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Polaris 2004-2005 Sportsman 6x6 Service Manual

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SPORTSMAN 6X6
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Summary of Contents for Polaris 2004-2005 Sportsman 6x6

  • Page 1 SPORTSMAN 6X6 SPORTSMAN 6X6...
  • Page 2 2004- -2005 Sportsman 6x6 ATV Service Manual (PN 9919504) ECopyright 2004 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 discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 3 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 Nyogel, Trademark of Wm. F. Nye Co.
  • Page 4 GENERAL MAINTENANCE ENGINE CARBURETION BODY AND STEERING CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...

  • Page 5: Table Of Contents

    GENERAL INFORMATION Specs Model Identification ..... . . Serial Number Location ....Machine Dimensions .

  • Page 6: Model Identification

    GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 0 5 C L 5 0 A A Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation ENGINE DESIGNATION NUMBERS EH500PLE104...
  • Page 7 GENERAL INFORMATION Sportsman 500 6x6 MODEL: ..MODEL NUMBER: A04CL50AA, A05CL50AA ENGINE MODEL: EH500PLE104 Category Dimension Length 105 in./266.7 cm Width 46 in./116.8 cm Height 48 in./121.9 cm Wheel Base 77 in./195.6 cm Ground Clearance 5.5 in./14 cm Gross Vehicle Weight...
  • Page 8 Dual Hydraulic Disc Alternator Output 250 w @ 5000 RPM Brake - - Rear Hydraulic Disc Voltage Regulator 3- -Phase Brake Fluid Polaris DOT 3 Brake Fluid Lights : High Beam 50 watts Low Beam 27 watts JETTING CHART AMBIENT TEMPERATURE Brake 26.9 watts...
  • Page 9 Dual Hydraulic Disc Alternator Output 250 w @ 5000 RPM Brake - - Rear Hydraulic Disc Voltage Regulator 3- -Phase Brake Fluid Polaris DOT 3 Brake Fluid Lights : High Beam 50 watts Low Beam 27 watts JETTING CHART AMBIENT TEMPERATURE Brake 26.9 watts...

  • Page 10: Optional Springs

    Sportsman 500 6x6 A05CL50AA 9919500 9919501 9919502 NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com PAINT CODES FRAME COLOR - (All) P067 Medium Gloss Black COLD WEATHER KITS FOR 4 CYCLE ATVS Engine Heater -- (PN 2871507)

  • Page 11: Special Tools

    10” Center Distance Tool PV- -43568 Fluket77 Digital Multimeter 2870630 Timing Light 2870836 Battery Hydrometer 2460761 Hall Sensor Probe Harness 2871745 Static Timing Light Harness NOTE: Polaris dealers can order the tools listed above through the Polaris Special Service Tools catalog.
  • Page 12 Standard Tools and Engine Tools machine. Some of the tools listed are mandatory and other tools maybe substituted with a similar tool, if available. Polaris reccommends the use of Polaris special tools when servicing any Polaris product. Standard Tools and Engine Tools...
  • Page 13 GENERAL INFORMATION Standard Tools and Engine Tools 2870303 -- Hone Kit 2871283 -- Crank/Water Pump Seal Install Kit Clutch (PVT) Tools 2870305 -- Stone Replacement Kit 2870506 -- Drive Clutch Puller 2870588 -- Hone Oil (12 oz.) 2870913 -- Driven Clutch Puller 2200634 -- Valve Seat Reconditioning Kit 2870654 -- ATV Clutch Align Tool...
  • Page 14 GENERAL INFORMATION Clutch (PVT) Tools Suspension Tools 2870341 -- Drive Clutch Spider Removal Tool 2870871 -- ATV Ball Joint Tool Kit 2870910 -- Roll Pin Tool 2871071 -- Shock Body Holding Tool 2871025 -- Clutch Bushing Replace Tool Kit 2871226 -- Clutch Bushing Replacement Kit 2870623 -- Shock Spring Compressor 2871572 -- Strut Rod Wrench...
  • Page 15 GENERAL INFORMATION Suspension Tools Fuel & Brake Systems 2870872 -- Shock Spanner Wrench 2870975 -- Mity Vac 2872608 -- Roll Pin Removal Tool Electrical Tools 2871351 -- Shock IFP Depth Tool PV--43568 --Fluke 77 Multimeter 2870772 -- 1.75” Wrench Transmission Tools PV--39617 -- Current Clamp 2871702 -- Shaft Drive Transmission &...
  • Page 16 GENERAL INFORMATION Electrical Tools 2870630 -- Timing Light 2871745 --Static Timing Light Harness 2460761 -- Hall Sensor Probe Harness PV--39991 -- Peak Reading Adapter PV--37453 -- Christie De--Sulfating Multi--Battery Charger PV--63070 -- Christie Multi--Battery Charger 1.12...

  • Page 17: Standard Torque Specifications

    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 exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections. Bolt Size Threads/In Grade 2...
  • Page 18 GENERAL INFORMATION SAE TAP DRILL SIZES DECIMAL EQUIVALENTS 1/64 ....0156 Thread Size/Drill Size Thread Size/Drill Size 1/32 ... .0312 .

  • Page 19: Conversion Table

    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. kg-m x 7.233 = ft.

  • Page 20: 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 = 3/8″ or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.
  • Page 21 MAINTENANCE Periodic Maintenance Chart ....2.2-2.5 Pre-Ride Inspection ..... . Recommended Lubricants and Capacities .

  • Page 22: Periodic Maintenance Chart

    Change oil immediately 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...

  • Page 23: Maintenance And Lubrication

    (if equipped) Transmission oil 25 H Monthly 155 (250) Inspect level; change yearly " " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.
  • Page 24 Inspect routing, condition " (1000) Valve clearance 100 H 12 M Inspect; adjust (1000) " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.
  • Page 25 Auxiliary brake 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) J Have an authorized Polaris dealer perform these services.

  • Page 26: Pre-Ride Inspection

    Fill hub at 4:00 or 8:00 position until fluid 2.31 Front Hubs Hub Fluid (PN 2871654) trickles out. Do not force fluid into hub. Brake Fluid Polaris DOT 3 Brake Fluid -Fill to indicated level inside reservoir. 2.33 (PN 2870990)
  • Page 27 MAINTENANCE POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS Part No. Description Part No. Description Engine Lubricant Additives / Sealants / Thread Locking Agents / Misc. 2870791 Fogging Oil (12 oz. Aerosol) 2870585 Loctitet Primer N, Aerosol, 25 g 2871098 Premium 2 Cycle Engine Oil (Quart) (12...
  • Page 28 MAINTENANCE POLARIS LUBES/FLUIDS FOR SPORTSMAN 6X6 MODELS Pure Polaris Lubricants and Maintenance Kits can be purchased at your local Polaris dealer. ATV Angle Drive Fluid 2873554 -- ATV Oil Change Kit - - Oil Filter & 3 Qts. of 0W- -40 oil...
  • Page 29 Change annually © Lubricant Approx. 27 oz. at change sion (PN 2873602) Brake Fluid Polaris DOT 3 Fill master cylinder reservoirs to As required. Change fluid every 2 years. Brake Fluid 1/4″ (6.4mm) from top, or between (PN 2870990) indicated lines. See Page 2.29.
  • 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 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 32: Transmission Lubrication

    3. Clean and reinstall the drain plug with a new sealing washer. Torque to specification. 4. Remove fill plug. 5. Add Polaris AGL Gearcase Lubricant to proper level as described above. Correct Fluid Level: Bottom Fill Plug Threads 6.

  • Page 33: Front Gearcase Lubrication

    MAINTENANCE FRONT GEARCASE 5. Install fill plug. Check for leaks. LUBRICATION Make sure vent is unobstructed Fill plug The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule. G -- Be sure vehicle is level before proceeding. G -- Check vent hose to be sure it is routed properly and unobstructed.
  • Page 34 MAINTENANCE SHIFT LINKAGE 5. Place gear selector in neutral. Make sure the transmission bell cranks are engaged in the ADJUSTMENT neutral position detents. Linkage rod adjustment is necessary when Adjust to align linkage rod end studs symptoms include: with holes in bellcrank(s). G No All Wheel Drive light G Noise on deceleration G Inability to engage a gear...

  • Page 35: Idle Speed Adjustment

    MAINTENANCE CARBURETOR/THROTTLE CHOKE (ENRICHER) INSPECTION ADJUSTMENT Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding. 1. Place the gear selector in neutral. 2. Set parking brake. 3.
  • Page 36 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. FRONT CAUTION: (Engine)

  • Page 37: Fuel System

    MAINTENANCE 5. Slowly turn mixture screw clockwise using the pilot screw wrench until engine begins to miss. 6. Slowly turn mixture screw counterclockwise until idle speed increases to maximum RPM. Continue turning counterclockwise until idle RPM begins to drop. 7. Center the pilot screw between the points in Step 5 and 6.

  • Page 38: Fuel Lines

    MAINTENANCE FUEL LINES CARBURETOR DRAINING 1. Check fuel lines for signs of wear, deterioration, The carburetor float bowl should be drained damage or leakage. Replace if necessary. periodically to remove moisture or sediment from the bowl, or before extended periods of storage. 2.

  • Page 39: Compression Test

    MAINTENANCE COMPRESSION TEST BATTERY MAINTENANCE NOTE: 4-Stroke engines are equipped with an automatic decompressor. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about 50-90 psi WARNING during a compression test. Smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition problems above idle speed.

  • Page 40: Spark Plug

    MAINTENANCE SPARK PLUG New Batteries: Batteries must be fully charged before use or battery life can be reduced by 10-30% of full potential. Charge battery for 3- -5 1. Remove spark plug high tension lead. Clean plug hours at a current equivalent of 1/10 of the area so no dirt and debris can fall into engine battery’s rated amp/hour capacity (i.e.

  • Page 41: Liquid Cooling System

    G Straight water or antifreeze may cause the 3. Remove any obstructions with compressed air or system to freeze, corrode, or overheat. low pressure water. COOLING SYSTEM Polaris 60/40 Anti-Freeze / Coolant PRESSURE TEST (PN 2871323) Refer to Page 3.5 for pressure test procedure. 2.21...

  • Page 42: Coolant Level

    Rack 1. Remove reservoir cap. Inner splash cap vent hole must be clear and open. 2. Fill reservoir to upper mark with Polaris Premium 60/40 Anti Freeze / Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.
  • Page 43 MAINTENANCE to the cover and seal all the way around. filter without folds, creases, or gaps. Proper Filter Placement Main Filter Filter Support Air Box 4. Loosen clamp remove filter assembly. Ill.2 Front 10. Reinstall filter on main filter mount. Place filter clamp over the assembly and tighten.

  • Page 44: Air Box Sediment Tube Service

    MAINTENANCE AIR BOX SEDIMENT TUBE Typical Breather Filter Location Periodically check the air box drain tube located toward the rear of the machine. Drain whenever deposits are visible in the clear tube. 1. Remove drain plug from end of sediment tube. 2.

  • Page 45: Engine Oil Service

    MAINTENANCE G -- Water will enter the recoil housing if the between the top line and the bottom line on the starter handle is disengaged from the rope dipstick. Add oil as indicated by the level on the guide when under water. dipstick.
  • Page 46 19. Reinstall drain plug. 20. Remove dipstick and fill tank with 2 quarts (1.9 L) 14. Place shop towels beneath oil filter (E) . Use Oil of Polaris Premium 4 Synthetic Oil (PN 2871844). Filter Wrench (PV- -43527), turn filter 21.

  • Page 47: Valve Clearance / Adjustment

    (PV- -43527) To Air Box Approx. Oil Tank Screen Fitting Torque: 14-17 ft. lbs. (19 Nm - -23 Nm) Recommended Engine Oil: Polaris Premium 4 All Season Slit Synthetic, 0W- -40, (PN 2871281) Oil Tank Pinch Off Ambient Temperature Range: (A) Vent Hose -40°...

  • Page 48: Steering

    MAINTENANCE 6. Repeat this step for the other intake valve. Sprocket alignment pin facing up INTAKE VALVE CLEARANCE .006″ (.15 mm) EXHAUST VALVE CLEARANCE ADJUSTMENT 500 Engine Crankshaft-to-Camshaft Centerline 6. Rotate engine slowly with recoil rope, watching the intake valve(s) open and close. NOTE: At this point watch the camshaft sprocket locating pin and slowly rotate engine until locating pin is facing upward, directly in line with the crankshaft to...

  • Page 49: Camber And Caster

    Due to the critical nature of the procedures out- lined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD- -certi- fied technician when replacing worn or dam- aged steering parts. Use only genuine Polaris replacement parts.

  • Page 50: Wheel Alignment

    MAINTENANCE WHEEL ALIGNMENT WHEEL ALIGNMENT METHOD 1: METHOD 2: CHALK STRAIGHTEDGE OR STRING 1. Place machine on a smooth level surface. 2. Set handlebars in a straight ahead position and Be sure to keep handlebars centered. See notes secure handlebars in this position. NOTE: The below.
  • Page 51 4 o’clock or 8 o’clock position. 3. Remove fill/check plug. Hold 4. Add Polaris Demand Drive Hub Fluid if necessary Rod End until fluid trickles out. NOTE: Do not force the fluid into the hub under pressure or seal damage may occur.

  • Page 52: Exhaust Pipe

    MAINTENANCE EXHAUST PIPE WARNING G Do not perform clean out immediately af- ter the engine has been run, as the ex- haust system becomes very hot. Serious burns could result from contact with ex- haust components. G To reduce fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor.

  • Page 53: Brake Pad Inspection

    MAINTENANCE BRAKE PAD INSPECTION G -- Use Polaris DOT 3 Brake Fluid (PN 2870990). Pads should be changed when the friction material is Sight Parking Brake worn to 3/64″ (.1 cm), or about the thickness of a dime. Glass Lock 3/64″...

  • Page 54: Drive Chain Service

    MAINTENANCE First, check foot brake effectiveness by applying 50 lb. within specification, adjust the chains. If the chains appear dry (no sign of lubrication), apply Chain Lube (approx.) downward force on the pedal. The top of the (PN 2872073), coating the plates and rollers as often pedal should be at least 1 inch, (25.4mm) above the as needed.

  • Page 55: Front Suspension

    If the rubber PRELOAD ADJUSTMENT boot exhibits any of these symptoms, replace the boot. Refer to Chapter 7 for CV boot replacement, or have you Polaris dealer replace the boot. Center Spring Adjustment Ring Operator weight and vehicle loading affect suspensionspringpreloadrequirements.

  • Page 56: Wheel Removal/Installation

    MAINTENANCE CONTROLS WHEEL, HUB, AND SPINDLE TORQUE TABLE Item Specification Front Wheel Nuts 27 Ft. Lbs. (27 Nm) Mid / Rear Wheel Nuts 50 Ft. Lbs.(68 Nm) Front Spindle Nut Refer to procedure listed in Chapter 7 Rear Hub Retaining Nut 80 Ft.

  • Page 57: Tire Pressure

    MAINTENANCE 2. Attach the wheel nuts and finger tighten them. Tire Tread Depth 3. Lower the vehicle to the ground. 4. Securely tighten the wheel nuts to the proper Always replace tires when tread depth is worn to torque listed in the table above. 1/8″...
  • Page 58 MAINTENANCE NOTES 2.38...
  • Page 59 GENERAL INFORMATION Torque Specifications ......EH50PL Service Data ......3.3-3.4 Special Tools .

  • Page 60: Torque Specifications

    GENERAL INFORMATION TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Size EH50PLE Ft. Lbs. (Nm) Blind Plug (Oil Pressure) 1/8 Pipe 6.5-11 (9-15 Nm) Thread Camshaft Sprocket 5-6.5 (7-9 Nm) Camshaft Chain Tensioner Lever 5-6.5 (7-9 Nm) Camshaft Chain Tensioner 5-6.5 (7-9 Nm) Camshaft Chain Tensioner Cap 11mm 14-19 (20-25 Nm)
  • Page 61 GENERAL INFORMATION EH50PLE10 ENGINE SERVICE DATA Cylinder Head / Valve EH50PLE10 Rocker Arm Rocker arm ID .8669-.8678″ (22.020-22.041 mm) Rocker shaft OD .8656-.8661″ (21.987-22.0 mm) Rocker shaft Oil Clear- .0008-.0021″ (.020-.054 mm) ance Limit .0039″ (.10 mm) Camshaft Cam lobe height 1.2884-1.2924″...
  • Page 62 GENERAL INFORMATION EH50PLE10 ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod EH50PLE10 Cylinder Surface warpage limit (mating with .0020″ (.05 mm) cylinder head) Cylinder bore 3.6221-3.6228″ (92.00-92.02 mm) Taper limit .0020″ (.050 mm) Out of round limit .0020″ (.050 mm) Piston clearance .0006-.0018″...

  • Page 63: Special Tools

    GENERAL INFORMATION SPECIAL TOOLS PISTON IDENTIFICATION The piston may have an identification mark or the PART NUMBER TOOL DESCRIPTION piston may not have an identification mark for piston placement. If the piston has an identification 2872105 Water Pump Mechanical Seal mark, follow the directions for piston placement Puller below.

  • Page 64: Cooling System Bleeding Procedure

    3. Always add coolant to the radiator first, filling to the top of 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 65 Vent hole inside cap reduce heat dissipation, resulting in possible engine liner must be clear. damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems, and comes pre-mixed and ready to use.

  • Page 66: Accessible Components

    GENERAL INFORMATION ACCESSIBLE COMPONENTS 12. Remove center drive and driven sprocket bolts and remove chain and sprockets as an assembly. The following components can be serviced or 13. Refer to PVT System to remove outer clutch removed with the engine installed in the frame: cover, drive belt, drive clutch, driven clutch, and inner cover.

  • Page 67: Honing To Oversize

    4 Cycle Engine Break-In Period is defined as the first 10 hours of engine operation, or 2 full tanks of fuel. 1. Use only Polaris Premium 4 All Season synthetic EXAMPLE OF CROSS HATCH PATTERN oil, or API certified “SH” oil. Never substitute or mix oil brands.

  • Page 68: Crankshaft Straightening

    *Oil Pressure Specification . . . 20 PSI @ 5500 RPM, Polaris 0W--40 Synthetic (Engine Hot) 2. To correct a situation like the one shown in the illustration at right, squeeze the crankshaft at point A. (Use tool from alignment kit).

  • Page 69: Oil Pressure Test

    The oil NOTE: Use Polaris Premium 4 Synthetic Engine is pumped through a delivery pipe to the oil filter. If the Lubricant (PN 2871281).

  • Page 70: Eh50Pl Oil Flow Diagram

    GENERAL INFORMATION EH50PL OIL FLOW DIAGRAM Internal passage to camshaft (front left head bolt) Oil filter Oil feed to filter From filter to crankshaft One way valve Top fitting is oil Bottom fitting is oil feed or intake exhaust or return from bottom of Oil Tank to tank...

  • Page 71: Eh50Pl Engine Exploded Views

    GENERAL INFORMATION EH50PL ENGINE EXPLODED VIEW Crankcase Cylinder/ Cylinder Head Crankshaft Valve Train and Piston 3.13...

  • Page 72: Engine Disassembly

    GENERAL INFORMATION ENGINE DISASSEMBLY should have clearance at this point. REFER TO PAGE 3.7 FOR ENGINE REMOVAL / INSTALLATION NOTES. CAM CHAIN TENSIONER/ROCKER ARM/CAMSHAFT REMOVAL 1. Remove ignition timing inspection plug from recoil housing. 5. Remove cam chain tensioner plug, sealing TDC “T”...
  • Page 73 GENERAL INFORMATION CAM CHAIN TENSIONER ROCKER ARM/SHAFT INSPECTION INSPECTION 1. Pull cam chain tensioner plunger outward to the 1. Mark or tag rocker arms to keep them in order for end of its travel. Inspect teeth on ratchet pawl (A) assembly.
  • Page 74 GENERAL INFORMATION ROCKER ARM/SHAFT INSPECTION, CONT. Rocker Shaft Oil Clearance: Std: .0008-.0021I (.020-.054 mm) Limit: .0039I (.10 mm) 5. Measure I.D. of both rocker arm shaft supports and visually inspect surface. Compare to specifications. 6. Subtract rocker shaft O.D. from rocker arm & shaft support I.D.
  • Page 75 GENERAL INFORMATION 3. Loosen three camshaft sprocket bolts. 7. Slide camshaft inward to allow removal of cam sprocket and remove sprocket from camshaft and chain. 8. Secure cam chain with a wire to prevent it from falling into the crankcase. Sprocket Teeth 4.

  • Page 76: Camshaft Inspection

    GENERAL INFORMATION If Camshaft Is Removed From Engine: 3. Turn the camshaft until the actuator ball is in the lowest position and install the release lever shaft. If Camshaft Is Installed In The Engine: 4. Use a small magnet to draw the actuator ball outward, or rotate the engine until the cam lobes face upward and install release lever shaft.

  • Page 77: Cylinder Head Removal

    GENERAL INFORMATION CYLINDER HEAD REMOVAL 3. Measure height of each cam lobe using a micrometer. Compare to specifications. 1. Remove the two 6mm flange bolts (A) from cylinder head. See next exploded view on next Journal O.D. page to view item A. 2.
  • Page 78 GENERAL INFORMATION CYLINDER HEAD EXPLODED VIEW, EH50PL EH50PL 3.20...
  • Page 79 GENERAL INFORMATION CYLINDER HEAD CYLINDER HEAD INSPECTION DISASSEMBLY WARNING: Wear eye protection or a face shield during cylinder head disassembly and reassembly. NOTE: Keep all parts in order with respect to their location in the cylinder head. 1. Thoroughly clean cylinder head (A) surface to remove all traces of gasket material and carbon.

  • Page 80: Valve Inspection

    GENERAL INFORMATION to specifications. Replace spring if either indicator. measurement is out of specification 3. Check end of valve stem for flaring, pitting, wear or damage (A). 4. Inspect split keeper groove for wear or flaring of the keeper seat area (B). NOTE: The valves cannot be re-faced or end ground.

  • Page 81: Combustion Chamber

    GENERAL INFORMATION VALVE SEAT SERVICE Valve Seat Inspection 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. See Valve Seat Reconditioning, Page 3.25.
  • Page 82 GENERAL INFORMATION Reaming The Valve Guide Good Uneven Wide Narrow NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. The valve must contact the valve seat over the entire circumference of the seat, and the seat must be the proper width all the way around.
  • Page 83 GENERAL INFORMATION If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation and must be Valve Seat Width: replaced. Be sure the cylinder head is at the proper temperature and replace the Intake Std: .028I (.7 mm) guide.

  • Page 84: Cylinder Head Assembly

    GENERAL INFORMATION 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.
  • Page 85 GENERAL INFORMATION EXHAUST VALVE CYLINDER/PISTON REMOVAL CLEARANCE ADJUSTMENT AND INSPECTION NOTE: Follow engine disassembly procedures to 500 Engine remove valve cover, camshaft and rocker arms, and cylinder head. Feeler Gauge for Both Valves NOTE: The exhaust valves share a common rocker arm, and must be adjusted using two feeler gauges.
  • Page 86 GENERAL INFORMATION PISTON REMOVAL 3. Loosen hose clamps and remove coolant inlet hose. 4. Remove the two 6 mm cylinder base bolts. 1. Remove circlip. Note piston directional arrow pointing toward the right (Mag) side of engine. 5. Loosen each of the four large cylinder base bolts 2.

  • Page 87: Cylinder Inspection

    GENERAL INFORMATION 3. Remove top compression ring. *Using a piston ring pliers: Carefully expand ring and lift it off the piston. CAUTION: Do not expand the 2. Inspect the top of the cylinder for warpage using a ring more than the amount necessary to remove it straight edge and feeler gauge.
  • Page 88 GENERAL INFORMATION PISTON-TO-CYLINDER 1. Measure piston pin bore. CLEARANCE Piston 40 mm Piston Pin Measurement Locations Piston Pin Piston Pin O.D. 1. Measure piston outside diameter at a point 40 mm .9053-.9055I (22.994-23.0 mm) down from the top of the piston at a right angle to the direction of the piston pin.
  • Page 89 GENERAL INFORMATION PISTON RING INSTALLED STARTER DRIVE REMOVAL/INSPECTION 1. Place each piston ring inside cylinder using piston 1. Remove recoil housing bolts and remove to push ring squarely into place as shown at right. housing. Feeler Gauge Cylinder 25-50mm Piston Ring 2.
  • Page 90 GENERAL INFORMATION 5. Measure the ID of the bushing in the recoil 6. Remove oil passage O-Ring (B). housing (A) and in the crankcase and record. Measure in two directions 90° apart to determine if bushing is out of round. Calculate bushing clearance.

  • Page 91: Crankcase Separation

    GENERAL INFORMATION 3. Remove cam chain (B). Inspect chain for worn or missing rollers or damage. Stretch chain tight on a flat surface and apply a 10 lb. (4.53 kg) load. One Way Valve Spring Free Length: Measure length of a 20 pitch section of chain. Std: 1.450″...

  • Page 92: Oil Pump

    GENERAL INFORMATION OIL PUMP 4. Remove three oil pump retaining bolts and pump. REMOVAL/INSPECTION 5. Inspect mating surface of crankcase and oil pump. Check for nicks, burrs, or surface irregularities. 1. Remove pump shaft bearing (A) and thrust washer (B) from pump shaft. 6.

  • Page 93: Oil Pump Assembly

    GENERAL INFORMATION 5. Install inner feed rotor and feed chamber cover with screw. 9. Measure pump end clearance using a feeler 6. Tighten screw securely. gauge and straight edge. 7. Install screen on pump body. 8. Install oil pump on crankcase and torque bolts to 6 ft.
  • Page 94 GENERAL INFORMATION CRANKSHAFT 2. Note the alignment dots on the balancer and crankshaft gears, the marks must be aligned REMOVAL/INSPECTION during reassembly. 1. Remove the shim washer (A) from the crankshaft. 3. Turn the shaft until balancer counter weights clear the crankshaft and remove the balancer shaft 2.

  • Page 95: Crankcase Bearing

    GENERAL INFORMATION PUMP SHAFT OIL SEAL/ 5. Measure the connecting rod big end radial clearance. WATER PUMP MECHANICAL SEAL REMOVAL (ENGINE Big End Radial Clearance: DISASSEMBLED) Std: .0004-.0015I (.011-.038 mm) Limit: .0020I (.05 mm) NOTE: The water pump mechanical seal can be removed without removing the engine.

  • Page 96: Bearing Installation

    GENERAL INFORMATION BEARING INSTALLATION NOTE: To ease bearing installation, warm the crankcase until hot to the touch. Place the bearings in a freezer. 1. Install the bearings so the numbers are visible. 2. Drive or press new bearings into the crankcases, using the proper driver.
  • Page 97 GENERAL INFORMATION 4. Measure the distance from the Magneto 7. Measure the width of the crankshaft at the crankcase mating surface to the main bearing bearing seats with a micrometer or dial caliper using the same method and record. and record. Crankshaft Width 8.
  • Page 98 GENERAL INFORMATION COUNTER BALANCER SHAFT END PLAY ADJUST. Counter Balancer Shaft End Play: .008″-.016″ (.02-.04 cm) Step 2 OIL PUMP SHAFT END PLAY ADJUSTMENT 1. Make sure the pump shaft bearing is firmly seated in the Magneto side crankcase. 1. Make sure all bearings are firmly seated in the crankcase.

  • Page 99: Crankcase Assembly

    GENERAL INFORMATION difficult, install two nuts on the end of the threaded rod and tighten against each other. Pump Shaft End Play: 3. Install the proper shim on the magneto end of the crankshaft. .008″-.016″ (.02-.04 cm) 4. Place the balancer shaft in the PTO crankcase aligning the timing marks on the crankshaft and balancer gears.

  • Page 100: Water Pump Mechanical Seal Installation

    GENERAL INFORMATION 4. Install the crankcase flange bolts and tighten in 3 steps following the pattern on Page 3.2 to Sealing Washer specified torque. Sealing Washer (Copper or Aluminum) Crankcase Bolt Torque: Coolant Drain Bolt 14 ft. lbs. (19 Nm) Seal Impeller Crankcase Sealant:...
  • Page 101 GENERAL INFORMATION ONE WAY VALVE 4. Ensure that the split between the puller legs is fully supported by the main body of the tool (Ill 4). INSTALLATION Install the one way valve plunger, spring, and plug Hex Socket Screws using a new sealing washer. Puller Legs One Way Valve Plug Torque: 16 ft.

  • Page 102: Piston Ring Installation

    GENERAL INFORMATION TENSIONER BLADE 5. Install the top ring (chrome faced) with the “R” mark facing up and the end gap facing forward INSTALLATION (toward the exhaust). (See ILL. 1). 6. Check to make sure the rings rotate freely in the 1.

  • Page 103: Cylinder Installation

    GENERAL INFORMATION compress the new clip more than necessary upon 3. Apply clean engine oil to the ring compressor installation to prevent loss of radial tension. Severe (Snap Ont PN RCL30) and install the engine damage may result if circlips are re-used or compressor following manufacturers...
  • Page 104 GENERAL INFORMATION 9. Tighten the cylinder bolts in three steps in a criss cross pattern and torque to specifications. 10. Install the two 6 mm bolts. Cylinder Bolt Torque: 10mm - 46 ft. lbs. (62 Nm) Guide in 6mm - 6 ft. lbs. (8 Nm) recess CYLINDER HEAD INSTALLATION...
  • Page 105 GENERAL INFORMATION 1. Apply Polaris Premium Starter Drive Grease (PN 2871460) to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil. (To install the compression release mechanism, refer to Page 3.17). 2. Install the camshaft with the lobes facing downward and the sprocket alignment pin facing upward.
  • Page 106 GENERAL INFORMATION CAMSHAFT TIMING Crankshaft to Camshaft Centerline Dots Sprocket Alignment Pin Single TDC Mark Aligned TDC Mark Rotation Do Not Use Advance Marks 3.48...
  • Page 107 GENERAL INFORMATION CAM CHAIN TENSIONER 2. Install a new O-Ring in the oil passage recess in the crankcase. INSTALLATION 3. Apply 3 Bond 1215 (PN 2871557) or an equivalent sealer to the stator plate outer surface and install a new O-Ring. 1.

  • Page 108: Thermostat Installation

    GENERAL INFORMATION Starter Drive 5. Be sure the dowel pins are in place and install the rocker shaft assembly. 6. Apply a light film of engine oil to the threads of the bolts and tighten evenly. Rocker Shaft Support Tower Bolt Torque: 9 ft.

  • Page 109: Oil Pipes

    GENERAL INFORMATION OIL PIPES 11. Remove center bolt from recoil friction plate (A). Install the oil pipes with new sealing washers. Tighten all bolts evenly to specified torque. Oil Pipe Bolt Torque: 20 ft. lbs. (27 Nm) RECOIL DISASSEMBLY/INSPECTION CAUTION: The recoil is under spring tension. A face shield and eye protection is required during this 12.

  • Page 110: Recoil Assembly

    GENERAL INFORMATION To reinstall an old spring: 1. Hook outer tab in place in recoil housing and wind spring in a counterclockwise direction one coil at a time while holding the installed coils in place. 2. Lubricate the spring with light lubricant such as Premium All Season Grease (PN 2871423).

  • Page 111: Spark Plug Fouling Checklist

    GENERAL INFORMATION SPARK PLUG FOULING Dead battery Starter motor does not turn Spark plug cap loose or faulty Engine seized, rusted, Choke cable adjustment mechanical failure plunger/cable sticking Engine Runs But Will Not Idle Foreign material on choke plunger Restricted carburetor pilot system seat or plunger Carburetor misadjusted Incorrect spark plug heat range or...
  • Page 112 GENERAL INFORMATION Cylinder head gasket leak Ignition timing misadjusted valve clearance incorrectly Low oil level adjusted Spark plug incorrect heat range Cylinder or piston worn Faulty hot light circuit Piston rings worn, leaking, broken, or Thermostat stuck closed or not opening sticking completely Bent valve or stuck valve...
  • Page 113 GENERAL INFORMATION Exploded View, Mikuni BST 34 Carburetor . . . Fuel Tank Asm. Exploded View ... . Fuel Flow Diagram ..... . . Special Tool &...
  • Page 114 GENERAL INFORMATION 1. Carburetor Assembly BST 34 CARBURETOR EXPLODED VIEW 2. Screw 3. Throttle Valve 4. Cover, Diaphragm 5. Jet Block Assembly 6. Spring 7. Diaphragm Assembly 8. Ring 9. “E” Ring 10. Ring 11. Needle Jet 12. Cover 13. O-Ring 14.

  • Page 115: Fuel Flow Diagram

    GENERAL INFORMATION FUEL TANK ASSEMBLY Vent Line Gasket Seal Foam Mounting Bracket Forward Foil Fuel Valve Fuel Valve Knob Foil Fuel Outlets FUEL FLOW Fuel Tank Fuel Tank Vent Fitting Screens Fuel Pump Filter Fuel Valve Carburetor Vent Engine Carburetor L Located Above Oil Tank...

  • Page 116: 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°...

  • Page 117: Cv Carburetor System Function (4 Cycle)

    GENERAL INFORMATION 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 Main routed.
  • Page 118 GENERAL INFORMATION 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 119: Float System

    GENERAL INFORMATION 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 120: Carburetor Cleaning

    GENERAL INFORMATION 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 121 GENERAL INFORMATION 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 122: Needle & Seat Leakage Test

    GENERAL INFORMATION 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 123: Fuel Level

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

  • Page 124: Fuel Pump Exploded View

    GENERAL INFORMATION FUEL PUMP EXPLODED VIEW 1. Fuel Pump Assembly 2. Diaphragm, Gasket Set 3. Screw and Washer Assembly 4. Screw and Washer Assembly 5. Screw and Washer Assembly 6. Pressure Regulator 7. Fuel Inlet 8. Fuel Outlet 4.12...

  • Page 125: Troubleshooting

    GENERAL INFORMATION 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 126 GENERAL INFORMATION NOTES 4.14...
  • Page 127 GENERAL INFORMATION Torque Specifications and Special Tools ..Cover/Panel Removal ......Dump Box, Exploded View .

  • Page 128: Cover/Panel Removal

    GENERAL INFORMATION TORQUE SPECIFICATIONS Lift and pull seat rearward, disengaging seat from tabs at the rear of the fuel tank Side Panels (See Page 5.6) Item Specification Remove: Seat Front A-Arm Attaching Bolt 30 ft. lbs. (41 Nm) Disengage tabs at front and rear Front A--Arm Ball JointStud 25 ft.

  • Page 129: Dump Box Exploded View

    GENERAL INFORMATION DUMP BOX EXPLODED VIEW Latch Paddle Latch Tailgate Shaft Latch Tailgate Cover Rod Hinge Reflector Tailgate Cable Latch Brackets Headrest Tail/Brake Light Shock Box Support Box Latch NOTE: All warning information labels must be in place when body parts are assembled.

  • Page 130: Body Assembly Exploded View

    GENERAL INFORMATION BODY ASSEMBLY EXPLODED VIEW Seat Rear Cab Rear Cab Assembly Rear Mud Guard Front Cover Side Cover Front Cab Front Cab Assembly Footrest Front Guard NOTE: All warning information labels must be in place when body parts are assembled.

  • Page 131: Headlight Pod Exploded View

    GENERAL INFORMATION HEADLIGHT POD Torque bolts evenly so gap is equal at front and rear of EXPLODED VIEW handlebar block 10--12 ft. lbs. (14--17 Nm) Disassembly Clean knurling when repositioning handlebars S Remove two side Phillips screws (A). S Remove one rear Phillips screw (B). Adjuster S Lift top half of pod.

  • Page 132: Side Panel Removal

    GENERAL INFORMATION SIDE PANEL REMOVAL Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove the seat. Grasp rear of side panel near Step 1. rear cab. With a quick and firm motion, pull the panel forward and outward to disengage the two rear tabs.

  • Page 133: Steering Assembly, Exploded View

    GENERAL INFORMATION STEERING ASSEMBLY, 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 positioned properly.

  • Page 134: A-Arm Replacement

    GENERAL INFORMATION A-ARM REPLACEMENT 1. Elevate and safely support vehicle with weight removed from front wheel(s). 2. Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud. 3.

  • Page 135: Concentric Swing Arm Removal

    GENERAL INFORMATION CONCENTRIC SWING ARM REMOVAL Removal / Disassembly 1. Lift rear of machine and support securely with wheels off the floor. 2. Remove drive chain. 3. Remove rear caliper. CAUTION: Do not allow the caliper to hang by the brake line. Brake line damage may result. 4.

  • Page 136: Concentric Swing Arm Assembly/Installation

    GENERAL INFORMATION CONCENTRIC SWING ARM ASSEMBLY/INSTALLATION Assembly / Installation 1. Install bushing (6) in left side of swingarm and two-piece bushings (3) in right side. 2. Clean threads of nut (1), and pivot bushings (4) with Loctitet Primer N (PN 2870585). Apply Loctitet 262 (PN 2871951) to threads of pivot bushing (4) and nut (1).
  • Page 137 GENERAL INFORMATION REAR STRUT STABILIZER 30 ft. lbs. (41 Nm) Grease Fittings Upper Stabilizer 30 ft. lbs. (41 Nm) Lower Stabilizer 30 ft. lbs. (41 Nm) Swingarm 40 ft. lbs. (54 Nm) 5.11...

  • Page 138: Rear Swing Arm Weldment

    GENERAL INFORMATION REAR SWING ARM WELDMENT Chain Cover 55 ft. lbs. 30 ft. lbs. (76 Nm) (48 Nm) Chain Cover Swing Arm Mounts Extension Swing Arm Bracket Hitch 50 ft. lbs. Lower Chain Guard (54 Nm) Guide 5.12...

  • Page 139: Strut Assembly

    GENERAL INFORMATION STRUT ASSEMBLY 15 ft. lbs. Strut Bumper (21 Nm) Spring Retainer Washer Spacer Rubber Clamp 18 ft. lbs. Upper Pivot Ball (25 Nm) 15 ft. lbs. (21 Nm) Wire retainer Washer Bolt Spacer Lower Pivot Ball Spring Retainer Washer Hub Coil Spring...

  • Page 140: Front Strut Cartridge Replacement

    GENERAL INFORMATION FRONT STRUT CARTRIDGE 3. Remove wheel nuts and wheels. REPLACEMENT NOTE: Refer to the Illustration on the previous page for this procedure. 1. Hold strut rod and remove top nut. 2. Compress spring using strut spring compressor tools. Strut Rod Wrench (PN 2871572) Strut Spring Compressor Tools (PN 2871573) and (PN 2871574)

  • Page 141: Steering Post Assembly

    GENERAL INFORMATION flame treating. Do not hold the torch too close to the surface. Keep the torch moving to prevent damage. 2. Apply the decal. STEERING POST ASSEMBLY 12 ft. lbs. (16 Nm) 8. To install new ball joint: Remove extension cap and attach puller guide using short bolts provided in the kit.
  • Page 142 GENERAL INFORMATION NOTES 5.16...
  • Page 143 CLUTCH Service Tools and Supplies ....PVT System Operation ....PVT Maintenance/Inspection .

  • Page 144: Driven Clutch Operation

    (initial vehicle movement), clutch Tool Kit upshift and backshift. During the development of a Polaris ATV, the PVT system is matched first to the engine power curve; then to average riding conditions and the vehicle’s intended usage. Therefore,...

  • Page 145: Pvt Maintenance/Inspection

    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 146 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 147: Pvt Disassembly

    CLUTCH PVT DISASSEMBLY 8. Remove driven clutch retaining bolt and driven clutch. Use the Driven Clutch Puller (PN 2870913) if necessary. NOTE: Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement. (See Page 6.6). Driven Clutch Puller (PN 2870913) 1.

  • Page 148: Pvt Assembly

    CLUTCH PVT ASSEMBLY Inner Cover Bolt Torque (Rear): 12 ft. lbs. (16.6 Nm) Seal this edge to cover on engine side Driven Clutch Retaining Bolt Torque: 17 ft. lbs. (23.5 Nm) Drive Clutch Retaining Bolt Torque: 40 ft. lbs. (55 Nm) 1.

  • Page 149: Pvt Sealing And Ducting Components

    CLUTCH PVT SEALING AND DUCTING COMPONENTS Outer Cover Seal Inner Cover Drain Inlet duct Plug Inlet Duct Inner Cover Seal Retainer Outer Cover Cover Bolts Exhaust Duct DRIVE CLUTCH EXPLODED VIEW Drive Clutch Teflont coated brass bushing Teflont coated brass bushing Mark with permanent marker before disassembly...

  • Page 150: Drive Clutch Spring Specifications

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

  • Page 151: Shift Weights

    CLUTCH SHIFT WEIGHTS Shown below are the shift weights which have been designed for, or which may be used in the PVT system. These shift weights have many 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 of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern.

  • Page 152: Shift Weight Inspection

    WASHER INSPECTION”, Page 6.12. clutch assembly! All PVT system maintenance repairs must be performed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this manual. Because of...

  • Page 153: Drive Clutch

    CLUTCH DRIVE CLUTCH DISASSEMBLY Inspect shaft Mark “X” Mark 4. Inspect area on shaft where bushing rides for wear, galling, nicks, or scratches. Replace clutch 1. Using a permanent marker, mark the cover, assembly if worn or damaged. spider, moveable and stationary sheaves, and 5.

  • Page 154: Drive Clutch Assembly

    CLUTCH Moveable Sheave Bushing Inspection the new pin during installation. 2. Inspect the Teflont coating on the moveable sheave bushing. 2. Rubber backed buttons can be used in all ATV clutches if the hollow roller pin is changed to the Teflont solid roller pin.

  • Page 155: Drive Belt Tension

    CLUTCH c) “X”, or the marks that were made earlier, under weight Spacer washers Spider Torque: 200 ft. lbs. (276 Nm) 2. Install moveable sheave onto fixed sheave. Cover Screw Torque: 3. Install spider spacers. Use same quantity and 90 in. lbs. (10.4 Nm) thickness as were removed.

  • Page 156: Drive Belt Removal/Inspection

    CLUTCH NOTE: Pinch the sheaves lightly together with clamp to prevent the belt from being pushed into the driven sheave. 1. Place a straight edge on top of the belt between drive and driven clutch. 2. Push down on drive belt until it is lightly tensioned. 3.

  • Page 157: Drive Belt Installation

    CLUTCH DRIVE BELT INSTALLATION 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 158: Drive Clutch Bushing Service

    CLUTCH CLUTCH OFFSET 1. Remove belt and install the Clutch Offset Alignment Tool (PN 2870654) as shown. 2. With tool touching rear of driven clutch inner Offset Alignment Tool sheave, the distance at point “A” should be 1/8″. (PN 2870654) If the distance is greater than 1/8″...
  • Page 159 CLUTCH 2. Remove nut from puller rod and set aside. Drive Clutch Cover 5020629 Bushing Removal/ Installation Tool (all clutches) Piston Pin Puller (PN 2870386) P--90 Driven Clutch 5020631 Cover Bushing Re- moval Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633...
  • Page 160 CLUTCH DRIVE CLUTCH COVER - 6. Turn sheave puller barrel together counterclockwise on puller rod until bushing is BUSHING REMOVAL removed. 7. Remove nut from puller rod and set aside. 8. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard. Piston Pin Puller (PN 2870386) DRIVE CLUTCH MOVEABLE...

  • Page 161: Driven Clutch Disassembly/Inspection

    CLUTCH 2. With the Main Puller Adapter (#8) (PN 5020632) 5. Turn clutch cover counterclockwise on puller rod on the puller, insert cover onto puller rod, placing until bushing is removed. outside of cover toward vise. 6. Remove nut from puller rod and set aside. 3.
  • Page 162 CLUTCH 6. Inspect ramp buttons in the moveable sheave and replace if worn. NOTE: The ramp buttons are secured by Torxt screws (T20). Belt deflection adjustment washers 1. Apply and hold downward pressure on the helix, or place driven clutch in the Clutch Compression Tool (PN 8700220).

  • Page 163: Driven Clutch Assembly

    CLUTCH DRIVEN CLUTCH ASSEMBLY Driven Spring Driven Clutch Sportsman 6X6 Driven Spring Placement: 2--2 Ill. 2 Moveable Spring Example: Helix Sheave Tension - - 1 Heavy Spring/ - - 2 Position - - 1 Align boss spline - - 3 to install helix - - 2 - - 3...
  • Page 164 CLUTCH DRIVEN CLUTCH MOVEABLE SHEAVE - BUSHING REMOVAL NOTE: Bushings are installed at the factory using Loctitet. In order to remove the bushing it will be necessary to apply heat. A press can be used to remove and install some of the bushings. Be sure to support the sheave or cover as close as possible to Clutch Bushing the bushing bore when using a press.
  • Page 165 CLUTCH 6. Install sheave onto puller. 2. Start new bushing evenly in moveable sheave. Apply Loctitet 680 (PN 2870584) to the back 7. Install nut onto puller rod and tighten by hand. side of new bushing. Turn puller barrel for further tension if needed. 8.
  • Page 166 CLUTCH 5. Turn clutch sheave counterclockwise until bushing is seated. 6. Remove nut from puller rod and set aside. 7. Remove installation tool and clutch sheave from puller. 8. Repeat installation procedure for other moveable bushing. 6.24...

  • Page 167: Troubleshooting

    CLUTCH TROUBLESHOOTING Situation Probable Cause Remedy Engine RPM -Wrong or broken drive clutch spring. -Replace with recommended spring. below specified operating -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine application. range, although engine is prop- -Driven clutch spring broken or installed in -Replace spring;...
  • Page 168 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 169 GENERAL INFORMATION Final Drive Torque Specifications ..AWD Operation Overview ... 7.2--7.3 AWD Front Hub Removal ... AWD Hub/Bearing Installation .

  • Page 170: Awd Operation Overview

    NOTE: In reverse gear the override button must be pushed to deliver power to the wheel coil. Electric hub With the Polaris All Wheel Drive System activated engagement offers an advantage over mechanical (AWD selected), the machine operates as a 2 wheel...
  • Page 171 GENERAL INFORMATION systems. When the AWD button is switched off, the possible damage brake machine will have the steering ease of a 2 wheel drive line. unit; and with the switch turned on, All wheel drive will be engaged whenever the rear wheels lose traction. FRONT HUB REMOVAL (AWD) If an AWD problem is encountered, thoroughly inspect the electrical portion of the system as well as the front...

  • Page 172: Awd Front Hub Bearing Adjustment

    Incorrect adjustment will increase bearing wear, 4:00 or 8:00 position. reduce braking action, and may affect front drive hub 8. Fill with Polaris Premium Demand Drive Hub engagement, which could result in serious personal Fluid or Type F Automatic Transmission Fluid injury or death.

  • Page 173: Awd Front Hub Exploded View

    GENERAL INFORMATION AWD FRONT HUB EXPLODED VIEW Garter Spring Brake Disc Armature Plate Seal Detail Bearing (1.000″ I.D.) DETAIL A Spacer Bearing Race Front Hub Clutch Front Hub Clutch Bearing (1.000″ I.D.) Cotter Pin Castle Nut ¡ (Use new cotter pin) O-Ring Bearing Race Washer...

  • Page 174: Awd Hub Seal Replacement

    It is very important that the brake disc be free of any oil or solvents. 6. Reinstall the brake disc using genuine Polaris 2. Remove brake disc attaching bolts and brake OEM bolts that have a pre-applied locking agent.
  • Page 175 GENERAL INFORMATION MAGNETIC COIL block to contain the coil wires. Make sure the foam block is bonded well to INSTALLATION protect the coil wires. NOTE: Coil wires must be contained in the brake line clip on the back side of the upper strut casting and the Brake Line wires must be snug against the casting.

  • Page 176: Awd Armature Plate Inspection

    GENERAL INFORMATION AWD ARMATURE PLATE 2870888) and into the groove of the rollers and cage. WARNING: If this procedure is not INSPECTION followed the spring will be over stressed and lose its tension. Springs with incorrect tension may allow rollers to move outward at high vehicle Seal Sleeve speeds.

  • Page 177: Awd Front Drive Axle Installation

    GENERAL INFORMATION 1. Loosen front wheel nuts slightly. 2. Elevate support machine under footrest/frame area with front wheels elevated. 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 drive axles or component parts.
  • Page 178 GENERAL INFORMATION 3. Install drive shaft in strut. cleaned. Refer to text for grease capacity of CV joints and CV joint boots. 4. Install lower ball joint, torque nut to 25 ft. lbs. (34.5 Nm) and install new cotter pin. FRONT DRIVE SHAFT CV 5.
  • Page 179 GENERAL INFORMATION 5. Remove clamps from rubber boot using the proper boot clamp pliers. CV Joint Grease - 30g PN 1350046 CV Joint Grease - 30g (PN 1350046) CV Boot Clamp Pliers: CV Boot Clamp Pliers: Retaining ring Earless Type (PN 8700226) Earless Type 8700226...

  • Page 180: Awd Front Drive Axle Exploded View

    GENERAL INFORMATION AWD FRONT DRIVE AXLE EXPLODED VIEW Front Drive Axle Components Boot Drive Axle CV Joint Assy Clamps Circlip Yoke U--Joint Assy Front Prop Shaft Components O-Ring Propshaft Assembly Prop Shaft Cross and Bearing Kit Yoke, Propshaft to Transmission Spring Pin Yoke, Front Gearcase 7.12...

  • Page 181: Bearing Replacement

    GENERAL INFORMATION AWD STRUT CASTING BEARING REPLACEMENT FRONT DRIVE AXLE SEAL NOTE FOR FRONT DRIVE REPLACEMENT AXLE AND FRONT HUB NOTE: The front axle bearings have a larger I.D. (1.0625″) than the hub bearings (1.000″). Be sure to install the bearings with the larger I.D. in the strut housing, and the bearings with the smaller I.D.

  • Page 182: Awd Front Prop Shaft Removal

    GENERAL INFORMATION Hub Seal Sleeve Replacement New front drive axle CV joint assemblies and drive axle assemblies have the seal sleeve installed from the factory. Not Unusual To See Seal Two Wear Rings Sleeve (Outer Magnet Pole) Inner Magnet Pole (Fixed) Coil Inner Pole Shoe...

  • Page 183: U-Joint Disassembly

    GENERAL INFORMATION U-JOINT DISASSEMBLY 4. Force U-joint cross to one side and lift out of inner yoke. CAUTION: Always wear eye protection. 1. Remove internal or external snap ring from all U-JOINT ASSEMBLY bearing caps. NOTE: If yoke or bearing is removed, cross bearing must be replaced.

  • Page 184: Awd Front Housing Removal

    GENERAL INFORMATION 3. Install snap ring to contain bearing cap just 3. Elevate support machine under installed. Repeat procedure for other side. footrest/frame area. CAUTION: Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.

  • Page 185: Awd Front Housing Disassembly

    GENERAL INFORMATION 2. Remove bolts and output shaft cover. 5. Remove pinion cover and O-ring. AWD FRONT HOUSING DISASSEMBLY, CONT. 6. Unscrew fill plug and remove pinion shaft assembly. Inspect pinion gear for chipped broken or missing teeth. NOTE: Pinion shaft assembly will not clear the fill plug unless it is backed out.
  • Page 186 GENERAL INFORMATION NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement side to side.
  • Page 187 Fill Plug 1. To install housing, reverse removal procedure. Use new roll pins in drive shafts. 2. Add Polaris Premium Front Housing Lubricant or GL5 80-90 gear lube to front housing. Check drain plug for proper torque. ATV Angle Drive Fluid (PN 2871653) (12 oz.)

  • Page 188: Awd Front Housing Exploded View

    GENERAL INFORMATION AWD FRONT HOUSING EXPLODED VIEW Vent Bushing Seal Output Shaft Pinion Shaft Pinion Cover Bearing Retaining Ring O-Ring Shim Output Cover Bearing O-Ring Thrust Button Seal Shim Seal 7.20...

  • Page 189: Middle Axle Removal

    GENERAL INFORMATION CONCENTRIC SWINGARM MIDDLE AXLE REMOVAL 5. Remove retaining ring (A), nut retainer (B) and foam seal (C) from right side of axle. 1. Securely support rear of machine with middle wheels off the floor. Remove middle wheels and hubs.

  • Page 190: Middle Axle Disassembly

    GENERAL INFORMATION 7. Remove the jam nut (D) and locking middle axle 10. Remove rear brake caliper. Support with wire or hub (E). tie strap. Do not hang caliper by brake line. 8. Remove swing arm housing (F), bearing spacer (G), and O-rings (H).

  • Page 191: Middle Axle Assembly

    GENERAL INFORMATION 3. Remove jam nut (D) and locking mid axle hub (E). 2. Install disc hub assembly on axle. Be sure hub Remove swing arm housing and O-rings (F). covers stop ring. Install disc in soft jawed vise. Discard O-rings. Inspect bearing and seals, Apply Never Seize to threads, install left axle nut replace if worn or damaged.

  • Page 192: Middle Axle Installation

    GENERAL INFORMATION 5. Install foam seal and nut retainer with taper inside of middle chain sprocket hub and slide toward locking hub. Install retaining ring. sprocket hub assembly onto the axle as the axle is being installed. Seat the hub against O-ring and bearing.
  • Page 193 13. Lubricate eccentric housing and swing arm by rolling ATV forward and checking chain tension housings grease fittings with Polaris Premium All in several places on chain. Season Grease until grease is purged on each side of eccentric and swing arm housing.
  • Page 194 GENERAL INFORMATION CONCENTRIC SWINGARM MIDDLE AXLE ASSY, EXPLODED VIEW 17 18 19 11 12 20 21 23 24 31 32 1. Retaining Ring 33 34 36 37 38 39 2. Retainer Nut 40 41 3. Foam Seal 19. Lip Seal 4.

  • Page 195: Middle Housing Removal

    GENERAL INFORMATION CONCENTRIC SWINGARM MIDDLE HOUSING MIDDLE HOUSING REMOVAL DISASSEMBLY/BEARING SERVICE 1. Remove middle axle. (See Page 7.20) Upper Bearing Caliper Mount Caliper Seal Seal Lower Caliper Mount Mount Bolts Bearing Race 2. Remove the upper and lowerbrake caliper 1. Remove seals from housing. mounting brackets.

  • Page 196: Rear Axle Removal

    GENERAL INFORMATION CONCENTRIC SWINGARM 4. Remove axle nut and washer. 5. Place a block of wood on end of axle or use a soft MIDDLE HOUSING face hammer, and drive axle out from right to left. INSTALLATION 6. Tap locating collar on left side of axle toward the right enough to expose the circlip retainer.
  • Page 197 GENERAL INFORMATION REAR DRIVE AXLE SERVICE Apply Loctitet 242 to the bolt threads. 150 ft. lbs. (207 Nm) 50 ft. lbs. (69 Nm) 80 ft. lbs. (110 Nm) 80 ft. lbs. (110 Nm) Flat Washer A. Retainer Ring B. Bearing Spacer C.
  • Page 198 GENERAL INFORMATION NOTES 7.30...
  • Page 199 TRANSMISSION Special Tools and Torque Specifications ..Gear Shift Selector Removal ....Gear Shift Selector Disassembly ... 8.2--8.3 Gear Shift Selector Assembly .

  • Page 200: Gear Shift Selector Removal

    TRANSMISSION SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2871710 10” Center Distance Tool Torque Specifications Transmission Case Bolts ..12 ft. lbs. (16.6 Nm) Bell Crank Nut ....12 ft.

  • Page 201: Gear Shift Selector Assembly

    10. Dry all gear shift selector parts and remove any jawed vise. corrosion with a wire brush. 4. Fill selector body with Polaris 0W-40 All Season Synthetic motor oil. The oil level should be at one half the height of the slides (approx. 1 oz.).

  • Page 202: Gear Shift Selector Installation

    TRANSMISSION 5. Slide boot off selector rod and replace with a new one. CAUTION: Too much oil could cause the selector to 6. Apply RTV silicone to selector rod to seal top of hydrolock. Be sure the selector box is level when boot.

  • Page 203: Transmission Removal

    TRANSMISSION TRANSMISSION REMOVAL TRANSMISSION DISASSEMBLY 1. Place both bellcranks in neutral position. 2. Remove sprocket retaining clip and sprocket. CAUTION: Remove switch(es) BEFORE removing case cover. 3. Remove the transmission cover bolts. Remove Gear Indicator Switches 1. Remove seat, cab and air box. 2.
  • Page 204 TRANSMISSION 6. Remove outer thrust washer. Low Gear (2) Remove needle bearing (1) Work gear back and forth until bearing is exposed 10. Remove snap ring from front drive input shaft. Ill. 3 11. Remove output shaft and gear assembly along with sprocket and chain, by tapping on shaft with a 7.

  • Page 205: Transmission Assembly

    TRANSMISSION 13. Use a 1/2″ wrench to rotate high/reverse bell crank and remove shift fork along with shafts. 2. Torque bolts in 3 steps using a criss-cross pattern 14. Remove front drive input shaft bearing retainer to 18 ft. lbs. (25 Nm). plate.
  • Page 206 17. Install drain plug with a new sealing washer. 8. Install snap ring. Torque drain plug to 14 ft. lbs. (19 Nm). 18. Install transmission and add Polaris AGL Gearcase Lubricant in the recommended Small I.D. washer amount.
  • Page 207 TRANSMISSION TRANSMISSION EXPLODED VIEW 1. Seal 12. Oil Fill Plug 23. Seal 34. 13 T Pinion Shaft 45. Washer 2. Screws 24. Bearing 13. H/L/R Bellcrank 35. Bearing 46. Retaining Ring 3. Snorkel Cover 25. Roller Chain 14. H/R Bellcrank 36.

  • Page 208: Troubleshooting

    TRANSMISSION TROUBLESHOOTING CHECKLIST Check the following items when shifting difficulty is encountered. G Idle speed adjustment G Transmission oil type/quality G Transmission torque stop adjustment G Engine torque stop adjustment G Drive belt deflection G Loose fasteners on rod ends G Loose fasteners on shifter G Worn rod ends, clevis pins, or pivot arm bushings G Linkage rod adjustment and rod end positioning...
  • Page 209 GENERAL INFORMATION Specifications/Torques ....Special Tools ..... . Brake System Service Notes .

  • Page 210: Specifications

    GENERAL INFORMATION SPECIFICATIONS Item Standard Service Limit Brake Pad Thickness .298 ± .0073″ / 7.56 ± .185 mm .180″ / 4.6 mm Brake Disc Thickness .150-.165″ / 3.810-4.191 mm .140″ / 3.556 mm Brake Disc Thickness Variance Between .002″ / .051 mm Measurements Brake Disc Runout .010″...

  • Page 211: Special Tools

    GENERAL INFORMATION SPECIAL TOOLS Test for brake drag after any brake system service and investigate cause if brake drag is evident. PART NUMBER TOOL DESCRIPTION Make sure caliper moves freely on guide pins. 2870975 Mity Vact Pressure Test Tool Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely.

  • Page 212: Hydraulic Brake System Operation

    When servicing Polaris ATV brake systems use only Polaris DOT 3 High Temperature Brake Fluid (PN 2870990). Polaris brake fluid is sold in 5.5 oz. bottles. WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid. Brake fluid is...

  • Page 213: Dual Hydraulic Caliper Bleeding

    GENERAL INFORMATION which can lead to early brake fade and the possibility of serious injury. DUAL HYDRAULIC CALIPER BLEEDING DH CALIPER CUTAWAY VIEW Left Hand Brake Bleed Screw Left Hand Brake Line Piston Right Hand Brake Bleed Screw Right Hand Brake Line Dust Seal Square Ring Piston Seals...

  • Page 214: Brake System Main Components

    REAR BRAKE CALIPER FRONT BRAKE CALIPER EXPLODED VIEW Adjuster Screw Square O--Rings Bleeder Screw Piston 35--60 IN. LBS. (4--6.5 NM) Caliper Body Pads Pin Boot Caliper Mount APPLY POLARIS DOT 3 BRAKE APPLY POLARIS ALL PURPOSE FLUID DURING ASSEMBLY GREASE DURING ASSEMBLY...

  • Page 215: Fluid Replacement/Bleeding Procedure

    5. Add brake fluid to the upper level mark on surfaces. reservoir. BRAKE BLEEDING - FLUID Polaris DOT 3 Brake Fluid CHANGE (PN 2870990) NOTE: This procedure should be used to change fluid or bleed brakes during regular maintenance.
  • Page 216 GENERAL INFORMATION 9. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Add fluid as necessary to maintain level in reservoir. CAUTION: Maintain at least 1/2″ (1.27 cm) of brake fluid in the reservoir to prevent air from entering the master cylinder.

  • Page 217: Master Cylinder Disassembly

    INSTALLATION Notice: When replacing the brake master cylinder assembly or master cylinder parts, use the correct parts. There are differnt brake master cylinders for the different Polaris ATV models. Refer to your parts manual or guide for the correct parts.

  • Page 218: Front Pad Removal

    GENERAL INFORMATION FRONT PAD REMOVAL 5 in.lbs. (0.56 Nm) 1. Elevate and support front of machine. Torque this bolt first Torque both bolts to 25 in.lbs. (3 Nm) 1. Install master cylinder on handlebars. Torque mounting bolts to 25 in. lbs. (3 Nm). Torque the inside bolt first as indicated in the illustration to the right.

  • Page 219: Front Pad Assembly

    FRONT PAD ASSEMBLY 1. Lubricate mounting bracket pins with a light film of 6. Measure the thickness of the pad material. Polaris Premium All Season Grease, and install Replace pads if worn beyond the service limit. rubber dust boots. 9.11...
  • Page 220 GENERAL INFORMATION 18 ft. lbs. (25 Nm) Front Caliper Mounting Bolts Polaris Premium All Season Grease Torque: 18 ft. lbs. (25Nm) (PN 2871423) 4. Slowly pump the brake lever until pressure has 2. Compress mounting bracket and make sure dust been built up.

  • Page 221: Brake Pad Burnishing Procedure

    GENERAL INFORMATION 7. Install wheels and torque wheel nuts. 3. Mount dial indicator as shown to measure disc runout. Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if Front Wheel Nut Torque runout exceeds specifications. 20 ft.

  • Page 222: Front Caliper Removal

    GENERAL INFORMATION CAUTION: Always use new brake disc mounting 2. Push upper pad retainer pin inward and slip brake bolts. The bolts have a pre-applied locking agent pads past edge. which is destroyed upon removal. FRONT CALIPER REMOVAL CAUTION: Use care when supporting vehicle so that it does not tip or fall.

  • Page 223: Front Caliper Inspection

    GENERAL INFORMATION FRONT CALIPER 3. Remove mounting bracket, pin assembly and dust boot. INSPECTION Remove 1. Inspect caliper body for nicks, scratches or wear. Mounting Bracket Measure bore size and compare to specifications. Replace if damage is evident or if worn beyond service limit.

  • Page 224: Front Caliper Assembly

    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 225: Front Caliper Installation

    GENERAL INFORMATION FRONT CALIPER INSTALLATION Front Wheel Nut Torque 20 ft. lbs. (27 Nm). 1. Install caliper on hub strut, and torque mounting bolts. REAR BRAKE PAD REMOVAL 18 ft. lbs. (25 Nm) Front Caliper Mounting Bolt Torque 18 ft. lbs. (25 Nm) 2.

  • Page 226: Rear Caliper Removal/Inspection

    GENERAL INFORMATION 5. It is recommended that a burnishing procedure be performed after installation of new brake pads to Rear Brake Pad Thickness extend service life and reduce noise. Start .38″ (9.65 mm) machine and slowly increase speed to 30 mph. Gradually apply brakes to stop machine.

  • Page 227: Rear Caliper Assembly

    GENERAL INFORMATION 5. Remove square-rings and dust seal. Clean 2. Seat dust seal in caliper body. square-ring grooves. 3. Install new O-rings in caliper mounting ears. 6. Clean disc, caliper body, and piston with brake 4. Install caliper and brake pads with friction material cleaner or alcohol.

  • Page 228: Troubleshooting

    GENERAL INFORMATION REAR BRAKE DISC TROUBLESHOOTING INSPECTION Brakes Squeal Dirty/contaminated friction pads 1. Visually inspect disc for scoring, scratches, or Improper alignment gouges. Replace the disc if any deep scratches Worn disc are evident. Worn disc splines Poor Brake Performance Air in system Rear Brake Disc...
  • Page 229 ELECTRICAL Special Tools and Electrical Notes ..10.2 Timing Check Procedure / Curve ..10.2 ECM Operation ....10.3-10.4 Trans.

  • Page 230: Electrical Service Notes

    ELECTRICAL SPECIAL TOOLS TIMING CHECK PROCEDURE PART NUMBER TOOL 1. The ignition timing check hole is in the starter DESCRIPTION recoil/magneto housing. Remove the check plug. PV- -43568 Fluket77 Digital NOTE: The ignition timing marks are stamped on the Multimeter outside of the flywheel.

  • Page 231: Ecm Operation

    The output can be reset by The ECM (logic box) integrates three electronic removing load from it by turning the key switch or features found on the Polaris ATV. These features are LHCA switch off. alternator rectifier/regulator, engine temperature The ACC_PWR switch has a linear current limit.

  • Page 232: Gear Position Indicator

    ELECTRICAL Wire Description Color Orange BAT_PROT -- Protected battery output used to power the headlight and instrument cluster. Brown GND -- Battery Negative Blue/ HOT_LAMP -- Engine hot signal. White Provides a ground path for a lamp. BAT+ -- Positive side of battery. Both pins should be used to carry current.
  • Page 233 Introduction 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 234 ELECTRICAL excessively high voltage on the DC bus. Begin entering the next service hour total by releasing and pressing the mode/reverse override Diagnostic Mode button. Each time the mode/reverse override button Refer to Page 10.13 on how to operate the diagnostic is pressed and released the service interval time is mode.
  • Page 235 ELECTRICAL NOTE: Any movement of the tires will trigger the To enter the diagnostics mode: speedometer out of the diagnostic mode. 1. Turn the key switch off and wait 10 seconds. 2. Set the park brake and shift the transmission to neutral.
  • Page 236 ELECTRICAL SPEEDOMETER TROUBLESHOOTING - - 2004 MODELS 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 237 ELECTRICAL SPEEDOMETER TROUBLESHOOTING - - 2004 MODELS TEST 2 - - NO SPEEDOMETER AND/OR ODOMETER DISPLAY CHECK FOR START HERE MINIMUM 6VDC REPLACE ON PIN B TO SPEEDO PIN C KEY & STOP 3 Pin Connector SWITCHES ON REPLACE SPEEDO A: D.C.
  • Page 238 ELECTRICAL SPEEDOMETER TROUBLESHOOTING - - 2004 MODELS 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 ABOVE 3100 RPM,IT MAY BE A MECHANICAL PROBLEM. SPEEDO TURN ATV CHECK...
  • Page 239 ELECTRICAL SPEEDOMETER TROUBLESHOOTING - - 2004 MODELS 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 CHECK 1. Red- - 12V Constant 9. Blue White- - Engine Overheat Switch INSTRUMENT SPEEDOMETER 2.
  • Page 240 ELECTRICAL SPEEDOMETER TROUBLESHOOTING - - 2004 MODELS TEST 7 SHIFT INDICATOR NOT WORKING (TRANSMISSION SWITCH) Operation: The Instrument cluster sends signals from the #12, #13, #14 and #15 output wires on the connector to the transmission switches. These signals complete their path on the Brown wire at the front transmission switch.
  • Page 241 ELECTRICAL SPEEDOMETER TROUBLESHOOTING CONT’D - - 2004 MODELS TEST 8 - - - - RESET SPEEDOMETER If the key switch or engine stop switch is turned off with the vehicle in motion, the speedometer indicator needle may stick, indicating the speed at which the vehicle was traveling when the speedometer lost power.
  • Page 242 Ill.2 Interval”. *Diagnostic Mode is for informational purposes only. Introduction Consumers should return the ATV to their Polaris Refer to Illustration 1: dealer. See “Diagnostic Mode Operation” on the The Polaris ATV Instrument Cluster is powered by next page for more information.

  • Page 243: Diagnostic Mode

    ELECTRICAL The initial screen display refers to the software version installed on your ATV. This information is only displayed briefly. Screen 1: The first screen indicates battery voltage. Refer to Ill. 2. 4. High/Low Battery Voltage This warning usually indicates that the ATV is being Ill.
  • Page 244 ELECTRICAL Screen 4: Gear circuit diagnostic. This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. NOTE: 10--20% variance from these readings is within normal parameters. 628 Ohms in High Screen 5: Programmable service interval. The purpose of the programmable service interval is to provide the consumer and dealer with a convenient 23 Ohms in Park...
  • Page 245 ELECTRICAL service interval mode. NOTE: To leave the diagnostic mode, turn the key 2. Press and hold the mode button for approximately switch off and on. 7 seconds until the word OFF appears in the Rider Information Center. The service interval is now off. NOTE: Any movement of the tires will trigger the 3.
  • Page 246 ELECTRICAL SPEEDOMETER TROUBLESHOOTING - - 2005 MODELS TEST 1 - - NO ALL WHEEL DRIVE Note: If AWD icon comes on, instru- START HERE - - ment cluster is O.K. Proceed to me- ENGINE OFF chanical tests (in Service Manual). - - KEY SWITCH ON Check the AWD icon on instrument clus- - - TRANSMISSION IN LOW...
  • Page 247 ELECTRICAL SPEEDOMETER TROUBLESHOOTING - - 2005 MODELS TEST 2 - - NO SPEEDOMETER AND/OR ODOMETER DISPLAY CHECK FOR REPLACE START HERE MINIMUM 6VDC SPEEDO ON PIN B TO PIN C KEY & STOP 3 Pin Connector SWITCHES ON REPLACE MEASURE SPEEDO BACK OF A: D.C.
  • Page 248 ELECTRICAL SPEEDOMETER TROUBLESHOOTING - - 2005 MODELS TEST 4 - - NO AWD HUB SAFETY LIMIT NOTE: IF THE AWD ICON DOES NOT COME ON OR IF 12 VDC IS NOT REGISTERING AND AWD IS ENGAGING START HERE ABOVE 3100 RPM,IT MAY BE A MECHANICAL PROBLEM. SPEEDO ATV IN NEUTRAL CHECK...
  • Page 249 ELECTRICAL SPEEDOMETER TROUBLESHOOTING - - 2005 MODELS 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. Orange/White- - 12V Ignition Switch 9. Blue White- - Engine Overheat Switch CHECK 2.
  • Page 250 ELECTRICAL SPEEDOMETER TROUBLESHOOTING - - 2005 MODELS TEST 7 SHIFT INDICATOR NOT WORKING (TRANSMISSION SWITCH) 16 Pin Connector Operation: The Instrument cluster sends signals from the #12, #13, #14 and #15 output wires on the connector to the transmission 1. Orange/White- - 12V Ignition Switch switches.
  • Page 251 ELECTRICAL INSTRUMENT CLUSTER INSTRUMENT CLUSTER REMOVAL INSTALLATION 1. Remove the three screws that secure the NOTE: Do not allow alcohol or petroleum products to headlight pod cover and disconnect the wire come in contact with the instrument cluster lens. connectors from the instrument cluster. 1.

  • Page 252: Fan Motor Current Draw

    ELECTRICAL TEMPERATURE SENSOR THERMISTER READING DURING OPERATION (THERMISTOR) TEST Condition Approx. Reading Temperature (Min- -Max) Hot Light 178Ω -- 190Ω 215° F (102° C) Fan Off 296Ω -- 316Ω 180° F (82° C) Fan On 236Ω -- 251Ω 195° F (91° C) FAN MOTOR CURRENT DRAW A current draw test will provide a good indication of fan motor condition.

  • Page 253: Etc Operation Test

    ELECTRICAL FAN CONTROL SWITCH ETC OPERATION TEST OPERATION TEST Remove throttle block cover by carefully releasing all tabs around edge of cover. The fan is controlled through the ECM and thermistor. Place transmission in neutral and apply parking Refer to “Engine Temperature Controller” for fan brake.

  • Page 254: Flywheel Identification

    ELECTRICAL FLYWHEEL IDENTIFICATION Flywheel Identification Stamp Location The flywheel can be identified by the stamp mark in location A. Refer to “I.D.” location in chart below. Do not use the cast mark to determine flywheel application. Engine Application Type Cast Stamp Comment I.D.
  • Page 255 ELECTRICAL COMPONENTS OF EH500PLE / 250 WATT ALTERNATOR NOTE: CDI boxes may look the same but have different internal circuitry. Be sure to always use the correct CDI box part number. Refer To Wiring Diagrams For Specified Stator Coil Resistance Resistor Ignition Coil...

  • Page 256: Ignition System Testing Flow Chart

    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 257: Charging System Testing Flow Chart

    ELECTRICAL CHARGING SYSTEM TESTING FLOW CHART Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not kinked or pinched. Using a multitester set on D.C. volts, mea- sure the battery open circuit voltage (See Remove the battery and properly ser- earlier test).

  • Page 258: Ignition System Troubleshooting

    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 259: Alternator Output Test

    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” point should occur at approximately 1500 RPM or lower.

  • Page 260: Battery Identification

    ELECTRICAL BATTERY IDENTIFICATION INITIAL BATTERY ACTIVATION NOTICE: It is important to identify what type of battery you have installed in your ATV. Different types WARNING of batteries require different service procedures. Proper servicing and upkeep of your battery is very important for maintaining long battery life.

  • Page 261: Battery Charging

    ELECTRICAL SEALED LOW MAINTENANCE case and shorten the life of the battery. Refer to the Battery Activation and Maintenance Video (PN BATTERY 9917987) for proper instruction on servicing Low Maintenance batteries. NOTE: All Low Maintenance batteries are fully NEVER attempt to add electrolyte or water to a Low charged and tested at the factory before Maintenance battery.

  • Page 262: Battery Installation

    ELECTRICAL Battery Charging Reference Table Whenever removing or reinstalling the battery, disconnect the negative (black) cable first and State of Voltage Action Charge reinstall the negative cable last! Charge Time (*See 3. Remove the battery. note below) 100% 12.8--13 V None, None Re- SEALED LOW MAINTENANCE...

  • Page 263: Battery Load Test

    ELECTRICAL GCharge at a rate no greater than 1/10 of OPEN CIRCUIT VOLTAGE the battery’s amp/hr capacity until State of Maintenance YuMicront the voltage reaches 13.0VDC or charge Free Type greater. 100% 13.0V 12.70V GStore the battery either in the machine 75% Charged 12.80V 12.50V...
  • Page 264 Use the section that BATTERY applies to the battery. TERMINALS/TERMINAL BOLTS WARNING Use Polaris corrosion resistant Nyogelt grease (PN 2871329) on battery bolts. See Battery Installation. Battery electrolyte is poisonous. It contains CONVENTIONAL BATTERY sulfuric acid. Serious burns can result from con- tact with skin, eyes or clothing.

  • Page 265: Starter Troubleshooting / Voltage Test

    ELECTRICAL 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, 2. Disconnect battery negative (-) (black) cable first, Specific Gravity Test and Load Test. followed by the positive (+) (red) cable.

  • Page 266: Off Season Storage

    ELECTRICAL CONVENTIONAL BATTERY OPEN CIRCUIT VOLTAGE OFF SEASON STORAGE State of Conventional YuMicront charge Lead-acid Type To prevent battery damage during extended periods 100% 12.60V 12.70V of non-use, the following basic battery maintenance Charged 12.40V 12.50V items must be performed: 75% Charged 12.10V 12.20V...
  • Page 267 ELECTRICAL CONVENTIONAL BATTERY HEADLIGHT LAMP REPLACEMENT CHARGING PROCEDURE CAUTION: Do not service while headlight is hot. 1. Remove the battery from the ATV to prevent Serious burns may result. Protect lamp during install. damage from leaking or spilled acid during Remove 3 screws charging.

  • Page 268: Brake Light Switch

    ELECTRICAL LOWER HEADLAMP 1. From the rear of the taillight remove two screws holding lens cover in place and remove lens REMOVAL/INSTALLATION cover. 2. Remove lamp and replace it with recommended lamp. Apply Nyogelt Grease (PN 2871329). Lower Headlamps 3. Test the taillight/brakelight to see it is working. 4.
  • Page 269 ELECTRICAL HIGH BEAM HEADLIGHT Position Snap pins knob in into tabs ADJUSTMENT slot and Slip O-Ring secure over pin in lock- 25’ (7.6 m) ing tabs Lamp Center Height Route Adjustment plug over Knob Stop handlebar 2″ (5.1 cm) 5. Carefully remove headlamp bulb from housing. 6.

  • Page 270: Headlamp Switch

    ELECTRICAL HEADLAMP SWITCH STARTER SYSTEM TROUBLESHOOTING Starter Motor Does Not Turn GBattery discharged - low specific gravity GLoose or faulty battery cables or corroded connections (see Voltage Drop Tests) GRelated wiring loose, disconnected, or corroded GPoor ground connections at battery cable, starter motor or starter solenoid (see Voltage Drop Tests) GFaulty starter button...

  • Page 271: Voltage Drop Test

    ELECTRICAL VOLTAGE DROP TEST 2. Remove the two bolts, washers, and sealing O-Rings. Inspect O-Rings and replace if damaged. The Voltage Drop Test is used to test for bad connections. When performing the test, you are testing the amount of voltage drop through the connection.

  • Page 272: Armature Testing

    ELECTRICAL BRUSH 4. Inspect surface of commutator for wear or discoloration. See Steps 3-6 of armature testing INSPECTION/REPLACEMENT on Page 10.44. 5. Install a new carbon brush assembly in the brush housing. NOTE: Be sure that the terminal bolt insulating washer is properly seated in the Brush Set housing, and the tab on the brush plate engages the notch in the brush plate housing.
  • Page 273 ELECTRICAL 3. Using digital multitester, measure 2. Place shims on drive end of armature shaft with resistance between each of the commutator phenolic washer outermost on shaft. Engage segments. The reading should be .3 ohms or tabs of stationary washer in drive end housing, less.

  • Page 274: Starter Drive

    (PN 7042039). Use either of the following methods to positioned properly so that it will hold the lock ring remove and install a new garter spring. in its groove. Starter Motor Exploded View Polaris Premium Starter Drive Grease Rear Brkt Assy Carbon (PN 2871460) Washer Set...

  • Page 275: Starter System Testing Flow Chart

    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 276 ELECTRICAL NOTES 10.48...
  • Page 277 ELECTRICAL WIRING DIAGRAM 2004 SPORTSMAN 6X6...
  • Page 278 ELECTRICAL WIRING DIAGRAM 2004 SPORTSMAN 6X6...
  • Page 279 ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN 6X6 (BUILT BEFORE JULY 12, 2004)
  • Page 280 ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN 6X6 (BUILT BEFORE JULY 12, 2004)
  • Page 281 ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN 6X6 (BUILT AFTER JULY 12, 2004)
  • Page 282 ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN 6X6 (BUILT AFTER JULY 12, 2004)
  • Page 283 Index Brake Hose/Fitting Inspection, 2.33 Brake Light Switch Testing, 10.40 Specifications, Brake Noise, Specifications, Brake Pad Application, Brake Pad Assembly, Front, 9.11 Brake Pad Inspection, 2.33 Brake Pad Installation, Rear, 9.18 A-Arm Replacement, Brake Pad Removal, Front, 9.10 Air Filter Service, 2.22 Brake Pad Removal, Rear, 9.17...
  • Page 284 Carburetor Needle and Seat Testing, 4.10 Counter Balancer Installation, 3.41 Carburetor Operation, Counter Balancer Shaft End Play, 3.40 Carburetor Pilot System, 2.16, Counter Balancer Shaft Removal/Inspection, 3.35 Cover/Panel Removal, Carburetor Starter System, Crankcase Assembly, 3.41 Carburetor System Function, Crankcase Bearing Inspection, 3.37 CDI Output Test, 10.30...
  • Page 285 Drive Belt Removal/Inspection, 6.14 ETC Operation Test, 10.25 ETC Switch Adjustment, 2.17 Drive Belt Tension, 6.13 ETC Switch Testing, 10.25 Drive Chain Inspection/Adjustment, 2.34 Exhaust System, Maintenance, 2.32 Drive Clutch Assembly, 6.12 Exhaust Valve Adjustment, 2.28, 3.27 Drive Clutch Bushing Service, 6.16, 6.18, 6.19 Drive Clutch Disassembly, 6.11, 6.12...
  • Page 286 Gear Shift Selector Assembly, Gear Shift Selector Disassembly, Jetting Guidelines, Gear Shift Selector Installation, Gear Shift Selector Removal, Gearcase Assembly, Front, 7.17 Gearcase Disassembly, Front, 7.16, 7.17 Keys, Replacement, Gearcase Exploded View, Front, 7.20 Gearcase Installation, Front, 7.19 Gearcase Lubrication, Front, 2.13 Load Test, 10.35, 10.38...
  • Page 287 Oil Pump Priming--Magnum 500, 2.27 Rear Axle Bend, 7.29 Oil Pump Removal/Inspection, 3.34 Rear Axle Installation, 7.28 Rear Axle Removal, 7.28 Oil Pump Shaft End Play, 3.40 Rear Drive Axle, Exploded View, 7.29 One Way Valve, 3.33 Rear Strut Stabilizer, 1.11 One Way Valve Installation, 3.43...
  • Page 288 Starter Drive Installation, 3.50 Transmission Removal, Starter Drive Removal/Inspection, 3.31 Troubleshooting, Brakes, 9.20 Starter Motor Armature Testing, 10.44 Troubleshooting, Cooling System, 3.54 Starter Motor Brush Inspection/Replacement, Troubleshooting, Engine, 3.53 10.44 Troubleshooting, Fuel System/Carb, 4.13 Starter System Test, 10.47 Troubleshooting, Ignition System, 10.30 Stator Installation, 3.49...

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