Polaris Trail Blazer Service Manual
  1. Manuals
  2. Brands
  3. Polaris Manuals
  4. Offroad Vehicle
  5. Trail Blazer
  6. Service manual
Polaris Trail Blazer Service Manual

Polaris Trail Blazer Service Manual

Hide thumbs Also See for Trail Blazer:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
Table Of Contents
666
Table of Contents

Advertisement

Quick Links

Download this manual See also: Owner's Manual

Advertisement

Table of Contents
loading

Related Manuals for Polaris Trail Blazer

Summary of Contents for Polaris Trail Blazer

  • Page 2 ....1.13 Model Specifications (1999) Trail Blazer ......1.14-1.15 Trail Boss .
  • Page 4 The carburetor I.D. number (A) is in one of the follow- Forward 2-Stroke ing locations: 4 stroke models - right side center of the carburetor body 2 stroke models - right side of carbu- retor body near choke plunger boss Forward 4-Stroke Carburetor I.D. Number Polaris Sales Inc. 4/99...
  • Page 5 Current ATVs and 6X6 Vehicles have a 17 digit Vehicle Identification Number (VIN). The VIN is organized as follows: Digits 1-3: World Manufacturer Identifier. For Polaris ATVs, this is 4XA. Digits 4-9: Vehicle Descriptor Section. Digits 10-17: Vehicle Indicator Section. Digits 4-8 of the VIN identify the body style, drive type, engine type, and emissions equipment.

  • Page 6: General Information

    Describes all current Polaris ignition systems. Provides working knowledge of ignition system theory and diagnostics. Charging System Diagnostics 9913278 Describes all current Polaris charging systems. Provides work- ing knowledge of charging system theory and diagnostics. Polaris Variable Transmissions 9913987 Theory, disassembly, assembly and troubleshooting of the (PVT) Polaris PVT system.
  • Page 7 GENERAL INFORMATION Paint Codes 1999 Paint Codes Model Item Color Material No. (Polaris #) PPG Ditzler No. Big Boss 500 6X6 Springs / Eddie B Green 8520150 (P195) 44931 Front Rack Rims Aluminum (P117) Sportsman 500 RSE Springs / Rims...
  • Page 8 14-18 ft. lbs. (19-25) 10 x 1.25 26-30 ft. lbs. (36-41) *To convert Ft. lbs. to N-m multiply foot pounds by 1.383. *To convert N-m to Kg-m move the decimal point to the left one position. Polaris Sales Inc. 4/99...
  • Page 9 ......9844 ... . 4/99 Polaris Sales Inc.
  • Page 10 Kilograms - force per square cm x 98.1 = Kilopascals (kPa) °C to °F: 9 (°C + 40) ÷ 5 - 40 = °F °F to °C: 5 (°F + 40) ÷ 9 - 40 = °C Polaris Sales Inc. 4/99...
  • Page 11 5/16 0.3125 5/16 9 x 1.25 5/16 0.3125 5/16 10 x 1.25 11/32 0.3437 11/32 10 x 1.50 0.339 11/32 11 x 1.50 0.375 12 x 1.50 13/32 0.406 13/32 12 x 1.75 13/32 0.406 13/32 4/99 Polaris Sales Inc.
  • Page 12 Because removal damages seals, replace any oil or grease seals removed with new parts. Polaris recommends the use of Polaris lubricants and greases, which have been specially formulated for the top performance and best protection of our machines. In some applications, such as the engine, warranty coverage may become void if other brands are substituted.
  • Page 13 (approx. 14KV - 32KV) through induction. Secondary voltage is high enough to ionize (jump) the air gap at the spark plug. Ignition Generating Coil: Exciter coil, primary charge coil. Stator plate coil which generates primary ignition voltage. 4/99 1.10 Polaris Sales Inc.
  • Page 14 Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings; Spark Plug Reach: Length of threaded portion of spark plug. Polaris uses 3/4″ (2 cm) reach plugs. Static Timing: Ignition timing when engine is at zero RPM.
  • Page 15 Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle. 4/99 1.12 Polaris Sales Inc.

  • Page 16: Special Tools

    FAX number listed below. Dealers serviced by a distributor should follow tool ordering procedures established by their respective distributor parts department. SPX Service Solutions 28635 Mound Road Warren, MI 48092-5509 TO PLACE AN ORDER 1--800--328--6657 www.polaris.spx.com Tool Order FAX Number 1--800--328--6657 Polaris Sales Inc. 1.13 4/99...
  • Page 17 GENERAL INFORMATION 1999 Model Specifications TRAIL BLAZER MODEL: ..MODEL NUMBER: A99BA25CA ENGINE MODEL: EC25PFE13 CARBURETION JETTING CHART Type ....
  • Page 18 Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PP2 Polaris Premium TC-W3 2 Stroke Oil *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant SUSPENSION / CHASSIS DRIVE TRAIN (Concentric Drive) Body Style .
  • Page 19 ..6000 RPM Idle RPM±200 ....700 RPM Compression Pressure ..(Std) ±15% 4/99 1.16 Polaris Sales Inc.
  • Page 20 N / A Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PP2 Polaris Premium TC-W3 2 Stroke Oil *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 21 ..5600 RPM Idle RPM±200 ....600 RPM Compression Pressure ..(Std) ±15% 4/99 1.18 Polaris Sales Inc.
  • Page 22 N / A Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PP2 Polaris Premium TC-W3 2 Stroke Oil *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W40 Synthetic Engine Lubricant SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 23 ..5600 RPM Idle RPM±200 ....600 RPM Compression Pressure ..(Std) ±15% 4/99 1.20 Polaris Sales Inc.
  • Page 24 Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PP2 Polaris Premium TC-W3 2 Stroke Oil *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS...
  • Page 25 Operating RPM±200 ..6000 RPM Idle RPM±200 (lights off) ..1200 RPM Compression Pressure ..(Std) ±15% 4/99 1.22 Polaris Sales Inc.
  • Page 26 2.5 oz. (75ml) PDD* Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 27 ..5700 RPM Idle RPM±200 ....600 RPM Compression Pressure ..(Std) ±15% 4/99 1.24 Polaris Sales Inc.
  • Page 28 Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PP2 Polaris Premium TC-W3 2 Stroke Oil *PPS Polaris Premium Synthetic Gear Case Oil *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PP4 Polaris 0W/40 Synthetic Engine Lubricant SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 29 ..5700 RPM Idle RPM±200 ....600 RPM Compression Pressure ..(Std) ±15% 4/99 1.26 Polaris Sales Inc.
  • Page 30 Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PP2 Polaris Premium TC-W3 2 Stroke Oil *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PDD Premium Demand Drive Hub Fluid...
  • Page 31 ..5700 RPM Idle RPM±200 ....600 RPM Compression Pressure ..(Std) ±15% 4/99 1.28 Polaris Sales Inc.
  • Page 32 Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PP2 Polaris Premium TC-W3 2 Stroke Oil *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid...
  • Page 33 Operating RPM±200 ..6500 RPM Idle RPM±200 (lights off) ..1200 RPM Compression Pressure ..(Std) ±15% 4/99 1.30 Polaris Sales Inc.
  • Page 34 Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PPS Polaris Premium Synthetic Gear Case Oil *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 35 Operating RPM±200 ..6000 RPM Idle RPM±200 (lights off) ..1200 RPM Compression Pressure ..(Std) ±15% 4/99 1.32 Polaris Sales Inc.
  • Page 36 Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 37 ..6000 RPM Idle RPM±200 (lights off) ..1200 RPM Compression Pressure ..(Std) ±15% *Remingtont Special Edition 4/99 1.34 Polaris Sales Inc.
  • Page 38 . . . 1 oz. (30ml) PP4* Lubricant Key *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 39 Operating RPM±200 ..6000 RPM Idle RPM±200 (lights off) ..1200 RPM Compression Pressure ..(Std) ±15% 4/99 1.36 Polaris Sales Inc.
  • Page 40 . . . 1 oz. (30ml) PP4* Lubricant Key *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 41 SPECIFICATIONS 2000 Model Specifications TRAIL BLAZER MODEL: ..MODEL NUMBER: A00BA25CA ENGINE MODEL: EC25PFE13 CARBURETION JETTING CHART Type ....
  • Page 42 Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PP2 Polaris Premium TC-W3 2 Stroke Oil *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant SUSPENSION / CHASSIS DRIVE TRAIN (Concentric Drive) Body Style .
  • Page 43 ..5800 RPM Idle RPM±200 ....700 RPM Compression Pressure ..(Std) ±15% Polaris Sales Inc. 1.40 99/00 ATV Update 12/99...
  • Page 44 Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PP2 Polaris Premium TC-W3 2 Stroke Oil *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS...
  • Page 45 Idle RPM±200 (lights off) ..1300 RPM Compression Ratio ..9.2:1 Compression Pressure ..(Std) ±15% Polaris Sales Inc. 1.42 99/00 ATV Update 12/99...
  • Page 46 N / A Shift Selector Box . . . N / A *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 47 Idle RPM±200 (lights off) ..1300 RPM Compression Ratio ..9.2:1 Compression Pressure ..(Std) ±15% Polaris Sales Inc. 1.44 99/00 ATV Update 12/99...
  • Page 48 Shift Selector Box . . . 1 oz. (30 ml) PP4* *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 49 Idle RPM±200 (lights off) ..1300 RPM Compression Ratio ..9.2:1 Compression Pressure ..(Std) ±15% Polaris Sales Inc. 1.46 99/00 ATV Update 12/99...
  • Page 50 Shift Selector Box . . . 1 oz. (30 ml) PP4* *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 51 3.1/1 (Shaft) Brake (Hand) ....S/L Hyd. Disc Brake (Auxiliary Foot) ..Hydraulic Polaris Sales Inc. 1.48 99/00 ATV Update 12/99...
  • Page 52 2.5 oz. (75 ml) PDD* Shift Selector Box . . . N / A *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid TIRES LOAD CAPACITY Tire Size - Front .
  • Page 53 ..6000 RPM Idle RPM±200 (lights off) ..1200 RPM Compression Pressure ..(Std) ±15% Polaris Sales Inc. 1.50 99/00 ATV Update 12/99...
  • Page 54 2.5 oz. (75ml) PDD* Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 55 ..5700 RPM Idle RPM±200 ....600 RPM Compression Pressure ..(Std) ±15% Polaris Sales Inc. 1.52 99/00 ATV Update 12/99...
  • Page 56 Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PP2 Polaris Premium TC-W3 2 Stroke Oil *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid...
  • Page 57 ..5700 RPM Idle RPM±200 ....600 RPM Compression Pressure ..(Std) ±15% Polaris Sales Inc. 1.54 99/00 ATV Update 12/99...
  • Page 58 Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PP2 Polaris Premium TC-W3 2 Stroke Oil *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PDD Premium Demand Drive Hub Fluid...
  • Page 59 ..5700 RPM Idle RPM±200 ....600 RPM Compression Pressure ..(Std) ±15% Polaris Sales Inc. 1.56 99/00 ATV Update 12/99...
  • Page 60 Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PP2 Polaris Premium TC-W3 2 Stroke Oil *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PDD Premium Demand Drive Hub Fluid...
  • Page 61 3.1/1 (Shaft) Brake (Hand) ....S/L Hyd. Disc Brake (Auxiliary Foot) ..Hydraulic Polaris Sales Inc. 1.58 99/00 ATV Update 12/99...
  • Page 62 2.5 oz. (75 ml) PDD* Shift Selector Box . . . N / A *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid TIRES LOAD CAPACITY Tire Size - Front .
  • Page 63 ..1200 RPM Compression Ratio ..10/2 Full Stroke Compression Pressure ..(Std) ±15% Polaris Sales Inc. 1.60 99/00 ATV Update 12/99...
  • Page 64 Shift Selector Box . . . 1 oz. (30 ml) PP4* *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 65 ..6500 RPM Idle RPM±200 (lights off) ..1200 RPM Compression Pressure ..(Std) ±15% Polaris Sales Inc. 1.62 99/00 ATV Update 12/99...
  • Page 66 Shift Selector Box . . . 1 oz. (30ml) PP4* *Lubricant *PPS Polaris Premium Synthetic Gear Case Oil *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 67 ..6000 RPM Idle RPM±200 (lights off) ..1200 RPM Compression Pressure ..(Std) ±15% *Remingtont Special Edition Polaris Sales Inc. 1.64 99/00 ATV Update 12/99...
  • Page 68 . . . 1 oz. (30ml) PP4* Lubricant Key *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 69 ..6000 RPM Idle RPM±200 (lights off) ..1200 RPM Compression Pressure ..(Std) ±15% Polaris Sales Inc. 1.66 99/00 ATV Update 12/99...
  • Page 70 . . . 1 oz. (30ml) PP4* Lubricant Key *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .
  • Page 71 NOTES...
  • Page 72 CHAPTER 2 MAINTENANCE Periodic Maintenance Chart ....2.1-2.2 Pre-Ride Inspection ......Recommended Lubricants and Capacities .
  • Page 74 Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for re- placement parts. Always use genuine Polaris parts. HCAUTION: Due to the nature of these adjustments, it is recommended that service be performed by an authorized Polaris dealer.
  • Page 75 MAINTENANCE Periodic Maintenance Chart, Cont. CHASSIS Frequency (Whichever comes first) Item Hours Calendar Miles Remarks (Km) General Lubrication 50 hrs 3 months 500 (800) Lubricate All Fittings, Pivots, Cables, Etc. " Front Hubs/Fluid Check 50 hrs 6 months 500 (800) Check monthly "...
  • Page 76 Hub Fluid trickles out. Do not force fluid into hub. Brake Fluid Polaris DOT 3 Brake Fluid -Fill between “Min” & “Max” indicators on plastic reservoir. Cold Weather Kits for 4 Cycle ATVs and 6x6 Oil Tank Cover -- PN 287187...
  • Page 77 MAINTENANCE Maintenance Products Polaris Premium Lubricant and Maintenance Product Part Numbers Part No. Description Engine Lubricant 2870791 Fogging Oil 2871281 Engine Oil (Quart) Premium 4 Synthetic 0-W40 (4-Cycle) 2871567 Engine Oil (16 Gallon) Premium 4 Synthetic 0-W40 (4-Cycle) 2871098 Premium 2 Cycle Engine Oil (Quart)
  • Page 78 Gear Case stick. NOTE: See page 2.10 for Lubricant models without a dipstick. Brake Fluid Polaris DOT 3 Fill master cylinder reservoir to As required. Change fluid every 2 years. Brake Fluid 1/4″ (6.4mm) from top, or between indicated lines. See page 2.57 .
  • Page 79 Polaris U-Joint Locate grease fitting and grease with grease gun. Semi-annually Joints Grease¢ ¡ Ball Joint Polaris All Season Locate grease fitting on back side of struts and Semi-annually Grease¢ grease with grease gun. ¡ Front A-Arm Pivot Polaris All Season...
  • Page 80 Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) ¡ Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) © Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or ¢ Mobilegrease Special Polaris Sales Inc.
  • Page 81 Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) ¡ Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) © Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or ¢ Mobilegrease Special 4/99 Polaris Sales Inc.
  • Page 82 Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) ¡ Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) © Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or ¢ Mobilegrease Special Polaris Sales Inc.
  • Page 83 (Late) Approximately 30 ml. (30 cc) = 1 fluid oz.. *(PPS = )Polaris Premium Synthetic Gearcase Lubricant ¡ Capacity when disassembled completely. Capacity at change (after draining) is approximately 20 fl. oz.. (592 ml.) © Middle Angle Drive (Complete Assembly) is P/N 1341239 ¢...
  • Page 84 S Current gearcases in use are shown by illustration. Refer to illustrations to determine type, and follow instruc- tions to check / change gearcase lubricant. S The correct gearcase lubricant to use is Polaris Premium GL5 80-90 Gear Lube, or an equivalent lubricant with a GL5 rating.
  • Page 85 Catch and discard used oil properly. 2. Clean and reinstall drain plug using a new sealing washer. 3. Remove fill plug. Drain plug 4. Add proper amount of lubricant. Refer to page 2.10. 5. Install fill plug. 6. Check for leaks. 4/99 Polaris Sales Inc.
  • Page 86 Specified Lubricant: through the fill plug. Hypoid or non-hypoid gearlube can Polaris Front Gearcase Lube PN 2871653 be used, provided it is API GL5 rated..Or API GL5 80-90 Gearlube 5. Reinstall fill plug. Tighten securely (14 ft. lbs/1.93 kgm).
  • Page 87 2.10 to determine type. Follow instructions on following pages to check / change transmission lubricant. Transmission Dipstick TRANSMISSION SPECIFICATIONS Specified Lubricant: Polaris Premium Synthetic Gearcase Lubricant PN 2871477 (Gallon) PN 2871478 (12 oz..) ..Refer to Quick Reference Capacity: Chart page 2.10...
  • Page 88 3. Clean and reinstall the drain plug with a new sealing washer. Torque to specification. View From Front 4. Remove fill plug. 5. Add Polaris Premium Synthetic Gearcase Lubricant to proper level as described above. 6. Check for leaks. 7. Reinstall propshaft shield.
  • Page 89 The dipstick should be screwed in Recoil fully to check. Do not overfill. If overfilled, excess oil will Drain Starter be expelled through the vent hose. Pinion Drain 5. Reinstall dipstick. 6. Check for leaks. 4/99 Polaris Sales Inc.
  • Page 90 (where applicable). 1. Loosen jam nut (A). 2. Turn adjuster bolt (B) out until it touches the frame, and then an additional 1/2 turn. 3. Tighten the jam nut securely while holding the adjuster bolt. Forward Polaris Sales Inc. 4/99...
  • Page 91 (Disconnect Low range linkage rod end from pivot arm on Sportsman 500 style linkage). 6. Place gear selector in neutral. Make sure the transmission bell cranks are engaged in the neutral position detents. 4/99 Polaris Sales Inc.
  • Page 92 The jam nuts must be tightened with both front and rear rod ends parallel to each other. If jam nuts are properly tightened, the rod should rotate Ill. 3 freely 1/4 turn without binding. 12. Repeat steps 7-10 for the High/Reverse rod. Polaris Sales Inc. 4/99...
  • Page 93 8. Turn linkage rod (A) to shorten or lengthen rod until end stud (B) is centered on hole in gear selector arm (C). 9. Hold rod end parallel to mounting surface and tighten jam nuts securely. 4/99 Polaris Sales Inc.
  • Page 94 (in-line adjusters) or until seated fully over adjuster. Choke Lever Freeplay - 2 Cycle 4 Cycle 1/8 - 1/4″ (.3 - .6 cm) Ill. 2 Adjust at carburetor Polaris Sales Inc. 4/99...
  • Page 95 Always check throttle cable freeplay after adjusting idle speed and adjust if necessary. 4. Turn the screw in (to richen) or out (to lean) the mixture. Adjust air screw for best throttle response and smooth idle. 5. Re-adjust idle speed if necessary. 4/99 Polaris Sales Inc.
  • Page 96 Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be permanently damaged. 6. Refer to pilot screw adjustment procedure. Drill Stop Plug Pilot Screw Spring Washer O-Ring Plug Polaris Sales Inc. 4/99...
  • Page 97 5. Again turn the pilot screw in or out slowly to obtain the highest idle RPM. Pilot Screw 6. Turn the pilot screw out (counterclockwise) 1/8 to 1/4 turn. 7. Re-adjust idle speed to specified RPM (1300 +100). 4/99 Polaris Sales Inc.
  • Page 98 NOTE: Adjusting the idle speed affects throttle cable freeplay and electronic throttle control (ETC) adjustment. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary. Idle Screw Idle Speed: Refer to Specifications VM Carburetor (2 Cycle Engines) Idle Screw Polaris Sales Inc. 4/99...
  • Page 99 If cable is routed properly and in good condition, repeat adjustment procedure. Direction of travel 1/16″ - 1/8″ Freeplay Ill. 3 Switch Plunger Must Be Held In By Cable Tension Throttle Cable Adjuster Lock Nut Ill. 4 4/99 Polaris Sales Inc.
  • Page 100 (C) is just starting to move off of its stop). NOTE: The pump stop keeps the pump arm from rotat- ing any farther down than the idle position so no visual alignment of marks is necessary. 8. Tighten the locknut. Forward Polaris Sales Inc. 4/99...
  • Page 101 8. Reinstall the ETC cover removed in step 1. , making sure cover gasket is properly seated. If not, moisture can enter the ETC and damage the Marks Must Align When switch. Throttle Begins To Open 4/99 Polaris Sales Inc.
  • Page 102 MAINTENANCE Oil Pump Bleeding (2 Cycle Engines) Oil Pump Bleeding Procedure Oil Outlet 1. Fill the oil reservoir with Polaris injector oil. Oil Inlet 2. Loosen the pump bleed screw one full turn. Allow Bleed Screw oil to flow from the bleed screw for five to ten seconds.
  • Page 103 1. Remove clamps, securing lines to filter. 2. Remove lines and replace filter with arrow pointing in direction of oil flow (towards pump). 3. Reinstall clamps on each line and check for leaks. Arrow Indicates Direction of Flow To Pump From Tank 4/99 Polaris Sales Inc.
  • Page 104 4. Install new filter and clamps onto fuel lines with arrow pointed in direction of fuel flow. To Carburetor 5. Install clamps on fuel line. 6. Turn fuel valve ON. 7. Start engine and inspect for leaks. 8. Reinstall fuel tank. Polaris Sales Inc. 4/99...
  • Page 105 4. Inspect the drained fuel for water or sediment. 5. Tighten drain screw. 6. Turn fuel valve to “on”. 7. Start machine and check for leaks. Fuel Valve 2-Strokes (400cc) Remove Plug Carburetor Bowl 4/99 Polaris Sales Inc.
  • Page 106 Cylinder Leakage Service Limit (4-Stroke) 10 % (Inspect for cause if leakage exceeds 10%) Engine Mounts Inspect rubber engine mounts (A) for cracks or damage. Fastener Torque - Engine Check engine fasteners and ensure they are tight. Polaris Sales Inc. 4/99...
  • Page 107 8. Reinstall battery, attaching positive (+) (red) cable first and then the negative (-) (black) cable. 9. Reattach vent hose making sure it is properly routed and not kinked or pinched. 10. Coat terminals and bolt threads with Polaris dielectric grease. 11. Reinstall battery cover and holder strap.
  • Page 108 8. Install spark plug and torque to 14 ft. lbs. Spark Plug Gap .024 - .028″ (.6 - .7 mm) Ignition Timing Refer to Electrical chapter for ignition timing procedure. Engine-To-Frame Ground Inspect engine-to-frame ground cable connection. Be sure it is clean and tight. Polaris Sales Inc. 4/99...
  • Page 109 S Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels often during the break-in period. S Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. Coolant Strength / Type Test the strength of the coolant using an antifreeze hydrometer.
  • Page 110 1. Remove reservoir cap. Inner splash cap vent hole must be clear and open. 2. Fill reservoir to upper mark with Polaris Premium 60/40 Anti Freeze / Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.
  • Page 111 Reinstall oil cap. Pressure Cap Gen IV - Remove the four screws securing front rack. Re- move front cover by placing your fingers under the front of Gen IV the cover and pulling upward. Front Cover Rack 4/99 Polaris Sales Inc.
  • Page 112 MAINTENANCE Air Cleaner, 2 Cycle Air Filter Service (Trail Blazer Style) 1. Release seat latch and lift up on the rear of the seat. Gray Collar 2. Pull the seat back and free of the tabs. Yellow Boot 3. Remove the primary air filter box.
  • Page 113 (B) is below the air intake opening of the air box intake duct (A). Improper installa- tion will restrict airflow to the engine possibly resulting in a rich mixture and poor running. 4/99 Polaris Sales Inc.
  • Page 114 2. If compressed air is used never exceed a pressure of 40 PSI. Always use a dispersion type nozzle to prevent filter damage and clean from the outside to the inside. Polaris Sales Inc. 4/99...
  • Page 115 2. If compressed air is used never exceed a pressure of 40 PSI. Always use a dispersion type nozzle to prevent filter damage and clean from the inside to the outside. 4/99 Polaris Sales Inc.
  • Page 116 Make certain foam is flush with front edge of airbox so air cannot enter engine breather fitting hole with- out first passing through the foam. 335 Air Intake Foam - Correct Position Incorrect Incorrect 335 Tank Foam; Correct Position Polaris Sales Inc. 4/99...
  • Page 117 1. Remove drain plug from end of sediment tube. 2. Drain tube. 3. Reinstall drain plug. Sediment Tube Sediment Tube 4/99 Polaris Sales Inc.
  • Page 118 Location A Breather Hose 1. Be sure breather line is routed properly and secured in place. CAUTION: Make sure lines are not kinked or pinched. In-Line Breather Filter Location B Foam Breather Filter Location C Air Box Polaris Sales Inc. 4/99...
  • Page 119 On 4-cycle engines, some en- gine oil will be lost if crankcase drain is opened. S On the Trail Blazer, the recoil handle must be be- hind the heat shield for it to seal properly. If it is not sealed properly, water may enter the recoil housing and damage components.
  • Page 120 Screw in completely to check Oil and Filter Change (4 Stroke) Recommended Engine Oil: 1. Place vehicle on a level surface. Polaris Premium 4 All Season 2. Run engine two to three minutes until warm. Stop Synthetic, 0W/40, PN 2871281 engine.
  • Page 121 Crankcase Drain 21. Remove dipstick and fill tank with 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. 22. Place gear selector in neutral and set parking brake. 23. Start the engine and let it idle for one to two minutes.
  • Page 122 The camshaft lobes should be pointing downward. Crankshaft-to-Camshaft Centerline 7. Verify accurate TDC positioning by observing the “T” mark aligned with the pointer in the timing inspection hole. In this position there should be clearance on all valves. Polaris Sales Inc. 4/99...
  • Page 123 2 Feeler Gauges .006″ (.15 mm) 3. When clearance is correct, hold adjuster screw and tighten locknut securely 4. Re-check the valve clearance. 5. Repeat adjustment procedure if necessary until clearance is correct with locknut secured. 4/99 Polaris Sales Inc.
  • Page 124 11. Reinstall the spark plug high tension lead. 12. Reinstall the fuel tank. 13. Reinstall the fuel tank shroud. 14. Reinstall the left and right body panels. Cover Bolt Torque: 72 in. lbs. Spark Plug Torque: 14 ft. lbs. Polaris Sales Inc. 4/99...
  • Page 125 Polaris parts. WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component re- pair and adjustment be performed by an authorized Polaris Dealer. Only a qualified technician should replace worn or damaged steering parts. Use only genuine Polaris replacement parts.
  • Page 126 .3 cm) more than front rim measure- ment. NOTE: The steering post arm (frog) can be used as an indicator of whether the handle- bars are straight. The frog should always point straight back from the steering post. Polaris Sales Inc. 4/99...
  • Page 127 Incorrectly ing arm or the steering frog, respectively, to prevent Correctly Tightened Tightened rod end damage. Jam Nut Jam Nut 8. After alignment is complete, torque jam nuts to 12-14 ft. lbs. (1.66-1.93 kg-m). 4/99 Polaris Sales Inc.
  • Page 128 2. Turn wheel until front hub fill/check plug is in either the 4:00 or 8:00 position. 3. Remove fill/check plug. 4. Add Polaris Demand Drive Hub Fluid if necessary until fluid trickles out. NOTE: Do not force the fluid into the hub under pressure or seal damage may occur.
  • Page 129 S Never run the engine in an enclosed area. The exhaust con- tains poisonous carbon monoxide gas. S Do not go under the machine while it is inclined. Failure to heed these warnings could result in serious personal injury or death. 4/99 Polaris Sales Inc.
  • Page 130 Keep fluid level in the master cylinder reservoir between “Min” & “Max” lines at all times. Maximum Use Polaris DOT 3 brake fluid (PN 2870990). Check brake system for fluid leaks. Minimum Check brake for excessive travel or spongy feel.
  • Page 131 If free play is correct and brake pedal travel is still exces- sive, air may be trapped somewhere in the system. Bleed the hydraulic auxiliary brake system in a conventional manner, following the procedure outlined in the Brake chapter. 4/99 Polaris Sales Inc.
  • Page 132 (See Illustration). Tighten the lock nut securely. (See Illustration 1 and 3). 3. Check brakes to be sure they are not dragging. Read- just pedal deflection if necessary. Side View Auxiliary Brake Adjustment - Type II Ill. 3 Polaris Sales Inc. 4/99...
  • Page 133 MAINTENANCE Drive Chain Drive Chain and Sprocket Inspection Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers. The sprockets and outer rollers require periodic lubrication. Lubricate the chain with Polaris O-Ring Chain Lubricant (PN 2871079).
  • Page 134 Verify proper chain deflection measurement after Step 5 - Torque nut side of pinch bolts. pinch bolts are tight, and readjust if necessary. 6. Reinstall chain guard (where applicable). 7. Adjust stone guard to allow 1/8″ clearance between sprocket and guide. Polaris Sales Inc. 4/99...
  • Page 135 Rear Axles (Tapered Roller Bearings) Loosen Eccentric clamp bolts (Step 2) 1. Loosen chain guard. 2. Loosen two eccentric clamp bolts. 3. Loosen caliper mounting bracket bolts. Loosen (2) caliper mounting bracket bolts (Step 3) 4/99 Polaris Sales Inc.
  • Page 136 5. Insert a pin punch through the sprocket hub and into Alternate Adjustment Method -- Pin Punch the eccentric axle housing. (Step 5 and 6) 6. Roll the vehicle ahead or back to adjust chain slack to the proper dimension. Polaris Sales Inc. 4/99...
  • Page 137 9. Tighten caliper mounting bracket bolts 10-12 ft. lbs. (14 - 17 Nm) 10.Reinstall chain guard (where applicable). NOTE: Reposition chain guide to allow 1/8″ (.3 cm) clearance between sprocket and guide. 10-12 ft. lbs 4/99 Polaris Sales Inc.
  • Page 138 When this bolt is tightened the chain deflection may change. Check deflection and adjust again if needed. Center and Front Drive Chain Adjustment: 1/4-1/2″ (6-13 mm) with 18 lbs. load (8.18 kg) 1/4″-1/2″ (6-13 mm) with 18 lbs load. Front Front 45 ft. lbs. (62Nm) Center Pin Punch 45 ft. lbs. (62Nm) Polaris Sales Inc. 4/99...
  • Page 139 Total slack, however, should be adjusted to 1/4″-1/2″ (6-13 mm). 6x6 Chain Deflection Middle Axle: 1 1/4″ to 1 1/2″ Middle Axle: (30-38 mm) 1 1/4- 1 1/2″(30- 38 mm) Rear Axle: 1/4-1/2″(6-13 mm) Rear Axle: 1/4″-1/2″ (6-13 mm) 4/99 Polaris Sales Inc.
  • Page 140 Shock Spanner Wrench PN 2870872 Controls Checkcontrolsforproperoperation,positioningandad- justment. Position Master Cylinder and Switch to Provide Clearance Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body. Polaris Sales Inc. 4/99...
  • Page 141 If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end of nut goes into taper Tapered nuts - install with on wheel. tapered side against wheel 4/99 Polaris Sales Inc.
  • Page 142 Frame, Nuts, Bolts, Fasteners Periodically inspect the tightness of all fasteners in accor- dance with the maintenance schedule. Check that all cot- ter pins are in place. Refer to specific fastener torques listed in each chapter. Polaris Sales Inc. 4/99...
  • Page 143 NOTES...
  • Page 144 CHAPTER 3 ENGINE Torque Specifications - 2 Stroke ....Torque Specifications - 4 Stroke ....Torque Patterns .
  • Page 146 5-6.5 (7-9) 5-6.5 (7-9) Spark Plug (New) 14mm 9-11 (12-15) 9-11 (12-15) 9-11 (12-15) Spark Plug (Used) 14mm 17-20 (23-27) 17-20 (23-27) 17-20 (23-27) Drive Clutch Bolt 7/16 - 20 40 (55) 40 (55) 40 (55) Polaris Sales Inc. 4/99...
  • Page 147 5-6.5 (7-9 Nm) Stator Plate 5-6.5 (7-9 Nm) 5-6.5 (7-9 Nm) 5-6.5 (7-9 Nm) Starter Motor 5-6.5 (7-9 Nm) 5-6.5 (7-9 Nm) 5-6.5 (7-9 Nm) Spark Plug 14mm 9-11 (12-15 Nm) 9-11 (12-15 Nm) 9-11 (12-15 Nm) 4/99 Polaris Sales Inc.
  • Page 148 Tighten cylinder head, cylinder base, and crankcase fasteners in 3 steps following the sequence outlined below. Cylinder Head Cylinder Base Cylinder Head 250 / 300 250 / 300 / 400 Cylinder Head Crankcase Crankcase Cylinder Base 400L 250/300 335 / 425 / 500 Crankcase 335 / 425 / 500 Polaris Sales Inc. 4/99...
  • Page 149 Clearance Svc. Model Disp. ( in./mm) (in./mm) Gap (Installed) Clearance Limit (CCs) in. (mm) in. (mm) (in. / mm) Trail Blazer EC25PF 2.8346 / 72 2.362 / 60 .009-.018 .0011-.0021 .006 / .15 Trail Boss (.23-.46) (.03-.05) Xpress 300 EC28PF 2.935 / 74.5 2.561 / 65...
  • Page 150 Stem oil clearance .0014-.0024″ (.035-.062 mm) .0016-.0026″ (.040-.067 mm) Limit .0059″ (.15 mm) Overall length 3.976″ (101.0 mm) 3.984″ (101.2 mm) Valve Spring Free length 1.654″ (42.0 mm) Limit 1.575″ (40.0 mm) Squareness .075″ (1.9 mm) 2.5° Polaris Sales Inc. 4/99...
  • Page 151 Connecting rod big end radial clear- .0004-.0015″ (.011-.038 mm) ance Limit .0020″ (.05 mm) Crankshaft Crankshaft runout limit .0024″ (.06 mm) KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power Take Off Side 4/99 Polaris Sales Inc.
  • Page 152 3.976″ (101.0 mm) 3.976″ (101.0 mm) 3.984″ (101.2 mm) 3.984″ (101.2 mm) Valve Spring Overall length 1.654″ (42.0 mm) 1.654″ (42.0 mm) Limit 1.575″ (40.0 mm) 1.575″ (40.0 mm) Squareness .075″ (1.9 mm) .075″ (1.9 mm) Polaris Sales Inc. 4/99...
  • Page 153 .0020″ (.05 mm) .0020″ (.05 mm) Crankshaft Crankshaft runout limit .0024″ (.06 mm) .0024″ (.06 mm) KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power Take Off Side 4/99 Polaris Sales Inc.
  • Page 154 Radiator Cap Pressure Test 1. Remove radiator cap and test using a cap tester (commercially available). 2. The radiator cap relief pressure is 13 lbs. for all models. Polaris Sales Inc. 4/99...
  • Page 155 Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems, and Forward comes pre-mixed and ready to use.
  • Page 156 *It may be necessary to loosen engine mounts and move engine slightly to access water pump on some 4 stroke models. Special tool PN 2872105 is required to replace mechanical seal with engine in frame. Polaris Sales Inc. 3.11 4/99...
  • Page 157 18. Disconnect coolant temperature sensor wire (where applicable). 19. Remove engine to chassis ground cable (where applicable). 20. Remove all engine mount nuts and / or engine mount plates. 21. Remove engine through right side of frame. 4/99 3.12 Polaris Sales Inc.
  • Page 158 2 Cycle Engine Break-In Period is defined as the first 3 hours of engine operation, or one full tank of fuel. 1. (2 - Cycle) Pre-mix the first FULL tank of fuel at a 40:1 ratio with Polaris Premium 2 Cycle Lubricant.
  • Page 159 PTO end and magneto end to separate case half from crankshaft. 5. After removing the crankshaft, thoroughly clean the bearings and lubricate. Check the crankshaft runout as outlined in Crankshaft Inspection procedure on page 3.40. 4/99 3.14 Polaris Sales Inc.
  • Page 160 .036″ (.9mm). Crankshaft Main Bearing Inspection 1. Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris Premium 2 engine oil. Carefully check each main bearing on the shaft. NOTE:Due to extremely close tolerances, the bearings must be inspected visually, and by feel.
  • Page 161 If PTO end bearings have not yet been installed, mea- sure distance as shown in photo at right, then pro- ceed to Step 2. 2. Measure distance from crank wheel to bearing seating surface (A). Record measurement. 4/99 3.16 Polaris Sales Inc.
  • Page 162 EC 25 and EC28 engines: For EC25PF - PN 3083629 - .008″ (.2 mm); and PN 3083630 - .004″ (.1 mm). For EC28PF and EC38PL - PN 3084778 - .008″ (.2 mm); and PN 3084779 - .012″ (.3 mm). Polaris Sales Inc. 3.17 4/99...
  • Page 163 Keystone rings are beveled to the inside. This bevel must be toward the top of the piston (letter and/or number marks near end gap of ring face upward. Straight Edge Piston Ring Cutaway Keystone Ring 4/99 3.18 Polaris Sales Inc.
  • Page 164 23. Reinstall piston pin. Warm piston crown lightly with heat gun to ease pin installation. CAUTION: Do not overheat piston. Do not apply heat to piston rings or loss of temper may result. 24. Repeat Step 17 through 20 for other C-clip. Polaris Sales Inc. 3.19 4/99...
  • Page 165 Coil must be installed with numbers out Use Sealer 6. Seal wire harness grommet to crankcase using RTV silicone sealant. 7. Refer to electrical section of this manual for starter motor inspection. Reinstall starter motor. 4/99 3.20 Polaris Sales Inc.
  • Page 166 EXAMPLE: A (Step 2) B (Step 3) -- Target clearance (.2-.6 mm) Total thickness of .3--.7mm shims required Spacer shim part numbers: PN 3083671 .15 mm/.006″ PN 3083672 .3 mm/.012″ PN 3083673 .6 mm/.024″ Polaris Sales Inc. 3.21 4/99...
  • Page 167 S Must be used with metal drive gear Engine oil check valve should release at 2 to 7 PSI Pump Bleed Screw Drive Gear Plastic (3084825) subs to Metal (3083429) Bushing Bushing end play adjustment shims 4/99 3.22 Polaris Sales Inc.
  • Page 168 9. Ratchet Friction Ring and Pawl Guide 10. Friction Spring 11. Ratchet Pawl Bracket 12. Reel Housing 13. Pawl Return Spring 14. Recoil Rope 15. Rope Handle 16. Recoil Cup 17. Timing Plug 18. Bushing Polaris Sales Inc. 3.23 4/99...
  • Page 169 1. If the recoil spring was removed, reinstall it in its recess in the flywheel housing. The spring should spiral counterclockwise toward the center. 2. Grease spring with Polaris low temperature grease. 3. Install recoil spring retaining plate. 4. Grease and install spring hook, making sure it properly engages the spring end.
  • Page 170 4. Check recoil and ratchet operation. 5. When reinstalling assembly onto engine, use Loctite 518 Gasket Eliminator between the flywheel housing and crankcase. Polaris Sales Inc. 3.25 4/99...
  • Page 171 3. Hold flywheel with holder tool and remove flywheel nut. Flywheel Holder PN 8700229 Holder 4. For starter removal, remove bolts retaining starter bracket on PTO side, and two bolts (A) on mag side. 5. Remove flywheel using puller. Flywheel Puller PN 2871043 4/99 3.26 Polaris Sales Inc.
  • Page 172 150 Watt alternator shown at right. 200 Watt alternator shown at right. 7. Remove six cylinder head bolts using a 12 mm socket. Note the position of the bleeder plug for the coolant system. Bleeder plug Polaris Sales Inc. 3.27 4/99...
  • Page 173 Reassembly Note: When reinstalling C clips, make sure that the open end of the retainer clip points either up or down, not to the side. 13. Remove piston pin using Polaris piston pin puller (PN 2870386). 14. Refer to page 3.35-3.40 to inspect parts.
  • Page 174 ENGINE EC38PL Engine Disassembly, Cont. 15. Remove slotted left hand thread crankshaft nut using Polaris tool (PN 2870967). Clockwise to Remove Reassembly Note: Refer to page 3.1 for torque spec- ification upon reassembly. 16. Remove five crankcase bolts (A) indicated in the photo at right with a 12 mm socket.
  • Page 175 Reassembly Note - Counter Balance Shaft: For reassembly of counterbalancer shaft after crankcase assembly, heat areas (D) and (E) and press the ba- lancer and bracket back into place. 4/99 3.30 Polaris Sales Inc.
  • Page 176 28. Tap cases apart with a soft faced hammer. as an assembly Inspect crankshaft runout and components. See page 3.40. Shims used to adjust crankshaft end play. Follow procedure on page 3.16-3.17. Align marks upon reassembly. Polaris Sales Inc. 3.31 4/99...
  • Page 177 Reassembly Notes: 1. Before assembling the crankcase, calculate crankshaft end play and place shims between as required. Follow procedure on page 3.16 - 3.17. Refer to page 3.40 for crankshaft inspection. 4/99 3.32 Polaris Sales Inc.
  • Page 178 1. Apply a small amount of putty or clay to the top of one impeller blade (A). 2. Assemble impeller and bearing/seal housing on balancer shaft. Polaris Sales Inc. 3.33 4/99...
  • Page 179 Next, press the oil seal into the seal bore until the weep hole is visible. Now press the water seal in until flush with the out- er edge of the seal bore. Press Water Seal Flush 4/99 3.34 Polaris Sales Inc.
  • Page 180 The valve should release between 2 and 7 PSI. The check valve is located on the cylinder. NOTE: Refer to page 3.22 for check valve testing on 250 and 300cc engines. 400 Check Valve Polaris Sales Inc. 3.35 4/99...
  • Page 181 (calculate clearance with a new piston) and recondition the cylinder or replace piston as necessary. Refer to page 3.4 for piston to Measure 3/8″ (10 mm) up from bottom of skirt cylinder clearance specifications. 4/99 3.36 Polaris Sales Inc.
  • Page 182 Refer to page 3.4 for specifications. Piston Ring NOTE:Always check piston ring installed gap after re- boring a cylinder or when installing new rings. NOTE:Install rings with mark facing UP. Mark Faces Up Polaris Sales Inc. 3.37 4/99...
  • Page 183 Selecting a hone which will straighten as well as remove material from the cylinder is very important. Using a common spring loaded finger type glaze breaker for honing is never advised. Polaris recommends using a rigid hone or arbor honing machine which also has the capability of oversizing.
  • Page 184 Replace pin and bearing if there is any resistance to rotation or excessive axial or radial movement. If play or roughness is evident with a new pin and bearing, replace the connecting rod. Piston Pin Measurement Locations Polaris Sales Inc. 3.39 4/99...
  • Page 185 When HIGH .005 (.13mm) rebuilding and straightening a crankshaft, runout must be as close to zero as possible. NOTE:Maximum allowable runout is .004I (.1 mm) for 2 stroke engines and .0024 for 4 stroke engines. 4/99 3.40 Polaris Sales Inc.
  • Page 186 ENGINE 4 Stroke Engine Service Polaris Sales Inc. 3.41 4/99...
  • Page 187 ENGINE Notes 4/99 3.42 Polaris Sales Inc.
  • Page 188 Oil Type ....Polaris Premium 4 Synthetic (PN 2871281); or API certified “SH” 5W30 oil Capacity ....
  • Page 189 Scavenged oil is directed through another crankcase oil passage through the outlet hose to the thermo-valve, and directly back to the oil tank. When the oil reaches a pre-determined temperature, the thermo-valve opens to direct oil through the cooler, and then back to the tank Oil Cooler Thermo Valve 4/99 3.44 Polaris Sales Inc.
  • Page 190 Cam Shaft Oil Jet Delivery Pipe Journal (Fixed) Crank Pin Through Front Left Bypass Oil Filter Cylinder Head Bolt Passage Oil Passage Indirect Crankshaft In Cylinder Lubrication Crankcase Stator Plate Delivery Pipe Oil Gallery Bushing Polaris Sales Inc. 3.45 4/99...
  • Page 191 The one-way valve requires very little maintenance. If engine oil drains into the sump when the engine is off, inspect the valve sealing surface for debris or damage. Inspect the return spring for distortion or damage. 4/99 3.46 Polaris Sales Inc.

  • Page 192: Eh50Pl Oil Flow Diagram

    One Way Valve Cam Lobe Large End Bearing Delivery Pipe Cam Shaft Metal Oil Jet Journal Crank Pin Bypass Oil Filter Through Cylinder Stud Front Left Delivery Pipe Crankshaft Crankcase Delivery Pipe Oil Gallery Polaris Sales Inc. 3.47 4/99...
  • Page 193 ENGINE ES33PFEngine Exploded View Cylinder/ Crankcase Cylinder Head Valve Train Crankshaft and Piston 4/99 3.48 Polaris Sales Inc.
  • Page 194 ENGINE EH50PL Engine Exploded View Crankcase Cylinder/ Cylinder Head Crankshaft Valve Train and Piston Polaris Sales Inc. 3.49 4/99...
  • Page 195 CAUTION: The plug is under spring tension. Maintain inward pressure while removing. 6. Remove the two 6x25 mm cam chain tensioner flange bolts. 7. Tap lightly on tensioner body with a soft face hammer and remove tensioner. 4/99 3.50 Polaris Sales Inc.
  • Page 196 4. Measure free length of tensioner spring. Replace spring excessively worn. Compare specifications on page 3.5 - 3.8. 5. Replace entire tensioner assembly if any part is worn or damaged. Polaris Sales Inc. 3.51 4/99...
  • Page 197 1. Loosen rocker shaft retaining bolt (A) to remove shaft. 2. Remove the four bolts securing rocker shaft supports, and remove the supports, rocker shaft and rocker arms as an assembly, being careful not to drop the dowel pins into the engine. 4/99 3.52 Polaris Sales Inc.
  • Page 198 NOTE: Always inspect camshaft lobe if rocker arms are worn or damaged. Wave washer EH50PL 3. Measure O.D. of rocker shaft. Inspect it for wear or damage. Compare to specifications on page 3.5 - 3.8. Polaris Sales Inc. 3.53 4/99...
  • Page 199 6. Inspect rocker adjuster screws for wear, pitting, or damage to threads of the adjuster or locknut. Replace all worn or damaged parts. NOTE: The end of the adjuster screw is hardened and cannot be ground or re-faced. EH50PL 4/99 3.54 Polaris Sales Inc.
  • Page 200 Camshaft Removal 1. Remove camshaft sprocket inspection cover. 2. Loosen three camshaft sprocket bolts. 3. Remove camshaft end cap and O-Ring. 4. Inspect camshaft end cap (thrust face) for wear. Replace if worn or damaged. Polaris Sales Inc. 3.55 4/99...
  • Page 201 8. Inspect cam sprocket teeth for wear or damage. Replace if necessary. 9. Slide camshaft out the PTO side of the cylinder head. Decompressor Shaft Inspect for Areas of Decompressor Ball Tooth Wear or Damage Retainer Sleeve 4/99 3.56 Polaris Sales Inc.
  • Page 202 Check operation of mechanism as outlined in step 1 of Removal (above). NOTE: When shaft is properly installed, actuator ball will be held in the “out” position. It is important to note that spring pressure is very light. Polaris Sales Inc. 3.57 4/99...
  • Page 203 ID. Compare to specifications on page 3.5 - 3.8. Journal Replace camshaft if damaged or if any part is worn past the service limit. Replace cylinder head if camshaft journal bore is damaged or worn excessively. 4/99 3.58 Polaris Sales Inc.
  • Page 204 ENGINE ES33PF, EH50PL Engine Engine Disassembly, Cont. Cylinder Head Exploded View, ES33PF ES33PF ES33PF 1. Remove the two 6mm flange bolts from cylinder head. Polaris Sales Inc. 3.59 4/99...
  • Page 205 ENGINE ES33PF, EH50PL Engine Cylinder Head Exploded View, EH50PL 1. Remove the two 6mm flange bolts (A) from cylinder head. EH50PL 4/99 3.60 Polaris Sales Inc.
  • Page 206 New head gasket must be installed with sealant facing upward. Cylinder Head Inspection 1. Thoroughly clean cylinder head surface to remove ES33PF all traces of gasket material and carbon. CAUTION: Use care not to damage sealing surface. Polaris Sales Inc. 3.61 4/99...
  • Page 207 NOTE:The valve springs should be positioned with the tightly wound coils against the cylinder head on progres- sively wound springs (A). 3. Push valve out, keeping it in order for reassembly in the same guide. 4/99 3.62 Polaris Sales Inc.
  • Page 208 Valve Spring Free Length Coil Fatigue/ Squareness 5. Remove valve seals. CAUTION: Replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup. Polaris Sales Inc. 3.63 4/99...
  • Page 209 5. Measure diameter of valve stem with a micrometer in three places and in two different directions (six measurements total). Compare to specifications on page 3.5 - 3.8. Measure valve stem in several places. 4/99 3.64 Polaris Sales Inc.
  • Page 210 NOTE: If valve guides are replaced, valve seats must be reconditioned. Refer to Valve Seat Reconditioning for pro- cedure. Combustion Chamber Clean all accumulated carbon deposits from combustion chamber and valve seat area with a soft wire brush. Polaris Sales Inc. 3.65 4/99...
  • Page 211 3. Heat cylinder head in an oven or use a hot plate to bring cylinder head temperature to 212° F (100° C). CAUTION: Do not use a torch to heat cylinder head or warpage may result from uneven heating. Head temperature can be checked with a pyrometer or a welding temperature stick. 4/99 3.66 Polaris Sales Inc.
  • Page 212 Continue to rotate reamer clockwise during removal of the tool. 6. Clean guides thoroughly with hot soapy water and a nylon brush. Rinse and dry with compressed air. Apply clean engine oil to guides. Polaris Sales Inc. 3.67 4/99...
  • Page 213 Prussian Blue™ paste to the valve seat. If using an interference angle (46°) apply black permanent marker to the entire valve face (A). 6. Insert valve into guide and tap valve lightly into place a few times. 4/99 3.68 Polaris Sales Inc.
  • Page 214 9. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve. Lapping is not required with an interference angle. Polaris Sales Inc. 3.69 4/99...
  • Page 215 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. 4/99 3.70 Polaris Sales Inc.
  • Page 216 2. Pour a small amount of clean, high flash point solvent into the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage. 3. Repeat for exhaust valves by pouring fluid into exhaust port. Polaris Sales Inc. 3.71 4/99...
  • Page 217 1. Remove cam chain guide at front of cylinder. 2. Loosen all four oil pipe banjo bolts and then remove the EH50PL Shown bolts and eight sealing washers. Remove the pipes. EH50PL 3. Loosen hose clamps and remove coolant inlet hose. EH50PL 4/99 3.72 Polaris Sales Inc.
  • Page 218 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. Remove dowel pins from crankcase. Polaris Sales Inc. 3.73 4/99...
  • Page 219 The top rail has a locating tab on the end which fits into a notch (A) in the upper oil ring land of the piston. 5. Remove the top rail first followed by the bottom rail. 6. Remove the expander. 4/99 3.74 Polaris Sales Inc.
  • Page 220 1/2″ Down From Top of Cylinder two different directions, front to back and side to side, on three different levels (1/2″ down from top, in the middle, and 1/2″ up from bottom). 1/2″ Up From Bottom Polaris Sales Inc. 3.75 4/99...
  • Page 221 2. Subtract this measurement from the maximum cylinder measurement obtained in step 5 above. 5 mm Piston to Cylinder Clearance Refer to Page 3.5 - 3.8 Piston Piston Pin Piston O.D.: Refer to Page 3.5 - 3.8 4/99 3.76 Polaris Sales Inc.
  • Page 222 6. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Replace piston and rings if ring-to-groove clearance exceeds service limits. Piston Ring-to-Groove Clearance Refer to Specifications on Page 3.5 - 3.8 Polaris Sales Inc. 3.77 4/99...
  • Page 223 Wipe cylinder bore with an oil rag immediately to re- move residue and prevent rust. Piston Ring Piston Ring Installed Gap Top Ring Second Ring Oil Ring Refer to Specifications on Page 3.5 - 3.8 4/99 3.78 Polaris Sales Inc.
  • Page 224 Calculate bushing clearance. Replace bushing if clearance exceeds the service limit. 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) Polaris Sales Inc. 3.79 4/99...
  • Page 225 4. Remove bolts and carefully remove stator assembly, being careful not to damage crankshaft bushing on stator plate. 5. Replace crankshaft seal. 6. Remove oil passage O-Ring. 7. Remove large sealing O-Ring from outer edge of stator plate. 4/99 3.80 Polaris Sales Inc.
  • Page 226 Stretch chain tight on a flat surface and apply a 10 lb. (4.53 kg) load. Measure length of a 20 pitch section of chain. Replace if worn past service limit. Chain Service Limit: 5.407″ (13.7 cm) Polaris Sales Inc. 3.81 4/99...
  • Page 227 2. Inspect free length of spring and check coils for distortion. One Way Valve Spring Free Length: Std: 1.450″ (3.68 cm) 3. Inspect valve for wear. 4. Check seat area for nicks or foreign material that may prevent proper sealing of valve. 4/99 3.82 Polaris Sales Inc.
  • Page 228 CAUTION: Do not strike the oil pump shaft at an angle or the shaft may bend, causing irreparable damage. Tap only lightly on the pump shaft if necessary. 4. Remove the Mag (RH) crankcase from the PTO case. Polaris Sales Inc. 3.83 4/99...
  • Page 229 3. Inspect drive gear teeth for cracks, damage or excessive wear. 4. Remove three oil pump retaining bolts and pump. 5. Inspect mating surface of crankcase and oil pump. Check for nicks, burrs, or surface irregularities. 4/99 3.84 Polaris Sales Inc.
  • Page 230 7. Clean screen thoroughly. 8. Remove pump body screw and feed chamber cover. 9. Measure pump end clearance using a feeler gauge and straight edge. Pump End Clearance: Std: .001-.003 (.0254-.0762 mm) Wear Limit: .004 (.1016 mm) Polaris Sales Inc. 3.85 4/99...
  • Page 231 6. Tighten screw securely. 7. Install screen on pump body. 8. Install oil pump on crankcase and torque bolts to 6 ft. lbs. (.828 kg-m). Oil Pump Attaching Bolt Torque: 6 ft. lbs. (.828 kg-m) 4/99 3.86 Polaris Sales Inc.
  • Page 232 The outer race of each bearing should fit tightly in the crankcase. The in- ner race should be firm with minimal side to side move- ment and no detectable up and down movement. Polaris Sales Inc. 3.87 4/99...
  • Page 233 Refer to page 3.40. Max Runout: .0024″ (.06 mm) 5. Measure the connecting rod big end radial clearance. Big End Radial Clearance: Refer to page 3.5-3.8. 6. Inspect the crankshaft main bearing journals for scoring and abnormal wear. 4/99 3.88 Polaris Sales Inc.
  • Page 234 3. Drive the water pump mechanical seal out of the crankcase from inside to outside. Note: The new mechanical seal must be installed after the crankcases are assembled, using a special tool. See Mechanical Seal Installation. Polaris Sales Inc. 3.89 4/99...
  • Page 235 CAUTION: Press only on outer race of bearing to prevent bearing damage. 70mm (2.755″) driver- For crankshaft main bearings. 46mm (1.810″) For counter balancer bearings. 28mm (1.100″) For pump shaft bearing. 4/99 3.90 Polaris Sales Inc.
  • Page 236 2. Measure the distance from the PTO crankcase mating surface to the main bearing using a dial caliper and a straight edge. 3. Subtract the thickness of the straightedge from the measurement obtained in Step 2 and record. PTO Case Depth Polaris Sales Inc. 3.91 4/99...
  • Page 237 9. Subtract the thickness of the existing shim from the result of step 8 to determine if a different shim Crankshaft End Play: is required. The result must be within the specified range listed below. .008″-.016″ (.02-.04 cm) 4/99 3.92 Polaris Sales Inc.
  • Page 238 7. Subtract the thickness of the existing shim from .008″-.016″ (.02-.04 cm) the result of step 6 to determine if a different shim is needed. The result must be within the specified range listed below. Polaris Sales Inc. 3.93 4/99...
  • Page 239 2. Drive or press the seal into place using a 25mm (.985″) seal driver, until flush with the bottom of the mechanical seal bore. 3. Lubricate the seal lip with grease. 4/99 3.94 Polaris Sales Inc.
  • Page 240 3. Remove the tool. 4. Install the crankcase flange bolts and tighten in 3 steps in a criss-cross pattern to specified torque. Crankcase Bolt Torque: Crankcase Sealant: 14 ft. lbs. (19-20 Nm) PN 2871557 Polaris Sales Inc. 3.95 4/99...
  • Page 241 Ill. 2 and turn T-Handle clockwise until it contacts water pump shaft. Continue rotating until outer portion of mechanical seal is sepa- rated from the metal seal body. T-Handle Main Puller Body Ill. 2 4/99 3.96 Polaris Sales Inc.
  • Page 242 7. Special tool (PN 5131135) is required to install the new mechanical seal. This tool is available separately and it is also included in the Crankshaft/Water Pump Seal Installation Kit (PN 2871283). Ill. 6 Polaris Sales Inc. 3.97 4/99...
  • Page 243 Tighten the nut to the specified torque. Slotted Nut Torque: 35-51 ft. lbs. (4.71-6.86 kg-m) Tensioner Blade Installation 1. Install the tensioner blade and tighten the mounting bolt to specified torque. Tensioner Blade Mounting Bolt Torque: 6 ft. lbs. (.828 kg-m) 4/99 3.98 Polaris Sales Inc.
  • Page 244 2. Install the oil ring top rail. NOTE: The top rail has a locating tab to prevent rota- tion. The tab must be positioned in the notch on the side of the piston as shown (A). Polaris Sales Inc. 3.99 4/99...
  • Page 245 6. Install the other circlip with the gap facing up or down and tang outward. (See Caution with step 3 above). Push the piston pin in both directions to make sure the clips are properly seated in the groove. 4/99 3.100 Polaris Sales Inc.
  • Page 246 Install the cylinder with a slight rocking motion until the rings are captive in the sleeve. 4. Remove the ring compressor. 5. Push the cylinder downward until fully seated on the base gasket. Polaris Sales Inc. 3.101 4/99...
  • Page 247 8. Tighten the cylinder bolts in three steps in a criss cross pattern and torque to specifications. 9. Install the two 6mm bolts. Cylinder Bolt Torque: 10mm - 46 ft. lbs. (6.348 kg-m) 6mm - 6 ft. lbs. (.828 kg-m) 4/99 3.102 Polaris Sales Inc.
  • Page 248 *Torque bolts to 11 ft. lbs. (1.52 kg-m) *From this point, tighten bolts evenly 90° (1/4 turn) *Finally, tighten another 90° (1/4 turn) *Install two 6mm bolts and torque to 6 ft. lbs. (.828 kg-m) Polaris Sales Inc. 3.103 4/99...
  • Page 249 Top Dead Center (TDC). Camshaft Timing 1. Apply Polaris Premium Starter Drive grease to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil.
  • Page 250 9. Check all cam timing marks to verify proper cam timing, and install the cam chain tensioner body with a new gasket. 10. After tensioner installation, rotate engine at least two revolutions and re-check marks/timing. Polaris Sales Inc. 3.105 4/99...
  • Page 251 ENGINE ES33PF, EH50PL Engine Assembly Camshaft Timing Crankshaft to Camshaft Centerline Dots Sprocket Alignment Pin Single TDC Mark Aligned TDC Mark Rotation Do Not Use Advance Marks 4/99 3.106 Polaris Sales Inc.
  • Page 252 4. Install the stator plate being careful not to damage the seal. Align timing reference marks on the plate and crankcase. Be sure the plate is fully seated. NOTE: This is a static timing mark. Strobe timing should be performed after start up. Polaris Sales Inc. 3.107 4/99...
  • Page 253 2. Apply grease to the drive bushing in the crankcase and all moving surfaces of the starter drive mechanism. Install the starter drive. 3. Install recoil housing gasket and recoil housing. Starter Drive Grease: PN 2871460 4/99 3.108 Polaris Sales Inc.
  • Page 254 Oil Pipes Install the oil pipes with new sealing washers. Tighten all bolts evenly to specified torque. Oil Pipe Bolt Torque: 20 ft. lbs. (2.76 kg-m) Polaris Sales Inc. 3.109 4/99...
  • Page 255 The spring should fit tightly on friction plate. 5. Remove ratchet pawl with spring and inspect. Replace spring or ratchet pawl if worn, broken, or damaged. NOTE:Long arm of spring engages reel. Short end against pawl. 4/99 3.110 Polaris Sales Inc.
  • Page 256 11. Pull knot out of of recoil reel. Untie knot. Remove rope from reel. Polaris Sales Inc. 3.111 4/99...
  • Page 257 10. Torque friction plate retaining bolt to 5-6 ft. lbs. (7-9 Nm). 11. Reinstall recoil housing using a new gasket. Seal stator wire harness grommet with RTV silicone. 4/99 3.112 Polaris Sales Inc.
  • Page 258 Weak ignition (loose coil ground, faulty coil, stator, or ETC switch) ETC switch mis-adjusted Restricted air filter (main or pre-cleaner) Improperly assembled air intake system Restricted engine breather system Oil contaminated with fuel Restricted oil tank vent Polaris Sales Inc. 3.113 4/99...
  • Page 259 -Oil pump cable not allowing pump to return to idle position -Lubricate or replace cable Engine coolant found in -Water pump gasket -Inspect/replace gasket counter balance assem- -Water pump seal -Replace bly (Liquid cooled mod- els) 4/99 3.114 Polaris Sales Inc.
  • Page 260 Air in oil pump / lines Air in cooling system / low coolant level Poor fuel quality Restricted exhaust Incorrect ignition timing Spark plug heat range incorrect Fan blade incorrectly installed or damaged Air box, carburetor, or exhaust modified Polaris Sales Inc. 3.115 4/99...
  • Page 261 PVT not operating properly Restricted exhaust muffler Carburetor vacuum slide sticking/diaphragm damaged Dirty carburetor Piston Failure - Scoring Lack of lubrication Dirt entering engine through cracks in air filter or ducts Engine oil dirty or contaminated 4/99 3.116 Polaris Sales Inc.
  • Page 262 Spark plug cap cracked/broken Ignition coil faulty Ignition or kill switch circuit faulty Ignition timing incorrect Sheared flywheel key Poor connections in ignition system System wiring wet Valve sticking Air leaks in intake Lean condition Polaris Sales Inc. 3.117 4/99...
  • Page 263 Faulty hot light circuit Thermostat stuck closed or not opening completely Temperature Too Low Thermostat stuck open Leak at Water Pump Weep Hole Faulty water pump mechanical seal (coolant leak) Faulty pump shaft oil seal (oil leak) 4/99 3.118 Polaris Sales Inc.
  • Page 264 CHAPTER 4 FUEL SYSTEM/CARBURETION Jetting Guidelines ......Main Jet Selection ......Fuel and Oil Tank Asm.
  • Page 266 Carburetors on Polaris ATV and 6x6 vehicles are calibrated for an altitude of 0-3000 ft. (0-900 meters) and ambi- ent temperatures between +40 and +80° F (+5° to +26° C). Carburetors must be re-calibrated if operated outside the production temperature and/or altitude range.
  • Page 267 Fuel Tank Assembly / Oil Tank Assembly Typical 2 Cycle model with tank- mounted fuel valve. Details vary by model. Refer to parts manual. Forward Fuel tank-mounted valve Oil Level Sensor Vent Hose Oil Tank Oil Filter Forward Polaris Sales Inc. 4/99...
  • Page 268 Tank to fuel valve connection -- Gold fitting (tall stand pipe) to “ON” (marked 1) on fuel valve “1 (ON)” Reserve Silver fitting (short stand pipe) to “Res” (marked 2) “2 (Reserve)” on fuel valve 4/99 Polaris Sales Inc.
  • Page 269 Fuel System Diagram - 4 Stroke Models Fuel Tank Fuel Tank Vent Fitting Screens Fuel Pump Filter Fuel Valve Carburetor Vent Engine Carburetor L 325 / 425 Under Headlamp Cover 335 / 500 Above Oil Tank Polaris Sales Inc. 4/99...
  • Page 270 3130117 3130118 3130119 Pilot Jet Part Numbers (4 Cycle) 3130120 Mikuni BST Carburetor 3130121 3130122 Jet Number Part Number 3130123 40.0 3130624 3130124 42.5 3130526 3130125 3130126 3130127 3130128 3130129 3130130 3130131 3130132 3130133 3130134 3130135 4/99 Polaris Sales Inc.
  • Page 271 Fuel Tank Assembly / Oil Tank Assembly Typical 2 Cycle model with tank- mounted fuel valve. Details vary by model. Refer to parts manual. Forward Fuel tank-mounted valve Oil Level Sensor Vent Hose Oil Tank Oil Filter Forward Polaris Sales Inc. 4/99...
  • Page 272 “E” ring inserted into one of the five slots provided in the head of the jet needle. The chart at right shows the variation of fuel flow based on the height of the “E” ring. 100% Throttle Valve Opening 4/99 Polaris Sales Inc.
  • Page 273 Clearance Clearance Clearance the cross sectioned area of the main jet. The main jet therefore has greater control over fuel flow. Closed One-half Full Throttle Throttle Throttle Polaris Sales Inc. 4/99...
  • Page 274 Mikuni Hex Larger numbers give a greater flow, resulting in a Style Main Jet richer mixture. Main jets are screwed directly into the needle jet base. Larger Number = Richer Mixture 4/99 Polaris Sales Inc.
  • Page 275 Cable Adjuster Cable Adjuster Lock Nut Plunger Spring Plunger Cap Throttle Valve Starter Plunger Inlet Starter Air Starter Emulsion Tube Inlet Bleed Air Starter Jet Polaris Sales Inc. 4.10 4/99...
  • Page 276 When the air screw is opened, the mixture is made more lean as the amount of air is increased. Throttle Valve Throttle Stop (Idle Speed) Screw pass Pilot Outlet Air Screw Pilot Jet 4/99 4.11 Polaris Sales Inc.
  • Page 277 The higher the number, the steeper the angle. Cutaway Angle Throttle Valve Jet Needle Air Jet By-pass Pilot Outlet Engine Side Air Box Side Pilot Jet Needle Jet Main Jet Larger Smaller Leaner Richer Polaris Sales Inc. 4.12 4/99...
  • Page 278 Letter and number codes are stamped into the needle and the jet indicating sizes and tapers of each. Clip Position (Shown in #3) Throttle Valve Jet Needle Air Jet By-pass Pilot Outlet Pilot Jet Needle Jet Main Jet Leaner Richer Jet Needle “E” Clip Position 4/99 4.13 Polaris Sales Inc.
  • Page 279 Thus the main jet is now controlling the amount of fuel flow. Throttle Valve Jet Needle Air Jet By-pass Pilot Outlet Pilot Jet Needle Jet Main Jet Polaris Sales Inc. 4.14 4/99...
  • Page 280 Port (Beneath Throttle throttle Slide), Air Jet, Pilot Outlet, Throttle Valve Cutaway Main System Main Jet, Main Air Passage, Supplies fuel at mid-range 1/4 to full throttle Needle Jet, Jet Needle, and high throttle settings. Throttle Valve 4/99 4.15 Polaris Sales Inc.
  • Page 281 Mity-Vac™ (PN 2870975) to the fuel inlet fitting. Apply 5 PSI pressure to inlet fitting. The needle and seat should hold pressure indefinitely. If not, inspect needle and seat and seat O-ring or gasket. Polaris Sales Inc. 4.16 4/99...
  • Page 282 26. Pin, Float 27. Gasket, Inlet Valve 28. Carb Body Assy. (1-30) 29. Needle Jet 30. E-Clip Check Valves To Carburetor Flow No Flow Use a spring loaded center punch to remove press-fit float pin. 4/99 4.17 Polaris Sales Inc.
  • Page 283 The lines must be To frame Vent lines free of kinks and restrictions and be properly routed to al- low fuel to flow in the proper amount and to prevent con- taminants from entering the carburetor. Polaris Sales Inc. 4.18 4/99...
  • Page 284 FUEL SYSTEM/CARBURETION Mikuni CV Carb Operation The constant velocity carburetor used on Polaris 4 Cycle ATVs and 6x6 incorporates a mechanically operated throttle plate and a vacuum controlled slide valve (vacuum slide). The venturi cross-sectional area in the carbure- tor bore is increased or decreased automatically by the vacuum slide, which moves according to the amount of negative pressure (less than atmospheric) present in the venturi.
  • Page 285 (8) extending from underneath the diaphragm. The rich fuel/air mixture for starting is discharged through starter out- let (6) in the the main bore. Polaris Sales Inc. 4.20 4/99...
  • Page 286 (5) and jet needle (7), and is discharged into the venturi (A). Mixture proportioning is accomplished in needle jet (5); the clear- ance through which the emulsified fuel must flow is determined ultimately by throttle position and vacuum slide height. 4/99 4.21 Polaris Sales Inc.
  • Page 287 44. Spring Washer 45. Screw 46. Air Jet 47. Cable Guide Jet Needle 48. Spring “E” Clip Position Refer to Page 4.5 for Jet Part Numbers 49. Ring 50. Adjust Screw 51. Screw and Washer Assy. Polaris Sales Inc. 4.22 4/99...
  • Page 288 27. O-Ring 28. Air Jet 29. Choke Plunger Guide 30. Spring 31. Choke Plunger 32. Cap 33. O-Ring 34. Jet Block Assembly 35. Needle Jet 36. Case Refer to Page 4.5 for Jet Part Numbers 4/99 4.23 Polaris Sales Inc.
  • Page 289 2. Use a small spring loaded center punch to remove pressed float pin. 3. Remove inlet needle seat retaining screw along with plate, and carefully remove needle seat. NOTE: Do not use a pliers to remove the seat or permanent damage may occur. Polaris Sales Inc. 4.24 4/99...
  • Page 290 O-Ring. If anti-tamper plug is installed in pilot screw cavity, refer to Maintenance chapter 2 for removal procedure. O-Ring Washer Spring Pilot Screw 5. NOTE: The starter jet is not removeable. Starter Jet 4/99 4.25 Polaris Sales Inc.
  • Page 291 4. Verify all passages and jets are unobstructed by spraying electrical contact cleaner through the passages. CAUTION: Do not use wire or welding tip cleaners on the jets as the orifice size may be altered. 5. Use low pressure air to dry carburetor body and all components. Polaris Sales Inc. 4.26 4/99...
  • Page 292 2. Inspect the inlet needle tapered surface for any sign of wear or damage. Be sure the spring loaded pin is free moving and returns freely when pushed. The inlet needle and seat should be pressure tested after Worn, Deposits Good Condition assembly. 4/99 4.27 Polaris Sales Inc.
  • Page 293 NOTE: The final pilot (idle) mixture must be adjusted with the engine running. Refer to Page 2.12a. Pilot Mixture Screw Base Setting (Turns Out) Pilot Screw Refer to General / Specifications Chapter 1 Polaris Sales Inc. 4.28 4/99...
  • Page 294 Std: BST 34 14.7mm (.58″) ± 1 mm BST 40 3. If adjustment is necessary, bend the tongue slightly. Float arms even Be sure float arms are even on left and right side. Bend to adjust float 4/99 4.29 Polaris Sales Inc.
  • Page 295 Start and run engine for 3 to 5 seconds to allow fuel level to stabilize in the line. If level is out of specification, remove carburetor and inspect inlet needle and seat, float height, passages, etc. Polaris Sales Inc. 4.30 4/99...
  • Page 296 Carefully remove all traces of old gasket and check the surfaces for damage. Replace diaphragms and gaskets as a set. 4. Reassemble the pump in the reverse order of disassembly. Tighten all screws evenly. 4/99 4.31 Polaris Sales Inc.
  • Page 297 Fuel Pump Exploded View 1. Fuel Pump Assembly 2. Diaphragm, Gasket Set 3. Screw and Washer Assembly 4. Screw and Washer Assembly 5. Screw and Washer Assembly 6. Pressure Regulator 7. Fuel Inlet 8. Fuel Outlet Polaris Sales Inc. 4.32 4/99...
  • Page 298 Poor Idle Symptoms: Idle too high. Idle adjusted improperly/idle mixture screw damaged Sticky vacuum slide (4 Strokes) or throttle valve (2 strokes) Throttle cable sticking, improperly adjusted, routed incorrectly Choke cable sticking, improperly adjusted, routed incorrectly 4/99 4.33 Polaris Sales Inc.
  • Page 299 Air leaks, dirty carburetor passages (pilot circuit) Pilot mixture screw damaged or adjusted incorrectly Tight valves Ignition timing incorrect Belt dragging Dirty air cleaner Engine worn Spark plug fouled Idle speed set incorrectly (speed limiter) Worn jet needle/needle jet Polaris Sales Inc. 4.34 4/99...
  • Page 300 CHAPTER 5 BODY / STEERING / SUSPENSION Torque Specifications and Special Tools ... . Gen II Body Assembly, Exploded View ... . . Gen II Cover/Panel Removal .
  • Page 302 Damper Rod Holding Tool ... 2871352 Fox™ Shock IFP Tool ....2871351 Polaris Sales Inc. 4/99...
  • Page 303 Body Assembly Exploded View (Gen ll - Typical) Seat Rear Cab Assembly Headlight Cover Fuel Tank Cover Front Cab Assembly Side Cover Front Cab All warning information labels must be in place when body parts are assembled. 4/99 Polaris Sales Inc.
  • Page 304 Fuel tank cover Headlight cover Front rack Fuel pump bracket 3 screws, nuts and washers from left footrest 2 screws, nuts and washers from right footrest 2 rivets at top of cab beneath fuel pump bracket Polaris Sales Inc. 4/99...
  • Page 305 BODY / STEERING / SUSPENSION Body Assembly Exploded View (Gen lll - Typical) Seat Release Latch Rear Cab Assembly Mud Flap Front Cover Panel or Headlight Cover Front Cab Assembly Front Cab Mud Flap 4/99 Polaris Sales Inc.
  • Page 306 2 rivets at top of cab beneath fuel pump bracket 2 screws at rear of front cab on each side 2 screws in front top of cab 2 Torx™ screws on key switch face plate Key switch face plate Polaris Sales Inc. 4/99...
  • Page 307 Pull UP on rear of seat and back to disengage tabs at front of seat Rear Cab Seat Latch Release Storage Rear Cab Assembly Rear Mud Guard Front Cover Side Cover Front Cab Assembly Front Cab Footrest Front Mud Guard 4/99 Polaris Sales Inc.
  • Page 308 Front rack Front bumper Front cover panel 3 screws from bottom left mudflap 3 screws from bottom right mudflap 1 inner screw from front cab to foot rest on each side 2 screws under front panel Polaris Sales Inc. 4/99...
  • Page 309 S Install three rear Phillips screws, aligning with Tinnerman™ clips. S To adjust headlight, refer to procedure outlined in Maintenance chapter. 4/99 Polaris Sales Inc.
  • Page 310 Push panel upward and forward until tabs Step 3. lock. Bend rear of side panel and insert the two tabs into the rear cab. To reinstall, align panel tabs with slots. Push upward and forward until tabs lock. Polaris Sales Inc. 99/00 ATV Update 12/99...
  • Page 311 30 ft. lbs. 41 Nm) Loctite™ 242 8 ft. lbs. (11 Nm) 25 ft. lbs. (35 Nm) Always use new patch lock bolts upon reassembly Always use new cotter pins upon reassembly. 99/00 ATV Update 12/99 5.10 Polaris Sales Inc.
  • Page 312 Bolt pointing UP Always use new bolts upon reassembly 30 ft. lbs. 41 Nm) Loctite™ 242 25 ft. lbs. 8 ft. lbs. Always use new (35 Nm) (11 Nm) cotter pins upon reassembly. Polaris Sales Inc. 5.11 99/00 ATV Update 12/99...
  • Page 313 (32 - 33 Nm) 30 ft. lbs. (41 Nm) Loctite™ Always use new bolts 25 ft. lbs. 8 ft. lbs. upon reassembly (35 Nm) (11 Nm) Always use new cotter pins upon reassembly. 99/00 ATV Update 12/99 5.12 Polaris Sales Inc.
  • Page 314 9. Locate grease fitting in center of A-arm tube and pump 25 ft. lbs. (35 Nm) A-arm full of grease. WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into regular service. Polaris Sales Inc. 5.13 4/99...
  • Page 315 Models with trailer hitch - 40 ft. lbs. (55 Nm) Models without trailer hitch - 30 ft. lbs. (41 Nm) Refer to Maintenance section for chain adjust- ment information on Concentric swingarm models (tapered rear axle bearings). 4/99 5.14 Polaris Sales Inc.
  • Page 316 (4) Pivot Bushing, Right (7) Pivot Bushing, Left Place flats of pivot bushing in vise to hold while removing and installing nut 150 ft. lbs. (207 Nm) Loctite 272 (5) Pivot Bolt 150 ft. lbs. (207 Nm) Polaris Sales Inc. 5.15 4/99...
  • Page 317 BODY / STEERING / SUSPENSION Standard Swing Arm and Rear Suspension Exploded View 25 ft. lbs. (35 Nm) 55 ft. lbs. (76 Nm) 55 ft. lbs. (76 Nm) 25 ft. lbs. (35 Nm) 60 ft. lbs. (83 Nm) 4/99 5.16 Polaris Sales Inc.
  • Page 318 BODY / STEERING / SUSPENSION Shaft Ride Swingarm Exploded View Polaris Sales Inc. 5.17 4/99...
  • Page 319 1/4 turn. Remove tool. If tool cannot be removed, repeat process. Apply Loctite 242 (Blue) to exposed threads of pivot bolts and lock nuts. .200″ (5mm) Torque lock nuts to 120 ft. lbs. (165 Nm). 4/99 5.18 Polaris Sales Inc.
  • Page 320 30 ft. lbs. (41 Nm) 35 ft. lbs. (48 Nm) Lower Control Upper Control Index Bushings Correctly 30 ft. lbs. (41 Nm) 30 ft. lbs. (41 Nm) 15 ft. lbs. (21 Nm) 100 ft. lbs. (48 Nm) Polaris Sales Inc. 5.19 4/99...
  • Page 321 BODY / STEERING / SUSPENSION Rear Strut Stabilizer, 6x6 Models 30 ft. lbs. (41 Nm) Grease Fittings 30 ft. lbs. (41 Nm) 30 ft. lbs. (41 Nm) 4/99 5.20 Polaris Sales Inc.
  • Page 322 Rear strut (1) and weldment (2) can only be replaced as an assembly. They are pressed and welded together at the factory and cannot be disassembled. Grease fittings (3 and 4). Check lubrication guide for service intervals. Polaris Sales Inc. 5.21 4/99...
  • Page 323 BODY / STEERING / SUSPENSION Front Swing Arm Weldment, 6x6 Models 55 ft. lbs. (76 Nm) 55 ft. lbs. (76 Nm) 17 ft. lbs. (24 Nm) 4/99 5.22 Polaris Sales Inc.
  • Page 324 Upper Pivot Ball Lower Pivot Ball Spacer Nut Spring Retainer Strut Bumper Spring Strut Cartridge Clamp Spring Retainer Washer Lock Nut 15 ft. lbs. (21 Nm) Strut Housing Washer Washer Bolt Spindle Ball Joint Grease Fitting Polaris Sales Inc. 5.23 4/99...
  • Page 325 If insert and strut do not match, strut replacement will be necessary. Grease fitting (2) location. Check lubrication guide for recommended service intervals. Specified pole gap is 0-.001″ (0-.0254mm) 4/99 5.24 Polaris Sales Inc.
  • Page 326 9. Reassemble spring and top pivot assembly. Be sure all parts are installed properly and seated fully. 10. Torque strut rod nut to specification. Do not over torque nut. Strut Rod Nut Torque 15 ft. lbs. (21 Nm) Polaris Sales Inc. 5.25 4/99...
  • Page 327 Torque screws to 8 ft. lbs. (11 Nm). 10. Install A-arm on ball joint and torque castle nut to 25 ft. lbs. (35 Nm). 11. Reinstall cotter pin with open ends toward rear of machine. 4/99 5.26 Polaris Sales Inc.
  • Page 328 NUMBER Trail Boss Springs Fire Red 72060 8520149 Rims Bright White 2185 8520153 Rack Fire Red 72060 8520149 Trail Blazer Springs Fire Red 72060 8520149 Rims Bright White 2185 8520153 Xpress 300 Xpress 300 Springs Springs Bonnie Blue Bonnie Blue...
  • Page 329 BODY / STEERING / SUSPENSION 2000 Paint Codes MODEL PAINTED PART COLOR DITZLER POLARIS DESCRIPTION NUMBER NUMBER Trail Blazer Springs Fire Red 72060 8520149 Rims Bright White 2185 8520153 Xplorer 4x4 Springs Black 9440 8520147 Rims Aluminum Trail Boss 325...
  • Page 330 This should occur after just a few seconds of flame treating. Do not hold the torch too close to the surface. Keep the torch moving to prevent damage. 2. Apply the decal. Polaris Sales Inc. 5.29 99/00 ATV Update...
  • Page 331 NOTES...
  • Page 332 CHAPTER 6 CLUTCHES Service Tools and Supplies ....PVT System Introduction ..... . PVT Maintenance/Inspection .
  • Page 334 5 ft. lbs. Drive Clutch Cover Plate ....90 in. lbs. Refer to General Chapter 1 for Specifications by model. Polaris Sales Inc. 4/99...
  • Page 335 Standard PVT System Introduction PVT Operation The Polaris variable transmission (PVT) consists of three major assemblies: 1) drive clutch; 2) drive belt; and 3) driven clutch. The internal components of the drive clutch and driven clutch control clutch engagement (for initial vehicle movement), clutch upshifting and backshifting.
  • Page 336 PVT Sealing and Ducting Components Type l Inner Cover Typical of Gen ll and Gen lV Seal Liquid Cooled 2-Strokes Sportsman Style Outlet Air Duct Inlet Air Ducting Outer Cover Polaris Sales Inc. 4/99...
  • Page 337 6. Remove drive clutch retaining bolt and remove drive clutch using puller. Drive Clutch Puller PN 2870506 4/99 Polaris Sales Inc.
  • Page 338 9. Bend back retainer tabs on three screws at the front of the inner cover (where applicable). Remove screws and retainer plate. 10. Remove inner cover retaining bolts at rear of cover. 11. Remove cover along with foam seal on back of cover or shaft. Polaris Sales Inc. 4/99...
  • Page 339 16. Apply a small amount of RTV silicone to the ends. Flat edge out 17. Reinstall PVT outer cover and secure with screws. (Toward outer cover) Apply anti-seize compound to screw threads before installation. 18. Reinstall rear cab assembly and seat. Cover Gasket 4/99 Polaris Sales Inc.
  • Page 340 CLUTCH Sealing and Ducting Components PVT Sealing and Ducting Components Type ll Typical of Gen ll 4-strokes Inlet Duct Outer Cover Seal Inner Cover Inner Cover Retainer Seal Outer Cover Exhaust Duct Polaris Sales Inc. 4/99...
  • Page 341 Typical of Gen lll Liquid Cooled (Scrambler; Sport) Type lV Typical of Gen lV Air Cooled (Xpress / Xplorer 300) Gen ll and Gen lll Air Cooled (Trail Boss / Trail Blazer) Trail Boss 1996 Trail Boss 4/99 Polaris Sales Inc.
  • Page 342 CLUTCH Sealing and Ducting Components Type lV Typical of Gen lV 4 Strokes (Sportsman 500 / Xplorer 500) To Engine Polaris Sales Inc. 4/99...
  • Page 343 If the weights are too heavy, or the spring rate too low, the engine RPM will be low 7000 and the drive clutch will upshift too fast, keeping the engine out of its power 6000 band. 5000 CLUTCH 4000 ENGAGEMENT 3000 2000 1000 4/99 6.10 Polaris Sales Inc.
  • Page 344 7041080 Blue/Gold .207I 3.50I 7041083 .192I 3.77I 7041102 Yellow .192I 2.92I 7041061 Brown .200I 3.06I 7041132 White .177I 2.92I 7041168 Green .177I 3.05I 7041148 Gold .207I 3.25I 7041150 Red/White .192I 3.59I 7041157 Blue/Green .177I 2.53I Polaris Sales Inc. 6.11 4/99...
  • Page 345 PN 5630418 50 gr PN 5630095 PN 5630509 PN 5630581 (High Alt. 350L) 53 gr 55 gr 58 gr PN 5630709* PN 5630710* PN 5630711* PN 5630513 44 gr 46 gr 47gr 50.5 gr 4/99 6.12 Polaris Sales Inc.
  • Page 346 All PVT system maintenance repairs must be per- formed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this manual.
  • Page 347 Drive Clutch Teflon coated brass bushing Teflon coated brass bushing Mark with permanent marker before disassembly EBS Drive Clutch Spider Lock Nut PTFE Washer One Way Clutch Spacer Sleeve Mark with permanent marker before disassembly 4/99 6.14 Polaris Sales Inc.
  • Page 348 Refer to bushing replacement in this chapter. 4. Inspect area on shaft where bushing rides for wear, Inspect shaft galling, nicks, or scratches. Replace clutch assembly if worn or damaged. 5. Remove and inspect spring. (See page 6.11) Polaris Sales Inc. 6.15 4/99...
  • Page 349 2. Inspect the Teflon™ coating on the moveable sheave bushing. Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflon™ is visible on the bushing. Refer to bushing replacement in this chapter. 4/99 6.16 Polaris Sales Inc.
  • Page 350 Pre-mature wear will result if the Driving side heat resistant O-rings are substituted with another O-ring type. Use only genuine Polaris parts. Do not install a Washer or flat washer on the driving side of the spider. Refer to O-ring the appropriate parts manual for placement and part numbers.
  • Page 351 Inverting the clutch while tighten- ing the spider will help position the washers. 5. Install shift weights using new lock nuts on the bolts. 6. Reinstall clutch spring. Rotation Nut on trailing side 4/99 6.18 Polaris Sales Inc.
  • Page 352 7. Reinstall cover, aligning “X” mark with other marks. Torque cover bolts evenly to specification. Spider Torque: 200 ft. lbs. (27.6 kg-m) Spider Torque EBS: 180 ft.lbs. (25.5 kg-m) Cover Screw Torque: 90 in. lbs. (1.04 kg-m) Polaris Sales Inc. 6.19 4/99...
  • Page 353 CLUTCH Standard P-90 (Non-EBS) Clutch 4/99 6.20 Polaris Sales Inc.
  • Page 354 CLUTCH NOTES Polaris Sales Inc. 6.21 4/99...
  • Page 355 If proper belt deflection cannot be obtained, measure drive belt width, length, and center distance of drive and driven clutch, outlined in this sec- tion; all have an effect on belt deflection. 4/99 6.22 Polaris Sales Inc.
  • Page 356 Troubleshooting Chart at the end of this chapter for 10″ +.1 / -.05 (254 +2.5 / -1.3mm) possible causes. NOTE: If a new belt is installed, check Belt Nominal Length - 40.875″± 3/16 belt deflection. (103.8 cm ± .48 cm) Polaris Sales Inc. 6.23 4/99...
  • Page 357 Adjust offset by adding or removing spacer Driven Clutch Offset washers between back of driven clutch and spacer as shown. To adjust, add or remove washers from behind the driven clutch Spacer Washer PN 7556401 4/99 6.24 Polaris Sales Inc.
  • Page 358 CLUTCH This Page Blank Polaris Sales Inc. 6.25 4/99...
  • Page 359 CLUTCH Drive Clutch Bushing Service Polaris Kit PN 2871226 Item Qty. Part Description Part No. P-90 Drive Clutch and Driven Clutch 5020628 Bushing Installation Tool Drive Clutch Cover Bushing Removal and 5020629 Installation Tool (for all drive clutches) P-90 Driven Clutch Bushing Removal Tool...
  • Page 360 5. Turn sheave and barrel together counterclockwise until bushing is seated. 6. Remove nut from puller rod and set aside. 7. Remove sheave from puller. 8. Remove installation tool. Polaris Sales Inc. 6.27 4/99...
  • Page 361 5. Turn clutch cover counterclockwise on puller rod until bushing is removed. 6. Remove nut from puller rod and set aside. 7. Remove bushing and bushing removal tool from puller. Discard bushing. 4/99 6.28 Polaris Sales Inc.
  • Page 362 4. Turn clutch cover barrel together counterclockwise on puller rod until bushing is seated. 5. Remove nut from puller rod and take installation tool and clutch cover off rod. Polaris Sales Inc. 6.29 4/99...
  • Page 363 2. Remove snap ring retainer. 3. Note location of spring and remove helix. Note hole location of spring in helix and sheave 4. Note location of spring in the moveable sheave, and remove the spring. 4/99 6.30 Polaris Sales Inc.
  • Page 364 NOTE: The ramp buttons are secured by Torx™ screws. 7. Remove moveable sheave and note the number of Belt deflection adjustment spacer washers. One spacer must remain washers between the sheaves when adjusting belt deflection. Polaris Sales Inc. 6.31 4/99...
  • Page 365 Teflon™ is visible on the bushing. Re- fer to bushing replacement in this chapter. 9. Inspect driven clutch faces for wear or damage. 10. Clean inspect splines helix transmission input shaft. 11. Lube splines with a light film of grease. 4/99 6.32 Polaris Sales Inc.
  • Page 366 1/2″ to 3/4″. Align boss spline to install helix 5. While holding downward pressure on helix, wind moveable sheave counterclockwise approximately 1/3 turn (120°). turn 6. Push helix into place and install snap ring. Polaris Sales Inc. 6.33 4/99...
  • Page 367 4. Using a hand held propane torch, apply heat directly on bushing until tiny smoke tailings appear. CAUTION: Clutch components will be hot! In order to avoid serious burns, wear some type of insulated gloves for the rest of the removal process. 4/99 6.34 Polaris Sales Inc.
  • Page 368 8. Turn clutch sheave counterclockwise until bushing is removed. Repeat steps 5. - 8. for other bushing. 9. Remove nut from puller rod and set aside. 10. Remove adapters from puller. 11. Remove bushing and removal tool from adapters. Discard bushing. Polaris Sales Inc. 6.35 4/99...
  • Page 369 2. Start new bushing evenly in moveable sheave. Apply Loctite 680 retaining compound to the back side of new bushing. 3. Install sheave onto puller with new bushing upward as shown. Install adaptor number two. 4/99 6.36 Polaris Sales Inc.
  • Page 370 5. Turn clutch sheave counterclockwise until bushing is seated. 6. Remove nut from puller rod and set aside. 7. Remove installation tool and clutch sheave from puller. 8. Repeat installation procedure for other moveable bushing. Polaris Sales Inc. 6.37 4/99...
  • Page 371 CLUTCH This Page Blank 4/99 6.38 Polaris Sales Inc.
  • Page 372 CLUTCH ENGINE BRAKING SYSTEM (EBS) Clutch Polaris Sales Inc. 6.39 4/99...
  • Page 373 Engine Braking System (EBS) Introduction EBS Theory Of Operation The Engine Braking System (EBS) combines the standard “no-shift” feature of the Polaris Variable Transmission (PVT) system with the added benefit of engine braking. Outwardly, both drive and driven clutch resemble those...
  • Page 374 WARNING All PVT system maintenance repairs must be performed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands PVT system maintenance and repair procedures. Because of the critical nature and precise balance of components within the PVT system, it is absolutely essential that no attempt at disassembly or repair be made without factory authorized special tools and service procedures.

  • Page 375: Ebs Exploded View

    Spring Torque to Compression 185 Ft. Lbs. Spring Cover Bushing Spacer Sleeve Screw Bushing Roller Flat Washer One Way Clutch (Driven) Roller/Bushing Drive Belt Assembly Bolts, Lock Washers PTFE Washer Retaining Ring Driven Clutch Assembly 4/99 6.42 Polaris Sales Inc.
  • Page 376 1. Remove moveable sheave spacer sleeve and the 2″ PTFE washer. Visually inspect the washer for damage. Measure the thickness and compare to specification. Replace if worn or damaged. PTFE Washer Thickness Standard: .030″ (.76mm) Service Limit: .025″ (.64mm) Polaris Sales Inc. 6.43 4/99...
  • Page 377 1. Inspect the Teflon™ coating on the moveable sheave bushing. Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflon™ is visible on the bushing. Refer to bushing replacement in this chapter. 4/99 6.44 Polaris Sales Inc.
  • Page 378 CLUTCH This Page Blank Polaris Sales Inc. 6.45 4/99...
  • Page 379 Do not disassemble the driven clutch from the outside snap ring. The driven clutch must be disassembled from the helix side or the one-way clutch seals may be damaged. Do not disassemble from this side 4/99 6.46 Polaris Sales Inc.
  • Page 380 Do not allow locking agent to Dry Locking contact the inside of the rollers. Do not lubricate the roll- Agent Applied er or roller pin. To New Screws Polaris Sales Inc. 6.47 4/99...
  • Page 381 8. Check for movement of the driven clutch shaft in the one-way clutch. If the shaft can be moved laterally, or if the one-way clutch does not function properly as described in Step 1 and 2 on page 6.46, replace driven clutch assembly. 4/99 6.48 Polaris Sales Inc.
  • Page 382 CLUTCH This Page Blank Polaris Sales Inc. 6.49 4/99...
  • Page 383 9. Turn sheave counterclockwise on puller rod until it comes free. Lift sheave off puller. 10. Remove nut from puller rod and set aside. 11. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard. 4/99 6.50 Polaris Sales Inc.
  • Page 384 4. Install nut on rod and hand tighten. Turn puller barrel to apply more tension if needed. 5. Turn clutch cover counterclockwise on puller rod until bushing is seated. 6. Remove nut from puller rod and take installation tool and clutch cover off rod. Polaris Sales Inc. 6.51 4/99...
  • Page 385 6. Turn clutch sheave counterclockwise until bushing is seated. 7. Remove nut (C) (left hand thread) from puller rod and Puller Adapter (10) set aside. EBS Driven Clutch Bushing Installation 8. Remove installation tool and clutch sheave from puller. 4/99 6.52 Polaris Sales Inc.
  • Page 386 (10) 8. Remove nut (C) (left hand thread) from puller rod and EBS Driven Clutch Outer set aside. Bushing Installation 9. Remove installation tool and clutch sheave from Bushing puller. Tool (2) Polaris Sales Inc. 6.53 4/99...
  • Page 387 Water ingestion -Cover seals or ducts leaking -Find leak and repair as necessary. -Operator error -Instruct operator on guidelines for operation in wet terrain as outlined in Owner’s Safety and Maintenance Manual. 4/99 6.54 Polaris Sales Inc.
  • Page 388 NOTES...
  • Page 389 -Inspect and repair as necessary. hitting clutches Engagement -Thin spots on belt, worn belt -Replace belt. Refer to belt burnt troubleshooting and instruct erratic or stabby operator. -Drive clutch bushings stick -Inspect and repair clutches. Polaris Sales Inc. 6.55 4/99...
  • Page 390 CHAPTER 7 FINAL DRIVE Final Drive Torque Specifications ......2x4 Front Hub Disassembly/Inspection ....7.2-7.3 2x4 Hub Bearing/Seal Replacement .

  • Page 392: Final Drive

    Refer to exploded views and text for torque values of other fasteners ¡ 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 or destroyed during removal. Polaris Sales Inc. 4/99...
  • Page 393 6. Rotate each bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. Replace bearing if moisture, dirt, corrosion, or roughness is evident. NOTE: If bearings are removed, they must be replaced. 4/99 Polaris Sales Inc.
  • Page 394 10. Clean hub and spacer thoroughly. 11. Inspect spacer for wear or damage. Measure length of spacer and replace if worn beyond service limit or if ends are rounded. Bearing Spacer Length: Service Limit: 2.1850″ (5.55 cm) Polaris Sales Inc. 4/99...
  • Page 395 2. Coat bearing spacer with grease and install into hub. Drive or press the other bearing into hub until seated against spacer. 3. Install seal into hub (with numbers facing out) until flush with end of seal bore. Seal 4/99 Polaris Sales Inc.
  • Page 396 Always use new brake caliper mounting bolts upon assembly. 12. Install wheel and wheel nuts and tighten evenly in a cross pattern to specified torque. Front Wheel Nut Torque 15 ft. lbs. (20.7 Nm) Polaris Sales Inc. 4/99...
  • Page 397 Strut Housing Spindle Bearing Brake Disc Seal Washer (domed side out) 18 ft. lbs. (24.9 Nm) Use new bolts with pre-applied Spacer locking agent. Bearing Cotter Pin Wheel Nut O-Ring Hub Cap 40 ft. lbs. (55.3 Nm) 4/99 Polaris Sales Inc.
  • Page 398 FINAL DRIVE This Page Blank Polaris Sales Inc. 4/99...
  • Page 399 FINAL DRIVE AWD Operation Overview With the Polaris All Wheel Drive System activated (AWD selected), the machine operates as a 2 wheel drive vehicle until the rear wheels lose traction. If the rear wheels lose traction the front wheel rotational speed will decrease, causing the front drive axle speed to exceed front wheel speed.
  • Page 400 Use wire to hang the caliper to prevent possible damage to the brake line. 4. Place a catch pan beneath the front hub and remove the hub cap. 5. Remove cotter pin and nut. 6. Remove front hub and bearings. Polaris Sales Inc. 4/99...
  • Page 401 4. Install wheel hub, outer bearing, washer, and attaching nut. NOTE: It is very important that the hub is not moved outward once installed, or the seal on the hub will disengage the armature plate. 4/99 7.10 Polaris Sales Inc.
  • Page 402 7. Remove fill check plug and rotate hole to either 4:00 or 8:00 position. 8. Fill with Polaris Premium Demand Drive Hub Fluid or Type F Automatic Transmission Fluid until fluid trickles out. NOTE: Do not force the oil into the hub under pressure.
  • Page 403 Bearing (1.000″ I.D.) DETAIL A Spacer Bearing Race Front Hub Clutch Front Hub Clutch Bearing (1.000″ I.D.) Cotter Pin Castle Nut ¡ Bearing Race Washer Wheel Nut ¡ Refer to text on page 7.11 for more information. 4/99 7.12 Polaris Sales Inc.
  • Page 404 FINAL DRIVE This Page Blank Polaris Sales Inc. 7.13 4/99...
  • Page 405 It is very important that the brake disc be free of any oil or solvents. 6. Reinstall the brake disc using genuine Polaris OEM bolts that have a pre-applied locking agent. Do not substitute bolts or use old ones.
  • Page 406 6. Route the wires smoothly and away from any moving parts and secure in place with tie straps. 7. Assemble front axle and connect hub wires. Polaris Sales Inc. 7.15 4/99...
  • Page 407 Current electro-mechanical spring, PN 3250032; wire Measure free length to inside of diameter .018″ (.46 mm); spring free length end to end loops as shown inside hooks 6.968″ (177 mm). 4/99 7.16 Polaris Sales Inc.
  • Page 408 If the unit is driven with the armature plate out of position, it will cause roller clutch damage. Armature Plate Tabs Polaris Sales Inc. 7.17 4/99...
  • Page 409 6. Place a catch pan beneath the front hub and remove the hub cap. 7. Remove cotter pin and nut. 8. Remove hub, bearings, hilliard assembly, and armature plate. 4/99 7.18 Polaris Sales Inc.
  • Page 410 4. Install lower ball joint, torque nut to 25 ft. lbs. (3.45 kg-m) and install new cotter pin. 5. Follow procedure install hilliard clutch components and hub as outlined on page 7.7. 6. Tighten hub nut following procedure on 7.11. Polaris Sales Inc. 7.19 4/99...
  • Page 411 3. Disconnect A-arm from ball joint using a tie rod fork. 4. Slide strut off end of drive shaft and tie it up out of the way of the shaft. NOTE: Be careful not to damage the wheel coil wires when positioning the strut. 4/99 7.20 Polaris Sales Inc.
  • Page 412 11. Position large end of boot on CV joint and secure 30g. (Total 60g) with clamp. FRONT SHAFT Joint Capacity 30 Grams Boot Capacity 30 Grams Front outboard joint capacity: 30g if boot is replaced only. Another 30g (60g total) if joint is cleaned. Polaris Sales Inc. 7.21 4/99...
  • Page 413 Front Drive Axle Components Boot Drive Axle CV Joint Assy Clamps Circlip Yoke U--Joint Assy Front Prop Shaft Components O-Ring Propshaft Assembly Prop Shaft Cross and Bearing Kit Yoke, Propshaft to Transmission Spring Pin Yoke, Front Gearcase 4/99 7.22 Polaris Sales Inc.
  • Page 414 NOTE: The front axle bearings have a larger I.D. (1.0625″) than the hub bearings (1.000″). Be sure to install the bearings with the larger I.D. in the strut housing, and the bearings with the smaller I.D. in the hub. Polaris Sales Inc. 7.23 4/99...
  • Page 415 Measure at 3 (Outer Magnet places 120_ Pole) (Adjustable) apart Seal Sleeve Installation Tool Set PN 2871199 Seal Sleeve Tool Seal Sleeve Use flat side to install seal sleeve (Outer Magnet Pole) Step Inner Pole Shoe 4/99 7.24 Polaris Sales Inc.
  • Page 416 Slide prop shaft back and away from front housing. Pull sharply forward to remove from transmission shaft. NOTE: If removing front housing, use a drift punch to remove the roll pins from both front drive axles. Polaris Sales Inc. 7.25 4/99...
  • Page 417 2. Support inner yoke as shown and drive outer yoke down (bearing cap out) with a soft face hammer. 3. Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing caps. 4/99 7.26 Polaris Sales Inc.
  • Page 418 2. Using a suitable arbor, fully seat bearing cap in one side. Continually check for free movement of bearing cross as bearing caps are assembled. 3. Install snap ring to contain bearing cap just installed. Repeat procedure for other side. Polaris Sales Inc. 7.27 4/99...
  • Page 419 7. When installation is complete, Yokes must pivot freely in all directions without binding. If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely in all directions. 4/99 7.28 Polaris Sales Inc.
  • Page 420 Type lll front housings, which have bolts securing the pinion cover and output shaft covers. Type l 2. Mount housing to front housing holding fixture as shown. Front Housing Holding Fixture PN 2871696 Type l Polaris Sales Inc. 7.29 4/99...
  • Page 421 Spanner Case Bolts Drain Plug Fill plug Drain Plug Type lll* Case Bolts Fill plug on top Drain plug Bolted Case * Primary difference between Type II and Type III is the drain plug location. 4/99 7.30 Polaris Sales Inc.
  • Page 422 While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable Type l up and down movement and minimal movement side- ways between inner and outer race. Polaris Sales Inc. 7.31 4/99...
  • Page 423 Remove cover, brass spacer, steel spacer, ring gear assembly and shaft. Clean all parts and inspect spacers for wear. Inspect ring gear for chipped, broken, or missing teeth. Type l 4/99 7.32 Polaris Sales Inc.
  • Page 424 Pinion Shaft Retainer Nut Torque Type l 20 ft. lbs. (2.76 kg-m) NOTE: On Type ll and Type lll, apply sealant and torque bolts to 14 ft. lbs. (19.4 Nm).. Polaris Sales Inc. 7.33 4/99...
  • Page 425 NOTE: The same shim thickness placed behind ring gear bearing must also be put behind the cover button. Type l Type II Cover Bolts Torque 14 ft. lbs. Equal Shims Type ll / lll 4/99 7.34 Polaris Sales Inc.
  • Page 426 180° and verify proper backlash at this point on the ring gear. 9. Install pinion shaft seal and both output shaft seals. Electrical tape can be applied to all shafts to protect seals during installation. Polaris Sales Inc. 7.35 4/99...
  • Page 427 Front Housing Installation 1. To install housing, reverse removal procedure. Use new roll pins in drive shafts. 2. Add Polaris Premium Front Housing Lubricant or GL5 80-90 gear lube to front housing. Check drain plug for proper torque. Premium Front Housing Fluid PN 2871653 (12 oz.)
  • Page 428 Pinion Cover Thrust Washer O-Ring O-Ring Type ll Shown Vent (Type lll Similar) Bushing Seal Output Shaft Pinion Shaft Pinion Cover Bearing Retaining Ring O-Ring Shim Output Cover Bearing O-Ring Thrust Button Seal Shim Seal Polaris Sales Inc. 7.37 4/99...

  • Page 429: Rear Drive

    FINAL DRIVE Rear Drive 4/99 7.38 Polaris Sales Inc.
  • Page 430 Small amounts of axle runout can be straightened using V blocks, a hydrau- lic press, and a dial indicator. CAUTION: Do not use heat on any part of the axle. Heat will destroy the temper and cause the shaft to become brittle. Polaris Sales Inc. 7.39 4/99...
  • Page 431 Rear Wheel Nuts: 50 ft. lbs. (69 Nm) 11. Install hub cap. 12. Place wheels on hubs and install wheel nuts with tapered side facing in. Torque evenly to specifications. 4/99 7.40 Polaris Sales Inc.
  • Page 432 Remove rear wheels and hubs. 2. Remove drive chain. 3. Remove snap ring (A), lock sleeve (B) and foam seal (C) from axle. 4. Remove sprocket hub nut. 5. Remove rear brake caliper. Remove caliper bolts Polaris Sales Inc. 7.41 4/99...
  • Page 433 FINAL DRIVE Concentric Swingarm Rear Axle Concentric Swingarm Rear Axle Removal, Cont. 6. Support rear caliper with wire or a tie strap. Do not hang caliper by brake line. 7. Slide axle assembly out left side. 4/99 7.42 Polaris Sales Inc.
  • Page 434 7. Install rear wheel hubs. Torque center hub nut to 80 ft. lbs. and install a new cotter pin. Torque wheel nuts to 50 ft. lbs. 8. Lubricate eccentric housing grease fitting with Polaris Premium All Season Grease. Polaris Sales Inc. 7.43 4/99...
  • Page 435 Sprocket Hub 18 ft. lbs. (2.49 kg-m) Caliper Foam Seal Axle Nut Lock Collar Caliper Mount, Upper Snap Ring Torque:50 ft. lbs. (6.91 kg-m) Caliper Mount, Lower Torque: 80 ft. lbs. 10-12 ft.lbs. (1.38-1.65kg-m) (11.06 kg-m) 4/99 7.44 Polaris Sales Inc.
  • Page 436 Concentric Swingarm Rear Axle Disassembly 1. Remove rear axle. (See page 7.39) 2. Remove snap ring, collar, foam seal and disc hub. 3. Remove nut, disc assembly, and stop ring. Disc Hub Stop Ring Groove Threads Splines Polaris Sales Inc. 7.45 4/99...
  • Page 437 Apply Loctite 272 to threads, install left axle nut and tighten to 120 ft. lbs (166 Nm). Axle Nut (Disc Side) Torque: 120 ft. lbs. (166 Nm) Stop ring 3. Lubricate spacer and new O-ring. Install on axle. 4/99 7.46 Polaris Sales Inc.
  • Page 438 Lock Sleeve (Tapered side toward nut) Concentric Swingarm Rear Housing Removal 1. Remove rear axle. (See page 7.39) 2. Remove sprocket hub. Note sealing O-ring between sprocket hub and bearing. 3. Remove brake caliper mounting bracket. Polaris Sales Inc. 7.47 4/99...
  • Page 439 FINAL DRIVE Concentric Swingarm Rear Axle Concentric Swingarm Rear Housing Removal, Cont. 4. Remove brake caliper pivot bushing from stud. NOTE: Flange inward as shown. 5. Remove rear housing. 4/99 7.48 Polaris Sales Inc.
  • Page 440 1. Place brake caliper pivot bushing on stud with flange inward as shown. 2. Loosely assemble upper and lower brake caliper mount. Do not tighten at this time. 3. Install rear axle. (See page 7.41) Polaris Sales Inc. 7.49 4/99...
  • Page 441 Serious injury could occur if machine tips or falls. 6. Remove left wheel. 7. Remove hub. 8. Remove brake line shield. Clip tie wrap from brake line tubes. Carefully unsnap brake lines from T--clip. Tie Strap T--clip 4/99 7.50 Polaris Sales Inc.
  • Page 442 12. Remove (3) left swing arm bolts. 13. Remove (4) axle tube bolts from rear gearcase. 14. Slide axle through rear gearcase to the right enough to allow the axle tube to slip off between axle and and swingarm. Polaris Sales Inc. 7.51 4/99...
  • Page 443 9. Install new greased o--ring on axle and slide brake disc on splines of the axle. 10. Install brake caliper on brake disc and torque bolts to 18 ft./lbs. 11. Install brake line shield. Torque to 85 ft./lbs. 4/99 7.52 Polaris Sales Inc.
  • Page 444 1. Remove left wheel and hub. (See page 7.20 of rear axle removal, steps 1 - 7) 2. Remove rear brake caliper and support it from machine frame. 3. Remove rear brake disc. 4. Remove and discard o--ring from axle shaft. Polaris Sales Inc. 7.53 4/99...
  • Page 445 Rear Axle Bearing Removal 5. Slide axle through rear gearcase to the right as far as it will go. 6. Remove outer axle seal and discard. 7. Remove outer bearing and spacer. Bearing Spacer Outer Bearing 4/99 7.54 Polaris Sales Inc.
  • Page 446 2. Torque brake caliper, rear hub nut, and rear wheel nuts to specifications. Brake Caliper Torque: 18 ft. lbs. (2.48 kg-m) Rear Hub Nut Torque: 80 ft. lbs. (11.06 kg-m) Rear Wheel Nut Torque 15 ft. lbs. (2.07 kg-m) Polaris Sales Inc. 7.55 4/99...
  • Page 447 4. Loosen the wheel nuts. 5. Safely support the rear of the ATV. CAUTION: Serious injury could occur if machine tips or falls. 6. Remove hub nut, domed washer and flat washer. 7. Remove wheel nuts and wheel. 4/99 7.56 Polaris Sales Inc.
  • Page 448 FINAL DRIVE Independent Rear Hub Rear Hub/Bearing Carrier Removal 8. Remove hub. 9. Remove upper control arm bolt as shown. 10. Remove both lower control arm bolts. 11. Remove bearing carrier. Polaris Sales Inc. 7.57 4/99...
  • Page 449 Rear Hub Nut Torque: 100 ft. lbs. (13.83 kg-m) Rear Wheel Nut Torque 15 ft. lbs. (2.07 kg-m) 9. Install a new cotter pin. Tighten nut slightly to align holes if required. 10. Install hub cap. 4/99 7.58 Polaris Sales Inc.
  • Page 450 4. Inspect bearing housing for scratches, wear or damage. Replace housing if damaged. Polaris Sales Inc. 7.59 4/99...
  • Page 451 2. Start bearing in housing. 3. Press bearing into place until outer race bottoms on housing. CAUTION: Use an arbor and press only on the outer race, as bear- ing damage may occur. 4. Install snap ring into groove. 4/99 7.60 Polaris Sales Inc.
  • Page 452 S Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned. Refer to text for grease capacity of CV Polaris Sales Inc. 7.61...
  • Page 453 CV joint boots. 4/99 7.62 Polaris Sales Inc.
  • Page 454 6. Install rear wheel and torque wheel nuts to specification. 100 ft. lbs. Flat Washer (138 Nm) Rear Wheel Nut Torque: 15 ft. lbs. (21 Nm) Cone 7. Grease all fittings thoroughly with Premium U-Joint Washer Lubricant. Cone washer dome to outside Polaris Sales Inc. 7.63 4/99...
  • Page 455 Small Yoke (.9958″) 2871814 3. Pull tool out and turn 90°. Slide tool through both bores. Tool must slide freely into both bores. If yoke tool does not slide freely in both bores, replace yoke. 4/99 7.64 Polaris Sales Inc.
  • Page 456 3. Open the snap ring using a snap ring pliers or small Spread ends of snap ring needle nose pliers. Tap CV housing off shaft with a to remove joint from shaft soft faced hammer while holding snap ring open. Tap CV Housing Off Shaft Polaris Sales Inc. 7.65 4/99...
  • Page 457 The air should be released after the plunging joint has been centered properly. Tighten boot clamp using boot clamp pliers. 4/99 7.66 Polaris Sales Inc.
  • Page 458 Inboard joint - 50g if boot is replaced only. Another 50g (100total) if joint is cleaned. INBOARD OUTBOARD CV Joint Grease - 30g PN 1350046 100g Total 80g Total 50g PN 1350047 Boot Capacity Boot Capacity 30 Grams 50 Grams Polaris Sales Inc. 7.67 4/99...
  • Page 459 FINAL DRIVE Independent Rear Suspension Exploded View Dual U-Joint Dual CV Shaft 4/99 7.68 Polaris Sales Inc.
  • Page 460 15-20 inch pounds. Be Lock Sprocket sure to tighten properly following procedure above. Washer Washer Seal Front of vehicle Shaft Bearing Bearing Race Grease Fitting Housing Cotter Pin Bearing Race Bearing Seal O-Ring Spacer Washer Sprocket Polaris Sales Inc. 7.69 4/99...
  • Page 461 S Install a new bearing, pressing on the outer race only, until bearing is fully seated in left end of housing (left side has grease fitting). Outer race of bearings must fit tightly in housing. S Turn housing over and support inner race of bearing installed in previous step. S Install shaft. 4/99 7.70 Polaris Sales Inc.
  • Page 462 FINAL DRIVE Center / Front Chain Tightener Exploded View Polaris Sales Inc. 7.71 4/99...
  • Page 463 NOTES...
  • Page 464 CHAPTER 8 TRANSMISSION SERVICE Torque Specifications ......Lubrication Chart ......Transmission Type Identification .
  • Page 466 Shaft drive front, chain drive rear. (i.e. Scrambler Type V Shaft / Chain 400 / 500) (High/Low/Reverse, High/Reverse) Used on models with Shaft Ride rear suspension. Type Vl Shaft Ride Shaft drive front (where applicable), shaft drive rear. (High/Reverse, High/Low/Reverse) Polaris Sales Inc. 4/99...
  • Page 467 Loosen each screw only a few turns, then proceed to another screw. NOTE: These parts are under pressure from the inter- nal spring. 4/99 Polaris Sales Inc.
  • Page 468 Stop Pin 12. Dry all gear shift selector parts and remove any Detent Pin Bearing Cup corrosion with a wire brush. Interlock Pin Selector Switch (If equipped) Interlock Butterfly High/Reverse (3 Notches) 2 Notches Selector Slides Polaris Sales Inc. 4/99...
  • Page 469 Shift Selector Disassembly. 4. Clamp gear shift selector body lightly in a soft jawed vise. 5. Fill selector body with Polaris 0W-40 All Season Synthetic motor oil. The oil level should be at one half the height of the slides.
  • Page 470 9. Push shift knob cover back into place. Allow Detent Pin Bearing Cup approximately 12 hours for RTV silicone to cure. Interlock Pin Selector Switch (If equipped) Interlock Butterfly High/Reverse (3 Notches) 2 Notches Selector Slides Polaris Sales Inc. 4/99...
  • Page 471 Work Low Gear gear back and forth as shown until bearing is exposed and slide bearing out. See Ill. 3. (2) Remove needle bearing (1) Work gear back and forth until bearing is exposed Ill. 3 4/99 Polaris Sales Inc.
  • Page 472 NOTE: High/Reverse bell crank must be in neutral to re- move Low gear shift fork shaft. 10. Remove output shaft and gear assembly by tapping on shaft with a soft faced hammer, from the back side of the gear case assembly. Polaris Sales Inc. 4/99...
  • Page 473 14. Inspect gear teeth for wear, cracks, chips or broken teeth. 15. Remove seals from transmission case. NOTE: New seals should be installed after the transmis- sion is completely assembled. 16. Inspect bearings for smooth operation. Check for excessive play between inner and outer race. 4/99 Polaris Sales Inc.
  • Page 474 See Ill. 1. Engagement dog splines Washer Dogs face (Large I.D.) Shaft pin Ill. 1 6. Install large I.D. washer on shaft (against splines). Polaris Sales Inc. 4/99...
  • Page 475 Apply Loctitet 518 or 3-Bond 1215 to mating surfaces. 11. Reinstall cover and torque bolts in 3 steps to 12 ft. lbs. (17 Nm) using a criss-cross pattern. 12. Install transmission and add Polaris Premium Synthetic Gear Case Lubricant recommended amount.
  • Page 476 12. Install skid plate and torque bolts to 5 ft. lbs. (7 Nm). 13. Install driven clutch spacer and dust seal(s). 14. Install inner cover and all PVT system components. Angle Refer to PVT Section for procedure. Drive 8-10 ft. lbs. (1.10-1.38 kg-m) Polaris Sales Inc. 8.11 4/99...
  • Page 477 18. Apply silicone to splines of brake disk and reinstall disk. 19. Install brake caliper on disk and bolt to frame with the rear caliper shield. Torque to specification. Caliper Attaching Bolt Torque: 12 ft. lbs. (17 Nm) 4/99 8.12 Polaris Sales Inc.
  • Page 478 30 ft. lbs. (41 Nm) Speedo Head Speedometer Service 1. Remove speedometer cable from speedometer head and lubricate it periodically Lube Here with Polaris cable lube (PN 2870510). Drive Key Polaris Cable Lube Adapter (LH Speedo Thread) Cable PN 2870510 Drive Key 2.
  • Page 479 Shift Shaft (Lower, Input Shaft Forward most) on Transmission Detent Spring High/Reverse Needle Reverse Engagement Dog Bearing Chain High Reverse Gear Gear Output Gear Output Shaft Vent O-Ring Oil Deflector Bushing Dipstick Drain Plug Output Shaft Seal 4/99 8.14 Polaris Sales Inc.
  • Page 480 7. Remove rear (auxiliary) brake caliper and disc (where applicable). Support caliper on right hand foot rest. 8. Disconnect transmission shift linkage rods. Remove right hand shock absorber. 9. Disconnect the sway bar from both sides. Remove right side upper control arm. Polaris Sales Inc. 8.15 4/99...
  • Page 481 Pivot upper control arm away from transmission as shown. 11. Remove both lower transmission mounting bolts from each side. Lower Mounting Bolts 12. Remove all 8 bolts attaching the stabilizer support bracket, and remove support. 4/99 8.16 Polaris Sales Inc.
  • Page 482 (below). Pull outward to remove form transmission 15. Lift right side drive shaft and hub up and out of the way. This will provide access to remove transmission out right side of frame. Polaris Sales Inc. 8.17 4/99...
  • Page 483 TRANSMISSION Type IV, Shaft Drive Transmission Transmission Removal, Cont. 16. Remove bottom transmission bolts as shown in illustration. Remove bolts 17. Lift and remove transmission out right side of frame. 4/99 8.18 Polaris Sales Inc.
  • Page 484 Transmission Installation 1. Apply anti-seize compound to splines of front output shaft and insert into prop shaft. 2. Rotate transmission into place from right side of frame. 3. Loosely install bottom transmission bolts. Install bolts Polaris Sales Inc. 8.19 4/99...
  • Page 485 6. Apply anti-seize to splines of drive shaft and install right side drive shaft in transmission with opening in U-joint upward. Support right hand hub and install right hand upper control arm attaching bolts. Install stabilizer bar arm on stabilizer bar. 4/99 8.20 Polaris Sales Inc.
  • Page 486 Whenever the drive shafts are disassembled, the inner and outer U-joint yokes on each shaft must be aligned as shown to prevent excessive driveline vibration. It is not necessary to align the left shaft yokes to the right. 8. Attach speedometer cable. Polaris Sales Inc. 8.21 4/99...
  • Page 487 Premium Synthetic Gear Case Lubricant PN 2871478 (12 oz.) PN 2871477 (Gallon) 15. Install rear wheel nuts and torque to specification. Rear Wheel Retaining Bolt Torque 15 ft. lbs. (2.08 kg-m) 16. Refer Maintenance Section adjust transmission linkage. 4/99 8.22 Polaris Sales Inc.
  • Page 488 Do not pry on case half sealing surfaces. 3. Mark chain rotation direction for assembly. Note location of chain tensioner cam. If fully extended, chain is worn beyond service limit. Replace chain and chain tensioner shoe. Polaris Sales Inc. 8.23 4/99...
  • Page 489 4. Remove chain tensioner along with mounting pins and spacers. Note position of spacers for assembly. 5. Remove rear output gear and chain as an assembly by lifting straight outward. 6. Remove oil deflector. Remove Screws 4/99 8.24 Polaris Sales Inc.
  • Page 490 9. Turn transmission so shafts are pointing down. Slide the Low gear in and out until needle bearing slides out of gear and can be removed. Remove needle bearing, low gear, and inner thrust washer. Polaris Sales Inc. 8.25 4/99...
  • Page 491 10. Inspect shift dogs for excessive rounding on the leading edges. Replace if worn. 11. Remove low range shift fork and dog. Replace along with mating gear if wear is evident. 12. Inspect face of shift fork for excessive wear, discoloration, or bending. 4/99 8.26 Polaris Sales Inc.
  • Page 492 14. Remove the remaining gears and shafts as an assembly. Rotate the shift bellcrank with a 1/2″ wrench to aid in removal. 15. Remove pinion gear retaining plate and pinion gear assembly. Polaris Sales Inc. 8.27 4/99...
  • Page 493 16. Inspect pinion gear for broken, chipped, or worn teeth. Check bearing condition, and snap ring location. 17. Loosen front output housing pinch bolts. Loosen Pinch Bolts 18. Mark housing and casting for reference upon reassembly. 4/99 8.28 Polaris Sales Inc.
  • Page 494 21. Bend the lock plate tab away from ring gear retaining bolt. 22. Using a strap wrench on splines to hold shaft, remove front output ring gear retaining bolt, lock tab washer, and flat washer. Ring Gear Flat Washer Lock Plate Polaris Sales Inc. 8.29 4/99...
  • Page 495 Apply electrical tape to threads of housing to prevent damage. 25. Using a brass hammer or a press, drive the shaft, bearing, retaining ring, and seal out of the housing from rear to front. Seal Retaining Ring Shim(s) Bearing Housing Shaft 4/99 8.30 Polaris Sales Inc.
  • Page 496 27. Inspect center shaft bushing for wear. If necessary, remove with the large end of bushing drive tool. Bushing Drive Tool PN 2871697 28. Remove all remaining seals from transmission cases and clean all parts thoroughly. Polaris Sales Inc. 8.31 4/99...
  • Page 497 Heat inner bearing on a hot plate or with a heat gun to ease installation. Install bearing on shaft until inner race bottoms on flange of shaft. CAUTION: Do not use a torch - bearing damage may re- sult. 4/99 8.32 Polaris Sales Inc.
  • Page 498 To measure end play: Install snap ring on shaft without shims in place. Clamp housing lightly in soft jawed vise. 5. Set up a dial indicator to measure shaft end play. Polaris Sales Inc. 8.33 4/99...
  • Page 499 .000″ - .003″ (0mm - .075mm) 7. Remove electrical tape and liberally apply anti-seize compound to the threads of the front output housing. 8. Screw in housing until O-ring is approximately 1/4″ (8mm) from transmission housing. 4/99 8.34 Polaris Sales Inc.
  • Page 500 Apply Loctite™ 242 or 243 (Blue) Front Output Housing (Snorkel) Backlash Adjustment 11. Lubricate front housing O-ring thoroughly with Polaris All Season grease. Continue to screw front housing in, making sure O-ring enters housing without damage. Be sure ring and pinion gear teeth mesh properly.
  • Page 501 90° to the tool surface), or indicated backlash will be inaccurate. To reduce backlash, rotate housing clockwise as viewed from front of housing. To increase backlash, rotate housing counter- clockwise. 15. Torque pinch bolts to specification. Verify backlash measurement. 4/99 8.36 Polaris Sales Inc.
  • Page 502 The outer gear dogs must face each other. Low Gear Reverse Gear Retainer Engagement Needle Bearing Washer Bearing Dog, Low Bearing Washer H/L/R Shaft Washer Bearing Washer Needle High Retainer Engagement Bearing Gear Dog, High/Rev Polaris Sales Inc. 8.37 4/99...
  • Page 503 Place the Hi/Reverse shift assembly in neutral position. If it is not located in neutral, the interlock mechanism will prevent installation of the low range shift fork in step 25. 4/99 8.38 Polaris Sales Inc.
  • Page 504 Make sure the shift shaft pin is located between the tail ends of the return spring. 24. Lubricate and install inner thrust washer, low gear, and needle bearing. Polaris Sales Inc. 8.39 4/99...
  • Page 505 (blue) to all screw threads. NOTE: Do not over-tighten deflector screws, or deflector may crack. Oil Deflector Screws Loctite™ 242 or 243 (Blue) 27. Install drive gear with chain. 28. Install chain tensioner. Refer to Illustration on following page. 4/99 8.40 Polaris Sales Inc.
  • Page 506 5. Lift leg of spring up and over the rear pin. Tensioner cam will lift shoe and tension chain. View From Left Side of Transmission Forward Lift Spring Over Rear Mounting Pin Hook Spring Leg Under Cam Polaris Sales Inc. 8.41 4/99...
  • Page 507 TRANSMISSION Type IV, Shaft Drive Transmission Transmission Assembly, Cont. 29. Pre-lubricate all bearings with Polaris Premium Synthetic GearCase Lubricant before installing cover. 30. Be sure sealing surfaces cover transmission case are clean. Apply 3Bondt 1215 to surface of case and install cover bolts. Torque to specification in three steps, following a criss cross pattern.
  • Page 508 Install seal to a depth of 1/8″ below the transmission housing. Refer to photo. 34. Install gear indicator switch(es). Apply Loctitet 242 (blue) to threads of switch screws and torque to 13-16 in. lbs. (1.5-1.9 Nm). Polaris Sales Inc. 8.43 4/99...
  • Page 509 Retainer Plate Shoe Pins Bearings Pinion Gear Tensioner Assembly Spacers Snap Tensioner Assembly Ring Seals Dipstick Vent Tube Front Output Shims Shaft Bearing Front Output Housing Bushing Front Output Ring Gear Seal Bottom Access Plate 4/99 8.44 Polaris Sales Inc.
  • Page 510 1. Reverse removal steps to install transmission. NOTE: Install center distance tool PN 2871710 on en- gine and transmission input shaft before tightening trans- mission mounting bolts. Align clutches as outlined in Clutch Chapter 6. Polaris Sales Inc. 8.45 4/99...
  • Page 511 Low Gear gear back and forth as shown until bearing is exposed and slide bearing out. See Ill. 3. (2) Remove needle bearing (1) Work gear back and forth until bearing is exposed Ill. 3 4/99 8.46 Polaris Sales Inc.
  • Page 512 12. Use a 1/2″ wrench to rotate high/reverse bell crank and remove shift fork along with shafts. Polaris Sales Inc. 8.47 4/99...
  • Page 513 19. Remove seals from transmission case. NOTE: New seals should be installed after the transmis- sion is completely assembled. 20. Inspect bearings for smooth operation. Check for excessive play between inner and outer race. 4/99 8.48 Polaris Sales Inc.
  • Page 514 NOTE: Make sure high/reverse shift shaft pin is properly positioned within legs of shift fork shaft return spring. NOTE: After installation, the High / Reverse shift arm must be placed in the neutral position to complete reas- sembly. Polaris Sales Inc. 8.49 4/99...
  • Page 515 11. Install low gear with slots facing dog gear. Needle bearing Large I.D. 12. Lubricate and install needle bearing in low gear. Dog gear 13. Install washer (small inside diameter) on shaft. 14. Install ball bearing. 4/99 8.50 Polaris Sales Inc.
  • Page 516 16. Reinstall cover and torque bolts in a criss-cross pattern in 3 steps to 18 ft. lbs. (25 Nm). 17. Install drain plug with a new sealing washer. Torque drain plug to 14 ft. lbs. (19 Nm). 18. Install transmission and add Polaris Premium Synthetic Gear Case Lubricant recommended amount.
  • Page 517 TRANSMISSION Type V, Shaft / Chain Transmission Transmission Exploded View 4/99 8.52 Polaris Sales Inc.
  • Page 518 11. Remove through-bolt from bottom of transmission. 12. Remove front transmission-to-engine mount bolts. 13. Position rear U-joint so front of transmission can be lifted up. 14. Remove recoil for added removal clearance. 15. Remove transmission from right side of frame. Front Polaris Sales Inc. 8.53 4/99...
  • Page 519 7. Loosely install lower right bracket bolt. 8. Loosely install front mounting bolts. 9. Install transmission alignment tool PN 2872315 as shown. 10. Tighten mounting fasteners in order A-F as shown. NOTE: Align clutches as outlined in Clutch Chapter 6. Front 4/99 8.54 Polaris Sales Inc.
  • Page 520 3. Remove case cover screws. 4. Remove the transmission cover bolts. 5. With a soft face hammer tap on the cover bosses and carefully remove the cover. 6. Remove bearing and 41 tooth helical gear. Polaris Sales Inc. 8.55 4/99...
  • Page 521 Type Vl, Shaft Ride Transmission Transmission Disassembly, cont. 7. Remove input shaft, reverse shaft, and both shift for shafts as an assembly. 8. Remove pinion shaft retainer plate and pinion shaft. 9. Remove front drive output housing cover screws. 4/99 8.56 Polaris Sales Inc.
  • Page 522 15. Remove seals from transmission case. NOTE: New seals should be installed after the transmis- sion is completely assembled. 16. Inspect bearings for smooth operation. Check for excessive play between inner and outer race. Polaris Sales Inc. 8.57 4/99...
  • Page 523 3. Install front and rear output shafts with chain as an assembly. 4. Reinstall cover and torque bolts in a criss-cross pattern in 3 steps to 18 ft. lbs. (25 Nm). 5. Install new front and rear output shaft seals. 4/99 8.58 Polaris Sales Inc.
  • Page 524 7. Install pinion shaft with bearing. 8. Install retainer plate with flat side toward bearing. 9. Apply Loctitet 242 (Blue) to screw threads and torque screws to 18 ft. lbs. (25 Nm). 10. Assemble shafts with chain and shift forks. Polaris Sales Inc. 8.59 4/99...
  • Page 525 3 steps to 18 ft. lbs. (25 Nm). 15. Install new input shaft seal. 16. Install drain plug with a new sealing washer. Torque drain plug to 14 ft. lbs. (19 Nm). Large I.D. 17. Install transmission and add Polaris Premium Synthetic Gear Case Lubricant recommended amount.

  • Page 526: Transmission Exploded View

    Sprocket, 12T Gearcase, RH Bearing 14 ft. lbs. (19 Nm) Seal Thrust Washer 14 ft. lbs. (19 Nm) Sealing Dowel Pin Washer Seal Sealing O-ring Washer Snap Ring Shaft, Front Bushing Bearing Output Chain Sprocket, 12T Polaris Sales Inc. 8.61 4/99...
  • Page 527 If it functions properly, the problem is outside the transmission. If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding), dam- age. Inspect all bearings for wear. 4/99 8.62 Polaris Sales Inc.
  • Page 528 CHAPTER 9 BRAKES Specifications, 1999 ......Torque Specifications ......Brake System Service Notes .
  • Page 530 Item Standard Service Limit Brake Pad Thickness .490″ / 12.45mm .150″ / 3.81mm Brake Disc Thickness .177-.187″ /4.496-4.750mm .167″ / 4.242mm Brake Disc Thickness Variance Between .002″ / .051mm Measurements Brake Disc Runout .010″ / .25mm Polaris Sales Inc. 4/99...
  • Page 531 Rear Axle Caliper Mounting Bolts 18.0 Master Cylinder Mounting Bolts *55 in. lbs. Master Cylinder Reservoir *45 in. lbs. Cover Bolt Brake Line Banjo Bolt 15.0 Front Brake Disc 18.0 Rear Brake Disc (6x6) 24.0 Front Wheel Mounting Nuts 15.0 4/99 Polaris Sales Inc.

  • Page 532: Brake System Service Notes

    Sportsman 500 Rear brake pad kit (contains Production rear pad for most Sportsman hy- 2 pads 1930859 for hydraulic auxiliary brake) draulic auxiliary brake 2201189 - Kit Rear brake pad kit Scrambler 400 / 500 Production pad for most Scrambler models Polaris Sales Inc. 4/99...
  • Page 533 Noise is from other source (chain, axle, hub, disc or If noise does not change when brake is applied check wheel) other sources. Inspect and repair as necessary Wrong pad for conditions Change to a softer or harder pad 4/99 Polaris Sales Inc.
  • Page 534 When servicing Polaris ATV brake systems use only Polaris DOT 3 high temperature brake fluid (PN 2870990). Polaris brake fluid is sold in 5.5 oz. bottles. WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
  • Page 535 NOTE: Caliper style and location of brake lines and bleeder screws may differ Upper bleed screw and brake line (A) is for hand brake system. Lower bleed screw and brake line (B) is for auxiliary (foot) brake Upper Bleed Screw system. Hand Brake Lower Bleed Screw Auxiliary Brake 4/99 Polaris Sales Inc.
  • Page 536 Dual Hydraulic caliper. Refer to page 9.6 for theory of operation and bleeding procedure. The auxiliary brake line applies pressure to the small (inner) diameter of the caliper piston. Use the outermost (lower) bleed screw to purge air. See photo on page 9.6. Polaris Sales Inc. 4/99...
  • Page 537 NOTE: Do not remove brake lever when reservoir fluid level is low. Mity Vac™ PN 2870975 5. Add brake fluid to the upper level mark on reservoir. Polaris DOT 3 Brake Fluid PN 2870990 DH Caliper Hand Brake Line 6. Begin bleeding procedure with the caliper that is Forward farthest from the master cylinder.
  • Page 538 With lever firmly applied, lever reserve should be no less than 1/2″ (1.3 cm) from handlebar. 16. Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasion. Replace hose if wear or abrasion is found. Polaris Sales Inc. 4/99...
  • Page 539 Master Cylinder Piston Assy 4. Remove cover and diaphragm from master cylinder and dispose of the fluid properly. Vent Slots 5. Be sure vents in cover are clean and unobstructed. 6. Remove brake lever. Cover Diaphragm 4/99 9.10 Polaris Sales Inc.
  • Page 540 9. Remove outer dust seal. Be ready to catch piston assembly. NOTE: The return spring may force piston out when dust seal has been removed. 10. Remove piston assembly and return spring from master cylinder. Replace piston assembly and spring. Outer Dust Seal Polaris Sales Inc. 9.11 4/99...
  • Page 541 2. Select the appropriate master cylinder piston installation tool and insert into master cylinder bore. A typical installation tool is shown at right. 2201190 Type IV Master Cylinder (Hand Brake) .750 (19mm) Installation Tool #2200879 2201191 Components of Kit 2200879 4/99 9.12 Polaris Sales Inc.
  • Page 542 6. Install reservoir with new seal. Be careful to install and torque screws evenly. 7. Apply a light film of grease to the lever bolt. Install lever and tighten bolt securely. 8. Install parking brake lever assembly. Polaris Sales Inc. 9.13 4/99...
  • Page 543 (2.07 kg-m) Brake Line 3. Fill reservoir with DOT 3 fluid. 4. Follow bleeding procedure on pages 9.8-9.9. Check all connections for leaks and repair if necessary. Polaris DOT 3 Brake Fluid PN 2870990 4/99 9.14 Polaris Sales Inc.
  • Page 544 Remove inner pad. Pad Retaining Pins 6. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. Front Brake Pad Thickness .275″/7.0 mm Service Limit .150″ / 3.81 mm Measure Thickness Polaris Sales Inc. 9.15 4/99...
  • Page 545 BRAKES Front Pad Brake Service Assembly 1. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust seal boots. Polaris Premium All Season Grease PN 2871423 2. Compress mounting bracket and make sure dust seals are fully seated.
  • Page 546 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 runout exceeds specifications. Brake Disc Runout Service Limit .020″ (.50 mm) Polaris Sales Inc. 9.17 4/99...
  • Page 547 The bolts have a pre-applied locking agent which is 18 ft. lbs. (24.9 Nm) destroyed upon removal. Use new bolts with pre-applied locking agent. Front Brake Disc Mounting Bolt Torque 18 ft. lbs. (24.9 Nm) 4/99 9.18 Polaris Sales Inc.
  • Page 548 3. Remove brake caliper and drain fluid into container. Caliper Disassembly 1. Remove brake pad adjuster screw. 2. Push upper pad retainer pin inward and slip brake pads past edge. 3. Remove mounting bracket, pin assembly and dust boot. Remove Mounting Bracket Polaris Sales Inc. 9.19 4/99...
  • Page 549 Measure diameter and replace if damaged or worn beyond service limit. Front Caliper Piston O.D. Std. 1.186-1.1875″ (30.13-30.16 mm) Service Limit 1.1855″ (30.11 mm) 3. Inspect the brake disc and pads as outlined for brake pad replacement this section. See page 9.17. 4/99 9.20 Polaris Sales Inc.
  • Page 550 Piston should slide in and out of bore smoothly, with light resistance. 3. Lubricate the mounting bracket pins with Polaris Premium All Season Grease, and install the rubber dust seal boots. Polaris Premium All Season Grease PN 2871423 4.
  • Page 551 Start machine and slowly in- crease speed to 30 mph. Gradually apply brakes to stop ma- chine. Repeat procedure 10 times. 4/99 9.22 Polaris Sales Inc.
  • Page 552 BRAKES Front Brake Caliper Exploded View Adjuster Screw Square O--Rings Piston Pin Boot Pads Caliper Mount Polaris Sales Inc. 9.23 4/99...
  • Page 553 5. Clean the caliper w/ brake cleaner or alcohol. 6. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. Rear Brake Pad Thickness .275″ (7.0 mm) Service Limit .150″ (3.81 mm) Measure Thickness 4/99 9.24 Polaris Sales Inc.
  • Page 554 4. It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise. Start machine and slowly increase speed to 30 mph. Gradually apply brakes to stop machine. Repeat procedure 10 times. Polaris Sales Inc. 9.25 4/99...
  • Page 555 5. Remove Allen head screw and separate caliper halves and remove pistons with piston pliers. 6. Remove O-rings and clean O-ring grooves. 7. Clean disc, caliper body, and pistons with brake cleaner or alcohol. 4/99 9.26 Polaris Sales Inc.
  • Page 556 2. Install new O-rings between caliper halves. O-Rings 3. Carefully assemble caliper body, making sure O-rings are properly positioned in groove. Torque body screw evenly to 18 ft. lbs. Caliper Body Torque 18 ft. lbs. (2.49 kg-m) Polaris Sales Inc. 9.27 4/99...
  • Page 557 8. Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when lever is released. If the brake drags, re-check assembly and installation. 4/99 9.28 Polaris Sales Inc.
  • Page 558 Brake Disc Thickness Variance Service Limit .002″ (.051 mm) difference between measurements 3. Mount dial indicator and measure disc runout. Replace the disc if runout exceeds specifications. Brake Disc Runout Service Limit .010″ (.25 mm) Polaris Sales Inc. 9.29 4/99...
  • Page 559 Torque 18 ft./lbs 2.48 Kg-m Hand Brake Line Hand Brake Bleed Auxiliary Brake Pads Auxiliary Brake Bleed Auxiliary Torque Brake Disc 45 ft./lbs 6.2 Kg-m Torque 8 ft./lbs 1.1 Kg-m Return Spring Auxiliary Master Cylinder 4/99 9.30 Polaris Sales Inc.
  • Page 560 Hand Brake Line Auxiliary Brake Line Torque 15 ft./lbs. 2.07 Kg-m Auxiliary Spacer Brake Pads Auxiliary Brake Bleed Auxiliary Brake Reservoir Torque 8 ft./lbs. 1.1 Kg-m Torque 18 ft./lbs. 2.48 Kg-m Return Spring Auxiliary Brake Master Cylinder Polaris Sales Inc. 9.31 4/99...
  • Page 561 2.07 Kg-m Auxiliary Brake Spacer Bleed Hand Brake Bleed Auxiliary Reservoir Torque 8 ft./lbs. Torque Auxiliary 1.1 Kg-m 15 ft./lbs. Master 2.07 Kg-m Cylinder Torque Return 8 ft./lbs. Spring 1.1 Kg-m Torque 8 ft./lbs. 1.1 Kg-m 4/99 9.32 Polaris Sales Inc.
  • Page 562 Do not slide the cloth in or out of bore while applying pressure as scratches may result. Do not use any other type of abrasive or abrasive cloth. 2. Inspect piston. Ill. 4 Polaris Sales Inc. 9.33 4/99...
  • Page 563 3. If piston pin or axillary brake arm were removed, lubricate all sliding surfaces of stationary and moveable brake ramps with a thin coat of Polaris high temp grease. 4. Align mark of stationary and moveable cam so long...
  • Page 564 7. Reinstall right front and rear mud flap bolt in footrest. 8. Refill master cylinder with DOT 3 brake fluid and reinstall cover and diaphragm. Polaris DOT 3 Brake Fluid PN 2870990 Master Cylinder Fluid Level 1/4″ - 5/16″ (6 - 8 mm) below top of master cylinder 9.
  • Page 565 Seat then tighten an additional 1/2 turn See step 5, page 9.34 Auxiliary Brake Pads Ramp (Moveable) Ramp (Stationary) Torque Auxiliary 5--6 ft./lbs. Caliper Arm .69-.83 Kg-m (Detail A) Xpress/ Trail Boss Xplorer 300 Detail A 4/99 9.36 Polaris Sales Inc.
  • Page 566 BRAKES Auxiliary Brake Caliper Mounting (Mechanical) Auxiliary Caliper Torque 12 ft./lbs. 1.65 Kg-m Spacer Polaris Sales Inc. 9.37 4/99...
  • Page 567 S Brake lever or pedal binding or unable to return fully S Parking brake left on S Residue build up under caliper seals S Operator riding brakes Brakes Lock S Alignment of caliper to disc. 4/99 9.38 Polaris Sales Inc.
  • Page 568 CHAPTER 10 ELECTRICAL Special Tools ........10.1 Headlamp Service, Gen II .
  • Page 570 SPay attention to the prefix on the multimeter reading (K, M, etc.) and the position of the decimal point. SFor resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply. Polaris Sales Inc. 10.1 4/99...
  • Page 571 Phillips screws from either side of this panel. Also remove the two Torx™ screws at the rear of this panel. 9. Ease the panel forward and up to allow you to reach the socket connected to the headlight lamp. 4/99 10.2 Polaris Sales Inc.
  • Page 572 NOTE: Do not touch a halogen lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot which will shorten the life of the lamp. Hold the lamp by the base. Polaris Sales Inc. 10.3 4/99...
  • Page 573 Scrambler 6. Adjust beam to desired position. 7. Tighten nut and bolt. Adjustment - Trail Blazer and Sport 8. adjust beam to desired position by turning adjustment Left headlight screws in headlight cover. Turning right screw clockwise adjustment moves the intense spot of light up to the left.
  • Page 574 5. Plug new bulb into wire harness, making sure it snaps into place. 6. Carefully insert bulb into back of housing. Twist to lock in place. 7. Reinstall plastic lens retaining bracket. 8. Reinstall Phillips screw in bottom of headlamp. Screw Polaris Sales Inc. 10.5 4/99...
  • Page 575 9. Reverse steps to install new housing and reassemble pod. 5 1/8″ (13 cm) 10.Adjust headlight aim by turning adjusting knob. Distance from headlamp parting line to end of adjustment knob stop is 5 1/8″ (13 cm). 4/99 10.6 Polaris Sales Inc.
  • Page 576 2. Using a small flexible tube (such as an oil delivery hose) grasp the burned out lamp and remove it. 3. Replace the removed lamp with a Polaris PN 4030042. 4. Replace the indicator light cover. NOTE: Check all lights daily for proper operation replace or repair if necessary.
  • Page 577 1. Remove the magneto housing. 2. Remove the flywheel. 3. Loosen the stator plate screws and adjust the stator plate position. NOTE: Moving the stator plate clockwise retards (delays) the ignition timing. Moving the plate counterclockwise advances it. 4/99 10.8 Polaris Sales Inc.
  • Page 578 * Actual advance point may vary by several hundred RPM either above or below 3500. Use the point of maximum advance when checking ignition timing. MAXIMUM ADVANCE POINT (*) 1000 2500 3000 3500 4000 4500 5000 5500 6000 Polaris Sales Inc. 10.9 4/99...
  • Page 579 .1370 3.633 .1509 4.124 .1620 3.759 .1480 4.138 .1629 4.451 .1750 4.045 .1590 4.453 .1753 4.790 .1890 4.341 .1710 4.778 .1881 5.140 .2020 4.646 .1830 5.114 .2013 5.501 .2170 4.960 .1950 5.459 .2149 5.872 .2310 4/99 10.10 Polaris Sales Inc.
  • Page 580 The flywheel can be identified by the stamp mark in location A or B. Refer to “I.D.” location in chart below. Do not use the cast mark to determine flywheel application. 1999 Engine Application Type Cast Stamp Comment Flywheel I.D. Stamp Trail Boss / Trail Blazer EC25PFE10, EC25PFE13 FF4564 FF45 With Ring Gear 300 Xplorer, Xpress EC28PFE02 FF4574 FF95 4574...
  • Page 581 Check coil mount for good ground to engine (0-.2 ) Ω NOTE: CDI boxes may look the same but have different internal circuitry. Be sure to always use the correct CDI box part number. 4/99 Polaris Sales Inc. 10.12...
  • Page 582 Secondary Coil NOTE: CDI boxes may look the same but have different internal circuitry. Be sure to always use Check coil mount for good the correct CDI box part number. ground to engine (0-.2 ) Ω Polaris Sales Inc. 10.13 4/99...
  • Page 583 Wire (Black) Coil Lead Ω Meter 5000 Ω Ω Meter 6300 Ω Ω Meter .3 Ω Ignition Coil Primary Winding Secondary Coil CDI Box Check coil mount for good ground to engine (0-.2 ) Ω 4/99 10.14 Polaris Sales Inc.
  • Page 584 (0-.2 ) Ω Stator Plate CDI Box Magnetic Switch Ignition Exciter Coils Battery Charging Coils Refer to wiring diagrams for Flywheel and specified stator coil resistance Ring Gear Casting. Refer to page 10.3b for identification. Polaris Sales Inc. 10.15 4/99...
  • Page 585 Are these values within specs? If all of the above tests are within specifications, and all grounds, connections, and wire color coding have been inspected, perform voltage output tests on following page or replace the CDI module. 4/99 10.16 Polaris Sales Inc.
  • Page 586 CDI module. Crank engine and check output of CDI wire to coil (130 DCV). Reconnect coil wire to CDI. Output w/ Peak output tester 130 DCV Average Output w/ Digital Voltmeter 20 DCV Polaris Sales Inc. 10.17 4/99...
  • Page 587 STrigger coil air gap too wide (where applicable) - should be .016-.040″ (.4-1.0 mm) SExcessive crankshaft runout on magneto (RH) end - should not exceed .005″ SWhite stator wire (150W alternators) not grounded to engine SFaulty CDI module** 4/99 10.18 Polaris Sales Inc.
  • Page 588 6. Check specific gravity of each cell with a hydrometer to assure each has a reading of 1.270 or higher. Battery Terminals/Terminal Bolts Use Polaris corrosion resistant dielectric grease (PN 2871027) on battery bolts. See Battery Installation on page 10.20.
  • Page 589 2. Reinstall battery, attaching positive (+) (red) cable first and then the negative (-) (black) cable. Coat terminals and bolt threads with Polaris dielectric grease PN 2871027. 3. Install clear battery vent tube from vehicle to battery vent. WARNING: Vent tube must be free from obstructions and kinks and securely installed.
  • Page 590 Differences of more than .025 between the lowest and highest cell readings indicate a need to replace the battery. OPEN CIRCUIT VOLTAGE State of Conventional YuMicron™ charge Lead-acid Type Polaris PN 2870876 100% 12.60V 12.70V Charged 12.40V 12.50V 75% Charged 12.10V 12.20V...
  • Page 591 +5° F 1.100 +18° F 1.050 +27° F 1. Install battery in vehicle with positive terminal toward the front. Coat threads of battery bolt with Polaris corrosion resistant dielectric grease. Polaris Dielectric Grease PN 2871329 (Nyogel) WARNING To avoid the possibility of explosion, connect positive (red) cable first and negative (black) cable last.
  • Page 592 Repair or replace faulty wiring or components. Is it? If all of the previous tests indicate a good condition, but the charging voltage does not rise above battery voltage at the connector or terminal board, replace the voltage regulator. Polaris Sales Inc. 10.23 4/99...
  • Page 593 STurn the lights on and lock parking brake to keep brake light on. SRepeat test, observing ammeter and tachometer. With lights on, charging should occur at or below 3000 RPM on 150 watt alternators and below 2000 RPM on 200 and 250 watt alternators. 4/99 10.24 Polaris Sales Inc.
  • Page 594 To Calculate Available Alternator Output Alternator Current Output: Minimum of 7 AC Amps 150W 12.5 Amps 200W 16.7 Amps 250W 20.8 Amps I = Current in Amps P = Power in Watts E = Electromotive Force (Volts) Polaris Sales Inc. 10.25 4/99...
  • Page 595 To perform the test, place the meter on DC volts and place the meter leads across the connection to be tested. Refer to the chart on next page to perform voltage drop tests on the starter system. Voltage should not exceed: .1 DC volts per connection 4/99 10.26 Polaris Sales Inc.
  • Page 596 The reading should be less than .1 V D.C. If all of these indicate a good condition, yet the starter still fails to turn, the starter must be removed for static testing and inspection. Polaris Sales Inc. 10.27 4/99...
  • Page 597 These marks must align during reassembly. 2. Remove the two bolts, washers, and sealing O-Rings. Inspect O-Rings and replace if damaged. 3. Remove brush terminal end of housing while holding other two sections together. 4/99 10.28 Polaris Sales Inc.
  • Page 598 5. Install a new carbon brush assembly in the brush housing. NOTE: Be sure that the terminal bolt insulating washer is properly seated in the housing, and the tab on the brush plate engages the notch in the brush plate housing. Polaris Sales Inc. 10.29 4/99...
  • Page 599 7. Install the O-Ring over the bolt. Make sure the O-ring is fully seated. 8. Remove the electrical tape and reinstall the two small phenolic washers, the large phenolic washer, flat washer, and nut. 4/99 10.30 Polaris Sales Inc.
  • Page 600 1/8″ (.3 cm) above armature coil laminates. Rotate armature 360°. If hacksaw blade is drawn to armature on any pole, the armature is shorted and must be replaced. Polaris Sales Inc. 10.31 4/99...
  • Page 601 6. Install starter motor cable. Make sure red protective cover is properly in place. 7. Install rock guard. 8. Install two bolts to starter from inside magneto housing. 9. Install magneto housing. 10. Install all components removed to gain access to magneto housing. 4/99 10.32 Polaris Sales Inc.
  • Page 602 The replacement spring is PN 7042039. Use either of the following methods to remove and install a new garter spring. Polaris Premium Starter Drive Grease PN 2871460 1. Screw the overrun clutch out to the engaged position on the pinion shaft assembly.
  • Page 603 COMMENTS 4060085 LR44 Reverse Limit - 3500 Trail Boss, Xpress / Xplorer ETC Limit - 1900 4060186 LR49-1 Reverse Limit - Trail Blazer, Sport 400 ETC Limit - 4060199 LR83-1 Scrambler 400 4060201 LR83-2 Reverse Limit - 3100 Scrambler 500...
  • Page 604 The RPM signal is delivered to the limiter module via Electronic Throttle Control Circuit Wires the Yellow/Red alternator wire. Shown In Bold Refer to following pages for test procedure. NOTE: The reverse RPM limit will override the ETC Limit when both are receiving voltage. Polaris Sales Inc. 10.35 4/99...
  • Page 605 4/99 10.36 Polaris Sales Inc.
  • Page 606 Check parts manual application machine application machine application -Incorrect alternator output Incorrect alternator output -Check wiring and alternator output Check wiring and alternator output -Faulty limiter module -Faulty limiter module -Replace limiter module -Replace limiter module Polaris Sales Inc. 10.37 4/99...
  • Page 607 ELECTRICAL Reverse Limit System 4/99 10.38 Polaris Sales Inc.
  • Page 608 TEST REGULATOR AND CHARGING ULE TO GROUND SYSTEM 3V-9V AC AT IDLE? DISCONNECT BLACK WIRE FROM LR83-2 MOD- TEST WIRING / TEST CDI (BLACK WIRE) ULE AND CONNECT TO GROUND. ENGINE STOP? REPLACE LIMITER MODULE Polaris Sales Inc. 10.39 4/99...
  • Page 609 ELECTRICAL Reverse Limit System Gry/Or 4/99 10.40 Polaris Sales Inc.
  • Page 610 5. Test AC voltage input at the Yellow/Red wire (on alternator side). Voltage should be a minimum 5 AC volts at idle. Refer to charging system testing if voltage is below 5 AC volts. 6. If voltage is present on the Yellow/Red wire and the system does not function correctly, replace the module. Polaris Sales Inc. 10.41 99/00 ATV Update...
  • Page 611 GRN/W wires. 5. Locate Green/White wire in switch harness and follow it to the terminal board. Disconnect this Green/White wire from the board and connect it to Gray/White terminal on terminal board. 99/00 ATV Update 12/99 10.42 Polaris Sales Inc.
  • Page 612 4000 RPM. WARNING: The procedures outlined above are for testing purposes only. Return all wires to the proper terminal on the terminal board (according to color) after testing. Verify proper neutral light operation. Polaris Sales Inc. 10.43 99/00 ATV Update 12/99...
  • Page 613 ELECTRICAL Speedometer System, Electronic Electronic Speedometer Troubleshooting Overview of Operation The Polaris Electronic ATV speedometer is powered by Engine Run Time Hour Meter battery voltage (12 VDC) and requires engine RPM, If the engine is running, the hour meter is recording the transmission gear, and wheel speed sensor input signals run time.
  • Page 614 ELECTRICAL Speedometer System, Electronic Electronic Speedometer Troubleshooting Overview of Operation The Polaris Electronic ATV speedometer is powered by Engine Run Time Hour Meter battery voltage (12 VDC) and requires engine RPM, If the engine is running, the hour meter is recording the transmission gear, and wheel speed sensor input signals run time.
  • Page 615 (6 Pin Connector) All tests done with key and engine stop switch “ON”. All voltages are with reference to pin B (ground). Polaris probe kit #2201209 will help in measurements but is not necessary if care is used when probing the connectors.
  • Page 616 SPEEDO POWER MOVE? ON PIN A TO PIN C. IS (TEST 6) SUPPLY VOLTAGE PRESENT? REPAIR 6PIN MEASURE REPLACE WIRING A-B 12VDC? SPEEDO REPLACE SPEEDO ODOMETER TEST DRIVE ODOMETER POINTER SPEEDO DISPLAY VEHICLE CHANGE? MOVE? Polaris Sales Inc. 10.47 4/99...
  • Page 617 VOLTAGE SHOULD REMAIN AT 12 VDC (AWD LAMP OFF). VAC? 4. LOWER RPM. AT APPROXIMATELY 2600 RPM, VOLTAGE SHOULD GO TO 1 VDC AND HUBS SHOULD ENGAGE (AWD LAMP SHOULD GO ON). CHECK CHARGING SYSTEM (STA- TOR, REGULATOR, AND WIRING) 4/99 10.48 Polaris Sales Inc.
  • Page 618 3. Elevate front right side of vehicle until tire is off the ground. 4. Slowly turn right front wheel while observing the test light. 5. If light flashes, sensor is O.K. Be sure connections are good and 9 volt battery is in good condition. Polaris Sales Inc. 10.49 4/99...
  • Page 619 1. Operate vehicle at a speed greater than indicated on speedometer (past point where needle is stuck). Needle will return to normal operation. 2. In the above example, the ATV speed would have to exceed 30 mph to reset. 4/99 10.50 Polaris Sales Inc.
  • Page 620 Polaris Sales Inc. 10.51 4/99...
  • Page 621 Disconnect the Purple, Gray/White, and Green wires at the terminal board or connector. Continuity should exist between color coded wires as shown in the chart below. Make sure to verify no continuity as well as continuity. Gry/W Free Pushed 4/99 10.52 Polaris Sales Inc.
  • Page 622 Inspect wiring between switch and terminal board and repair or replace if damaged. Replace the switch if battery voltage is not indicated or if voltage is present when the selector is moved out of the specific range. Polaris Sales Inc. 10.53...
  • Page 623 Disconnect temperature sensor wire lead and short it to ground on the cylinder head. Turn key and auxiliary switch to “ON” position. The hot lamp should come on. Check the bulb and related wiring if the lamp does not illuminate. 4/99 10.54 Polaris Sales Inc.
  • Page 624 SShort thermistor leads together - fan and hot light ON? (If not, test hot light, fan motor and circuit) SDisconnect thermistor wires and test the resistance of the thermistor (refer to temperature/resistance table). Replace thermistor if out of specified range. SReplace LR60 and test system. Polaris Sales Inc. 10.55 99/00 ATV Update 12/99...
  • Page 625 Green/White wire, through the lamp and to ground via the Brown wire. If the light is not on when neutral is selected, check the bulb. If the bulb is good, check the wiring, transmission switch, and lamp socket ground path. 99/00 ATV Update 12/99 10.56 Polaris Sales Inc.
  • Page 626 Switch Testing Gear Position Indicator Switch Test Switch Continuity Table High/Neutral/Reverse Switch Low/Neutral Switch High Range Reverse Neutral Low Range Switch Schematic L / N Switch H / N / R Switch Polaris Sales Inc. 10.57 99/00 ATV Update 12/99...
  • Page 627 If the ETC system is functioning properly engine RPM will be limited to the speci- fied “ETC Limit” RPM. Refer to Speed Limiter System Testing on page 10.38. 99/00 ATV Update 12/99 10.58 Polaris Sales Inc.
  • Page 628 Electronic Throttle Control System Operation Electronic Throttle Control (ETC) Switch (Composite Throttle Housing) This system is used on all 1999 Trail Blazer, Sport 400, Scrambler 400 (Late), Xplorer 400, Scrambler 500, Magnum 500, Sportsman 500, Sportsman 500 RSE models. The Electronic Throttle Control (ETC) system is designed to limit the engine RPM of an ATV in the event of a mechanical problem with the throttle mechanism.
  • Page 629 CHAPTER 11 WIRING DIAGRAMS 7UDLO %OD]HU                                  7UDLO %RVV                                    ;SORUHU ;SUHVV  ...
  • Page 630 ELECTRICAL Wiring Diagram 1999 Trail Blazer  Polaris Industries Inc. 4/99...
  • Page 631 ELECTRICAL Wiring Diagram 1999 Trail Boss  4/99 Polaris Industries Inc.
  • Page 632 ELECTRICAL Wiring Diagram 1999 Xplorer 300 / Xpress 300  Polaris Industries Inc. 4/99...
  • Page 633 ELECTRICAL Wiring Diagram 1999 Sportsman 335  4/99 Polaris Industries Inc.
  • Page 634 ELECTRICAL Wiring Diagram 1999 Sport 400  Polaris Industries Inc. 4/99...
  • Page 635 ELECTRICAL Wiring Diagram 1999 Scrambler 400 (Early)  4/99 Polaris Industries Inc.
  • Page 636 ELECTRICAL Wiring Diagram 1999 Scrambler 400 (Late)  Polaris Industries Inc. 4/99...
  • Page 637 ELECTRICAL Wiring Diagram 1999 Xplorer 400  4/99 Polaris Industries Inc.
  • Page 638 ELECTRICAL Wiring Diagram 1999 Scrambler 500  Polaris Industries Inc. 4/99...
  • Page 639 ELECTRICAL Wiring Diagram 1999 Magnum 500  4/99 Polaris Industries Inc.
  • Page 640 ELECTRICAL Wiring Diagram 1999 Sportsman 500 / Sportsman 500 RSE  Polaris Industries Inc. 4/99...
  • Page 641 ELECTRICAL Wiring Diagram 1999 Worker 500 (International)  4/99 Polaris Industries Inc.
  • Page 642 ELECTRICAL Wiring Diagram 1999 Big Boss 500 6x6  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 643 ELECTRICAL Wiring Diagram 2000 Trail Blazer  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 644 ELECTRICAL Wiring Diagram 2000 Xplorer 4x4  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 645 ELECTRICAL Wiring Diagram 2000 Trail Boss 325  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 646 ELECTRICAL Wiring Diagram 2000 Magnum 325 2x4  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 647 ELECTRICAL Wiring Diagram 2000 Magnum 325 4x4  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 648 ELECTRICAL Wiring Diagram 2000 Xpedition 325  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 649 ELECTRICAL Wiring Diagram 2000 Sportsman 335 (Early)  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 650 ELECTRICAL Wiring Diagram 2000 Sportsman 335 (Late)  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 651 ELECTRICAL Wiring Diagram 2000 Xplorer 400  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 652 ELECTRICAL Wiring Diagram 2000 Scrambler 400 2x4  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 653 ELECTRICAL Wiring Diagram 2000 Scrambler 400 4x4  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 654 ELECTRICAL Wiring Diagram 2000 Xpedition 425  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 655 ELECTRICAL Wiring Diagram 2000 Magnum 500 (Early)  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 656 ELECTRICAL Wiring Diagram 2000 Magnum 500 (Late)  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 657 ELECTRICAL Wiring Diagram 2000 Scrambler 500 (Early)  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 658 ELECTRICAL Wiring Diagram 2000 Scrambler 500 (Late)  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 659 ELECTRICAL Wiring Diagram 2000 Sportsman 500 (Early)  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 660 ELECTRICAL Wiring Diagram 2000 Sportsman 500 (Late)  99/00 ATV Update 12/99 Polaris Sales Inc.
  • Page 661 Electronic Throttle Control System Operation Electronic Throttle Control (ETC) Switch (Composite Throttle Housing) This system is used on all 1999 Trail Blazer, Sport 400, Scrambler 400 (Late), Xplorer 400, Scrambler 500, Magnum 500, Sportsman 500, Sportsman 500 RSE models. The Emergency Throttle Control (ETC) system is designed to limit the engine RPM of an ATV in the event of a mechanical problem with the throttle mechanism.
  • Page 662 Carburetor Inspection ........4.33 Carburetor Installation -CV .
  • Page 663 INDEX Drive Clutch Inspection ........6.19 Front Strut Ball Joint Replacement .
  • Page 664 Jetting Guidelines ........Pilot Jet .
  • Page 665 INDEX Shaft Drive Transmission Removal ....8.18-8.20 Tightening Tool, Drive Clutch Spider ......1.19 Shift Linkage Adjustment .

This manual is also suitable for:

Trail bossSport 400Xpress 300Scrambler 400Xplorer 400Scrambler 500 ... Show all

Table of Contents