position switch harness. (19--24 Nm) Transmission Mount Bolts . . and inner PVT cover (refer to Clutch Chapter 6). lbs. . both drive and driven clutch. (16--24 Nm) Transmission Drain Plug 14--18 ft. Disconnect shift linkage rod end from transmission bellcrank. . . Remove two bolts attaching gear selector mount to machine frame. Lift gear selector out of mounting bracket and away from frame. Transmission Switch 5. . Remove Roll Pin 8. 25 ft. 2. 8. Disconnect transmission vent line. (37--46 Nm) Bell Crank Nut . Disconnect linkage rod from gear selector handle. Remove auxiliary brake mounting bracket from frame and secure out of way for transmission removal. 12--18 ft. and right footwell (if required for access). . 14--18 ft. Remove PVT outer cover. rear cab. Remove seat. . . . Use the Roll Pin Removal Tool (PN 2872608) to remove the roll pins from the front prop shaft and the rear prop shaft. Linkage Rod LUBRICATION Refer to maintenance section for transmission lubricant type and capacity. GEAR SELECTOR REMOVAL 1. 3. . (34. 3. Remove the front propshaft. lbs. and exhaust system. (12--16 Nm) 4. lbs.4 . (19--24 Nm) Shift Cover Bolt Torque .

TRANSMISSION TRANSMISSION REMOVAL CONT’D 9. 8. Slide rear output shaft into propshaft yoke. Loosely install left side and rear mounting brackets. 13. 2. and washer that secure the bell crank. Position transmission in frame. C Park Lock Spring A F E Tighten Bolts In Sequence A through F TRANSMISSION DISASSEMBLY 1. Loosely install front mounting bolts. Align rear output shaft to rear propshaft yoke and roll pin hole. Place the bellcrank in neutral position. Move the rear gearcase back just enough to slide the rear propshaft from the transmission shaft. Bellcrank Detent Pawl Case 2. 7. See illustration. and lower right bracket bolt. rear bracket. lbs. Remove the nut. 4. Remove left side transmission bracket. Transmission Mounting Bolts Torque 25 ft. NOTE: Align clutches as outlined in Clutch Chapter 6. Install transmission from right side of vehicle.5 . 12. 8.5 Nm) D B Remove or Loosen Rear Gearcase Bolts 10. 5. Loosely install lower right bracket bolt. Remove front transmission-to-engine mount bolts. Shift Shaft Cover NO TAG TRANSMISSION INSTALLATION 1. Tighten mounting fasteners in order A-F as shown. Loosen or remove the bolts that secure the rear gearcase. Remove the park lock spring. 11. 9. 6. Remove the bellcrank. Remove transmission from right side of frame. Install front propshaft and roll pin. 3. (34.

Remove the detent spring. Remove the e--clip and then remove the transmission switch. Mark the shift lockout disc. Remove the shift gears from the case. Remove the shift lockout disc.6 . NOTE: It may be helpful to place a mark just above the keyed spline. Remove the detent gear from the case. this will indicate which sideof the disc faces outward during assembly. 8. Spring 5. Remove the shift shaft and detent lever. Transmission Switch 4. Mark the detent gear with a white pen.TRANSMISSION TRANSMISSION DISASSEMBLY CONT’D 3. Note the timing marks on the shift gears. 6. NOTE: It may be helpful to place a mark just above the keyed spline. 8. 7. Remove the five bolts that secure the cover.

14.70--25. 13.TRANSMISSION TRANSMISSION DISASSEMBLY CONT’D NOTE: It may be helpful to accent the timing marks using a white marking pen. Lift shift rail 0. so the the forks’ pins disengage fro the drum. Note the correct position of each fork. 12. 10. Set the upper gear cluster on a flat surface and inspect the components. 11. 8.7 . Remove the bolts on the LH transmission case. Remove the shift drum. 9. Remove the upper gear cluster and shift forks. You may need to move the assembly back and forth to aid in removal.5--1” (12. Remove the shift forks from the assembly. Then rotate the shift rail/forks and shift drum.40 mm). Tap the cover off with a soft face hammer if necessary. NOTE: You may have to tap the shift drum from the backside of the case to aid in removal.

Remove the snap ring and washer from the reverse shaft.8 . Remove the bearing from the reverse shaft using a puller. 18. 8. 19. Remove the bearing from the input shaft with a puller. Engagement Dogs 17. Remove the wave spring and reverse engagement dog. 16.TRANSMISSION TRANSMISSION DISASSEMBLY CONT’D 15. Remove low gear (33T) and the needle bearing. Remove the park lock engagement dog.

24. Make note of the direction of the gear and hub location. and split bearing. Remove the rest of the bearings from the shafts. Use a press to remove the gear from the shaft. Remove the snap ring. 25. washer. 22. gear. and washer from the reverse shaft. Remove the gear. Slide off the shift dogs and wave springs. 23.TRANSMISSION TRANSMISSION DISASSEMBLY CONT’D 20. 21.9 . split bearing. 8. Remove the reverse gear shaft. 26.

TRANSMISSION TRANSMISSION DISASSEMBLY CONT’D 27. Remove bearing and the helical gear. 29. Remove the front housing cover. 34. 32. thrust button. shim. Inspect engagement dogs of gears and replace if edgesare rounded. and thrust button shim. 33. Note Location of Hubs 30. 8. Remove the front housing cover screws.10 . Remove the shafts as an assembly. 28. Remove the pinion shaft retainer plate and the pinion shaft. 31. Remove the silent chain from the assembly for shaft inspection. Clean all components in a parts washer and inspect for wear.

chips or broken teeth. Inspect gear teeth for wear. (36. Crankcase Sealant (PN 2871557) 4. Reinstall the thrust button shim.50--46 Nm). 8. and other shims into the cover. Check for excessive play between inner and outer race. Crankcase Sealant (PN 2871557) to the mating surfaces. Install new front and rear output shaft seals. Apply 5.46 Nm) - 3. Apply grease to the seal lips. TRANSMISSION REASSEMBLY 1. 8.34 ft. Install retainer plate with flat side toward bearing. 36.50. Before installing the cover make sure the sealing surfaces are clean and dry. 6. Install front and rear output shafts into the case.TRANSMISSION TRANSMISSION DISASSEMBLY CONT’D 35. Reinstall the chain onto the front output shaft and rear output shaft. (36. Remove seals from transmission case. lbs. Front Cover Bolt Torque: 27. 2. IMPORTANT: New seals should be installed after the transmission is completely assembled. NOTE: Make sure that the case locating pins (knock pipes) are in place. thrust button. Note the location of the hubs on the gear. cracks. Inspect bearings for smooth operation. Reinstall cover and torque bolts in a criss-cross pattern in 3 steps to 27--34 ft. Install pinion shaft with bearing. and shafts are fully seated in the transmission case. lbs.11 . (8--16 Nm). lbs. Apply Loctitet 262 (Red) (PN 2871951) to screw threads and torque screws to 6--12 ft. 37. Cover the splines of the shaft to protect the seal lips during installation. 7.

If the snap ring is over--stressed. (8. Install the ball bearing onto the end of the input shaft. open the the snap ring just far enough to go over the shaft. Install the a new needle bearing. lbs. and bearing.16 Nm) 9. washer. the thrustwasher and the snap ring. Install the engagement dogs. to avoid stressing the snap ring.TRANSMISSION TRANSMISSION REASSEMBLY CONT’D NOTE: Install a new snap ring at this time. 12.12 . Keep the spring in place while the fork is being installed on the shaft and while placing the shafts into the case. it could come off the shaft and cause internal damage to the transmission.12 ft. Install a new needle bearing. 10. the low gear. 14. 8. Use of a new snap ring is recommended. As the engagement dogs are installed onto the shaft. 11. Install the shift dogs and wave spring. Install the washer. Slide the reverse shaft assembly through the silent chain. When installing the new snap ring. 13. place the wave springs into the spring groove. a new needle bearing and the high gear. the 24T reverse sprocket. wave springs. Pinion Retainer Plate Bolt Torque: 6. and a new snap ring. Install the press fit gear and ball bearing.

Position the shift forks up and so the the pins point toward the 9 o’clock position. NOTE: Use caution when installing the fork. before installing the shift drum assembly. 16. 15. Replace and grease the O--rings on the shift drum before installation. the spring can easily fall out. Carefully install the shaft assembly and gear cluster as a unit into their respective bearing case recesses.TRANSMISSION TRANSMISSION REASSEMBLY CONT’D 17. Install the shift drum into the case. NOTE: Make sure shift shaft pins are properly positioned in the slot on selector arms. shift dogs.13 . 8. Tap with a soft face hammer to seat shaft assemblies. and the springs in place. NOTE: Installing the shift rail will aid in keeping the shift forks. 18.

(19. Apply a light coating of grease on the gear teeth. Install the shift gear (16T) on the shift drum shaft. Reinstall cover and torque bolts in a criss-cross pattern in 3 steps to 27--34 ft. Install the lockout disc.46 Nm) 22. Install the detent pawl and spring. Install the sector gear in the bushing pocket on the left side. Grease the o--ring on the end of the shift drum.TRANSMISSION TRANSMISSION REASSEMBLY CONT’D 19. Lift the shift rail slightly and rotate the rail/fork assembly so it meshes with the tracks on the shiftdrum. 20. Detent Star Front Cover Bolt Torque: 27. 26. Clean the mating surfaces of the case and cover.14 . Install the helical gear and bearing onto the pinion shaft. Be sure the locating pins (knock pipes) are in place.50. Apply electricians tape or somehow cover the splines of the shaft to protect the seal lips during installation. (36.34 ft. Note the keyed spline on the end of the shaft.18 ft. Keyed Spline 27. Install a new o--ring onto the shift shaft after the detent pawl is assembled to the shaft. Install the shift shaft and the detent star. lbs.50--46 Nm). lbs. Drain Plug Torque: 14. Place a small amount of grease on the small O--ring on the shift shaft and on the detent star. Torque drain plug to 14--18 ft. Place a small amount of grease (PN 2871551) into the pocket before installing the sector gear. lbs. Grease the seal lips of the input shaft seal.24 Nm) 24. Use the white marks that were previously applied for reference. Install drain plug with a new sealing washer. (36. (19--24 Nm). 8. Sector Gear Lockout Disc NOTE: Note the location of the skip tooth on the splines. 23. 25. lbs. 21. Apply Crankcase Sealant (PN 2871557) to the mating surfaces. Install new input shaft seal. Aligning the timing marks on the gears. Be sure the wave springs are properly in place and that the shift rail is seated into the pocket on the backside of the case.

lbs.24 Nm) 31. (12--16 Nm). 8. Hook up the switch harness and reconnect the lockout plunger spring. Note the keyed spline on the bellcrank and shaft. Install transmission and add Polaris Premium Synthetic Gear Case Lubricant (PN 2871477) in the recommended amount.15 . NOTE: Rotate the bellcrank to line the flat side of the switch up to the flat side of the shaft. Install the park lockout assembly. Install the retaining clip. (12-16 Nm) 30. lbs. 29.TRANSMISSION TRANSMISSION REASSEMBLY CONT’D 28. Install a new bellcrank onto the shift shaft. (16--24 Nm). Apply Crankcase Sealant (PN 2871557) onto the cover and case mating surfaces.14 ft. Install the washer and nut. Install the cover and torque the cover bolts to 6--12 ft. lbs. Bellcrank Nut Torque: 12. (16. Install the shift switch. lbs. Refer to Maintenance Chapter 2 for more information. lbs. (16--19 Nm). Torque the bellcrank nut to 12--18 ft. 32. Install Cover and Bolts Park Lockout Cover Bolt Torque: 6-12 ft.18 ft. Torque park lockout to 12 -.

16 .TRANSMISSION NOTES 8.

. . . . .19 9. . . . . . . . Rear Caliper Removal/Inspection . . .4 9.3 9. . . . . . . . . . Brake System Service Notes . .17 9. . . . . . . . . . . . . . . . . . . Front Pad Assembly . . . . . . . . . . Rear Caliper Reassembly . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Caliper Bleeding . . . . . . Hydraulic Brake System Overview . . . . . . . .1 .13 9. . . . Front Caliper Installation . . . . . . . . . . . . . . . . .5 9. . . . . . Front Caliper Reassembly . . . . . . . . . .7 9. . . . .8 9. .16 9. . . . . . . Front Caliper Disassembly .2 9. . . . . . . .9 9. . . . . . . . . . . .10 9. . . . . . . . . . . . .15--9. . . . . . . . . . . . . . . . .3 9. . . . . . . .10 9. . . . . . . . . . . .7 9. . . . . . Brake Noise Troubleshooting . . . .20 9 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9--9. . . . Front Caliper Removal . .12 9. . . . . .12 9. . . . . . . . .13 9. . . . .16 9. . . . . . Front Caliper Exploded View . . . .11-9. . . .5--9. . . . Front Disc Inspection . . . . . . . . . . . . . . . . Front Disc Removal/Replacement .18--9. . . Brake Bleeding / Fluid Change . . . . . . .12--9. . . . . . . Front Pad Removal .20 9. . . . . . Rear Disc Inspection . . . . . . Master Cylinder Installation . . . . . . . . . . .19 9.6 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .8--9. . . . . . .BRAKES CHAPTER 9 BRAKES Special Tools/Specifications/Torques . . . . . . . . . . . . Front Caliper Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4--9. . . .6--9. . Rear Caliper Exploded View . . . . . . .19 9. . . . . . . . . Rear Auxiliary Master Cylinder Exploded View . Brake Burnishing . . .14 9. . . . . . . . . . . . . . . . . . . . . . . . . . Master Cylinder Removal . . . . . . . . . . . . . . Rear Pad Installation . . . . .10 9. . 9. .9 9. . . . . . . . . . . . . . . . . . . . . . Rear Pad Removal . . . . . . . . . . . . . . . . . .

6mm .0 Master Cylinder Reservoir Cover Bolt Brake Line Banjo Bolt Front Brake Disc Front Wheel Mounting Nuts *5 in.0 20.Front Master Cylinder I.0 *25 in. 15.166mm - Service Limit .002² / .005² / .D. except where noted*) Torque (Nm) 22 21 Front Caliper Mounting Bolts Output Shaft Caliper Mounting Bolts Master Cylinder Mounting Bolts 16.180² / 4. lbs.0 15.150-. Some special procedures are used when torquing certain bolts and fasteners.298² / 7.187² /4.2 .242mm .6mm .002² / .6mm .BRAKES SPECIAL TOOLS PART NUMBER 2870975 TOOL DESCRIPTION Mity Vact Pressure Test Tool SPECIFICATIONS Front Brake Caliper Item Brake Pad Thickness Brake Disc Thickness Brake Disc Thickness Variance Between Measurements Standard .051mm .56 21 25 28 NOTE:Refer to the tightening procedures in this chapter when torquing the bolts.005² / .750² .0 18. lbs. Rear .177-.318² / 7.180² / 4. 9.500² TORQUE SPECIFICATIONS Item Torque (ft.0 0.164² / 3.D. lbs. .750mm - Service Limit .140² / 3.6mm .25mm Brake Disc Thickness Variance Between Measurements Brake Disc Runout Master Cylinder I. 3.167² / 4.496-4. .Aux.50mm Rear Axle Brake Caliper Item Brake Pad Thickness Brake Disc Thickness Standard .810-4.556mm .051mm Brake Disc Runout - .

Replace disc Inspect and repair as necessary If noise does not change when brake is applied check other sources. Check wheel and hub for abnormal movement. Set to proper level Clean compensating port Inspect. Make sure the brake lever and pedal returns freely and completely. axle. Permatext Disc Brake Quiet (PN 2872113) can be applied to the back of the pads. dust. low maintenance and perform well in the conditions ATVs routinely encounter. or imbedded material on pads or disc Remedy Spray disc and pads with CRC Brake Kleent or equivalent non-flammable aerosol brake cleaner. Remove pads and/or disc hub to clean imbedded material from disc or pads. Check and adjust master cylinder reservoir fluid level after pad service. If cleaning does not reduce the occurrence of brake noise. Adjust stop pin on front caliper after pad service. Inspect and repair as necessary Change to a softer or harder pad Wrong pad for conditions 9. hub. Do not over-fill the master cylinder fluid reservoir. there are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life. Optional pads are available to suit conditions in your area.3 . Follow directions on the package. Repair as necessary Clean piston(s) seal Pad(s) dragging on disc (noise or premature pad wear) Improper adjustment Insufficient lever or pedal clearance Master cylinder reservoir overfilled Master cylinder compensating port restricted G G G G G G G Educate operator Master cylinder piston not returning completely Caliper piston(s) not returning Operator error (riding the brake / park brake applied) Loose wheel hub or bearings Brake disc warped or excessively worn Brake disc misaligned or loose Noise is from other source (chain. Select a pad to fit riding style and environment. Brake Noise Troubleshooting Possible Cause Dirt. Adjust pad stop (front calipers) Check position of controls & switches. Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely. Make sure atmospheric vent on reservoir is unobstructed. Test for brake drag after any brake system service and investigate cause if brake drag is evident.BRAKES BRAKE SYSTEM SERVICE NOTES Polaris disc brake systems are light weight. However. This will keep pads in contact with caliper piston(s) to reduce the chance of squeaks caused by dirt or dust. G Perform a brake burnishing procedure after installing new pads to maximize service life. disc or wheel) G G BRAKE NOISE TROUBLESHOOTING Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). Make sure caliper moves freely on guide pins (where applicable).

This causes the boiling temperature of the brake fluid to drop. If the reservoir is over filled or the diaphragm vent is plugged the expanding fluid may build pressure in the brake system leading to brake failure. Because the hand and foot brake hydraulic systems are separate. each system must be bled separately. The resulting friction reduces brake disc and vehicle speed. and a vent port (F) located between the gasket and the cover. hydraulic hose.9. which can lead to brake fade and the possible loss of control. The caliper pistons are “T”-shaped. be sure this port is open. The Polaris disc brake system consists of the following components or assemblies: brake lever. As the temperature within the hydraulic system changes. Too little fluid will allow air to enter the system and cause the brakes to feel spongy.4 .27.5.. meaning it rapidly absorbs moisture. The hand brake system applies hydraulic pressure to both front calipers and only the outer diameter of the rear caliper pistons. A B Moveable Brake Pad G D When servicing Polaris ATV brake systems. Brake fluid level is critical to proper system operation.80 cm) from top of the cylinder. The auxiliary (foot) brake applies pressure to the inner portion of the rear caliper pistons. use only Polaris DOT 3 Brake Fluid (PN 2870990). there are also two bleed screws -. however.4 . WARNING: Once a bottle is opened. this port compensates for fluid expansion (heated fluid) or contraction (cooled fluid). The friction applied to the brake pads will cause the pads to wear. but remain separated by seals. use what is necessary and discard the rest in accordance with local laws. the piston within the caliper moves further outward and becomes self adjusting. This pad contacts the brake disc and moves the caliper in its floating bracket. the piston (D) located in the brake caliper moves outward and applies pressure to the brake pad. and one for the inner fluid chamber (foot brake). As the master cylinder piston moves inward it closes a small opening (compensating port C) within the cylinder and starts to build pressure within the brake system. it is very important that the master cylinder reservoir have adequate space to allow for fluid expansion. master cylinder. This system also incorporates a diaphragm (E) as part of the cover gasket. Hydraulic Auxiliary Brake inspection and adjustment is outlined in Chapter 2 beginning on Page 2. Never overfill the reservoir! Fill to 1/4² .BRAKES HYDRAULIC BRAKE SYSTEM OPERATION OVERVIEW Typical Hydraulic Brake System Compensating port compensates E Must be clear for temperature to allow changes by allowproper diaing fluid back to phragm moveC master cylinder ment F when the lever is released and the master cylinder piston is outward. When the hand activated brake lever (A) is applied it contacts piston (B) within the master cylinder. Too much fluid could cause brakes to drag due to fluid expansion. brake pads.one for the outer fluid chamber (hand brake). Fluid from the reservoir fills the additional area created when the caliper piston moves outward. Located within the master cylinder is the compensating port (C) which is opened and closed by the master cylinder piston assembly.64 .5/16² (. As the lever pressure is increased. brake calipers (slave cylinder). which allows both hand and foot brake to use the same caliper piston. Do not store or use a partial bottle of brake fluid. As these pads wear. Make sure the vent is open and allowed to function. pulling the stationary side pad into the brake disc. The combination diaphragm and vent allow for the air above the fluid to equalize pressure as the fluid expands or contracts. and brake discs. which are secured to the drive line. As the pressure within the system is increased. The basic procedure for bleeding the brake system is the same as outlined on page 9. During system service. the braking affect is also increased. Brake fluid is hygroscopic. 9. The port is open HYDRAULIC CALIPER BLEEDING This caliper is a single piston design. Due to the high temperatures created within the system during heavy braking.

5 . If changing fluid. Attach a clean. C Sight Glass B Polaris DOT 3 Brake Fluid (PN 2870990) 6.BRAKES NOTE: Uppermost (inner) bleed screw and brake line (A) is for hand brake system. cover and diaphragm (C) from reservoir. Mity Vact (PN 2870975) 5. Begin bleeding procedure with the caliper that is farthest from the master cylinder. Add brake fluid to the indicated MAX level inside reservoir. Clean reservoir cover thoroughly. NOTE: Do not remove brake lever when reservoir fluid level is low. This procedure should be used to change fluid or bleed brakes during regular maintenance. always start with the caliper farthest from the master cylinder. 1. remove old fluid from reservoir with a Mity Vact pump or similar tool. Lower (outer) bleed screw and brake line (B) is for auxiliary (foot) brake system. Outer Bleed Screw Auxiliary Brake Inner Bleed Screw Hand Brake A D EB F 9. CAUTION: Always wear safety glasses during these procedures. Outer Bleed Screw Auxiliary Brake Inner Bleed Screw Hand Brake 4. (E) is Auxiliary Brake Line. Remove screws. Do not allow brake fluid to come in contact with finished surfaces. 2. Install a box end wrench on caliper bleeder screw.FLUID CHANGE NOTE: When bleeding the brakes or replacing the fluid. Be sure the hose fits tightly on fitting. (F) is Hand Brake Line. Inspect vent slots (A) in cover and remove any debris or blockage. clear hose to fitting and place the other end in a clean container. Brake fluid will damage finished surfaces. 3. MAX BB A BRAKE BLEEDING .

Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasion. CAUTION: Maintain at least 1/2² (1. Add fluid as necessary to maintain level in reservoir. lbs. 12. 11. Bleeder Screw Torque 25-30 in. Reservoir Cover Torque 5 in. 10. (2. With lever firmly applied. (0. Clean master cylinder and reservoir assembly. (2.80 -3. (0.BRAKES BRAKE BLEEDING CONT’D NOTE: Fluid may be forced from supply port (B) when brake lever is pumped. Torque the bleeder screw to 25--30 in. 8. Close bleeder screw and release brake lever. Install diaphragm. Master Cylinder Fluid Level: MAX level inside reservoir Sight glass must look dark. if sight glass is clear.lbs. NOTE: Do not release lever before bleeder screw is tight or air may be drawn into caliper. See Illustration above.6 .56 Nm) 14. Tighten bleeder screw securely and remove bleeder hose. 13.80 --3. Tighten screws to 5 in.27 cm) of brake fluid in the reservoir to prevent air from entering the master cylinder.40 Nm) 9. 7. Place diaphragm (C) in reservoir to prevent spills. open bleeder screw. While maintaining lever pressure. Check for proper braking action and lever reserve. MASTER CYLINDER REMOVAL 1.40 Nm). cover and screws. fluid level is too low 9. Repeat procedure Steps 5-9 for the remaining caliper(s). Replace hose if wear or abrasion is found. Add Polaris Dot 3 Brake Fluid (PN 2870990) to MAX level inside reservoir. Do not install cover. Slowly pump brake lever (D) until pressure builds and holds. 15. lever reserve should be no less than 1/2² (1.3 cm) from handlebar.lbs.56 Nm). lbs. Make sure you have a clean work area to disassemble brake components. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Field test machine at low speed before putting into service.

BRAKES
2. Place a shop towel under brake line connection at master cylinder. Loosen banjo bolt; remove bolt and sealing washers. CAUTION: Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 3. Remove master cylinder from handlebars. 4. Hold brake upright and continue to remove master cylinder. Cover brake line to avoid spillage. 2. Place new sealing washers on each side of banjo line and torque banjo bolt to specification. Torque to 15 ft.lbs. (21 Nm)

Banjo Bolt Sealing Washers Brake Line

MASTER CYLINDER INSTALLATION
Notice: When replacing the brake master cylinder assembly or master cylinder parts, use the correct parts. There are different brake master cylinders for the different Polaris ATV models. Refer to your parts manual or guide for the correct parts. This master cylinder is not servicable and is replaced as a 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. 5 in.lbs. (0.56 Nm)

Master Cylinder Mounting Bolt Torque 25 in. lbs. (3 Nm) Brake Line Banjo Bolt Torque 15 ft. lbs. (21 Nm) 3. Fill reservoir with DOT3 Brake Fluid (PN 2870990).

Torque this bolt first Torque both bolts to 25 in.lbs. (3 Nm) Polaris DOT 3 Brake Fluid (PN 2870990) 4. Follow bleeding procedure on Pages 9.7-9.8. Check all connections for leaks and repair if necessary.

NOTE: To speed up the brake bleeding procedure, the master cylinder can be purged of air before brake line is attached. Fill with DOT3 Brake Fluid (PN 2870990) and pump lever slowly two to three times with finger over the outlet end to purge master cylinder of air.

9.7

BRAKES

FRONT PAD REMOVAL
1. Elevate and support front of machine.

6. Measure the thickness of the pad material. Replace pads if worn beyond the service limit.

CAUTION:

Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.
2. Remove the front wheel. Loosen pad adjuster screw 2-3 turns. 3. Remove caliper from mounting bracket. 4. Push caliper piston into caliper bore slowly using a C-clamp or locking pliers with pads installed. Measure Thickness

Front Brake Pad Thickness New .298²/7.6 mm Service Limit .180² / 4.0 mm

FRONT PAD ASSEMBLY
1. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots.

NOTE: Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 5. Push mounting bracket inward and slip outer brake pad past edge. Remove inner pad.

9.8

BRAKES
6. Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap. Polaris Premium All Season Grease (PN 2871423) 2. Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other. Be sure pads and disc are free of dirt or grease. 3. Install caliper on hub strut, and torque mounting bolts. Master Cylinder Fluid Up to MAX line inside reservoir

7. Install wheels and torque wheel nuts.

Front Wheel Nut Torque 20 ft. lbs. (27 Nm)

BRAKE BURNISHING PROCEDURE
18 ft. lbs. (25 Nm) 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. 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.

Front Caliper Mounting Bolts Torque: 18 ft. lbs. (25Nm) 4. Slowly pump the brake lever until pressure has been built up. Maintain at least 1/2² (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 5. Install the adjuster screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise).

FRONT DISC INSPECTION
1. Visually inspect the brake disc for nicks, scratches, or damage. 2. Measure the disc thickness at eight different points around the pad contact surface using a 0-1² micrometer. Replace disc if worn beyond service limit.

9.9

BRAKES
Brake Disc Thickness New .150-.164² (3.810-4.166 mm) Service Limit .140² / 3.556 mm Brake Disc Thickness Variance Service Limit: .002² (.051 mm) difference between measurements. 3. Mount dial indicator as shown to measure disc runout. Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if runout exceeds specifications. 2. 3. 4. 5. Remove bolts and disc. Clean mating surface of disc and hub. Install disc on hub. Install new bolts and tighten to specified torque. Front Brake Disc Mounting Bolt Torque 18 ft. lbs. (25 Nm) CAUTION: Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal.

FRONT CALIPER REMOVAL
CAUTION:

Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.
1. Remove brake pads. See Page 9.9--9.10. 2. Using a line wrench, loosen and remove brake line to caliper. Place a container under caliper to catch fluid draining from brake line. Brake Disc Runout Service Limit .005² (.127 mm)

FRONT BRAKE DISC REMOVAL / REPLACEMENT
NOTE: To reduce the possibility of warpage, try removing the brake disc mounting bolts before applying heat to the bolts. 1. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent.

3. Remove brake caliper and drain fluid into container. Do not reuse brake fluid.

18 ft. lbs. (25 Nm) new bolts have pre-applied locking agent.

9.10

BRAKES

FRONT CALIPER DISASSEMBLY
1. Remove brake pad adjuster screw.

Remove Mounting Bracket

4. Remove piston, dust seal and piston seal.

2. Push upper pad retainer pin inward and slip brake pads past edge.

5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTE: Be sure to clean seal grooves in caliper body.

3. Remove mounting bracket, pin assembly and dust boot.

Clean Components

9.11

Piston should slide in and out of bore smoothly.30 mm) FRONT CALIPER REASSEMBLY 1.191-1.10.28 mm) Service Limit 1. Compress the mounting bracket and make sure the dust seals are fully seated.192² (30. with light resistance. and install the rubber dust seal boots. 2. scratches or wear. 3. Measure diameter and replace if damaged or worn beyond service limit.11.193² (30. See Pages 9. oil or grease.25-30. Lubricate the mounting bracket pins with Polaris Premium All Season Grease. wear or damage. 9. Inspect piston for nicks. scratches. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt. Install the pads as shown on Page 9. Inspect caliper body for nicks. Be sure groove is clean and free of residue or brakes may drag upon assembly. Std.10--9. Coat piston with clean Polaris DOT 3 Brake Fluid (C). Polaris Premium All Season Grease (PN 2871423) 3. Front Caliper Piston Bore I.D. 4. Measure bore size and compare to specifications. Inspect the brake disc and pads as outlined for brake pad replacement this section.12 . Replace if damage is evident or if worn beyond service limit. Install new O-rings (A) in the caliper body (B).BRAKES FRONT CALIPER INSPECTION 1. 1. C B D A 2. Install piston (D) with a twisting motion while pushing inward.

(25 Nm) Front Caliper Mounting Bolt Torque 18 ft. then back off 1/2 turn. 9. 18 ft. lbs. Follow brake bleeding procedure outlined on Pages 9.6. 5. Install wheels and torque wheel nuts to specification.BRAKES FRONT CALIPER INSTALLATION 1.13 . lbs.5-9. 3. 4. Install the adjuster screw and turn until stationary pad contacts disc. and torque mounting bolts. (25 Nm) 2. Install brake line and tighten securely with a line wrench. Install caliper on hub strut. Front Wheel Nut Torque 20 ft. lbs. (27 Nm).

LBS.BRAKES FRONT BRAKE CALIPER EXPLODED VIEW 3 APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT APPLY POLARIS ALL PURPOSE GREASE Socket Set Screw Bushing Boot 3 O--Rings Square 3 Piston Bleeder Screw 35--60 IN.14 .5 NM) Brake Pads Caliper Assembly Boot Bushing Caliper Mount 9. (4--6.

Support the machine. 3. 4. Remove Brake Pads 7. 6. Remove excess fluid from reservoir as required. Remove the rear tire. Allow pads and disc to cool sufficiently during the procedure. Gradually apply brakes to stop machine. be careful not to damage brake line. 5. 9.BRAKES BRAKE BURNISHING 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. Remove a slide bolt with a hex wrench. Clean the caliper with brake cleaner or alcohol. NOTE: Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. 2. Remove the brake pads from the caliper. Repeat this procedure 10 times. NOTE: When removing caliper. Support caliper so as not to kink or bend brake line. Remove caliper mounting bolts and lift caliper off of disc. Push caliper pistons into caliper bore slowly with pads installed.15 . Remove the clip from the slide bolt. Do not allow pads or disc to become hot or warpage may result. Clip REAR BRAKE PAD REMOVAL 1.

lbs. lbs. Install Pads Torque Mounting Bolts Rear Brake Caliper Torque: 18 ft. 9.180² (4.0 mm) Service Limit: . (41 Nm-48 Nm) 5. Replace pads if worn beyond the service limit. Caliper Slide Pin Torque: 30-35 ft. Install new brake pads in caliper body.BRAKES REAR BRAKE PAD REMOVAL CONT’D 8. (41 Nm--48 Nm). Repeat procedure 10 times. Slowly pump the brake lever until pressure has been built up. It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise. Start machine and slowly increase speed to 30 mph. Install caliper and torque the mounting bolts. Measure the thickness of the pad material.7 mm) of brake fluid in the reservoir to prevent air from entering the master cylinder. (25 Nm) 2.6 mm) REAR BRAKE PAD INSTALLATION 1. Torque Slide Pin Measure Thickness 4. 3. 6. Maintain at least 1/2² (12. Tighten the slide pin with a hex wrench. Gradually apply brakes to stop machine. lbs. Install the slide bolt snap ring. Torque the slide pin to 30--35 ft. Rear Brake Pad Thickness New: .318² (8.16 .

7. 5. Clean the O-ring grooves. Place a container to catch brake fluid draining from brake lines. Using a flare nut wrench. the slide pins(B). Caliper Anvil Bolts Seal Piston & O--rings 6. Caliper C O--ring Bushing D 9.17 . Remove the two caliper bolts and the caliper. Remove the slide bolt bushings. Remove the anvil bolts and separate caliper halves and remove pistons with piston pliers. Clean caliper area before removal. Clean disc. scratches. Inspect the bushings and O--rings and replace if necessary. Inspect surface of caliper piston for nicks. Inspect caliper piston bore for scratches. 4. the bracket pad (C). Remove seals and O-rings. caliper body. and pistons with brake cleaner or alcohol. or galling and replace if necessary. Remove the slide bolt snap rings (A). 8. remove hand brake (inner) and auxiliary brake (outer) lines. Remove inner and outer brake lines 3. B Inspect A 10. or damage and replace if necessary. severe corrosion. and the brake pads (D).BRAKES REAR CALIPER REMOVAL/INSPECTION 1. 2. 9.

Tighten the caliper anvil bolts and then torque the anvil bolts evenly to 16--18 ft. 9. (41--48 Nm). lbs. Torque Mounting Bolts Caliper Mounting Bolt Torque 18 ft. making sure O-rings are properly positioned in groove. Install the slide pins and the slide pin retaining ring. or piston may bind in bore.lbs. Torque the slide pins to 30--35 ft. (22 Nm-25 Nm) 3. (22--25 Nm). (41 Nm-48 Nm) O-Rings 2. Carefully assemble caliper body.18 . Be sure O-ring and seal grooves are thoroughly cleaned of all residue. lbs. lbs. 4. Install new O-rings in the slide bolt bushing holes. lbs. Seals Caliper Slide Pin Torque: 30-35 ft. Apply brake fluid to piston seals and install carefully with a twisting motion to ease assembly until fully seated. Install brake pads in caliper body with friction material facing each other. (25 Nm) Caliper Anvil Bolt Torque: 16-18 ft.BRAKES REAR CALIPER ASSEMBLY 1.lbs (25 Nm). Install caliper and torque mounting bolts to 18 ft.

051 mm) Limit difference between measurements 3. Replace disc if worn beyond service limit.177-. Hand Brake Line Brake Disc Runout Service Limit .002² (. 2. Field test unit for proper braking action before putting into service. REAR BRAKE DISC INSPECTION 1. Replace the disc if any deep scratches are evident.BRAKES 5. re-check assembly and installation.6-9. (21 Nm) 6. lbs. Follow bleeding procedure outlined on Pages 9. Mount dial indicator and measure disc runout. Rear Brake Disc Measure Thickness Brake Disc Thickness New . Use a 0-1² micrometer and measure disc thickness at 8 different points around perimeter of disc. Make sure the brake is not dragging when lever is released.496-4. 7. Replace the disc if runout exceeds specifications.750 mm) Service Limit . scratches.3.2--9. Visually inspect disc for scoring. TROUBLESHOOTING Brakes Squeal G Dirty/contaminated friction pads G Improper alignment G Worn disc G Worn disc splines Poor Brake Performance G Air in system G Water in system (brake fluid contaminated) G Caliper/disc misaligned G Caliper dirty or damaged G Brake line damaged or lining ruptured G Worn disc and/or friction pads G Incorrectly adjusted lever G Incorrectly adjusted stationary pad G Worn or damaged master cylinder or components G Improper clearance between lever and switch Lever Vibration G Disc damaged G Disc worn (runout or thickness variance exceeds service limit) Caliper Overheats (Brakes Drag) G Compensating port plugged G Pad clearance set incorrectly G Auxiliary brake pedal incorrectly adjusted G Brake lever or pedal binding or unable to return fully G Parking brake left on G Residue build up under caliper seals G Operator riding brakes Brakes Lock G Alignment of caliper to disc. Inspect for fluid leaks and firm brakes.005² (.167² (4.187² (4. Install brake lines and tighten to specified torque.19 .242 mm) 9. If the brake drags. Brake Disc Thickness Variance Service . or gouges.127 mm) Auxiliary Brake Line Banjo Bolt Torque 15 ft.7 of this section and refer to system overview and illustrations on Pages 9.

(22--25 Nm) 3 Piston Bleed Screws Torque 25--30 in.80--3.lbs. (2.40) Nm Bracket Pads Seals O--rings 3 Torque 30--35 ft. lbs. (41--48 Nm) Slide Pins Bushings Seal Front Caliper Snap Ring REAR AUXILIARY MASTER CYLINDER Brake Reservoir Frame Rear Brake Line Bolt Seal Clamp Reservoir Hose Rear Brake Master Cylinder Screw Spring Brake Mount Washer Bushing Washer Bushing Screw 9.lbs.20 .BRAKES REAR BRAKE CALIPER EXPLODED VIEW 3 APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT Anvil Bolts Washers Rear Caliper Torque 16--18 ft.

. Battery Activation/Service . . . . . . .31 10 10. . . . . . . . Starter Assembly Expoded View . . . . Transmission Gear Position Switch Test . .29 10. . . Starter System Testing . . . . . . . . . . . . Coolant Sensor Tests . .26--10--27 10. .4 10. . 10. . . . . . . . Speedometer Troubleshooting . . . Starter Drive . . . . Starter Motor Service . . . Ignition System Troubleshooting .3--10. . . . . . . . . . . . . . . .13 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .12 10.2 10. . . . . . . . . . .ELECTRICAL CHAPTER 10 ELECTRICAL 330 Watt Alternator Exploded View . . . . . . . . .5--10. . . . . . .14 10. . . . . . . . . . . Speedometer Removal/Installation . . .8--10. . . . . . . Fan Control Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . .23 10. .15--10. . . Special Tools/Service Notes . . . . . . .21 10. . . . . . Flywheel Identification . . . . . . . . Fan Motor Tests . . . Timing Check Procedure . . .4 10. . . . . . .22 10. . . . . . . . . . . Ignition System Testing Flow Chart . . . .18--10. . . . . .22 10. . .2 10. .1 . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Cluster Troubleshooting . . . . . . . . . . . . . . . . . .12 10. . . . . . .4 10. Starter System Troubleshooting . . . . Trigger Coil Gap . . . . . . . . .21--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 10. . . Wiring Diagram . . . .7 10. . . . . . . . . . . . . . . . . . .7 10. . . . . . .23--10. . . . . . . . . . . . . . . .28 10.15 10. . . . . . . . . . .17 10. . . . . . Starter System Testing Flow Chart . . . . . . .26 10. . . . . . . . . . . . . . . . . . Electronic Throttle Circuit System Operation . . . . . . . . . . . . . .3 10. . . . . . Head Light/Brake Light Lamp Service . . . . . . . . . . . . . .12 10. . . . . . Charging System Testing . . . . . . . . . . . . . . . . . . CDI Output Tests . . . . . . . . . . . . . . .13 10.

EH059OLE. the production date. EH068OLE Cast 4060152 Stamp 8_ Comment 300 W 10. direction of rotation.2 . Be sure to always use the correct CDI box part number.ELECTRICAL COMPONENTS OF 600/700 300 WATT ALTERNATOR Stator Assembly NOTE: CDI boxes may look the same but have different internal circuitry. Wire Holddown Flywheel Cap LR390 Spark Plug Wire Ignition Controller Magnetic Switch Bumper Area COMPONENT LOCATION Refer to wiring diagrams for specified stator coil resistance FLYWHEEL IDENTIFICATION The flywheel can be identified by the tag located on the flywheel. and has timing marks to time the engine. The tag indicates the Polaris Part Number. Flywheel Identification Stamp Location Polaris Part Number Production Date Direction of Rotation Engine Application EH68ALOE1.

NOTE: The ignition timing marks are stamped on the outside of the flywheel. etc. Ignition timing must be inspected with the engine at room temperature (68°F / 20° C). GBecome familiar with the operation of your meter. The timing will retard approximately 2° when the engine is warm. and resistance values in this manual were obtained with a Fluket 77 Digital Multimeter.ELECTRICAL SPECIAL TOOLS TOOL DESCRIPTION Fluket77 Digital Multimeter Timing Light Battery Hydrometer Hall Sensor Probe Harness Static Timing Light Harness PART NUMBER PV-43568 2870630 2870836 2460761 2871745 TIMING CHECK PROCEDURE 1. Connect the leads together and record the resistance. Direct the timing light at the ignition timing check hole and check the ignition timing. GPay attention to the prefix on the multimeter reading (K. If the ignition timing is not within the specified range. This meter is used for diagnosing electrical problems. The ignition timing check hole is in the starter recoil/magneto housing. 3.3 . start the engine and open throttle until engine is at 5000 ± 200 RPM. GRefer to wiring diagram for stator and electrical component resistance specifications. 2. With the transmission in neutral. Direction of Rotation 10. Remove the check plug. Check Plug ELECTRICAL SERVICE NOTES Keep the following notes in mind when diagnosing an electrical problem.) and the position of the decimal point. The resistance of the component is equal to tested value minus the lead resistance. The timing tag on the flywheel indicates the direction of rotation and the scale for ignition timing. Refer to the Owner’s manual included with your meter for more information. Readings obtained with other meters may differ. test the ignition components for signs of failure. Be sure leads are in the proper jack for the test being performed (i. Disconnect it from the wiring harness or power supply. amperage. 10A jack for current readings).e. GFor resistance readings. M. isolate the component to be tested. GWhen measuring resistance of a component that has a resistance value under 10 Ohms. GAll Voltage. remember to subtract meter lead resistance from the reading. NOTE: Do not allow the engine to warm up.

D.56--. The gap should be .C.71 mm) 10.4 .56-. Use the point of maximum advance when checking ignition timing 30 28 26 IGNITION TIMING (DEGREES) B. Measure Trigger Coil Gap Trigger Coil Gap: . 24 22 20 18 16 GEAR POSITION INDICATOR SWITCH TEST TRANSMISSION SWITCH High/Low/Neutral/Reverse/Park Switch A B C D E F A B C D E F High Range Low Range Neutral Reverse Park F F F F F F 12 8 0 1000 2500 3000 3500 4000 4500 5000 5500 6000 35 Brown 18 Purple 51 White / Blue TRIGGER COIL GAP Measure trigger coil gap with a feeler gauge.T.ELECTRICAL TIMING CHECK PROCEDURE CONT’D Typical Ignition Timing Curve * Actual advance point may vary by several hundred RPM above or below 5000 .022-.71 mm).028 inch (.028 inch (.022--.

When the ATV leaves the factory. or that a failed battery or voltage regulator is causing an excessively high voltage on the DC bus. and wheel speed sensor for proper operation. transmission gear.In addition to depicting vehicle speed. High Engine Coolant Temperature 5. High/Low Battery Voltage Indicates that the battery is nearing full discharge. Speedometer Needle -. Rider Information Center 2.S.ELECTRICAL INSTRUMENT CLUSTER TROUBLESHOOTING Introduction The Polaris ATV Instrument Cluster is powered by battery voltage (12 VDC) and requires inputs from the engine RPM. odometer. The speedometer head does not differentiate between forward and reverse wheel rotation. High Engine Coolant Temperature Indicates the engine is overheating. High/Low Battery Voltage Vehicle Speed and Odometer An electronic wheel speed sensor located on the right front brake caliper bracket senses vehicle speed. Gear Indicator 4. 10. and one from the vehicle main harness. Static Timing Light Harness (PN 2871745). the electronic speedometer provides the following functions: (See Illustration) 1. which is initially indicated by the “wrench” icon and the word “OFF”. this needle will flash to indicate a fault condition. and trip odometer. 3. Speedometer graph depicting both miles per hour and kilometers per hour. Programmable Service Interval To enable the programmable service interval function. Programmable Service Interval The purpose of the programmable service interval is to provide the consumer and their dealer with a convenient way to schedule routine maintenance.) mode. scroll to the Programmable Service Interval (P. Hour Meter (Engine Run Time) Logs the total hours the engine has been in operation. Two harnesses plug into the cluster head.I.5 . Hour meter 2. release the button. Refer to Chapter 3 “Cooling System Troubleshooting” for help with diagnosis of overheating. Diagnostic Mode Refer to Page 10.6 on how to operate the diagnostic mode. Kilometers Per Hour (KPH). In addition to the ground speed in Miles Per Hour (MPH). one from the wheel sensor. When the wrench icon begins to flash. You must enable this feature if you intend to use it to track maintenance requirements. with the Hall Sensor Probe Harness (PN 2460761). can be used to quickly test the sensor. The illumination lamp inside the gauge is non-serviceable and is designed to last for the life of the unit. 1. Low Oil Pressure 6. Low Oil Pressure Indicates that the engines is operating on low oil pressure or that the engine is running low on oil. A non-serviceable internal memory battery maintains odometer and hour meter data when the machine is not running. 1 2 3 4 5 6 2 3 1 1. this feature is turned “OFF”. Press and hold the mode/reverse override button until the wrench icon begins flashing. Programmable Service Interval 3.

Diagnostic Mode Warning Indications Information Center Warning Indication Displayed on Rider Warning Explanation Most of the time this error message indicates that you are between gears. NOTE: If the gauge will not indicate what gear it is in and will not allow AWD operation.6 . the wrench icon will flash for five seconds during vehicle start up to remind the driver that the next scheduled service is due. 2.is displayed when the mode/override button is stuck in for more than ten seconds in any mode except Programmable Service Interval or Diagnostic modes.I.I. This is usually the result of an open battery condition. 5. When the desired hour total has been reached. hold the button down until the count turns over to “0”. then counts down from this total per hours of engine operation. “E” “StAtr” Ill.is displayed when the gauge senses ground speed but no engine rpm for at least 10 seconds. Begin entering the next service hour total by releasing and pressing the mode/reverse override button. The gauge is designed to survive such an event.S. “Stator” -. Ill. Turn the key switch off and wait 10 seconds. The first screen indicates battery voltage. May indicate a failing stator or wiring problem. “Handlebar” -. off.S. The initial screen displayed looks similar to Ill. the wrench icon will remain lit. The P. It can also indicate that the transmission switch is broken. This mode is not operational while in motion. 3. This information is only briefly displayed. Refer to Ill. To turn the P. toggle to the service interval mode and press the mode/reverse override button for approximately seven seconds until the word “OFF” appears in the Rider Information Center. NOTE: Continuing to hold down the mode button will add to the hour total faster. 2 Screen three (Ill. If you scroll past the intended number. Once the wrench icon quits flashing the service hours are set. 4) is the tachometer for setting idle speed. 4 NOTE: As long as you are in the diagnostic mode. 1 and is referring to the software version currently installed in your instrument cluster. When the number reaches “0”. 3. Ill. 1 Use the mode/reverse override button to toggle through the diagnostic screens. 10. Set the park brake and shift the transmission to neutral. To enter the diagnostics mode: 1. At this point you can re--attempt to set the number. “hdLbr” NOTE: The gauge will shut itself off if the voltage on the DC bus is too excessive. stop pressing the mode/reverse override button and wait for the wrench icon to quit flashing.ELECTRICAL PROGRAM SERVICE INTERVAL CONT’D 2. 4. Each time the mode/reverse override button is pressed and released the service interval time is increased by an hour. 2. AWD can still be enabled by holding in the mode/override button. Hold the mode/reverse override button as you turn the key switch on.

2. either shift the machine out of neutral or turn the key switch off and on. 10. 2. Spray a soap and water mixture onto the outer surface area of the instrument cluster. Bezel Instrument Cluster Pod Push Instrument Cluster Outward NOTE: Do not remove the rubber grommet in the pod. NOTE: Do not allow alcohol or petroleum products to come in contact with the instrument cluster lens. to ensure proper alignment. NOTE: Any movement of the tires will trigger the speedometer out of the diagnostic mode.ELECTRICAL To leave the diagnostic mode. while securely holding the pod. SPEEDOMETER REMOVAL 1.7 . Remove the headlight pod cover and disconnect the wire connectors from the instrument cluster. Push the instrument cluster out from the backside of the pod. NOTE: Be sure the key on the instrument cluster housing is aligned with the keyway in the rubber grommet. Only remove the rubber grommet if necessary. 3. This will help the instrument cluster slide into the pod assembly more easily. Twist the instrument cluster gently in a clockwise motion to properly seat the instrument cluster into the pod assembly. SPEEDOMETER INSTALLATION 1. Apply pressure on the bezel while pressing down on the instrument cluster. Hold the pod assembly securely and insert the instrument cluster into the pod assembly. Be sure the rubber grommet inside the pod is fully installed and that the indexing key is in the headlight pod keyway.

Green/White. instrument cluster is O. The AWD switch is directly powered by switched 12 volts (red/white).AWD SWITCH ON - Note: If AWD light comes on.Oil Pressure Switch 11. Brown/White. CHECK AWD SWITCH AND HUB COIL Y LEAVE AWD SWITCH ON TURN KEY SWITCH OFF DISCONNECT 16 PIN CONNECTOR FROM CLUSTER TURN KEY SWITCH ON CHECK FOR 12V FROM BRN/WHITE TO GROUND Note: Reversing polarity when connecting the battery or other DC power source backwards will fail the AWD control and the instrument cluster If the key switch and the AWD switch are turned on. 16 Pin Connector 1.RPM Input 8. Orange/Red.12V Switched 3.Ground 9.ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 1 .Low Gear 15.AWD Control - Y ON HUB COIL CONNECTOR (LEAVE IT CONNECTED) MEASURE FOR 12V FROM BROWN/WHITE TO THE COIL BODY (GROUND) N NOT AN INSTRUMENT CLUSTER PROBLEM. Purple. Red/White. N/C 6. White/Blue.Reverse Gear 13. Brown. Grey/Orange.K. the cluster must be displaying low or high gear. Blue/Red.High Gear 16. To enable AWD. 10. Yellow/Red.Park Gear 12. The gear switch only interfaces with the instrument cluster. Shade the AWD light with your hand to verify it’s operation. N/C 7. Blue White.NO ALL WHEEL DRIVE START HERE CHECK SPEEDOMETER (PERFORM TEST 2) SPEED READOUT OK? N Y .Engine Overheat Switch 10.KEY SWITCH ON . Proceed to mechanical tests (in Service Manual).8 .Ignition Kill 5. Red.Mode/Override button 4.TRANSMISSION IN NEUTRAL . N WIRING PROBLEM REPLACE INSTRUMENT CLUSTER Y LEAVE KEY SWITCH OFF REMOVE THROTTLE CONTROL COVER DISCONNECT THROTTLE CONTROL HARNESS CHECK FOR CONTINUITY ACROSS AWD INDICATOR BULB Y TURN KEY SWITCH OFF RECONNECT CLUSTER LEAVE HEADLIGHT POD DISASSEMBLED SHIFT TO LOW OR HIGH LEAVE AWD ON N BAD AWD BULB. or reverse gear with the override button pushed in. Purple/Yellow.Neutral 14. Black. PROCEED TO MECHANICAL AWD COMPONENTS IF AWD PROBLEM PERSISTS.12V Constant 2.

NO REVERSE SPEED LIMIT (VEHICLE EXCEEDS 7.High Gear 16.Oil Pressure Switch 11.AWD Control - N IS THE SPEEDO READ OUT OK? CHECK SPEEDOMETER (PERFORM TEST 2) NOTE: Mode/Override button provides a grounding (sinking) input to the instrument cluster.9 MPH IN REVERSE) START HERE 16 Pin Connector 1. Power B: Signal C: Ground Y Y REPLACE SPEEDO POINTER MOVE? N CHECK WHEEL SPEED SENSOR (TEST 6) CHECK SENSOR POWER SUPPLY PIN A Y S MEASURE BACK OF S SPEEDO WITH CONNECTORS PLUGGED IN Y 16PIN MEASURE 12VDC ON PINS 1 &8 AND 2 & 8 AT BACK OF SPEEDO: CHECK FOR 10-12 VDCON PIN A TO PIN C ON THE 3 PIN CONNECTOR? N REPAIR WIRING N N REPLACE SPEEDO REPLACE SPEEDO N N ODOMETER DISPLAY Y TEST DRIVE ODOMETER CHANGE? Y POINTER MOVE? Y SPEEDO OK TEST 3 . Brown/White. Grey/Orange. Blue White. INSPECT WIRING AND CDI Y TEST TRANSMISSION (SHIFT) SWITCH AND WIRING N SHIFT INTO REVERSE: IS REVERSE INDICATOR ON? N H Measure Harness Side RESTART ATV H TURN KEY SWITCH OFF Y REMOVE 16 PIN PLUG FROM BACK OF SPEEDOMETER HEAD JUMPER TO PIN 4 (BLACK) TO PIN 8 (BROWN).NO SPEEDOMETER AND/OR ODOMETER DISPLAY START HERE KEY & STOP SWITCHES ON 3 Pin Connector S Y REPLACE SPEEDO CHECK FOR MINIMUM 6VDC ON PIN B TO N REPLACE SPEEDO A: D. Purple/Yellow.Reverse Gear 13.9 .Engine Overheat Switch 10.Ignition Kill 5. Purple.12V Switched 3.ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 2 .12V Constant 2.RPM Input 8. Orange/Red.Ground 9.Low Gear 15.Mode/Override button 4. Red/White.Park Gear 12. Black. Blue/Red. Green/White. Brown.Neutral 14. N/C 6. Yellow/Red. White/Blue. DOES ENGINE STOP? Y REPLACE SPEEDO 10. Red. N/C 7.C.

TURN AWD ON. TURN AWD OFF.High Gear 16. Brown/White. MONITOR VOLTAGE AT HUB COIL CONNECTOR. Grey/Orange. ENGINE IDLING MEASURE AC VOLTAGE BETWEEN PIN 7 AND PIN 8.Mode/Override button 4. 2. RAISE ATV WHEELS OFF GROUND AND SUPPORT IN A SAFE MANNER.Reverse Gear 13.10 . REGULATOR. Black. Blue/Red. THERE IS AN OPEN IN THE HUB COIL.Ignition Kill 5. Purple/Yellow. BETWEEN BROWN/WHITE AND GROUND REMOVE 16 PIN CONNECTOR FROM BACK OF INSTRUMENT CLUSTER. Yellow/Red.ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 4 .Park Gear 12. N/C 7. START THE ENGINE REV AND HOLD THE RPM’S ABOVE 3100.AWD Control - Y IS THE AWD LIGHT ON? Y INSPECT HUB COIL WIRING FOR SHORT CIRCUITS TO GROUND. TOGGLE TO TACHOMETER SETTING & REV ENGINE. (DISCONNECT CONNECTOR & MEASURE BETWEEN HUB COIL BROWN/WHT & GROUND.NO AWD HUB SAFETY LIMIT NOTE: IF THE AWD LIGHT DOES NOT COME ON OR IF 12 VDC IS NOT REGISTERING AND AWD IS ENGAGING START HERE IS SPEEDO FUNCTIONING CORRECTLY? TURN ATV ON IN DIAGNOSTIC MODE. DOES IT APPEAR ACCURATE? Y N CHECK SPEEDO (TEST NO. OVER 3 VAC? Y REPLACE SPEEDOMETER NOTE: IF THE AWD LIGHT IS FLICKERING RATHER THAN ON CONTINUOUSLY.OIl Pressure Switch 11.Neutral 14. Green/White.RPM Input 8. Red. AND WIRING) N NO PROBLEM 16 Pin Connector 1. 2) N TURN KEY SWITCH OFF RESTART ATV 1. DOES FRONT DRIVE ENGAGE? N CHECK CHARGING SYSTEM (STATOR.Low Gear 15. Purple. Blue White. N/C 6.12V Switched 3.12V Constant 2. Red/White.Engine Overheat Switch 10.Ground 9. White/Blue. Orange/Red.) N REPLACE SPEEDOMETER N MECHANICAL PROBLEM Y REPAIR HUB COIL WIRING 10. HOLD UNTIL DISPLAY STABILIZES. Brown.

Elevate front right side of vehicle until tire is off the ground. Red.12V Switched 3. Grey/Orange. Blue/Red. Connect wires from test light to sensor 3 Pin connector as shown at right.K.Low Gear 15. White/Blue. sensor is O. Red/White.Mode/Override button 4. N/C 7. 3. Orange/Red.High Gear 16.AWD Control - SHIFT TO LOW OR HIGH GEARS. Purple/Yellow.11 . Brown.Neutral 14. 680W Brn Wht To Sensor Red -To test wheel speed sensor: + LED Blk 9V To Sensor White To Sensor Black 1.Oil Pressure Switch 11. Static Timing Light Harness (PN 2871745) 10. Blue White. IS REVERSE INDICATOR LIGHT ON OR GEAR ON? CHECK FUEL & IGNITION SYSTEMS N TURN KEY SWITCH OFF REMOVE 16 PIN PLUG FROM BACK OF INSTRUMENT CLUSTER RESTART ATV AND TEST DRIVE Y N DOES THE LETTER “E” APPEAR? PROBLEM REMAINS? REPLACE SPEEDOMETER Y TEST TRANSMISSION SWITCH CHECK RELATED WIRING NOTE: OVERRIDE SWITCH PLAYS NO ROLE IN REVERSE GEAR OUTPUT ON THE SPORTSMAN 700 TEST 6 WHEEL SPEED SENSOR Tools Required: GStatic Timing Light Harness (PN 2871745) GHall Sensor Probe Harness (PN 2460761) or equivalent jumper wires. 5. 2.12V Constant 2.Reverse Gear 13.ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 5 REVERSE SPEED LIMITER ACTIVATED IN FORWARD GEAR (Engine loses spark when vehicle speed is above 7-9 mph. Disconnect 3 Pin connector from speedometer.RPM Input 8. N/C 6. Slowly turn right front wheel while observing the test light. If light flashes. Purple. Black.Ignition Kill 5.Engine Overheat Switch 10.Park Gear 12.) START HERE CHECK SPEEDOMETER 16 Pin Connector (PERFORM TEST 2) INSTRUMENT CLUSTER FUNCTION OK? Y 1. using the Hall Sensor Probe Harness (PN 2460761) or jumper leads. Yellow/Red. Green/White. Brown/White. 4.Ground - 9. Be sure connections are good and 9 volt battery is in good condition.

check the fan control switch and connector terminals. Repair or replace as necessary. When the fan switch reaches the specified temperature. If the fan runs with the jumper wire installed. turn the ignition key (and engine stop switch) “ON”.12 . FAN CONTROL SWITCH BYPASS TEST 1. Needle should return to normal operation. In normal operating conditions. speedo may indicate 30 mph until reset: 1. Disconnect harness from fan switch on radiator. indicating the speed at which the vehicle was traveling when the speedometer lost power. 2. the temperature sensor is non-conductive (open). The fan should start running. the speedometer indicator needle may stick. Turn ignition key and engine stop switch to “ON” position. disconnect lead and measure resistance of sensor between connector terminal and ground. Connect a DC ammeter in between the fan switch harness wires as shown. For example: If the ATV was traveling 30 mph when the engine stop switch is turned off. 3. Be sure cooling system is full and purged of air. CAUTION: Keep hands away from fan blades during this procedure. power is delivered to the hot light via the Red/White wire. If the fan does not run or runs slowly with the jumper wire installed. Fan Switch Harness Red/Blk 1. With the ATV in “Park” and with the parking brake on. With engine cold. If engine coolant reaches the specified temperature. which causes a reduction in blade speed and reduced cooling. The ground path for the fan motor is through the Brown harness wire. 2. There should be no continuity or very high resistance (megohms). 3. Hot Light On 230° F (110° C) FAN MOTOR CURRENT DRAW A current draw test will provide a good indication of fan motor condition. Operate vehicle at a speed greater than indicated on speedometer (past point where needle is stuck). NOTE: The fan switch may not function or operation may be delayed if coolant level is low or if air is trapped in the cooling system. COOLANT TEMPERATURE SENSOR TEST (HOT LIGHT) With the ignition switch (and engine stop switch) “ON”. Read the current draw on ammeter with fan running. Disconnect the harness from the fan switch. Power is supplied to the fan switch via the Red/Black wire when the ignition key is ON. Be sure fan blade is free to rotate. and motor condition (refer to Fan Motor Testing this section). the sensor becomes conductive completing the ground path for the light. 4. The Blue/White wire (ground) out of the light socket is connected to the coolant temperature sensor on the cylinder head.. A worn or damaged fan motor will draw more current. the ATV speed would have to exceed 30 mph to reset. 2. check the fan motor wiring. ground. it becomes conductive and sends power to the fan motor through to the Orange/Black wire. Serious personal injury could result. 10. Place a jumper wire between the Red/Blk and Org/Blk wires in the connector. Fan Motor Or/Blk Or/Blk Brn Connect ammeter to R/B and Or/Blk FAN CONTROL CIRCUIT OPERATION / TESTING The fan switch is located on the radiator.ELECTRICAL SPEEDOMETER TROUBLESHOOTING CONT’D TEST 7 .RESET SPEEDOMETER -If the key switch or engine stop switch is turned off with the vehicle in motion. 4. In the above example. Refer to Maintenance Chapter 2 for cooling system information.

Test the ETC switch at the harness connector.13 . Heat the coolant slowly and monitor the temperature with a thermometer or Fluket meter pyrometer. and is held in the open position (contacts are separated (as shown below) by throttle cable tension. NOTE: Adjust throttle cable freeplay (ETC switch) and make sure throttle mechanism is functioning properly before testing the switch.ELECTRICAL 5. Do not allow threads to contact container or inaccurate reading will result. replace the motor. 2. Start engine and open throttle lever slightly until engine RPM is just above idle speed. This is the same as turning the key or engine stop switch “OFF”. Refer to Maintenance Chapter 2 for cable adjustment procedure. This is a normally closed switch. REFER TO PARTS MANUAL FOR FAN SWITCH APPLICATION Fan Switch Part Number 4010161 Continuity (On) 180° F (82° C) ± 3°F No Continuity (Off) 149° F (65° C) ± 8°F ELECTRONIC THROTTLE CONTROL (ETC) SWITCH The Electronic Throttle Control (ETC) system is designed to stop the engine of an ATV in the event of a mechanical problem with the throttle mechanism. In the event of a mechanical problem in the throttle mechanism (cable tension is lost). Hold throttle cable with fingers at point “A” as shown below and release throttle lever. connecting the CDI black wire to ground. Place transmission in neutral and apply parking brake. Electronic Throttle Control (ETC) Switch (Composite Throttle Housing) ETC switch contacts are closed in a fault condition (throttle cable slack). the switch contacts close. If the fan motor draws more than 13 Amps. If the ETC system is functioning properly. Switch contacts are open during normal operation FAN CONTROL SWITCH OPERATION TEST 1. The ETC switch is mounted independently of the throttle actuator lever inside the throttle block assembly. The switch should be closed (conductive) at the “ON” temperature indicated in the chart. Place switch in a water bath and submerse it to the base of the threads. The contacts are “open” during normal operation regardless of throttle lever position. ETC OPERATION TEST Remove throttle block cover by carefully releasing all tabs around edge of cover. Fan Motor Current Draw: Should Be Less Than 15 Amps NOTE: This fan motor current draw specification only applies to Sportsman 600/700. the engine will lose spark and stop. and stay conductive until the “OFF” temperature is reached. Blk Brn Brn A CDI UNIT 10. which prevents ignition spark.

The coil mount should have good continuity to ground on the engine (0-. and speed limiter circuit for shorts to ground.3 to . and all grounds. Are all within specifications? No Inspect connectors. engine stop switch. Repair ground wire connections. Use the following pages as a guide for troubleshooting.300W Cap removed . 10. No Disconnect the exciter coil and pulse coil connector from the CDI module. perform voltage output tests on following page or replace the CDI module.2 W). Replace the component if a wiring problem cannot be found.14 .11. -Check connectors for moisture. Also be sure that colors match when wires are connected. Measure the resistance of the exciter coil and pulse coil (where applicable). and wire color coding have been inspected. Yes Check coil ground connection between engine and coil mount using an ohmmeter.Primary Wire Tab to Ground (on coil mount or engine): . Condition: No Spark or intermittent spark Replace Spark Plug Disconnect the black wire at the CDI module to isolate the ignition from the kill system. wiring and grounds to the component in question. If all of the above tests are within specifications. first check all terminal connections to be sure they are clean and tight. The resistance values are also given on the specification pages. wire color matching or corrosion. Resistance values should be: Primary Side .Cap installed . Yes Disconnect and check the secondary coil. Refer to the wiring schematic for meter connections and specifications. Does it have spark? Yes -Test the ignition switch.ELECTRICAL IGNITION SYSTEM TESTING FLOW CHART Whenever troubleshooting an electrical problem. Compare results to the specifications on the exploded views.6300W Are these values within specs? Yes No Replace the ignition coil. connections.5 Ohms Secondary Side High Tension Wire to High Tension Wire-. No Clean coil mounting area.

The starter system must be in good condition and the battery fully charged. Output w/ Peak output tester 130 DCV Average Output w/ Digital Voltmeter 20 DCV 10. Follow the directions provided with the adaptor. corroded GPoor ignition coil ground (e. and compare to the chart.should not exceed . All measurements are indicated in DC Volts.g.4-1. CDI OUTPUT TEST USING PEAK READING ADAPTOR Re-connect all CDI wires to stator wires.016-.040² (. A peak reading voltmeter must be used to perform the tests. Crank engine and check output of CDI wire to coil (130 DCV). A variety of peak reading adaptors are commercially available for use with the Fluke t 77 Digital Multitester (PV-43568) and other digital VOMs which will allow peak voltage tests to be performed accurately. If the draw is excessive. Check for current draw with the key off. The following measurements are obtained when cranking the engine with the electric starter. Damage will occur to electrical components. Reconnect coil wire to CDI. loads should be disconnected from the system one by one until the draw is eliminated. Test output from exciter coil. or corroded GEngine Stop switch or ignition switch faulty GETC switch misadjusted or faulty GWire harness or connections wet.15 .0024² GFaulty CDI module CDI CRANKING OUTPUT TEST WITH PEAK READING VOLTMETER The following peak voltage tests will measure the amount of output directly from each component. Disconnect CDI module wire from ignition coil primary terminal.KEY OFF CAUTION: Do not connect or disconnect the battery cable or ammeter with the engine running. shorted.ELECTRICAL IGNITION SYSTEM TROUBLESHOOTING No Spark. coil mount loose or corroded) GFaulty stator (measure resistance of all ignition related windings) GIncorrect wiring (inspect color coding in connectors etc) GFaulty ignition coil winding (measure resistance of primary and secondary) GWorn magneto (RH) end Crankshaft bearings GSheared flywheel key GFlywheel loose or damaged GTrigger coil air gap too wide (where applicable) . pulse (trigger) coil. Refer to Illustration 1 on the next page. 330 Watt 4 Stroke (Sportsman 700) Coil Connect Meter Wires To: Reading (With Peak Reading Volt meter) 34 DCV 3. Check component wiring as well as the component for partial shorts to ground to eliminate the draw. Disconnect the stator connectors from the CDI module. Weak or Intermittent Spark GSpark plug gap incorrect GFouled spark plug GFaulty spark plug cap or poor connection to high tension lead GRelated wiring loose.0 mm) GExcessive crankshaft runout on magneto (RH) end . disconnected. Readings obtained without a peak reading adaptor will be significantly different. Connect one meter lead to engine ground and the other to the ignition coil primary wire leading from the CDI module. spark plug installed.3 DCV Exciter 1 Pulse (Trigger) Brown and Yellow Black and Red CURRENT DRAW .should be . Connect an ammeter in series with the negative battery cable.

Start the engine and let it idle. 8. Current Draw Inspection Key Off + YB30L--B -- Ill. Increase engine RPM while observing ammeter and tachometer. Turn the lights on and engage parking brake lock to keep brake light on. Alternator Current Output: Minimum of 7 AC Amps at Idle 10. disconnect the negative cable from the battery post without disturbing the meter leads. Reverse meter leads if a positive reading is indicated. 4. With lights on. Note RPM at which the battery starts to charge (ammeter indication is positive).) and begins to charge the battery. Reading should be a minimum of 7A/AC at idle.7 Amps = 20. CHARGING SYSTEM “BREAK EVEN” TEST CAUTION: Do not allow the battery cable or ammeter to become disconnected with the engine running.ELECTRICAL 5. 6. 9. 7. 2. 1 Current Draw . With lights and other electrical load off. Do not increase idle RPM or perform this test longer than required to obtain a reading.01 DCA (10 mA) ALTERNATOR OUTPUT TEST (AC AMP) This test measures AC amperage from the alternator. the ammeter should read negative amps (battery discharge). Place the red lead on the tester in the 10A jack. The alternator stator windings may overheat. charging should occur at or below 2000 RPM. The “break even” point of the charging system is the point at which the alternator overcomes all system loads (lights. Connect the meter leads to the Yellow and Yellow/Red wires leading from the alternator. Observe meter readings To Calculate Available Alternator Output I = P E 200W 12V 250W 12V I = Current in Amps P = Power in Watts E = Electromotive Force (Volts) = 16. engine.Key Off: Maximum of . With the negative cable still connected to the battery. etc. Repeat test. Do not run test for extended period of time. the break even point may vary slightly. Damage to the meter or meter fuse will result. 5.8 Amps 1. Shift transmission into neutral and start the With the engine running at idle. 2. Follow the steps below as outlined to reduce the chance of damage to electrical components. 4. observing ammeter and tachometer. 3--5 seconds is acceptable. Turn the selector dial to the AC amps (A ) position. The battery should be fully charged before performing this test. With engine off and the key and kill switch in the ON position. DO NOT increase engine RPM above idle. Connect a tachometer according to manufacturer’s instructions. the “break even” point should occur at approximately 1500 RPM or lower. CAUTION: This test simulates a “full load” on the alternator at idle. 3. 1. Depending on battery condition and system load. connect one meter lead (set to DC amps) to the battery post and the other to the negative battery cable 3.16 . WARNING: Never start the engine with the ammeter connected in series. Do not run test with high amperage accessories. Maximum alternator output will be indicated on the meter.

If all of the previous tests indicate a good condition.16. and discuss operating habits. With the transmission in neutral. It should be 12.ELECTRICAL CHARGING SYSTEM TESTING FLOW CHART Whenever charging system problems are suspected.17 .0 and 14. Is it? Yes Meter Setting: DC Volts No Remove the battery and properly service. battery connections. Repair or replace faulty wiring or components. 10. Are they? No Meter Setting: DC Amps Yes Check Key off Current Draw Perform system “Break Even Amperage” test outlined on Page 10. Continued problems would call for battery inspection. perform an Alternator Output (AC amp) test. Is it? Yes No Check regulator/rectifier connections and ground. Battery voltage must be present on red wire terminal on harness side of voltage regulator connector. volts. Inspect the flywheel magnets.16 for procedure. Using a multitester. replace the voltage regulator. Disconnect the Yellow/Red.19). but the charging voltage does not rise above battery voltage at the connector or wire harness.C. Meter Setting: AC Amps Yes Check for owner modification. remove the recoil and flywheel. continue with alternator output test. start the engine and increase RPM to between 3000 and 4000. Reconnect the alternator wires. Reinstall the fully charged battery or a fully charged shop battery. If no damage is found. Using a multitester set on D.4 volts or more. Is output above 5 amps? Yes Meter Setting: DC Volts No Inspect the wiring harness between the panel and the stator for damage. The battery will continually discharge if operated below the “Break Even” RPM.C. proceed with the following system check. circuit breaker and connecting wires. Does charging occur as specified? No Ohm stator wire (Y/YR) If bad replace. if good. See test procedure on Page 10. Readings should increase to between 13. Yellow wires from the regulator/rectifier.6 V D. Repair or replace any damaged components. stator coils and stator wire harness for damage. measure the battery open circuit voltage (See Page 10. Read battery voltage with the multitester. Note: Red wire must be connected to harness.

wash the affected area with large quantities of cool water and seek immediate medical attention. See Battery Installation on Page 10. 4. BATTERY TERMINALS/TERMINAL BOLTS Use Polaris corrosion resistant Nyogelt grease (PN 2871329) on battery bolts. 5. KEEP OUT OF REACH OF CHILDREN. 2. Remove vent plug from vent fitting. flame. Examples: 1/10 of 9 amp battery = . Ventilate when charging or using in an enclosed space.8 amp (recommended charging rates). If battery acid gets on anyone. Batteries produce explosive gases. NOTE: This is the last time that electrolyte should be added. add only distilled water. After initial service. NOTE: Do not service the battery unless it will be put into regular service within 30 days. Remove cell caps. eyes or clothing.270 or higher. 6. Fill battery with electrolyte to upper level marks on case. or vegetable oil. Internal: Drink large quantities of water or milk.ELECTRICAL INITIAL BATTERY ACTIVATION WARNING Battery electrolyte is poisonous. remove the battery and fill with distilled water to the upper level line. Serious burns can result from contact with skin.18 . Check specific gravity of each cell with a hydrometer to assure each has a reading of 1. Inspect the battery fluid level. WARNING:The gases given off by a battery are explosive. 1/10 of 18 amp battery = 1. Keep sparks. To remove the battery: Maintain between upper and lower level marks 1. Eyes: Flush with water for 15 minutes and get prompt medical attention. add only distilled water to the battery. cigarettes. Always shield eyes when working near batteries. 3. Any spark or open flame near a battery can cause an explosion which will spray battery acid on anyone close to it. BATTERY INSPECTION/REMOVAL The battery is located under the seat. Call physician immediately.19. If the level becomes low after this point. Charge battery at 1/10 of its amp/hour rating. away. Set battery aside to allow for acid absorption and stabilization for 30 minutes. etc. It contains sulfuric acid. When the battery fluid nears the lower level. Follow with milk of magnesia. NOTE: New Battery: Battery must be fully charged before use or battery life will be significantly reduced 10-30% of the battery’s full potential. To ensure maximum service life and performance from a new battery. Add electrolyte to bring level back to upper level mark on case. perform the following steps. beaten egg.9 amp. To activate a new battery: 1. 10. Disconnect holder strap and remove cover. Never add electrolyte after a battery has been in service.4 amp. 1/10 of 14 amp battery = 1. Antidote: External: Flush with water.

The vent tube should be routed away from frame and body to prevent contact with electrolyte. CAUTION Whenever removing or reinstalling the battery. Reinstall battery. See charts and Load Test on below.6 volts or less require further battery testing and charging. Remove the filler caps and add distilled water only as needed to bring each cell to the proper level.10 1.ELECTRICAL 2.40V 12. reducing the efficiency and service life of the battery. the electrolyte goes from a heavy (more acidic) state at full charge to a light (more water) state when discharged. Disconnect battery negative (-) (black) cable first. Electrolyte level should be kept between the low and full marks. as severe burns could result. 5. Following are three tests which can easily be made on a battery to determine its condition: OCV Test.025 between the lowest and highest cell readings indicate a need to replace the battery. Do not overfill the battery.30 OPEN CIRCUIT VOLTAGE BATTERY TESTING Whenever a service complaint is related to either the starting or charging systems. or with low electrolyte levels. If not. Corrosion can be removed using a solution of one cup water and one tablespoon baking soda. Clean battery cables and terminals with a stiff wire brush. Route the cables correctly.90V less than 11. Reinstall the battery caps.15 Detail A 1. Readings of 1. the battery should be checked first. Rinse well with clean water and dry thoroughly. hard crystal sulfation will form on the plates.20 1.OPEN CIRCUIT VOLTAGE TEST SPECIFIC GRAVITY TEST A tool such as a Battery Hydrometer (PN 2870836) can be used to measure electrolyte strength or specific gravity. Install clear battery vent tube from vehicle to battery vent. Tap water contains minerals which are harmful to a battery. Avoid skin contact with electrolyte.19 . State of charge 100% Charged 75% Charged 50% Charged 25% Charged 0% Charged Conventional Lead-acid 12.80V YuMicront Type 12. Differences of more than . Do not allow cleaning solution or tap water inside the battery. WARNING: Vent tube must be free from obstructions and kinks and securely installed.0V less than 11. BATTERY INSTALLATION 1. 2. 5. 3. Refill using only distilled water. If the battery is stored or used in a partially charged condition. Coat terminals and bolt threads with Nyogelt Grease (PN 2871329). Reinstall the holder strap. The hydrometer can measure state of charge and differences between cells in a multi-cell battery. attaching positive (+) (red) cable first and then the negative (-) (black) cable. Battery voltage should be checked with a digital multitester. If electrolyte contacts the vehicle frame.270 or greater should be observed in a fully charged battery. Remove the battery. disconnect the negative (black) cable first and reinstall the negative cable last! 3. NOTE: Lead-acid batteries should be kept at or near a full charge as possible.25 1. Battery Hydrometer (PN 2870836) 1.70V 12. followed by the positive (+) (red) cable. battery gases could accumulate and cause an explosion. 4.50V 12.10V 11. Battery life may be reduced. Readings of 12.20V 12. As the battery goes through the charge/discharge cycle. Specific Gravity Test and Load Test.60V 12.9V Contiued on next page 10. corrosion will occur. 4. OCV .

10. After connecting the battery cables. GMake sure that the electrolyte is at the proper level.20 . WARNING To avoid the possibility of explosion. Continue the test for 15 seconds. During cranking the observed voltage should not drop below 9. NOTE: Stored batteries lose their charge at the rate of 1% per day. replace the battery.150 1. To perform this test. For this reason.6 volts or greater. A battery may indicate a full charge condition in the OCV test and the specific gravity test.115 GCharge at a rate no greater than 1/10 of the battery’s amp/hr capacity until the electrolyte’s specific gravity reaches 1. The reading should be 12.160 1. CHARGING PROCEDURE 1. a battery capacity or load test should be conducted whenever poor battery performance is encountered.225 1.120 less than 1. but still may not have the storage capacity necessary to properly function in the electrical system.270 or greater. NOTE: This test can only be performed on machines with electric starters.5 volts during the test.135 less than 1. Remove the battery from the ATV to prevent damage from leaking or spilled acid during charging. 3.100 YuMicront Type 1. The chart below indicates freezing points by specific gravity.175 1. or store in a cool place. GUsing a wire brush or knife. Add distilled water if necessary. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. install the cover on the battery and attach the hold down strap. Dielectric Grease (PN 2871329) 4. remove any corrosion from the cables and terminals. 5.100 1. Install battery in vehicle with positive terminal toward the front. Connect battery cables. Recharge to full capacity every 30 to 60 days during a non-use period.6 volts or higher and the cranking voltage drops below 9. Charge as needed to raise the specific gravity to 1. Coat threads of battery bolt with a corrosion resistant dielectric grease.225 1. OFF SEASON STORAGE To prevent battery damage during extended periods of non-use. This test cannot be performed with an engine or starting system that is not working properly.265 1. Engage the starter and observe the battery voltage while cranking the engine.270 or greater.275 1. electrolyte will freeze at higher temperatures as the battery discharges.5 volts. If the beginning voltage is 12.200 1.ELECTRICAL SPECIFIC GRAVITY State of charge* 100% Charged 75% Charged 50% Charged 25% Charged 0% Charged Conventional lead-acid 1.050 Freezing Point -75° F -35° F -17° F +5° F +18° F +27° F * At 80_F NOTE: Subtract . connect positive (red) cable first and negative (black) cable last.01 from the specific gravity reading at 40_ F.265 1.210 1. GStore the battery either in the machine with the cables disconnected. Rinse with lots of fresh water after cleaning. the following basic battery maintenance items must be performed: GRemove the battery from the machine and wash the case and battery tray with a mild solution of baking soda and water. If the battery is stored during the winter months. Electrolyte Freezing Points Specific Gravity of Electrolyte 1. hook a multitester to the battery in the same manner as was done in the OCV test. NOTE: Do not get any of the baking soda into the battery or the acid will be neutralized. 2. LOAD TEST CAUTION: To prevent shock or component damage. remove spark plug high tension leads and connect securely to engine ground before proceeding.

Unplug speedometer from harness. 7. HEADLIGHT HOUSING REPLACEMENT 2. 2. 3. 1. 3. If not. Push in and turn plastic retainer counter clockwise and remove. Vent should be routed away from frame and body to prevent contact with electrolyte. Unplug headlamp from wiring harness. 4. Remove three Phillips screws on the headlight pod. On machines with separate low beam lights. corrosion will occur.21 . 6. Reverse procedure to install new headlamp bulb. Start the engine and turn the headlight switch to high beam.3 cm) in 25’ from the center of the low beam lamp. Remove rubber shield from headlamp housing. Avoid skin contact with electrolyte. Carefully remove headlamp bulb from housing. Unplug indicator lights from harness and remove pod cover. WARNING: Vent tube must be free from obstructions and kinks and securely installed. 25’ (7. Adjust beam to desired position . HIGH BEAM HEADLIGHT LAMP REPLACEMENT CAUTION: Do not service while headlight is hot. 4. 5.6 m) Lamp Center Height Adjustment Knob Stop Route plug over handlebar 2² (5.6 m) from a wall. Route cables so they are tucked away in front and behind battery. Observe headlight aim. The most intense part of the headlight beam should be aimed 2² (5. Install clear battery vent tube from vehicle to battery vent. 3. Lift pod cover up. 5.1 cm) 1. battery gases could accumulate and cause an explosion. Lift pod cover up. Position knob in slot and secure in locking tabs Snap pins into tabs Slip O-Ring over pin HIGH BEAM HEADLIGHT ADJUSTMENT 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. Serious burns may result. Remove O-Ring from headlight pivot pins. O-Ring 10. If electrolyte contacts the vehicle frame. 4. 1. as severe burns could result. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 2. Place the vehicle on a level surface with the headlight approximately 25’ (7. Protect lamp during install. 7. Unplug headlamp from wiring harness. the drop should be 8² (20.ELECTRICAL 6. Remove three Phillips screws on the headlight pod.1 cm) below the mark placed on the wall in Step 2 NOTE: Rider weight must be included on the seat.

Remove the headlamp and replace with a new headlamp. Reading should be infinite ( ). 2. Remove the front cover. 4. Brown Yellow Headlamp Plug Wires BRAKE LIGHT SWITCH 1. Adjust headlight aim by turning adjusting knob. Pull headlight housing up to release from locking tabs. Reinstall the lens cover removed in step 1. 5 1/8² (13 cm) Distance from headlamp parting line to end of adjustment knob stop is 5 1/8² (13 cm). Turn headlight on. Connect an ohmmeter across switch contacts. 4. 2. Replace 10. Remove lamp and replace it with recommended lamp. Brake Lamp Switch TAILLIGHT/BRAKELIGHT LAMP REPLACEMENT If the taillight/brakelight does not work the lamp may need to be replaced. Disconnect wire harness from switch. 9. Turn the headlight harness counterclockwise to secure the headlamp into place. 3. HEADLAMP SWITCH Remove the headlight pod cover. Probe the headlamp plug wires (Brown and Yellow) at back of connector. 4. Reverse steps to install new housing and reassemble pod. 3. 3. From the rear of the taillight remove two screws holding lens cover in place and remove lens cover. HEADLIGHT HOUSING REPLACMENT CONT’D 5. Lift adjusting knob up to remove from locking tabs. Pull the harness assembly out from the headlight assembly. 6. 7. 8. 2. Carefully pull assembly up and out of pod. Turn the back of the headlight harness in a clockwise direction. Apply brake at handlebar lever and check for continuity between switch contacts. 1. Test the taillight/brakelight to see it is working.ELECTRICAL LOWER HEADLAMP REMOVAL/INSTALLATION Lower Headlamp Lens Cover Turn Harness Assembly to Remove and Install the Headlamp Bulb 1. Install the new headlamp and harness assembly into the headlight assembly. Apply Dielectric Grease (PN 2871329).22 .

Remove the starter from the engine.23 . washers. Inspect O-Rings and replace if damaged.seized or binding (Can engine be rotated easily?) GFaulty or worn brushes in starter motor GAutomatic compression release inoperative 1. Starter Motor Turns .Engine Does Not Rotate GFaulty starter drive GFaulty starter drive gears or starter motor gear GFaulty flywheel gear or loose flywheel VOLTAGE DROP TEST The Voltage Drop Test is used to test for bad connections. the meter when testing connections should not exceed . and sealing O-Rings. Remove the two bolts.seized or binding (Can engine be rotated easily with recoil starter?) STARTER MOTOR DISASSEMBLY NOTE: Use electrical contact cleaner to clean starter motor parts. disconnected. Starter Motor Turns Over Slowly GBattery discharged . starter motor or starter solenoid (see Voltage Drop Tests) GFaulty key switch GFaulty kill switch GFaulty starter solenoid or starter motor.1 VDC per connection or component. When performing the test.1 DC volts per connection STARTER SYSTEM TROUBLESHOOTING Starter Motor Does Not Turn GBattery discharged. you are testing the amount of voltage drop through the connection. Voltage shown on 10. place the meter on DC volts and place the meter leads across the connection to be tested.27 to perform voltage drop tests on the starter system. or corroded GPoor ground connections at battery cable. A poor or corroded connection will appear as a high voltage reading. Some solvents may leave a residue or damage internal parts and insulation. Refer to the chart on 10. 2. GEngine problem .low specific gravity GExcessive circuit resistance . Voltage should not exceed . Low specific gravity GLoose or faulty battery cables or corroded connections (see Voltage Drop Tests) GRelated wiring loose. To perform the test.5 ohms resistance when the brake is applied with slight pressure.ELECTRICAL switch if there is no continuity or greater than .poor connections (see Voltage Drop Test below) GEngine problem .

3 ohms or less.24 . Replace brush assembly when worn to 5/16² (8 mm) or less. BRUSH INSPECTION/REPLACEMENT 1. Remove the front bracket assembly and the rear bracket assembly. Measure resistance between starter input terminal and insulated brushes. Slide brush end frame off end of starter.3 ohms or less. The brushes must slide freely in their holders. 3. pull brushes out of their guides and remove brush plate. Resistance should be . These marks must align during reassembly. (OL). Remember to subtract meter lead resistance. 3.ELECTRICAL NOTE: Note the alignment marks on both ends of the starter motor casing. Slide positive brush springs to the side. O--rings Shims NOTE: The shims will be replaced during reassembly. Limit 5/16² (8mm) Brush Replacement 10. Reading should be infinite. Brush Length 2. Inspection 1. Measure resistance between ground brush and brush plate. NOTE: The electrical input post must stay with the field coil housing. Measure length of each carbon brush. Inspect insulation on brush wires for damage and repair or replace as necessary. Remove the shims from the armature shaft and inspect the O--rings located on the armature housing. 4. The reading should be . Measure resistance between insulated brush and starter housing.

the armature is shorted and must be replaced. Care should be exercised when selecting an appropriate solvent. 10. Remove terminal nut with lock washer. Replace if excessively worn or damaged. Measure the resistance between each commutator segment and the armature shaft. pull brushes out of their guides and remove brush plate. The reading should be . starter must be replaced. Remove armature from starter casing.3 ohms or less. The reading should be infinite (no continuity). 5. large phenolic washer. flat washer. the small phenolic spacers. Inspect surface of commutator. measure the resistance between each of the commutator segments. and sealing O-ring.25 . Check commutator bars for discoloration. 2. If the commutator needs cleaning use only electrical contact cleaner. Turn growler on and position a hacksaw blade or feeler gauge lengthwise 1/8² (. 2. If hacksaw blade is drawn to armature on any pole. 6. 3. Inspect O-ring and replace if damaged. Use care when handling starter housing.3 cm) above armature coil laminates. Using a digital multitester. Cleaning CAUTION: Some cleaning solvents may damage the insulation in the starter. 4. If magnets are damaged. Rotate armature 360°. requiring replacement of the starter motor. Note order of shims on drive end for reassembly. Do not drop or strike the housing as magnet damage is possible.ELECTRICAL 1. Bars discolored in pairs indicate shorted coils. Slide positive brush springs to the side. Place armature in a growler. CAUTION: ARMATURE TESTING 1.

10.6 ohms. connect one meter lead to the Yellow/Red wire and the other to ground. Lightly grease pinion shaft and install pinion. While holding brush springs away from brushes. Inspect seal for wear or damage. spring stopper.ELECTRICAL STARTER REASSEMBLY 1. lock washer. and terminal nut. Align brush plate and install cover and screws. flat washer. Replace drive end cap if necessary. Roller Bearing Seal 6. 4. large phenolic washer.26 . lubricate brush end bushing and install shims. two small phenolic spacers. 2. Dielectric Grease (PN 2871329) 8. STARTER SOLENOID BENCH TEST To measure the resistance of the pull-in coil. Slide armature into field magnet housing. Install brush plate to field magnet housing aligning index tab. Using a non-petroleum grease. Release brushes. Lightly grease the drive roller bearing and reinstall drive end frame on armature.8-3. 3. STARTER REASSEMBLY CONT’D 7. and snap ring. Be sure wire insulation is in place around positive brush wire and pushed completely into slot on phenolic plate. The resistance should be 2. 9. Install O-ring. push brushes back and hold in place. Refer to Electric Starter System Testing in this section to further test the solenoid. 5.

Use a small piece of wire with the end bent in a hook and pick the old spring out of its channel. Screw the overrun clutch off the end of the pinion shaft. 2. Garter Spring Replacement If the garter spring is damaged. thrust washer. Use either of the following methods to remove and install a new garter spring. Slide the new spring over the overrun clutch and into the spring groove. Remove the old spring and install a new one. Spring Cover Stopper Gear Assembly Thrust Washer Bushing Retaining Thrust Ring Washer Polaris Premium Starter Drive Grease (PN 2871460) 1. Remove the retaining ring. the overrun clutch may fail to return properly. spring retainers and clutch return spring.27 . Make sure the end washer is positioned properly so that it will hold the lock ring in its groove. Make sure that the spring is positioned between the shoe alignment pins and the back flange of the anti kick-out shoes. end washer and lock ring in the reverse order. Screw the overrun clutch out to the engaged position on the pinion shaft assembly. Lightly grease the pinion shaft and reinstall the clutch. Slide it off the end of the shaft.Anti Kick-out Shoe. spring. retainers.ELECTRICAL STARTER DRIVE Pinion Gear . 10.

15. 12.ELECTRICAL STARTER ASSEMBLY 11 16 6 2 7* 1* 8 3 1* 15 9 10 17 4 18 12 13 14 15 5* Ref.28 . Description Rubber Ring* Brush Spring Thrust Washer Gear Assembly O-Ring* Brush Complete O-Ring* Thrust Washer Shaft Complete Ref. 8. 3. Replace with new parts. 18. 13. Gear Assembly Though Bolt Cover Stopper Snap Ring Washer Flange Bolt Thrust Washer Flange Bushing Description *Do not reuse. 2. 10. 10. 14. 9. 4. 7. 6. 5. 16. 17. 1. 11.

Depress the starter button.4 V D. With the tester on the VDC position. No Yes Voltage Drop Testing See Page 10.1 V D. Depress starter button. Yes Connect the black tester lead to solenoid end of battery-to-solenoid cable.C.C. Yes If all of these indicate a good condition. Resistance should be 3. Tester should read battery voltage. Check solenoid ground path by measuring resistance between mounting plate and battery negative terminal (-). Depress starter button. Reading should be less than . The reading should be less than . A digital multitester must be used for this test. The voltage on both sides should be the same. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. Install fully charged shop battery to continue test. Yes Connect the black tester lead to the solenoid end of the solenoid-to-starter cable. Turn on ignition switch and depress the starter button. yet the starter still fails to turn. Reading should be less than . place the tester’s black lead on the battery negative and the red lead on the battery positive. Connect the tester black lead to the battery positive and the red lead to the solenoid end of the battery-to-solenoid wire. NOTE: The ignition switch and engine stop switch must be on and the key switch turned to “Start”. ignition switch/engine stop switch and starter button.1 V D. Reconnect the solenoid.1 V D. Connect red tester lead to White/ Red harness wire at solenoid.4W.ELECTRICAL STARTER SYSTEM TESTING FLOW CHART Condition: Starter fails to turn motor. Yes Check voltage on both sides of circuit breaker. Connect tester black wire to battery ground. No Clean the solenoid-to-starter cable ends or replace the cable. No Remove battery and properly service. Disconnect White/Red engagement coil wire from the starter solenoid. No Clean the battery-to-solenoid cable ends or replace the cable. Reading should be 12. Test starter solenoid coil by connecting an ohmmeter between the solenoid red wire and the solenoid mounting plate. Connect the red tester lead to the starter end of the same cable. 10. the starter must be removed for static testing and inspection.23 for instructions. Connect red tester lead to solenoid end of solenoid-to-starter cable. No Replace the starter solenoid. or greater. C. Replace the defective component.29 .C.

30 .ELECTRICAL NOTES 10.

ELECTRICAL WIRING DIAGRAM 2002 SPORTSMAN 700 10.31 .

32 .ELECTRICAL WIRING DIAGRAM 2003 SPORTSMAN 600/700 10.

19 Alternator Output Test. 9.20 Battery Terminal Bolts. 4. 9. Front.3 Brake Pad Removal.9 Carburetor Main System. 9. Rear. 10. 9.26 Brake System Operation. 9. 9.23 Compression Test. Front. Testing. 10.15 Brake Caliper Disassembly.27 Brake Pad Installation. 4. 2. 10. 1. 10.17 Choke Adjustment. Auxiliary. 6. 9.20 Body Assembly Exploded View. 4. 4.6. 10. 3.16 Clutch Offset.11 Carburetor Inspection. 9. Hydraulic. 2. 4.8 Brake Pad Inspection. Front. Front.19. 5. 2. 4.24 A A--Arm Replacement.19 Battery. 10. 4. 9.19 Battery Maintenance.6 Carburetor System Function. 4. 2.16 Brake System Inspection. 9.Numbers 2003 Sportsman 600/700 Models. Rear. Front. 9.16 Combustion Chamber.38 Cam Gear Disassembly . Front. 2.10 Carburetor Operation.5 Carburetor Pilot System. Rear.19 Brake Disc Removal/Replacement.11 Brake Caliper Exploded View. 10. 2.7 Carburetor Exploded View.10 Brake Caliper Removal/Inspection. Front.17 Brake Disc Inspection. 3. 2.14 Carburetor Float Height Adjustment. 10.27 Brake. 9.20 Breather Hose Inspection.27 Brakelight Lamp Replacement. 3. 3. 4. 4. Rear.14 Controls Inspection. Rear.2 Carburetor Float Bowl Draining.9.28 . 2.16 Charging System Testing. 9.7 Carburetor Needle and Seat Testing. 5.9 Brake Disc Inspection. Rear.3 Brake Bleeding/Fluid Change. 9. 10. 9.15.15 Battery Service.7 Carburetor Fuel Level Testing.16 Brake Pad Removal.6 Carburetor Starter System. 3.37 Cam Gear Removal. 2. BST34.9 Air Filter Service.16 B Battery Charging.10 Carburetor Float System.20 Battery Installation. 2. 4.22 Brake Master Cylinder Exploded View.22 Breather Filter Maintenance. 9. 9. 10.11 Clutch Alignment. 4. 10. 2. 9. 9. Front. Front.10 Brake Fluid Level.5 CDI Output Test. 4.4 Brake. 9.15 Charging System Break Even Test.12 Brake Caliper Installation.13 Brake Caliper Removal. 10. 4. 6.14 Brake Caliper Exploded View. 2. 9. Auxiliary.9 Carburetor Disassembly. 2. 2. 2.3 Brake Pad Assembly. 10.27 Brake Light Switch Testing.20 Brake Caliper Inspection.5.18. 9.37 Camber & Caster. 10.8. 10.23 Camshaft Inspection.20 Brake Noise.20 Brush Replacement.8 C Cam Gear Assembly.18 Battery Testing. Off Season Storage.26 Brake Hose/Fitting Inspection.44 Carburetor Assembly. Starter Motor.

10.12.17 Engine Removal.21 Cylinder Head Assembly. 9.13 Exhaust System.8 Cranking Output Test. 3.2 E EBS Drive Clutch Bushing Service. 6.15 Engine Serial Number Location. 7. 3. 3.4. 6.15 Current Draw. 3. 3.7 Engine Bottom End Disassembly. 3.17 Cooling System Overview . 6.20. Sportsman 700.2.14 Diagnostic Mode. 6. 3. 3. 6.13 Drive Clutch Exploded View. 6.4.2 Engine Service Data.12 Fan Control Switch Testing.23 Cylinder Head Removal. 2.29.13 Fan Motor Current Draw Test. 10. 10.18.19. 3.17 Coolant Temperature Sensor. 6. 3.12 Fan Control Switch Bypass Test. Maintenance. 3. 3.22 EBS Driven Clutch Disassembly. 10.12 Decimal Equivalent Chart.37 Engine Lower Reassembly.4 Drive Shaft Boot Replacement.15 CV Joint Handling Tips. 10. 3.13 Engine to Frame Ground.12.11.21 Cylinder Head Inspection.29 Front Axle Exploded View.19. 10.3 Engine Accessible Components. 3.18 EBS One Way Driven Clutch Inspection.4. 10. 1. 2002.27.29 EBS Driven Clutch Bushing Service.6 Engine Eploded View.58 Engine Fastener Torque Patterns. 3.44 Engine Break in Period. 2.12 Flywheel Identification.26 D Decal Replacement.20 EBS Exploded View. 3. 6.26 Cylinder Head Warpage. 6.16 Engine Top End Disassembly.13 ETC Switch Adjustment.14 Drive Clutch Disassembly.26 ETC Operation Test. 6. Fasteners. 10.3 Electrical Special tools.11 Drive Clutch Operation. 3.20 Cylinder Honing.16 Drive Belt Removal/Inspection. 10.11 Engine Service Data. 600 Engine. 3. 3. 2. 6.5 Dual Hydraulic Caliper Bleeding. 10.18 EBS One Way Drive Clutch Inspection. 3. 6. 10.25 Cylinder Head Disassembly.18 Coolant Strength. 3.6 Drive Belt Installation.17 Cooling System Test.12 ETC Switch Testing. 6. 2.22.17.17 .18 Electrical Service Notes. 6. 5.45 Engine Lubrication. 6.9 Engine Head Assembly. 6. 3. 2. 3. 3. 3.28 Engine Lower Disassembly/Inspection. 1.30.2 Drive Clutch Inspection.4 F Fan Control Circuit Testing. 3. 6. 3. 5.17 Cylinder Inspection. 6.36. 10.17 Cover/Panel Removal.12 Cooling System Hoses. 1.5.20 Cylinder Head Reconditioning.32 Engine Bottom End Disassembly/Inspection. 7. 6. 10.30 Cylinder Removal/Inspection. 3.10. 3. 6. 3. 6. 3. 3. 10. 2.3. 3. 3.5 Driven Clutch Operation. Bolts. 3. 2.2 Frame.3 EBS Moveable Sheave Bushing Inspection. 700 Engine. 2.16 Engine Designation Numbers. 3. 3. 3.20 EBS Drive Clutch Inspection. 7.14 Drive Clutch Assembly. 6.Coolant Level Inspection . 2.2 Engine Exploded View. Nuts.5. 7.13.

22 Headlight Adjustment. 10. 10.8 Lubrication.3 Master Cylinder Installation. Rear .12 Gearcase Coil Resistance. 2. 3. 2.6 Model & Serial Number Location.16 Gearcase Exploded View.21 High Engine Coolant Temperature. 10.5 Hub Installation.Front Axle Installation.5 O Oil Check . Replacement. Recommended. Rear .7 Master Cylinder Removal. Front.14 Fuel Pump Service. 2. 9.15 Gearcase Installation. 7. 4.51 Maintenance Chart.12 Ignition System Components. 1. 9. 2. 10. Rear .18 J Jetting Guidelines.Centralized Hilliard.18 Hub Removal. 7.21. 7.10 Gearcase Diagnosis -. 10.13 Fuel Tank Assembly. 8. 7. Rear. 2. Front.10 Gearcase Disassembly.2 Ignition System Testing.14 Gearcase Disassembly.12 L Load Test.4 Gearcase Assembly.26 Gearcase Assembly/Inspection.11 Fuel Filter Maintenance. 2. 10. 10.28 Gearcase Installation. 5.4 K Keys. Front. 7. 2. 4. 2. 8.20 Low Oil Pressure.9 Gearcase Operation (4X4). 3. 10. 10.17. 10.25 Gearcase Exploded View.5 Mag Cover Seal Replacement. 7. 2. Front. Periodic.4 Front Axle Removal.14 Ignition Timing Curve. 7.7. 2. Rear . 7. 1.2.4 Lubrication Charts. 7.2 Model Identification. 7.11 Fuel System.5 G Gear Position Switch Test.22 Headlamp Switch Testing. 1. 7.8 Gearcase Removal.6 Front Strut Assembly. Engine.3 High/Low Battery Voltage. 7.21 . 7.5 Honing to Oversize. 1. 7. Exploded View.9 Gearcase Removal.5 Lubricants. Transmission. 7. Front.17 Hour Meter. 7. 7. 4.10.3 Front Prop Shaft Removal. 5.5 Lubricants. 7. Rear. 10.24 Glossary of Terms.4.17 I Idle Speed Adjustment. 10.2 H Headlamp Service. 7. 10. Front. 2.4 M Machine Dimensions. 1. 2.4 Instrument Cluster Troubleshooting. 7.3 Front Hub Assembly. Front. Rear . 1. Front. 7. 10.24 Gearcase Lubrication.4 Gear Shift Selector Removal.6 Front Hub Disassembly. 1.6 Front Hub Inspection. Front/Rear.7 Front Strut Ball Joint Replacement.

10. 3.34 Piston to Cylinder Clearance.11 Specifications. 2.4 Specifications.12 Push Rod Inspection.8 PVT Disassembly.4. 2.21 Oil Flow. 6. 2.7. 5. 10. 3.3. 10. 6.9 Piston Removal.9 Spark Plug Maintenance. Rear . 7. 7.33. 2. 10. Torque.9 Specifications.9. 3.5 Programmable Service Interval.20 Hub Disassembly. 6.29 P Paint Codes. 1. 6. 2. 10. Torque.10.29 Piston Ring Installed Gap. Suspension.4 Speedometer Installation. Torque. PVT. Torque. 10. 7.20. 3. 10. 3. 5.8 Specifications. 10.31 Piston/Rod Inspection. Torque.6 . 6. Final Drive. 1.19 PVT Assembly.16 Special Tools. 6. Engine.10 Side Panel Removal.18 Oil Pressure Test.7 PVT Drying. 3.26 Starter System Test.6 Publication Numbers. PVT.8. Maintenance. 10. Rear .18 Radiator. 10.7 Special Tools. 5. 5.19 Shift Linkage Adjustment.12 Speedometer Removal. 6.10.17 Rocker Arm Inspection. Standard. 2.33 Starter Motor Armature Testing. 9. Cooling System.19 S Sediment Tube.28 Starter Disassembly.5.18 Radiator Front Cover Removal. 3.21 Rear Drive Shaft Removal.2 PVT Troubleshooting. 9.23 Starter Drive. 10.25 Starter Motor Brush Inspection/Replacement. 10.8.8 Specifications. Drive Clutch Spring. 6.19 Rear Suspension Exploded View.22 Hub Assembly.2 Special Tools. 2. 10.24. Brake.7 Speedometer/Odometer. 10. 8.24 Starter Motor Cleaning. Torque. 10. Model. 3. 1. 3. 2.8 Specifications. 3.13 Specifications. 10. Brakes. 10. 10.3 Progammable Service Interval. Steering.11 Shift Weights.4 Specifications. 1. Transmission. 3. 1. 6.4 PVT Overheating. 6. CH 3.3 Specifications. 1.26. 6. 1.12 Starter Assembly. 7. 7. 7.25 Starter Solenoid Bench Test.7 Speedometer Troubleshooting. 10. 3.18 Rear Drive Shaft Installation. 6.6. 7.17 Rear Caliper Assembly.5 PVT Operation.9.11.25 R Radiator Coolant Level Inspection.12 Piston Identification. 9.12 Pilot Screw Adjustment. 3. 6. 2.20 Rear Drive Shaft Service. Torque. Torque.32 Pre-Ride Inspection. Maintenance. 2. 1.5 Spider Removal. 10.Oil Filter Change. 3.6 PVT System Sealing/Ducting Components.27 Starter Drive Removal/Inspection.14 Specifications. 1.5 PVT Maintenance. 6. 9. 4. 2.2 Specifications.6.2 Specifications.

12 V Valve Inspection. 3.7 Unit of Measure Conversion Table. 2. 8. Ignition System.10. 8. Brakes. Rear. 2. 10. 8.23 U U--Joint Assembly. 2003. 10.4 Tire Inspection. 8. 8. 4. Exploded View.23 Timing Check Procedure. 3. 3. 8.28 Wiring Diagram. 1. Engine. 2.16 Throttle Cable Adjustment. 3.29 Tire Tread Depth.6 Water/Oil Pump Removal. 2. 8. 3.2 Transmission Installation. 7.28 Suspension. Engine. Inspection.22 Steering Post Assembly. 2. 2. 3.11 Tie Rod Inspection. 8.29 Tire Pressure.15 Transmission Removal.41 Wheel Inspection. 1. 8. Sportsman 700. 8. 3. 8. 2.23 Voltage Test Open Circuit.5 Transmission. 10. 2. 8.3 Trigger Coil Gap. 10. Fuel System/Carb.28 Wheel Installation. 3. 3. Inspection.6.31 Wiring Diagram. 2.11. 10.56.28 Wheel. 8.12 Throttle Operation.26 Valve Seat Inspection.57 Troubleshooting. 2.23.25 Torque Patterns.5. 3.22 Tap Drill Chart. 2. 1.13.15 Troubleshooting.14 VIN Identification.7. 3.10 Suspension Preload Adjustment. 2002.D.2 Voltage Drop Test.14.19 W Warning Indications for Rider Information Center. Starter System.19 Troubleshooting.15 T Taillight Lamp Replacement. 10. 2.32 . Front. 10.4 Troubleshooting. 10. 2. 5.22 Valve Lifter Removal/Inspection. Location.7 U--Joint Disassembly. 8.9 Transmission Disassembly.23 Valve Seat Reconditioning.12.28 Troubleshooting.56 Troubleshooting.29 Wheel Removal Front or Rear. 8.5 Transmission Reassembly. 10.2. Cooling System. 3. 9. 8. 2.29 Valve Seal Testing.35 Steering Maintenance. 7. Sportsman 600/700.34. 10. 3. 1. 3.3.11 Transmission I.57 Troubleshooting.4.28 Suspension.9. Spindle Torque.29 Toe Alignment.Stator Removal/Inspection.25 Vent Line Maintenance. 2. 3. Spark Plug. 10. 2.24. 8. Hub.8.

PN 9918066 Printed in USA .

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