Polaris Sportsman 700 Efi 2005 Service Manual
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Polaris Sportsman 700 Efi 2005 Service Manual

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2005 SPORTSMAN 700 EFI
2005 SPORTSMAN 800 EFI
SERVICE MANUAL
PN 9919820

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Summary of Contents for Polaris Sportsman 700 Efi 2005

  • Page 1 2005 SPORTSMAN 700 EFI 2005 SPORTSMAN 800 EFI SERVICE MANUAL PN 9919820...
  • Page 2 2005 Sportsman 700/800 EFI ATV Service Manual (PN 9919820) 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: Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle Nyogel, Trademark of Wm. F. Nye Co.
  • Page 4 GENERAL MAINTENANCE ENGINE ELECTRONIC FUEL INJECTION BODY AND STEERING CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...

  • Page 5: Table Of Contents

    GENERAL INFORMATION Specs Model Identification ..... . . Serial Number Location ....2005 Sportsman EFI 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 M H 6 8 A U Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation ENGINE DESIGNATION NUMBERS EH068OLE...

  • Page 7: Sportsman 800 Efi

    GENERAL INFORMATION 2005 SPORTSMAN 700 EFI MODEL: ..MODEL NUMBER: A05MH68AU ENGINE MODEL: EH068OLE22 Category Dimension / Capacity Length 83 in./205.74 cm Width 48 in./116.8 cm Height 48 in./119.4 cm Seat Height 34 in./86.4 cm Wheel Base 50.75 in./128.9 cm...

  • Page 8: Specifications

    Lubrication Pressurized Wet Sump Front Suspension / Shock A- -arm / MacPherson Strut Oil Requirements / Capacity Polaris 0W- -40 2 qt. / 1.9 ltr Front Travel 8.2 in. / 21 cm Exhaust System Single Pipe Rear Suspension / Shock...
  • Page 9 Lubrication Pressurized Wet Sump Front Suspension / Shock A- -arm / MacPherson Strut Oil Requirements / Capacity Polaris 0W- -40 2 qt. / 1.9 ltr Front Travel 6.7 in. / 17.02 cm Exhaust System Dual Pipe / Silencer Rear Suspension / Shock...

  • Page 10: Publication Numbers

    Sportsman 800 EFI A05MH76AU 9917720 9917721 9917722 *When ordering service parts be sure to use the correct parts manual. NOTE: Some Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com. PAINT CODES PAINTED PART COLOR DITZLER POLARIS...

  • Page 11: Special Tools

    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 recommends the use of Polaris special tools when servicing any Polaris product. Standard Tools and Engine Tools...
  • Page 12 GENERAL INFORMATION SPECIAL TOOLS Standard Tools and Engine Tools Clutch (PVT) Tools 2870506 -- Drive Clutch Puller 2870303 -- Hone Kit 2870913 -- Driven Clutch Puller 2870305 -- Stone Replacement Kit 2872292 -- EBS Clutch Align Tool 2870588 -- Hone Oil (12 oz.) 9914177--A -- Drive Clutch Holding Tool 2200634 -- Valve Seat Reconditioning Kit...
  • Page 13 GENERAL INFORMATION Clutch (PVT) Tools Suspension Tools 2871025 -- Clutch Bushing Replace 2870871 -- ATV Ball Joint Tool Kit Tool Kit 2870910 -- Roll Pin Tool 2871071 -- Shock Body Holding Tool 2871226 -- Clutch Bushing Replacement Kit 2870623 -- Shock Spring Compressor 2871572 -- Strut Rod Wrench 2201379 -- EBS Bushing Replacement Kit...
  • Page 14 GENERAL INFORMATION Electrical Tools Suspension Tools 2870872 -- Shock Spanner Wrench 2870630 -- Timing Light 2872608 -- Roll Pin Removal Tool 2871745 --Static Timing Light Harness 2871351 -- Shock IFP Depth Tool 2460761 -- Hall Sensor Probe Harness Fuel & Brake Systems PV--39991 -- Peak Reading Adapter PV--37453 -- Christie Se--Sulfating 2870975 -- Mity Vac...
  • Page 15 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 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 GENERAL INFORMATION SAE TAP DRILL SIZES DECIMAL EQUIVALENTS 1/64 ....0156 Thread Size/Drill Size Thread Size/Drill Size 1/32 ... .0312 .

  • Page 18: Glossary Of Terms

    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. Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase.
  • Page 19 MAINTENANCE Periodic Maintenance Chart ....2.2-2.5 Component Locations ....Lubricant and Maintenance Product Numbers 2.7 Special Tools .

  • Page 20: 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 21: 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 22 Inspect routing, condition " (1000) Valve clearance 100 H 12 M Inspect; (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 23 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 24: Component Locations

    MAINTENANCE SPORTSMAN COMPONENT LOCATIONS Instrument Cluster AWD Switch (Speedometer) Brake Fluid Reservoir Work light Brake Lever Light Control & Run Switch Reverse Override Throttle Front Storage Ignition/Key EFI Diagnostic Compartment Plug Cover & Rack Rear Storage Compartment Front Gearcase (Behind Radiator) Oil Dipstick PVT Cover Drain Gas Cap...
  • Page 25 MAINTENANCE POLARIS LUBRICANTS/FLUIDS FOR SPORTSMAN MODELS Pure Polaris Lubricants and Maintenance Kits can be purchased at your local Polaris dealer. ATV ANGLE DRIVE FLUID 2859066 -- Sportsman 600/700 Maintenance Kit - - Oil Filter & 2 Qts. of 0W- -40 oil...

  • Page 26: Special Tools

    PU- -47086 and 8700220 Clutch Compression Tool 2871025 Clutch Bushing Replacement Tool Kit 2872608 Roller Pin Removal Tool 8700226 CV Boot Clamp Pliers PV- -43568 Fluket77 Digital Multimeter 2870630 Timing Light 2870836 Battery Hydrometer *Special Tools Can be ordered through SPX Corporation (www.polaris.spx.com)
  • 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 Ill.
  • Page 28 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 29: Front & Rear Gearcase Lubrication

    PARK. G Check vent hose to be sure it is routed properly and unobstructed. G The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid. FRONT GEARCASE SPECIFICATIONS 11 ft.lbs (15 Nm) Specified Lubricant: Premium Demand Drive Hub Fluid 1.

  • Page 30: Rear Gearcase

    2. Clean and reinstall drain plug (A) using a new G The correct rear gearcase lubricant to use is sealing washer (B). Polaris ATV Angle Drive Fluid. 3. Remove fill plug (C). REAR GEARCASE SPECIFICATIONS 4. Fill with the recommended fluid amount or fill to the bottom of the fill plug hole threads.

  • Page 31: Transmission Lubrication

    2. Clean and reinstall the drain plug. Torque to Fill Plug specification. 3. Remove fill plug. 4. Add 15 oz. of Polaris AGL Gearcase Lubricant or fill to top of the fill plug hole threads. 5. Check for leaks. 6. Reinstall fill plug and torque to 10--14 ft.lbs.

  • Page 32: Throttle Cable

    MAINTENANCE THROTTLE CABLE / THROTTLE INSPECTION ELECTRONIC THROTTLE Check for smooth throttle opening and closing in all CONTROL (ETC SWITCH) handlebar positions. Throttle lever operation should be smooth and lever must return freely without ADJUSTMENT binding. 1. Place the gear selector in neutral. 1.

  • Page 33: Compression Test

    MAINTENANCE SHIFT LINKAGE INSPECTION VENT LINES NOTE: Shift rod is preset at time of manufacture. Check fuel tank, oil tank, carburetor, battery and transmission vent lines signs wear, deterioration, damage or leakage. Replace every two Shift Linkage Rod years. Be sure vent lines are routed properly and secured with cable ties.

  • Page 34: Battery Maintenance

    MAINTENANCE BATTERY MAINTENANCE A cylinder leakdown test is the best indication of engine condition. Follow manufacturer’s instructions to perform a cylinder leakage test. (Never use high pressure leakage testers, as crankshaft seals may dislodge and leak). WARNING Cylinder Compression Battery electrolyte is poisonous. It contains Standard: 150-200 PSI sulfuric acid.

  • Page 35: Spark Plug

    MAINTENANCE To remove the battery: erosion of the electrodes. 1. Disconnect holder strap and remove cover. Inspect electrode for 2. Disconnect battery negative (-) (black) cable first, wear and buildup followed by the positive (+) (red) cable. CAUTION To reduce the chance of sparks: Whenever removing the battery, disconnect the negative (black) cable first.

  • Page 36: Liquid Cooling System

    OVERVIEW to freeze, corrode, or overheat. The engine coolant level is controlled or maintained Polaris 60/40 Anti-Freeze / Coolant by the recovery system. The recovery system components are the recovery bottle, radiator filler (PN 2871323) neck, radiator pressure cap and connecting hose.

  • Page 37: Coolant Level

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

  • Page 38: Radiator Screen Removal

    MAINTENANCE AIR FILTER/PRE-FILTER To access the radiator pressure cap: Remove the four screws securing front rack. Turn SERVICE handle bars full left or right to provide more clearance. Remove front cover by placing your fingers under the It is recommended that the air filter and pre filter be front of the cover and pulling upward.

  • Page 39: Air Box Sediment Tube Service

    MAINTENANCE AIR BOX SEDIMENT TUBE 9. Inspect main filter and replace if necessary. If the filter has been soaked with fuel or oil it must be replaced. Periodically check the air box drain tube located Installation: toward the rear of the machine. Drain whenever deposits are visible in the clear tube.

  • Page 40: Pvt Drying & Pvt Drain Plug

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

  • Page 41: Engine Oil Level

    MAINTENANCE ENGINE OIL LEVEL 4. Reinstall dipstick and push it into place. Do not lock the dipstick. The 700 engine is a wet--sump engine, meaning the NOTE: Make certain the dipstick is inserted all the oil is contained in the bottom of the crankcase. To way into the filler tube to keep the angle and depth of check the oil level: stick consistent.

  • Page 42: Oil And Filter Change

    1/2 turn. 12. Remove dipstick and fill sump with 2 quarts (1.9 l) Crankcase Drain of Polaris Premium 4 Synthetic Oil (PN 2871281). Recommended Engine Oil Polaris Premium 4 All Season Synthetic, 0W- -40 (PN 2871281)

  • Page 43: Camber And Caster

    Polaris recommends components). 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: 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 45: Toe Alignment

    MAINTENANCE TOE ALIGNMENT EXHAUST PIPE ADJUSTMENT The exhaust pipe must be periodically purged of accumulated carbon as follows: If toe alignment is incorrect, measure the distance 1. Remove the clean out plugs located on the between vehicle center and each wheel. This will tell bottom of the muffler as shown in illustration 1.

  • Page 46: Brake Pad Inspection

    3/64″ (.1 cm), or about the thickness of a dime. maintenance schedule and before each ride. Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir. Use Polaris DOT 3 Brake Fluid (PN 2870990). Sight Parking Brake Glass Lock 3/64″...

  • Page 47: Auxiliary Brake

    MAINTENANCE HOSE/FITTING INSPECTION First, check foot brake effectiveness by applying 50 lb. (approx.) downward force on the pedal. The top of the pedal should be at least 1 inch, (25.4mm) above the Check brake system hoses and fittings for cracks, surface of the footrest.

  • Page 48: Controls

    Inspect the cv shaft boots in the front and rear of the ATV for damage, tears, wear, or leaking grease. If the rubber 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. 2.30...

  • Page 49: Wheel Installation

    MAINTENANCE WHEELS 4. Remove the wheel nuts and remove the wheel. Inspect all wheels for runout or damage. Check wheel WHEEL INSTALLATION nuts and ensure they are tight. Do not over tighten the wheel nuts. 1. With the transmission in gear and the parking brake locked, place the wheel in the correct WHEEL, HUB, TORQUE position on the wheel hub.

  • Page 50: Tire Inspection

    MAINTENANCE TIRE INSPECTION FRONT / REAR STORAGE COMPARTMENTS Improper tire inflation may affect ATV maneuverability. The front and rear storage compartments are easily When replacing a tire always use accessible. To open the front compartment turn the original equipment size and type. latch handle to the horizontal position on both sides.

  • Page 51: Warn® Winch Operation

    MAINTENANCE WARN WINCH OPERATION The mini--rocker (IN/OUT) control controls the ® direction of the cable for the winch. IN pulls the cable (If Equipped) into the winch and OUT feeds the cable out of the winch. This information is for Sportsman models equipped with a 2500 lb.
  • Page 52 MAINTENANCE Winch Wire Locations The Red wire (6 Ga.) with the yellow crimp cover is located under the left rear fender next to the starter The winch wires can be located under the front cab solenoid. The red wire connects to the battery. area.

  • Page 53: Cleaning And Storage

    Storage Tips automotive paste wax. Avoid the use of harsh Polaris offers storage kits for you ATV, see Page 2.7 cleaners since they can scratch the body finish. for the part numbers of Polaris products. Polaris offers a detailing kit for your ATV, see Page 2.7.

  • Page 54: 800 Efi Exhaust Canister Maintenance

    7. Treat the fuel system with Polaris Carbon Clean. 8. If Polaris fuel system additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline. To eliminate any fuel remaining in the carburetor, run the engine until it stops.
  • Page 55 ENGINE Engine Exploded Views ..... . 3.2--3.7 Exhaust System View / Notes ....Special Tools .

  • Page 56: Engine Exploded Views

    ENGINE ENGINE EXPLODED VIEW CRANKCASE Camshaft Thrust Plate Journal Bearings 115 ± 12 in. lbs. Balance Shaft (13 ± 1.35 Nm) Flange Seal 60 ± 6 in. lbs. Woodruff Key (6.8 ± .68 Nm) Crankshaft Oil Pickup Journal Bearings Baffle 60 ±...
  • Page 57 108 ± 12 in. lbs. (6.8 ± .68 Nm) * NOTE: Apply Corrosion Resistant Grease to Stator Grommet Area TIMING MARKS Mag Cover Bolt Tighten Sequence Apply Polaris 0W--40 oil to component. Apply White GEAR TIMING AT TDC Lithium Grease.
  • Page 58 ENGINE ENGINE EXPLODED VIEW Apply Polaris MAG SIDE Starter Grease. Apply Polaris 0W--40 oil to seal. Loctitet Pipe Sealant (PN 2871956) Bolts Water Pump Cover Bolt Gasket (Tighten Top Bolt First) Tighten Sequence (NO Grease or Oil!) 8 ft. lbs.

  • Page 59: Top End

    Apply 0W--40 to lifters. Pushrods Bushing Do not install expansion plug more than 1.5 mm inward. Expansion 1.5 mm Plug Cylinder Side View Piston Assembly Circlip UP for Install Gasket Hydraulic Lifter Apply Polaris 0W--40 oil. Apply Moly Lube Grease.
  • Page 60 ENGINE ENGINE EXPLODED VIEW OUTER COMPONENTS Screws 8 in. lbs. ± (9.5 0.9 Nm) ± Rocker Cover Breather O--ring Seal 5 in. lbs. ± Breather Bolts (2.5 0.55 Nm) ± Spark Plugs 24 in. lbs. ± (24.5 2.7 Nm) ± (*Apply Dielectric Grease Tips of Spark Plugs) Carburetor Boot 24 in.

  • Page 61: Electrical Components

    ENGINE ENGINE EXPLODED VIEW ELECTRICAL COMPONENTS Fuel Injector Fuel Rail 24 in. lbs. ± (24.5 2.7 Nm) ± EFI Harness NOTE: See Chapter 4 for more information the EFI system.

  • Page 62: Exhaust System

    Silencer removal requires replacement of the silencer grommets, item #24, as they become damaged during removal. 800 EFI Exhaust Canister Maintenance The exhaust canisters on Polaris 800 EFIs are ceramic coated. To maintain a beautiful finish and prevent corrosion, E 2004 Polaris Sales Inc.

  • Page 63: Special Tools

    ENGINE SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION PV- -43527 Oil Filter Wrench 2200634 Valve Seat Reconditioning Kit PU- -45257 Valve Spring Compressor PU- -45652 Valve Pressure Hose 2871043 Flywheel Puller 2870390 Piston Support Block PU- -45497- -2 Cam Gear Tooth Alignment Tool PU- -45497- -1 Cam Gear Spring Installation Kit (Tapered Pins) PU- -45498...

  • Page 64: Torque Specifications

    ENGINE TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Size 700/800 700/800 in. Lbs. (Nm) ft.lbs. (Nm) Camshaft Gear 8 mm 22 ± 2 (30 ± 3) Camshaft Thrust Plate 6 mm 115 ± 12 (13 ± 1.35) Carburetor Adaptor Bolts 8 mm 216 ±...

  • Page 65: Engine Fastener Torque Patterns

    ENGINE ENGINE FASTENER TORQUE PATTERNS Tighten cylinder head/cylinder base, and crankcase fasteners in the following sequence outlined below. CRANKCASE BOLT TIGHTEN SEQUENCE 2 ft. lbs. ± 3 Nm) ± CYLINDER HEAD BOLT TIGHTEN SEQUENCE Lubricate threads and between washer and underside of bolt with engine oil. Torque in sequence to spec provided, allow the gasket to set for 1 minute, then tighten in sequence 90°...
  • Page 66 ENGINE 700/800 EFI ENGINE SERVICE DATA **Cylinder Head / Valve EFI Engine No. - - EH680OLE / EH780OLE Camshaft Cam lobe height In 1.3334” (33.8674 mm) 1.3334” (33.8674 mm) Camshaft journal OD 1.654” ± 0.00039” (42 ± 0.010 mm) Center 1.634”...
  • Page 67 ENGINE 700/800 EFI ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod EFI Engine No. EFI Engine No. EH680OLE EH780OLE Cylinder Surface warpage limit 0.004” (0.10 mm) Same (mating with cylinder head) Cylinder bore 3.1495” (80 mm) Same Taper limit 0.00031”...
  • Page 68 ENGINE 700/800 EFI ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod EFI Engine No. EFI Engine No. EH680OLE EH780OLE Piston Piston ring installed Top ring 0.0059-- 0.0138” 0.0059 -- 0.0138” Ring (0.15 ± 0.35 mm) (0.15 ± 0.35 mm) Limit >...

  • Page 69: Cooling System Specifications

    2. The radiator cap relief pressure is 13 lbs. Replace reduce heat dissipation, resulting in possible engine cap if it does not meet this specification. damage. Polaris Premium 60/40 Antifreeze/Coolant is Upper Engine Hose recommended for use in all cooling systems and comes Surge Tank pre-mixed, ready to use.
  • Page 70 ENGINE ENGINE REMOVE & INSTALL 12. Remove the crank position sensor (E) located on the mag cover. WARNING Always wear safety glasses and proper shop clothing when performing the procedures in this manual. Failing to do so may lead to possible injury or death.

  • Page 71: Engine Installation Notes

    ENGINE 2. Adjust clutch offset, alignment, and belt deflection. (Chapter 6) 3. Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing. (Chapter 6) Transmission 1. Inspect transmission operation and adjust linkage if necessary. Refer to Chapter 2 and Chapter 8. Exhaust 1.
  • Page 72 ENGINE Engine Break In Period The break in period for a Polaris ATV engine is defined as the first ten hours of operation, or the time it takes to use two full tanks of gasoline. No single action on your part is as important as a proper break in period.

  • Page 73: Cylinder Hone Selection And Honing Procedure

    Rinse thoroughly, dry with compressed air, A finished cylinder should have a cross-hatch pattern and oil the bore immediately with Polaris 4 Cycle to ensure piston ring seating and to aid in the retention Lubricant to prevent the formation of surface rust.

  • Page 74: Oil Flow

    ENGINE OIL FLOW This chart describes the flow of oil through the 600/700/800 engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.

  • Page 75: Rocker Arm/Pushrod Inspection

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

  • Page 76: Cylinder Head Disassembly/Inspection

    ENGINE CYLINDER HEAD INSPECTION WARNING 1. Thoroughly clean cylinder head surface to Wear eye protection or a face shield during remove all traces of gasket material and carbon. cylinder head disassembly and reassembly. CAUTION: Use care not to damage sealing surface. 1.
  • Page 77 ENGINE CYLINDER HEAD DISASSEMBLY, CONT. NOTE: Carefully remove the cylinder components. Valve Spring Length: Place the hydraulic lifters (C), pushrods (D), and rocker arms (E) in a safe, clean area. Std: 1.735I (44.069 mm) 6. Remove valve guide seals. IMPORTANT: It is recommended to replace seals whenever the cylinder head is disassembled.

  • Page 78: Valve Inspection

    ENGINE VALVE INSPECTION Valve Stem Diameter: 1. Remove all carbon from valves with a soft wire Intake: 0.2356” ± 0.00039” wheel or brush. (5.985 ± 0.01 mm) 2. Check valve face for runout, pitting, and burnt Exhaust: 0.2351” ± 0.00039” spots.

  • Page 79: Combustion Chamber

    1. Install pilot into valve guide. VALVE SEAT RECONDITIONING Cylinder Head Reconditioning NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area. NOTE: The cylinder head valve guides cannot be replaced. WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly.
  • Page 80 ENGINE VALVE SEAT RECONDITIONING CONT’D If the seat is too narrow, widen using the 45° cutter and re-check contact If the contact area of the cutter is in point on the valve face and seat width the same place, the valve guide is after each cut.

  • Page 81: Cylinder Head Assembly

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

  • Page 82: Valve Sealing Test

    ENGINE VALVE SEALING TEST 1. Clean and dry the combustion chamber area (A). Refer to Page 3.25 for cleaning tips. 2. Pour a small amount of clean solvent onto the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage.

  • Page 83: Engine Head Reassembly

    ENGINE ENGINE HEAD REASSEMBLY 4. Lubricate push rods (D) and install into lifters. Before reassembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts. 1. Install the head gasket (A) on the cylinder (B). 5.
  • Page 84 ENGINE ENGINE HEAD REASSEMBLY CONT’D 11. Install thermostat (J), O--ring, thermostat housing. Torque thermostat housing 8. Install breather reed (G) into rocker cover (H). bolts to 84 ± 8 in.lbs. (9.5 ± 0.9 Nm). Lightly apply black RTV sealant to the outer edges of the breather reed.

  • Page 85: Cylinder Removal

    ENGINE CYLINDER REMOVAL 4. Check the lifters for wear or scores. 5. Check the bottom end of lifter to make sure that it 1. Follow engine disassembly procedures to has a slight convex. remove rocker cover and cylinder head. 6. If the bottom surface has worn flat, it may be used with the original camshaft only.

  • Page 86: Cylinder Inspection

    ENGINE CYLINDER INSPECTION 2. Remove piston circlip and push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch. CAUTION: Do not 1. Remove all gasket material from the cylinder apply heat to the piston rings. The ring may lose sealing surfaces.
  • Page 87 ENGINE 3. Inspect cylinder for wear, scratches, or damage. 5. Record measurements. If cylinder is tapered or out of round beyond .002, the cylinder must be replaced. Cylinder Taper Limit: .002I (.05mm)Max. Cylinder Out of Round Limit: .002I (.05mm)Max. Standard Bore Size (Both Cylinders): Sportsman 700 / 800 : 3.1496I (80 mm) PISTON-TO-CYLINDER 4.

  • Page 88: Piston/Rod Inspection

    ENGINE PISTON/ROD INSPECTION 3. Measure connecting rod small end ID. 1. Measure piston pin bore. Piston Pin Bore: Refer To Engine Service Connecting Rod Small End I.D. Data Pg. 3.12 - - 3.14 Refer To Engine Service Data Pg. 3.12 - - 3.14 2.

  • Page 89: Piston Ring Installed Gap

    ENGINE 4. Measure piston ring to groove clearance by placing the ring in the ring land and measuring Piston Ring Installed Gap with a thickness gauge. Replace piston and rings if ring-to-groove clearance exceeds service limits. Refer To Engine Service Data Pg.

  • Page 90: Starter Bendix Removal/Inspection

    ENGINE STARTER DRIVE/BENDIX 6. Inspect gear teeth on starter drive (B). Replace starter drive if gear teeth are cracked, worn, or REMOVAL/INSPECTION broken. 7. Inspect the bendix bushing (C) in the mag cover 1. Remove stator housing bolts and remove for wear.

  • Page 91: Flywheel/Stator Removal/Inspection

    ENGINE FLYWHEEL/STATOR REMOVAL/INSPECTION 1. Remove stator housing bolts and remove housing. 5. Remove the bendix (E) if necessary. FLYWHEEL/STATOR INSTALLATION Remove Stator Cover NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any 2.

  • Page 92: Engine Crankcase Disassembly/Inspection

    ENGINE Stator Housing Bolt Torque: Flywheel Nut Torque: 96 ± 12 in.lbs. (1.85 ± 1.35 Nm) 65 ± 7 ft. lbs. (88 ± 9.50 Nm) *Torque Bolts In Sequence 3.4) 5. Inspect the mating surface around the gear/stator housing cover and the crankcase for oil seepage. ENGINE CRANKCASE If there is seepage between the mating surfaces, DISASSEMBLY/INSPECTION...
  • Page 93 ENGINE 4. Install Flywheel Puller (PN 2871043) and remove flywheel (F). CAUTION: Do not thread the puller bolts into the flywheel more than 1/4″ or stator coils may be damaged. 2871043 7. Note the positions of the gears in the photo. Camshaft Gear 5.

  • Page 94: Cam Gear Removal

    ENGINE NOTE: If replacing one of the gears, it is 11. The cam gear assembly contains three loaded recommended that all of the gears be replaced. A springs. To open the cam gear assembly: gear kit is available in the parts book. Place the cam gear on a flat surface with the timing mark side facing up.
  • Page 95 ENGINE Inspect Teeth & Tabs PU- -45497- -1 Replace Three Springs To assemble: Cam Gear Reassembly Hold the spring with one finger. 15. Install the new springs into the grooves of the cam Start the pointed end of the tapered gear.
  • Page 96 ENGINE (R) to align the teeth of the cam gears, as shown in the picture. Cam Gear Spring Installation Tool Kit: NOTE: Install the Cam Gear Alignment Tool (PU- -45497) (PU- -45497- -2) into one assembly hole counter clockwise from the timing mark. Tapered Pins: (PU- -45497- -1) Cam Gear Tooth Align Tool:...
  • Page 97 ENGINE balance shaft gear. 2871043 2871043 23. Inspect the crankshaft gear (Q) for broken or worn Water/Oil Pump Removal/Disassembly teeth. If the crankshaft gear does not need to be replaced, it does not need to be removed. If the crankshaft gear is damaged, remove the 26.
  • Page 98 ENGINE Oil Rotor Clearance 28. Use a feeler gauge to measure the clearance between the two rotors. Measure the gap 22 ± 2 ft.lbs between the two rotor tips as shown below. The (30 ± 3 Nm) clearance should not exceed 0.006” (0.15 mm). Chamfered end first NOTE: Be sure to place the tapered end of the valve...
  • Page 99 ENGINE WATER/OIL PUMP REASSEMBLY 34. Press new bearing onto the shaft. Press out shaft and bearing assembly Bearing Bearing Retaining Ring 33. Place the shaft in a press to remove the bearing. 35. Press the bearing/shaft assembly using the bearing’s outer race. Do not use the shaft to press the assembly into the housing, as bearing Bearing damage may result.
  • Page 100 ENGINE CRANKCASE DISASSEMBLY CONT’D 37. Remove thrust plate (U). 40. Remove balance shaft and crankshaft. 38. Remove PTO end engine mount. Remove crankcase bolts. Tap on the reinforced areas on the cases using soft hammer. Carefully separate the two crankcase halves. Separate the crankcase halves...

  • Page 101: Camshaft Inspection

    ENGINE CAMSHAFT INSPECTION Camshaft Journal O.D. : 1. Thoroughly clean the cam shaft. 2. Visually inspect each cam lobe for wear, chafing A. (Mag): 1.654” ± .00039” (42 ± .010 mm) or damage. B. (Ctr.): 1.634” ± .00039” (41.50 ± .010 mm) C.
  • Page 102 ENGINE 1. Install oil pick up (A), if removed. Torque bolt to 60 4. Apply Moly Lube Grease to cam journals and ± 6 in. lbs. (6.8 ± 0.68 Nm). balance shaft bearing surfaces of the MAG case halve. Install cam and balance shafts. 2.
  • Page 103 ENGINE 7. Assemble the crankcase halves. Apply LocTitet 10. Lubricate connecting rods with 0W--40 engine oil. 242 (PN 2871949)to the threads and pipe sealant to the bolt flanges. Torque bolts to 22 ± 2 ft. lbs. (30 ± 3 Nm) following torque pattern on Page 3.11.
  • Page 104 ENGINE 13. Install piston assemblies into cylinder aligning the NOTE: While installing in piston pins, cover all piston pin holes, to ensure proper alignment of the engine passages. The clip could fall into the engine pistons to the connecting rods upon assembly. during installation.
  • Page 105 ENGINE NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing Line Up Marks bolts and new Loctitet. 20. Install oil pump housing bolts (H). The new bolts contain patch lock, so Loctitet is not needed on the new bolts.
  • Page 106 ENGINE (J). (I). Install washer and bolt. Use the Gear Holder (PU- -45838). Torque to 22 ± 2 ft. lbs.(30 ± 3 Nm). PU- -45838 CAUTION: Balance Shaft Gear Bolt Torque: The crankshaft gear is extremely hot! Severe burns or injury can occur if the gear is not 22 ±...
  • Page 107 ENGINE Timing Marks PU- -45498 Timing Marks 27. Reinstall the camshaft gear; so the timing marks Counterbalance Gear and Camshaft are properly aligned. Install the washer and bolt. Gear Bolt Torque: Torque to 22 ± 2 ft. lbs.(30 ± 3 Nm). 22 ±...
  • Page 108 ENGINE PA- -44995 Seal lip goes towards the crankcase. 30. Once the crankshaft seal is installed into the gear/ stator housing cover, set the direction of the paper lip by sliding the Main Crankshaft Seal Saver (PA- -45658) into the crankshaft seal from the rubber lipped side to the paper lip side.(Back to NOTE: To remove the water pump seal, the...
  • Page 109 ENGINE 34. Apply Crankcase Sealant (PN 2871557) to the outside edges of the crankcase halves (See arrows), where the crankcases mate. (See photos below.) This helps to prevent coolant leakage. (PA- -45658) 32. Before installing the gear/stator housing cover, install the Water Pump Seal Saver (PA- -45401) onto the water pump shaft.
  • Page 110 ENGINE (PA- -45401) (PA- -45658) Gear/Stator Housing Bolt Torque: 96 ± 12 in. lbs. (10.85 ± 0.35 Nm) Water Pump Impeller Nut Torque: *Torque in Proper Sequence (Pg. 3.3) 108 ± 12 in. lbs. (6.8 ± 0.68 Nm) NOTE: Before assembly, clean the bolts and bolt 39.
  • Page 111 ENGINE 40. Sparingly apply Starter Drive Grease (PN 43. Install the flywheel, washer, nut, and key. Torque 2871423) to the starter drive. Install the starter flywheel nut to 65 ± 7 ft. lbs. (88 ± 9.50 Nm). bendix. NOTE: There are thrust washers on both sides of starter drive.
  • Page 112 46. Remove primer plug from the engine. Install the Oil System Priming Adapter (PU- -45778) into the oil plug hole. Push 3--5 oz. (approx.) of Polaris 0W--40 into the adapter until resistance is felt. Remove the adapter. Apply pipe dope or Teflon tape to the plug threads.

  • Page 113: Troubleshooting

    ENGINE TROUBLESHOOTING Spark Plug Fouling Spark plug cap loose or faulty Engine Idles But Will Not Rev Up Incorrect spark plug heat range or Spark plug fouled/weak spark Broken throttle cable Obstruction in air intake PVT system calibrated incorrectly/ components worn or mis-adjusted Air box removed (reinstall all intake components) Fuel quality poor (old) or octane too...

  • Page 114: Cooling System

    ENGINE TROUBLESHOOTING, CONT Air leaks in intake Lean condition Piston Failure - Scoring COOLING SYSTEM Lack of lubrication TROUBLESHOOTING Dirt entering engine through cracks in air filter or ducts Overheating Engine oil dirty or contaminated Low coolant level Excessive Smoke and Carbon Buildup Air in cooling system Excessive piston-to-cylinder clearance...
  • Page 115 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 116 ENGINE NOTES 3.62...
  • Page 117 FUEL SYSTEM / FUEL INJECTION Special Tools ......Service Notes ......EFI System Exploded View .

  • Page 118: Special Tools

    Test Valve Always stop the engine and refuel outdoors or in a well ventilated area. Polaris EFI Diagnostic Software - - PU- -47063 This dealer--only software installs on laptop computers equipped with a CD drive and serial port connection, and is designed to replace multiple shop tools often used to test EFI components.

  • Page 119: Service Notes

    For the purpose of troubleshooting negative (--) cable to negative (--) difficult running issues, a known--good battery terminal. ECU from another Polaris ATV EFI Never start the engine when the may be used without damaging cables are loose or poorly connected system or engine components.

  • Page 120: Efi System Exploded View

    FUEL SYSTEM / FUEL INJECTION EFI SYSTEM EXPLODED VIEW 1. Electronic Control Unit (ECU) 2. Intake Air Temperature and Barometric Air Pressure Sensor (T--BAP) 3. Crankshaft Position Sensor (CPS) 4. Fuel Injectors 5. Fuel Filter(s) 6. Fuel Pump / Regulator / Gauge Sender Assembly (located in tank as an assembly) 7.

  • Page 121: Efi System Component Locations

    FUEL SYSTEM / FUEL INJECTION EFI SYSTEM COMPONENT LOCATIONS 1. Electronic Control Unit (ECU) 2. Intake Air Temperature and Barometric Air Pressure Sensor (T--BAP) 3. Crankshaft Position Sensor (CPS) 4. Fuel Injectors 5. 2 Fuel Filters (1 located in tank, 1 under front cab cover not pictured) 6.
  • Page 122 FUEL SYSTEM / FUEL INJECTION FUEL TANK ASSEMBLY Tank Vent Fuel Pump/Tank Assembly Rear Tank Mount Protective Foil Front of ATV Frame E 2003 Polaris Sales Inc. FUEL FLOW Fuel Tank Fuel Tank Vent Excess Fuel Fuel Pump / Pressure Regulator Fuel Filter Unit...

  • Page 123: Electronic Fuel Injection System

    NOTE: Accurate testing of EFI components is An in--tank electric fuel pump is used to move fuel recommended utilizing the Polaris Diagnostic from the tank through the fuel line and in--line fuel filter. Software (dealer only). The in--tank fuel pressure regulator maintains a system operating pressure of 39 psi and returns any excess fuel to the tank.

  • Page 124: Electronic Control Unit

    All operating and control functions within the ECU are pre--set. No internal servicing or readjustment may be performed. If a problem is encountered, and you determine the ECU to be faulty, contact the Polaris Service Department for specific handling instructions. Do not replace the ECU without factory authorization.

  • Page 125: Fuel Pump/Tank Assembly

    1. Remove the fuel test valve cap. Connect the system for start--up. pressure hose of the Polaris pressure tester The ECU switches off the pump preventing the to the test valve on the fuel rail. Route...

  • Page 126: Replacement

    FUEL SYSTEM / FUEL INJECTION 2. Turn on the key switch to activate the pump and 3. Remove the gas tank cover vent hose. Be sure to check the system pressure on the gauge. If properly route the vent hose upon reassembly. system pressure of 39 psi ±...

  • Page 127: Fuel Pressure Regulator

    FUEL SYSTEM / FUEL INJECTION 6. Relieve the fuel pressure at the fuel test valve. 8. Remove the air box cover and remove the two gas tank mounting bolts at the rear of the gas tank. Remove 2 Bolts Test Valve 7.

  • Page 128: Test

    FUEL SYSTEM / FUEL INJECTION FUEL INJECTORS FUEL PRESSURE REGULATOR TEST Refer to the Fuel Pump Test procedure. NOTE: 800 EFI fuel connections are quick--connect couplings vs 700 EFI connections. FUEL PRESSURE REGULATOR The fuel injectors mount into the intake manifold, and REPLACEMENT the fuel rail attaches to them at the top end.

  • Page 129: Service

    FUEL SYSTEM / FUEL INJECTION FUEL INJECTOR SERVICE FUEL INJECTOR REPLACEMENT Injector problems typically fall into three general 1. Engine must be cool. Depressurize fuel system categories-- electrical, dirty/clogged, or leakage. An through test valve in fuel rail. electrical problem usually causes one or both of the 2.

  • Page 130: Test

    (T--BAP) is a non--serviceable item. If it is faulty, it must be replaced. This sensor requires a 5 Vdc input to operate, therefore the T- -BAP sensor should only be tested using the Polaris Diagnostic Software (dealer only). Refer to the EFI Diagnostic Software Manual for more information.

  • Page 131: Replacement

    FUEL SYSTEM / FUEL INJECTION THROTTLE POSITION THROTTLE POSITION SENSOR REPLACEMENT SENSOR (TPS) The correct position of the TPS is established and The throttle position sensor (TPS) is used to indicate set at the factory. If the TPS is repositioned, throttle plate angle to the ECU.
  • Page 132 FUEL SYSTEM / FUEL INJECTION Step 2 With engine off, back out air flow screw until it no longer is in contact Establishing correct flow: Now that the zero offset with throttle plate cam. The throttle voltage has been set, you can now set the throttle plate should seal off throttle bore body to the correct air flow value.

  • Page 133: Replacement

    ’ON’. ENGINE TEMPERATURE SENSOR TEST Refer to Chapter 10 for testing. Polaris dealers can also test the sensor by using the Polaris Digital Wrencht Software (dealer only). Refer to the Digital Wrencht Software Manual for more information.

  • Page 134: Diagnostics Using "Blink Codes

    FUEL SYSTEM / FUEL INJECTION DIAGNOSTICS USING “BLINK CODES” To enable the blink codes, turn the ignition from ’off’ to ’on’ 3 times, leaving it ’on’ the 3rd time, within 5 seconds. Any “blink codes” stored in the ECU will display, one at a time, in numerical order.

  • Page 135: Troubleshooting

    FUEL SYSTEM / FUEL INJECTION TROUBLESHOOTING POOR IDLE Idle Too High (If greater than 1300 RPM when FUEL STARVATION/LEAN MIXTURE engine is warm) Symptoms: Hard start or no start, bog, backfire, Throttle stop screw set incorrect popping through intake / exhaust, hesitation, Throttle cable sticking, improperly detonation, low power, spark plug erosion, engine adjusted, routed incorrectly...
  • Page 136 FUEL SYSTEM / FUEL INJECTION NOTES 4.20...
  • Page 137 BODY / STEERING / SUSPENSION Torque Specifications and Special Tools ..Cover/Panel Removal ..... . . 5.2--5.3 Side Panel Removal .
  • Page 138 PLASTIC INSERT REMOVAL / Rear Wheel Hub Nut INSTALLATION Upper Stabilizer Support Some Polaris ATVs use a two piece plastic insert in place of a metal screw. The plastic inserts are easy Nuts to remove and install. Upper Control Arm Mount- 1.

  • Page 139: Side Panel Removal

    BODY / STEERING / SUSPENSION SIDE PANEL REMOVAL 2. Next, use the diagonal side cutters under outside insert (B) to completely remove the assembly. Side panel removal is quick and easy, use the NOTE: The inside insert (A) will still be installed in following instructions for removal and installation.

  • Page 140: Front Cover Removal

    BODY / STEERING / SUSPENSION FRONT COVER REMOVAL / FOOT WELL REMOVAL / INSTALLATION INSTALLATION 1. Open the front storage compartment. 1. Remove the four plastic inserts (A) that secure the wheel well to the front and rear cabs. (See 2.

  • Page 141: Front Storage Removal/Install

    BODY / STEERING / SUSPENSION FRONT STORAGE REMOVAL 2. Remove the strut tower caps (B). Squeeze the caps inward and lift up to remove. Front Storage Inserts 3. Remove the four bolts that secure the storage rack to the frame. Front Cab - - T- -25 Screws Remove Bolts...
  • Page 142 BODY / STEERING / SUSPENSION the groove in the rack, then press in the bottom of the cover until the notches snap into place. T--25 Screws 1. Place Lip in Groove Groove 2. Press Tabs In View -- Under Right Fender 7.

  • Page 143: Rear Rack Removal/Install

    BODY / STEERING / SUSPENSION FRONT STORAGE INSTALLATION Front Storage REAR RACK REMOVAL/ INSTALLATION Inserts Front Cab - - T- -25 Screw C. 10 in.lbs. (1.13 Nm) A. 14 ft.lbs. (19 Nm) D. 24 in.lbs. (2.7 Nm) B. 10 in.lbs. (1.13 Nm) 1.
  • Page 144 BODY / STEERING / SUSPENSION Rear Rack Installation 3. Place spacers on frame. 24 in.lbs. (2.7 Nm) 4. Remove the side panels (D), refer to the “SIDE PANEL REMOVAL” section. 5. Remove the plastic inserts (E) that secure the 4. Install rear rack onto rear frame and cab. front foot wells...

  • Page 145: Rear Storage Removal/Install

    BODY / STEERING / SUSPENSION REAR CAB / FENDER 4. Disconnect the rear lights by pulling the locks on each side and removing the connectors. Lift the REMOVAL / INSTALLATION rear cab from the frame. 1. Follow the ““REAR RACK REMOVAL” procedure to remove the rear rack.

  • Page 146: Radiator Screen Removal

    BODY / STEERING / SUSPENSION RADIATOR SCREEN REMOVAL 1. Pull out slightly on the top of the radiator screen. 2. With the top free, pull out on the bottom of the screen to remove the screen. 3. To install the screen, simply press the tabs on the screen back into the mounting grommets.

  • Page 147: Body Assembly Exploded View

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

  • Page 148: Body Rack Exploded View

    BODY / STEERING / SUSPENSION BODY RACK EXPLODED VIEW Rack Rails Rear Rack Support Rear Rack Rack Mounting Hardware Rack Rails Box Latches Front Front Brush Guard Cover Assy. Support Strut Covers Radiator Shield Radiator Screen Grill Front Bumper Panel 5.12...

  • Page 149: Headlight Pod Exploded View

    BODY / STEERING / SUSPENSION HEADLIGHT POD EXPLODED VIEW Controls Worklight Switch Instrument Cluster Brake Clean knurling when repositioning handlebars Disassembly S Remove two side Phillips screws (A). S Remove one rear Phillips screw (B). S Lift top half of pod. S Disconnect instrument cluster wire connectors.

  • Page 150: Handlebar Block Installation Procedure

    BODY / STEERING / SUSPENSION HANDLEBAR BLOCK INSTALLATION PROCEDURE 1. The pin (A) on the bottom side of the top handlebar block faces down and to the front of the ATV. 2. The bottom handle bar block has a side with 3 holes, the side with 3 holes faces up and to the front of the ATV. 3.
  • Page 151 BODY / STEERING / SUSPENSION STEERING/A- -ARM 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; 25-30 ft.

  • Page 152: 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 153: Rear Suspension Assembly

    BODY / STEERING / SUSPENSION REAR SUSPENSION ASSEMBLY 17 ft. lbs. (24 Nm) 17 ft. lbs. (24 Nm) Stabilizer Support 35 ft. lbs. (48 Nm) 35 ft. lbs. (48 Nm) 30 ft. lbs. (41 Nm) 35 ft. lbs. (48 Nm) Upper Control Bushings Rear Shock...

  • Page 154: Strut Assembly

    BODY / STEERING / SUSPENSION STRUT ASSEMBLY 15 ft. lbs. (21 Nm) Strut Bumper Spacer Rubber Washer Upper Pivot Ball Strut Washer Clamp 18 ft. lbs. Spacer (25 Nm) 15 ft. lbs. Bolt Lower Pivot Ball (21 Nm) Spring Retainer Lubrication Fitting Spring Hubstrut Bearing...

  • Page 155: Front Strut Cartridge Replacement

    BODY / STEERING / SUSPENSION FRONT STRUT CARTRIDGE 3. Remove wheel nuts and wheels. REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5.18 1. Hold strut rod and remove top nut. 2. Remove upper strut pivot assembly. Strut Rod Wrench (PN 2871572) Strut Spring Compressor Tools (PN 2871573) and (PN 2871574) 4.

  • Page 156: Steering Post Assembly

    BODY / STEERING / SUSPENSION To flame treat the decal area: 1. Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appears slightly glossy. This should occur after just a few seconds of flame treating.
  • Page 157 CLUTCH Drive Clutch Exploded View ....PVT Sealing and Ducting Components ..EBS System Exploded View ....Special Tools, Supplies &...

  • Page 158: Pvt Sealing And Ducting Components

    Mark with permanent marker before disassembly to maintain clutch balance 800 EFI 800 EFI One way clutch 700 EFI 700 EFI One way clutch E 2004 Polaris Sales Inc. PVT SEALING AND DUCTING COMPONENTS Clutch Inlet Duct Transmission Cover Seal...
  • Page 159 CLUTCH ENGINE BRAKING SYSTEM (EBS) EXPLODED VIEW Drive Clutch Assembly (700 EFI Shown) 2.25″ PTFE Washer One Way Clutch Drive Screws Brass Washer Shift Weights Torque to Coil 200 Ft. Lbs. Cam Assy. Spring (271 Nm) Spacer Sleeve Cover Bushing Retaining Drive Belt Ring...

  • Page 160: Pvt Operation Overview

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

  • Page 161: Pvt Drying

    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 162: Pvt Overheating/Diagnosis

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

  • Page 163: Pvt Disassembly

    CLUTCH PVT DISASSEMBLY NOTE: Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement. 1. Remove seat. 2. Remove or loosen rear cab fasteners as necessary to gain access to PVT outer cover. 3.

  • Page 164: Pvt Assembly/Inspection

    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 165: Drive Clutch Spring Specifications

    CLUTCH DRIVE CLUTCH SPRING SPECIFICATIONS The drive clutch spring has two NEUTRAL 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 166: Shift Weights /Inspection

    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 167: Drive Clutch Disassembly/Inspection

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

  • Page 168: Spider Removal

    CLUTCH SPIDER REMOVAL DRIVE CLUTCH DISASSEMBLY CONT’D 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 169: Drive Clutch Inspection

    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. ONE-WAY CLUTCH Moveable Sheave Bushing Inspection: INSPECTION (DRIVE Replace the cover bushing if more brass...

  • Page 170: Moveable Sheave Bushing Inspection

    CLUTCH Shaft Diameter Standard: 1.3745″ - 1.375″ Thrust Washer Thickness Service Limit: 1.3730″ Standard: .030″ (.76mm) Service Limit: .025″ (.64mm) 4. Remove 2 1/2″ PTFE washer from shaft. Visually inspect the washer for damage. Measure the thickness and compare to specification. Replace 2.

  • Page 171: Drive Clutch Reassembly

    CLUTCH DRIVE CLUTCH REASSEMBLY CONT’D 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 moveable sheave.

  • Page 172: Drive Belt Removal/Inspection

    CLUTCH 8. Reinstall cover, aligning bosses on the tower and cover. Torque cover bolts evenly to specification Spider Torque: 200 ft. lbs. (271 Nm) Cover Screw Torque: 90 in. lbs. (10.4 Nm) Special Tool NOTE: When reinstalling the belt with the drive clutch and driven clutch already removed follow these steps: DRIVE BELT...

  • Page 173: Drive Belt Installation

    CLUTCH Place another straight edge on top of belt. Measure the distance where the side straight edges intersect the top, as shown in the illustration. Projected Belt Width Center Distance Clutch Center Distance - 10″ +.1 / -.05 (254 +2.5 / -1.3mm) Belt Nominal Length - 40.875″±...

  • Page 174: Clutch Alignment/Offset

    CLUTCH CLUTCH ALIGNMENT Special Tool NOTE: On some models, minor adjustments can be made by adding shims between the frame and front lower left engine mount to 1. Remove belt and install the Clutch Offset increase the distance at point “A”. If a shim is present, Alignment Tool (PN 2872292) as shown.

  • Page 175: Bushing Service

    Bushing Removal Tool 9. Turn sheave counterclockwise on puller rod until it PA- -47336. Order from Polaris tool supplier SPX comes free. Lift sheave off puller. 1- -800- -328- -6657. 10. Remove nut from puller rod and set aside. REMOVAL AND INSTALLATION 11.
  • Page 176 CLUTCH EBS Drive Moveable Bushing Installation EBS Drive Clutch Cover Bushing Removal 1. Place main adapter (Item 8) on puller. 1. Install main adapter (Item 8) on puller. Puller Tool (A/B) Nut (C) Nut (C) Removal Tool (3) Side “A” toward sheave Bushing Adapter...
  • Page 177 CLUTCH EBS DRIVEN CLUTCH 1. Remove driven clutch from the transmission input shaft. Do not attempt disassembly of the driven DISASSEMBLY/INSPECTION - clutch from the outside snap ring. The driven clutch must be disassembled from the helix side. EBS Driven Clutch Operation This EBS driven clutch provides the same engine braking abilities as the earlier EBS driven clutch.
  • Page 178 CLUTCH cylinder of the holding tool on top of the spider assembly and retaining ring. Install the clutch holding tool handle and slowly compress the spider onto the shaft. Push helix inward. Remove snap ring (A). 7. Remove the E--clip (F), washer (G), and the clutch rollers (H).
  • Page 179 CLUTCH CLUTCH ROLLER REMOVAL 9. Press out the spring pins (K) in the inner sheave. Press Shaft/Bearing Out 10. Pull out the clutch roller pins (L) and rollers (M). Inspect Bearing 12. Inspect the bearing for wear. Spin the bearing, if the bearing does not spin smoothly replace as needed.
  • Page 180 CLUTCH EBS DRIVEN CLUTCH 4. Line up the “X” ont the moveable sheave with the “X” on the stationary sheave or use the marks REASSEMBLY previously used. Put the sheaves together. 1. Press the bearing onto the output shaft using a press.
  • Page 181 CLUTCH 6. Install the roller pin into the sheave assembly. 9. Install the spring over the shaft. (Both sides). The flat side of the roller pin faces downward when the shaft side is laying flat on the bench. Install Spring Flat Side of Roller 10.
  • Page 182 CLUTCH 13. Install the compression cylinder of the holding tool 15. Install the cam assembly (helix) over the shaft. on top of the spider assembly and retaining ring. Line up the “X” on the cam, “X” on spider, and “X” Install the clutch holding tool handle and slowly on the stationary sheave or use the marks compress the spider onto the shaft.
  • Page 183 CLUTCH EBS DRIVEN CLUTCH EXPLODED VIEW 1. Torx Screw 2. Cam Assembly 3. Retaining Ring 4. E--clip 5. Washer 6. Roller 7. Outer Spider 8. Spring 9. Shaft 10. Thrust Washer 11. Moveable Sheave 12. Roller Pin 13. Spring Pin 14.

  • Page 184: Troubleshooting

    CLUTCH 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. -Install correct shift weight kit to match engine application. although engine is properly -Driven clutch spring broken or installed -Replace spring;...
  • Page 185 CLUTCH 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 -Vehicle operated with park brake on.
  • Page 186 CLUTCH NOTES 6.30...
  • Page 187 FINAL DRIVE Final Drive Torque Specifications ..AWD Front Axle Remove/Install ..7.2-7.3 AWD Front CV Joint Boot Replace..7.4-7.5 AWD Front Drive Axle Exploded View 7.15 Front Hub Disass./Assemble .

  • Page 188: Final Drive

    FINAL DRIVE WHEEL AND HUB TORQUE TABLE COMPONENT FT. LBS. (IN.LBS.) F/R Steel Wheel Nuts F/R Aluminum Wheel Nuts Front Hub Nut Rear Hub Nut CAUTION: Locking nuts, and bolts with preapplied 8. Remove hub. locking agent should be replaced if removed. The self-locking properties of the nut or bolt are reduced or destroyed during removal.
  • Page 189 FINAL DRIVE New Cotter Key Front Hub Retaining Nut Torque 11. With short, sharp jerks, remove drive shaft from front gearcase. 70 ft. lbs. (95 Nm) DRIVE SHAFT (CV) BOOT INSPECTION Check the front and rear driveshaft cv boots for any tears or leaking grease.
  • Page 190 FINAL DRIVE FRONT DRIVE SHAFT CV JOINT BOOT REPLACEMENT Retaining ring 1. Remove wheel, brake caliper and wheel hub. Refer to Front Drive Axle Removal Page 7.2 for procedure. 2. Remove cotter pin and castle nut from A-arm ball joint. Pull shaft to remove from CV joint 7.

  • Page 191: Front Hub Assembly

    FINAL DRIVE BE TAKEN TO AVOID DAMAGE TO THE NEWLY INSTALLED BOOT. NOTE: Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be 13. Install the small clamp on the boot. removed.
  • Page 192 FINAL DRIVE FRONT PROP SHAFT NOTE: If yoke or bearing is removed, cross bearing must be replaced. Note orientation of grease fitting REMOVAL and mark inner and outer yoke for correct re-positioning during installation. 1. Using Roll Pin Removal Tool (PN 2872608), remove the roll pin from prop shaft at rear of housing.
  • Page 193 FINAL DRIVE 4. Force U-joint cross to one side and lift out of inner yoke. U-JOINT ASSEMBLY 4. Install outer yoke, aligning marks made before disassembly. 5. Repeat Steps 1-3 to install bearing caps on outer yoke. 1. Install new bearing caps in yoke by hand. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft.

  • Page 194: Awd Front Drive Axle Exploded View

    FINAL DRIVE AWD FRONT DRIVE AXLE EXPLODED VIEW NOTE: Refer to your parts manual for the proper replacement parts. Front Drive Axle Components Inner CV Joint Inner Boot Circlip Circlip Outer Boot Circlip Outer CV Joint Clamp Front Drive Boot Replacement Kits Inner Clamp 3.5 oz.
  • Page 195 FINAL DRIVE FRONT GEARCASE in True All Wheel Drive. OPERATION - - CENTRALIZED CAUTION: If the rear wheels are spinning, release the throttle before turning the AWD switch on. If AWD HILLIARD) is engaged while the wheels are spinning, severe drive shaft and clutch damage could result.
  • Page 196 FINAL DRIVE with a piece of wire. 9. Pull both driveshafts from the front gearcase. Replace the circlip on the driveshaft end for reassembly. 10. Remove the roller pin from the front prop shaft. Use the Roller Pin Removal Tool (PN 2872608). 11.
  • Page 197 FINAL DRIVE Gearcase Coil Resistance NOTE: To test the gearcase coils resistance, use the coil harness. The gearcase coils should measure between 22.8 ohms and 25.2 ohms. 3. Remove output shaft assembly. 8. Inspect roll cage (B) sliding surface. This surface must be clean and free of nicks, burrs or scratches.
  • Page 198 FINAL DRIVE 10. Remove the spacer washer (D), armature plate (E), and rubber O--ring from the output cover. O--ring 13. Inspect the magnetic coil (I) in the output housing. NOTE: See “FRONT GEARCASE DIAGNOSIS” 11. Inspect the armature plate (E) for a consistent later in this chapter for more details on the coil.
  • Page 199 FINAL DRIVE 18. Remove and replace the O--rings and seals from the assembly. 16. Remove the input cover (M), bearing (N), and the FRONT GEARCASE pinion gear (O). Inspect the pinion gear (O) for chipped, broken, or missing teeth. Replace the REASSEMBLY/INSPECTION input cover O--ring.
  • Page 200 FINAL DRIVE 5. Install the output hub (A) into the gearcase housing. The output hub should spin freely. 9. Install the ring gear onto the output hub on the output cover. 6. Install the other output hub (B) and thrust bearing (C) into the output cover.
  • Page 201 FINAL DRIVE Cover Bolts Torque 14 ft. lbs. (19 Nm) 13. Install new seals into the gearcase housing and gearcase housing cover. Back Lash Pad (Thrust Pad) Adjustment 14. Lay the gearcase on the side with the output cover facing up. 15.
  • Page 202 FINAL DRIVE band of wear is present (or if there is wear between the two bands, inspect the coil area as indicated in Step 4. A band with an interrupted wear mark may indicate a warped plate, which may cause intermittent operation. See Illustration Armature Plate 19.
  • Page 203 FINAL DRIVE 3233952). 30 ft.lbs. (41 Nm) Gearcase Cover Coil U--shaped insert Side Cutaway View of Centralized Hilliard Cover 5. Inspect the rollers for nics and scratches. The rollers must slide up and down and in and out freely within the roll cage sliding surfaces. New Roller Pin 3.
  • Page 204 FINAL DRIVE FRONT GEARCASE - - CENTRALIZED HILLIARD EXPLODED VIEW Ref. Qty. Description Ref. Qty. Description 1 Asm., Mid Gearcase 1 O- - Ring 1 Cover, Output 1 Seal 1 O- - Ring 11 Kit, Bolt 1 Insert 1 Cover, Input 1 Coil 1 Bearing, Roller Ball 1 Kit, Shim Set (Incl.
  • Page 205 FINAL DRIVE REAR HUB REMOVAL 8. Remove hub nut, domed washer and flat washer. 1. Place the ATV in Park and lock the parking brake. Remove rear hub cap. 9. Remove hub. 2. Remove cotter pin. 3. Loosen the hub retaining nut. 4.

  • Page 206: Rear Hub Installation

    FINAL DRIVE 11. Remove both lower control arm bolts. Rear Hub Nut Torque: 12. Remove bearing carrier. 80 ft. lbs. (109 Nm) Rear Wheel Nut Torque: REAR HUB INSTALLATION Refer to Page 7.2 1. Insert bearing carrier on drive shaft. 2.

  • Page 207: Rear Hub Assembly

    FINAL DRIVE REAR HUB DISASSEMBLY REAR HUB ASSEMBLY 1. Support bottom of bearing carrier housing. 1. Remove outer snap ring. 2. Start bearing in housing. 2. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown. 3.

  • Page 208: Rear Drive Shaft Removal

    FINAL DRIVE DRIVESHAFT AND CV JOINT CAUTION: HANDLING TIPS Use an arbor press only on the outer race, as bearing damage may occur. Care should be exercised during driveshaft removal or when servicing CV joints. Driveshaft components 4. Install snap ring into groove. are precision parts.

  • Page 209: Rear Drive Shaft Installation

    FINAL DRIVE REAR DRIVE SHAFT 6. Install rear wheel and torque wheel nuts to specification. INSTALLATION 80 ft. lbs. 1. Slide shaft assembly into bearing carrier hub. Flat Washer (109 Nm) Cone Washer Cone washer dome to outside Rear Wheel Nut Torque: 2.

  • Page 210: Rear Drive Shaft 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 211 FINAL DRIVE (Boot Replacement) 5. Refit CV joint on interconnecting shaft by tapping with a plastic hammer on the joint housing. Take 1. Remove CV joint from end of shaft. care not to damage threads on the outboard CV joint. The joint is fully assembled when the snap 2.
  • Page 212 FINAL DRIVE (BOOT INSTALLATION) Joint Capacity Joint Capacity 5. Slide the new clamp and boot (small end first) 50 Grams 50 Grams over the splined shaft, then slide (tap) the CV joint into the splines of the axle. 6. Add grease through large end of boot. 7.
  • Page 213 FINAL DRIVE 3. Remove the shim, thrust button, and thrust button 5. Inspect the ring gear for abnormal wear, broken, shim from the gearcase. or chipped teeth. Spin the bearing to check the ball bearings for smoothness. Replace the bearing if needed. 6.
  • Page 214 FINAL DRIVE REAR GEARCASE 3. Install the pinion shaft into the gearcase housing. Install the pinion shaft cover and torque the cover REASSEMBLY bolts to 25 ft. lbs. (34 Nm). 1. Inspect the pinion shaft bushing for wear. Pinion Shaft Cover Bolt Torque: 25 ft.

  • Page 215: Rear Gearcase Installation

    2. Torque the installation bolts and nuts to the torques specified. 3. Refill the rear gearcase with 5 oz. (150 ml) of Polaris Premium Gearcase Lubricant (PN 2871653). Torque the fill plug to 14--18 ft. lbs. (19--24 Nm). Fill / Check Gearcase Cover Bolt Torque: 25 ft.
  • Page 216 FINAL DRIVE REAR GEARCASE EXPLODED VIEW 14--18 FT.LBS. (19--24 NM) 14--18 FT.LBS. (19--24 NM) Ref. Qty. Description Ref. Qty. Description 1 Asm., Rear Gearcase 2 Ball Bearing 1 RH Gearcase 1 Ball Bearing 1 LH Cover 2 Triple Lip Seal 1 31T Straight Bevel Gear 1 Triple Lip Seal 1 10T Straight Bevel Pinion...
  • Page 217 TRANSMISSION Transmission, Exploded View ....8.2--8.5 Torque Specifications/Lubrication ... Gear Shift Selector Removal ....Transmission Removal .

  • Page 218: Transmission Exploded View

    7- - 9 ft.lbs. (9.5- - 12 Nm) Apply White Lithium 15- -19 ft.lbs. (20- -26 Nm) Based Grease. 27- -34 ft.lbs. (37- -46 Nm) Apply Polaris Crankcase Sealant 6- -12 ft.lbs. (8- -16 Nm) Apply Loctitet 262 to 14- -18 ft.lbs. (19- -24 Nm) the bolt threads.
  • Page 219 TRANSMISSION TRANSMISSION EXPLODED VIEW, CONT. Ref. Qty. Description Ref. Qty. Description 1 22T Sprocket 1 Nut 1 19T Sprocket 1 Shift Drum Bellcrank 1 Silent Chain 5 Sector Cover Screws 1 Front Main Output Shaft 1 Sector Cover 1 10T Spiral Pinion Shaft 1 Sector Cover Gasket 1 Ball Bearing 1 O- - ring...

  • Page 220: Torque Specifications/Lubrication

    TRANSMISSION TRANSMISSION Transmission Mounting INFORMATION TORQUE SPECIFICATIONS Front COMPONENT FT. LBS. (IN.LBS.) Transmission Case Bolts 27--34 37--46 Oil Deflector Screws (16--30) 2--3.3 Shift Cover Bolt 6--12 8--16 Bell Crank Nut 12--18 16--24 2. Disconnect transmission vent line. 3. Drain transmission lubricant. Trans.

  • Page 221: Transmission Installation

    TRANSMISSION 6. Remove auxiliary brake mounting bracket from 10. Remove the park lock spring. frame and secure out of way for transmission removal. 7. Remove PVT outer cover, both drive and driven Park Lock Spring clutch, and inner PVT cover (refer to Clutch Chapter 6).

  • Page 222: Transmission Disassembly

    TRANSMISSION Transmission Switch 4. Remove the five bolts that secure the cover. Remove the detent spring. Tighten Bolts In Sequence A through E TRANSMISSION DISASSEMBLY 1. Place the bellcrank in neutral position. Spring Shift Shaft Cover NO TAG 5. Mark the detent gear with a white pen. Remove the detent gear from the case.
  • Page 223 TRANSMISSION NOTE: It may be helpful to place a mark just above 8. Note the timing marks on the shift gears. Remove the keyed spline. Note the raised edge on the detent the shift gears from the case. gear for reassembly. 6.
  • Page 224 TRANSMISSION 11. Remove the shift forks from the assembly. Note the correct position of each fork. Engagement Dogs 14. Remove the bearing from the input shaft with a puller. 12. Remove the bearing from the reverse shaft using a puller. 15.
  • Page 225 TRANSMISSION 16. Remove low gear (33T) and the needle bearing. 21. Remove the gear, split bearing, and washer from 17. Remove the reverse gear shaft. the reverse shaft. 18. Remove the rest of the bearings from the shafts. 22. Slide off the shift dogs and wave springs. 19.
  • Page 226 TRANSMISSION 26. Remove the front housing cover screws. 24. Remove bearing and the helical gear. 25. Remove the pinion shaft retainer plate and the pinion shaft. 8.10...

  • Page 227: Transmission Reassembly

    TRANSMISSION 27. Remove the front housing cover, shim, thrust 31. Inspect engagement dogs of gears and replace if button, and thrust button shim. edges are rounded. 32. Inspect gear teeth for wear, cracks, chips or broken teeth. Note the location of the hubs on the gear.
  • Page 228 TRANSMISSION 3. Before installing the cover make sure the sealing 8. Apply Loctitet 262 (Red) (PN 2871951) to screw surfaces are clean and dry, and shafts are fully threads and torque screws to 6--12 ft. lbs. (8--16 seated in the transmission case. Apply Nm).
  • Page 229 TRANSMISSION NOTE: Install a new snap ring at this time. When installing the new snap ring, open the the snap ring just far enough to go over the shaft, to avoid stressing the snap ring. If the snap ring is over--stressed, it could come off the shaft and cause internal damage to the transmission.
  • Page 230 TRANSMISSION 16. Position the shift forks up and so the the pins point 19. Lift the shift rail slightly and rotate the rail/fork toward the 9 o’clock position, before installing the assembly so it meshes with the tracks on the shift drum assembly.
  • Page 231 TRANSMISSION 24. Place a small amount of grease (PN 2871551) into the pocket before installing the sector gear. Install the shift gear (16T) on the shift drum shaft. Install the sector gear in the bushing pocket on the left side. Aligning the timing marks on the gears. 28.
  • Page 232 NOTE: Rotate the bellcrank to line the flat side of the switch up to the flat side of the shaft. 34. Install transmission and add Polaris AGL Gearcase Lubricant (PN 2873602) in the recommended amount. Refer to Maintenance Chapter 2 for more information.
  • Page 233 BRAKES Special Tools/Specifications/Torques ... Brake System Components ....Rear Caliper Exploded View .

  • Page 234: 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 .298″ / 7.6mm .180″ / 4.6mm Brake Disc Thickness .150-.165″ / 3.81-4.19mm .140″ / 3.556mm Brake Disc Thickness Variance Between .002″...

  • Page 235: Brake System Components

    BRAKES BRAKE SYSTEM MAIN COMPONENTS...

  • Page 236: Rear Caliper Exploded View

    BRAKES REAR BRAKE CALIPER EXPLODED VIEW Anvil Bolts APPLY POLARIS DOT 3 BRAKE Torque FLUID TO COMPONENT 16--18 ft.lbs. Washers (22--25 Nm) Rear Housing Bleed Piston Screws Torque 25--30 in. lbs. O--rings Bracket (2.80--3.40) Nm Seals Pads Slide Pins Torque Bushings 30--35 ft.lbs.

  • Page 237: Brake System Service Notes

    NOTES cause if brake drag is evident. Make sure caliper moves freely on Polaris disc brake systems are light weight, low guide pins (where applicable). maintenance and perform well in the conditions ATVs Inspect caliper piston seals for routinely encounter.

  • Page 238: Hydraulic Brake System Overview

    Pad G compensating port restricted Educate operator Master cylinder pis- The Polaris disc brake system consists of the ton not returning com- following components or assemblies: brake lever; pletely master cylinder; hydraulic hose; brake calipers (slave cylinder); brake pads; and brake discs, which are Caliper piston(s) not secured to the drive line.

  • Page 239: Hydraulic Caliper Bleeding

    BRAKE BLEEDING - FLUID When servicing Polaris ATV brake systems, use only Polaris DOT 3 Brake Fluid (PN 2870990). CHANGE WARNING: Once a bottle is opened, use what is...
  • Page 240 6. Begin bleeding procedure with the caliper that is caliper(s). farthest from the master cylinder. Install a box 12. Add Polaris Dot 3 Brake Fluid (PN 2870990) to end wrench on caliper bleeder screw. Attach a MAX level inside reservoir.

  • Page 241: Master Cylinder Removal

    Reservoir Cover Torque - parts. There are different brake master cylinders for the different Polaris ATV models. Refer to your parts 5 in. lbs. (.56 Nm) manual or guide for the correct parts. This master cylinder is not serviceable and is replaced as a unit.

  • Page 242: Front Pad Removal

    15 ft. lbs. (21 Nm) 3. Fill reservoir with DOT3 Brake Fluid (PN 2870990). 3. Remove caliper from mounting bracket. Polaris DOT 3 Brake Fluid (PN 2870990) 4. Push caliper piston into caliper bore slowly using a C-clamp or locking pliers with pads installed.
  • Page 243 BRAKES Measure Thickness Front Brake Pad Thickness .298″/7.6 mm NOTE: Brake fluid will be forced through Service Limit .180″ / 4.6 mm compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 5.

  • Page 244: Front Pad Assembly

    BRAKES 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. lbs. (24Nm) 4. Slowly pump the brake lever until pressure has been built up.

  • Page 245: Brake Burnishing

    BRAKES 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. See Page 7.2 BRAKE BURNISHING PROCEDURE...

  • Page 246: Front Caliper Removal

    BRAKES 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 247: Front Caliper Inspection

    Front Caliper Piston Bore I.D. Std. 1.188″ (30.2 mm) Service Limit 1.193″ (30.30 mm) 2. Coat piston with clean Polaris DOT 3 Brake Fluid (PN 2870990) (C). Install piston (D) with a twisting motion while pushing inward.

  • Page 248: Front Caliper Installation

    1. Install caliper on hub strut, and torque mounting bolts. 15 ft. lbs. (21 Nm) 18 ft. lbs. Polaris Premium All Season Grease (24 Nm) (PN 2871423) 4. Compress the mounting bracket and make sure Torque Specifications the dust seals are fully seated. Install the pads as Front Caliper Mounting Bolt: shown on Page 9.10.
  • Page 249 BRAKES BRAKE BURNISHING 4. Remove caliper mounting bolts and lift caliper off of disc. PROCEDURE NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink It is required that a burnishing procedure be or bend brake line.

  • Page 250: Rear Pad Installation

    BRAKES 18 ft.lbs. (24 Nm) Measure Thickness Rear Brake Pad Thickness New: .318″ (8.0 mm) Service Limit: .180″ (4.6 mm) Torque Specifications: Rear Brake Caliper: REAR BRAKE PAD 18 ft. lbs. (24 Nm) Caliper Slide Pin Torque: INSTALLATION 30- -35 ft. lbs. (41 Nm- -48 Nm) 1.

  • Page 251: 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 252: Rear Caliper Assembly

    BRAKES Seals .94 in. 23.88 mm 1.5 in. 38.1 mm O-Rings 10. Inspect caliper piston bore for scratches, severe 2. Carefully assemble caliper body, making sure corrosion, or galling and replace if necessary. O-rings are properly positioned in groove. Tighten the caliper anvil bolts and then torque the anvil bolts evenly to 16--18 ft.

  • Page 253: Rear Disc Inspection

    BRAKES 5. Install brake line and tighten securely with a line wrench. Torque the brake lines to the proper torque specification. 6. Follow bleeding procedure outlined on Pages 9.6-9.7 of this section and refer to system overview and illustrations on Pages 9.2--9.3. 7.
  • Page 254 BRAKES REAR (AUXILIARY) BRAKE Rear Brake Master Cylinder Removal / Install REMOVAL / INSTALL 1. If necessary, remove the rear brake line from the master cylinder. Use a suitable container to catch Brake Pedal Removal / Install the brake fluid. Dispose of brake fluid properly. 1.

  • Page 255: Troubleshooting

    BRAKES REAR BRAKE CALIPER EXPLODED VIEW Anvil Bolts APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT Torque 16--18 ft.lbs. Washers (22--24 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.
  • Page 256 BRAKES NOTES 9.24...
  • Page 257 ELECTRICAL Crankshaft Position Sensor Gap ....10.2 Gear Position Switch Test ....10.2 Instrument Cluster Overview .

  • Page 258: Crankshaft Position Sensor Gap

    ELECTRICAL CRANKSHAFT POSITION GEAR POSITION INDICATOR SENSOR GAP SWITCH TEST Measure trigger coil gap with a feeler gauge. The gap NOTE: Also see “INSTRUMENT CLUSTER should be .059 inch (1.0 mm). TROUBLESHOOTING” for gear switch re- sistance. TRANSMISSION SWITCH High/Low/Neutral/Reverse/Park Switch Crankshaft Position Sensor High Range Low Range...

  • Page 259: Instrument Cluster Overview

    “Cooling System Troubleshooting” for help with Refer to Illustration 1: diagnosis of overheating. 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 260: Diagnostic Mode

    ELECTRICAL 5. Engine Hour Display Indicator Screen 1: The first screen indicates battery voltage. Displays number of hours of engine operation. Refer to Ill. 2. 6. AWD Indicator Illuminates when the electrical portion of the AWD system is enabled. 7. Gear Indicator Specifies what position...
  • Page 261 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 262: Efi Diagnostic Mode

    EFI module. the button and wait for the wrench icon to stop Polaris dealers are equipped with the proper flashing. The new service interval is now set. diagnostic tools to further diagnose the blink code.
  • Page 263 ELECTRICAL Blink Code Identification Table 3. The word “Wait” will appear, the EFI module is now searching for blink codes. If any blink codes are stored they will display on the instrument Blink Failure Description Blink Failure Descrip- cluster one at a time. NOTE: The check engine Code Code tion...

  • Page 264: Speedometer Removal/Installation

    ELECTRICAL SPEEDOMETER REMOVAL SPEEDOMETER INSTALLATION 1. Remove the three screws that secure the 1. Spray a soap and water mixture onto the outer headlight pod cover and disconnect the wire surface area of the instrument cluster. This will connectors from the instrument cluster. help the instrument cluster slide into the pod assembly more easily.
  • Page 265 ELECTRICAL SPEEDOMETER TROUBLESHOOTING 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 ter to verify it’s operation.
  • Page 266 ELECTRICAL SPEEDOMETER TROUBLESHOOTING 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. Power SPEEDO WITH B: Signal CONNECTORS...
  • Page 267 ELECTRICAL SPEEDOMETER TROUBLESHOOTING 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 268 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 Ignition Switch 9. Blue White- - Engine Overheat Switch CHECK 2.
  • Page 269 ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 7 FUEL GAUGE DISPLAY NOT WORKING 16 Pin Connector START HERE 1. Red- - 12V Ignition Switch 9. Blue White- - Engine Overheat Switch 2. Red/White- - 12V ETC and AWD Switch 10. N/C 11. Black/White- - Engine Check Light 3.

  • Page 270: Fan Motor Tests

    ELECTRICAL COOLANT TEMPERATURE 2. With the ATV in “Park” and with the parking brake on, turn the ignition key (and engine stop switch) SENSOR “ON”. The fan should start running. 3. If the fan does not run or runs slowly, check the fan The coolant temperature sensor can be tested using an motor wiring, ground, motor condition and ohmeter or voltmeter.

  • Page 271: Etc Operation Test

    ELECTRICAL ELECTRONIC THROTTLE ETC OPERATION TEST CONTROL (ETC) SWITCH Remove throttle block cover by carefully releasing all tabs around edge of cover. The Electronic Throttle Control (ETC) system is Place transmission in neutral and apply parking designed to stop the engine of an ATV in the event of brake.

  • Page 272: Flywheel Identification

    ELECTRICAL FLYWHEEL IDENTIFICATION Kokusan EFI Flywheel Timing Marks Production Date Part Number 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 Cast Stamp...
  • Page 273 ELECTRICAL COMPONENTS OF EFI 500 WATT ALTERNATOR/IGNITION SYSTEM Ignition Coils Battery to Solenoid Cable Solenoid Switch (starter switch) 30 Amp Hr. Battery Coil Wires Solenoid to Starter Cable Control Module Relays Negative Battery Cable Spark Plugs Fuses Pre--Wire Winch Cables (Steering Post Area) Voltage Regulator Stator Assembly...

  • Page 274: Ignition System Operation

    ELECTRICAL IGNITION SYSTEM TROUBLESHOOTING Current Draw Inspection Key Off No Spark, Weak or Intermittent Spark Spark plug gap incorrect Fouled spark plug Faulty spark plug cap or poor YB30L--B connection to high tension lead Related wiring loose, disconnected, shorted, or corroded Engine Stop switch or ignition Ill.

  • Page 275: Alternator Output Test

    ELECTRICAL CHARGING SYSTEM “BREAK ALTERNATOR OUTPUT TEST EVEN” TEST Three tests can be performed using a multimeter to determine the condition of the stator (alternator). CAUTION: Do not allow the battery cables to become disconnected with the engine running. Follow the steps below as outlined to reduce the chance of damage to electrical components.
  • Page 276 ELECTRICAL RELAYS TEST 3: Measure AC Voltage Output of Each Stator Leg at Charging RPM These relays, located next to the ECU, assist with 1. Set the selector dial to measure AC Voltage. component operation such as the fan, fuel pump, etc. 2.

  • Page 277: 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 278: Battery Identification

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

  • Page 279: Conventional Battery Installation

    BATTERY TERMINALS/TERMINAL BOLTS Use Polaris corrosion resistant Nyogelt grease (PN 1. Disconnect holder strap and remove covers. 2871329) on battery bolts. See Battery Installation on 2. Disconnect battery negative (-) (black) cable first, Page 10.23.

  • Page 280: Conventional Battery Specific Gravity Test

    ELECTRICAL electrolyte. Avoid skin contact with electrolyte, as severe burns could result. If electrolyte contacts the vehicle frame, corrosion will occur. 5. Reinstall the holder strap. Battery Hydrometer (PN 2870836) CONVENTIONAL BATTERY 1.10 TESTING 1.15 Detail A 1.20 Whenever a service complaint is related to either the starting or charging systems, the battery should be 1.25 checked first.

  • Page 281: Charging Procedure

    ELECTRICAL CHARGING PROCEDURE or load test should be conducted whenever poor battery performance is encountered. To perform this test, hook a multitester to the battery in the same manner as was 1. Remove the battery from the ATV to prevent done in the OCV test.

  • Page 282: Battery Charging

    ELECTRICAL 2. Check the voltage with a voltmeter or multimeter. To service a Low Maintenance battery: A fully charged battery should be 12.8 V or 1. Remove battery from the vehicle higher. 2. Test battery with a voltage meter or load tester to 3.

  • Page 283: Battery Testing

    ELECTRICAL LOW MAINTENANCE LOW MAINTENANCE BATTERY INSPECTION/ BATTERY TESTING REMOVAL Whenever a service complaint is related to either the starting or charging systems, the battery should be The battery is located under the seat. checked first. Following are three tests which can easily be made on a battery to determine its condition: OCV Test, Specific Gravity Test and Load Test.

  • Page 284: Battery Load Test

    ELECTRICAL LOW MAINTENANCE NOTE: Stored batteries lose their charge at the rate of 1% per day. Recharge to full capacity every 30 to BATTERY LOAD TEST 60 days during a non-use period. If the battery is stored during the winter months, electrolyte will freeze CAUTION: To prevent shock or component at higher temperatures as the battery discharges.

  • Page 285: Bulb Replacement

    ELECTRICAL HIGH BEAM HEADLIGHT 4. Turn the headlight lamp socket counter--clockwise and remove. BULB REPLACEMENT CAUTION: Do not service while headlight is hot. Serious burns may result. Protect lamp during install. Turn Harness Assembly Remove 3 screws Tighten Loosen 5. Carefully remove headlamp bulb from housing. 6.
  • Page 286 ELECTRICAL HEADLIGHT HOUSING 5. Pull the headlight housing up to release from the locking tabs. REPLACEMENT 1. Remove three Phillips screws on the headlight pod. 2. Disconnect instrument cluster harness (A) and work light switch (B). Both Sides 6. Lift the adjusting knob up to remove from the locking tabs.
  • Page 287 ELECTRICAL HIGH BEAM HEADLIGHT LOWER HEADLAMP ADJUSTMENT REMOVAL/INSTALLATION The headlight beam can be adjusted to any position desired by turning the adjusting knob located on the bottom right side of the headlight pod. Raise Headlight -- Turn knob counter-- counterclockwise Turn Harness Assembly Lower Headlight -- Turn knob clockwise Loosen...

  • Page 288: Headlamp Switch Test

    ELECTRICAL HEADLAMP SWITCH TEST Lower Headlamp Housing Removal (if required) 1. Remove the headlight pod cover. 5. Remove the screw that secures the lower 2. Set meter to DC Volts and probe the headlamp headlamp. plug wires (Brown and Yellow) at back of connector for 12 Volts.
  • Page 289 ELECTRICAL Check for continuity between the switch 2. To remove the brake light electrical connector (B), contacts -- Place meter leads between two press in on the tab on the connector to unlock the contacts with switch in ON position. connector and pull the connector from the bulb assembly.

  • Page 290: Fuel Sender Test

    ELECTRICAL BRAKE LIGHT SWITCH FUEL SENDER TEST 1. Remove the front cover. 1. Drain the fuel tank and remove it from the atv. 2. Set the fuel tank on a flat surface. 3. Hook up an ohm meter to the fuel sender harness Violet/White wire (B) and Brown wire (C).

  • Page 291: Accessory Wire Connections

    ELECTRICAL ACCESSORY WIRE Orange / White Wires CONNECTIONS Winch Installation The 2005 Sportsman models have the main winch cables routed and installed from the factory. This enables quick installation. Refer to Chapter 2 for more information on winch installation and operation. Accessory Power Wires Accessory Wires The accessory power leads for all accessories are...
  • Page 292 ELECTRICAL BASIC WINCH WIRING - - 2005 ATV MODELS 10.36...

  • Page 293: Starter System Troubleshooting

    ELECTRICAL STARTER SYSTEM drop tests on the starter system. TROUBLESHOOTING Voltage should not exceed .1 DC volts per connection Starter Motor Does Not Turn Battery discharged. Low specific STARTER MOTOR REMOVAL/ gravity Loose or faulty battery cables or DISASSEMBLY corroded connections (see Voltage Drop Tests) NOTE: Use electrical contact cleaner to clean starter Related wiring loose, disconnected,...
  • Page 294 ELECTRICAL O--rings Shims NOTE: The shims will be replaced during 3. Slide positive brush springs to the side, pull reassembly. brushes out of their guides and remove brush plate. Slide brush end frame off end of starter. BRUSH NOTE: The electrical input post must stay with the field coil housing.

  • Page 295: Armature Testing

    ELECTRICAL Brush Length Limit 5/16″ (8mm) Brush Replacement 1. Remove terminal nut with lock washer, flat washer, large phenolic washer, the small phenolic spacers, and sealing O-ring. Inspect O-ring and replace if damaged. 2. Inspect surface of commutator. Replace if excessively worn or damaged.
  • Page 296 ELECTRICAL 6. Place armature in a growler. Turn growler on and position a hacksaw blade or feeler gauge lengthwise 1/8″ (.3 cm) above armature coil Roller Bearing laminates. Rotate armature 360°. If hacksaw blade is drawn to armature on any pole, the Seal armature is shorted and must be replaced.

  • Page 297: Starter Drive

    Washer To measure the resistance of the pull-in coil, connect one meter lead to the solenoid lead wire and the other Polaris Premium Starter Drive Grease to ground. The resistance should be 2.8-3.6 ohms. (PN 2871460) Refer to Electric Starter System Testing in this section to further test the solenoid.

  • Page 298: Starter Assembly

    ELECTRICAL STARTER ASSEMBLY Ref. Ref. Description Description 1. Rubber Ring* Gear Assembly 2. Brush Spring Though Bolt 3. Thrust Washer Cover 4. Gear Assembly Stopper 5. O-Ring* Snap Ring 6. Brush Complete Washer 7. O-Ring* Flange Bolt 8. Thrust Washer Thrust Washer 9.

  • Page 299: 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 300 ELECTRICAL NOTES 10.44...
  • Page 301 ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN 700/800 EFI 10.39...
  • Page 302 ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN 700/800 EFI 10.40...
  • Page 303 Brake Master Cylinder Exploded View, Rear, 9.5, 9.22 Brake Noise, A-Arm Replacement, 5.16 Brake Pad Assembly, Front, 9.12 Air Filter Service, 2.20 Brake Pad Inspection, 2.28 Alternator Output Test, 10.19 Brake Pad Installation, Rear, 9.18 ATV Specifications, 1.3, 1.4, 1.5 Brake Pad Removal, Front, 9.10 Auxiliary Brake Removal,...
  • Page 304 Current Draw, 10.18 EBS Moveable Sheave Bushing Inspection, 6.14 CV Joint Handling Tips, 7.22 EBS One Way Drive Clutch Inspection, 6.13 EFI Component Locations, CV Shaft Boot, Inspection, 2.30 EFI Diagnostic Mode, 10.6 Cylinder Head Assembly, 3.27 EFI System Exploded View, Cylinder Head Disassembly, 3.22, 3.23 EFI System Overview,...
  • Page 305 Front Axle Removal, Gearcase Lubrication, Front, 2.11 Gearcase Lubrication, Rear, 2.12 Front Cab Removal / Installation, Gearcase Removal, Front, Front Cover Removal / Install, Glossary of Terms, 1.14 Front Drive Axle Exploded View, Front Gearcase Assembly/Inspection, 7.13 Front Gearcase Diagnosis -- Centralized Hilliard, 7.16 Headlamp Service, 10.30, 10.31, 10.32...
  • Page 306 Rear Drive Shaft Installation, 7.23 Rear Drive Shaft Removal, 7.22 Odometer, Tachometer,Trip Meter, 10.3 Rear Drive Shaft Service, 7.24 Oil / Water Pump Disassembly, 3.44 Hub Assembly, Rear , 7.21 Oil Check , Engine, 2.23 Hub Disassembly, Rear , 7.21 Oil Filter Change, 2.24 Rear Rack Removal / Installation,...
  • Page 307 Starter Drive, 10.41 Trigger Coil Gap, 10.2 Troubleshooting, Brakes, 9.23 Starter Drive Removal/Inspection, 3.36 Troubleshooting, Cooling System, 3.60 Starter Motor Armature Testing, 10.39 Troubleshooting, Engine, 3.59, 3.60 Starter Motor Brush Inspection/Replacement, 10.38 Troubleshooting, Fuel System, 4.19 Starter Motor Cleaning, 10.39 Troubleshooting, Ignition System, 10.18 Starter Solenoid Bench Test,...
  • Page 308 Polaris Service Publications Publication Title, Part Number: ____________________________ Page(s)____________ Publication Title, Part Number: ____________________________ Page(s)____________ Product and Year :_______________________________________ Error - Suggestion - Comments Comments Please communicate to Polaris any suggestions concerning our publica- tions. Simply fill out the form and mail it to the address listed below the form.
  • Page 309 PART # 9919820 Printed in USA...

This manual is also suitable for:

Sportsman 800 efi 2005

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