Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional number is stamped on the center top of crankcase beneath the cylinder coolant elbow.
REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is necessary.
Standard Tools and Engine Tools Special Tools may be required while servicing your machine. Some of the tools listed are mandatory and other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris special tools when servicing any Polaris product.
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa) Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi) Kilopascals (kPa) x 0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1...
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and grip the drive belt.
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.
Inspect level; change yearly (if equipped) Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
1000 (1600) Replace with oil change Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services...
Inspect periodically; adjust when parts are replaced Auxiliary brake Pre- Ride Inspect daily; adjust as needed Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
DOT3 Brake Fluid (12 Count) local Polaris dealer. 2871557 Crankcase Sealant, 3-Bond 1215 (5oz.) 2872893 Engine Degreaser (12oz.) (12 Count) NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.
- www.instant-manuals.com - MAINTENANCE POLARIS LUBRICANT SYMBOL IDENTIFICATION NOTE: The symbols are used to properly identify the correct lube or grease to use in the maintenance section. Polaris ATV Polaris Synthetic Polaris All Season Grease Polaris DOT 3 Polaris Synthetic...
1 Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) 2 Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) 3 Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special.
• Be sure vehicle is level before proceeding. • Be sure vehicle is level before proceeding. • Check vent hose to be sure it is routed properly and unobstructed. • Check vent hose to be sure it is routed properly and unobstructed.
Brass Plug Removed Connect an accurate tachometer that will read in increments of + or - 50 RPM such as the PET 2100DX (PN 8712100DX) or the PET 2500 (PN 8712500). Set idle speed to 1200 RPM. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.
- www.instant-manuals.com - MAINTENANCE Slowly turn mixture screw counterclockwise until idle • Do not overfill the tank. Do not fill the tank neck. speed increases to maximum RPM. Continue turning • If you get gasoline in your eyes or if you swallow counterclockwise until idle RPM begins to drop.
For this reason, a Low Maintenance battery case is condition on models with automatic decompression. Follow dark and the cell caps are not removable, since there is no need tester manufacturer’s instructions to perform a cylinder leakage to check electrolyte level.
Remove the seat and left hand side panel. Disconnect holder strap. Remove spark plug high tension lead. Clean plug area so no dirt and debris can fall into engine when plug is removed. Disconnect battery negative (-) (black) cable first, followed by the positive (+) (red) cable.
MAIN AIR FILTER CLEANING Remove air filter assembly. It is advisable to replace the filter when it is dirty. However, in Cleaning: an emergency it is permissible to clean the main filter if you observe the following practices.
The ATV should be checked immediately. Support To release any water that maybe trapped in the CVT cover, simply remove the CVT drain plug and O-ring located on the bottom of the CVT cover and let the water drain out. Air Box Rear III. 3 NOTE: The air filter should rest on the filter support.
CAUTION Remove the dipstick and wipe it clean. Reinstall the dipstick completely Hot oil may result in serious burns. Do not allow hot oil to contact skin. Remove the dipstick an check the oil level. 10. Add oil as needed to bring the level between the minimum Place a drain pan under the vehicle.
21. Turn off the engine. Check for oil leaks. Re-check the valve clearance. 22. Check the oil level. Add oil as needed to bring the level Repeat adjustment procedure if necessary until clearance is between the min. and max marks. Do not overfill.
CAMBER AND CASTER TIE ROD END/STEERING INSPECTION The camber and caster are non-adjustable. To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement. TOE ALIGNMENT • Repeat inspection for inner tie rod end (on steering Place machine on a smooth level surface.
EXHAUST CLEANING If toe alignment is incorrect, measure the distance between WARNING vehicle center and each wheel. This will tell you which tie rod needs adjusting. NOTE: Be sure handlebars are straight ahead before determining which tie rod(s) need adjustment.
Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks.Tighten any loose fittings and replace any • Check the fluid level “eye”. If it is clear, it is an worn or damaged parts. indication that fluid is needed or the brake pads may be worn, which can reduce the fluid level.
Hand Brake Lever Free Play Rear Foot Brake Rear Brake Check foot brake effectiveness by applying approximately 50 lb. (23 kg) downward force on the pedal. The top of the pedal should travel not more than 1 inch (25.4mm). 1” or greater 50 lbs...
• Check all rear suspension components for wear or With the transmission in gear and the parking brake locked, damage. place the wheel in the correct position on the wheel hub. Be • Inspect shock for leakage. sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.
MAINTENANCE WHEEL INSTALLATION Tire Tread Depth Always replace tires when tread depth is worn to 1/8” (3 mm) With the transmission in gear and the parking brake locked, or less. place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.
- www.instant-manuals.com - ENGINE GENERAL ENGINE SERVICE ENGINE EXPLODED VIEW Crankcase Cylinder/ Cylinder Head 6 ft. lbs. 8 ft. lbs. 15 ft. lbs. 15 ft. lbs. PROCEDURE 12-14 ft. lbs. 5.5 ft. lbs. 16 ft. lbs. 5.5 ft. lbs. Crankshaft...
Degree of fit Push (by hand) fit @ 68 F (20 C) (Standard clearance 0-.0005" (0-.012mm) Piston Ring Piston Ring Installed Gap Top ring Std .008-.0012" (.2-.3 mm) Limit .032" (.8 mm) Second .018-.019" (.35-.50 mm) ring Limit .039" (1.0mm) Oil ring .0079-.0275"...
Rocker Arm Rocker Shaft Valve Springs ES300PFE010 Chain Room Camshaft Cylinder Head Sprocket & Chain (RH Cam Journal) Connecting Rod Small End Piston Skirt / Rings Right Rear Nozzle Cylinder Bolt Counter Balance Gear Crankshaft Main Bearing Connecting Rod Big End...
Replace crankshaft as an assembly. PISTON RING IDENTIFICATION ENGINE SERVICE The piston ring profile is shown below. Install top and second ring with marking UP. Refer to text for oil control ENGINE REMOVAL ring installation. NOTE: The engine removal procedure described...
13. CVT air intake and exhaust ducts 14. Remove carburetor. Insert a clean shop towel into the 8. Front prop shaft (4x4 models) (Drive pin out at front carburetor flange to prevent dirt from entering the gearcase, pull shaft back, then forward. Refer to Drive intake port.
- www.instant-manuals.com - ENGINE 17. Recoil housing, flywheel and stator (or if front cab is 23. Top rear shock bolts. removed, remove front cab and disconnect wires.) 24. Top bolts from sway bar bracket. See “Flywheel Removal / Inspection” on page 3.28. for 25.
26. Support engine and remove (9) transmission-to- Engine Break In Period engine bolts. 4 Cycle Engine Break-In Period is defined as the first 10 hours of engine operation or 2 full tanks of fuel. • Use only Polaris Premium 4 All Season Synthetic Oil, or API certified “SH”...
11. Rear fuel tank bracket. 12. CVT air inlet duct. 7. Front prop shaft (4x4 models) (Drive pin out at front gearcase, pull shaft back, then forward. Refer to Drive Chapter) 13. Support frame under engine with a stable platform jack.
- www.instant-manuals.com - ENGINE 15. Remove rear plate (lower control arm bolts) and upper 22. Loosen, but do not remove the 4 bolts from the rear control arm bolts. transmission hanger bracket. 16. Remove rear shocks. 23. Remove (9) transmission-to-engine bolts.
- www.instant-manuals.com - ENGINE ENGINE LUBRICATION CAM CHAIN TENSIONER REMOVAL Oil Type: ..Polaris Premium 0W-50 Synthetic To position crankshaft at Top Dead Center (TDC) on compression stroke: Capacity (DRY): 1.64-1.95 U.S. Quarts (1.55-1.85 l) 4.
TDC on the compression stroke (there should be clearance on both rocker arm adjusters). CAM CHAIN TENSIONER INSPECTION 1. Pull cam chain tensioner plunger (A) out to the end of its travel and inspect ratchet teeth on plunger and pawl. Inspect spring (B) for wear or damage.
- www.instant-manuals.com - ENGINE 5. Inspect the rocker arm shaft and the shaft bore in the 4. If not removing the cylinder for other service, secure cylinder head for wear or signs of scoring. the cam chain with a wire to prevent it from falling into the crankcase.
Replace cam if worn below minimum height (service limit). 3. Remove bolts (A) and tap the cam support tower with a plastic hammer until loose. Remove. 4. After removing the camshaft and securing the cam chain, tap cylinder head lightly with a plastic hammer until loose.
3. Push valve out, keeping it in order for reassembly in the same guide. 1. Lay a straight edge across the surface of the head at 4. Measure free length of the inner and outer springs several different points and measure warpage by with a Vernier caliper, Ill.1.
6. Measure valve guide inside diameter at the top middle VALVE INSPECTION and end of the guide using a small hole gauge and a 1. Remove all carbon from valve with a soft wire wheel. micrometer. Measure in two directions, front to back and side to side.
If the pilot is bent it must be replaced. NOTE: Valve seat width and point of contact on the valve • If the contact area of the cutter is in the same place, face is very important for proper sealing. The valve must...
8. Clean all filings from the area with hot soapy water, rinse, and dry with compressed air. • If the indicated seat contact is at the top edge of the 9. Lubricate the valve guides with clean engine oil, and...
7. Repeat procedure for remaining valve. NOTE: Assemble the valves one at a time to maintain 8. When all valves are installed, tap lightly with soft faced proper order. hammer on the end of the valves to seat the Split keepers.
If necessary, heat the crown of the piston slightly with a propane torch. CAUTION: Do not apply 1. Lift to remove cam chain guide at front of cylinder. heat to the piston rings. The ring may lose radial 2. Remove the two 6 mm cylinder base bolts.
1. Remove all gasket material from the cylinder sealing surfaces. CAUTION 2. Inspect the top of the cylinder for warpage using a straight edge and feeler gauge. A hone which will straighten as well as remove ma- terial from the cylinder is very important. Using a common spring loaded glaze breaker for honing is not advised.
EXAMPLE OF CROSS HATCH PATTERN PISTON INSPECTION 1. Measure piston outside diameter at a point 7 mm up from the bottom of the piston at a right angle to the direction of the piston pin. Piston Pin Measurement Locations 5. Measure connecting rod small end ID. Replace crankshaft if out-of-round.
Oil Ring Std: .008- .028” (0.2- 0.7 mm) Limit: .059” (1.5 mm) 2. Measure the gap with a feeler gauge at both the top and bottom of the cylinder. NOTE: Measure at two points in the cylinder A difference in end gap indicates cylinder taper. The...
2. Remove the starter drive clutch and washer by pulling stator. the shaft and tilting the gear slightly. 3. Measure the OD of the starter drive shaft on both ends Using the Slotted Nut Socket, remove the crankshaft for out-of-round.
- www.instant-manuals.com - ENGINE 5. Open the staked portion of the nut (A) with a center 8. Inspect the shoes and springs of the starting clutch. punch. Inspect the one-way clutch hub surface on the Measure the thickness of the friction material on the starting clutch (B).
14-15.5 ft. lbs. (19-21 Nm) crankcase evenly. 3. Lift the right case half off of the left, leaving the 12. CHECK the clutch shaft to be sure it rotates smoothly crankshaft and balance shaft in the left case. in the clockwise direction and will not rotate in the counterclockwise direction.
The inner race of PTO bearing each bearing should fit tightly on the crankshaft. The outer race should be firm with minimal side to side movement and no detectable up and down movement. The MAG end bearing usually stays in the case. Check the inner race of the MAG bearing in the same manner.
2. The cam chain can be removed by removing the engine top end, the recoil assembly, flywheel and 1. Pull the strainer screen (A) from the case carefully and flywheel key, stator plate, and slotted nut. clean or replace it if heavily clogged, or if damaged.
2. Lay a straightedge on the left (PTO) crankcase and measure the distance from the straightedge to the bottom of the main bearing bore (if bearing is still on the crankshaft) or to the bearing race (if the bearing is installed in the case) using a dial caliper.
- www.instant-manuals.com - ENGINE 6. Add the readings recorded in Step 3 and Step 5 and COUNTER BALANCER SHAFT END PLAY record below. ADJUST. NOTE: The counterbalance shaft end play measurement procedure is the same as that outlined Total Case Width_________________ for the crankshaft.
The ends should butt squarely together and must not overlap. 2. Install the oil ring top rail with the end gap at least 30 from the end of the expander. 3. Install the bottom rail with the gap at least 30...
4. Apply clean engine oil liberally to the bore and tapered area of the cylinder. Place the cylinder on to the studs. 4. Install the two 6 mm bolts on cylinder base and on the head, but do not tighten.
- www.instant-manuals.com - ENGINE 6. Loop the cam chain over the sprocket and shift the assembly with a new gasket and tighten the bolts to chain on the sprocket until it can be installed onto the specification. camshaft. Tensioner Bolt Torque: 7.
2. Slide the shaft through the tower just enough to install STARTER DRIVE ASSEMBLY the wave washer (A). 1. Be sure the washer is positioned on the back of the NOTE: The flats of the wave washer are positioned drive gear.
• Starter motor does not turn • Lack of lubrication • Engine seized, rusted, or mechanical failure • Dirt entering engine through cracks in air filter or ducts Engine Runs But Will Not Idle • Engine oil dirty or contaminated •...
• Rocker arm sticking Backfiring • ETC or speed limiter system malfunction • Fouled spark plug or incorrect plug or plug gap • Carburetion faulty - lean condition • Intake / Exhaust system air leaks • Ignition system faulty: •Spark plug cap cracked/broken...
Always stop the engine and refuel outdoors or in a well ventilated area. Do not overfill the tank. The tank is at full ca- pacity when the fuel reaches the bottom of the filler neck. Leave room for expansion of fuel.
Starter Bleed settings and CAUTION Pipe) idle A main jet that is too small will cause a lean operat- Pilot (Idle Pilot Jet/ Primarily Mainly idle ing condition resulting in serious engine damage. System) Passage-ways,...
(and The carburetor float bowl vent lines supply atmospheric therefore in the chamber above the diaphragm) becomes pressure to the float bowl. The lines must be free of kinks, significantly lower than atmospheric.
(1) or slightly opened. The fuel from When the choke cable (1) is activated, the starter plunger float chamber (2) is metered by pilot jet (3) where it mixes (5) is lifted off the seat. with air coming in through pilot air jet (4). The mixture then goes up through pilot passage to pilot screw (5).
Consequently the vacuum slide (2) moves upward. The inlet needle seat (4), and around the inlet needle (2). As fuel in float chamber (3) is metered by main jet (4), and the fuel fills the float chamber, the float (1) rises and...
100% Throttle Valve Opening Pilot Screw Location A carburetor with a slide type throttle valve is also called a variable venturi type carburetor. In this type of carburetor, the needle jet and jet needle serve to control proper air/ fuel mixture ratio at the medium throttle valve opening (between 1/4 and 3/4 opening).
CARBURETOR DISASSEMBLY – MIKUNI CV plate, and carefully remove needle seat. NOTE: Do Use the following disassembly, assembly, and inspection not use a pliers to remove the seat or permanent techniques to service a CV carburetor. damage may occur. 1. Remove carburetor diaphragm chamber cover with a ratchet style screwdriver.
To check, slide a slightly larger new jet diately. needle into the needle jet and hold it to a light source. Carburetor cleaners can be extremely caustic. Ex- Light will be visible between the needle and needle jet tended periods of soaking can loosen the adhesive if it is worn.
FUEL LEVEL TEST 3. Measure the height from the float bowl mating surface to the top of step of the float as shown in Illustration 2. A fuel level test can be performed on some models if the Both sides of float should be parallel to each other.
- www.instant-manuals.com - FUEL SYSTEM / CARBURETION AIR INTAKE SYSTEM Air Intake System Table 4-4: Air Intake System Reference Description Reference Description Pre-Filter Crankcase Breather Hose Air Filter Intake Box Snorkel Intake Box Cover Cover Seal Crankcase Breather Foam Intake Box Drains Carburetor Snorkel 4.17...
- www.instant-manuals.com - FUEL SYSTEM / CARBURETION EXHAUST SYSTEM Exhaust System Table 4-6: Exhaust System Reference Description Tip / Spark Arrestor Muffler Pipe Clamp Gasket Head Pipe Flange Gasket 4.19...
NOTE: The outside insert (B) should be flush Removal / Installation surface after installation. Some Polaris ATVs use a two piece plastic insert in place of a metal screw. The plastic inserts are simple to remove and install. Use a a pair of diagonal side cutters to lift the plastic insert (A) until you feel some slight pressure or lift the insert approximately 1/4"...
BODY AND STEERING FRONT CAB/FENDER seat. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the panel outward to disengage the side panel. Pull the panel downward and rearward to remove it from the ATV.
Remove the fuel tank cover (4). Remove the side panels (1,3). Remove the plastic rivets on the mud guards (below) and remove them from the front cab assembly. Remove the battery connections (negative first). Remove the battery from the battery compartment.
Remove the screws (1,19) that secure the rear cab to the Exploded View frame. Remove the plastic inserts (9) that secure the rear cab to the frame footwells (11,14). Disconnect the rear lights. Lift the rear cab (4) from the frame.
Remove the plastic dart clips(1) from the pod (2). Press the center and pull the speedo connection away from the speedo (3). Remove the key switch connection by turning the ignition nut (9) counter clock wise. Remove the choke connection by turing the choke nut (14) counterclockwise.
Replace the handlebar assembly into the steering post to the desired angle. Place the handlebar block onto the steering post. Make sure that the peg (C) is inserted to the steering post dimple (D). Insert the bolts through the top of the handlebar block.
“HANDLEBAR REMOVAL” on page 5.8. Remove the fuel tank bracket (A). 10. Remove the steering post bracket (F) at the front gear case (4x4 shown)/plate (2x4). Turn the fuel valve to the “OFF” position Remove the fuel line (B) from the fuel pump (C).
NOTE: Make sure that the cotter pin is not obstructing steering movement. Place the tie rod retainer (H) on to a tie rod bolt (I). Insert the tie rod bolts from the bottom of the tie rod, and line up the retainer to the bottom of the tie rods.
12. Tighten the fuel tank bracket fasteners. 13. Hook up the fuel line to the fuel pump and move the clamp to the correct area. NOTE: To avoid damage to tie rods and other steering components, be sure to install tie rod end bolts in the proper direction.
Insert the ball joint (13) far enough into the carrier bearing assembly so that the pinch bolt (10) can be inserted. Insert the pinch bolt (10) so that the flange head is at the front of the machine and the flange nut (9) is at the rear.
Remove the wheel on the side of the strut that is to be replaced. Remove the front cab. With an open end wrench hold the shock tower nut (16) and with a socket turn the shock rod. Remove the screw that holds on the brake line to the strut.
Remove the snap ring (1) from the ball joint. Press out the old ball joint (2). Press in new ball joint into A-Arm. Replace the snap ring (1) onto the new ball joint. Assemble the A-Arm, See “A-ARM ASSEMBLY” on page 5.13.
(1,3) fasteners and pivot shaft locations. Remove the x short grey bushings (2) and pivot shafts (3,14). Remove the Lower Control Arm (LCA) (11) fasteners (4,5,12) from the frame and bearing carrier. Note the long (5,8) and short (12,14) fasteners and pivot shaft locations.
Brake Line Flare Fittings 12-15 16-21 Bleeder Screw (36-46 in.lbs.) NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures are used when torquing certain bolts and fasteners. Do not re-use fasteners that have pre-applied locking agents.
TROUBLESHOOTING Brake Noise Possible Cause Remedy Dirt or dust buildup on the brake pads and disc is the most If noise does not change common cause of brake noise (squeal caused by vibration). If Noise is from other source when brake is applied cleaning does not reduce the occurrence of brake noise, a ™...
- www.instant-manuals.com - BRAKES BRAKE SYSTEM MAIN COMPONENTS System Exploded View 2 screws - 7 in. lbs. (.79Nm ) All Flare Style Fittings: 12-15 ft.lbs. (16-21 Nm) All Bleed Screws: 36-46 in.lbs. (4-5 Nm) Apply a Light Amount of Pipe Sealant to Threads All Banjo Style Fittings: 15 ft.lbs.
- www.instant-manuals.com - BRAKES BRAKE CALIPER Exploded View A.Bleeder Screw B. Caliper Body C. Internal Caliper Slide Pin O-rings (small) D. Square Seals E. Piston F. Caliper Mount G. Brake Pads H. Internal Caliper Slide Pin O-rings (large) I. Caliper mount O-ring...
Never overfill the reservoir! Fill to 1/4, - 5/16, (.64 - .80 cm) from top of the cylinder. The Polaris disc brake system consists of the following This system also incorporates a diaphragm (E) as part of the components or assemblies: hand brake lever;...
Operation Overview CAUTION Brake Fluid Reservoir Use only DOT 3 or 4 brake fluid as an assembly aid for all procedures described in this chapter to prevent brake system contamination. DO NOT USE LUBRICANTS OF ANY KIND FOR ASSEMBLY, AS THEIR USE CAN CAUSE RUBBER COMPONENTS TO SWELL.
Attach a clean, clear hose to fitting allow the reservoir to drain completely. Continue this and place the other end in a container. Be sure the hose fits process at each bleeder until the fluid runs clear.
Install diaphragm, cover and screws. Align any marks (if present) into the proper holes in the master cylinder. CYLINDER Wiggle and press down on the cap to be sure it fits evenly and snug. Torque the screw to 7 in.lbs. (0.79 Nm). Removal Clean master cylinder and reservoir assembly.
Banjo Bolt Install master cylinder on handlebars. Torque mounting bolts to 70 in. lbs. (7.9 Nm). Torque the inside bolt first as indicated in the illustration to the right. 7 in.lbs. (.79 Nm) Brake Line Torque Bolt First Fill reservoir with DOT3 or DOT 4 brake fluid.
Loosen the wheel nuts. Elevate and support front of machine and remove the tire(s). CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. Remove caliper from mounting bracket.
(30 Nm) Slowly pump the brake lever until pressure has been built up. Maintain at least 1/2, (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. Compress mounting bracket. Install pads with friction Verify fluid level in reservoir is up to MAX line inside material facing each other.
Use caution the piston square seals using a wooden or plastic pick. Use not to bend or damage the retainer or the brake pad ears. caution not to scratch or damage the piston or the bore of the caliper.
O-rings for reassembly. Clean the Inspect caliper body for nicks, scratches or wear. Measure caliper body, piston, and retaining bracket with brake bore size and check for out of round. Replace if damage is cleaner or alcohol. evident or if worn.
Install new piston square seals (A) in the caliper body (B). Clean the disc and pads with brake parts cleaner or Be sure groove is clean and free of residue or brakes may denatured alcohol to remove any dirt, oil or grease.
Start machine and slowly increase speed to 30 m.p.h.. Gradually apply brakes to stop machine. Allow pads and disc to cool sufficiently after each stop during the procedure. Do not allow pads or disc to become hot or warping may result. Repeat this procedure 10 times. BRAKE DISC...
FOOT BRAKE removing the brake disc mounting bolts before applying heat to the bolts. Apply heat to the hub in the area of the brake disc Foot Pedal Removal / Install mounting bolts to soften the bolt locking agent. Remove the cotter key (A).
Replace parts as needed. To install the rear brake master cylinder, mount the master LEVER VIBRATION cylinder to the mount plate and torque bolts to 8 ft.lbs. (11 Nm). • Disc damaged Reinstall the brake line and torque the banjo bolt (with •...
Serious injury could occur if machine tips or falls. equipped with (aluminum or steel wheel) when torquing wheel nuts. Remove wheels. Remove cotter pin and nut from lower A-arm ball joint. Table 7-1: Torque Table Remove lower A-arm from ball joint using a suitable tool. ft.lbs.
- www.instant-manuals.com - FINAL DRIVE CV BOOT SERVICE Pull sharply or use a pry bar to remove CV shaft from the gearcase. Inspection Check the front and rear driveshaft CV boots for signs of cracking, tearing, punctures or leaking grease. If the driveshaft boot loses all of the grease, CV joint failure will occur.
This will allow the air pressure to equalize in the necessary. Front drive axle CV boot replacement CV boot in the position that the joint will spend most of its requires 4 oz. of grease. life. Before you remove the instrument, verify the small end of the boot is in its correct location on the axle.
Remove outer snap ring. Press bearing into place until outer race bottoms on housing. CAUTION When using an arbor press be sure to press only on the outer race, as bearing damage may occur. Install snap ring into groove. FRONT PROP SHAFT...
Always wear eye protection! Remove internal or external snap ring from all bearing caps. Force U-joint cross to one side and lift out of inner yoke. NOTE: If yoke or bearing is removed, cross bearing must be replaced. Note orientation of grease fitting and mark inner and outer yoke for correct re- positioning during installation.
Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown. Using a suitable arbor, fully seat bearing cap in one side. Continually check for free movement of bearing cross as bearing caps. Using a suitable arbor, fully seat bearing cap in one side.
- www.instant-manuals.com - FINAL DRIVE AWD FRONT DRIVE AXLE EXPLODED VIEW Front Drive Shafts and Propshafts NOTE: Refer to your parts manual for the proper replacement parts. Drive Axle Components Outer CV Joint Inner Boot Inner CV Joint Outer Boot...
- www.instant-manuals.com - FINAL DRIVE FRONT GEARCASE - to the output hubs that link both front axles, resulting in True All Wheel Drive. CENTRALIZED HILLIARD Operation Overview Roller Cage & Bearings Ring Gear Engaging Front Gearcase: The AWD switch may be turned on or off while the vehicle is moving.
Elevate machine until the front wheels are off the ground and 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 proce- dure. Wear eye protection when removing and installing bearings and seals.
Remove the front gearcase from either side of frame. Front Gearcase Removal Remove 4 Bolts 13. Pull the strut assembly out and pull the drive-shaft out of the hub. (Hubs removed for clarity - removal not required) DISASSEMBLY Drain and properly dispose of used oil. Remove any metal particles from the drain plug magnet.
- www.instant-manuals.com - FINAL DRIVE Remove ring gear and roller assembly. Remove the ring gear, roll cage assembly, rollers, and H- springs from the gearcase. Clean all parts and inspect for wear. Inspect ring gear backlash pad (arrow) for wear or damage.
13. Inspect the armature plate (E) for a consistent wear pattern. Uneven wear of the armature plate surface (E) indicates a warped plate, which may cause intermittent operation. 11. Inspect the output hub thrust bearing. Replace if wear or damage is found. 7.14...
Replace case half needed. Clean the inside surfaces of both gearcase halves. if coil is found to be non-functional or if the coil surface is damaged. 17. Remove and replace the O-rings and seals (arrows) from the gearcase halve assemblies.
Install the output hub (A) into the gearcase housing. Apply Install the ring gear over the output hub and into the output a small amount of grease to the seal and seal surface as this cover. Insert the backlash pad (G) and set assembly will aid assembly.
Inspect the armature plate for a consistent wear pattern. There should one or two distinct wear bands (one band inside the other). If only one band of wear is present (or if there is wear between the two bands, inspect the coil area as indicated in Step 4.
The top of the coil should be seated below the U-shaped insert. The U-shaped insert controls the pole gap. If the top of the coil is above the surface of the U-shaped insert it raises the armature plate, thereby increasing pole gap.
Remove wheel nuts and wheel. drain plug for proper torque. Refer to Chapter 2 for fluid fill and change information. Remove the rear brake caliper and safely suspend the caliper from the frame with a piece of wire. (Left side only) 7.19...
- www.instant-manuals.com - FINAL DRIVE Remove hub nut, domed washer and flat washer. 11. Remove both lower control arm bolts. Remove hub. 12. Remove bearing carrier. Disassembly Remove outer snap ring. 10. Remove upper control arm bolt as shown. 7.20...
- www.instant-manuals.com - FINAL DRIVE From the back side, tap on the outer bearing race with a Start bearing in housing. drift punch in the reliefs as shown. Press bearing into place until outer race bottoms on NOTE: Drive bearing out evenly by tapping on outer housing.
Install cone washers with domed side facing outward. Install retainer nut, wheel and wheel nuts. Remove jackstand and torque axle nut and wheel nuts. Install a new cotter pin. Tighten nut slightly to align holes if required. DRIVE SHAFT AND CV JOINT...
• Do not allow boots to come into contact with sharp edges or hot engine and exhaust components. • Shafts should never be used as a lever arm to position other suspension components. • Never use a hammer or sharp tools to remove or to install boot clamps.
Clamp Pliers (PN 8700226) (A). Tap CV housing off shaft Place a new snap ring in the groove of the CV joint inner hub, with tabs facing the shaft as shown. NOTE: Photo below is shown without shaft for clarity. Wipe grease away from recess in CV joint...
This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life. Before you remove your instrument, be sure the small end of the boot is in its correct location on the axle.
SPECIAL TOOLS SHIFT LINKAGE INSPECTION SPECIAL TOOLS NOTE: Shift rod is preset at time of manufacture. 1. Inspect shift linkage rod bushing clips and replace if worn or damaged. Lubrication of rod ends is not required. GEAR SELECTOR REMOVAL 1. Push linkage rod out of bushing clip to remove.
CVT cover, remove the CVT drain plug located on the downhill) and throttle settings are constant, the drive and bottom of the CVT cover and let the water drain out. driven clutches upshift or backshift accordingly to (The location of the CVT drain plug is shown on the maintain optimum engine RPM.
Clamps CVT OVERHEATING/DIAGNOSIS During routine maintenance or whenever CVT system overheating is evident, it’s important to check the inlet and outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase CVT system operating temperatures. The ATV should be operated in LOW RANGE (if equipped) when pulling or plowing heavy loads, or if extended low speed operation is anticipated.
Warm engine at least 5 min., then with transmission in neutral, advance low ambient temperatures. throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning. Slow and easy clutch engagement.
Rotate the inner race to be sure it rotates freely without binding after installation. 5. Install the snap ring. Be sure it is fully seated in the groove. 8. Separate driven clutch sheaves and force belt down Cover Bearing into the sheaves.
10. Remove the primary sliding sheave and cam plate assembly as one assembly. Inspect the movable sheave for scoring, grooving, or abnormal wear. NOTE: If tool is not installed, be sure to hold cam plate and primary sliding sheave together to prevent Cam Plate Bushing rollers from falling out of the assembly.
Do not apply any lubricants balance. to the components. Apply Loctite 242 (Blue) to threads and torque the retaining nut to 185 ft. lbs. (250 X mark Nm). IMPORTANT: Be sure splines of cam plate are fully...
Standard Length: damaged. 7.52” (191.1 mm) 15. Apply a light film of moly grease to seal lips and to the inside of the roller pin hub. Install the moveable 9. Carefully pry up the roller cover to remove it. Inspect sheave over the shaft of the fixed sheave until the sheaves contact each other.
The surface of the pins must be and install nut hand tight. approximately flush with the surface of the roller pin 31. Release the tool and torque the nut to 45 ft lbs (61 hub. Nm) using the same tools for removal of the nut.
8. Inspect all bearings, gear teeth, and splines for wear or damage. Inspect gear dogs carefully and replace if the edge of the dog is worn or rounded, chipped, or broken. 9. Inspect the reverse chain for damage.
- www.instant-manuals.com - CVT TRANSMISSION 10. Gear dogs should be square at the corners. Replace 13. Reassemble the drum starting with shaft guide, detent both mating gears if any are rounded. cam (wide flange faces toward the threaded end of drum), the flat washer, and snap ring.
17. Assemble the shafts with chain and shift drum and fork, small spring, and shaft support onto the shaft. install the assembly into the case. The dot on the shaft support faces away from the fork. Shaft Support Shaft Support...
19. Apply 3-Bond 1215 sealant evenly to clean and oil- free case sealing surfaces. 20. Install the left case and tap it into place until seated. 21. Install bolts and torque in two steps following a cross pattern to 18 ft. lbs. (24.5 Nm).
A fusible link is installed on the battery voltage circuit that supplies power to the main 15A fuse. The link is located at the • Become familiar with the operation of your meter. Be starter motor solenoid + post.
The instrument gauge determines engine RPM from the Y/RED AC signal from the voltage regulator. The gauge is powered by switched R/BLK and switched R/WHT battery voltage. Both the key and the RUN switches have to be closed to power-up the gauge.
To test the circuit: forth across the face of the sensor while monitoring the multimeter. Turn the ignition key to the ON position and move the RUN/OFF switch to run. The multimeter display should flip between a voltage and 0vDC every time the screwdriver blade passes by the Verify there is battery voltage present on the ORANGE sensor face.
AWD Control System Battery voltage is supplied to the AWD coil when the operator turns the key switch to RUN, moves the AWD switch to AWD The front differential coil is controlled by the speedometer the and moves the RUN/OFF switch to RUN.
If the ETC switch connects to ground, the instrument gauge will shut the engine off. The operator can override the RPM speed limit in reverse, but not the ETC RPM limit, by pressing and holding the reverse override button located on the left handlebar.
- www.instant-manuals.com - ELECTRICAL Charging System The charging system consists of:. • Stator • Battery • Regulator / Rectifier The regulator / rectifier is responsible for converting AC voltage to DC voltage, and generating the tachometer pulse.
TEST 1: Resistance Value of Each Stator Leg Measure the resistance value of each of the three stator legs: W1 to W2, W1 to W3, and W2 to W3. Each should measure 0.314ohms. Measure each of the white wires to ground, the reading should be (O.L.).
VOLTMETER output from each component. A peak reading voltmeter can be used to perform the tests. A variety of peak reading adaptors are Re-connect all CDI wires to stator wires. Disconnect CDI commercially available for use with the Fluke™ 77 Digital module wire from ignition coil primary terminal.
CONTROL (ETC) SWITCH Whenever troubleshooting an electrical problem you should first check all terminal connections to be sure they are clean The Electronic Throttle Control (ETC) switch is designed to and tight. Also be sure that colors match when wires are close in the event where the throttle cable sticks or breaks.
Cap removed - 3,200Ω 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.
- www.instant-manuals.com - ELECTRICAL • Fouled spark plug • Faulty spark plug cap or poor connection to high tension lead • Related wiring loose, disconnected, shorted, or corroded • Engine Stop switch or ignition switch faulty • ETC switch misadjusted or faulty •...
- www.instant-manuals.com - ELECTRICAL CHARGING SYSTEM TESTING Whenever charging system problems are suspected, proceed with the following system checks: Remove the battery and properly ser- Using a multitester set on D.C. volts, mea- vice. Reinstall the fully charged battery sure the battery open circuit voltage (see or a fully charged shop battery.
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. Check component wiring as well as the component for partial shorts to ground to eliminate the draw.
• Maximum alternator output will be indicated on the meter. It is not necessary to increase engine RPM above idle. • Place the red lead on the tester in the 10A jack. • Turn the selector dial to the AC amps (A ) position.
Charge battery at 1/10 of its amp/hour rating. Examples: 1/ acid. Serious burns can result from contact with 10 of 9 amp battery = .9 amp; 1/10 of 14 amp battery = 1.4 skin, eyes or clothing. Antidote: amp; 1/10 of 18 amp battery = 1.8 amp (recommended charging rates).
Whenever removing or reinstalling the battery, dis- connect the negative (black) cable first and reinstall Following are three tests which can easily be made on a battery the negative cable last! to determine its condition: OCV Test, Specific Gravity Test and Load Test.
As the battery goes through the charge/discharge cycle, the electrolyte 100% Charged 1.265 1.275 goes from a heavy (more acidic) state at full charge to a light (more water) state when discharged. The hydrometer can 75% Charged 1.210 1.225...
• Using a wire brush or knife, remove any corrosion from the cables and terminals. (PN 2871329) • Make sure that the electrolyte is at the proper level. Add distilled water if necessary. Connect battery cables. • Charge at a rate no greater than 1/10 of the battery’s WARNING amp/hr capacity until the electrolyte’s specific gravity...
ELECTRICAL STARTER SYSTEM TESTING FLOW CHART Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test. With the tester on the VDC position, place the tes- Remove battery and properly service.
- www.instant-manuals.com - ELECTRICAL STARTER SYSTEM 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 1.47 to perform voltage drop tests on the starter Troubleshooting system.
O-rings located on the armature housing. O-Rings Shims Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate. Slide brush end frame off end of starter. NOTE: The shims will be replaced during NOTE: The electrical input post must stay with the reassembly.
Measure the resistance between each commutator segment and the armature shaft. The reading should be infinite (no continuity). Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate. CAUTION Some cleaning solvents may damage the insulation in the starter.
Install O-ring, two small phenolic spacers, large phenolic washer, flat washer, lock washer, and terminal nut. 10. Install the starter onto the engine case. Hand tighten each of the starter bolts. Torque the bottom bolt first to 9 ft.lbs. While holding brush springs away from brushes, push (12 Nm).
Screw the overrun clutch out to the engaged position on the pinion shaft assembly. Use a small piece of wire with the end bent in a hook and pick the old spring out of its channel. Slide it off the end of the shaft. Slide the new spring over the overrun clutch and into the spring groove.