Polaris 2005 Sportsman MV7 Service Manual
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Polaris 2005 Sportsman MV7 Service Manual

Polaris 2005 Sportsman MV7 Service Manual

Pn 9919963
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2005 SPORTSMAN MV
7
SERVICE MANUAL
PN 9919963

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Summary of Contents for Polaris 2005 Sportsman MV7

  • Page 1 2005 SPORTSMAN MV SERVICE MANUAL PN 9919963...
  • Page 2 Service Manual (PN 9919963) ECopyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 3 NOTE: A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm.

  • Page 4: Table Of Contents

    CHAPTER INDEX CHAPTER 1 GENERAL CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE CHAPTER 4 FUEL SYSTEM CHAPTER 5 BODY/SUSPENSION CHAPTER 6 PVT SYSTEM CHAPTER 7 FINAL DRIVE CHAPTER 8 TRANSMISSION CHAPTER 9 BRAKES CHAPTER 10 ELECTRICAL...
  • Page 5 GENERAL INFORMATION Specs Model Identification ..... . . Serial Number Location ....Publications Numbers / Replacement Keys 2005 Sportsman MV / Dimensions...

  • Page 6: Model Identification

    GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 0 5 M H 6 8 A P Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation ENGINE DESIGNATION NUMBERS EH068OLE...

  • Page 7: Publications Numbers / Replacement Keys

    9919959 9919960 9919961 9919934 NOTE: Military MV units utilize a different parts manual. Contact Polaris Industries customer service for the part number at (763) 417--8650. NOTE: Some publications can be found at the Polaris website: www.polarisindustries.com or purchased from www.purepolaris.com.

  • Page 8: 2005 Sportsman Mv

    GENERAL INFORMATION 2005 SPORTSMAN MV MODEL: ..MODEL NUMBER: A05MH68 ENGINE MODEL: EH068OLE Category Dimension / Capacity Length 89 in./226 cm Width 48 in./122 cm Height 50 in./127 cm Wheel Base 50.75 in./129 cm Dry Weight 992 lbs./450 kg...

  • Page 9: Jetting Chart

    Lubrication Pressurized Wet Sump Front Suspension / Shock A- -arm / MacPherson Strut Oil Requirements / Capacity Polaris 0W- -40 2 qt. / 1.9 ltr Front Travel 8.2 in. / 21 cm Exhaust System Single Pipe Rear Suspension / Shock...

  • Page 10: Special Tools

    GENERAL INFORMATION SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN PV- -43527 Oil Filter Wrench 2870872 Shock Spanner Wrench 2, 5 8712100 or 8712500 Tachometer 2,10 2200634 Valve Seat Reconditioning Kit PU- -45257 Valve Spring Compressor 2871043 Flywheel Puller 2870390 Piston Support Block PU- -45497- -2...
  • Page 11 Standard Tools and Engine Tools machine. Some of the tools listed are mandatory and other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris special tools when servicing any Polaris product. Standard Tools and Engine Tools...
  • Page 12 GENERAL INFORMATION SPECIAL TOOLS Standard Tools and Engine Tools Clutch (PVT) Tools 2870506 -- Drive Clutch Puller 2870303 -- Hone Kit 2870913 -- Driven Clutch Puller 2870305 -- Stone Replacement Kit 2872292 -- EBS Clutch Align Tool 2870588 -- Hone Oil (12 oz.) 9914177--A -- Drive Clutch Holding Tool 2200634 -- Valve Seat Reconditioning Kit...
  • Page 13 GENERAL INFORMATION Clutch (PVT) Tools Suspension Tools 2871025 -- Clutch Bushing Replace Tool Kit 2870871 -- ATV Ball Joint Tool Kit 2870910 -- Roll Pin Tool 2871071 -- Shock Body Holding Tool 2871226 -- Clutch Bushing Replacement Kit 2870623 -- Shock Spring Compressor 2871572 -- Strut Rod Wrench 2201379 -- EBS Bushing Replacement Kit...
  • Page 14 GENERAL INFORMATION Electrical Tools Suspension Tools 2870872 -- Shock Spanner Wrench 2870630 -- Timing Light 2872608 -- Roll Pin Removal Tool 2871745 --Static Timing Light Harness 2871351 -- Shock IFP Depth Tool 2460761 -- Hall Sensor Probe Harness Fuel & Brake Systems PV--39991 -- Peak Reading Adapter PV--37453 -- Christie De--Sulfating 2870975 -- Mity Vac...

  • Page 15: 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 16: Conversion Table

    GENERAL INFORMATION CONVERSION TABLE Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m x .7376 = ft.lbs. kg-m x 7.233 = ft.
  • Page 17 GENERAL INFORMATION SAE TAP DRILL SIZES DECIMAL EQUIVALENTS 1/64 ....0156 Thread Size/Drill Size Thread Size/Drill Size 1/32 ... .0312 .

  • Page 18: Glossary Of Terms

    Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8″ or 1 cm). Polaris measures chain length in number of pitches. Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase.
  • Page 19 MAINTENANCE Periodic Maintenance Chart ....2.2-2.5 Component Locations ....Lubricant and Maintenance Product Numbers 2.7 Recommended Lubricants .

  • Page 20: Periodic Maintenance Chart

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

  • Page 21: Maintenance And Lubrication

    (if equipped) Transmission oil 25 H Monthly 155 (250) Inspect level; change yearly " " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.

  • Page 22: General

    Inspect routing, condition " (1000) Valve clearance 100 H 12 M Inspect; adjust (1000) " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.
  • Page 23 Auxiliary brake Inspect daily; adjust as needed " Headlight aim Adjust as needed " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.
  • Page 24 MAINTENANCE SPORTSMAN MV7 COMPONENT LOCATIONS Instrument Cluster AWD Switch Winch (Speedometer) Winch Switch Selection Switch Brake Lever Light Control Reverse Throttle & Run Switch Override Choke Ignition/Key Front Storage Rack Fuel Valve Rear Winch Access Door Gear Shifter Oil Dipstick PVT Cover Drain Plug Recoil Rear Rack...

  • Page 25: Polaris Lubricant Symbol Identification

    MAINTENANCE POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS Part No. Description Part No. Description Engine Lubricant Additives / Sealants / Thread Locking Agents / Misc. 2870791 Fogging Oil (12 oz. Aerosol) 2870585 Loctitet Primer N, Aerosol, 25 g 2871098 Premium 2 Cycle Engine Oil (Quart) (12...
  • Page 26 MAINTENANCE POLARIS LUBRICANTS/FLUIDS FOR SPORTSMAN MODELS Pure Polaris Lubricants and Maintenance Kits can be purchased at your local Polaris dealer. ATV Angle Drive Fluid 2859066 -- Sportsman 600/700 Maintenance Kit - - Oil Filter & 2 Qts. of 0W- -40 oil...
  • Page 27 Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) © More often under severe conditions (operating in water or hauling heavy loads) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or ¢ Mobilegrease Special Ill.

  • Page 28: Pre-Ride Inspection

    Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) © More often under severe conditions (operating in water or hauling heavy loads) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or ¢ Mobilegrease Special...

  • Page 29: Front Gearcase Lubrication

    PARK. G Check vent hose to be sure it is routed properly and unobstructed. G The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid. 11 ft.lbs (15 Nm) FRONT GEARCASE SPECIFICATIONS Specified Lubricant: View Under Front of ATV...

  • Page 30: Transmission Lubrication/Linkage Inspection

    Fill Plug specification. 3. Remove fill plug. 4. Add 15 oz. (450 ml) of Polaris AGL Gearcase Lubricant or fill to top of the fill plug hole threads. 5. Check for leaks. 6. Reinstall fill plug and torque to 14 ft.lbs. (19 Nm).

  • Page 31: Rear Gearcase Lubrication

    G Check vent hose to be sure it is routed properly and unobstructed. G The correct rear gearcase lubricant to use is Polaris ATV Angle Drive Fluid. REAR GEARCASE SPECIFICATIONS Specified Lubricant: ATV Angle Drive Fluid (PN 2871653) 2. Clean and reinstall drain plug (A) using a new Capacity: 10 Oz.

  • Page 32: Lubrication / Grease Points

    MAINTENANCE LUBRICATION / GREASE SHIFT LINKAGE INSPECTION POINTS NOTE: Shift rod is preset at time of manufacture. As shown on Page 2.10, there are only 3 grease zerks on the Sportsman MV, two front ball joints and rear Shift Linkage Rod prop shaft.

  • Page 33: Idle Speed Adjustment

    MAINTENANCE cable tension as needed until lock--to--lock turning Illustration of choke may vary with models. can be accomplished with no rise in engine rpm. 5. Replace the throttle cable if worn, kinked, or damaged. To remove the ETC cover: 1. Use a medium flat blade screwdriver and insert blade into the pocket of the cover starting on the #1 position.
  • Page 34 MAINTENANCE PILOT SCREW THROTTLE CABLE / ELECTRONIC THROTTLE The pilot system supplies fuel during engine operation with the throttle valve closed or slightly opened. The CONTROL (ETC SWITCH) fuel/air mixture is metered by pilot screw and ADJUSTMENT discharged into the main bore through the pilot outlet. 1.

  • Page 35: Maintenance

    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 36: Vent Lines

    MAINTENANCE VENT LINES 7. Start machine and check for leaks. NOTE: All tubes attached to the carburetor must be Check fuel tank, oil tank, carburetor, battery and check for pinching or blockage, as this will effect transmission vent lines signs wear, engine performance.

  • Page 37: Battery Maintenance

    MAINTENANCE BATTERY MAINTENANCE A cylinder leakdown test is the best indication of engine condition. Follow manufacturer’s instructions to perform a cylinder leakage test. (Never use high pressure leakage testers, as crankshaft seals may dislodge and leak). WARNING Cylinder Compression Battery electrolyte is poisonous. It contains Standard: 150-170 PSI sulfuric acid.

  • Page 38: Spark Plug

    MAINTENANCE To remove the battery: 3. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or 1. Disconnect holder strap and remove cover. erosion of the electrodes. 2. Disconnect battery negative (-) (black) cable first, followed by the positive (+) (red) cable.

  • Page 39: Liquid Cooling System

    OVERVIEW to freeze, corrode, or overheat. The engine coolant level is controlled or maintained Polaris 60/40 Anti-Freeze / Coolant by the recovery system. The recovery system (PN 2871323) components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.

  • Page 40: Radiator Coolant Level

    2. Remove reservoir cap. Verify the inner splash cap vent hole is clear and open. RADIATOR 3. Fill reservoir to upper mark with Polaris Premium 60/40 Anti Freeze / Coolant (PN 2871323) or a mixture of antifreeze and distilled water as 1.
  • Page 41 MAINTENANCE 3. Remove the pressure cap (1). 4. Using a funnel, slowly add coolant through the radiator filler neck. 5. Reinstall the pressure cap. 6. Reinstall the front rack. NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. Contact your dealer for the correct replacement part.

  • Page 42: Breather Filter / Line Inspection

    MAINTENANCE AIR BOX SEDIMENT TUBE 11. Reinstall filter on main filter mount. Place filter clamp over the assembly and tighten. Periodically check the air box drain tube located NOTE: Apply a small amount of general purpose toward the rear of the machine. Drain whenever grease to the sealing edges of the filter before deposits are visible in the clear tube.

  • Page 43: Recoil Housing

    MAINTENANCE RECOIL HOUSING Breather Filter Orientation -- Arrow To Engine Recoil Drain Plug Recoil Assembly Location NOTE: For recoil disassembly, refer to Chapter 3. Drain the housing periodically to remove moisture. Drain the recoil housing after operating the ATV in very wet conditions. This should also be done before storing the ATV.

  • Page 44: Pvt Drying & Pvt Drain Plug

    MAINTENANCE ENGINE OIL LEVEL engine oil will be lost if crankcase drain is opened. If recoil handle (B) seal has been The 600/700 engine is a wet--sump engine, meaning damaged, the handle should be replaced. the oil is contained in the bottom of the crankcase. To check the oil level: PVT DRYING &...

  • Page 45: Oil And Filter Change

    MAINTENANCE OIL AND FILTER CHANGE 4. Reinstall dipstick and push it into place. Do not lock the dipstick. 1. Place vehicle on a level surface. NOTE: Make certain the dipstick is inserted all the 2. Run engine two to three minutes until warm. Stop way into the filler tube to keep the angle and depth of engine.
  • Page 46 NOTE: Whenever steering 12. Remove dipstick and fill sump with 2 quarts (1.9 l) components are replaced, check front end alignment. of Polaris Premium 4 Synthetic Oil (PN 2871281). Use only genuine Polaris parts. Recommended Engine Oil...
  • Page 47 MAINTENANCE WHEEL ALIGNMENT METHOD 1: Replace worn steering components. Steering should move STRAIGHTEDGE OR STRING freely through entire range of travel without binding. Be sure to keep handlebars centered. See notes Elevate front end of machine so front below. wheels are off the ground. Check for any looseness in front hub / wheel NOTE: String should just touch side sur- assembly by grasping the tire firmly...

  • Page 48: Toe Alignment

    MAINTENANCE WHEEL ALIGNMENT TOE ALIGNMENT METHOD 2: CHALK ADJUSTMENT 1. Place machine on a smooth level surface. If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell 2. Set handlebars in a straight ahead position and you which tie rod needs adjusting.
  • Page 49 Make sure the machine is in Park and repeat Steps 2 and 3. Keep fluid level in the master cylinder SEE WARNING reservoir to the indicated level inside reservoir. Use Polaris DOT 3 Brake Fluid (PN 2870990). 1 ft. 2.31...
  • Page 50 MAINTENANCE Sight Parking Brake Glass Lock Brake Pad Measure Thickness Service Limit -- .180″ (4.6 mm) Rear Master Cylinder Reservoir Min. Auxiliary Brake Reservoir Check brake system for fluid leaks. Check brake for excessive travel or spongy feel. Check friction pads wear, damage or looseness.

  • Page 51: Auxiliary Brake Testing

    MAINTENANCE HOSE/FITTING INSPECTION First, check foot brake effectiveness by applying 50 lb. (approx.) downward force on the pedal. The top of the pedal should be at least 1 inch, (25.4mm) above the Check brake system hoses and fittings for cracks, surface of the footrest.

  • Page 52: Controls

    Inspect the cv shaft boots in the front and rear of the ATV for damage, tears, wear, or leaking grease. If the rubber boot exhibits any of these symptoms, replace the boot. Refer to Chapter 7 for CV boot replacement, or have you Polaris dealer replace the boot. 2.34...
  • Page 53 MAINTENANCE WHEELS WHEEL INSTALLATION Inspect all wheels for runout or damage. Check wheel 1. With the transmission in Park and the parking nuts and ensure they are tight. Do not over tighten the brake locked, place the wheel in the correct wheel nuts.

  • Page 54: Warn ® Winch Operation

    MAINTENANCE TIRE INSPECTION WARN WINCH OPERATION ® Improper tire inflation may affect ATV NOTE: See Chapter 5 for winch mounting. See maneuverability. Chapter 10 for winch wiring information. When replacing a tire always use NOTE: For more information on winch operation and original equipment size and type.
  • Page 55 MAINTENANCE The mini--rocker switch or IN / OUT control controls the direction of the cable for the winch. IN pulls the cable into the winch and OUT feeds the cable out of the winch. ENGAGE Mini--rocker Switch FREESPOOL Warn® Winch Control The winch control located on the side of the winch gives the operator easy access to switch between ENGAGED and FREESPOOL.

  • Page 56: Cleaning And Storage

    NOTE: Grease all zerk fittings immediately after washing, and allow the vehicle to run for a while If you choose not to use Polaris Fogging Oil, perform to evaporate any water that may have entered the the following procedure.
  • Page 57 1-2” off the ground. Be sure the storage area is well ventilated, and cover the machine with a genuine Polaris ATV cover. NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

  • Page 58: Maintenance Schedule

    MAINTENANCE MAINTENANCE SCHEDULE Service Date Hours / Miles Service Performed Serviced By: 2.40...
  • Page 59 ENGINE Engine Exploded Views ..... . 3.2--3.6 Special Tools ....... Piston Identification .

  • Page 60: Engine Exploded Views

    ENGINE ENGINE EXPLODED VIEW CRANKCASE Camshaft Thrust Plate Journal Bearings Ball Bearing 115 ± 12 in. lbs. Balance Shaft (13 ± 1.35 Nm) Flange Seal 60 ± 6 in. lbs. (6.8 ± .68 Nm) Bushing Woodruff Key Crankshaft Oil Pickup Journal Bearings Baffle 60 ±...
  • Page 61 ± (10.85 .35 Nm) ± 108 ± 12 in. lbs. (6.8 ± .68 Nm) Oil Pump Bolt Tighten Sequence TIMING MARKS Mag Cover Bolt Tighten Sequence Apply Polaris 0W--40 oil to component. Apply White GEAR TIMING AT TDC Lithium Grease.
  • Page 62 ENGINE ENGINE EXPLODED VIEW Apply Polaris MAG SIDE Starter Grease. Apply Polaris 0W--40 oil to seal. Loctitet Pipe Sealant (PN 2871956) Bolts Water Pump Cover Bolt Gasket (Tighten Top Bolt First) Tighten Sequence (NO Grease or Oil!) 8 ft. lbs.

  • Page 63: Top End

    Apply 0W--40 to lifters. Pushrods Bushing Do not expansion plug install more than 1.5 mm inward. Expansion 1.5 mm Plug Cylinder Side View Piston Assembly Circlip UP for Install Gasket Hydraulic Lifter Apply Polaris 0W--40 oil. Apply Moly Lube Grease.
  • Page 64 ENGINE ENGINE EXPLODED VIEW OUTER COMPONENTS Screws 8 in. lbs. ± (9.5 0.9 Nm) ± Rocker Cover Breather O--ring Seal 5 in. lbs. ± Breather Bolts (2.5 0.55 Nm) ± Spark Plugs 24 in. lbs. ± (24.5 2.7 Nm) ± Carburetor Boot 24 in.

  • Page 65: Special Tools

    ENGINE SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION PV- -43527 Oil Filter Wrench 2200634 Valve Seat Reconditioning Kit PU- -45257 Valve Spring Compressor PU- -45652 Valve Pressure Hose 2871043 Flywheel Puller 2870390 Piston Support Block PU- -45497- -2 Cam Gear Tooth Alignment Tool PU- -45497- -1 Cam Gear Spring Installation Kit (Tapered Pins) PU- -45498...

  • Page 66: Torque Specifications

    ENGINE TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Size 600/700 600/700 in. Lbs. (Nm) ft.lbs. (Nm) Camshaft Gear 8 mm 22 ± 2 (30 ± 3) Camshaft Thrust Plate 6 mm 115-± 12 (13 ± 1.35) Carburetor Adaptor Bolts 8 mm 216 ± 24 (24.5-± 2.7) Counterbalance Gear 8 mm 22 ±...

  • Page 67: Engine Fastener Torque Patterns

    ENGINE ENGINE FASTENER TORQUE PATTERNS Tighten cylinder head/cylinder base, and crankcase fasteners in the following sequence outlined below. CRANKCASE BOLT TIGHTEN SEQUENCE 2 ft. lbs. ± 3 Nm) ± CYLINDER HEAD BOLT TIGHTEN SEQUENCE Lubricate threads and between washer and underside of bolt with engine oil. Torque in sequence to spec provided, allow the gasket to set for 1 minute, then tighten in sequence 90°...

  • Page 68: 600 Engine Service Data

    ENGINE 600 ENGINE SERVICE DATA Cylinder Head / Valve Engine No. - - EH059OLE Camshaft Cam lobe height In 1.3194” (33.5118 mm) 1.3194” (33.5118 mm) Camshaft journal OD 1.654” ± 0.00039” (42 ± 0.010 mm) Center 1.634” ± 0.00039” (41.50 ± 0.010 mm) 1.614”...
  • Page 69 ENGINE 600 ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod Engine No. - - EH590ALOE Cylinder Surface warpage limit (mating with cyl- 0.004” (0.10 mm) inder head) Cylinder bore 3.0118” (76.5mm) Taper limit 0.00031” (0.008 mm) Out of round limit 0.00030”...
  • Page 70 ENGINE 700 ENGINE SERVICE DATA Cylinder Head / Valve Engine No. - - EH68ALOE / EH068OLE Camshaft Cam lobe height In 1.3194” (33.5118 mm) 1.3194” (33.5118 mm) Camshaft journal OD 1.654” ± 0.00039” (42 ± 0.010 mm) Center 1.634” ± 0.00039” (41.50 ± 0.010 mm) 1.614”...
  • Page 71 ENGINE 700 ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod Engine No. - - EH68ALOE / EH068OLE Cylinder Surface warpage limit (mating with cyl- 0.004” (0.10 mm) inder head) Cylinder bore 3.1495” (80 mm) Taper limit 0.00031” (0.008 mm) Out of round limit 0.00030”...

  • Page 72: Cooling System Specifications

    2. The radiator cap relief pressure is 13 lbs. Replace reduce heat dissipation, resulting in possible engine cap if it does not meet this specification. damage. Polaris Premium 60/40 Antifreeze/Coolant is Upper Engine Hose recommended for use in all cooling systems and comes Surge Tank pre-mixed, ready to use.
  • Page 73 ENGINE ENGINE REMOVE & INSTALL 12. Disconnect the coolant hoses. Properly dispose of any antifreeze from the engine or hoses. 1. Clean work area. 13. Refer to PVT System Chapter 6 to remove outer clutch cover, drive belt, drive clutch, driven clutch, 2.

  • Page 74: Pvt System

    ENGINE INSTALLATION NOTES Engine Break In Period The break in period for a Polaris ATV engine is defined After the engine is installed in the frame, review this as the first ten hours of operation, or the time it takes checklist and perform all steps that apply: to use two full tanks of gasoline.
  • Page 75 Rinse thoroughly, dry with compressed air, A finished cylinder should have a cross-hatch pattern and oil the bore immediately with Polaris 4 Cycle to ensure piston ring seating and to aid in the retention Lubricant to prevent the formation of surface rust.

  • Page 76: Oil Flow

    ENGINE OIL FLOW This chart describes the flow of oil through the EH68 and the EH059 engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.

  • Page 77: Rocker Arm/Pushrod Inspection

    ENGINE ROCKER ARM INSPECTION 5. If the push rod (A) is visibly bent, it should be replaced. 1. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. CYLINDER HEAD REMOVAL 2. Inspect the wear pad at the valve end of the rocker arm for indications of scuffing or abnormal wear.

  • Page 78: Cylinder Head Warpage

    ENGINE CYLINDER HEAD INSPECTION WARNING 1. Thoroughly clean cylinder head surface to Wear eye protection or a face shield during remove all traces of gasket material and carbon. cylinder head disassembly and reassembly. CAUTION: Use care not to damage sealing surface. 1.
  • Page 79 ENGINE CYLINDER HEAD DISASSEMBLY, CONT. Valve Spring Length: NOTE: Carefully remove the cylinder components. Place the hydraulic lifters (C), pushrods (D), and Std: 1.827I (46.40 mm) rocker arms (E) in a safe, clean area. Installed Height: 1.47” (37.34 mm) 6. Remove valve guide seals. IMPORTANT: It is recommended to replace seals whenever the cylinder head is disassembled.

  • Page 80: Valve Inspection

    ENGINE VALVE INSPECTION Valve Stem Diameter: 1. Remove all carbon from valves with a soft wire Intake: 0.2356” ± 0.00039” wheel or brush. (5.985 ± 0.01 mm) 2. Check valve face for runout, pitting, and burnt Exhaust: 0.2346” ± 0.00039” spots.

  • Page 81: Combustion Chamber

    1. Install pilot into valve guide. VALVE SEAT RECONDITIONING Cylinder Head Reconditioning NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area. NOTE: The cylinder head valve guides cannot be replaced. WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly.
  • Page 82 ENGINE VALVE SEAT RECONDITIONING CONT’D If the seat is too narrow, widen using the 45° cutter and re-check contact If the contact area of the cutter is in point on the valve face and seat width the same place, the valve guide is after each cut.

  • Page 83: Cylinder Head Assembly

    ENGINE VALVE SEAT RECONDITIONING CONT”D 8. Clean all filings from the area with hot soapy water, rinse, and dry with compressed air. WARNING Wear eye protection or a face shield when working with compressed air during cylinder head disassembly and reassembly. 9.

  • Page 84: Valve Sealing Test

    ENGINE VALVE SEALING TEST 1. Clean and dry the combustion chamber area (A). Refer to Page 3.23 for cleaning tips. 2. Pour a small amount of clean solvent onto the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage.

  • Page 85: Engine Head Reassembly

    ENGINE ENGINE HEAD REASSEMBLY 4. Lubricate push rods (D) and install into lifters. Before reassembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts. 1. Install the head gasket (A) on the cylinder (B). 5.
  • Page 86 ENGINE ENGINE HEAD REASSEMBLY CONT’D 11. Install thermostat (J), O--ring, thermostat housing. Torque thermostat housing 8. Install breather reed (G) into rocker cover (H). bolts to 84 ± 8 in.lbs. (9.5 ± 0.9 Nm). Lightly apply black RTV sealant to the outer edges of the breather reed.

  • Page 87: Cylinder Removal

    ENGINE CYLINDER REMOVAL 4. Check the lifters for wear or scores. 5. Check the bottom end of lifter to make sure that it 1. Follow engine disassembly procedures to has a slight convex. remove rocker cover and cylinder head. 6. If the bottom surface has worn flat, it may be used with the original camshaft only.

  • Page 88: Cylinder Inspection

    ENGINE apply heat to the piston rings. The ring may lose b) Remove the expander. radial tension. 3. Remove top compression ring: *Using a piston ring pliers: Carefully expand ring and lift it off the piston. CAUTION: Do not expand the Compression Rings ring more than the amount necessary to remove it...
  • Page 89 ENGINE 1/2″ Down From Top of Cylinder Ill.2 Cylinder Warpage. 1/2″ Up From Bottom .004″ (0.1 mm) Max. 5. Record measurements. If cylinder is tapered or out of round beyond .002, the cylinder must be replaced. 3. Inspect cylinder for wear, scratches, or damage. Cylinder Taper Limit: .002I (.05mm)Max.
  • Page 90 ENGINE 2. Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance. 5 mm Piston Piston Pin Piston Pin Measurement Locations Piston to Cylinder Clearance 600: .0022” ± .00067” (.055 ± .017 mm) Piston Pin O.D. 700: .0016” ± .00063” (.041 ± .016 mm) 0.7874”...

  • Page 91: Piston Ring Installed Gap

    ENGINE Piston Ring Installed Gap Piston Top Ring: 0.01181” ± 0.00393” (0.30 ± 0.10 mm) Ring Second Ring Limit: 0.01476” ± 0.00492” (0.375 ± 0.125 mm) Oil Ring Limit: 0.00984” ± .00393” (0.25 ± 0.10 mm) Top Ring Limit: 0.01083” ± 0.00295” Feeler Gauge (0.275 ±...

  • Page 92: Starter Bendix Removal/Inspection

    ENGINE STARTER DRIVE/BENDIX 7. Inspect the bendix bushing (C) in the mag cover for wear. Replace as needed. REMOVAL/INSPECTION 1. Remove stator housing bolts and remove housing. 2. Remove the flywheel nut and washer. Install Flywheel Puller (PN 2871043) and remove flywheel.

  • Page 93: Flywheel/Stator Removal/Inspection

    ENGINE FLYWHEEL/STATOR REMOVAL/INSPECTION 2871043 1. Remove the recoil housing bolts on the Sportsman MV. Then remove the lower recoil housing and recoil pulley. Refer to the “RECOIL DISASSEMBLY/INSPECTION” section later in this chapter to disassemble the recoil. CAUTION: The recoil is under spring tension. A face shield and eye protection is required duing the procedure.
  • Page 94 ENGINE bolts to 96 ± 12 in.lbs. (10.85 ± 0.35 Nm). FLYWHEEL/STATOR INSTALLATION Sportsman MV Models 6. Install recoil pulley and 3 screws. Torque screws to 12 ± 1 ft. lbs. (16 ± 1.5 Nm). 7. Clean the areas of the lower recoil housing that have sealant on them before reinstallation.

  • Page 95: Engine Crankcase Disassembly/Inspection

    ENGINE ENGINE CRANKCASE DISASSEMBLY/INSPECTION 1. Remove the recoil housing bolts on the Sportsman MV. Then remove the lower recoil housing and recoil pulley. Refer to the “RECOIL DISASSEMBLY/INSPECTION” section later in this chapter to disassemble the recoil. CAUTION: The recoil is under spring tension. A face shield and eye protection is required duing the procedure.
  • Page 96 ENGINE Water Pump Gear Timing Marks 7. Remove the gear/stator housing bolts and remove the gear/stator housing cover (J) and gasket from the crankcase. Be sure to catch the excess oil from the crankcase. NOTE: If replacing one of the gears, it is recommended that all of the gears be replaced.
  • Page 97 ENGINE 11. Inspect the cam gear teeth and check to make sure there is spring tension offsetting the teeth between the two gears. If there is no tension, Accent the Timing Marks check the springs inside of the cam gear assembly.
  • Page 98 ENGINE Cam Gear Spring Installation Tool Kit: (PU- -45497) Tapered Pins: (PU- -45497- -1) Cam Gear Tooth Align Tool: (PU- -45497- -2) 19. Line up the two gears using the timing marks and the three gear tabs that were referenced earlier. Push the gears back together, using both hands PU- -45497- -1 and hold securely.
  • Page 99 ENGINE (R) to align the teeth of the cam gears, as shown balance shaft gear. in the picture. NOTE: Install the Cam Gear Alignment Tool (PU- -45497- -2) into one assembly hole counter 2871043 clockwise from the timing mark. PU- -45497- -2 24.
  • Page 100 ENGINE Oil Rotor Clearance 2871043 29. Use a feeler gauge to measure the clearance between the two rotors. Measure the gap between the two rotor tips as shown below. The clearance should not exceed 0.006” (0.15 mm). 0.006” (0.15 mm) Water/Oil Pump Removal/Disassembly Max Tip Clearance 27.
  • Page 101 ENGINE NOTE: Be sure to place the tapered end of the valve 34. Place the shaft in a press to remove the bearing. (dowel) in first. If the valve is installed incorrectly, oil pressure and oil priming problems will occur. DISASSEMBLY OF WATER/OIL PUMP SHAFT Bearing WARNING...
  • Page 102 ENGINE WATER/OIL PUMP REASSEMBLY CRANKCASE DISASSEMBLY CONT’D 35. Press new bearing onto the shaft. 38. Remove thrust plate (U). Bearing 36. Press the bearing/shaft assembly using the 39. Remove PTO end engine mount. Remove bearing’s outer race. Do not use the shaft to press crankcase bolts.

  • Page 103: Camshaft Inspection

    ENGINE CAMSHAFT INSPECTION 1. Thoroughly clean the cam shaft. 2. Visually inspect each cam lobe for wear, chafing or damage. 41. Remove balance shaft and crankshaft. Lobe height 3. Measure height of each cam lobe using a micrometer. Compare to specifications. Cam Lobe Height (Intake &...

  • Page 104: Engine Crankcase Assembly

    ENGINE 1. Install oil pick up (A), if removed. Torque bolt to 60 ± 6 in. lbs. (6.8 ± 0.68 Nm). Camshaft Journal O.D. : A. (Mag): 1.654” ± .00039” (42 ± .010 mm) B. (Ctr.): 1.634” ± .00039” (41.50 ± .010 mm) C.
  • Page 105 ENGINE 4. Apply Moly Lube Grease to cam journals and 7. Assemble the crankcase halves. Apply LocTitet balance shaft bearing surfaces of the MAG case 242 (PN 2871949)to the threads and pipe sealant halve. Install cam and balance shafts. to the bolt flanges. Torque bolts to 22 ± 2 ft. lbs. (30 ±...
  • Page 106 ENGINE 10. Lubricate connecting rods with 0W--40 engine oil. 13. Install piston assemblies into cylinder aligning the piston pin holes, to ensure proper alignment of the pistons to the connecting rods upon assembly. Partially install the piston pins into the pistons. Cylinder Installation 11.
  • Page 107 ENGINE NOTE: While installing in piston pins, cover all engine passages. The clip could fall into the engine during installation. Line Up Marks 18. Apply moly lube, lubriplate, or oil to the rotors on the oil pump shaft. NOTE: The application of oil or lubriplate aids in priming the oil pump during initial engine start up.
  • Page 108 ENGINE debris. This will ensure proper sealing when installing bolts and new Loctitet. 20. Install oil pump housing bolts (H). The new bolts contain patch lock, so Loctitet is not needed on the new bolts. Torque bolts to 84 ± 8 in.lbs. (9.50 ± 0.90 Nm) and follow the torque sequence on Pg.
  • Page 109 ENGINE (PU- -45838). Torque to 22 ± 2 ft. lbs.(30 ± 3 Nm). PU- -45498 PU- -45838 27. Reinstall the camshaft gear; so the timing marks are properly aligned. Install the washer and bolt. Balance Shaft Gear Bolt Torque: Torque to 22 ± 2 ft. lbs.(30 ± 3 Nm). 22 ±...
  • Page 110 ENGINE (no lubricant) during assembly. Use of lubricants (oil, soapy water, etc.) will not allow the seal to PU- -45543 wear- -in and seal properly. Do not touch seal surface or allow seal surface to come in contact with contaminates during installation.
  • Page 111 ENGINE Important: Set PA- -45401 the direction of the paper seal lip PA- -45658 31. Carefully install the tapered end of the 33. Install the new gasket to the gear/stator housing Crankshaft Seal Protection Tool (PA- -45658) cover and crankcase. With the tools installed, through the paper side of the crankshaft seal.
  • Page 112 ENGINE Gear/Stator Housing Bolt Torque: 96 ± 12 in. lbs. (10.85 ± 0.35 Nm) *Torque in Proper Sequence (Pg. 3.3) NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts.
  • Page 113 ENGINE 39. Install water pump cover (R) with new O-ring seal. NOTE: Be sure the stator wires are routed properly Torque bolts to 96 ± 12 in. lbs. (10.85 ± 0.35 Nm) under the wire hold down bracket. in proper sequence (See Pg. 3.4). Replace 2 bolts with new bolts Install Dry Do not use lubricants or...
  • Page 114 Oil System Priming Adapter (PU- -45778) into the 16 ± 2 ft. lbs. Housing (22 ± 2.7 Nm) oil plug hole. Push 3--5 oz. (approx.) of Polaris 2 Screws 0W--40 into the adapter until resistance is felt. Remove the adapter. Apply pipe dope or Teflon 16 ±...
  • Page 115 ENGINE RECOIL INSPECTION CAUTION: The recoil is under spring tension. A face shield and eye protection is required during this procedure. Replace any parts found to be worn or damaged. 1. Pull recoil rope so it is extended approximately 12-18″. 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 rope.

  • Page 116: Troubleshooting

    ENGINE TROUBLESHOOTING Spark Plug Fouling Spark plug cap loose or faulty Engine flooded Low compression (high cylinder Choke cable adjustment or leakage) plunger/cable sticking No spark (Spark plug fouled) Foreign material on choke plunger ignition component failure seat or plunger Engine Does Not Turn Over Incorrect spark plug heat range or Dead battery...
  • Page 117 ENGINE TROUBLESHOOTING, CONT Valve sticking Air leaks in intake Piston Failure - Scoring Lean condition Lack of lubrication COOLING SYSTEM Dirt entering engine through cracks in air filter or ducts TROUBLESHOOTING Engine oil dirty or contaminated Overheating Excessive Smoke and Carbon Buildup Low coolant level Excessive piston-to-cylinder clearance...
  • Page 118 3. Always add coolant to the radiator first, filling to the top of the neck to replace air that has been purged from the system. Polaris Premium Antifreeze Fill the reservoir only after you have completely filled the cool- 2871534 Quart ing system at the radiator filler neck.
  • Page 119 FUEL SYSTEM / CARBURETION Exploded View, Mikuni BST 34 Carburetor . . . Fuel Tank Asm. Exploded View ... . Fuel Flow Diagram ..... . . Special Tool &...
  • Page 120 FUEL SYSTEM / CARBURETION BST 34 CARBURETOR EXPLODED VIEW 1. Ring 2. E--Ring Torque 3. Jet Needle Specifications 4. Ring 5. Diaphragm 11. 16 in.lbs. (1.8 Nm) 6. Needle Jet 20. 18 in.lbs. 7. Screw (2 Nm) 8. Spring Washer 22.
  • Page 121 FUEL SYSTEM / CARBURETION FUEL TANK ASSEMBLY To Headlight Pod Fuel Valve Vent Line Knob Brackets 3-- Way Valve Foam Fuel Lines Fuel Sender Foil Gasket Tank Fuel Fitting Front Fuel Rear Fuel Tank Vent Tank Vent Fuel Cap Rear Gas Tank Gas Tank Foil Vent Tank...

  • Page 122: Fuel Flow Diagram

    FUEL SYSTEM / CARBURETION FUEL FLOW FUEL FLOW Fuel Tanks Fuel Tank Vent Fitting Screens Fuel Pump Filter Fuel Valve Carburetor Vent Engine Carburetor L Located Above Oil Tank NOTE: See Chapter 2 “FUEL TANKS AND FUEL VALVE” for more information on proper usage. Fuel Flow Diagram Rear Fuel Tank REAR...

  • Page 123: Carburetor Jetting

    3130571 dense with reduced oxygen. 157.5 3130572 3131141 Polaris ATV Carburetors are calibrated for an altitude 162.5 3131142 0-6000 ft. (0-1800 meters) and ambient 3131143 temperatures between +40 and +80° F (+5° to +26°...

  • Page 124: Cv Carburetor System Function (4 Cycle)

    FUEL SYSTEM / CARBURETION CV CARBURETOR SYSTEM VENT SYSTEMS - CV FUNCTION CARBURETOR The carburetor float bowl vent lines supply atmospheric pressure to the float bowl. The lines Carburetor Component Function must be free of kinks, restrictions and be properly System Main Main...
  • Page 125 FUEL SYSTEM / CARBURETION CARBURETOR OPERATION CONT’D When the throttle plate is opened and engine speed begins to increase, the pressure in the venturi (and therefore in the chamber above the diaphragm) becomes significantly lower than atmospheric. Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward, raising the slide against spring pressure.

  • Page 126: Float System

    FUEL SYSTEM / CARBURETION FLOAT SYSTEM Fuel enters the float chamber (3) by means of the inlet pipe and passage, through a screen on the back of the inlet needle seat (4), and around the inlet needle (2). As the fuel fills the float chamber, the float (1) rises and forces the inlet needle against the seat, shutting off the orifice in the seat.
  • Page 127 FUEL SYSTEM / CARBURETION PILOT SCREW may be permanently damaged. The pilot system supplies fuel during engine operation with the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet. CAUTION: The pilot screw is calibrated at the factory to meet EPA / CARB regulations for air quality standards and is sealed with a brass...

  • Page 128: Carburetor Inspection

    FUEL SYSTEM / CARBURETION installed over the pilot screw cavity, it must be 1. Thoroughly clean the carburetor body, jets, and removed for access. all passages with carburetor cleaner or electrical contact cleaner. 2. If carburetor extremely dirty contaminated with fuel residue and varnish, soak for short periods only in carburetor cleaner, and rinse in hot water.

  • Page 129: Carburetor Assembly

    FUEL SYSTEM / CARBURETION pressure tested after assembly. Worn, Deposits Good Condition Seat Wear areas Needle CARBURETOR ASSEMBLY NOTE: Refer to the exploded view of the BST 34 3. Replace parts in proper order. The spring seat Carburetor at the beginning of this chapter for torque washer (B) is stepped and must be placed on specifications.

  • Page 130: Needle & Seat Leakage Test

    FUEL SYSTEM / CARBURETION CARBURETOR ASSEMBLY CONT’D 3. If adjustment is necessary, bend the tongue slightly. Be sure float measurement is even on left 5. Install the pilot mixture screw, spring, washer, and and right side. O-ring as an assembly. Lubricate the O-Ring with oil or light grease before installation.

  • Page 131: Fuel Level

    Remove the valve and wash with soap and water. Carburetor cleaner may be The Polaris Sportsman 600/700 is equipped with a used to clean the pump body when the check pressure regulated fuel pump (1-3 PSI). The pump is valves are removed.

  • Page 132: Fuel Sender Service

    FUEL SYSTEM / CARBURETION FUEL SENDER REMOVAL/INSTALL Fuel Sender Removal 1. Disconnect the negative battery cable. 2. Remove the side panels and front cab assembly. Refer to “COVER PANEL REMOVAL” in Chapter 5 for details. 3. Remove the gas tank cover vent hose. Be sure to properly route the vent hose upon reassembly.
  • Page 133 FUEL SYSTEM / CARBURETION TROUBLESHOOTING Loose jets Worn jet needle/needle jet or other FUEL STARVATION/LEAN MIXTURE carburetor parts Dirty carburetor (air bleed Symptoms: Hard start or no start, bog, backfire, passages or jets) popping through intake / exhaust, hesitation, Weak or damaged vacuum piston detonation, low power, spark plug erosion, engine return spring runs hot, surging, high idle, idle speed erratic.
  • Page 134 FUEL SYSTEM / CARBURETION NOTES 4.16...
  • Page 135 BODY / STEERING / SUSPENSION Torque Specifications and Special Tools ..Plastic Insert Removal/Install ....5.2--5.3 Side Panel Removal .

  • Page 136: Plastic Insert Removal/Install

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

  • Page 137: Side Panel Removal

    BODY / STEERING / SUSPENSION SIDE PANEL REMOVAL 2. Next, use the diagonal side cutters under outside insert (B) to completely remove the assembly. Side panel removal is quick and easy, use the NOTE: The inside insert (A) will still be installed in following instructions for removal and installation.

  • Page 138: Front Cover Removal/Install

    BODY / STEERING / SUSPENSION FRONT COVER REMOVAL / PLASTIC FOOT WELL INSTALLATION REMOVAL / INSTALLATION 1. Remove the front cover shield screws (A) (2 1. Remove the four plastic inserts (A) that secure philiips screws), if needed. the wheel well to the front and rear cabs. (See “PLASTIC INSERT REMOVAL...
  • Page 139 BODY / STEERING / SUSPENSION 4. Remove the footwell from the front and rear Front Tube to Front Rack plastic cabs. Reassembly: 14--16 ft.lbs (19--22 Nm) Rear Tube to Rear Rack 5. Reverse the removal procedures to install the foot well.

  • Page 140: Front Rack/Brushguard Removal/Install

    BODY / STEERING / SUSPENSION FRONT RACK 5. Remove the two T--27 torx screws (C) on the top of the rack. REMOVAL/INSTALL Reassembly: 14--16 ft.lbs. (19--22 Nm) 1. Remove the T--27 torx screws (A) on the front of the rack. 2.
  • Page 141 BODY / STEERING / SUSPENSION FRONT BRUSHGAURD 5. Remove the bolts (B) that secure the bottom of the front brushguard to the brushguard mount. REMOVAL/INSTALL 1. With the front top rack removed, remove the bolts (A) that secure the front brushgaurd to the main frame (each side).
  • Page 142 BODY / STEERING / SUSPENSION REAR RACK & GAS TANK REMOVAL/INSTALL Reassembly: 14--16 ft.lbs. (19--22 Nm) NOTE: The rear rack and rear brush guard maybe removed as one piece. Refer to the REAR BRUSHGUARD REMOVAL/INSTALL“ after this section. 1. Remove the T--27 screws (A) that secure the rear rack to the rear frame extension.

  • Page 143: Rear Rack/Brushguard Removal/Install

    BODY / STEERING / SUSPENSION 8. The rear gas tank is now accessible for removal. Rear Top Rack Installed Remove the the bolt at the front of the tank that 1. If the rear top rack is installed; first remove the secures the tank to the frame.

  • Page 144: Warn ® Winch Removal/Installation

    BODY / STEERING / SUSPENSION 5. Remove the T--27 screws (C) that secure the side tube supports to the rear rack (each side). Top View with Top Rack Removed Reassembly: 14--16 ft.lbs. (19--22 Nm) 3. Remove the hook from the winch cable. 6.
  • Page 145 BODY / STEERING / SUSPENSION WARN WINCH /CONTACTOR REAR WARN® WINCH ® 6. Disconnect the negative battery cable. LOCATION 7. Disconnect wires (D) from the Warn® winch. Both the front and rear winch contactor are located under the left rear fender. Winch Contactors 8.
  • Page 146 BODY / STEERING / SUSPENSION WARN WINCH SWITCH ® INSTALLATION 1. Remove the front (A) and rear (B) bolts from the master cylinder clamp. Be careful not to lose the spacers (C). 2. Rotate the winch mini--rocker switch upward and mount as shown.

  • Page 147: Headlight Pod Exploded View

    BODY / STEERING / SUSPENSION HEADLIGHT POD EXPLODED VIEW Controls Winch Selection Switch Instrument Cluster Brake Clean knurling when repositioning handlebars Disassembly S Remove two side Phillips screws (A). S Remove one rear Phillips screw (B). S Lift top half of pod. S Disconnect instrument cluster wire connectors.

  • Page 148: Handlebar Block Installation Procedure

    BODY / STEERING / SUSPENSION HANDLEBAR BLOCK INSTALLATION PROCEDURE 1. The pin (A) on the bottom side of the top handlebar block faces down and to the front of the ATV. 2. The bottom handle bar block has a side with 3 holes, the side with 3 holes faces up and to the front of the ATV. 3.

  • Page 149: Body Assembly Exploded View

    BODY / STEERING / SUSPENSION BODY ASSEMBLY EXPLODED VIEW Pull UP on rear of seat and back to disengage tabs at front of seat Rear Cab Assembly Seat Seat Latch Release Seat Latch Rear Cab Foot Well Support Brace Foot Well Frame Front Cab Assembly Side Cover...
  • Page 150 BODY / STEERING / SUSPENSION BODY RACK & BUMPER EXPLODED VIEW A. Front Rack (Platform) B. Corner Support Bracket C. Rubber Bumper D. Side Vent E. Headlight F. Front Brushguard G. Access Door H. Front Rack Support I. Front Brush Guard Mount J.
  • Page 151 BODY / STEERING / SUSPENSION BODY / RACK EXPLODED VIEW REAR RACK / GUARD A. Rear Rack B. Rear Brush Guard C. Rear Platform Mount D. Warn® Winch E. Corner Bracket F. Storage Container RACKS / FOOT WELL ASSY. A. Rear Rack B.
  • Page 152 BODY / STEERING / SUSPENSION STEERING/A- -ARM EXPLODED VIEW NOTE: To avoid damage to tie rods and other steering components, be sure to install tie rod end bolts in the proper direction. The steering post arm bolt (B) points up; 25-30 ft.

  • Page 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.

  • Page 154: Rear Suspension Assembly

    BODY / STEERING / SUSPENSION REAR SUSPENSION ASSEMBLY 17 ft. lbs. (24 Nm) 17 ft. lbs. (24 Nm) Stabilizer Support 35 ft. lbs. (48 Nm) 35 ft. lbs. (48 Nm) 30 ft. lbs. (41 Nm) 35 ft. lbs. (48 Nm) Upper Control Bushings Rear Shock...

  • Page 155: Strut Assembly

    BODY / STEERING / SUSPENSION STRUT ASSEMBLY 15 ft. lbs. (21 Nm) Strut Bumper Spacer Rubber Washer Upper Pivot Ball Strut Washer Clamp 18 ft. lbs. Spacer (25 Nm) 15 ft. lbs. Bolt Lower Pivot Ball (21 Nm) Spring Retainer Lubrication Fitting Spring Hubstrut Bearing...

  • Page 156: Front Strut Cartridge Replacement

    BODY / STEERING / SUSPENSION FRONT STRUT CARTRIDGE 3. Remove wheel nuts and wheels. REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5.21 1. Hold strut rod and remove top nut. 2. Remove upper strut pivot assembly. Strut Rod Wrench (PN 2871572) Strut Spring Compressor Tools (PN 2871573) and (PN 2871574) 4.

  • Page 157: Steering Post Assembly

    BODY / STEERING / SUSPENSION To flame treat the decal area: 1. Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appears slightly glossy. This should occur after just a few seconds of flame treating.
  • Page 158 BODY / STEERING / SUSPENSION NOTES 5.24...
  • Page 159 CLUTCH Drive Clutch Exploded View ....PVT Sealing and Ducting Components ..Special Tools, Supplies & Torques ..PVT Operation Overview .

  • Page 160: Drive Clutch Exploded View

    CLUTCH DRIVE CLUTCH EXPLODED VIEW Mark with permanent marker before disassembly One way clutch EBS Drive Clutch PVT SEALING AND DUCTING COMPONENTS Clutch Inlet Duct Transmission Cover Seal Inner Clutch Cover Clamps Boot Duct Clutch Cover Seal Inner Cover Seal Seal Retainer Bracket Drain Plug...

  • Page 161: Pvt Operation Overview

    2871226 control engagement (initial vehicle movement), clutch Replacement Tool upshift and backshift. During the development of a Polaris ATV, the PVT system is matched first to the Piston Pin Puller 2870386 engine power curve; then to average riding conditions EBS Clutch 2872292 and the vehicle’s intended usage.

  • Page 162: Pvt Drying

    CLUTCH DRIVEN CLUTCH OPERATION CONT’D air ducts, as well as the inner and outer covers, must be properly sealed to ensure clean air is As engine RPM and horsepower increase, the load being used for cooling the PVT system. This also from the drive belt increases, resulting in the belt will prevent water and other contaminants from rotating up toward the outer diameter of the drive...

  • Page 163: Pvt Overheating/Diagnosis

    10 seconds. PVT seals should be inspected for damage if repeated leaking occurs. Clutch malfunction. Inspection/repair of clutch components should be performed by a certified Polaris MSD techinician.

  • Page 164: Pvt Cover Removal/Install

    CLUTCH PVT COVER REMOVAL/INSTALL 1. Refer to the “PLASTIC FOOT WELL REMOVAL / INSTALLATION“ in Chapter 5 for removal procedure to gain access to the PVT cover. 2. The PVT cover should now be accessible. If necessary remove the rear right cab assembly. Remove the three plastic inserts that secure the rear cab to the frame.

  • Page 165: Pvt Disassembly

    CLUTCH PVT DISASSEMBLY NOTE: Some fasteners and procedures will vary. Driven Clutch Puller (PN 2870913) Refer to the appropriate parts manual for proper fasteners and fastener placement. 1. Remove seat. 2. Remove or loosen rear cab fasteners as 8. Remove driven clutch offset spacers from the necessary to gain access to PVT outer cover.

  • Page 166: Pvt Assembly/Inspection

    CLUTCH PVT ASSEMBLY/INSPECTION 7. Install clutch offset spacer(s) on transmission input shaft. 1. Inspect PVT inner cover-to-engine seal. Replace if cracked or damaged. Align the alignment mark on the cover with the mark on the engine seal. Seal this edge to cover on engine side Offset Spacer 8.

  • Page 167: Drive Clutch Spring Specifications

    CLUTCH DRIVE CLUTCH SPRING SPECIFICATIONS NEUTRAL The drive clutch spring has two FULL UPSHIFT primary functions: ATV TRAVEL 1. Controls clutch engagement RPM. The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM. 2.

  • Page 168: Shift Weights /Inspection

    CLUTCH SHIFT WEIGHTS Shown below are optional shift weights which may be used in the PVT system. These shift weights have many different factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding the effects they have on belt to sheave clearance, clutch balance, engagement and shifting characteristics.

  • Page 169: Shift Weight Inspection

    Never replace parts with used parts from another clutch assembly! All PVT maintenance or repairs should be performed only by a certified Polaris Master Service Dealer (MSD) technician who has received the proper training and understands the procedures outlined in this manual.
  • Page 170 CLUTCH SPIDER REMOVAL DRIVE CLUTCH DISASSEMBLY CONT’D 2. Remove cover bolts evenly in a cross pattern and 1. Remove the limiter nut using the Clutch Spider remove cover plate. Nut Socket (PN 2870338). Install clutch in 3. Inspect cover bushing (A). The outer cover holding fixture...

  • Page 171: Drive Clutch Reassembly

    CLUTCH Moveable Sheave Bushing Inspection button is positioned toward the solid roller pin. It is recommended to switch all buttons to the rubber 2. Inspect the Teflont coating on the moveable version during service (if needed). sheave bushing. Moveable Sheave Bushing Inspection: DRIVE CLUTCH REASSEMBLY Replace the cover bushing if more brass than Teflont is visible on the bushing.

  • Page 172: Drive Belt Removal/Inspection

    CLUTCH DRIVE CLUTCH REASSEMBLY CONT’D 7. Reinstall cover, aligning bosses on the tower and cover. Torque cover bolts evenly to specification 2. Install moveable sheave onto fixed sheave. 3. Compress spider buttons for each tower and install spider, making sure that “X”, or the marks that were made earlier, on spider aligns with “X”, or the marks that were made earlier on the moveable sheave.
  • Page 173 CLUTCH Place a straight edge on each side of the drive belt. Place another straight edge on top of belt. Measure the distance where the side straight edges intersect the top, as shown in the illustration. Projected Belt Width Belt Width: New 1.174 - 1.188″...

  • Page 174: Drive Belt Installation

    CLUTCH end of this chapter for possible causes. Offset Alignment Tool (PN 2872292) - EBS 1/8I +0 / -- 1/16 Center 3.2mm +0 / -- 1.6 mm) Distance Clutch Center Distance - 10″ +.1 / -.05 (254 +2.5 / -1.3mm) Belt Nominal Length - 40.875″±...

  • Page 175: Clutch Offset

    CLUTCH shaft without slipping. If problems are noted in either direction, continue with disassembly. Shim Kit (PN 2200126) CLUTCH OFFSET Important: Inspect clutch alignment and center distance before adjusting offset. Offset is correct when rear of tool contacts rear of inner sheave with driven clutch pushed completely inward on shaft and bolt torqued.

  • Page 176: Moveable Sheave Bushing Inspection

    CLUTCH MOVEABLE SHEAVE noted. BUSHING INSPECTION 1. Inspect the Teflont coating on the moveable sheave bushing. Inspect BOTH sheaves for signs of wear, grooving or cracking. Clean surfaces with a 3Mt pad if needed Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflont is visible on the bushing.

  • Page 177: Driven Clutch Disassembly/Assembly

    CLUTCH SPORTSMAN 700 EBS 1. Remove driven clutch from the transmission input shaft. Do not attempt disassembly of the driven DRIVEN CLUTCH clutch from the outside snap ring. The driven DISASSEMBLY/INSPECTION - clutch must be disassembled from the helix side. EBS Driven Clutch Operation This EBS driven clutch provides the same engine braking abilities as the earlier EBS driven clutch.
  • Page 178 CLUTCH inward. Remove snap ring (A). Press Down on Spider 7. Remove the E--clip (F), washer (G), and the 5. Remove the spider assembly, spring (B), and clutch rollers (H). Inspect the rollers for wear spacer washer (C). NOTE: The spring is a replace if worn.
  • Page 179 CLUTCH CLUTCH ROLLER REMOVAL 9. Press out the spring pins (K) in the inner sheave. Press Shaft/Bearing Out 10. Pull out the clutch roller pins (L) and rollers (M). Inspect Bearing 12. Inspect the bearing for wear. Spin the bearing, if the bearing does not spin smoothly replace as needed.
  • Page 180 CLUTCH EBS DRIVEN CLUTCH 4. Line up the “X” on the moveable sheave with the “X” on the stationary sheave or use the marks REASSEMBLY previously used. Put the sheaves together. 1. Press the bearing onto the output shaft using a press.
  • Page 181 CLUTCH 6. Install the roller pin into the sheave assembly. 9. Install the spring over the shaft. (Both sides). The flat side of the roller pin faces downward when the shaft side is laying flat on the bench. Install Spring Flat Side of Roller 10.
  • Page 182 CLUTCH 13. Press down on the top of the spider assembly, 15. Install the cam assembly (helix) over the shaft. pushing the spider onto the shaft. Align the marks Line up the “X” on the cam, “X” on spider, and “X” on the spider with the skip tooth on the shaft.
  • Page 183 CLUTCH EBS DRIVEN CLUTCH EXPLODED VIEW 1. Torx Screw 2. Cam Assembly 3. Retaining Ring 4. E--clip 5. Washer 6. Roller 7. Outer Spider 8. Spring 9. Shaft 10. Thrust Washer 11. Moveable Sheave 12. Roller Pin 13. Spring Pin 14.

  • Page 184: Removal And Installation

    CLUTCH EBS DRIVE BUSHING 6. With towers pointing toward the vise, slide sheave onto puller rod. SERVICE 7. Install removal tool (Item A/B) into center of sheave with “A side” toward sheave. EBS CLUTCH BUSHING REMOVAL AND 8. Install nut (C) onto end of puller rod and hand INSTALLATION (Use Tool Kit PN 2201379) tighten.

  • Page 185: Troubleshooting

    CLUTCH EBS Drive Clutch Cover Bushing Removal 5. Install nut onto puller rod and hand tighten. Turn puller barrel to increase tension as needed. 1. Install main adapter (Item 8) on puller. 6. Turn clutch cover counterclockwise on puller rod until bushing is removed and cover comes free.
  • Page 186 CLUTCH Engine RPM -Incorrect drive clutch spring (too high -Install correct recommended spring. above specified spring rate). operating range. -Drive clutch shift weights incorrect for ap- -Install correct recommended shift weights. plication (too light). -Drive clutch binding. -Disassemble and clean clutch, inspecting shift weights and rollers.

  • Page 187: Final Drive

    FINAL DRIVE Final Drive Torque Specifications ..AWD Front Axle Remove/Install ..7.2-7.3 AWD Front CV Joint Boot Replace..7.4-7.5 AWD Front Drive Axle Exploded View 7.15 Front Hub Disass./Assemble .
  • Page 188 FINAL DRIVE WHEEL AND HUB TORQUE TABLE COMPONENT FT. LBS. (IN.LBS.) Front/Rear Wheel Nuts Front Hub Nut Rear Hub Nut CAUTION: Locking nuts, and bolts with preapplied locking agent should be replaced if removed. The self-locking properties of the nut or bolt are reduced 8.
  • Page 189 FINAL DRIVE 10. Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly. New Cotter Key Front Hub Retaining Nut Torque 70 ft. lbs. (95 Nm) 11. With short, sharp jerks, remove drive shaft from front gearcase.
  • Page 190 FINAL DRIVE FRONT DRIVE SHAFT CV JOINT BOOT REPLACEMENT Retaining ring 1. Remove wheel, brake caliper and wheel hub. Refer to Front Drive Axle Removal Page 7.2 for procedure. 2. Remove cotter pin and castle nut from A-arm ball joint. Pull shaft to remove from CV joint 7.

  • Page 191: Front Hub Assembly

    FINAL DRIVE BE TAKEN TO AVOID DAMAGE TO THE NEWLY INSTALLED BOOT. NOTE: Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be 13. Install the small clamp on the boot. removed.
  • Page 192 FINAL DRIVE FRONT PROP SHAFT NOTE: If yoke or bearing is removed, cross bearing must be replaced. Note orientation of grease fitting REMOVAL and mark inner and outer yoke for correct re-positioning during installation. 1. Using Roll Pin Removal Tool (PN 2872608), remove the roll pin from prop shaft at rear of housing.
  • Page 193 FINAL DRIVE 4. Force U-joint cross to one side and lift out of inner yoke. U-JOINT ASSEMBLY 4. Install outer yoke, aligning marks made before disassembly. 5. Repeat Steps 1-3 to install bearing caps on outer yoke. 1. Install new bearing caps in yoke by hand. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft.

  • Page 194: Awd Front Drive Axle Exploded View

    FINAL DRIVE AWD FRONT DRIVE AXLE EXPLODED VIEW NOTE: Refer to your parts manual for the proper replacement parts. Front Drive Axle Components Inner CV Joint Inner Boot Circlip Circlip Outer Boot Circlip Outer CV Joint Clamp Front Drive Boot Replacement Kits Inner Clamp 3.5 oz.
  • Page 195 FINAL DRIVE FRONT GEARCASE in True All Wheel Drive. OPERATION - - CENTRALIZED CAUTION: If the rear wheels are spinning, release the throttle before turning the AWD switch on. If AWD HILLIARD) is engaged while the wheels are spinning, severe drive shaft and clutch damage could result.
  • Page 196 FINAL DRIVE with a piece of wire. 9. Pull both driveshafts from the front gearcase. Replace the circlip on the driveshaft end for reassembly. 10. Remove the roller pin from the front prop shaft. Use the Roller Pin Removal Tool (PN 2872608). 11.
  • Page 197 FINAL DRIVE Gearcase Coil Resistance NOTE: To test the gearcase coils resistance, use the coil harness. The gearcase coils should measure between 22.8 ohms and 25.2 ohms. 3. Remove output shaft assembly. 8. Inspect roll cage (B) sliding surface. This surface must be clean and free of nicks, burrs or scratches.
  • Page 198 FINAL DRIVE 10. Remove the spacer washer (D), armature plate (E), and rubber O--ring from the output cover. O--ring 13. Inspect the magnetic coil (I) in the output housing. NOTE: See “FRONT GEARCASE DIAGNOSIS” 11. Inspect the armature plate (E) for a consistent later in this chapter for more details on the coil.
  • Page 199 FINAL DRIVE 18. Remove and replace the O--rings and seals from the assembly. 16. Remove the input cover (M), bearing (N), and the FRONT GEARCASE pinion gear (O). Inspect the pinion gear (O) for chipped, broken, or missing teeth. Replace the REASSEMBLY/INSPECTION input cover O--ring.
  • Page 200 FINAL DRIVE 5. Install the output hub (A) into the gearcase housing. The output hub should spin freely. 9. Install the ring gear onto the output hub on the output cover. 6. Install the other output hub (B) and thrust bearing (C) into the output cover.
  • Page 201 FINAL DRIVE Cover Bolts Torque 14 ft. lbs. (19 Nm) 13. Install new seals into the gearcase housing and gearcase housing cover. Back Lash Pad (Thrust Pad) Adjustment 14. Lay the gearcase on the side with the output cover facing up. 15.
  • Page 202 FINAL DRIVE band of wear is present (or if there is wear between the two bands, inspect the coil area as indicated in Step 4. A band with an interrupted wear mark may indicate a warped plate, which may cause intermittent operation. See Illustration Armature Plate 19.
  • Page 203 FINAL DRIVE 3233952). Gearcase Cover Coil New Roller Pin U--shaped insert 3. Add the proper lubricant to the front gearcase. Check drain plug for proper torque. Refer to Chapter 2 for fluid fill and change information. Side Cutaway View of Centralized Hilliard Cover 5.
  • Page 204 FINAL DRIVE FRONT GEARCASE - - CENTRALIZED HILLIARD EXPLODED VIEW Ref. Qty. Description Ref. Qty. Description 1 Asm., Mid Gearcase 1 O- - Ring 1 Cover, Output 1 Seal 1 O- - Ring 11 Kit, Bolt 1 Insert 1 Cover, Input 1 Coil 1 Bearing, Roller Ball 1 Kit, Shim Set (Incl.
  • Page 205 FINAL DRIVE REAR HUB REMOVAL 8. Remove hub nut, domed washer and flat washer. 1. Place the ATV in Park and lock the parking brake. Remove rear hub cap. 9. Remove hub. 2. Remove cotter pin. 3. Loosen the hub retaining nut. 4.

  • Page 206: Rear Hub Installation

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

  • Page 207: Rear Hub Disassembly/Assembly

    FINAL DRIVE REAR HUB DISASSEMBLY REAR HUB ASSEMBLY 1. Support bottom of bearing carrier housing. 1. Remove outer snap ring. 2. Start bearing in housing. 2. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown. 3.

  • Page 208: Rear Drive Shaft Removal

    FINAL DRIVE CAUTION: Use an arbor press only on the outer race, as bearing damage may occur. 4. Install snap ring into groove. REAR DRIVE SHAFT REMOVAL 1. Remove rear hub and bearing carrier. (See Pages 7.19). 2. Tip hub outward and remove shaft from hub. 3.

  • Page 209: Rear Driveshaft Installation

    FINAL DRIVE DRIVESHAFT AND CV JOINT 2. Apply anti-seize compound to splines of shaft. 3. Install a new lock ring and install the shaft. HANDLING TIPS 4. Lift bearing carrier into place and install bolt to upper control arm. Torque bolt to 35 ft. lbs. (48 Care should be exercised during driveshaft removal Nm).

  • Page 210: Rear Driveshaft Service

    FINAL DRIVE REAR DRIVE SHAFT SERVICE Spread ends of snap ring to remove joint from shaft 1. Remove clamps from rubber boot(s) using the CV Boot Clamp Pliers (PN 8700226) (A). Tap CV Housing Off Shaft 4. Place a new snap ring in the groove of the CV joint inner hub, with tabs facing the shaft as shown.
  • Page 211 FINAL DRIVE (Boot Replacement) 5. Refit CV joint on interconnecting shaft by tapping with a plastic hammer on the joint housing. Take 1. Remove CV joint from end of shaft. care not to damage threads on the outboard CV joint. The joint is fully assembled when the snap 2.

  • Page 212: Rear Gearcase Service

    FINAL DRIVE (BOOT INSTALLATION) Joint Capacity Joint Capacity 5. Slide the new clamp and boot (small end first) 50 Grams 50 Grams over the splined shaft, then slide (tap) the CV joint into the splines of the axle. 6. Add grease through large end of boot. 7.
  • Page 213 FINAL DRIVE 3. Remove the shim, thrust button, and thrust button 5. Inspect the ring gear for abnormal wear, broken, shim from the gearcase. or chipped teeth. Spin the bearing to check the ball bearings for smoothness. Replace the bearing if needed. 6.
  • Page 214 FINAL DRIVE REAR GEARCASE 3. Install the pinion shaft into the gearcase housing. Install the pinion shaft cover and torque the cover REASSEMBLY bolts to 25 ft. lbs. (34 Nm). 1. Inspect the pinion shaft bushing for wear. Pinion Shaft Cover Bolt Torque: 25 ft.

  • Page 215: Rear Gearcase Installation

    FINAL DRIVE REAR GEARCASE 5. Apply Crankcase Sealant (PN 2871557) to surface of case and install cover bolts. Install the INSTALLATION gearcase cover onto the gearcase housing. Torque the cover bolts to 25 ft. lbs. in a criss cross 1. To install the rear gearcase, reverse the removal pattern.
  • Page 216 FINAL DRIVE REAR GEARCASE EXPLODED VIEW Ref. Qty. Description Ref. Qty. Description 1 Asm., Rear Gearcase 1 10T Pinion Shaft 1 Cover, Output, LH 1 Ball Bearing 8 Screw 1 O- - ring 1 Tube Vent 1 Cover, Input 2 Washer 1 Seall 2 Plug 1 Rear Gearcase Housing...
  • Page 217 TRANSMISSION Transmission, Exploded View ....8.2--8.3 Torque Specifications/Lubrication ... Gear Shift Selector Removal ....Transmission Removal .

  • Page 218: Transmission Exploded View

    7- - 9 ft.lbs. (9.5- - 12 Nm) Apply White Lithium 15- -19 ft.lbs. (20- -26 Nm) Based Grease. 27- -34 ft.lbs. (37- -46 Nm) Apply Polaris Crankcase Sealant 6- -12 ft.lbs. (8- -16 Nm) Apply Loctitet 262 to 14- -18 ft.lbs. (19- -24 Nm) the bolt threads.
  • Page 219 TRANSMISSION TRANSMISSION EXPLODED VIEW, CONT. Ref. Qty. Description Ref. Qty. Description 1 22T Sprocket 1 Nut 1 19T Sprocket 1 Shift Drum Bellcrank 1 Silent Chain 5 Sector Cover Screws 1 Front Main Output Shaft 1 Sector Cover 1 10T Spiral Pinion Shaft 1 Sector Cover Gasket 1 Ball Bearing 1 O- - ring...

  • Page 220: Transmission

    TRANSMISSION TRANSMISSION Transmission Mounting INFORMATION TORQUE SPECIFICATIONS Front COMPONENT FT. LBS. (IN.LBS.) Transmission Case Bolts 27--34 37--46 Oil Deflector Screws (16--30) 2--3.3 Shift Cover Bolt 6--12 8--16 Bell Crank Nut 12--18 16--24 2. Disconnect transmission vent line. 3. Drain transmission lubricant. Trans.

  • Page 221: Transmission Installation

    TRANSMISSION 6. Remove auxiliary brake mounting bracket from 10. Remove the park lock spring. frame and secure out of way for transmission removal. 7. Remove PVT outer cover, both drive and driven Park Lock Spring clutch, and inner PVT cover (refer to Clutch Chapter 6).

  • Page 222: Transmission Disassembly

    TRANSMISSION Transmission Switch 4. Remove the five bolts that secure the cover. Remove the detent spring. Tighten Bolts In Sequence A through E TRANSMISSION DISASSEMBLY 1. Place the bellcrank in neutral position. Spring Shift Shaft Cover NO TAG 5. Mark the detent gear with a white pen. Remove the detent gear from the case.
  • Page 223 TRANSMISSION NOTE: It may be helpful to place a mark just above 8. Note the timing marks on the shift gears. Remove the keyed spline. Note the raised edge on the detent the shift gears from the case. gear for reassembly. 6.
  • Page 224 TRANSMISSION 11. Remove the shift forks from the assembly. Note the correct position of each fork. Engagement Dogs 14. Remove the bearing from the input shaft with a puller. 12. Remove the bearing from the reverse shaft using a puller. 15.
  • Page 225 TRANSMISSION 16. Remove low gear (33T) and the needle bearing. 21. Remove the gear, split bearing, and washer from 17. Remove the reverse gear shaft. the reverse shaft. 18. Remove the rest of the bearings from the shafts. 22. Slide off the shift dogs and wave springs. 19.
  • Page 226 TRANSMISSION 26. Remove the front housing cover screws. 24. Remove bearing and the helical gear. 25. Remove the pinion shaft retainer plate and the pinion shaft. 8.10...

  • Page 227: Transmission Reassembly

    TRANSMISSION 27. Remove the front housing cover, shim, thrust 31. Inspect engagement dogs of gears and replace if button, and thrust button shim. edges are rounded. 32. Inspect gear teeth for wear, cracks, chips or broken teeth. Note the location of the hubs on the gear.
  • Page 228 TRANSMISSION 3. Before installing the cover make sure the sealing 8. Apply Loctitet 262 (Red) (PN 2871951) to screw surfaces are clean and dry, and shafts are fully threads and torque screws to 6--12 ft. lbs. (8--16 seated in the transmission case. Apply Nm).
  • Page 229 TRANSMISSION NOTE: Install a new snap ring at this time. When installing the new snap ring, open the the snap ring just far enough to go over the shaft, to avoid stressing the snap ring. If the snap ring is over--stressed, it could come off the shaft and cause internal damage to the transmission.
  • Page 230 TRANSMISSION 16. Position the shift forks up and so the the pins point 19. Lift the shift rail slightly and rotate the rail/fork toward the 9 o’clock position, before installing the assembly so it meshes with the tracks on the shift drum assembly.
  • Page 231 TRANSMISSION 24. Place a small amount of grease (PN 2871551) into the pocket before installing the sector gear. Install the shift gear (16T) on the shift drum shaft. Install the sector gear in the bushing pocket on the left side. Aligning the timing marks on the gears. 28.
  • Page 232 NOTE: Rotate the bellcrank to line the flat side of the switch up to the flat side of the shaft. 34. Install transmission and add Polaris AGL Gearcase Lubricant (PN 2873602) in the recommended amount. Refer to Maintenance Chapter 2 for more information.
  • Page 233 BRAKES Special Tools/Specifications/Torques ... Brake System Components ....Rear Caliper Exploded View .
  • Page 234 BRAKES SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2870975 Mity Vact Pressure Test Tool SPECIFICATIONS Front Brake Caliper Item Standard Service Limit Brake Pad Thickness .298″ / 7.6mm .180″ / 4.6mm Brake Disc Thickness .150-.165″ / 3.81-4.19mm .140″ / 3.556mm Brake Disc Thickness Variance Between .002″...

  • Page 235: Brake System Components

    BRAKES BRAKE SYSTEM MAIN COMPONENTS...

  • Page 236: Rear Caliper Exploded View

    BRAKES REAR BRAKE CALIPER EXPLODED VIEW Anvil Bolts APPLY POLARIS DOT 3 BRAKE Torque FLUID TO COMPONENT 16--18 ft.lbs. Washers (22--25 Nm) Rear Housing Bleed Piston Screws Torque 25--30 in. lbs. O--rings Bracket (2.80--3.40) Nm Seals Pads Slide Pins Torque Bushings 30--35 ft.lbs.

  • Page 237: Brake System Service Notes

    NOTES cause if brake drag is evident. Make sure caliper moves freely on Polaris disc brake systems are light weight, low guide pins (where applicable). maintenance and perform well in the conditions ATVs Inspect caliper piston seals for routinely encounter.

  • Page 238: Hydraulic Brake System Overview

    Pad G compensating port restricted Educate operator Master cylinder pis- The Polaris disc brake system consists of the ton not returning com- following components or assemblies: brake lever; pletely master cylinder; hydraulic hose; brake calipers (slave cylinder); brake pads; and brake discs, which are Caliper piston(s) not secured to the drive line.

  • Page 239: Hydraulic Caliper Bleeding

    BRAKE BLEEDING - FLUID When servicing Polaris ATV brake systems, use only Polaris DOT 3 Brake Fluid (PN 2870990). CHANGE WARNING: Once a bottle is opened, use what is...
  • Page 240 6. Begin bleeding procedure with the caliper that is caliper(s). farthest from the master cylinder. Install a box 12. Add Polaris Dot 3 Brake Fluid (PN 2870990) to end wrench on caliper bleeder screw. Attach a MAX level inside reservoir.

  • Page 241: Master Cylinder Removal

    Reservoir Cover Torque - parts. There are different brake master cylinders for the different Polaris ATV models. Refer to your parts 5 in. lbs. (.56 Nm) manual or guide for the correct parts. This master cylinder is not serviceable and is replaced as a unit.

  • Page 242: Front Pad Removal

    15 ft. lbs. (21 Nm) 3. Fill reservoir with DOT3 Brake Fluid (PN 2870990). 3. Remove caliper from mounting bracket. Polaris DOT 3 Brake Fluid (PN 2870990) 4. Push caliper piston into caliper bore slowly using a C-clamp or locking pliers with pads installed.
  • Page 243 BRAKES Measure Thickness Front Brake Pad Thickness .298″/7.6 mm NOTE: Brake fluid will be forced through Service Limit .180″ / 4.6 mm compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 5.

  • Page 244: Front Pad Assembly

    BRAKES FRONT PAD ASSEMBLY 1. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots. 18 ft. lbs. (25 Nm) Front Caliper Mounting Bolts Torque: 18 ft. lbs. (24Nm) 4. Slowly pump the brake lever until pressure has been built up.

  • Page 245: Brake Burnishing

    BRAKES 7. Install wheels and torque wheel nuts. 3. Mount dial indicator as shown to measure disc runout. Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if Front Wheel Nut Torque runout exceeds specifications. 27 ft.

  • Page 246: Front Caliper Removal

    BRAKES CAUTION: Always use new brake disc mounting 2. Push upper pad retainer pin inward and slip brake bolts. The bolts have a pre-applied locking agent pads past edge. which is destroyed upon removal. FRONT CALIPER REMOVAL CAUTION: Use care when supporting vehicle so that it does not tip or fall.

  • Page 247: Front Caliper Inspection

    Front Caliper Piston Bore I.D. Std. 1.188″ (30.2 mm) Service Limit 1.193″ (30.30 mm) 2. Coat piston with clean Polaris DOT 3 Brake Fluid (PN 2870990) (C). Install piston (D) with a twisting motion while pushing inward.

  • Page 248: Front Caliper Installation

    1. Install caliper on hub strut, and torque mounting bolts. 15 ft. lbs. (21 Nm) 18 ft. lbs. Polaris Premium All Season Grease (24 Nm) (PN 2871423) 4. Compress the mounting bracket and make sure Torque Specifications the dust seals are fully seated. Install the pads as Front Caliper Mounting Bolt: shown on Page 9.10.

  • Page 249: Rear Pad Removal

    BRAKES BRAKE BURNISHING 4. Remove caliper mounting bolts and lift caliper off of disc. PROCEDURE NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink It is required that a burnishing procedure be or bend brake line.

  • Page 250: Rear Pad Installation

    BRAKES 18 ft.lbs. (24 Nm) Measure Thickness Rear Brake Pad Thickness New: .318″ (8.0 mm) Service Limit: .180″ (4.6 mm) Torque Specifications: Rear Brake Caliper: REAR BRAKE PAD 18 ft. lbs. (24 Nm) Caliper Slide Pin Torque: INSTALLATION 30- -35 ft. lbs. (41 Nm- -48 Nm) 1.

  • Page 251: Rear Caliper Removal/Inspection

    BRAKES REAR CALIPER 5. Remove the anvil bolts and separate caliper halves and remove pistons with piston pliers. REMOVAL/INSPECTION Caliper 1. Clean caliper area before removal. 2. Using a flare nut wrench, remove hand brake (inner) and auxiliary brake (outer) lines. Place a container to catch brake fluid draining from brake lines.

  • Page 252: Rear Caliper Assembly

    BRAKES Seals .94 in. 23.88 mm 1.5 in. 38.1 mm O-Rings 10. Inspect caliper piston bore for scratches, severe 2. Carefully assemble caliper body, making sure corrosion, or galling and replace if necessary. O-rings are properly positioned in groove. Tighten the caliper anvil bolts and then torque the anvil bolts evenly to 16--18 ft.

  • Page 253: Rear Disc Inspection

    BRAKES 5. Install brake line and tighten securely with a line wrench. Torque the brake lines to the proper torque specification. 6. Follow bleeding procedure outlined on Pages 9.6-9.7 of this section and refer to system overview and illustrations on Pages 9.2--9.3. 7.
  • Page 254 BRAKES REAR (AUXILIARY) BRAKE Rear Brake Master Cylinder Removal / Install REMOVAL / INSTALL 1. If necessary, remove the rear brake line from the master cylinder. Use a suitable container to catch Brake Pedal Removal / Install the brake fluid. Dispose of brake fluid properly. 1.

  • Page 255: Troubleshooting

    BRAKES TROUBLESHOOTING Brakes Squeal G Dirty/contaminated friction pads G Improper alignment G Worn disc G Worn disc splines Poor Brake Performance G Air in system G Water in system (brake fluid contaminated) G Caliper/disc misaligned G Caliper dirty or damaged G Brake line damaged or lining ruptured G Worn disc and/or friction pads G Incorrectly adjusted lever...
  • Page 256 BRAKES NOTES 9.24...

  • Page 257: Electrical

    ELECTRICAL Trigger Coil Gap Procedure ....10.2 Gear Position Switch Test ....10.2 ECM Operation / Overview .

  • Page 258: Trigger Coil Gap Procedure

    ELECTRICAL TRIGGER COIL GAP GEAR POSITION INDICATOR SWITCH TEST Measure trigger coil gap with a feeler gauge. The gap should be .022--.028 inch (.56--.71 mm). NOTE: Also see “INSTRUMENT CLUSTER TROUBLESHOOTING” for gear switch re- sistance. Measure Trigger Coil Gap TRANSMISSION SWITCH High/Low/Neutral/Reverse/Park Switch High Range...

  • Page 259: Ecm Operation / Overview

    The ECM (Sure Power Box) integrates three that output turns off. The output can be reset by electronic features found on the Polaris ATV. These removing load from it by turning the key switch or features are alternator rectifier/regulator, engine LHCA switch off.

  • Page 260: Instrument Cluster Overview

    ELECTRICAL INSTRUMENT CLUSTER of the solid--state device is exceeded it will shut off. It will automatically turn back on when it has cooled. OVERVIEW Reverse Alternator BAT+ Polarity Protection 3 Phase (A) Speedo Needle (also flashes Input Regulator during warning condition) BAT_PROT (B) Speedometer in MPH/KPH...
  • Page 261 Do not continue to operate the Refer to Illustration 1: ATV if this warning appears. Refer to Chapter 3 The Polaris ATV Instrument Cluster is powered by “Cooling System Troubleshooting” for help with battery voltage (12 VDC) and requires inputs from the diagnosis of overheating.

  • Page 262: Diagnostic Mode

    ELECTRICAL DIAGNOSTIC MODE NOTE: This gauge features auto shut--off protection if the voltage on the DC bus is excessive. This is usually the result of an open battery condition, and the gauge is designed to survive such an event. NOTE: If the gauge will not indicate what gear it is in and will not allow AWD operation, AWD can still be enabled by holding in the mode/override button.
  • Page 263 ELECTRICAL 75 Ohms in Reverse Set at 50 hrs. from Factory SETTING A NEW SERVICE INTERVAL: Setting Service Interval After Countdown (zero): 1. While in the service interval mode, press and hold the mode/override button until the wrench icon flashes. When it begins to flash, release the button. 2.

  • Page 264: Speedometer Removal/Installation

    ELECTRICAL SPEEDOMETER REMOVAL 2. Wait 5 seconds and then press the mode button in until the wrench icon flashes. Press the mode button again to set the desired service increment. Release 1. Remove the three screws that secure the the button and wait for the wrench icon to stop headlight pod cover and disconnect the wire flashing.
  • Page 265 ELECTRICAL SPEEDOMETER INSTALLATION 3. Hold the pod assembly securely and insert the instrument cluster into the pod assembly. Twist the instrument cluster gently in a clockwise 1. Spray a soap and water mixture onto the outer motion to properly seat the instrument cluster into surface area of the instrument cluster.

  • Page 266: Speedometer Operation Troubleshooting

    ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 1 - - NO ALL WHEEL DRIVE Note: If AWD icon comes on, instru- ment cluster is O.K. Proceed to me- START HERE chanical tests (in Service Manual). Check the AWD icon on instrument clus- CHECK ter to verify it’s operation.
  • Page 267 ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 2 - - NO SPEEDOMETER AND/OR ODOMETER DISPLAY Note: Before starting diagnosis, turn off speedometer and wait 10 seconds, then turn on again to see if problem clears CHECK FOR REPLACE MINIMUM 6VDC SPEEDO ON PIN B TO START HERE PIN C 3 Pin Connector...
  • Page 268 ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 4 - - NO AWD HUB SAFETY LIMIT NOTE: IF THE AWD ICON DOES NOT COME ON OR IF 12 VDC IS NOT REGISTERING AND AWD IS ENGAGING START HERE ABOVE 3100 RPM,IT MAY BE A MECHANICAL PROBLEM. SPEEDO CHECK FUNCTIONING...
  • Page 269 ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 5 REVERSE SPEED LIMITER ACTIVATED IN FORWARD GEAR (Engine loses spark when vehicle speed is above 7-9 mph.) START HERE 16 Pin Connector 1. Orange/White- - 12V Constant CHECK 9. Blue White- - Engine Overheat Switch INSTRUMENT 2.
  • Page 270 ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 7 FUEL GAUGE DISPLAY NOT WORKING 16 Pin Connector START HERE 1. Orange/White- - 12V Constant 9. Blue White- - Engine Overheat Switch 2. Red/White- - 12V Switched 10. N/C 3. Grey/Orange- - Mode/Override button 11. N/C CHECK 4.
  • Page 271 ELECTRICAL SPEEDOMETER be no continuity or very high resistance (see chart below). TROUBLESHOOTING CONT’D See “Engine Temperature Controller” on Page 10.5 for information on thermistor operation. TEST 7 - - - - RESET SPEEDOMETER SITUATION OHMS DIAGNOSIS / If the key switch or engine stop switch is turned off with READING ACTION the vehicle in motion, the speedometer indicator...

  • Page 272: Fan Motor Current Draw

    ELECTRICAL FAN CONTROL CIRCUIT FAN MOTOR CURRENT DRAW OPERATION A current draw test will provide a good indication of fan motor condition. A worn or damaged fan motor will A thermistor is located on the cylinder head. supplies draw more current, which causes a reduction in blade a resistance reading to the Sure Power box via the speed and reduced cooling.

  • Page 273: Etc Operation Test

    ELECTRICAL ELECTRONIC THROTTLE CONTROL (ETC) SWITCH Electronic Throttle Control (ETC) Switch The Electronic Throttle Control (ETC) system is (Composite Throttle Housing) designed to stop the engine of an ATV in the event of a mechanical problem with the throttle mechanism. ETC switch contacts are The ETC switch is mounted independently of the closed in a fault condition...

  • Page 274: Flywheel Identification

    ELECTRICAL FLYWHEEL IDENTIFICATION Kokusan Flywheel Polaris Part Number Timing Marks Production Date 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.
  • Page 275 ELECTRICAL COMPONENTS OF 600/700 330 WATT ALTERNATOR IGNITION SYSTEM NOTE: Control modules may look the same but have different internal circuitry. Be sure to always use the correct part number. Positive Battery Cable Battery Starter Solenoid Ignition Coil Ignition Controller Negative Battery Cable...

  • Page 276: Ignition System Testing Flow Chart

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

  • Page 277: Ignition System Troubleshooting

    ELECTRICAL IGNITION SYSTEM TROUBLESHOOTING No Spark, Weak or Intermittent Spark Spark plug gap incorrect 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 Wire harness or connections wet,...
  • Page 278 ELECTRICAL CHARGING SYSTEM “BREAK Disconnect the stator connectors from the CDI module. Test output from the detection and pulse EVEN” TEST (trigger) coil, and compare to the chart. The following measurements were obtained when cranking the CAUTION: Do not allow the battery cables to engine with the electric starter, spark plug installed.

  • Page 279: Alternator Output Test

    ELECTRICAL ALTERNATOR OUTPUT TEST (AC AMP) Three tests can be performed using a multimeter to determine the condition of the stator (alternator). TEST 2: Resistance Value of Stator Leg to Ground 1. Measure the resistance value of each of the stator legs to ground: Y1 to Ground, Y2 to Ground, Y3 to Y/BRN Ground.

  • Page 280: Charging System Testing Flow Chart

    ELECTRICAL CHARGING SYSTEM TESTING FLOW CHART Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not kinked or pinched. Using a multitester set on D.C. volts, mea- sure the battery open circuit voltage (See Remove the battery and properly ser- earlier test).

  • Page 281: Battery Identification

    3. Set battery aside to allow for acid absorption and stabilization for 30 minutes. Polaris sticker 4. Add electrolyte to bring level back to upper level mark on case. NOTE: This is the last time that electrolyte should be added. If the level becomes low after this point, add only distilled water.
  • Page 282 4. Remove the filler caps and add distilled water only as needed to bring each cell to the proper level. Do not overfill the battery. Use Polaris corrosion resistant Nyogelt grease (PN 2871329) on battery bolts. See Battery Installation on Refill using only distilled water.

  • Page 283: Load Test

    ELECTRICAL Following are three tests which can easily be made on OPEN CIRCUIT VOLTAGE a battery to determine its condition: OCV Test, State of Conventional Sealed Specific Gravity Test and Load Test. charge Lead-acid Type 100% 12.60V 12.70V CONVENTIONAL BATTERY Charged 12.40V 12.50V...

  • Page 284: Charging Procedure

    ELECTRICAL Remove battery from 3. Install battery in vehicle with positive terminal machine and wash the case and toward the front. Coat threads of battery bolt with battery tray with a mild solution of a corrosion resistant dielectric grease. baking soda and water. Rinse with lots of fresh water after cleaning.

  • Page 285: Battery Charging

    ELECTRICAL To service a Low Maintenance battery: 1. Remove battery from the vehicle 2. Test battery with a voltage meter or load tester to determine battery condition. This will determine the length of time required to charge the battery to full capacity.

  • Page 286: Battery Testing

    ELECTRICAL LOW MAINTENANCE LOW MAINTENANCE BATTERY INSPECTION/ BATTERY TESTING REMOVAL Whenever a service complaint is related to either the starting or charging systems, the battery should be The battery is located under the seat. checked first. Following are three tests which can easily be made on a battery to determine its condition: OCV Test, Specific Gravity Test and Load Test.

  • Page 287: Low Maintenance Battery Charging

    ELECTRICAL NOTE: This test can only be performed on machines Electrolyte Freezing Points with electric starters. This test cannot be performed Specific Gravity Freezing with an engine or starting system that is not working of Electrolyte Point properly. 1.265 -75° F A battery may indicate a full charge condition in the OCV test and the specific gravity test, but still may not have 1.225...

  • Page 288: High Beam Headlight Bulb Replacement

    ELECTRICAL HIGH BEAM HEADLIGHT 4. Turn the headlight lamp socket counter--clockwise and remove. BULB REPLACEMENT CAUTION: Do not service while headlight is hot. Serious burns may result. Protect lamp during install. Turn Harness Assembly Remove 3 screws Tighten Loosen 5. Carefully remove headlamp bulb from housing. 6.
  • Page 289 ELECTRICAL HEADLIGHT HOUSING 5. Pull the headlight housing up to release from the locking tabs. REPLACEMENT 1. Remove three Phillips screws on the headlight pod. 2. Disconnect instrument cluster harness (A) and winch selection switch (B). Both Sides 6. Lift the adjusting knob up to remove from the locking tabs.
  • Page 290 ELECTRICAL HIGH BEAM HEADLIGHT 4. Observe headlight aim. The most intense part of the headlight beam should be aimed 2″ (5.1 cm) ADJUSTMENT below the mark placed on the wall in Step 2 NOTE: Rider weight must be included on the The headlight beam can be adjusted to any position seat.
  • Page 291 ELECTRICAL TAIL LIGHT/BRAKE LIGHT BRAKE LIGHT SWITCH LAMP REPLACEMENT 1. Remove the front cover. If the tail light/brake light does not work the lamp may need to be replaced. Rear Tail Light Brake Lamp Switch Lens Cover Brake Switch Location: Under front cover below headlight pod.

  • Page 292: Fuel Sender Test

    ELECTRICAL FUEL SENDER TEST 1. Remove the fuel sender from the fuel tank. Refer Chapter “FUEL SENDER REMOVAL/INSTALLATION”. 2. Stand the fuel sender on a flat surface. 3. Hook up an ohm meter to the fuel sender harness (Brown & Purple / White). 4.
  • Page 293 ELECTRICAL WARN WINCH /CONTACTOR WARN WINCH SWITCH ® ® LOCATION INSTALLATION Both the front and rear winch contactor are located 1. Remove the front (A) and rear (B) bolts from the under the left rear fender. master cylinder clamp. Be careful not to lose the spacers (C).
  • Page 294 ELECTRICAL BASIC WINCH WIRING NOTE: See the wiring diagram in back of the book for more winch wiring information. Cable Boot Blue Cable (6 ga.) Battery (20 ga.) Rocker Switch (IN/OUT) Black (6 ga.) Green Yellow Black Cable (6 ga.) 12V Contact Red Cable (6 ga.) Fairlead Roller...

  • Page 295: Starter Motor Removal

    ELECTRICAL STARTER SYSTEM drop tests on the starter system. TROUBLESHOOTING Voltage should not exceed .1 DC volts per connection Starter Motor Does Not Turn Battery discharged. Low specific STARTER MOTOR REMOVAL/ gravity Loose or faulty battery cables or DISASSEMBLY corroded connections (see Voltage Drop Tests) NOTE: Use electrical contact cleaner to clean starter Related wiring loose, disconnected,...
  • Page 296 ELECTRICAL O--rings Shims NOTE: The shims will be replaced during 3. Slide positive brush springs to the side, pull reassembly. brushes out of their guides and remove brush plate. Slide brush end frame off end of starter. BRUSH NOTE: The electrical input post must stay with the field coil housing.

  • Page 297: Armature Testing

    ELECTRICAL Brush Length Limit 5/16″ (8mm) Brush Replacement 1. Remove terminal nut with lock washer, flat washer, large phenolic washer, the small phenolic spacers, and sealing O-ring. Inspect O-ring and replace if damaged. 2. Inspect surface of commutator. Replace if excessively worn or damaged.
  • Page 298 ELECTRICAL 6. Place armature in a growler. Turn growler on and position a hacksaw blade or feeler gauge lengthwise 1/8″ (.3 cm) above armature coil Roller Bearing laminates. Rotate armature 360°. If hacksaw blade is drawn to armature on any pole, the Seal armature is shorted and must be replaced.

  • Page 299: Starter Drive

    Washer To measure the resistance of the pull-in coil, connect one meter lead to each solenoid lead wire. The Polaris Premium Starter Drive Grease resistance should be 2.8-3.6 ohms. Refer to Electric (PN 2871460) Starter System Testing in this section to further test the solenoid.
  • Page 300 ELECTRICAL STARTER ASSEMBLY Ref. Ref. Description Description 1. Rubber Ring* Gear Assembly 2. Brush Spring Though Bolt 3. Thrust Washer Cover 4. Gear Assembly Stopper 5. O-Ring* Snap Ring 6. Brush Complete Washer 7. O-Ring* Flange Bolt 8. Thrust Washer Thrust Washer 9.

  • Page 301: Starter System Testing Flow Chart

    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- ter’s black lead on the battery negative and the red Remove battery and properly service.
  • Page 302 ELECTRICAL NOTES 10.46...
  • Page 303 ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN MV (CIVILIAN VERSION)
  • Page 304 ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN MV (CIVILIAN VERSION)
  • Page 305 Brake Master Cylinder Exploded View, Rear, 9.5, 9.22 Brake Noise, A-Arm Replacement, 5.19 Brake Pad Assembly, Front, 9.12 Air Filter Service, 2.23 Brake Pad Inspection, 2.32 Alternator Output Test, 10.23 Brake Pad Installation, Rear, 9.18 ATV Specifications, 1.4, 1.5 Brake Pad Removal, Front, 9.10 Auxiliary Brake Removal, 9.22...
  • Page 306 Charging System Break Even Test, 10.22 Drive Clutch Disassembly, 6.11, 6.12, 6.13 Charging System Testing, 10.24 Drive Clutch Exploded View, Choke Adjustment, 2.15 Drive Clutch Inspection, 6.11 Drive Clutch Operation, Cleaning the ATV, 2.38 Drive Shaft Boot Inspection, Clutch Alignment, 6.16 Drive Shaft Boot Replacement, Clutch Offset,...
  • Page 307 ETC Switch Testing, 10.17 Gear Position Switch Test, 10.2 Exhaust System, Maintenance, 2.30 Gear Shift Selector Removal, Gearcase Assembly, Rear , 7.28 Gearcase Coil Resistance, Front, 7.11 Gearcase Disassembly, Rear , 7.26 Fan Control Circuit Testing, 10.16 Gearcase Exploded View, Rear , 7.30 Fan Control Switch Bypass Test, 10.15...
  • Page 308 Lubricant Symbol I.D. Chart, Publication Numbers, Lubricants, Push Rod Inspection, 3.19 PVT Assembly, Lubrication / Grease Points, 2.14 PVT Cover Removal/Install, Lubrication Charts, 2.9, 2.10 PVT Disassembly, Lubrication, Transmission, 2.12, 8.4 PVT Drying, 2.26, 6.4 PVT Maintenance, PVT Operation, Mag Cover Seal Replacement, 3.51 PVT Overheating, MAINTENANCE AND LUBRICATION,...
  • Page 309 Specifications, Torque, Brakes, Tie Rod Inspection, 2.28 Specifications, Torque, Engine, Tire Inspection, 2.36 Specifications, Torque, Final Drive, Tire Pressure, 2.35 Tire Tread Depth, 2.36 Specifications, Torque, PVT, Toe Alignment, 2.30 Specifications, Torque, Standard, 1.3, 1.11 Torque Patterns, Engine, Specifications, Torque, Steering, Transmission Disassembly, Specifications, Torque, Suspension, Transmission I.D.
  • Page 310 Wheel Installation, 2.35 Wheel Removal Front or Rear, 2.35 Washing the ATV, 2.38 Wheel, Hub, Spindle Torque, 2.35 Water/Oil Pump Removal, 3.42 Winch Removal / Install, 5.10 Wheel Inspection, 2.35 Winch Switch Installation, 5.12, 10.37...
  • Page 311 Polaris Service Publications Publication Title, Part Number: ____________________________ Page(s)____________ Publication Title, Part Number: ____________________________ Page(s)____________ Product and Year :_______________________________________ Error - Suggestion - Comments Comments Please communicate to Polaris any suggestions concerning our publica- tions. Simply fill out the form and mail it to the address listed below the form.
  • Page 312 PART # 9919963 Printed in USA...

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