Page 1: Table Of Contents
CHAPTER 1 GENERAL INFORMATION Model Identification ......Serial Number Location ..... . . Machine Dimensions .
Page 3: General Information
GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 0 1 A A 3 2 A A Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation ENGINE DESIGNATION NUMBERS 32 ES32PFE06/07/08...
Page 4: Machine Dimensions
GENERAL INFORMATION MACHINE DIMENSIONS 36.25 in 92 cm FRONT 45.5 in 115.6 cm 72 in 182.8 cm 35.5 in 90.1 cm 13 in 33.02 cm SIDE 9.75 in 13.5 in 48.75 in 23.5 cm 34.2 cm 123.8 cm...
Page 5 GENERAL INFORMATION MACHINE DIMENSIONS 40.6 in 103.1 cm 45.5 in 115.6 cm Hitch 10.5 in 26.67 cm REAR Rock Guard 5.5 in 13.9 cm 34.75 in 88.27 cm 44.6 in 113.3 cm...
Page 6 GENERAL INFORMATION 2001 TRAIL BOSS 325 MODEL: ..MODEL NUMBER: A01AA32AA ENGINE MODEL: ES32PFE06/07/08 JETTING CHART 06/07 AMBIENT TEMPERATURE CARBURETION Altitude Altitude Below 40qF Below 40 F +40_F to +80_F +40 F to +80 F Below 5qC +5_C to +26_C Type...
Page 7 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 8: Publication Numbers
A01AA32AA 9915754 9915754 9916381 9916381 9916382 9916382 When ordering service parts be sure to use the correct parts manual. PAINT CODES PAINTED PART COLOR DITZLER POLARIS DESCRIPTION NUMBER NUMBER Springs Fire Red 72060 P-093 Rims Bright White 2185 P-133 Rack(s)
Page 9: Standard Torque Specifications
GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.
Page 10 GENERAL INFORMATION TORQUE CONVERSIONS Newton Metre to Pound Foot and Pound Inch...
Page 11 GENERAL INFORMATION TORQUE CONVERSIONS Newton Metre to Pound Foot and Pound Inch...
Page 12 GENERAL INFORMATION DECIMAL EQUIVALENTS 1/64 ......0156 1/32 ....0312 .
Page 13: Conversion Table
GENERAL INFORMATION CONVERSION TABLE Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.383 = Nm in. lbs. x .0115 = kg-m x .7376 = ft. lbs. kg-m x 7.233 = ft.
Page 14 GENERAL INFORMATION SAE TAP DRILL SIZES Thread Size Drill Size Thread Size Drill Size #0-80 3/64 1/2-13 27/64 #1-64 1/2-20 29/64 #1-72 9/16-12 31/64 #2-56 9/16-18 33/64 #2-64 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 3/4-10 21/32 #4-40 3/4-16 11/16 #4-48 7/8-9 49/64...
Page 15: Glossary Of Terms
CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8s or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.
Page 16 Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch System) qt.: Quart/quarts. RPM: Revolutions per minute. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Page 17 CHAPTER 2 MAINTENANCE Periodic Maintenance Chart ....2.1-2.2 Pre-Ride Inspection ......Recommended Lubricants .
Page 19: Periodic Maintenance Chart
10 mph. NOTE: Inspection may reveal the need for replace- ment 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 20: Pre-Ride Inspection
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 Wheel Bearings Annually 12 months Inspect and replace if necessary Drive Belt 50 hrs 6 months...
Page 21: Recommended Lubricants
Transmission Polaris Synthetic Gear Refer to procedures outlined later in this Case Lubricant chapter. Brake Fluid Polaris DOT 3 Brake Fluid Fill to indicated level inside reservoir. 2.29 COLD WEATHER KITS FOR 4 STROKE ATVS Engine Heater -- PN 2871507...
Page 22 MAINTENANCE POLARIS PREMIUM LUBRICANT AND MAINTENANCE PROD- UCT 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) Gearcase / Transmission Lubricants 2871477 Premium Synthetic Gearcase Lubricant (1 Gal.)
Page 23 Add lube to full level on dipstick Change annually ic Gear Case Lubricant Brake Fluid Polaris DOT 3 Fill master cylinder reservoir to in- As required. Change fluid every 2 years. Brake Fluid dicated level inside reservoir. See page 2.29 .
Page 24 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...
Page 25: Transmission Lubrication
S Check vent hose to be sure it is routed properly and unobstructed. S Follow instructions on following pages to check / change transmission lubricant. TRANSMISSION SPECIFICATIONS Specified Lubricant: Polaris Premium Synthetic Gearcase Lubricant PN 2871477 (Gallon) PN 2871478 (12 oz..) Capacity: ..
Page 26 MAINTENANCE TRANSMISSION GEARSHIFT LINKAGE ADJUSTMENT, PRELIMINARY INSPECTION S If shifting problems are encountered, the transmis- Linkage rod will rotate sion linkage should be adjusted. 1/8 -1/4 turn if rod ends are tightened properly. S Tighten shift linkage rod end jam nuts properly after adjustment.
Page 27 MAINTENANCE IDLE SPEED ADJUSTMENT 1. Start engine and warm it up thoroughly. CV Carburetor 2. Adjust idle speed by turning the idle adjustment screw in (clockwise) to increase or out (counterclockwise) to decrease RPM. (Refer to Ill. at right). NOTE: Adjusting the idle speed affects throttle cable freeplay and electronic throttle control (ETC) adjustment.
Page 28 MAINTENANCE THROTTLE CABLE FREEPLAY/ ELECTRONIC THROTTLE CONTROL (ETC SWITCH) ADJUSTMENT Check for smooth throttle opening and closing in all han- dlebar positions. Throttle lever operation should be smooth and lever must return freely without binding. 1. Slide boot off throttle cable adjuster and jam nut. 2.
Page 29 MAINTENANCE THROTTLE CABLE FREEPLAY/ ELECTRONIC THROTTLE CONTROL (ETC SWITCH) ADJUSTMENT, CONT. 8. Turn handlebars from left to right through the entire Switch contacts are open turning range. If idle speed increases, check for during normal operation proper cable routing. If cable is routed properly and in good condition, repeat adjustment procedure.
Page 30: Fuel System
MAINTENANCE FUEL SYSTEM WARNING Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
Page 31 MAINTENANCE CARBURETOR DRAINING The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl, or before ex- tended periods of storage. NOTE: The bowl drain screw is located on the bottom left side of the float bowl. Drain tube 1.
Page 32: Compression Test
MAINTENANCE COMPRESSION TEST NOTE: 4-Stroke engines are equipped with an automatic decompressor. Compression readings will vary in pro- portion to cranking speed during the test. Average compression (measured) is about 50-90 psi during a compres- sion test. Smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition problems above idle speed.
Page 33: Battery Maintenance
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 34 MAINTENANCE SPARK PLUG 1. Remove spark plug high tension lead. Clean plug area Recommended Spark Plug: so no dirt and debris can fall into engine when plug is removed. Refer to Specifications 2. Remove spark plug. 3. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of Spark Plug Torque: 14 Ft.
Page 35: Air Filter Service
MAINTENANCE PREFILTER AND AIR FILTER SERVICE 1. Remove seat. 2. Remove spring clamps securing the airbox lid and remove lid. 3. Pull foam breather filter out. 4. Loosen clamp and remove filter. 5. Remove foam or mesh pre-filter from main filter. 6.
Page 36: Recoil Housing
MAINTENANCE RECOIL HOUSING S Drain the housing periodically to remove moisture. S Drain the recoil housing after operating the ATV in Crankcase Drain very wet conditions. This should also be done before storing the ATV. The drain screw is located at the bot- tom of the recoil housing.
Page 37: Oil Change/Filter
7. Reinstall drain plug and torque to 14 ft. lbs. (19 Nm). Crankcase Drain Recommended Engine Oil: Polaris Premium 4 All Season Synthetic, 0W-40 Ambient Temperature Range: -40q F to 120q F Engine Sump Drain Plug - Bottom View 2.19...
Page 38 1/2 turn. 12. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. 13. Place gear selector in neutral and set parking brake. 14. Start the engine and let it idle for one to two minutes.
Page 39: Valve Clearance
MAINTENANCE VALVE CLEARANCE Inspect and adjust valve clearance while the engine is cold and the piston positioned at Top Dead Center (TDC) on compression stroke. 1. Remove the seat. 2. Remove body panels and fuel tank as necessary to 325 Valve Plugs gain access to valve cover.
Page 40 MAINTENANCE INTAKE VALVE CLEARANCE ADJUSTMENT 1. Insert a .006s (.15mm) feeler gauge between end of intake valve stem and clearance adjuster screw. 2. Using a 10 mm wrench and a screwdriver, loosen adjuster lock nut and turn adjusting screw until there is a slight drag on the feeler gauge.
Page 41 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 42 MAINTENANCE TOE ALIGNMENT - METHOD 1: STRAIGHTEDGE OR STRING Be sure to keep handlebars centered. See note below. NOTE: String should just touch side surface of rear tire on each side of machine. Measure from string to rim at front and rear of rim.
Page 43 MAINTENANCE TOE ALIGNMENT - METHOD 2: CHALK 1. Place machine on a smooth level surface. 2. Set handlebars in a straight ahead position and secure handlebars in this position. NOTE: The steering frog can be used as an indicator of whether the handlebars are straight.
Page 44 MAINTENANCE EXHAUST PIPE The exhaust pipe must be periodically purged of accumu- lated carbon as follows: 1. Remove the clean out plugs located on the bottom of the muffler as shown at right. 2. Place the transmission in neutral and start the engine. Purge accumulated carbon from the system by Clean Out Plug momentarily revving the engine several times.
Page 45 Parking Brake dicated level inside reservoir at all times. Glass Lock Use Polaris DOT 3 brake fluid (PN 2870990). Check brake system for fluid leaks. Check brake for excessive travel or spongy feel. Check friction pads for wear, damage and looseness.
Page 46 MAINTENANCE AUXILIARY BRAKE ADJUSTMENT (HYDRAULIC) Use the following procedure to inspect the hydraulic auxil- 1/8s to 1/4s iary (foot) brake system and adjust or bleed if necessary. Free Play 1. First check foot brake effectiveness by applying a 50 1s or greater 50 lbs lb.
Page 47 MAINTENANCE 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). Inspect the drive chain for missing or damaged O-Rings, link plates, or rollers. Do not wash the chain with a high pressure washer, gasoline or solvents;...
Page 48 MAINTENANCE DRIVE CHAIN ADJUSTMENT, CONCENTRIC SWINGARM CAUTION: Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result. Break-In: It is extremely important to maintain proper chain tension to ensure the best possible chain life. There is a chain break-in period of approximately 100 miles or two (2) tanks of fuel.
Page 49 MAINTENANCE ADJUSTMENT PROCEDURE - CONCENTRIC SWINGARM, CONT. 4. Insert a pin punch through the sprocket hub and into the eccentric axle housing. Pin Punch 5. Move the ATV forward or back to move the eccentric housing and adjust to the proper tension (approx.
Page 50 MAINTENANCE ADJUSTMENT PROCEDURE - CONCENTRIC SWINGARM, CONT. 7. Tighten caliper mounting bracket bolts 10-12 ft. lbs. Caliper Mount Bracket (14 - 17 Nm) 8. Remove pin punch. 9. Roll ATV forward checking chain tension at the same point in several places around the chain. The chain is adjusted correctly when the tightest portion of the chain has approximately 3/8, (10 mm) of deflection.
Page 51 MAINTENANCE SUSPENSION SPRING PRELOAD ADJUSTMENT Operator weight and vehicle loading affect suspension spring preload requirements. Adjust as necessary. FRONT SUSPENSION Compress and release front suspension. Damping should be smooth throughout the range of travel. Check all front suspension components for wear or dam- age.
Page 52: Wheel Removal/Installation
MAINTENANCE WHEELS Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts. WHEEL, HUB, AND SPINDLE TORQUE TABLE Item Specification Front Wheel Nuts 20 Ft. Lbs. Rear Wheel Nuts 50 Ft.
Page 53: Tire Inspection
MAINTENANCE TIRE PRESSURE Tire Pressure Inspection (PSI - Cold) Front Rear TIRE INSPECTION CAUTION: S Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the vehicle. S Improper tire inflation may affect ATV maneuverability. Tread Depth 1/8I (3 mm) S When replacing a tire always use original equipment size and type.
Page 54 NOTES...
Page 55 CHAPTER 3 ENGINE Torque Specifications ......Torque Patterns ....... . . Piston Identification .
Page 57: Torque Specifications
ENGINE TORQUE SPECIFICATIONS ENGINE TORQUE SPECIFICATIONS Fastener Size ES32PFE Ft. Lbs. (Nm) Camshaft Chain Tensioner Lever 5-6.5 (7-9 Nm) Camshaft Chain Tensioner 5-6.5 (7-9 Nm) Camshaft Chain Tensioner Cap 11mm 14-19 (20-25 Nm) Camshaft Sprocket 10mm 25-29 (34-40 Nm) Carburetor Adaptor 12-14 (16-20 Nm) Connecting Rod 8.5mm...
Page 58: Torque Patterns
ENGINE ENGINE FASTENER TORQUE PATTERNS Tighten cylinder head, cylinder base, and crankcase fasteners in 3 steps following the sequence outlined below. Cylinder Head Cylinder Base Crankcase PISTON IDENTIFICATION Note the directional and identification marks when viewing the pistons from the top. The letter “F”, “ ! ”, “ "” or : must always be toward the flywheel side of the engine.
Page 59 ENGINE ES32PFE ENGINE SERVICE DATA Cylinder Head / Valve ES32PFE Rocker Arm Rocker arm ID .8669-.8678s (22.020-22.041 mm) Rocker shaft OD .8656-.8661s (21.987-22.0 mm) Rocker shaft Oil Clearance .0008-.0021s (.020-.054 mm) Limit .0039s (.10 mm) Camshaft Cam lobe height 1.2955-1.2995s (32.881-32.981 mm) Limit 1.2837s (32.581 mm) 1.2955-1.2995s (32.881-32.981 mm)
Page 60 ENGINE ES32PFE ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod ES32PFE Cylinder Surface warpage limit (mating with cylinder head) .0020s (0.050 mm) Cylinder bore 3.0732-3.0740s (78.000-78.020 mm) Taper limit .0020s (0.050 mm) Out of round limit .0020s (0.050 mm) Piston clearance .0015-.0032s (0.038-0.082 mm) Limit...
Page 61: Engine Removal
ENGINE ACCESSIBLE COMPONENTS The following components can be serviced or The following components require engine removed with the engine installed in the frame: removal for service: SFlywheel SConnecting Rod SAlternator/Stator SCrankshaft SStarter Motor/Starter Drive SCrankshaft Main Bearings SCylinder Head SCrankcase SCylinder SPiston/RIngs SOil pump...
Page 62: Engine Installation Notes
4 Cycle Engine Break-In Period is defined as the first 10 hours of engine operation, or 2 full tanks of fuel. 1. Use only Polaris Premium 4 All Season synthetic oil, or API certified “SH” oil. 2. Use fuel with a minimum octane of 87 (R+M)/2 method.
Page 63 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 64: Engine Lubrication
Oil Type ......Polaris Premium 4 Synthetic (PN 2871281); or API certified “SH” 5W30 Capacity .
Page 65 Magneto end crankshaft main bearing. NOTE:The oil lines and clamps are designed for high pressure. DO NOT SUBSTITUTE. Use genuine Polaris oil lines and clamps. Oil Cooler Mounted Thermo Valve...
Page 66 ENGINE OIL FLOW DIAGRAM - ES32PF Chain Room Small End Bearing Piston Rocker Arm / Cylinder Sleeve Oil Jet Rocker Shaft / (Fixed) Sprocket / Chain Main Bearing Connecting Rod Indirect Cam Shaft Lubrication Journal Large End Bearing Cam Shaft Through Front Right Cam Lobe Journal...
Page 67 ENGINE ES32PFE ENGINE EXPLODED VIEW Cylinder/ Crankcase Cylinder Head ES32PFE06/07/08 EARLY ES32PFE06 Valve Train Crankshaft and Piston 3.11...
Page 68 ENGINE ENGINE REMOVAL REFER TO PAGE 3.5 - 3.6 FOR ENGINE REMOVAL / INSTALLATION NOTES. CAM CHAIN TENSIONER REMOVAL 1. Remove ignition timing inspection plug from recoil housing. To position crankshaft at Top Dead Center (TDC) on compression stroke: Single TDC Mark Aligned TDC Mark 2.
Page 69 ENGINE CAM CHAIN TENSIONER INSPECTION 1. Pull cam chain tensioner plunger outward to the end of its travel. Inspect teeth on ratchet pawl (A) and plunger teeth (B)for wear or damage. 2. Push ratchet pawl and hold it. The plunger should move smoothly in and out of the tensioner body.
Page 70 ENGINE ROCKER ARM/SHAFT INSPECTION 1. Remove breather box. 2. Remove rocker cover. 3. Mark or tag rocker arms to keep them in order for assembly. Wave washer 4. Inspect each rocker arm cam follower surface. If there is any damage or uneven wear, replace the rocker arm.
Page 71 ENGINE ROCKER ARM/SHAFT INSPECTION, CONT. 7. Measure I.D. of each rocker arm and compare to specifications. Rocker Arm & Support I.D.: .8669-.8678I (22.020-22.041 mm) 8. Measure I.D. of both rocker arm shaft support areas and visually inspect surface. Compare to specifications.
Page 72 ENGINE CAMSHAFT REMOVAL 1. Remove cam shaft end plug (A). 2. Remove camshaft sprocket flange bolt and washer. 3. Place a clean shop towel in the area below cam chain sprocket. 4. Remove sprocket from camshaft and chain. 5. Secure cam chain with a wire to prevent it from falling into the crankcase.
Page 73 ENGINE CAMSHAFT REMOVAL, CONT. 6. Inspect cam sprocket teeth for wear or damage. Replace if necessary. 7. Remove camshaft. Inspect for Areas of Tooth Wear or Damage Return spring (spacer) Dowel pin Release lever 3.17...
Page 74 ENGINE AUTOMATIC COMPRESSION RELEASE REMOVAL/INSPECTION NOTE: The automatic compression release mecha- nism can be inspected and serviced without removing the camshaft from the cylinder head. 1. Check release lever shaft for smooth operation throughout the entire range of rotation. 2. Remove release lever shaft and return spring Lobe (spacer).
Page 75 ENGINE CAMSHAFT INSPECTION 1. Visually inspect each cam lobe for wear, chafing or damage. 2. Thoroughly clean the cam shaft, making sure the oil feed holes are not obstructed. 3. Measure height of each cam lobe using a micrometer. Compare to specifications. Lubrication holes Cam Lobe Height (Intake &...
Page 76 ENGINE CYLINDER HEAD REMOVAL 7. Loosen each of the four cylinder head bolts evenly 1/8 turn each time in a cross pattern until loose. 8. Remove bolts (A) and tap cylinder head lightly with a plastic hammer until loose. CAUTION: Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging casting.
Page 77 ENGINE CYLINDER HEAD WARPAGE 1. Lay a straight edge across the surface of the cylinder head at several different points and measure warpage by inserting a feeler gauge between the straight edge and the cylinder head surface. If warpage exceeds the service limit, replace the cylinder head.
Page 78 ENGINE CYLINDER HEAD DISASSEMBLY, CONT. 4. Measure free length of spring with a Vernier caliper, Ill.1. Check spring for squareness as shown in Ill.2. Compare to specifications. Replace spring if either measurement is out of specification. Valve Spring Length: Valve Spring Std: 1.654I (42.0 mm) Free Length Limit: 1.575I (40.0 mm)
Page 79 ENGINE VALVE INSPECTION 1. Remove all carbon from valve with a soft wire wheel. 2. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” blocks and a dial indicator. 3.
Page 80 ENGINE VALVE INSPECTION, CONT. 6. Measure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer. Measure in two directions, front to back and side to side. 7. Subtract valve stem measurement to obtain stem to guide clearance.
Page 81 ENGINE VALVE SEAT RECONDITIONING Valve Seat Inspection Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be reconditioned. See Valve Seat Reconditioning, page 3.26. If the valve seat is cracked the cylinder head must be replaced.
Page 82 ENGINE VALVE SEAT RECONDITIONING, CONT. Follow the manufacturers instructions provided with the valve seat cutters in the Cylinder Head Recondi- tioning Kit (PN 2200634). Abrasive stone seat re- conditioning equipment can also be used. Keep all valves in order with their respective seat. NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing.
Page 83 ENGINE VALVE SEAT RECONDITIONING, CONT. 1. Install pilot into valve guide. 2. Apply cutting oil to valve seat and cutter. 3. Place 46q cutter on the pilot and make a light cut. 4. Inspect the cut area of the seat. SIf the contact area is less than 75% of the circum- ference of the seat, rotate the pilot 180q and make another light cut.
Page 84 ENGINE VALVE SEAT RECONDITIONING, CONT. 7. Remove valve and check where the Prussian Blue¥ or black marker indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width (A).
Page 85 ENGINE VALVE SEAT RECONDITIONING, CONT. 10. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem. 11. Rotate the valve rapidly back and forth until the cut sounds smooth.
Page 86 ENGINE CYLINDER HEAD ASSEMBLY, CONT. 5. Dip valve spring and retainer in clean engine oil and install spring with closely spaced coils toward the cylinder head. Closely spaced coils toward cylinder head 6. Place retainer on spring and install valve spring compressor.
Page 87: Engine Bottom End Disassembly
ENGINE ENGINE BOTTOM END DISASSEMBLY CYLINDER REMOVAL Follow engine disassembly procedures to remove valve cover, camshaft and rocker arms, and cylinder head. 1. Remove cam chain guide at front of cylinder. 2. Remove the two 6 mm cylinder base bolts. 3.
Page 88 ENGINE PISTON REMOVAL 1. Remove circlip. Note that opening for circlip access is on the intake side. 2. Remove piston circlip and push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch. CAUTION: Do not apply heat to the piston rings.
Page 89 ENGINE CYLINDER INSPECTION 1. Remove all gasket material from the cylinder sealing surfaces. 2. Inspect the top of the cylinder for warpage using a straight edge and feeler gauge. Cylinder Warpage: .002s (.05 mm) 3. Inspect cylinder for wear, scratches, or damage. 4.
Page 90 ENGINE CYLINDER INSPECTION, CONT. 5. Record measurements. If cylinder is tapered or out of round beyond .002, the cylinder must be re-bored oversize, or replaced. Cylinder Taper Limit: .002 Max. Cylinder Out of Round Limit: .002 Max. Standard Bore Size: 3.0732-3.0740I (78.000-78.020 mm) PISTON INSPECTION 1.
Page 91 ENGINE PISTON INSPECTION, CONT. 3. Measure piston pin bore. Piston Pin Bore: .7095-.7097I (18.007-18.013 mm) 4. Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance. Piston Pin O.D. .7092-.7095I (18.001-18.007 mm) Piston Pin Measurement Locations 5. Measure connecting rod small end ID. Connecting Rod Small End I.D.
Page 92 ENGINE PISTON INSPECTION, CONT. 6. Measure piston ring to groove clearance by Ring to groove clearance placing the ring in the ring land and measuring with Piston a thickness gauge. Replace piston and rings if ring-to-groove clearance exceeds service limits. Ring Piston Ring-to-Groove Clearance Top Ring Std: .0014-.0030I (.035-.075 mm)
Page 93 ENGINE CRANKCASE DISASSEMBLY NOTE: The recoil starter, starter motor, starter drive, flywheel, stator, cam chain and sprockets can be serv- iced with the engine in the frame. STARTER DRIVE REMOVAL/INSPECTION 1. Remove recoil housing bolts and remove housing. 2. Remove starter drive assembly. Note the thrust washer located at the rear of the drive mechanism.
Page 94 ENGINE FLYWHEEL/STATOR REMOVAL/INSPECTION 1. Remove flywheel nut and washer. 2. Install flywheel puller (PN 2870159) and remove flywheel. CAUTION: Do not thread the puller bolts into the flywheel more than 1/4s or stator coils may be damaged. 3. Mark or note position of stator plate on crankcase. 4.
Page 95 ENGINE CAM CHAIN/TENSIONER BLADE 1. Remove bolt securing tensioner blade to crankcase (A). 2. Remove blade and inspect for cracks, wear, or damage. 3. Remove cam chain. Inspect chain for worn or missing rollers or damage. Stretch chain tight on a flat surface and apply a 10 lb.
Page 96 ENGINE DRIVE SPROCKET REMOVAL / INSPECTION 1. Using the special socket (PN 2871293), remove the crankshaft slotted nut (A). NOTE: The slotted nut is a left hand thread. 2. Remove cam chain drive sprocket (B) and Woodruff key from crankshaft. 3.
Page 97 ENGINE OIL PUMP REMOVAL/INSPECTION 1. Remove the five screws on the oil pump cover with an impact driver. 2. Inspect rotors and mating surface of oil pump cover. Check for nicks, burrs, or surface irregularities. 3. Measure pump end clearance using a feeler gauge and straight edge.
Page 98 ENGINE OIL PUMP ASSEMBLY 1. Clean and dry all parts thoroughly. Apply clean engine oil to all parts. Do not use gasket sealer on the pump cover mating surfaces or clearances will be incorrect, and oil passages may become plugged. 2.
Page 99 ENGINE CRANKSHAFT REMOVAL/INSPECTION 1. Support the MAG side crankcase and crankshaft; press the crankshaft out. Be careful not to damage the crankcase mating surface or connecting rod. 2. Use a feeler gauge to measure the connecting rod big end side clearance. Connecting Rod Big End Side Clearance: Std: .0028-.0118 (0.07-0.30 mm) Limit: .0138 (.35 mm)
Page 100 ENGINE CRANKSHAFT INSPECTION, CONT. 3. Visually inspect bearing journal for scoring, damage or excessive wear. Replace crankshaft if it fails visual inspection. 4. Measure the O.D. of the crankshaft rod journal in four places and in two directions away from the oil hole.
Page 101 ENGINE CONNECTING ROD BEARING INSPECTION 1. Inspect bearing inserts for unusual wear, peeling, scoring, damage etc. Replace as necessary. NOTE: If one insert requires replacement, replace both connecting rod bearing inserts as a set. CONNECTING ROD BEARING CLEARANCE INSPECTION 1. Clean all oil from bearing inserts and crank pin. “...
Page 102 ENGINE CRANKCASE BEARING INSPECTION 1. Inspect the crankshaft main bearing in the MAG side crankcase. NOTE: Due to extremely close tolerances and minimal wear, the bearing must be inspected visually, and by feel. Look for signs of discoloration, scoring or galling. Turn the inner race of bearing.
Page 103 ENGINE CRANKCASE INSPECTION 1. Remove all traces of gasket sealer from the crankcase mating surfaces. Inspect the surfaces closely for nicks, burrs or damage. BEARING INSTALLATION NOTE: To ease crankshaft bearing installation, warm the crankcase until hot to the touch. Place the bearing in a freezer.
Page 104 ENGINE CRANKSHAFT END PLAY ADJUSTMENT, CONT. 3. Subtract the thickness of the straightedge from the measurement obtained in Step 2 and record. Repeat step 2 and 3 for the PTO case. If PTO bearings are not installed in the crankcase, measure to the bearing seat in the case.
Page 105 ENGINE CONNECTING ROD INSTALLATION 1. Clean all oil off connecting rod, connecting rod cap and bearing inserts. 2. Install bearing inserts onto connecting rod and cap. NOTE:First, install bearing tab into groove, then press the rest of the bearing into place. 3.
Page 106 ENGINE CRANKSHAFT INSTALLATION Lubricate all bearings with clean engine oil before assembly. 1. Install the crankshaft into the PTO side crankcase. 2. Install the proper shim on the magneto end of the crankshaft. CRANKCASE OIL STRAINER INSPECTION 1. Remove bolt securing oil strainer to the MAG side crankcase. 2.
Page 107 ENGINE OIL RELIEF VALVE INSTALLATION Install the oil relief valve, spring, and plug using a new sealing washer. Oil Relief Valve Plug Torque: 14-17 ft. lbs. (19-23 Nm) CAM CHAIN DRIVE SPROCKET INSTALLATION 1. Install the Woodruff key, drive sprocket, and slotted nut.
Page 108 ENGINE PISTON RING INSTALLATION NOTE: Apply clean engine oil to all ring surfaces and ring lands. Always check piston ring installed gap before rings are installed on piston. See page 3.36. If the piston has been in service clean any accumulated carbon from the ring grooves and oil control ring holes.
Page 109 ENGINE CYLINDER INSTALLATION 1. Position the piston support block PN 2870390 (A) beneath the piston skirt to support the piston during cylinder installation. 2. Apply clean engine oil to the ring compressor (Snap On¥ PN RCL30 or equivalent) and install the compressor following manufacturer’s instructions.
Page 110 ENGINE CYLINDER HEAD INSTALLATION Clean the gasket surfaces on the cylinder head and cylin- der. Remove all traces of old gasket material. Refer to disassembly photos. 1. Install the cam chain tensioner guide. Be sure bottom end of guide is located properly in crankcase. Torque in cross pattern per procedure 2.
Page 111 Use a wire to pull the chain up through the cylinder and cylinder head, and secure it to hold the chain in place. 3. Apply Polaris Low Temp Grease PN 2870577, or Plated link engine assembly lubricant to the camshaft main aligned w/dot journals and cam lobes.
Page 112 ENGINE CAMSHAFT INSTALLATION - TIMING METHOD 1. CONT. 7. Install the sprocket on the camshaft. Apply Loctite 242 to the cam sprocket bolt and torque to specifications. Cam Sprocket Bolt Torque: 25-29 ft. lbs. (34-40 Nm) 8. Check all cam timing marks to verify proper cam timing, and install the cam chain tensioner.
Page 113 ENGINE CAMSHAFT TIMING - METHOD 1 Method 1 - Camshaft Timing with Stator Removed Crankshaft to Camshaft Centerline Single Plated Sprocket marks aligned with gasket surface at TDC on Link and Dot on compression stroke (cam Cam Sprocket lobes facing downward) Single Plated Link and Rectangular...
Page 114 ENGINE CAMSHAFT INSTALLATION - TIMING METHOD 2. REFER TO ILLUSTRATION, PAGE 3.59 1. Apply Polaris Low Temp Grease PN 2870577, or molybdenum disulfide grease to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil. (To install the compression release mechanism, refer to page 3.18).
Page 115 ENGINE CAMSHAFT TIMING - METHOD 2 Method 2 - Camshaft Timing Using Flywheel TDC Mark Crankshaft to Camshaft Centerline Do not use dot on sprocket for cam timing Decompressor arm stop pin UP (Cam lobes DOWN) Sprocket marks aligned with gasket surface at TDC on compression stroke (cam lobes facing downward, de-...
Page 116 ENGINE CAM CHAIN TENSIONER INSTALLATION 1. Release the ratchet pawl (A) and push the tensioner plunger (B) all the way into the tensioner body. 2. Install the tensioner body with a new gasket and tighten the bolts. Tensioner Bolt Torque: 5-6.5 ft.
Page 117 ENGINE STATOR INSTALLATION, CONT. 4. Torque bolts evenly to specification. Stator Plate Bolt Torque: 5-6.5 ft. lbs. (7-9 Nm) 5. Seal stator wire grommet with 3 Bond 1215 (P/N 2871557). FLYWHEEL INSTALLATION 1. Install flywheel, washer, and nut. Torque flywheel to specification.
Page 118 ENGINE ROCKER SHAFT/ROCKER ARM ASSEMBLY INSTALLATION 1. Assemble rocker arms, rocker shaft and wave washer into rocker cover. 2. Install and tighten rocker cover block plug. 3. Apply Premium All Season or engine assembly lube to the cam lobes and cam follower surfaces. 4.
Page 119 ENGINE RECOIL DISASSEMBLY/INSPECTION CAUTION: The recoil is under spring tension. A face shield and eye protection is required during this proce- dure. Replace any parts found to be worn or damaged. 1. Remove bolts and recoil housing. 2. Pull recoil rope so it is extended approximately 12-18s.Check handle c-ring for proper tension, and the handle for cracks or damage which may allow water or dirt to enter the recoil housing through the...
Page 120 ENGINE RECOIL DISASSEMBLY/INSPECTION, CONT. 6. Hold reel firmly in housing. Pull rope handle until 12-18s of rope is exposed, and hold reel in place. 7. Place rope in notch on outer edge of reel. Release tension on hub and allow reel to unwind approximately 6-7 turns until spring tension is released.
Page 121 ENGINE RECOIL ASSEMBLY CAUTION: Be sure to wear a face shield and eye protec- tion when performing this procedure. To install a new spring: 1. Place spring in housing with the end positioned so the spring spirals inward in a counterclockwise direction. See photo at right.
Page 122 ENGINE SPARK PLUG FOULING TROUBLESHOOTING SSpark plug cap loose or faulty SChoke cable adjustment or plunger/cable sticking SForeign material on choke plunger seat or plunger SIncorrect spark plug heat range or gap SCarburetor inlet needle and seat worn SJet needle and/or needle jet worn or improperly adjusted SExcessive carburetor vibration (loose or missing needle jet locating pins) SLoose jets in carburetor or calibration incorrect for altitude/temperature SIncorrect float level setting...
Page 123 ENGINE TROUBLESHOOTING Engine Turns Over But Fails to Start SNo fuel SDirt in fuel line or filter SFuel will not pass through fuel valve SFuel pump inoperative/restricted STank vent plugged SCarb starter circuit SEngine flooded SLow compression (high cylinder leakage) SNo spark (Spark plug fouled) Engine Does Not Turn Over SDead battery...
Page 124 ENGINE TROUBLESHOOTING Piston Failure - Scoring SLack of lubrication SDirt entering engine through cracks in air filter or ducts SEngine oil dirty or contaminated Excessive Smoke and Carbon Buildup SExcessive piston-to-cylinder clearance SWet sumping SWorn rings, piston, or cylinder SWorn valve guides or seals SRestricted breather SAir filter dirty or contaminated Low Compression...
Page 125 CHAPTER 4 FUEL SYSTEM/CARBURETION Jetting Guidelines ......Fuel Tank Assy. Exploded View ....Fuel Flow Diagram .
Page 127: Jetting Guidelines
FUEL SYSTEM/CARBURETION JETTING GUIDELINES Changes in altitude and temperature affect air density, which is essentially the amount of oxygen available for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense. Carburetors are calibrated for an altitude of 0-3000 ft.
Page 128 FUEL SYSTEM/CARBURETION FUEL TANK ASSEMBLY Vent line routed smoothly into center of steering post Forward 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”...
Page 129: Fuel Flow Diagram
FUEL SYSTEM/CARBURETION FUEL FLOW DIAGRAM Fuel Tank Fuel Tank Vent Fitting Screens Fuel Pump Filter Fuel Valve Carburetor Vent Engine Carburetor L Located Under Headlamp Cover MIKUNI JET PART NUMBERS Main Jet Part Numbers Pilot Jet Part Numbers Mikuni BST Carburetor Mikuni BST Carburetor Jet Number Part Number...
Page 130 FUEL SYSTEM/CARBURETION CV CARBURETOR SYSTEM FUNCTION Carburetor Component Function System Main Components Main Function Main Affect Float System Inlet Pipe, Needle and Seat, Maintains specified fuel level All systems (Fuel Level Control) Float, Float Pin in float chamber (carburetor All throttle ranges float bowl) Venting Vent Passages in Carburetor,...
Page 131 FUEL SYSTEM/CARBURETION MIKUNI CV CARB OPERATION The constant velocity carburetor incorporates a mechanically operated throttle plate and a vacuum controlled slide valve (vacuum slide). The venturi cross-sectional area in the carburetor bore is increased or decreased automatically by the vacuum slide, which moves according to the amount of negative pressure (less than atmo- spheric) present in the venturi.
Page 132 FUEL SYSTEM/CARBURETION PILOT (IDLE AND SLOW) SYSTEM This system supplies fuel during engine operation with throttle valve closed (1) or slightly opened. The fuel from float cham- ber (2) is metered by pilot jet (3) where it mixes with air coming in through pilot air jet (4).
Page 133 FUEL SYSTEM/CARBURETION FLOAT SYSTEM Fuel enters the float chamber (3) by means of the inlet pipe and passage, through a screen on the back of the inlet needle seat (4), and around the inlet needle (2). As the fuel fills the float cham- ber, the float (1) rises and forces the inlet needle against the seat, shutting off the orifice in the seat.
Page 134: Mikuni Bst Carburetor, Exploded View
FUEL SYSTEM/CARBURETION Mikuni BST 31 Carburetor 1. Carburetor Assembly Exploded View 2. Screw 3. Throttle Valve 4. Cover, Diaphragm 5. Jet Block Assembly 6. Spring 7. Diaphragm Assembly 8. Ring 9. “E” Ring 10. Ring 11. Needle Jet 12. Cover 13.
Page 135 FUEL SYSTEM/CARBURETION CARBURETOR DISASSEMBLY Use the following disassembly, assembly, and inspection techniques to service a CV carburetor. 1. Remove carburetor diaphragm chamber cover with a ratchet style screwdriver. DO NOT use an impact driver to remove the screws or carburetor may be permanently damaged.
Page 136 FUEL SYSTEM/CARBURETION CARBURETOR DISASSEMBLY, CONT. 4. Do not misplace the pilot mixture screw, spring, flat washer, or 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.
Page 137 FUEL SYSTEM/CARBURETION CARBURETOR CLEANING 1. Thoroughly clean the carburetor body, jets, and all passages with carburetor cleaner or electrical contact cleaner. WARNING Protect eyes from contact with cleaner. If you get cleaner in your eyes or if you swallow cleaner, see your doctor immediately.
Page 138 FUEL SYSTEM/CARBURETION CARBURETOR INSPECTION 1. Inspect jet needle and needle jet for wear. Look for discoloration, shiny spots, or an area that looks Spring seat washer different than the rest of the needle. The middle to upper portion of the needle where it contacts the needle jet is the most likely wear point.
Page 139 FUEL SYSTEM/CARBURETION CARBURETOR ASSEMBLY 1. Inspect the diaphragm (A) for holes, deterioration, or damage. Make sure the diaphragm is pliable but not swollen. The diaphragm should fit properly in the carburetor body. Replace diaphragm assembly if diaphragm is damaged. Be sure diaphragm seals tightly on slide in area (F).
Page 140 FUEL SYSTEM/CARBURETION FLOAT HEIGHT ADJUSTMENT 1. Place the carburetor on a level surface as shown at right to remove weight from float arm. In this position, the float tongue will rest lightly on the inlet needle valve pin without compressing the spring. 2.
Page 141 FUEL SYSTEM/CARBURETION NEEDLE AND SEAT LEAKAGE TEST 1. Install the float bowl. Invert the carburetor and install a 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.
Page 142 FUEL SYSTEM/CARBURETION FUEL PUMP The Trail Boss is equipped with a pressure regulated fuel pump (about 1-3 PSI). The pump is located under the headlight cover at the front of the machine. Refer to illustration on following page for fuel pump component identifi- cation.
Page 143: Fuel Pump Exploded View
FUEL SYSTEM/CARBURETION 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 4.17...
Page 144: Troubleshooting
FUEL SYSTEM/CARBURETION TROUBLESHOOTING FUEL STARVATION/LEAN MIXTURE Symptoms: Hard start or no start, bog, backfire, popping through intake / exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle speed erratic. No fuel in tank Restricted tank vent, or routed improperly Fuel lines or fuel valve restricted Fuel filter plugged Carburetor vent line(s) restricted...
Page 145 FUEL SYSTEM/CARBURETION TROUBLESHOOTING POOR IDLE Symptoms: Idle too high. Idle adjusted improperly/idle mixture screw damaged Sticky vacuum slide Throttle cable sticking, improperly adjusted, routed incorrectly Choke cable sticking, improperly adjusted, routed incorrectly IDLE TOO LOW Choke cable bending or incorrectly adjusted Idle speed set incorrectly Idle mixture screw misadjusted or damaged Belt dragging...
Page 146 NOTES...
Page 147 CHAPTER 5 BODY AND STEERING Torque Specifications and Special Tools ... . Body Assembly, Exploded View ....Cab &...
Page 149 BODY/STEERING/SUSPENSION TORQUE SPECIFICATIONS Front A-Arm Attaching Bolt ....30 ft. lbs. (41 Nm) Front A-Arm Ball Joint Stud Nut ... . . 25 ft.
Page 150: Body Assembly Exploded View
BODY/STEERING/SUSPENSION BODY ASSEMBLY EXPLODED VIEW 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.
Page 151 BODY/STEERING/SUSPENSION COVER/PANEL REMOVAL To Remove: Perform These Steps: Seat ..... . . Pull release lever at the rear of the seat Lift and pull seat rearward, disengaging seat from tabs at the rear of the fuel tank Fuel tank cover .
Page 152: Steering Assembly, Exploded View
BODY/STEERING/SUSPENSION STEERING ASSEMBLY, EXPLODED VIEW NOTE: To avoid damage to tie rods and other steering components, be sure to install tie rod end bolts in the proper direction. The steering post arm bolt (B) points up; the rod end bolts (A) point down. Be sure inner rod ends are placed between the steering post arms.
Page 153: A-Arm Replacement
BODY/STEERING/SUSPENSION A-ARM REPLACEMENT 1. Elevate and safely support vehicle with weight removed from front wheel(s). 2. Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud. 3. Using a soft face hammer, tap nut to loosen A-arm from bolt. Remove nut and A-arm from hub strut assembly. 4.
Page 154 BODY/STEERING/SUSPENSION CONCENTRIC SWING ARM REMOVAL Removal / Disassembly 1. Lift rear of machine and support securely with wheels off the floor. 2. Remove drive chain. 3. Remove rear caliper. CAUTION: Do not allow the caliper to hang by the brake line. Brake line damage may result. 4.
Page 155: Concentric Swingarm Assembly/Installation
BODY/STEERING/SUSPENSION CONCENTRIC SWING ARM ASSEMBLY/INSTALLATION Assembly / Installation 1. Lubricate and install bushing (6) in left side of swingarm and two-piece bushings (3) in right side. 2. Clean threads of nut (1), pivot bolts (5) and (8), and pivot bushings (4) and (7) with Loctite Primer T or Primer N.
Page 156: Strut Assembly Exploded View
BODY/STEERING/SUSPENSION STRUT ASSEMBLY EXPLODED VIEW Nut - 15 ft. lbs. (21 Nm) Washer Spacer Rubber 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...
Page 157: Front Strut Weldment Replacement
BODY/STEERING/SUSPENSION FRONT STRUT WELDMENT REPLACEMENT Front Strut Cartridge Replacement Refer to Illustration on Page 5.8. 1. Hold strut rod with holder wrench and remove top nut. 2. Compress spring using strut spring compressor tools. Strut Rod Holder Wrench PN 2871572 Strut Spring Compressor Tools PN 2871573 and PN 2871574 3.
Page 158: Front Strut Ball Joint Replacement
BODY/STEERING/SUSPENSION FRONT STRUT BALL JOINT REPLACEMENT Refer to Illustration on Page 5.8. 1. Loosen front wheel nuts slightly. 2. Elevate and safely support machine under footrest/frame area. CAUTION: Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.
Page 159: Steering Post Assembly
BODY/STEERING/SUSPENSION STEERING POST ASSEMBLY Grease Fitting 12 ft. lbs. (16 Nm) 1. Hand tighten. 2. Align cotter pin hole. 3. Install cotter pin. Bend both ends of cotter pin around nut in opposite directions. 4. Check steering, must move freely and easily from full left to full right without binding.
Page 160 NOTES...
Page 161 CHAPTER 6 CLUTCHES Service Tools and Supplies ....PVT System Introduction ..... . PVT Maintenance/Inspection .
Page 163 CLUTCH SPECIAL SERVICE TOOLS AND SUPPLIES Description Part Number Drive Clutch Puller ......2870506 Clutch Holding Fixture .
Page 164 CLUTCH 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. During the development of an ATV, the PVT system is matched first of all to the engine power curve;...
Page 165: Pvt Maintenance/Inspection
CLUTCH PVT MAINTENANCE/INSPECTION Under normal operation the PVT system will provide years of trouble free operation. Periodic inspection and main- tenance is required to keep the system operating at peak performance. The following list of items should be in- spected and maintained to ensure maximum performance and service life of PVT components. Refer to the trou- bleshooting checklist at the end of this chapter for more information.
Page 166 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch malfunction. For inspection of clutch components, please contact your Polaris dealer. Poor engine performance. Fouled plugs, foreign material in gas tank, fuel lines, or carburetor.
Page 167: Pvt Disassembly
CLUTCH PVT DISASSEMBLY NOTE: Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement. (See page 6.8). 1. Remove seat. 2. Remove or loosen rear cab fasteners as necessary to gain access to PVT outer cover. 3.
Page 168 CLUTCH PVT DISASSEMBLY, CONT. 7. Remove driven clutch retaining bolt and driven clutch. Use puller if necessary. Driven Clutch Puller PN 2870913 8. Remove driven clutch offset spacers from the transmission input shaft. Keep Spacers In Order 9. Bend back retainer tabs on three screws at the front of the inner cover (where applicable).
Page 169: Pvt Assembly
CLUTCH PVT ASSEMBLY 1. Inspect PVT inner cover-to engine seal. Replace if cracked or damaged. Seal this edge to cover on engine side 2. Place a new foam seal on transmission input shaft. 3. Apply RTV silicone sealant to outside edge of inner cover-to-engine seal, to ensure a water tight fit between the seal and the cover on engine side.
Page 170: Pvt Sealing And Ducting Components
CLUTCH PVT SEALING AND DUCTING COMPONENTS Clutch Cover Bracket Shield Inlet Duct Outer Cover Seal Inner Cover Inner Cover Seal Retainer Outer Cover Exhaust Duct...
Page 171 CLUTCH RELATIONSHIP OF DRIVE CLUTCH WEIGHTS AND SPRING IN MAINTAINING OPERATING RPM The drive clutch is an RPM and torque sensing unit designed to transfer the maximum amount of horsepower from the engine to the ground. This is accomplished through weights and a spring inside the unit which react to the centrifugal force applied to the clutch from the engine RPM.
Page 172: Drive Clutch Spring Specifications
CLUTCH DRIVE CLUTCH SPRING SPECIFICATIONS The drive clutch spring has two prima- FULL UPSHIFT NEUTRAL ry functions: Blue/Blue- Gold ATV TRAVEL 7041080 1. To control clutch engagement Gold RPM. The springs which have a 7041148 Silver higher rate when the clutch is in 7041062 neutral will...
Page 173: Shift Weights
CLUTCH SHIFT WEIGHTS Shown below are the shift weights which have been designed for, or which may be used in the PVT system. These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern.
Page 174 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 175: Drive Clutch Exploded View
CLUTCH DRIVE CLUTCH EXPLODED VIEW Drive Clutch Teflon coated brass bushing Teflon coated brass bushing Mark with permanent marker before disassembly 6.13...
Page 176 CLUTCH DRIVE CLUTCH DISASSEMBLY 1. Using a permanent marker, mark the cover, spider, Mark moveable and stationary sheaves, and steel post to the stationary sheave for reference. The X’s may not have been in alignment before disassembly. 2. Remove cover bolts evenly in a cross pattern, and remove cover plate.
Page 177 CLUTCH SPIDER REMOVAL 1. Install clutch in holding fixture and loosen the spider (counterclockwise) using spider removal tool. Clutch Holding Fixture: PN 2871358 Spider Removal Tool: PN 2870341 NOTE: It is important that the same number and thickness of washers are reinstalled beneath the spider during as- sembly.
Page 178 CLUTCH ROLLER, PIN AND THRUST WASHER INSPECTION 3. Inspect all rollers, bushings and roller pins by pulling a flat metal rod across the roller. Turn roller with your finger. If you notice resistance, galling, or flat spots, replace rollers, pins and thrust washers in sets of three.
Page 179: Drive Clutch Assembly
CLUTCH DRIVE CLUTCH ASSEMBLY NOTE: It is important that the same number and thick- ness of washers are reinstalled beneath the spider dur- ing assembly. The Teflon bushings are self-lubricating. Do not apply oil or grease to the bushings. 1. Reassemble drive clutch in the following sequence. Be sure the “X”, or the marks that were made earlier, are aligned during each phase of assembly.
Page 180: Drive Belt Tension
CLUTCH DRIVE CLUTCH ASSEMBLY, CONT. 8. Reinstall cover, aligning “X” mark with other marks. Torque cover bolts evenly to specification. Spider Torque: 200 ft. lbs. (276 Nm) Cover Screw Torque: 90 in. lbs. (10.4 Nm) DRIVE BELT TENSION NOTE: Pinch the sheaves lightly together with clamp to prevent the belt from being pushed into the driven sheave. 1.
Page 181: Drive Belt Removal/Inspection
CLUTCH DRIVE BELT REMOVAL/INSPECTION 1. Remove outer PVT cover as described in PVT Disassembly. 2. Mark drive belt direction of rotation so that it can be installed in the same direction. NOTE: Normally positioned so part numbers are easily read. 3.
Page 182: Drive Belt Installation
CLUTCH DRIVE BELT REMOVAL/INSPECTION, CONT. 7. Measure belt length with a tape measure around the outer circumference of the belt. Belts which measure longer than nominal length may require driven shimming or engine adjustment for a longer center distance to obtain proper belt deflection. Belts which measure shorter than nominal length may require driven shimming or a shorter center distance.
Page 183: Clutch Alignment /Offset
CLUTCH CLUTCH ALIGNMENT 1. Remove belt and install offset/alignment tool as shown. Offset Alignment Tool 2. With tool touching rear of driven clutch inner sheave, the PN 2870654 distance at point “A” should be 1/8s. If the distance is greater than 1/8s or less than 1/16s, clutch alignment must be adjusted as follows: 3.
Page 184: Drive Clutch Bushing Service
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 185 CLUTCH DRIVE CLUTCH MOVEABLE SHEAVE - BUSHING REMOVAL, CONT. 6. Turn sheave puller barrel together counterclockwise on puller rod until bushing is removed. 7. Remove nut from puller rod and set aside. 8. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard.
Page 186 CLUTCH DRIVE CLUTCH COVER - BUSHING REMOVAL 1. Install main adapter (Item 8) on puller. Piston Pin Puller PN 2870386 Main Adaptor 2. From outside of clutch cover, insert removal tool (Item 3) into cover bushing. 3. With inside of cover toward vise, slide cover onto puller.
Page 187 CLUTCH DRIVE CLUTCH COVER - BUSHING INSTALLATION 1. Apply Loctite 680 retaining compound to the back side of new bushing. Working from inside of cover, insert bushing and bushing installation tool into center of clutch cover. Bushing PN 3576510 Loctitet 680 PN 2870584 2.
Page 188: Driven Clutch Disassembly/Inspection
CLUTCH DRIVEN CLUTCH DISASSEMBLY/INSPECTION Used to adjust belt tension. One must always be installed. CAUTION: Wear eye protection when removing snap ring to prevent serious personal injury. 1. Apply and hold downward pressure on the helix, or place driven clutch in compressor tool PN 8700220. 2.
Page 189 CLUTCH DRIVEN CLUTCH DISASSEMBLY / INSPECTION, CONT. 5. Check alignment of tabs on spring. Replace the spring if tabs are misaligned or the spring coils are distorted. Tabs Aligned 6. Inspect ramp buttons in the moveable sheave and replace if worn. NOTE: The ramp buttons are secured by Torx¥...
Page 190 CLUTCH DRIVEN CLUTCH DISASSEMBLY / INSPECTION, CONT. 8. Inspect the Teflon¥ coating on the moveable sheave bushing. Inspect bushings for wear Moveable Sheave Bushing Inspection: Replace the bushing if more brass than Teflon¥ is visible on the bushing. Re- fer to bushing replacement in this chapter.
Page 191: Driven Clutch Assembly
CLUTCH DRIVEN CLUTCH ASSEMBLY 1. Install moveable sheave with spacer washers. Important: At least one spacer washer must be installed. Teflon bushings are self-lubricating. Do not apply oil or grease to the bushings. 2. Install spring, inserting spring tab into proper hole in moveable sheave.
Page 192 CLUTCH DRIVEN CLUTCH MOVEABLE SHEAVE - BUSHING REMOVAL NOTE: Bushings are installed at the factory using Loc- tite. In order to remove the bushing it will be necessary to apply heat. A press can be used to remove and install some of the bushings.
Page 193 CLUTCH DRIVEN CLUTCH MOVEABLE SHEAVE - BUSHING REMOVAL, CONT. 5. Working from the top, install bushing removal tool (Item 5) into center of clutch sheave with smaller diameter toward bushing to be removed. illustration at right. Bushing Removal Tool (#5) 6.
Page 194 CLUTCH DRIVEN CLUTCH MOVEABLE SHEAVE - BUSHING INSTALLATION 1. Working from the top, insert adapter number ten onto puller. See illustration at right. 2. Start new bushing evenly in moveable sheave. Apply Loctite 680 retaining compound to the back side of new bushing. Adapter Number Ten 3.
Page 195 CLUTCH DRIVEN CLUTCH MOVEABLE SHEAVE - BUSHING INSTALLA- TION, CONT. 4. Install nut onto puller rod and hand tighten against installation tool. 5. Turn clutch sheave counterclockwise until bushing is seated. 6. Remove nut from puller rod and set aside. 7.
Page 196: Troubleshooting
CLUTCH TROUBLESHOOTING Situation Probable Cause Remedy Engine RPM -Wrong or broken drive clutch spring. -Replace with recommended spring. below specified operating -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine application. range, although engine is prop- -Driven clutch spring broken or installed in -Replace spring;...
Page 197 CLUTCH TROUBLESHOOTING Situation Probable Cause Remedy Belt slippage -Belt worn out -Replace belt. -Water ingestion -Inspect and seal PVT system. -Belt contaminated with oil or grease -Inspect and clean. Belt burnt, thin -Abuse (continued throttle application when -Caution operator to operate machine within guidelines. spots vehicle is stationary, excess load) -Dragging brake...
Page 198 NOTES...
Page 199 CHAPTER 7 FINAL DRIVE Final Drive Torque Specifications ....Front Hub Disassembly/Inspection ....7.2-7.3 Front Hub Assembly .
Page 201 FINAL DRIVE WHEEL, HUB, AND SPINDLE TORQUE TABLE ¡ Item Specification Front Wheel Nuts 20 Ft. Lbs. Rear Wheel Nuts 50 Ft. Lbs. Front Spindle Nut 40 Ft. Lbs. Rear Hub Retaining Nut 80 Ft. Lbs. ¡ 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.
Page 202: Front Hub Disassembly/Inspection
FINAL DRIVE FRONT HUB DISASSEMBLY/INSPECTION 1. Elevate front end and safely support machine under footrest / frame area. CAUTION: Serious injury may result if machine tips or falls. Be sure machine is secure before be- ginning this service procedure. Wear eye protec- tion when removing bearings and seals.
Page 203 FINAL DRIVE FRONT HUB DISASSEMBLY, CONT. 7. Place a shop towel on hub to protect surface. Carefully pry seal out of hub. 8. Using a brass drift, tap bearing spacer to one side Tap spacer to side to expose inner bearing race. Drive bearing out using a drift through opposite side of hub and discard.
Page 204: Front Hub Assembly
FINAL DRIVE FRONT HUB ASSEMBLY 1. Drive or press one new bearing into hub using a 1.180 (46 mm) bearing driver. CAUTION: Do not drive on the inner race of the bearing. Seal Premium All-Season Grease PN 2871322 (3 oz. Tube) PN 2871423 (14 oz.
Page 205: Front Hub Installation
FINAL DRIVE FRONT HUB INSTALLATION 1. Inspect spindle seal and bearing surface for wear or damage. Inspect and Grease 2. Apply grease to spindle. 3. Install hub on spindle. 4. Apply grease to washer and install with domed side out. Cone Washer 5.
Page 206: Front Hub Exploded View
FINAL DRIVE FRONT HUB EXPLODED VIEW 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)
Page 207: Concentric Swingarm Rear Axle Removal
FINAL DRIVE CONCENTRIC SWINGARM REAR AXLE REMOVAL 1. Securely support rear of machine with rear wheels off the floor. Remove rear wheels and hubs. 2. Remove drive chain. 3. Remove snap ring (A), lock sleeve (B) and foam seal (C) from axle. 4.
Page 208 FINAL DRIVE 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.
Page 209: Concentric Swingarm Rear Axle Disassembly
FINAL DRIVE CONCENTRIC SWINGARM REAR AXLE DISASSEMBLY 1. Remove rear axle. (See page 7.7) 2. Remove snap ring, collar, and foam seal. 3. Remove nut, brake disc assembly, and stop ring. Disc Hub Stop Ring Groove in spline Threads Splines...
Page 210: Concentric Swingarm Rear Axle Assembly
FINAL DRIVE CONCENTRIC SWINGARM REAR AXLE ASSEMBLY 1. Install stop ring in groove on left side of axle. NOTE:Left side of axle is identified by the small Disc Hub groove in the middle of the spline. Stop Ring Groove in spline 2.
Page 211 FINAL DRIVE CONCENTRIC SWINGARM REAR AXLE ASSEMBLY, CONT. 4. Install foam seal and axle nut lock sleeve with taper toward nut. Install snap ring to retain the Foam Seal lock sleeve. Snap Ring Lock Sleeve (Tapered side toward nut) 7.11...
Page 212: Concentric Swingarm Rear Axle Installation
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 through grease fitting with Polaris Premium All Season Grease until grease is purged on each side of eccentric. 7.12...
Page 213 FINAL DRIVE CONCENTRIC SWINGARM REAR AXLE ASSY, EXPLODED VIEW Left Axle Nut (120 ft. lbs.) Foam Seal Brake Disc Snap Ring Disc Hub Lock Collar Stop Ring Seal Sleeve O-Ring Bearing Seal Bearing Race Eccentric Housing Grease Fitting Left side of axle identified by groove in spline Axle Bearing Race...
Page 214: Concentric Swingarm Rear Housing Removal
FINAL DRIVE CONCENTRIC SWINGARM REAR HOUSING REMOVAL 1. Remove rear axle. (See page 7.7) 2. Remove sprocket hub. Note sealing O-ring between sprocket hub and bearing. 3. Remove brake caliper mounting bracket. 4. Remove brake caliper pivot bushing from stud. NOTE: Flange inward as shown.
Page 215 FINAL DRIVE CONCENTRIC SWINGARM REAR HOUSING REMOVAL, CONT. 5. Remove rear housing. 7.15...
Page 216: Concentric Swingarm Rear Housing Installation
FINAL DRIVE REAR HOUSING DISASSEMBLY/BEARING SERVICE 1. Remove seals from housing. Seal Bearing 2. Remove bearings. 3. Drive bearing race out from opposite sides. 4. Inspect housing for cracks or wear. Replace if damaged. Seal Bearing Race REAR HOUSING ASSEMBLY/BEARING SERVICE 1.
Page 217 CHAPTER 8 TRANSMISSION SERVICE Torque Specifications ......Transmission Remove/Install ....Transmission Disassembly .
Page 219: Torque Specifications
TRANSMISSION TORQUE SPECIFICATIONS Transmission Case Bolts ......... 12 ft.
Page 220 TRANSMISSION TRANSMISSION REMOVAL 1. Remove seat, cab and air box. 2. Remove right side heat and reservoir bracket. 3. Remove PVT outer cover, both drive and driven clutch, and inner PVT cover (refer to Clutch Chapter 4. Remove rear PVT bracket. 5.
Page 221: Transmission Disassembly
TRANSMISSION TRANSMISSION DISASSEMBLY 1. Remove gear position switch. CAUTION: If switch is not removed prior to disassembly, switch dam- age will result. 2. Place bellcrank in neutral position. 3. Remove sprocket retaining clip and sprocket. 4. Remove the transmission cover bolts. 5.
Page 222 TRANSMISSION TRANSMISSION DISASSEMBLY, CONT. 8. Remove shift assembly and gear as an assembly. NOTE: Direction of shift fork. 9. Inspect shift fork surface for wear or damage. Replace if necessary. 10. Remove shift fork guide pin.
Page 223 TRANSMISSION TRANSMISSION DISASSEMBLY, CONT. 11. Mark orientation of bellcrank to the shift fork shaft. 12. Remove bellcrank. Use a small puller if necessary. 13. Remove snap ring and washer. Pull down and rotate shift fork shaft back and forth to remove.
Page 224 TRANSMISSION TRANSMISSION DISASSEMBLY, CONT. 14. Inspect shift fork shaft O-ring. Replace if necessary. Lubricate O-ring to ease in reassembly and to protect O-ring during assembly. 15. Remove input shaft bearing. 16. Inspect gears for galling and wear on teeth and bearing surface.
Page 225 TRANSMISSION TRANSMISSION DISASSEMBLY, CONT. 17. Remove bearing from other end of input shaft. Remove two snap rings and gear. 18. Inspect gear bushing. Replace if 50% of teflon surface is gone. 19. Inspect output shaft gear, sprocket and bearing. Replace if necessary. Output Shaft Bearing Sprocket...
Page 226 TRANSMISSION TRANSMISSION DISASSEMBLY, CONT. 20. Stretch chain tight on a flat surface and measure the length of 8 pitches in a minimum of three places on chain. Replace chain if measurement is longer than 3.0904I. Measure 8 pitches Chain Stretch Limit 8 pitch length = 3.0904I Maximum...
Page 227: Transmission Assembly
TRANSMISSION TRANSMISSION ASSEMBLY 1. Assemble input shaft assembly. Sprocket NOTE: Install bearings with numbers and letters facing Dog Gear out so they can be read after assembly. Sprocket cogs face the dog gear. Input Shaft NOTE: Input gear cogs face inward on input shaft. Thrust Washer 2.
Page 228 TRANSMISSION ASSEMBLY, CONT. 7. Prior to reinstalling the cover make sure the mating cover surfaces are clean and dry. Apply Polaris case sealant P/N 2871557 to mating surfaces. 8. Reinstall cover and torque bolts in a cross pattern in 3 steps to 12 ft.
Page 229: Transmission Exploded View
TRANSMISSION TRANSMISSION EXPLODED VIEW High/Reverse Dog Input Shaft Position Switch Shift Fork Dipstick Drain Plug Silent Chain Output Shaft 8.11...
Page 230 TRANSMISSION TROUBLESHOOTING CHECKLIST Check the following items when shifting difficulty is encountered. S Idle speed adjustment S Transmission oil type/quality S Transmission torque stop adjustment S Drive belt deflection S Loose fasteners on rod ends S Loose fasteners on shifter S Worn rod ends, clevis pins, or pivot arm bushings S Linkage rod adjustment and rod end positioning S *Worn, broken or damaged internal transmission components...
Page 231: Troubleshooting
CHAPTER 9 BRAKES Specifications/Torques ......Brake System Service Notes ..... . Brake Pad Kits .
Page 233 BRAKES SPECIFICATIONS Front Brake Caliper Item Standard Service Limit Brake Pad Thickness .275s / 7.0mm .150s / 3.81mm Brake Disc Thickness .150-.164s / 3.810-4.166mm .140s / 3.556mm Brake Disc Thickness Variance Between .002s / .051mm Measurements Brake Disc Runout .010s / .25mm Rear Axle Brake Caliper Item Standard...
Page 234: Brake System Service Notes
BRAKES BRAKE SYSTEM SERVICE NOTES Disc brake systems are light weight, low maintenance, and perform well in the conditions ATVs routinely en- counter. There are a few things to remember when replacing disc brake pads or performing brake system ser- vice to ensure proper system function and maximum pad service life.
Page 235: Brake Noise Troubleshooting
BRAKES BRAKE NOISE TROUBLESHOOTING Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning does not reduce the occurrence of brake noise, Permatext Disc Brake Quiet (available from most auto parts stores) can be applied to the back of the pads.
Page 236: Hydraulic Brake System Operation
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.
Page 237: Dual Hydraulic Caliper Bleeding
BRAKES DUAL HYDRAULIC CALIPER BLEEDING This caliper is a dual opposed piston design, with two independent hydraulic systems contained in the same cali- per body (see Ill.1). The caliper pistons are T-shaped, which allows both hand and foot brake to use the same caliper piston, but remain separated by seals.
Page 238: Fluid Replacement/Bleeding Procedure
NOTE: Do not remove brake lever when reservoir fluid level is low. Mity Vac¥ PN 2870975 5. Add brake fluid to the indicated MAX level inside 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 239 BRAKES BRAKE BLEEDING - FLUID CHANGE CONT. 7. Slowly pump brake lever (D) until pressure builds and holds. 8. While maintaining lever pressure, open bleeder screw. Close bleeder screw and release brake lever. NOTE: Do not release lever before bleeder screw is tight or air may be drawn into caliper.
Page 240: Master Cylinder Removal
BRAKES MASTER CYLINDER REMOVAL 1. Clean master cylinder and reservoir assembly. Make sure you have a clean work area to disassemble brake components. 2. Place a shop towel under brake line connection at master cylinder. Loosen brake line 1/4 to 1/2 turn. CAUTION: Brake fluid will damage finished surfaces.
Page 241: Master Cylinder Disassembly
BRAKES MASTER CYLINDER DISASSEMBLY 1. Remove cover and diaphragm from master cylinder and dispose of the fluid properly. Vent Slots 2. Be sure vents in cover are clean and unobstructed. 3. Remove brake lever. Cover 4. Clean surfaces of the reservoir and master cylinder body.
Page 242: Master Cylinder Inspection
BRAKES MASTER CYLINDER INSPECTION 1. Clean the master cylinder assembly with clean Dot 3 brake fluid, brake parts cleaner, or denatured alcohol. Dry thoroughly. Inspect the bore for nicks, scratches or wear. Replace if damage is evident or if worn. 2.
Page 243 BRAKES MASTER CYLINDER ASSEMBLY, CONT. 3. Dip piston in clean DOT 3 brake fluid, attach spring to piston, and install assembly into installation tool. CAUTION: Do not attempt to install the piston without the required installation tool. Do not allow the lip of the seals to turn in- side out or fold.
Page 244: Master Cylinder Installation
Master Cylinder Mounting Bolt Torque 55 in. lbs. (6 Nm) 4. Fill reservoir with DOT 3 fluid. 5. Follow bleeding procedure on pages 9.6-9.7. Check all connections for leaks and repair if necessary. Polaris DOT 3 Brake Fluid PN 2870990 9.12...
Page 245: Front Pad Removal
BRAKES FRONT PAD REMOVAL 1. Elevate and support front of machine. CAUTION: Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 2. Remove the front wheel. Loosen pad adjuster screw 2-3 turns.
Page 246: Front Pad Assembly
BRAKES FRONT PAD ASSEMBLY 1. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots. Polaris Premium All Season Grease PN 2871423 2. Compress mounting bracket and make sure dust boots are fully seated.
Page 247: Front Disc Inspection
BRAKES FRONT PAD ASSEMBLY, CONT. 7. Install wheels and torque wheel nuts. 8. 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.
Page 248 BRAKES FRONT BRAKE DISC REMOVAL / REPLACEMENT 1. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent. 2. Remove bolts and disc. 3. Clean mating surface of disc and hub. 4.
Page 249: Front Caliper Removal
BRAKES FRONT CALIPER REMOVAL CAUTION: Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 1. Remove brake pads. See page 9.13. 2. Using a line wrench, loosen and remove brake line to caliper.
Page 250: Front Caliper Inspection
BRAKES FRONT CALIPER DISASSEMBLY, CONT. 4. Remove piston, dust seal and piston seal. 5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTE: Be sure to clean seal grooves in caliper body. FRONT CALIPER INSPECTION 1.
Page 251: Front Caliper Assembly
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 252: Front Caliper Installation
BRAKES FRONT CALIPER INSTALLATION 1. Install caliper on hub strut, and torque mounting bolts. Front Caliper Mounting Bolt Torque 18 ft. lbs. (25 Nm) 2. Install brake line and tighten securely with a line wrench. 3. Install the adjuster screw and turn until stationary pad contacts disc, then back off 1/2 turn.
Page 253 BRAKES FRONT BRAKE CALIPER EXPLODED VIEW Adjuster Screw Square O--Rings Piston Pin Boot Pads Caliper Mount 9.21...
Page 254 BRAKES REAR BRAKE PAD REMOVAL 1. Remove caliper mounting bolts and lift caliper off of disc. NOTE: When removing caliper, be careful not to dam- age brake line. Support caliper so as not to kink or bend brake line. 2. Push caliper pistons into caliper bore slowly with pads installed.
Page 255 BRAKES REAR BRAKE PAD INSTALLATION 1. Install new pads in caliper body. Be sure to put aluminum spacer between pads. 2. Install caliper and torque mounting bolts. DH Brake Caliper Torque 18 ft. lbs. (25 Nm) Spacer 3. Slowly pump the brake lever until pressure has been built up.
Page 256 BRAKES REAR CALIPER REMOVAL/INSPECTION 1. Clean caliper area before removal. 2. Using a flare nut wrench, remove hand brake (inner) and Remove inner auxiliary brake (outer) lines. Place a container to catch and outer brake fluid draining from brake lines. brake lines 3.
Page 257 BRAKES REAR CALIPER REMOVAL/INSPECTION CONT. 8. Inspect caliper piston bore for scratches, severe corrosion, or galling and replace if necessary. 9. Inspect surface of caliper piston for nicks, scratches, or damage and replace if necessary. REAR CALIPER ASSEMBLY 1. Install new O-rings in caliper body (2 piston seals per caliper half).
Page 258 BRAKES REAR CALIPER ASSEMBLY CONT. 4. Install brake pads in caliper body with friction material facing each other. If equipped with a pad spacer, install the spacer between the pads. Install retaining pin through outer pad, pad spacer and inner pad. 5.
Page 259 BRAKES REAR BRAKE DISC INSPECTION 1. Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. 2. Use a 0-1s micrometer and measure disc thickness at 8 different points around perimeter of disc. Rear Brake Replace disc if worn beyond service limit.
Page 260 BRAKES DH (REAR AXLE MOUNTED) CALIPER/MASTER CYLINDER Torque 18 ft./lbs. 24.8 Nm Caliper Hand Brake Bleed Hand Brake Line Auxiliary Brake Line Torque 15 ft./lbs. 20.7 Nm Auxiliary Spacer Brake Pads Auxiliary Brake Bleed Torque Auxiliary Brake Torque 8 ft./lbs. Reservoir 18 ft./lbs.
Page 261: Troubleshooting
BRAKES TROUBLESHOOTING Brakes Squeal S Dirty/contaminated friction pads S Improper alignment S Worn disc S Worn disc splines Poor Brake Performance S Air in system S Water in system (brake fluid contaminated) S Caliper/disc misaligned S Caliper dirty or damaged S Brake line damaged or lining ruptured S Worn disc and/or friction pads S Incorrectly adjusted lever...
Page 262 NOTES...
Page 263 CHAPTER 10 ELECTRICAL Special Tools ........10.1 Headlamp Service .
Page 265: Special Tools
ELECTRICAL SPECIAL TOOLS Fluke 73 Multitester or Tektronix DMM 155 . . . PN 2870659 Strobe Timing Light ..... . . PN 2870630 Hydrometer .
Page 266 ELECTRICAL HEADLIGHT ADJUSTMENT 25’ (7.6 m) The high beam headlight can be adjusted to any position desired by turning the four screws at the outer corners of Lamp Center Height the lamp housing. Use the following procedure: 1. Place the vehicle on a level surface with the headlight approximately 25’...
Page 267 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 268: Timing Check Procedure
ELECTRICAL TIMING CHECK PROCEDURE 1. The ignition timing check hole is in the starter recoil/magneto housing. Remove the check plug. NOTE: The ignition timing marks are stamped on the outside of the flywheel. Ignition timing must be inspected with the engine at room temperature (68qF / 20q C). 2.
Page 269: Typical Ignition Timing Curve
ELECTRICAL TYPICAL IGNITION TIMING CURVE * Actual advance point may vary by several hundred RPM either above or below the specified timing RPM. Use the point of maximum advance when checking ignition timing. MAXIMUM ADVANCE POINT (*) ES32PF 1000 2500 3000 3500 4000...
Page 270: Flywheel Identification
ELECTRICAL FLYWHEEL IDENTIFICATION Flywheel Identification Stamp Location The flywheel can be identified by the stamp mark in location A. Refer to “I.D.” location in chart below. Do not use the cast mark to determine flywheel application. Engine Application Type Cast Stamp Comment Flywheel...
Page 271 ELECTRICAL COMPONENTS OF ES32PF / 200 WATT ALTERNATOR NOTE: CDI boxes may look the same but have different internal circuitry. Be sure to always use the correct CDI box part number. Refer To Wiring Diagrams For Meter Specified Stator Coil Resistance .3 : Meter :...
Page 272 ELECTRICAL IGNITION SYSTEM Whenever troubleshooting an electrical problem you should first check all terminal connections to be sure they are clean and tight. Also be sure that colors match when wires are connected. Use the following pages as a guide for troubleshooting.
Page 273 ELECTRICAL CRANKING OUTPUT TEST WITH PEAK READING VOLTMETER The following peak voltage tests will measure the amount of output directly from each component. A peak reading voltmeter must be used to perform the tests. A variety of peak reading adaptors are commercially available for use with the Fluke ¥...
Page 274: Ignition System Troubleshooting
ELECTRICAL IGNITION SYSTEM TROUBLESHOOTING No Spark, Weak or Intermittent Spark SSpark plug gap incorrect SFouled spark plug SFaulty spark plug cap or poor connection to high tension lead SRelated wiring loose, disconnected, shorted, or corroded SEngine Stop switch or ignition switch faulty SETC switch misadjusted or faulty STerminal board or connections wet, corroded SPoor ignition coil ground (e.g.
Page 275: Battery Service
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 Nyogelt grease (PN 2871329) on battery bolts. See Battery Installation on page 10.12.
Page 276 ELECTRICAL BATTERY INSPECTION/REMOVAL The battery is located under the left rear fender. Inspect the battery fluid level. When the battery fluid nears the lower level, the battery should be removed and distilled water should be added to the upper level line. To remove the battery: 1.
Page 277 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% Charged 12.60V 12.70V 75% Charged 12.40V 12.50V 1.10 50% Charged 12.10V...
Page 278 +27q F 1. Install battery in vehicle with positive terminal toward the front. Coat threads of battery bolt with a corrosion resistant Nyogelt 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 279: Charging System Testing
ELECTRICAL CHARGING SYSTEM TESTING Whenever charging system problems are suspected, proceed with the following system check. Using a multitester set on D.C. volts, mea- sure the battery open circuit voltage (See Remove the battery and properly ser- page 10.12). It should be 12.4 volts or vice.
Page 280 ELECTRICAL CURRENT DRAW - KEY OFF CAUTION: Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to light bulbs and speed limiter. Connect an ammeter in series with the negative battery cable. Check for current draw with the key off. If the draw is excessive, loads should be disconnected from the system one by one until the draw is eliminated.
Page 281 ELECTRICAL ALTERNATOR OUTPUT TEST (AC AMP) This test measures AC amperage from the alternator. SMaximum alternator output will be indicated on the meter. It is not necessary to increase engine RPM above idle. SPlace the red lead on the tester in the 10A jack. STurn the selector dial to the AC amps (A) position.
Page 282: Starter System Troubleshooting
ELECTRICAL STARTER SYSTEM TROUBLESHOOTING Starter Motor Does Not Turn SBattery discharged - low specific gravity SLoose or faulty battery cables or corroded connections (see Voltage Drop Tests) SRelated wiring loose, disconnected, or corroded SPoor ground connections at battery cable, starter motor or starter solenoid (see Voltage Drop Tests) SFaulty starter button SFaulty ignition switch or engine stop switch (Do other systems function?)
Page 283 ELECTRICAL STARTER SYSTEM Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test. With the tester on the VDC position, place the tes- ter’s black lead on the battery negative and the red Remove battery and properly service.
Page 284 ELECTRICAL STARTER MOTOR DISASSEMBLY NOTE: Use electrical contact cleaner to clean starter motor parts. Some solvents may leave a residue or damage inter- nal parts and insulation. 1. Note the alignment marks on both ends of the starter motor casing. These marks must align during reassembly.
Page 285 ELECTRICAL STARTER MOTOR DISASSEMBLY, CONT. 4. Remove shims from armature shaft. NOTE: All shims must be replaced during reassembly. BRUSH INSPECTION/REPLACEMENT 1. Using a digital multitester, measure the resistance between the cable terminal and the insulated brush. The reading should be .3 ohms or less. Measure the resistance between the cable terminal and brush housing.
Page 286 ELECTRICAL BRUSH INSPECTION/REPLACEMENT, CONT. 6. Place a wrap of electrical tape on the threads of the terminal bolt to prevent O-Ring damage during reinstallation. 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.
Page 287 ELECTRICAL ARMATURE TESTING 1. Remove armature from starter casing. Note order of shims on drive end for reassembly. 2. Inspect surface of commutator. Replace if excessively worn or damaged. 3. Using a digital multitester, measure the resistance between each of the commutator segments. The reading should be .3 ohms or less.
Page 288 ELECTRICAL STARTER ASSEMBLY 1. Place armature in field magnet casing. 2. Place shims on drive end of armature shaft with phenolic washer outermost on shaft. Engage tabs of stationary washer in drive end housing, holding it in place with a light film of grease. 3.
Page 289: Starter Drive
Replace spring. 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 Starter Motor Exploded View position on the pinion shaft assembly.
Page 290 ELECTRICAL LIMITER SPECIFICATIONS Speed Limiter NOTE:The part number is printed on some late model Module LR LR modules. Whenever possible, use part number ID Number to identify the module. Modules may have same “LR” I.D. number, with different part numbers, terminals, and internal function.
Page 291 ELECTRICAL REVERSE LIMIT SYSTEM Gry/Or 10.27...
Page 292 ELECTRICAL REVERSE SPEED LIMIT SYSTEM APPLY PARKING BRAKE. START ENGINE. NO REVERSE SPEED LIMIT SHIFT TO REVERSE GEAR (LR44-3 Limit Module) TEST GEAR POSITION INDICATOR REVERSE LAMP SWITCH AND INDICATOR LAMP MEASURE DC VOLTS ON TEST WIRING GRY/OR WIRE. TO GROUND AT LR44- - 3 MODULE 12 VOLTS DC? MEASURE AC VOLTS ON...
Page 293 ELECTRICAL OIL COOLER FAN CONTROL SThermistor resistance decreases as temperature increases SBoth fan and hot light should be on with thermistor leads shorted together (low resistance) SFan blade should rotate drawing air in through cooler (blowing on engine) THERMISTOR RESISTANCE VS. TEMPERATURE Resistance r 20% Temperature Fan ON/OFF...
Page 294 ELECTRICAL FAN MOTOR CURRENT DRAW A current draw test will provide a good indication of fan motor condition. A worn or damaged fan motor will draw more current, which causes a reduction in blade speed and reduced cooling. 1. Turn key to off. 2.
Page 295 ELECTRICAL GEAR POSITION INDICATOR SWITCH TEST Switch Continuity Table High/Neutral/Reverse Switch High Range Reverse Neutral Switch Schematic 10.31...
Page 296 ELECTRICAL ELECTRONIC THROTTLE CONTROL (ETC) SWITCH The Electronic Throttle Control (ETC) system is designed to stop the engine of an ATV in the event of a mechanical problem with the throttle mechanism. The ETC switch is mounted independently of the throttle actuator lever inside the throttle block assembly.

Polaris TRAIL BOSS 325 2001 Manual

Chapter 1 General Information

Chapter 2 Maintenance

Chapter 3 Engine

Chapter 4 Fuel System/Carburetion

Chapter 5 Body and Steering

Chapter 6 Clutches

Chapter 7 Final Drive 7

Chapter 8 Transmission Service

Chapter 9 Brakes

Chapter 10 Electrical

Quick Links

Chapters

Troubleshooting

Related Manuals for Polaris TRAIL BOSS 325 2001

Summary of Contents for Polaris TRAIL BOSS 325 2001

Table of Contents