Polaris SPORTSMAN 400 2003 Service Manual
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Polaris SPORTSMAN 400 2003 Service Manual

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T h e Wa y O u t .
2003 SPORTSMAN 400 / 500
SERVICE MANUAL
PN 9918065

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  • Page 1 T h e Wa y O u t . 2003 SPORTSMAN 400 / 500 SERVICE MANUAL PN 9918065...
  • Page 2 2003 Sportsman 400/500 ATV Service Manual (PN 9918065) 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 improcvements 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 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 STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm.

  • 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 6 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION Model Identification ..... . . Serial Number Location ....Machine Dimensions .

  • Page 7: General Information

    GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 0 3 C H 5 0 A A Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation ENGINE DESIGNATION NUMBERS 42 EH42PLE05...

  • Page 8: General Information

    GENERAL INFORMATION MACHINE DIMENSIONS SPORTSMAN 400/500 47 in 114 cm 11 in 28 cm 46 in 117 cm 46 in 117 cm 81 in 400 -- 205.7 cm 500 -- 85 in 216 cm 51 in 128 cm 51 in 129.5 cm...
  • Page 9 GENERAL INFORMATION SPORTSMAN 400 MODEL: ..MODEL NUMBER: A03CH42 ENGINE MODEL: EH42PLE05 JETTING CHART AMBIENT TEMPERATURE CARBURETION Altitude ltitude Below 40°F Below 40 F +40_F and above +40 F and above Below +5°C +5_C and above Type...
  • Page 10 . . . 1 oz. (30ml) PP4* Lubricant Key *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 11 GENERAL INFORMATION SPORTSMAN 500 H.O. MODEL: ..MODEL NUMBER: A03CH50 ENGINE MODEL: EH50PLE13 JETTING CHART AMBIENT TEMPERATURE CARBURETION Altitude ltitude Below 40°F Below 40 F +40_F and above +40 F and above Below +5°C +5_C and above Type...
  • Page 12 . . . 1 oz. (30ml) PP4* Lubricant Key *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .

  • Page 13: Publication Numbers

    GENERAL INFORMATION PUBLICATION NUMBERS Year Model Model No. Owner’s Parts Parts Manual PN Manual PN Micro Fiche PN 2003 Sportsman 400 A03CH42 9917492 9917537 9917538 2003 Sportsman 500 A03CH50 9917492 9917541 9917542 When ordering service parts be sure to use the correct parts manual. FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147.

  • Page 14: Standard Torque Specifications

    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 15: Decimal Equivalents

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

  • Page 16: 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 17: Decimal Equivalent Chart

    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 7/8-9 49/64...

  • Page 18: 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 19 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 20 MAINTENANCE CHAPTER 2 MAINTENANCE Periodic Maintenance Chart ....2.2-2.3 Pre-Ride Inspection ..... . Recommended Lubricants and Capacities .

  • Page 21: 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. CAUTION: Due to the nature of these adjustments, it is recommended that service be performed by an authorized Polaris dealer.

  • Page 22: Pre-Ride Inspection

    MAINTENANCE Headlamp Inspection Daily Daily Check operation daily; Apply Nyogelt Grease to connector when lamp is replaced Tail Lamp Inspection Daily Daily Check Operation Daily; Apply Nyogelt Grease to socket when lamp is replaced CHASSIS Frequency (Whichever comes first) Item Hours Calendar Miles...

  • Page 23: Maintenance

    Fill hub at 4:00 or 8:00 position until fluid 2.27 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. 2.28 (PN 2870990) COLD WEATHER KITS FOR 4 CYCLE ATV’S...
  • Page 24 MAINTENANCE POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS Part No. Description Part No. Description Engine Lubricant 2871954 Loctitet Threadlock 271 (36 ml.) (6 Count) 2870791 Fogging Oil (12 oz. Aerosol) 2870584 Loctitet 680-Retaining Compound (10 2871098 Premium 2 Cycle Engine Oil (Quart) (12 ml.)

  • Page 25: Special Tools

    MAINTENANCE SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN PA- -44689 Valve Clutch Adjuster 2872105 Water Pump Mechanical Seal Puller 8712100 or 8712500 Tachometer 2,10 2200634 Valve Seat Reconditioning Kit 2870390 Piston Support Block 2871043 Flywheel Puller 2871283 Crankshaft/Water Pump Seal Install Kit 5131135 Water Pump Install Kit...
  • Page 26 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 27 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 28: Transmission Lubrication

    Check vent hose to be sure it is routed routed properly and unobstructed. properly and unobstructed. The correct gearcase lubricant to use is TRANSMISSION SPECIFICATIONS Polaris Premium GL5 80-90 Gear Lube (PN 2871653) Specified Lubricant: Polaris Premium Synthetic Gearcase Lubricant PN 2871477 (Gallon) PN 2871478 (12 oz..)

  • Page 29: Transmission

    MAINTENANCE 2. Clean and reinstall drain plug using a new sealing SHIFT LINKAGE washer. ADJUSTMENT 3. Remove fill plug. 4. Add proper amount of lubricant. Linkage rod adjustment is necessary when 5. Install fill plug. Check for leaks. symptoms include: No All Wheel Drive light Make sure vent Noise on deceleration...
  • Page 30 MAINTENANCE neutral position detents. tightened, the rod should rotate freely 1/4 turn without binding. 11. Repeat Steps 7-10 for the High/Reverse rod. Adjust to align linkage rod end studs with holes in bellcrank(s). THROTTLE INSPECTION Check for smooth throttle opening and closing in all handlebar positions.

  • Page 31: Idle Speed Adjustment

    MAINTENANCE CHOKE (ENRICHER) 2100DX (PN 8712100DX) or the PET 2500 (PN 8712500). ADJUSTMENT 4. Set idle speed to 1200 RPM. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary. 5. Slowly turn mixture screw clockwise using the pilot screw wrench until engine begins to miss.

  • Page 32: Maintenance

    MAINTENANCE THROTTLE CABLE / FUEL SYSTEM ELECTRONIC THROTTLE WARNING CONTROL (ETC SWITCH) Gasoline is extremely flammable and explosive ADJUSTMENT under certain conditions. Always stop the engine and refuel 1. Slide boot off throttle cable adjuster and jam nut. outdoors or in a well ventilated 2.

  • Page 33: Fuel Filter

    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 34: 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. WARNING Average compression (measured) is about 50-90 psi during a compression test. Smooth idle generally indicates good compression. Battery electrolyte is poisonous.

  • Page 35: Electrical

    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 36: Liquid Cooling System Overview

    1. Check radiator (A) air passages for restrictions or damage. Check and clean the radiator screen Polaris 60/40 Anti-Freeze / Coolant (B). 2. Carefully straighten any bent radiator fins. (PN 2871323) 3. Remove any obstructions with compressed air or low pressure water.

  • Page 37: Coolant Level Inspection

    2. Fill reservoir to upper mark with Polaris Premium Remove front cover by placing your fingers under the 60/40 Anti Freeze / Coolant or 50/50 or 60/40 front of the cover and pulling upward.

  • Page 38: Air Box Sediment Tube Service

    MAINTENANCE 2. Pull the seat back and free of the tabs. NOTE: NOTE: Apply a small amount of general purpose When reinstalling seat, make sure the slots in the grease to the sealing edges of the filter before seat engage the tabs in the fuel tank. reinstalling.

  • Page 39: Breather Filter

    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. RECOIL HOUSING Crankcase Drain Sediment Tube Ill.1 NOTE: The sediment tube will require more frequent service if the vehicle is operated in wet conditions or at high throttle openings for extended periods.

  • Page 40: Oil Change/Filter

    MAINTENANCE ENGINE OIL LEVEL OIL AND FILTER CHANGE WARNING Personal injury can occur when han- dling used oil. Hot oil can cause burns or skin damage. NOTICE: Care must be taken to ensure that fluids are contained. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembly any component containing fluids.
  • Page 41 19. Reinstall drain plug. Slit 20. Remove dipstick and fill tank with 2 quarts (1.9 L) Oil Tank Pinch Off of Polaris Premium 4 Synthetic Oil (PN 2871844). Vent Hose 2.22...

  • Page 42: Valve Clearance

    MAINTENANCE 1. Clamp or pinch off vent line approximately 2I 6. Rotate engine slowly with recoil rope, watching from oil tank to avoid the end of oil tank vent fitting, the intake valve(s) open and close. and the vent line’s pressure relief slit NOTE: At this point watch the camshaft sprocket 2.

  • Page 43: Exhaust Valve Clearance Adjustment

    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 44: Camber And Caster

    MAINTENANCE TIE ROD END/STEERING INSPECTION WHEEL ALIGNMENT CONT’D METHOD 1: If abnormal movement is detected, STRAIGHTEDGE OR STRING inspect the hub and wheel assembly to determine the cause ( possible Be sure to keep handlebars centered. See notes loose wheel nuts or loose front hub below.
  • Page 45 MAINTENANCE should always point straight back from the Hold steering post. Rod End 3. Place a chalk mark on the center line of the front tires approximately 10² (25.4 cm) from the floor or as close to the hub/axle center line as possible. NOTE: It is important that the height of both marks be equally positioned in order to get an accurate measurement.

  • Page 46: Exhaust Pipe

    4 o’clock or 8 o’clock position. WARNING 3. Remove fill/check plug. 4. Add Polaris Demand Drive Hub Fluid if necessary until fluid trickles out. NOTE: Do not force the S Do not perform clean out immediately after the engine has been run, as the ex- fluid into the hub under pressure or seal damage haust system becomes very hot.

  • Page 47: Brake Pad Inspection

    Tighten any loose reservoir to the indicated level inside fittings and replace any worn or damaged parts. reservoir. Use Polaris DOT 3 Brake Fluid (PN AUXILIARY BRAKE TESTING 2870990). Sight The auxiliary brake should be checked for proper...

  • Page 48: Controls

    MAINTENANCE AUXILIARY BRAKE SUSPENSION SPRING ADJUSTMENT (HYDRAULIC) PRELOAD ADJUSTMENT Center Spring Adjustment Ring Auxiliary Brake Operator weight and vehicle loading affect suspensionspringpreloadrequirements. Adjustas necessary. Use the following procedure to inspect the hydraulic FRONT SUSPENSION auxiliary (foot) brake system and adjust or bleed if necessary: Compress and release front suspension.

  • Page 49: Wheel Removal/Installation

    MAINTENANCE WHEEL, HUB, AND SPINDLE Throttle TORQUE TABLE assembly clamp Item Specification Front Wheel Nuts 20 Ft. Lbs. (27 Nm) Rear Wheel Nuts 20 Ft. Lbs. (27 Nm) Front Spindle Nut Refer to procedure listed in Chapter 7 Rear Hub Retaining Nut 100 Ft.

  • Page 50: Tire Inspection

    MAINTENANCE If wheels are improperly installed it could affect FRAME, NUTS, BOLTS, vehicle handling and tire wear. On vehicles with FASTENERS tapered rear wheel nuts, make sure tapered end of nut goes into taper on wheel. Periodically inspect the torque of all fasteners in accordance with the maintenance schedule.
  • Page 51 MAINTENANCE NOTES 2.32...
  • Page 52 ENGINE CHAPTER 3 ENGINE Torque Specifications ......Special Tools ....... EH50PL Service Data .

  • Page 53: Torque Specifications

    ENGINE TORQUE SPECIFICATIONS Water Pump 5-6.5 (7-9 Nm) Housing Cover Stator Plate 5-6.5 (7-9 Nm) TORQUE SPECIFICATIONS Starter Motor 5-6.5 (7-9 Nm) Fastener Size EH42PLE/ EH50PLE Spark Plug 14mm 9-11 (12-15 Nm) Ft. Lbs. (Nm) Blind Plug (Oil 1/8 PT 6.5-11 (9-15 Nm) Pressure) (28tpi)

  • Page 54: Engine Service Data

    ENGINE ENGINE SERVICE DATA Cylinder Head / Valve EH42PLE EH50PLE Rocker Arm Rocker arm ID .8669-.8678² (22.020-22.041 mm) .8669-.8678² (22.020-22.041 mm) Rocker shaft OD .8656-.8661² (21.987-22.0 mm) .8656-.8661² (21.987-22.0 mm) Rocker shaft Oil Clearance .0008-.0021² (.020-.054 mm) .0008-.0021² (.020-.054 mm) Limit .0039²...
  • Page 55 ENGINE ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod EH42PLE EH50PLE Cylinder Surface warpage limit (mating with cylinder head) .0020² (.05 mm) .0020² (.05 mm) Cylinder bore 3.4606-3.614² (87.900-87.920 mm) 3.6221-3.6228² (92.00-92.02 mm) Taper limit .0020² (.050 mm) .0020² (.050 mm) Out of round limit .0020²...

  • Page 56: Engine Fastener Torque Patterns

    ENGINE ENGINE FASTENER TORQUE Engine Oversize Piston Standard Model Length Piston Iden- Available* PATTERNS tification (mm) Tighten cylinder head, cylinder base, and crankcase EH50PLE 72 mm fasteners in 3 steps following the sequence outlined below. EH42PLE 66 mm *Pistons and rings marked 25 equal .25mm (.010I) oversized Pistons and rings marked 50 equal .50mm (.020I) oversized...

  • Page 57: Cooling System

    ENGINE COOLING SYSTEM and serious burns may result. Allow the engine and cooling system to cool before servicing. WARNING: Never remove radiator cap when engine System Pressure Test is warm or hot. The cooling system is under pressure 1. Remove front cover. FLOW 2.

  • Page 58: Cooling System Specifications

    Polaris Premium 60/40 ENGINE REMOVAL (TYPICAL) Antifreeze/Coolant is recommended for use in all cooling systems, and comes pre-mixed and ready to 1.

  • Page 59: Engine Installation Notes

    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 oil, or API certified “SH” oil. Never substitute or mix oil brands.

  • Page 60: Honing To Oversize

    Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris 2 Cycle Lubricant. CRANKSHAFT STRAIGHTENING Lubricate the bearings and clamp the crankshaft securely in the Crankshaft Truing Stand (PN 2870569).

  • Page 61: Oil Pressure Test

    3. Start engine and allow it to reach operating temperature, monitoring gauge indicator. NOTE: Use Polaris Premium 4 Synthetic Engine Lubricant (PN 2871281). 2. To correct a situation like the one shown in the...
  • Page 62 ENGINE OIL FLOW - - EH50PL The chart on Page 3.12 describes the flow of oil through the EH50PL engine. Beginning at the oil tank, the oil flows through a screen fitting in the bottom of the tank and into the oil supply hose. The feed side of the oil pump draws oil through the hose and into the crankcase oil gallery, and then pumps the oil through another passage to the one way valve.

  • Page 63: Eh50Pl Oil Flow Diagram

    ENGINE 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 64: Eh50Pl Engine Exploded View

    ENGINE EH50PL ENGINE EXPLODED VIEW Crankcase Cylinder/ Cylinder Head Crankshaft Valve Train and Piston 3.13...
  • Page 65 ENGINE ENGINE REMOVAL should have clearance at this point. REFER TO PAGE 3.7- -3.8 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 66: Cam Chain Tensioner Inspection

    ENGINE 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. and plunger teeth (B) for wear or damage.
  • Page 67 ENGINE 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 68 ENGINE 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 69: Automatic Compression Release Installation

    ENGINE Stop pin Spring in relaxed position 1. Check release lever shaft (A) for smooth operation throughout the entire range of rotation. The spring (B) should hold the shaft weight against the stop pin. In this position, the actuator ball (C) will be held outward in the compression release mode.
  • Page 70 ENGINE Camshaft Oil Clearance: Std: .0022-.0035I (.055-.090 mm) Limit: .0039I (.10 mm) Lubrication holes NOTE: Replace camshaft if damaged or if any part is worn past the service limit. Lobe height NOTE: Replace cylinder head if camshaft journal bore is damaged or worn excessively. CYLINDER HEAD EXPLODED Cam Lobe Height (Intake &...
  • Page 71 ENGINE CYLINDER HEAD EXPLODED VIEW, EH50PL EH50PL 3.20...

  • Page 72: Cylinder Head Inspection

    ENGINE 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 73: Valve Inspection

    ENGINE 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 74: Valve Seat Reconditioning

    ENGINE Clean all accumulated carbon deposits from combustion chamber and valve seat area with a soft wire brush. VALVE SEAT RECONDITIONING 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.
  • Page 75 ENGINE 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 76 ENGINE 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 77: Cylinder Head Assembly

    ENGINE 1. Install new valve seals on valve guides. 2. Apply engine oil to valve guides and seats. 3. Coat valve stem with molybdenum disulfide grease. 4. Install valve carefully with a rotating motion to avoid damaging valve seal. 5. Dip valve spring and retainer in clean engine oil and install spring with closely spaced coils toward the cylinder head.
  • Page 78 ENGINE EXHAUST VALVE CLEARANCE ADJUSTMENT 500 Engine Feeler Gauge for Both Valves 1. Remove cam chain guide at front of cylinder. NOTE:The exhaust valves share a common rocker arm, and must be adjusted using two feeler gauges. 1. Insert .006 feeler gauge(s) between end of exhaust valve stem and adjuster screw(s).

  • Page 79: Piston Removal

    ENGINE 6. Tap cylinder lightly with a plastic hammer in the reinforced areas only until loose. 7. Rock cylinder forward and backward and lift it from the crankcase, supporting piston and connecting rod. Support piston with Piston Support Block (PN 2870390). 8.

  • Page 80: Cylinder Inspection

    ENGINE scratch the ring lands. 2. Inspect the top of the cylinder for warpage using a straight edge and feeler gauge. Cylinder Warpage: .002² (.05 mm) 3. Inspect cylinder for wear, scratches, or damage. 1/2² Down From Top of Cylinder 4.

  • Page 81: Piston/Rod Inspection

    ENGINE PISTON-TO-CYLINDER CLEARANCE Piston 40 mm Piston Pin Measurement Locations Piston Pin Piston Pin O.D. .9053-.9055I (22.994-23.0 mm) 1. Measure piston outside diameter at a point 40 mm down from the top of the piston at a right angle to the direction of the piston pin.

  • Page 82: Crankcase Disassembly

    ENGINE below specified limit, file ring ends until gap is within specified range. Piston Ring-to-Groove Clearance NOTE: Always check piston ring installed gap after re-boring a cylinder or when installing new rings. A Top Ring Std: .0016-.0031I (.040-.080 mm) re-bored cylinder should always be scrubbed Limit: .0059I (15 mm) thoroughly with hot soapy water, rinsed, and dried Second Ring Std: .0012-.0028I (.030-.070 mm)
  • Page 83 ENGINE 5. Replace crankshaft seal (A). Std. Bushing ID: .4735²-.4740² (11.11-12.04 mm) Std. Shaft OD: .470²-.472² (11.93-11.99 mm) Starter Drive Bushing Clearance: Std: .0015²-.004² (.038-.102 mm) Service Limit: .008² (.203 mm) 4. Measure the OD of the starter drive shaft on both ends and record.

  • Page 84: Crankcase Separation

    ENGINE 2. Remove blade and inspect for cracks, wear, or damage. 1. Remove cap bolt (A), sealing washer (B), spring (C), and one way valve (D) from PTO side 3. Remove cam chain (B). Inspect chain for worn or crankcase. missing rollers or damage.

  • Page 85: Oil Pump Removal/Inspection

    ENGINE 2. Separate crankcase by tapping with a soft faced hammer in reinforced areas. 3. Tap lightly on balancer gear with a brass drift through the hole in the crankcase if necessary, to ensure the balancer shaft stays in the PTO side crankcase.

  • Page 86: Oil Pump Assembly

    ENGINE 8. Remove pump body screw and feed chamber 11. Measure rotor tip clearance with a feeler gauge. cover. 12. Remove inner and outer feed rotor and pump chamber body. 13. Repeat measurements for scavenge rotor. 14. Remove inner and outer scavenge rotor and inspect pump shaft for wear.

  • Page 87: Crankshaft Removal/Inspection

    ENGINE 1. Remove the shim washer (A) from the counter CRANKSHAFT balancer shaft. REMOVAL/INSPECTION 1. Remove the shim washer (A) from the crankshaft. 2. Note the alignment dots on the balancer and crankshaft gears, the marks must be aligned 2. Support the PTO side crankcase and crankshaft; during reassembly.

  • Page 88: Crankcase Bearing Inspection

    ENGINE 5. Measure the connecting rod big end radial PUMP SHAFT OIL SEAL/ 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 89: Bearing Installation

    ENGINE 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 90 ENGINE 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 91: Oil Pump Shaft End Play Adjustment

    ENGINE COUNTER BALANCER SHAFT END PLAY ADJUST. Counter Balancer Shaft End Play: .008²-.016² (.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 92: Pump Shaft Oil Seal Installation

    ENGINE 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. .008²-.016² (.02-.04 cm) 4. Place the balancer shaft in the PTO crankcase aligning the timing marks on the crankshaft and balancer gears.

  • Page 93: Water Pump Mechanical Seal Installation

    ENGINE Sealing Washer Crankcase Sealant: Sealing Washer (Copper or Aluminum) (PN 2871557) Coolant Drain Bolt WATER PUMP MECHANICAL Seal SEAL INSTALLATION Impeller 1. Clean the seal cavity to remove all traces of old sealer. Mechanical Seal Ill. 1 2. Place a new mechanical seal in the seal drive collar, and install on the pump shaft.

  • Page 94: One Way Valve Installation

    ENGINE 7. The Water Pump Install Kit (PN 5131135) is required to install the new mechanical seal. This tool is available separately and it is also included Main puller in the Crankshaft/Water Pump Seal Installation body Kit (PN 2871283). ONE WAY VALVE INSTALLATION Install the one way valve plunger, spring, and plug Position the split...

  • Page 95: Piston Ring Installation

    ENGINE 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 96: Cylinder Installation

    ENGINE 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 97: Cylinder Head Installation

    ENGINE 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 98 ENGINE 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 3.21). 2. Install the camshaft with the lobes facing downward and the sprocket alignment pin facing upward.
  • Page 99 ENGINE 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 100: Cam Chain Tensioner Installation

    ENGINE CAM CHAIN TENSIONER 1. Apply a light film of grease to the crankshaft seal. Apply molybdenum disulfide grease or assembly INSTALLATION lubricant to the crankshaft bushing. 2. Install a new O-Ring in the oil passage recess in the crankcase. 3.

  • Page 101: Thermostat Installation

    ENGINE 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 102: Oil Pipes

    ENGINE 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 103: Recoil Assembly

    ENGINE 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). To complete recoil assembly: 1.

  • Page 104: Spark Plug Fouling Checklist

    ENGINE 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 105 ENGINE 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 106 FUEL SYSTEM/CARBURETION CHAPTER 4 FUEL SYSTEM/CARBURETION Exploded View, Mikuni BST 34/40 Carburetor 4.2--4.3 Fuel Tank Asm. Exploded View ... . Fuel Flow Diagram ..... . . Special Tool &...
  • Page 107 FUEL SYSTEM/CARBURETION 1. Carburetor Assembly BST 34 CARBURETOR 2. Screw 3. Throttle Valve EXPLODED VIEW 4. Cover, Diaphragm 5. Jet Block Assembly 6. Spring 7. Diaphragm Assembly 8. Ring 9. “E” Ring 10. Ring 11. Needle Jet 12. Cover 13. O-Ring 14.
  • Page 108 FUEL SYSTEM/CARBURETION BST 40 CARBURETOR EXPLODED VIEW 1. Cover, Diaphragm 2. Spring 3. Spring Seat 4. “E” Clip 5. Spacer 6. Jet Needle 7. Diaphragm Assembly 8. Throttle Valve 9. Cable Guide 10. Spring 11. Adjuster Cable 12. Drain Plug 13.

  • Page 109: Fuel Flow Diagram

    FUEL SYSTEM/CARBURETION FUEL TANK ASSEMBLY Vent Line Gasket Seal Foam Mounting Bracket Forward Spacer 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 110: 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 111: Cv Carburetor System Function (4 Cycle)

    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 Main routed.
  • Page 112 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 113: Float System

    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 114: Carburetor Cleaning

    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 115 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 116: Float Height Adjustment

    FUEL SYSTEM/CARBURETION CARBURETOR ASSEMBLY CONT’D BST 40 5. Install the pilot mixture screw, spring, washer, and O-ring as an assembly. Lubricate the O-Ring with oil or light grease before installation. CAUTION: Do not damage the O-ring during installation. Turn the screw in until it lightly contacts the seat. Back out the specified number of turns.

  • Page 117: Needle And Seat Leakage Test

    FUEL SYSTEM/CARBURETION NEEDLE AND SEAT LEAKAGE TEST 1. Install the float bowl. Invert the carburetor and install a Mity-Vact (PN 2870975) to the fuel inlet fitting. Apply 5 PSI pressure to inlet fitting. The needle and seat should hold pressure indefinitely. 1.5 mm If not, inspect needle and seat and seat O-ring.

  • Page 118: Fuel Pump Disassembly

    FUEL SYSTEM/CARBURETION FUEL PUMP DISASSEMBLY 1. Fuel Pump Assembly 2. Diaphragm, Gasket Set 3. Screw and Washer Assembly 1. Remove the screws from the pump diaphragm 4. Screw and Washer Assembly cover. Note the location of the two longer screws. 5.

  • Page 119: Troubleshooting

    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 120 BODY / STEERING / SUSPENSION CHAPTER 5 BODY AND STEERING Torque Specifications and Special Tools ..Cover/Panel Removal ......5.2--5.3 Side Panel Removal .

  • Page 121: Cover/Panel Removal

    BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS 2870623 Shock Absorber Spring Compression Tool COMPONENT FT. LBS. 2871572 Strut Rod Wrench (IN.LBS.) 2871573 LH Strut Spring Compressor Front Wheel Nuts 2871574 RH Strut Spring Compressor Front A-Arm Attaching Bolt 7052069 Charging Needle 2200421 Gas Shock Front A-Arm Ball Joint Stud...

  • Page 122: Side Panel Removal

    BODY / STEERING / SUSPENSION 2 screws at rear bottom of cab assembly near tail light Disconnect taillight harness Step 2. Front Rack Remove: 4 screws, lock washers, and flat washers Front Cab Assembly Remove: Seat Side panels 2 screws at rear of cab at fuel tank mount bracket Front rack Front bumper...

  • Page 123: Body Assembly Exploded View

    BODY / STEERING / SUSPENSION BODY ASSEMBLY EXPLODED VIEW Pull UP on rear of seat and back to disengage tabs at front of seat Rear Cab Seat Latch Release Storage Rear Cab Assembly Rear Mud Guard Front Cover Side Cover Front Cab Assembly Front Cab Footrest...

  • Page 124: Headlight Pod Exploded View

    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 S Remove two side Phillips screws (A). S Remove one rear Phillips screw (B).

  • Page 125: Steering Assembly, Exploded View

    BODY / STEERING / SUSPENSION 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.

  • Page 126: A-Arm Replacement

    BODY / STEERING / SUSPENSION 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 127: Rear Suspension Assembly

    BODY / STEERING / SUSPENSION REAR SUSPENSION ASSEMBLY 17 ft. lbs. (24 Nm) 17 ft. lbs. (24 Nm) Front of Machine 35 ft. lbs. (48 Nm) 35 ft. lbs. (48 Nm) 30 ft. lbs. (41 Nm) 35 ft. lbs. (48 Nm) Lower Control Upper...

  • Page 128: Strut Assembly

    BODY / STEERING / SUSPENSION 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...

  • Page 129: Front Strut Cartridge Replacement

    BODY / STEERING / SUSPENSION FRONT STRUT CARTRIDGE 3. Remove wheel nuts and wheels. REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5.8. 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) 4.

  • Page 130: Steering Post Assembly

    BODY / STEERING / SUSPENSION 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. Insert new ball joint (K) into driver (L).
  • Page 131 BODY / STEERING / SUSPENSION NOTES 5.12...

  • Page 132: Pvt System

    CLUTCH CHAPTER 6 PVT SYSTEM Service Tools, Supplies & Torques ..PVT System Operation ....6.2--6.3 PVT Maintenance/Inspection .

  • Page 133: Drive Clutch Operation

    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 134: 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 135 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 136: Pvt Disassembly

    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. (See Page 6.8). 1. Remove seat. 2. Remove or loosen rear cab fasteners as 8.

  • Page 137: Pvt Assembly

    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 138: Pvt Sealing And Ducting Components

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

  • Page 139: Drive Clutch Spring Specifications

    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. 2.

  • Page 140: Shift Weights

    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 141: Drive Clutch 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 142: Spider Removal

    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 143: Drive Clutch Reassembly

    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 144: Drive Belt Tension

    CLUTCH DRIVE CLUTCH REASSEMBLY CONT’D 8. Reinstall cover, aligning “X” mark with other marks. Torque cover bolts evenly to specification. 2. Install moveable sheave onto fixed sheave. 3. Install spider spacers. Use same quantity and thickness as were removed. 4. Compress spider buttons for each tower and install spider, making sure that “X”, or the marks that were made earlier, on spider aligns with “X”, or the marks that were made earlier on the...

  • Page 145: Drive Belt Removal/Inspection

    CLUTCH Straight Edge 1 1/8² (28.5 mm) Belt Deflection (Tension): 1 1/8² (2.9 cm) - 1 1/4² (3.2 cm) If belt deflection is out of specification, adjust by removing or adding shims between the driven clutch sheaves. Remove shims to decrease belt deflection Add shims to increase belt deflection See Driven Clutch Disassembly/Inspection, Pages...

  • Page 146: Drive Belt Installation

    CLUTCH shown in the illustration. Projected Belt Width Center Distance Clutch Center Distance - 10² +.1 / -.05 (254 +2.5 / -1.3mm) Belt Nominal Length - 40.875²± 3/16 ( 103.8 cm ± .48 cm) Belt Width: New 1.174 - 1.188² (2.98-3.02 cm) DRIVE BELT INSTALLATION Wear Limit 1.125²...

  • Page 147: Clutch Alignment /Offset

    CLUTCH CLUTCH ALIGNMENT NOTE: On some models, minor adjustments can be made by adding shims between the frame and front lower left engine mount to increase the distance at 1. Remove belt and install the Clutch Offset point “A”. If a shim is present, it can be removed to Alignment Tool) as shown.

  • Page 148: Drive Clutch Bushing Service

    CLUTCH DRIVE CLUTCH BUSHING 2. Remove nut from puller rod and set aside. SERVICE Piston Pin Puller *Clutch Bushing Replacement Tool Kit (PN (PN 2870386) 2871226) Stamp Qty. Part Desciption Part # P--90 Drive/Driven 5020628 Cluth Bushing Install Tool Main Puller Adaptor (#8) Drive Clutch Cover 5020629 Bushing Removal/...
  • Page 149 CLUTCH 8. Pull bushing removal tool and adapter from puller DRIVE CLUTCH COVER - rod. Remove bushing from tool and discard. BUSHING REMOVAL DRIVE CLUTCH MOVEABLE SHEAVE - BUSHING Piston Pin Puller INSTALLATION (PN 2870386) 1. Place the Main Puller Adapter (#8) (PN 5020632) onto the puller.

  • Page 150: Driven Clutch Disassembly/Inspection

    CLUTCH Bushing (PN 3576510) Loctitet 680 (PN 2870584) 5. Turn clutch cover counterclockwise on puller rod until bushing is removed. 2. With the Main Puller Adapter (#8) (PN 5020632) 6. Remove nut from puller rod and set aside. on the puller, insert cover onto puller rod, placing 7.
  • Page 151 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 7.

  • Page 152: Driven Clutch Assembly

    CLUTCH DRIVEN CLUTCH ASSEMBLY 4. Line up boss spline and push helix down until it engages the splines 1/2² to 3/4². turn Moveable Spring Example: Helix Sheave Tension 5. While holding downward pressure on helix, wind - - 1 Heavy moveable sheave counterclockwise...
  • Page 153 CLUTCH 3. Remove ramp buttons from moveable sheave. 6. Install sheave onto puller. 7. Install nut onto puller rod and tighten by hand. Turn puller barrel for further tension if needed. 4. Using a hand held propane torch, apply heat 8.
  • Page 154 CLUTCH 2. Start new bushing evenly in moveable sheave. Apply Loctitet 680 (PN 2870584) to the back side of new bushing. 3. Install sheave onto puller with new bushing upward as shown. Install the Number Two Puller Adapter (#10) (PN 5020633). 4.
  • Page 155 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 Cover...

  • Page 156: Drive Clutch Inspection

    CLUTCH EBS DRIVE CLUTCH EXPLODED VIEW Mark with permanent marker before disassembly One way clutch EBS Drive Clutch ONE-WAY CLUTCH DRIVE CLUTCH INSPECTION INSPECTION (DRIVE NOTE: Remove cover, spring, and spider following CLUTCH) instructions for drive clutch removal, then proceed as follows: 1.

  • Page 157: Ebs Driven Clutch Disassembly/Inspection

    CLUTCH PTFE Washer Thickness Brass Washer Thickness Standard: .030² (.76mm) Standard: .030² (.76mm) Service Limit: .025² (.64mm) Service Limit: .025² (.64mm) 2. Lift one-way clutch off shaft. Replace as an MOVEABLE SHEAVE assembly if worn, damaged, or if problems were BUSHING INSPECTION noted.
  • Page 158 CLUTCH counterclockwise direction as shown at right. The sheave should rotate on the shaft with only a slight amount of drag. There should not be any binding or rough spots. Move Freely Do not disassemble from this side 4. Place the driven assembly into the clutch holder. Push helix inward.
  • Page 159 CLUTCH DRIVEN CLUTCH DISASSEMBLY/ INSPECTION CONT’D 7. Inspect moveable sheave bushing for wear. Rollers Inspect BOTH sheaves for signs of wear, grooving or cracking. Clean surfaces with a 3Mt pad if needed ROLLER PIN DISASSEMBLY New roller retaining bolts have a dry locking agent applied to the threads.

  • Page 160: Ebs Drive Clutch Bushing Service

    CLUTCH EBS DRIVE BUSHING 6. With towers pointing toward the vise, slide sheave onto puller rod. SERVICE 7. Install removal tool (Item A/B) into center of sheave with “A side” toward sheave. EBS CLUTCH BUSHING REMOVAL AND 8. Install nut (C) onto end of puller rod and hand INSTALLATION (Use Tool Kit PN 2201379) tighten.

  • Page 161: Ebs Driven Clutch Bushing Service

    CLUTCH EBS Drive Clutch Cover Bushing Removal EBS DRIVEN BUSHING 1. Install main adapter (Item 8) on puller. SERVICE EBS Driven - Bushing Removal Nut (C) Removal Tool (3) 1. Install puller adapter (Item 10) onto puller. Adapter Reducer (9) Main Adapter Piston Pin Puller...
  • Page 162 CLUTCH 8. Remove nut (C) (left hand thread) from puller rod 7. Turn clutch sheave counterclockwise until and set aside. bushing is removed and sheave comes free. 9. Remove adapters from puller. 8. Remove nut (C) (left hand thread) from puller rod and set aside.

  • Page 163: Troubleshooting

    CLUTCH 8. Remove nut (C) (left hand thread) from puller rod 9. Remove installation tool and clutch sheave from and set aside. puller. TROUBLESHOOTING Situation Probable Cause Remedy Engine RPM -Wrong or broken drive clutch spring. -Replace with recommended spring. below specified operating range -Drive clutch shift weight too heavy.
  • Page 164 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 165 CLUTCH NOTES 6.34...

  • Page 166: Final Drive

    FINAL DRIVE CHAPTER 7 FINAL DRIVE Final Drive Torque Specifications ..AWD Operation Overview ... 7.2--7.3 AWD Front Hub Removal ... AWD Hub/Bearing Installation .

  • Page 167: 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 168 FINAL DRIVE 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 169: 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 until fluid trickles out. NOTE: Do not force injury or death.

  • Page 170: Awd Front Hub Exploded View

    FINAL DRIVE AWD FRONT HUB EXPLODED VIEW Garter Spring Brake Disc Armature Plate Seal Detail Bearing (1.000² I.D.) DETAIL A Spacer Bearing Race Front Hub Clutch Front Hub Clutch Bearing (1.000² I.D.) Cotter Pin ¡ Castle Nut (Use new cotter pin) O-Ring Bearing Race Washer...

  • Page 171: Awd Hub Seal Replacement

    It is very important that the brake disc be free of any oil or solvents. 2. Remove brake disc attaching bolts and brake 6. Reinstall the brake disc using genuine Polaris disc. OEM bolts that have a pre-applied locking agent.
  • Page 172 FINAL DRIVE 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 173: Awd Armature Plate Inspection

    FINAL DRIVE 2870888) and into the groove of the rollers and AWD ARMATURE PLATE 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 174: Awd Front Drive Axle Installation

    FINAL DRIVE 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 175 FINAL DRIVE 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. 5.
  • Page 176 FINAL DRIVE 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 8700226 Earless Type 8700226...

  • Page 177: Awd Front Drive Axle Exploded View

    FINAL DRIVE 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 178 FINAL DRIVE 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. (1.0625²) than the hub bearings (1.000²). Be sure to install the bearings with the larger I.D. in the strut housing, and the bearings with the smaller I.D.

  • Page 179: Awd Front Prop Shaft Removal

    FINAL DRIVE 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 Max.

  • Page 180: U-Joint Disassembly

    FINAL DRIVE U-JOINT DISASSEMBLY 3. Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing caps. CAUTION: Always wear eye protection. 4. Force U-joint cross to one side and lift out of inner 1. Remove internal or external snap ring from all yoke.

  • Page 181: Awd Front Housing Removal

    FINAL DRIVE 2. Using a suitable arbor, fully seat bearing cap in 3. Elevate support machine under one side. Continually check for free movement of footrest/frame area. bearing cross as bearing caps are assembled. CAUTION: Serious injury may result if machine tips 3.

  • Page 182: Awd Front Housing Disassembly

    FINAL DRIVE AWD FRONT HOUSING 6. Unscrew fill plug and remove pinion shaft assembly. Inspect pinion gear for chipped broken DISASSEMBLY, CONT. or missing teeth. NOTE: Pinion shaft assembly will not clear the fill plug unless it is backed out. AWD FRONT HOUSING ASSEMBLY 1.
  • Page 183 14 ft. lbs. (19 Nm) 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.

  • Page 184: Awd Front Housing Exploded View

    FINAL DRIVE 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 7.19...

  • Page 185: Rear Hub/Bearing Carrier Removal

    FINAL DRIVE REAR HUB/BEARING 7. Remove wheel nuts and wheel. CARRIER REMOVAL 1. Lock the parking brake. Remove rear hub cap. 2. Remove cotter pin. 8. Remove hub. 3. Loosen the hub retaining nut. 4. Loosen the wheel nuts. 5. Safely support the rear of the ATV. CAUTION: Serious injury could occur if machine tips or falls.

  • Page 186: Rear Hub Installation

    FINAL DRIVE 10. Remove both lower control arm bolts. Install Upper 11. Remove bearing carrier. Control Arm Bolt Lower Control Arm Bolt Torque: 30 ft. lbs. (41 Nm) Upper Control Arm Bolt Torque: 35 ft. lbs. (48 Nm) REAR HUB INSTALLATION 4.

  • Page 187: Rear Hub Disassembly/Assembly

    FINAL DRIVE REAR HUB DISASSEMBLY no detectable up and down movement and minimal movement sideways between inner and outer race. 1. Remove outer snap ring (A). 4. Inspect bearing housing for scratches, wear or damage. Replace housing if damaged. REAR HUB ASSEMBLY 1.

  • Page 188: Rear Drive Shaft Removal

    FINAL DRIVE Pull outward sharply away from the transmission to remove the shaft 4. Install snap ring into groove. DRIVESHAFT AND CV JOINT REAR DRIVE SHAFT HANDLING TIPS REMOVAL Care should be exercised during driveshaft removal or when servicing CV joints. Driveshaft 1.

  • Page 189: Rear Driveshaft Installation

    FINAL DRIVE REAR DRIVE SHAFT INSTALLATION 1. Slide shaft assembly into bearing carrier hub (A) 5. Install hub, flat washer, domed washer (domed side out) and nut. Torque center nut to 100 ft. lbs. (138 Nm). Install new cotter pin and hub cap. 6.

  • Page 190: Rear Driveshaft Service

    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 CV Boot Clamp Pliers (PN 8700226) (A). 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 191 FINAL DRIVE 5. Refit CV joint on interconnecting shaft by tapping housing, making sure boot is seated in groove. with a plastic hammer on the joint housing. Take Position clamp over boot end and make sure care not to damage threads on the outboard CV clamp tabs are located in slots.
  • Page 192 FINAL DRIVE 7. Tighten boot clamp using boot clamp pliers. 8. Fill boot with grease supplied with boot service kit and spread remaining grease evenly inside CV joint. 9. Be sure to use only the Constant Velocity Joint grease supplied with boot service kit. IF CV JOINT WAS CLEANED, add the recommended amount of grease to the joint in addition to the grease pack supplied with boot kit.
  • Page 193 FINAL DRIVE NOTES 7.28...
  • Page 194 TRANSMISSION CHAPTER 8 TRANSMISSION SERVICE Torque Specifications ..... Special Tools ......Gear Shift Selector Removal .

  • Page 195: Torque Specifications

    TRANSMISSION TORQUE SPECIFICATIONS 4. Lift gear selector out of mounting bracket and away from frame. GEAR SHIFT SELECTOR COMPONENT FT. LBS. DISASSEMBLY (IN.LBS.) Transmission Case Bolts 16.6 CAUTION: Bell Crank Nut 16.6 Wear eye protection during this procedure. Read each step completely before proceeding. Essential Transmission Drain Plug parts may be lost or damaged if you do not heed this caution!

  • Page 196: Gear Shift Selector Assembly

    TRANSMISSION 4. Remove the three springs from gear shift Inspect shift boot closely if moisture is present in selector. selector box. 5. Slowly tilt gear shift selector body sideways to 6. Tap gear shift selector body, top down, against a drain oil.

  • Page 197: Gear Shift Selector Installation

    TRANSMISSION 4. Fill selector body with Polaris 0W-40 All Season BOOT REPLACEMENT Synthetic motor oil. The oil level should be at one half the height of the slides (approx. 1 oz.). NOTE: If moisture is found in the gear shift selector the boot should be replaced.

  • Page 198: Transmission Removal

    TRANSMISSION TRANSMISSION REMOVAL All operations regarding transmission front output housing assembly performed with transmission installed in frame. 1. Remove the inner PVT cover. Refer to Clutch Chapter. 2. Remove complete airbox assembly transmission vent line. 3. Loosen rear wheel nuts slightly. 4.

  • Page 199: Transmission Installation

    14. Remove all 8 bolts attaching the stabilizer support TRANSMISSION bracket, and remove support. INSTALLATION 1. Apply Polaris Premium All Season Grease (PN 2871423) to splines of front output shaft ,install new O-ring in prop shaft, insert output shaft into prop shaft.
  • Page 200 10. Install airbox assembly and transmission vent line. Be sure vent line is not kinked or pinched. 11. Add Polaris Premium Synthetic Gearcase Lubricant to the proper level on dipstick. (Approximately 1 quart). Do not overfill. Premium Synthetic Gear Case Lubricant (PN 2871478) (12 oz.)

  • Page 201: Transmission Disassembly

    TRANSMISSION TRANSMISSION Remove all bolts DISASSEMBLY 1. Remove gear indicator switches BEFORE disassembly. Remove switches CAUTION: Do not pry on case half sealing surfaces. 4. Mark chain rotation direction for assembly. Note location of chain tensioner cam. If fully extended, 2.
  • Page 202 TRANSMISSION 5. Remove chain tensioner along with mounting pins 8. Make sure hole in oil deflector is clear and and spring. unobstructed. Be sure hole is clear 9. Using a puller remove Hi/Lo/Reverse (HLR) shaft 6. Remove rear output gear and chain as an bearing, and bearing thrust washer.
  • Page 203 TRANSMISSION 10. Turn transmission so shafts are pointing down. 13. Inspect face of shift fork for excessive wear, Slide the Low gear in and out until needle bearing discoloration, or bending. slides out of gear and can be removed. Remove needle bearing, low gear, and inner thrust washer.
  • Page 204 TRANSMISSION inch wrench to aid in removal. Loosen Pinch Bolts Pinch Bolts 16. Remove pinion gear retaining plate and pinion 19. Mark housing and casting for reference upon gear assembly. reassembly. 17. Inspect pinion gear for broken, chipped, or worn 20.
  • Page 205 TRANSMISSION 25. Unscrew front drive housing and remove it from case. Apply electrical tape to threads of housing to prevent damage. 21. Remove bottom access plate. 26. Using a brass hammer or a press, drive the shaft, 22. Bend the lock plate tab away from ring gear bearing, retaining ring, and seal out of the housing retaining bolt.
  • Page 206 TRANSMISSION 1. Inspect center shaft bushing for wear. If 2. Apply Loctite t 243 (blue) to threads of screws necessary, remove with the large end of bushing and install center shaft cover. Tighten screws drive securely. tool. Center Drive Bushing Tool (PN 2871697) Shaft Bearing Plug...
  • Page 207 TRANSMISSION 5. Set up a dial indicator to measure shaft end play. 2. Install shaft with bearing in front output housing. FRONT OUTPUT HOUSING (SNORKEL) INSTALLATION Transmission Bearing End of Housing 6. Measured end play will be between .030² -.070². Shims must be added between bearing and circlip to reduce end play.
  • Page 208 17 - 20 ft. lbs. (24-27 Nm) 11. Lubricate front housing O-ring thoroughly with Apply Loctitet 242 (PN 2871949) Polaris All Season grease. Continue to screw front housing in, making sure O-ring enters housing without damage. Be sure ring and pinion gear teeth mesh properly.
  • Page 209 TRANSMISSION 12. Rotate front shaft while slowly turning housing inward. As gear backlash is reduced to zero, the Front Gearcase Transmission shaft will begin to bind. At this point back off 1/4 Use This Mark Front Output turn. Shaft Use This Mark 1.875²...

  • Page 210: Transmission Assembly

    TRANSMISSION TRANSMISSION ASSEMBLY, CONT. 16. Make sure surface of access plate and transmission are clean and free of oil and grease. Apply Crankcase Sealant (PN 2871557) to mating surface of transmission case. Install access plate with notch to front as shown, torque screws to specification.
  • Page 211 TRANSMISSION 18. Assemble Hi/Low/Reverse shaft shown. 20. Assemble the input shaft and Hi/Low/Reverse Machined (flat) side of retainer should face direction gear cluster as shown. of thrust. Sliding high/reverse engagement dog is symmetrical and can be installed either way. The low gear dog must face low gear.
  • Page 212 TRANSMISSION 23. Install center shaft assembly. 26. Install outer thrust washer and bearing. 24. Install Low shift fork with sliding dog in place. 27. Install plastic oil deflector. Apply Loctitet 242 Dogs must be positioned outward (toward you). (PN 2871949) to screw threads. Be sure Slide the shift dog over the spline and the low deflector pin seats into case.
  • Page 213 Drive seal into place using large end of slide hammer. Repeat procedure for other side. Hook Spring Leg Under Cam 32. Pre-lubricate all bearings with Polaris Premium Synthetic GearCase Lubricant (PN 2871477) before installing cover. 33. Place the bellcranks in neutral so shift fork shafts will engage into the spring loaded detents of case 8.20...

  • Page 214: Troubleshooting

    TRANSMISSION Seal Installation Tool Rear Output Seal Driver (PN 2871698) Rear Driveshaft Seal Guide (PN 2871699) TROUBLESHOOTING CHECKLIST Check the following items when shifting difficulty is encountered. 36. Apply grease to the lip of a new input shaft seal. Install the seal, being careful to work the lip of the Idle speed adjustment seal over the step in the shaft before using the Transmission oil type/quality...

  • Page 215: Transmission Exploded View

    TRANSMISSION TRANSMISSION EXPLODED 9. 10. VIEW 8.22...
  • Page 216 TRANSMISSION TRANSMISSION EXPLODED VIEW CONT. 1 Screw Item Qty Description 2 Bearing, Ball 1 Washer, Steel 1 Shaft, 60T 1 Gear, 31T 1 Shaft, Center 1 O-Ring 1 Chain, Silent 1 Tube, Snorkel 2 Bearing, Ball 1 Spacer 3 Pin, Dowel 1 Ring, Retaining 1 Gearcase, LH 1 Bearing, Ball...
  • Page 217 TRANSMISSION NOTES 8.24...
  • Page 218 BRAKES CHAPTER 9 BRAKES Rear Auxiliary Master Cylinder Exploded View Main Brake System ......Front Caliper Exploded View .

  • Page 219: Brake System Main Components

    BRAKES BRAKE SYSTEM MAIN COMPONENTS Top View Master Cylinder Right Caliper Left Caliper Brake Switch Cross Fitting Rear Brake Reservoir Rear Caliper REAR AUXILIARY MASTER CYLINDER Brake Reservoir Frame Clamp Rear Brake Line Reservoir Hose Bolt Seal Rear Brake Master Cylinder Brake Mount Screw Spring...
  • Page 220 BRAKES REAR BRAKE CALIPER EXPLODED VIEW Anvil Bolts 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 Torque Bushings 30--35 ft.lbs. Seal (41--48 Nm) Front Caliper O--ring FRONT BRAKE CALIPER EXPLODED VIEW Socket Set Screw...

  • Page 221: Specifications

    BRAKES SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2870975 Mity Vact Pressure Test Tool SPECIFICATIONS 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 222: 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 223: 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 224: 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 225: 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 226: 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 227: Front Pad Removal

    BRAKES FRONT PAD REMOVAL 1. Elevate and support front of machine. NOTE: Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 5. Push mounting bracket inward and slip outer brake pad past edge.

  • Page 228: Front Pad Assembly

    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. 18 ft. lbs. (25 Nm) Front Caliper Mounting Bolts Torque: 18 ft.

  • Page 229: Brake Burnishing

    BRAKES 5. Install the adjuster screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise). Brake Disc Thickness .150-.164² (3.810-4.166 mm) Service Limit .140² / 3.556 mm 6. Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap.

  • Page 230: Front Caliper Removal

    BRAKES 1. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent. 18 ft. lbs. (25 Nm) new bolts have pre-applied locking agent. 2. Remove bolts and disc. 3. Remove brake caliper and drain fluid into 3.

  • Page 231: Front Caliper Inspection

    BRAKES 5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTE: Be sure to clean seal grooves in caliper body. Clean Components 3. Remove mounting bracket, pin assembly and dust boot. FRONT CALIPER Remove INSPECTION Mounting Bracket 1.

  • Page 232: Front Caliper Reassembly

    2. Coat piston with clean Polaris DOT 3 Brake Fluid (PN 2870990) (C). Install piston (D) with a twisting motion while pushing inward.

  • Page 233: Front Caliper Installation

    BRAKES FRONT CALIPER INSTALLATION Front Wheel Nut Torque 20 ft. lbs. (27 Nm). 1. Install caliper on hub strut, and torque mounting bolts. 18 ft. lbs. (25 Nm) Front Caliper Mounting Bolt Torque 18 ft. lbs. (25 Nm) 2. Install brake line and tighten securely with a line wrench.

  • Page 234: Brake Burnishing Procedure

    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 235 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 236: Rear Caliper Removal/Inspection

    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 237: Rear Caliper Assembly

    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 238: Troubleshooting

    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 239 BRAKES 9.22...

  • Page 240: Electrical

    ELECTRICAL CHAPTER 10 ELECTRICAL Special Tools/Service Notes ....10.2 Timing Check Procedure ..... 10.2 Gear Position Switch Test .

  • Page 241: Special Tools/Service Notes

    ELECTRICAL GPay attention to the prefix on the multimeter SPECIAL TOOLS reading (K, M, etc.) and the position of the decimal point. PART NUMBER TOOL DESCRIPTION GFor resistance readings, isolate component to be tested. Disconnect it PV- -43568 Fluket77 Digital Multimeter from the wiring harness or power supply.

  • Page 242: Gear Position Indicator

    ELECTRICAL Stator Adjustment GEAR POSITION INDICATOR 1. Remove the magneto housing. SWITCH TEST 2. Remove the flywheel. 3. Loosen the stator plate screws and adjust the Switch Continuity Table stator plate position. NOTE: Moving the stator plate clockwise retards (delays) the ignition Front Trans.

  • Page 243: 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 244: Diagnostic Mode

    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 245: Speedometer Removal/Installation

    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 246: Speedometer Troubleshooting

    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 247 ELECTRICAL SPEEDOMETER TROUBLESHOOTING 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. Power MEASURE B: Signal BACK OF C: Ground...
  • Page 248 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 ABOVE 3100 RPM,IT MAY BE A MECHANICAL PROBLEM. SPEEDO TURN ATV CHECK...
  • Page 249 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 SPEEDOMETER 2.

  • Page 250: Fan Motor Current Draw

    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 251: Etc Operation Test

    ELECTRICAL 5. If the fan motor draws more than 6.5 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 6.5 Amps brake.

  • Page 252: 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 253: 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 254: 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 255: Charging System Testing Flow Chart

    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). It should be 12.4 volts or vice.
  • Page 256 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 257: Battery Installation

    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 258: Load Test

    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 259: High Beam Headlight Adjustment

    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 260: Headlamp Switch

    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 261: Starter System Troubleshooting

    ELECTRICAL switch if there is no continuity or greater than .5 VOLTAGE DROP TEST ohms resistance when the brake is applied with slight pressure. 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 STARTER SYSTEM connection.
  • Page 262 ELECTRICAL 2. Remove the two bolts, washers, and sealing BRUSH O-Rings. Inspect O-Rings and replace if damaged. INSPECTION/REPLACEMENT Brush Set 1. Using digital multitester, measure resistance between the cable terminal and the insulated brush. The reading should be .3 ohms 3.

  • Page 263: Armature Testing

    ELECTRICAL 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 housing, and the tab on the brush plate engages the notch in the brush plate housing. 6.

  • Page 264: Starter Drive

    ELECTRICAL STARTER ASSEMBLY Starter Motor Exploded View Rear Brkt Assy Carbon Brush Washer Set Armature 1. Place armature in field magnet casing. Rubber Rings Washer 2. Place shims on drive end of armature shaft with O-ring phenolic washer outermost on shaft. Engage tabs of stationary washer in drive end housing, holding it in place with a light film of grease.

  • Page 265: 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 266 (LOCATED ON TOP OF ENGINE) IF THE CONNECTOR IN LOCATION A IS AN EIGHT PIN CONNECTOR (NOT LIKE THE CONNECTOR IN LOCATION A ) USE THE SPORTSMAN 400 LATE BUILD SCHEMATIC ON PAGE 10.28...
  • Page 267 SPARK PLUG (LOCATED TOP OF ENGINE) IF THE CONNECTOR IS A MOLDED 3 PIN CONNECTOR, (NOT LIKE CONNECTOR A BELOW), USE SPORTSMAN 400 EARLY BUILD SCHEMATIC ON PAGE 10.27...
  • Page 268 Brake Pad Removal, Rear, 9.17, 9.18 Brake System Inspection, 2.28 A-Arm Replacement, 5.7 Brake System Main Components, 9.2 Air Filter Service, 2.18 Brake System Operation, 9.6 Alternator Output Test, 10.15 Brake, Auxiliary, Hydraulic, 2.29 AWD Armature Plate Inspection, 7.8 Brake, Auxiliary, Testing, 2.28 AWD Magnetic Coil Installation, 7.7 Brakelight Lamp Replacement, 10.21 AWD Magnetic Coil Removal, 7.6...
  • Page 269 Clutch Alignment, 6.16 Cylinder Head Warpage, 3.21 Clutch Offset, 6.16 Cylinder Honing, 3.8 Cylinder Inspection, 3.29 Cold Weather Kits, 1.8, 2.4 Cylinder Installation, 3.45 Combustion Chamber, 3.23 Cylinder Removal/Inspection, 3.27 Compression Release Removal/Inspection, 3.17, 3.18 Compression Test, 2.15 Controls Inspection, 2.29 Decal Replacement, 5.11 Coolant Level Inspection , 2.18 Decimal Equivalent Chart, 1.10...
  • Page 270 Engine Accessible Components, 3.7 Front Hub Exploded View, AWD, 7.5 Engine Assembly, 3.37, 3.38, 3.40, 3.41, 3.42, Front Hub Fluid Change, 2.27 3.43, 3.44, 3.45, 3.46, 3.48, 3.49, 3.50 Front Hub Fluid Level Inspection, 2.26 Engine Bottom End Disassembly, 3.27, 3.28, Front Hub Seal Replacement, AWD, 7.6 3.29, 3.30, 3.31, 3.32, 3.33, 3.34, 3.35, 3.36, Front Hub/Wheel Bearing Installation, 7.3...
  • Page 271 Oil Pump Assembly, 3.35 Oil Pump Installation, 3.41 Idle Speed Adjustment, 2.12 Oil Pump Priming, 3.10 Ignition System Testing, 10.13 Oil Pump Priming--Magnum 500, 2.22 Ignition Timing Curve, 10.3 Oil Pump Removal/Inspection, 3.34 Instrument Cluster Troubleshooting, 10.4 Oil Pump Shaft End Play, 3.40 Intake Valve Adjustment, 2.23 One Way Valve, 3.33 One Way Valve Installation, 3.43...
  • Page 272 Rear Caliper Assembly, 9.20 Speedometer Removal, 10.6 Speedometer/Odometer, 10.4 Rear Drive Shaft Installation, 7.24 Spider Removal, 6.11 Rear Drive Shaft Removal, 7.23 Starter Assembly, 10.25 Rear Drive Shaft Service, 7.25 Starter Disassembly, 10.22 Rear Hub Assembly, 7.22 Starter Drive, 10.25 Rear Hub Disassembly, 7.22 Starter Drive Installation, 3.50 Rear Hub Installation, 7.21...
  • Page 273 Transmission I.D. Location, 1.2 Valve Inspection, 3.22 Transmission Installation, 8.6 Valve Seal Testing, 3.26 Transmission Linkage Adjustment, 2.10 Valve Seat Inspection, 3.23 Transmission Removal, 8.5 Valve Seat Reconditioning, 3.23 Transmission Tensioner Installation, 8.20 Vent Line Maintenance, 2.14 VIN Identification, 1.2 Transmission, Exploded View, 8.22, 8.23 Troubleshooting, Brakes, 9.21 Voltage Drop Test, 10.22...
  • Page 274 PN 9918065 Printed in USA...

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Sportsman 500 2003

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