Polaris SPORTSMAN 600 2003 Service Manual
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Polaris SPORTSMAN 600 2003 Service Manual

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2003 SPORTSMAN 600
2002 - 2003 SPORTSMAN 700
SERVICE MANUAL
PN 9918066

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Summary of Contents for Polaris SPORTSMAN 600 2003

  • Page 1 2003 SPORTSMAN 600 2002 - 2003 SPORTSMAN 700 SERVICE MANUAL PN 9918066...
  • Page 2 NOTE: A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm.
  • Page 3 2002 Sportsman 600/700 ATV Service Manual (PN 9918066) ECopyright 2002 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor descrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 4: Table Of Contents

    CHAPTER INDEX CHAPTER 1 GENERAL CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE CHAPTER 4 FUEL SYSTEM CHAPTER 5 BODY/SUSPENSION CHAPTER 6 PVT SYSTEM CHAPTER 7 FINAL DRIVE CHAPTER 8 TRANSMISSION CHAPTER 9 BRAKES CHAPTER 10 ELECTRICAL...
  • Page 5 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION Model Identification ..... . . Serial Number Location ....2003 Sportsman Models .

  • Page 6: General Information

    GENERAL INFORMATION MODEL IDENTIFICA TION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 0 3 C H 6 8 A A Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation ENGINE DESIGNATION NUMBERS...
  • Page 7 GENERAL INFORMATION GENERAL INFORMATION 2003 SPRORTSMAN 600 & 700 MODELS SPORTSMAN 600 SPORTSMAN 700 NOTE: MODELS WILL VARY IN COLOR.
  • Page 8 GENERAL INFORMATION MACHINE DIMENSIONS FRONT 46 in 116.84 cm 85 in 215.90 cm SIDE 50.75 in 128.90 cm...
  • Page 9 GENERAL INFORMATION GENERAL INFORMATION MACHINE DIMENSIONS 46 in 116.84 cm 47 in 119.38 cm 11 in 27.94 cm REAR 46 in 116.84 cm...
  • Page 10 GENERAL INFORMATION GENERAL INFORMATION 2002 SPORTSMAN 700 MODEL: ..MODEL NUMBER: A02CH68AA/CA ENGINE MODEL: EH68ALOE1 JETTING CHART AMBIENT TEMPERATURE Altitude ltitude CARBURETION Below 40°F Below 40 F +40_F and above +40 F and above Below +5°C +5_C and above Type...
  • Page 11 LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant Electric Start ..Standard *PPS Polaris Premium Synthetic Gear Case Oi Instrument Cluster *PP4 Polaris 0W--40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS...

  • Page 12: 2003 Sportsman Models

    GENERAL INFORMATION 2003 SPORTSMAN 600 MODEL: ..MODEL NUMBER: A03CH59 ENGINE MODEL: EH059OLE JETTING CHART AMBIENT TEMPERATURE CARBURETION Altitude Altitude Below 40 F Below 40 F +40_F and above +40 F and above Below +5 C +5_C and above Type...
  • Page 13 LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant Electric Start ..Standard *PPS Polaris Premium Synthetic Gear Case Lube Instrument Cluster *PP4 Polaris 0W--40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS...
  • Page 14 GENERAL INFORMATION 2003 SPORTSMAN 700 MODEL: ..MODEL NUMBER: A03CH68 ENGINE MODEL: EH068OLE JETTING CHART AMBIENT TEMPERATURE CARBURETION Altitude Altitude Below 40 F Below 40 F +40_F and above +40 F and above Below +5 C +5_C and above Type...
  • Page 15 LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant Electric Start ..Standard *PPS Polaris Premium Synthetic Gear Case Lube Instrument Cluster *PP4 Polaris 0W--40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS...

  • Page 16: Publication Numbers

    9918213 9917718 9917719 When ordering service parts be sure to use the correct parts manual. PAINT CODES PAINTED PART COLOR DITZLER POLARIS DESCRIPTION NUMBER NUMBER Springs Black 9440 P-067 FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147.

  • Page 17: Standard Torque Specifications

    GENERAL INFORMATION GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.

  • Page 18: Decimal Equivalents

    GENERAL INFORMATION GENERAL INFORMATION DECIMAL EQUIVALENTS 1/64 ......0156 1/32 ....0312 .

  • Page 19: Conversion Table

    GENERAL INFORMATION GENERAL INFORMATION CONVERSION TABLE Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m x .7376 = ft.lbs.

  • Page 20: Decimal Equivalent Chart

    GENERAL INFORMATION GENERAL INFORMATION SAE TAP DRILL SIZES Thread Size Drill Size Thread Size Drill Size #0-80 3/64 1/2-13 27/64 #1-64 1/2-20 29/64 #1-72 9/16-12 31/64 #2-56 9/16-18 33/64 #2-64 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 3/4-10 21/32 #4-40 3/4-16 11/16 #4-48...

  • Page 21: Glossary Of Terms

    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 = 3/8² or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.
  • Page 22 Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch System) qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
  • Page 23 MAINTENANCE MAINTENANCE CHAPTER 2 MAINTENANCE Periodic Maintenance Chart ....2.2-2.3 Pre-Ride Inspection ..... . Recommended Lubricants and Capacities .

  • Page 24: Periodic Maintenance Chart

    Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 mph. Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. The following symbols denote potential items to be aware of during maintenance: H= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized Polaris dealer.

  • Page 25: Pre-Ride Inspection

    MAINTENANCE MAINTENANCE PERIODIC MAINTENANCE CHART, CONT. CHASSIS Item Maintenance Interval Remarks (Whichever comes first) Hours Calendar Miles (Km) " General Lubrication 50 hrs 3 months 500 (800) Lubricate All Fittings, Pivots, Cables, Etc. " Front Gearcase Lubricant 100 hrs 12 months 1000 (1600) Inspect Monthly;...

  • Page 26: Maintenance

    Brake Fluid Polaris DOT 3 Brake Fluid Fill to indicated level inside reservoir. 2.26 NOTE: Quick Reference Lubricants and maintenance product part numbers are listed on page 2.5...

  • Page 27: Engine

    MAINTENANCE MAINTENANCE POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS Part No. Description 2871954 Loctitet Threadlock 271 (36 ml.) (6 Count) Engine Lubricant 2870584 Loctitet 680-Retaining Compound (10 2870791 Fogging Oil (12 oz. Aerosol) ml.) 2871098 Premium 2 Cycle Engine Oil (Quart) (12...

  • Page 28: Special Tools

    MAINTENANCE MAINTENANCE SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN PV- -43527 Oil Filter Wrench 2870872 Shock Spanner Wrench 2, 5 8712100 or 8712500 Tachometer 2,10 2200634 Valve Seat Reconditioning Kit PU- -45257 Valve Spring Compressor PU- -45652 Valve Pressure Hose 2871043 Flywheel Puller...
  • Page 29 Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) © More often under severe conditions (operating in water or hauling heavy loads) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or ¢ Mobilegrease Special Ill.
  • Page 30 Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) © More often under severe conditions (operating in water or hauling heavy loads) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or ¢ Mobilegrease Special...
  • Page 31 G Check vent hose to be sure it is routed properly and unobstructed. G The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid. G The correct rear gearcase lubricant to use is Polaris Premium Gear Drive Fluid.

  • Page 32: Transmission Lubrication

    Catch and discard used oil properly. 3. Clean and reinstall the drain plug with a new sealing washer. Torque to specification. 4. Remove fill plug. 5. Add Polaris Premium Synthetic Gearcase View From Front Lubricant to proper level as described above. 6. Check for leaks.

  • Page 33: Brakes

    MAINTENANCE MAINTENANCE SHIFT LINKAGE INPSECTION 4. Turn handlebars from full right to full left. If idle speed increases at any point in the turning range, NOTE: Shift rod is preset at time of manufacture. inspect throttle cable routing and condition. Adjust cable tension as needed until lock--to--lock turning can be accomplished with no rise in Shift Linkage Rod...

  • Page 34: Idle Speed Adjustment

    MAINTENANCE MAINTENANCE Verify free play of 1/16--3/16” (1.6--4.76 mm) and 4. Set idle speed to 1100 RPM. Always check smooth operation of choke cable. throttle cable freeplay after adjusting idle speed and adjust if necessary. If smooth choke operation is not obtainable, inspect 5.

  • Page 35: Fuel System

    MAINTENANCE MAINTENANCE FUEL SYSTEM THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL (ETC SWITCH) ADJUSTMENT CONT’D WARNING 3. Start engine and set idle to specified RPM. Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel Adjuster Boot Lock- Boot...

  • Page 36: Vent Lines

    MAINTENANCE MAINTENANCE VENT LINES 3. Turn drain screw out two turns and allow fuel in the float bowl and fuel line to drain completely. Check fuel tank, oil tank, carburetor, battery and 4. Inspect the drained fuel for water or sediment. transmission vent lines...

  • Page 37: Battery Maintenance

    MAINTENANCE MAINTENANCE COMPRESSION TEST CONT’D BATTERY MAINTENANCE A cylinder leakdown test is the best indication of engine condition. Follow manufacturer’s instructions to perform a cylinder leakage test. (Never use high pressure leakage testers, as crankshaft seals may WARNING dislodge and leak). Battery electrolyte is poisonous.

  • Page 38: Electrical

    MAINTENANCE MAINTENANCE To remove the battery: 5. Measure gap with a wire gauge. Refer to specifications for proper spark plug type and gap. 1. Disconnect holder strap and remove cover. Adjust gap if necessary by bending the side 2. Disconnect battery negative (-) (black) cable first, electrode carefully.
  • Page 39 Do not add straight antifreeze or straight water to the system. Straight water or antifreeze may cause the system to freeze, corrode, or overheat. Polaris 60/40 Anti-Freeze / Coolant (PN 2871323) 2.17...

  • Page 40: Coolant Level Inspection

    Cover 1. Remove reservoir cap. Verify the inner splash cap vent hole is clear and open. 2. Fill reservoir to upper mark with Polaris Premium 60/40 Anti Freeze / Coolant (PN 2871323) or a Rack mixture of antifreeze and distilled water as required for freeze protection in your area.

  • Page 41: Air Box Sediment Tube Service

    MAINTENANCE MAINTENANCE AIR FILTER/PRE-FILTER NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before SERVICE reinstalling. It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty Filter Clamp conditions, replacement is required more often.

  • Page 42: Breather Filter

    MAINTENANCE MAINTENANCE 3. Reinstall drain plug. BREATHER HOSE 1. Be sure breather line is routed properly and secured in place. CAUTION: Make sure lines are not kinked or pinched. PVT DRYING & PVT DRAIN PLUG NOTE: If operating the ATV in or through water, be sure to check the PVT cover and other components for water ingestion.

  • Page 43: Engine Oil Level

    MAINTENANCE MAINTENANCE ENGINE OIL LEVEL side of the dipstick. Proper level indication is determined on the upper surface of the dipstick as it is being removed, regardless of the level marks being The 600/700 engine is a wet--sump engine, meaning on top or on bottom.
  • Page 44 12. Remove dipstick and fill sump with 2 quarts (1.9 l) periodically for loose fasteners, worn tie rod ends, and of Polaris Premium 4 Synthetic Oil (PN 2871281). damage. Also check to make sure all cotter pins are in place. If cotter pins are removed, they must not be re-used.

  • Page 45: Final Drive

    ( possible performed by an authorized Polaris MSD- -certi- loose wheel nuts or loose front hub fied technician when replacing worn or dam- components).
  • Page 46 MAINTENANCE MAINTENANCE WHEEL ALIGNMENT METHOD 1: STRAIGHTEDGE OR STRING Be sure to keep handlebars centered. See notes below. NOTE: String should just touch side sur- face of rear tire on each side of machine. Rear rim Measure measure- from string ment should to rim at be 1/16²...
  • Page 47 MAINTENANCE MAINTENANCE WHEEL ALIGNMENT TOE ALIGNMENT METHOD 2: CHALK ADJUSTMENT 1. Place machine on a smooth level surface. If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell 2. Set handlebars in a straight ahead position and you which tie rod needs adjusting.

  • Page 48: Exhaust Pipe

    Set the hand brake and block reservoir. the wheels to prevent roll back. Use Polaris DOT 3 Brake Fluid (PN 2870990). Failure to heed these warnings could result in serious personal injury or death.

  • Page 49: Brake Pad Inspection

    MAINTENANCE MAINTENANCE BRAKE PAD INSPECTION Auxiliary Foot Brake Pads should be changed when the friction material is Pedal worn to 3/64² (.1 cm), or about the thickness of a dime. Full Full Height Engagement Floor Board Surface 3/64² (.1cm) Minimum AUXILIARY BRAKE Thickness ADJUSTMENT (HYDRAULIC)

  • Page 50: Controls

    MAINTENANCE MAINTENANCE a conventional manner, following the procedure CONTROLS outlined in Brake Chapter 9. Check controls for proper operation, positioning and adjustment. SUSPENSION: SPRING PRELOAD ADJUSTMENT Operator weight and vehicle loading affect suspensionspringpreloadrequirements. Adjustas necessary. Shock Spanner Wrench (PN 2870872) FRONT SUSPENSION Brake control and switch must be positioned to allow brake lever to travel throughout entire range without...

  • Page 51: Tire Pressure

    MAINTENANCE MAINTENANCE 4. Remove the wheel nuts and remove the wheel. The use of non-standard size or type tires may affect ATV handling. WHEEL INSTALLATION Tire Tread Depth Always replace tires when tread depth is worn to 1. With the transmission in gear and the parking 1/8²...
  • Page 52 MAINTENANCE MAINTENANCE 2.30...
  • Page 53 ENGINE ENGINE CHAPTER 3 ENGINE Engine Exploded Views ..... . 3.2--3.6 Special Tools ....... Torque Specifications .

  • Page 54: Engine Exploded Views

    ENGINE ENGINE ENGINE EXPLODED VIEW 20-24 ft. lbs. Crankcase (27-33 Nm) Oil Dipstick Crankcase Assembly Bearing Seal Bushing 4.5-5.5 ft. lbs. Bearing (6-7 Nm) O--Ring Gasket 4.5-5.5 ft. lbs. (6-7 Nm) Seals Journal Oil Pickup Bearings Magnetic Plug 20--22 ft. lbs. 8.5-9.5 ft.
  • Page 55 ENGINE ENGINE ENGINE EXPLODED VIEW Cylinder/ Cylinder Head Reed 8.5-9.5 ft. lbs. (12-13 Nm) Breather Cover Rocker Cover 27--33 in. lbs. (3--4 Nm) 20-24 ft. lbs. 60--64 ft. lbs. (27-33 Nm) (81--87 Nm) 16--20 ft. lbs. (22--27 Nm) 8.5-9.5 ft. lbs. Thermostat (12-13 Nm) Cover...
  • Page 56 ENGINE ENGINE ENGINE EXPLODED VIEW Crankshaft and Pistons Valve Train Camshaft 26-30 ft. lbs. (35-41 Nm) Camshaft Gears Piston Assembly Thrust Plate 4.5-5.5 ft. lbs. (6--7 Nm) 20-24 ft. lbs. (27-33 Nm) Rocker Arms Crankshaft Pushrods Valve Springs Woodruff Key Valve Seals Gears...
  • Page 57 ENGINE ENGINE ENGINE EXPLODED VIEW Water Pump / Oil Pump 8.5-9.5 ft. lbs. Oil Filter (12-13 Nm) Oil Plug 20-24 ft. lbs. 33-37 ft. lbs. (27-33 Nm) (45-50 Nm) Oil Filter Nipple 8.5-9.5 ft. lbs. (12-13 Nm) Water/Oil Pump Gear Bearing Gerotor Oil Pressure...
  • Page 58 ENGINE ENGINE ENGINE EXPLODED VIEW Stator/Starter Stator Wire Holddown 4.5-5.5 ft. lbs. 8.5--9.5 ft. lbs. (6-7 Nm) (11.5--13 Nm) 80-100 ft. lbs. (109-136 Nm) Stator Bolts Flywheel Flywheel Nut Stator Housing Sound Cover Outer Cover O--rings Timing Plug 7-9 ft. lbs. Washers (10-12 Nm) 8.5-9.5 ft.

  • Page 59: Special Tools

    ENGINE ENGINE SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION PV- -43527 Oil Filter Wrench 2200634 Valve Seat Reconditioning Kit PU- -45257 Valve Spring Compressor PU- -45652 Valve Pressure Hose 2871043 Flywheel Puller PU- -44693 Valve Train Table 2870390 Piston Support Block PU- -45497- -2 Cam Gear Tooth Alignment Tool PU- -45497- -1...

  • Page 60: Torque Specifications

    ENGINE ENGINE TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Size 600/700 Ft. Lbs. (Nm) Camshaft Gear 8 mm 26-30 (35-41 Nm) Camshaft Thrust Plate 6 mm 4.5-5.5 (6-7 Nm) Carburetor Adaptor 8 mm 11-13 (15-18 Nm) Counterbalance Gear 8 mm 26-30 (35-41 Nm) Crankcase 8 mm 20-24 (27-33 Nm)

  • Page 61: Engine Fastener Torque Patterns

    ENGINE ENGINE ENGINE FASTENER TORQUE PATTERNS Tighten cylinder head/cylinder base, and crankcase fasteners in the following sequence outlined below. Cylinder Head Crankcase PISTON IDENTIFICATION Four stroke engine rings have a rectangular profile. See text on Page 3.27 for ring installation. Use the information below to identify pistons and rings.

  • Page 62: 600 Engine Service Data

    ENGINE ENGINE 600 ENGINE SERVICE DATA Cylinder Head / Valve Engine No. - - EH059OLE Camshaft Cam lobe height In 0 .2170” 0.00236” (5.5118 0.060 mm) 0 .2170” 0.00236” (5.5118 0.060 mm) Camshaft journal OD 1.654” 0.00039” (42 0.010 mm) Center 1.634”...
  • Page 63 ENGINE ENGINE 600 ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod Engine No. - - EH590ALOE Cylinder Surface warpage limit (mating with cyl- 0.004” (0.10 mm) inder head) Cylinder bore 3.0118” (76.5mm) Taper limit 0.00031” (0.008 mm) Out of round limit 0.00030”...
  • Page 64 ENGINE ENGINE 700 ENGINE SERVICE DATA Cylinder Head / Valve Engine No. - - EH68ALOE / EH068OLE Camshaft Cam lobe height In 0 .2170” 0.00236” (5.5118 0.060 mm) 0 .2170” 0.00236” (5.5118 0.060 mm) Camshaft journal OD 1.654” 0.00039” (42 0.010 mm) Center 1.634”...
  • Page 65 ENGINE ENGINE 700 ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod Engine No. - - EH68ALOE / EH068OLE Cylinder Surface warpage limit (mating with cyl- 0.004” (0.10 mm) inder head) Cylinder bore 3.1495” (80 mm) Taper limit 0.00031” (0.008 mm) Out of round limit 0.00030”...

  • Page 66: Cooling System Specifications

    2. The radiator cap relief pressure is 13 lbs. Replace damage. Polaris Premium 60/40 Antifreeze/Coolant is cap if it does not meet this specification. recommended for use in all cooling systems and comes Surge Tank pre-mixed, ready to use.
  • Page 67 ENGINE ENGINE ENGINE REMOVE & INSTALL 12. Disconnect the coolant hoses. Properly dispose of any antifreeze from the engine or hoses. 1. Clean work area. 13. Refer to PVT System Chapter 6 to remove outer clutch cover, drive belt, drive clutch, driven clutch, 2.

  • Page 68: Engine Installation Notes

    ENGINE INSTALLATION NOTES Engine Break In Period The break in period for a Polaris ATV engine is defined After the engine is installed in the frame, review this as the first ten hours of operation, or the time it takes checklist and perform all steps that apply: to use two full tanks of gasoline.

  • Page 69: Cylinder Hone Selection And Honing Procedure

    ENGINE LUBRICATION instructions, or these guidelines: Use a motor speed of approximately Oil Type - - Polaris Premium 4 Synthetic (PN 2871281) 300-500 RPM, run the hone in and or API certified “SH” 5W30 oil out of the cylinder rapidly until cutting tension decreases.

  • Page 70: Oil Flow

    ENGINE ENGINE OIL FLOW This chart describes the flow of oil through the EH68 and the EH059 engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.

  • Page 71: Rocker Arm/Pushrod Inspection

    ENGINE ENGINE ROCKER ARM INSPECTION 5. If the push rod (A) is visibly bent, it should be replaced. 1. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. CYLINDER HEAD REMOVAL 2. Inspect the wear pad at the valve end of the rocker arm for indications of scuffing or abnormal wear.

  • Page 72: Cylinder Head Disassembly/Inspection

    ENGINE ENGINE CYLINDER HEAD INSPECTION WARNING 1. Thoroughly clean cylinder head surface to Wear eye protection or a face shield during remove all traces of gasket material and carbon. cylinder head disassembly and reassembly. CAUTION: Use care not to damage sealing surface. 1.
  • Page 73 ENGINE ENGINE CYLINDER HEAD DISASSEMBLY, CONT. Valve Spring Length: NOTE: If working on the cylinder head while removed from the engine assembly, use the Valve Train Table Std: 1.827I (46.40 mm) (PU- -44693) to perform cylinder head work. The cylinder head attaches simply to the table. Place the Installed Height: 1.47”...

  • Page 74: Valve Inspection

    ENGINE ENGINE VALVE INSPECTION Valve Stem Diameter: 1. Remove all carbon from valves with a soft wire Intake: 0.2356” 0.00039” wheel or brush. (5.985 0.01 mm) 2. Check valve face for runout, pitting, and burnt Exhaust: 0.2346” 0.00039” spots. To check for bent valve stems, mount (5.96 0.01 mm) valve in a drill or use “V”...

  • Page 75: Combustion Chamber

    1. Install pilot into valve guide. VALVE SEAT RECONDITIONING Cylinder Head Reconditioning NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area. NOTE: The cylinder head valve guides cannot be replaced. WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly.
  • Page 76 ENGINE ENGINE VALVE SEAT RECONDITIONING CONT’D If the seat is too narrow, widen using the 45° cutter and re-check contact If the contact area of the cutter is in point on the valve face and seat width the same place, the valve guide is after each cut.

  • Page 77: Cylinder Head Reassembly

    ENGINE ENGINE VALVE SEAT RECONDITIONING CONT”D 8. Clean all filings from the area with hot soapy water, rinse, and dry with compressed air. WARNING Wear eye protection or a face shield when working with compressed air during cylinder head disassembly and reassembly. 9.

  • Page 78: Valve Sealing Test

    ENGINE ENGINE VALVE SEALING TEST 1. Clean and dry the combustion chamber area (A). Refer to Page 3.23 for cleaning tips. 2. Pour a small amount of clean solvent onto the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage.

  • Page 79: Engine Head Reassembly

    ENGINE ENGINE ENGINE HEAD REASSEMBLY 4. Lubricate push rods (D) and install into lifters. Before reassembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts and new Loctitet.
  • Page 80 ENGINE ENGINE ENGINE HEAD REASSEMBLY CONT’D 11. Install thermostat (J). Apply Loctitet 271 (PN 2871954) to the bolts of the cover. Torque bolts to 8. Install breather reed (G) into rocker cover (H). 8.5-9.5 ft. lbs. (12-13 Nm). Lightly apply black RTV sealant to the outer edges of the breather reed.

  • Page 81: Cylinder Removal

    ENGINE ENGINE CYLINDER REMOVAL 4. Check the lifters for wear or scores. 5. Check the bottom end of lifter to make sure that it 1. Follow engine disassembly procedures to has a slight convex. remove rocker cover and cylinder head. If the bottom surface has worn flat, it may be used 2.

  • Page 82: Cylinder Inspection

    ENGINE ENGINE apply heat to the piston rings. The ring may lose b) Remove the expander. radial tension. 3. Remove top compression ring: *Using a piston ring pliers: Carefully expand ring and lift it off the piston. CAUTION: Do not expand the Compression Rings ring more than the amount necessary to remove it...
  • Page 83 ENGINE ENGINE 1/2 Down From Top of Cylinder Ill.2 Cylinder Warpage. 1/2 Up From Bottom .004 (0.1 mm) Max. 5. Record measurements. If cylinder is tapered or out of round beyond .002, the cylinder must be replaced. 3. Inspect cylinder for wear, scratches, or damage. Cylinder Taper Limit: .002I (.05mm)Max.
  • Page 84 ENGINE ENGINE 2. Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance. 5 mm Piston Piston Pin Piston Pin Measurement Locations Piston to Cylinder Clearance 600: .0022” .00067” (.055 .017 mm) Piston Pin O.D. 700: .0018” .00063”...

  • Page 85: Starter Bendix Removal/Inspection

    ENGINE ENGINE Piston Ring Installed Gap Piston Top Ring: 0.01181” 0.00393” (0.30 0.10 mm) Ring Second Ring Limit: 0.01476” 0.00492” (0.375 0.125 mm) Oil Ring Limit: 0.00984” .00393” (0.25 0.10 mm) Top Ring Limit: 0.01083” 0.00295” Feeler Gauge (0.275 0.075 mm) Second Ring Limit: 0.0177”...

  • Page 86: Flywheel/Stator Removal/Inspection

    ENGINE ENGINE 4. Inspect the thrust washer for wear or damage and replace if necessary. FLYWHEEL/STATOR REMOVAL/INSPECTION 5. After the bendix is removed, tap on the starter assembly with a soft faced mallet to loosen the starter from the crankcase. 1.

  • Page 87: Flywheel/Stator Installation

    ENGINE ENGINE lock, so Loctitet is not needed on the new bolts. Torque bolts to 9--10 ft. lbs. (12--14 Nm). 2871043 4. Use caution when removing the wire holddown (B), trigger coil (C), and the stator assembly (D). Do not tap or bump the gear /stator housing 3.

  • Page 88: Engine Lower Disassembly/Inspection

    ENGINE ENGINE Torque the bolts to 8.50--9.50 ft. lbs. (12--13 Nm). 3. Remove flywheel nut and washer. 4. Install Flywheel Puller (PN 2871043) and remove flywheel (F). CAUTION: Do not thread the puller Stator Housing Bolt Torque: bolts into the flywheel more than 1/4² or stator coils may be damaged.
  • Page 89 ENGINE ENGINE ENGINE DISASSEMBLY CONT’D camshaft gear (K), water/oil pump gear (L), crankshaft gear (M), or counterbalance gear (N). 6. Remove the gear/stator housing bolts and remove the gear/stator housing cover (J) and Cam Gear Removal gasket from the crankcase. Be sure to catch the 9.
  • Page 90 ENGINE ENGINE Place the cam gear on a flat surface with the timing mark side facing up. Inspect Teeth & Tabs While holding both gears together, lightly work small flathead screwdriver between the two gears. Remove the top gear. The springs should stay in place.
  • Page 91 ENGINE ENGINE CAM GEAR REASSEMBLY CONT’D To assemble: Align Timing Marks Hold the spring with one finger. Start the pointed end of the tapered pin into the cam gear hole and slowly push the dowel through the hole until the end of the dowel is almost flush with the spring.
  • Page 92 ENGINE ENGINE 2871043 PU- -45497- -2 23. Inspect the crankshaft gear (Q) for broken or worn teeth. If the crankshaft gear does not need to be replaced, it does not need to be removed. If NOTE: For ease of installing the Cam Gear the crankshaft gear is damaged, remove the Alignment Tool (PU- -45497- -2) (R), use a twisting crankshaft gear with the Flywheel Puller (PN...
  • Page 93 ENGINE ENGINE 2871043 Mark Rotors NOTE: If replacing the old rotors, new replacement rotors will fit into the old oil/water pump housing. Water/Oil Pump Removal/Disassembly 28. Remove the oil pressure relief. The oil pressure relief consists of a bolt, washer, spring, and valve (dowel).
  • Page 94 ENGINE ENGINE NOTE: Be sure to place the tapered end of the valve (dowel) in first. If the valve is installed incorrectly, oil Press out gear pressure and oil priming problems will occur. DISASSEMBLY OF WATER/OIL PUMP SHAFT WARNING Wear appropriate safety gear during this procedure.
  • Page 95 ENGINE ENGINE clothing and eyewear are required. 37. Remove thrust plate (U). Gear Boss 35. Apply Loctitet 609 to the pump shaft to help secure the bearing. Press on a new bearing. 38. Remove PTO end engine mount. Remove crankcase bolts. Tap on the reinforced areas on the cases using soft hammer.

  • Page 96: Camshaft Inspection

    ENGINE ENGINE ENGINE LOWER DISASSEMBLY/INSPECTION CONT’D 39. Remove and clean oil pick up (V) and oil baffle weldment (W). CAMSHAFT INSPECTION 1. Thoroughly clean the cam shaft. 40. Remove balance shaft and crankshaft. 2. Visually inspect each cam lobe for wear, chafing or damage.

  • Page 97: Engine Lower Assembly

    ENGINE ENGINE ENGINE LOWER Journal O.D.’s REASSEMBLY WARNING: After any reassembly or rebuild, the engine must be primed using the Oil Priming Adapter (PU- - 45778) and a 3/4- -full oil filter before initial start- -up. Follow Steps 44- - 45 in this section to properly prime the engine and to help aid proper engine break in.
  • Page 98 Crankcase Bolt Torque: to crank pins and rods (D). Apply Starter Drive Grease (PN 2871460) to the main journals and 20-24 ft. lbs. (27-33 Nm) bearings. 8. Grease cam lobes and valve lifters with Polaris Starter Drive Grease (PN 2871460). 3.46...
  • Page 99 ENGINE ENGINE NOTE: Apply a small amount of grease to the cylinder gasket to help hold it in place during cylinder Grease Cam Lobes assembly. DO NOT USE SILICONE. Grease Lifters 9. Lubricate lifters with engine oil and install in the original order as removed in disassembly.
  • Page 100 ENGINE ENGINE NOTE: New bolts have patch lock on the threads and do not require Loctitet. Push in Piston Pins 14. Install the piston pin keepers (F). The pin keeper 16. Assemble rotors as marked when disassembled. ends should be installed at the 12 O’clock Use a cleaner to remove the marks previously position.
  • Page 101 ENGINE ENGINE NOTE: For assembly of the gears, the cam gear and the crankshaft gear are stamped with “This Side Out.” This indicates the side of the gear that faces outward or away from the case. This Side Out NOTE: Before assembly, clean the bolts and bolt Oil Pump Bolt Torque: holes with Primer N (PN 2870585) to remove any debris.
  • Page 102 ENGINE ENGINE CAUTION: The crankshaft gear is extremely hot! Severe burns or injury can occur if the gear is not handled with extreme care and caution. Follow the procedure below to help ensure safety. 22. Use extreme caution when removing the crankshaft gear from the hot plate.
  • Page 103 ENGINE ENGINE 27. Before installing the gear/stator housing, replace PU- -45498 the seals in the cover. Install a new water pump seal (N) into the gear/stator housing (O). Use the Water Pump Mechanical Seal Installer (PA- -44995) to properly install the seal to the correct depth in the cover.
  • Page 104 ENGINE ENGINE NOTE: Install the crankshaft seal (P) with the seal lip facing out (towards the crankcase). Seal lip goes towards the crankcase. (PA- -45658) 29. Once the crankshaft seal is installed into the gear/ stator housing cover, set the direction of the paper 31.
  • Page 105 ENGINE ENGINE 35. Secure the gear/stator housing cover (O) to the crankcase with the cover bolts. Apply Loctitet 242 (PN 2871949) to the bolts. Torque bolts to 8.5-9.5 ft.lbs. (12-13 Nm) in a criss--cross pattern. Remove seal protectors from the shaft ends once secure.
  • Page 106 ENGINE ENGINE 40. Install stator assembly (S) and bolts. Apply Water Pump Impeller Nut Torque: Loctitet 242 (PN 2871949) to the bolts. Torque bolts to 9-10 ft. lbs. (12-14 Nm). 9- -11 ft. lbs. (12-15 Nm) 41. Install the the wire hold down bracket (T). Install two new wire hold down bolts.
  • Page 107 Fill 3/4 full with 0W--40 oil 45. Remove primer plug from the engine. Install the Oil System Priming Adapter (PU- -45778) into the oil plug hole. Push 3--5 oz. (approx.) of Polaris Flywheel Nut Torque: 0W--40 into the adapter until resistance is felt.

  • Page 108: Troubleshooting

    ENGINE ENGINE TROUBLESHOOTING Spark Plug Fouling Spark plug cap loose or faulty Engine flooded Low compression (high cylinder Choke cable adjustment or leakage) plunger/cable sticking No spark (Spark plug fouled) Foreign material on choke plunger ignition component failure seat or plunger Engine Does Not Turn Over Incorrect spark plug heat range or Dead battery...
  • Page 109 ENGINE ENGINE TROUBLESHOOTING, CONT Valve sticking Air leaks in intake Piston Failure - Scoring Lean condition Lack of lubrication COOLING SYSTEM Dirt entering engine through cracks in air filter or ducts TROUBLESHOOTING Engine oil dirty or contaminated Overheating Excessive Smoke and Carbon Buildup Low coolant level Excessive piston-to-cylinder clearance...
  • Page 110 3. Always add coolant to the radiator first, filling to the top of Remote Filler Cooling System the neck to replace air that has been purged from the system. Polaris Premium Antifreeze Fill the reservoir only after you have completely filled the cool- 2871534 Quart ing system at the radiator filler neck.
  • Page 111 FUEL SYSTEM/CARBURETION FUEL SYSTEM/CARBURETION CHAPTER 4 FUEL SYSTEM/CARBURETION Exploded View, Mikuni BST 40 Carburetor . . . Fuel Tank Asm. Exploded View ... . Fuel Flow Diagram ..... . . Special Tool &...
  • Page 112 FUEL SYSTEM/CARBURETION FUEL SYSTEM/CARBURETION 1. Carburetor Assembly BST 34 CARBURETOR 2. Screw 3. Throttle Valve EXPLODED VIEW 4. Cover, Diaphragm 5. Jet Block Assembly 6. Spring 7. Diaphragm Assembly 8. Ring 9. “E” Ring 10. Ring 11. Needle Jet 12. Cover 13.

  • Page 113: Fuel Flow Diagram

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

  • Page 114: Carburetor Jetting

    3130571 dense with reduced oxygen. 157.5 3130572 3131141 Polaris ATV Carburetors are calibrated for an altitude 162.5 3131142 0-6000 ft. (0-1800 meters) and ambient 3131143 temperatures between +40 and +80 F (+5 to +26 167.5...

  • Page 115: Cv Carburetor System Function (4 Cycle)

    FUEL SYSTEM/CARBURETION FUEL SYSTEM/CARBURETION CV CARBURETOR SYSTEM VENT SYSTEMS - CV FUNCTION CARBURETOR The carburetor float bowl vent lines supply atmospheric pressure to the float bowl. The lines Carburetor Component Function must be free of kinks, restrictions and be properly System Main Main...
  • Page 116 FUEL SYSTEM/CARBURETION FUEL SYSTEM/CARBURETION CARBURETOR OPERATION CONT’D When the throttle plate is opened and engine speed begins to increase, the pressure in the venturi (and therefore in the chamber above the diaphragm) becomes significantly lower than atmospheric. Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward, raising the slide against spring pressure.

  • Page 117: Float System

    FUEL SYSTEM/CARBURETION FUEL SYSTEM/CARBURETION FLOAT SYSTEM Fuel enters the float chamber (3) by means of the inlet pipe and passage, through a screen on the back of the inlet needle seat (4), and around the inlet needle (2). As the fuel fills the float chamber, the float (1) rises and forces the inlet needle against the seat, shutting off the orifice in the seat.

  • Page 118: Carburetor Cleaning

    FUEL SYSTEM/CARBURETION FUEL SYSTEM/CARBURETION CARBURETOR DISASSEMBLY CONT’D NOTE: The starter jet is not removeable. Upon disassembly, place the parts in a container for safe 2. Remove float bowl and carefully remove the keeping. pressed float pin. Support Here Pilot Screw Starter Jet NOTE: Be careful not to damage the float pin tower during the float pin removal.

  • Page 119: Carburetor Inspection

    FUEL SYSTEM/CARBURETION FUEL SYSTEM/CARBURETION CARBURETOR INSPECTION CARBURETOR ASSEMBLY 1. Inspect jet needle and needle jet for wear. Look Inspect the diaphragm (A) for holes, deterioration, or for discoloration, shiny spots, or an area that damage. Make sure the diaphragm is pliable but not looks different than the rest of the needle.

  • Page 120: Float Height Adjustment

    FUEL SYSTEM/CARBURETION FUEL SYSTEM/CARBURETION CARBURETOR ASSEMBLY CONT’D 3. If adjustment is necessary, bend the tongue slightly. Be sure float measurement is even on left 5. Install the pilot mixture screw, spring, washer, and and right side. O-ring as an assembly. Lubricate the O-Ring with oil or light grease before installation.

  • Page 121: Fuel Level

    Remove the valve and wash with soap and water. Carburetor cleaner may be The Polaris Sportsman 600/700 is equipped with a used to clean the pump body when the check pressure regulated fuel pump (1-3 PSI). The pump is valves are removed.

  • Page 122: Troubleshooting

    FUEL SYSTEM/CARBURETION FUEL SYSTEM/CARBURETION TROUBLESHOOTING Loose jets Worn jet needle/needle jet or other FUEL STARVATION/LEAN MIXTURE carburetor parts Dirty carburetor (air bleed Symptoms: Hard start or no start, bog, backfire, passages or jets) popping through intake / exhaust, hesitation, Weak or damaged vacuum piston detonation, low power, spark plug erosion, engine return spring runs hot, surging, high idle, idle speed erratic.
  • Page 123 BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION Body Assembly, Exploded View ....5.2--5.3 Headlight Pod Exploded View .
  • Page 124 BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION BODY ASSEMBL Y Rear Cab Assembly Pull UP on rear of seat and back to disengage tabs at front of seat EXPLODED VIEW Seat Latch Seat Latch Release Storage Rear Cab Clutch Guard Frame Brace Rear Mud Guard...
  • Page 125 BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION Rear Rack Extender Rear Support Rack Rear Rack Reflector Frame Front Rack Extender Front Rack Front Support Rack Bumper Panel Frame Brush Guard Lower Bumper Radiator Cover Grill Side Shield...

  • Page 126: Headlight Pod Exploded View

    BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION HEADLIGHT POD Torque bolts evenly so gap is equal at front and rear of EXPLODED VIEW handlebar block 11-13 ft. lbs. (15-18 Nm) Disassembly Clean knurling when repositioning handlebars G Remove two side Phillips screws (A). G Remove one rear Phillips screw (B).

  • Page 127: Steering/A--Arm Exploded View

    BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION STEERING/A- -ARM NOTE: To avoid damage to tie rods and other steering EXPLODED VIEW components, be sure to install tie rod end bolts in the proper direction. The steering post arm bolt (B) points up; the rod end bolts (A) point down.

  • Page 128: Rear Suspension Exploded View

    BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION REAR SUSPENSION EXPLODED VIEW 17 ft. lbs. (24 Nm) Stabilizer Support 17 ft. lbs. (24 Nm) 35 ft. lbs. (48 Nm) Forward Upper Control Skid Plate Strap tabilizer Bar Arm 35 ft.

  • Page 129: Front Strut Assembly Exploded View

    BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION FRONT STRUT ASSEMBLY EXPLODED VIEW 15 ft. lbs. (21 Nm) Strut Bumper Spacer Rubber Washer Upper Pivot Ball Strut Washer Clamp 18 ft. lbs. Spacer (25 Nm) 15 ft. lbs. Bolt Lower Pivot Ball (21 Nm)

  • Page 130: Cover/Panel Removal

    BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION SPECIAL TOOLS COVER/PANEL REMOVAL TOOL PART NUMBER To Remove: Seat DESCRIPTION Pull release lever at the rear of the Ball Joint 2870871 seat Lift and pull seat rearward, Replacement Tool disengaging seat from tabs at the Shock Spanner 2870872...

  • Page 131: Side Panel Removal

    BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION SIDE PANEL REMOVAL NOTE:Side panel removal may be difficult until the Step 3. locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove seat. Grasp rear of side panel near rear cab.

  • Page 132: Steering Post Assembly

    BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION A- -ARM REPLACEMENT CONT’D WARNING 9. Attach A-arm to hub strut assembly. Tighten ball Upon A-arm installation completion, test vehicle at joint nut to 25 ft. lbs. (35 Nm). If cotter pin holes low speeds before putting into regular service.

  • Page 133: Front Strut Cartridge Replacement

    BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION FRONT STRUT CARTRIDGE REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5.7 1. Compress spring using strut spring compressor tools. Strut Spring Compressor Tools (PN 2871573) and (PN 2871574) 2. Hold strut rod and remove top nut. 3.

  • Page 134: Decal Replacement

    BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION BALL JOINT REPLACEMENT CONT’D DECAL REPLACEMENT 8. To install new ball joint: WARNING Remove extension cap and attach puller guide using short bolts The following procedure involves the use of an provided in the kit.
  • Page 135 CLUTCH CLUTCH CHAPTER 6 PVT SYSTEM Drive Clutch Exploded View ....PVT Sealing and Ducting Components ..EBS System Exploded View .

  • Page 136: Drive Clutch Exploded View

    CLUTCH CLUTCH DRIVE CLUTCH EXPLODED VIEW Mark with permanent marker before disassembly One way clutch EBS Drive Clutch PVT SEALING AND DUCTING COMPONENTS Clutch Inlet Duct Transmission Cover Seal Inner Clutch Cover Clamps Boot Duct Clutch Cover Seal Inner Cover Seal Seal Retainer Bracket...
  • Page 137 CLUTCH CLUTCH ENGINE BRAKING SYSTEM (EBS) EXPLODED VIEW Flat Spacer Drive Clutch Assembly Retaining Ring Ramp 2.25² PTFE Washer One Way Clutch Drive Ramp Bushing Washer Brass Washer Shift Weights Compression Torque to Coil Spring 200 Ft. Lbs. Spring Bushing (271 Nm) Screw Spacer Sleeve...

  • Page 138: Pvt Operation Overview

    2871226 control engagement (initial vehicle movement), clutch Replacement Tool upshift and backshift. During the development of a Polaris ATV, the PVT system is matched first to the Piston Pin Puller 2870386 engine power curve; then to average riding conditions EBS Clutch 2872292 and the vehicle’s intended usage.

  • Page 139: Pvt Drying

    CLUTCH CLUTCH DRIVEN CLUTCH OPERATION CONT’D air ducts, as well as the inner and outer covers, must be properly sealed to ensure clean air is As engine RPM and horsepower increase, the load being used for cooling the PVT system. This also from the drive belt increases, resulting in the belt will prevent water and other contaminants from rotating up toward the outer diameter of the drive...

  • Page 140: Pvt Overheating/Diagnosis

    10 seconds. PVT seals should be inspected for damage if repeated leaking occurs. Clutch malfunction. Inspection/repair of clutch components should be performed by a certified Polaris MSD techinician.

  • Page 141: Pvt Disassembly

    CLUTCH CLUTCH PVT DISASSEMBLY NOTE: Some fasteners and procedures will vary. Driven Clutch Puller (PN 2870913) Refer to the appropriate parts manual for proper fasteners and fastener placement. 1. Remove seat. 2. Remove or loosen rear cab fasteners as 8. Remove driven clutch offset spacers from the necessary to gain access to PVT outer cover.

  • Page 142: Pvt Assembly/Inspection

    CLUTCH CLUTCH PVT ASSEMBLY/INSPECTION 7. Install clutch offset spacer(s) on transmission input shaft. 1. Inspect PVT inner cover-to-engine seal. Replace if cracked or damaged. Align the alignment mark on the cover with the mark on the engine seal. Seal this edge to cover on engine side Offset Spacer 8.

  • Page 143: Drive Clutch Spring Specifications

    CLUTCH CLUTCH DRIVE CLUTCH SPRING SPECIFICATIONS NEUTRAL The drive clutch spring has two FULL UPSHIFT primary functions: ATV TRAVEL 1. Controls clutch engagement RPM. The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM.

  • Page 144: Shift Weights /Inspection

    CLUTCH CLUTCH SHIFT WEIGHTS Shown below are optional shift weights which may be used in the PVT system. These shift weights have many different factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding the effects they have on belt to sheave clearance, clutch balance, engagement and shifting characteristics.

  • Page 145: Drive Clutch Disassembly/Inspection

    Never replace parts with used parts from another clutch assembly! All PVT maintenance or repairs should be performed only by a certified Polaris Master Service Dealer (MSD) technician who has received the proper training and understands the procedures outlined in this manual.

  • Page 146: Spider Removal

    CLUTCH CLUTCH DRIVE CLUTCH DISASSEMBLY CONT’D SPIDER REMOVAL 2. Remove cover bolts evenly in a cross pattern and 1. Remove the limiter nut using the Clutch Spider remove cover plate. Nut Socket (PN 2870338). Install clutch in 3. Inspect cover bushing (A). The outer cover holding fixture...

  • Page 147: Drive Clutch Reassembly

    CLUTCH CLUTCH Moveable Sheave Bushing Inspection button is positioned toward the solid roller pin. It is recommended to switch all buttons to the rubber 2. Inspect the Teflont coating on the moveable version during service (if needed). sheave bushing. Moveable Sheave Bushing Inspection: DRIVE CLUTCH REASSEMBLY Replace the cover bushing if more brass NOTE: It is important that the same number and...

  • Page 148: Drive Belt Removal/Inspection

    CLUTCH CLUTCH DRIVE CLUTCH REASSEMBLY CONT’D 8. Reinstall cover, aligning “X” mark with other marks. Torque cover bolts evenly to specification. 2. Install moveable sheave onto fixed sheave. 3. Install spider spacers. Use same quantity and thickness as were removed. 4.
  • Page 149 CLUTCH CLUTCH Belt Width: New 1.174 - 1.188² (2.98-3.02 cm) Wear Limit 1.125² (2.86 cm) 5. Inspect belt for loose cords, missing cogs, cracks, abrasions, thin spots, or excessive wear. Replace if necessary. 6. Inspect belt for hour glassing (extreme circular wear in at least one spot and on both sides of the belt).

  • Page 150: Drive Belt Installation

    CLUTCH CLUTCH DRIVE BELT INSTALLATION 2. With tool touching rear of driven clutch inner sheave, the distance at point “A” should be 1/8². 1. Loop belt over drive and over top of driven NOTE:If the distance is greater than 1/8² or less than sheave.
  • Page 151 CLUTCH CLUTCH 1. Install offset alignment tool as shown. Remember DRIVE CLUTCH INSPECTION measure above and below the shaft centerlines. NOTE: Remove cover, spring, and spider following instructions for drive clutch removal, then proceed as follows: Offset Alignment Tool should contact rear edge 1.
  • Page 152 CLUTCH ONE-WAY CLUTCH INSPECTION (DRIVE CLUTCH) CONT’D 3. Inspect surface of shaft for pitting, grooves, or damage. Measure the outside diameter and compare to specifications. Replace the drive clutch assembly if shaft is worn or damaged. EBS DRIVEN CLUTCH DISASSEMBLY/INSPECTION - CAUTION: driven clutch...
  • Page 153 CLUTCH 2. When rotated clockwise, the outer sheave should NOTE: Rotating the moveable sheave so that the lock to the shaft and inner sheave without rollers are not in contact with either helix ramp slipping. surfaces will lessen the effort needed to push the helix inward.
  • Page 154 CLUTCH CLUTCH EBS DRIVE BUSHING DRIVEN CLUTCH DISASSEMBLY/ INSPECTION CONT’D SERVICE 7. Inspect moveable sheave bushing for wear. Inspect BOTH sheaves for signs of wear, EBS CLUTCH BUSHING REMOVAL AND grooving or cracking. Clean surfaces with a 3Mt INSTALLATION (Use Tool Kit PN 2201379) pad if needed The contents of this kit include: Item...
  • Page 155 CLUTCH CLUTCH 6. With towers pointing toward the vise, slide sheave EBS Drive Clutch Cover Bushing Removal onto puller rod. 1. Install main adapter (Item 8) on puller. 7. Install removal tool (Item A/B) into center of sheave with “A side” toward sheave. 8.
  • Page 156 CLUTCH CLUTCH EBS DRIVEN BUSHING 8. Remove nut (C) (left hand thread) from puller rod and set aside. SERVICE 9. Remove adapters from puller. 10. Remove bushing and removal tool from adapters. EBS Driven - Bushing Removal Discard bushing. 1. Install puller adapter (Item 10) onto puller. EBS Driven - Bushing Installation 1.
  • Page 157 CLUTCH CLUTCH 7. Turn clutch sheave counterclockwise until 8. Remove nut (C) (left hand thread) from puller rod bushing is removed and sheave comes free. and set aside. 8. Remove nut (C) (left hand thread) from puller rod 9. Remove installation tool and clutch sheave from and set aside.

  • Page 158: Troubleshooting

    CLUTCH CLUTCH TROUBLESHOOTING Situation Probable Cause Remedy -Replace with recommended spring. Engine RPM -Wrong or broken drive clutch spring. below specified operating range -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine application. although engine is properly -Driven clutch spring broken or installed -Replace spring;...
  • Page 159 CLUTCH CLUTCH TROUBLESHOOTING Situation Probable Cause Remedy Belt slippage -Belt worn out -Replace belt. -Water ingestion -Inspect and seal PVT system. -Belt contaminated with oil or grease -Inspect and clean. Belt burnt, thin -Abuse (continued throttle application when -Caution operator to operate machine within guidelines. spots vehicle is stationary, excess load) -Dragging brake...
  • Page 160 CLUTCH CLUTCH NOTES 6.26...
  • Page 161 FINAL DRIVE FINAL DRIVE CHAPTER 7 FINAL DRIVE AWD Axle/Propshaft Exploded Views ..Special Tools & Torque Specifications ..Front Hub Inspection ..... Front Drive Axle Removal .

  • Page 162: Awd Front Drive Axle Exploded View

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

  • Page 163: Front Hub Inspection

    FINAL DRIVE FINAL DRIVE SPECIAL TOOLS 7. Remove the two brake caliper attaching bolts. CAUTION: Do not hang the caliper by the brake PART NUMBER TOOL line. Use wire to hang the caliper to prevent DESCRIPTION possible damage to the brake line. 2872608 Roller Pin Removal Tool...

  • Page 164: Front Drive Axle Installation

    FINAL DRIVE FINAL DRIVE New Cotter Key Front Hub Retaining Nut Torque 11. With short, sharp jerks, remove drive shaft from front gearcase. 70 ft. lbs. (95 Nm) DRIVESHAFT AND CV JOINT HANDLING TIPS Care should be exercised during driveshaft removal or when servicing CV joints.
  • Page 165 FINAL DRIVE FINAL DRIVE FRONT DRIVE SHAFT CV JOINT BOOT REPLACEMENT Retaining ring 1. Remove wheel, brake caliper and wheel hub. Refer to Front Drive Axle Removal Page 7.3 for procedure. 2. Remove cotter pin and castle nut from A-arm ball joint.
  • Page 166 FINAL DRIVE FINAL DRIVE bell, lift one edge of boot to let out excess air NOTE: Drive bearing out evenly by tapping on outer Secure with clamp. race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed.

  • Page 167: U-Joint Disassembly

    FINAL DRIVE FINAL DRIVE Roll Pin Remover Tool (PN 2872608) NOTE: If removing front housing, use roll pin removal tool to remove the pins from both front drive axles. U-JOINT DISASSEMBLY CAUTION: Wear eye protection at all times. 1. Remove internal or external snap ring from all bearing caps.

  • Page 168: Front Gearcase Removal

    FINAL DRIVE FINAL DRIVE 2. Using a suitable arbor or vise, fully seat bearing cap in one side. Continually check for free movement of bearing cross as bearing caps are assembled. 7. When installation is complete, Yokes must pivot freely in all directions without binding. If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely in all directions.

  • Page 169: Front Gearcase Operation

    FINAL DRIVE FINAL DRIVE CAUTION: Do not hang the caliper by the brake line. Use wire to hang the caliper to prevent possible Frame damage to the brake line. 6. Remove the front hub from the drive shaft. 7. Remove cotter pin, lower ball joint nut and A-arm from ball joint.
  • Page 170 FINAL DRIVE FINAL DRIVE CAUTION: If the rear wheels are spinning, release 2. Remove bolts and output shaft cover. the throttle before turning the AWD switch on. If AWD is engaged while the wheels are spinning, severe drive shaft and clutch damage could result. Output Roller Cage &...
  • Page 171 FINAL DRIVE FINAL DRIVE 5. Remove the roll cage assembly, rollers, and H--springs. H--spring 9. Remove the ring gear (C), the output hub (D), the shim (E), and the armature plate (F) from the 6. Thoroughly clean all parts. Inspect the rollers (A) output cover.
  • Page 172 FINAL DRIVE FINAL DRIVE 12. Remove the other output hub from the main FRONT GEARCASE gearcase. REASSEMBLY/INSPECTION 1. Replace O--rings, seals, worn components. 2. Press the pinion shaft seal into the pinion cover, until the seal is flush with the sealing surface. 3.
  • Page 173 FINAL DRIVE FINAL DRIVE 6. Install the ring gear into the gearcase housing. 9. Install the armature plate onto the ring gear. 7. Slide the roll cage into the ring gear. Insert the NOTE: Be sure armature plate tabs are placed into rollers as the roll cage is installed.

  • Page 174: Front Gearcase Diagnosis

    FINAL DRIVE FINAL DRIVE bands (one band inside the other). If only one Cover Bolts Torque band of wear is present (or if there is wear between the two bands, inspect the coil area as 14 ft. lbs. (19 Nm) indicated in Step 4.
  • Page 175 FINAL DRIVE FINAL DRIVE New spring Gearcase Cover Coil U--shaped insert 2. Add the proper lubricant to the front gearcase. Side Cutaway View of Centralized Hilliard Cover Check drain plug for proper torque. Refer to Page 2.10 in the maintenance chapter for fill capacities. 5.

  • Page 176: Front Gearcase Exploded View

    FINAL DRIVE FINAL DRIVE FRONT GEARCASE EXPLODED VIEW Ref. Qty. Description Ref. Qty. Description 1 Asm., Mid Gearcase 1 O- - Ring 1 Cover, Output 1 Seal 1 O- - Ring 11 Kit, Bolt 1 Insert 1 Cover, Input 1 Coil 1 Bearing, Roller Ball 1 Kit, Shim Set (Incl.

  • Page 177: Rear Hub Removal

    FINAL DRIVE FINAL DRIVE REAR HUB REMOVAL 8. Remove hub nut, domed washer and flat washer. 1. Place the ATV in Park and lock the parking brake. Remove rear hub cap. 9. Remove hub. 2. Remove cotter pin. 3. Loosen the hub retaining nut. 4.

  • Page 178: Rear Hub Installation

    FINAL DRIVE FINAL DRIVE 10. Remove upper control arm bolt as shown. Install upper and lower bolts 11. Remove both lower control arm bolts. Lower Control Arm Bolt Torque: 40 ft. lbs. (54 Nm) Upper Control Arm Bolt Torque: 35 ft. lbs. (48 Nm) 3.

  • Page 179: Rear Hub Disassembly

    FINAL DRIVE FINAL DRIVE 5. Pull drive shaft outward and install hub onto driveshaft splines. 6. Install cone washers with domed side facing outward. 7. Install retainer nut, wheel and wheel nuts. 8. Remove jackstand and torque axle nut and wheel nuts.

  • Page 180: Rear Hub Assembly

    FINAL DRIVE FINAL DRIVE REAR HUB ASSEMBLY CAUTION: 1. Support bottom of bearing carrier housing. Use an arbor press only on the outer race, as bearing damage may occur. 4. Install snap ring into groove. REAR DRIVE SHAFT REMOVAL 1. Remove rear hub and bearing carrier. (See Pages 7.17 - 7.18).

  • Page 181: Rear Driveshaft Installation

    FINAL DRIVE FINAL DRIVE DRIVESHAFT AND CV JOINT 2. Apply anti-seize compound to splines of shaft. 3. Install a new lock ring and install the shaft. HANDLING TIPS 4. Lift bearing carrier into place and install bolt to upper control arm. Torque bolt to 35 ft. lbs. (48 Care should be exercised during driveshaft removal Nm).

  • Page 182: Rear Driveshaft Service

    FINAL DRIVE FINAL DRIVE REAR DRIVE SHAFT SERVICE Spread ends of snap ring to remove joint from shaft 1. Remove clamps from rubber boot(s) using the proper boot clamp pliers. Tap CV Housing Off Shaft 4. Place a new snap ring in the groove of the CV joint inner hub, with tabs facing the shaft as shown.
  • Page 183 FINAL DRIVE FINAL DRIVE 5. Refit CV joint on interconnecting shaft by tapping 2. Remove boot from shaft. with a plastic hammer on the joint housing. Take NOTE: When replacing a damaged boot, check the care not to damage threads on the outboard CV grease for contamination by rubbing it between two joint.

  • Page 184: Rear Gearcase Removal

    Ill. 1. 30 ft. lbs. (41 Nm) Nm) (4 bolts) Ill.1 3. Refill the rear gearcase with 5 oz. (150 ml) of Polaris Premium Gearcase Lubricant (PN 2871653). Torque the fill plug to 14 ft. lbs. (19 Nm). 7.24...

  • Page 185: Rear Gearcase Disassembly

    FINAL DRIVE FINAL DRIVE REAR GEARCASE DISASSEMBLY Thrust Button Shims 1. Drain and properly dispose of used oil. 2. Remove the gearcase housing cover bolts and the gearcase housing cover. 4. Remove rear bevel gear from the gearcase housing. cover. 3.

  • Page 186: Rear Gearcase Assembly

    FINAL DRIVE FINAL DRIVE REAR GEARCASE REASSEMBLY 1. Inspect the pinion shaft bushing for wear. 7. Inspect the ring gear for abnormal wear, broken, or chipped teeth. Spin the bearing to check the ball bearings for smoothness. Replace the bearing if needed. 2.
  • Page 187 FINAL DRIVE FINAL DRIVE Gearcase Cover Bolt Torque: 25 ft. lbs. (34 Nm) Pinion Shaft Cover Bolt Torque: 25 ft. lbs. (34 Nm) 6. Install the drain plugs. Replace the drain plug washers to ensure proper sealing after filling. 4. Install the original shim(s), thrust button, and thrust button shims into the gearcase cover.

  • Page 188: Rear Gearcase Exploded View

    FINAL DRIVE FINAL DRIVE REAR GEARCASE EXPLODED VIEW Ref. Qty. Description Ref. Qty. Description 1 Asm., Rear Gearcase 1 10T Pinion Shaft 1 Cover, Output, LH 1 Ball Bearing 8 Screw 1 O- - ring 1 Tube Vent 1 Cover, Input 2 Washer 1 Seall 2 Plug...
  • Page 189 TRANSMISSION TRANSMISSION CHAPTER 8 TRANSMISSION SERVICE Transmission, Exploded View ....8.2--8.3 Torque Specifications/Lubrication ... Gear Shift Selector Removal .

  • Page 190: Transmission Exploded View

    TRANSMISSION TRANSMISSION TRANSMISSION EXPLODED VIEW 9 10 17 16...
  • Page 191 TRANSMISSION TRANSMISSION TRANSMISSION EXPLODED VIEW, CONT. Ref. Qty. Description Ref. Qty. Description 1 Asm., 4x4 Transmission 1 28T Gear 1 Nut 1 40T Gear 1 Washer 1 44T Gear 8 Screw 4 Screw 1 Cover 1 Cover Bearing 1 Detent Pawl 1 Ring 1 O- - ring 1 Ball Bearing...

  • Page 192: Transmission Removal

    TRANSMISSION TRANSMISSION TORQUE SPECIFICATIONS 4. Disconnect shift linkage rod end from transmission bellcrank. Transmission Case Bolts 27--34 ft. lbs. (37--46 Nm) Bell Crank Nut ..12--18 ft. lbs. (16--24 Nm) Linkage Rod Transmission Drain Plug 14--18 ft.

  • Page 193: Transmission Disassembly

    TRANSMISSION TRANSMISSION TRANSMISSION REMOVAL CONT’D 6. Loosely install left side and rear mounting brackets. 7. Loosely install lower right bracket bolt. 9. Loosen or remove the bolts that secure the rear 8. Loosely install front mounting bolts. gearcase. Move the rear gearcase back just 9.
  • Page 194 TRANSMISSION TRANSMISSION TRANSMISSION DISASSEMBLY CONT’D 6. Mark the shift lockout disc, this will indicate which sideof the disc faces outward during assembly. 3. Remove the e--clip and then remove the Remove the shift lockout disc. transmission switch. Transmission Switch 4. Remove the five bolts that secure the cover. Remove the detent spring.
  • Page 195 TRANSMISSION TRANSMISSION TRANSMISSION DISASSEMBLY CONT’D NOTE: You may have to tap the shift drum from the backside of the case to aid in removal. NOTE: It may be helpful to accent the timing marks 12. Remove the upper gear cluster and shift forks. using a white marking pen.
  • Page 196 TRANSMISSION TRANSMISSION TRANSMISSION DISASSEMBLY CONT’D 18. Remove the snap ring and washer from the reverse shaft. 15. Remove the bearing from the reverse shaft using a puller. 19. Remove low gear (33T) and the needle bearing. 16. Remove the park lock engagement dog. Remove the wave spring and reverse engagement dog.
  • Page 197 TRANSMISSION TRANSMISSION TRANSMISSION DISASSEMBLY CONT’D 20. Remove the reverse gear shaft. 25. Slide off the shift dogs and wave springs. 21. Remove the rest of the bearings from the shafts. 22. Use a press to remove the gear from the shaft. 26.
  • Page 198 TRANSMISSION TRANSMISSION TRANSMISSION DISASSEMBLY CONT’D 27. Remove bearing and the helical gear. 31. Remove the shafts as an assembly. 28. Remove the pinion shaft retainer plate and the pinion shaft. 32. Remove the silent chain from the assembly for shaft inspection. 29.
  • Page 199 TRANSMISSION TRANSMISSION TRANSMISSION DISASSEMBLY CONT’D Crankcase Sealant (PN 2871557) to the mating surfaces. 35. Inspect gear teeth for wear, cracks, chips or broken teeth. Note the location of the hubs on the gear. 36. Remove seals from transmission case. IMPORTANT: New seals should be installed after the transmission is completely assembled.
  • Page 200 TRANSMISSION TRANSMISSION TRANSMISSION REASSEMBLY CONT’D NOTE: Install a new snap ring at this time. When installing the new snap ring, open the the snap ring just far enough to go over the shaft, to avoid stressing the snap ring. If the snap ring is over--stressed, it could come off the shaft and cause internal damage to the transmission.
  • Page 201 TRANSMISSION TRANSMISSION TRANSMISSION REASSEMBLY CONT’D 17. Replace and grease the O--rings on the shift drum before installation. NOTE: Use caution when installing the fork, the spring can easily fall out. NOTE: Installing the shift rail will aid in keeping the 18.
  • Page 202 TRANSMISSION TRANSMISSION TRANSMISSION REASSEMBLY CONT’D 19. Lift the shift rail slightly and rotate the rail/fork assembly so it meshes with the tracks on the shiftdrum. Be sure the wave springs are properly in place and that the shift rail is seated into the pocket on the backside of the case.
  • Page 203 6- -12 ft. lbs. (12- -16 Nm) switch up to the flat side of the shaft. 32. Install transmission and add Polaris Premium Synthetic Gear Case Lubricant (PN 2871477) in 30. Install a new bellcrank onto the shift shaft. Note the recommended amount.
  • Page 204 TRANSMISSION TRANSMISSION NOTES 8.16...
  • Page 205 BRAKES BRAKES CHAPTER 9 BRAKES Special Tools/Specifications/Torques ... Brake System Service Notes ....Brake Noise Troubleshooting .
  • Page 206 BRAKES BRAKES SPECIAL T OOLS PART NUMBER TOOL DESCRIPTION 2870975 Mity Vact Pressure Test Tool SPECIFICA TIONS Front Brake Caliper Item Standard Service Limit Brake Pad Thickness .298² / 7.6mm .180² / 4.6mm Brake Disc Thickness .150-.164² / 3.810-4.166mm .140² / 3.556mm Brake Disc Thickness Variance Between .002²...

  • Page 207: Brake System Service Notes

    Dirt, dust, or im- Spray disc and pads bedded material with CRC Brake Kleent Polaris disc brake systems are light weight, low on pads or disc or equivalent non-flam- maintenance and perform well in the conditions ATVs mable aerosol brake routinely encounter.

  • Page 208: Hydraulic Caliper Bleeding

    Move- able When servicing Polaris ATV brake systems, use only Brake Polaris DOT 3 Brake Fluid (PN 2870990). Pad G WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws.

  • Page 209: Brake Bleeding / Fluid Change

    CHANGE NOTE: When bleeding the brakes or replacing the fluid, always start with the caliper farthest from the master cylinder. Polaris DOT 3 Brake Fluid CAUTION: (PN 2870990) Always wear safety glasses during these procedures. Brake fluid will damage finished surfaces.

  • Page 210: Master Cylinder Removal

    Replace 11. Repeat procedure Steps 5-9 for the remaining hose if wear or abrasion is found. caliper(s). 12. Add Polaris Dot 3 Brake Fluid (PN 2870990) to MASTER CYLINDER MAX level inside reservoir. REMOVAL 1.

  • Page 211: Master Cylinder Installation

    15 ft. lbs. (21 Nm) parts. There are different brake master cylinders for the different Polaris ATV models. Refer to your parts manual or guide for the correct parts. This master 3. Fill reservoir with DOT3 Brake Fluid (PN cylinder is not servicable and is replaced as a 2870990).

  • Page 212: Front Pad Removal

    New .298²/7.6 mm Service Limit .180² / 4.0 mm FRONT PAD ASSEMBLY 1. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots. NOTE: Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper.

  • Page 213: Brake Burnishing

    BRAKES BRAKES 6. Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap. Polaris Premium All Season Grease (PN 2871423) Master Cylinder Fluid Up to MAX line inside reservoir 2. Compress mounting bracket and make sure dust boots are fully seated.

  • Page 214: Front Caliper Removal

    BRAKES BRAKES 2. Remove bolts and disc. Brake Disc Thickness 3. Clean mating surface of disc and hub. .150-.164² (3.810-4.166 mm) 4. Install disc on hub. Service Limit .140² / 3.556 mm 5. Install new bolts and tighten to specified torque. Brake Disc Thickness Variance Front Brake Disc Mounting Bolt Torque Service Limit: .002²...

  • Page 215: Front Caliper Disassembly

    BRAKES BRAKES FRONT CALIPER DISASSEMBLY Remove Mounting Bracket 1. Remove brake pad adjuster screw. 4. Remove piston, dust seal and piston seal. 2. Push upper pad retainer pin inward and slip brake pads past edge. 5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol.

  • Page 216: Front Caliper Inspection

    Front Caliper Piston Bore I.D. Std. 1.191-1.192² (30.25-30.28 mm) Service Limit 1.193² (30.30 mm) 2. Coat piston with clean Polaris DOT 3 Brake Fluid (C). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.

  • Page 217: Front Caliper Installation

    BRAKES BRAKES 4. Follow brake bleeding procedure outlined on Pages 9.5-9.6. FRONT CALIPER 5. Install wheels and torque wheel nuts to INSTALLATION specification. 1. Install caliper on hub strut, and torque mounting bolts. Front Wheel Nut Torque 20 ft. lbs. (27 Nm). 18 ft.
  • Page 218 BRAKES BRAKES FRONT BRAKE CALIPER EXPLODED VIEW APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT APPLY POLARIS ALL PURPOSE GREASE Socket Set Screw Bushing Boot Square Piston O--Rings Bleeder Screw Brake Pads 35--60 IN. LBS. (4--6.5 NM) Caliper Assembly Boot Bushing Caliper Mount 9.14...
  • Page 219 BRAKES BRAKES BRAKE BURNISHING 4. Remove the clip from the slide bolt. PROCEDURE It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise. Start machine and slowly increase speed to 30 mph. Clip Gradually apply brakes to stop machine.
  • Page 220 BRAKES BRAKES REAR BRAKE PAD REMOVAL CONT’D 8. Measure the thickness of the pad material. Torque Replace pads if worn beyond the service limit. Slide Pin Measure Thickness 4. Install caliper and torque the mounting bolts. Rear Brake Pad Thickness New: .318²...

  • Page 221: Rear Caliper Removal/Inspection

    BRAKES BRAKES REAR CALIPER 5. Remove the anvil bolts and separate caliper halves and remove pistons with piston pliers. REMOVAL/INSPECTION Caliper 1. Clean caliper area before removal. 2. Using a flare nut wrench, remove hand brake (inner) and auxiliary brake (outer) lines. Place a container to catch brake fluid draining from brake lines.

  • Page 222: Rear Caliper Assembly

    BRAKES BRAKES REAR CALIPER ASSEMBLY 1. Install new O-rings in the slide bolt bushing holes. Be sure O-ring and seal grooves are thoroughly cleaned of all residue, or piston may bind in bore. Apply brake fluid to piston seals and install carefully with a twisting motion to ease assembly until fully seated.

  • Page 223: Troubleshooting

    BRAKES BRAKES 5. Install brake lines and tighten to specified torque. Brake Disc Thickness Variance Service Limit .002² (.051 mm) difference between measurements Hand Brake Line 3. Mount dial indicator and measure disc runout. Replace the disc if runout exceeds specifications. Brake Disc Runout Service Limit .005²...
  • Page 224 BRAKES BRAKES REAR BRAKE CALIPER EXPLODED VIEW Anvil Bolts APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT Torque 16--18 ft.lbs. Washers (22--25 Nm) Rear Caliper Bleed Piston Screws Torque 25--30 in. lbs. Bracket O--rings (2.80--3.40) Nm Seals Pads Slide Pins...
  • Page 225 ELECTRICAL ELECTRICAL CHAPTER 10 ELECTRICAL 330 Watt Alternator Exploded View ... . 10.2 Flywheel Identification ..... . . 10.2 Special Tools/Service Notes .

  • Page 226: Flywheel Identification

    COMPONENT LOCATION FLYWHEEL IDENTIFICATION The flywheel can be identified by the tag located on the flywheel. The tag indicates the Polaris Part Number, the production date, direction of rotation, and has timing marks to time the engine. Flywheel Identification Stamp Location...

  • Page 227: Timing Check Procedure

    ELECTRICAL ELECTRICAL SPECIAL TOOLS TIMING CHECK PROCEDURE TOOL DESCRIPTION PART NUMBER 1. The ignition timing check hole is in the starter recoil/magneto housing. Remove the check plug. Fluket77 Digital Multimeter PV- -43568 Timing Light 2870630 Battery Hydrometer 2870836 Hall Sensor Probe Harness 2460761 Check Plug Static Timing Light Harness...

  • Page 228: Trigger Coil Gap

    ELECTRICAL ELECTRICAL TIMING CHECK PROCEDURE CONT’D GEAR POSITION INDICATOR Typical Ignition Timing Curve SWITCH TEST * Actual advance point may vary by several hundred RPM TRANSMISSION SWITCH above or below 5000 . Use the point of maximum advance High/Low/Neutral/Reverse/Park Switch when checking ignition timing High Range Low Range...

  • Page 229: Instrument Cluster Troubleshooting

    Refer to Page 10.6 on how to operate the diagnostic Introduction mode. The Polaris ATV Instrument Cluster is powered by battery voltage (12 VDC) and requires inputs from the engine RPM, transmission gear, and wheel speed sensor for proper operation. Two harnesses plug into the cluster head;...
  • Page 230 ELECTRICAL ELECTRICAL PROGRAM SERVICE INTERVAL CONT’D NOTE: If the gauge will not indicate what gear it is in and will not allow AWD operation, AWD can still be Begin entering the next service hour total by enabled by holding in the mode/override button. releasing and pressing the mode/reverse override To enter the diagnostics mode: button.

  • Page 231: Speedometer Removal/Installation

    ELECTRICAL ELECTRICAL To leave the diagnostic mode, either shift the machine out of neutral or turn the key switch off and on. NOTE: Any movement of the tires will trigger the speedometer out of the diagnostic mode. SPEEDOMETER REMOVAL 1. Remove the headlight pod cover and disconnect the wire connectors from the instrument cluster.

  • Page 232: Speedometer Troubleshooting

    ELECTRICAL ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 1 - - NO ALL WHEEL DRIVE Note: If AWD light comes on, instru- START HERE ment cluster is O.K. Proceed to me- chanical tests (in Service Manual). Shade the AWD light with your hand to CHECK SPEED verify it’s operation.
  • Page 233 ELECTRICAL ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 2 - - NO SPEEDOMETER AND/OR ODOMETER DISPLAY CHECK FOR START HERE MINIMUM 6VDC REPLACE ON PIN B TO SPEEDO KEY & STOP 3 Pin Connector SWITCHES ON REPLACE SPEEDO A: D.C. Power MEASURE B: Signal BACK OF C: Ground SPEEDO WITH...
  • Page 234 ELECTRICAL ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 4 - - NO AWD HUB SAFETY LIMIT NOTE: IF THE AWD LIGHT DOES NOT COME ON OR IF 12 VDC IS NOT REGISTERING AND AWD IS ENGAGING START HERE SPEEDO TURN ATV CHECK FUNCTIONING ON IN DIAGNOSTIC SPEEDO CORRECTLY?
  • Page 235 ELECTRICAL ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 5 REVERSE SPEED LIMITER ACTIVATED IN FORWARD GEAR (Engine loses spark when vehicle speed is above 7-9 mph.) START HERE 16 Pin Connector 1. Red- - 12V Constant CHECK 9. Blue White- - Engine Overheat Switch INSTRUMENT 2.

  • Page 236: Fan Motor Current Draw

    ELECTRICAL ELECTRICAL SPEEDOMETER NOTE: The fan switch may not function or operation may be delayed if coolant level is low or if air is trapped TROUBLESHOOTING CONT’D in the cooling system. Be sure cooling system is full and purged of air. Refer to Maintenance Chapter 2 for TEST 7 - - - - RESET SPEEDOMETER cooling system information.
  • Page 237 ELECTRICAL ELECTRICAL 5. If the fan motor draws more than 13 Amps, ETC OPERATION TEST replace the motor. Remove throttle block cover by carefully releasing all tabs around edge of cover. Fan Motor Current Draw: Place transmission in neutral and apply parking Should Be Less Than 15 Amps brake.

  • Page 238: Ignition System Testing Flow Chart

    ELECTRICAL ELECTRICAL IGNITION SYSTEM TESTING FLOW CHART Whenever troubleshooting an electrical problem, 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.

  • Page 239: Ignition System Troubleshooting

    ELECTRICAL ELECTRICAL IGNITION SYSTEM CDI CRANKING OUTPUT TROUBLESHOOTING TEST WITH PEAK READING VOLTMETER No Spark, Weak or Intermittent Spark GSpark plug gap incorrect The following peak voltage tests will measure the amount of output directly from each component. A GFouled spark plug peak reading voltmeter must be used to perform the GFaulty spark plug cap or poor tests.

  • Page 240: Alternator Output Test

    ELECTRICAL ELECTRICAL 5. Increase engine RPM while observing ammeter and tachometer. Current Draw Inspection 6. Note RPM at which the battery starts to charge Key Off (ammeter indication is positive). 7. With lights and other electrical load off, the “break even”...

  • Page 241: Charging System Testing Flow Chart

    ELECTRICAL ELECTRICAL CHARGING SYSTEM TESTING FLOW CHART Whenever charging system problems are suspected, proceed with the following system check. Using a multitester set on D.C. volts, mea- sure the battery open circuit voltage (See Remove the battery and properly ser- Page 10.19).
  • Page 242 TERMINALS/TERMINAL BOLTS sulfuric acid. Serious burns can result from con- tact with skin, eyes or clothing. Antidote: Use Polaris corrosion resistant Nyogelt grease (PN External: Flush with water. 2871329) on battery bolts. See Battery Installation on Internal: Drink large quantities of water or milk.

  • Page 243: Battery Installation

    ELECTRICAL ELECTRICAL 2. Disconnect battery negative (-) (black) cable first, OCV - OPEN CIRCUIT followed by the positive (+) (red) cable. VOLTAGE TEST CAUTION Battery voltage should be checked with a digital Whenever removing or reinstalling the battery, multitester. Readings of 12.6 volts or less require disconnect the negative (black) cable first and further battery testing and charging.
  • Page 244 ELECTRICAL ELECTRICAL GCharge at a rate no greater than 1/10 of SPECIFIC GRAVITY the battery’s amp/hr capacity until State of Conventional YuMicront the electrolyte’s specific gravity charge* lead-acid Type reaches 1.270 or greater. 100% 1.265 1.275 GStore the battery either in the machine Charged 1.210 1.225...

  • Page 245: High Beam Headlight Adjustment

    ELECTRICAL ELECTRICAL 6. Install clear battery vent tube from vehicle to HIGH BEAM HEADLIGHT battery vent. WARNING: Vent tube must be free LAMP REPLACEMENT from obstructions and kinks and securely installed. If not, battery gases could accumulate CAUTION: Do not service while headlight is hot. and cause an explosion.
  • Page 246 ELECTRICAL ELECTRICAL LOWER HEADLAMP REMOVAL/INSTALLATION Lens Cover Lower Headlamp Bulb Turn Harness Assembly to Remove and Install the Headlamp 1. From the rear of the taillight remove two screws holding lens cover in place and remove lens cover. 2. Remove lamp and replace it with recommended 1.

  • Page 247: Starter System Troubleshooting

    ELECTRICAL ELECTRICAL switch if there is no continuity or greater than .5 the meter when testing connections should not ohms resistance when the brake is applied with exceed .1 VDC per connection or component. slight pressure. To perform the test, place the meter on DC volts and place the meter leads across the connection to be tested.
  • Page 248 ELECTRICAL ELECTRICAL NOTE: Note the alignment marks on both ends of the starter motor casing. These marks must align during reassembly. 3. Remove the front bracket assembly and the rear bracket assembly. Remove the shims from the armature shaft and inspect the O--rings located on the armature housing.

  • Page 249: Armature Testing

    ELECTRICAL ELECTRICAL 1. Remove terminal nut with lock washer, flat washer, large phenolic washer, the small phenolic spacers, and sealing O-ring. Inspect O-ring and replace if damaged. 2. Slide positive brush springs to the side, pull brushes out of their guides and remove brush 5.
  • Page 250 ELECTRICAL ELECTRICAL STARTER REASSEMBLY STARTER REASSEMBLY CONT’D 1. Install brush plate to field magnet housing aligning index tab. 7. Using a non-petroleum grease, lubricate brush end bushing and install shims. 2. Install O-ring, two small phenolic spacers, large phenolic washer, flat washer, lock washer, and terminal nut.

  • Page 251: Starter Drive

    Retaining Thrust Ring Washer Polaris Premium Starter Drive Grease (PN 2871460) 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.
  • Page 252 ELECTRICAL ELECTRICAL STARTER ASSEMBLY Ref. Ref. Description Description 1. Rubber Ring* Gear Assembly 2. Brush Spring Though Bolt 3. Thrust Washer Cover 4. Gear Assembly Stopper 5. O-Ring* Snap Ring 6. Brush Complete Washer 7. O-Ring* Flange Bolt 8. Thrust Washer Thrust Washer 9.

  • Page 253: Starter System Testing Flow Chart

    ELECTRICAL 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.
  • Page 254 ELECTRICAL ELECTRICAL NOTES 10.30...
  • Page 257 Brake Pad Removal, Rear, 9.15, 9.16 Numbers Brake System Inspection, 2.26 2003 Sportsman 600/700 Models, 1.3 Brake System Operation, 9.4 Brake, Auxiliary, Hydraulic, 2.27 Brake, Auxiliary, Testing, 2.27 Brakelight Lamp Replacement, 10.22 A--Arm Replacement, 5.9 Breather Filter Maintenance, 2.20 Air Filter Service, 2.19 Breather Hose Inspection, 2.20 Alternator Output Test, 10.16 Brush Replacement, Starter Motor, 10.24...
  • Page 258 Coolant Level Inspection , 2.18 EBS Driven Clutch Bushing Service, 6.22 Coolant Strength, 2.17 EBS Driven Clutch Disassembly, 6.18, 6.20 Coolant Temperature Sensor, 10.12 EBS Exploded View, 6.3 Cooling System Hoses, 2.17 EBS Moveable Sheave Bushing Inspection, 6.18 EBS One Way Drive Clutch Inspection, 6.17, 6.18 Cooling System Overview , 2.17 EBS One Way Driven Clutch Inspection, 6.18 Cooling System Test, 2.17...
  • Page 259 Front Axle Installation, 7.4 High/Low Battery Voltage, 10.5 Honing to Oversize, 3.17 Front Axle Removal, 7.3 Hour Meter, 10.5 Front Hub Assembly, 7.6 Hub Installation, Rear, 7.18 Front Hub Disassembly, 7.6 Hub Removal, Rear, 7.17 Front Hub Inspection, 7.3 Front Prop Shaft Removal, 7.6 Front Strut Assembly, 5.7 Front Strut Ball Joint Replacement, 5.11 Idle Speed Adjustment, 2.12...

  • Page 260: Paint Codes

    Oil Filter Change, 2.21 Rocker Arm Inspection, 3.19 Oil Flow, 3.18 Oil Pressure Test, 3.17 Sediment Tube, Maintenance, 2.19 Shift Linkage Adjustment, 2.11 Shift Weights, 6.10 Paint Codes, 1.12 Side Panel Removal, 5.9 Pilot Screw Adjustment, 2.12 Spark Plug Maintenance, 2.16 Piston Identification, 3.9 Special Tools, 2.6, 4.4, 7.3, 9.2 Piston Removal, 3.29...

  • Page 261: Conversion Table

    Stator Removal/Inspection, 3.34, 3.35 Troubleshooting, Ignition System, 10.15 Steering Maintenance, 2.22 Troubleshooting, Spark Plug, 3.56 Steering Post Assembly, 5.10 Troubleshooting, Starter System, 10.23 Suspension Preload Adjustment, 2.28 Suspension, Front, Inspection, 2.28 Suspension, Rear, Inspection, 2.28 U--Joint Assembly, 7.7 U--Joint Disassembly, 7.7 Unit of Measure Conversion Table, 1.15 Taillight Lamp Replacement, 10.22 Tap Drill Chart, 1.16...
  • Page 262 PN 9918066 Printed in USA...

This manual is also suitable for:

Sportsman 700 2003Sportsman 700 2002

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