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1998 Sportsman 500
Polaris 1998 Sportsman 500 Manuals
Manuals and User Guides for Polaris 1998 Sportsman 500. We have
2
Polaris 1998 Sportsman 500 manuals available for free PDF download: Service Manual
Polaris 1998 Sportsman 500 Service Manual (634 pages)
Polaris ATV And Light Utility Vehicle Service Manual
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 48.29 MB
Table of Contents
Safety Labels and Instructions
2
Table of Contents
3
General Information
5
Table of Contents
5
Model Identification
6
Engine Serial Number Locationi
6
Transmission ID Number Location
6
Carburetor ID Number Location
6
1996 Model Identification
7
Vehicle Identification Number (1997 and Later Model Years)
8
1996 Publication Numbers
10
1997 Publication Numbers
10
1998 Publication Numbers
11
Service Traning Videos
11
Service/Information Bulletins
12
Bulleting Index - 1996 by Model
13
Bulleting Index - 1997 by Model
14
Bulleting Index - 1998 by Model
14
1997 Paint Codes
16
Specifications 1997
18
Specifications 1998
23
Standard Torque Specifications
26
Decimal Equivalents
27
Conversion Table
28
Tap Drill Charts
29
SAE Tap Drill Sizes
29
Metric Tap Drill Sizes
29
Warranty
30
Service Tips
31
Glossary of Terms
32
Special Tools
35
Routing Diagrams
36
Magnum Routing Diagram
36
Hoses Diagram
39
300 Fan Motor Wiring Diagram
40
Wire Harness Diagram
41
Chassis/Suspension Service Tools
42
Transmission Tool Kit - Shaft Drive
42
Yoke Gauge Tool - Shaft Drive
42
Mity Vac Pump Kit
43
Small Battery Hydrometer
43
Transmission Seal/Bearing Driver - 50 MM
43
CV Boot Clamp Pliers
43
Glossary (2)
45
Magnum Routing Diagram (Cont.)
48
Hosed Diagram (2)
51
300 Fan Motor Wiring Diagram (2)
52
Wire Harness Diagram (2)
53
Oil Tank Vent Line Routing (1996 Sportsman 500) Diagram
54
Maintenance
56
Periodic Maintenance Chart
58
Pre-Ride/Daily Inspection
59
Recommended Lubricants and Capacities
60
Lubrication Chart
62
Lubrication Chart - Type IV Transmission (Shaft Drive)
65
Front Gearcase Lubrication
67
Gearcase Lubricant Change
67
Carburetor Adjustments
68
Idle Speed Adjustment
68
Throttle Cable/Electronic Throttle Control ETC Switch Adjustment
68
Throttle Operation
68
Throttle Cable Adjustment
69
Choke Adjustments
69
Throttle Control Lever Stop Adjustment
69
Air Screw Adjustment - 2-Stroke Models
70
Pilot Screw (Idle Mixture) Adjustment - 4-Stroke Models
70
Fuel Lines
72
Vent Lines
72
Fuel Filter
72
Carburetor Float Bowl Draining
72
Carburetor Draining
73
Breather System (4 Strokes)
74
Breather Filter Inspection
74
Breather Hose
74
General Maintenance
76
Compression Test
76
Battery Maintenance
77
Spark Plug Maintenance
78
Ignition Timing
78
Engine Mounts
78
Coolant Level Inspection
79
Coolant Strength
79
Cooling System Pressure Test
79
Radiator
79
Oil Pump Adjustment Procedure
80
Oil Pump Bleeding Procedure
83
If Oil Starvation Is Suspected
83
Recoil Housing
84
Counter Balancer Lubrication (400)
84
Procedure for Adding Oil (400)
84
Counter Balance Oil Changing Procedure
84
Air Cleaner - Trail Boss, Xpress 300, Xplorer 300, Xplorer 400
85
Dual Stage Air Cleaner
85
Primary Pre-Cleaner Foam Boot
85
Secondary (Main) Filter
86
Secondary Filter Removal and Installation Procedure
86
Cleaning the Main Filter
86
Air Filter Service -Sport, Scrambler 400
87
Air Filter Service - Trail Blazer
88
2 Stroke Engine Maintenance
89
Oil Filter (2 Strokes)
89
4 Stroke Engine Maintenance
90
Air Filter - 4 Stroke Engine
92
Pre-Filter Service
92
Air Filter Main Element
92
Air Box Sediment Tube
93
Air Filter Service - Scrambler 500
94
Air Filter Service - Sportsman 500, Xplorer 500
94
Check Engine Oil (4 Stroke)
96
Oil and Filter Change (4 Stroke)
96
Engine Sump Drain Plug View
97
Valve Clearance
100
Intake Valve Clearance Adjustment
101
Exhaust Valve Clearance Adjustment
101
Throttle Cable Lubrication
102
Toe Alignment Inspection
103
Chassis Maintenance
104
Steering Maintenance
104
Camber and Caster Adjustment
104
Toe Alignment Inspection (Chassis Maintenance)
104
The Rod End Inspection
105
Front Hubs (4X4 AWD Model)
105
Changing Front Hub Fluid
105
Exhaust Pipe
106
Brake System Inspection
107
Brake Fluid Level Inspection
107
Wear Line
107
Auxiliary Mechanical Brake System
108
Auxiliary Brake Testing
108
Auxiliary Brake Adjustment
108
Hose/Fitting Inspection
108
Drive Chain and Sprocket Inspection
109
Rear Drive Chain Note
109
Drive Chain Inspection
109
Rear Drive Chain Tension Adjustment
110
Drive Chain Adjustment, Concentric Swingarm
111
Center/Front Drive Chain Slack Adjustment
113
Center/Front Drive Chain Inspection/Adjustment
113
Sprocket Inspection
113
Drive Chain Inspection/Adjustment
114
Rear Axle (6X6 Middle Axle) Adjustment Procedure
114
Final Drive Chain
114
6X6 Rear Axle Drive Chain Adjustment
114
Front Suspension
115
Rear Suspension
115
Controls Check
115
Transmission Lubrication
116
Transmission Oil Changing Procedure
116
Transmission Oil Change - Dipstick Models
116
Transmission Lubrication - Type V Shaft/Chain
117
Transmission Oil Change Procedure
117
Transmission Vent Line Routing
118
Transmission Linkage Adjustment
118
Wheels Inspection
119
Wheel, Hub, and Spindle Torque Table
119
Wheel Removal Front or Rear
119
Wheel Installation
119
Tire Pressure
120
Tire Tread Depth
120
Frame, Nuts, Bolts, Fasteners
120
Engine
122
2 Stroke Engine Torque Specifications
124
4 Stroke Engine Torque Specifications
124
Engine Fastener Torque Patterns
125
1996 To Current Engine Specifications
126
Piston Identification
126
EC38PL Engines
127
Jetting Guidelines for Round-Port Pistons
127
EH42PL/EH50PL Engine Service Data
129
Cooling System
131
System Pressure Test
131
Radiator Cap Pressure Test
131
Recommended Coolant
132
Cooling System Specifications
132
2 Stroke Engine Removal
133
Engine Removal Preparation, Typical (2 Stroke)
133
Engine Installation Notes (2 Stroke)
136
Bleed Cooling System
136
Transmission Readjustment
136
Engine Break in Period (2 Strokes)
136
EC25PF/EC28PF Engines Disassembly
137
Crankshaft Alignment
138
EC25PF/EC28PF Engines Assembly
139
Measure Crankshaft Width - Bearings Installed
139
Connecting Rod Side Clearance
140
EC25PF/EC28PF Engines Installation
144
Oil Pump End Play Adjustment
145
Oil Check Valve Testing (250/400)
146
Oil Check Valve Testing (300)
146
EC25PF Engine - Recoil Disassembly
147
EC25PF Engine - Recoil Assembly
148
EC38PL Engine Disassembly
150
Water Pump Impeller Clearance
156
Cylinder Hone Selection/Honing Procedure
158
Piston/Cylinder Clearance (2 Strokes)
159
Cylinder Inspection/Measurement
159
Piston Inspection/Measurement (Generic)
159
Piston Ring Installed Gap
160
Piston Pin/Needle Bearing Inspection
160
Connecting Rod Small End Inspection
161
EH42PL/EH50PL Engine Exploded View
162
EH42PL/EH50PL Lubrication/Oil Flow
163
Oil Pressure Test
163
EH42PL/EH50PL Engine Diagram
164
EH42PL/EH50PL Oil Flow Chart
164
EH42PL/EH50PL Engine Removal
165
Cylinder Head Bolts
165
Crankcase
165
AWD Models
166
PVT Disassembly, All Models
166
Recoil/Starter Removal
167
Final Coolant Draining/Engine Removal
169
EH42PL/EH50PL Engine Installation
170
Oil Supply
170
EH42PL/EH50PL Engine: Bleed Cooling System
170
Cam Chain Tensioner/Rocker Arm/Camshaft Removal
170
To Position Crankshaft at Top Dead Center (TDC) on Compression Stroke
171
Cam Chain Tensioner
171
Rocker Arm/Shaft Removal
172
Rocker Arm/Shaft Inspection
172
Camshaft Removal
174
Automatic Compression Release Removal/Inspection
175
Automatic Compression Release Installation
175
Camshaft Inspection
176
Cylinder Head Removal
177
Cylinder Head Disassembly/Inspection
178
Cylinder Head Warpage
179
Cylinder Head Disassembly
179
Valve Inspection
181
Combustion Chamber
182
Valve Seat Inspection
182
Cylinder Head Reconditioning
182
Valve Guide Removal/Installation
182
Valve Seat Reconditioning
183
Cylinder Head Assembly
186
Valve Sealing Test
187
Cylinder/Piston Removal and Inspection
187
Piston Removal
188
Cylinder Inspection
189
Piston to Cylinder Clearance
190
Piston Ring Installed Gap (EH42PL/EH50PL)
192
Crankcase Disassembly
192
Starter Drive Removal/Inspection
193
Flywheel/Stator Removal/Inspection
194
Cam Chain/Tensioner Blade
194
Stator Plate
194
One Way Valve
195
Crankcase Separation
195
Oil Pump Removal/Inspection
196
Oil Pump Assembly
198
Counter Balancer Shaft Removal/Inspection
198
Crankshaft Removal/Inspection
199
Crankcase Bearing Inspection
200
Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal
200
EH42PL/EH50PL Engine Assembly
201
Crankcase Assembly
201
End Play Inspection/Adjustment
201
Crankshaft
201
Counter Balancer
203
Pump Shaft
203
Pump Shaft Oil Seal Installation
203
Crankshaft, Counter Balancer and Oil Pump Installation
204
To Assemble the Crankcase
204
Water Pump Mechanical Seal Installation
205
Water Pump Mechanical Seal Removal - Engine Installed
205
Piston Installation
208
Cylinder Installation
209
Cylinder Head Installation
210
Cam Chain/Camshaft Installation
211
Camshaft Installation - Timing Method
212
Method 1 - Camshaft Timing with Stator Removed
213
Camshaft Installation - Timing Method 2
214
Method 2 Camshaft Timing Using Flywheel TDC Mark
215
Cam Chain Tensioner Installation
216
Stator, Flywheel and Starter Drive Installation
216
Rocker Shaft/Rocker Arm Assembly Installation
218
Thermostat Installation
218
Oil Pipes
218
Engine - Sealed Recoil
219
Recoil Disassembly/Inspection
219
Recoil Assembly
220
To Install a New Spring
220
To Reinstall an Old Spring
220
Spark Plug Fouling - 2 Stroke Engine
222
Spark Plug Fouling - 4 Stroke Engine
222
2 Stroke Engine Troubleshooting
223
Starter Motor
224
4 Stroke Engine Troubleshooting
225
Piston Damage Checklist - 2 Stroke Engines
227
Fuel System/Carburetion
228
Fuel System/Carburetion - 1996 Specifications
230
Jetting Guidelines
230
Jetting Compensation for Altitude and Temperature - 1996 Models
230
Fuel System/Carburetion - 1997 Specifications
234
Jetting Compensation for Altitude and Temperature (1997)
234
Fuel System/Carburetion - 1998 Specifications
235
1998 Trail Boss W98AA25C (Engine -EC-25PFE-10) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
235
1998 Trail Blazer W98AA25C (Engine -EC-25PFE-11) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
236
XPRESS 300 W98CA28C (Engine -EC-28PFE-12) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
237
XLPORER 300 W98CC28C (Engine -EC-28PFE-02) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
238
1998 XLPORER 400 W98CC38C (Engine -EC-38PFE-06) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
239
1998 Sport 400 W98BA38C (Engine - EC-38PLE-07) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
240
1998 Scrambler 400 W98BC38C (Engine - EC38PLE-09) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
241
Magnum 2 X 2 W98AA42A (Engine - EH-42PLE-02) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
242
Magnum 4 X 4 W98AC42A (Engine - EH-42PLE-02) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
243
1998 Scrambler 500 W98BC50A (Engine - EH50PLE-04) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
244
Sportsman 500 W98CH50A (W90CH50AB) (Engine - EH-50PLE-07) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
245
1998 Big Boss 500 6X6 W98AE50A (Engine - EH50PLE-06) - Specifications and Clutching and Jetting Guidelines for Altitude and Temperature
246
Fuel System/Carburetion - Jet Part Numbers
247
Oil Tank and Fuel Tank Assembly - Gen II (Except Magnum)
248
Fuel Tank Assembly (Magnum)
249
Oil Tank and Fuel Tank Assembly (Gen III Typical)
250
Fuel Tank Assembly (Gen IV)
251
Fuel Tank Assembly - 500 Models (1997 Xplorer 500, Sportsman 500)
252
Fuel Flow Diagrams
253
Mikuni VM Carburetor Exploded Diagram
254
Carburetor Function
255
Float System
255
Component Functions
256
Pilot Jet
256
Pilot Air Screw
256
Air/Fuel Mixture Ratio
256
Jet Needle
257
Needle Jet
257
Throttle Opening Vs. Fuel Flow
257
Throttle Valve
258
Main Jet
258
Starter System - Closed Throttle
259
Pilot System (0-3/8 Throttle)
260
Slide Cutaway (1/8-3/8 Throttle)
261
Jet Needle/Needle Jet (3/8-3/4 Throttle)
262
Main System (3/4 to Full Throttle)
263
Component Effect Vs. Throttle Opening
264
Mikuni VM Fuel Delivery Chart
264
Mikuni VM Carburetor System Components
265
Venting Systems
265
Mikuni BST 34 Carburetor Exploded View
266
Venting Systems (Mikuni CV)
267
Mikuni CV Carb Operation
268
Pilot (Idle and Slow) Systems
269
Starter System (Choke or Enrichment)
269
Float System (Mikuni CV)
270
Main System (Mikuni CV)
270
Magnum Fuel Tank Removal
271
Carburetor Removal ( Mikuni CV)
272
Carburetor Disassembly - Mikuni CV
273
Carburetor Cleaning - Mikuni CV
276
Carburetor Assembly - Mikuni CV
279
Carburetor Assembly/Adjustment - Mikuni CV
280
Float Height Adjustment (Mikuni CV)
280
CV Carburetor Installation
282
Needle and Seat Pressure Test Mikuni CV
283
Inlet Needle and Seat
283
Fuel Level (Mikuni CV)
283
Float Bowl Draining
284
Fuel Pump Exploded View
286
Fuel Pump Testing
287
Fuel Pump Disassembly
287
Fuel Pump Inspection/Assembly
287
Fuel System/Carburetion Troubleshooting
288
Fuel Starvation/Lean Mixture
288
Rick Mixture
288
Poor Idle
288
Idle too Low
289
Erratic Idle
289
Body and Steering
290
Body and Steering - Torque Specifications and Special Tools
292
Body Styles
293
1996 Body Styles
293
1997 Body Styles
293
1998 Body Styles
293
Body Assembly Exploded View (Gen II - Typical)
295
Cover/Panel Removal (Gen II - Typical)
296
Cover/Panel Removal (Gen III - Typical)
297
Cover/Panel Removal (Gen IV - Typical)
298
Body Assembly Exploded View (Gen III - Typical)
299
Body Assembly Exploded View (Gen IV - Typical)
300
Body Assembly Exploded View (Gen IV - Headlight Pod)
301
Headlight Pod Service (Gen IV Typical) - Disassembly
302
Headlight Pod Service (Gen IV Typical) - Installation
303
Side Panel Removal (Gen IV - Typical)
304
Toe Alignment
305
Toe Alignment - Method 2
306
Typical Steering Assembly, Exploded View, Trail Boss 250
307
Steering Assembly, Exploded View, 2X4 Models (Except Trail Boss 250)
308
Steering Assembly, Exploded View, 4X4 and 6X6 Models
309
Steering Stop Adjustment
310
Rear Axle Bend
310
A-Arm Replacement
310
Rear Drive Axle, Hub and Wheel Assembly, - 2X4 and 4X4 (Except Sportsman 500)
311
Concentric Swingarm Rear Axle Assembly, Exploded View - 1998 Scrambler 400/500
312
Concentric Swingarm Exploded View 1998 Scrambler 400/500
313
Rear Drive Axle, Hub and Wheel Assembly - Shaft Drive Models
314
Rear Strut Stabilizer, 6X6 Models
315
Rear Swing Arm Weldment, 6X6 Models
316
Swing Arm and Rear Suspension Exploded View
318
Swing Arm Removal
319
Swing Arm Removal/Inspection
320
Swing Arm Assembly/Installation
321
Concentric Swingarm Removal/Disassembly
322
Concentric Swingarm Assembly/Installation
323
Strut Assembly - 400L AWD, Magnum AWD
324
Front Strut Weldment Replacement
325
Front Strut Cartridge Replacement
325
Strut Assembly - 2X4 Models
325
Front Strut Service
326
Front Strut Removal
326
Front Strut Installation
327
Front Strut Ball Joint Replacement
328
2X4 Hub Bearing Service
329
2X4 Front Hub Disassembly/Inspection
329
2X4 Front Hub Assembly
330
2X6 Hub Bearing Service
331
2X4 Front Hub Installation
331
Fox Shock Service
332
Foxtm Shock Service
333
Fox Shock Standard Valving Chart
339
1996 Optional Suspension Springs
340
1997 Optional Suspension Springs
341
1996 Paint Codes
342
1997 Paint Codes
343
Clutches
344
Clutch - Specifications
346
Clutch - Special Service Tools and Supplies
346
1996 Productoin Specifications
346
1996 Clutch Recommendations for Altitude
346
1997 Production Specifications
347
1997 Clutch Recommendations for Altitude
347
1998 Production Specifications
348
1998 Clutch Recommendations for Altitude
348
Shift Weights
349
Drive Clutch Spring Specifications
351
Clutches Overview
352
Relationship of Drive Clutch Weights and Spring in Maintaining Operating RPM
352
PVT System Indroduction
353
Drive Clutch Operation
353
Driven Clutch Operation
353
Clutch Maintenance
354
PVT Maintenance/Inspection
354
PVT Overheating
354
PVT Sealing and Ducting Components - Type I
354
PVT Sealing and Ducting Components - Type II
355
PVT Sealing and Ducting Components - Type III
356
PVT Sealing and Ducting Components - Type IV
356
Typical PVT Disassembly
358
PVT Assembly
359
Drive Belt Tension
361
Drive Belt Removal/Inspection
361
Clutch Alignment /Offset
362
Driven Clutch Disassembly
363
Driven Clutch Assembly
365
Drive Clutch - Springs Specifications Table
367
Drive Clutch Inspection
368
Spider Removal
368
Moveable Sheave Bushing Inspection
368
Drive Clutch Disassembly
369
Roller, Pin and Thrust Washer Inspection
369
Drive Clutch Assembly
371
Clutch Bushing Removal and Installation
372
Polaris Kit PN 2871226
372
Drive Clutch Moveable Sheave - Bushing Removal
372
Drive Clutch Moveable Sheave - Bushing Installation
373
Drive Clutch Cover - Bushing Removal
374
Drive Clutch Cover - Bushing Installation
375
Driven Clutch Moveable Sheave - Bushing Removal
376
Driven Clutch Moveable Sheave - Bushing Installation
378
Engine Braking System (EBS)
380
One-Way Clutch
380
Driven Clutch Spring
380
High Elevation Setup
380
EBS Exploded View
381
Drive Clutch Disassembly - EBS
382
Drive Belt Removal - EBS
382
One-Way Clutch Inspection (Drive Clutch)
382
Inspection of Moveable Sheave Bushing
383
Driven Clutch Disassembly - EBS
384
One-Way Clutch Preliminary Inspection (Driven)
384
Roller Pin Disassembly
385
Operation Guidelines for EBS Clutches
387
Clutches Troubleshooting
388
Final Drive
390
Final Drive Torque Specifications
392
Wheel, Hub, and Spindle Torque
392
Rolling Torque
392
Final Drive Exploded View
393
AWD Front Hub
393
Demand 4 Operation - AWD Models
394
Electricl Hub Engagement (4X4)
394
Front Hub Disassembly (4X4)
395
Hilliard Clutch Disassembly/Inspection
396
Hilliard Clutch Assembly Testing
397
Seal Sleeve Replacement
397
Strut Seal Sleeve Replacement
398
Magnetic Coil Replacement
399
Wheel Hub Seal Replacement
400
Strut Casting Seal Replacement
401
Drive Shaft Boot Replacement
402
Front Drive Shaft CV Joint Boot Replacement (4X4 Models)
402
Hub/Wheel Bearing Installation (4X4 Models)
403
Hublwheel Bearing Installation
403
Front Hub Bearing Adjustment (AWD Models)
404
Front Hub Bearing Adjustment (AWD Models Equipped with Cotter Pins)
405
Front Axle Identification
407
Front Drive Axle Removal
409
Front Drive Axle Installation
410
U-Joint Service
411
U-Joint Disassembly (Typical)
411
U-Joint Inspection
412
U-Joint Assembly (Typical)
412
2X4 Front Hub Disassembly and Inspection
414
2X4 Front Hub Assembl.
415
2X4 Front Hub Install.
416
Rear Axle Removal
417
Rear Axle Installation
419
6X6 Middle Axle Sprocket Service
422
6X6 Middle Axle Sprocket Removal
422
Brake Disc Hub Removal
425
Middle Axle Assembly
426
Rear Hub/Bearing Carrier Removal (Type IV Shaft Drive)
428
Rear Hub Disassembly (Shaft Drive)
430
Rear Hub Assembly (Shaft Drive)
431
Rear Hub Installation
432
Rear Drive Shaft Removal
433
Rear Drive Shaft Disassembly
434
Rear Drive Shaft Assembly
434
Rear Drive Shaft Installation
435
Rear Eccentric Removal
436
Rear Eccentric Disassembly
436
Rear Eccentric Assembly
437
Rear Eccentric Installation
439
Center Eccentric Removal
440
Center Eccentric Disassembly
441
Center Eccentric Assembly
441
Center Eccentric Installation
443
Front Eccentric Removal
445
Front Eccentric Assembly
447
Front Eccentric Installation
449
Front Gearcase Removal
451
Prop Shaft Removal
451
Front Gearcase Disassembly
452
Front Gearcase Assembly
455
Front Gearcase Installation
458
Concentric Swingarm Rear Axle Removal
460
Concentric Swingarm Rear Axle Assembly
461
Concentric Swingarm Rear Axle Installation
461
Concentric Swingarm Rear Axle Assembly, Exploded View
463
Transmission Service
464
Transmission Service - Torque Specifications
466
Transmission Service - Lubrication
466
Gear Ratios
467
Torque Stop/Shift Linkage Adjustment
468
Shift Linkage Rod End Positioning
470
Transmission Service - Troubleshooting
471
Gear Shift Selector Removal
472
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Polaris 1998 Sportsman 500 Service Manual (505 pages)
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 47.62 MB
Table of Contents
Table of Contents
1
Quick Reference Data
5
Tire Inflation Pressure
5
Recommended Lubricants, Fluids and Capacities
5
Recommended Capacities
5
Maintenance and Tune-Up Torque Specifications
6
Maintenance and Tune-Up Specifications
6
Replacement Bulbs
6
General Information
7
Manual Organization
7
Chapter One
7
Notes, Cautions and Warnings
8
Safety First
8
Cleaning Parts
9
Handling Gasoline Safely
9
Service Hints
10
Torque Specifications
12
Fas Teners
12
ISO Metric Screw Threads
13
Machine Screws
13
Nuts
13
Self-Locking Fasteners
14
Washers
14
Cotter Pins
14
Circlips
14
Lubricants
15
Engine Oil
15
Threadlocking Compound
16
RTV Gasket Sealant
16
Expendable Supplies
16
Grease
16
Serial Numbers
17
Warning and Information Labels
18
Basic Hand Tools
18
Screwdrivers
18
Pliers
18
Locking Pliers
19
Circlip Pliers
19
Box, Open-End and Combination Wrenches
19
Adjustable Wrenches
19
Socket Wrenches
20
Allen Wrenches
20
Torque Wrench
20
Impact Driver
20
Precision Measuring Tools
21
Feeler Gauge
21
Vernier Caliper, Dial Caliper and Digital Electronic Caliper
21
Outside Micrometers
21
Micrometer Range
22
How to Read a Micrometer
22
Standard Inch Micrometer
22
Decimal Place Values
23
Vernier Inch Micrometer
24
Standard Metric Micrometer
25
Micrometer Accuracy Check
26
Proper Care of a Micrometer
28
Cylinder Bore Gauge
28
Small Hole Gauges
28
Telescoping Gauges
29
Multimeter
29
Voltage
29
Resistance
30
To Calibrate an Analog Ohmmeter
30
Continuity Test
30
Amperage
30
Special Tools
31
Fabricating Tools
31
Mechanic's Tips
31
Removing Frozen Nuts and Screws
31
Bearing Replacement
32
Bearing Removal
32
Removing Broken Screws and Bolts
32
Bearing Installation
34
Shrink Fit
34
Seals
35
Storage
36
Selecting a Storage Area
36
Preparing Vehicle for Storage
36
After Storage
37
Model Year and Number
37
General Dimensions
38
Vehicle Weight (DRY)
38
Decimal and Metric Equivalents
38
General Torque Specifications
39
Conversoin Tables
39
Technical Abbreviations
40
Metric Tap and Drill Sizes
41
Troubleshooting
42
Operating Requirements
42
Chapter Two
42
Troubleshooting Instruments
43
Starting the Engine
43
Starting a Cold Engine
43
Starting Difficulties
44
Starting a Warm or Hot Engine
44
Starting a Flooded Engine
44
Engine Fails to Start (Spark Test)
45
Engine Is Difficult to Start
46
Engine Starting System
47
Engine Compression
47
Poor Idle Speed Performance
47
Poor Medium - and High-Speed Performance
47
Charging System
48
Starter Troubleshooting
48
Ignition System
49
Ignition System Precautions
49
Switch Test
49
Ignition Coil Test
49
Ignition System
50
Electronic Throttle Control Switch Testing
51
Fuel System
52
Engine Overheating
52
Engine Preignition
52
Engine Detonation
52
Engine Noises
53
Cylinder Leakdown Test
53
Power Loss
53
Piston Seizure
53
Power Train
54
Low Engine Operating Speed
54
Engine Operating Speed too High
54
Engine Speed Erratic During Speed or Load Changes
54
Steering
55
Drive Belt Not Operating Smoothly in Primary Sheave
55
Glazed Drive Belt
55
Erratic Shifting
55
Disc Brake Troubleshooting
56
Frame Noise
57
Brakes
57
Generally Poor or Unpredictable Handling
57
Loose Steering
57
Electrical Specifications
58
Lubrication, Maintenance and Tune-Up
59
Pre-Ride Checklist
59
Tires and Wheels
61
Tire Pressure
61
Tire Inspection
61
Battery
62
Rim Inspection
62
Safety Precautions
62
Electrolyte Level Check
63
Battery Removal/Installation
63
Cleaning, Inspection and Adding Water
64
Battery Testing
65
Charging
66
New Battery Installation
66
Battery Electrical Cable Connectors
67
Periodic Lubrication
67
Engine Oil Level Check
67
Engine Oil and Filter Change
68
Engine Oil Pressure Test
70
Transmission Oil Level Check
71
Transmission Oil Change
71
Front Gearcase Oil Level Check
72
Front Gearcase Oil Change
72
Grease Service
73
Front Hub Oil Level Check
74
Front Hub Oil Change
74
Periodic Maintenance
76
Control Cable Lubrication
76
Drive Belt Inspection
76
Disc Brake System Inspection
76
Disc Brake Fluid Level Check and Fill
77
Disc Brake Hoses
77
Auxiliary Brake Testing and Adjustment
78
Throttle Cable/Electronic Throttle Control Adjustment
78
Throttle Cable Adjustment
79
Air Filter Element
80
Coolant Inspection
81
Coolant Change
82
Exhaust System
84
Fuel Hose Inspection
85
Fuel Filter Replacement
85
Steering System and Front Suspension Inspection
85
Front Wheel Toe-Out
86
Front Hub Wheel Bearings
87
Rear Suspension
87
Nuts, Bolts and Other Fasteners
87
Wire Harness, Control Cables and Hose Lines
87
Unscheduled Inspection and Maintenance
88
Recoil Starter
88
Body Fasteners
88
Fuel Tank and Lines
88
Valve Clearance Measurement
89
Valve Clearance Adjustment
90
Cam Chain Adjustment
91
Spark Plug Heat Range
91
Spark Plug Removal
91
Gapping and Installing the Spark Plug
92
Reading Spark Plugs
92
Normal Condition
93
Carbon-Fouled
93
Oil-Fouled
93
Gap Bridging
93
Spark Plug Condition
94
Worn out
95
Preignition
95
Checking Ignition Timing
95
Adjusting Ignition Timing
95
Carburetor Idle Mixture Adjustment
96
Idle Speed
97
Maintenance and Lubrication Schedule
97
Recommended Lubricants and Fluids
98
Capacities
99
Engine Top End
100
Engine Principles
100
Engine Cooling
100
Four-Stroke Operating Principles
101
Engine Lubrication
102
Servicing the Engine in the Frame
102
Cylinder Head Cover
105
Rocker Arm Assembly
105
Rocker Arm
107
Camshaft Removal
109
Camshaft Inspection
110
Automatic Compression Release Mechanism Testing
112
Camshaft Installation
113
Cylinder Head Removal
116
Cylinder Head Inspection
117
Cylinder Head Installation
118
Valves and Valve Components
119
Solvent Test
120
Valve Removal
120
Valve Inspection
121
Valve Troubleshooting
122
Valve Installation
123
Valve Guide Replacement
124
Valve Lapping
124
Cylinder Block Removal
125
Cylinder Block Inspection
126
Cylinder Block Installation
128
Spec Ial Tools
128
Piston and Piston Rings
130
Piston Removal
130
Piston Inspection
131
Piston Pin Inspection
133
Piston Clearance
133
Piston Installation
134
Piston Ring Inspection and Removal
134
Piston Ring Installation
136
Camshaft Chain and Sprockets Removal
137
Camshaft Chain and Sprockets Inspection
138
Camshaft Chain and Sprockets Installation
139
Camshaft Chain Wear
139
Break-In Procedure
140
General Engine Specifications
140
Engine Lubrication System
140
Engine Top End Tightening Torque Specifications
141
Engine Top End Specifications
141
Engine Lower End
143
Engine
143
Engine Removal
144
Flywheel and Stator Plate Removal
147
Flywheel and Stator Plate Installation
149
Recoil Starter Removal/Installation
150
Recoil Starter Disassembly and Starter Rope Removal
150
Recoil Starter Inspection and Assembly
150
Crankcase
152
Crankcase Separation
153
Crankcase Inspection
156
Crankshaft Seal Replacement
156
Crankcase Bearing Replacement
157
Seals
157
Water Pump Mechanical Seal and Bearing Replacement
161
Crankcase Assembly
162
Crankshaft Inspection
168
Crankshaft and Balancer
169
Balancer Shaft Inspection
169
Shaft End Float Measurement and Shim Selection
169
Crankshaft End Play
171
Balancer Shaft End Play
172
Oil Pump Removal/Disassembly
174
Oil Pump Inspection
174
Oil Pump Assembly/Installation
177
Oil System One-Way Check Valve
178
Oil System One-Way Check Valve Break-In Procedure
179
Engine Lower End Torque Specifications
180
Engine Lower End Specifications
180
Carburetor Operation
181
Carburetor Removal/Installation
182
Carburetor Disassembly
183
Mikuni Carburetor 34 MM
184
Carburetor Cleaning and Inspection
189
Carburetor Tests and Adjustments
192
Inlet Valve Seat Inspection
192
Float Level Height Adjustment
192
Jet Needle Adjustment
193
Main Jet Replacement
193
Throttle Cable Replacement
194
Starting Enrichment (Choke) Cable Removal/Installation
194
Fuel Tank Removal/Installation
196
Fuel Shutoff Valve
197
Air Filter Air Box Removal/Installation
198
Fuel Pump Testing
198
Fuel Pump Removal/Installation
202
Fuel Pump Disassembly/Assembly
203
Carburetor Specifications
203
Cooling Systems
204
Polaris Variable Transmission (PVT) Air Cooling System
204
PVT Cooling System
205
Clutch Outer and Inner Cover Ducting
205
Clutch Outer Cover Removal/Installation
205
Clutch Inner Cover Removal/Installation
206
Engine Cooling System
208
Liquid Cooling System (Typical)
209
Hoses and Hose Clamps
210
Engine Gaskets/Seals
210
Radiator Assembly
211
Cooling System Inspection
211
Radiator Removal/Installation
211
Radiator Inspection
214
Cooling Fan Removal/Installation
215
Thermostat Removal/Installation
217
Temperature Sensors
218
Cooling System Specifications
218
Clutch/Drive Belt System
219
Drive Unit
219
Drive Pulley
221
Fixed and Sliding Pulley Halves
221
Drive Pulley Spring
221
Eng Ine no Ises
221
Driven Pulley
222
Centrifugal Weight Levers
222
Release Spring
222
Power Tra in
222
Drive Belt
224
Torque Sensing Cam Angle
224
Drive Belt Deflection
226
Pulley Center-To-Center Distance
227
Drive Belt Alignment
227
Pulley Alignment
228
Pulley Offset
228
Drive Pulley Removal
230
Drive Pulley Bolt Inspection
241
Clutch Outer and Iinner Cover
252
Drive Belt and Pulley Specifications
253
Drive Pulley Spring Specifications
254
Shift Weights and Driven Pulley Specifications
254
Tightening Torque Specifications
254
Transmission
255
Transmission Service Notes
255
Transmission Removal/Installation
256
Transmission Case Disassembly
258
Transmission Case
259
Transmission Case Assembly
265
Transmission Shafts Disassembly
273
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