Polaris 2005 SPORTSMAN 500 Servise Manual
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Polaris 2005 SPORTSMAN 500 Servise Manual

Polaris 2005 SPORTSMAN 500 Servise Manual

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SPORTSMAN 400/500
SPORTSMAN 400/500
99194
99194

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Summary of Contents for Polaris 2005 SPORTSMAN 500

  • Page 1 SPORTSMAN 400/500 SPORTSMAN 400/500 99194 99194...
  • Page 2 2005 Sportsman 400/500 ATV Service Manual (PN 9919425) 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 Mity Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of the Warn Industries Some Polaris factory publications can be downloaded from www.polarisindustries.com or purchased from www.purepolaris.com or contact your nearest Polaris dealer.
  • Page 4 GENERAL MAINTENANCE ENGINE CARBURETION BODY AND STEERING CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...

  • Page 5: Table Of Contents

    GENERAL INFORMATION Specs Model Identification ..... . . Serial Number Location ....Publication Numbers .

  • 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 5 0 A A Model Option Year Designation Basic Chassis Designation Engine Designation ENGINE DESIGNATION NUMBERS 42 EH42PLE .

  • Page 7: Publication Numbers

    9919416 9919417 NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com ATV PAINT INFORMATION FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147.
  • Page 8 Rear Rack Capacity 180 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Hitch Tongue Weight 120 lbs./54.4 kg Body Style SPIRIT 2005 Sportsman 500 MODEL: ..MODEL NUMBER: A05MH50 ENGINE MODEL: Category Dimension Length 83 in./211 cm...
  • Page 9 Brake - - Front Dual Hydraulic Disc 87 Octane (minimum) Brake - - Rear Single Hydraulic Disc 89 Oxygenated Brake Fluid Polaris DOT 3 Brake Fluid Electrical Alternator Output 240 w @ 3000 RPM JETTING CHART AMBIENT TEMPERATURE Voltage Regulator 3- -Phase - - Sure Power Below 40°F...
  • Page 10 Brake - - Front Dual Hydraulic Disc 87 Octane (minimum) Brake - - Rear Single Hydraulic Disc 89 Oxygenated Brake Fluid Polaris DOT 3 Brake Fluid Electrical Alternator Output 240 w @ 3000 RPM JETTING CHART AMBIENT TEMPERATURE Voltage Regulator 3- -Phase - - Sure Power Below 40°F...

  • Page 11: Special Tools

    GENERAL INFORMATION SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN PA- -44689 Valve Clutch Adjuster 2872105 Water Pump Mechanical Seal Puller 8712100 or 8712500 Tachometer 2,10 2200634 Valve Seat Reconditioning Kit 2870390 Piston Support Block 2871043 Flywheel Puller 2871283 Crankshaft/Water Pump Seal Install Kit 5131135...
  • Page 12 2460761 Hall Sensor Probe Harness 2871745 Static Timing Light Harness NOTE: Polaris dealers can order the tools listed above through their Polaris Special Service Tools catalog. SPECIAL TOOLS Special Tools maybe required while servicing your Standard Tools and Engine Tools machine.
  • Page 13 GENERAL INFORMATION Standard Tools and Engine Tools 2870303 -- Hone Kit 2871283 -- Crank/Water Pump Seal Install Kit Clutch (PVT) Tools 2870305 -- Stone Replacement Kit 2870506 -- Drive Clutch Puller 2870588 -- Hone Oil (12 oz.) 2870913 -- Driven Clutch Puller 2200634 -- Valve Seat 2870654 -- ATV Clutch Align Tool Reconditioning Kit...
  • Page 14 GENERAL INFORMATION Clutch (PVT) Tools Suspension Tools 2870341 -- Drive Clutch Spider Removal Tool 2870871 -- ATV Ball Joint Tool Kit 2870910 -- Roll Pin Tool 2871071 -- Shock Body Holding Tool 2871025 -- Clutch Bushing Replace Tool Kit 2871226 -- Clutch Bushing Replacement Kit 2870623 -- Shock Spring Compressor 2871572 -- Strut Rod Wrench...
  • Page 15 GENERAL INFORMATION Suspension Tools Fuel & Brake Systems 2870872 -- Shock Spanner Wrench 2870975 -- Mity Vac 2872608 -- Roll Pin Removal Tool Electrical Tools 2871351 -- Shock IFP Depth Tool Transmission Tools PV--43568 --Fluke 77 Multimeter PV--39617 -- Current Clamp 2871702 -- Shaft Drive Transmission &...
  • Page 16 GENERAL INFORMATION Electrical Tools 2870630 -- Timing Light 2871745 --Static Timing Light Harness 2460761 -- Hall Sensor Probe Harness PV--39991 -- Peak Reading Adapter PV--37453 -- Christie Se--Sulfating Multi--Battery Charger PV--63070 -- Christie Multi--Battery Charger 1.12...

  • Page 17: Standard Torque Specifications

    GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.
  • Page 18 GENERAL INFORMATION SAE TAP DRILL SIZES DECIMAL EQUIVALENTS 1/64 ....0156 Thread Size/Drill Size Thread Size/Drill Size 1/32 ... .0312 .

  • Page 19: Conversion Table

    GENERAL INFORMATION CONVERSION TABLE Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m x .7376 = ft. lbs. kg-m x 7.233 = ft.

  • Page 20: Glossary Of Terms

    CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8″ or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.
  • Page 21 MAINTENANCE Periodic Maintenance Chart ....2.2-2.5 Lubricant and Maintenance Product Numbers 2.6--2.7 ATV Component Locations ....Lubrication Charts .

  • Page 22: Periodic Maintenance Chart

    Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.) E= Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING: Improperly performing the procedures marked with a could result in component failure and lead...

  • Page 23: Maintenance And Lubrication

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

  • Page 26: Polaris Lubricant Symbol Identification

    MAINTENANCE POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS Part No. Description Part No. Description Engine Lubricant Additives / Sealants / Thread Locking Agents / Misc. 2870791 Fogging Oil (12 oz. Aerosol) 2870585 Loctitet Primer N, Aerosol, 25 g 2871098 Premium 2 Cycle Engine Oil (Quart) (12...
  • Page 27 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 2859061 - - Sportsman 500 Maintenance Kit - - Oil Filter & 3 Qts. of 0W- -40 oil...
  • Page 28 MAINTENANCE SPORTSMAN 400/500 COMPONENT LOCATIONS Instrument Cluster AWD Switch (Speedometer) Brake Fluid Reservoir Worklight Brake Lever Light Control & Run Switch Reverse Override Throttle Choke Front Storage Ignition/Key Compartment Fuel Valve & Rack Rear Storage Compartment Front Gearcase Oil Dipstick (Behind Radiator) PVT Cover Gas Cap...
  • Page 29 Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) © More often under severe conditions (operating in water or hauling heavy loads) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or ¢ Mobilegrease Special...

  • Page 30: Front Gearcase Lubrication

    S Be sure vehicle is level before proceeding and in PARK. S Check vent hose to be sure it is routed properly and unobstructed. S The correct front gearcase lubricant to use is Polaris Premium Demand Drive Hub Fluid. 2.10...

  • Page 31: Transmission Lubrication

    MAINTENANCE TRANSMISSION To change gearcase lubricant: LUBRICATION The transmission lubricant level should be checked and changed in accordance with the maintenance schedule. SPORTSMAN 400/500 TRANSMISSION 11 ft.lbs (15 Nm) View Under Front of ATV Drain Plug 1. Remove gearcase drain plug (A) (11 mm) located Drain Plug on the bottom of the gearcase and drain oil.

  • Page 32: Lubrications Points

    MAINTENANCE TRANSMISSION SPECIFICATIONS Specified Lubricant: AGL Gearcase Lubricant: (PN 2873603) (Gallon) (PN 2873602) (12 oz.) Capacity: ..At change: Approx. 32 oz. (948 ml) Drain Plug & Fill Plug: 22 ft. lbs. (30 Nm) To check the level: 1.

  • Page 33: Throttle Inspection

    MAINTENANCE 2. Note orientation of tie rod end studs with the ends that are up down (vertical). Remove both rod end bolts from transmission bell crank. Shifter Mount Ball Joint Zerk View -- Right Side Under Recoil Housing Shifter SHIFT LINKAGE INSPECTION Shift Linkage Rod NOTE: Shift rod is preset at time of manufacture.
  • Page 34 MAINTENANCE PILOT SCREW To remove the ETC cover: 1. Use a medium flat blade screwdriver and insert The pilot system supplies fuel during engine operation blade into the pocket of the cover starting on the with the throttle valve closed or slightly opened. The #1 position.

  • Page 35: Pilot Screw Adjustment

    MAINTENANCE PILOT SCREW ADJUSTMENT 6. Slowly turn mixture screw counterclockwise until idle speed increases to maximum RPM. Continue turning counterclockwise until idle RPM begins to drop. 7. Center the pilot screw between the points in Step 5 and 6. 8. Re adjust idle speed if not within specification. FRONT (Engine) IDLE SPEED ADJUSTMENT...

  • Page 36: Throttle Cable

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

  • Page 37: Vent Lines

    MAINTENANCE VENT LINES CARBURETOR DRAINING Check fuel tank, oil tank, carburetor, battery and The carburetor float bowl should be drained transmission vent lines signs wear, periodically to remove moisture or sediment from the deterioration, damage or leakage. Replace every two bowl, or before extended periods of storage.

  • Page 38: Compression Test

    MAINTENANCE COMPRESSION TEST SPARK PLUG NOTE: 4-Stroke 500 and 425 engines are equipped 1. Remove spark plug high tension lead. Clean plug with an automatic decompressor. Compression area so no dirt and debris can fall into engine readings will vary in proportion to cranking speed when plug is removed.

  • Page 39: Battery Maintenance

    MAINTENANCE BATTERY MAINTENANCE hours at a current equivalent of 1/10 of the battery’s rated amp/hour capacity (i.e. 12amp hr x .10 = 1.2 amp charging). Do not use the alternator to charge a new battery. WARNING Low- -Maintenance batteries are permanently sealed at the time of manufacture.

  • Page 40: Cooling System Pressure Test

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

  • Page 41: Radiator Coolant Level

    1. Remove reservoir cap. Inner splash cap vent hole must be clear and open. INSPECTION 2. Fill reservoir to upper mark with Polaris Premium 60/40 Anti Freeze / Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as NOTE: This procedure is only required if the cooling required for freeze protection in your area.

  • Page 42: Air Box Sediment Tube Service

    MAINTENANCE NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling. Filter Clamp 4. Loosen clamp and remove air filter assembly. Cover Ill.2 Proper Filter Placement Main Filter Gasket Pre-filter Main Element Filter Support Ill.1 Carb Boot...

  • Page 43: Breather Filter

    MAINTENANCE 2. Drain tube. maintained properly. Never operate the engine without the pre-filter. 3. Reinstall drain plug. RECOIL HOUSING Sediment Tube Ill.1 Recoil Drain NOTE: The sediment tube will require more frequent service if the vehicle is operated in wet conditions or at high throttle openings for extended periods.

  • Page 44: Engine Oil Level

    MAINTENANCE engine oil will be lost if crankcase drain is 5. Remove dipstick and check to see that the oil opened. level is in the normal range. The oil should be between the top line and the bottom line on the If recoil handle (B) seal has been dipstick.
  • Page 45 19. Reinstall drain plug. 20. Remove dipstick and fill tank with 2 quarts (1.9 L) of Polaris Premium 4 Synthetic Oil (PN 2871844). 21. Place gear selector in Park and set parking brake. NOTE: Clamp or pinch off the vent line 2” from the oil tank as shown below in the Oil Pump Priming Procedure for the 400/500 engine.

  • Page 46: Oil Pump Priming

    To Air Box Oil Tank Screen Fitting Torque: Approx. 14-17 ft. lbs. (19 Nm - -23 Nm) Recommended Engine Oil: Polaris Premium 4 All Season Synthetic, 0W- -40, (PN 2871281) Slit Ambient Temperature Range: Oil Tank -40° F to 120° F...
  • Page 47 MAINTENANCE INTAKE VALVE CLEARANCE CAUTION: Failure to position the crankshaft at TDC on compression stroke will result in improper valve ADJUSTMENT adjustment. 1. Insert a .006″ (.15mm) feeler gauge between end of intake valve stem and clearance adjuster Sprocket alignment pin facing up screw.
  • Page 48 ( possible steering component repair and adjustment be loose wheel nuts or loose front hub performed by an authorized Polaris MSD- -certi- components). fied technician when replacing worn or dam- aged steering parts. Use only genuine Polaris replacement parts.

  • Page 49: Camber And Caster

    MAINTENANCE CAMBER AND CASTER 2. Set handlebars in a straight ahead position and secure handlebars in this position. NOTE: The steering arm “frog” can be used as an indicator of The camber and caster are non-adjustable. whether the handlebars are straight. The frog should always point straight back from the WHEEL ALIGNMENT steering post.

  • Page 50: Exhaust Pipe

    MAINTENANCE is positioned incorrectly it will not pivot, and may 2. Place the transmission in Park and start the break. engine. Purge accumulated carbon from the system by momentarily revving the engine several times. Hold Rod End 3. If some carbon is expelled, cover the exhaust outlet and lightly tap on the pipe around the clean out plugs with a rubber mallet while revving the engine several more times.

  • Page 51: Brake System Inspection

    Pads should be changed when the friction material is Keep fluid level in the master cylinder worn to 3/64″ (.1 cm), or about the thickness of a dime. reservoir to the indicated level inside reservoir. Use Polaris DOT 3 Brake Fluid (PN 2870990). Sight Parking Brake Glass Lock 3/64″...

  • Page 52: Auxiliary Brake Testing

    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 53: Controls

    Refer to Chapter 7 for CV boot replacement, Align throttle control assembly clamp with knurl on or have you Polaris dealer replace the boot. handlebar WHEELS Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight.

  • Page 54: Wheel Removal/Installation

    MAINTENANCE WHEEL REMOVAL FRONT OR TIRE PRESSURE REAR CAUTION: Front & Rear Wheels Maintain proper tire pressure. Refer to the warning Front & Rear tire pressure decal applied to the vehicle. Wheel Nuts (4) 27 ft. lbs. (37 Nm) Tire Pressure Inspection (PSI - Cold) Front Rear Front Hub Nut...
  • Page 55 MAINTENANCE FRAME, NUTS, BOLTS, FASTENERS Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter. FRONT / REAR STORAGE COMPARTMENTS The front and rear storage compartments are easily Rear Storage -- Latched accessible.

  • Page 56: Warnt Winch Operation

    MAINTENANCE WARNt WINCH OPERATION Mini--Rocker Switch The 2005 Sportsmans are pre--wired with the proper Warnt winch wiring for quick and easy installation of a Warnt Winch in the front. Refer to the installation instructions with the winch kit for more details on proper installation.
  • Page 57 MAINTENANCE Winch Wire Locations The winch wires can be located under the front cab Winch Connecting Wires area. Locate the wires, remove the cap and hook up to winch the Blue and Yellow (6 Ga.) wires to the winch. Refer to the installation instructions for more details.
  • Page 58 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 59 5. Treat the fuel system with Polaris Carbon Clean. 6. 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 60: Maintenance Schedule

    MAINTENANCE MAINTENANCE SCHEDULE Service Date Hours / Miles Service Performed Serviced By: 2.40...
  • Page 61 ENGINE Torque Specifications ......Special Tools ....... EH50PL Service Data .

  • Page 62: Torque Specifications

    ENGINE TORQUE SPECIFICATIONS Water Pump 5-6.5 (7-9 Nm) Housing Cover Stator Plate 5-6.5 (7-9 Nm) TORQUE SPECIFICATIONS Starter Motor 5-6.5 (7-9 Nm) Fastener Size EH42PLE/ EH50PLE Spark Plug 14mm 9-11 (12-15 Nm) Ft. Lbs. (Nm) Thermistor ---- 26 ± 2.1 (35 ± 3 Blind Plug (Oil 1/8 PT 6.5-11 (9-15 Nm)

  • Page 63: Engine Service Data

    ENGINE ENGINE SERVICE DATA Cylinder Head / Valve EH42PLE EH50PLE Rocker Arm Rocker arm ID .8669-.8678″ (22.020-22.041 mm) .8669-.8678″ (22.020-22.041 mm) Rocker shaft OD .8656-.8661″ (21.987-22.0 mm) .8656-.8661″ (21.987-22.0 mm) Rocker shaft Oil Clearance .0008-.0021″ (.020-.054 mm) .0008-.0021″ (.020-.054 mm) Limit .0039″...
  • Page 64 ENGINE ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod EH42PLE EH50PLE Cylinder Surface warpage limit (mating with cylinder head) .0020″ (.05 mm) .0020″ (.05 mm) Cylinder bore 3.4606-3.614″ (87.900-87.920 mm) 3.6221-3.6228″ (92.00-92.02 mm) Taper limit .0020″ (.050 mm) .0020″ (.050 mm) Out of round limit .0020″...

  • Page 65: Torque Patterns

    ENGINE ENGINE FASTENER TORQUE Engine Oversize Piston Standard Model Length Piston Iden- Available* PATTERNS tification (mm) Tighten cylinder head, cylinder base, and crankcase EH50PLE 72 mm fasteners in 3 steps following the sequence outlined below. EH42PLE 66 mm *Pistons and rings marked 25 equal .25mm (.010I) oversized Pistons and rings marked 50 equal .50mm (.020I) oversized...
  • Page 66 ENGINE COOLING SYSTEM and serious burns may result. Allow the engine and cooling system to cool before servicing. WARNING: Never remove radiator cap when engine System Pressure Test is warm or hot. The cooling system is under pressure 1. Remove radiator cap cover located in storage FLOW box.

  • Page 67: Engine Removal

    6. Remove springs from exhaust pipe and remove and reduce heat dissipation, resulting in possible pipe. engine damage. Polaris Premium 60/40 7. Drain coolant and engine oil. Antifreeze/Coolant is recommended for use in all cooling systems, and comes pre-mixed and ready to 8.

  • Page 68: Engine Installation Notes

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

  • Page 69: Honing To Oversize

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

  • Page 70: Oil Pressure Test

    3. Start engine and allow it to reach operating temperature, monitoring gauge indicator. NOTE: Use Polaris Premium 4 Synthetic Engine Lubricant (PN 2871281). 2. To correct a situation like the one shown in the illustration at right, squeeze the crankshaft at Oil Pressure at 5500 RPM (Engine Hot): point A.
  • Page 71 ENGINE OIL PUMP PRIMING OIL FLOW - - EH50PL PROCEDURE The chart on Page 3.12 describes the flow of oil through the EH50PL engine. Beginning at the oil tank, NOTE: This priming procedure must be the oil flows through a screen fitting in the bottom of performed whenever the oil hose connection the tank and into the oil supply hose.

  • Page 72: Eh50Pl Oil Flow Diagram

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

  • Page 73: Eh50Pl Engine Exploded View

    ENGINE EH50PL ENGINE EXPLODED VIEW Crankcase Cylinder/ Cylinder Head Crankshaft Valvetrain and Piston 3.13...
  • Page 74 ENGINE ENGINE REMOVAL should have clearance at this point. REFER TO PAGE 3.7- - 3.8 FOR ENGINE REMOVAL / INSTALLATION NOTES. CAM CHAIN TENSIONER/ROCKER ARM/CAMSHAFT REMOVAL 1. Remove ignition timing inspection plug from recoil housing. 5. Remove cam chain tensioner plug, sealing TDC “T”...
  • Page 75 ENGINE CAM CHAIN TENSIONER ROCKER ARM/SHAFT INSPECTION INSPECTION 1. Pull cam chain tensioner plunger outward to the 1. Mark or tag rocker arms to keep them in order for end of its travel. Inspect teeth on ratchet pawl (A) assembly. and plunger teeth (B) for wear or damage.
  • Page 76 ENGINE ROCKER ARM/SHAFT INSPECTION, CONT. Rocker Shaft Oil Clearance: Std: .0008-.0021I (.020-.054 mm) Limit: .0039I (.10 mm) 5. Measure I.D. of both rocker arm shaft supports and visually inspect surface. Compare to specifications. 6. Subtract rocker shaft O.D. from rocker arm & shaft support I.D.
  • Page 77 ENGINE 3. Loosen three camshaft sprocket bolts. 7. Slide camshaft inward to allow removal of cam sprocket and remove sprocket from camshaft and chain. 8. Secure cam chain with a wire to prevent it from falling into the crankcase. Sprocket Teeth 4.

  • Page 78: Automatic Compression Release Installation

    ENGINE Stop pin Spring in relaxed position 1. Check release lever shaft (A) for smooth operation throughout the entire range of rotation. The spring (B) should hold the shaft weight against the stop pin. In this position, the actuator ball (C) will be held outward in the compression release mode.
  • Page 79 ENGINE Camshaft Oil Clearance: Std: .0022-.0035I (.055-.090 mm) Limit: .0039I (.10 mm) Lubrication holes NOTE: Replace camshaft if damaged or if any part is worn past the service limit. Lobe height NOTE: Replace cylinder head if camshaft journal bore is damaged or worn excessively. CYLINDER HEAD EXPLODED Cam Lobe Height (Intake &...
  • Page 80 ENGINE CYLINDER HEAD EXPLODED VIEW, EH50PL EH50PL 3.20...

  • Page 81: Cylinder Head Disassembly

    ENGINE CYLINDER HEAD CYLINDER HEAD INSPECTION DISASSEMBLY WARNING: Wear eye protection or a face shield during cylinder head disassembly and reassembly. NOTE: Keep all parts in order with respect to their location in the cylinder head. 1. Thoroughly clean cylinder head (A) surface to remove all traces of gasket material and carbon.

  • Page 82: Valve Inspection

    ENGINE to specifications. Replace spring if either indicator. measurement is out of specification 3. Check end of valve stem for flaring, pitting, wear or damage (A). 4. Inspect split keeper groove for wear or flaring of the keeper seat area (B). NOTE: The valves cannot be re-faced or end ground.
  • Page 83 ENGINE Clean all accumulated carbon deposits from combustion chamber and valve seat area with a soft wire brush. VALVE SEAT RECONDITIONING Valve Seat Inspection Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be reconditioned.
  • Page 84 ENGINE Reaming The Valve Guide Good Uneven Wide Narrow NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. The valve must contact the valve seat over the entire circumference of the seat, and the seat must be the proper width all the way around.
  • Page 85 ENGINE If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation and must be Valve Seat Width: replaced. Be sure the cylinder head is at the proper temperature and replace the Intake Std: .028I (.7 mm) guide.

  • Page 86: Cylinder Head Assembly

    ENGINE 1. Install new valve seals on valve guides. 2. Apply engine oil to valve guides and seats. 3. Coat valve stem with molybdenum disulfide grease. 4. Install valve carefully with a rotating motion to avoid damaging valve seal. 5. Dip valve spring and retainer in clean engine oil and install spring with closely spaced coils toward the cylinder head.
  • Page 87 ENGINE EXHAUST VALVE CLEARANCE ADJUSTMENT 500 Engine Feeler Gauge for Both Valves 1. Remove cam chain guide at front of cylinder. NOTE: The exhaust valves share a common rocker arm, and must be adjusted using two feeler gauges. 1. Insert .006 feeler gauge(s) between end of exhaust valve stem and adjuster screw(s).

  • Page 88: Piston Support Block

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

  • Page 89: Cylinder Inspection

    ENGINE scratch the ring lands. 2. Inspect the top of the cylinder for warpage using a straight edge and feeler gauge. Cylinder Warpage: .002″ (.05 mm) 3. Inspect cylinder for wear, scratches, or damage. 1/2″ Down From Top of Cylinder 4.
  • Page 90 ENGINE PISTON-TO-CYLINDER CLEARANCE Piston 40 mm Piston Pin Measurement Locations Piston Pin Piston Pin O.D. .9053-.9055I (22.994-23.0 mm) 1. Measure piston outside diameter at a point 40 mm down from the top of the piston at a right angle to the direction of the piston pin.

  • Page 91: Crankcase Disassembly

    ENGINE below specified limit, file ring ends until gap is within specified range. Piston Ring-to-Groove Clearance NOTE: Always check piston ring installed gap after re-boring a cylinder or when installing new rings. A Top Ring Std: .0016-.0031I (.040-.080 mm) re-bored cylinder should always be scrubbed Limit: .0059I (15 mm) thoroughly with hot soapy water, rinsed, and dried Second Ring Std: .0012-.0028I (.030-.070 mm)

  • Page 92: Flywheel Puller

    ENGINE 5. Replace crankshaft seal (A). Std. Bushing ID: .4735″-.4740″ (11.11-12.04 mm) Std. Shaft OD: .470″-.472″ (11.93-11.99 mm) Starter Drive Bushing Clearance: Std: .0015″-.004″ (.038-.102 mm) Service Limit: .008″ (.203 mm) 4. Measure the OD of the starter drive shaft on both ends and record.

  • Page 93: Crankcase Separation

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

  • Page 94: Oil Pump

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

  • Page 95: Oil Pump Assembly

    ENGINE 8. Remove pump body screw and feed chamber 12. Remove inner and outer feed rotor and pump cover. chamber body. 13. Repeat measurements for scavenge rotor. 14. Remove inner and outer scavenge rotor and inspect pump shaft for wear. OIL PUMP ASSEMBLY 1.
  • Page 96 ENGINE CRANKSHAFT 1. Remove the shim washer (A) from the counter balancer shaft. REMOVAL/INSPECTION 1. Remove the shim washer (A) from the crankshaft. 2. Note the alignment dots on the balancer and crankshaft gears, the marks must be aligned 2. Support the PTO side crankcase and crankshaft; during reassembly.

  • Page 97: Crankcase Bearing

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

  • Page 98: Bearing Installation

    ENGINE BEARING INSTALLATION NOTE: To ease bearing installation, warm the crankcase until hot to the touch. Place the bearings in a freezer. 1. Install the bearings so the numbers are visible. 2. Drive or press new bearings into the crankcases, using the proper driver.
  • Page 99 ENGINE 4. Measure the distance from the Magneto 7. Measure the width of the crankshaft at the crankcase mating surface to the main bearing bearing seats with a micrometer or dial caliper using the same method and record. and record. Crankshaft Width 8.
  • Page 100 ENGINE COUNTER BALANCER SHAFT END PLAY ADJUST. Counter Balancer Shaft End Play: .008″-.016″ (.02-.04 cm) Step 2 OIL PUMP SHAFT END PLAY ADJUSTMENT 1. Make sure the pump shaft bearing is firmly seated in the Magneto side crankcase. 1. Make sure all bearings are firmly seated in the crankcase.

  • Page 101: Crankcase Assembly

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

  • Page 102: Water Pump Mechanical Seal Installation

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

  • Page 103: Water Pump Install Kit

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

  • Page 104: Piston Ring Installation

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

  • Page 105: Cylinder Installation

    ENGINE compress the new clip more than necessary upon 3. Apply clean engine oil to the ring compressor installation to prevent loss of radial tension. Severe (Snap Ont PN RCL30) and install the engine damage may result if circlips are re-used or compressor following manufacturers...
  • Page 106 ENGINE 9. Tighten the cylinder bolts in three steps in a criss cross pattern and torque to specifications. 10. Install the two 6 mm bolts. Cylinder Bolt Torque: 10mm - 46 ft. lbs. (62 Nm) Guide in 6mm - 6 ft. lbs. (8 Nm) recess CYLINDER HEAD INSTALLATION...
  • Page 107 ENGINE 1. Apply Polaris Premium Starter Drive Grease (PN 2871460) to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil. (To install the compression release mechanism, refer to Page 3.18). 2. Install the camshaft with the lobes facing downward and the sprocket alignment pin facing upward.
  • Page 108 ENGINE CAMSHAFT TIMING Crankshaft to Camshaft Centerline Dots Sprocket Alignment Pin Single TDC Mark Aligned TDC Mark Rotation Do Not Use Advance Marks 3.48...
  • Page 109 ENGINE CAM CHAIN TENSIONER 1. Apply a light film of grease to the crankshaft seal. Apply molybdenum disulfide grease or assembly INSTALLATION lubricant to the crankshaft bushing. 2. Install a new O-Ring in the oil passage recess in the crankcase. 3.

  • Page 110: Thermostat Installation

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

  • Page 111: Oil Pipes

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

  • Page 112: Recoil Assembly

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

  • Page 113: Spark Plug Fouling Checklist

    ENGINE SPARK PLUG FOULING Dead battery Starter motor does not turn Spark plug cap loose or faulty Engine seized, rusted, Choke cable adjustment mechanical failure plunger/cable sticking Engine Runs But Will Not Idle Foreign material on choke plunger Restricted carburetor pilot system seat or plunger Carburetor misadjusted Incorrect spark plug heat range or...

  • Page 114: Cooling System

    ENGINE Cylinder head gasket leak Ignition timing misadjusted valve clearance incorrectly Low oil level adjusted Spark plug incorrect heat range Cylinder or piston worn Faulty hot light circuit Piston rings worn, leaking, broken, or Thermostat stuck closed or not opening sticking completely Bent valve or stuck valve...
  • Page 115 FUEL SYSTEM/CARBURETION Exploded View, Mikuni BST 34/40 Carburetor 4.2--4.3 Fuel Tank Asm. Exploded View ... . Fuel Flow Diagram ..... . . Fuel Component Overview .
  • Page 116 FUEL SYSTEM/CARBURETION 1. Ring BST 34 CARBURETOR EXPLODED VIEW 2. E--Ring 3. Jet Needle 400 Engine Carburetor 4. Ring 5. Diaphragm 6. Needle Jet 7. Screw 8. Spring Washer 9. Jet Block 10. Washer 11. Main Jet 12. Seal 13. Packing 14.
  • Page 117 FUEL SYSTEM/CARBURETION 1. Cable Guide BST 40 CARBURETOR EXPLODED VIEW 2. Throttle Shaft Assy. 3. Ring 500 Engine Carburetor 4. Spring 5. Screw 6. Washer 7. Case 8. Air Jet 9. Carburetor 10. Plunger Assy. 11. Spring 12. Plunger Cap 13.

  • Page 118: Fuel Flow Diagram

    FUEL SYSTEM/CARBURETION FUEL TANK ASSEMBLY Gas Cap Vent Line Fuel Knob Bracket Fuel Valve 18--24 in.lbs. (2--3 Nm) Gasket Fuel Sender Foam Foil Tank FUEL FLOW Fuel Tank Fuel Tank Vent Fitting Screens Fuel Pump Filter Fuel Valve Carburetor Vent Engine Carburetor L Located Above Oil Tank...

  • Page 119: Fuel Component Overview

    FUEL SYSTEM/CARBURETION FUEL SYSTEM COMPONENT OVERVIEW Fuel Tank Vent Line Fuel Pump Tank to Pump Line Carburetor Fuel Filter Impulse Line Pump to Carburetor Line FUEL SENDER REMOVAL/INSTALL Fuel Sender Removal 1. Disconnect the negative battery cable. 2. Remove the side panels and front cab assembly. Refer to “COVER PANEL REMOVAL”...

  • Page 120: Carburetor Float Adjustment Tool

    Refer to Chapter 10 for fuel sender troubleshooting. Polaris ATV Carburetors are calibrated for an altitude 0-6000 ft. (0-1800 meters) and ambient temperatures between +40 and +80° F (+5° to +26°...

  • Page 121: Carburetor Jetting

    FUEL SYSTEM/CARBURETION CV CARBURETOR SYSTEM outside this temperature and/or altitude range. The jetting installed in production is not intended for all FUNCTION altitudes and/or temperatures. In addition, air screw / pilot screw adjustments and PVT adjustments may be required to suit operating conditions. Carburetor Component Function CARBURETOR JETTING System...

  • Page 122: Cv Carburetor Operation

    FUEL SYSTEM/CARBURETION VENT SYSTEMS - CV CARBURETOR OPERATION CONT’D CARBURETOR When the throttle plate is opened and engine speed begins to increase, the pressure in the venturi (and therefore in the chamber above the diaphragm) The carburetor float bowl vent lines supply becomes significantly lower than atmospheric.

  • Page 123: Float System

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

  • Page 124: Main System

    FUEL SYSTEM/CARBURETION MAIN SYSTEM PILOT SCREW As throttle valve (1) is opened, engine speed rises, The pilot system supplies fuel during engine operation and this increases negative pressure in the venturi. with the throttle valve closed or slightly opened. The Consequently the vacuum slide (2) moves upward.
  • Page 125 FUEL SYSTEM/CARBURETION CARBURETOR DISASSEMBLY - MIKUNI CV Use the following disassembly, assembly, and inspection techniques to service a CV carburetor. 1. Remove carburetor diaphragm chamber cover with a ratchet style screwdriver. DO NOT use an impact driver to remove the screws or carburetor may be permanently damaged.

  • Page 126: Carburetor Cleaning

    FUEL SYSTEM/CARBURETION CARBURETOR CLEANING WARNING Jet Needle Needle Jet Protect eyes from contact with cleaner. Take appropriate safety measures during these procedures. Safety glasses and chemical resistant Inspect this area gloves are required. Should you get cleaner in your eyes or if you swallow cleaner, seek medical attention immediately.

  • Page 127: Carburetor Assembly

    FUEL SYSTEM/CARBURETION CARBURETOR ASSEMBLY 5. Install the pilot mixture screw, spring, washer, and O-ring as an assembly. Lubricate the O-Ring with oil or light grease before installation. CAUTION: Inspect the diaphragm (A) for holes, deterioration, or Do not damage the O-ring during installation. damage.
  • Page 128 FUEL SYSTEM/CARBURETION FLOAT HEIGHT BST 40 ADJUSTMENT 1. Place the carburetor on a level surface as shown at right to remove weight from float arm. In this position, the float tongue will rest lightly on the inlet needle valve pin without compressing the spring.

  • Page 129: Needle & Seat Leakage Test

    FUEL SYSTEM/CARBURETION FUEL LEVEL Float arms even A fuel level test can be performed on some models if the drain hose fitting is accessible. Be sure to re-attach the bowl drain hose after performing the test. A fuel level test allows you to observe the height of the fuel in the float bowl without removing the carburetor.

  • Page 130: Fuel Pump Disassembly

    FUEL SYSTEM/CARBURETION Fuel Pump Inspect Fuel Lines Impulse line FUEL PUMP DISASSEMBLY 1. Remove the screws from the pump diaphragm cover. Note the location of the two longer screws. 2. Remove diaphragm cover gasket, diaphragm, and valve body gasket. 3. Remove the outlet check valve cover, diaphragm, and gasket.

  • Page 131: Troubleshooting

    FUEL SYSTEM/CARBURETION FUEL PUMP EXPLODED VIEW TROUBLESHOOTING Fuel Pump Exploded View at Right 1. Fuel Pump Assembly FUEL STARVATION/LEAN MIXTURE 2. Diaphragm, Gasket Set 3. Screw and Washer Assembly Symptoms: Hard start or no start, bog, backfire, 4. Screw and Washer Assembly popping through intake / exhaust, hesitation, 5.
  • Page 132 FUEL SYSTEM/CARBURETION Poor fuel quality (old fuel) Plugged or restricted idle jet Loose jets Worn jet needle/needle jet or other carburetor parts Dirty carburetor (air bleed passages or jets) Weak or damaged vacuum piston return spring Fouled spark plug POOR IDLE Idle Too High Idle adjusted improperly/idle mixture screw damaged...
  • Page 133 BODY / STEERING / SUSPENSION Torque Specifications and Special Tools ..Plastic Insert Removal/Install ....5.2--5.3 Side Panel Removal .

  • Page 134: Plastic Insert Removal/Install

    PLASTIC INSERT REMOVAL / Rear Shock Bolt (Lower) INSTALLATION Rear Wheel Hub Nut Some Polaris ATVs use a two piece plastic insert in place of a metal screw. The plastic inserts are easy Rear Wheel Nuts to remove and install.

  • Page 135: 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 136: 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 137: 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 138 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 139: Front Storage Installation

    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 140 BODY / STEERING / SUSPENSION Rear Rack Installation 3. Remove the two screws (B) that secure the front cab to the frame in the fuel tank mount area. 3. Place spacers on frame. 24 in.lbs. (2.7 Nm) 4. Install rear rack onto rear frame and cab. 5.
  • Page 141 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 142: 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 143: 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 Footwell Front Cab Assembly Front Cover Side Cover Frame...

  • Page 144: 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 145: 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 146: 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 147 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 148: 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 149: 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 150: 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 151: Front Strut Cartridge Replacement

    BODY / STEERING / SUSPENSION FRONT STRUT CARTRIDGE 3. Remove wheel nuts and wheels. REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5.12 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 152: 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 153 CLUTCHING Service Tools, Supplies & Torques ..PVT System Operation ....6.2--6.3 PVT Maintenance/Inspection .

  • Page 154: Clutch Puller

    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 155: Pvt Drying

    CLUTCHING 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 156 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 157: Pvt Disassembly

    CLUTCHING PVT DISASSEMBLY NOTE: Some fasteners and procedures will vary. Driven Clutch Puller (PN 2870913) Refer to the appropriate parts manual for proper fasteners and fastener placement. (See Page 6.8). 1. Remove seat. 2. Remove or loosen rear cab fasteners as 8.
  • Page 158 CLUTCHING 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 159: Pvt Sealing And Ducting Components

    CLUTCHING PVT SEALING AND DUCTING COMPONENTS Drain Plug Outer Cover Inlet Duct Outlet Duct Clutch Cover Seal Inner Cover Cover Bolts Clutch Seal Bracket Cover Case Seal NON- -EBS DRIVE CLUTCH EXPLODED VIEW Drive Clutch Teflont coated brass bushing Teflont coated brass bushing Mark with permanent marker before disassembly...

  • Page 160: Drive Clutch Spring Specifications

    CLUTCHING 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 161: Shift Weights

    CLUTCHING 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 162: Shift Weight 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 163 CLUTCHING NON- -EBS- -SPIDER REMOVAL DRIVE CLUTCH DISASSEMBLY CONT’D 2. Remove cover bolts evenly in a cross pattern and 1. Install clutch in holding fixture and loosen the remove cover plate. spider (counterclockwise) using Clutch Spider 3. Inspect cover bushing (A). The outer cover Install Tool (PN 2870341).
  • Page 164 CLUTCHING Moveable Sheave Bushing Inspection button is positioned toward the solid roller pin. It is recommended to switch all buttons to the rubber 2. Inspect the Teflont coating on the moveable version during service (if needed). sheave bushing. Moveable Sheave Bushing Inspection: NON- -EBS - - DRIVE CLUTCH REASSEMBLY Replace the cover bushing if more brass...
  • Page 165 CLUTCHING 7. Reinstall clutch spring. Engine Rotation Nut on trailing side 2. Install moveable sheave onto fixed sheave. 8. Reinstall cover, aligning bosses on the tower and 3. Install spider spacers. Use same quantity and cover. Torque cover bolts evenly to specification thickness as were removed.
  • Page 166 CLUTCHING NON- -EBS - - DRIVE BELT ALL MODELS - - DRIVE BELT TENSION REMOVAL/INSPECTION 1. Remove outer PVT cover as described in PVT NOTE: Belt tension is not adjustable on EBS Disassembly. models. 2. Mark drive belt direction of rotation so that it can NOTE: Pinch the sheaves lightly together with clamp be installed in the same direction.
  • Page 167 CLUTCHING 4. Measure belt width and replace if worn. deflection is the desired goal - - not a specific Generally, belts should be replaced if clutches center distance. can no longer be adjusted to provide proper belt 8. Replace belt if worn past the service limit. Belts deflection.

  • Page 168: Clutch Offset Alignment Tool

    CLUTCHING ALL MODELS - - CLUTCH NOTE: On some models, minor adjustments can be made by adding shims between the frame and front ALIGNMENT lower left engine mount to increase the distance at point “A”. If a shim is present, it can be removed to 1.

  • Page 169: Clutch Bushing Replacement Tool Kit

    CLUTCHING NON- -EBS - - DRIVE CLUTCH 2. Remove nut from puller rod and set aside. BUSHING SERVICE Piston Pin Puller *Clutch Bushing Replacement Tool Kit (PN (PN 2870386) 2871226) Stamp Qty. Part Description Part # P--90 Drive/Driven 5020628 Clutch Bushing Install Tool Main Puller Adaptor (#8) Drive Clutch Cover...
  • Page 170 CLUTCHING NON- -EBS DRIVE CLUTCH 8. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard. COVER - BUSHING REMOVAL NON- -EBS - - DRIVE CLUTCH MOVEABLE SHEAVE - Piston Pin Puller BUSHING INSTALLATION (PN 2870386) 1.
  • Page 171 CLUTCHING Bushing (PN 3576510) Loctitet 680 (PN 2870584) 5. Turn clutch cover counterclockwise on puller rod until bushing is removed. 2. With the Main Puller Adapter (#8) (PN 5020632) 6. Remove nut from puller rod and set aside. on the puller, insert cover onto puller rod, placing 7.

  • Page 172: Clutch Compression Tool

    CLUTCHING 6. Inspect ramp buttons in the moveable sheave and replace if worn. NOTE: The ramp buttons are secured by Torxt screws (T20). Belt deflection adjustment washers 1. Apply and hold downward pressure on the helix, or place driven clutch in the Clutch Compression 7.
  • Page 173 CLUTCHING NON- -EBS - - DRIVEN CLUTCH ASSEMBLY Driven Spring Driven Clutch Sportsman 400 Driven Spring Placement: 2--2 Ill. 2 Moveable Spring Example: Helix Sheave Tension - - 1 Heavy Align boss spline Spring/ - - 2 to install helix Position - - 1 - - 3...

  • Page 174: Bushing Service

    CLUTCHING NON- -EBS - - DRIVEN CLUTCH BUSHING SERVICE NOTE: Bushings are installed at the factory using Loctitet. In order to remove the bushing it will be necessary to apply heat. A press can be used to remove and install some of the bushings. Be sure to support the sheave or cover as close as possible to the bushing bore when using a press.
  • Page 175 CLUTCHING 6. Install sheave onto puller. 2. Start new bushing evenly in moveable sheave. Apply Loctitet 680 (PN 2870584) to the back 7. Install nut onto puller rod and tighten by hand. side of new bushing. Turn puller barrel for further tension if needed. 8.

  • Page 176: Ebs Drive Clutch Exploded View

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

  • Page 177: Clutch Bushing Replacement Tool Kit

    CLUTCHING EBS - - MOVEABLE SHEAVE 2. Lift one-way clutch off shaft. Replace as an assembly if worn, damaged, or if problems were BUSHING INSPECTION noted. 1. Inspect the Teflont coating on the moveable sheave bushing. Inspect BOTH sheaves for signs of wear, grooving or cracking.

  • Page 178: Removal And Installation

    CLUTCHING REMOVAL AND INSTALLATION 1. Place main adapter (Item 8) on puller. INSTRUCTIONS Puller Tool (A/B) NOTE: Bushings are installed at the factory using Nut (C) Side “A” toward Loctitet 609. In order to remove bushings it will be sheave necessary to apply heat evenly to the area around each bushing.
  • Page 179 CLUTCHING STOP PLATE 2. Install adapter reducer (Item 9). 3. From outside of clutch cover, insert removal tool DISASSEMBLY/INSPECTION - (Item 3) into cover bushing. EBS Driven Clutch Operation 4. With inside of cover toward vise, slide cover onto puller. The late model EBS driven clutch provides the same 5.
  • Page 180 CLUTCHING DRIVEN DISASSEMBLY/ASSEMBLY spring only and has no torsional wind. 1. Remove driven clutch from the transmission input shaft. Do not attempt disassembly of the driven clutch from the outside snap ring. The driven clutch must be disassembled from the helix side. 2.
  • Page 181 CLUTCHING Heat Area Roller Lightly Apply Loctitet 680 To Tapered Portion Of Screw Dry Locking Agent Applied To New Screws Roller Retaining Screw 5. Inspect surface of rollers for flat spots and wear. Rollers must rotate freely on pins without excessive clearance.
  • Page 182 CLUTCHING 7. Check for movement of the shaft in the stationary 9. Remove the snap ring (F). sheave. The shaft should rotate freely until the stop plate makes contact with the sheave casting. Some lateral movement is allowable. amount of movement shall be limited to prevent the plate from raising out of the sheave pocket.
  • Page 183 CLUTCHING DRIVEN CLUTCH DRIVEN BUSHING SERVICE” later in this chapter for replacement of driven bushings . REASSEMBLY 2. Be sure to use the alignment marks for reassembly. 1. Simply reverse the steps of the disassembly process. Replace any parts needed. See “EBS EBS DRIVEN CLUTCH EXPLODED VIEW 1.
  • Page 184 CLUTCHING EBS DRIVEN BUSHING 8. Remove nut (C) (left hand thread) from puller rod and set aside. SERVICE 9. Remove adapters from puller. 10. Remove bushing and removal tool from adapters. EBS Driven - Bushing Removal Discard bushing. 1. Install puller adapter (Item 10) onto puller. EBS Driven - Bushing Installation 1.
  • Page 185 CLUTCHING 7. Turn clutch sheave counterclockwise until 8. Remove nut (C) (left hand thread) from puller rod bushing is removed and sheave comes free. and set aside. 8. Remove nut (C) (left hand thread) from puller rod 9. Remove installation tool and clutch sheave from and set aside.
  • Page 186 CLUTCHING 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 187 CLUTCHING TROUBLESHOOTING Situation Probable Cause Remedy Belt slippage -Belt worn out -Replace belt. -Water ingestion -Inspect and seal PVT system. -Belt contaminated with oil or grease -Inspect and clean. Belt burnt, thin -Abuse (continued throttle application when -Caution operator to operate machine within guidelines. spots vehicle is stationary, excess load) -Dragging brake...
  • Page 188 CLUTCHING NOTES 6.36...
  • Page 189 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 190: Roller Pin Removal Tool

    FINAL DRIVE WHEEL AND HUB TORQUE TABLE COMPONENT FT. LBS. (IN.LBS.) Front/Rear Wheel Nuts Front Hub Nut Rear Hub Nut CAUTION: Locking nuts, and bolts with preapplied locking agent should be replaced if removed. The self-locking properties of the nut or bolt are reduced 8.

  • Page 191: Final Drive

    FINAL DRIVE 10. Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly. New Cotter Key Front Hub Retaining Nut Torque 70 ft. lbs. (95 Nm) 11. With short, sharp jerks, remove drive shaft from front gearcase.
  • Page 192 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 193: 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 194 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 195 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 196: 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 197 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 198 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 199 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 200 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 201 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 202 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 203 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 204 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 205 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 206 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 207 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 208: Rear Hub Installation

    FINAL DRIVE 11. Remove both lower control arm bolts. 12. Remove bearing carrier. Rear Hub Nut Torque: 80 ft. lbs. (109 Nm) REAR HUB INSTALLATION Rear Wheel Nut Torque 27 ft. lbs. (37 Nm) 1. Insert bearing carrier on drive shaft. 2.

  • Page 209: Rear Hub Disassembly

    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 210: Rear Drive Shaft

    FINAL DRIVE CAUTION: Use an arbor press only on the outer race, as bearing damage may occur. 4. Install snap ring into groove. REAR DRIVE SHAFT REMOVAL 1. Remove rear hub and bearing carrier. (See Pages 7.19). 2. Tip hub outward and remove shaft from hub. 3.
  • Page 211 FINAL DRIVE DRIVESHAFT AND CV JOINT 2. Apply anti-seize compound to splines of shaft. 3. Install a new lock ring and install the shaft. HANDLING TIPS 4. Lift bearing carrier into place and install bolt to upper control arm. Torque bolt to 35 ft. lbs. (48 Care should be exercised during driveshaft removal Nm).
  • Page 212 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 213 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 214 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 215 TRANSMISSION Transmission Mounting ... . . Torque Specifications ....Special Tools ..... . Transmission Removal .

  • Page 216: Transmission Mounting

    TRANSMISSION TRANSMISSION MOUNTING 400/500 FRAME 2 BOLTS 2 BOLTS & NUTS 1 BOLT & NUT 1 BOLT 1 BOLT & NUT 2 BOLTS (UNDERNEATH)

  • Page 217: Torque Specifications

    TRANSMISSION TORQUE SPECIFICATIONS TRANSMISSION REMOVAL 1. Remove seat, rear rack, rear cab, air box, and COMPONENT FT. LBS. exhaust system, and right footwell (if required for access). (IN.LBS.) 2. Disconnect transmission vent line. Transmission Case Bolts 27--34 36--46 Bell Crank Nut 12--18 16--24 Transmission Fill/Drain Plug...
  • Page 218 TRANSMISSION 7. Remove the cotter key and bushings that secure 11. Disconnect the sway bar (A) from both sides. the auxiliary brake pedal to the frame. Remove right side upper and lower control arms (B). Refer to Chapter 7 for more details. 12.

  • Page 219: Transmission Installation

    TRANSMISSION TRANSMISSION Stabilizer Mounting Bolts INSTALLATION 1. Apply Polaris Premium All Season Grease (PN 2871423) to splines of front output shaft ,install new O-ring in prop shaft, insert output shaft into prop shaft. 2. Rotate transmission into place from right side of frame.
  • Page 220 TRANSMISSION Forward Front Transmission Support Bracket Apply anti-- seize to splines 9. Install the rear brake disc and brake caliper. 5. Loosely install lower front transmission mounting bolts, upper transmission mounting bolts, and all Caliper Mount Bolts: of the longer bolts and nuts. Tighten transmission 18 ft.lbs.

  • Page 221: Transmission Disassembly

    Polaris Remove Bellcrank Gearcase Lubricant to the proper level. See Page 2.11 Chapter 2 for proper fill procedures. Polaris AGL Gearcase Lubricant (PN 2873602) (12 oz.) 4. Drain and properly dispose of transmission oil. (PN 2873603) (Gallon) 17. Install the rear wheel nuts and torque to...
  • Page 222 TRANSMISSION 7. Remove the compression spring (A). Drain 5. Remove the park lockout. 8. Remove the detent star (B). Note how the detent star fits onto the splined shaft and the raised edge facing outward for reassembly. 9. Slide the detent pawl (C) off of the shift shaft (D). 6.
  • Page 223 TRANSMISSION NOTE: Note the the timing marks on the shift gears 13. Mark chain and gear rotation direction for (F) for reassembly. reassembly. Note location of chain tensioner cam. If fully extended, chain is worn beyond service limit. Replace chain and chain tensioner shoe. Timing Marks 12.
  • Page 224 TRANSMISSION 15. Remove the rear output gear (L) and chain (K), by 18. Remove the shift drum (O) from the gearcase by pulling the assembly straight upward. moving the drum up and to the right to clear the shift shaft. 19.
  • Page 225 TRANSMISSION Gear Cluster Disassembly Reverse Shaft 25. Remove the rest of the bearings from the shafts. 26. Remove the engagement dog from the reverse Needle shaft. Bearing (Q) 27. Remove the gear, split bearing, and washer from the reverse shaft. 33T Gear (R) Washer Retaining Ring...
  • Page 226 TRANSMISSION 28. To disassemble the shift fork rail remove the snap ring from the end of the shift rail on either side. REVERSE SHAFT CAUTION: Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury.
  • Page 227 TRANSMISSION 31. Use a 2 3/8” wrench to loosen and remove the front drive shaft snorkel tube (T). 33. Remove the second snap ring and spacer from the snorkel shaft. Front Drive Snorkel Assembly NOTE: Shim may or may not be present. Depending on input shaft tolerance.

  • Page 228: Transmission Assembly

    TRANSMISSION 35. To remove the remaining bearing on the snorkel 3. Inspect the output gear assembly (A), replace shaft (U), remove the retaining ring and press the bearings if needed. Inspect the 91T gear for nics , bearing off. chips, or abnormal worn teeth. TRANSMISSION ASSEMBLY 1.
  • Page 229 TRANSMISSION 6. Install the output gear assembly. Be sure to Photo For Reference Only! Snorkel properly mesh the snorkel shaft bevel gear with Shaft is installed in this procedure. the output bevel gear (A). Install the 4 torx screws (B) to secure the output gear assembly into place. Torque screws to 8--12 ft.lbs.
  • Page 230 TRANSMISSION 8. Once the gear backlash is found, to install the 10. Assemble the input shaft assembly if previously snorkel lock screw, you may have to rotate the disassembled. snorkel tube clockwise or counterclockwise slightly. This will allow the snorkel lock screw to A.
  • Page 231 TRANSMISSION 12. Inspect the shift drum for any damage or wear. Inspect the splines of the shift drum. Replace the O--rings on the end of the shift drum and lubricate them before assembly. 15. With the gearcase on it’s side, hold the gear cluster assembly and output assembly together.
  • Page 232 TRANSMISSION 17. Install the oil deflector shield into the gearcase. Tensioner Assembly - Top View Apply Loctitet 262 (PN 2871952) to the threads of the screws. Torque the screws to 16--30 in.lbs. (2--3.3 Nm). Forward 16--30 in.lbs. Spring Leg Tensioner 18.
  • Page 233 TRANSMISSION 20. Install the oil baffle into the gearcase. 23. Install the shift gear (16T) (G) on the shift drum shaft. Install the sector gear (F) in the bushing pocket on the left side. Aligning the timing marks on the gears. Timing Marks 21.

  • Page 234: Troubleshooting

    TRANSMISSION 26. Install the compression spring (K). 6--12 ft.lbs. (12--16 Nm) Tighten This Bolt First 30. Install the transmission switch and secure the switch with the retaining ring. 27. Install the park lockout assembly. Torque the park 31. Install the bellcrank onto the shift shaft. Note the lockout to 14--18 ft.lbs.

  • Page 235: Transmission Exploded View

    TRANSMISSION TRANSMISSION EXPLODED VIEW FOR REASSEMBLY Apply Polaris Crankcase Sealant Apply Loctitet 262 to the bolt threads. TORQUE SPECIFICATIONS Item Torque 27- - 34 fl.lbs. (37- - 46 Nm) 16- -30 in.lbs. (1.8- -3.4 Nm) 6- -12 ft.lbs. (8- -16 Nm) 12- -18 ft.lbs.
  • Page 236 TRANSMISSION TRANSMISSION EXPLODED VIEW CONT. Item Qty Description 1 Silent Chain 1 Bellcrank 1 Spacer 1 Screw 1 Retaining Ring 8 Screw 1 O- - ring 1 Gear Cover 1 Triple Lip Seal 1 Detent Pawl 2 Retaining Ring 1 Shift Shaft 1 Ball Bearing 2 Triple Lip Seal 1 Snorkel Tube...
  • Page 237 BRAKES Special Tools/Specifications/Torques ... Brake System Components ....Rear Caliper Exploded View .

  • Page 238: 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 239 BRAKES BRAKE SYSTEM MAIN COMPONENTS...
  • Page 240 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 241: 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 242 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 243: 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 244 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 245: 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 246: 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 247 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 248: 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. (24 Nm) Front Caliper Mounting Bolts Torque: 18 ft. lbs. (24Nm) 4. Slowly pump the brake lever until pressure has been built up.

  • Page 249: 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. 27 ft.

  • Page 250: 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 251: 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 252: 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 253 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 254: Rear Brake Pad

    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. (25 Nm) Caliper Slide Pin Torque: INSTALLATION 30- -35 ft. lbs. (41 Nm- -48 Nm) 1.

  • Page 255: 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 256: 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 257: Rear Brake Disc

    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 258 BRAKES REAR (AUXILIARY) BRAKE Remove the cotter key Remove the washers, bushings, and REMOVAL / INSTALL tension spring 2. Reverse the steps for installation, use a new cotter key during installation. Rear Brake Master Cylinder Removal / Install 1. If necessary, remove the rear brake line from the master cylinder.

  • Page 259: Troubleshooting

    BRAKES REAR BRAKE CALIPER EXPLODED VIEW Anvil Bolts APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT Torque 16--18 ft.lbs. Washers (22--25 Nm) Rear Caliper Bleed Piston Screws Torque 25--30 in. lbs. Bracket O--rings (2.80--3.40) Nm Seals Pads Slide Pins Torque Bushings 30--35 ft.lbs.
  • Page 260 BRAKES NOTES 9.24...
  • Page 261 ELECTRICAL Special Tools/Service Notes ....10.2 Gear Position Switch Test ....10.2 ECM Operation .

  • Page 262: Timing Light

    ELECTRICAL SPECIAL TOOLS GEAR POSITION INDICATOR SWITCH TEST PART NUMBER TOOL DESCRIPTION PV- -43568 Fluket77 Digital TRANSMISSION SWITCH Multimeter 2870630 Timing Light High/Low/Neutral/Reverse/Park Switch 2870836 Battery Hydrometer 2460761 Hall Sensor Probe Harness 2871745 Static Timing Light Harness ELECTRICAL SERVICE NOTES High Range Low Range Keep the following notes in mind when diagnosing an...

  • Page 263: Ecm Operation

    The ECM (Sure Power Box) integrates three The BAT_PROT output is protected from overloads electronic features found on the Polaris ATV. These and short circuits. If a overload or short circuit occurs features are alternator rectifier/regulator, engine that output turns off.

  • Page 264: Electrical Components

    ELECTRICAL IGNITION SYSTEM/ BASIC It will automatically turn back on when it has cooled. ELECTRICAL COMPONENTS Rev. BAT Alternator BAT+ 3 Phase Protect Input Regulator BAT_PROT Ignition Coil Ground ACC_PWR Bulkhead of ATV Hot Lamp CDI Box Engine Thermistor Temp Controller Wire Description...
  • Page 265 NOTE: To reset the Service Interval, follow the directions on the on Page 10.9, “Setting New Service Interval”. *Diagnostic Mode is for informational purposes only. Consumers should return the ATV to their Polaris dealer. See “Diagnostic Mode Operation” on the Ill.2 next page for more information.

  • Page 266: Diagnostic Mode

    ELECTRICAL operated at an RPM too low to keep the battery 3. Hold the mode/reverse override button as you charged. A low battery warning may also occur under turn the key switch on. normal operation if the machine is at idle and high 4.
  • Page 267 ELECTRICAL 297 Ohms in Low AWD On 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.
  • Page 268 ELECTRICAL 3. When the desired time increment is displayed, release the button and wait for the wrench to stop flashing. When the wrench stops blinking, your service hours are set. NOTE: If you scroll past the intended number, hold the button down until the count turns over to 0. You can then reset the number.

  • Page 269: Speedometer Removal

    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 and work help the instrument cluster slide into the pod light switch.

  • Page 270: Speedometer Troubleshooting

    ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 1 - - NO ALL WHEEL DRIVE Note: If AWD icon comes on, instru- ment cluster is O.K. Proceed to me- START HERE chanical tests (in Service Manual). Check the AWD icon on instrument clus- CHECK ter to verify it’s operation.
  • Page 271 ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 2 - - NO SPEEDOMETER AND/OR ODOMETER DISPLAY Note: Before starting diagnosis, turn off speedometer and wait 10 seconds, then turn on again to see if problem clears CHECK FOR REPLACE MINIMUM 6VDC SPEEDO ON PIN B TO START HERE PIN C 3 Pin Connector...
  • Page 272 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 CHECK FUNCTIONING...
  • Page 273 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. Orange/White- - 12V Constant CHECK 9. Blue White- - Engine Overheat Switch INSTRUMENT 2.
  • Page 274 ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 7 FUEL GAUGE DISPLAY NOT WORKING 16 Pin Connector START HERE 1. Orange/White- - 12V Constant 9. Blue White- - Engine Overheat Switch 2. Red/White- - 12V Switched 10. N/C 3. Grey/Orange- - Mode/Override button 11. N/C CHECK 4.

  • Page 275: Fan Motor Tests

    ELECTRICAL SPEEDOMETER COOLANT TEMPERATURE TROUBLESHOOTING CONT’D SENSOR (THERMISTOR) TEST TEST 7 - - - - RESET SPEEDOMETER If the key switch or engine stop switch is turned off with the vehicle in motion, the speedometer indicator needle may stick, indicating the speed at which the vehicle was traveling when the speedometer lost power.

  • Page 276: Etc Operation Test

    ELECTRICAL ETC OPERATION TEST (THERMISTOR) TEST” for Fan ON and Fan OFF readings on the previous page. Remove throttle block cover by carefully releasing all ELECTRONIC THROTTLE tabs around edge of cover. CONTROL (ETC) SWITCH Place transmission in neutral and apply parking brake.
  • Page 277 ELECTRICAL FLYWHEEL IDENTIFICATION Flywheel Identification Stamp Location The flywheel can be identified by the stamp mark in location A. Refer to “I.D.” location in chart below. Do not use the cast mark to determine flywheel application. Engine Application Comment Sportsman 400 -- EH42PLE 240W Sportsman 500 -- EH50PLE 240W...
  • Page 278 ELECTRICAL COMPONENTS OF EH42/50PLE / 240 WATT ALTERNATOR (DC/CDI IGNITION) NOTE: CDI boxes may look the same but have different internal circuitry. Be sure to always use the correct CDI box part number. Refer To Wiring Diagrams For Specified Stator Coil Resistance Resistor Check coil mount for good ground to engine (0-.2 )

  • Page 279: Ignition System Testing Flow Chart

    ELECTRICAL IGNITION SYSTEM TESTING FLOW CHART Whenever troubleshooting an electrical problem, first check all terminal connections to be sure they are clean and tight. Also be sure that colors match when wires are connected. Use the following pages as a guide for troubleshooting.

  • Page 280: Ignition System Troubleshooting

    ELECTRICAL IGNITION SYSTEM Test Connect Me- Reading TROUBLESHOOTING ter Wires To: CDI Output White/Blue to 300 Volts DC No Spark, Weak or Intermittent Spark Ground GSpark plug gap incorrect CDI CRANKING OUTPUT GFouled spark plug TEST GFaulty spark plug cap or poor connection to high tension lead The following peak voltage tests will measure the GRelated wiring loose, disconnected,...

  • Page 281: Alternator Output Test

    ELECTRICAL 8. With the engine running, turn the lights on and Current Draw Inspection engage parking brake lock to keep brake light on. Key Off 9. Repeat test, observing ammeter and tachometer. With lights on, charging should occur at or below 2000 RPM.

  • Page 282: Timing Check Procedure

    ELECTRICAL Stator Adjustment Alternator Current Output Reading should be no less than 30- -40V AC above 2000 RPM on each 1. Remove the magneto housing. ’leg’. 2. Remove the flywheel. NOTE: If one or more of the stator leg output AC 3.

  • Page 283: 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 284: Battery Identification

    Top View BATTERY *NOTE: All Low Maintenance batteries are fully charged and tested at the factory before Polaris sticker installation. Expected shelf life varies on storage conditions. As a general rule before placing the battery into service, check the battery condition and charge accordingly.

  • Page 285: Battery Charging

    ELECTRICAL Battery Check: 2. Test battery with a voltage meter or load tester to determine battery condition. This will determine 1. Check the date label on the side of the battery to the length of time required to charge the battery to calculate when to check voltage.

  • Page 286: Battery Installation

    ELECTRICAL SEALED LOW MAINTENANCE BATTERY - - OCV - OPEN Battery Location CIRCUIT VOLTAGE TEST Battery voltage should be checked with a digital multitester. Readings of 12.8 volts or less require further battery testing and charging. See charts and Load Test. *NOTE: Lead-acid batteries should be kept at or near a full charge as possible.

  • Page 287: Battery Activation/Service

    ELECTRICAL SEALED LOW MAINTENANCE 3. Install battery in vehicle with positive terminal toward the front. Coat threads of battery bolt with BATTERY OFF- -SEASON a corrosion resistant Nyogelt Grease (PN 2871329). STORAGE 4. Route cables so they are tucked away in front and behind battery.

  • Page 288: Conventional Battery Installation

    TERMINALS/TERMINAL BOLTS 3. Remove the battery. 4. Remove the filler caps and add distilled water Use Polaris corrosion resistant Dielectric Grease (PN only as needed to bring each cell to the proper 2871329) on battery bolts. See Battery Installation on level.
  • Page 289 ELECTRICAL 4. Install clear battery vent tube from vehicle to battery vent. WARNING: Vent tube must be free from obstructions and kinks and securely installed. If not, battery gases could accumulate and cause an Battery Hydrometer (PN 2870836) explosion. The vent tube should be routed away from frame and body to prevent contact with electrolyte.

  • Page 290: Off Season Storage

    ELECTRICAL CONVENTIONAL BATTERY voltage while cranking the engine. Continue the test for 15 seconds. During cranking the observed voltage CHARGING PROCEDURE should not drop below 9.5 volts. If the beginning voltage is 12.6 volts or higher and the cranking voltage drops below 9.5 volts during the test, replace the battery.

  • Page 291: High Beam Headlight Bulb Replacement

    ELECTRICAL HIGH BEAM HEADLIGHT BULB REPLACEMENT CAUTION: Do not service while headlight is hot. Serious burns may result. Protect lamp during install. Loosen Tighten Remove 3 screws 5. Carefully remove headlamp bulb from housing. 6. Remove the harness from the socket and replace the headlamp.
  • Page 292 ELECTRICAL 3. Unplug headlamp from wiring harness. 5 1/8″ (13 cm) *NOTE: The distance from the headlamp parting line 4. Remove O-Ring (C) from headlight pivot pins. to the end of the adjustment knob stop is 5 1/8, (13 (Both Sides) cm).
  • Page 293 ELECTRICAL 4. Tighten the screw. 25’ (7.6 m) LOWER HEADLAMP Lamp Center Height REMOVAL/INSTALLATION 2″ (5.1 cm) 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at Remove Harness the same height.

  • Page 294: Headlamp Switch

    ELECTRICAL the life of the lamp. 4. Install the new headlamp and harness assembly into the headlight assembly. HEADLAMP SWITCH 2. To remove the brake light electrical connector (B), Remove the headlight pod cover. Probe the press in on the tab on the connector to unlock the headlamp plug wires (Brown and Yellow) at back of connector and pull the connector from the bulb connector.

  • Page 295: Fuel Sender Test

    ELECTRICAL Brake Lamp Switch Squeeze Tabs -- Push Thru to Remove Brake Switch Location: Under front cover below headlight pod. If the rear work lights will not come on, check the following: 2. Disconnect wire harness from switch. 3. Connect an ohmmeter across switch contacts. GCheck for continuity between the switch Reading should be infinite (∞).

  • Page 296: Accessory Wire Hookup

    ELECTRICAL Orange / White Wires Accessory Wires ACCESSORY WIRE Located in Pod Area HOOKUPS 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.
  • Page 297 ELECTRICAL BASIC WINCH WIRING - - 2005 ATV MODELS 10.37...

  • Page 298: Starter System Troubleshooting

    ELECTRICAL STARTER SYSTEM drop tests on the starter system. TROUBLESHOOTING Voltage should not exceed Starter Motor Does Not Turn .1 DC volts per connection GBattery discharged. Low specific gravity STARTER MOTOR GLoose or faulty battery cables or corroded connections (see Voltage DISASSEMBLY Drop Tests) GRelated wiring loose, disconnected, or...
  • Page 299 ELECTRICAL Brush Length 5/16″ (.8 cm) Brush Length Service Limit: 5/16″ (.8 cm) 3. Remove brush plate and brushes. Measure length of brushes and replace if worn past the service limit. Replace springs if they are 4. Remove shims from armature shaft. NOTE: All discolored or have inadequate tension.

  • Page 300: Armature Testing

    ELECTRICAL ARMATURE TESTING STARTER ASSEMBLY 1. Remove armature from starter casing. Note order of shims on drive end for reassembly. 2. Inspect surface of commutator. Replace if excessively worn or damaged. 1. Place armature in field magnet casing. 2. Place shims on drive end of armature shaft with phenolic washer outermost on shaft.

  • Page 301: Starter Drive

    Pinion Gear - Anti Kick-out Shoe, Garter Spring Replacement If the garter spring is damaged, the overrun clutch Polaris Premium Starter Drive Grease may fail to return properly. The replacement spring is (PN 2871460) (PN 7042039). Use either of the following methods to remove and install a new garter spring.

  • Page 302: Starter System

    ELECTRICAL STARTER SYSTEM 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 303 ELECTRICAL WIRING DIAGRAM - - 2005 SPORTSMAN MODELS...
  • Page 304 ELECTRICAL WIRING DIAGRAM - - 2005 SPORTSMAN MODELS...
  • Page 305 Brake Pad Assembly, Front, 9.12 Brake Pad Inspection, 2.31 A-Arm Replacement, 5.16 Brake Pad Installation, Rear, 9.18 Air Filter Service, 2.21 Brake Pad Removal, Front, 9.10 Alternator Output Test, 10.21 Brake Pad Removal, Rear, 9.17 Auxiliary Brake Removal, 9.22 Brake System Inspection, 2.31 Brake System Main Components, Brake System Operation,...
  • Page 306 CDI Output Test, 10.20 Cylinder Head Assembly, 3.26 Cylinder Head Disassembly, 3.21 Charging System Break Even Test, 10.21 Cylinder Head Inspection, 3.21 Charging System Testing, 10.23 Cylinder Head Installation, 3.46 Choke Adjustment, 2.14 Cylinder Head Reconditioning, 3.23 Cleaning the ATV, 2.38 Cylinder Head Removal, 3.19, 3.20...
  • Page 307 EBS Drive Clutch Inspection, 6.24 Frame, Nuts, Bolts, Fasteners, 2.35 Front / Rear Storage Compartment, 2.35 EBS Driven Clutch Bushing Service, 6.32 Front Axle Installation, EBS Driven Clutch Disassembly, 6.27, 6.31 Front Axle Removal, EBS Moveable Sheave Bushing Inspection, 6.25 Front Cab Removal / Installation, EBS One Way Drive Clutch Inspection, 6.24...
  • Page 308 Glossary of Terms, 1.16 MAINTENANCE AND LUBRICATION, 2.3, 2.4, Maintenance, ATV Component Location, Headlamp Service, 10.31, 10.32, 10.33 Master Cylinder Installation, 9.9 Headlamp Switch Testing, 10.34 Master Cylinder Removal, Headlight Adjustment, 10.32, 10.33 Model & Serial Number Location, Model Identification, High Engine Coolant Temperature, 10.5 High/Low Battery Voltage,...
  • Page 309 Publication Numbers, Spark Plug Maintenance, 2.18 Special Tools, 1.7, 1.8, 3.2, 4.6, 5.2, 7.2, 8.3, 9.2 Pump Shaft Oil Seal Installation, 3.41 Special Tools, PVT, PVT Assembly, Specifications, 1.4, 1.5, 1.6 PVT Disassembly, Specifications, PVT Drying, Specifications, Brake, PVT Maintenance, Specifications, Cooling System, 3.5, 3.7 PVT Operation,...
  • Page 310 Tensioner Blade Installation, 3.44 Thermostat Installation, 3.50 U--Joint Assembly, Throttle Cable Adjustment, 2.16 U--Joint Disassembly, Throttle Operation, 2.13 Unit of Measure Conversion Table, 1.15 Tie Rod Inspection, 2.28 Timing Check Procedure, 10.22 Tire Inspection, 2.34 Tire Pressure, 2.34 Valve Clearance, 2.26 Tire Tread Depth, 2.34...
  • Page 311 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.

This manual is also suitable for:

2005 sportsman 400

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