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GENERAL INFORMATION

CHAPTER 1
GENERAL INFORMATION
1
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2007 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2007 HAWKEYE 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2007 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MODEL: 2007 HAWKEYE 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

VEHICLE IDENTIFICATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.

Machine Model Number Identification


A 0 7 LB 27 AA
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Year Designation Emissions &


Model Option
Basic Chassis
Designation Engine Designation

Engine Designation Number


ES30PFESingle, Air Cooled, SOHC 4 Stroke, Electric Start

1.1
GENERAL INFORMATION
Vehicle Identification Number (VIN)
World
Mfg. ID
Vehicle Descriptor Vehicle Identifier
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A L H 2 7 A * 5 P 0 0 0 0 0 0

}
Engine Model
Year Individual Serial Number
Body Style
Emissions Plant No
Powertrain * This could be either
Check Digit a number or a letter

Vehicle and Engine Serial Number Locations


Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be
found on the sticker applied to the recoil housing on the right side of engine. An additional number is stamped on the center top of
the crankcase beneath the cylinder.
The machine serial number (1- lower frame rail) and engine number (2- right side engine) are important for vehicle identification.

1.2
GENERAL INFORMATION
SPECIFICATIONS
MODEL: 2007 HAWKEYE 2x4
1
MODEL NUMBER: . . . . . . . . .A07LB27AA, A07LB27AC
A07LB27FA (International)
ENGINE MODEL: . . . . . . . . . .ES30PFE
Category Dimension
Length 74 in./188 cm
Width 42 in./107 cm
Height 45.5 in./116 cm
Wheel Base 46 in./117 cm
Ground Clearance 8 in./20.3 cm
Dry Weight 525 lbs./238 kg
Gross Vehicle Weight 930 lbs./422 kg
Front Rack Capacity 70 lbs./31.75 kg
Rear Rack Capacity 100 lbs./45 kg
Towing Capacity 750 lbs./340 kg
Hitch Tongue Weight 75 lbs./34 kg
Body Style Recreational/Utility

MODEL: 2007 HAWKEYE 4x4


MODEL NUMBER: . . . . . . . . .A07LH27AA, A07LH27AB, A07LH27AC, A07LH27AD
A07LH27FA (International)
ENGINE MODEL: . . . . . . . . . .ES30PFE
Category Dimension
Length 74 in./188 cm
Width 42 in./107 cm
Height 45.5 in./116 cm
Wheel Base 46 in./117 cm
Ground Clearance 8 in./20.3 cm
Dry Weight 550 lbs./250 kg
Gross Vehicle Weight 930 lbs./422 kg
Front Rack Capacity 70 lbs./31.75 kg
Rear Rack Capacity 100 lbs./45 kg
Towing Capacity 750 lbs./340 kg
Hitch Tongue Weight 75 lbs./34 kg
Body Style Recreational/Utility

1.3
GENERAL INFORMATION
MODEL: 2007 HAWKEYE 2x4 Drivetrain
Transmission Type H-N-R
MODEL NUMBER: A07LB27
ENGINE MODEL: ES30PFE Transmission Capacity Level with fill plug
Gear Ratio : Foward 15.18:1
Engine Reverse 14.05:1
Platform Fuji 4 stroke, Single Cylinder Clutch Type CVT w/EBS
Engine Model Number ES300PFE010 Belt 3211108
Engine Displacement 299cc
Steering / Suspension
Number of Cylinders 1
Front Suspension / Shock Mac Pherson Strut
Bore & Stroke (mm) 78.5 x 68 mm
Front Travel 7 in. / 17.8 cm
Compression Ratio 9.2:1 Full Stroke
Rear Suspension Independent
Compression Pressure 120-140 psi Style / Shock Coil-over Adjustable
Engine Idle Speed 1400 RPM Rear Travel 8 in. / 20.3 cm
Cooling System/Capacity Air/Oil Cooled Ground Clearance 8 in. / 20.3 cm
Overheat Warning None Shock Preload Adjustment Front - Cam
Lubrication Wet Sump Front / Rear Rear - Cam

Oil Requirements Polaris 0W-50 / 1.7 qts (1.6L) Turning Radius 62.5 in. (159 cm) unloaded

Exhaust System Single Pipe - USFS Approved Toe Out 0-1/16 in. (0-.159 mm)
Carburetion Wheels / Brakes
Carburetor model Mikuni BST 34mm Tire/Rim Size - Front 22 x 7-12
Main Jet 140 Tire/Rim Size - Rear 22 x 10-12
Pilot Jet 45 Air Press. F/R Tires 3-5 psi
Jet Needle 4HC57-3 Brake - Front Single Control Hydraulic Disc
Needle Jet 05-m Brake - Rear Single Control Hydraulic Disc

Pilot/Air Screw 2.5 Turns Out (Initial setting) Brake Fluid Polaris DOT 3 or 4 Brake Fluid

Float Height 13mm from carburetor body JETTING CHART


Fuel Delivery Fuel Pump AMBIENT TEMPERATURE
Altitude Below 40oo F Above +40oo F
Fuel Capacity / 4.5 gal. (17 L) Below 5 C Above +5 C
Requirement 87 Octane (minimum) 0-1800 145 140
89 Oxygenated Meters (0-6000)
(Feet) 1800-3700 140 135
Electrical (6000-12000)
Alternator Output 250 watt / 18.6 Amp @ 6000
CLUTCH CHART
Voltage Regulator 3-phase
Lights : High Beam -- Altitude Shift Weight Number Installed
Low Beam 37.5 watts 0-5000 13 g
(0-1534) 8
5412988
Brake 12V / 26.9 watts
Feet 5000-10,000 10 g
Tail 12V / 8.26 watts 8
(Meters) (1534 - 3048) 5412986
Ignition System DC CDI 10,000 + 10 g
6
Ignition Timing BTDC 30°+/-2 @ 5000 RPM (3048 +) 5412986

Spark plug / Gap NGK CR8EB Note: Remove opposite rollers to retain proper clutch balance
.031 in. / .8 mm
Battery / Model / Amp Hr Conventional 14 Amp/hr
Circuit Breakers Fusible Link / 15 amp Main / 15 Amp Accsy

Starting Electric / Recoil Back-up


Indicator Panel LCD / Indicator lights

1.4
GENERAL INFORMATION
MODEL: 2007 HAWKEYE 4x4 Drivetrain

MODEL NUMBER: A07LH27 Transmission Type H-N-R 1


ENGINE MODEL: ES30PFE Transmission Capacity Level with fill plug
Front Gearcase Capacity Level with fill plug
Engine
Platform Fuji 4 stroke, Single Cylinder Gear Ratio : Front Output Fwd 5.17:1 / Rev 4.79:1
Rear Output Fwd 15.18:1 / Rev 14.05:1
Engine Model Number ES300PFE010 Clutch Type CVT w/EBS
Engine Displacement 299cc
Belt 3211108
Number of Cylinders 1
Steering / Suspension
Bore & Stroke (mm) 78.5 x 68 mm
Front Suspension / Shock Mac Pherson Strut
Compression Ratio 9.2:1 Full Stroke
Front Travel 7 in. / 17.8 cm
Compression Pressure 120-140 psi
Rear Suspension Independent
Engine Idle Speed 1400 RPM Style / Shock Coil-over Adjustable
Cooling System/Capacity Air/Oil Cooled Rear Travel 8 in. / 20.3 cm
Overheat Warning None Ground Clearance 8 in. / 20.3 cm
Lubrication Wet Sump Shock Preload Adjustment Front - Cam
Oil Requirements Polaris 0W-50 / 1.7 qts (1.6L) Front / Rear Rear - Cam

Exhaust System Single Pipe - USFS Approved Turning Radius 62.5 in. (159 cm) unloaded
Carburetion Toe Out 0-1/16 in. (0-.159 mm)
Carburetor model Mikuni BST 34mm Wheels / Brakes
Main Jet 140 Tire/Rim Size - Front 22 x 7-12
Pilot Jet 45 Tire/Rim Size - Rear 22 x 10-12
Jet Needle 4HC57-3 Air Press. F/R Tires 3-5 psi
Needle Jet 05-m Brake - Front Single Control Hydraulic Disc

Pilot/Air Screw 2.5 Turns Out (Initial setting) Brake - Rear Single Control Hydraulic Disc
Brake Fluid Polaris DOT 3 or 4 Brake Fluid
Float Height 13mm from carburetor body
Fuel Delivery Fuel Pump JETTING CHART
Fuel Capacity / 4.5 gal. (17 L) AMBIENT TEMPERATURE
Requirement 87 Octane (minimum) Altitude Below 40oo F Above +40oo F
89 Oxygenated Below 5 C Above +5 C
0-1800 145 140
Electrical Meters (0-6000)
(Feet) 1800-3700 140 135
Alternator Output 250 watt / 18.6 Amp @ 6000 (6000-12000)
Voltage Regulator 3-phase
CLUTCH CHART
Lights : High Beam --
Low Beam 37.5 watts Altitude Shift Weight Number Installed
Brake 12V / 26.9 watts 0-5000 13 g
(0-1534) 8
Tail 12V / 8.26 watts 5412988

Ignition System DC CDI Feet 5000-10,000 10 g


8
(Meters) (1534 - 3048) 5412986
Ignition Timing BTDC 30°+/-2deg. @ 5000 RPM
10,000 + 10 g
NGK CR8EB 6
Spark plug / Gap (3048 +) 5412986
.031 in. / .8 mm
Note: Remove opposite rollers to retain proper clutch balance
Battery / Model / Amp Hr Conventional 14 Amp/hr
Circuit Breakers Fusible Link / 15 amp Main / 15 Amp Accsy

Starting Electric / Recoil Back-up


Indicator Panel LCD / Indicator lights

1.5
GENERAL INFORMATION

GENERAL INFORMATION
Publication Numbers

Year Model Model No. Owner’s Manual Parts Manual


PN PN

2007 Hawkeye 2x4 A07LB27AA, AC 9920787 9920789

2007 Hawkeye 4x4 A07LH27AA, AB, 9920787 9920789


AC, AD

2007 Hawkeye 2x4 Intl’ A07LB27FB 9920788 9920790

2007 Hawkeye 4x4 Intl’ A07LH27FA 9920788 9920790

NOTE: When ordering service parts, be sure to use the correct parts manual.

NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com or purchased from
www.purepolaris.com.

Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key
and refer to the chart to for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is
necessary.
Series # Part Number
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278

1.6
GENERAL INFORMATION
Standard Torque Specifications
The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS, refer to the
1
exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8


Torque in. lbs. (Nm)
#10 - 24 . . . . . . . . . . . . . . . . . 27 (3.1) . . . . . . . . . 43 (5.0) . . . . . . . . .60 (6.9)
#10 - 32 . . . . . . . . . . . . . . . . . 31 (3.6) . . . . . . . . . 49 (5.6) . . . . . . . . .68 (7.8)
Torque ft. lbs. (Nm)*
1/4 - 20 . . . . . . . . . . . . . . . . . 5 (7) . . . . . . . . . . . . 8 (11) . . . . . . . . . . .12 (16)
1/4 - 28 . . . . . . . . . . . . . . . . . 6 (8) . . . . . . . . . . . . 10 (14). . . . . . . . . .14 (19)
5/16 - 18 . . . . . . . . . . . . . . . . . 11(15) . . . . . . . . . . 17 (23). . . . . . . . . .25 (35)
5/16 - 24 . . . . . . . . . . . . . . . . . 12(16) . . . . . . . . . . 19 (26). . . . . . . . . .29 (40)
3/8 - 16 . . . . . . . . . . . . . . . . . 20(27) . . . . . . . . . . 30 (40). . . . . . . . . .45 (62)
3/8 - 24 . . . . . . . . . . . . . . . . . 23(32) . . . . . . . . . . 35 (48). . . . . . . . . .50 (69)
7/16 - 14 . . . . . . . . . . . . . . . . . 30(40) . . . . . . . . . . 50 (69). . . . . . . . . .70 (97)
7/16 - 20 . . . . . . . . . . . . . . . . . 35(48) . . . . . . . . . . 55 (76). . . . . . . . . .80 (110)
1/2 - 13 . . . . . . . . . . . . . . . . . 50(69) . . . . . . . . . . 75 (104). . . . . . . . .110 (152)
1/2 - 20 . . . . . . . . . . . . . . . . . 55(76) . . . . . . . . . . 90 (124). . . . . . . . .120 (166)

Metric / Torque
6 x 1.0. . . . . . . . . . 72-78 In.lbs. . . . . . . . . .8 x 1.25 14-18 ft.lbs . . . . 10 x 1.25 26-30 ft.lbs.

1.7
GENERAL INFORMATION
Sae Tap Drill Sizes Decimal Equivalents
Thread Size/ Drill Size Thread Size / Drill Size 1/64 ................. .0156
1/32 . . . . . . . . . . . . . .0312. . . 1 mm= .0394"
#0-80 3/64 1/2-13 27/64 3/64 ................. .0469
#1-64 53 1/2-20 29/64 1/16 . . . . . . . . . . . . . .0625
#1-72 53 9/16-12 31/64 5/64 ................. .0781. . . 2 mm = .0787"
3/32 . . . . . . . . . . . . . .0938
#2-56 51 9/16-18 33/64 7/64 ................. .1094. . . 3 mm =.1181"
#2-64 50 5/8-11 17/32 1/8 . . . . . . . .1250
#3-48 5/64 5/8-18 37/64 9/64 ................. .1406
5/32 . . . . . . . . . . . . . .1563. . . 4 mm = .1575"
#3-56 45 3/4-10 21/32 11/64 ................. .1719
#4-40 43 3/4-16 11/16 3/16 . . . . . . . . . . . . . .1875. . . 5mm= .1969"
13/64 ................. .2031
#4-48 42 7/8-9 49/64
7/32 . . . . . . . . . . . . . .2188
#5-40 38 7/8-14 13/16 15/64 ................. .2344. . . 6 mm = .2362"
#5-44 37 1-8 7/8 1/4 . . . . . . . .25
17/64 ................. .2656. . . 7 mm = .2756"
#6-32 36 1-12 59/64 9/32 . . . . . . . . . . . . . .2813
#6-40 33 1 1/8-7 63/64 19/64 ................. .2969
#8-32 29 1 1/8-12 1 3/64 5/16 . . . . . . . . . . . . . .3125. . . 8mm= .3150"
21/64 ................. .3281
#8-36 29 1 1/4-7 1 7/64 11/32 . . . . . . . . . . . . .3438. . . 9 mm = .3543"
#10-24 24 1 1/4-12 1 11/64 23/64 ................. .3594
#10-32 21 1 1/2-6 1 11/32 3/8 . . . . . . . .375
25/64 ................. .3906. . . 10 mm = .3937"
#12-24 17 1 1/2-12 1 27/64 13/32 . . . . . . . . . . . . .4063
#12-28 4.6mm 1 3/4-5 1 9/16 27/64 ................. .4219. . . 11 mm =.4331"
1/4-20 7 1 3/4-12 1 43/64 7/16 . . . . . . . . . . . . . .4375
29/64 ................. .4531
1/4-28 3 2-4 1/2 1 25/32 15/32 . . . . . . . . . . . . .4688. . . 12 mm = .4724"
5/16-18 F 2-12 1 59/64 31/64 ................. .4844
1/2 . . . . . . . .5 ..... . . . . . . . 13mm = .5118"
5/16-24 I 2 1/4-4 1/2 2 1/32
33/64 ................. .5156
3/8-16 O 2 1/2-4 2 1/4 17/32 . . . . . . . . . . . . .5313
3/8-24 Q 2 3/4-4 2 1/2 35/64 ................. .5469. . . 14 mm = .5512"
9/16 . . . . . . . . . . . . . .5625
7/16-14 U 3-4 2 3/4 37/64 ................. .5781. . . 15 mm = .5906"
7/16-20 25/64 19/32 . . . . . . . . . . . . .5938
39/64 ................. .6094
Metric Tap Drill Sizes 5/8 . . . . . . . .625 ... . . . . . . . 16mm=. 6299"
41/64 ................. .6406
21/32 . . . . . . . . . . . . .6563. . . 17 mm =.6693"
Tap Size Drill Size Decimal Nearest 43/64 ................. .6719
Equivalent Fraction 11/16 . . . . . . . . . . . . .6875
3x.50 #39 0.0995 3/32 45/64 ................. .7031. . . 18 mm = .7087"
3x.60 3/32 0.0937 3/32 23/32 . . . . . . . . . . . . .7188
47/64 ................. .7344. . . 19 mm = .7480"
4x.70 #30 0.1285 1/8 3/4 . . . . . . . .75
4x.75 1/8 0.125 1/8 49/64 ................. .7656
5x.80 #19 0.166 11/64 25/32 . . . . . . . . . . . . .7813. . . 20 mm = .7874"
51/64 ................. .7969
5x.90 #20 0.161 5/32 13/16 . . . . . . . . . . . . .8125. . . 21 mm =.8268"
6x1.00 #9 0.196 13/64 53/64 ................. .8281
27/32 . . . . . . . . . . . . .8438
7x1.00 16/64 0.234 15/64 55/64 ................. .8594. . . 22 mm = .8661"
8x1.00 J 0.277 9/32 7/8 . . . . . . . .875
8x1.25 17/64 0.265 17/64 57/64 ................. .8906. . . 23 mm = .9055"
29/32 . . . . . . . . . . . . .9063
9x1.00 5/16 0.3125 5/16 59/64 ................. .9219
9x1.25 5/16 0.3125 5/16 15/16 . . . . . . . . . . . . .9375. . . 24 mm = .9449"
10x1.25 11/32 0.3437 11/32 61/64 ................. .9531
31/32 . . . . . . . . . . . . .9688. . . 25 mm = .9843"
10x1.50 R 0.339 11/32 63/64 ................. .9844
11x1.50 3/8 0.375 3/8 1 . . . . . . . . . 1.0
12x1.50 13/32 0.406 13/32
12x1.75 13/32 0.406 13/32

1.8
GENERAL INFORMATION
Conversion Table

Unit of Measure Multiplied by Converts to


1
ft. lbs. x 12 = in. lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.356 = Nm
in. lbs. x .0115 = kg-m
Nm x .7376 = ft. lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 = in. lbs.
kg-m x 10 = Nm
in. x 25.4 =mm
mm x .03937 = in.
in. x 2.54 = cm
mile (mi.) x 1.6 = km
km x .6214 = mile (mi.)
Ounces (oz.) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x 0.035 = Ounces (oz.)
lb. x .454 = kg
kg x 2.2046 = lb.
Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in)
Imperial pints (Imp pt.) x 0.568 = Liters (l)
Liters (l) x 1.76 = Imperial pints (Imp pt.)
Imperial quarts (Imp qt.) x 1.137 = Liters (l)
Liters (l) x 0.88 = Imperial quarts (Imp qt.)
Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.)
US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.)
US quarts (US qt.) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt.)
US gallons (US gal) x 3.785 =Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x 0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)
π(3.14)xR x H (height)
2
= Cylinder Volume

°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F


°F to °C: 5 (°F + 40) ÷ 9 - 40 = °C

1.9
GENERAL INFORMATION
Glossary Of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches.
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and
grip the drive belt.
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. Measure at various points especially at PTO.
CVT: Centrifugal Variable Transmission (Drive Clutch System)
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore.
Electrical Open: Open circuit. An electrical circuit which isn't complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching
the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm2: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in2: Pounds per square inch.
Left or Right Side: Always referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy
is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040".
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.

1.10
MAINTENANCE
CHAPTER 2
MAINTENANCE
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2
LUBRICANTS / FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS. . . . . . . . . . . . . 2.6
POLARIS LUBRICANT SYMBOL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
VEHICLE INSPECTION / MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
HAWKEYE HANDLEBAR COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
FRONT GEARCASE LUBRICATION (4X4 ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
LUBRICATION / GREASE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
THROTTLE OPERATION - ALL MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
CHOKE (ENRICHER) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
PILOT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
PILOT SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
ELECTRONIC THROTTLE CONTROL / THROTTLE CABLE ADJUSTMENT . . . . . . . 2.12
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
ENGINE FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
MAIN AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
AIR FILTER/PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
AIR BOX SEDIMENT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
CVT DRAIN PLUG & DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
TIE ROD END/STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
TOE ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
TOE ALIGNMENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
EXHAUST CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
BRAKE SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
HOSE/FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
BRAKE FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
SUSPENSION SPRING FRONT / REAR PRELOAD ADJUSTMENT. . . . . . . . . . . . . . 2.22
FRONT SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
REAR SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
WHEEL REMOVAL/INSTALLATION- FRONT OR REAR . . . . . . . . . . . . . . . . . . . . . . . 2.22
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

2.1
MAINTENANCE
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubri-
cation of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genu-
ine Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately
10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition:
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use
and determine the cause or see your dealer.

Maintenance Chart Key


The following symbols denote potential items to be aware of during maintenance:
= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.
= SEVERE USE ITEM: If vehicle is subjected to severe use, decrease interval by 50%
(Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm
use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is required
under these conditions. Fluid changes, cable, chain and chassis lubrication are required more frequently. For
engine oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A rising
oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil imme-
diately and monitor level. If oil level begins to rise, discontinue use and determine cause.)
E= Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING

Improperly performing the procedures marked with


a could result in component failure and lead to
serious injury or death. Have an authorized Polaris
dealer perform these services.

2.2
MAINTENANCE
Maintenance And Lubrication
Periodic Maintenance Chart

Item Maintenance Interval Remarks


(whichever comes first)
Hours Calendar Miles
(KM) 2
Steering - Pre-Ride - Check for free operation.
 Front-suspension - Pre-Ride - Make adjustments as needed. See Pre-
 Rear-suspension - Pre-Ride - Ride Checklist on Page 2.8.
Tires - Pre-Ride -
Engine Stop Switch - Check Operation
Make adjustments as needed. See Pre-
 Brake fluid level - Pre-Ride -
Ride Checklist on Page 2.8
 Brake lever travel - Pre-Ride - Make adjustments as needed. See Pre-
Brake systems - Pre-Ride - Ride Checklist on Page 2.8
Throttle - Pre-Ride - Check Operation
Wheels /fasteners - Pre-Ride - Make adjustments as needed. See Pre-
Frame Fasteners - Pre-Ride - Ride Checklist on Page 2.8
 Engine oil level - Pre-Ride -
Make adjustments as needed. See Pre-
E Ride Checklist on Page 2.8
 Air filter, pre-filter - Daily - Inspect;clean often
E
 Air box sediment tube - Daily - Drain deposits when visible
E
Coolant Check level daily, change coolant every 2
- Daily -
(if applicable) years
Check operation; apply dielectric grease if
Headlamp/tail lamp - Daily -
replacing
 Air filter, - Weekly - Inspect; replace as needed
E main element
Recoil housing Drain water as needed, check often if
- Weekly -
(if equipped) operating in wet conditions
 Brake pad wear 10 H Monthly 100 (160) Inspect periodically

Battery 20 H Monthly 200 (320) Check terminals; clean; test
 Engine oil change (break- 20 H 1M 100 (160) Perform a break-in oil change at one month
Ein)
Front gearcase oil (if
 equipped) 25 H Monthly 250 (400) Inspect level; change yearly

 Middle gearcase oil (if 25 H Monthly 250 (400) Inspect level; change yearly
equipped)
Rear gearcase oil
 (if equipped)
25 H Monthly 250 (400) Inspect level; change yearly

 Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly


Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
 Have an authorized Polaris dealer perform these services.

2.3
MAINTENANCE
Item Maintenance Interval Remarks
(whichever comes first)
Hours Calendar Miles
(KM)
 Engine breather 25 H Monthly 250 (400) Inspect; replace if necessary
E filter (if equipped)
Engine breather
100 H 6M 1000 (1600) Inspect
hose
General Lubricate all grease fittings, pivots,
 lubrication
50 H 3M 500 (800)
cables, etc.
Shift Linkage 50 H 6M 500 (800) Inspect, lubricate, adjust

Steering 50 H 6M 500 (800) Inspect daily, Lubricate

 Front suspension 50 H 6M 500 (800) Inspect, Lubricate, Tighten Fasteners
 Rear suspension 50 H 6M 500 (800) Inspect, Lubricate, Tighten Fasteners
Carburetor float Drain bowl periodically and prior to
50 H 6M 500 (800)
bowl storage
 Throttle Cable/ Inspect; adjust; lubricate; replace if
50 H 6M 500 (800)
E ETC Switch necessary
 Inspect; adjust; lubricate; replace if
Choke cable 50 H 6M 500 (800)
E necessary
Carburetor air Inspect ducts for proper sealing/air
E 50 H 6M 500 (800)
intake ducts/flange leaks
Drive belt 100 H 12 M 1000 (1600) Inspect; adjust; replace as needed
Cooling system Inspect coolant strength seasonally;
50 H 6M 500 (800)
(if applicable) pressure test system yearly
Engine oil change 500 Perform a break-in oil change at 20
*Severe Duty 25 H 6M (800) hours/one month, change more
 frequently during cold weather
E **Normal Duty 50 H 12 M 1000
(1600)
Engine oil change 500 Replace at oil change
*Severe Duty 25 H 6M (800)

**Normal Duty 50 H 12 M 1000


(1600)
 Oil filter change 100 H 6M 1000 (1600) Replace with oil change
E
 Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust
E
 Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
 Have an authorized Polaris dealer perform these services

2.4
MAINTENANCE
Item Maintenance Interval Remarks
(whichever comes first)
Hours Calendar Miles
(Km)
 1000 Check for leaks at tank cap, lines, fuel valve, filter,
Fuel system 100 H 12M
E (1600) pump, carburetor, replace lines every two years

E
Fuel Filter 100 H 12M
1000
(1600)
Replace yearly
2
Radiator 1000
 (if applicable) 100 H 12M
(1600)
Inspect; clean external surfaces
Cooling hoses 1000
 (if applicable) 100 H 12M
(1600)
Inspect for leaks
1000
 Engine mounts 100 H 12M
(1600)
Inspect
Exhaust muffler / 1000
100 H 12M Inspect
pipe (1600)
 1000
Spark plug 100 H 12M Inspect; replace as needed
E (1600)
 1000
Ignition Timing 100 H 12M Inspect
E (1600)
1000 Inspect for wear, routing, security; apply dielectric
 Wiring 100 H 12M
(1600) grease to connectors subjected to water, mud, etc.
Clutches (drive 1000
 100 H 12M Inspect;clean; replace worn parts
and driven) (1600)
Front wheel 1000
 100 H 12M Inspect; replace as needed
bearings (1600)
2000
 Brake fluid 200 H 24M Change every two years
(3200)
3000
Spark arrestor 300 H 36M Clean out
(4800)
E Idle Speed - Adjust as needed
 Toe adjustment - Inspect periodically; adjust when parts are replaced
 Auxiliary brake Pre- Ride Inspect daily; adjust as needed

Headlight aim - Adjust as needed
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
 Have an authorized Polaris dealer perform these services.

2.5
MAINTENANCE

LUBRICANTS / FLUIDS Additives / Sealants / Thread Locking Agents / Misc.

Polaris Lubricants,Maintenance and Service 2874275 Loctite‘ Primer N, Aerosol


Products
2871956 Loctite‘ Thread Sealant 565

Part No. Description 2871950 Loctite‘ Threadlock 242


Engine Lubricant 2871951 Loctite‘ Threadlock 262
2870791 Fogging Oil (12 oz. Aerosol) 2871953 Loctite‘ Threadlock 271
2874865 0W-50 Quarts 2871557 3-Bond 1215 Sealant
2874867 0W-50 55 Gallon Drum
2871326 Premium Carbon Clean
Gearcase / Transmission Lubricants
2870652 Fuel Stabilizer (16 oz.) (12 count)
2876251 Demand Drive LT Premium Hub Fluid
2871957 Black RTV Silicone Sealer
Premium Synthetic AGL Gearcase Lube
2873602 2871958 Black RTV Silicone Sealer
(12 oz. bottle) (12 count)
Premium Synthetic AGL Gearcase Lube 2870990 DOT 3 Brake Fluid (12 count)
2873603
(1 Gal. bottle) (4 count) 2871557 Crankcase Sealant, 3 Bond 1215 (5 oz.)
NOTE: Each item can be purchased separately at your Grease / Specialized Lubricants
local Polaris dealer. Premium All Season Grease
2871322
2871423 Premium All Season Grease
2871460 Starter Drive Grease (12 count)
2871515 Premium U-Joint Lube

2871551 Premium U-Joint Lube

NOTE: The number count indicated by each part number in the table above indicates the number of units that are
shipped with each order.
Polaris Lubricant Symbol Identification
NOTE: The symbols are used to properly identify the correct lube or grease to use in the maintenance section.

Polaris DOT Polaris Synthetic Polaris Synthetic Polaris All Season Grease Polaris ATV
Brake Fluid Gearcase Lube OW-50 Oil Demand Drive Hub Fluid

2.6
MAINTENANCE
VEHICLE INSPECTION / MAINTENANCE
Pre-ride / Daily Inspection
Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
• Tires - check condition and pressures
• Fuel and oil - fill both to their proper level; Do not overfill
2
• All brakes - check operation(includes auxiliary brake)
• Throttle - check for free operation
• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
• Engine stop switch - check for proper function
• Wheels - check for loose wheel nuts
• Air cleaner element - check for dirt or water; clean or replace
• Steering - check for free operation, noting any unusual looseness in any area
• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
• Engine coolant(if applicable) - check for proper level at the recovery bottle

Hawkeye Handlebar Component Locations


Brake Fluid Reservoir
Indicator Lights 4x4 switch
(if applicable)
Front Brake LCD

Light Control Throttle


& Run Switch

Choke
Ignition/Start Key
Reverse
Override

2.7
MAINTENANCE
Maintenance quick reference

III. # Item Lube Rec. Method Frequency*

Change after 1st month (25


hours), 50 hours thereafter;
Engine Oil Polaris 0W-50 Change more often (25 hours)
1 Add oil to proper level.
Synthetic in severe duty conditions, or
short trip cold weather
operation.

Polaris AGL
2 Transmission See procedure. Change annually o
Lubricant

Fill master cylinder reservoir


As required. Change fluid
3 Brake Fluid Polaris DOT Brake Fluid to indicated level inside
every 2 years.
reservoir.

Drain and refill with pre-


Front Polaris Demand Drive
4 measured amount of As required*
Gearcase Fluid
lubricant.

Polaris All Season Locate grease fitting on


A-Arm
5 swing arm and grease with Semi-annually n
Bushings Grease p
grease gun.

* More often under severe use, such as operated in water or under severe loads.

n Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)

o Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)

p Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special.
NOTE: Refer to Polaris lubricant Identification table for.

1. Engine Oil 2. Transmission Oil


5. Inner A-Arm Upper / Lower
Reservoir Level Pivot Points
Outer A-Arm Upper / Lower
Bearing Carrier Pivot Points
Prop Shaft

3. Brake Fluid
4. Front Gearcase Oil

2.8
MAINTENANCE
Transmission Lubrication Front Gearcase Lubrication (4x4 Only)
The transmission lubricant level should be checked and changed The front gearcase lubricant level should be checked and
in accordance with the maintenance schedule. changed in accordance with the maintenance schedule.
• Be sure vehicle is level before proceeding. • Be sure vehicle is level before proceeding.
• Check vent hose to be sure it is routed properly • Check vent hose to be sure it is routed properly
and unobstructed. and unobstructed. 2
TRANSMISSION SPECIFICATIONS FRONT GEARCASE SPECIFICATIONS
Specified Lubricant: Specified Lubricant:
Polaris AGL Gearcase Lubricant: Polaris Demand Drive LT Premium Hub Fluid:
(PN 2873603) (Gallon) (PN 2873602) (12 oz.) (PN 2876251) (8 oz.)
Capacity: Capacity:
Even with fill plug Even with fill plug
Drain Plug and Fill Plug Torque: Drain Plug Torque:
15 ft. lbs. (20 Nm) 8-10 ft. lbs. (11-13 Nm)
Fill / Check Plug Torque:
To change / check transmission fluid: 8-10 ft. lbs. (11-13 Nm)

1. Place a drain pan beneath oil pan and remove drain plug
from the crankcase. Allow oil to drain completely.
2. Reinstall the drain plug. Tighten to specification.
3. Add the proper amount of lubricant to bring level into A
operating range as shown. Do not over fill.

Drain Plug Level Check


1. Position the vehicle on a level surface.
Gearcase oil 2. Remove the check/fill plug (A) and view the oil level. The
flush with the bottom oil level should be at the bottom of the check plug (B)
of thread area. threads.
3. Reinstall the check/fill plug (A). Torque to specification.
4. Verify fluid level is correct and no leaks are present. 4. Reinstall the check plug (A) and a new sealing washer.
Torque to specification.
5. Check for leaks.

2.9
MAINTENANCE
Change Carburetor Draining
1. Remove the drain plug (C). Drain the oil into an The carburetor float bowl should be drained periodically to
appropriate container. Discard used oil properly remove moisture or sediment from the bowl, or before extended
2. Clean and reinstall the drain plug with a new sealing periods of storage.
washer. Torque to specification. NOTE: The bowl drain screw is located on the bottom
3. Remove the fill plug (A) and add a pre-measured amount left side of the float bowl.
of Polaris Angle Drive Fluid. The fluid should not be above
the bottom of the check plug (B) threads. 1. Turn fuel valve to the OFF position.
2. Place a clean container beneath the bowl drain spigot or
4. Reinstall the fill plug (A). Torque to specification.
bowl drain hose.
5. Check for leaks.
3. Turn drain screw out two turns and allow fuel in the float
bowl and fuel line to drain completely.
Lubrication / Grease points 4. Inspect the drained fuel for water or sediment.
There are grease zerks rear lower control arm inner pivots, lower 5. Tighten drain screw.
rear bearing carrier pivots, and the prop shaft. Apply grease until 6. Turn fuel valve to “ON”.
it is visible on the ends of the pivot points.
7. Start machine and check for leaks.
Throttle Operation - All Models NOTE: All tubes attached to the carburetor must be
Check for smooth throttle opening and closing in all handlebar check for pinching or blockage, as this will effect engine
positions. Throttle lever operation should be smooth and lever performance
must return freely without binding.
1. Place the gear selector in neutral.
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle speed
increases at any point in the turning range, inspect throttle
cable routing and condition. If cable is routed properly and
in good condition, repeat adjustment procedure.
5. Replace the throttle cable if worn, kinked, or damaged.

Choke (Enricher) Adjustment

III. 1 Drain tube attached here Drain Screw

CHOKE

Verify free play and smooth operation of choke


cable.Adjustments to the freeplay can be made by loosening the
choke cable adjustment in or out to gain the desired freeplay.

= In. / mm.

Choke Cable Freeplay:


1/16-3/16” (1.6-4.76 mm)

If smooth choke operation is not obtainable, inspect choke cable


for kinks or sharp bends in routing.

2.10
MAINTENANCE
Pilot Screw Pilot Screw Adjustment
The pilot system supplies fuel during engine operation with the
throttle valve closed or slightly opened. The fuel/air mixture is
metered by pilot screw and discharged into the main bore
through the pilot outlet.

CAUTION 2
FRONT
The pilot screw is calibrated at the factory to meet (Engine)
EPA / CARB regulations for air quality standards and
is sealed with a brass plug to prevent tampering.
Removal of the tamper proof plug is not permitted. Pilot Screw
For service purposes, cleaning of the pilot circuit can
be done only by a certified repair shop to ensure air
quality standards are not exceeded.

1. Start engine and warm it up to operating temperature


(about 10 minutes).
2. Turn pilot screw in (clockwise) until lightly seated. Turn
screw out the specified number of turns. NOTE: Do not
tighten the pilot screw forcefully against the seat or the
screw and/or seat will be permanently damaged.

Pilot screws are calibrated at the factory. Each


carburetor has a slightly different pilot screw
setting. The specifications may require additional
Pilot Screw Location tuning to achieve the desired results.

3. Connect an accurate tachometer that will read in increments


of + or - 50 RPM such as the PET 2100DX (PN
8712100DX) or the PET 2500 (PN 8712500).
4. Verify idle speed is 1400 RPM. Always check throttle cable
freeplay after adjusting idle speed and adjust if necessary.
Brass Plug Installed
5. Slowly turn mixture screw clockwise using the pilot screw
wrench until engine begins to stumble and/or RPM begins
to drop.
6. Slowly turn mixture screw counter-clockwise, noting how
far the mixture screw is turned out, until idle RPM begins
to drop.
7. Center the pilot screw halfway between the points noted in
Step 5 and 6.
Brass Plug Removed 8. Readjust idle RPM if not within specification. Always
check throttle cable freeplay after adjusting idle speed and
adjust if necessary.

Engine Idle RPM


1400 RPM

2.11
MAINTENANCE
Electronic Throttle Control (ETC Switch)/ Fuel System
Throttle Cable Adjustment
1. Slide the boots off inline cable adjuster sleeve. Loosen WARNING
adjuster locknut.
2. With handlebars centered and wheels pointing forward, Gasoline is extremely flammable and explosive
turn adjuster sleeve until 1/16” - 1/8” freeplay is achieved under certain conditions.
at the thumb lever. After making any adjustment, “flip” the
lever slightly to confirm adjustment. • Always stop the engine and refuel outdoors or in a
well ventilated area.
• Do not smoke or allow open flames or sparks in or
near the area where refueling is performed or
where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.

Boot • If you get gasoline in your eyes or if you swallow


Locknut gasoline, seek medical attention immediately.
Boot
Adjuster • If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water and
Sleeve change clothing.
• Never start the engine or let it run in an enclosed
Direction area. Engine exhaust fumes are poisonous and
can result loss of consciousness or death in a
of travel short time.
1/16” to 1/8”
Freeplay • Never drain the float bowl when the engine is hot.
Severe burns may result.

= In. / mm. Fuel Lines


1. Check fuel lines for signs of wear, deterioration, damage,
ETC/ Throttle Cable Freeplay: or leakage. Replace if necessary.
1/16-1/8” (1.6-3.1 mm) 2. Be sure fuel lines are routed properly and secured with
cable ties.
3. Tighten locknut and slide boots over cable adjuster until
they touch at the middle point of the adjuster. CAUTION
4. With engine running, turn the handlebars from full left to
full right with transmission in neutral. Engine RPM should Make sure lines are not kinked or pinched
not change and the engine should not die. If either of these
occur, return to the first step. 3. Replace all fuel lines every two years.
NOTE: If the throttle cable is adjusted too tight, the ETC
will limit operation at low throttle positions. Vent Lines
1. Check fuel tank, crankcase, carburetor, battery and
transmission vent lines for signs of wear, deterioration,
damage or leakage. Replace every two years.
2. Verify vent lines are routed properly and secured with cable
ties.

CAUTION

Make sure lines are not kinked or pinched

2.12
MAINTENANCE
Fuel Filter Engine Mounts
The fuel filter should be replaced in accordance with the Inspect rubber engine mounts for cracks or damage.
Periodic Maintenance Chart. The fuel filter is located between
the fuel tank and carburetor. Engine Fastener Torque
1. Clamp fuel lines
Check engine fasteners and ensure they are tight
2.
3.
Remove line clamps at both ends of the filter.
Remove fuel lines from filter. Battery Maintenance
2
4. Install new filter and clamps onto fuel lines with arrow
pointed in direction of fuel flow.
WARNING

Battery electrolyte is poisonous. It contains sulfuric


acid. Serious burns can result from contact with
skin, eyes or clothing. Antidote:

External: Flush with water.


Fuel Filter
Internal: Drink large quantities of water or milk.
To Carburetor Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get


5. Install clamps on fuel line. prompt medical attention.
6. Start engine and inspect for leaks.
Batteries produce explosive gases. Keep sparks,
7. Remove clamps
flame, cigarettes, etc. away. Ventilate when
charging or using in an enclosed space. Always
Compression Test shield eyes when working near batteries. KEEP
NOTE: This 4-Stroke engine is equipped with an OUT OF REACH OF CHILDREN.
automatic decompressor. Compression readings will
NOTE: All Hawkeye batteries are Low Maintenance
vary in proportion to cranking speed during the test.
design and construction. All Low Maintenance
Average compression (measured) is about 120-140 psi
batteries are fully charged and tested at the factory
during a compression test.
before installation. Expected shelf life is 6-8 months
Smooth idle generally indicates good compression. Low engine depending on storage conditions. As a general rule
compression is rarely a factor in running condition problems before placing the battery into service, check the
above idle speed. Abnormally high compression can be caused battery condition and charge accordingly.
by a decompressor malfunction, or worn or damaged exhaust
cam lobes. Inspect camshaft and automatic decompression
mechanism if compression is abnormally high. Low Maintenance batteries are permanently sealed at the time of
manufacture. The use of lead-calcium and AGM technology
A cylinder leak-down test is the best indication of engine instead of lead-antimony allows the battery acid to be fully
condition on models with automatic decompression. Follow absorbed. For this reason, a Low Maintenance battery case is
tester manufacturer’s instructions to perform a cylinder leak- dark and the cell caps are not removable, since there is no need
down test. (Never use high pressure leakage testers as to check electrolyte level.
crankshaft seals may dislodge and leak).
NEVER attempt to add electrolyte or water to a Low
Maintenance battery. Doing so will damage the case and shorten
the life of the battery. Refer to the Battery Maintenance Video
Cylinder Compression (PN 9917987) for proper instruction on servicing Low
Standard: 120-140 PSI Maintenance batteries.
Cylinder Leakage
Service Limit: 10%
(Inspect for cause if leakage exceeds 10%)

2.13
MAINTENANCE
The battery is located under front rack. Spark Plug

To remove the battery: 1. Remove the seat and left hand side panel.
1. Disconnect holder strap. 2. Remove spark plug high tension lead. Clean plug area so
2. Disconnect battery negative (-) (black) cable first, followed no dirt and debris can fall into engine when plug is
by the positive (+) (red) cable. removed.
3. Remove spark plug.
CAUTION 4. Inspect electrodes for wear and carbon buildup. Look for a
sharp outer edge with no rounding or erosion of the
To reduce the chance of sparks: Whenever electrodes.
removing the battery, disconnect the negative Inspect electrode for wear and buildup
(black) cable first. When reinstalling the battery,
install the negative cable last. Spark Plug Gap
3. Remove the battery.
4. Clean battery cables and terminals with a stiff wire brush.
Corrosion can be removed using a solution of one cup water
and one tablespoon baking soda. Rinse well with clean
water and dry thoroughly.
5. Reinstall battery, attaching positive (+) (red) cable first and 5. Clean with electrical contact cleaner or a glass bead spark
then the negative (-) (black) cable. plug cleaner only. CAUTION: A wire brush or coated
6. Coat terminals and bolt threads with Dielectric Grease (PN abrasive should not be used.
2871329). 6. Measure gap with a wire gauge. Refer to specifications for
7. Reinstall battery cover and holder strap. proper spark plug type and gap. Adjust gap if necessary by
bending the side electrode carefully.
7. If necessary, replace spark plug with proper type.
CAUTION: Severe engine damage may occur if the
incorrect spark plug is used.
8. Apply a small amount of anti-seize compound to the spark
plug threads.
9. Install spark plug and torque to 9-11 ft. lbs (12-14 Nm).
10. Replace side panel and seat.

Recommended Spark Plug:


NGK CR8EB
Spark Plug Torque: 9-11 Ft. Lbs.
(12 - 14 Nm)

2.14
MAINTENANCE
Ignition Timing Cleaning:

Timing is CDI controlled and has no adjustment procedure. 5. Slip the pre-filter element off of main element. Clean the
pre filter with hot soapy water.
6. Rinse and dry thoroughly.
Ignition Timing:
7. Inspect element for tears or damage.
30o + 2o BTDC @ 5000RPM 8. Inspect main filter and replace if necessary. If the filter has
been soaked with fuel or oil it must be replaced.
2
Main Air Filter Cleaning Installation:
It is advisable to replace the filter when it is dirty. However, in 9. Reinstall pre-filter element over main filter. Be sure the
an emergency it is permissible to clean the main filter if you
observe the following practices. element covers entire surface of main filter without folds,
creases, or gaps.
• Never immerse the filter in water since dirt can be
transferred to the clean air side of the filter. 10. Reinstall filter on main filter mount. Place filter clamp over
the assembly and tighten.
• If compressed air is used never exceed a NOTE: Apply a small amount of general purpose grease
pressure of 40 PSI. Always use a dispersion type
nozzle to prevent filter damage and clean from the to the sealing edges of the filter before reinstalling.
inside to the outside.
• Replace the air filter every 50 hours, and possibly
more often in very dirty conditions.

Air Filter/Pre-Filter Service


It is recommended that the air filter and pre filter be replaced
annually. When riding in extremely dusty conditions,
replacement is required more often.
The pre filter should be cleaned before each ride using the
following procedure:
1. Remove the seat.
2. Remove clips from air box cover (A) and remove cover.

Proper Filter Placement


A Main Filter
Filter
Support

Air Box

3. Inspect the gasket. It should adhere tightly to the cover and III. 3 Rear
seal all the way around.
4. Remove air filter assembly. NOTE: The air filter should rest on the filter support.
Proper placement of the air filter is important to prevent
rattles and air leaks. See Illustration above.
11. Install air box cover and secure with clips.

2.15
MAINTENANCE
Air Box Sediment Tube Engine Oil Level
Periodically check the air box drain tube located toward the rear To check the oil level:
of the machine. Drain whenever deposits are visible in the clear
tube. 1. Set machine on a level surface.
2. Place the transmission in neutral.
3. Lock the parking brake.

Sediment Tube

NOTE: The sediment tube will require more frequent


service if the vehicle is operated in wet conditions or at 4. Start the engine. Allow it to idle for 30 seconds.
high throttle openings for extended periods.
5. Turn the engine off.
1. Remove drain plug from end of sediment tube. 6. The oil dipstick and fill hole are located behind the recoil
2. Drain Tube. on the right side of the ATV.
3. Reinstall drain plug.

CVT Drain Plug & Drying


NOTE: If operating the ATV through water, be sure to
check the CVT and other components for water
ingestion. The ATV should be checked immediately.

1. To release any water that maybe trapped in the CVT cover,


simply remove the CVT drain plug and O-ring located on
the bottom of the CVT cover and let the water drain out.
7. Remove the dipstick and wipe it clean.
8. Reinstall the dipstick completely
9. Remove the dipstick an check the oil level.
10. Add oil as needed to bring the level between the minimum
and maximum marks. Do not over fill.
11. Reinstall the dipstick.

2. To further expel water from the cover and to dry out the
CVT system, shift the transmission to neutral and rev
engine slightly to expel the moisture and air-dry the belt and
clutches. Allow engine RPM to settle to idle speed, shift
transmission to lowest available range and test for belt
slippage. Operate ATV in lowest available range for a short
period of time until CVT system is dry.

2.16
MAINTENANCE
Oil and Filter Change 12. Place towels under the oil filter.
13. Using an oil filter wrench, turn the filter counter clockwise
1. Set machine on a level surface.
to remove it.
2. Place the transmission in neutral.
3. Lock the parking brake.

14. Clean the filter sealing area on the engine.


4. Start the engine. Allow it to idle for two to three minuets. 15. Lubricate the filter o-ring with clean oil as shown. Check
to make sure the o-ring is in good condition.
5. Turn the engine off.
6. Clean the area around the drain plug.

16. Install the new oil filter, After the filter contacts the engine
surface turn it 1/2 turn by hand.

CAUTION

Hot oil may result in serious burns. Do not allow hot


oil to contact skin.

7. Place a drain pan under the vehicle.


8. Remove the drain plug. Use a 6mm Allen wrench.
9. Drain the oil.
17. Remove the dipstick.
18. Add required amount of 0W/50 oil. (Chapter 1)

10. Reinstall the drain plug with a new sealing washer.


11. Torque to 14 ft-lb (19Nm).
NOTE: The sealing surfaces on the drain plug and 19. Reinstall the dipstick.
crankcase should be clean and free of burrs, nicks 20. Start the engine and allow it to idle for two minuets.
or scratches. 21. Turn off the engine. Check for oil leaks.

2.17
MAINTENANCE
22. Verify the oil level. Add oil as needed to bring the level Steering
between the min. and max marks. Do not overfill.
The steering components should be checked periodically for
loose fasteners, worn tie rod ends, and damage. Also check to
make sure all cotter pins are in place. If cotter pins are removed,
they must not be re-used. Always use new cotter pins.
Replace any worn or damaged steering components. Steering
should move freely through entire range of travel without
23. Discard used oil and filter properly. binding. Check routing of all cables, hoses, and wiring to be sure
the steering mechanism is not restricted or limited. NOTE:
Whenever steering components are replaced, check front end
Valve Clearance Adjustment alignment. Use only genuine Polaris parts.

WARNING

Due to the critical nature of the procedures outlined in this


chapter, Polaris recommends steering component repair and
adjustment be performed by an authorized Polaris Dealer.
Only a qualified technician should replace worn or damaged
steering parts. Use only genuine Polaris replacement parts.

Tie Rod End/Steering Inspection


To check for play in the tie rod end, grasp the steering tie rod,
pull in all directions feeling for movement.
• Repeat inspection for inner tie rod end (on steering
INTAKE VALVE CLEARANCE post).
1. Verify cam lobes are pointed down. • Replace any worn steering components. Steering
2. Insert a .006” (.15 mm) feeler gauge between end of intake should move freely through entire range of travel
without binding.
valve stem and adjuster screw.
3. When clearance is correct, hold adjuster screw and tighten
locknut securely.
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until clearance is
correct with locknut secured.

INTAKE/ EXHAUST VALVE CLEARANCE


.006” (.15 mm)

EXHAUST VALVE CLEARANCE


1. Verify cam lobes are pointed down.
2. Insert an .006” (.15 mm) feeler gauge between end of
exhaust valve stem and adjuster screw.
3. Loosen locknut and turn adjuster screw until there is a slight
drag on feeler gauge.
4. When clearance is correct, hold adjuster screw and tighten
locknut securely.
5. Re-check the valve clearance.
6. Repeat adjustment procedure if necessary until clearance is
correct with locknut secured.

2.18
MAINTENANCE
• Elevate front end of machine so front wheels are 6. Again measure the distance between the marks and record.
off the ground. Check for any looseness in front Call this measurement “B”. Subtract measurement “B”
hub / wheel assembly by grasping the tire firmly at
top and bottom first, and then at front and rear. Try from measurement “A”. The difference between
to move the wheel and hub by pushing inward and measurements “A” and “B” is the vehicle toe alignment.
pulling outward. The recommended vehicle toe tolerance is 1/8” to 1/4” (.3
to.6 cm) toe out. This means the measurement at the front
of the tire (A) is 1/8” to 1/4” (.3 to.6 cm) wider than the
measurement at the rear (B).
2

Check for Loose Wheel or Hub


Chalk Line
• If abnormal movement is detected, inspect the hub Measurement
and wheel assembly to determine the cause. “A” Measurement “B”
Camber and Caster
The camber and caster are non-adjustable. = In. / mm.
Toe Alignment
Wheel Toe-out Alignment:
1. Place machine on a smooth level surface. 1/8-1/4” (.3-.6 cm)
2. Set handlebars in a straight ahead position and secure
handlebars in this position. NOTE: The steering arm can
be used as an indicator of whether the handlebars are Toe Alignment Adjustment
straight. The arm should always point straight back from If toe alignment is incorrect, measure the distance between
the steering post. vehicle center and each wheel. This will tell you which tie rod
needs adjusting. NOTE: Be sure handlebars are straight ahead
3. Place a chalk mark on the center line of the front tires before determining which tie rod(s) need adjustment.
approximately 10” (25.4 cm) from the floor or as close to
the hub/axle center line as possible. NOTE: It is important
that the height of both marks be equally positioned in order CAUTION
to get an accurate measurement.
4. Measure the distance between the marks and record the During tie rod adjustment, it is very important that the
measurement. Call this measurement “A”. following precautions be taken when tightening tie
5. Rotate the tires 180o by moving vehicle forward or rod end jam nuts. If the rod end is positioned
backward. Position chalk marks facing rearward, even with incorrectly it will not pivot, and may break
the hub/axle centerline.
To adjust toe alignment:
• Hold tie rod end to keep it from rotating.
• Loosen jam nuts at both end of the tie rod.
• Shorten or lengthen the tie rod until alignment is as
required to achieve the proper toe setting - (1/8” to
1/4”).

2.19
MAINTENANCE
• Important: When tightening the tie rod end jam 2. Place the transmission in Park and start the engine. Purge
nuts, the rod ends must be held parallel to prevent accumulated carbon from the system by momentarily
rod end damage and premature wear. Damage
may not be immediately apparent if done revving the engine several times.
incorrectly. See illustration. 3. If some carbon is expelled, cover the exhaust outlet and
lightly tap on the pipe around the clean out plugs with a
Hold Tie-Rod End Parallel
rubber mallet while revving the engine several more times.

x
Correctly Incorrectly
Tightened Tightened
Jam Nut Jam Nut
4. If particles are still suspected to be in the muffler, back the
machine onto an incline so the rear of the machine is one
Exhaust Pipe Cleaning foot higher than the front. Set the hand brake and block the
wheels. Make sure the machine is in Park and repeat Steps
WARNING
2 and 3. SEE WARNING
5. If particles are still suspected to be in the muffler, drive the
machine onto the incline so the front of the machine is one
• Do not perform clean out immediately after the
engine has been run, as the exhaust system foot higher than the rear. Set the hand brake and block the
becomes very hot. Serious burns could result wheels. Make sure the machine is in Park and repeat Steps
from contact with exhaust components. 2 and 3. SEE WARNING
• To reduce fire hazard, make sure that there are no
combustible materials in the area when purging
the spark arrestor.
• Wear eye protection.
• Do not stand behind or in front of the vehicle
while purging the carbon from the spark arrestor.
• Never run the engine in an enclosed area.Exhaust
contains poisonous carbon monoxide gas.
• Do not go under the machine while it is
inclined.Set the hand brake and block the wheels 1 ft.
to prevent roll back.
Failure to heed these warnings could result in serious
personal injury or death. 6. Repeat steps 2 through 5 until no more particles are
expelled when the engine is revved.
The exhaust pipe must be periodically purged of accumulated
carbon as follows: 7. Stop the engine and allow the arrestor to cool.
1. Remove the clean out plugs located on the bottom of the 8. Reinstall the clean out plugs.
muffler.
Brake System Inspection
The following checks are recommended to keep the brake
system in good operating condition. Service life of brake system
components depends on operating conditions. Inspect brakes in
accordance with the maintenance schedule and before each ride.
• Keep fluid level in the master cylinder reservoir to
the indicated level inside reservoir.
Clean Out Plug
III. 1

2.20
MAINTENANCE
• Check the fluid level “eye”. If it is clear, it is an 3. If excessive free play exists, inspect brake pads, pedal,
indication that fluid is needed or the brake pads linkage springs, and hoses for wear or damage and replace
may be worn, which can reduce the fluid level.
any parts as needed.
• Use Polaris DOT 3 or DOT 4 Brake Fluid

SIGHT GLASS .40” - .80”


(10-20 mm)
2

Hand Brake Lever Free Play

Rear Foot Brake


• Check brake system for fluid leaks, excessive
travel or spongy feel.
• Check brake pads for wear, damage or looseness.
• Check surface condition of the disc.
• Inspect thickness of brake pad friction material.

Brake Pad Inspection


Front Brake Pads

Rear Brake

4. Check foot brake effectiveness by applying approximately


50 lb. (23 kg) downward force on the pedal. The top of the
pedal should travel not more than 1 inch (25.4mm).
Brake Pad
Measure
Thickness
Service Limit - .059” (1.5 mm)
50 lbs 1” or greater
Brake pads should be changed when friction material is worn to
.59” (1.5 mm).

Hose/Fitting Inspection
Check brake system hoses and fittings for cracks, deterioration,
abrasion, and leaks.Tighten any loose fittings and replace any Floorboard
worn or damaged parts.

Brake Freeplay
5. If more than one inch, two things must be examined:
Hand Brake Lever
• Free play of the brake pedal should be 1/8 - 1/4
1. Check the brake lever, and foot brake for loose inch (3.2 - 6.35 mm).
connections, free play, and damage.
2. Measure the hand brake lever freeplay. Freeplay should be • If free play is excessive: Inspect brake pads,
pedal, linkage springs, and hoses for wear or
0.40-0.80 in. (10-20 mm). damage and replace any parts as needed.

2.21
MAINTENANCE
Suspension Spring FRONT / REAR Preload Wheel Removal/Installation- Front or Rear
Adjustment
Wheel Removal
Operator weight and vehicle loading affect suspension spring
preload requirements. Using Spanner Wrench (PN 2870872) 1. Stop the engine, place the transmission in gear and lock the
adjust as necessary to avoid bottoming of the shocks. parking brake.
2. Loosen the wheel nuts slightly.
Shock Spanner Wrench 3. Elevate the side of the vehicle by placing a suitable stand
under the footrest frame.
(PN 2870872)
4. Remove the wheel nuts and remove the wheel.

Front Suspension Inspection Wheel Installation


1. With the transmission in gear and the parking brake
Compress and release front suspension. Damping locked, place the wheel in the correct position on the wheel
should be smooth throughout the range of travel. hub. Be sure the valve stem is toward the outside and
• Check all front suspension components for wear or rotation arrows on the tire point toward forward rotation.
damage. NOTE:Apply an anti-seize compound on the front
wheel spindle before hub/wheel installation.
• Inspect shocks for leakage. 2. Attach the wheel nuts and finger tighten them.
Rear Suspension Inspection 3. Lower the vehicle to the ground.
4. Securely tighten the wheel nuts to the proper torque listed
Compress and release rear suspension. Damping in the table.
should be smooth throughout the range of travel.
Wheel Nuts
• Check all rear suspension components for wear or
damage.
• Inspect shocks for leakage.

Controls
Cotter
Check controls for proper operation, positioning and Key
adjustment.
• Brake control and switch must be positioned to
allow brake lever to travel throughout entire range
without contacting switch body.

Wheels Hub Retaining Nut


Inspect all wheels for runout or damage. Check wheel nuts and
ensure they are tight. Do not over tighten the wheel nuts. CAUTION
Wheel, Hub, And Spindle
Torque Table Improperly installed wheels could affect vehicle
handling and tire wear. On vehicles with tapered rear
wheel nuts, make sure tapered end of nut goes into
Item Specification taper on wheel. Be sure to properly torque and
Front Wheel Nuts - Steel 27 Ft. Lbs. (37Nm) install all wheel nuts.

Rear Wheel Nuts - Steel 27 Ft. Lbs. (37Nm)


Hub Retaining Nut 80 Ft. Lbs. (108 Nm)

2.22
MAINTENANCE
Tire Pressure Frame, Nuts, Bolts, Fasteners
Periodically inspect the torque of all fasteners in accordance
Tire Pressure Inspection (PSI - Cold) with the maintenance schedule. Check that all cotter pins are in
place. Refer to specific fastener torques listed in each chapter.
Front Rear
4 4
2
Tire Inspection

WARNING

Operating an ATV with worn tires will increase the


possibility of the vehicle skidding and possible loss
of control.

Worn tires can cause an accident.

Always replace tires when the tread depth


measures 1/8” (.3 cm) or less.

CAUTION

• Maintain proper tire pressure. Refer to the


warning tire pressure decal applied to the
vehicle.
• Improper tire inflation may affect ATV
maneuverability.
• When replacing a tire always use original
equipment size and type.
• The use of non-standard size or type tires
may affect ATV handling.

Tire Tread Depth


Always replace tires when tread depth is worn to 1/8” (3 mm)
or less.

Tread
Depth 1/8” (3 mm)

2.23
MAINTENANCE

NOTES

2.24
ENGINE
CHAPTER 3
ENGINE
TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3
OIL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
PISTON RING IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
TRANSMISSION INSTALLATION NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
OIL FLOW / PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
ENGINE BREATHER / OIL SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
CAM CHAIN TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
ROCKER ARM/SHAFT DISASSEMBLY AND INSPECTION. . . . . . . . . . . . . . . . . . . . . 3.16
CAMSHAFT REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
COMBUSTION CHAMBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
ENGINE BOTTOM END DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CAM CHAIN GUIDE AND TENSIONER BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
CYLINDER HONE SELECTION/ HONING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . 3.26
HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
FLYWHEEL REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
STARTER DRIVE CLUTCH REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
CAM CHAIN DRIVE SPROCKET REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . 3.29
OIL PUMP INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
STARTING CLUTCH AND ENGINE BRAKING CLUTCH REMOVAL /INSPECTION . . 3.30
STARTING CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION. . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKCASE OIL PASSAGES & PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . 3.33

3.1
ENGINE
CAMSHAFT CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
BALANCE SHAFT BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
CRANKCASE OIL PICKUP STRAINER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
BEARING /SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
END PLAY INSPECTION/ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
CRANKSHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
BALANCER SHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
CAM CHAIN, OIL PUMP, & TENSIONER BLADE INSTALLATION. . . . . . . . . . . . . . . . 3.37
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
CYLINDER HEAD AND CAMSHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
CAMSHAFT INSTALLATION & TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
ROCKER ARM INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
STARTER DRIVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
SPARK PLUG FOULING TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
ENGINE TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43

3.2
ENGINE
TOOLS Oil Pressure Relief
14 mm 15-17 (20-23 Nm)
Valve Plug
Special Tools
Recoil Housing 6mm 7-8 (9-11 Nm)
PART NUMBER TOOL DESCRIPTION
Rocker Adjuster Screw 5mm 3.5-5 (5-7 Nm)
Valve Seat Reconditioning
2200634
Kit Rocker Cover 6mm 5-6.5 (7-9 Nm)
2870390 Piston Support Block
Rocker Adjuster Screw
PA-47308 Flywheel Puller 5mm 3.7-5.0 (5-7 Nm)
Lock Nut
PA-47457 Starting Clutch Holder

2871293-B
Crankshaft Slotted Nut
Socket
Stator Plate to
Crankcase
6mm 7-8 (9-11 Nm) 3
Stator to Stator Plate
5mm 5-6.5 (7-9 Nm)
Screws
TORQUE SPECIFICATIONS
Starter Motor 6mm 5-6.5 (7-9 Nm)
Engine Torque Specifications
Starting Clutch Cover 8mm 14-15.5 (19-21Nm)
ENGINE TORQUE SPECIFICATIONS 103-118
Starting Clutch Nut 16mm
(140-160 Nm)
Thread ES300PFE010
Fastener
Size Ft. Lbs. (Nm) Spark Plug (New) 12mm 7.5-9 (10-12 Nm)
Camshaft Chain Tighten 30-45
6mm 5-6.5 (7-9 Nm)
Tensioner Lever Spark Plug (Used) 12mm degrees after
Camshaft Chain gasket contact
6mm 6.5-8.0 (9-11 Nm)
Tensioner Body
Torque Patterns
Camshaft Chain
8mm 6-7.5 (8-10 Nm)
Tensioner Cap Tightening method for cylinder head nuts:
Camshaft Sprocket
6mm 6.5-8.0 (9-11 Nm) 1) Apply engine oil to washer and threads of 10mm bolts.
Cover
2) Tighten 10mm bolts in pattern below to 18.5 ft. lbs. (25 Nm)
Camshaft Sprocket Bolt 10mm 30-34 (40-46 Nm)
3) Loosen 180 degrees
Carburetor
8mm 12-14 (16-20 Nm)
Adaptor 4) Tighten to 11 ft. lbs. (15 Nm)
Refer to Torque
Cylinder Head Bolts 10mm 5) Tighten 90 degrees
Procedure
Cylinder & Head 6mm 6) Tighten 60 degrees
6mm 5-7 (7-9 Nm)
Bolts
Crankcase 6mm 6.5-8.0 (9-11 Nm) 7) Tighten 6mm head and base bolts to 8 ft. lbs. (11 Nm)
Crankshaft Sprocket
25mm 34 (46 Nm) Cylinder Head / Cylinder Base
Slotted Nut
Flywheel Nut 16mm 66-81 (90-110 Nm) 2
3
5
Oil Drain Bolt 6 mm
14mm 13-16 (18-22 Nm)
(Crankcase)
6
Oil Filter Pipe Fitting 4
20mm 9.5-12 (13-16 Nm) 1
(Crankcase)

Oil Pressure Blind Plug 1/4 NPT 20-24 (27-33 Nm)

3.3
ENGINE
GENERAL ENGINE SERVICE
Engine Exploded View
Crankcase Cylinder/
Cylinder Head
6 ft. lbs.

8 ft. lbs.

15 ft. lbs.

15 ft. lbs. SEE


PROCEDURE

12-14 ft. lbs.

5.5 ft. lbs.

16 ft. lbs.

5.5 ft. lbs.

Crankshaft Valve Train


and Piston
3.5 ft. lbs.
7 ft. lbs.

6 ft. lbs.

6 ft. lbs.

30-34 ft. lbs.


34 ft. lbs.

3.4
ENGINE
Engine Service Data

Cylinder Head / Valvetrain ES300PFE010


Camshaft Lobe Height In Std 1.2938-1.2977" (32.863 - 32.963mm)
Limit 1.2820" (32.563 mm)
Ex Std 1.2938-1.2977" (32.863 - 32.963mm)
Limit 1.2820" (32.563 mm)
Journal O.D. PTO 1.0998-1.1004" (27.935-27.950mm)
Journal O.D. MAG 1.5328-1.5334" (38.935-38.950mm)
Journal Bore I.D. PTO 1.1025-1.1033" (28.005-28.025mm) 3
Journal Bore I.D. MAG 1.5356-1.5364" (39.005-39.025mm)
Std .0021-.0035" (.055 - .090mm)
Camshaft Journal Oil Clearance
Limit .0039" (.10mm)
Camshaft Chain Install new as a part of any crankshaft removal

Cylinder Head Surface Warpage Limit .0020” (.05 mm)


Rocker Arm/Shaft Rocker arm ID .8669-.8677" (22.02-22.04 mm)
Rocker shaft OD .8656-.8661" (21.987-22.00 mm)
Oil Clearance (Limit) .0039" (.10 mm)
Valve Clearance In Std .006" (.15 mm)
Ex Std .006" (.15 mm)
Valve Seat Angle Contacting Width In Std .039" (1.0 mm)
Limit .055" (1.4 mm)
Ex Std .059" (1.5 mm)
Limit .070" (1.8 mm)
Valve Stem Diameter In .2342-.2348" (5.950-5.965 mm)
Ex .2340-.2346" (5.945-5.960 mm)
Limit .1921" (4.9 mm)
In 3.976" (101.0mm)
Stem Length
Ex 3.984" (101.2mm)
In Limit .031" (.8mm)
Margin
Ex Limit .031" (.8mm)
Valve Guide Inner Diameter In .2362-.2367" (6.0-6.012 mm)
Ex .2362-.2367" (6.0-6.012 mm)
Stem to Guide Oil Clearance Limit .006" (.15 mm)
Valve Spring Free Length 1.640" (41.66 mm)
1.377" (35.0 mm)
Squareness 0.075” (1.9 mm)

KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off

3.5
ENGINE
Engine Service Data

Cylinder / Piston / Connecting Rod ES300PFE010


Cylinder Surface warpage limit (mating with cylinder .002” (0.05 mm)
head)
Cylinder bore Std 3.0590-3.0598" (77.70-77.72 mm)
Taper or Out-of-Round Limit Limit .002” (0.05 mm)
Piston to cylinder clearance Std .0015-.0032" (0.038-0.082 mm)
Limit .0043" (0.11 mm)
1st O.S. + .0098” (.25 mm)
Boring Limit
2nd O.S. + .0197” (.50 mm)
Piston Outer diameter Std 3.0566-3.0575" (77.638-77.662 mm)
1st O.S. .0098" (.25 mm) Oversize
2nd O.S. .0197" (.50 mm) Oversize
Pin Bore - Inner Diameter .7089-.7094" (18.007-18.020 mm)
Piston Pin Pin outer diameter clearance in piston .00015- .00047” (.004- .012 mm)
Degree of fit Push (by hand) fit @ 68o F (20o C) (Standard
clearance 0-.0005" (0-.012mm)
Piston Ring Piston Ring Installed Gap Top ring Std .008-.0012" (.2-.3 mm)
Limit .032" (.8 mm)
Second Std .018-.019" (.35-.50 mm)
ring
Limit .039" (1.0mm)
Oil ring Std .0079-.0275" (.2-.7 mm)
Limit .059" (1.5 mm)
Top ring Std .0006-.0029" (.015.-.074 mm)
Limit .006" (.15 mm)
Piston Ring to Ring Groove Second Std .0009-.0025" (.025-.065 mm)
Clearance ring
Limit .006" (0.15 mm)
Oil ring Std .002-.0057" (.055-.145 mm)
Limit N/A
Connecting Rod Connecting rod small end ID .7089-.7094" (18.007-18.020 mm)
Connecting rod small end radial Std 0 - .0007" (0 - 0.019 mm)
clearance (to piston pin) Limit .0011" (.03 mm)
Connecting rod big end axial (side) Std
.0035-.0196" (.09-.50 mm)
clearance
Limit
.023" (.60 mm)

Connecting rod big end radial Std


0.0004-.0014" (.011-0.038 mm)
clearance
Limit
.0019" (.05 mm)

3.6
ENGINE

Crankshaft / Counter Balancer / Oil Pump ES300PFE010


Crankshaft Crankshaft End Runout Limit 0.0024" (0.06 mm)
Std 0.006-.012" (.15 - .30 mm)
Crankshaft End Play
Limit N/A
Std 0.004-.029" (0.1 - .74 mm)
Counter Balancer Counter Balancer Shaft End Play
Limit N/A
Oil Pump Oil Pump Shaft End Play N/A

Std 0.0027-.0051" (.070 - .130 mm) 3


Oil Pump End Clearance
Limit N/A

Std 0.0047" (.12 mm)


Pump Rotor Tip Clearance
Limit N/A

Std 0.006 - 008" (.15 - .21 mm)


Pump Feed Rotor to Pump Body
Clearance
Limit N/A

Std Above 9 PSI


Oil Pressure (Polaris 0W-50 @ Normal
Operating Temperature @ Idle Speed)
Limit Below 9 PSI

KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off.

3.7
ENGINE
Oil Flow Diagram

Rocker Arm
Rocker Shaft
Valve Springs

ES300PFE010
Chain Room

Cylinder Head Camshaft


(RH Cam Journal) Sprocket & Chain

Connecting Rod Small End


Piston Skirt / Rings

Nozzle Right Rear


Cylinder Bolt

Counter Balance Gear Crankshaft


Main Bearing
Connecting Rod Big End

MAG SIDE
Starting Clutch
One Way Clutch Crankcase
Stator Plate
Oil Passage

Crankcase
Oil Cooler / Filter
Main Bearing Oil Passage

PTO SIDE Oil Pressure Inspection


& Accessory Oil Cooler
Crankcase Fitting Location
Starting Clutch Oil Passage

Oil Pump

Crankcase Oil Pickup Engine Sump


OIL FLOW DIAGRAM KEY Oil Passage Screen

Direct

Indirect

3.8
ENGINE
Piston Identification Accessible Components
Piston is identified by the marking ES30A. The following components can be serviced or removed with
the engine installed in the frame:
Note the directional and identification marks when viewing the
pistons from the top. The letters “IN” must always be toward the • Flywheel
intake side of the engine. • Alternator/Stator
Piston rings must be installed correctly to ensure engine • Starter Motor/Starter Drive
performance. The numbers or letters on all rings (except oil
• Oil pump
control rings) must be positioned upward. See text for oil control
ring upper rail installation. Use the information below to
identify pistons and rings.
• Rocker Arms / Rocker Shaft
• Camshaft
3
Engine Model Oversize Standard Piston • Cam Chain and Sprockets
No. Available (mm) Identification
• Cylinder
Valve Pocket to
.25mm • Cylinder Head
ES300PFE010 Rear
.50mm
(Intake Side) • Valves
• Carburetor
Piston Ring Identification
• Piston/RIngs
The piston ring profile is shown below. Install top and second
ring with marking UP. Refer to text for oil control ring The following components require engine removal for
installation. service:

• Starting Clutch (transmission removal required)


Piston Ring Installation Note Profile
• One-Way Clutch (engine braking)
Inner Bevel; Barrel
TOP RING Mark Faces UP • Crankshaft
Face
Undercut; • Crankshaft Main Bearings
SECOND RING Mark Faces UP
Taper Face
• Counter Balance Shaft or Bearings
• Crankcase
• Transmission
NOTE: Crankshaft components are not serviceable.
Replace crankshaft as an assembly.

3.9
ENGINE
ENGINE SERVICE 10. Disconnect gear indicator switch harness (at transmission)

Engine Removal
NOTE: The engine removal procedure described
A
below removes the engine and transmission as an
assembly, and the engine is then removed from the
transmission case. The transmission can be
removed separately from the engine (see
Transmission Removal procedure in this chapter).

1. Clean work area. B


2. Thoroughly clean the ATV engine and chassis.
3. Disconnect battery cables at battery.
4. Drain engine oil. 11. Disconnect speed sensor from transmission (left rear side).
5. Disconnect spark plug high tension lead. 12. Rear fuel tank bracket
6. Remove the following parts: 13. CVT air intake and exhaust ducts

• Seat
• Left and Right Side Covers
• Rear cab
7. Remove CVT cover and both clutches (refer to CVT
Chapter 8)

14. Remove carburetor. Insert a clean shop towel into the


carburetor flange to prevent dirt from entering the intake
port.
15. Remove exhaust head pipe.
8. Front prop shaft (4x4 models) (Drive pin out at front 16. Starter motor positive (+) and negative (-) cables at starter
gearcase, pull shaft back, then forward. Refer to Drive motor.
Chapter)
17. Recoil housing, flywheel and stator (or if front cab is
removed, remove front cab and disconnect wires.) See
“Flywheel Removal / Inspection” on page 3.28. for
flywheel removal procedure.

9. Remove transmission linkage rod (A) and vent hose (B)

3.10
ENGINE
NOTE: If front cab is already removed, the stator 25. Lower the jack and pull engine / transmission assembly out
wires can be disconnected. Disregard the steps to the rear.
remove recoil cover, flywheel, and stator from the
engine.

18. Front engine mount


19. Support lower sub-frame with a stable platform jack.
20. Rear lower engine mount
21. Sub frame bolts (2 each side)

Rear mount 2 both sides

22. Rear wheel (left side) and brake caliper.


NOTE: Re-install rear wheel after caliper removal.

23. Top rear shock bolts.


24. Top bolts from sway bar bracket.

3.11
ENGINE
26. Support engine and remove (9) transmission-to- Engine Break In Period
engine bolts.
4 Cycle Engine Break-In Period is defined as the first 10 hours
of engine operation or 2 full tanks of fuel.

• Use only Polaris Premium 4 All Season Synthetic


Oil, or API certified “SH” oil.
• Use fuel with a minimum octane of 87 (R+M)/2
method.
• Change break-in oil and filter at 20 hours or 100
miles, whichever comes first.

IMPORTANT: DO NOT LIFT ENGINE BY THE


STARTING CLUTCH SHAFT!

Engine Installation Notes


After the engine is installed in the frame, review this checklist
and perform all steps that apply:

General Items

• Install previously removed components using new


gaskets, seals, and fasteners where applicable.
• Perform checks on fluid levels, controls, and all
important areas on the vehicle as outlined in the
daily pre-ride inspection checklist (refer to Chapter
2).

CVT System

• Clean clutch sheaves thoroughly and inspect inlet


and outlet ducts for proper routing and sealing.
• Inspect drive and driven clutch as described in
chapter 8.
Transmission

• Inspect transmission operation.


Exhaust

• Replace exhaust gaskets. Seal connections if


necessary with high temp sealant.
• After running the engine, verify all bolted exhaust
connections are tight and in good condition.
Engine Mount Torque

• Inspect all engine mount fasteners and verify they


are tightened properly

3.12
ENGINE
Transmission Removal 9. Disconnect gear indicator switch harness (at transmission)

NOTE: The transmission can be removed separately


from the engine. Follow this procedure if engine
removal is not required.
A
1. Clean work area.
2. Thoroughly clean the ATV engine and chassis.
3. Disconnect battery cables at battery.
4. Drain transmission oil.
5. Remove the following parts:
B
3
• Seat
• Left and Right Side Covers 10. Disconnect speed sensor at transmission (left rear side).
• Rear cab 11. Remove rear fuel tank bracket.
6. Remove CVT cover and both clutches (refer to CVT 12. Remove CVT air inlet duct.
Chapter 8)

7. Front prop shaft (4x4 models) (Drive pin out at front


gearcase, pull shaft back, then forward. Refer to Drive 13. Support frame under engine with a stable platform jack.
Chapter) 14. Remove rear wheels and brake caliper.

8. Remove transmission linkage rod (A) and vent hose (B) 15. Remove rear plate (lower control arm bolts) and upper
control arm bolts.

3.13
ENGINE
16. Remove rear shocks. 24. Remove the top 2 rear bracket bolts.
25. Carefully lower the transmission jack until rear bracket is
clear of frame.
26. Slide transmission to the left until alignment pins in cover
are release from engine case.
27. Remove transmission out to the left side.
28. Remove sway bar bracket from transmission.
29. Refer to transmission disassembly in CVT/Transmission
Chapter 8.

Transmission Installation Notes


1. Install new gasket on engine
17. Remove rear suspension (both sides) with drive shafts.
2. Install transmission to engine until alignment pins are
18. Rear lower engine mount engaged, and screw in 4 bolts to hold in place but do not
completely tighten at this time.
19. Sub frame bolts (A - 2 each side)
3. Loosely install upper frame mount bolts and all sub-frame
bolts.
4. Install all remaining transmission-to-engine crankcase
bolts and tighten all in 2 steps to specified torque following
a cross pattern.
5. Tighten sub-frame to main frame bolts (4) and rear engine
mount bolts.
6. Tighten rear upper bracket bolts.
7. Tighten rear upper bracket bolts.

Rear mount
A

20. Remove sub frame.


21. Support transmission with another jack.

22. Loosen, but do not remove the 4 bolts from the rear
transmission hanger bracket.
23. Remove (9) transmission-to-engine bolts.

3.14
ENGINE
Engine Lubrication Cam Chain Tensioner Removal
Oil Type:Polaris Premium 0W-50 Synthetic To position crankshaft at Top Dead Center (TDC) on
compression stroke:
Capacity (DRY):
1.64-1.95 U.S. Quarts (1.55-1.85 l) 4. Remove the valve cover.

Capacity (OIL/FILTER/COOLING BLOCK CHANGE): 5. Rotate engine in normal direction and watch the intake
1.4-1.7 U.S. Quarts (1.3-1.6 l) valve open and begin to close.
6. Continue to rotate engine slowly while watching camshaft
Drain Plug:14-18 ft. lbs. (19-24.4 Nm) sprocket marks and the mark in the timing inspection hole.
Oil Pressure Specification:
(Using Polaris 0W-50 Synthetic @ Operating Temperature @
Single TDC Mark Aligned 3
Idle) Any pressure reading above 9 PSI. TDC Mark

Oil Flow / Pressure Test


Rotation
WARNING

Oil temperature can cause serious injury and


damage. Wear the proper safety gear when
performing these procedures.
7. Align single (T) mark on flywheel with in the inspection
NOTE: Due to the engine assembly having a majority of hole, and the cam sprocket pin (facing upward) aligned with
roller bearings, oil pressure readings hot or cold will be the camshaft to crankshaft center line. NOTE: The
very low. Low oil pressure is not an indication of a oil sprocket marks align with gasket surface, the cam lobes
delivery problem. should be pointing down and the valves should have
clearance at this point.
1. Remove plug from the crankcase.
2. Insert a 1/4 Pipe Thread oil pressure gauge adaptor into the
crankcase and attach an oil pressure gauge.
3. Start engine and allow it to reach operating temperature
while monitoring gauge indicator. Any pressure above 9 Dot
PSI is an indication of good oil flow.

Engine Breather / Oil separator


Breather / oil separators are located behind the gas tank on the Marks Aligned
left side and on the cylinder. The breather provides ventilation
for the valve cover and crankcase through the air box.
TO AIR BOXA 8. Remove the cam chain tensioner end cap.
CAUTION: The plunger is under spring tension. Maintain
inward pressure while removing.
9. Remove 2 cam chain tensioner bolts.

BREATHER FITTING LOCATIONS

3.15
ENGINE
10. Tap lightly on tensioner body with a soft face hammer to Rocker Arm/Shaft Disassembly and
loosen and remove tensioner if required. Inspection
NOTE: Orientation of the components is important for
reassembly. Mark all components before disassembly.

1. Remove the valve cover. Be sure engine is positioned at


TDC on the compression stroke (there should be clearance
on both rocker arm adjusters).

Cam Chain Tensioner Inspection


1. Pull cam chain tensioner plunger (A) out to the end of its
travel and inspect ratchet teeth on plunger and pawl.
Inspect spring (B) for wear or damage.
2. Mark the rocker arms to keep them in order for assembly.
A
3. Slide the rocker shaft out and be prepared to catch the wave
washer (A) positioned on the PTO end of the shaft between
the casting and the intake rocker arm.

2. Hold the ratchet open and slide the plunger in and out of
the tensioner body. The plunger should move smoothly
throughout the travel range.
3. Replace entire tensioner assembly if any part is worn or
damaged.
4. Inspect each rocker arm cam follower surface. If there is
any damage or uneven wear, replace the rocker arm.
NOTE: Always replace camshaft if lobe of either rocker
arm is worn or damaged.

Inspect surface of followers

5. Inspect the rocker arm shaft and the shaft bore in the
cylinder head for wear or signs of scoring.

3.16
ENGINE
6. Measure I.D. of each rocker arm (A) for out-of-round and 4. If not removing the cylinder for other service, secure the
visually inspect the I.D. surface. Replace arm if excessive cam chain with a wire to prevent it from falling into the
wear is evident. crankcase.
7. Inspect rocker adjuster screws (B) for wear, pitting, or
damage to threads of the adjuster or locknut. Replace all
worn or damaged parts. NOTE: The end of the adjuster is
hardened and cannot be ground or re-faced.

5. Inspect cam sprocket teeth for wear or damage.

8. Measure O.D. of rocker shafts for out-of -round. Inspect


them for wear or damage. Replace if excessive wear is
evident. NOTE: Orientation of the rocker shafts is
important for reassembly.
6. Inspect the automatic compression release mechanism.
Replace the cam if parts are worn.

Camshaft Removal and Inspection


NOTE: Cam chain tensioner must be removed before
Compression Release-one-way operation
performing this procedure.
1. Remove the camshaft end cover.
2. Remove the sprocket bolt.
3. Slip the chain over the sprocket and remove sprocket.

Camshaft Inspection
1. Thoroughly clean the camshaft.
2. Visually inspect each cam lobe and bearing journal for
wear, scoring, or damage. Verify oil delivery passages are
clean.
3. Check the automatic decompressor spring legs and replace
if broken. Spring preload is very light (about 45 degrees).

3.17
ENGINE
4. Measure the height of the cam lobes with a micrometer and 1/4 turn each time in a cross pattern until loose.
compare to specification. Replace cam if worn below
minimum height (service limit).

3. Remove bolts (A) and tap the cam support tower with a
plastic hammer until loose. Remove.
4. After removing the camshaft and securing the cam chain,
tap cylinder head lightly with a plastic hammer until loose.
= In. / mm. CAUTION: Tap only in reinforced areas or on thick parts
of cylinder head casting.
Cam Lobe Height - Intake & Exhaust
5. Remove cylinder head, gasket, front chain guide and dowel
Std: 1.2938”-1.2977 (32.863-32.963 mm)
pins.
Limit: 1.2820” (32.563 mm)

Cylinder Head Removal


NOTE: Cam chain and tensioner must be removed. If no
crankshaft service is being performed, secure cam chain
with wire to avoid dropping chain into the crankcase.

1. Remove the (two) 6mm screws on the cylinder head and


the two on the cylinder base.

Cylinder Head Inspection


Thoroughly clean cylinder head surface to remove all traces of
gasket material and carbon.

CAUTION
2. Loosen each of the four cylinder head bolts evenly.
Use care not to damage sealing surface. If there is
damage found on the cylinder head combustion
chamber, it is recommended the component be
replaced.

3.18
ENGINE
Cylinder Head Warp Inspection Cylinder Head Disassembly
1. Lay a straight edge across the surface of the head at several
different points and measure warpage by inserting a feeler WARNING
gauge between the straight edge and the cylinder head
surface. If warpage exceeds the service limit, replace the Wear eye protection or a face shield during cylinder
cylinder head. head disassembly and reassembly. Cylinder head
service should be performed by a technician
knowledgeable in cylinder head reconditioning in a
properly equipped shop.

NOTE: Keep all parts in order with respect to their


location in the cylinder head.
3
1. Using a valve spring compressor, compress the valve
springs and remove the split keeper. NOTE: To prevent
loss of tension, do not compress the valve spring more than
necessary.
2. Remove spring retainer and spring.
NOTE: The valve springs should be positioned with the
tightly wound coils (A) against the cylinder head.

= In. / mm.

Cylinder Head Warp Limit:


.002” (.05 mm)

Combustion Chamber Inspection


Clean all accumulated carbon deposits from combustion
chamber and valve seat area with a soft wire brush. Inspect the
combustion chamber for cracks and/or damage from foreign
debris.

3.19
ENGINE
3. Push valve out, keeping it in order for reassembly in the Valve Inspection
same guide.
1. Remove all carbon from valve with a soft wire wheel.
4. Measure free length of the inner and outer springs with a
Vernier caliper, Ill.1. Check spring for squareness as shown 2. Check valve face for runout, pitting, and burnt spots. To
in Ill.2. Replace spring if measurements are out of check for bent valve stems, mount valve in a drill or use “V”
specification. blocks and use a dial indicator.

A
Valve Spring
Free Length

III.1 3. Check end of valve stem for flaring, pitting, wear or damage
(A).

Coil fatigue/
Squareness

4. Inspect split keeper groove for wear or flaring of the keeper


seat area (B). NOTE: The valves cannot be re-faced or end
III.2 ground. Valves must be replaced if worn, bent, or damaged.
5. Measure diameter of valve stem with a micrometer in three
5. Remove valve seals. NOTE: Replace seals whenever the places and in two different directions (six measurements
cylinder head is disassembled. Hardened, cracked or worn total). Replace if excessive wear is evident.
valve seals will cause excessive oil consumption and
carbon buildup. Measure valve stem in
several places

6. Measure valve guide inside diameter at the top middle and


end of the guide using a small hole gauge and a micrometer.

3.20
ENGINE
Measure in two directions, front to back and side to side. provided in the Valve Seat Reconditioning Kit (PN
2200634).

CAUTION

Wear eye protection when performing cylinder head


service. Valve guide replacement will require
heating of the cylinder head. Wear gloves to prevent
burns.

Follow the manufacturers instructions provided with the valve


seat cutters in the Valve Seat Reconditioning Kit (PN 2200634).
3
Abrasive stone seat reconditioning equipment can also be used.
Keep valves in order with their respective seat.

7. Subtract valve stem measurement to obtain stem to guide NOTE: Valve seat width and point of contact on the
clearance. NOTE: Be sure to measure each guide and valve valve face is very important for proper sealing. The valve
combination individually. must contact the valve seat over the entire
circumference of the seat, and the seat must be the
8. Replace valve and/or guide if clearance is excessive.
proper width all the way around. If the seat is uneven,
NOTE: If valve guides are replaced, valve seats must be compression leakage will result. If the seat is too wide,
reconditioned. Refer to Valve Seat Reconditioning for seat pressure is reduced, causing carbon accumulation
procedure. and possible compression loss. If the seat is too narrow,
heat transfer from valve to seat is reduced and the valve
Valve Seat Reconditioning may overheat and warp, resulting in burnt valves.

Valve Seat Inspection 1. Install pilot into valve guide.

Inspect valve seat in cylinder head for pitting, burnt spots,


roughness, and uneven surface. If any of the above conditions
exist, the valve seat must be reconditioned. If the valve seat is
cracked the cylinder head must be replaced.

Too Uneven Good Too


Wide Narrow
2. Apply cutting oil to valve seat and cutter.
Cylinder Head Reconditioning 3. Place 46o cutter on the pilot and make a light cut.

NOTE: Servicing the valve guides and valve seats


requires special tools and a thorough knowledge of
reconditioning techniques. Follow the instructions

3.21
ENGINE
4. Inspect the cut area of the seat. • If the indicated seat contact is at the top edge of
the valve face and contacts the margin area(B) it is
• If the contact area is less than 75% of the too high on the valve face. Use the 30o cutter to
circumference of the seat, rotate the pilot 180o and lower the valve seat.
make another light cut.
• If too low use the 60o or 75o cutter to raise the
• If the cutter now contacts the uncut portion of the seat. When contact area is centered on the valve
seat, check the pilot. Look for burrs, nicks, or face, measure seat width.
runout. If the pilot is bent it must be replaced.
• If the seat is too wide or uneven, use both top and
• If the contact area of the cutter is in the same bottom cutters to narrow the seat.
place, the valve guide is distorted from improper
installation and must be replaced. Be sure the • If the seat is too narrow, widen using the 45o cutter
cylinder head is at the proper temperature and and re-check contact point on the valve face and
replace the guide. seat width after each cut.
• If the contact area of the initial cut is greater than Bottom 60o or 75o Seat - 45o or 46o
75%, continue to cut the seat until all pits are
removed and a new seat surface is evident. Top - 30o
NOTE: Remove only the amount of material
necessary to repair the seat surface.
5. To check the contact area of the seat on the valve face, apply
a thin coating of Prussian Blue™ paste to the valve seat. If
using an interference angle (46o)apply black marker to the
entire valve face (A).

(A)
NOTE: When using an interference angle, the seat
contact point on the valve will be very narrow, and is a
normal condition. Look for an even and continuous
contact point on the black marker, all the way around the
valve face.

6. Insert valve into guide and tap valve lightly into place a few
times.
7. Remove valve and check where the Prussian Blue™ or
black marker indicates seat contact on the valve face. The Seat
valve seat should contact the middle of the valve face or Width
slightly above, and must be the proper width (A).
(B)

(A)
8. Clean all filings from the area with hot soapy water, rinse,
and dry with compressed air.
9. Lubricate the valve guides with clean engine oil, and apply
oil or water based lapping compound to the face of the
valve. Lapping is not required with an interference angle.
10. Insert the valve into its respective guide and lap using a
Proper Seat Contact On Valve Face lapping tool or a section of fuel line connected to the valve
stem.

3.22
ENGINE
11. Rotate the valve rapidly back and forth until the cut sounds Cylinder Head Assembly
smooth. Lift the valve slightly off of the seat, rotate 1/4 turn,
and repeat the lapping process. Do this four to five times
until the valve is fully seated, and repeat process for the CAUTION
other valve.
12. Clean cylinder head, valves, and camshaft oil supply Wear eye protection during assembly.
passages thoroughly.
NOTE: Assemble the valves one at a time to maintain
13. Spray electrical contact cleaner into oil passages and dry proper order.
using compressed air.
1. Install new valve seals on valve guides.

2. Apply engine oil to valve guides and seats.


3. Coat valve stem with molybdenum disulfide grease.
4. Install valve carefully with a rotating motion to avoid
damaging valve seal.
5. Dip valve spring and retainer in clean engine oil and install
spring with closely spaced coils toward the cylinder head.

Closely spaced
coils toward
cylinder head

3.23
ENGINE
6. Place retainer on springs and install valve spring Cam Chain Guide And Tensioner Blade
compressor. Compress spring only enough to allow split
keeper installation and prevent loss of spring tension. 1. The guide can be removed after cylinder head is removed
Install split keepers with the gap even on both sides. by pulling it upward out of the channel in the crankcase.

7. Repeat procedure for remaining valve. 2. Remove blade and inspect. Replace if worn., cracked, or
damaged.
8. When all valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the Split keepers. 3. Tensioner blade removal requires recoil, flywheel, and
stator plate removal. Refer to lower end service procedures
Valve Sealing Test to access the bolt securing the tensioner blade to the
crankcase.
1. Clean and dry the combustion chamber area.
2. Pour a small amount of cleaning solvent into each port and
check for leakage around each valve. The valve seats
should hold fluid with no seepage.

Engine Bottom End Disassembly


Cylinder Removal

Follow engine disassembly procedures to remove valve cover,


camshaft and rocker arms, and cylinder head.

1. Lift to remove cam chain guide at front of cylinder.


2. Remove the two 6 mm cylinder base bolts.

3. Tap cylinder lightly with a plastic hammer in reinforced


areas only until loose.
4. Rock cylinder forward and backward and lift it from the
crankcase, supporting piston and connecting rod. Support
piston with Piston Support Block (PN 2870390).

3.24
ENGINE
Piston Removal Cylinder Inspection
1. Remove one circlip. Note valve pocket on intake side of 1. Remove all gasket material from the cylinder sealing
piston for installation. surfaces.
2. Remove piston circlip and push piston pin out of piston. If 2. Inspect the top of the cylinder for warpage using a straight
necessary, heat the crown of the piston slightly with a edge and feeler gauge.
propane torch. CAUTION: Do not apply heat to the piston
rings. The ring may lose radial tension.

= In. / mm.
3. Remove the compression rings, starting with the top ring. Cylinder Warp:
.002” (.05 mm) MAX
*Using a piston ring pliers: Carefully expand ring and
lift it off the piston. CAUTION: Do not expand the ring 3. Inspect cylinder for wear, scratches, or damage.
more than the amount necessary to remove it from the 4. Inspect cylinder for taper and out of round with a
piston, or the ring may break. telescoping gauge or a dial bore gauge. Measure in two
different directions, front to back and side to side, on three
*By hand: Placing both thumbs at end gap, carefully spread the different levels (1/2” down from top, in the middle, and 1/
ring open and lift ring over piston at the opposite side. Use care 2” up from bottom).
to not scratch the ring lands. 1/2” Down From Top of Cylinder
4. Repeat procedure for second ring. X Y
5. The oil control ring is a three piece design consisting of a
top and bottom steel rail and a center expander section.
Remove the top rail first followed by the bottom rail and Y
expander. X

Y
X

1/2” Up From Bottom


5. Record measurements. If cylinder is tapered or out of round
beyond specification, the cylinder must be honed, bored or
replaced.

= In. / mm.

Cylinder Taper / Cylinder Out of Round


Limit: .002” (.05 mm) Max.

3.25
ENGINE
Cylinder Hone Selection/ Honing Procedure If cylinder wear or damage is excessive, it will be necessary to
replace the cylinder. Hone only enough to deglaze the outer
layer of the cylinder bore.
CAUTION

A hone which will straighten as well as remove


material from the cylinder is very important. Using a
common spring loaded glaze breaker for honing is
not advised. Polaris recommends using a rigid hone
or arbor honing machine.

Cylinders may be wet or dry honed depending upon the hone


manufacturer’s recommendations. Wet honing removes more
material faster and leaves a more distinct pattern in the bore.

EXAMPLE OF CROSS HATCH PATTERN


Honing To Deglaze
Piston Inspection
A finished cylinder should have a cross-hatch pattern to ensure
piston ring seating and to aid in the retention of the fuel/oil 1. Measure piston outside diameter at a point 7 mm up from
mixture during initial break in. Hone cylinder according to hone the bottom of the piston at a right angle to the direction of
manufacturer’s instructions, or these guidelines: the piston pin.

• Use a motor speed of approximately 300-500


RPM, run the hone in and out of the cylinder
rapidly until cutting tension decreases. Remember 7mm
to keep the hone drive shaft centered (or cylinder
centered on arbor) and to bring the stones
approximately 1/2” (1.3 cm) above and below the
bore at the end of each stroke.
• Release the hone at regular intervals and inspect Piston
the bore to determine if it has been sufficiently Piston Pin
deglazed, and to check for correct cross-hatch.
NOTE: Do not allow cylinder to heat up during
honing.
2. Subtract this measurement from the maximum cylinder
• After honing has been completed, THOROUGHLY measurement obtained earlier.
clean the cylinder to remove all honing residue.
IMPORTANT: Clean the Cylinder After Honing
= In. / mm.
Wash the cylinder in a solvent, then in hot, soapy water. Use
electrical contact cleaner if necessary to clean areas that cannot
be scrubbed. Rinse thoroughly, dry with compressed air, and oil Piston to Cylinder Clearance
the bore immediately with Polaris 4 Cycle Lubricant to prevent Std: .0015- .0032” (0.038- 0.082 mm)
the formation of surface rust. Limit: .0043” (.11 mm)

3. Measure piston pin bore. Replace piston if out-of-round.

Piston Pin Bore

3.26
ENGINE
4. Measure piston pin O.D. Replace piston pin if out-of-round. Piston Ring Installed Gap
1. Place each piston ring inside cylinder using piston to push
ring squarely into place as shown.
Piston ring installed end gap

Feeler Gauge

Piston Pin Measurement Locations Cylinder 25-50 mm 3


5. Measure connecting rod small end ID. Replace crankshaft
if out-of-round.
Piston Ring

= In. / mm.

Piston Ring Installed Gap

Top Ring
Std: .008- .012” (.2- .3 mm)
Limit: .032” (0.8 mm)
Second Ring
6. Measure piston ring to groove clearance by placing the ring Std: .014- .020” (0.35- 0.50 mm)
in the ring land and measuring with a thickness gauge. Limit: .039” (1.0 mm)
Replace piston and rings if ring-to-groove clearance Oil Ring
exceeds service limits. Std: .008- .028” (0.2- 0.7 mm)
Limit: .059” (1.5 mm)

Piston 2. Measure the gap with a feeler gauge at both the top and
bottom of the cylinder.
Ring
NOTE: Measure at two points in the cylinder A
difference in end gap indicates cylinder taper. The
cylinder should be measured for excessive taper and out
of round.
Feeler Gauge
3. If the installed gap measurement exceeds the limit, replace
the rings. If using new rings and the measurement is too
small, file the ring ends to achieve the proper gap.
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 an oil rag immediately to remove residue and
prevent rust.

3.27
ENGINE
Flywheel Removal / Inspection Starter Drive Clutch Removal/Inspection
1. Remove the recoil housing, recoil hub, and flywheel nut. 1. Remove recoil housing bolts and remove housing.
2. Remove the starter drive clutch and washer by pulling the
shaft and tilting the gear slightly.

2. Install Flywheel Puller (PN PA-47308) and remove


flywheel. CAUTION: Do not hammer or strike the tool
while attached to the crankshaft end.

3. Measure the O.D. of the starter drive shaft on both ends for
out-of-round.
4. Measure the I.D. of the bushings in the recoil housing and
in the crankcase (A) in two directions 90o apart to determine
if out-of-round. Replace worn bushings.

5. Inspect gear teeth on starter drive. Replace starter drive if


gear teeth are cracked, worn, or broken.

3.28
ENGINE
Cam Chain Drive Sprocket Removal / Oil Pump Inspection / Removal
Inspection
NOTE: Mark the oil pump geroters to keep parts mated
1. Remove recoil housing, flywheel, flywheel key, and for assembly.
stator.
1. Remove recoil housing, flywheel, flywheel key, and
stator.
2. Use a feeler gauge to check oil pump rotor tip clearance at
“A”, and pump body clearance at “B”. Compare to
specifications. Replace the oil pump assembly if any parts
are damaged, scored, or measure beyond the service limit.
3

A
B
2. Using the Slotted Nut Socket, remove the crankshaft slotted
nut by turning it clockwise. NOTE: Slotted nut is left hand
thread.

3. Mark the oil pump geroters and shaft and carefully lift the
geroters from the housing.

REMOVE

Slotted Nut Socket


(PN 2871293-A)

3. Remove cam chain drive sprocket and Woodruff key from


crankshaft.
4. Inspect sprocket teeth for wear or damage.

Visually inspect for


tooth wear or damage

5. Inspect Woodruff key for wear.

3.29
ENGINE
Starting Clutch And Engine Braking Clutch 5. Open the staked portion of the nut (A) with a center punch.
Removal /Inspection Inspect the one-way clutch hub surface on the starting
clutch (B). The hub must be smooth without any nicks or
NOTE: The transmission must be removed from the burrs. Replace the starting clutch assembly if the one-way
engine to access the starting clutch and one-way clutch hub is uneven or damaged
engine braking clutch.
Inspect entire surface of
1. Inspect the starting clutch drum bearing in the housing. one-way clutch hub.
The shaft must turn smoothly (by hand) without binding B
in the clockwise direction, and should not turn by hand in
the counter clockwise direction. Minimal movement in the
shaft is NORMAL with engine removed due to the lack of
clutch cover bearing support on the free end of the shaft
(approximately 0-.060” (0-1.5mm). Press the shaft out of A
the housing and replace the bearing if worn or rough.
DO NOT LIFT ENGINE WITH
CLUTCH SHAFT

6. Install the starting clutch holder (PA-47457) onto the


A starting clutch and engage the tabs (C).
B
C

2. Remove all screws from the starting clutch housing.


3. Remove the one-way clutch from the starting clutch drum
with a twisting motion. Note direction of installation with
flange toward drum for assembly.
7. Remove the nut (counterclockwise). This is a standard
thread.
Inspect Drum For
Wear or Damage

Flange toward drum

4. Inspect the one-way clutch closely for cracks or damage on


the one-way bearing shoes and the cage.

8. Inspect the shoes and springs of the starting clutch. Measure


the thickness of the friction material on the shoes as shown,
from the bottom of the friction material to the top at the

3.30
ENGINE
thinnest point. 9. Install one-way clutch in starting clutch drum with the
flanged side toward the hub, using a rotating motion.
Standard Thickness: .100” (2.54mm)
LIMIT: .039” (1.00mm)

Flange side toward hub


3

Starting Clutch Assembly


1. Clean the mating surfaces of the crankcase and clutch 10. Install a new housing gasket.
starting clutch housing to remove all gasket material.
11. Install the drum / housing assembly onto the case, install the
2. Install the starting clutch on the shaft. housing bolts and torque in two steps using a cross pattern
3. Start a NEW stake nut on the shaft. to specification.

4. Install the starting clutch holder on the clutch.


=T
5. Torque the nut to specification.
Starting Clutch Drum Housing:
=T 14-15.5 ft. lbs. (19-21 Nm)

12. CHECK the clutch shaft to be sure it rotates smoothly in


Starting Clutch Stake Nut:
the clockwise direction and will not rotate in the
103-118 ft. lbs. (140-160 Nm)
counterclockwise direction. If binding is evident, or if the
6. Use a center punch or a pin punch to thoroughly stake the shaft rotates in both directions (without turning the engine
nut at the depression in the shaft. over) disassemble and inspect the one-way clutch and hub.

Crankcase Disassembly
7. If drum bearing was replaced in the starting clutch housing, NOTE: Engine must be removed from the frame to
press the drum/shaft into the housing until fully seated. perform any crankcase or crankshaft removal.
8. Clean the inside of the starting clutch drum and lubricate NOTE: The starter, starter drive, flywheel, stator, oil
the drum and one-way clutch with engine oil. pump and transmission can be serviced with the
engine in the frame.
3.31
ENGINE
Crankcase Separation crankshaft, or balance shaft. See procedure this
chapter.
NOTE: Stator housing, flywheel and gears have are
previously removed for this procedure. Use care during
the removal process to avoid damage to the cam chain.

NOTE: Valvetrain and cylinder removal must be


performed prior to this procedure.

1. Remove all bolts and the pressure relief valve (A) from the
magneto side crankcase.

Crankshaft / Cam Chain / Sprocket


Inspection
A 1. Inspect the crankshaft main bearings for wear or damage.

2. Tap carefully on reinforced areas of the cases to separate


the halves. Watch the gap along the crankcase mating
surface and separate the crankcase evenly.
3. Lift the right case half off of the left, leaving the crankshaft
and balance shaft in the left case.

NOTE: Due to extremely close tolerances and minimal


movement, the ball bearings must be inspected visually,
and by feel. Look for signs of discoloration, scoring or
galling. Turn the outer race of each bearing. The
bearings should turn smoothly and quietly. The inner
race of PTO bearing each bearing should fit tightly on the
crankshaft. The outer race should be firm with minimal
side to side movement and no detectable up and down
movement. The MAG end bearing usually stays in the
case. Check the inner race of the MAG bearing in the
same manner.
Crankshaft Removal 2. Replace the main bearings if the components fail visual
1. Lift the crankshaft and balance shaft from the left case. inspection.

2. Note the number and thickness of any shims installed on 3. The connecting rod utilizes a roller bearing. Clearance can
either shaft. be measured with a dial indicator to check radial clearance.
Visually inspect the connecting rod, crank pin, and thrust
NOTE: Crankshaft and balance shaft end play must washers for scoring, damage, excessive wear, or signs of
be measured and adjusted with shims if any new overheating. Check for roughness or noise when rotating
components are installed (bearings, crankcase, the connecting rod on the crank pin. Replace crankshaft if
it fails visual inspection, or if any up and down movement

3.32
ENGINE
is detectable in the connecting rod. Camshaft Chain
1. Replace the cam chain as part of any crankshaft repair.
2. The cam chain can be removed by removing the engine top
end, the recoil assembly, flywheel and flywheel key, stator
plate, and slotted nut.
3. Lift the sprocket slightly until chain clears the crankcase to
remove.

ote: Install new chain as a part of crankshaft repa


3
= In. / mm.

Connecting Rod Big End Radial Clearance:


.0004-.0014” (.011-.038 mm)
LIMIT: .0019” (.05mm)

4. Check connecting rod side clearance with a feeler gauge.


5. Refer to piston inspection in this chapter to inspect the
connecting rod small end.
Balance Shaft Bearing Inspection
NOTE: Replace all seals whenever the crankcase is
= In. / mm. disassembled.

Connecting Rod Side Clearance: 1. Inspect the balance shaft bearings in the crankcase.
.0035-.0196” (.09-.50mm) NOTE: Due to extremely close tolerances and minimal
Limit: .023” (.60mm) movement, the bearing must be inspected visually and
by feel. Look for signs of discoloration, scoring or galling.
6. Clean crankshaft oil passages by running a stream of clean Turn the inner race of bearing. The bearing should turn
solvent through the crankshaft. Be sure all passages are smoothly and quietly. The outer race should fit tightly in
clear and free of nicks or scratches. the crankcase. The inner race should be firm with
minimal side to side movement and no detectable up and
Crankcase Oil Passages & Pressure Relief down movement.
Valve
2. To remove balance shaft bearings, use a blind hole bearing
1. Remove the pressure relief valve assembly from the case.
puller.
NOTE: Bearings are stressed during the removal
procedure and should not be re-used.

2. Clean crankcase oil passages with clean solvent.

3.33
ENGINE
Crankcase Oil Pickup Strainer Inspection End Play Inspection/Adjustment
Before reassembling the crankcase, the following steps should
be performed to determine the amount of crankshaft, counter
balancer shaft, and pump shaft end play. Excessive end play may
cause engine noise at idle and slow speeds. Too little play will
side load the bearings which may lead to premature bearing
failure.

Crankshaft End Play Adjustment


NOTE: The method described here is shown with
the PTO main bearing on the crankshaft, which is the
most common situation. If the bearing is in the case,
A the procedure is the same, but the photo examples
will differ.
1. Pull the strainer screen (A) from the case carefully and
1. Make sure all bearings are firmly seated in the crankcase.
clean or replace it if heavily clogged, or if damaged.

Bearing /Seal Installation


NOTE: To ease crankcase bearing installation, warm
the crankcase until hot to the touch. Placing the bearing
in a freezer prior to installation will assist the assembly
process.

1. Install the bearing so the numbers are visible.


2. Drive or press the new bearing into the crankcase, using the
proper driver.

CAUTION 2. Lay a straightedge on the left (PTO) crankcase and measure


the distance from the straightedge to the bottom of the main
Press only on outer race of bearing to prevent bearing bore (if bearing is still on the crankshaft) or to the
bearing damage. bearing race (if the bearing is installed in the case) using a
dial caliper.
3. Install new seals with the lip facing in.

CAUTION

Press only on outer diameter to prevent damage.

3.34
ENGINE
3. Subtract the thickness of the straightedge from the 6. Add the readings recorded in Step 3 and Step 5 and record
measurement obtained in Step 2 and record. below.

Total Case Width_________________

7. Measure the width of the crankshaft at the bearing seats (or


to the outside of bearing if bearing is on the crankshaft as
shown) with a micrometer or dial caliper and record.

PTO Case Depth_________________________

4. Measure the distance from the Magneto crankcase mating


surface to the main bearing using the same method and
record.
Crankshaft Width____________

8. Subtract the Crankshaft Width measured in Step 7 from the


Total Case Width recorded in Step 6, and record below.

Total End Play_____________

9. Subtract the thickness of the existing shim from the result


of Step 8 to determine if a different shim is required. The
result must be within the specified range listed below.

5. Subtract the thickness of the straightedge from the


measurement obtained in Step 4 and record.

= In. / mm.

Crankshaft End Play:


.006-.012” (.15-.30 mm)

Mag Case Depth_______________

3.35
ENGINE
Balancer Shaft End Play Adjustment 7. Subtract the thickness of the existing shim from the result
of Step 6 to determine if a different shim is needed. The
NOTE: The balancer shaft end play measurement result must be within the specified range listed at below.
procedure is the same as that outlined for the
crankshaft. The exception is that measurements are 8. Add or subtract shims or change shim thickness as required
taken to the balancer shaft bearings in the case, and install them upon assembly.
rather than the crankshaft main bearings, and the
width of the balancer shaft is measured, not the
crankshaft. = In. / mm.
1. Make sure the counter balance shaft bearings are firmly
Counter Balance Shaft End Play:
seated in each crankcase.
.004”-.029” (.1-.74 mm)
Measure to balance shaft bearing race

Crankcase Reassembly
Crankshaft Installation

Lubricate all bearings with clean engine oil before assembly. Be


sure crankcase mating surfaces are clean and free from oil or
grease.

1. Place the required shims on the crankshaft and balance


2. Measure the distance from the Mag crankcase mating shaft.
surface to the balance shaft bearing using a dial caliper and
a straight edge. Subtract the thickness of the straightedge
and record.

MAG Case Depth_________________________

3. Measure the distance from the PTO crankcase mating


surface to the bearing using the same method outlined for
the MAG side.

PTO Case Depth_________________________

4. Measure the width of the counter balancer shaft at the


bearing seats with a dial caliper or micrometer, and record
reading. 2. Support the PTO side crankcase on blocks. Install the
crankshaft and balance shaft in the case, aligning the
balance dots on the gears.

5. Add the readings obtained in Step 2 and Step 3.


6. Subtract the counter balancer shaft width measured in Step
4 from the result obtained in Step 5.

3.36
ENGINE
3. Be sure balance dots on gear teeth are aligned. Cam Chain, Oil Pump, & Tensioner Blade
Installation
1. Install the cam chain over the drive sprocket.
2. Lubricate and install the oil pump geroters, aligning the
marks made during disassembly. Clean the marks off the
geroters.

4. Apply a thin coat of crankcase sealant to the outer mating


surface of the left crankcase. Sealant is not required on the
inner mating surfaces (A).
Geroters
A
3. Install the tensioner blade and tighten the mounting bolt to
specified torque.

Crankcase Sealant
PN 2871557

5. Install the mag side case and tap with a soft faced hammer
to seat.
6. Install case screws and torque in a cross pattern to
specification. =T
Tensioner Blade Mounting Bolt Torque:
5-6.5 ft. lbs. (7-9 Nm)

4. Install a new O-ring on the stator plate.


5. Lubricate the stator plate seal and bushing with engine oil
and install the stator plate.

=T
Crankcase Bolt Torque:
6.5-8.0 ft. lbs. (9-11 Nm)

3.37
ENGINE
6. IMPORTANT! Be sure the sealed screw is placed in the 5. Install the top ring with the marking facing up. The top ring
hole that aligns with the cam chain cavity or an oil leak may has an inner bevel with a barrel face.
result. If you are installing the old screw, seal it with Loctite Top Ring:
242 (blue) before installation. Bevel on Inner Edge Install with
mark UP
This screw must be sealed

Second Ring
Mark Faces UP

6. Verify proper installation of rings by checking to be sure


the top and second rings rotate freely in the groove when
compressed by hand.
7. Torque the screws to specification.
Piston Installation
=T
CAUTION
Stator Plate Screw Torque:
6.5-8.0 ft. lbs. (9-11 Nm) Do not re-use circlips. Circlips become deformed
during the removal process. Do not compress the
8. Install the flywheel key and flywheel. new clip more than necessary to prevent loss of
radial tension. Severe engine damage may result if
=T circlips are re-used or deformed during installation.

Flywheel Nut: 1. Install a new circlip on one side of the piston with the end
67-81 ft. lbs. (90-110 Nm) gap facing up or down.
Recoil Drive Hub: 2. Apply clean engine oil to the piston rings, ring lands, piston
12-14 ft. lbs. (17-19 Nm) pin bore, piston pin, and piston skirt. Lubricate the
connecting rod (both ends) and crankshaft main bearing
Piston Ring Installation area.

NOTE: Apply clean engine oil to all ring surfaces and 3. IMPORTANT- Install the piston on the connecting rod
ring lands. Always check piston ring installed gap before with the valve pocket facing the intake side of engine.
rings are installed on piston. If the piston has been in The piston pin should be a push fit into the piston.
service, clean any accumulated carbon from the ring Pocket
grooves and oil control ring holes.
1. Place the oil control ring expander in oil ring groove with
the end gap facing forward. The expander has no up or
down marking and can be installed either way. The ends
should butt squarely together and must not overlap.
2. Install the oil ring top rail with the end gap at least 30o from
the end of the expander.
3. Install the bottom rail with the gap at least 30o from the end
of the expander on the side opposite the top rail gap.
4. Install the second ring with the mark facing up. The second 4. Install the other circlip with the gap facing up or down. Push
ring has an undercut with a tapered face. Position the end the piston pin in both directions to make sure the clips are
gap toward the rear (intake) side of the piston. properly seated in the groove.

3.38
ENGINE
5. Lubricate the piston and rings with engine oil and install a 5. Loop the cam chain through the cylinder chain room and
ring compressor on the piston assembly. Verify that the ring secure with mechanic’s wire.
gaps are 120o - 180o apart from each other before
installation.

Cylinder Installation
NOTE: Clean the gasket surfaces on the crankcase and
cylinder. Remove all traces of old gasket material or
sealant. The surfaces must be oil-free!

1. Apply a small amount of crankcase sealant at the case


parting lines (A). Do not allow sealant to dry. Assemble 3
the top end immediately.

6. Install cylinder carefully with a front to back rocking


motion until rings are fully captive in the sleeve, then
remove the compressor and support block.
7. Seat the cylinder firmly onto the base gasket.
A
8. Install the cam chain guide and dowel pins into the cylinder.
Verify the bottom end of the guide is seated properly in the
crankcase.

2. Install the dowel pin(s).


3. Install a new base gasket onto the mating surface and
position the Piston Support Block (PN 2870390) beneath
the piston skirt to support the piston during cylinder
installation.
4. Apply clean engine oil liberally to the bore and tapered area
of the cylinder. Place the cylinder on to the studs.
NOTE: Route cam chain through the cylinder chain
room and secure it, holding it up to avoid damage to the
chain, drive sprocket teeth or tensioner blade.

3.39
ENGINE
Cylinder Head and Camshaft Installation 6. Torque the cylinder head following the procedure and
pattern below.
NOTE: Clean the gasket surfaces on the cylinder head
and cylinder. Remove all traces of old gasket material. Cylinder Head / Cylinder Base
The surfaces must be oil-free!

1. Install the dowel pin(s) and a new cylinder head gasket. 3 2


5
2. Pull the cam chain through the cylinder head chain room 6 mm
and secure with mechanic’s wire. 6
3. Place the cylinder head on the cylinder. 1 4

4. Install the two 6 mm bolts on cylinder base and on the head, Forward
but do not tighten.
=T
Cylinder Gasket Torque Sequence:
Tighten M10 bolts to 18.5 ft. lbs. (25 Nm)
Loosen 180 degrees
Tighten to 11 ft. lbs. (15 Nm)
Tighten M10 bolts 90 degrees
Tighten M10 bolts another 60 degrees
Tighten 6mm bolts to 8 ft.lbs.(11 Nm)

Camshaft Installation & Timing

CAUTION
5. Lubricate the washers and the threads of the cylinder head
bolts and install the bolts with washers. Serious engine damage will result if the camshaft is
not properly timed to the crankshaft.

IMPORTANT CAMSHAFT TIMING NOTE: In order to


time the camshaft to the crankshaft, the piston must be precisely
located at Top Dead Center (TDC). If flywheel key and flywheel
are not installed, install them at this time. The recoil housing
must also be temporarily installed to use the timing inspection
hole.

1. Rotate the crankshaft until the “T” (Top Dead Center)


timing mark on the flywheel is aligned with the mark in the
timing inspection window of the recoil housing. Be sure to
use the correct mark when installing the cam. Do not use
any advance timing marks.

3.40
ENGINE
2. Apply engine oil or starter drive grease (molybdenum 8. Verify all marks are aligned. Install the cam sprocket bolt
disulfide paste) to the camshaft main journals and cam and torque to specification.
lobes. Lubricate automatic compression release
mechanism with clean engine oil.
=T
Starter Drive Grease: Camshaft Sprocket Bolt
(PN 2871460) 35.5-50 ft. lbs. (48-70 Nm)

3. Orient the camshaft with the lobes facing downward, and Cam Chain Tensioner Installation
install the cam into the cylinder head.
1. Hold the tensioner ratchet pawl (A) open and push the
plunger (B) in to the fully retracted position. 3
A
B

4. Disconnect the wire or tie strap securing the cam chain (if
used).
5. Be sure the pin on the camshaft is pointing DOWN. 2. With the plunger retracted, install the tensioner assembly
with a new gasket and tighten the bolts to specification.
6. Loop the cam chain over the sprocket and shift the chain
on the sprocket until it can be installed onto the camshaft.

A
B

B
A

=T
7. VERIFY the following: Tensioner Bolt Torque: 5-6.5 ft. lbs. (7-9 Nm)
• “T” Mark on flywheel is aligned with the 3. Install the pin, spring, and tensioner cap with a new sealing
projection in the timing hole of the recoil
housing. washer. Torque cap to specification.

• The mark (A) on the camshaft sprocket is


aligned with the projection (B) in the camshaft =T
cover window as shown above.
Tensioner Cap Torque: 6-7.5 ft. lbs. (8-10 Nm)

3.41
ENGINE
4. Slowly rotate engine two to three revolutions in the Starter Drive Assembly
direction of rotation and re-check cam timing.
1. Be sure the washer is positioned on the back of the drive
Rocker Arm Installation gear.

1. Lubricate the rocker arms and shaft with engine oil. Apply
a light film of starter grease (moly grease) to the cam
follower pad on the rocker arms.

Starter Drive Grease:


(PN 2871460)

2. Slide the shaft through the tower just enough to install the
wave washer (A).
NOTE: The flats of the wave washer are positioned
against the intake rocker arm.

Starter Drive Grease:


(PN 2871460)

2. Apply Starter Drive Grease (PN 2871460) to the drive


bushings in the cases and all moving surfaces of the starter
drive gears and install.
3. Install recoil housing and torque bolts to specification.

3. Install the rocker arms in the same position as marked


during disassembly.

4. Turn the engine through several revolutions to be sure parts


rotate freely and smoothly.
5. Adjust valve clearance as outlined in Chapter 2.

3.42
ENGINE
TROUBLESHOOTING Engine Does Not Turn Over

Spark Plug Fouling troubleshooting • Dead battery

• Restricted air filter (main or pre-cleaner), or air • Starter motor does not turn
inlet ducts. • Engine seized, rusted, or mechanical failure
• Choke cable adjustment or plunger/cable sticking
Engine Runs But Will Not Idle
• Foreign material on choke plunger seat or plunger
• Idle speed set too low
• Incorrect spark plug heat range or gap
• Faulty ETC system
• Jet needle and/or needle jet worn or improperly
adjusted • Restricted carburetor pilot system 3
• Excessive carburetor vibration (check all engine • Carburetor misadjusted
and carburetor mounts)
• Choke not adjusted properly or sticking plunger
• Oil contaminated with fuel
• Low compression
• ETC switch mis-adjusted
• Crankcase breather restricted
• Low compression
• Air filter restriction
• Spark plug cap loose or faulty
Engine Idles But Will Not Rev Up
• Loose jets in carburetor or calibration incorrect for
altitude/temperature
• Spark plug fouled/weak spark
• Incorrect float level setting
• Broken throttle cable
• Carburetor inlet needle and seat worn
• Obstruction in air intake
• CVT system calibrated incorrectly or components
worn or mis-adjusted • Air box removed (reinstall all intake components)

• Fuel quality poor (old) • Incorrect or restricted carburetor jetting

• Restricted exhaust • ETC switch limiting speed

• Restricted crankcase breather system • Reverse speed limiter limiting speed

• Weak ignition (loose coil ground, faulty coil, stator, • Carburetor vacuum slide sticking/diaphragm
engine to chassis ground, or ETC switch) damaged

• Improperly assembled air intake system • Incorrect ignition timing


• Restricted exhaust system
ENGINE Troubleshooting
• Camshaft lobes worn
Engine Turns Over But Fails to Start
• Flywheel key sheared
• No fuel
Engine Has Low Power
• Dirt in fuel line or filter
• Spark plug fouled
• Fuel will not pass through fuel valve
• Cylinder, piston, ring, or valve wear or damage
• Fuel pump inoperative/restricted (check compression)
• Fuel tank vent plugged • CVT not operating properly
• Carburetor starter circuit restricted • Restricted exhaust muffler
• Engine flooded • Dirty carburetor
• Low compression (high cylinder leakage) • Cam lobe worn
• No spark (Spark plug fouled)

3.43
ENGINE
Piston Failure - Scoring Backfiring

• Lack of lubrication • ETC or speed limiter system malfunction


• Dirt entering engine through cracks in air filter or • Fouled spark plug or incorrect plug or plug gap
ducts
• Carburetion faulty - lean condition
• Engine oil dirty or contaminated
• Intake / Exhaust system air leaks
Excessive Smoke and Carbon Buildup
• Ignition system faulty:
• Oil level too high •Spark plug cap cracked/broken
• Excessive piston-to-cylinder clearance •Ignition coil faulty
• Worn rings, piston, or cylinder •Ignition or kill switch circuit faulty
• Worn valves, guides or seals •Ignition timing incorrect
• Restricted crankcase vent •Sheared flywheel key
• Air filter dirty or contaminated • Poor connections in ignition system
Low Compression • System wiring wet
• Decompressor stuck • Cam lobe worn or Valve sticking
• Cylinder head gasket leak • Lean condition
• No valve clearance or incorrectly adjusted
• Cylinder or piston worn
• Piston rings worn, leaking, broken, or sticking
• Bent valve or stuck valve
• Valve spring broken or weak
• Valve not seating properly (bent or carbon
accumulated on valve area)
• Rocker arm sticking

3.44
FUEL / AIR / EXHAUST
CHAPTER 4
FUEL / AIR / EXHAUST
GENERAL INFORMATION AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
CARBURETOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
CARBURETOR JETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
MIKUNI JET PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
CARBURETION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
BST 34 CARBURETOR EXPLODED VIEW 1 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
BST 34 CARBURETOR EXPLODED VIEW 2 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
CARBURETOR VENTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
CV CARBURETOR SYSTEM FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
CARBURETOR VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
MIKUNI CV CARB OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
STARTER SYSTEM (CHOKE OR ENRICHMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
PILOT (IDLE AND SLOW) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4
MAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
FLOAT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
PILOT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
AIR/FUEL MIXTURE RATIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
NEEDLE JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
THROTTLE OPENING VS. FUEL FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
CARBURETOR DISASSEMBLY – MIKUNI CV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
CARBURETOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
CARBURETOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
FLOAT HEIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
NEEDLE AND SEAT LEAKAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL LEVEL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
FUEL TANK/FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
FUEL TANK / FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18

4.1
FUEL / AIR / EXHAUST
GENERAL INFORMATION AND Carburetor Specifications
SPECIFICATIONS
2007 Hawkeye 2x4 / 4x4
Special Tools (Domestic and International)

TOOL Ambient Below 40° F Above 40° F


PART NUMBER Temperature (Below 5° C) (Above 5° C)
DESCRIPTION

2870975 Mity VacTM Pressure Test 0-6000 145 140


Tool (0-1800)
Altitude
Carburetor Float Feet 135
2872314
Adjustment Tool (Meters)
OR
6000-12000 Six 1/2” holes
140
(1800-3700) in air box
Hole Plugs
WARNING PN 5412981

Gasoline is extremely flammable and explosive Carburetor Jetting


under certain conditions.
IMPORTANT: The following guidelines must be followed
when establishing a main jet setting:
Always stop the engine and refuel outdoors
or in a well ventilated area. 1. Select the lowest anticipated temperature and altitude at
which the machine will be operated.
Do not overfill the tank. The tank is at full 2. Select the correct main jet according to the engines fuel/
capacity when the fuel reaches the bottom of performance requirements.
the filler neck. Leave room for expansion of
fuel. CAUTION

Never start the engine or let it run in an A main jet that is too small will cause a lean
enclosed area. Gasoline powered engine operating condition resulting in serious engine
exhaust fumes are poisonous and can cause damage. Select the correct main jet carefully for
loss of consciousness and death in a short elevation and temperature according to the charts in
time. the Specifications section or in the Owner’s Safety
and Maintenance Manual for each particular model.
Never drain the float bowl when the engine is
hot. Severe burns may result.
Mikuni Jet Part Numbers
Do not smoke or allow open flames or sparks Main Jets Pilot Jets
in or near the area where refueling is Jet Number Part Number Jet Number Part Number
performed or where gasoline is stored. 130 3130561 25 n/a
132.5 3130562 27.5 n/a
If you get gasoline in your eyes or if you 135 3130563 30 n/a
137.5 3130564 32.5 n/a
should swallow gasoline, seek medical 140 3130527 35 n/a
attention immediately. 142.5 3130566 37.5 n/a
145 3130567 40 3130624
147.5 3130568 42.5 3130526
If you spill gasoline on your skin or clothing, 152.5 3130570 45 3131397
immediately wash with soap and water and 155 3130571 47.5 3131226
change clothing. 157.5 3130572 50 3131132
160 3131141 55 n/a
NOTE: It is strongly recommended that Polaris Carbon 162.5 3131142 57.5 n/a
165 3131143 60 n/a
Clean be added regularly as directed to the fuel systems 167.5 3131144 65 n/a
of all Polaris ATVs. Carbon Clean stabilizes the fuel, 170 3131145 70 n/a
preventing clogging of the small passages and orifices
common to ATV carburetors, and ensures constant
performance, reliability and easier starting.

4.2
FUEL / AIR / EXHAUST
CARBURETION
BST 34 Carburetor Exploded View 1 of 2

A
G

H
4
C
N
M
P L
D
J

E
F

Table 4-1: Carburetor Components


REFERENCE DESCRIPTION REFERENCE DESCRIPTION
A Jet Needle J Throttle Control Cover Plate

B Diaphragm Assembly K Carburetor Body

C Needle Jet L Enrichment Plunger

D Jet Block Assembly M Enrichment Spring

E Washer N Cable guide

F Main jet P Pilot Air Jet

G Cover

H Spring

4.3
FUEL / AIR / EXHAUST
BST 34 Carburetor Exploded View 2 of 2

A D

B F

C
E

J
K

Table 4-2: Carburetor Components


REFERENCE DESCRIPTION REFERENCE DESCRIPTION
A Throttle Plate Shaft Retaining Components J Float Bowl O Ring

B Pilot Jet K Float Bowl

C Needle Valve Assembly L Float Bowl Drain Screw

D Throttle Plate M Throttle Shaft

E Idle RPM Speed Adjustment Screw N Throttle Shaft Return Spring

F Spring

G Needle Valve Retaining Plate

H Floats

4.4
FUEL / AIR / EXHAUST
Carburetor Venting System

D
B
E
C

Table 4-3: Carburetor Venting System


REFERENCE DESCRIPTION
A Check Valve

B Hose (Float Bowl Drain)

C Hose (Vents)

D Tee Fitting

E Filter

4.5
FUEL / AIR / EXHAUST
CV Carburetor System Function Carburetor Venting
The carburetor float bowl vent lines supply atmospheric
Carburetor Component Function pressure to the float bowl. The lines must be free of kinks,
Main Main Main restrictions and be properly routed. This allows fuel to flow in
System the proper amount and prevents contaminants from entering the
Components Function Affect carburetor.
Float Inlet Pipe, Maintains All systems
System Needle and specified fuel All throttle Mikuni CV Carb Operation
(Level Seat, Float, level in float ranges
Control) Float Pin chamber The constant velocity carburetor incorporates a mechan-
(carburetor float ically operated throttle plate and a vacuum controlled
bowl) slide valve (vacuum slide). The venturi cross–sectional
Venting Passages in Supplies All systems area in the carburetor bore is increased or decreased
Carburetor, Vent atmospheric All throttle automatically by the vacuum slide, which moves accord-
lines pressure to float ranges ing to the amount of negative pressure (less than atmo-
to frame chamber spheric) present in the venturi.
A diaphragm attached to the top of the vacuum slide is sealed to
Starter Choke Lever, Supplies All throttle the slide and to the carburetor body forming two chambers. The
chamber above the diaphragm is connected to the venturi area
(Choke/ Cable, Plunger, additional fuel ranges by a drilled orifice in the center of the vacuum slide. The
Enrichment) Return Spring, air mixture Greatest chamber below the diaphragm is vented to atmospheric pressure
Carb Passages necessary for effect at low by a passage on the air box side of the carburetor. A spring,
installed in the center of the vacuum slide, dampens the slide
(Starter Jet, cold starting throttle movement and assists the return of the slide.
Starter Bleed settings and
Pipe) idle
Low Pressure
Diaphragm
From Venturi

Pilot (Idle Pilot Jet/ Primarily Mainly idle


Atmospheric
System) Passage-ways, supplies fuel at to 1/4 Pressure
Pilot–Mixture idle and low throttle
Screw with throttle positions Minimal
Spring Washer effect after Atmospheric
Air inlet
and Sealing O– 1/2 throttle
Ring, By-pass
Ports (Behind
Throttle Plate), Vacuum
Slide
Pilot Air Jet, Pilot
Outlet, Throttle Throttle Plate
Plate
Main Main Jet, Main Supplies fuel at 1/4 to full
System Air Jet, Main Air mid–range and throttle Venturi
Passage, high throttle
Needle Jet, Jet settings.
Needle, Vacuum
Slide, Throttle
Plate
= Air Flow = Low pressure

4.6
FUEL / AIR / EXHAUST
When the throttle plate is opened and engine speed begins to Starter System (Choke or Enrichment)
increase, the pressure in the venturi (and therefore in the
chamber above the diaphragm) becomes significantly lower When the choke cable (1) is activated, the starter plunger (5) is
than atmospheric. Atmospheric pressure in the chamber below lifted off the seat.
the diaphragm forces the diaphragm upward, raising the slide
against spring pressure. When the pressure above and below the 8
diaphragm are nearly equal, the slide moves downward under 5 1
spring pressure. Raising or lowering the slide increases or
decreases the cross sectional area in the venturi, and therefore
the air velocity in the venturi is kept relatively constant. This
provides improved fuel atomization and optimum fuel/air ratio.

7 6

2
3 4
Fuel is drawn into the starter circuit from the float chamber (2)
through the starter jet (3). Starter jet meters this fuel, which then
flows into starter pipe (4) and mixes with the air (7) coming from
the float chamber. The mixture, rich in fuel content, reaches
starter plunger and mixes again with the air coming through a
passage (8) extending from underneath the diaphragm. The rich
fuel/air mixture for starting is discharged through starter outlet
(6) in the main bore.

Note: Diagrams are for explanation of theory only, and are not true
representations of Mikini BST carburetor.

4.7
FUEL / AIR / EXHAUST
Pilot (Idle and Slow) System Main System
This system supplies fuel during engine operation with throttle As throttle valve (1) is opened, engine speed rises, and this
valve closed (1) or slightly opened. The fuel from float chamber increases negative pressure in the venturi. Consequently the
(2) is metered by pilot jet (3) where it mixes with air coming in vacuum slide (2) moves upward. The fuel in float chamber (3)
through pilot air jet (4). The mixture then goes up through pilot is metered by main jet (4), and the metered fuel enters needle jet
passage to pilot screw (5). A part of the mixture is discharged (5), in which it mixes with the air admitted through main air jet
into the main bore out of bypass ports (6). The remainder is then (6) to form an emulsion. The emulsified fuel then passes through
metered by pilot screw and discharged into the main bore the clearance between needle jet (5) and jet needle (7), and is
through pilot outlet (7). discharged into the venturi (A). Mixture proportioning is
accomplished in needle jet (5); the clearance through which the
emulsified fuel must flow is determined ultimately by throttle
position and vacuum slide height.

1
1

A
6
5
2
3

5 3

4.8
FUEL / AIR / EXHAUST
Float System Pilot Screw
Fuel enters the float chamber (3) by means of the inlet pipe and The pilot system supplies fuel during engine operation with the
passage, through a screen on the back of the inlet needle seat (4), throttle valve closed or slightly opened. The fuel/air mixture is
and around the inlet needle (2). As the fuel fills the float metered by pilot screw and discharged into the main bore
chamber, the float (1) rises and forces the inlet needle against the through the pilot outlet.
seat, shutting off the orifice in the seat. When fuel level is up in
float chamber, floats are up and needle valve remains pushed up
against valve seat. Under this condition, no fuel enters the float CAUTION
chamber. As the fuel level falls, floats go down and needle valve
unseats itself to allow fuel into the chamber. In this manner, the
needle valve releases and shuts off fuel alternately to maintain The pilot screw is calibrated at the factory to meet
a constant fuel level inside the float chamber. EPA / CARB regulations for air quality standards
and is sealed with a brass plug to prevent tampering.
Removal of the tamper proof plug is not permitted.
For service purposes, cleaning of the pilot circuit can
be done only by a certified repair shop to ensure air
quality standards are not exceeded.
4

Inlet
Pipe
Pilot Screw Location

Brass Plug Installed


3
1

4 2

Brass Plug Removed

4.9
FUEL / AIR / EXHAUST
Air/Fuel Mixture Ratio higher produces a leaner mixture. If the taper is worn due to
vibration, fuel flow may be significantly affected.
E-Clip Position vs. Fuel Flow Jet Needle
2
3 Leaner
4
Position#
4
Richer

Needle Jet
15 50 75 100% The needle jet works in conjunction with the jet needle to
Throttle Valve Opening regulate fuel flow rate. An air bleed opening in the side of the
needle jet brings in air measured by the air jet. This air initiates
the mixing and atomizing process inside the needle jet.
A carburetor with a slide type throttle valve is also called a
variable venturi type carburetor. In this type of carburetor, the
needle jet and jet needle serve to control proper air/fuel mixture
ratio at the medium throttle valve opening (between 1/4 and 3/ Needle Jet
4 opening).
Having the proper needle jet and jet needle has a major impact
on engine performance at partial load. The jet needle tapers off
at one end and the clearance between the jet needle and the
needle jet increases as the throttle valve opening gets wider. The
air/fuel mixture ratio is controlled by the height of the “E” clip
inserted into one of the five slots provided in the head of the jet
needle. The previous chart shows the variation of fuel flow
based on the height of the “E” clip. Main Jet

Jet Needle
The jet needle has five adjustment grooves cut into the upper
portion, and is tapered from approximately the middle of the
needle to the lower end. The top is fixed to the center of the
throttle valve by the needle clip, and the tapered end extends into
the needle jet. Fuel flows through the space between the needle
jet and jet needle. This space does not vary until the throttle
reaches the 1/4 open point. At that time the tapered portion of the
needle begins to move out of the jet, affecting fuel flow as the
opening enlarges. If the needle clip is changed from the standard
position to a lower groove, the needle taper starts coming out of
the jet sooner, resulting in a richer mixture. Moving the clip

4.10
FUEL / AIR / EXHAUST
Throttle Opening vs. Fuel Flow 2. Remove float bowl. Remove the float pin screw. The float
and float pin can be removed.
In a full throttle condition the cross sectioned area between the
jet needle and the needle jet is larger than the cross sectioned
area of the main jet. The main jet therefore has greater control
over fuel flow.
Small Medium Large
Clearance Clearance Clearance

4
3. Remove inlet needle seat retaining screw along with plate,
and carefully remove needle seat. NOTE: Do not use a
pliers to remove the seat or permanent damage may occur.

Closed One-half Full


Throttle Throttle Throttle

Carburetor Disassembly – Mikuni CV


Use the following disassembly, assembly, and inspection
techniques to service a CV carburetor.
1. Remove carburetor diaphragm chamber cover with a
ratchet style screwdriver. DO NOT use an impact driver to
remove the screws or carburetor may be permanently
damaged.
Remove Screw

4. Remove the pilot mixture screw, spring, flat washer, and


O–Ring. If an anti–tamper plug is installed over the pilot
screw cavity, it must be removed for access.

O-Ring
Washer
Spring

Pilot Screw

4.11
FUEL / AIR / EXHAUST
NOTE: The starter jet is removable. Upon disassembly, Carburetor Inspection
place the parts in a container for safe keeping.
1. Inspect jet needle and needle jet for wear. Look for
discoloration, shiny spots, or an area that looks different
than the rest of the needle. The middle to upper portion of
the needle contacts the needle jet and is the most likely
wear point. If jet needle shows signs of wear replace both
the needle and needle jet to prevent a rich condition. TIP:
A worn needle jet is difficult to spot. To check, slide a
slightly larger new jet needle into the needle jet and hold it
to a light source. Light will be visible between the needle
and needle jet if it is worn.

Needle Jet
Jet Needle

Carburetor Cleaning

Inspect this
WARNING area

Protect eyes from contact with cleaner. Take


appropriate safety measures during these
procedures. Safety glasses and chemical resistant 2. Inspect the inlet needle tapered surface for any sign of wear
gloves are required. Should you get cleaner in your or damage. Be sure the spring loaded pin is free moving and
eyes or if you swallow cleaner, seek medical returns freely when pushed. The inlet needle and seat
attention immediately. should be pressure tested after assembly.
Carburetor cleaners can be extremely caustic.
Extended periods of soaking can loosen the Good Condition Worn, Deposits
adhesive sealer on the passage drill-way plugs. Do
not soak rubber or plastic components (such as the
vacuum slide diaphragm, needle seat screen, or O-
Rings in caustic cleaning solutions. Irreparable Seat
damage may occur. Do not use agitator-type
carburetor cleaning equipment. Rubber parts must
be cleaned with mild detergent and hot water only.
Wear areas
1. Thoroughly clean the carburetor body, jets, and all
passages with carburetor cleaner or electrical contact
cleaner.
2. If the carburetor is extremely dirty or contaminated with
Needle
fuel residue and varnish, soak for short periods only in
carburetor cleaner, and rinse in hot water.
3. Replace the jets if they have a buildup of fuel residue or
bacterial growth that cannot be removed. Even a small
amount of residue will reduce the flow characteristics of the
jet.
4. Verify all passages and jets are unobstructed by spraying
electrical contact cleaner through the passages.
CAUTION: Do not use wire or welding tip cleaners as the
orifice size may be altered.
5. Use low pressure air to dry carburetor body and all
components.

4.12
FUEL / AIR / EXHAUST
Carburetor Assembly the engine running. Refer to Chapter 2.

Inspect the diaphragm (A) for holes, deterioration, or damage.


Make sure the diaphragm is pliable but not swollen. The Pilot Screw Base Setting
diaphragm should fit properly in the carburetor body. Replace (Set at Factory)
diaphragm assembly if diaphragm is damaged.
Factory Specification: 2.5 Turns Out

Float Height Adjustment


1. Place the throttle side of the carburetor on a level surface
to remove weight from float arm. In this position, the float
tongue will rest slightly outward.

2. With the carburetor still resting on the level surface, use one
hand to slightly tilt the carburetor back. The float will then
1. Replace parts in proper order. The spring seat (B) is fall into the correct position, with the float tongue resting
stepped and must be placed on TOP of “E” Clip (C). lightly on the inlet needle valve pin without compressing
Spacer washer (D) must be installed below the E–Clip. the spring. The bottom of the float should be parallel with
Refer to parts manual for more information. the float bowl mating surface. NOTE: If the float is past
2. Be sure the tab (E) on outer edge of diaphragm is positioned parallel with the mating surface, the carburetor has been
properly in the carburetor body. tilted back too far and the float tongue is likely compressing
the needle valve pin.

FRONT
(Engine)

Pilot Screw

Float parallel with float


bowl mating surface
3. Install the pilot mixture screw, spring, washer, and O–ring
as an assembly. Lubricate the O–Ring with oil or light
grease before installation. CAUTION: Do not damage the
O–ring during installation. Turn the screw in until it lightly
contacts the seat. Back out the specified number of turns.
NOTE: The final pilot (idle) mixture must be adjusted with

4.13
FUEL / AIR / EXHAUST
3. Measure the height from the float bowl mating surface to Fuel Level test
the top of step of the float as shown in Illustration 2. Both
sides of float should be parallel to each other. The A fuel level test can be performed on some models if the drain
measurement should be made at the mid–point on top of the hose fitting is accessible. Be sure to re–attach the bowl drain
float using Float Adjustment Tool (PN 2872314) or a hose after performing the test. A fuel level test allows you to
vernier caliper. When measuring the height, be sure the observe the height of the fuel in the float bowl without removing
inlet needle valve spring is not compressed. the carburetor. The fuel level can be observed with the engine
either running or shut off, however, engine must run briefly to
allow fuel level to stabilize.
Float Bowl Height: 13-14 mm
1. Attach a clear line to drain fitting. Be sure line fits tightly
4. If adjustment is necessary, bend the tongue slightly. Be sure on fitting. Position hose along side of carburetor as shown.
float measurement is even on left and right side.

1.5 mm
.060 in. Bowl Mating
Surface

2. Open bowl drain screw by turning counterclockwise


approximately two turns. Start and run engine for 3 to 5
Needle and Seat Leakage Test seconds to allow fuel level to stabilize in the line. If level
1. Install the float bowl. Invert the carburetor and install a is out of specification, remove carburetor and inspect inlet
Mity–Vac™ (PN 2870975) to the fuel inlet fitting. Apply needle and seat, float height, passages, etc.
5 PSI pressure to inlet fitting. The needle and seat should NOTE: If a line was removed to perform this procedure,
hold pressure indefinitely. If not, inspect needle and seat it must be replaced.
and seat O–ring.

Mity VacTM (PN 2870975)


Apply 5 psi to fuel inlet fitting

4.14
FUEL / AIR / EXHAUST
Troubleshooting POOR IDLE

FUEL STARVATION/LEAN MIXTURE Idle Too High


Symptoms: Hard start or no start, bog, backfire, popping • Idle adjusted improperly/idle mixture screw
through intake / exhaust, hesitation, detonation, low power, damaged
spark plug erosion, engine runs hot, surging, high idle, idle
speed erratic. • Sticky vacuum slide

• No fuel in tank • Throttle cable sticking, improperly adjusted, routed


incorrectly
• Restricted tank vent, or routed improperly
• Choke cable sticking, improperly adjusted, routed
• Fuel lines or fuel valve restricted incorrectly

• Fuel filter plugged • Plugged or restricted idle jet

• Carburetor vent line(s) restricted Idle Too Low


• Choke cable bending or incorrectly adjusted
• Plugged or restricted inlet needle and seat screen
or inlet passage
• Clogged jets or passages
• Idle speed set incorrectly
• Idle mixture screw misadjusted or damaged
4
• Float stuck, holding inlet needle closed or inlet • Belt dragging
needle stuck
• Ignition timing incorrect
• Float level too low
• Worn jet needle/needle jet
• Intake air leak ( throttle shaft, intake ducts, airbox
or air cleaner cover) • Plugged or restricted idle jet
• Jet needle position incorrect Erratic Idle
• Incorrect pilot screw adjustment • Choke cable bending or incorrectly adjusted

RICH MIXTURE • Throttle cable incorrectly adjusted


Symptoms: Fouls spark plugs, black, sooty exhaust smoke, • Air leaks, dirty carburetor passages (pilot circuit)
rough idle, poor fuel economy, engine runs rough/ misses, poor
performance, bog, engine loads up, backfire. • Pilot mixture screw damaged or adjusted
incorrectly
• Air intake restricted (inspect intake duct)
• Tight valves
• Air filter dirty/plugged
• Ignition timing incorrect
• Electric choke inoperative
• Belt dragging
• Incorrect pilot air/fuel screw adjustment
• Dirty air cleaner
• Faulty inlet needle and seat
• Engine worn
• Faulty inlet needle seat O-Ring
• Spark plug fouled
• Float level too high
• Idle speed set incorrectly (speed limiter)
• Poor fuel quality (old fuel)
• Worn jet needle/needle jet
• Loose jets
• Plugged or restricted idle jet
• Worn jet needle/needle jet or other carburetor
parts
• Dirty carburetor (air bleed passages or jets)

4.15
FUEL / AIR / EXHAUST
AIR INTAKE SYSTEM
Air Intake System

G H

Table 4-1: Air Intake System


REFERENCE DESCRIPTION REFERENCE DESCRIPTION
A Pre-Filter J Crankcase Breather Hose
B Air Filter
C Intake Box Snorkel
D Intake Box Cover
E Cover Seal
F Crankcase Breather Foam
G Intake Box Drains
H Carburetor Snorkel

4.16
FUEL / AIR / EXHAUST
FUEL TANK/FUEL DELIVERY SYSTEM
Fuel Tank / Fuel Delivery System

B D

E 4
F

N
J

G
K

Table 4-2: Fuel Tank / Fuel Delivery System


REFERENCE DESCRIPTION REFERENCE DESCRIPTION
A Fuel Cap J Hose (Fuel Tank-To-Supply petcock)
B Fuel Cap O Ring K Fuel Pump
C Fuel Level Gauge L Hose (Fuel Pump-To-Carburetor)
D Fuel Tank Vent M Hose (Fuel Pump-To-Carburetor Vacuum Impulse)
E Fuel Tank Hold-Down Bracket / Pad N Fuel Filter (Arrow points in direction of fuel flow to carburetor.)
F Fuel Tank
G Fuel Supply Petcock
H Hose (Supply Petcock-To-Fuel Pump)

4.17
FUEL / AIR / EXHAUST
EXHAUST SYSTEM
Exhaust System

Table 4-3: Exhaust System


REFERENCE DESCRIPTION
1 Clean-out Plug

2 Muffler

3 Gasket - Plug

4 Gasket - Muffler

5 Head Pipe

6 Nut

7 Washer

8 Flange Gasket
9 Bolt

10 Nut

11 Springs

4.18
BODY / STEERING / SUSPENSION
CHAPTER 5
BODY / STEERING / SUSPENSION
PLASTIC RETAINER INSERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SEAT / SIDE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
FRONT CAB/FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
FRONT CAB/FENDER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
FRONT CAB/FENDER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
REAR CAB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
FOOTWELL REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
BODY RACK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
REAR RACK REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
POD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
POD/KEY SWITCH/CHOKE/SPEEDO CONNECTION REMOVAL/INSTALLATION. . . . 5.9
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
HANDLEBAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
HANDLEBAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5
STEERING POST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
STEERING POST BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
STEERING POST INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
A-ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
A-ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
FRONT STRUT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
FRONT STRUT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
FRONT STRUT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
BALL JOINT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
REAR CONTROL ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
UPPER AND LOWER REAR CONTROL ARM REMOVAL/INSTALLATION . . . . . . . . . 5.19

5.1
BODY / STEERING / SUSPENSION
PLASTIC RETAINER INSERTS 3. To install the inserts, press outside insert (B) into the hole.
Press inside insert (A) until it snaps into place.
Removal / Installation NOTE: The outside insert (B) should be flush
surface after installation.
Some Polaris ATVs use a two piece plastic insert in place of a
metal screw. The plastic inserts are simple to remove and install.
1. Use a a pair of diagonal side cutters to lift the plastic insert
(A) until you feel some slight pressure or lift the insert
approximately 1/4" (6.35 mm). Apply just enough pressure
on the side cutters to lift up on the insert. DO NOT apply
too much pressure on the side cutters, or damage to the
insert will occur.

A
The inside insert (A) should be flush with the top of the outside
insert (B).

A
B
2. Next, use the diagonal side cutters under outside insert (B)
to completely remove the assembly. NOTE: The inside
insert (A) will still be installed in the outside insert (B).

NOTE: The inside insert (A) will still be installed in


the outside insert (B).

5.2
BODY / STEERING / SUSPENSION
SEAT / SIDE PANEL 3. Reinstall the side panel by reversing the removal procedure.
Step 3
Removal / Installation
Use the following instructions for removal and installation:
1. Remove seat by releasing the latch and lifting up on the
seat.

Step 1

4. Reinstall the seat. Verify latch is secure.

5
2. Grasp the rear of the side panel near the rear cab. With a
firm motion, pull the panel outward to disengage the side
panel from the grommet. Pull the panel downward and
rearward to remove it from the ATV.

Step 2

5.3
BODY / STEERING / SUSPENSION
FRONT CAB/FENDER

5.4
BODY / STEERING / SUSPENSION
Front Cab/Fender Removal
For this procedure please refer to the diagram on 5.4.
1. Remove the seat.
2. Remove the fuel tank cover (4).
3. Remove the side panels (1,3).
4. Remove the plastic rivets on the mud guards (below) and remove them from the front cab assembly.

5
5. Remove the battery connections (negative first).
6. Remove the battery from the battery compartment.
7. Route the battery cables through the front compartment.
8. Remove the front cab fasteners (8).
9. Remove the plastic rivets from the footwells.
10. Carefully lift off the front cab.

Front Cab/Fender Installation


For this procedure please refer to the diagram on 5.4.
1. Carefully place front of the cab onto the frame.
2. Route the battery connections through the cab and into the battery box.
3. Insert the mud guards and plastic rivets.
4. Replace the fuel tank cover (4).
5. Replace the plastic rivets into the footwells.
6. Install the front cab fasteners.
7. Install the battery.

5.5
BODY / STEERING / SUSPENSION
BODY ASSEMBLY
Exploded View

5.6
BODY / STEERING / SUSPENSION
Rear Cab Removal/Installation
1. Follow the procedure to remove the rear rack. See “Rear Rack Removal/installation” on page 5.8.
2. Remove the screws (1,19) that secure the rear cab to the frame.
3. Remove the plastic inserts (9) that secure the rear cab to the frame footwells (11,14).
4. Disconnect the rear lights.
5. Lift the rear cab (4) from the frame.
6. Reverse the removal steps for installation.

Footwell Removal/Installation
1. Remove the plastic inserts (A) that secure the wheel well to the front and rear cabs. See “PLASTIC RETAINER INSERTs”
on page 5.2.
2. Remove the screws (B) from the bottom of the foot well. Remove the footwell.
3. Reverse the removal procedures to install the foot well.
NOTE: Be sure to properly align the cab ends into the footwells upon reassembly.
B

5.7
BODY / STEERING / SUSPENSION
BODY RACK EXPLODED VIEW

Rear Rack Removal/installation


1. Remove the fasteners 2,3,7,9,10 and 11.
2. Remove the rear rack.
3. Replace in reverse order.

5.8
BODY / STEERING / SUSPENSION
POD EXPLODED VIEW

Pod/Key Switch/Choke/Speedo Connection Removal/Installation


1. Remove the plastic dart clips(1) from the pod (2).
2. Press the center and pull the speedo connection away from the speedo (3).
3. Remove the key switch connection by turning the ignition nut (9) counter clock wise.
4. Remove the choke connection by turing the choke nut (14) counterclockwise.
5. Remove the choke cable (13) from the pod.
6. Replace in reverse order of removal.
5.9
BODY / STEERING / SUSPENSION
STEERING
Handlebar Block Installation Procedure

Clean knurling when


repositioning handlebars
B

1. The pin (A) on the bottom side of the top handlebar block faces down and to the front of the ATV.

2. The bottom handle bar block has a side with 3 holes, the side with 3 holes faces up and to the front of the ATV.

3. Align the pin (A) in the top block with the middle hole (B) in the bottom block for proper installation. The pin (A) and middle
hole (B) should face the front of the ATV.

4. Install the pin side bolts first and evenly tighten the bolts down. Torque the 2 front bolts to specification.

=T
Handle Bar Bolt Torque
11-13 ft.lbs.(15-18 Nm)

5. Install the rear bolts and tighten evenly. Evenly torque the 2 rear bolts to specification.

NOTE: Pod bracket installation required (Refer to page 5.9). There will also be a slight gap on the backside of
the blocks after the procedure is performed.

5.10
BODY / STEERING / SUSPENSION
Steering Post Removal 9. Remove the steering tie rod ends (D) from the steering
bracket (E). Note the orentation of the fasteners and bracket
1. Remove the front cab. See “FRONT CAB/FENDER” on on the steering assembly.
page 5.4.
2. Remove the handle bar pod. See “Pod/Key Switch/Choke/
Speedo Connection Removal/Installation” on page 5.9.
E
3. Remove the handle bar. See “POD EXPLODED VIEW” on
page 5.9. D
4. Remove the fuel tank bracket (A).

10. Remove the steering post bracket (F) at the front gear case
(4x4 shown)/plate (2x4).

F
5
5. Turn the fuel valve to the “OFF” position
6. Remove the fuel line (B) from the fuel pump (C).

C
11. Remove the top steering bracket (G).

B G

7. Remove the vent line from the frame that comes from the
top of the fuel tank. Note the vent line routing.
8. Remove the fuel tank from the frame.

12. Remove the steering post.

5.11
BODY / STEERING / SUSPENSION
Steering Post Bearing Replacement Steering Post Installation
1. Remove the steering post. 1. Insert the steering post assembly into the chassis.
2. Press out the steering post cotter pin (A). 2. Place the lower bracket (F) into the front gear case on the
3. Remove the steering post nut (B), bushing (C). 4x4 units, and into the bracket on the 2x4 units.
4. Inspect the bushings 3. Apply blue Loctite to the threads of the bracket bolts.
5. Remove and replace the bearing (D). 4. Torque the bolts to specification.
6. Install the bearing as shown in the image.
7. Torque the steering post nut (B) to specification. F
8. Install a new cotter pin (A).
NOTE: Make sure that the cotter pin is not
obstructing steering movement.

B
=T
A
2x4 4x4 Steering Post Bearing Bracket
19-22 ft-lb (26-30Nm)

5. Place the steering post upper bracket to the frame, torque


=T the upper nuts to specification.

Steering Post Nut


50 ft-lb (68Nm) G

=T
Upper Steering Post Bracket
22 ft-lb (30Nm)

6. Place the tie rod retainer (H) on to a tie rod bolt (I).
7. Insert the tie rod bolts from the bottom of the tie rod, and
line up the retainer to the bottom of the tie rods.

5.12
BODY / STEERING / SUSPENSION
8. Torque the tie rod fasteners to specification. 13. Hook up the fuel line to the fuel pump and move the clamp
to the correct area.

I H

=T 5
Tie Rod Fasteners
40 ft-lb (54Nm)

9. Replace the fuel tank into the frame.


10. Make sure that the routing of the vent line is correct.

11. Place the fuel tank bracket in place. Note to get the routing
of the throttle cable and carburetor venting correct.
12. Tighten the fuel tank bracket fasteners.

5.13
BODY / STEERING / SUSPENSION
FRONT SUSPENSION
Exploded View

NOTE: To avoid damage to tie rods and other steering components, be sure to install tie rod end bolts in the
proper direction. The steering post arm bolt (B) points up; the rod end bolts (A) point down. Be sure inner rod
ends are placed between the steering post arms. Replace all cotter pins if removed (4,11).

REF. DESCRIPTION REF. DESCRIPTION

1 Retainer 13 Ball Joint


2 Boot, Seal 14 Screw (4x4)
3 Nut, Flange 15 CV Shield LH,RH
4 Cotter Pin 16 A-Arm
5 Tie Rod Assembly 17 Bushing, A-Arm
6 Screw, Flange 18 Tube, Pivot
7 Rod End, LH 19 Screw, Flange
8 Boot, Seal 20 Rod End, RH
9 Nut, Flange 21 Jam Nut, RH
10 Screw, Flange 22 Jam Nut, LH
11 Cotter Pin 23 Washer
12 Ring, Retainer External 24 Fitting, Lubrication

5.14
BODY / STEERING / SUSPENSION
A-arm Removal
Refer to drawing on page 5.14
1. Apply parking brake and loosen the lug nuts.
2. Elevate the front of the machine and secure it with jack stands.
3. Remove the rim from the hub and release the parking brake.
4. Remove the pinch bolt (10) and nut (9) that hold the A-Arm ball joint (13) to the carrier bearing assembly.
5. Remove the flange bolt (19) and flange nut (3) from the frame.
6. Remove A-Arm.

WARNING

The locking features on the existing bolts were


destroyed during removal. DO NOT reuse old bolts.
Serious injury or death could result if fasteners
come loose during operation.

A-Arm Assembly
Refer to drawing on page 5.14 5
1. Assemble A-Arm with all bushings (17), pivot tube (18), ball joint (12,13), and brush guard (15) (if applicable).
2. Place the A-Arm to the frame and insert the flange bolt (19) with the head toward the front of the machine and the flange nut
(3) toward the rear.
3. Torque the flange bolt (19) to specification.

=T
A-Arm Flange Bolt
40 ft-lb (54Nm)

4. Insert the ball joint (13) far enough into the carrier bearing assembly so that the pinch bolt (10) can be inserted.
5. Insert the pinch bolt (10) so that the flange head is at the front of the machine and the flange nut (9) is at the rear.
6. Torque the pinch bolt to specification.

=T
Pinch Bolts
20 ft-lb (27Nm)

WARNING

Upon A-arm installation completion, test vehicle at


low speeds before putting into regular service.

5.15
BODY / STEERING / SUSPENSION
FRONT STRUT SERVICE

5.16
BODY / STEERING / SUSPENSION
Front Strut Removal BALL JOINT
Refer to drawing on page 5.16
Replacement
1. Remove the wheel on the side of the strut that is to be
replaced.
2. Remove the front cab.
3. With an open end wrench hold the shock tower nut (16) and
with a socket turn the shock rod.
4. Remove the screw that holds on the brake line to the strut. 1
5. Remove the carrier bearing assembly fasteners (4,7).
6. Remove the strut from the vehicle.

Front Strut Installation


Refer to drawing on page 5.16
2
1. Place strut assembly into the frame and insert the strut
flange nut (16).
2. Insert the strut into the carrier bearing assembly and insert 1. Remove the A-Arm. See “A-arm Removal” on page 5.15.
the fasteners (4,7). 2. Remove the snap ring (1) from the ball joint.
3. Torque the top strut flange nut (16) to specification. 3. Press out the old ball joint (2). 5
4. Press in new ball joint into A-Arm.
=T 5. Replace the snap ring (1) onto the new ball joint.
6. Assemble the A-Arm, See “A-Arm Assembly” on
Strut Flange Nut page 5.15.
40 ft-lb (54Nm)

4. Torque the carrier bearing fasteners (7) to specification.

=T
Carrier Bearing Fasteners
37 ft-lb (50Nm)

5. Replace the torx fastener that holds the brake line in place.
6. Replace front cab.

Bearing Replacement
Refer to drawing on page 5.16
1. Remove the front bearing carrier (1).
2. Remove the snap ring (3) from the bearing carrier.
3. Press out the bearing (2).
4. Press in new bearing.
5. Replace the snap ring
6. Install bearing carrier.
7. Torque the bearing carrier to strut mounting fasteners to
specification.

5.17
BODY / STEERING / SUSPENSION
REAR CONTROL ARMS
Exploded View

REF. DESCRIPTION REF. DESCRIPTION

1 Screw, Flange 10 Fitting, Lubrication


2 Bushing, Upper 11 Control Arm, Lower
3 Tube, Pivot 12 Screw, Flange
4 Nut, Flange 13 Bushing, Carrier
5 Screw, Flange 14 Tube, Pivot
6 Screw 15 Control Arm, Upper
7 Bracket, Support 16 Nut, Flange
8 Tube, Pivot 17 Fitting, Lubrication
9 Bushing, Lower 18 Tube, Pivot
19 Screw, Flange

5.18
BODY / STEERING / SUSPENSION
Upper And Lower Rear Control Arm Removal/Installation
Described in this section is for one side of the machine. Duplicate this process for the other side.
1. Raise and secure the rear of the machine.
2. Remove the rear wheel.
3. Remove the rear shock.
4. Remove the Upper Control Arm (UCA) (15) fasteners (1,4,12) from the transmission and bearing carrier. Note the long (12,14)
and short (1,3) fasteners and pivot shaft locations.
5. Remove the x short grey bushings (2) and pivot shafts (3,14).
6. Remove the Lower Control Arm (LCA) (11) fasteners (4,5,12) from the frame and bearing carrier. Note the long (5,8) and
short (12,14) fasteners and pivot shaft locations.
7. Remove the long grey bushings (9) and pivot shaft (8) from the frame.
8. Remove the short bushings (13) and pivot shaft (14) from the bearing carrier.
9. Remove the LCA (11) from the unit.
10. Replace in reverse order with the following torque values.

=T
• LCA to Bearing Carrier 40 ft-lb (54Nm) 5
• LCA to Frame 40 ft-lb (54Nm)
• UCA to Bearing Carrier 40 ft-lb (54Nm)
• UCA to Transmission 40 ft-lb (54Nm)
• Shock Mounts (top and bottom) 40 ft-lb (54Nm)
• Wheel Lug Nuts 27 ft-lb (37Nm)

5.19
BODY / STEERING / SUSPENSION

NOTES

5.20
BRAKES
CHAPTER 6
BRAKES
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
BRAKES / TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
BRAKE NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
BRAKE SYSTEM MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
REAR MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
HAND BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
FRONT CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
THICKNESS / RUNOUT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
WEAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
FOOT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
FOOT PEDAL REMOVAL / INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
FOOT BRAKE MASTER CYLINDER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . 6.18
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
BRAKE SQUEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19

6.1
BRAKES
SPECIFICATIONS
Brakes / Torque

Table 6-1: FRONT BRAKE


ITEM STANDARD SERVICE LIMIT

Brake Pad Thickness .275” / 7 mm .155” / 3.9 mm


Brake Disc Thickness .157” / 4.0 ± 2 mm .140” / 3.55 mm
Brake Disc Thickness Variance
-- .002” / .051 mm
Between Measurement
Brake Disc Runout -- .010” / .254 mm
Caliper Piston Diameter (Front) 1.250” / 31.75 mm --

Table 6-2: REAR BRAKE


ITEM STANDARD SERVICE LIMIT

Brake Pad Thickness .275” / 7 mm .155” / 3.9 mm


Brake Disc Thickness .157” / 4.0 ± 2 mm .140” / 3.55 mm
Brake Disc Thickness Variance
-- .002” / .051 mm
Between Measurements
Brake Disc Runout -- .010” / .254 mm
Caliper Piston Diameter (Rear) 1.250” / 31.75 mm --

Table 6-3: TORQUE SPECIFICATIONS


ITEM TORQUE FT.LBS. (IN.LBS.) TORQUE (NM)

Front / Rear Caliper Mounting Bolts 22 30


Handlebar Master Cylinder Clamp Bolts (70 in.lbs.) 7.9
Hand Master Cylinder Reservoir Cover (7 in.lbs.) .79
Brake Line Banjo Bolt 15 20
Brake Disc Bolts 18 24
Brake Line Flare Fittings 12-15 16-21
Bleeder Screw (36-46 in.lbs.) 4-5

NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures
are used when torquing certain bolts and fasteners. Do not re-use fasteners that have pre-applied locking
agents.

6.2
BRAKES
TROUBLESHOOTING
Brake Noise
Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning
does not reduce the occurrence of brake noise, a product such as Permatex™ Disc Brake Quiet or an equivalent can be applied to
the back of the pads. Follow directions on the package. This will keep pads in contact with caliper piston(s) to reduce the chance
of squeaks caused by dirt or dust.

Table 6-1: BRAKE NOISE TROUBLESHOOTING


POSSIBLE CAUSE REMEDY

Spray disc and pads with a


non-flammable aerosol brake
Dirt, dust, or imbedded
cleaner. Remove pads and/or
material on pads or disc
disc hub to clean imbedded
material from disc or pads.
Pad(s) dragging on disc (noise Adjust pad stop
or premature pad wear) (front calipers)
Insufficient lever or pedal
Set to proper level
clearance
Master cylinder reservoir Check brake fluid level,
overfilled adjust as needed
O-rings worn Rebuild Caliper 6
Master cylinder
compensating port
restricted, Master cylinder
Clean piston(s) seal
piston not returning
completely, Caliper piston(s)
not returning
Operator error (riding the
brake / park brake Educate operator
applied)
Tighten wheel nuts or replace
Loose wheel hub or bearings
bearing if worn
Brake disc warped or
Replace disc
excessively worn
Brake disc misaligned or Inspect and repair as
loose necessary
If noise does not change when
Noise is from other source
brake is applied check other
(chain, axle, hub, disc or
sources. Inspect and repair as
wheel)
necessary
Wrong pad for Change to a softer or harder
conditions pad (if available)

6.3
BRAKES

BRAKE SYSTEM MAIN COMPONENTS


System Exploded View

2 screws - 7 in. lbs. (.79Nm )

All Flare Style Fittings: 12-15 ft.lbs. (16-21 Nm)

All Bleed Screws: 36-46 in.lbs. (4-5 Nm)

Apply a Light
Amount of Pipe
Sealant to Threads

All Banjo Style Fittings: 15 ft.lbs. (20 Nm)

6.4
BRAKES
BRAKE CALIPER
Exploded View
A.Bleeder Screw C A
B. Caliper Body
C. Internal Caliper Slide Pin O-rings (small) B
D. Square Seals
E. Piston
F. Caliper Mount
G. Brake Pads D
H. Internal Caliper Slide Pin O-rings (large)
I. Caliper mount O-ring

E
H

6
F

6.5
BRAKES
HYDRAULIC BRAKE SYSTEM master cylinder piston is outward. As the temperature within the
hydraulic system changes, this port compensates for fluid
Operation Overview expansion (heated fluid) or contraction (cooled fluid). During
system service, be sure this port is open. Due to the high
Must be clear to Compensating port temperatures created within the system during heavy braking, it
allow proper E compensates for is very important that the master cylinder reservoir have
diaphragm temperature changes adequate space to allow for fluid expansion. Never overfill the
by allowing fluid back reservoir! Fill to 1/4, - 5/16, (.64 - .80 cm) from top of the
to master cylinder cylinder.

F C This system also incorporates a diaphragm (E) as part of the


cover gasket; and a vent port (F) located between the gasket and
the cover. The combination diaphragm and vent allow for the
air above the fluid to equalize pressure as the fluid expands or
contracts. Make sure the vent is open and allowed to function.
A B 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 fail

When servicing Polaris ATV brake systems, use only DOT 3 or


D DOT 4 Brake Fluid.
Move Brake Pad

WARNING
The Polaris disc brake system consists of the following Once a bottle is opened, use what is necessary and
components or assemblies: hand brake lever; foot brake lever, discard the rest in accordance with local laws. Do
hand and foot brake master cylinders; hydraulic hoses; brake not store or use a partial bottle of brake fluid. Brake
calipers (slave cylinders); brake pads; and brake discs, which fluid is hygroscopic, meaning it rapidly absorbs
are secured to the drivetrain. moisture. This causes the boiling temperature of
the brake fluid to drop, which can lead to brake fade
When the hand activated brake lever (A) is applied it contacts
and the possible loss of control.
piston (B) within the master cylinder. 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. As the pressure within the system is increased,
the piston (D) located in the brake caliper moves outward and
applies pressure to the brake pad. This pad contacts the brake
disc and moves the caliper in its floating bracket, pulling the
stationary side pad into the brake disc. The resulting friction
reduces brake disc and vehicle speed. As the lever pressure is
increased, the braking affect is also increased.

The friction applied to the brake pads will cause the pads to
wear. As these pads wear, the piston within the caliper moves
further outward and becomes self adjusting. Fluid from the
reservoir fills the additional area created when the caliper piston
moves outward.

Brake fluid level is critical to proper system operation. Too little


fluid will allow air to enter the system and cause the brakes to
feel spongy. Too much fluid could cause brakes to drag due to
fluid expansion.

Located within the master cylinder is the compensating port (C)


which is opened and closed by the master cylinder piston
assembly. The port is open when the lever is released and the

6.6
BRAKES
REAR MASTER CYLINDER • Make sure the brake lever and pedal returns freely and
completely.
Operation Overview • Adjust stop pin on front caliper after pad service.

Brake Fluid Reservoir • Check and adjust master cylinder reservoir fluid level
after pad service.
• 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.
• Make sure caliper moves freely on guide pins (where
Rear Brake MC applicable).
Frame • Inspect caliper piston seals for foreign material that
could prevent caliper pistons from returning freely.
Rear Brake Line

CAUTION
Spring
Use only DOT 3 or 4 brake fluid as an assembly aid
for all procedures described in this chapter to
Brake Mount prevent brake system contamination. DO NOT USE
LUBRICANTS OF ANY KIND FOR ASSEMBLY, AS
THEIR USE CAN CAUSE RUBBER
Brake Lever COMPONENTS TO SWELL.

6
When the foot activated brake lever is applied it contacts piston
of the master cylinder. As the pressure within the system is
increased, the piston located in the brake calipers move outward
and apply equal pressure to the brake pads.

• Perform a brake burnishing procedure after installing


new pads to maximize service life.
• Optional pads are available to suit conditions in your
area. Select a pad to fit riding style and environment.
• Do not over-fill the master cylinder fluid reservoir.

6.7
BRAKES
BRAKE BLEEDING bleeder until the fluid runs clear.

Sight Glass
Fluid Change C

NOTE: When bleeding the brakes or replacing the


fluid, always start with the caliper farthest from the D
master cylinder. B
A

CAUTION

Always wear safety glasses during these


procedures. Brake fluid will damage finished
surfaces. Do not allow brake fluid to come in contact
with finished surfaces. MAX Level - Brake

NOTE: Do not move brake lever when reservoir fluid


level is low.

This procedure should be used to change fluid or bleed brakes


during regular maintenance.

1. Clean reservoir cover thoroughly.


2. Remove screws, cover and diaphragm (C) from reservoir.
3. Inspect vent slots (A) in cover and remove any debris or
blockage.
4. If changing fluid, remove old fluid from reservoir and lines
at the bleeders with a Mity Vac™ pump or similar tool,
topping off the reservoir with fresh DOT 3 or DOT 4 fluid
as it drains to the MIN reservoir level. DO NOT allow the
reservoir to drain completely. Continue this process at each

6.8
BRAKES
Bleeding Procedure 9. Install diaphragm, cover and screws. Align any marks (if
present) into the proper holes in the master cylinder.
1. Begin bleeding procedure with the caliper that is farthest Wiggle and press down on the cap to be sure it fits evenly
from the master cylinder. Install a box end wrench on and snug. Torque the screw to 7 in.lbs. (0.79 Nm).
caliper bleeder screw. Attach a clean, clear hose to fitting
and place the other end in a container. Be sure the hose fits
tightly on fitting.
NOTE: Fluid may be forced from supply port (B) if
brake lever is pumped. Place diaphragm (C) in
reservoir to prevent spills. Do not install cover tight.
See Illustration above.

2. Slowly pump brake lever (D) until pressure builds and


holds.
3. While maintaining lever pressure, open bleeder screw.
Allow lever to relax slowly toward the hand grip while
tightening the bleeder screw. Watch for signs of air bubbles
in the fluid as the screw is tightened. When no air is present,
the bleeding procedure should be complete.
4. Allow lever to return back to it’s normal position once the
brake bleeder is securely tightened.
NOTE: Do not release lever before bleeder screw is
tight or air may be drawn into caliper.

5. Repeat procedure until clean fluid appears in bleeder hose


and all air has been purged. Add fluid as necessary to
maintain level in reservoir.
6
CAUTION Cap Must Be Even

Maintain at least 1/2, (1.27 cm) of brake fluid 7 in.lbs. (0.79 Nm)
in the reservoir to prevent air from
entering the master cylinder.

6. Tighten bleeder screw securely and remove bleeder hose.


Torque the bleeder screw to specification.
7. Repeat procedure for the remaining caliper(s).
8. Add DOT 3 or DOT 4 brake fluid to the MAX level inside
Torque Outer
reservoir.
Screw First

10. Field test machine at low speed before putting into service.
Check for proper braking action and lever reserve. With
lever firmly applied, lever reserve should be no less than 1/
2”, (1.3 cm) from handlebar.
11. Check brake system for fluid leaks and inspect all hoses and
lines for wear or abrasion. Replace hose if wear or abrasion
is found.

6.9
BRAKES
HAND BRAKE MASTER CYLINDER Installation
NOTE: When replacing the brake master cylinder
Removal
assembly or master cylinder parts, use the correct
1. Clean master cylinder and reservoir assembly. Make sure parts. There are different brake master cylinders for
you have a clean work area to disassemble brake the different Polaris ATV models. Refer to your parts
components. manual or guide for the correct parts. Some master
cylinders are not serviceable and are replaced as an
assembly.

1. Install master cylinder on handlebars. Torque mounting


bolts to 70 in. lbs. (7.9 Nm). Torque the inside bolt first
as indicated in the illustration to the right.
7 in.lbs. (.79 Nm)

Torque Bolt First

2. Remove the banjo bolt that connects the brake line to the
master cylinder. Discard the copper washers.

CAUTION 70 in.lbs. (7.9 Nm)

Brake fluid will damage finished surfaces.


Do not allow brake fluid to come in
NOTE: To speed up the brake bleeding procedure,
contact with finished surfaces.
the master cylinder can be purged of air before
3. Remove master cylinder clamps from handlebars. brake line is attached. Fill with DOT 3 or DOT 4
4. Hold brake upright and continue to remove master cylinder. Brake Fluid and pump lever slowly two to three
Cover brake line to avoid spilling of fluid. times with finger over the outlet end to purge master
cylinder of air.

6.10
BRAKES
2. Place NEW sealing washers on each side of banjo line and BRAKE PADS
torque banjo bolt to specification.
Torque to specification (15 ft.lbs.) Removal
Sealing Washer 1. Loosen the wheel nuts. Elevate and support front of
machine and remove the tire(s).

CAUTION
Banjo Bolt
Use care when supporting vehicle so that it does not
tip or fall. Severe injury may occur if machine tips
or falls.

2. Remove caliper from mounting bracket.


Brake Line

3. Fill reservoir with DOT3 or DOT 4 brake fluid.

3. Push caliper piston into caliper bore slowly using a C-


clamp or locking pliers with pads installed.

4. Follow bleeding procedures. Check all connections for


leaks and repair if necessary.

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.

6.11
BRAKES
4. Push mounting bracket inward and slip outer brake pad past Installation
edge. Remove inner pad.
1. Lubricate mounting bracket pins and external slide pin O-
ring with a light film of Polaris Premium All Season
Grease (PN 2871423).

5. Measure the thickness of the pad material. Replace pads if


worn beyond the service limit.

2. Compress mounting bracket. Install pads with friction


material facing each other.

WARNING

If the brake pads are contaminated with grease, oil, or


liquid soaked do not use the pads, use only new clean
pads.

Measure Pad

Front Brake Pad Thickness


New : .275”/ 7 mm
Service Limit: .155” / 3.9 mm

6.12
BRAKES
3. Install caliper on hub strut, and torque mounting bolts. 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. Using a line wrench, loosen and remove brake line to


caliper. Place a container under caliper to catch fluid
draining from brake line.
22 ft.lbs.
(30 Nm)

4. Slowly pump the brake lever until pressure has been built
up. Maintain at least 1/2, (12.7 mm) of brake fluid in the
reservoir to prevent air from entering the brake system.
5. Verify fluid level in reservoir is up to MAX line inside
reservoir and install reservoir cap.
6. Install wheels and torque wheel nuts to specification.
NOTE: Front Wheel Nut Torque: Refer to Torque
Table at beginning of chapter. 6

2. Push pad retainer pin inward and slip brake pads past the
pin edges. A pliers may be used to compress the pad retainer
for removal if the pads are too thick. Use caution not to bend
or damage the retainer or the brake pad ears.

6.13
BRAKES
3. Remove mounting bracket pin assembly . 5. Remove the four (4) O-rings from the caliper body. Note
the orientation of the O-rings for reassembly. Clean the
caliper body, piston, and retaining bracket with brake
cleaner or alcohol.
NOTE: Be sure to clean grooves in caliper body. Do
not use a petroleum based spray to clean the caliper.

4. Remove piston using a twisting, pulling motion. Remove NOTE: O-ring grooves are size-specific
the piston square seals using a wooden or plastic pick. Use
caution not to scratch or damage the piston or the bore of
the caliper.
NOTE: Do not use a metal pick or awl to remove the
Clean Components
square seals.

The use of compressed air may be required


to remove the piston.

CAUTION

Always wear eye protection


when using compressed air.

6.14
BRAKES
Inspection Reassembly
1. Inspect caliper body for nicks, scratches or wear. Measure 1. Install new piston square seals (A) in the caliper body (B).
bore size and check for out of round. Replace if damage is Be sure groove is clean and free of residue or brakes may
evident or if worn. drag upon assembly.

C
B

2. Inspect piston for nicks, scratches, wear or damage. 2. Coat piston with clean Polaris DOT 3 or DOT 4 Brake Fluid
Measure diameter and replace if damaged or worn beyond (C). Install piston (D) with a twisting motion while pushing
service limit. inward. Piston should slide in and out of bore smoothly,
with light resistance.
3. Install new slide pin O-rings in the caliper body for the 6
Lubricate the mounting bracket pins with Polaris Premium
All Season Grease (PN 2871423), and install..
NOTE: Do not use grease on the square seals.
Petroleum based lubricants will cause the square
seals to swell. Lubricate with brake fluid only.

3. Inspect the brake disc and pads as outlined for brake pad
replacement this section. See “BRAKE PAD
INSPECTION” in this chapter.

NOTE: O-ring grooves are size-specific

6.15
BRAKES
4. Compress the mounting bracket into the caliper and make BRAKE BURNISHING PROCEDURE
sure the O-rings are fully seated. Install the brake pads.
Clean the disc and pads with brake parts cleaner or Overview
denatured alcohol to remove any dirt, oil or grease.
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 m.p.h.. Gradually


apply brakes to stop machine. Allow pads and disc to cool
sufficiently after each stop during the procedure. Do not allow
pads or disc to become hot or warping may result. Repeat this
procedure 10 times.

Installation
1. Install caliper on hub strut, and torque mounting bolts.

15 ft.lbs. (20 Nm)

22 ft.lbs.
(30 Nm)

2. Install brake line and tighten securely with a line wrench.


Torque the banjo brake lines to the proper torque
specification.
3. Perform brake bleeding procedure as outlined earlier in this
chapter.
4. Install wheels and torque wheel nuts to specification (See
Chapter 2).

6.16
BRAKES
BRAKE DISC Wear Inspection
1. visually inspect disc for scoring, scratches, or gouges.
Thickness / Runout Inspection
replace the disc if any deep scratches are evident.
1. Visually inspect the brake disc for nicks, scratches, or 2. use a 0-1” micrometer and measure disc thickness at 8
damage. different points around perimeter of disc. replace disc if
2. Measure the disc thickness at eight different points around worn beyond service limit.
the pad contact surface using a 0-1, micrometer. Replace
disc if worn beyond service limit.
BRAKE DISC

Disc Thickness
6
= In. / mm.

Brake Disc Thickness:


New: .157”(4.0 ± .2mm)
Service Limit: .140” / 3.556 mm = In. / mm.
3. Mount dial indicator as shown to measure disc runout.
Slowly rotate the disc and read total runout on the dial Brake Disc Thickness:
indicator. Replace the disc if runout exceeds specifications. New: .157”(4.0 ± .2mm)
Service Limit: .140” / 3.556 mm

Brake Disc Thickness Variance:


Service Limit: .002” (.051 mm)
difference between measurements

Brake Disc Runout:


Service Limit: .010” (.254 mm)

Brake Disc Runout


Service Limit: .010” / .254 mm

6.17
BRAKES
Removal / Replacement FOOT BRAKE
NOTE: To reduce the possibility of warping, try
Foot Pedal Removal / Install
removing the brake disc mounting bolts before
applying heat to the bolts. 1. Remove the cotter key (A).
2. Remove the washers, bushings, and tension spring and
1. Apply heat to the hub in the area of the brake disc remove the brake lever (F).
mounting bolts to soften the bolt locking agent.
3. Reverse the steps for installation, using a new cotter key
during installation.

Foot Brake Master Cylinder Removal /


Installation
1. If necessary, remove the rear brake lines (B) from the
master cylinder (C). Use a suitable container to catch the
brake fluid. Dispose of brake fluid properly.
2. Remove the two bolts that secure the rear master cylinder
to the brake mount plate. Replace parts as needed.
3. To install the rear brake master cylinder, mount the master
cylinder to the mount plate and torque bolts to
specification.

=T
2. Remove bolts and disc. Master Cylinder Fasteners: 8 ft.lbs. (11 Nm)
3. Clean mating surface of disc and hub.
4. Reinstall the brake line and torque the banjo bolt (with new
4. Install new disc on hub. copper washers installed) to specification. Torque the
5. Install NEW bolts and tighten to specification. flared fitting (if removed) to specification.

=T
Banjo Bolts: 22 ft.lbs. (30 Nm)

=T
Flare Fittings: 12-15 ft.lbs. (16-21Nm)

5. Bleed the master cylinder following the procedure outlined


in the brake bleeding section of this manual.

=T
C
Brake Rotor Fasteners: 18 ft.lbs. (24 Nm)
D
CAUTION

Always use NEW brake disc mounting bolts. F


The bolts have a pre-applied locking agent
which is destroyed upon removal. A

6.18
BRAKES
TROUBLESHOOTING
Brake Squeal
• Dirty/contaminated friction pads
• Improper alignment
• Worn disc
• Worn caliper

Poor Brake Performance


• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted lever
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Improper clearance between lever and switch 6
Lever Vibration
• Disc damaged
• Disc warp (runout or thickness variance exceeds
service limit)

Caliper Overheats (Brakes Drag)


• Compensating port plugged
• Foot brake pedal incorrectly adjusted
• Brake lever or pedal binding or unable to return fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes

Brakes Lock
• Alignment of caliper to disc
• Compensating port plugged
• Parking brake left on

6.19
BRAKES

NOTES

6.20
FINAL DRIVE
CHAPTER 7
FINAL DRIVE
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
FRONT BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
BEARING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
PROPSHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
FRONT GEARCASE / CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
ALL WHEEL DRIVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
CENTRALIZED HILLIARD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
AWD DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
GEARCASE REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
REAR BEARING CARRIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
BEARING CARRIER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
BEARING CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
BEARING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
BEARING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
7
DRIVE SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
FRONT DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
REAR DRIVE SHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
OUTER CV JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
INNER PLUNGING JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
FRONT DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
REAR DRIVE SHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24

7.1
FINAL DRIVE
GENERAL SPECIFICATIONS FRONT BEARING CARRIER
Torque Specifications Bearing Carrier Removal
1. Elevate front end and safely support machine under
Item Specification footrest / frame area.

Wheel Hub Retaining Nuts


(Front and Rear)
80 ft. lbs. (108 Nm) CAUTION
Strut to Bearing Carrier Bolts 37 ft. lbs. (50 Nm) Serious injury may result if machine tips or falls.
Brake Caliper Mounting Bolts 22 ft. lbs. (30 Nm) Be sure machine is secure before beginning this
service procedure. Wear eye protection when
Tie Rod Fasteners 40 ft. lbs. (54 Nm) removing bearings and seals.
Front Gearcase Mounting Bolts 30 ft. lbs. (41 Nm)
2. Check bearings for side play by grasping the tire/wheel and
Lower A-arm Pinch Bolts 20 ft. lbs. (27 Nm) checking for movement. The tire should rotate smoothly.
Rear Control Arm Bolts 40 ft. lbs. (54 Nm) 3. Remove the front wheel nuts and wheel.

Item Nut Type Specification 4. Remove the A-arm pinch bolt and remove the ball joint
from the bearing carrier (see Chapter 5 “A-arm Removal”).
Lug Nut
Aluminum Wheels 90 ft. lbs. (122 Nm) 5. Remove the steering tie rod from the front bearing carrier.
#1
Bolt
Steel Wheels Flange Nut
27 ft. lbs. (37 Nm)
(Black / Camo) #2 Tie Rod

Washer

#1 #2

Nut
Aluminum Wheel Steel Wheel Cotter Pin
90 ft. lbs. (122 Nm) 27 ft. lbs. (37 Nm)

CAUTION 6. Remove the two brake caliper mounting bolts.


CAUTION: Do not hang caliper by the brake line. Use
Locking nuts, and bolts with pre-applied locking agent wire to hang caliper to prevent damage to the brake line.
should be replaced if removed.
The self-locking properties of the nut or bolt
are reduced or destroyed during removal

Special Tools
Part Number Tool Description

2872608 Roller Pin Removal Tool


8700226 CV Boot Clamp Pliers

7.2
FINAL DRIVE
7. Remove the cotter pin, wheel hub castle nut and washer. Bearing Removal
Then remove the front wheel hub assembly from the ATV.
1. Remove the inner snap ring retaining the bearing.
Wheel Hub
2. From the front side of the housing, tap on the outer bearing
race with a drift punch in the reliefs as shown.
Bearing
Washer
Snap Ring
Cotter Castle
Pin Nut

8. Remove the (2) fasteners retaining the front bearing carrier


Casting
to the front strut assembly. Reliefs

NOTE: Drive bearing out evenly by tapping on outer


race only. Once bearing is at bottom of casting,
Front Strut support casting on outer edges so bearing can be
removed.
3. Discard bearing once removed.
Bearing Carrier
Nuts NOTE: Always replace bearings that have been
removed.

Bolts
4. Inspect the bearing housing for scratches, wear or damage.
Replace front bearing carrier if damaged.
7
Bearing Installation
1. Thoroughly clean the bearing housing and the outer race
on the new bearing. Be sure that all oil residue has been
9. Remove the front bearing carrier and rotate the bearing to removed from each surface.
check for smooth rotation. Visually inspect bearing for 2. Apply Loctite® RC™ 680 to the outer circumference of the
moisture, dirt, or corrosion. Replace bearing if any of these
new bearing race.
conditions exist.
NOTE: Use care to not allow any of the Loctite®
Bearing Carrier
compound to get in the bearing.
3. Support the bearing carrier in a press or suitable device.

CAUTION
Rotate
Bearing When using an arbor press be sure to press only
on the outer race, as bearing damage may occur.

4. Carefully press the new bearing into the front bearing


carrier until the outer race bottoms in the housing.
5. Wipe the housing clean of any excess compound and install
the snap ring into the groove.

7.3
FINAL DRIVE
Bearing Carrier Installation 6. Install a new cotter pin. Tighten nut slightly if necessary
to align cotter pin holes.
1. Install the front bearing carrier over the drive shaft and
reinstall the bearing carrier onto the strut. Torque strut 7. Install the front brake caliper and torque mounting bolts to
fasteners to specification. specification.

22 ft. lbs.
(30 Nm)

37 ft. lbs.
(50 Nm)

=T
Brake Caliper Mounting Bolts:
=T 22 ft. lbs. (30 Nm)

Front Strut to Bearing Carrier Bolts: 8. Attach the steering tie rod to the front bearing carrier and
37 ft. lbs. (50 Nm) torque the fastener to specification.
40 ft. lbs.
2. Place the A-arm ball joint into the lower portion of the (54 Nm)
bearing carrier and install the pinch bolt (see Chapter 5
“A-arm Installation”).
3. Apply grease to the drive shaft splines.
4. Install the front wheel hub onto the drive shaft and into the
front bearing carrier. Apply grease to the washer and install
the washer with the domed side facing out.
5. Install the castle nut and torque to specification.
NEW
Cotter Pin
NEW 80 ft. lbs.
Cotter Pin (108 Nm)

=T
Tie Rod Fasteners:
40 ft. lbs. (54 Nm)

9. Install a new cotter pin. Tighten nut slightly if necessary


to align cotter pin holes.
=T 10. Install the wheel and wheel nuts. Refer to “Torque
Specifications” on Page 7.2.
Wheel Hub Castle Nut:
80 ft. lbs. (108 Nm) 11. Rotate wheel and check for smooth operation.

7.4
FINAL DRIVE
PROPSHAFT SERVICE PROPSHAFT U-JOINT SERVICE
Removal Disassembly
1. Remove right-hand mud guard to allow access to the 1. Remove internal or external snap ring from bearing caps.
propshaft roll pin (see Chapter 5 “Front Cab Removal”).
2. Using Roll Pin Removal Tool (PN 2872608), remove the CAUTION
roll pin from the propshaft at the rear of the front gearcase.
Always wear eye protection.

Roll Pin Removal Tool (PN 2872608)


NOTE: If yoke or bearing is removed, cross bearing
must be replaced. Note orientation of grease fitting
3. Slide prop shaft back and away from front gearcase. Pull and mark inner and outer yoke for correct re-
sharply forward to remove from transmission output shaft. positioning during installation.

Installation 2. Support inner yoke as shown and drive outer yoke down
(bearing cap out) with a soft face hammer. 7
1. Apply anti-seize compound to all splines. Slide propshaft
back onto the transmission output shaft, then slide it up
onto the front gearcase input shaft, verify pin holes are
aligned.
2. Using Roll Pin Tool (PN 2872608), install a NEW roll pin
(spring pin) into the prop shaft.
3. Reinstall the right-hand mud guard (see Chapter 5 “Front
Cab Installation”).

7.5
FINAL DRIVE
3. Support U-joint in vise as shown and drive inner yoke down 3. Using a suitable arbor, fully seat the bearing cap in one side.
to remove remaining bearing caps. Continually check for free movement of bearing cross as
bearing caps are assembled.

4. Force U-joint cross to one side and lift out of inner yoke.
4. Install snap ring to contain bearing cap just installed.
Repeat procedure for other side.
5. Install outer yoke, aligning marks made at disassembly and
repeat Steps 1-3 to install bearing caps on outer yoke.
6. Seat all bearing caps against snap rings by supporting cross
shaft and tapping on each corner as shown.

Assembly
1. Install new bearing caps in yoke by hand. Carefully install
U-joint cross with grease fitting properly positioned
inward toward center of shaft. Take care not to dislodge
needle bearings upon installation of cross joint.
7. When installation is complete, yokes must pivot freely in
2. Tighten vise to force bearing caps in.
all directions without binding. If the joint is stiff or binding,
tap the yoke lightly to center the joint until it pivots freely.

7.6
FINAL DRIVE
FRONT GEARCASE AWD Engagement: When the AWD switch is activated, the
AWD coil is powered by a 12 Vdc input which creates a
CENTRALIZED HILLIARD magnetic field. This magnetic field attracts an armature plate
that is keyed to the roll cage. When the ring gear and roll cage
All Wheel Drive Operation are spinning (vehicle is moving), the energized coil and
armature plate will apply drag to the roll cage that indexes the
The AWD switch may be turned on or off while the vehicle is rollers inside the ring gear to an engagement position. While in
moving, however, AWD will not enable until the engine RPM
drops below 3100. Once the AWD is enabled, it remains the engagement position, the front drive will be in an “over-
enabled until the switch is turned off. running” condition (not engaged), until the rear wheels lose
traction. Once the rear wheels begin to lose traction, the front
Engage the AWD switch before getting into conditions where
the front wheel drive may be needed. If the rear wheels are drive will engage by coupling the output hubs to the ring gear via
spinning, release the throttle before switching to AWD. the rollers. The front drive will remain engaged until the torque
requirement goes away (i.e. rear wheels regain traction).

CAUTION Roller Rollers


Cage

Switching to AWD while the rear wheels are


spinning may cause severe drive shaft and
gearcase damage. Always switch to AWD while
the rear wheels have traction or are at rest.

With the AWD switch off, the vehicle drives through the
rearwheels only (2 wheel drive). When the AWD is enabled, the
front drive acts as an on-demand AWD system. This means, the
front drive will engage once the rear wheels have lost traction,
and will remain engaged until the torque requirement goes away Armature External Cam /
(i.e. rear wheels regain traction). Plate Ring Gear

Output Hub Armature


Plate CAUTION

If the rear wheels are spinning, release the


7
throttle before turning the AWD switch on.
If AWD is engaged while the wheels are
spinning, severe drive shaft and clutch
damage could result.

AWD Disengagement: Once the rear wheels regain traction,


Output Hub the front wheels will return to the “over-running” condition.The
Ring Gear vehicle is now back to rear wheel drive until the next loss of rear
with Roller Cage wheel traction occurs.

7.7
FINAL DRIVE
Centralized Hilliard Exploded View

7-11 ft. lbs.


8-10 ft. lbs. (10-15 Nm)
(11-14 Nm)

8-10 ft. lbs.


(11-14 Nm)

7-11 ft. lbs.


(10-15 Nm)

7-11 ft. lbs.


(10-15 Nm)

REF# DESCRIPTION QTY REF# DESCRIPTION QTY

1 Clutch Asm. 1 11 Set Screw 1


2 Input Cover Asm. 1 12 Input Cover 1
3 Output Cover Asm. 1 13 Bearing 1
4 Roll Cage Asm. 1 14 Pinion Gear, 12T 1
5 Drain Plug Asm. 1 15 Fill Plug 1
6 Gearcase, Asm. 1 16 Clutch Housing / Ring Gear, 44T 1
7 Roller Kit 1 17 Armature Plate 1
8 Seal Repair Kit 1 18 Output Hub (Male) 1
9 Bolt Kit 1 19 Bearing 3
10 Output Hub (Female) 1 20 Thrust Plate Asm. 1

7.8
FINAL DRIVE
AWD Diagnosis 4. Check to make sure the coil is seated in the U-shaped insert
that is pressed into the gearcase housing. The top of the coil
Symptom: AWD Will Not Engage should be seated below the U-shaped insert. The U-shaped
1. Check the gearcase coil resistance. To test the gearcase insert controls the pole gap. If the top of the coil is above
coil resistance, use the coil harness. The gearcase coil the surface of the U-shaped insert it raises the armature
should measure between 21-24 Ohms and at 68 F (20 C). plate, thereby increasing pole gap. If the pole gap increases
the coil will not be strong enough to engage the AWD
system.
BN/WH to GY
Side Cutaway View of Gearcase Cover

Coil

U-Shaped Insert

5. Inspect the rollers for nicks and scratches. The rollers must
slide up and down, and in and out freely within the roll cage
2. Check the minimum battery voltage at the wire harness sliding surfaces.
connection that supplies voltage to the hub coil. There
should be a minimum of 11.80-12.0 Volts present for Rollers
proper operation.

3. Inspect the armature plate for a consistent wear pattern.


There should one or two distinct wear bands (one band
7
inside the other). If only one band of wear is present (or if
there is wear between the two bands, inspect the coil area
as indicated in Step 4. A band with an interrupted wear
mark may indicate a warped plate, which may cause
intermittent operation (see the following illustrations).
Wear Ring on
Armature Plate

Poor Condition:
(Wear from Coil on
Armature Plate)

7.9
FINAL DRIVE
Gearcase Removal 12. Remove the upper steering post bracket from the frame
bulkhead.
1. Stop engine, place machine in gear and set parking brake.

2. Loosen front wheel nuts slightly.

3. Remove cotter pin and loosen hub retaining nut slightly.

4. Elevate machine until the front wheels are off the ground
and support machine under footrest/frame area.

CAUTION

Serious injury may result if machine tips or falls.


Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing and installing bearings and seals.

5. Remove hub retaining nuts, wheel nuts and wheels. 13. Remove the lower steering post bracket fasteners.

6. To remove the gearcase, the following items must be 14. Lift the steering post assembly from the front gearcase and
removed or disconnected so that the steering post brackets move it toward the center of the vehicle to allow enough
can be accessed and the post raised up: room for gearcase removal.

• Battery and cables (Sportsman 300)


• Seat
• Side Panels
• Head Light Harnesses
• AWD Hub Coil Harness
• Gearcase vent line
7. Remove the front bumper (see Chapter 5).

8. Remove both front mud guards (see Chapter 5).

9. Remove the fuel tank cover (see Chapter 5). Place gas cap
back on tank to avoid spills.

10. Remove the front cab (see Chapter 5). 15. Remove cotter pin, ball joint pinch bolt, and remove the
A-arm from the front bearing carrier.
11. Remove the fuel tank (see Chapter 4).

7.10
FINAL DRIVE
16. Pull the strut assembly out and pull the drive-shaft out of Disassembly
the front bearing carrier.
1. Drain and properly dispose of used fluid. Remove any
17. Remove both front drive shafts from the front gearcase. metal particles from the drain plug magnet.
18. Remove the roll pin (spring pin) from the prop shaft. Use 2. Remove the T30 Torx screws and output cover.
the Roller Pin Removal Tool (PN 2872608).

3. Remove the ring gear and roller cage assembly.


19. Remove bolts securing the bottom of the front gearcase
housing to the frame.

20. Remove the gearcase vent line.

21. Remove the front gearcase from either side of the frame.

4. Clean all parts and inspect for wear. Inspect ring gear
backlash pad (arrow) for wear or damage.

Vent Line
Route inside
steering column

Remove Bolts
NOTE: Backlash for the front gearcase is set at the
factory. No adjustment can be made.

7.11
FINAL DRIVE
5. Remove the output hub assembly from the left-hand 9. Inspect roll cage (B) sliding surface. This surface must be
gearcase half. Inspect surfaces for wear or signs of damage. clean and free of nicks, burrs or scratches. Inspect the H-
Replace component if found to worn or damaged. springs, but do not remove them. Replace any H-springs
that appear damaged or have lost radial tension.

B H-Spring

6. Remove the ring gear, roll cage assembly, rollers, and H-


springs from the gearcase. 10. Remove the output hub assembly from the right-hand
gearcase half. Inspect surfaces for wear or signs of damage.
Replace component if found to worn or damaged.

7. Thoroughly clean all parts. Inspect the rollers (A) for nicks
and scratches. The rollers must slide up and down freely
within the roller cage surfaces (B). 11. Inspect the output hub thrust bearing. Replace if wear or
damage is found.
B A

C E

8. Inspect the ring gear (C) for consistent wear patterns. The
surfaces should be free of nicks and scratches.

7.12
FINAL DRIVE
12. Inspect the output hub bearings (arrows). Replace bearings 14. Inspect the magnetic coil (I) in the output housing. Test the
if wear or damage is found. resistance of the coil using an ohmmeter. Replace case half
if coil is found to be non-functional or if the coil surface is
damaged.

NOTE: Due to extremely close tolerances and


minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and NOTE: To test the gearcase coil resistance, use the
quietly, with no detectable up and down movement AWD coil harness. The gearcase coil should
and minimal movement side to side. measure between 21-24 Ohms at 68 F (20 C).
13. Inspect the armature plate (E) for a consistent wear pattern.
Uneven wear of the armature plate surface (E) indicates a AWD Gearcase Coil Resistance:
warped plate, which may cause intermittent operation. 21-24 Ohms at 68 F (20 C)

E 15. Remove and inspect the input cover (M), bearing (N), and
the pinion gear (O). Inspect the pinion gear (O) for chipped,
7
broken, or missing teeth. Replace the input cover O-ring
and seal.

M
N

7.13
FINAL DRIVE
16. Inspect the output shaft bushing (arrow). Replace as Gearcase Reassembly
needed. Clean the inside surfaces of both gearcase halves.
1. Replace all O-rings, seals, and worn components as
previously mentioned.

2. Press the pinion shaft seal into the pinion cover, until the
seal is flush with the sealing surface.

3. Install pinion shaft into the bearing cover, using a small


amount of grease on the seal, bearing and input cover with
new o-ring. Torque screws to specification.

17. Remove and replace the O-rings and seals (arrows) from
the gearcase halve assemblies.

=T
Gearcase T30 Torx Screws:
7-11 ft. lbs. (10-15 Nm)

4. Install the output hub (A) into the gearcase housing. Apply
a small amount of grease to the seal and seal surface as this
will aid assembly. The output hub should spin freely.

7.14
FINAL DRIVE
5. Install the rollers and roll cage into the ring gear. Insert the 8. Install the other output hub (B) and thrust bearing (C) into
rollers as the roll cage is installed, installing the lower row the output case half. Apply a small amount of grease onto
first and then the upper row. the seal surfaces to aid installation.

C B

6. Install the ring gear over the output hub and into the output 9. Install the left output case half onto the right-hand assembly
cover. Insert the backlash pad (G) and set assembly upright. by holding it as shown. Verify the backlash plate thrust
bearing and armature plate stay in place during assembly.

7. Install the armature plate (D) onto the ring gear. Verify the
plate tabs are places into the slots on the roller cage.
NOTE: Verify backlash plate stays in place.

7.15
FINAL DRIVE
10. Torque screws to specification. 2. Coat drive shaft splines with anti-seize compound. Install
both drive shafts into the gearcase. Light tapping may be
required to properly seat the splines into the gearcase.

3. Pull strut assembly out while pivoting the front drive shaft
upward until it enters the front bearing carrier assembly.

4. Install the lower A-arm ball joints into the front bearing
carriers.

5. Install and torque the pinch bolts to specification.

=T
Lower A-arm Pinch Bolt:
20 ft. lbs. (27 Nm)
=T
6. Install the wheel hubs, washers and hub retaining nuts.
Torque the wheel hub nuts to specification.
Gearcase T30 Torx Screws:
7-11 ft. lbs. (10-15 Nm)
=T
Installation
Wheel Hub Retaining Nut:
1. Install gearcase into the frame. Torque mounting bolts to 80 ft. lbs. (109 Nm)
specification and reinstall the vent line.
7. Install new cotter pins into the wheel hub castle nuts.

8. Install the wheels and wheel nuts.

9. Safely lift and lower the front of the ATV.

10. Torque the wheel nuts to specification. Refer to “Torque


Specifications” on Page 7.2.

11. Add the proper lubricant to the front gearcase. Check drain
plug for proper torque (see Chapter 2 “Maintenance” for
fluid fill and change information).
Vent Line
Route inside
steering column

30 ft. lbs. (41 Nm)

=T
Front Gearcase Mounting Bolt:
30 ft. lbs. (41 Nm)

7.16
FINAL DRIVE
REAR BEARING CARRIER 8. Remove the wheel hub castle nut, washer, and remove the
wheel hub from the rear drive shaft and rear bearing carrier.
Bearing Carrier Inspection Wheel Hub

1. Support machine securely with rear wheels elevated.

2. Grasp wheel / hub and check for movement. Washer


Cotter Pin
3. If movement is detected; inspect the hub, retaining nut
torque and bearing condition. Correct as necessary.
Castle Nut

CAUTION

Serious injury may result if machine tips or falls.


RH Hub Shown
Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals. 9. Remove the upper and lower control arm bolts from the rear
bearing carrier.

Bearing Carrier Removal


Upper
Control Arm
1. Place the ATV in neutral and lock the parking brake.
Bolt
2. Remove the cotter pin from the wheel hub castle nut and
loosen the hub nut slightly.

3. Loosen the wheel nuts, but do not remove.

4. Elevate rear end and safely support machine under main Nut
frame area.

5. Remove wheel nuts and wheel.


7
Bearing Carrier
6. Remove the two brake caliper mounting bolts and remove
the rear brake caliper (only if servicing the left-hand side).

Bolt

Lower
Control Arm

Nut
LH Side Only

10. Remove the rear bearing carrier. Inspect the bearing for
smoothness and side to side movement, replace as needed.
7. Safely suspend the caliper from the frame with a piece of
wire. CAUTION: Do not hang the caliper by the brake
line. Use wire to hang the caliper to prevent possible
damage to the brake line.

7.17
FINAL DRIVE
Bearing Removal Bearing Carrier Installation
1. Remove the inner snap ring retaining the bearing. 1. Grease the bushings and pivot tubes and slide them into
place in the rear bearing carrier.
2. From the front side of the housing, tap on the outer bearing
race with a drift punch in the reliefs as shown. 2. Insert drive shaft into the back side of the rear bearing
carrier.
Snap Ring
3. Align bottom of rear bearing carrier and lower control arm.
Bearing
Bearing Carrier 4. Install and torque lower control arm bolt to specification.

5. Move the upper control arm down towards the bearing


carrier until it aligns with the top hole of the carrier. Install
and torque upper control arm bolt to specification.

Upper
Control Arm
Casting 40 ft. lbs.
Reliefs (54 Nm)

NOTE: Drive bearing out evenly by tapping on outer


race only. Once bearing is at bottom of casting,
support casting on outer edges so bearing can be
removed.
3. Discard bearing once removed.
NOTE: Always replace bearings that have been Bearing Carrier
removed.
4. Inspect the bearing housing for scratches, wear or damage. 40 ft. lbs.
Replace rear bearing carrier if damaged. (54 Nm)

Bearing Installation
1. Thoroughly clean the bearing housing and the outer race
on the new bearing. Be sure that all oil residue has been
Lower
removed from each surface. Control Arm

2. Apply Loctite® RC™ 680 to the outer circumference of the


new bearing race.
NOTE: Use care to not allow any of the Loctite®
compound to get in the bearing.
3. Support the bearing carrier in a press or suitable device. =T
Rear Control Arm Bolt Torque:
CAUTION 40 ft. lbs. (54 Nm)

When using an arbor press be sure to press only 6. Pull drive shaft outward and apply grease to the drive shaft
on the outer race, as bearing damage may occur. splines.

4. Carefully press the new bearing into the rear bearing carrier 7. Install the wheel hub onto the drive shaft splines.
until the outer race bottoms in the housing. 8. Install the washer with domed side facing outward.
5. Wipe the housing clean of any excess compound and install
the snap ring into the groove.
7.18
FINAL DRIVE
9. Install the wheel hub castle nut and torque to specification. DRIVE SHAFT SERVICE
Wheel Hub
Front Drive Shaft Removal
1. Remove the cotter pin from the wheel hub castle nut and
NEW Washer slightly loosen the nut.
Cotter Pin
2. Elevate front of vehicle and safely support machine under
80 ft. lbs. the frame area.
(108 Nm)

CAUTION

Serious injury may result if machine tips or falls.


RH Hub Shown Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.
=T
3. Remove the wheel nuts and front wheel.
Wheel Hub Castle Nut: 4. Remove cotter pin and nut from the front bearing carrier
80 ft. lbs. (108 Nm) pinch bolt retaining the lower A-arm ball joint. Remove
lower A-arm ball joint from the bearing carrier using a
10. Install a new cotter pin. Tighten nut slightly if necessary suitable tool.
to align cotter pin holes.

11. Install the rear brake caliper and torque mounting bolts to
specification (only if servicing the left-hand side).

LH Side Only

22 ft. lbs. 5. Remove the wheel hub castle nut and washer.
(30 Nm)
6. Pull front bearing carrier assembly out while pivoting front
drive shaft downward until it clears the bearing carrier.
=T 7. With short sharp jerks, remove drive shaft from front
gearcase.
Brake Caliper Mounting Bolts:
22 ft. lbs. (30 Nm)

12. Install the wheel and wheel nuts. Refer to “Torque


Specifications” on Page 7.2.

13. Rotate wheel and check for smooth operation.

7.19
FINAL DRIVE
Rear Drive Shaft Removal • Over-angling of joints beyond their capacity can result
in boot or joint damage.
1. Remove the rear bearing carrier (see “REAR BEARING
CARRIER - Bearing Carrier Removal”). • Make sure surface-ground areas and splines of shaft are
protected during handling to avoid damage.
NOTE: The rear bearing carrier does not need to be
completely removed. The lower control can remain • Do not allow boots to come into contact with sharp
attached to the rear bearing carrier during this edges or hot engine and exhaust components.
procedure. • Shafts should never be used as a lever arm to position
2. Tip the rear bearing carrier down and remove the drive shaft other suspension components.
from the bearing carrier. • Never use a hammer or sharp tools to remove or to
install boot clamps.
• 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.

Outer CV Joint / Boot Replacement


1. Remove the drive shaft from the vehicle (see “Front Drive
Shaft Removal” or “Rear Drive Shaft Removal”).
2. Remove and discard the boot clamps.

CV Boot Clamp Pliers


3. Pry and pull sharply outward to remove drive shaft from Earless Type: 8700226
transmission.
3. Remove the large end of the boot from the CV joint and
Pull outward sharply to slide the boot back.
remove from transmission 4. Use a soft-faced hammer or brass drift to separate the CV
joint from the drive shaft.
NOTE: If using a brass drift, be sure to tap on the
inner race of the joint only.

Circlip

Drive Shaft / CV Joint Handling Tips


Care should be exercised during drive shaft removal or when Pull shaft to remove
servicing CV joints. Drive shaft components are precision parts. from CV joint

Cleanliness and following these instructions is very important to 5. Make sure the circlip remains on the shaft and not left in
ensure proper shaft function and a normal service life. the joint.
• The complete drive shaft / joint should be handled by
the interconnecting shaft to avoid disassembly or
potential damage to the drive shaft joints.

7.20
FINAL DRIVE
6. Remove the boot from the drive shaft.
BOOT KIT PN: 2203170 Large
Clamp
CAUTION Small
Clamp Boot
Complete disassembly of the CV joint is NOT
recommended. The internal components are a
precision fit and develop their own characteristic
wear patterns. Intermixing the internal
components could result in looseness, binding,
and/or premature failure of the joint.

IMPORTANT: If the grease in the joint is obviously NOTE: The amount of grease that’s provided is pre-
contaminated with water and/or dirt, the joint should measured, so use all the grease.
be replaced.
13. Slide the joint onto the drive shaft splines and align the
7. Thoroughly clean the joint with an appropriate solvent and circlip with the lead-in chamfer on the inner race of the
dry the joint to prevent any residual solvent from being left joint.
in the joint upon reassembly.
14. Use a soft-faced hammer to tap the joint onto the drive shaft
8. Visually inspect the joint by tilting the inner race to one side until it locks into place.
to expose each ball. Severe pitting, galling, play between
the ball and its cage window, any cracking or damage to the 15. Pull on the joint to make sure it is securely locked into place.
cage, pitting or galling or chips in raceways call for joint 16. Remove excess grease from the CV joint’s external
replacement. surfaces and place the excess grease in the boot.
NOTE: Shiny areas in ball tracks and on the cage 17. Pull the boot over the joint and position the boot lips into
spheres are normal. Do not replace CV joints the grooves on the joint housing and shaft. Make sure the
because parts have polished surfaces. Replace CV boot is not dimpled or collapsed.
joint only if components are cracked, broken, worn
or otherwise unserviceable. 18. Install and secure the CV boot with the large clamp using
9. Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.
the “earless” clamp pliers.
7
CV Boot Clamp Pliers
10. Slide the small boot clamp and boot (small end first) onto Earless Type: 8700226
the drive shaft and position the boot in it’s groove machined
in the shaft.
19. While pulling out on the CV shaft, fully extend the CV joint
11. Install a NEW circlip on the end of the shaft. and slide a straight O-ring pick or a small slotted screw
12. Grease the joint with the special CV joint grease provided driver between the small end of the boot and the shaft. This
in the boot replacement kit. Fill the cavity behind the balls will allow the air pressure to equalize in the CV boot in the
and the splined hole in the joint’s inner race. Pack the ball position that the joint will spend most of its life. Before you
tracks and outer face flush with grease. Place any remove your instrument, be sure the small end of the boot
remaining grease into the boot. is in its correct location on the shaft.

CAUTION

The grease provided in the replacement kit is


specially formulated for wear resistance and
durability. DO NOT use substitutes
or mix with other lubricants.

7.21
FINAL DRIVE
20. Install and secure the small clamp on the boot using the 10. Slide the small boot clamp and boot (small end first) onto
“earless” clamp pliers. the drive shaft and position the boot in it’s groove machined
in the shaft.
CV Boot Clamp Pliers 11. Install a NEW circlip on the end of the shaft.
Earless Type: 8700226 12. Grease the joint with the special CV joint grease provided
in the boot replacement kit. Fill the cavity behind the balls
and the splined hole in the joint’s inner race. Pack the ball
tracks and outer face flush with grease. Place any
Inner Plunging Joint / Boot Replacement
remaining grease into the boot.
1. Remove the drive shaft from the vehicle (see “Front Drive
Shaft Removal” or “Rear Drive Shaft Removal”).
CAUTION
2. Remove and discard the boot clamps.
The grease provided in the replacement kit is
CV Boot Clamp Pliers specially formulated for wear resistance and
Earless Type: 8700226 durability. DO NOT use substitutes
or mix with other lubricants.

3. Remove the large end of the boot from the plunging joint
and slide the boot back. BOOT KIT PN: 2203170 Large
Clamp
4. Use a soft-faced hammer or brass drift to separate the Small
plunging joint from the drive shaft. Clamp Boot

NOTE: If using a brass drift, be sure to tap on the


inner race of the joint only.
5. Make sure the circlip remains on the shaft and not left in
the joint.
6. Remove the boot from the drive shaft.
NOTE: The amount of grease that’s provided is pre-
CAUTION measured, so use all the grease.

13. Fully compress the joint and push the drive shaft firmly into
Complete disassembly of the plunging joint is
the inner race.
NOT recommended. The internal components
are a precision fit and develop their own 14. Align the circlip with the lead-in chamfer.
characteristic wear patterns. Intermixing the
internal components could result in looseness, 15. Use a soft-faced hammer to tap the joint onto the drive shaft
binding, and/or premature failure of the joint. until it locks into place.
16. Pull on the joint to make sure it is securely locked into place.
IMPORTANT: If the grease in the joint is obviously
contaminated with water and/or dirt, the joint should 17. Remove excess grease from the plunging joint’s external
be replaced. surfaces and place the excess grease in the boot.
7. Thoroughly clean the joint with an appropriate solvent and 18. Pull the boot over the joint and position the boot lips into
dry the joint to prevent any residual solvent from being left the grooves on the joint housing and shaft. Make sure the
in the joint upon reassembly. boot is not dimpled or collapsed.
8. Visually inspect the joint by tilting the inner race to one side 19. Install and secure the small clamp on the boot using the
to expose each ball. Severe pitting, galling, play between “earless” clamp pliers.
the ball and its cage window, any cracking or damage to the
cage, pitting or galling or chips in raceways call for joint
CV Boot Clamp Pliers
replacement.
Earless Type: 8700226
9. Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.

7.22
FINAL DRIVE
20. Pull out on the drive shaft to center the joint in the housing. Front Drive Shaft Installation
Slide a straight O-ring pick or a small slotted screw driver
between the large end of the boot and the joint housing and 1. Install a new circlip on the end of the plunging joint and
lift up to equalize the air pressure in the boot. apply an anti-seize compound to the drive shaft splines.

21. Position the boot lip in its groove. Install and secure the 2. Align drive shaft splines with front gearcase and install by
boot with the large clamp using the “earless” clamp pliers. lightly tapping on drive shaft with a rubber faced hammer.
3. Install drive shaft into the front bearing carrier.
CV Boot Clamp Pliers
4. Install lower A-arm ball joint into the front bearing carrier.
Earless Type: 8700226
5. Install the ball joint pinch bolt into the bearing carrier.
Torque to 20 ft. lbs. (27 Nm) and install a new cotter pin.

Exploded View
NOTE: Refer the “Electronic Parts Catalog” to
obtain the required parts to service the drive shaft.

20 ft. lbs.
(27 Nm)

CV Joint

NEW
Cotter Pin

Large Circlip
Clamp =T
Boot Lower A-arm Pinch Bolt:
20 ft. lbs. (27 Nm) 7
6. Install the washer and castle nut onto the wheel hub.
Tighten hub nut to specification and install new cotter pin.

Small
Clamps

Boot

Large
Clamp
Circlip
=T
Plunging Wheel Hub Retaining Nut:
Joint Circlip 80 ft. lbs. (109 Nm)

7. Install the wheel and wheel nuts. Refer to “Torque


Specifications” on Page 7.2.
7.23
FINAL DRIVE
Rear Drive Shaft Installation 7. Refer to “REAR BEARING CARRIER - Bearing Carrier
Installation” if the brake caliper was removed (only if
1. Install a new circlip on the end of the plunging joint and servicing the left-hand side).
apply an anti-seize compound to the drive shaft splines.
8. Install the wheel and wheel nuts. Refer to “Torque
2. Align drive shaft splines with transmission and install by Specifications” on Page 7.2.
lightly tapping on drive shaft with a rubber faced hammer.
3. Install drive shaft into the rear bearing carrier.
4. Lift bearing carrier into place and install the upper control
arm attachment bolt. Torque bolt to 40 ft. lbs. (54 Nm).

=T
Control Arm to Bearing Carrier Bolt:
40 ft. lbs. (54 Nm)

5. Reinstall the rear wheel hub.


6. Install the washer (domed side out) and castle nut onto the
wheel hub. Tighten hub nut to specification and install new
cotter pin.
Wheel Hub

NEW Washer
Cotter Pin

80 ft. lbs.
(108 Nm)

RH Hub Shown

=T
Wheel Hub Retaining Nut:
80 ft. lbs. (109 Nm)

7.24
CVT / TRANSMISSION
CHAPTER 8
CVT / TRANSMISSION
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
CVT TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
GEAR SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SHIFT LINKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
GEAR SELECTOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
CLUTCH ROLLER WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
CVT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
CVT OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
STARTING CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
DRIVEN CLUTCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
ENGINE BRAKING CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
CVT MAINTENANCE/INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
CVT DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
CVT OVERHEATING/DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
CVT SYSTEM DISASSEMBLY / DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
CVT SYSTEM / DRIVEN CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
TRANSMISSION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
TRANSMISSION REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
4X4 TRANSMISSION OUTPUT EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
STARTING CLUTCH EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18

8.1
CVT / TRANSMISSION
TORQUE SPECIFICATIONS
CVT Torque Specifications

96 in. lbs. (10.8 Nm)

185 ft. lbs (250 Nm)


Use Clutch Holder PA-47478

14 ft. lbs. (19 Nm)

Clamps - 25 in. lbs.

8.2
CVT / TRANSMISSION
GEAR SELECTION SPECIAL TOOLS
Shift Linkage Inspection Special Tools
NOTE: Shift rod is preset at time of manufacture.
1. Inspect shift linkage rod bushing clips and replace if worn
or damaged. Lubrication of rod ends is not required.

Gear Selector Removal


1. Push linkage rod out of bushing clip to remove.
2. Remove bolts attaching gear selector mount to frame.
3. To remove gear selector handle, pry cap off and remove
screw.

Clutch Compression Tool 8700220


Arm, Clutch Spring Compressor
PA-47457-1
(Use with 8700220)
Clutch Adaptor PA-47457-2
Spring Retainer Alignment Tool PA-47457-3
Retainer Nut Socket, Driven Clutch PA-46076
Starting Clutch Holder PA-47475
Clutch Roller Weights Drive Clutch Clamping Tool 2875563

Shown below are roller shift weights which may be used in the
8
CVT system. These shift weights control engagement RPM and Order tools from SPX Corp. 1-800-328-6657
shifting patterns. Shift weights should not be changed or altered
without first having a thorough understanding the effects they
have on clutch balance, engagement and shifting characteristics.
• 14 gram - PN 5412989
• 13 gram - PN 5412988
• 12 gram - PN 5412987
• 10 gram - PN 5412986

8.3
CVT / TRANSMISSION
CVT OPERATION Drive Clutch Operation
The CVT drive clutch, mounted on the starting clutch hub shaft,
CVT Operation Overview is RPM sensitive. The drive clutch basic components are the
inner (fixed) sheave, the outer (moveable) sheave, the rollers
(weights) and the cover plate.
WARNING
The drive clutch begins to rotate when engine RPM reaches
engagement speed and the starter clutch engages.
All CVT maintenance or repairs should be performed
only by a certified Polaris Master Service Dealer (MSD) At low RPM, the drive belt is located at the bottom (smallest
diameter) of the drive clutch sheaves resulting in a low “gear”
technician who has received the proper training and ratio. As engine RPM increases, centrifugal force moves the
understands the procedures outlined in this manual. drive clutch shift rollers outward in their respective tracks
Because of the critical nature and precision balance toward the outside of the drive clutch. This forces the moveable
sheave farther inward toward the fixed sheave. The inward
incorporated into the CVT components, it is movement of the sheave forces the drive belt farther upward in
absolutely essential that no disassembly or repair the sheaves toward progressively higher “gear” ratios (larger
be made without factory authorized special tools diameter).
and service procedures.
Driven Clutch Operation
The power of the engine is transferred to the wheels through the The driven clutch is connected to the drive clutch via the drive
following components: Starting Clutch, Drive Clutch, Drive belt and is mounted on the main gearcase input shaft. The CVT
Belt, Driven Clutch, Transmission, Drive shaft(s), and Rear driven clutch consists of a fixed sheave, a moveable sheave with
Gearcase (and Front Gearcase on 4x4 models). roller tracks, rollers, and a compression style return spring.
During the development of a Polaris ATV, the CVT system is The driven clutch is primarily torque sensitive, reacting to the
matched first to the engine power curve; then to average riding forces of engine power and vehicle load to control the upshift
conditions and the vehicle’s intended usage. Therefore, and downshift of the CVT system.
modifications or variations of components at random are never
recommended.
Engine power is sensed by the driven clutch via the drive belt.
Proper clutch setup and careful inspection of existing Vehicle loads are sensed by the driven clutch through the main
components must be the primary objective when gearcase input shaft.
troubleshooting and tuning.
If forces on the drive belt (engine power) exceed the forces on
The Continuously Variable Transmission (CVT) consists of the transmission shaft (vehicle loads) the drive clutch sheaves
four major assemblies: 1) Starting Clutch; 2) Drive Clutch; 3) move inward and the belt upward, which forces the sheaves of
Drive Belt; and 4) Driven Clutch. the driven clutch apart against spring pressure. The drive belt
moves downward into the sheaves of the driven clutch to a
smaller diameter (higher “gear” ratio), increasing the speed of
Starting Clutch Operation the driven clutch. This process is called upshifting.
The starting clutch is located on the left (CVT) side of the engine If the torque resistance at the transmission input shaft is greater
crankshaft. It is an RPM sensitive clutch that connects the than the force through the drive belt, the driven clutch spring
engine crankshaft to the CVT System. forces the moveable sheave inward, and the drive belt is forced
toward the outer diameter of the sheaves. This action, which
When engine RPM is below the factory determined engagement decreases the driven clutch speed, is called backshifting.
speed of the vehicle, return springs on the staring clutch shoes
hold the shoes inward away from the starter clutch hub. In situations where loads vary (such as uphill and downhill) and
throttle settings are constant, the drive and driven clutches
When engine RPM is increased, centrifugal force causes the upshift or backshift accordingly to maintain optimum engine
shoes to overcome the return spring force and swing outward. RPM.
When the shoes contact the surface of the starter clutch hub, the
hub rotates at engine speed. This causes the CVT drive clutch At full throttle a perfectly matched CVT maintains engine RPM
mounted on the shaft of the starting clutch hub to rotate at the at the peak of the power curve during upshift and backshift. In
same RPM. this respect, the CVT system is similar to a conventional power
governor, but it functions by varying the load rather than by
Refer to the ENGINE section for more information. varying throttle position.

Engine Braking Clutch


The engine braking clutch is a one-way clutch located inside the
starting clutch hub. This clutch “locks” the starting clutch hub
to the crankshaft whenever drive belt (and drive clutch) speeds
exceed the engine RPM, such as when travelling down hill with
the throttle released, which provides engine braking.
Refer to the Chapter 3 ENGINE section for repair information.

8.4
CVT / TRANSMISSION
CVT Maintenance/Inspection CVT Drying
Periodic inspection and maintenance is required to keep the NOTE: If operating the ATV through water, be sure to
system operating at peak performance. The following list of check the CVT cover and other ATV components for
items should be inspected and maintained to ensure maximum
performance and service life of CVT components. Refer to the water ingestion. The ATV should be checked
troubleshooting checklist for more information. immediately. Refer to Owner’s Manual for Safe Riding
1. Drive and Driven Clutch Rollers (Weights), Buttons Tips.
and Bushings, and Driven Clutch Spring. Inspect for 1. To drain any water that may be trapped inside the CVT
wear. cover, remove the CVT drain plug located on the bottom
2. Drive Belt. Inspect condition and width of belt. of the CVT cover and let the water drain out. (The location
of the CVT drain plug is shown on the following page.)
3. Sheave Faces. Clean and inspect for wear.
4. CVT System Sealing. The CVT system is air cooled by fins NOTE: To further expel water in the CVT cover and to
on the drive clutch stationary sheave. The fins create a low dry out the CVT system, shift the transmission to neutral
pressure area in the CVT area, drawing fresh air into the and rev engine slightly to expel the moisture. This will
system through the intake air duct. The opening for this also air-dry the belt and clutches. Allow engine RPM to
intake duct is located at a high point on the vehicle. All settle to idle speed, shift transmission to lowest available
connecting air ducts and the outer cover must be properly range and test for belt slippage. Repeat as needed.
sealed to reduce the chance of water ingestion into the CVT Operate ATV in lowest available range for a short period
area. A sealed CVT is especially critical on units subjected of time until CVT system is dry.
to frequent water forging.

8.5
CVT / TRANSMISSION
CVT DUCTING

Air Intake Duct

Drain Plug Location

Air Intake Duct


ct

Air Exhaust Duct

Clamps

8.6
CVT / TRANSMISSION
CVT Overheating/Diagnosis
During routine maintenance or whenever CVT system overheating is evident, it’s important to check the inlet and outlet ducting for
obstructions. Obstructions to air flow through the ducts will significantly increase CVT system operating temperatures. The ATV
should be operated in LOW RANGE (if equipped) when pulling or plowing heavy loads, or if extended low speed operation is
anticipated.

Low Range (if equipped): Heavy pulling, basic operational speeds less
GENERAL OPERATION RANGE than 7 MPH, riding through rough terrain (swamps, mountains, etc.), low
GUIDELINES: ground speeds.
High Range: High ground speeds, speeds above 7 MPH.
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 (if equipped) during loading of the ATV to
when in high range. prevent belt burning.
Starting out going up a steep incline. When starting out on an incline, use low range (if equipped), or perform
the “K” turn to turn around. Warning: Excessive throttle may cause
loss of control and vehicle overturn.
Driving at low RPM or low ground speed Drive at higher speed or use Low Range. (if equipped) The use of Low
(at approximately 3-7 MPH). Range is highly recommended for cooler CVT operating temperatures
and longer component life.
Insufficient warm-up of ATVs exposed to Warm engine at least 5 min., then with transmission in neutral, advance
low ambient temperatures. throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will
become more flexible and prevent belt burning.
Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement. Continuous
operation at the point of engagement (initial vehicle movement)
increases CVT temperatures and component wear.
Towing/Pushing at low RPM/low ground Use Low Range only. (if equipped)
speed.
Plowing snow, dirt, etc./utility use. Use Low Range only. (if equipped)
Stuck in mud or snow. Shift the transmission to Low Range (if equipped), carefully use fast,
aggressive throttle application to engage clutch. Warning: Excessive
8
throttle may cause loss of control and vehicle overturn.
Climbing over large objects from a Shift the transmission to Low Range (if equipped), carefully use fast,
stopped position. aggressive, throttle application to engage clutch. Warning: Excessive
throttle may cause loss of control and vehicle overturn.
Belt slippage from water or snow Shift the transmission to neutral. Using the throttle, vary engine rpm from
ingestion into the CVT system. idle to 3/4 throttle. Engage transmission in the lowest possible range (if
equipped) and test for belt slippage Repeat several times as required.
During this procedure, the throttle should not be held at the full
position. Inspect CVT system for sealing or damage if repeated water
ingestion occurs.
Clutch malfunction. Inspection/repair of clutch components should be performed by a
certified Polaris MSD technician.

8.7
CVT / TRANSMISSION
CVT System Disassembly / Drive Clutch 7. Before removing drive belt, install the tool 2875563 as
shown to prevent drive clutch moveable sheave from
NOTE: Do not lubricate drive clutch components. moving inward.
NOTE: If tool is not available, use two hands to hold
1. Remove seat, left side cover, left foot well, rear rack and
the cam plate and the primary sliding sheave
rear cab. (Rear tire removal not required but helpful.)
together when removing the primary sliding sheave
2. Remove all CVT cover screws and CVT cover. and the cam plate assembly. This prevents the
rollers from falling out of the assembly.

3. Replace cover bearing if worn. Remove the snap ring and


draw bearing out with a blind hole puller or slide hammer
style puller.
NOTE: Do not re-use bearing if removed from cover.

4. Press or drive a new bearing into the cover. Press or drive


only on the outer race of bearing. Fit should be snug with
no tightness or sticking. Rotate the inner race to be sure it
rotates freely without binding after installation.
5. Install the snap ring. Be sure it is fully seated in the groove.

Cover Bearing 2875563

8. Separate driven clutch sheaves and force belt down into the
sheaves. Remove belt from driven, then from drive clutch.

6. Inspect the CVT cover gasket and replace if damaged.

8.8
CVT / TRANSMISSION
9. Measure belt width and compare to specification. Replace 11. Remove sleeve and fixed sheave. Inspect the cooling fins
if any area is worn below the minimum width, if belt is for damage, the sleeve for wear or rough spots, and the face
unevenly worn (hour glassed) or if damaged. of the fixed sheave for wear, grooving or rough surface.

Fixed Sheave

Sleeve

= In. / mm.
12. Remove the rollers from the primary sliding sheave. Check
Drive Belt Service Limit: the rollers for wear, deep scoring, or flat spots. Remove and
1.320” (33.52mm) inspect the slide bushings and cam plate. Replace any
components that found to be worn excessively or appears
10. Remove the primary sliding sheave and cam plate assembly abnormal.
as one assembly. Inspect the movable sheave for scoring,
grooving, or abnormal wear. Slide Bushings
NOTE: If tool is not installed, be sure to hold cam
plate and primary sliding sheave together to prevent Rollers
rollers from falling out of the assembly.

Bushing Cam Plate 8


13. Note direction of roller thrust surface (wide edge) toward
thrust face of sheave.
14. Inspect bushing for wear.
15. When installing cam plate, be sure to align offset hole in
cover with threaded hole in sheave.
Wide Surface Of Roller Against Thrust
Surface Of Roller Track

Wide Surface

Bushing
Threaded Hole

8.9
CVT / TRANSMISSION
16. Install the fixed sheave and spacer sleeve. CVT System / Driven Clutch Service
1. Remove retaining bolt.
2. Pull the clutch off the shaft using flywheel puller as shown.

17. Install tool 2875563 in the offset hole of the moveable


sheave assembly to hold it together for installation.

2875563
3. Remove the puller and place the driven clutch spring side
up in the clutch spring compressor 8700220.
4. Install arm PA-47457-1 on the spring compressor.
5. Install adaptor PA-47457-2 on the arm.
6. Remove nut (counterclockwise) using tool PA-46076 or a
standard socket.
7. Compress spring enough to remove the chain lock and
slowly release spring tension.

18. Install the assembly, engaging the splines and install the
nut. Do not apply any lubricants to the components. Apply
Loctite 242 (Blue) to threads and torque the retaining nut
to specification.
IMPORTANT: Be sure splines of cam plate are fully
engaged on shaft spline before tightening the nut!

=T
CVT Drive Clutch Nut Torque
185 ft. lbs. (250 Nm)
Loctite 242 (Blue)
CAUTION

Spring Pressure can cause components to eject


suddenly. Use care during removal.

NOTE: Use Loctite™ 242 upon reassembly.

8.10
CVT / TRANSMISSION
8. Measure the free length of spring. Standard free length is 10. Remove roller pins using a needle-nose pliers and
7.52” (191.1mm). Replace spring if length is less than remove top and bottom O-rings.
standard or if spring coils are distorted.

NOTE “X” MARKS FOR ASSEMBLY

11. Clean all parts to remove old grease before inspecting the
= In. / mm. components.
12. Carefully inspect the roller tracks in the hub of the
Driven Compression Spring moveable sheave. Replace clutch assembly if tracks are
Standard Length: visibly worn.
7.52” (191.1 mm) 13. Check the pin holes in the shaft of the fixed sheave. Pins
should be a firm fit in the holes.
9. Carefully pry up the roller cover to remove it. Inspect cover
for wear. 14. Inspect sheaves for wear, damage, or rough spots. Replace
the clutch assembly if sheaves are worn or damaged.
15. Apply a light film of moly grease to seal lips and to the
inside of the roller pin hub. Install the moveable sheave
over the shaft of the fixed sheave until the sheaves contact
each other.
16. Lift the moveable sheave enough to clean all excess grease
from the shaft and the sheave faces to prevent belt
contamination after assembly.

17. With sheaves together, rotate the moveable sheave to


ALIGN THE “X” MARK of moveable sheave with the “X”
mark on fixed sheave.

8.11
CVT / TRANSMISSION
18. Lubricate the roller pins with grease and install all pins until
fully seated. The surface of the pins must be approximately
flush with the surface of the roller pin hub.
19. Install new O-rings on top and bottom of roller pin hub.
20. Pack all roller tracks with grease.
21. Install the roller pin sleeve and push it down until fully
seated against moveable sheave.
22. Clean the threads of the shaft, and threads of the spring
retaining nut to remove all oil or grease.
23. Place the driven clutch assembly in the compressor tool.
24. Install spring.
25. Install spring retainer on spring, visually aligning the flats
of the retainer with the flats on the threaded shaft.
26. Install tool PA-47457-3
27. Retainer Alignment Tool onto spring retainer.

Turn to align flats

28. Compress the clutch spring slowly, turning the retainer with
the tool as required to align the flats.
29. When flats are aligned, fully compress the spring and
secure the compressor arm with the chain.
30. Apply Loctite™ 242 to threads of the nut and the shaft, and
install nut hand tight.
31. Release the tool and torque the nut to specification using
the same tools for removal of the nut.

=T
Driven Clutch Spring Retainer Nut Torque:
45 ft. lbs. (61 Nm)
Loctite™ 242 (Blue)

8.12
CVT / TRANSMISSION
TRANSMISSION

18 ft. lbs. (24.5 Nm)

8.13
CVT / TRANSMISSION
Transmission Service 6. Remove input shaft, counter shaft, and shift drum as an
assembly.
1. Drain transmission fluid.
2. Remove Transmission. Refer to the Engine Section for
transmission removal procedure.

Transmission Disassembly
1. Clean the exterior of the transmission.
2. Remove all case screws.
3. Remove the left case from the right. Be sure shafts stay with
right case.

7. Clean all parts. Remove seals from gear case and install
new using an appropriate size seal driver.
8. Inspect all bearings, gear teeth, and splines for wear or
damage. Inspect gear dogs carefully and replace if the edge
of the dog is worn or rounded, chipped, or broken.
9. Inspect the reverse chain for damage.
Gear Teeth
Bearings Reverse Chain

4. Remove output gear and shaft and pull oil deflector from
right case. Note orientation for installation later.
Oil Deflector

Splines
Engagement Dogs

10. Gear dogs should be square at the corners. Replace both


mating gears if any are rounded or damaged.
Output Gear

5. Remove gear position switch and shift bell crank.

8.14
CVT / TRANSMISSION
11. Inspect the shift drum tracks for wear or damage. Inspect 2. Place fork shaft through guide with pointed end as shown.
shift fork for bending and the surface for wear, burning, or
scoring.

Inspect Shift Fork

3. Slide the spring collar, large diameter spring, shift fork,


12. Inspect the shift fork shaft and all springs. Inspect detent small spring, and shaft support onto the shaft. The dot on
cam and pawl for wear. the shaft support faces away from the fork.

Shaft Support
Spring Collar
Small Spring
Large Spring
Fork

8
Transmission Reassembly
1. Reassemble the drum starting with shaft guide, detent cam DOT
(wide flange faces toward the threaded end of drum), the
flat washer, and snap ring.

8.15
CVT / TRANSMISSION
4. Install the detent ratchet with spring. Install the snap ring. 7. Apply 3-Bond 1215 sealant evenly to clean and oil-free
case sealing surfaces.

5. Assemble the shafts with chain and shift drum and install
the assembly into the case.
8. Install the left case and tap it into place until seated.
9. Install bolts and torque in two steps following a cross
pattern to specification.

=T
Gearcase Bolt Torque:
(18 ft. lbs. (24.5 Nm)

10. Install the shift arm (bell crank).


11. Rotate the shafts to be sure they turn smoothly. Verify
shifting through all gears while rotating the shafts.
12. Verify drain plug is torqued to specification. Fill
transmission with specified type and quantity. (Refer to
NOTE: Reference page 8.18 for 4x4 assembly Chapter 2 for procedure).
illustration and torque specifications.

6. Install the output gear and oil deflector. Lubricate all


=T
components.
Drain Plug Torque:
Oil Deflector
(18 ft. lbs. (24.5 Nm)
Output Gear

NOTE: Reference page 8.18 for 4x4 assembly


illustration and torque specifications.

8.16
CVT / TRANSMISSION
4x4 Transmission Output Exploded View

7-10 ft. lbs.


(9.5-13.5Nm)

8.17
CVT / TRANSMISSION
Starting Clutch Exploded View
Complete disassembly, inspection and installation procedures are located in Chapter 3.

8.18
ELECTRICAL
CHAPTER 9
ELECTRICAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
FUSIBLE LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
FUSE SPLICE SAVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
INSTRUMENT GAUGE POWER / FWD / NEUTRAL SWITCHES / RPM SIGNAL . . . . . 9.4
AWD CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
SPEED SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
GEAR POSITION INDICATOR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
GEAR POSITION SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
ETC / REVERSE RPM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
ETC / REVERSE RPM CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
IGNITION SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
RPM LIMIT MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
IGNITION COIL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
CDI OUTPUT TEST USING PEAK READING ADAPTOR OR VOLTMETER . . . . . . . . 9.10
CDI CRANKING OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
IGNITION SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
IGNITION SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
CHARGING SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
ALTERNATOR OUTPUT TEST (AC AMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
STATOR FUNCTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
VOLTAGE DROP TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
BRUSH INSPECTION & REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
ARMATURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
STARTER REASSEMBLY & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
9
STARTER SOLENOID BENCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
STARTER MOTOR EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
PINION GEAR - ANTI-KICK OUT SHOE, GARTER SPRING REPLACEMENT . . . . . . 9.23
STARTER SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
CONDITION: STARTER FAILS TO TURN MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24

9.1
ELECTRICAL
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
BATTERY IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
CONVENTIONAL BATTERY ACTIVATION/ SVC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
BATTERY TERMINALS/TERMINAL BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CONVENTIONAL BATTERY INSPECTION/REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CONVENTIONAL BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CONVENTIONAL BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CONVENTIONAL BATTERY OCV - OPEN CIRCUIT VOLTAGE TEST . . . . . . . . . . . . 9.27
CONVENTIONAL BATTERY SPECIFIC GRAVITY TEST . . . . . . . . . . . . . . . . . . . . . . . 9.27
CONVENTIONAL BATTERY LOAD TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
CONVENTIONAL BATTERY OFF-SEASON STORAGE. . . . . . . . . . . . . . . . . . . . . . . . 9.28
CONVENTIONAL BATTERY CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 9.28

9.2
ELECTRICAL
GENERAL INFORMATION Fuse Splice Saver

Special Tools The fuse splice saver is near the battery under the front storage
compartment.

PART NUMBER TOOL DESCRIPTION


Fluke™77 Digital
PV-43568
Multimeter
2870836 Battery Hydrometer
2870630 Timing Light

Electrical Service Notes


Keep the following notes in mind when diagnosing an electrical
problem.
• Refer to wiring diagram for stator and electrical
component resistance specifications.
• When measuring resistance of a component that has a
low resistance value (under 10 Ohms), remember to
subtract meter lead resistance from the reading. NOTE: Use only the recommended fuse capacity, as
Connect the leads together and record the resistance.
The resistance of the component is equal to tested value use of a higher amperage fuse to correct blown-fuse
minus the lead resistance. situations could lead to electrical component damage.
• Become familiar with the operation of your meter. Be
sure leads are in the proper jack for the test being
performed (i.e. 10A jack for current readings). Refer to
the Owner’s manual included with your meter for more
information.
• Voltage, amperage, and resistance values included in
this manual are obtained with a Fluke™ 77 Digital
Multimeter (PV-43568). This meter is acceptable for
use when diagnosing electrical problems. Readings
obtained with other meters may differ.
• Pay attention to the prefix on the multimeter reading (K,
M, etc.) and the position of the decimal point.
• For resistance readings, isolate the component to be
tested. Disconnect it from the wiring harness or power
supply.

Fusible Link
A fusible link is installed on the battery voltage circuit that
9
supplies power to the main 15A fuse. The link is located at the
starter motor solenoid + post.

Fusible Link PN: 2202607


Always replace a blown fusible link with a new link after
diagnosing the cause of the failure. Never use a piece of wire or
metal in place of the link.

9.3
ELECTRICAL
Instrument Gauge Power / FWD / Neutral Switches / RPM Signal
The instrument gauge displays engine RPM via an A/C signal from the Y/RED of the voltage regulator.

The gauge is powered by switched R/BLK and switched R/WHT battery voltage. Both the key and the RUN switches have to be
closed to power-up the gauge.
The gear selector switch provides a ground path for the FWD (BLU/RED) or neutral (GRN/WHT) circuits.

9.4
ELECTRICAL
AWD Control System
The front differential coil is controlled by the speedometer the AWD switch, and the RUN/OFF switch.

Battery voltage is supplied to the AWD coil when the operator turns the key switch to RUN, moves the AWD switch to AWD and
moves the RUN/OFF switch to RUN.
The AWD coil ground circuit is supplied by the instrument gauge. The speedometer will not allow the AWD to engage when the
engine RPM is 3100 RPM or higher.

9.5
ELECTRICAL
SPEED SENSOR
Vehicle Speed Sensor
The vehicle speed sensor is mated to the transmission housing and reads the speed of the transmission output gear.

The instrument gauge supplies the sensor with battery voltage via the ORANGE circuit, a reference ground via the BRN/RED circuit
and receives a return signal via the GRN/RED circuit.
To test the circuit:
1. Turn the ignition key to the ON position and move the RUN/OFF switch to run.
2. Verify there is battery voltage present on the ORANGE circuit. If voltage is not found, inspect the wiring harness, or replace
the instrument gauge.
3. If voltage is found, test the BRN/RED ground circuit. Verify there is continuity between the circuit and chassis ground.
4. If all circuits function, remove the speed sensor from the transmission. Verify the sensor is not damaged.
5. Back-probe the GRN/RED and BRN/RED wires with the connector still connected to the sensor. Turn the multimeter to measure
vDC. Wave a screwdriver back in forth across the face of the sensor while monitoring the multimeter.
6. The multimeter display should flip between a voltage and 0vDC every time the screwdriver blade passes by the sensor face. If
this does not occur, replace the sensor.

9.6
ELECTRICAL
ELECTRONIC THROTTLE CONTROL GEAR POSITION INDICATOR SWITCH
(ETC) SWITCH
Gear Position Switch Test
Electronic Throttle Control (ETC) Switch
1. Locate the gear selector switch on the transmission.
The Electronic Throttle Control (ETC) switch is designed to Remove the wiring harness connector and insert the two
close in the event where the throttle cable sticks or breaks. multimeter probes into the switch.
2. Move the gear selector handle to each of the three drive
During normal operation, the ETC switch contacts are open (not positions (FWD, NEU, or REV).
touching). The contacts will close when slack is present in the
cable. 3. Using an ohmmeter, test for continuity between the switch
contacts and connector leads. Replace the switch if no
Electronic Throttle Control (ETC) Switch continuity or high resistance is found.

9
NOTE: The throttle cable must have the proper amount of
end-play adjustment. A cable that is too tight will cause ETC
interruption, resulting in false engine RPM limiting.

Electronic Throttle Control


Open / Closed ETC Switch is OPEN.
Throttle
Slack in Cable / ETC Switch is CLOSED
Throttle Stuck

9.7
ELECTRICAL
ETC / REVERSE RPM CONTROL
ETC / Reverse RPM Control System
The instrumentation gauge will signal the CDI controller to limit engine RPM to approximately 3100 RPM (6.5 MPH) whenever
the transmission is in reverse gear. If the ETC switch connects to ground, the instrument gauge will shut the engine off.

The operator can override the RPM speed limit in reverse, but not the ETC RPM limit, by pressing and holding the reverse override
button located on the left handlebar.
The reverse override button also serves as the mode switch button for the instrumentation gauge. The mode button toggles between
the several function the gauge performs.

To rule out engine RPM limiting caused by the CDI or instrument gauge, disconnect the BLACK wire from the CDI controller.

9.8
ELECTRICAL
IGNITION
Ignition System Diagram
The ignition system consists of:.

• CDI Controller
• Battery
• Ignition Coil
• Stator - Pulse Coil
• ETC / Key / Run-Off Switches / Instrument Gauge

9.9
ELECTRICAL
RPM Limit Modes CDI Output Test Using Peak Reading
Adaptor or Voltmeter
Engine RPM is limited when:
Re-connect all CDI wires to stator wires. Disconnect CDI
• Operator selects reverse gear. The maximum vehicle module wire from ignition coil primary terminal. Connect one
speed when reverse gear is selected is 6.5 MPH meter lead to engine ground and the other to the ignition coil
primary wire leading from the CDI module. Crank engine and
• If the wheel speed sensor malfunctions, the check output of CDI wire to coil. Reconnect CDI wire to the coil.
speedometer will limit engine RPM to approximately
3500 RPM when the transmission is in reverse.
• Maximum engine RPM is reached.
The reverse engine RPM limit can be overridden when the
operator presses and holds the override button.
On AWD models, the speedometer also limits the maximum
engine RPM in which the operator can engage the AWD system.
The speedometer will not allow the AWD to engage when the
engine RPM is at or above 3100 RPM.

Ignition Coil Testing

Connect Meter
Test Reading
Wires To:
200 - 250
CDI Output W/BLU to Ground
Volts DC

Wire Description Resistance


Primary Coil (BLK/W to BLK) .21 Ohms

Secondary Coil (Black to High Tension lead


3.2KOhms
without cap.)

9.10
ELECTRICAL
CDI Cranking Output Test Ignition System Troubleshooting
The following peak voltage tests will measure the amount of No Spark, Weak or Intermittent Spark
output from each component. A peak reading voltmeter can be
used to perform the tests. A variety of peak reading adaptors are • No12 volt power or ground to CDI
commercially available for use with the Fluke™ 77 Digital
Multimeter (PV-43568) and other digital VOMs which will • Spark plug gap incorrect
allow peak voltage tests to be performed accurately. Follow the
directions provided with the adaptor. All measurements are • Fouled spark plug
indicated in Volts. Readings obtained without a peak reading
adaptor will be significantly different. • Faulty spark plug cap or poor connection to high
tension lead
Disconnect the stator connectors from the CDI module. Test
output from the detection and pulse (trigger) coil, and compare • Related wiring loose, disconnected, shorted, or
to the chart. The following measurements were obtained when corroded
cranking the engine with the electric starter, spark plug installed.
The starting system must be in good condition and the battery • Engine Stop switch or ignition switch faulty
fully charged.
• ETC switch misadjusted or faulty
Voltage Connect Reading Reading • Poor ignition coil ground (e.g. corroded)
Test Meter Wires (With VOM) (With Peak
To: Reading • Faulty stator (measure resistance of all ignition related
windings)
Adapter)
Pulse Coil W/R and B 0.15 Volts 5.3 - 5.4 • Incorrect wiring (inspect color coding in connectors
etc)
minimum AC Volts
@ cranking minimum DC • Faulty ignition coil winding (measure resistance of
RPM @ cranking primary and secondary)
RPM • Worn magneto (RH) end Crankshaft bearings
• Sheared flywheel key
Ohm Connect Reading Reading
Test Meter Wires (With Peak • Flywheel loose or damaged
To: Reading • Excessive crankshaft runout on magneto (RH)
Adapter) end - should not exceed .005”
Pulse Coil W/R and B 520 Ohms n/a • Faulty CDI module
W/R to
O.L.
Ground

9.11
ELECTRICAL
Ignition System Testing
Whenever troubleshooting an electrical problem you should first check all terminal connections to be sure they are clean and tight.
Also be sure that colors match when wires are connected. Use the following pages as a guide for troubleshooting. The resistance
values are also given on the specification pages.

Condition: No spark or intermittent spark.


Verify 12 Volt DC power is present on the wire to CDI. Replace Spark Plug.

Disconnect the BLACK wire at the CDI -Test the ignition switch, engine stop
module to isolate the ignition from the switch, and speed limiter circuit for
over-ride systems, but verify the CDI has a Yes shorts to ground.
good ground (BROWN) for operation. - Check connectors for moisture,
wire color matching or corrosion.
Does it have spark?

No

Verify that a minimum of 10.5 VDC is getting to


the CDI module during cranking. Refer to the Inspect battery condition, connec-
wiring schematic for connections and specifica- No tors, wiring and grounds to the
tions. Compare results to the specifications on component in question. Replace
the exploded views. Are all within specifications? the component if a wiring problem
cannot be found.

Yes

Check coil ground connection between BROWN and coil


No Clean coil mounting area.
mount using an ohmmeter. The coil mount should
Repair ground wire connections.
have good continuity to ground (0-.2 Ω).

Yes

Disconnect and check the secondary coil. Resis-


tance values should be:
Primary Side - Primary Wire Tab to Ground
(on coil mount or engine): .21 Ohms No Replace the ignition coil.
Secondary Side High Tension Wire to engine
ground- Cap installed - 8,200Ω
Cap removed - 3,200Ω
Are these values within specs?

Yes
If all of the above tests are within specifications, and all grounds, connections, and wire color coding
have been inspected, perform voltage output tests on following page or replace the CDI module.

9.12
ELECTRICAL
CHARGING SYSTEM
Charging System
The charging system consists of:.

• Stator
• Battery
• Regulator / Rectifier
The regulator / rectifier is responsible for converting AC voltage to DC voltage, and generating the tachometer pulse.

9.13
ELECTRICAL
Charging System Testing
Whenever charging system problems are suspected, proceed with the following system checks:

Using a multitester set on D.C. volts, mea- Remove the battery and properly ser-
sure the battery open circuit voltage (see No vice. Reinstall the fully charged battery
procedure later in chapter). It should be or a fully charged shop battery.
12.4 volts or more. Is it?
Yes

Meter Setting: DC Volts


With the transmission in neutral, start the
engine and increase RPM to between 3000
and 4000. Read battery voltage with the Yes Check Key off Current Draw.
multitester. Readings should be between Refer to Page 9.11.
13.0 and 14.6 V D.C.
Is it?
No
Check for owner modification, and
Meter Setting: DC Amps discuss operating habits. The battery
Perform system “Break Even Amperage” will continually discharge if operated
test outlined on Page 9.11. Yes below the “Break Even” RPM. Con-
tinued problems would call for battery
Does charging occur as specified? inspection.
No

Meter Setting: AC Amps


Disconnect the wires leading from the regu- Inspect the wiring harness be-
lator/rectifier. Using a multitester, perform tween the panel and the stator for
an Alternator Output (AC amp) test. See damage. If no damage is found,
test procedure on Page 9.11 for procedure. No remove the recoil and flywheel.
Inspect the flywheel magnets, sta-
Is output above 5 amps? tor coils and stator wire harness
for damage. Repair or replace
Yes any damaged components.

Meter Setting: DC Volts


Reconnect the alternator wires. Note: Red
wire must be connected to harness. Battery
Check regulator/rectifier connections
voltage must be present on red wire terminal
and ground, battery connections, cir-
on harness side of voltage regulator connector. No cuit breaker and connecting wires.
Is it? Repair or replace faulty wiring or
components.
Yes

If all of the previous tests indicate a


good condition, but the charging voltage does
not rise above battery voltage at the
connector or terminal board, replace the
voltage regulator.

9.14
ELECTRICAL
Current Draw - Key Off Charging System “Break Even” Test

CAUTION CAUTION

Do not connect or disconnect the battery cable or Do not connect or disconnect the battery cable or
ammeter with the engine running. Damage will occur to ammeter with the engine running.
light bulbs and speed limiter.
Connect an ammeter in series with the negative battery cable.
Check for current draw with the key off. If the draw is excessive, CAUTION
loads should be disconnected from the system one by one until
the draw is eliminated. Check component wiring as well as the
component for partial shorts to ground to eliminate the draw. Never use the electric starter with an ammeter
connected in series, as damage to the meter or meter
fuse may result. Do not run test for extended period of
Current Draw - Key Off: time. Do not run test with high amperage accessories.
Maximum of .02 DCA (20mA)
The “break even” point of the charging system is the point at
which the alternator overcomes all system loads (lights, etc.)
and begins to charge the battery. Depending on battery condition
and system load, the break even point may vary slightly. The
battery should be fully charged before performing this test.
• Clamp an inductive ammeter or connect an ammeter
(set to DC amps) in series between the negative battery
cable and terminal.

Current Drain Inspection


Key Off

Less Than 9 mA
Do not use electric start.

• Connect a tachometer according to manufacturer’s


instructions.
• With engine off and the RUN/OFF switch in the RUN
position, the ammeter should read negative amps
9
(battery discharge). Reverse meter leads if a positive
reading is indicated
• Shift transmission into neutral and start the engine.
• Turn headlight on, and apply the brake light. Increase
engine RPM while observing ammeter and tachometer.
• Note RPM at which the battery starts to charge
(ammeter indication is positive).
• With lights and other electrical load off, this should
occur at approximately 1500 RPM or lower.
• Turn the lights on and lock parking brake to keep brake
light on.
• Repeat test, observing ammeter and tachometer. With
lights on, charging should occur at or below 2000 RPM.

9.15
ELECTRICAL
Alternator Output Test (AC amp) Stator Function Test
This test measures AC amperage from the alternator. Three tests can be performed using a multimeter to determine
the condition of the stator.

CAUTION

This test simulates a “full load” on the alternator. Do


not perform this test longer than required to obtain
a reading or the alternator stator windings may
overheat. Do not exceed idle rpm during this test.

To Calculate Available Alternator Output


P 150 W = 12.5 Amps
I=
E 12 V

I = Current in Amps
P = Power in Watts
E = Electromotive Force (Volts)

Alternator Current Output:


Minimum of 8 AC Amps
TEST 1: Resistance Value of Each Stator Leg

• Maximum alternator output will be indicated on the 1. Measure the resistance value of each of the three stator
meter. It is not necessary to increase engine RPM above legs: W1 to W2, W1 to W3, and W2 to W3. Each should
idle. measure 0.314ohms.
• Place the red lead on the tester in the 10A jack. 2. Measure each of the white wires to ground, the reading
should be (O.L.).
• Turn the selector dial to the AC amps (A~) position.
NOTE: Significant variations in resistance readings
• Connect the meter leads to the wires leading from the between each circuit is an indication that one of the three
alternator (see schematic for proper wiring colors). circuits may be weak or failed.
• Start the engine and let it idle. Reading should be a
minimum of 8A at idle. TEST 2: Stator Output.
1. Place the red lead on the tester in the 10A jack.
2. Turn the selector dial to the AC-AMPs position.
3. Start the engine and let it idle.
4. Separately test each leg of the stator by connecting the
meter leads to the wires leading from the alternator (W1 to
W2, W1 to W3, W2 to W3). Alternator Current Output
Reading should be no less than 8 AMPS.
NOTE: Use an inductive amp meter to test stator
amperage for engine speeds over 1200 RPM.

9.16
ELECTRICAL
STARTER
Starter / Starter Lockout System
The starter and starter lockout system consists of:

• Battery
• Key Switch / Run-Off Switch
• Solenoid
• Brake / Neutral Switches
• Diodes
• Starter Motor

9.17
ELECTRICAL
Troubleshooting Voltage Drop Testing
Starter Motor Does Not Run The Voltage Drop Test is used to test for bad connections. When
performing the test, you are testing the amount of voltage drop
• Battery discharged. Low specific gravity through the connection. A poor or corroded connection will
appear as a high voltage reading. Voltage shown on the meter
• Loose or faulty battery cables or corroded connections when testing connections should not exceed.1 VDC per
(see Voltage Drop Tests) connection or component.
• Related wiring loose, disconnected, or corroded To perform the test, place the meter on DC volts and place the
meter leads across the connection to be tested. Refer to the chart
• Failed Diode on 1.47 to perform voltage drop tests on the starter system.
• Poor wire connections: harness, grounds, at battery
cable, starter motor or starter solenoid (see Voltage
Drop Tests) Voltage should not exceed
.1 DC volts per connection
• Faulty key switch
• Faulty kill switch
Removal / Disassembly
• Faulty brake switch
NOTE: Use electrical contact cleaner to clean starter
• Faulty transmission switch motor parts. Some solvents may leave a residue or
• Faulty starter solenoid or starter motor. damage internal parts and insulation.

• Engine problem - seized or binding (Can engine be 1. Remove the starter from the engine.
rotated easily with recoil starter?) 2. Remove the two bolts, washers, and sealing O-Rings.
Inspect O-Rings and replace if damaged.
Starter Motor Turns Over Slowly
• Battery discharged - low specific gravity
• Excessive circuit resistance - poor connections (see
Voltage Drop Test below)
• Engine problem - seized or binding (Can engine be
rotated easily?)
• Faulty or worn brushes in starter motor
Starter Motor Turns - Engine Does Not Rotate
• Faulty starter drive
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel

NOTE: Note the alignment marks on both ends of


the starter motor casing. These marks must align
during reassembly.

9.18
ELECTRICAL
3. Remove the front bracket assembly and the rear bracket as necessary.
assembly. Remove the shims from the armature shaft and
inspect the O-rings located on the armature housing.

O-Rings

Shims
3. Slide positive brush springs to the side, pull brushes out of
their guides and remove brush plate. Slide brush end frame
off end of starter.
NOTE: The shims will be replaced during
reassembly. NOTE: The electrical input post must stay with the
field coil housing.
Brush Inspection & Replacement 4. Measure resistance between ground brush and brush plate.
Resistance should be .3 ohms or less.
1. Measure resistance between starter input terminal and
insulated brushes. The reading should be .3 ohms or less.
Remember to subtract meter lead resistance.

Brush Inspection
9
2. Measure resistance between insulated brush and starter
housing. Reading should be infinite. (OL). Inspect 1. Measure length of each carbon brush. Replace brush
insulation on brush wires for damage and repair or replace assembly when worn to 5/16” (8 mm) or less. The brushes
must slide freely in their holders.

Brush Length

Limit 5/16” (8 mm)

9.19
ELECTRICAL
Brush Replacement 3. Using a digital multitester, measure the resistance between
each of the commutator segments. The reading should be
1. Remove terminal nut with lock washer, flat washer, large .3 ohms or less.
phenolic washer, the small phenolic spacers, and sealing
4. Measure the resistance between each commutator segment
O-ring. Inspect O-ring and replace if damaged.
and the armature shaft. The reading should be infinite (no
continuity).

2. Slide positive brush springs to the side, pull brushes out of


their guides and remove brush plate.

CAUTION

Some cleaning solvents may damage the insulation


in the starter. Care should be exercised when
selecting an appropriate solvent. If the commutator
needs cleaning use only electrical contact cleaner. 5. Check commutator bars for discoloration. Bars discolored
in pairs indicate shorted coils, requiring replacement of the
Armature Testing starter motor.
6. Place armature in a growler. Turn growler on and position
1. Remove armature from starter casing. Note order of shims a hacksaw blade or feeler gauge lengthwise 1/8” (.3 cm)
on drive end for reassembly. above armature coil laminates. Rotate armature 360°. If
hacksaw blade is drawn to armature on any pole, the
armature is shorted and must be replaced.

CAUTION

Use care when handling starter housing. Do not


drop or strike the housing as magnet damage is
possible. If magnets are damaged, starter must be
replaced.

2. Inspect surface of commutator. Replace if excessively


worn or damaged.

9.20
ELECTRICAL
Starter Reassembly & Installation 9. Lightly grease pinion shaft and install pinion, spring
stopper, and snap ring.
1. Install brush plate to field magnet housing aligning index
tab.

10. Starter installation - Install the starter onto the engine


case. Hand tighten each of the starter bolts. Torque the
2. Install O-ring, two small phenolic spacers, large phenolic bottom bolt first to 9 ft.lbs. (12 Nm). Then torque the top
washer, flat washer, lock washer, and terminal nut. bolt to the same specification.
3. While holding brush springs away from brushes, push NOTE: It is important to tighten the bottom starter
brushes back and hold in place. bolt first, as the bottom hole acts as a pilot hole to
4. Slide armature into field magnet housing. Release brushes. properly align the starter drive (bendix) with the
5. Lightly grease the drive roller bearing and reinstall drive flywheel. This helps to prevent binding and starter
end frame on armature. Inspect seal for wear or damage. damage.
Replace drive end cap if necessary.
Starter Solenoid Bench Testing
Roller Bearing
To measure the resistance of the pull-in coil, connect meter leads
to the solenoid lead wires. The resistance should be 3.7 ohms.
Seal Refer to “Electric Starter System Testing” in this section to
further test the solenoid.

9
6. Be sure wire insulation is in place around positive brush
wire and pushed completely into slot on phenolic plate.
7. Using Dielectric Grease (PN 2871329), lubricate brush end
bushing and install shims.
8. Align brush plate and install cover and screws.

9.21
ELECTRICAL
Starter Motor Exploded View

BRUSH LENGTH SERVICE LIMIT:


5/16″ (8 MM)

9.22
ELECTRICAL
STARTER DRIVE
Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement
If the garter spring is damaged, the overrun clutch may fail to return properly. Use either of the following methods to remove and
install a new garter spring:

H
G
A F
D

A. Gear Assembly E
B. Thrust Washer C
C. Bushing
D. Retaining Ring
E. Thrust Washer
F. Stopper
G. Cover
H. Spring

1. Screw the overrun clutch out to the engaged position on the pinion shaft assembly. Use a small piece of wire with the end bent
in a hook and pick the old spring out of its channel. Slide it off the end of the shaft. Slide the new spring over the overrun clutch
and into the spring groove. Make sure that the spring is positioned between the shoe alignment pins and the back flange of the
anti kick-out shoes.
2. Remove the retaining ring, thrust washer, spring retainers and clutch return spring. Screw the overrun clutch off the end of the
pinion shaft. Remove the old spring and install a new one. Lightly grease the pinion shaft and reinstall the clutch, spring,
retainers, end washer and lock ring in the reverse order. Make sure the end washer is positioned properly so that it will hold
the lock ring in its groove.

9.23
ELECTRICAL
STARTER SYSTEM TESTING FLOW CHART
Condition: Starter Fails To Turn Motor
NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester
must be used for this test.
With the tester on the VDC position, place the tes-
ter’s black lead on the battery negative and the red Remove battery and properly service.
lead on the battery positive. No Install fully charged shop battery to
continue test.
Reading should be 12.4 volts or greater.

Yes

Check voltage on both sides of the fuse,


Disconnect Blue/White engagement wire from ignition switch/engine stop switch and
the starter solenoid. Connect tester black wire to starter button. The
battery ground. Connect red tester lead to RED/ voltage on both sides should be the same.
No
WHITE harness wire at solenoid.Turn on ignition NOTE: The ignition switch and engine stop
switch and depress the starter button. switch must be on, the starter button
Tester should read battery voltage. depressed. Replace the defective
component.

Test starter solenoid coil by connecting an ohmmeter between the coil leads
Yes Resistance should be 3.7Ω + 1. Check solenoid ground path between the
BLUE wire and battery NEG. with transmission in NEUTRAL and the hand
Voltage Drop Testing brake applied. Set the meter to check continuity of a diode.
See Page 9.22 for instructions.

Reconnect the solenoid. Connect the tester black


Clean the battery-to-solenoid cable ends or
lead to the battery positive and the red lead to the No replace the cable.
solenoid end of the battery-to-solenoid wire.
Depress starter button.
Reading should be less than .1 V D.C.

Yes

Connect the black tester lead to solenoid end of


battery-to-solenoid cable. Connect red tester lead No Replace the starter solenoid.
to solenoid end of solenoid-to-starter cable.
Depress starter button.
Reading should be less than .1 V D.C.

Yes

Connect the black tester lead to solenoid end of


the solenoid-to-starter cable. Connect the red tester Clean the solenoid-to-starter cable ends or
No
lead to the starter end of the same cable. Depress replace the cable.
the starter button.
Reading should be less than .1 V D.C.

Yes

If all of these indicate a good condition, yet the starter still fails to turn, the
starter must be removed for static testing and inspection.

9.24
ELECTRICAL
BATTERY battery type in the vehicle. Use the section that applies to
the battery.
Battery Identification
WARNING
NOTICE: It is important to identify what type of battery you
have installed in your ATV. Different types of batteries require
different service procedures. Proper servicing and upkeep of Battery electrolyte is poisonous. It contains sulfuric
your battery is very important for maintaining long battery life. acid. Serious burns can result from contact with
Your ATV may have a Conventional Battery or a Sealed Low skin, eyes or clothing. Antidote:
Maintenance Battery. To identify which type of battery your
ATV has, refer to the illustration below and follow the correct External: Flush with water.
service and charging procedures that follow in the manual.
CONVENTIONAL BATTERY Internal: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.
Removable
Caps
Eyes: Flush with water for 15 minutes and get
prompt medical attention.

Batteries produce explosive gases. Keep sparks,


flame, cigarettes etc. away. Ventilate when
Top View charging or using in an enclosed space. Always
shield eyes when working near batteries. KEEP
OUT OF REACH OF CHILDREN.
Electrolyte Level
Indicator

WARNING

The gases given off by a battery are explosive. Any


Side View spark or open flame near a battery can cause an
explosion which will spray battery acid on anyone
close to it. Should there be contact with battery
acid, wash the affected area with large quantities of
Conventional Battery Activation/ SVC cool water and seek immediate medical attention.

To ensure maximum service life and performance from a


battery, perform the following steps.

NOTE: This section contains information for both


Conventional Lead-Acid batteries and Sealed Low
9
Maintenance batteries. Before service, identify the

9.25
ELECTRICAL
NOTE: New Battery: Battery must be fully charged 2. Disconnect battery negative (-) (black) cable first, followed
before use or battery life will be significantly reduced 10- by the positive (+) (red) cable.
30% of the battery’s full potential.
CAUTION
To activate a new battery:
1. Remove vent plug from vent fitting. Remove cell caps. Whenever removing or reinstalling the battery,
2. Fill battery with electrolyte to upper level marks on case. disconnect the negative (black) cable first and
3. Set battery aside to allow for acid absorption and reinstall the negative cable last!
stabilization for 30 minutes.
3. Remove the battery.
4. Add electrolyte to bring level back to upper level mark on
4. Remove the filler caps and add distilled water only as
case. NOTE: This is the last time that electrolyte should be
needed to bring each cell to the proper level. Do not overfill
added. If the level becomes low after this point, add only
the battery.
distilled water.
5. Charge battery at 1/10 of its amp/hour rating. Examples: 1/ Refill using only distilled water. Tap water contains minerals
10 of 9 amp battery = .9 amp; 1/10 of 14 amp battery = 1.4 which are harmful to a battery.
amp; 1/10 of 18 amp battery = 1.8 amp (recommended
Do not allow cleaning solution or tap water inside the battery.
charging rates). Battery life may be reduced.Reinstall the battery caps.
6. Check specific gravity of each cell with a hydrometer to
assure each has a reading of 1.270 or higher. 5. Reinstall the battery caps.

Battery Terminals/Terminal Bolts Conventional Battery Installation


Use Polaris corrosion resistant Nyogel™ grease (PN 2871329) 1. Clean battery cables and terminals with a stiff wire brush.
on battery bolts. See Battery Installation. Corrosion can be removed using a solution of one cup
water and one tablespoon baking soda. Rinse well with
Conventional Battery Inspection/Removal clean water and dry thoroughly.
2. Route the cables correctly.
The battery is located in the front rack storage compartment.
3. Reinstall battery, attaching positive (+) (red) cable first and
Inspect the battery fluid level. When the battery fluid nears the then the negative (-) (black) cable. Coat terminals and bolt
lower level, remove the battery and fill with distilled water only threads with Nyogel™ Grease (PN 2871329).
to the upper level line. To remove the battery:
4. Install clear battery vent tube from vehicle to battery vent.
WARNING: Vent tube must be free from obstructions and
kinks and securely installed. If not, battery gases could
accumulate and cause an explosion. The vent tube should
Maintain be routed away from frame and body to prevent contact
between upper with electrolyte. Avoid skin contact with electrolyte, as
and lower level severe burns could result. If electrolyte contacts the vehicle
marks frame, corrosion will occur.
5. Reinstall the holder strap.

Conventional Battery Testing


Whenever a service complaint is related to either the starting or
charging systems, the battery should be checked first.
1. Disconnect holder strap and remove covers.
Following are three tests which can easily be made on a battery
to determine its condition: OCV Test, Specific Gravity Test and
Load Test.

9.26
ELECTRICAL
Conventional Battery OCV - Open Circuit Conventional Battery Specific Gravity Test
Voltage Test
A tool such as a Battery Hydrometer (PN 2870836) can be used
Battery voltage should be checked with a digital multitester. to measure electrolyte strength or specific gravity. As the battery
goes through the charge/discharge cycle, the electrolyte goes
Readings of 12.6 volts or less require further battery testing from a heavy (more acidic) state at full charge to a light (more
and charging. See charts and Load Test on below. water) state when discharged. The hydrometer can measure
state of charge and differences between cells in a multi-cell
NOTE: Lead-acid batteries should be kept at or near a battery. Readings of 1.270 or greater should be observed in a
full charge as possible. Electrolyte level should be kept fully charged battery. Differences of more than .025 between the
lowest and highest cell readings indicate a need to replace the
between the low and full marks. If the battery is stored or battery.
used in a partially charged condition, or with low
electrolyte levels, hard crystal sulfation will form on the
plates, reducing the efficiency and service life of the
battery.

OPEN CIRCUIT VOLTAGE


State of Conventional Low Maintenance Battery Hydrometer (PN 2870836)
charge Lead-acid Type
1.10
100% Charged 12.60 V 12.70 V
1.15
75% Charged 12.40 V 12.50 V Detail A 1.20

50% Charged 12.10 V 12.20 V 1.25

25% Charged 11.90 V 12.0 V 1.30

0% Charged less than less than


11.80 V 11.9 V

SPECIFIC GRAVITY
State of charge* Conventional Lead-acid
100% Charged 1.265
75% Charged 1.210
50% Charged 1.160
25% Charged 1.120
0% Charged less than 1.100
* At 80oF
NOTE: Subtract .01 from the specific gravity reading at 40o F. 9

9.27
ELECTRICAL
Conventional Battery Load Test Electrolyte Freezing Points

Specific Gravity Freezing


CAUTION of Electrolyte Point

To prevent shock or component damage, remove 1.265 -75o F


spark plug high tension leads and connect securely
to engine ground before proceeding. 1.225 -35o F

NOTE: This test can only be performed on machines 1.200 -17o F


with electric starters. This test cannot be performed with
an engine or starting system that is not working properly. 1.150 +5o F

A battery may indicate a full charge condition in the OCV test 1.100 +18o F
and the specific gravity test, but still may not have the storage
capacity necessary to properly function in the electrical system. 1.050 +27o F
For this reason, a battery capacity or load test should be
conducted whenever poor battery performance is encountered.
To perform this test, hook a multitester to the battery in the same Conventional Battery Charging Procedure
manner as was done in the OCV test. The reading should be 12.6
volts or greater. Engage the starter and observe the battery 1. Remove the battery from the ATV to prevent damage from
voltage while cranking the engine. Continue the test for 15
seconds. During cranking the observed voltage should not drop leaking or spilled acid during charging.
below 9.5 volts. If the beginning voltage is 12.6 volts or higher 2. Charge the battery with a charging output no larger than 1/
and the cranking voltage drops below 9.5 volts during the test, 10 of the battery’s amp/hr rating. Charge as needed to raise
replace the battery.
the specific gravity to 1.270 or greater.
Conventional Battery Off-Season Storage 3. Install battery in vehicle. Coat threads of battery bolt with
a corrosion resistant dielectric grease.
To prevent battery damage during extended periods of non-use,
the following basic battery maintenance items must be Dielectric Grease
performed:
(PN 2871329)
• Remove the battery from the machine and wash the
case and battery tray with a mild solution of baking
soda and water. Rinse with lots of fresh water after 4. Connect battery cables.
cleaning.NOTE: Do not get any of the baking soda into
the battery or the acid will be neutralized.
WARNING
• Using a wire brush or knife, remove any corrosion from
the cables and terminals.
To avoid the possibility of explosion, connect
• Make sure that the electrolyte is at the proper level. Add positive (red) cable first and negative (black)
distilled water if necessary. cable last.
• Charge at a rate no greater than 1/10 of the battery’s
amp/hr capacity until the electrolyte’s specific gravity 5. After connecting the battery cables, attach the hold down
reaches 1.270 or greater. strap.
6. Install clear battery vent tube from vehicle to battery vent.
• Store the battery either in the machine with the cables
disconnected, or store in a cool place. WARNING: Vent tube must be free from obstructions and
kinks and securely installed. If not, battery gases could
NOTE: Stored batteries lose their charge at the rate of accumulate and cause an explosion. Vent should be routed
up to 1% per day. Recharge to full capacity every 30 to away from frame and body to prevent contact with
60 days during a non-use period. If the battery is stored electrolyte. Avoid skin contact with electrolyte, as severe
during the winter months, electrolyte will freeze at higher burns could result. If electrolyte contacts the vehicle frame,
temperatures as the battery discharges. The chart below corrosion will occur.
indicates freezing points by specific gravity.
7. Route cables so they are tucked away in front and behind
battery.

9.28
QUADRICYCLE
CHAPTER 10
QUADRICYCLE
HAWKEYE QUADRICYCLE ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
TRANSMISSION SWITCH - BREAKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
FUSE HOLDER - BREAKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
FLASHER RELAY - BREAKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
HEADLIGHT / TAILLIGHT - EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
HAWKEYE QUADRICYCLE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
FOOT BRAKE SYSTEM - EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
AUXILIARY HAND BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
AUXILIARY HAND MASTER CYLINDER - EXPLODED VIEW . . . . . . . . . . . . . . . . . . . 10.6

NOTE: This chapter illustrates components that are unique to the Hawkeye 2x4 / 4x4 Quadricycle.
Except where noted, any servicing of these components or other components
on the ATV can be done using this service manual’s procedures and illustrations.

10

10.1
QUADRICYCLE
HAWKEYE QUADRICYCLE ELECTRICAL
Transmission Switch - Breakout
A mechanical PARK lock is built into
the transmission on quadricycle models

Fuse Holder - Breakout


R - Constant 12V Battery feed to Hazard Switch
R - Constant 12V from Battery
BLU - LH Signal Control
R/BLU - Input 12V From Hazard Switch
BLU/R - RH Signal Control
R/BLU - Input 12V From Hazard Switch

ORN/W - Key-On 12V Power to Accessory Lead


10
R/BLK - Key-On 12V Power
R/W - Key-On 12V Power to CDI Box
R/BLK - Key-On 12V Power
R/W - Key-On 12V Power to R/W Splice / Marker Lights
R/BLK - Key-On 12V Power

10.2
QUADRICYCLE
Flasher Relay - Breakout
RH Turn Indicator

LH Turn Indicator

LH Turn Indicator

Splice

RH Turn Indicator

High beam Indicator

Headlight / Taillight - Exploded View


5
3

REF # DESCRIPTION QTY REF # DESCRIPTION QTY 10


1 Taillight Asm 1 4 Headlight Bulb 2
2 Taillight Bulb 1 5 Running Light Bulb 2
3 Headlight Asm 1

10.3
QUADRICYCLE
HAWKEYE QUADRICYCLE BRAKE SYSTEM
Overview
The Hawkeye Quadricycle brake system consists of a complete hydraulic brake system. All-wheel braking is integrated into the
foot brake pedal. This allows brake control on three wheel discs.

When the foot brake is applied, the two front calipers and the LH rear caliper are used. When applied, the brake pressure is routed
from the foot brake master cylinder through one line to the junction block and front calipers, while the other line feeds the LH rear
caliper. The foot brake master cylinder is equipped with a dual banjo fitting allowing brake fluid to be forced down both lines to
the front and rear when the foot brake is applied.

When the hand brake is applied, only the rear RH brake caliper is active and under pressure. This allows for rear wheel braking
only. The handlebar master cylinder only allows fluid to flow to the RH rear brake caliper.

Controlled by the
Auxiliary Hand Brake
LH Rear Caliper

22 ft. lbs
(30 Nm)

22 ft. lbs
(30 Nm)

LH Front Caliper

RH Rear Caliper

22 ft. lbs
(30 Nm)

22 ft. lbs
(30 Nm)

RH Front Caliper
Controlled by the
Foot Brake

10.4
QUADRICYCLE
Foot Brake System - Exploded View

3
4 T
2

7
1 T
10

T
8
9

5
2

T Torque Banjo Bolts to


15 ft. lbs. (20 Nm)

REF # DESCRIPTION QTY REF # DESCRIPTION QTY


10
1 Rear Brake Reservoir 1 6 Brake Line - Rear Master to Front Caliper 1
Brake Line - Rear Master to LH Rear
2 LH Brake Caliper 2 7 1
Caliper
3 RH Brake Caliper 1 8 Seals 9
4 Banjo Bolt 1 9 Red Hose Clamps 2
5 Foot Master Cylinder Asm. 1 10 Double Banjo Switch 1

10.5
QUADRICYCLE
Auxiliary Hand Brake System

B D
F
15 ft. lbs.
(20 Nm)

15 ft. lbs.
(20 Nm)
C
E
A. Rear Brake Caliper
B. Handlebar Master Cylinder
C. Banjo Bolt
D. Brake Line - Front Master to Rear RH Caliper
A
E. Seals
F. Brake Pressure Switch

Auxiliary Hand Master Cylinder - Exploded View


5-7 in. lbs 60-80 in. lbs.
(.6-.8 Nm) W V (7-9 Nm)

M
S

O
K
I
L
G. Reservoir Body Q
H. Brake Lever
I. Piston
J. Park Brake Lever
K. Primary Cup
L. O-Ring T
M. Cover
N. Park Lever Pivot Pin P H
O. Piston Return Spring N
P. Pivot Pin
Q. Dust Boot
R. Return Lever Spring
S. Clamp
T. Retaining Ring J
U. Push-On R
V. Torx Screws U
W. Cover Screws

10.6
WIRE DIAGRAM

2007 HAWKEYE 2X4/ 4X4

WD-1
WIRE DIAGRAM

WD-2
WIRE DIAGRAM

2007 HAWKEYE 2X4/ 4X4 QUADRICYCLE

WD-3
WIRE DIAGRAM

WD-4
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
1
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2007 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2007 HAWKEYE 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2007 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MODEL: 2007 HAWKEYE 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

VEHICLE IDENTIFICATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.

Machine Model Number Identification


A 0 7 LB 27 AA
}
}

}
}

Year Designation Emissions &


Model Option
Basic Chassis
Designation Engine Designation

Engine Designation Number


ES30PFESingle, Air Cooled, SOHC 4 Stroke, Electric Start

1.1
GENERAL INFORMATION
Vehicle Identification Number (VIN)
World
Mfg. ID
Vehicle Descriptor Vehicle Identifier
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A L H 2 7 A * 5 P 0 0 0 0 0 0

}
Engine Model
Year Individual Serial Number
Body Style
Emissions Plant No
Powertrain * This could be either
Check Digit a number or a letter

Vehicle and Engine Serial Number Locations


Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be
found on the sticker applied to the recoil housing on the right side of engine. An additional number is stamped on the center top of
the crankcase beneath the cylinder.
The machine serial number (1- lower frame rail) and engine number (2- right side engine) are important for vehicle identification.

1.2
GENERAL INFORMATION
SPECIFICATIONS
MODEL: 2007 HAWKEYE 2x4
1
MODEL NUMBER: . . . . . . . . .A07LB27AA, A07LB27AC
A07LB27FA (International)
ENGINE MODEL: . . . . . . . . . .ES30PFE
Category Dimension
Length 74 in./188 cm
Width 42 in./107 cm
Height 45.5 in./116 cm
Wheel Base 46 in./117 cm
Ground Clearance 8 in./20.3 cm
Dry Weight 525 lbs./238 kg
Gross Vehicle Weight 930 lbs./422 kg
Front Rack Capacity 70 lbs./31.75 kg
Rear Rack Capacity 100 lbs./45 kg
Towing Capacity 750 lbs./340 kg
Hitch Tongue Weight 75 lbs./34 kg
Body Style Recreational/Utility

MODEL: 2007 HAWKEYE 4x4


MODEL NUMBER: . . . . . . . . .A07LH27AA, A07LH27AB, A07LH27AC, A07LH27AD
A07LH27FA (International)
ENGINE MODEL: . . . . . . . . . .ES30PFE
Category Dimension
Length 74 in./188 cm
Width 42 in./107 cm
Height 45.5 in./116 cm
Wheel Base 46 in./117 cm
Ground Clearance 8 in./20.3 cm
Dry Weight 550 lbs./250 kg
Gross Vehicle Weight 930 lbs./422 kg
Front Rack Capacity 70 lbs./31.75 kg
Rear Rack Capacity 100 lbs./45 kg
Towing Capacity 750 lbs./340 kg
Hitch Tongue Weight 75 lbs./34 kg
Body Style Recreational/Utility

1.3
GENERAL INFORMATION
MODEL: 2007 HAWKEYE 2x4 Drivetrain
Transmission Type H-N-R
MODEL NUMBER: A07LB27
ENGINE MODEL: ES30PFE Transmission Capacity Level with fill plug
Gear Ratio : Foward 15.18:1
Engine Reverse 14.05:1
Platform Fuji 4 stroke, Single Cylinder Clutch Type CVT w/EBS
Engine Model Number ES300PFE010 Belt 3211108
Engine Displacement 299cc
Steering / Suspension
Number of Cylinders 1
Front Suspension / Shock Mac Pherson Strut
Bore & Stroke (mm) 78.5 x 68 mm
Front Travel 7 in. / 17.8 cm
Compression Ratio 9.2:1 Full Stroke
Rear Suspension Independent
Compression Pressure 120-140 psi Style / Shock Coil-over Adjustable
Engine Idle Speed 1400 RPM Rear Travel 8 in. / 20.3 cm
Cooling System/Capacity Air/Oil Cooled Ground Clearance 8 in. / 20.3 cm
Overheat Warning None Shock Preload Adjustment Front - Cam
Lubrication Wet Sump Front / Rear Rear - Cam

Oil Requirements Polaris 0W-50 / 1.7 qts (1.6L) Turning Radius 62.5 in. (159 cm) unloaded

Exhaust System Single Pipe - USFS Approved Toe Out 0-1/16 in. (0-.159 mm)
Carburetion Wheels / Brakes
Carburetor model Mikuni BST 34mm Tire/Rim Size - Front 22 x 7-12
Main Jet 140 Tire/Rim Size - Rear 22 x 10-12
Pilot Jet 45 Air Press. F/R Tires 3-5 psi
Jet Needle 4HC57-3 Brake - Front Single Control Hydraulic Disc
Needle Jet 05-m Brake - Rear Single Control Hydraulic Disc

Pilot/Air Screw 2.5 Turns Out (Initial setting) Brake Fluid Polaris DOT 3 or 4 Brake Fluid

Float Height 13mm from carburetor body JETTING CHART


Fuel Delivery Fuel Pump AMBIENT TEMPERATURE
Altitude Below 40oo F Above +40oo F
Fuel Capacity / 4.5 gal. (17 L) Below 5 C Above +5 C
Requirement 87 Octane (minimum) 0-1800 145 140
89 Oxygenated Meters (0-6000)
(Feet) 1800-3700 140 135
Electrical (6000-12000)
Alternator Output 250 watt / 18.6 Amp @ 6000
CLUTCH CHART
Voltage Regulator 3-phase
Lights : High Beam -- Altitude Shift Weight Number Installed
Low Beam 37.5 watts 0-5000 13 g
(0-1534) 8
5412988
Brake 12V / 26.9 watts
Feet 5000-10,000 10 g
Tail 12V / 8.26 watts 8
(Meters) (1534 - 3048) 5412986
Ignition System DC CDI 10,000 + 10 g
6
Ignition Timing BTDC 30°+/-2 @ 5000 RPM (3048 +) 5412986

Spark plug / Gap NGK CR8EB Note: Remove opposite rollers to retain proper clutch balance
.031 in. / .8 mm
Battery / Model / Amp Hr Conventional 14 Amp/hr
Circuit Breakers Fusible Link / 15 amp Main / 15 Amp Accsy

Starting Electric / Recoil Back-up


Indicator Panel LCD / Indicator lights

1.4
GENERAL INFORMATION
MODEL: 2007 HAWKEYE 4x4 Drivetrain

MODEL NUMBER: A07LH27 Transmission Type H-N-R 1


ENGINE MODEL: ES30PFE Transmission Capacity Level with fill plug
Front Gearcase Capacity Level with fill plug
Engine
Platform Fuji 4 stroke, Single Cylinder Gear Ratio : Front Output Fwd 5.17:1 / Rev 4.79:1
Rear Output Fwd 15.18:1 / Rev 14.05:1
Engine Model Number ES300PFE010 Clutch Type CVT w/EBS
Engine Displacement 299cc
Belt 3211108
Number of Cylinders 1
Steering / Suspension
Bore & Stroke (mm) 78.5 x 68 mm
Front Suspension / Shock Mac Pherson Strut
Compression Ratio 9.2:1 Full Stroke
Front Travel 7 in. / 17.8 cm
Compression Pressure 120-140 psi
Rear Suspension Independent
Engine Idle Speed 1400 RPM Style / Shock Coil-over Adjustable
Cooling System/Capacity Air/Oil Cooled Rear Travel 8 in. / 20.3 cm
Overheat Warning None Ground Clearance 8 in. / 20.3 cm
Lubrication Wet Sump Shock Preload Adjustment Front - Cam
Oil Requirements Polaris 0W-50 / 1.7 qts (1.6L) Front / Rear Rear - Cam

Exhaust System Single Pipe - USFS Approved Turning Radius 62.5 in. (159 cm) unloaded
Carburetion Toe Out 0-1/16 in. (0-.159 mm)
Carburetor model Mikuni BST 34mm Wheels / Brakes
Main Jet 140 Tire/Rim Size - Front 22 x 7-12
Pilot Jet 45 Tire/Rim Size - Rear 22 x 10-12
Jet Needle 4HC57-3 Air Press. F/R Tires 3-5 psi
Needle Jet 05-m Brake - Front Single Control Hydraulic Disc

Pilot/Air Screw 2.5 Turns Out (Initial setting) Brake - Rear Single Control Hydraulic Disc
Brake Fluid Polaris DOT 3 or 4 Brake Fluid
Float Height 13mm from carburetor body
Fuel Delivery Fuel Pump JETTING CHART
Fuel Capacity / 4.5 gal. (17 L) AMBIENT TEMPERATURE
Requirement 87 Octane (minimum) Altitude Below 40oo F Above +40oo F
89 Oxygenated Below 5 C Above +5 C
0-1800 145 140
Electrical Meters (0-6000)
(Feet) 1800-3700 140 135
Alternator Output 250 watt / 18.6 Amp @ 6000 (6000-12000)
Voltage Regulator 3-phase
CLUTCH CHART
Lights : High Beam --
Low Beam 37.5 watts Altitude Shift Weight Number Installed
Brake 12V / 26.9 watts 0-5000 13 g
(0-1534) 8
Tail 12V / 8.26 watts 5412988

Ignition System DC CDI Feet 5000-10,000 10 g


8
(Meters) (1534 - 3048) 5412986
Ignition Timing BTDC 30°+/-2deg. @ 5000 RPM
10,000 + 10 g
NGK CR8EB 6
Spark plug / Gap (3048 +) 5412986
.031 in. / .8 mm
Note: Remove opposite rollers to retain proper clutch balance
Battery / Model / Amp Hr Conventional 14 Amp/hr
Circuit Breakers Fusible Link / 15 amp Main / 15 Amp Accsy

Starting Electric / Recoil Back-up


Indicator Panel LCD / Indicator lights

1.5
GENERAL INFORMATION

GENERAL INFORMATION
Publication Numbers

Year Model Model No. Owner’s Manual Parts Manual


PN PN

2007 Hawkeye 2x4 A07LB27AA, AC 9920787 9920789

2007 Hawkeye 4x4 A07LH27AA, AB, 9920787 9920789


AC, AD

2007 Hawkeye 2x4 Intl’ A07LB27FB 9920788 9920790

2007 Hawkeye 4x4 Intl’ A07LH27FA 9920788 9920790

NOTE: When ordering service parts, be sure to use the correct parts manual.

NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com or purchased from
www.purepolaris.com.

Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key
and refer to the chart to for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is
necessary.
Series # Part Number
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278

1.6
GENERAL INFORMATION
Standard Torque Specifications
The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS, refer to the
1
exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8


Torque in. lbs. (Nm)
#10 - 24 . . . . . . . . . . . . . . . . . 27 (3.1) . . . . . . . . . 43 (5.0) . . . . . . . . .60 (6.9)
#10 - 32 . . . . . . . . . . . . . . . . . 31 (3.6) . . . . . . . . . 49 (5.6) . . . . . . . . .68 (7.8)
Torque ft. lbs. (Nm)*
1/4 - 20 . . . . . . . . . . . . . . . . . 5 (7) . . . . . . . . . . . . 8 (11) . . . . . . . . . . .12 (16)
1/4 - 28 . . . . . . . . . . . . . . . . . 6 (8) . . . . . . . . . . . . 10 (14). . . . . . . . . .14 (19)
5/16 - 18 . . . . . . . . . . . . . . . . . 11(15) . . . . . . . . . . 17 (23). . . . . . . . . .25 (35)
5/16 - 24 . . . . . . . . . . . . . . . . . 12(16) . . . . . . . . . . 19 (26). . . . . . . . . .29 (40)
3/8 - 16 . . . . . . . . . . . . . . . . . 20(27) . . . . . . . . . . 30 (40). . . . . . . . . .45 (62)
3/8 - 24 . . . . . . . . . . . . . . . . . 23(32) . . . . . . . . . . 35 (48). . . . . . . . . .50 (69)
7/16 - 14 . . . . . . . . . . . . . . . . . 30(40) . . . . . . . . . . 50 (69). . . . . . . . . .70 (97)
7/16 - 20 . . . . . . . . . . . . . . . . . 35(48) . . . . . . . . . . 55 (76). . . . . . . . . .80 (110)
1/2 - 13 . . . . . . . . . . . . . . . . . 50(69) . . . . . . . . . . 75 (104). . . . . . . . .110 (152)
1/2 - 20 . . . . . . . . . . . . . . . . . 55(76) . . . . . . . . . . 90 (124). . . . . . . . .120 (166)

Metric / Torque
6 x 1.0. . . . . . . . . . 72-78 In.lbs. . . . . . . . . .8 x 1.25 14-18 ft.lbs . . . . 10 x 1.25 26-30 ft.lbs.

1.7
GENERAL INFORMATION
Sae Tap Drill Sizes Decimal Equivalents
Thread Size/ Drill Size Thread Size / Drill Size 1/64 ................. .0156
1/32 . . . . . . . . . . . . . .0312. . . 1 mm= .0394"
#0-80 3/64 1/2-13 27/64 3/64 ................. .0469
#1-64 53 1/2-20 29/64 1/16 . . . . . . . . . . . . . .0625
#1-72 53 9/16-12 31/64 5/64 ................. .0781. . . 2 mm = .0787"
3/32 . . . . . . . . . . . . . .0938
#2-56 51 9/16-18 33/64 7/64 ................. .1094. . . 3 mm =.1181"
#2-64 50 5/8-11 17/32 1/8 . . . . . . . .1250
#3-48 5/64 5/8-18 37/64 9/64 ................. .1406
5/32 . . . . . . . . . . . . . .1563. . . 4 mm = .1575"
#3-56 45 3/4-10 21/32 11/64 ................. .1719
#4-40 43 3/4-16 11/16 3/16 . . . . . . . . . . . . . .1875. . . 5mm= .1969"
13/64 ................. .2031
#4-48 42 7/8-9 49/64
7/32 . . . . . . . . . . . . . .2188
#5-40 38 7/8-14 13/16 15/64 ................. .2344. . . 6 mm = .2362"
#5-44 37 1-8 7/8 1/4 . . . . . . . .25
17/64 ................. .2656. . . 7 mm = .2756"
#6-32 36 1-12 59/64 9/32 . . . . . . . . . . . . . .2813
#6-40 33 1 1/8-7 63/64 19/64 ................. .2969
#8-32 29 1 1/8-12 1 3/64 5/16 . . . . . . . . . . . . . .3125. . . 8mm= .3150"
21/64 ................. .3281
#8-36 29 1 1/4-7 1 7/64 11/32 . . . . . . . . . . . . .3438. . . 9 mm = .3543"
#10-24 24 1 1/4-12 1 11/64 23/64 ................. .3594
#10-32 21 1 1/2-6 1 11/32 3/8 . . . . . . . .375
25/64 ................. .3906. . . 10 mm = .3937"
#12-24 17 1 1/2-12 1 27/64 13/32 . . . . . . . . . . . . .4063
#12-28 4.6mm 1 3/4-5 1 9/16 27/64 ................. .4219. . . 11 mm =.4331"
1/4-20 7 1 3/4-12 1 43/64 7/16 . . . . . . . . . . . . . .4375
29/64 ................. .4531
1/4-28 3 2-4 1/2 1 25/32 15/32 . . . . . . . . . . . . .4688. . . 12 mm = .4724"
5/16-18 F 2-12 1 59/64 31/64 ................. .4844
1/2 . . . . . . . .5 ..... . . . . . . . 13mm = .5118"
5/16-24 I 2 1/4-4 1/2 2 1/32
33/64 ................. .5156
3/8-16 O 2 1/2-4 2 1/4 17/32 . . . . . . . . . . . . .5313
3/8-24 Q 2 3/4-4 2 1/2 35/64 ................. .5469. . . 14 mm = .5512"
9/16 . . . . . . . . . . . . . .5625
7/16-14 U 3-4 2 3/4 37/64 ................. .5781. . . 15 mm = .5906"
7/16-20 25/64 19/32 . . . . . . . . . . . . .5938
39/64 ................. .6094
Metric Tap Drill Sizes 5/8 . . . . . . . .625 ... . . . . . . . 16mm=. 6299"
41/64 ................. .6406
21/32 . . . . . . . . . . . . .6563. . . 17 mm =.6693"
Tap Size Drill Size Decimal Nearest 43/64 ................. .6719
Equivalent Fraction 11/16 . . . . . . . . . . . . .6875
3x.50 #39 0.0995 3/32 45/64 ................. .7031. . . 18 mm = .7087"
3x.60 3/32 0.0937 3/32 23/32 . . . . . . . . . . . . .7188
47/64 ................. .7344. . . 19 mm = .7480"
4x.70 #30 0.1285 1/8 3/4 . . . . . . . .75
4x.75 1/8 0.125 1/8 49/64 ................. .7656
5x.80 #19 0.166 11/64 25/32 . . . . . . . . . . . . .7813. . . 20 mm = .7874"
51/64 ................. .7969
5x.90 #20 0.161 5/32 13/16 . . . . . . . . . . . . .8125. . . 21 mm =.8268"
6x1.00 #9 0.196 13/64 53/64 ................. .8281
27/32 . . . . . . . . . . . . .8438
7x1.00 16/64 0.234 15/64 55/64 ................. .8594. . . 22 mm = .8661"
8x1.00 J 0.277 9/32 7/8 . . . . . . . .875
8x1.25 17/64 0.265 17/64 57/64 ................. .8906. . . 23 mm = .9055"
29/32 . . . . . . . . . . . . .9063
9x1.00 5/16 0.3125 5/16 59/64 ................. .9219
9x1.25 5/16 0.3125 5/16 15/16 . . . . . . . . . . . . .9375. . . 24 mm = .9449"
10x1.25 11/32 0.3437 11/32 61/64 ................. .9531
31/32 . . . . . . . . . . . . .9688. . . 25 mm = .9843"
10x1.50 R 0.339 11/32 63/64 ................. .9844
11x1.50 3/8 0.375 3/8 1 . . . . . . . . . 1.0
12x1.50 13/32 0.406 13/32
12x1.75 13/32 0.406 13/32

1.8
GENERAL INFORMATION
Conversion Table

Unit of Measure Multiplied by Converts to


1
ft. lbs. x 12 = in. lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.356 = Nm
in. lbs. x .0115 = kg-m
Nm x .7376 = ft. lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 = in. lbs.
kg-m x 10 = Nm
in. x 25.4 =mm
mm x .03937 = in.
in. x 2.54 = cm
mile (mi.) x 1.6 = km
km x .6214 = mile (mi.)
Ounces (oz.) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x 0.035 = Ounces (oz.)
lb. x .454 = kg
kg x 2.2046 = lb.
Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in)
Imperial pints (Imp pt.) x 0.568 = Liters (l)
Liters (l) x 1.76 = Imperial pints (Imp pt.)
Imperial quarts (Imp qt.) x 1.137 = Liters (l)
Liters (l) x 0.88 = Imperial quarts (Imp qt.)
Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.)
US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.)
US quarts (US qt.) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt.)
US gallons (US gal) x 3.785 =Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x 0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)
π(3.14)xR x H (height)
2
= Cylinder Volume

°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F


°F to °C: 5 (°F + 40) ÷ 9 - 40 = °C

1.9
GENERAL INFORMATION
Glossary Of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches.
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and
grip the drive belt.
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. Measure at various points especially at PTO.
CVT: Centrifugal Variable Transmission (Drive Clutch System)
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore.
Electrical Open: Open circuit. An electrical circuit which isn't complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching
the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm2: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in2: Pounds per square inch.
Left or Right Side: Always referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy
is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040".
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.

1.10
MAINTENANCE
CHAPTER 2
MAINTENANCE
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2
LUBRICANTS / FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS. . . . . . . . . . . . . 2.6
POLARIS LUBRICANT SYMBOL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
VEHICLE INSPECTION / MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
HAWKEYE HANDLEBAR COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
FRONT GEARCASE LUBRICATION (4X4 ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
LUBRICATION / GREASE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
THROTTLE OPERATION - ALL MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
CHOKE (ENRICHER) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
PILOT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
PILOT SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
ELECTRONIC THROTTLE CONTROL / THROTTLE CABLE ADJUSTMENT . . . . . . . 2.12
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
ENGINE FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
MAIN AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
AIR FILTER/PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
AIR BOX SEDIMENT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
CVT DRAIN PLUG & DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
TIE ROD END/STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
TOE ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
TOE ALIGNMENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
EXHAUST CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
BRAKE SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
HOSE/FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
BRAKE FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
SUSPENSION SPRING FRONT / REAR PRELOAD ADJUSTMENT. . . . . . . . . . . . . . 2.22
FRONT SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
REAR SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
WHEEL REMOVAL/INSTALLATION- FRONT OR REAR . . . . . . . . . . . . . . . . . . . . . . . 2.22
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

2.1
MAINTENANCE
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubri-
cation of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genu-
ine Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately
10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition:
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use
and determine the cause or see your dealer.

Maintenance Chart Key


The following symbols denote potential items to be aware of during maintenance:
= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.
= SEVERE USE ITEM: If vehicle is subjected to severe use, decrease interval by 50%
(Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm
use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is required
under these conditions. Fluid changes, cable, chain and chassis lubrication are required more frequently. For
engine oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A rising
oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil imme-
diately and monitor level. If oil level begins to rise, discontinue use and determine cause.)
E= Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING

Improperly performing the procedures marked with


a could result in component failure and lead to
serious injury or death. Have an authorized Polaris
dealer perform these services.

2.2
MAINTENANCE
Maintenance And Lubrication
Periodic Maintenance Chart

Item Maintenance Interval Remarks


(whichever comes first)
Hours Calendar Miles
(KM) 2
Steering - Pre-Ride - Check for free operation.
 Front-suspension - Pre-Ride - Make adjustments as needed. See Pre-
 Rear-suspension - Pre-Ride - Ride Checklist on Page 2.8.
Tires - Pre-Ride -
Engine Stop Switch - Check Operation
Make adjustments as needed. See Pre-
 Brake fluid level - Pre-Ride -
Ride Checklist on Page 2.8
 Brake lever travel - Pre-Ride - Make adjustments as needed. See Pre-
Brake systems - Pre-Ride - Ride Checklist on Page 2.8
Throttle - Pre-Ride - Check Operation
Wheels /fasteners - Pre-Ride - Make adjustments as needed. See Pre-
Frame Fasteners - Pre-Ride - Ride Checklist on Page 2.8
 Engine oil level - Pre-Ride -
Make adjustments as needed. See Pre-
E Ride Checklist on Page 2.8
 Air filter, pre-filter - Daily - Inspect;clean often
E
 Air box sediment tube - Daily - Drain deposits when visible
E
Coolant Check level daily, change coolant every 2
- Daily -
(if applicable) years
Check operation; apply dielectric grease if
Headlamp/tail lamp - Daily -
replacing
 Air filter, - Weekly - Inspect; replace as needed
E main element
Recoil housing Drain water as needed, check often if
- Weekly -
(if equipped) operating in wet conditions
 Brake pad wear 10 H Monthly 100 (160) Inspect periodically

Battery 20 H Monthly 200 (320) Check terminals; clean; test
 Engine oil change (break- 20 H 1M 100 (160) Perform a break-in oil change at one month
Ein)
Front gearcase oil (if
 equipped) 25 H Monthly 250 (400) Inspect level; change yearly

 Middle gearcase oil (if 25 H Monthly 250 (400) Inspect level; change yearly
equipped)
Rear gearcase oil
 (if equipped)
25 H Monthly 250 (400) Inspect level; change yearly

 Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly


Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
 Have an authorized Polaris dealer perform these services.

2.3
MAINTENANCE
Item Maintenance Interval Remarks
(whichever comes first)
Hours Calendar Miles
(KM)
 Engine breather 25 H Monthly 250 (400) Inspect; replace if necessary
E filter (if equipped)
Engine breather
100 H 6M 1000 (1600) Inspect
hose
General Lubricate all grease fittings, pivots,
 lubrication
50 H 3M 500 (800)
cables, etc.
Shift Linkage 50 H 6M 500 (800) Inspect, lubricate, adjust

Steering 50 H 6M 500 (800) Inspect daily, Lubricate

 Front suspension 50 H 6M 500 (800) Inspect, Lubricate, Tighten Fasteners
 Rear suspension 50 H 6M 500 (800) Inspect, Lubricate, Tighten Fasteners
Carburetor float Drain bowl periodically and prior to
50 H 6M 500 (800)
bowl storage
 Throttle Cable/ Inspect; adjust; lubricate; replace if
50 H 6M 500 (800)
E ETC Switch necessary
 Inspect; adjust; lubricate; replace if
Choke cable 50 H 6M 500 (800)
E necessary
Carburetor air Inspect ducts for proper sealing/air
E 50 H 6M 500 (800)
intake ducts/flange leaks
Drive belt 100 H 12 M 1000 (1600) Inspect; adjust; replace as needed
Cooling system Inspect coolant strength seasonally;
50 H 6M 500 (800)
(if applicable) pressure test system yearly
Engine oil change 500 Perform a break-in oil change at 20
*Severe Duty 25 H 6M (800) hours/one month, change more
 frequently during cold weather
E **Normal Duty 50 H 12 M 1000
(1600)
Engine oil change 500 Replace at oil change
*Severe Duty 25 H 6M (800)

**Normal Duty 50 H 12 M 1000


(1600)
 Oil filter change 100 H 6M 1000 (1600) Replace with oil change
E
 Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust
E
 Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
 Have an authorized Polaris dealer perform these services

2.4
MAINTENANCE
Item Maintenance Interval Remarks
(whichever comes first)
Hours Calendar Miles
(Km)
 1000 Check for leaks at tank cap, lines, fuel valve, filter,
Fuel system 100 H 12M
E (1600) pump, carburetor, replace lines every two years

E
Fuel Filter 100 H 12M
1000
(1600)
Replace yearly
2
Radiator 1000
 (if applicable) 100 H 12M
(1600)
Inspect; clean external surfaces
Cooling hoses 1000
 (if applicable) 100 H 12M
(1600)
Inspect for leaks
1000
 Engine mounts 100 H 12M
(1600)
Inspect
Exhaust muffler / 1000
100 H 12M Inspect
pipe (1600)
 1000
Spark plug 100 H 12M Inspect; replace as needed
E (1600)
 1000
Ignition Timing 100 H 12M Inspect
E (1600)
1000 Inspect for wear, routing, security; apply dielectric
 Wiring 100 H 12M
(1600) grease to connectors subjected to water, mud, etc.
Clutches (drive 1000
 100 H 12M Inspect;clean; replace worn parts
and driven) (1600)
Front wheel 1000
 100 H 12M Inspect; replace as needed
bearings (1600)
2000
 Brake fluid 200 H 24M Change every two years
(3200)
3000
Spark arrestor 300 H 36M Clean out
(4800)
E Idle Speed - Adjust as needed
 Toe adjustment - Inspect periodically; adjust when parts are replaced
 Auxiliary brake Pre- Ride Inspect daily; adjust as needed

Headlight aim - Adjust as needed
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
 Have an authorized Polaris dealer perform these services.

2.5
MAINTENANCE

LUBRICANTS / FLUIDS Additives / Sealants / Thread Locking Agents / Misc.

Polaris Lubricants,Maintenance and Service 2874275 Loctite‘ Primer N, Aerosol


Products
2871956 Loctite‘ Thread Sealant 565

Part No. Description 2871950 Loctite‘ Threadlock 242


Engine Lubricant 2871951 Loctite‘ Threadlock 262
2870791 Fogging Oil (12 oz. Aerosol) 2871953 Loctite‘ Threadlock 271
2874865 0W-50 Quarts 2871557 3-Bond 1215 Sealant
2874867 0W-50 55 Gallon Drum
2871326 Premium Carbon Clean
Gearcase / Transmission Lubricants
2870652 Fuel Stabilizer (16 oz.) (12 count)
2876251 Demand Drive LT Premium Hub Fluid
2871957 Black RTV Silicone Sealer
Premium Synthetic AGL Gearcase Lube
2873602 2871958 Black RTV Silicone Sealer
(12 oz. bottle) (12 count)
Premium Synthetic AGL Gearcase Lube 2870990 DOT 3 Brake Fluid (12 count)
2873603
(1 Gal. bottle) (4 count) 2871557 Crankcase Sealant, 3 Bond 1215 (5 oz.)
NOTE: Each item can be purchased separately at your Grease / Specialized Lubricants
local Polaris dealer. Premium All Season Grease
2871322
2871423 Premium All Season Grease
2871460 Starter Drive Grease (12 count)
2871515 Premium U-Joint Lube

2871551 Premium U-Joint Lube

NOTE: The number count indicated by each part number in the table above indicates the number of units that are
shipped with each order.
Polaris Lubricant Symbol Identification
NOTE: The symbols are used to properly identify the correct lube or grease to use in the maintenance section.

Polaris DOT Polaris Synthetic Polaris Synthetic Polaris All Season Grease Polaris ATV
Brake Fluid Gearcase Lube OW-50 Oil Demand Drive Hub Fluid

2.6
MAINTENANCE
VEHICLE INSPECTION / MAINTENANCE
Pre-ride / Daily Inspection
Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
• Tires - check condition and pressures
• Fuel and oil - fill both to their proper level; Do not overfill
2
• All brakes - check operation(includes auxiliary brake)
• Throttle - check for free operation
• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
• Engine stop switch - check for proper function
• Wheels - check for loose wheel nuts
• Air cleaner element - check for dirt or water; clean or replace
• Steering - check for free operation, noting any unusual looseness in any area
• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
• Engine coolant(if applicable) - check for proper level at the recovery bottle

Hawkeye Handlebar Component Locations


Brake Fluid Reservoir
Indicator Lights 4x4 switch
(if applicable)
Front Brake LCD

Light Control Throttle


& Run Switch

Choke
Ignition/Start Key
Reverse
Override

2.7
MAINTENANCE
Maintenance quick reference

III. # Item Lube Rec. Method Frequency*

Change after 1st month (25


hours), 50 hours thereafter;
Engine Oil Polaris 0W-50 Change more often (25 hours)
1 Add oil to proper level.
Synthetic in severe duty conditions, or
short trip cold weather
operation.

Polaris AGL
2 Transmission See procedure. Change annually o
Lubricant

Fill master cylinder reservoir


As required. Change fluid
3 Brake Fluid Polaris DOT Brake Fluid to indicated level inside
every 2 years.
reservoir.

Drain and refill with pre-


Front Polaris Demand Drive
4 measured amount of As required*
Gearcase Fluid
lubricant.

Polaris All Season Locate grease fitting on


A-Arm
5 swing arm and grease with Semi-annually n
Bushings Grease p
grease gun.

* More often under severe use, such as operated in water or under severe loads.

n Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)

o Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)

p Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special.
NOTE: Refer to Polaris lubricant Identification table for.

1. Engine Oil 2. Transmission Oil


5. Inner A-Arm Upper / Lower
Reservoir Level Pivot Points
Outer A-Arm Upper / Lower
Bearing Carrier Pivot Points
Prop Shaft

3. Brake Fluid
4. Front Gearcase Oil

2.8
MAINTENANCE
Transmission Lubrication Front Gearcase Lubrication (4x4 Only)
The transmission lubricant level should be checked and changed The front gearcase lubricant level should be checked and
in accordance with the maintenance schedule. changed in accordance with the maintenance schedule.
• Be sure vehicle is level before proceeding. • Be sure vehicle is level before proceeding.
• Check vent hose to be sure it is routed properly • Check vent hose to be sure it is routed properly
and unobstructed. and unobstructed. 2
TRANSMISSION SPECIFICATIONS FRONT GEARCASE SPECIFICATIONS
Specified Lubricant: Specified Lubricant:
Polaris AGL Gearcase Lubricant: Polaris Demand Drive LT Premium Hub Fluid:
(PN 2873603) (Gallon) (PN 2873602) (12 oz.) (PN 2876251) (8 oz.)
Capacity: Capacity:
Even with fill plug Even with fill plug
Drain Plug and Fill Plug Torque: Drain Plug Torque:
15 ft. lbs. (20 Nm) 8-10 ft. lbs. (11-13 Nm)
Fill / Check Plug Torque:
To change / check transmission fluid: 8-10 ft. lbs. (11-13 Nm)

1. Place a drain pan beneath oil pan and remove drain plug
from the crankcase. Allow oil to drain completely.
2. Reinstall the drain plug. Tighten to specification.
3. Add the proper amount of lubricant to bring level into A
operating range as shown. Do not over fill.

Drain Plug Level Check


1. Position the vehicle on a level surface.
Gearcase oil 2. Remove the check/fill plug (A) and view the oil level. The
flush with the bottom oil level should be at the bottom of the check plug (B)
of thread area. threads.
3. Reinstall the check/fill plug (A). Torque to specification.
4. Verify fluid level is correct and no leaks are present. 4. Reinstall the check plug (A) and a new sealing washer.
Torque to specification.
5. Check for leaks.

2.9
MAINTENANCE
Change Carburetor Draining
1. Remove the drain plug (C). Drain the oil into an The carburetor float bowl should be drained periodically to
appropriate container. Discard used oil properly remove moisture or sediment from the bowl, or before extended
2. Clean and reinstall the drain plug with a new sealing periods of storage.
washer. Torque to specification. NOTE: The bowl drain screw is located on the bottom
3. Remove the fill plug (A) and add a pre-measured amount left side of the float bowl.
of Polaris Angle Drive Fluid. The fluid should not be above
the bottom of the check plug (B) threads. 1. Turn fuel valve to the OFF position.
2. Place a clean container beneath the bowl drain spigot or
4. Reinstall the fill plug (A). Torque to specification.
bowl drain hose.
5. Check for leaks.
3. Turn drain screw out two turns and allow fuel in the float
bowl and fuel line to drain completely.
Lubrication / Grease points 4. Inspect the drained fuel for water or sediment.
There are grease zerks rear lower control arm inner pivots, lower 5. Tighten drain screw.
rear bearing carrier pivots, and the prop shaft. Apply grease until 6. Turn fuel valve to “ON”.
it is visible on the ends of the pivot points.
7. Start machine and check for leaks.
Throttle Operation - All Models NOTE: All tubes attached to the carburetor must be
Check for smooth throttle opening and closing in all handlebar check for pinching or blockage, as this will effect engine
positions. Throttle lever operation should be smooth and lever performance
must return freely without binding.
1. Place the gear selector in neutral.
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle speed
increases at any point in the turning range, inspect throttle
cable routing and condition. If cable is routed properly and
in good condition, repeat adjustment procedure.
5. Replace the throttle cable if worn, kinked, or damaged.

Choke (Enricher) Adjustment

III. 1 Drain tube attached here Drain Screw

CHOKE

Verify free play and smooth operation of choke


cable.Adjustments to the freeplay can be made by loosening the
choke cable adjustment in or out to gain the desired freeplay.

= In. / mm.

Choke Cable Freeplay:


1/16-3/16” (1.6-4.76 mm)

If smooth choke operation is not obtainable, inspect choke cable


for kinks or sharp bends in routing.

2.10
MAINTENANCE
Pilot Screw Pilot Screw Adjustment
The pilot system supplies fuel during engine operation with the
throttle valve closed or slightly opened. The fuel/air mixture is
metered by pilot screw and discharged into the main bore
through the pilot outlet.

CAUTION 2
FRONT
The pilot screw is calibrated at the factory to meet (Engine)
EPA / CARB regulations for air quality standards and
is sealed with a brass plug to prevent tampering.
Removal of the tamper proof plug is not permitted. Pilot Screw
For service purposes, cleaning of the pilot circuit can
be done only by a certified repair shop to ensure air
quality standards are not exceeded.

1. Start engine and warm it up to operating temperature


(about 10 minutes).
2. Turn pilot screw in (clockwise) until lightly seated. Turn
screw out the specified number of turns. NOTE: Do not
tighten the pilot screw forcefully against the seat or the
screw and/or seat will be permanently damaged.

Pilot screws are calibrated at the factory. Each


carburetor has a slightly different pilot screw
setting. The specifications may require additional
Pilot Screw Location tuning to achieve the desired results.

3. Connect an accurate tachometer that will read in increments


of + or - 50 RPM such as the PET 2100DX (PN
8712100DX) or the PET 2500 (PN 8712500).
4. Verify idle speed is 1400 RPM. Always check throttle cable
freeplay after adjusting idle speed and adjust if necessary.
Brass Plug Installed
5. Slowly turn mixture screw clockwise using the pilot screw
wrench until engine begins to stumble and/or RPM begins
to drop.
6. Slowly turn mixture screw counter-clockwise, noting how
far the mixture screw is turned out, until idle RPM begins
to drop.
7. Center the pilot screw halfway between the points noted in
Step 5 and 6.
Brass Plug Removed 8. Readjust idle RPM if not within specification. Always
check throttle cable freeplay after adjusting idle speed and
adjust if necessary.

Engine Idle RPM


1400 RPM

2.11
MAINTENANCE
Electronic Throttle Control (ETC Switch)/ Fuel System
Throttle Cable Adjustment
1. Slide the boots off inline cable adjuster sleeve. Loosen WARNING
adjuster locknut.
2. With handlebars centered and wheels pointing forward, Gasoline is extremely flammable and explosive
turn adjuster sleeve until 1/16” - 1/8” freeplay is achieved under certain conditions.
at the thumb lever. After making any adjustment, “flip” the
lever slightly to confirm adjustment. • Always stop the engine and refuel outdoors or in a
well ventilated area.
• Do not smoke or allow open flames or sparks in or
near the area where refueling is performed or
where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.

Boot • If you get gasoline in your eyes or if you swallow


Locknut gasoline, seek medical attention immediately.
Boot
Adjuster • If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water and
Sleeve change clothing.
• Never start the engine or let it run in an enclosed
Direction area. Engine exhaust fumes are poisonous and
can result loss of consciousness or death in a
of travel short time.
1/16” to 1/8”
Freeplay • Never drain the float bowl when the engine is hot.
Severe burns may result.

= In. / mm. Fuel Lines


1. Check fuel lines for signs of wear, deterioration, damage,
ETC/ Throttle Cable Freeplay: or leakage. Replace if necessary.
1/16-1/8” (1.6-3.1 mm) 2. Be sure fuel lines are routed properly and secured with
cable ties.
3. Tighten locknut and slide boots over cable adjuster until
they touch at the middle point of the adjuster. CAUTION
4. With engine running, turn the handlebars from full left to
full right with transmission in neutral. Engine RPM should Make sure lines are not kinked or pinched
not change and the engine should not die. If either of these
occur, return to the first step. 3. Replace all fuel lines every two years.
NOTE: If the throttle cable is adjusted too tight, the ETC
will limit operation at low throttle positions. Vent Lines
1. Check fuel tank, crankcase, carburetor, battery and
transmission vent lines for signs of wear, deterioration,
damage or leakage. Replace every two years.
2. Verify vent lines are routed properly and secured with cable
ties.

CAUTION

Make sure lines are not kinked or pinched

2.12
MAINTENANCE
Fuel Filter Engine Mounts
The fuel filter should be replaced in accordance with the Inspect rubber engine mounts for cracks or damage.
Periodic Maintenance Chart. The fuel filter is located between
the fuel tank and carburetor. Engine Fastener Torque
1. Clamp fuel lines
Check engine fasteners and ensure they are tight
2.
3.
Remove line clamps at both ends of the filter.
Remove fuel lines from filter. Battery Maintenance
2
4. Install new filter and clamps onto fuel lines with arrow
pointed in direction of fuel flow.
WARNING

Battery electrolyte is poisonous. It contains sulfuric


acid. Serious burns can result from contact with
skin, eyes or clothing. Antidote:

External: Flush with water.


Fuel Filter
Internal: Drink large quantities of water or milk.
To Carburetor Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get


5. Install clamps on fuel line. prompt medical attention.
6. Start engine and inspect for leaks.
Batteries produce explosive gases. Keep sparks,
7. Remove clamps
flame, cigarettes, etc. away. Ventilate when
charging or using in an enclosed space. Always
Compression Test shield eyes when working near batteries. KEEP
NOTE: This 4-Stroke engine is equipped with an OUT OF REACH OF CHILDREN.
automatic decompressor. Compression readings will
NOTE: All Hawkeye batteries are Low Maintenance
vary in proportion to cranking speed during the test.
design and construction. All Low Maintenance
Average compression (measured) is about 120-140 psi
batteries are fully charged and tested at the factory
during a compression test.
before installation. Expected shelf life is 6-8 months
Smooth idle generally indicates good compression. Low engine depending on storage conditions. As a general rule
compression is rarely a factor in running condition problems before placing the battery into service, check the
above idle speed. Abnormally high compression can be caused battery condition and charge accordingly.
by a decompressor malfunction, or worn or damaged exhaust
cam lobes. Inspect camshaft and automatic decompression
mechanism if compression is abnormally high. Low Maintenance batteries are permanently sealed at the time of
manufacture. The use of lead-calcium and AGM technology
A cylinder leak-down test is the best indication of engine instead of lead-antimony allows the battery acid to be fully
condition on models with automatic decompression. Follow absorbed. For this reason, a Low Maintenance battery case is
tester manufacturer’s instructions to perform a cylinder leak- dark and the cell caps are not removable, since there is no need
down test. (Never use high pressure leakage testers as to check electrolyte level.
crankshaft seals may dislodge and leak).
NEVER attempt to add electrolyte or water to a Low
Maintenance battery. Doing so will damage the case and shorten
the life of the battery. Refer to the Battery Maintenance Video
Cylinder Compression (PN 9917987) for proper instruction on servicing Low
Standard: 120-140 PSI Maintenance batteries.
Cylinder Leakage
Service Limit: 10%
(Inspect for cause if leakage exceeds 10%)

2.13
MAINTENANCE
The battery is located under front rack. Spark Plug

To remove the battery: 1. Remove the seat and left hand side panel.
1. Disconnect holder strap. 2. Remove spark plug high tension lead. Clean plug area so
2. Disconnect battery negative (-) (black) cable first, followed no dirt and debris can fall into engine when plug is
by the positive (+) (red) cable. removed.
3. Remove spark plug.
CAUTION 4. Inspect electrodes for wear and carbon buildup. Look for a
sharp outer edge with no rounding or erosion of the
To reduce the chance of sparks: Whenever electrodes.
removing the battery, disconnect the negative Inspect electrode for wear and buildup
(black) cable first. When reinstalling the battery,
install the negative cable last. Spark Plug Gap
3. Remove the battery.
4. Clean battery cables and terminals with a stiff wire brush.
Corrosion can be removed using a solution of one cup water
and one tablespoon baking soda. Rinse well with clean
water and dry thoroughly.
5. Reinstall battery, attaching positive (+) (red) cable first and 5. Clean with electrical contact cleaner or a glass bead spark
then the negative (-) (black) cable. plug cleaner only. CAUTION: A wire brush or coated
6. Coat terminals and bolt threads with Dielectric Grease (PN abrasive should not be used.
2871329). 6. Measure gap with a wire gauge. Refer to specifications for
7. Reinstall battery cover and holder strap. proper spark plug type and gap. Adjust gap if necessary by
bending the side electrode carefully.
7. If necessary, replace spark plug with proper type.
CAUTION: Severe engine damage may occur if the
incorrect spark plug is used.
8. Apply a small amount of anti-seize compound to the spark
plug threads.
9. Install spark plug and torque to 9-11 ft. lbs (12-14 Nm).
10. Replace side panel and seat.

Recommended Spark Plug:


NGK CR8EB
Spark Plug Torque: 9-11 Ft. Lbs.
(12 - 14 Nm)

2.14
MAINTENANCE
Ignition Timing Cleaning:

Timing is CDI controlled and has no adjustment procedure. 5. Slip the pre-filter element off of main element. Clean the
pre filter with hot soapy water.
6. Rinse and dry thoroughly.
Ignition Timing:
7. Inspect element for tears or damage.
30o + 2o BTDC @ 5000RPM 8. Inspect main filter and replace if necessary. If the filter has
been soaked with fuel or oil it must be replaced.
2
Main Air Filter Cleaning Installation:
It is advisable to replace the filter when it is dirty. However, in 9. Reinstall pre-filter element over main filter. Be sure the
an emergency it is permissible to clean the main filter if you
observe the following practices. element covers entire surface of main filter without folds,
creases, or gaps.
• Never immerse the filter in water since dirt can be
transferred to the clean air side of the filter. 10. Reinstall filter on main filter mount. Place filter clamp over
the assembly and tighten.
• If compressed air is used never exceed a NOTE: Apply a small amount of general purpose grease
pressure of 40 PSI. Always use a dispersion type
nozzle to prevent filter damage and clean from the to the sealing edges of the filter before reinstalling.
inside to the outside.
• Replace the air filter every 50 hours, and possibly
more often in very dirty conditions.

Air Filter/Pre-Filter Service


It is recommended that the air filter and pre filter be replaced
annually. When riding in extremely dusty conditions,
replacement is required more often.
The pre filter should be cleaned before each ride using the
following procedure:
1. Remove the seat.
2. Remove clips from air box cover (A) and remove cover.

Proper Filter Placement


A Main Filter
Filter
Support

Air Box

3. Inspect the gasket. It should adhere tightly to the cover and III. 3 Rear
seal all the way around.
4. Remove air filter assembly. NOTE: The air filter should rest on the filter support.
Proper placement of the air filter is important to prevent
rattles and air leaks. See Illustration above.
11. Install air box cover and secure with clips.

2.15
MAINTENANCE
Air Box Sediment Tube Engine Oil Level
Periodically check the air box drain tube located toward the rear To check the oil level:
of the machine. Drain whenever deposits are visible in the clear
tube. 1. Set machine on a level surface.
2. Place the transmission in neutral.
3. Lock the parking brake.

Sediment Tube

NOTE: The sediment tube will require more frequent


service if the vehicle is operated in wet conditions or at 4. Start the engine. Allow it to idle for 30 seconds.
high throttle openings for extended periods.
5. Turn the engine off.
1. Remove drain plug from end of sediment tube. 6. The oil dipstick and fill hole are located behind the recoil
2. Drain Tube. on the right side of the ATV.
3. Reinstall drain plug.

CVT Drain Plug & Drying


NOTE: If operating the ATV through water, be sure to
check the CVT and other components for water
ingestion. The ATV should be checked immediately.

1. To release any water that maybe trapped in the CVT cover,


simply remove the CVT drain plug and O-ring located on
the bottom of the CVT cover and let the water drain out.
7. Remove the dipstick and wipe it clean.
8. Reinstall the dipstick completely
9. Remove the dipstick an check the oil level.
10. Add oil as needed to bring the level between the minimum
and maximum marks. Do not over fill.
11. Reinstall the dipstick.

2. To further expel water from the cover and to dry out the
CVT system, shift the transmission to neutral and rev
engine slightly to expel the moisture and air-dry the belt and
clutches. Allow engine RPM to settle to idle speed, shift
transmission to lowest available range and test for belt
slippage. Operate ATV in lowest available range for a short
period of time until CVT system is dry.

2.16
MAINTENANCE
Oil and Filter Change 12. Place towels under the oil filter.
13. Using an oil filter wrench, turn the filter counter clockwise
1. Set machine on a level surface.
to remove it.
2. Place the transmission in neutral.
3. Lock the parking brake.

14. Clean the filter sealing area on the engine.


4. Start the engine. Allow it to idle for two to three minuets. 15. Lubricate the filter o-ring with clean oil as shown. Check
to make sure the o-ring is in good condition.
5. Turn the engine off.
6. Clean the area around the drain plug.

16. Install the new oil filter, After the filter contacts the engine
surface turn it 1/2 turn by hand.

CAUTION

Hot oil may result in serious burns. Do not allow hot


oil to contact skin.

7. Place a drain pan under the vehicle.


8. Remove the drain plug. Use a 6mm Allen wrench.
9. Drain the oil.
17. Remove the dipstick.
18. Add required amount of 0W/50 oil. (Chapter 1)

10. Reinstall the drain plug with a new sealing washer.


11. Torque to 14 ft-lb (19Nm).
NOTE: The sealing surfaces on the drain plug and 19. Reinstall the dipstick.
crankcase should be clean and free of burrs, nicks 20. Start the engine and allow it to idle for two minuets.
or scratches. 21. Turn off the engine. Check for oil leaks.

2.17
MAINTENANCE
22. Verify the oil level. Add oil as needed to bring the level Steering
between the min. and max marks. Do not overfill.
The steering components should be checked periodically for
loose fasteners, worn tie rod ends, and damage. Also check to
make sure all cotter pins are in place. If cotter pins are removed,
they must not be re-used. Always use new cotter pins.
Replace any worn or damaged steering components. Steering
should move freely through entire range of travel without
23. Discard used oil and filter properly. binding. Check routing of all cables, hoses, and wiring to be sure
the steering mechanism is not restricted or limited. NOTE:
Whenever steering components are replaced, check front end
Valve Clearance Adjustment alignment. Use only genuine Polaris parts.

WARNING

Due to the critical nature of the procedures outlined in this


chapter, Polaris recommends steering component repair and
adjustment be performed by an authorized Polaris Dealer.
Only a qualified technician should replace worn or damaged
steering parts. Use only genuine Polaris replacement parts.

Tie Rod End/Steering Inspection


To check for play in the tie rod end, grasp the steering tie rod,
pull in all directions feeling for movement.
• Repeat inspection for inner tie rod end (on steering
INTAKE VALVE CLEARANCE post).
1. Verify cam lobes are pointed down. • Replace any worn steering components. Steering
2. Insert a .006” (.15 mm) feeler gauge between end of intake should move freely through entire range of travel
without binding.
valve stem and adjuster screw.
3. When clearance is correct, hold adjuster screw and tighten
locknut securely.
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until clearance is
correct with locknut secured.

INTAKE/ EXHAUST VALVE CLEARANCE


.006” (.15 mm)

EXHAUST VALVE CLEARANCE


1. Verify cam lobes are pointed down.
2. Insert an .006” (.15 mm) feeler gauge between end of
exhaust valve stem and adjuster screw.
3. Loosen locknut and turn adjuster screw until there is a slight
drag on feeler gauge.
4. When clearance is correct, hold adjuster screw and tighten
locknut securely.
5. Re-check the valve clearance.
6. Repeat adjustment procedure if necessary until clearance is
correct with locknut secured.

2.18
MAINTENANCE
• Elevate front end of machine so front wheels are 6. Again measure the distance between the marks and record.
off the ground. Check for any looseness in front Call this measurement “B”. Subtract measurement “B”
hub / wheel assembly by grasping the tire firmly at
top and bottom first, and then at front and rear. Try from measurement “A”. The difference between
to move the wheel and hub by pushing inward and measurements “A” and “B” is the vehicle toe alignment.
pulling outward. The recommended vehicle toe tolerance is 1/8” to 1/4” (.3
to.6 cm) toe out. This means the measurement at the front
of the tire (A) is 1/8” to 1/4” (.3 to.6 cm) wider than the
measurement at the rear (B).
2

Check for Loose Wheel or Hub


Chalk Line
• If abnormal movement is detected, inspect the hub Measurement
and wheel assembly to determine the cause. “A” Measurement “B”
Camber and Caster
The camber and caster are non-adjustable. = In. / mm.
Toe Alignment
Wheel Toe-out Alignment:
1. Place machine on a smooth level surface. 1/8-1/4” (.3-.6 cm)
2. Set handlebars in a straight ahead position and secure
handlebars in this position. NOTE: The steering arm can
be used as an indicator of whether the handlebars are Toe Alignment Adjustment
straight. The arm should always point straight back from If toe alignment is incorrect, measure the distance between
the steering post. vehicle center and each wheel. This will tell you which tie rod
needs adjusting. NOTE: Be sure handlebars are straight ahead
3. Place a chalk mark on the center line of the front tires before determining which tie rod(s) need adjustment.
approximately 10” (25.4 cm) from the floor or as close to
the hub/axle center line as possible. NOTE: It is important
that the height of both marks be equally positioned in order CAUTION
to get an accurate measurement.
4. Measure the distance between the marks and record the During tie rod adjustment, it is very important that the
measurement. Call this measurement “A”. following precautions be taken when tightening tie
5. Rotate the tires 180o by moving vehicle forward or rod end jam nuts. If the rod end is positioned
backward. Position chalk marks facing rearward, even with incorrectly it will not pivot, and may break
the hub/axle centerline.
To adjust toe alignment:
• Hold tie rod end to keep it from rotating.
• Loosen jam nuts at both end of the tie rod.
• Shorten or lengthen the tie rod until alignment is as
required to achieve the proper toe setting - (1/8” to
1/4”).

2.19
MAINTENANCE
• Important: When tightening the tie rod end jam 2. Place the transmission in Park and start the engine. Purge
nuts, the rod ends must be held parallel to prevent accumulated carbon from the system by momentarily
rod end damage and premature wear. Damage
may not be immediately apparent if done revving the engine several times.
incorrectly. See illustration. 3. If some carbon is expelled, cover the exhaust outlet and
lightly tap on the pipe around the clean out plugs with a
Hold Tie-Rod End Parallel
rubber mallet while revving the engine several more times.

x
Correctly Incorrectly
Tightened Tightened
Jam Nut Jam Nut
4. If particles are still suspected to be in the muffler, back the
machine onto an incline so the rear of the machine is one
Exhaust Pipe Cleaning foot higher than the front. Set the hand brake and block the
wheels. Make sure the machine is in Park and repeat Steps
WARNING
2 and 3. SEE WARNING
5. If particles are still suspected to be in the muffler, drive the
machine onto the incline so the front of the machine is one
• Do not perform clean out immediately after the
engine has been run, as the exhaust system foot higher than the rear. Set the hand brake and block the
becomes very hot. Serious burns could result wheels. Make sure the machine is in Park and repeat Steps
from contact with exhaust components. 2 and 3. SEE WARNING
• To reduce fire hazard, make sure that there are no
combustible materials in the area when purging
the spark arrestor.
• Wear eye protection.
• Do not stand behind or in front of the vehicle
while purging the carbon from the spark arrestor.
• Never run the engine in an enclosed area.Exhaust
contains poisonous carbon monoxide gas.
• Do not go under the machine while it is
inclined.Set the hand brake and block the wheels 1 ft.
to prevent roll back.
Failure to heed these warnings could result in serious
personal injury or death. 6. Repeat steps 2 through 5 until no more particles are
expelled when the engine is revved.
The exhaust pipe must be periodically purged of accumulated
carbon as follows: 7. Stop the engine and allow the arrestor to cool.
1. Remove the clean out plugs located on the bottom of the 8. Reinstall the clean out plugs.
muffler.
Brake System Inspection
The following checks are recommended to keep the brake
system in good operating condition. Service life of brake system
components depends on operating conditions. Inspect brakes in
accordance with the maintenance schedule and before each ride.
• Keep fluid level in the master cylinder reservoir to
the indicated level inside reservoir.
Clean Out Plug
III. 1

2.20
MAINTENANCE
• Check the fluid level “eye”. If it is clear, it is an 3. If excessive free play exists, inspect brake pads, pedal,
indication that fluid is needed or the brake pads linkage springs, and hoses for wear or damage and replace
may be worn, which can reduce the fluid level.
any parts as needed.
• Use Polaris DOT 3 or DOT 4 Brake Fluid

SIGHT GLASS .40” - .80”


(10-20 mm)
2

Hand Brake Lever Free Play

Rear Foot Brake


• Check brake system for fluid leaks, excessive
travel or spongy feel.
• Check brake pads for wear, damage or looseness.
• Check surface condition of the disc.
• Inspect thickness of brake pad friction material.

Brake Pad Inspection


Front Brake Pads

Rear Brake

4. Check foot brake effectiveness by applying approximately


50 lb. (23 kg) downward force on the pedal. The top of the
pedal should travel not more than 1 inch (25.4mm).
Brake Pad
Measure
Thickness
Service Limit - .059” (1.5 mm)
50 lbs 1” or greater
Brake pads should be changed when friction material is worn to
.59” (1.5 mm).

Hose/Fitting Inspection
Check brake system hoses and fittings for cracks, deterioration,
abrasion, and leaks.Tighten any loose fittings and replace any Floorboard
worn or damaged parts.

Brake Freeplay
5. If more than one inch, two things must be examined:
Hand Brake Lever
• Free play of the brake pedal should be 1/8 - 1/4
1. Check the brake lever, and foot brake for loose inch (3.2 - 6.35 mm).
connections, free play, and damage.
2. Measure the hand brake lever freeplay. Freeplay should be • If free play is excessive: Inspect brake pads,
pedal, linkage springs, and hoses for wear or
0.40-0.80 in. (10-20 mm). damage and replace any parts as needed.

2.21
MAINTENANCE
Suspension Spring FRONT / REAR Preload Wheel Removal/Installation- Front or Rear
Adjustment
Wheel Removal
Operator weight and vehicle loading affect suspension spring
preload requirements. Using Spanner Wrench (PN 2870872) 1. Stop the engine, place the transmission in gear and lock the
adjust as necessary to avoid bottoming of the shocks. parking brake.
2. Loosen the wheel nuts slightly.
Shock Spanner Wrench 3. Elevate the side of the vehicle by placing a suitable stand
under the footrest frame.
(PN 2870872)
4. Remove the wheel nuts and remove the wheel.

Front Suspension Inspection Wheel Installation


1. With the transmission in gear and the parking brake
Compress and release front suspension. Damping locked, place the wheel in the correct position on the wheel
should be smooth throughout the range of travel. hub. Be sure the valve stem is toward the outside and
• Check all front suspension components for wear or rotation arrows on the tire point toward forward rotation.
damage. NOTE:Apply an anti-seize compound on the front
wheel spindle before hub/wheel installation.
• Inspect shocks for leakage. 2. Attach the wheel nuts and finger tighten them.
Rear Suspension Inspection 3. Lower the vehicle to the ground.
4. Securely tighten the wheel nuts to the proper torque listed
Compress and release rear suspension. Damping in the table.
should be smooth throughout the range of travel.
Wheel Nuts
• Check all rear suspension components for wear or
damage.
• Inspect shocks for leakage.

Controls
Cotter
Check controls for proper operation, positioning and Key
adjustment.
• Brake control and switch must be positioned to
allow brake lever to travel throughout entire range
without contacting switch body.

Wheels Hub Retaining Nut


Inspect all wheels for runout or damage. Check wheel nuts and
ensure they are tight. Do not over tighten the wheel nuts. CAUTION
Wheel, Hub, And Spindle
Torque Table Improperly installed wheels could affect vehicle
handling and tire wear. On vehicles with tapered rear
wheel nuts, make sure tapered end of nut goes into
Item Specification taper on wheel. Be sure to properly torque and
Front Wheel Nuts - Steel 27 Ft. Lbs. (37Nm) install all wheel nuts.

Rear Wheel Nuts - Steel 27 Ft. Lbs. (37Nm)


Hub Retaining Nut 80 Ft. Lbs. (108 Nm)

2.22
MAINTENANCE
Tire Pressure Frame, Nuts, Bolts, Fasteners
Periodically inspect the torque of all fasteners in accordance
Tire Pressure Inspection (PSI - Cold) with the maintenance schedule. Check that all cotter pins are in
place. Refer to specific fastener torques listed in each chapter.
Front Rear
4 4
2
Tire Inspection

WARNING

Operating an ATV with worn tires will increase the


possibility of the vehicle skidding and possible loss
of control.

Worn tires can cause an accident.

Always replace tires when the tread depth


measures 1/8” (.3 cm) or less.

CAUTION

• Maintain proper tire pressure. Refer to the


warning tire pressure decal applied to the
vehicle.
• Improper tire inflation may affect ATV
maneuverability.
• When replacing a tire always use original
equipment size and type.
• The use of non-standard size or type tires
may affect ATV handling.

Tire Tread Depth


Always replace tires when tread depth is worn to 1/8” (3 mm)
or less.

Tread
Depth 1/8” (3 mm)

2.23
MAINTENANCE

NOTES

2.24
ENGINE
CHAPTER 3
ENGINE
TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3
OIL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
PISTON RING IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
TRANSMISSION INSTALLATION NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
OIL FLOW / PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
ENGINE BREATHER / OIL SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
CAM CHAIN TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
ROCKER ARM/SHAFT DISASSEMBLY AND INSPECTION. . . . . . . . . . . . . . . . . . . . . 3.16
CAMSHAFT REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
COMBUSTION CHAMBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
ENGINE BOTTOM END DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CAM CHAIN GUIDE AND TENSIONER BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
CYLINDER HONE SELECTION/ HONING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . 3.26
HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
FLYWHEEL REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
STARTER DRIVE CLUTCH REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
CAM CHAIN DRIVE SPROCKET REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . 3.29
OIL PUMP INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
STARTING CLUTCH AND ENGINE BRAKING CLUTCH REMOVAL /INSPECTION . . 3.30
STARTING CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION. . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKCASE OIL PASSAGES & PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . 3.33

3.1
ENGINE
CAMSHAFT CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
BALANCE SHAFT BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
CRANKCASE OIL PICKUP STRAINER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
BEARING /SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
END PLAY INSPECTION/ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
CRANKSHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
BALANCER SHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
CAM CHAIN, OIL PUMP, & TENSIONER BLADE INSTALLATION. . . . . . . . . . . . . . . . 3.37
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
CYLINDER HEAD AND CAMSHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
CAMSHAFT INSTALLATION & TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
ROCKER ARM INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
STARTER DRIVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
SPARK PLUG FOULING TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
ENGINE TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43

3.2
ENGINE
TOOLS Oil Pressure Relief
14 mm 15-17 (20-23 Nm)
Valve Plug
Special Tools
Recoil Housing 6mm 7-8 (9-11 Nm)
PART NUMBER TOOL DESCRIPTION
Rocker Adjuster Screw 5mm 3.5-5 (5-7 Nm)
Valve Seat Reconditioning
2200634
Kit Rocker Cover 6mm 5-6.5 (7-9 Nm)
2870390 Piston Support Block
Rocker Adjuster Screw
PA-47308 Flywheel Puller 5mm 3.7-5.0 (5-7 Nm)
Lock Nut
PA-47457 Starting Clutch Holder

2871293-B
Crankshaft Slotted Nut
Socket
Stator Plate to
Crankcase
6mm 7-8 (9-11 Nm) 3
Stator to Stator Plate
5mm 5-6.5 (7-9 Nm)
Screws
TORQUE SPECIFICATIONS
Starter Motor 6mm 5-6.5 (7-9 Nm)
Engine Torque Specifications
Starting Clutch Cover 8mm 14-15.5 (19-21Nm)
ENGINE TORQUE SPECIFICATIONS 103-118
Starting Clutch Nut 16mm
(140-160 Nm)
Thread ES300PFE010
Fastener
Size Ft. Lbs. (Nm) Spark Plug (New) 12mm 7.5-9 (10-12 Nm)
Camshaft Chain Tighten 30-45
6mm 5-6.5 (7-9 Nm)
Tensioner Lever Spark Plug (Used) 12mm degrees after
Camshaft Chain gasket contact
6mm 6.5-8.0 (9-11 Nm)
Tensioner Body
Torque Patterns
Camshaft Chain
8mm 6-7.5 (8-10 Nm)
Tensioner Cap Tightening method for cylinder head nuts:
Camshaft Sprocket
6mm 6.5-8.0 (9-11 Nm) 1) Apply engine oil to washer and threads of 10mm bolts.
Cover
2) Tighten 10mm bolts in pattern below to 18.5 ft. lbs. (25 Nm)
Camshaft Sprocket Bolt 10mm 30-34 (40-46 Nm)
3) Loosen 180 degrees
Carburetor
8mm 12-14 (16-20 Nm)
Adaptor 4) Tighten to 11 ft. lbs. (15 Nm)
Refer to Torque
Cylinder Head Bolts 10mm 5) Tighten 90 degrees
Procedure
Cylinder & Head 6mm 6) Tighten 60 degrees
6mm 5-7 (7-9 Nm)
Bolts
Crankcase 6mm 6.5-8.0 (9-11 Nm) 7) Tighten 6mm head and base bolts to 8 ft. lbs. (11 Nm)
Crankshaft Sprocket
25mm 34 (46 Nm) Cylinder Head / Cylinder Base
Slotted Nut
Flywheel Nut 16mm 66-81 (90-110 Nm) 2
3
5
Oil Drain Bolt 6 mm
14mm 13-16 (18-22 Nm)
(Crankcase)
6
Oil Filter Pipe Fitting 4
20mm 9.5-12 (13-16 Nm) 1
(Crankcase)

Oil Pressure Blind Plug 1/4 NPT 20-24 (27-33 Nm)

3.3
ENGINE
GENERAL ENGINE SERVICE
Engine Exploded View
Crankcase Cylinder/
Cylinder Head
6 ft. lbs.

8 ft. lbs.

15 ft. lbs.

15 ft. lbs. SEE


PROCEDURE

12-14 ft. lbs.

5.5 ft. lbs.

16 ft. lbs.

5.5 ft. lbs.

Crankshaft Valve Train


and Piston
3.5 ft. lbs.
7 ft. lbs.

6 ft. lbs.

6 ft. lbs.

30-34 ft. lbs.


34 ft. lbs.

3.4
ENGINE
Engine Service Data

Cylinder Head / Valvetrain ES300PFE010


Camshaft Lobe Height In Std 1.2938-1.2977" (32.863 - 32.963mm)
Limit 1.2820" (32.563 mm)
Ex Std 1.2938-1.2977" (32.863 - 32.963mm)
Limit 1.2820" (32.563 mm)
Journal O.D. PTO 1.0998-1.1004" (27.935-27.950mm)
Journal O.D. MAG 1.5328-1.5334" (38.935-38.950mm)
Journal Bore I.D. PTO 1.1025-1.1033" (28.005-28.025mm) 3
Journal Bore I.D. MAG 1.5356-1.5364" (39.005-39.025mm)
Std .0021-.0035" (.055 - .090mm)
Camshaft Journal Oil Clearance
Limit .0039" (.10mm)
Camshaft Chain Install new as a part of any crankshaft removal

Cylinder Head Surface Warpage Limit .0020” (.05 mm)


Rocker Arm/Shaft Rocker arm ID .8669-.8677" (22.02-22.04 mm)
Rocker shaft OD .8656-.8661" (21.987-22.00 mm)
Oil Clearance (Limit) .0039" (.10 mm)
Valve Clearance In Std .006" (.15 mm)
Ex Std .006" (.15 mm)
Valve Seat Angle Contacting Width In Std .039" (1.0 mm)
Limit .055" (1.4 mm)
Ex Std .059" (1.5 mm)
Limit .070" (1.8 mm)
Valve Stem Diameter In .2342-.2348" (5.950-5.965 mm)
Ex .2340-.2346" (5.945-5.960 mm)
Limit .1921" (4.9 mm)
In 3.976" (101.0mm)
Stem Length
Ex 3.984" (101.2mm)
In Limit .031" (.8mm)
Margin
Ex Limit .031" (.8mm)
Valve Guide Inner Diameter In .2362-.2367" (6.0-6.012 mm)
Ex .2362-.2367" (6.0-6.012 mm)
Stem to Guide Oil Clearance Limit .006" (.15 mm)
Valve Spring Free Length 1.640" (41.66 mm)
1.377" (35.0 mm)
Squareness 0.075” (1.9 mm)

KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off

3.5
ENGINE
Engine Service Data

Cylinder / Piston / Connecting Rod ES300PFE010


Cylinder Surface warpage limit (mating with cylinder .002” (0.05 mm)
head)
Cylinder bore Std 3.0590-3.0598" (77.70-77.72 mm)
Taper or Out-of-Round Limit Limit .002” (0.05 mm)
Piston to cylinder clearance Std .0015-.0032" (0.038-0.082 mm)
Limit .0043" (0.11 mm)
1st O.S. + .0098” (.25 mm)
Boring Limit
2nd O.S. + .0197” (.50 mm)
Piston Outer diameter Std 3.0566-3.0575" (77.638-77.662 mm)
1st O.S. .0098" (.25 mm) Oversize
2nd O.S. .0197" (.50 mm) Oversize
Pin Bore - Inner Diameter .7089-.7094" (18.007-18.020 mm)
Piston Pin Pin outer diameter clearance in piston .00015- .00047” (.004- .012 mm)
Degree of fit Push (by hand) fit @ 68o F (20o C) (Standard
clearance 0-.0005" (0-.012mm)
Piston Ring Piston Ring Installed Gap Top ring Std .008-.0012" (.2-.3 mm)
Limit .032" (.8 mm)
Second Std .018-.019" (.35-.50 mm)
ring
Limit .039" (1.0mm)
Oil ring Std .0079-.0275" (.2-.7 mm)
Limit .059" (1.5 mm)
Top ring Std .0006-.0029" (.015.-.074 mm)
Limit .006" (.15 mm)
Piston Ring to Ring Groove Second Std .0009-.0025" (.025-.065 mm)
Clearance ring
Limit .006" (0.15 mm)
Oil ring Std .002-.0057" (.055-.145 mm)
Limit N/A
Connecting Rod Connecting rod small end ID .7089-.7094" (18.007-18.020 mm)
Connecting rod small end radial Std 0 - .0007" (0 - 0.019 mm)
clearance (to piston pin) Limit .0011" (.03 mm)
Connecting rod big end axial (side) Std
.0035-.0196" (.09-.50 mm)
clearance
Limit
.023" (.60 mm)

Connecting rod big end radial Std


0.0004-.0014" (.011-0.038 mm)
clearance
Limit
.0019" (.05 mm)

3.6
ENGINE

Crankshaft / Counter Balancer / Oil Pump ES300PFE010


Crankshaft Crankshaft End Runout Limit 0.0024" (0.06 mm)
Std 0.006-.012" (.15 - .30 mm)
Crankshaft End Play
Limit N/A
Std 0.004-.029" (0.1 - .74 mm)
Counter Balancer Counter Balancer Shaft End Play
Limit N/A
Oil Pump Oil Pump Shaft End Play N/A

Std 0.0027-.0051" (.070 - .130 mm) 3


Oil Pump End Clearance
Limit N/A

Std 0.0047" (.12 mm)


Pump Rotor Tip Clearance
Limit N/A

Std 0.006 - 008" (.15 - .21 mm)


Pump Feed Rotor to Pump Body
Clearance
Limit N/A

Std Above 9 PSI


Oil Pressure (Polaris 0W-50 @ Normal
Operating Temperature @ Idle Speed)
Limit Below 9 PSI

KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off.

3.7
ENGINE
Oil Flow Diagram

Rocker Arm
Rocker Shaft
Valve Springs

ES300PFE010
Chain Room

Cylinder Head Camshaft


(RH Cam Journal) Sprocket & Chain

Connecting Rod Small End


Piston Skirt / Rings

Nozzle Right Rear


Cylinder Bolt

Counter Balance Gear Crankshaft


Main Bearing
Connecting Rod Big End

MAG SIDE
Starting Clutch
One Way Clutch Crankcase
Stator Plate
Oil Passage

Crankcase
Oil Cooler / Filter
Main Bearing Oil Passage

PTO SIDE Oil Pressure Inspection


& Accessory Oil Cooler
Crankcase Fitting Location
Starting Clutch Oil Passage

Oil Pump

Crankcase Oil Pickup Engine Sump


OIL FLOW DIAGRAM KEY Oil Passage Screen

Direct

Indirect

3.8
ENGINE
Piston Identification Accessible Components
Piston is identified by the marking ES30A. The following components can be serviced or removed with
the engine installed in the frame:
Note the directional and identification marks when viewing the
pistons from the top. The letters “IN” must always be toward the • Flywheel
intake side of the engine. • Alternator/Stator
Piston rings must be installed correctly to ensure engine • Starter Motor/Starter Drive
performance. The numbers or letters on all rings (except oil
• Oil pump
control rings) must be positioned upward. See text for oil control
ring upper rail installation. Use the information below to
identify pistons and rings.
• Rocker Arms / Rocker Shaft
• Camshaft
3
Engine Model Oversize Standard Piston • Cam Chain and Sprockets
No. Available (mm) Identification
• Cylinder
Valve Pocket to
.25mm • Cylinder Head
ES300PFE010 Rear
.50mm
(Intake Side) • Valves
• Carburetor
Piston Ring Identification
• Piston/RIngs
The piston ring profile is shown below. Install top and second
ring with marking UP. Refer to text for oil control ring The following components require engine removal for
installation. service:

• Starting Clutch (transmission removal required)


Piston Ring Installation Note Profile
• One-Way Clutch (engine braking)
Inner Bevel; Barrel
TOP RING Mark Faces UP • Crankshaft
Face
Undercut; • Crankshaft Main Bearings
SECOND RING Mark Faces UP
Taper Face
• Counter Balance Shaft or Bearings
• Crankcase
• Transmission
NOTE: Crankshaft components are not serviceable.
Replace crankshaft as an assembly.

3.9
ENGINE
ENGINE SERVICE 10. Disconnect gear indicator switch harness (at transmission)

Engine Removal
NOTE: The engine removal procedure described
A
below removes the engine and transmission as an
assembly, and the engine is then removed from the
transmission case. The transmission can be
removed separately from the engine (see
Transmission Removal procedure in this chapter).

1. Clean work area. B


2. Thoroughly clean the ATV engine and chassis.
3. Disconnect battery cables at battery.
4. Drain engine oil. 11. Disconnect speed sensor from transmission (left rear side).
5. Disconnect spark plug high tension lead. 12. Rear fuel tank bracket
6. Remove the following parts: 13. CVT air intake and exhaust ducts

• Seat
• Left and Right Side Covers
• Rear cab
7. Remove CVT cover and both clutches (refer to CVT
Chapter 8)

14. Remove carburetor. Insert a clean shop towel into the


carburetor flange to prevent dirt from entering the intake
port.
15. Remove exhaust head pipe.
8. Front prop shaft (4x4 models) (Drive pin out at front 16. Starter motor positive (+) and negative (-) cables at starter
gearcase, pull shaft back, then forward. Refer to Drive motor.
Chapter)
17. Recoil housing, flywheel and stator (or if front cab is
removed, remove front cab and disconnect wires.) See
“Flywheel Removal / Inspection” on page 3.28. for
flywheel removal procedure.

9. Remove transmission linkage rod (A) and vent hose (B)

3.10
ENGINE
NOTE: If front cab is already removed, the stator 25. Lower the jack and pull engine / transmission assembly out
wires can be disconnected. Disregard the steps to the rear.
remove recoil cover, flywheel, and stator from the
engine.

18. Front engine mount


19. Support lower sub-frame with a stable platform jack.
20. Rear lower engine mount
21. Sub frame bolts (2 each side)

Rear mount 2 both sides

22. Rear wheel (left side) and brake caliper.


NOTE: Re-install rear wheel after caliper removal.

23. Top rear shock bolts.


24. Top bolts from sway bar bracket.

3.11
ENGINE
26. Support engine and remove (9) transmission-to- Engine Break In Period
engine bolts.
4 Cycle Engine Break-In Period is defined as the first 10 hours
of engine operation or 2 full tanks of fuel.

• Use only Polaris Premium 4 All Season Synthetic


Oil, or API certified “SH” oil.
• Use fuel with a minimum octane of 87 (R+M)/2
method.
• Change break-in oil and filter at 20 hours or 100
miles, whichever comes first.

IMPORTANT: DO NOT LIFT ENGINE BY THE


STARTING CLUTCH SHAFT!

Engine Installation Notes


After the engine is installed in the frame, review this checklist
and perform all steps that apply:

General Items

• Install previously removed components using new


gaskets, seals, and fasteners where applicable.
• Perform checks on fluid levels, controls, and all
important areas on the vehicle as outlined in the
daily pre-ride inspection checklist (refer to Chapter
2).

CVT System

• Clean clutch sheaves thoroughly and inspect inlet


and outlet ducts for proper routing and sealing.
• Inspect drive and driven clutch as described in
chapter 8.
Transmission

• Inspect transmission operation.


Exhaust

• Replace exhaust gaskets. Seal connections if


necessary with high temp sealant.
• After running the engine, verify all bolted exhaust
connections are tight and in good condition.
Engine Mount Torque

• Inspect all engine mount fasteners and verify they


are tightened properly

3.12
ENGINE
Transmission Removal 9. Disconnect gear indicator switch harness (at transmission)

NOTE: The transmission can be removed separately


from the engine. Follow this procedure if engine
removal is not required.
A
1. Clean work area.
2. Thoroughly clean the ATV engine and chassis.
3. Disconnect battery cables at battery.
4. Drain transmission oil.
5. Remove the following parts:
B
3
• Seat
• Left and Right Side Covers 10. Disconnect speed sensor at transmission (left rear side).
• Rear cab 11. Remove rear fuel tank bracket.
6. Remove CVT cover and both clutches (refer to CVT 12. Remove CVT air inlet duct.
Chapter 8)

7. Front prop shaft (4x4 models) (Drive pin out at front


gearcase, pull shaft back, then forward. Refer to Drive 13. Support frame under engine with a stable platform jack.
Chapter) 14. Remove rear wheels and brake caliper.

8. Remove transmission linkage rod (A) and vent hose (B) 15. Remove rear plate (lower control arm bolts) and upper
control arm bolts.

3.13
ENGINE
16. Remove rear shocks. 24. Remove the top 2 rear bracket bolts.
25. Carefully lower the transmission jack until rear bracket is
clear of frame.
26. Slide transmission to the left until alignment pins in cover
are release from engine case.
27. Remove transmission out to the left side.
28. Remove sway bar bracket from transmission.
29. Refer to transmission disassembly in CVT/Transmission
Chapter 8.

Transmission Installation Notes


1. Install new gasket on engine
17. Remove rear suspension (both sides) with drive shafts.
2. Install transmission to engine until alignment pins are
18. Rear lower engine mount engaged, and screw in 4 bolts to hold in place but do not
completely tighten at this time.
19. Sub frame bolts (A - 2 each side)
3. Loosely install upper frame mount bolts and all sub-frame
bolts.
4. Install all remaining transmission-to-engine crankcase
bolts and tighten all in 2 steps to specified torque following
a cross pattern.
5. Tighten sub-frame to main frame bolts (4) and rear engine
mount bolts.
6. Tighten rear upper bracket bolts.
7. Tighten rear upper bracket bolts.

Rear mount
A

20. Remove sub frame.


21. Support transmission with another jack.

22. Loosen, but do not remove the 4 bolts from the rear
transmission hanger bracket.
23. Remove (9) transmission-to-engine bolts.

3.14
ENGINE
Engine Lubrication Cam Chain Tensioner Removal
Oil Type:Polaris Premium 0W-50 Synthetic To position crankshaft at Top Dead Center (TDC) on
compression stroke:
Capacity (DRY):
1.64-1.95 U.S. Quarts (1.55-1.85 l) 4. Remove the valve cover.

Capacity (OIL/FILTER/COOLING BLOCK CHANGE): 5. Rotate engine in normal direction and watch the intake
1.4-1.7 U.S. Quarts (1.3-1.6 l) valve open and begin to close.
6. Continue to rotate engine slowly while watching camshaft
Drain Plug:14-18 ft. lbs. (19-24.4 Nm) sprocket marks and the mark in the timing inspection hole.
Oil Pressure Specification:
(Using Polaris 0W-50 Synthetic @ Operating Temperature @
Single TDC Mark Aligned 3
Idle) Any pressure reading above 9 PSI. TDC Mark

Oil Flow / Pressure Test


Rotation
WARNING

Oil temperature can cause serious injury and


damage. Wear the proper safety gear when
performing these procedures.
7. Align single (T) mark on flywheel with in the inspection
NOTE: Due to the engine assembly having a majority of hole, and the cam sprocket pin (facing upward) aligned with
roller bearings, oil pressure readings hot or cold will be the camshaft to crankshaft center line. NOTE: The
very low. Low oil pressure is not an indication of a oil sprocket marks align with gasket surface, the cam lobes
delivery problem. should be pointing down and the valves should have
clearance at this point.
1. Remove plug from the crankcase.
2. Insert a 1/4 Pipe Thread oil pressure gauge adaptor into the
crankcase and attach an oil pressure gauge.
3. Start engine and allow it to reach operating temperature
while monitoring gauge indicator. Any pressure above 9 Dot
PSI is an indication of good oil flow.

Engine Breather / Oil separator


Breather / oil separators are located behind the gas tank on the Marks Aligned
left side and on the cylinder. The breather provides ventilation
for the valve cover and crankcase through the air box.
TO AIR BOXA 8. Remove the cam chain tensioner end cap.
CAUTION: The plunger is under spring tension. Maintain
inward pressure while removing.
9. Remove 2 cam chain tensioner bolts.

BREATHER FITTING LOCATIONS

3.15
ENGINE
10. Tap lightly on tensioner body with a soft face hammer to Rocker Arm/Shaft Disassembly and
loosen and remove tensioner if required. Inspection
NOTE: Orientation of the components is important for
reassembly. Mark all components before disassembly.

1. Remove the valve cover. Be sure engine is positioned at


TDC on the compression stroke (there should be clearance
on both rocker arm adjusters).

Cam Chain Tensioner Inspection


1. Pull cam chain tensioner plunger (A) out to the end of its
travel and inspect ratchet teeth on plunger and pawl.
Inspect spring (B) for wear or damage.
2. Mark the rocker arms to keep them in order for assembly.
A
3. Slide the rocker shaft out and be prepared to catch the wave
washer (A) positioned on the PTO end of the shaft between
the casting and the intake rocker arm.

2. Hold the ratchet open and slide the plunger in and out of
the tensioner body. The plunger should move smoothly
throughout the travel range.
3. Replace entire tensioner assembly if any part is worn or
damaged.
4. Inspect each rocker arm cam follower surface. If there is
any damage or uneven wear, replace the rocker arm.
NOTE: Always replace camshaft if lobe of either rocker
arm is worn or damaged.

Inspect surface of followers

5. Inspect the rocker arm shaft and the shaft bore in the
cylinder head for wear or signs of scoring.

3.16
ENGINE
6. Measure I.D. of each rocker arm (A) for out-of-round and 4. If not removing the cylinder for other service, secure the
visually inspect the I.D. surface. Replace arm if excessive cam chain with a wire to prevent it from falling into the
wear is evident. crankcase.
7. Inspect rocker adjuster screws (B) for wear, pitting, or
damage to threads of the adjuster or locknut. Replace all
worn or damaged parts. NOTE: The end of the adjuster is
hardened and cannot be ground or re-faced.

5. Inspect cam sprocket teeth for wear or damage.

8. Measure O.D. of rocker shafts for out-of -round. Inspect


them for wear or damage. Replace if excessive wear is
evident. NOTE: Orientation of the rocker shafts is
important for reassembly.
6. Inspect the automatic compression release mechanism.
Replace the cam if parts are worn.

Camshaft Removal and Inspection


NOTE: Cam chain tensioner must be removed before
Compression Release-one-way operation
performing this procedure.
1. Remove the camshaft end cover.
2. Remove the sprocket bolt.
3. Slip the chain over the sprocket and remove sprocket.

Camshaft Inspection
1. Thoroughly clean the camshaft.
2. Visually inspect each cam lobe and bearing journal for
wear, scoring, or damage. Verify oil delivery passages are
clean.
3. Check the automatic decompressor spring legs and replace
if broken. Spring preload is very light (about 45 degrees).

3.17
ENGINE
4. Measure the height of the cam lobes with a micrometer and 1/4 turn each time in a cross pattern until loose.
compare to specification. Replace cam if worn below
minimum height (service limit).

3. Remove bolts (A) and tap the cam support tower with a
plastic hammer until loose. Remove.
4. After removing the camshaft and securing the cam chain,
tap cylinder head lightly with a plastic hammer until loose.
= In. / mm. CAUTION: Tap only in reinforced areas or on thick parts
of cylinder head casting.
Cam Lobe Height - Intake & Exhaust
5. Remove cylinder head, gasket, front chain guide and dowel
Std: 1.2938”-1.2977 (32.863-32.963 mm)
pins.
Limit: 1.2820” (32.563 mm)

Cylinder Head Removal


NOTE: Cam chain and tensioner must be removed. If no
crankshaft service is being performed, secure cam chain
with wire to avoid dropping chain into the crankcase.

1. Remove the (two) 6mm screws on the cylinder head and


the two on the cylinder base.

Cylinder Head Inspection


Thoroughly clean cylinder head surface to remove all traces of
gasket material and carbon.

CAUTION
2. Loosen each of the four cylinder head bolts evenly.
Use care not to damage sealing surface. If there is
damage found on the cylinder head combustion
chamber, it is recommended the component be
replaced.

3.18
ENGINE
Cylinder Head Warp Inspection Cylinder Head Disassembly
1. Lay a straight edge across the surface of the head at several
different points and measure warpage by inserting a feeler WARNING
gauge between the straight edge and the cylinder head
surface. If warpage exceeds the service limit, replace the Wear eye protection or a face shield during cylinder
cylinder head. head disassembly and reassembly. Cylinder head
service should be performed by a technician
knowledgeable in cylinder head reconditioning in a
properly equipped shop.

NOTE: Keep all parts in order with respect to their


location in the cylinder head.
3
1. Using a valve spring compressor, compress the valve
springs and remove the split keeper. NOTE: To prevent
loss of tension, do not compress the valve spring more than
necessary.
2. Remove spring retainer and spring.
NOTE: The valve springs should be positioned with the
tightly wound coils (A) against the cylinder head.

= In. / mm.

Cylinder Head Warp Limit:


.002” (.05 mm)

Combustion Chamber Inspection


Clean all accumulated carbon deposits from combustion
chamber and valve seat area with a soft wire brush. Inspect the
combustion chamber for cracks and/or damage from foreign
debris.

3.19
ENGINE
3. Push valve out, keeping it in order for reassembly in the Valve Inspection
same guide.
1. Remove all carbon from valve with a soft wire wheel.
4. Measure free length of the inner and outer springs with a
Vernier caliper, Ill.1. Check spring for squareness as shown 2. Check valve face for runout, pitting, and burnt spots. To
in Ill.2. Replace spring if measurements are out of check for bent valve stems, mount valve in a drill or use “V”
specification. blocks and use a dial indicator.

A
Valve Spring
Free Length

III.1 3. Check end of valve stem for flaring, pitting, wear or damage
(A).

Coil fatigue/
Squareness

4. Inspect split keeper groove for wear or flaring of the keeper


seat area (B). NOTE: The valves cannot be re-faced or end
III.2 ground. Valves must be replaced if worn, bent, or damaged.
5. Measure diameter of valve stem with a micrometer in three
5. Remove valve seals. NOTE: Replace seals whenever the places and in two different directions (six measurements
cylinder head is disassembled. Hardened, cracked or worn total). Replace if excessive wear is evident.
valve seals will cause excessive oil consumption and
carbon buildup. Measure valve stem in
several places

6. Measure valve guide inside diameter at the top middle and


end of the guide using a small hole gauge and a micrometer.

3.20
ENGINE
Measure in two directions, front to back and side to side. provided in the Valve Seat Reconditioning Kit (PN
2200634).

CAUTION

Wear eye protection when performing cylinder head


service. Valve guide replacement will require
heating of the cylinder head. Wear gloves to prevent
burns.

Follow the manufacturers instructions provided with the valve


seat cutters in the Valve Seat Reconditioning Kit (PN 2200634).
3
Abrasive stone seat reconditioning equipment can also be used.
Keep valves in order with their respective seat.

7. Subtract valve stem measurement to obtain stem to guide NOTE: Valve seat width and point of contact on the
clearance. NOTE: Be sure to measure each guide and valve valve face is very important for proper sealing. The valve
combination individually. must contact the valve seat over the entire
circumference of the seat, and the seat must be the
8. Replace valve and/or guide if clearance is excessive.
proper width all the way around. If the seat is uneven,
NOTE: If valve guides are replaced, valve seats must be compression leakage will result. If the seat is too wide,
reconditioned. Refer to Valve Seat Reconditioning for seat pressure is reduced, causing carbon accumulation
procedure. and possible compression loss. If the seat is too narrow,
heat transfer from valve to seat is reduced and the valve
Valve Seat Reconditioning may overheat and warp, resulting in burnt valves.

Valve Seat Inspection 1. Install pilot into valve guide.

Inspect valve seat in cylinder head for pitting, burnt spots,


roughness, and uneven surface. If any of the above conditions
exist, the valve seat must be reconditioned. If the valve seat is
cracked the cylinder head must be replaced.

Too Uneven Good Too


Wide Narrow
2. Apply cutting oil to valve seat and cutter.
Cylinder Head Reconditioning 3. Place 46o cutter on the pilot and make a light cut.

NOTE: Servicing the valve guides and valve seats


requires special tools and a thorough knowledge of
reconditioning techniques. Follow the instructions

3.21
ENGINE
4. Inspect the cut area of the seat. • If the indicated seat contact is at the top edge of
the valve face and contacts the margin area(B) it is
• If the contact area is less than 75% of the too high on the valve face. Use the 30o cutter to
circumference of the seat, rotate the pilot 180o and lower the valve seat.
make another light cut.
• If too low use the 60o or 75o cutter to raise the
• If the cutter now contacts the uncut portion of the seat. When contact area is centered on the valve
seat, check the pilot. Look for burrs, nicks, or face, measure seat width.
runout. If the pilot is bent it must be replaced.
• If the seat is too wide or uneven, use both top and
• If the contact area of the cutter is in the same bottom cutters to narrow the seat.
place, the valve guide is distorted from improper
installation and must be replaced. Be sure the • If the seat is too narrow, widen using the 45o cutter
cylinder head is at the proper temperature and and re-check contact point on the valve face and
replace the guide. seat width after each cut.
• If the contact area of the initial cut is greater than Bottom 60o or 75o Seat - 45o or 46o
75%, continue to cut the seat until all pits are
removed and a new seat surface is evident. Top - 30o
NOTE: Remove only the amount of material
necessary to repair the seat surface.
5. To check the contact area of the seat on the valve face, apply
a thin coating of Prussian Blue™ paste to the valve seat. If
using an interference angle (46o)apply black marker to the
entire valve face (A).

(A)
NOTE: When using an interference angle, the seat
contact point on the valve will be very narrow, and is a
normal condition. Look for an even and continuous
contact point on the black marker, all the way around the
valve face.

6. Insert valve into guide and tap valve lightly into place a few
times.
7. Remove valve and check where the Prussian Blue™ or
black marker indicates seat contact on the valve face. The Seat
valve seat should contact the middle of the valve face or Width
slightly above, and must be the proper width (A).
(B)

(A)
8. Clean all filings from the area with hot soapy water, rinse,
and dry with compressed air.
9. Lubricate the valve guides with clean engine oil, and apply
oil or water based lapping compound to the face of the
valve. Lapping is not required with an interference angle.
10. Insert the valve into its respective guide and lap using a
Proper Seat Contact On Valve Face lapping tool or a section of fuel line connected to the valve
stem.

3.22
ENGINE
11. Rotate the valve rapidly back and forth until the cut sounds Cylinder Head Assembly
smooth. Lift the valve slightly off of the seat, rotate 1/4 turn,
and repeat the lapping process. Do this four to five times
until the valve is fully seated, and repeat process for the CAUTION
other valve.
12. Clean cylinder head, valves, and camshaft oil supply Wear eye protection during assembly.
passages thoroughly.
NOTE: Assemble the valves one at a time to maintain
13. Spray electrical contact cleaner into oil passages and dry proper order.
using compressed air.
1. Install new valve seals on valve guides.

2. Apply engine oil to valve guides and seats.


3. Coat valve stem with molybdenum disulfide grease.
4. Install valve carefully with a rotating motion to avoid
damaging valve seal.
5. Dip valve spring and retainer in clean engine oil and install
spring with closely spaced coils toward the cylinder head.

Closely spaced
coils toward
cylinder head

3.23
ENGINE
6. Place retainer on springs and install valve spring Cam Chain Guide And Tensioner Blade
compressor. Compress spring only enough to allow split
keeper installation and prevent loss of spring tension. 1. The guide can be removed after cylinder head is removed
Install split keepers with the gap even on both sides. by pulling it upward out of the channel in the crankcase.

7. Repeat procedure for remaining valve. 2. Remove blade and inspect. Replace if worn., cracked, or
damaged.
8. When all valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the Split keepers. 3. Tensioner blade removal requires recoil, flywheel, and
stator plate removal. Refer to lower end service procedures
Valve Sealing Test to access the bolt securing the tensioner blade to the
crankcase.
1. Clean and dry the combustion chamber area.
2. Pour a small amount of cleaning solvent into each port and
check for leakage around each valve. The valve seats
should hold fluid with no seepage.

Engine Bottom End Disassembly


Cylinder Removal

Follow engine disassembly procedures to remove valve cover,


camshaft and rocker arms, and cylinder head.

1. Lift to remove cam chain guide at front of cylinder.


2. Remove the two 6 mm cylinder base bolts.

3. Tap cylinder lightly with a plastic hammer in reinforced


areas only until loose.
4. Rock cylinder forward and backward and lift it from the
crankcase, supporting piston and connecting rod. Support
piston with Piston Support Block (PN 2870390).

3.24
ENGINE
Piston Removal Cylinder Inspection
1. Remove one circlip. Note valve pocket on intake side of 1. Remove all gasket material from the cylinder sealing
piston for installation. surfaces.
2. Remove piston circlip and push piston pin out of piston. If 2. Inspect the top of the cylinder for warpage using a straight
necessary, heat the crown of the piston slightly with a edge and feeler gauge.
propane torch. CAUTION: Do not apply heat to the piston
rings. The ring may lose radial tension.

= In. / mm.
3. Remove the compression rings, starting with the top ring. Cylinder Warp:
.002” (.05 mm) MAX
*Using a piston ring pliers: Carefully expand ring and
lift it off the piston. CAUTION: Do not expand the ring 3. Inspect cylinder for wear, scratches, or damage.
more than the amount necessary to remove it from the 4. Inspect cylinder for taper and out of round with a
piston, or the ring may break. telescoping gauge or a dial bore gauge. Measure in two
different directions, front to back and side to side, on three
*By hand: Placing both thumbs at end gap, carefully spread the different levels (1/2” down from top, in the middle, and 1/
ring open and lift ring over piston at the opposite side. Use care 2” up from bottom).
to not scratch the ring lands. 1/2” Down From Top of Cylinder
4. Repeat procedure for second ring. X Y
5. The oil control ring is a three piece design consisting of a
top and bottom steel rail and a center expander section.
Remove the top rail first followed by the bottom rail and Y
expander. X

Y
X

1/2” Up From Bottom


5. Record measurements. If cylinder is tapered or out of round
beyond specification, the cylinder must be honed, bored or
replaced.

= In. / mm.

Cylinder Taper / Cylinder Out of Round


Limit: .002” (.05 mm) Max.

3.25
ENGINE
Cylinder Hone Selection/ Honing Procedure If cylinder wear or damage is excessive, it will be necessary to
replace the cylinder. Hone only enough to deglaze the outer
layer of the cylinder bore.
CAUTION

A hone which will straighten as well as remove


material from the cylinder is very important. Using a
common spring loaded glaze breaker for honing is
not advised. Polaris recommends using a rigid hone
or arbor honing machine.

Cylinders may be wet or dry honed depending upon the hone


manufacturer’s recommendations. Wet honing removes more
material faster and leaves a more distinct pattern in the bore.

EXAMPLE OF CROSS HATCH PATTERN


Honing To Deglaze
Piston Inspection
A finished cylinder should have a cross-hatch pattern to ensure
piston ring seating and to aid in the retention of the fuel/oil 1. Measure piston outside diameter at a point 7 mm up from
mixture during initial break in. Hone cylinder according to hone the bottom of the piston at a right angle to the direction of
manufacturer’s instructions, or these guidelines: the piston pin.

• Use a motor speed of approximately 300-500


RPM, run the hone in and out of the cylinder
rapidly until cutting tension decreases. Remember 7mm
to keep the hone drive shaft centered (or cylinder
centered on arbor) and to bring the stones
approximately 1/2” (1.3 cm) above and below the
bore at the end of each stroke.
• Release the hone at regular intervals and inspect Piston
the bore to determine if it has been sufficiently Piston Pin
deglazed, and to check for correct cross-hatch.
NOTE: Do not allow cylinder to heat up during
honing.
2. Subtract this measurement from the maximum cylinder
• After honing has been completed, THOROUGHLY measurement obtained earlier.
clean the cylinder to remove all honing residue.
IMPORTANT: Clean the Cylinder After Honing
= In. / mm.
Wash the cylinder in a solvent, then in hot, soapy water. Use
electrical contact cleaner if necessary to clean areas that cannot
be scrubbed. Rinse thoroughly, dry with compressed air, and oil Piston to Cylinder Clearance
the bore immediately with Polaris 4 Cycle Lubricant to prevent Std: .0015- .0032” (0.038- 0.082 mm)
the formation of surface rust. Limit: .0043” (.11 mm)

3. Measure piston pin bore. Replace piston if out-of-round.

Piston Pin Bore

3.26
ENGINE
4. Measure piston pin O.D. Replace piston pin if out-of-round. Piston Ring Installed Gap
1. Place each piston ring inside cylinder using piston to push
ring squarely into place as shown.
Piston ring installed end gap

Feeler Gauge

Piston Pin Measurement Locations Cylinder 25-50 mm 3


5. Measure connecting rod small end ID. Replace crankshaft
if out-of-round.
Piston Ring

= In. / mm.

Piston Ring Installed Gap

Top Ring
Std: .008- .012” (.2- .3 mm)
Limit: .032” (0.8 mm)
Second Ring
6. Measure piston ring to groove clearance by placing the ring Std: .014- .020” (0.35- 0.50 mm)
in the ring land and measuring with a thickness gauge. Limit: .039” (1.0 mm)
Replace piston and rings if ring-to-groove clearance Oil Ring
exceeds service limits. Std: .008- .028” (0.2- 0.7 mm)
Limit: .059” (1.5 mm)

Piston 2. Measure the gap with a feeler gauge at both the top and
bottom of the cylinder.
Ring
NOTE: Measure at two points in the cylinder A
difference in end gap indicates cylinder taper. The
cylinder should be measured for excessive taper and out
of round.
Feeler Gauge
3. If the installed gap measurement exceeds the limit, replace
the rings. If using new rings and the measurement is too
small, file the ring ends to achieve the proper gap.
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 an oil rag immediately to remove residue and
prevent rust.

3.27
ENGINE
Flywheel Removal / Inspection Starter Drive Clutch Removal/Inspection
1. Remove the recoil housing, recoil hub, and flywheel nut. 1. Remove recoil housing bolts and remove housing.
2. Remove the starter drive clutch and washer by pulling the
shaft and tilting the gear slightly.

2. Install Flywheel Puller (PN PA-47308) and remove


flywheel. CAUTION: Do not hammer or strike the tool
while attached to the crankshaft end.

3. Measure the O.D. of the starter drive shaft on both ends for
out-of-round.
4. Measure the I.D. of the bushings in the recoil housing and
in the crankcase (A) in two directions 90o apart to determine
if out-of-round. Replace worn bushings.

5. Inspect gear teeth on starter drive. Replace starter drive if


gear teeth are cracked, worn, or broken.

3.28
ENGINE
Cam Chain Drive Sprocket Removal / Oil Pump Inspection / Removal
Inspection
NOTE: Mark the oil pump geroters to keep parts mated
1. Remove recoil housing, flywheel, flywheel key, and for assembly.
stator.
1. Remove recoil housing, flywheel, flywheel key, and
stator.
2. Use a feeler gauge to check oil pump rotor tip clearance at
“A”, and pump body clearance at “B”. Compare to
specifications. Replace the oil pump assembly if any parts
are damaged, scored, or measure beyond the service limit.
3

A
B
2. Using the Slotted Nut Socket, remove the crankshaft slotted
nut by turning it clockwise. NOTE: Slotted nut is left hand
thread.

3. Mark the oil pump geroters and shaft and carefully lift the
geroters from the housing.

REMOVE

Slotted Nut Socket


(PN 2871293-A)

3. Remove cam chain drive sprocket and Woodruff key from


crankshaft.
4. Inspect sprocket teeth for wear or damage.

Visually inspect for


tooth wear or damage

5. Inspect Woodruff key for wear.

3.29
ENGINE
Starting Clutch And Engine Braking Clutch 5. Open the staked portion of the nut (A) with a center punch.
Removal /Inspection Inspect the one-way clutch hub surface on the starting
clutch (B). The hub must be smooth without any nicks or
NOTE: The transmission must be removed from the burrs. Replace the starting clutch assembly if the one-way
engine to access the starting clutch and one-way clutch hub is uneven or damaged
engine braking clutch.
Inspect entire surface of
1. Inspect the starting clutch drum bearing in the housing. one-way clutch hub.
The shaft must turn smoothly (by hand) without binding B
in the clockwise direction, and should not turn by hand in
the counter clockwise direction. Minimal movement in the
shaft is NORMAL with engine removed due to the lack of
clutch cover bearing support on the free end of the shaft
(approximately 0-.060” (0-1.5mm). Press the shaft out of A
the housing and replace the bearing if worn or rough.
DO NOT LIFT ENGINE WITH
CLUTCH SHAFT

6. Install the starting clutch holder (PA-47457) onto the


A starting clutch and engage the tabs (C).
B
C

2. Remove all screws from the starting clutch housing.


3. Remove the one-way clutch from the starting clutch drum
with a twisting motion. Note direction of installation with
flange toward drum for assembly.
7. Remove the nut (counterclockwise). This is a standard
thread.
Inspect Drum For
Wear or Damage

Flange toward drum

4. Inspect the one-way clutch closely for cracks or damage on


the one-way bearing shoes and the cage.

8. Inspect the shoes and springs of the starting clutch. Measure


the thickness of the friction material on the shoes as shown,
from the bottom of the friction material to the top at the

3.30
ENGINE
thinnest point. 9. Install one-way clutch in starting clutch drum with the
flanged side toward the hub, using a rotating motion.
Standard Thickness: .100” (2.54mm)
LIMIT: .039” (1.00mm)

Flange side toward hub


3

Starting Clutch Assembly


1. Clean the mating surfaces of the crankcase and clutch 10. Install a new housing gasket.
starting clutch housing to remove all gasket material.
11. Install the drum / housing assembly onto the case, install the
2. Install the starting clutch on the shaft. housing bolts and torque in two steps using a cross pattern
3. Start a NEW stake nut on the shaft. to specification.

4. Install the starting clutch holder on the clutch.


=T
5. Torque the nut to specification.
Starting Clutch Drum Housing:
=T 14-15.5 ft. lbs. (19-21 Nm)

12. CHECK the clutch shaft to be sure it rotates smoothly in


Starting Clutch Stake Nut:
the clockwise direction and will not rotate in the
103-118 ft. lbs. (140-160 Nm)
counterclockwise direction. If binding is evident, or if the
6. Use a center punch or a pin punch to thoroughly stake the shaft rotates in both directions (without turning the engine
nut at the depression in the shaft. over) disassemble and inspect the one-way clutch and hub.

Crankcase Disassembly
7. If drum bearing was replaced in the starting clutch housing, NOTE: Engine must be removed from the frame to
press the drum/shaft into the housing until fully seated. perform any crankcase or crankshaft removal.
8. Clean the inside of the starting clutch drum and lubricate NOTE: The starter, starter drive, flywheel, stator, oil
the drum and one-way clutch with engine oil. pump and transmission can be serviced with the
engine in the frame.
3.31
ENGINE
Crankcase Separation crankshaft, or balance shaft. See procedure this
chapter.
NOTE: Stator housing, flywheel and gears have are
previously removed for this procedure. Use care during
the removal process to avoid damage to the cam chain.

NOTE: Valvetrain and cylinder removal must be


performed prior to this procedure.

1. Remove all bolts and the pressure relief valve (A) from the
magneto side crankcase.

Crankshaft / Cam Chain / Sprocket


Inspection
A 1. Inspect the crankshaft main bearings for wear or damage.

2. Tap carefully on reinforced areas of the cases to separate


the halves. Watch the gap along the crankcase mating
surface and separate the crankcase evenly.
3. Lift the right case half off of the left, leaving the crankshaft
and balance shaft in the left case.

NOTE: Due to extremely close tolerances and minimal


movement, the ball bearings must be inspected visually,
and by feel. Look for signs of discoloration, scoring or
galling. Turn the outer race of each bearing. The
bearings should turn smoothly and quietly. The inner
race of PTO bearing each bearing should fit tightly on the
crankshaft. The outer race should be firm with minimal
side to side movement and no detectable up and down
movement. The MAG end bearing usually stays in the
case. Check the inner race of the MAG bearing in the
same manner.
Crankshaft Removal 2. Replace the main bearings if the components fail visual
1. Lift the crankshaft and balance shaft from the left case. inspection.

2. Note the number and thickness of any shims installed on 3. The connecting rod utilizes a roller bearing. Clearance can
either shaft. be measured with a dial indicator to check radial clearance.
Visually inspect the connecting rod, crank pin, and thrust
NOTE: Crankshaft and balance shaft end play must washers for scoring, damage, excessive wear, or signs of
be measured and adjusted with shims if any new overheating. Check for roughness or noise when rotating
components are installed (bearings, crankcase, the connecting rod on the crank pin. Replace crankshaft if
it fails visual inspection, or if any up and down movement

3.32
ENGINE
is detectable in the connecting rod. Camshaft Chain
1. Replace the cam chain as part of any crankshaft repair.
2. The cam chain can be removed by removing the engine top
end, the recoil assembly, flywheel and flywheel key, stator
plate, and slotted nut.
3. Lift the sprocket slightly until chain clears the crankcase to
remove.

ote: Install new chain as a part of crankshaft repa


3
= In. / mm.

Connecting Rod Big End Radial Clearance:


.0004-.0014” (.011-.038 mm)
LIMIT: .0019” (.05mm)

4. Check connecting rod side clearance with a feeler gauge.


5. Refer to piston inspection in this chapter to inspect the
connecting rod small end.
Balance Shaft Bearing Inspection
NOTE: Replace all seals whenever the crankcase is
= In. / mm. disassembled.

Connecting Rod Side Clearance: 1. Inspect the balance shaft bearings in the crankcase.
.0035-.0196” (.09-.50mm) NOTE: Due to extremely close tolerances and minimal
Limit: .023” (.60mm) movement, the bearing must be inspected visually and
by feel. Look for signs of discoloration, scoring or galling.
6. Clean crankshaft oil passages by running a stream of clean Turn the inner race of bearing. The bearing should turn
solvent through the crankshaft. Be sure all passages are smoothly and quietly. The outer race should fit tightly in
clear and free of nicks or scratches. the crankcase. The inner race should be firm with
minimal side to side movement and no detectable up and
Crankcase Oil Passages & Pressure Relief down movement.
Valve
2. To remove balance shaft bearings, use a blind hole bearing
1. Remove the pressure relief valve assembly from the case.
puller.
NOTE: Bearings are stressed during the removal
procedure and should not be re-used.

2. Clean crankcase oil passages with clean solvent.

3.33
ENGINE
Crankcase Oil Pickup Strainer Inspection End Play Inspection/Adjustment
Before reassembling the crankcase, the following steps should
be performed to determine the amount of crankshaft, counter
balancer shaft, and pump shaft end play. Excessive end play may
cause engine noise at idle and slow speeds. Too little play will
side load the bearings which may lead to premature bearing
failure.

Crankshaft End Play Adjustment


NOTE: The method described here is shown with
the PTO main bearing on the crankshaft, which is the
most common situation. If the bearing is in the case,
A the procedure is the same, but the photo examples
will differ.
1. Pull the strainer screen (A) from the case carefully and
1. Make sure all bearings are firmly seated in the crankcase.
clean or replace it if heavily clogged, or if damaged.

Bearing /Seal Installation


NOTE: To ease crankcase bearing installation, warm
the crankcase until hot to the touch. Placing the bearing
in a freezer prior to installation will assist the assembly
process.

1. Install the bearing so the numbers are visible.


2. Drive or press the new bearing into the crankcase, using the
proper driver.

CAUTION 2. Lay a straightedge on the left (PTO) crankcase and measure


the distance from the straightedge to the bottom of the main
Press only on outer race of bearing to prevent bearing bore (if bearing is still on the crankshaft) or to the
bearing damage. bearing race (if the bearing is installed in the case) using a
dial caliper.
3. Install new seals with the lip facing in.

CAUTION

Press only on outer diameter to prevent damage.

3.34
ENGINE
3. Subtract the thickness of the straightedge from the 6. Add the readings recorded in Step 3 and Step 5 and record
measurement obtained in Step 2 and record. below.

Total Case Width_________________

7. Measure the width of the crankshaft at the bearing seats (or


to the outside of bearing if bearing is on the crankshaft as
shown) with a micrometer or dial caliper and record.

PTO Case Depth_________________________

4. Measure the distance from the Magneto crankcase mating


surface to the main bearing using the same method and
record.
Crankshaft Width____________

8. Subtract the Crankshaft Width measured in Step 7 from the


Total Case Width recorded in Step 6, and record below.

Total End Play_____________

9. Subtract the thickness of the existing shim from the result


of Step 8 to determine if a different shim is required. The
result must be within the specified range listed below.

5. Subtract the thickness of the straightedge from the


measurement obtained in Step 4 and record.

= In. / mm.

Crankshaft End Play:


.006-.012” (.15-.30 mm)

Mag Case Depth_______________

3.35
ENGINE
Balancer Shaft End Play Adjustment 7. Subtract the thickness of the existing shim from the result
of Step 6 to determine if a different shim is needed. The
NOTE: The balancer shaft end play measurement result must be within the specified range listed at below.
procedure is the same as that outlined for the
crankshaft. The exception is that measurements are 8. Add or subtract shims or change shim thickness as required
taken to the balancer shaft bearings in the case, and install them upon assembly.
rather than the crankshaft main bearings, and the
width of the balancer shaft is measured, not the
crankshaft. = In. / mm.
1. Make sure the counter balance shaft bearings are firmly
Counter Balance Shaft End Play:
seated in each crankcase.
.004”-.029” (.1-.74 mm)
Measure to balance shaft bearing race

Crankcase Reassembly
Crankshaft Installation

Lubricate all bearings with clean engine oil before assembly. Be


sure crankcase mating surfaces are clean and free from oil or
grease.

1. Place the required shims on the crankshaft and balance


2. Measure the distance from the Mag crankcase mating shaft.
surface to the balance shaft bearing using a dial caliper and
a straight edge. Subtract the thickness of the straightedge
and record.

MAG Case Depth_________________________

3. Measure the distance from the PTO crankcase mating


surface to the bearing using the same method outlined for
the MAG side.

PTO Case Depth_________________________

4. Measure the width of the counter balancer shaft at the


bearing seats with a dial caliper or micrometer, and record
reading. 2. Support the PTO side crankcase on blocks. Install the
crankshaft and balance shaft in the case, aligning the
balance dots on the gears.

5. Add the readings obtained in Step 2 and Step 3.


6. Subtract the counter balancer shaft width measured in Step
4 from the result obtained in Step 5.

3.36
ENGINE
3. Be sure balance dots on gear teeth are aligned. Cam Chain, Oil Pump, & Tensioner Blade
Installation
1. Install the cam chain over the drive sprocket.
2. Lubricate and install the oil pump geroters, aligning the
marks made during disassembly. Clean the marks off the
geroters.

4. Apply a thin coat of crankcase sealant to the outer mating


surface of the left crankcase. Sealant is not required on the
inner mating surfaces (A).
Geroters
A
3. Install the tensioner blade and tighten the mounting bolt to
specified torque.

Crankcase Sealant
PN 2871557

5. Install the mag side case and tap with a soft faced hammer
to seat.
6. Install case screws and torque in a cross pattern to
specification. =T
Tensioner Blade Mounting Bolt Torque:
5-6.5 ft. lbs. (7-9 Nm)

4. Install a new O-ring on the stator plate.


5. Lubricate the stator plate seal and bushing with engine oil
and install the stator plate.

=T
Crankcase Bolt Torque:
6.5-8.0 ft. lbs. (9-11 Nm)

3.37
ENGINE
6. IMPORTANT! Be sure the sealed screw is placed in the 5. Install the top ring with the marking facing up. The top ring
hole that aligns with the cam chain cavity or an oil leak may has an inner bevel with a barrel face.
result. If you are installing the old screw, seal it with Loctite Top Ring:
242 (blue) before installation. Bevel on Inner Edge Install with
mark UP
This screw must be sealed

Second Ring
Mark Faces UP

6. Verify proper installation of rings by checking to be sure


the top and second rings rotate freely in the groove when
compressed by hand.
7. Torque the screws to specification.
Piston Installation
=T
CAUTION
Stator Plate Screw Torque:
6.5-8.0 ft. lbs. (9-11 Nm) Do not re-use circlips. Circlips become deformed
during the removal process. Do not compress the
8. Install the flywheel key and flywheel. new clip more than necessary to prevent loss of
radial tension. Severe engine damage may result if
=T circlips are re-used or deformed during installation.

Flywheel Nut: 1. Install a new circlip on one side of the piston with the end
67-81 ft. lbs. (90-110 Nm) gap facing up or down.
Recoil Drive Hub: 2. Apply clean engine oil to the piston rings, ring lands, piston
12-14 ft. lbs. (17-19 Nm) pin bore, piston pin, and piston skirt. Lubricate the
connecting rod (both ends) and crankshaft main bearing
Piston Ring Installation area.

NOTE: Apply clean engine oil to all ring surfaces and 3. IMPORTANT- Install the piston on the connecting rod
ring lands. Always check piston ring installed gap before with the valve pocket facing the intake side of engine.
rings are installed on piston. If the piston has been in The piston pin should be a push fit into the piston.
service, clean any accumulated carbon from the ring Pocket
grooves and oil control ring holes.
1. Place the oil control ring expander in oil ring groove with
the end gap facing forward. The expander has no up or
down marking and can be installed either way. The ends
should butt squarely together and must not overlap.
2. Install the oil ring top rail with the end gap at least 30o from
the end of the expander.
3. Install the bottom rail with the gap at least 30o from the end
of the expander on the side opposite the top rail gap.
4. Install the second ring with the mark facing up. The second 4. Install the other circlip with the gap facing up or down. Push
ring has an undercut with a tapered face. Position the end the piston pin in both directions to make sure the clips are
gap toward the rear (intake) side of the piston. properly seated in the groove.

3.38
ENGINE
5. Lubricate the piston and rings with engine oil and install a 5. Loop the cam chain through the cylinder chain room and
ring compressor on the piston assembly. Verify that the ring secure with mechanic’s wire.
gaps are 120o - 180o apart from each other before
installation.

Cylinder Installation
NOTE: Clean the gasket surfaces on the crankcase and
cylinder. Remove all traces of old gasket material or
sealant. The surfaces must be oil-free!

1. Apply a small amount of crankcase sealant at the case


parting lines (A). Do not allow sealant to dry. Assemble 3
the top end immediately.

6. Install cylinder carefully with a front to back rocking


motion until rings are fully captive in the sleeve, then
remove the compressor and support block.
7. Seat the cylinder firmly onto the base gasket.
A
8. Install the cam chain guide and dowel pins into the cylinder.
Verify the bottom end of the guide is seated properly in the
crankcase.

2. Install the dowel pin(s).


3. Install a new base gasket onto the mating surface and
position the Piston Support Block (PN 2870390) beneath
the piston skirt to support the piston during cylinder
installation.
4. Apply clean engine oil liberally to the bore and tapered area
of the cylinder. Place the cylinder on to the studs.
NOTE: Route cam chain through the cylinder chain
room and secure it, holding it up to avoid damage to the
chain, drive sprocket teeth or tensioner blade.

3.39
ENGINE
Cylinder Head and Camshaft Installation 6. Torque the cylinder head following the procedure and
pattern below.
NOTE: Clean the gasket surfaces on the cylinder head
and cylinder. Remove all traces of old gasket material. Cylinder Head / Cylinder Base
The surfaces must be oil-free!

1. Install the dowel pin(s) and a new cylinder head gasket. 3 2


5
2. Pull the cam chain through the cylinder head chain room 6 mm
and secure with mechanic’s wire. 6
3. Place the cylinder head on the cylinder. 1 4

4. Install the two 6 mm bolts on cylinder base and on the head, Forward
but do not tighten.
=T
Cylinder Gasket Torque Sequence:
Tighten M10 bolts to 18.5 ft. lbs. (25 Nm)
Loosen 180 degrees
Tighten to 11 ft. lbs. (15 Nm)
Tighten M10 bolts 90 degrees
Tighten M10 bolts another 60 degrees
Tighten 6mm bolts to 8 ft.lbs.(11 Nm)

Camshaft Installation & Timing

CAUTION
5. Lubricate the washers and the threads of the cylinder head
bolts and install the bolts with washers. Serious engine damage will result if the camshaft is
not properly timed to the crankshaft.

IMPORTANT CAMSHAFT TIMING NOTE: In order to


time the camshaft to the crankshaft, the piston must be precisely
located at Top Dead Center (TDC). If flywheel key and flywheel
are not installed, install them at this time. The recoil housing
must also be temporarily installed to use the timing inspection
hole.

1. Rotate the crankshaft until the “T” (Top Dead Center)


timing mark on the flywheel is aligned with the mark in the
timing inspection window of the recoil housing. Be sure to
use the correct mark when installing the cam. Do not use
any advance timing marks.

3.40
ENGINE
2. Apply engine oil or starter drive grease (molybdenum 8. Verify all marks are aligned. Install the cam sprocket bolt
disulfide paste) to the camshaft main journals and cam and torque to specification.
lobes. Lubricate automatic compression release
mechanism with clean engine oil.
=T
Starter Drive Grease: Camshaft Sprocket Bolt
(PN 2871460) 35.5-50 ft. lbs. (48-70 Nm)

3. Orient the camshaft with the lobes facing downward, and Cam Chain Tensioner Installation
install the cam into the cylinder head.
1. Hold the tensioner ratchet pawl (A) open and push the
plunger (B) in to the fully retracted position. 3
A
B

4. Disconnect the wire or tie strap securing the cam chain (if
used).
5. Be sure the pin on the camshaft is pointing DOWN. 2. With the plunger retracted, install the tensioner assembly
with a new gasket and tighten the bolts to specification.
6. Loop the cam chain over the sprocket and shift the chain
on the sprocket until it can be installed onto the camshaft.

A
B

B
A

=T
7. VERIFY the following: Tensioner Bolt Torque: 5-6.5 ft. lbs. (7-9 Nm)
• “T” Mark on flywheel is aligned with the 3. Install the pin, spring, and tensioner cap with a new sealing
projection in the timing hole of the recoil
housing. washer. Torque cap to specification.

• The mark (A) on the camshaft sprocket is


aligned with the projection (B) in the camshaft =T
cover window as shown above.
Tensioner Cap Torque: 6-7.5 ft. lbs. (8-10 Nm)

3.41
ENGINE
4. Slowly rotate engine two to three revolutions in the Starter Drive Assembly
direction of rotation and re-check cam timing.
1. Be sure the washer is positioned on the back of the drive
Rocker Arm Installation gear.

1. Lubricate the rocker arms and shaft with engine oil. Apply
a light film of starter grease (moly grease) to the cam
follower pad on the rocker arms.

Starter Drive Grease:


(PN 2871460)

2. Slide the shaft through the tower just enough to install the
wave washer (A).
NOTE: The flats of the wave washer are positioned
against the intake rocker arm.

Starter Drive Grease:


(PN 2871460)

2. Apply Starter Drive Grease (PN 2871460) to the drive


bushings in the cases and all moving surfaces of the starter
drive gears and install.
3. Install recoil housing and torque bolts to specification.

3. Install the rocker arms in the same position as marked


during disassembly.

4. Turn the engine through several revolutions to be sure parts


rotate freely and smoothly.
5. Adjust valve clearance as outlined in Chapter 2.

3.42
ENGINE
TROUBLESHOOTING Engine Does Not Turn Over

Spark Plug Fouling troubleshooting • Dead battery

• Restricted air filter (main or pre-cleaner), or air • Starter motor does not turn
inlet ducts. • Engine seized, rusted, or mechanical failure
• Choke cable adjustment or plunger/cable sticking
Engine Runs But Will Not Idle
• Foreign material on choke plunger seat or plunger
• Idle speed set too low
• Incorrect spark plug heat range or gap
• Faulty ETC system
• Jet needle and/or needle jet worn or improperly
adjusted • Restricted carburetor pilot system 3
• Excessive carburetor vibration (check all engine • Carburetor misadjusted
and carburetor mounts)
• Choke not adjusted properly or sticking plunger
• Oil contaminated with fuel
• Low compression
• ETC switch mis-adjusted
• Crankcase breather restricted
• Low compression
• Air filter restriction
• Spark plug cap loose or faulty
Engine Idles But Will Not Rev Up
• Loose jets in carburetor or calibration incorrect for
altitude/temperature
• Spark plug fouled/weak spark
• Incorrect float level setting
• Broken throttle cable
• Carburetor inlet needle and seat worn
• Obstruction in air intake
• CVT system calibrated incorrectly or components
worn or mis-adjusted • Air box removed (reinstall all intake components)

• Fuel quality poor (old) • Incorrect or restricted carburetor jetting

• Restricted exhaust • ETC switch limiting speed

• Restricted crankcase breather system • Reverse speed limiter limiting speed

• Weak ignition (loose coil ground, faulty coil, stator, • Carburetor vacuum slide sticking/diaphragm
engine to chassis ground, or ETC switch) damaged

• Improperly assembled air intake system • Incorrect ignition timing


• Restricted exhaust system
ENGINE Troubleshooting
• Camshaft lobes worn
Engine Turns Over But Fails to Start
• Flywheel key sheared
• No fuel
Engine Has Low Power
• Dirt in fuel line or filter
• Spark plug fouled
• Fuel will not pass through fuel valve
• Cylinder, piston, ring, or valve wear or damage
• Fuel pump inoperative/restricted (check compression)
• Fuel tank vent plugged • CVT not operating properly
• Carburetor starter circuit restricted • Restricted exhaust muffler
• Engine flooded • Dirty carburetor
• Low compression (high cylinder leakage) • Cam lobe worn
• No spark (Spark plug fouled)

3.43
ENGINE
Piston Failure - Scoring Backfiring

• Lack of lubrication • ETC or speed limiter system malfunction


• Dirt entering engine through cracks in air filter or • Fouled spark plug or incorrect plug or plug gap
ducts
• Carburetion faulty - lean condition
• Engine oil dirty or contaminated
• Intake / Exhaust system air leaks
Excessive Smoke and Carbon Buildup
• Ignition system faulty:
• Oil level too high •Spark plug cap cracked/broken
• Excessive piston-to-cylinder clearance •Ignition coil faulty
• Worn rings, piston, or cylinder •Ignition or kill switch circuit faulty
• Worn valves, guides or seals •Ignition timing incorrect
• Restricted crankcase vent •Sheared flywheel key
• Air filter dirty or contaminated • Poor connections in ignition system
Low Compression • System wiring wet
• Decompressor stuck • Cam lobe worn or Valve sticking
• Cylinder head gasket leak