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Fast-track to a desired topic with these helpful links. Vehicle Maintenance. Page 32 - projex inbox. Change fluid every 2 years. Brake Fluid dicated level inside reservoir. See page 2. S Check vent hose to be sure it is routed properly and unobstructed. Page Transmission Lubrication S Check vent hose to be sure it is routed properly and unobstructed. At change: Approx. Page Transmission Gearshift Adjustment - projex inbox.
S Tighten shift linkage rod end jam nuts properly after adjustment. Page 40 - projex inbox. Place gear selector in neutral. Make sure the transmission bell cranks are engaged in the neutral position detents. Be sure the shift linkage rod ends are firmly attached to the gear selector slides. Adjust the low range inside rod so the rod end is centered on the transmission bell crank. Page Throttle Operation - projex inbox. Throttle lever operation should be smooth and lever must return freely without binding.
Place the gear selector in neutral. Set parking brake. Page Pilot Screw Adjustment - projex inbox. Start engine and warm it up to operating temperature about 10 minutes. This is a very important step. Page 43 - projex inbox. Slide boot off throttle cable adjuster and jam nut. Place shift selector in neutral and set parking brake.
Start engine and set idle to specified RPM, then shut off engine. Page Fuel System - projex inbox. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
Page Carburetor Draining - projex inbox. NOTE: The bowl drain screw is located on the bottom left side of the float bowl. Page Compression Test - projex inbox. Compression readings will vary in pro- portion to cranking speed during the test. Average compression measured is about psi during a compres- sion test.
Smooth idle generally indicates good compression. Page Battery Maintenance - projex inbox. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Page Spark Plug - projex inbox.
Remove spark plug high tension lead. Clean plug area Recommended Spark Plug: so no dirt and debris can fall into engine when plug is removed.
Refer to Specifications 2. Remove spark plug. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of Spark Plug Torque: 14 Ft. Page Cooling System Hoses S Overheating of engine could occur if air is not fully purged from system.
Do not dilute with water. Page Coolant Level Inspection 1. Remove reservoir cap. Inner splash cap vent hole must be clear and open. Page 51 - projex inbox. When riding in extremely dusty conditions re- placement will be required more often. Gasket The pre filter should be cleaned before each ride, using the following procedure. Drain whenever deposits are visible in the clear tube.
NOTE: The sediment tube will require more frequent ser- vice if the vehicle is operated in wet conditions or at high throttle openings for extended periods. Page Recoil Housing - projex inbox.
This should also be done before storing the ATV. The drain screw is located at the bot- tom of the recoil housing. Run engine two to three minutes until warm. Stop engine. Clean area around drain plug B at bottom of oil tank. Place a drain pan beneath oil tank and remove drain Ambient Temperature Range: plug. Page 55 Reinstall drain plug. Crankcase Drain Remove dipstick and fill tank with 2 quarts 1.
Place gear selector in neutral and set parking brake. Prime oil pump using procedure below. Stop the engine and inspect for leaks. Page Valve Clearance - projex inbox. Remove the seat. Remove body panels and fuel tank as necessary to gain access to valve cover. Page Intake Valve Clearance Adjustment - projex inbox.
Insert a. Using a 10 mm wrench and a screwdriver, loosen adjuster lock nut and turn adjusting screw until there is a slight drag on the feeler gauge. Page 58 Polaris parts. WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component re- pair and adjustment be performed by an authorized Polaris Dealer. Only a qualified technician should replace worn or damaged steering parts. Use only genuine Polaris replacement parts. Page 59 - projex inbox.
See note below. NOTE: String should just touch side surface of rear tire on each side of machine. Measure from string to rim at front and rear of rim. Page 60 - projex inbox. Place machine on a smooth level surface. Set handlebars in a straight ahead position and secure handlebars in this position.
NOTE: The steering frog can be used as an indicator of whether the handlebars are straight. Page 61 2. NOTE: Do not force the fluid into the hub under pressure or seal damage may occur. Page Exhaust Pipe - projex inbox.
Remove the clean out plugs located on the bottom of the muffler as shown at right. Place the transmission in neutral and start the engine. Purge accumulated carbon from the system by momen- Clean Out Plug tarily revving the engine several times. Check brake system for fluid leaks. Check brake for excessive travel or spongy feel. Check friction pads for wear, damage and looseness. Check surface condition of the disc.
Page Auxiliary Brake Testing - projex inbox. Free Play 1. Page Front Suspension - projex inbox. Adjust as necessary. Damping should be smooth throughout the range of travel. Check all front suspension components for wear or dam- age. Page Controls - projex inbox. Spacer Tab Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body.
Align throttle control assembly clamp with knurl on handle- Throttle assembly clamp Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts. Rear Wheel Nuts 20 Ft. Page Tire Pressure - projex inbox. Refer to the warning tire pressure decal applied to the vehicle. Page Engine - projex inbox. Torque Patterns Piston Identification.
Page Torque Specifications - projex inbox. Nm Ft. Page Torque Patterns - projex inbox. Page Piston Identification - projex inbox. The other numbers are used for identification as to diameter, length and design. Page Engine Service Data - projex inbox. Page 74 - projex inbox. Page Cooling System - projex inbox.
The cooling system is under pressure and serious burns may result. Allow the engine and cooling system to cool before servicing.
Page Cooling System Specifications Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Page Accessible Components - projex inbox. Clean work area. Thoroughly clean the ATV engine and chassis.
Disconnect battery negative - cable. Remove the following parts as required. Never substitute or mix oil brands. Page Honing To Oversize Selecting a hone which will straighten as well as remove material from the cylinder is very important. Using a common spring loaded finger type glaze breaker for honing is never advised.
Polaris recommends using a rigid hone or arbor honing machine which also has the capability of oversizing. Page Crankshaft Straightening - projex inbox. Refer to the illustrations below. Page 82 Oil Type Page 83 - projex inbox. Beginning at the oil tank, the oil flows through a screen fitting in the bottom of the tank and into the oil supply hose. The feed side of the oil pump draws oil through the hose and into the crankcase oil gallery, and then pumps the oil through another passage to the one way valve.
Page 86 - projex inbox. Remove ignition timing inspection plug from recoil housing. Page Cam Chain Tensioner Inspection - projex inbox. Pull cam chain tensioner plunger outward to the end of its travel. Inspect teeth on ratchet pawl A and plunger teeth B for wear or damage. Push ratchet pawl and hold it. The plunger should move smoothly in and out of the tensioner body.
Mark or tag rocker arms to keep them in order for assembly. Inspect each rocker arm cam follower surface. If there is any damage or uneven wear, replace the rocker arm. NOTE: Always inspect camshaft lobe if rocker arms are worn or damaged. Page 89 - projex inbox. Measure I. Compare to specifications. Page Camshaft Removal - projex inbox.
Remove thermostat housing. Remove camshaft sprocket inspection cover. Loosen three camshaft sprocket bolts. Remove camshaft end cap and O-Ring. Inspect camshaft end cap thrust face for wear. Replace if worn or damaged. Page 91 - projex inbox. Place a clean shop towel in the area below cam chain sprocket and remove sprocket retaining bolts. Slide camshaft inward to allow removal of cam sprocket and remove sprocket from camshaft and chain.
Page Automatic Compression Release Installation - projex inbox. The actuator ball in the camshaft is not replaceable.
Replace the cam- shaft as an assembly if the actuator ball is worn or dam- aged. Page Camshaft Inspection - projex inbox. Visually inspect each cam lobe for wear, chafing or damage. Thoroughly clean the cam shaft, making sure the oil feed holes are not obstructed. Measure height of each cam lobe using a micrometer. Page Cylinder Head Exploded View - projex inbox.
Remove the two 6mm flange bolts A from cylinder head. Page Cylinder Head Inspection - projex inbox. Remove bolts A and tap cylinder head lightly with a plastic hammer until loose. Page Cylinder Head Disassembly - projex inbox.
NOTE: Keep all parts in order with respect to their location in the cylinder head. Using a valve spring compressor, compress the valve spring and remove the split keeper. Page 97 - projex inbox. Measure free length of spring with a Vernier caliper. Check spring for squareness. Replace spring if either measurement is out of specification.
Page Valve Inspection - projex inbox. Remove all carbon from valve with a soft wire wheel. Check valve face for runout, pitting, and burnt spots. Page Combustion Chamber - projex inbox.
Measure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer. Measure in two directions, front to back and side to side. Page Valve Seat Reconditioning - projex inbox. If any of the above conditions exist, the valve seat must be reconditioned. See Valve Seat Reconditioning, page 3. If the valve seat is cracked the cylinder head must be replaced. Page - projex inbox.
Follow the manufacturers instructions provided with the valve seat cutters in the Cylinder Head Recondi- tioning Kit PN Abrasive stone seat re- conditioning equipment can also be used. Keep all valves in order with their respective seat. NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. Install pilot into valve guide. Apply cutting oil to valve seat and cutter. Inspect the cut area of the seat.
The valve seat should contact the middle of the valve face or slightly above, and must be the proper width. If the indicated seat contact is at the top edge of the valve face and contacts the margin area B it is too high on the valve face. Page Cylinder Head Assembly - projex inbox. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem. Rotate the valve rapidly back and forth until the cut sounds smooth.
Page Valve Sealing Test - projex inbox. Dip valve spring and retainer in clean engine oil and install spring with closely spaced coils toward the cylinder head. Closely spaced coils toward cylinder head 6. Place retainer on spring and install valve spring compressor.
Remove cam chain guide at front of cylinder. Loosen all four oil pipe banjo bolts and then remove the bolts and eight sealing washers. Remove the two 6 mm cylinder base bolts. Page Piston Removal - projex inbox. Remove circlip.
Note piston directional arrow pointing toward the right Mag side of engine. Remove piston circlip and push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch.
Page Cylinder Inspection - projex inbox. Remove all gasket material from the cylinder sealing surfaces. Inspect the top of the cylinder for warpage using a straight edge and feeler gauge. Cylinder Warpage:. Inspect cylinder for wear, scratches, or damage.
Record measurements. If cylinder is tapered or out of round beyond. Cylinder Taper Limit:. Cylinder Out of Round Limit:. Standard Bore Size: 3. Measure piston pin bore. Piston Pin Bore:. Measure piston pin O.
Piston Pin O. Page Piston Ring Installed Gap - projex inbox. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with Piston a thickness gauge. Replace piston and rings if ring-to-groove clearance exceeds service limits. Remove recoil housing bolts and remove housing. Remove flywheel nut and washer. Install flywheel puller PN and remove flywheel. Remove bolt securing tensioner blade to crankcase A. Remove blade and inspect for cracks, wear, or damage.
Remove cam chain. Inspect chain for worn or missing rollers or damage. Stretch chain tight on a flat surface and apply a 10 lb. Page One Way Valve - projex inbox. Using the special socket, remove the crankshaft slotted nut A. NOTE: The slotted nut is a left hand thread. Remove cam chain drive sprocket B and Woodruff key from crankshaft.
Page Crankcase Separation - projex inbox. Remove flange bolts 10 from magneto side crankcase evenly in a cross pattern. Separate crankcase by tapping with a soft faced hammer in reinforced areas. Tap lightly on balancer gear with a brass drift through the hole in the crankcase if necessary, to ensure the balancer shaft stays in the PTO side crankcase.
Remove pump shaft bearing A and thrust washer B from pump shaft. Remove 2 bolts holding pump drive gear C. Remove the three screws and strainer screen from pump. Clean screen thoroughly. Remove pump body screw and feed chamber cover. Measure pump end clearance using a feeler gauge and straight edge. Page Oil Pump Assembly - projex inbox. Measure clearance between outer feed rotor and pump body with a feeler gauge.
Measure rotor tip clearance with a feeler gauge. Rotor Tip Clearance: Std:. Remove the shim washer from the counter balancer shaft. Note the alignment dots on the balancer and crankshaft gears, the marks must be aligned during reassembly. Turn the shaft until balancer counter weights clear the crankshaft and remove the balancer shaft from the crankcase. Remove the shim washer from the crankshaft. Support the PTO side crankcase and crankshaft; press the crankshaft out.
Be careful not to damage the crankcase mating surface or connecting rod. Use a feeler gauge to measure the connecting rod big end side clearance. Page Crankcase Bearing Inspection - projex inbox. Remove the seal from the PTO side crankcase. Inspect the crankshaft main bearings, balancer shaft bearings, and pump shaft bearing.
NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. Page Crankcase Inspection - projex inbox.
Remove all traces of gasket sealer from the crankcase mating surfaces. Inspect the surfaces closely for nicks, burrs or damage. Check the oil pump and oil passage mating surfaces to be sure they are clean and not damaged. Page Crankshaft End Play Adjustment - projex inbox. Excessive end play may cause engine noise at idle and slow speeds. Measure the distance from the Magneto crankcase mating surface to the main bearing using the same method and record.
Subtract the thickness of the straightedge from the measurement obtained in Step 4 and record. Mag Case Depth 6. Make sure all bearings are firmly seated in the crankcase. Step 2 2. Measure the width of the counter balancer shaft at the bearing seats with a dial caliper or micrometer, and record reading. Make sure the pump shaft bearing is firmly seated in the Magneto side crankcase.
Measure the distance from the magneto crankcase mating surface to the bearing using a dial caliper and a straight edge. Page Crankcase Assembly - projex inbox. Use the crankshaft installation tool kit PN to prevent damage to the crankshaft and main bearings during installation.
Install the crankshaft into the PTO side crankcase. Screw the threaded rod into the crankshaft until the threads are engaged a minimum of one inch Clean the seal cavity to remove all traces of old sealer. Place a new mechanical seal in the seal drive collar, and install on the pump shaft. Screw the guide onto the end of the pump shaft.
Insert the puller legs between the water pump drive shaft and the remaining portion of the mechanical seal. Attach the puller legs to the main puller body. Page One Way Valve Installation - projex inbox. One Way Valve Plug Torque: 16 ft. Install the Woodruff key, drive sprocket, and slotted nut. Page Piston Ring Installation - projex inbox. Always check piston ring installed gap before rings are installed on piston. See page 3. If the piston has been in service clean any accumulated carbon from the ring grooves and oil control ring holes.
Page Piston Installation - projex inbox. Clean the gasket surfaces on the cylinder and crankcase. Remove all traces of old gasket material. Make sure the cylinder mounting bolt holes are clean and free of debris. Install a new circlip on one side of the piston with the end gap facing up or down, and tang outward. Page Cylinder And Head Installation - projex inbox. Place the dowel pins in the crankcase and install a new cylinder base gasket.
Position the piston support block PN A beneath the piston skirt to support the piston during cylinder installation. Page Cylinder Head Installation - projex inbox. Apply a light film of oil to the threads and flange surface of the cylinder mounting bolts. Install all four bolts finger tight.
Rotate the engine and position the piston at BDC. NOTE: If cam chain is installed, hold it up while rotating the engine to avoid damage to the chain, drive sprocket Cylinder Bolt Torque Apply Polaris Premium Starter Drive grease to the camshaft main journals and cam lobes.
Lubricate automatic compression release mechanism with clean engine oil. Loop the cam chain on the cam sprocket with the dots on the sprocket facing outward and the alignment pin notch facing directly upward. Before positioning the sprocket on the camshaft, check the position of the cam sprocket alignment pin. Page Cam Chain Tensioner Installation - projex inbox. Release the ratchet pawl A and push the tensioner plunger B all the way into the tensioner body.
Install the tensioner body with a new gasket and tighten the bolts. Tensioner Bolt Torque: 6 ft. Torque bolts evenly to specification. Stator Plate Bolt Torque: 5. Seal stator wire grommet with 3 Bond or equivalent sealer.
Flywheel 1. Install flywheel, washer, and nut. Torque flywheel to specification. Page Thermostat Installation - projex inbox. Assemble rocker arms, rocker shaft, and shaft supports.
Install and tighten rocker arm shaft locating bolt. Do not over- fill. Make sure the handlebars are straight. The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections The following checks are recommended to keep the brake system in good operating condition. Repeat the measurement procedure on the other side of the vehicle. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle.
Side Panel Removal 1. Remove the seat. Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com- ponent operations. All service must be performed by your authorized Polaris dealer. Loosen the wheel nuts slightly. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground. Page Wheel Installation Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed.
See your Polaris dealer. Place the wheel on the wheel Release the air box cover clips, and remove the air box cover. Loosen the clamp and remove the filter. Use the following procedure to make the adjustment. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.
Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Page Recoil Housing Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi- tions. Drain the housing before storing the vehicle. Make sure the hous- ing is completely dry before reinstalling the drain plug.
Page Spark Plugs Spark Plug Recommendations Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification.
There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service.
NOTE: The tip should not be flaky and white. Take the vehicle to your dealer before starting the engine. If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below.
Page Spark Arrestor Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. See your dealer as outlined in the owner's manual. Do not install it in any other product. Use the following instructions to dry it out before operating. Move the vehicle out of the water.
Remove the PVT drain plug. Use a 17 mm wrench, a flat screw- driver, or the spark plug wrench. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Page Battery Removal Battery Improperly connecting or disconnecting battery cables can result in an explo- sion and cause serious injury or death. When removing the battery, always disconnect the negative black cable first.
When reinstalling the battery, always connect the negative black cable last. Battery Removal 1. It can also hinder vehicle performance. Follow the battery charging instructions on page before installing the battery. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. When using a constant current charger, use the following guidelines for recharging.
Always verify battery con- dition before and hours after the end of charging. State of Voltage Charge Page Cleaning And Storage Certain products, including insect repellents and chemicals, will damage plastic surfaces.
Do not allow these types of products to contact the vehicle. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system. Page Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years.
NOTE: Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned. Page Storage Tips Make any necessary repairs and clean the vehicle as recommended. Stabilize the Fuel 1. Fill the fuel tank. Follow the instructions on the container for the recommended amount. Page 7.
If Polaris fuel system additive is not used, the fuel tank, fuel lines, and carburetor should be completely drained of gasoline. Page Accessories Auxiliary power outlets provide volt power for operating accesso- ries.
Accessory outlets are available for all models. Polaris also has a wide range of additional accessories available for your ATV. Always install accessories that are approved for ATV use. Please see your Polaris dealer. Turn the fuel valve off.
Secure the fuel cap, oil cap and seat. Page Adjustments The front and rear shock absorber springs are adjustable. Rotate the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Always adjust both sides equally. Rear Adjuster Front Adjuster Page Follow the adjustment procedures exactly, or see your Polaris dealer for service.
Loosen the four handlebar bolts. Locate the throttle cable adjuster at the handlebar. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. Inspect clutch seals for damage if repeated leaking occurs. Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Page Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Idle set too low Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug s Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Page Engine Overheating Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Overuse of choke Fouled or defective spark plug s Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Polaris also gives a one year limited warranty on the final drive chain for failure due to defects.
This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any ATV that When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.
If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Page Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Page Polaris standard limited warranty for this vehicle.
Polaris warrants that this vehicle is; 1 designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR and, 2 free from defects in materials and workmanship that may keep it from meeting these requirements.
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