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  • Page 1


  • Page 2: Table Of Contents

    ......1.8-1.10 Specifications - Sportsman 400 ....

  • Page 3: General Information, Identification Numbers, Model Identification, Engine Serial Number Location

    - - GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 0 1 C H 5 0 A A Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation...

  • Page 4: Replacement Keys

    - - GENERAL INFORMATION REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Series # Part Number 4110141...

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  • Page 10: Machine Dimensions

    - - GENERAL INFORMATION MACHINE DIMENSIONS SPORTSMAN 400 22 in 55.8 cm 41 in 104.1 cm 30 in 76.2 cm 45 in 114.3 cm SPORTSMAN 500 22 in 55.8 cm 42 in 106.6 cm 32 in 81.2 cm 46 in...

  • Page 11

    - - GENERAL INFORMATION MACHINE DIMENSIONS SPORTSMAN 400 81 in 205.7 cm 35 in 89 cm 13.5 in 34.29 cm 51 in 129.5 cm SPORTSMAN 500 81 in 205.7 cm 34 in 86.3 cm 15 in 38.1 cm 50.5 in...

  • Page 12

    - - GENERAL INFORMATION MACHINE DIMENSIONS 45 in SPORTSMAN 400 114.3 cm 46 in 116.8 cm 9.25 in 23.5 cm 38 in 96.5 cm 47 in 119.4 cm 45 in 114.3 cm SPORTSMAN 500 48 in 121.9 cm 10 in 25.4 cm...

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  • Page 14

    . . . 1 oz. (30ml) PP4* Lubricant Key *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .

  • Page 15: Spring Position (sheave)

    - - GENERAL INFORMATION SPORTSMAN 500 DUSE MODEL: ..MODEL NUMBER: A01CH50AD ENGINE MODEL: EH50PLE09 JETTING CHART AMBIENT TEMPERATURE Altitude Altitude Below 40°F Below 40 F +40_F and above +40 F and above CARBURETION Below +5°C +5_C and above...

  • Page 16

    . . . 1 oz. (30ml) PP4* Lubricant Key *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .

  • Page 17

    - - GENERAL INFORMATION SPORTSMAN 500 H.O. MODEL: ..MODEL NUMBER: A01CH50AA/AB/AE/AF/AJ ENGINE MODEL: EH50PLE13 JETTING CHART AMBIENT TEMPERATURE Altitude Altitude Below 40°F Below 40 F +40_F and above +40 F and above CARBURETION Below +5°C +5_C and above...

  • Page 18

    . . . 1 oz. (30ml) PP4* Lubricant Key *PP6 Polaris Premium 60/40 Antifreeze/Coolant *PPS Polaris Premium Synthetic Gear Case Oil *PP4 Polaris 0W/40 Synthetic Engine Lubricant *PDD Premium Demand Drive Hub Fluid SUSPENSION / CHASSIS DRIVE TRAIN Body Style .

  • Page 19: Publication Numbers, Paint Codes

    - - GENERAL INFORMATION PUBLICATION NUMBERS Year Model Model No. Owner’s Manual Parts Parts Manual PN Micro Fiche PN 2001 Sportsman 400 A01CH42AA/AB/AC 9915754 9916443 9916444 2001 Sportsman 500 DUSE A01CH50AD 9915754 9916002 9916003 2001 Sportsman 500 H.O. A01CH50AA/AB/AE/...

  • Page 20: 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 21

    - - GENERAL INFORMATION TORQUE CONVERSIONS Newton Meter to Pound Foot and Pound Inch 1.19...

  • Page 22

    - - GENERAL INFORMATION TORQUE CONVERSIONS Newton Meter to Pound Foot and Pound Inch 1.20...

  • Page 23: Decimal Equivalents

    - - GENERAL INFORMATION DECIMAL EQUIVALENTS 1/64 ......0156 1/32 ....0312 .

  • Page 24: 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.

  • Page 25: Sae Tap Drill Sizes

    - - GENERAL INFORMATION SAE TAP DRILL SIZES Thread Size Drill Size Thread Size Drill Size #0-80 3/64 1/2-13 27/64 #1-64 1/2-20 29/64 #1-72 9/16-12 31/64 #2-56 9/16-18 33/64 #2-64 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 3/4-10 21/32 #4-40 3/4-16 11/16...

  • Page 26: Glossary Of Terms

    CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8″ or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.

  • Page 27

    Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch System) qt.: Quart/quarts. RPM: Revolutions per minute. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.

  • Page 28

    - - CHAPTER 2 MAINTENANCE Periodic Maintenance Chart ....2.1-2.2 Pre-Ride Inspection ......Recommended Lubricants and Capacities .

  • Page 29: Periodic Maintenance Chart

    Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for re- placement parts. Always use genuine Polaris parts. HCAUTION: Due to the nature of these adjustments, it is recommended that service be performed by an authorized Polaris dealer.

  • Page 30

    - - MAINTENANCE PERIODIC MAINTENANCE CHART, CONT. CHASSIS Frequency (Whichever comes first) Item Hours Calendar Miles Remarks (Km) " General Lubrication 50 hrs 3 months 500 (800) Lubricate All Fittings, Pivots, Cables, Etc. " Front Hubs/Fluid Check 50 hrs 6 months 500 (800) Check monthly...

  • Page 31

    2.33 Hub Fluid trickles out. Do not force fluid into hub. Brake Fluid Polaris DOT 3 Brake Fluid Fill to indicated level inside reservoir. 2.35 COLD WEATHER KITS FOR 4 CYCLE ATVS Oil Tank Cover -- PN 287187 Engine Heater -- PN 2871507...

  • Page 32

    - - MAINTENANCE POLARIS PREMIUM LUBRICANT AND MAINTENANCE PROD- UCT PART NUMBERS Part No. Description Engine Lubricant 2870791 Fogging Oil 2871281 Engine Oil (Quart) Premium 4 Synthetic 0-W40 (4-Cycle) 2871567 Engine Oil (16 Gallon) Premium 4 Synthetic 0-W40 (4-Cycle)

  • Page 33

    Add lube to FULL level on dip- Change annually © ic Gear Case stick. Lubricant Brake Fluid Polaris DOT 3 Fill master cylinder reservoir to in- As required. Change fluid every 2 years. Brake Fluid dicated level inside reservoir. See page 2.36.

  • Page 34

    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 35

    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 36

    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 37: Front Gearcase Lubrication

    S Be sure vehicle is level before proceeding. S Check vent hose to be sure it is routed properly and unobstructed. S The correct gearcase lubricant to use is Polaris Premium GL5 80-90 Gear Lube, or an equivalent lubricant with a GL5 rating.

  • Page 38: Transmission Lubrication

    S Check vent hose to be sure it is routed properly and unobstructed. TRANSMISSION SPECIFICATIONS Dipstick Specified Lubricant: Polaris Premium Synthetic Gearcase Lubricant PN 2871477 (Gallon) PN 2871478 (12 oz..) Capacity: ..At change: Approx. 20 oz.

  • Page 39: Transmission Gearshift Adjustment, Shift Linkage Adjustment

    - - MAINTENANCE TRANSMISSION GEARSHIFT LINKAGE ADJUSTMENT, PRE- LIMINARY INSPECTION S If shifting problems are encountered, the transmis- Linkage rod will rotate sion linkage can be adjusted. 1/8 -1/4 turn if rod ends are tightened properly. S Tighten shift linkage rod end jam nuts properly after adjustment.

  • Page 40

    - - MAINTENANCE SHIFT LINKAGE ADJUSTMENT, CONT. 5. Place gear selector in neutral. Make sure the transmission bell cranks are engaged in the neutral position detents. 6. Be sure the shift linkage rod ends are firmly attached to the gear selector slides. Adjust the low range (inside) rod so the rod end is centered on the transmission bell crank.

  • Page 41: Throttle Operation

    - - MAINTENANCE THROTTLE OPERATION Check for smooth throttle opening and closing in all han- dlebar positions. Throttle lever operation should be smooth and lever must return freely without binding. 1. Place the gear selector in neutral. 2. Set parking brake. 3.

  • Page 42: Pilot Screw Adjustment, Idle Speed

    - - MAINTENANCE PILOT SCREW ADJUSTMENT Pilot Screw (Idle Mixture) Adjustment Notes Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be permanently damaged. Start engine and warm it up to operating temperature (about 10 minutes). This is a very important step. 1.

  • Page 43

    - - MAINTENANCE THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL (ETC SWITCH) ADJUSTMENT 1. Slide boot off throttle cable adjuster and jam nut. 2. Place shift selector in neutral and set parking brake. 3. Start engine and set idle to specified RPM, then shut off engine.

  • Page 44: Fuel System, Fuel Filter

    - - 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 45: Carburetor Draining

    - - MAINTENANCE CARBURETOR DRAINING The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl, or before ex- tended periods of storage. NOTE: The bowl drain screw is located on the bottom left side of the float bowl.

  • Page 46: Compression Test, Engine Mounts

    - - MAINTENANCE COMPRESSION TEST NOTE: 4-Stroke engines are equipped with an automatic decompressor. Compression readings will vary in pro- portion to cranking speed during the test. Average compression (measured) is about 50-90 psi during a compres- sion test. Smooth idle generally indicates good compression.

  • Page 47: Battery Maintenance

    - - MAINTENANCE BATTERY MAINTENANCE WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.

  • Page 48: Spark Plug, Ignition Timing

    - - MAINTENANCE SPARK PLUG 1. Remove spark plug high tension lead. Clean plug area Recommended Spark Plug: so no dirt and debris can fall into engine when plug is removed. Refer to Specifications 2. Remove spark plug. 3. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of Spark Plug Torque: 14 Ft.

  • Page 49: Cooling System Hoses

    S Overheating of engine could occur if air is not fully purged from system. S Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. COOLANT STRENGTH / TYPE Test the strength of the coolant using an antifreeze hydrometer.

  • Page 50: Coolant Level Inspection, Radiator Coolant Level Inspection

    1. Remove reservoir cap. Inner splash cap vent hole must be clear and open. 2. Fill reservoir to upper mark with Polaris Premium 60/40 Anti Freeze / Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.

  • Page 51

    - - MAINTENANCE AIR FILTER PRE-FILTER SERVICE It is recommended that the air filter and pre filter be replaced Cover annually. When riding in extremely dusty conditions re- placement will be required more often. Gasket The pre filter should be cleaned before each ride, using the following procedure.

  • Page 52: Air Box Sediment Tube, Breather Filter Inspection, Breather Hose

    - - MAINTENANCE AIR BOX SEDIMENT TUBE Periodically check the air box drain tube located toward the rear of the machine. Drain whenever deposits are visible in the clear tube. NOTE: The sediment tube will require more frequent ser- vice if the vehicle is operated in wet conditions or at high throttle openings for extended periods.

  • Page 53: Recoil Housing

    - - MAINTENANCE RECOIL HOUSING S Drain the housing periodically to remove moisture. S Drain the recoil housing after operating the ATV in Crankcase Drain very wet conditions. This should also be done before storing the ATV. The drain screw is located at the bot- tom of the recoil housing.

  • Page 54: Engine Oil Level

    Recommended Engine Oil: 2. Run engine two to three minutes until warm. Stop engine. Polaris Premium 4 All Season Synthetic, 0W/40, PN 2871281 3. Clean area around drain plug (B) at bottom of oil tank. 4. Place a drain pan beneath oil tank and remove drain Ambient Temperature Range: plug.

  • Page 55

    20. Reinstall drain plug. Crankcase Drain 21. Remove dipstick and fill tank with 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. 22. Place gear selector in neutral and set parking brake. 23. Prime oil pump using procedure below. Stop the engine and inspect for leaks.

  • Page 56: Valve Clearance

    - - MAINTENANCE VALVE CLEARANCE Inspect and adjust valve clearance while the engine is cold and the piston positioned at Top Dead Center (TDC) on compression stroke. 1. Remove the seat. 2. Remove body panels and fuel tank as necessary to gain access to valve cover.

  • Page 57: Intake Valve Clearance Adjustment, Exhaust Valve Clearance Adjustment

    - - MAINTENANCE INTAKE VALVE CLEARANCE ADJUSTMENT 1. Insert a .006″ (.15mm) feeler gauge between end of intake valve stem and clearance adjuster screw. 2. Using a 10 mm wrench and a screwdriver, loosen adjuster lock nut and turn adjusting screw until there is a slight drag on the feeler gauge.

  • Page 58

    Polaris parts. WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component re- pair and adjustment be performed by an authorized Polaris Dealer. Only a qualified technician should replace worn or damaged steering parts. Use only genuine Polaris replacement parts.

  • Page 59

    - - MAINTENANCE METHOD 1: STRAIGHTEDGE OR STRING Be sure to keep handlebars centered. See note below. NOTE: String should just touch side surface of rear tire on each side of machine. Measure from string to rim at front and rear of rim.

  • Page 60

    - - MAINTENANCE METHOD 2 CHALK 1. Place machine on a smooth level surface. 2. Set handlebars in a straight ahead position and secure handlebars in this position. NOTE: The steering frog can be used as an indicator of whether the handlebars are straight.

  • Page 61

    2. Turn wheel until front hub fill/check plug is in either the 4:00 or 8:00 position. 3. Remove fill/check plug. 4. Add Polaris Demand Drive Hub Fluid if necessary until fluid trickles out. NOTE: Do not force the fluid into the hub under pressure or seal damage may occur.

  • Page 62: Exhaust Pipe

    - - MAINTENANCE EXHAUST PIPE The exhaust pipe must be periodically purged of accumu- lated carbon as follows: 1. Remove the clean out plugs located on the bottom of the muffler as shown at right. 2. Place the transmission in neutral and start the engine. Purge accumulated carbon from the system by momen- Clean Out Plug tarily revving the engine several times.

  • Page 63: Brake Pad Inspection

    Parking Brake dicated level inside reservoir. Glass Lock Use Polaris DOT 3 brake fluid (PN 2870990). Check brake system for fluid leaks. Check brake for excessive travel or spongy feel. Check friction pads for wear, damage and looseness. Check surface condition of the disc.

  • Page 64: Auxiliary Brake Testing

    - - MAINTENANCE AUXILIARY BRAKE ADJUSTMENT (HYDRAULIC) Use the following procedure to inspect the hydraulic auxil- 1/8″ to 1/4″ iary (foot) brake system and adjust or bleed if necessary. Free Play 1. First check foot brake effectiveness by applying a 50 1″...

  • Page 65: Front Suspension, Rear Suspension

    - - MAINTENANCE SUSPENSION SPRING PRELOAD ADJUSTMENT Operator weight and vehicle loading affect suspension spring preload requirements. Adjust as necessary. FRONT SUSPENSION Rear Spring Adjustment Cam Compress and release front suspension. Damping should be smooth throughout the range of travel. Check all front suspension components for wear or dam- age.

  • Page 66

    - - MAINTENANCE CONTROLS Check controls for proper operation, positioning and adjustment. Spacer Tab Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body. Align throttle control assembly clamp with knurl on handle- Throttle assembly clamp...

  • Page 67: Wheel Installation

    - - MAINTENANCE WHEELS Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts. WHEEL, HUB, AND SPINDLE TORQUE TABLE Item Specification Front Wheel Nuts 20 Ft. Lbs. Rear Wheel Nuts 20 Ft.

  • Page 68: Tire Pressure, Tire Inspection

    - - MAINTENANCE TIRE PRESSURE Tire Pressure Inspection (PSI - Cold) Front Rear TIRE INSPECTION CAUTION: S Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the vehicle. Tread S Improper tire inflation may affect ATV maneuverability. Depth 1/8I (3 mm) S When replacing a tire always use original equipment size and type.

  • Page 69

    - - CHAPTER 3 ENGINE Torque Specifications ......Torque Patterns ....... . . Piston Identification .

  • Page 70: Torque Specifications

    - - ENGINE TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Size EH42PLE EH50PLE Ft. Lbs. (Nm) Ft. Lbs. (Nm) Blind Plug (Oil Pressure) 1/8 PT 6.5-11 (9-15 Nm) 6.5-11 (9-15 Nm) (28tpi) Camshaft Sprocket 5-6.5 (7-9 Nm) 5-6.5 (7-9 Nm) Camshaft Chain Tensioner Lever 5-6.5 (7-9 Nm) 5-6.5 (7-9 Nm) Camshaft Chain Tensioner...

  • Page 71

    - - ENGINE ENGINE FASTENER TORQUE PATTERNS Tighten cylinder head, cylinder base, and crankcase fasteners in 3 steps following the sequence outlined below. Cylinder Head Crankcase Cylinder Base 425 / 500 425 / 500...

  • Page 72: Piston Identification

    - - ENGINE PISTON IDENTIFICATION Note the directional and identification marks when viewing the pistons from the top. The letter “F”, “ ! ”, “ "” or : must always be toward the flywheel side of the engine. The other numbers are used for identification as to diameter, length and design.

  • Page 73: Engine Service Data

    - - ENGINE ENGINE SERVICE DATA Cylinder Head / Valve EH42PLE05 EH50PLE09/13 Rocker Arm Rocker arm ID .8669-.8678″ (22.020-22.041 mm) .8669-.8678″ (22.020-22.041 mm) Rocker shaft OD .8656-.8661″ (21.987-22.0 mm) .8656-.8661″ (21.987-22.0 mm) Rocker shaft Oil Clearance .0008-.0021″ (.020-.054 mm) .0008-.0021″...

  • Page 74

    - - ENGINE ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod EH42PLE05 EH50PLE09/13 Cylinder Surface warpage limit (mating with cylinder head) .0020″ (.05 mm) .0020″ (.05 mm) Cylinder bore 3.4606-3.614″ (87.900-87.920 mm) 3.6216-3.6224″ (91.99-92.01 mm) Taper limit .0020″ (.050 mm) .0020″...

  • Page 75: Cooling System

    - - ENGINE COOLING SYSTEM WARNING: Never remove radiator cap when engine is warm or hot. The cooling system is under pressure and serious burns may result. Allow the engine and cooling system to cool before servicing. System Pressure Test FLOW 1.

  • Page 76: Cooling System Specifications

    Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems, and comes pre-mixed and ready to use.

  • Page 77: Accessible Components

    - - ENGINE ACCESSIBLE COMPONENTS The following components can be serviced or removed with the engine installed in the frame: Flywheel Alternator/Stator Starter Motor/Starter Drive Cylinder Head Cylinder Piston/RIngs Camshaft Rocker Arms Cam Chain and Sprockets Water Pump / Water Pump Mechanical Seal* The following components require engine removal for service: Oil pump / Oil Pump Drive Gear Counterbalance Shaft or Bearing(s)

  • Page 78

    - - ENGINE ENGINE REMOVAL (TYPICAL) 1. Clean work area. 2. Thoroughly clean the ATV engine and chassis. 3. Disconnect battery negative (-) cable. 4. Remove the following parts as required. Seat Left and Right Side Covers (Refer to Chapter 5) Fuel Tank Cover / Front Cab (Refer to Chapter 5) Fuel Tank (Refer to Chapter 4) 5.

  • Page 79: Engine Installation Notes

    4 Cycle Engine Break-In Period is defined as the first 10 hours of engine operation, or 2 full tanks of fuel. 1. Use only Polaris Premium 4 All Season synthetic oil, or API certified “SH” oil. Never substitute or mix oil brands.

  • Page 80: Honing To Oversize, Cleaning The Cylinder After Honing

    Selecting a hone which will straighten as well as remove material from the cylinder is very important. Using a common spring loaded finger type glaze breaker for honing is never advised. Polaris recommends using a rigid hone or arbor honing machine which also has the capability of oversizing.

  • Page 81: Crankshaft Straightening

    - - ENGINE CRANKSHAFT STRAIGHTENING Lubricate the bearings and clamp the crankshaft securely in the holding fixture. Refer to the illustrations below. Crankshaft Alignment Fixture PN 2870569 NOTE:The rod pin position in relation to the dial indicator position tells you what action is required to straighten the shaft.

  • Page 82

    Oil Type ....Polaris Premium 4 Synthetic (PN 2871281); or API certified “SH” 5W30 oil Capacity ....

  • Page 83

    - - ENGINE OIL FLOW - - EH42PL / EH50PL The chart on page 3.15 describes the flow of oil through the EH50PL engine. Beginning at the oil tank, the oil flows through a screen fitting in the bottom of the tank and into the oil supply hose. The feed side of the oil pump draws oil through the hose and into the crankcase oil gallery, and then pumps the oil through another passage to the one way valve.

  • Page 84

    - - ENGINE EH42PL / EH50PL OIL FLOW DIAGRAM EH42PL / EH50PL Engine Internal passage to camshaft (front left head bolt) Oil filter Oil feed to filter From filter to crankshaft One way valve Top fitting is oil Bottom fitting is oil feed or intake exhaust or return from bottom of...

  • Page 85

    - - ENGINE EH42PL / EH50PL ENGINE EXPLODED VIEW Crankcase Cylinder/ Cylinder Head Crankshaft Valve Train and Piston 3.16...

  • Page 86: Engine Removal

    - - ENGINE ENGINE REMOVAL REFER TO PAGE 3.8 - 3.10 FOR ENGINE REMOVAL / INSTALLATION NOTES. CAM CHAIN TENSIONER/ROCKER ARM/CAMSHAFT REMOVAL 1. Remove ignition timing inspection plug from recoil housing. To position crankshaft at Top Dead Center (TDC) on compression stroke: TDC “T”...

  • Page 87: Cam Chain Tensioner Inspection

    - - ENGINE CAM CHAIN TENSIONER INSPECTION 1. Pull cam chain tensioner plunger outward to the end of its travel. Inspect teeth on ratchet pawl (A) and plunger teeth (B) for wear or damage. 2. Push ratchet pawl and hold it. The plunger should move smoothly in and out of the tensioner body.

  • Page 88: Rocker Arm/shaft Inspection

    - - ENGINE ROCKER ARM/SHAFT INSPECTION 1. Mark or tag rocker arms to keep them in order for assembly. 2. Inspect each rocker arm cam follower surface. If there is any damage or uneven wear, replace the rocker arm. NOTE: Always inspect camshaft lobe if rocker arms are worn or damaged.

  • Page 89

    - - ENGINE ROCKER ARM/SHAFT INSPECTION, CONT. 4. Measure I.D. of each rocker arm and compare to specifications. Rocker Arm & Support I.D.: .8669-.8678I (22.020-22.041 mm) 5. Measure I.D. of both rocker arm shaft supports and visually inspect surface. Compare to specifications. 6.

  • Page 90: Camshaft Removal

    - - ENGINE CAMSHAFT REMOVAL 1. Remove thermostat housing. 2. Remove camshaft sprocket inspection cover. 3. Loosen three camshaft sprocket bolts. 4. Remove camshaft end cap and O-Ring. 5. Inspect camshaft end cap (thrust face) for wear. Replace if worn or damaged. 3.21...

  • Page 91

    - - ENGINE CAMSHAFT REMOVAL, CONT. 6. Place a clean shop towel in the area below cam chain sprocket and remove sprocket retaining bolts. 7. Slide camshaft inward to allow removal of cam sprocket and remove sprocket from camshaft and chain.

  • Page 92: Automatic Compression Release Installation

    - - ENGINE AUTOMATIC COMPRESSION RELEASE REMOVAL/INSPECTION NOTE: The automatic compression release mecha- nism can be inspected and serviced without removing the camshaft from the cylinder head. The actuator ball in the camshaft is not replaceable. Replace the cam- shaft as an assembly if the actuator ball is worn or dam- aged.

  • Page 93: Camshaft Inspection

    - - ENGINE CAMSHAFT INSPECTION 1. Visually inspect each cam lobe for wear, chafing or damage. 2. Thoroughly clean the cam shaft, making sure the oil feed holes are not obstructed. 3. Measure height of each cam lobe using a micrometer. Compare to specifications.

  • Page 94: Cylinder Head Exploded View

    - - ENGINE CYLINDER HEAD EXPLODED VIEW 1. Remove the two 6mm flange bolts (A) from cylinder head. 3.25...

  • Page 95: Cylinder Head Inspection, Cylinder Head Warpage

    - - ENGINE CYLINDER HEAD REMOVAL, CONT. 2. Loosen each of the four cylinder head bolts evenly 1/8 turn each time in a criss-cross pattern until loose. 3. Remove bolts (A) and tap cylinder head lightly with a plastic hammer until loose. CAUTION: Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging the thread.

  • Page 96: Cylinder Head Disassembly

    - - ENGINE CYLINDER HEAD DISASSEMBLY WARNING: Wear eye protection or a face shield during cylinder head disassembly and reassembly. NOTE: Keep all parts in order with respect to their location in the cylinder head. 1. Using a valve spring compressor, compress the valve spring and remove the split keeper.

  • Page 97

    - - ENGINE CYLINDER HEAD DISASSEMBLY, CONT. 4. Measure free length of spring with a Vernier caliper. Check spring for squareness. Compare to specifications. Replace spring if either measurement is out of specification. Valve Spring Free Length Valve Spring Length: Std: 1.654I (42.0 mm) Limit: 1.575I (40.0 mm) Squareness:...

  • Page 98: Valve Inspection

    - - ENGINE VALVE INSPECTION 1. Remove all carbon from valve with a soft wire wheel. 2. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” blocks and a dial indicator. 3.

  • Page 99: Combustion Chamber

    - - ENGINE VALVE INSPECTION, CONT. 6. Measure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer. Measure in two directions, front to back and side to side. 7.

  • Page 100: Valve Seat Reconditioning

    - - ENGINE VALVE SEAT RECONDITIONING Valve Seat Inspection Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be reconditioned. See Valve Seat Reconditioning, page 3.32. If the valve seat is cracked the cylinder head must be replaced.

  • Page 101

    - - ENGINE VALVE SEAT RECONDITIONING, CONT. Follow the manufacturers instructions provided with the valve seat cutters in the Cylinder Head Recondi- tioning Kit (PN 2200634). Abrasive stone seat re- conditioning equipment can also be used. Keep all valves in order with their respective seat. NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing.

  • Page 102

    - - ENGINE VALVE SEAT RECONDITIONING, CONT. 1. Install pilot into valve guide. 2. Apply cutting oil to valve seat and cutter. 3. Place 46° cutter on the pilot and make a light cut. 4. Inspect the cut area of the seat. If the contact area is less than 75% of the cir- cumference of the seat, rotate the pilot 180°...

  • Page 103

    - - ENGINE VALVE SEAT RECONDITIONING, CONT. 7. Remove valve and check where the Prussian Blue™ indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width. If the indicated seat contact is at the top edge of the valve face and contacts the margin area(B) it is too high on the valve face.

  • Page 104: Cylinder Head Assembly

    - - ENGINE VALVE SEAT RECONDITIONING, CONT. 10. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem. 11. Rotate the valve rapidly back and forth until the cut sounds smooth.

  • Page 105: Valve Sealing Test

    - - ENGINE CYLINDER HEAD ASSEMBLY, CONT. 5. Dip valve spring and retainer in clean engine oil and install spring with closely spaced coils toward the cylinder head. Closely spaced coils toward cylinder head 6. Place retainer on spring and install valve spring compressor.

  • Page 106

    - - ENGINE CYLINDER/PISTON REMOVAL AND INSPECTION Follow engine disassembly procedures to remove valve cover, camshaft and rocker arms, and cylinder head. 1. Remove cam chain guide at front of cylinder. 2. Loosen all four oil pipe banjo bolts and then remove the bolts and eight sealing washers.

  • Page 107

    - - ENGINE CYLINDER/PISTON REMOVAL AND INSPECTION, CONT. 4. Remove the two 6 mm cylinder base bolts. 5. Loosen each of the four large cylinder base bolts 1/4 turn at a time in a criss-cross pattern until loose and remove bolts.

  • Page 108: Piston Removal

    - - ENGINE PISTON REMOVAL 1. Remove circlip. Note piston directional arrow pointing toward the right (Mag) side of engine. 2. Remove piston circlip and push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch.

  • Page 109: Cylinder Inspection

    - - ENGINE CYLINDER INSPECTION 1. Remove all gasket material from the cylinder sealing surfaces. 2. Inspect the top of the cylinder for warpage using a straight edge and feeler gauge. Cylinder Warpage: .002″ (.05 mm) 3. Inspect cylinder for wear, scratches, or damage. 4.

  • Page 110

    - - ENGINE CYLINDER INSPECTION, CONT. 5. Record measurements. If cylinder is tapered or out of round beyond .002, the cylinder must be re-bored oversize, or replaced. Cylinder Taper Limit: .002 Max. Cylinder Out of Round Limit: .002 Max. Standard Bore Size: 3.6216-3.6224I (91.99-92.01 mm) PISTON-TO-CYLINDER CLEARANCE...

  • Page 111: Piston/rod Inspection

    - - ENGINE PISTON/ROD INSPECTION 1. Measure piston pin bore. Piston Pin Bore: .9055-.9057I (23.0-23.006 mm) 2. Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance. Piston Pin O.D. .9053-.9055I (22.994-23.0 mm) Piston Pin Measurement Locations 3.

  • Page 112: Piston Ring Installed Gap

    - - ENGINE PISTON/ROD INSPECTION, CONT. 4. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with Piston a thickness gauge. Replace piston and rings if ring-to-groove clearance exceeds service limits. Ring Piston Ring-to-Groove Clearance Feeler Gauge Top Ring Std: .0016-.0031I (.040-.080 mm)

  • Page 113: Crankcase Disassembly, Starter Drive Removal/inspection

    - - ENGINE CRANKCASE DISASSEMBLY NOTE: The recoil starter, starter motor, starter drive, flywheel, stator, cam chain and sprockets can be serv- iced with the engine in the frame. STARTER DRIVE REMOVAL/INSPECTION 1. Remove recoil housing bolts and remove housing. 2.

  • Page 114

    - - ENGINE FLYWHEEL/STATOR REMOVAL/INSPECTION 1. Remove flywheel nut and washer. 2. Install flywheel puller (PN 2870159) and remove flywheel. CAUTION: Do not thread the puller bolts into the flywheel more than 1/4″ or stator coils may be damaged. 3.

  • Page 115

    - - ENGINE CAM CHAIN/TENSIONER BLADE 1. Remove bolt securing tensioner blade to crankcase (A). 2. Remove blade and inspect for cracks, wear, or damage. 3. Remove cam chain. Inspect chain for worn or missing rollers or damage. Stretch chain tight on a flat surface and apply a 10 lb.

  • Page 116: One Way Valve

    - - ENGINE CAM CHAIN/TENSIONER BLADE, CONT. 4. Using the special socket, remove the crankshaft slotted nut (A). NOTE: The slotted nut is a left hand thread. 5. Remove cam chain drive sprocket (B) and Woodruff key from crankshaft. 6.

  • Page 117: Crankcase Separation

    - - ENGINE CRANKCASE SEPARATION 1. Remove flange bolts (10) from magneto side crankcase evenly in a cross pattern. 2. Separate crankcase by tapping with a soft faced hammer in reinforced areas. 3. Tap lightly on balancer gear with a brass drift through the hole in the crankcase if necessary, to ensure the balancer shaft stays in the PTO side crankcase.

  • Page 118: Oil Pump Removal/inspection

    - - ENGINE OIL PUMP REMOVAL/INSPECTION 1. Remove pump shaft bearing (A) and thrust washer (B) from pump shaft. 2. Remove (2) bolts holding pump drive gear (C). NOTE: On 500 H.O. models this gear is retained by (3) bolts.

  • Page 119

    - - ENGINE OIL PUMP REMOVAL/INSPECTION, CONT. 6. Remove the three screws and strainer screen from pump. 7. Clean screen thoroughly. 8. Remove pump body screw and feed chamber cover. 9. Measure pump end clearance using a feeler gauge and straight edge.

  • Page 120: Oil Pump Assembly

    - - ENGINE OIL PUMP REMOVAL/INSPECTION, CONT. 10. Measure clearance between outer feed rotor and pump body with a feeler gauge. Outer Feed Rotor to Pump Body Clearance: Std: .001-.003 (.0254-.0762 mm) Wear Limit: .004 (.1016 mm) 11. Measure rotor tip clearance with a feeler gauge. Rotor Tip Clearance: Std: .005 (.127 mm) Wear Limit: .008 (.2032 mm)

  • Page 121: Counter Balancer Shaft Removal/inspection

    - - ENGINE COUNTER BALANCER SHAFT REMOVAL/INSPECTION 1. Remove the shim washer from the counter balancer shaft. 2. Note the alignment dots on the balancer and crankshaft gears, the marks must be aligned during reassembly. 3. Turn the shaft until balancer counter weights clear the crankshaft and remove the balancer shaft from the crankcase.

  • Page 122: Crankshaft Removal/inspection

    - - ENGINE CRANKSHAFT REMOVAL/INSPECTION 1. Remove the shim washer from the crankshaft. 2. Support the PTO side crankcase and crankshaft; press the crankshaft out. Be careful not to damage the crankcase mating surface or connecting rod. 3. Use a feeler gauge to measure the connecting rod big end side clearance.

  • Page 123: Crankcase Bearing Inspection

    - - ENGINE CRANKCASE BEARING INSPECTION 1. Remove the seal from the PTO side crankcase. 2. Inspect the crankshaft main bearings, balancer shaft bearings, and pump shaft bearing. NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel.

  • Page 124: Crankcase Inspection

    - - ENGINE CRANKCASE INSPECTION 1. Remove all traces of gasket sealer from the crankcase mating surfaces. Inspect the surfaces closely for nicks, burrs or damage. 2. Check the oil pump and oil passage mating surfaces to be sure they are clean and not damaged.

  • Page 125: Crankshaft End Play Adjustment

    - - ENGINE END PLAY INSPECTION/ADJUSTMENT Before reassembling the crankcase,the following steps should be performed to determine the amount of crank- shaft, counter balancer shaft, and pump shaft end play. Excessive end play may cause engine noise at idle and slow speeds.

  • Page 126

    - - ENGINE CRANKSHAFT END PLAY ADJUSTMENT, CONT. 4. Measure the distance from the Magneto crankcase mating surface to the main bearing using the same method and record. 5. Subtract the thickness of the straightedge from the measurement obtained in Step 4 and record. Mag Case Depth 6.

  • Page 127: Counter Balancer Shaft End Play Adjustment

    - - ENGINE COUNTER BALANCER SHAFT END PLAY ADJUSTMENT 1. Make sure all bearings are firmly seated in the crankcase. Step 2 2. Measure the width of the counter balancer shaft at the bearing seats with a dial caliper or micrometer, and record reading.

  • Page 128: Pump Shaft Oil Seal Installation

    - - ENGINE PUMP SHAFT END PLAY ADJUSTMENT 1. Make sure the pump shaft bearing is firmly seated in the Magneto side crankcase. 2. Measure the distance from the magneto crankcase mating surface to the bearing using a dial caliper and a straight edge.

  • Page 129: Crankcase Assembly

    - - ENGINE CRANKSHAFT/COUNTER BALANCE/OIL PUMP INSTALLATION Lubricate all bearings with clean engine oil before assembly. Use the crankshaft installation tool kit PN 2871283 to prevent damage to the crankshaft and main bearings during installation. 1. Install the crankshaft into the PTO side crankcase. Screw the threaded rod into the crankshaft until the threads are engaged a minimum of one inch (25.4mm).

  • Page 130: Water Pump Mechanical Seal Installation

    - - ENGINE WATER PUMP MECHANICAL SEAL INSTALLATION 1. Clean the seal cavity to remove all traces of old sealer. 2. Place a new mechanical seal in the seal drive collar, and install on the pump shaft. 3. Screw the guide onto the end of the pump shaft. 4.

  • Page 131

    - - ENGINE WATER PUMP MECHANICAL SEAL REMOVAL - ENGINE INSTALLED, CONT. 3. Insert the puller legs between the water pump drive shaft and the remaining portion of the mechanical seal. Attach the puller legs to the main puller body. Ill. 3 Puller Legs Ill.

  • Page 132: One Way Valve Installation

    - - ENGINE ONE WAY VALVE INSTALLATION Install the one way valve plunger, spring, and plug us- ing a new sealing washer. One Way Valve Plug Torque: 16 ft. lbs. (2.2 kg-m) CAM CHAIN DRIVE SPROCKET INSTALLATION 1. Install the Woodruff key, drive sprocket, and slotted nut.

  • Page 133: Piston Ring Installation

    - - ENGINE PISTON RING INSTALLATION NOTE: Apply clean engine oil to all ring surfaces and ring lands. Always check piston ring installed gap before rings are installed on piston. See page 3.43. If the piston has been in service clean any accumulated carbon from the ring grooves and oil control ring holes.

  • Page 134: Piston Installation

    - - ENGINE PISTON INSTALLATION 1. Clean the gasket surfaces on the cylinder and crankcase. Remove all traces of old gasket material. 2. Make sure the cylinder mounting bolt holes are clean and free of debris. 3. Install a new circlip on one side of the piston with the end gap facing up or down, and tang outward.

  • Page 135: Cylinder And Head Installation, Cylinder Installation

    - - ENGINE CYLINDER INSTALLATION 1. Place the dowel pins in the crankcase and install a new cylinder base gasket. 2. Position the piston support block PN 2870390 (A) beneath the piston skirt to support the piston during cylinder installation. 3.

  • Page 136: Cylinder Head Installation

    - - ENGINE CYLINDER INSTALLATION, CONT. 7. Apply a light film of oil to the threads and flange surface of the cylinder mounting bolts. 8. Install all four bolts finger tight. Rotate the engine and position the piston at BDC. NOTE: If cam chain is installed, hold it up while rotating the engine to avoid damage to the chain, drive sprocket Cylinder Bolt Torque:...

  • Page 137: Camshaft Installation And Timing, Camshaft Timing

    Top Dead Center (TDC). CAMSHAFT TIMING 1. Apply Polaris Premium Starter Drive grease to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil.

  • Page 138

    - - ENGINE CAMSHAFT TIMING, CONT. 4. Loop the cam chain on the cam sprocket with the dots on the sprocket facing outward and the alignment pin notch facing directly upward. 5. Before positioning the sprocket on the camshaft, check the position of the cam sprocket alignment pin.

  • Page 139

    - - ENGINE CAMSHAFT TIMING Crankshaft to Camshaft Centerline Dots Sprocket Alignment Pin Single TDC Mark Aligned TDC Mark Rotation Do Not Use Advance Marks 3.70...

  • Page 140: Cam Chain Tensioner Installation

    - - ENGINE CAM CHAIN TENSIONER INSTALLATION 1. Release the ratchet pawl (A) and push the tensioner plunger (B) all the way into the tensioner body. 2. Install the tensioner body with a new gasket and tighten the bolts. Tensioner Bolt Torque: 6 ft.

  • Page 141

    - - ENGINE STATOR, FLYWHEEL AND STARTER DRIVE INSTALLATION, CONT. 5. Torque bolts evenly to specification. Stator Plate Bolt Torque: 5.1-6.5 ft. lbs. (.68-.88 kg-m) 6. Seal stator wire grommet with 3 Bond 1215 or equivalent sealer. Flywheel 1. Install flywheel, washer, and nut. Torque flywheel to specification.

  • Page 142: Thermostat Installation, Oil Pipes

    - - ENGINE ROCKER SHAFT/ROCKER ARM ASSEMBLY INSTALLATION 1. Assemble rocker arms, rocker shaft, and shaft supports. 2. Install and tighten rocker arm shaft locating bolt. 3. Apply starter drive grease to the cam lobes and cam follower surfaces. 4.

  • Page 143: Recoil Disassembly/inspection

    - - ENGINE RECOIL DISASSEMBLY/INSPECTION CAUTION: The recoil is under spring tension. A face shield and eye protection is required during this proce- dure. Replace any parts found to be worn or damaged. 1. Remove bolts and recoil housing. 2.

  • Page 144

    - - ENGINE RECOIL DISASSEMBLY/INSPECTION, CONT. 6. Hold reel firmly in housing. Pull rope handle until 12-18″ of rope is exposed, and hold reel in place. 7. Place rope in notch on outer edge of reel. Release tension on hub and allow reel to unwind...

  • Page 145: Recoil Assembly

    - - ENGINE RECOIL ASSEMBLY CAUTION: Be sure to wear a face shield and eye protec- tion when performing this procedure. To install a new spring: 1. Place spring in housing with the end positioned so the spring spirals inward in a counterclockwise direction. See photo at right.

  • Page 146

    - - ENGINE SPARK PLUG FOULING Spark plug cap loose or faulty Choke cable adjustment or plunger/cable sticking Foreign material on choke plunger seat or plunger Incorrect spark plug heat range or gap Carburetor inlet needle and seat worn Jet needle and/or needle jet worn or improperly adjusted Excessive carburetor vibration (loose or missing needle jet locating pins) Loose jets in carburetor or calibration incorrect for altitude/temperature...

  • Page 147: Troubleshooting

    - - ENGINE TROUBLESHOOTING Engine Turns Over But Fails to Start No fuel Dirt in fuel line or filter Fuel will not pass through fuel valve Fuel pump inoperative/restricted Tank vent plugged Carb starter circuit Engine flooded Low compression (high cylinder leakage) No spark (Spark plug fouled) Engine Does Not Turn Over Dead battery...

  • Page 148

    - - ENGINE TROUBLESHOOTING, CONT Excessive Smoke and Carbon Buildup Excessive piston-to-cylinder clearance Wet sumping Worn rings, piston, or cylinder Worn valve guides or seals Restricted breather Air filter dirty or contaminated Low Compression Decompressor stuck Cylinder head gasket leak No valve clearance or incorrectly adjusted Cylinder or piston worn Piston rings worn, leaking, broken, or sticking...

  • Page 149

    - - ENGINE COOLING SYSTEM TROUBLESHOOTING Overheating Low coolant level Air in cooling system Wrong type of coolant Faulty pressure cap or system leaks Restricted system (mud or debris in radiator fins or restriction to air flow, passages blocked in radiator, lines, pump, or water jacket) Lean mixture (restricted jets, vents, fuel pump or fuel valve) Fuel pump output weak...

  • Page 150

    - - CHAPTER 4 FUEL SYSTEM/CARBURETION Jetting Guidelines ......Main Jet Selection .

  • Page 151: Jetting Guidelines

    - - FUEL SYSTEM/CARBURETION JETTING GUIDELINES Changes in altitude and temperature affect air density, which is essentially the amount of oxygen available for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense.

  • Page 152


  • Page 153

    - - FUEL SYSTEM/CARBURETION FUEL FLOW DIAGRAM Fuel Tank Fuel Tank Vent Fitting Screens Fuel Pump Filter Fuel Valve Carburetor Vent Engine Carburetor L Located Above Oil Tank...

  • Page 154: Mikuni Jet Part Numbers

    - - FUEL SYSTEM/CARBURETION MIKUNI JET PART NUMBERS Main Jet Part Numbers Mikuni BST Carburetor Jet Number Part Number 112.5 3130554 3130555 117.5 3130556 3130557 122.5 3130558 3130559 127.5 3130560 3130561 132.5 3130562 3130563 137.5 3130564 3130527 142.5 3130566 3130567 147.5 3130568...

  • Page 155: Cv Carburetor System Function

    - - FUEL SYSTEM/CARBURETION CV CARBURETOR SYSTEM FUNCTION Carburetor Component Function System Main Components Main Function Main Affect Float System Inlet Pipe, Needle and Seat, Maintains specified fuel level All systems (Fuel Level Control) Float, Float Pin in float chamber (carburetor All throttle ranges float bowl) Venting...

  • Page 156: Mikuni Cv Carb Operation

    - - FUEL SYSTEM/CARBURETION MIKUNI CV CARB OPERATION The constant velocity carburetor incorporates a mechanically operated throttle plate and a vacuum controlled slide valve (vacuum slide). The venturi cross-sectional area in the carburetor bore is increased or decreased automatically by the vacuum slide, which moves according to the amount of negative pressure (less than atmo- spheric) present in the venturi.

  • Page 157

    - - FUEL SYSTEM/CARBURETION PILOT (IDLE AND SLOW) SYSTEM This system supplies fuel during engine operation with throttle valve closed (1) or slightly opened. The fuel from float cham- ber (2) is metered by pilot jet (3) where it mixes with air coming in through pilot air jet (4).

  • Page 158: Float System, Main 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 cham- ber, the float (1) rises and forces the inlet needle against the seat, shutting off the orifice in the seat.

  • Page 159

    - - FUEL SYSTEM/CARBURETION BST 34 CARBURETOR EXPLODED VIEW 1. Carburetor Assembly 2. Screw 3. Throttle Valve 4. Cover, Diaphragm 5. Jet Block Assembly 6. Spring 7. Diaphragm Assembly 8. Ring 9. “E” Ring 10. Ring 11. Needle Jet 12.

  • Page 160

    - - FUEL SYSTEM/CARBURETION BST 40 CARBURETOR EXPLODED VIEW 1. Cover, Diaphragm 2. Spring 3. Spring Seat 4. “E” Clip 5. Spacer 6. Jet Needle 7. Diaphragm Assembly 8. Throttle Valve 9. Cable Guide 10. Spring 11. Adjuster Cable 12.

  • Page 161

    - - FUEL SYSTEM/CARBURETION CARBURETOR DISASSEMBLY - MIKUNI CV Use the following disassembly, assembly, and inspection techniques to service a CV carburetor. 1. Remove carburetor diaphragm chamber cover with a ratchet style screwdriver. DO NOT use an impact driver to remove the screws or carburetor may be permanently damaged.

  • Page 162: Carburetor Cleaning

    - - FUEL SYSTEM/CARBURETION CARBURETOR DISASSEMBLY - MIKUNI CV, CONT. 4. Do not misplace the pilot mixture screw, spring, flat washer, or O-Ring. If anti-tamper plug is installed in pilot screw cavity, refer to Maintenance chapter 2 for removal procedure. O-Ring Washer Spring...

  • Page 163: Carburetor Inspection

    - - FUEL SYSTEM/CARBURETION CARBURETOR INSPECTION 1. Inspect jet needle and needle jet for wear. Look for discoloration, shiny spots, or and area that looks different than the rest of the needle. The middle to upper portion of the needle where it contacts the needle jet is the most likely wear point.

  • Page 164: Carburetor Assembly

    - - FUEL SYSTEM/CARBURETION CARBURETOR ASSEMBLY 1. Inspect the diaphragm (A) for holes, deterioration, or damage. Make sure the diaphragm is pliable but not swollen. The diaphragm should fit properly in the carburetor body. Replace diaphragm assembly if diaphragm is damaged. 2.

  • Page 165: Float Height Adjustment

    - - FUEL SYSTEM/CARBURETION FLOAT HEIGHT ADJUSTMENT 1. Place the carburetor on a level surface as shown at right to remove weight from float arm. In this position, the float tongue will rest lightly on the inlet needle valve pin without compressing the spring.

  • Page 166: Needle And Seat Leakage Test, Fuel Level

    - - FUEL SYSTEM/CARBURETION NEEDLE AND SEAT LEAKAGE TEST 1. Install the float bowl. Invert the carburetor and install a Mity-Vac™ (PN 2870975) to the fuel inlet fitting. Apply 5 PSI pressure to inlet fitting. The needle and seat should hold pressure indefinitely.

  • Page 167: Fuel Pump, Fuel Pump Disassembly

    FUEL PUMP The Polaris Sportsman is equipped with a pressure regulated fuel pump (about 1-3 PSI). The pump is located under the headlight cover at the front of the machine. Refer to illustration on following page for fuel pump compo- nent identification.

  • Page 168

    - - FUEL SYSTEM/CARBURETION FUEL PUMP EXPLODED VIEW 1. Fuel Pump Assembly 2. Diaphragm, Gasket Set 3. Screw and Washer Assembly 4. Screw and Washer Assembly 5. Screw and Washer Assembly 6. Pressure Regulator 7. Fuel Inlet 8. Fuel Outlet 4.18...

  • Page 169

    - - FUEL SYSTEM/CARBURETION TROUBLESHOOTING Fuel Starvation/Lean Mixture Symptoms: Hard start or no start, bog, backfire, popping through intake / exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle speed erratic. No fuel in tank Restricted tank vent, or routed improperly Fuel lines or fuel valve restricted Fuel filter plugged...

  • Page 170

    - - FUEL SYSTEM/CARBURETION TROUBLESHOOTING, CONT. Idle Too Low Choke cable bending or incorrectly adjusted Idle speed set incorrectly Idle mixture screw misadjusted or damaged Belt dragging Ignition timing incorrect Worn jet needle/needle jet Erratic Idle Choke cable bending or incorrectly adjusted Throttle cable incorrectly adjusted Air leaks, dirty carburetor passages (pilot circuit) Pilot mixture screw damaged or adjusted incorrectly...

  • Page 171: Table Of Contents

    - - CHAPTER 5 BODY AND STEERING Torque Specifications and Special Tools ... . Body Assembly, Exploded View ....Cover/Panel Removal .

  • Page 172

    - - BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS Front A-Arm Attaching Bolt ....30 ft. lbs. (41 Nm) Front A-Arm Ball Joint Stud Nut .

  • Page 173: 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 Seat Latch Release Storage Rear Cab Assembly Rear Mud Guard Front Cover Side Cover Front Cab Assembly Front Cab...

  • Page 174: Cover/panel Removal

    - - BODY / STEERING / SUSPENSION COVER/PANEL REMOVAL To Remove: Perform These Steps: Seat ..... . . Pull release lever at the rear of the seat Lift and pull seat rearward, disengaging seat from tabs at the rear of the fuel tank Side panels (See page 5.5) .

  • Page 175: Headlight Pod Exploded View

    - - BODY / STEERING / SUSPENSION HEADLIGHT POD EXPLODED VIEW Torque bolts evenly so gap is equal at front and rear of handlebar block 11-13 ft. lbs. (15-18 Nm) To harness connector Disassembly Clean knurling when repositioning handlebars S Remove two front Phillips screws (A).

  • Page 176: Side Panel Removal

    - - BODY / STEERING / SUSPENSION SIDE PANEL REMOVAL Side panel removal may be difficult until the locking tabs and receivers have been snapped and un- snapped a few times. 1. Remove seat. Grasp rear of side panel near rear Step 1.

  • Page 177: Steering Assembly, Exploded View

    - - BODY / STEERING / SUSPENSION STEERING ASSEMBLY, EXPLODED VIEW NOTE: To avoid damage to tie rods and other steering components, be sure to install tie rod end bolts in the proper direction. The steering post arm bolt (B) points up; the rod end bolts (A) point down.

  • Page 178: 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 179: Rear Suspension Assembly

    - - BODY / STEERING / SUSPENSION REAR SUSPENSION ASSEMBLY 17 ft. lbs. (24 Nm) 17 ft. lbs. (24 Nm) Forward 35 ft. lbs. (48 Nm) 35 ft. lbs. (48 Nm) 30 ft. lbs. (41 Nm) 35 ft. lbs. (48 Nm) Lower Control...

  • Page 180: Strut Assembly

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

  • Page 181: Front Strut Cartridge Replacement

    - - BODY / STEERING / SUSPENSION FRONT STRUT CARTRIDGE REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5.9. 1. Hold strut rod and remove top nut. 2. Compress spring using strut spring compressor tools. Strut Spring Compressor Tools PN 2871573 and PN 2871574 3.

  • Page 182: Ball Joint Replacement

    - - BODY / STEERING / SUSPENSION BALL JOINT REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5.9. 1. Loosen front wheel nuts slightly. 2. Elevate and safely support machine under footrest/frame area. CAUTION: Serious injury may result if machine tips or falls.

  • Page 183: Steering Post Assembly, Decal Replacement

    - - BODY / STEERING / SUSPENSION STEERING POST ASSEMBLY Grease Fitting 12 ft. lbs. (16 Nm) 1. Hand tighten. 2. Align cotter pin hole. 3. Install cotter pin. Bend both ends of cotter pin around nut in opposite directions. 4.

  • Page 184: Table Of Contents

    - - CHAPTER 6 PVT SYSTEM Service Tools, Supplies & Torques ....PVT System Operation ......PVT Maintenance/Inspection .

  • Page 185: Pvt System Fastener Torques

    - - CLUTCH SPECIAL SERVICE TOOLS AND SUPPLIES Description Part Number Drive Clutch Puller ......2870506 Clutch Holding Fixture .

  • Page 186: Pvt Operation, Drive Clutch Operation, Driven Clutch Operation

    CLUTCH PVT OPERATION The Polaris variable transmission (PVT) consists of three major assemblies: 1) drive clutch; 2) drive belt; and 3) driven clutch. The internal components of the drive clutch and driven clutch control clutch engagement (for initial vehicle movement), clutch upshifting and backshifting. During the development of an ATV, the PVT system is matched first of all to the engine power curve;...

  • Page 187: Pvt Maintenance/inspection, Pvt Drying

    - - CLUTCH PVT MAINTENANCE/INSPECTION Under normal operation the PVT system will provide years of trouble free operation. Periodic inspection and main- tenance is required to keep the system operating at peak performance. The following list of items should be in- spected and maintained to ensure maximum performance and service life of PVT components.

  • Page 188: Pvt Overheating

    10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch malfunction. For inspection of clutch components, please contact your Polaris dealer. Poor engine performance. Fouled plugs, foreign material in gas tank, fuel lines, or carburetor.

  • Page 189: Pvt Disassembly

    - - CLUTCH PVT DISASSEMBLY NOTE: Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement. (See page 6.8). 1. Remove seat. 2. Remove or loosen rear cab fasteners as necessary to gain access to PVT outer cover.

  • Page 190

    - - CLUTCH PVT DISASSEMBLY, CONT. 7. Remove driven clutch retaining bolt and driven clutch. Use puller if necessary. Driven Clutch Puller PN 2870913 8. Remove driven clutch offset spacers from the transmission input shaft. Keep Spacers In Order 9.

  • Page 191: Pvt Assembly

    - - CLUTCH PVT ASSEMBLY 1. Inspect PVT inner cover-to engine seal. Replace if cracked or damaged. Seal this edge to cover on engine side 2. Place a new foam seal on transmission input shaft. 3. Apply RTV silicone sealant to outside edge of inner cover-to-engine seal, to ensure a water tight fit between the seal and the cover on engine side.

  • Page 192: Pvt Sealing And Ducting Components

    - - CLUTCH PVT SEALING AND DUCTING COMPONENTS Clip Outer Cover Seal Inner Cover Inlet duct Inner Cover Seal Outer Cover Retainer Exhaust Duct...

  • Page 193

    - - CLUTCH RELATIONSHIP OF DRIVE CLUTCH WEIGHTS AND SPRING IN MAINTAINING OPERATING RPM The drive clutch is an RPM sensing unit designed to transfer the maximum amount of horsepower from the engine to the ground. This is accomplished through weights and a spring inside the unit which react to the centrifugal force applied to the clutch from the engine RPM.

  • Page 194: Drive Clutch Spring Specifications

    - - CLUTCH DRIVE CLUTCH SPRING SPECIFICATIONS The drive clutch spring has two prima- FULL UPSHIFT NEUTRAL ry functions: Blue/Blue- Gold ATV TRAVEL 1. To control clutch engagement 7041080 Gold RPM. The springs which have a 7041148 higher rate when the clutch is in Silver 7041062 neutral...

  • Page 195: Shift Weights

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

  • Page 196: Shift Weight Inspection, Button To Tower Clearance Inspection

    All PVT system maintenance repairs must be per- formed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this manual.

  • Page 197: Drive Clutch Exploded View

    - - CLUTCH DRIVE CLUTCH EXPLODED VIEW Drive Clutch Teflon coated brass bushing Teflon coated brass bushing Mark with permanent marker before disassembly EBS Drive Clutch Spider Lock Nut PTFE Washers One Way Clutch Spacer Sleeve Mark with permanent marker before disassembly 6.13...

  • Page 198: Drive Clutch Disassembly

    - - CLUTCH DRIVE CLUTCH DISASSEMBLY 1. Using a permanent marker, mark the cover, spider, Mark and moveable and stationary sheaves for reference. The X’s may not have been in alignment before disassembly. 2. Remove cover bolts evenly in a cross pattern, and remove cover plate.

  • Page 199: Spider Removal

    - - CLUTCH SPIDER REMOVAL 1. Install clutch in holding fixture and loosen the spider (counterclockwise) using spider removal tool. Clutch Holding Fixture: PN 2871358 Spider Removal Tool: PN 2870341 NOTE: It is important that the same number and thickness of washers are reinstalled beneath the spider during as- sembly.

  • Page 200

    - - CLUTCH ROLLER, PIN AND THRUST WASHER INSPECTION 3. Inspect all rollers, bushings and roller pins by pulling a flat metal rod across the roller. Turn roller with your finger. If you notice resistance, galling, or flat spots, replace rollers, pins and thrust washers in sets of three.

  • Page 201: Drive Clutch Assembly

    - - CLUTCH DRIVE CLUTCH ASSEMBLY NOTE: It is important that the same number and thick- ness of washers are reinstalled beneath the spider dur- ing assembly. The Teflon bushings are self-lubricating. Do not apply oil or grease to the bushings. 1.

  • Page 202: Drive Belt Tension

    - - CLUTCH DRIVE CLUTCH ASSEMBLY, CONT. 8. Reinstall cover, aligning “X” mark with other marks. Torque cover bolts evenly to specification. Spider Torque: 200 ft. lbs. (276 Nm) Cover Screw Torque: 90 in. lbs. (10.4 Nm) DRIVE BELT TENSION NOTE: Pinch the sheaves lightly together with clamp to prevent the belt from being pushed into the driven sheave.

  • Page 203: Drive Belt Removal/inspection

    - - CLUTCH DRIVE BELT REMOVAL/INSPECTION 1. Remove outer PVT cover as described in PVT Disassembly. 2. Mark drive belt direction of rotation so that it can be installed in the same direction. NOTE: Normally positioned so part numbers are easily read. 3.

  • Page 204: Drive Belt Installation

    - - CLUTCH DRIVE BELT REMOVAL/INSPECTION, CONT. 7. Measure belt length with a tape measure around the outer circumference of the belt. Belts which measure longer than nominal length may require driven shimming or engine adjustment for a longer center distance to obtain proper belt deflection.

  • Page 205: Clutch Alignment, Clutch Offset

    - - CLUTCH CLUTCH ALIGNMENT 1. Remove belt and install offset/alignment tool as shown. Offset Alignment Tool PN 2870654 - STD 2. With tool touching rear of driven clutch inner sheave, the PN 2872292 - EBS distance at point “A” should be 1/8″. If the distance is greater than 1/8″...

  • Page 206: Drive Clutch Bushing Service

    - - CLUTCH DRIVE CLUTCH BUSHING SERVICE Polaris Kit PN 2871226 Item Qty. Part Description Part No. P-90 Drive Clutch and Driven Clutch 5020628 Bushing Installation Tool Drive Clutch Cover Bushing Removal and 5020629 Installation Tool (for all drive clutches)

  • Page 207

    - - CLUTCH DRIVE CLUTCH MOVEABLE SHEAVE - BUSHING REMOVAL, CONT. 6. Turn sheave puller barrel together counterclockwise on puller rod until bushing is removed. 7. Remove nut from puller rod and set aside. 8. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard.

  • Page 208

    - - CLUTCH DRIVE CLUTCH COVER - BUSHING REMOVAL 1. Install main adapter (Item 8) on puller. Piston Pin Puller PN 2870386 Main Adaptor 2. From outside of clutch cover, insert removal tool (Item 3) into cover bushing. 3. With inside of cover toward vise, slide cover onto puller.

  • Page 209

    - - CLUTCH DRIVE CLUTCH COVER - BUSHING INSTALLATION 1. Apply Loctite 680 retaining compound to the back side of new bushing. Working from inside of cover, insert bushing and bushing installation tool into center of clutch cover. Bushing PN 3576510 Loctitet 680 PN 2870584 2.

  • Page 210

    - - CLUTCH DRIVEN CLUTCH DISASSEMBLY/INSPECTION (NON EBS) Used to adjust belt tension. One must always be installed. CAUTION: Wear eye protection when removing snap ring to prevent serious personal injury. 1. Apply and hold downward pressure on the helix, or place driven clutch in compressor tool PN 8700220.

  • Page 211

    - - CLUTCH DRIVEN CLUTCH DISASSEMBLY / INSPECTION, CONT. 5. Check alignment of tabs on spring. Replace the spring if tabs are misaligned or the spring coils are distorted. Tabs Aligned 6. Inspect ramp buttons in the moveable sheave and replace if worn.

  • Page 212

    - - CLUTCH DRIVEN CLUTCH DISASSEMBLY / INSPECTION, CONT. 8. Inspect the Teflon™ coating on the moveable sheave bushing. Inspect bushings for wear Moveable Sheave Bushing Inspection: Replace the bushing if more brass than Teflon™ is visible on the bushing. Re- fer to bushing replacement in this chapter.

  • Page 213: Driven Clutch Assembly

    - - CLUTCH DRIVEN CLUTCH ASSEMBLY 1. Install moveable sheave with spacer washers. Important: At least one spacer washer must be installed. Teflon bushings are self-lubricating. Do not apply oil or grease to the bushings. 2. Install spring, inserting spring tab into proper hole in moveable sheave.

  • Page 214

    - - CLUTCH DRIVEN CLUTCH MOVEABLE SHEAVE - BUSHING REMOVAL NOTE: Bushings are installed at the factory using Loc- tite. In order to remove the bushing it will be necessary to apply heat. A press can be used to remove and install some of the bushings.

  • Page 215

    - - CLUTCH DRIVEN CLUTCH MOVEABLE SHEAVE - BUSHING REMOVAL, CONT. 5. Working from the top, install bushing removal tool (Item 5) into center of clutch sheave with smaller diameter toward bushing to be removed. illustration at right. Bushing Removal Tool (#5) 6.

  • Page 216

    - - CLUTCH DRIVEN CLUTCH MOVEABLE SHEAVE - BUSHING INSTALLATION 1. Working from the top, insert adapter number ten onto puller. See illustration at right. 2. Start new bushing evenly in moveable sheave. Apply Loctite 680 retaining compound to the back side of new bushing.

  • Page 217

    - - CLUTCH DRIVEN CLUTCH MOVEABLE SHEAVE - BUSHING INSTALLA- TION, CONT. 4. Install nut onto puller rod and hand tighten against installation tool. 5. Turn clutch sheave counterclockwise until bushing is seated. 6. Remove nut from puller rod and set aside. 7.

  • Page 218: Ebs Theory Of Operation

    CLUTCH EBS THEORY OF OPERATION The Engine Braking System (EBS) combines the standard “no-shift” feature of the Polaris Variable Transmission (PVT) system with the added benefit of engine braking. Outwardly, both drive and driven clutch resemble those used in a standard PVT system, however, there are some important differences in the EBS clutches: Belt Deflection - It’s important to note that the belt is always “tight”...

  • Page 219

    WARNING All PVT system maintenance repairs must be performed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands PVT system maintenance and repair procedures. Because of the critical nature and precise balance of components within the PVT system, it is absolutely essential that no attempt at disassembly or repair be made without factory authorized special tools and service procedures.

  • Page 220: Ebs Exploded View

    - - CLUTCH ENGINE BRAKING SYSTEM (EBS) EBS Exploded View Drive Clutch Assembly Retaining Ring 2.25″ PTFE Flat Spacer Washer Ramp One Way Clutch Drive Ramp Bushing Shift Weights 2″ PTFE Washer Washer Compression Bushing Spring Torque to Cover Compression 185 Ft.

  • Page 221: Drive Clutch Inspection

    - - CLUTCH Mark with permanent marker before disassembly One way clutch EBS Drive Clutch ONE-WAY CLUTCH INSPECTION (DRIVE CLUTCH) 1. Rotate one-way clutch clockwise (as viewed from the cover plate side). The clutch should rotate on the shaft with only slight amount of drag. There should not be any binding or rough spots.

  • Page 222: Moveable Sheave Bushing Inspection

    - - CLUTCH DRIVE CLUTCH INSPECTION, CONT. 2. Remove moveable sheave. 3. Lift one-way clutch off shaft. Replace as an assembly if worn, damaged, or if problems were noted on page 6.37. 4. Inspect surface of shaft for pitting, grooves, or damage.

  • Page 223

    - - CLUTCH DRIVEN CLUTCH DISASSEMBLY/INSPECTION - EBS CAUTION: The driven clutch must be disassembled from the helix end to lessen the chance of damage to seals in the one-way clutch. Review all information below before proceeding. ONE-WAY CLUTCH PRELIMINARY INSPECTION (DRIVEN) 1.

  • Page 224

    - - CLUTCH DRIVEN CLUTCH DISASSEMBLY/ INSPECTION, CONT. 4. Push helix inward. Remove snap ring, washer, helix, and spring. The spring is a compression spring only and has no torsional wind. NOTE: Rotating the moveable sheave so that the roll- ers are not in contact with either helix ramp surfaces will lessen the effort needed to push helix inward.

  • Page 225

    - - CLUTCH DRIVEN CLUTCH DISASSEMBLY/ INSPECTION, CONT. 7. Inspect moveable sheave bushing for wear. Moveable Sheave Bushing Inspection: Replace the bushing if more brass than Teflon™ is visible on the surface of the bushing. 8. Check for movement of the driven clutch shaft in the one-way clutch.

  • Page 226

    - - CLUTCH BUSHING REPLACEMENT, EBS DRIVE EBS CLUTCH BUSHING REMOVAL AND INSTALLATION Use Tool Kit PN 2201379 The contents of this kit include: Item Qty. Part Description Part No. EBS Drive Clutch and Driven Clutch 5132027 Puller Tool EBS Drive Clutch and Driven Clutch 5132501 Puller Nut...

  • Page 227

    - - CLUTCH BUSHING REPLACEMENT, EBS DRIVE, CONT. EBS Drive Moveable - Bushing Installation 1. Place main adapter (Item 8) on puller. Puller Tool (A/B) Nut (C) Side “A” toward 2. Apply Loctitet 609 evenly to bushing bore inside sheave moveable sheave.

  • Page 228

    - - CLUTCH BUSHING REPLACEMENT, EBS DRIVEN EBS Driven - Bushing Removal 1. Install puller adapter (Item 10) onto puller. 2. Insert EBS main adapter (Item D) onto puller. See Ill. 1. 3. Install bushing removal tool (Item E) into center of clutch sheave.

  • Page 229

    - - CLUTCH BUSHING REPLACEMENT, EBS DRIVEN, CONT. EBS Driven - Backside (Outer) Bushing Removal 1. Install main puller adapter (Item 8) onto puller. 2. Install adapter reducer (Item 9). 3. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear.

  • Page 230

    - - CLUTCH TROUBLESHOOTING Situation Probable Cause Remedy Engine RPM -Wrong or broken drive clutch spring. -Replace with recommended spring. below specified operating -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine application. range, although engine is prop- -Driven clutch spring broken or installed in -Replace spring;...

  • Page 231

    - - CLUTCH TROUBLESHOOTING Situation Probable Cause Remedy Belt slippage -Belt worn out -Replace belt. -Water ingestion -Inspect and seal PVT system. -Belt contaminated with oil or grease -Inspect and clean. Belt burnt, thin -Abuse (continued throttle application when -Caution operator to operate machine within guidelines.

  • Page 232: Table Of Contents

    - - CHAPTER 7 FINAL DRIVE Final Drive Torque Specifications ....AWD Operation Overview ..... . Front Hub Disassembly .

  • Page 233: Final Drive

    - - FINAL DRIVE WHEEL AND HUB TORQUE TABLE ¡ Item Specification Front Wheel Nuts 20 Ft. Lbs. Rear Wheel Nuts 20 Ft. Lbs. Front Hub Nut Refer to text for procedure (Pg 7.5) Rear Hub Retaining Nut 100 Ft. Lbs. ¡...

  • Page 234: Awd Operation Overview

    - - FINAL DRIVE AWD OPERATION OVERVIEW With the Polaris All Wheel Drive System activated (AWD selected), the machine operates as a 2 wheel drive vehicle until the rear wheels lose traction. If the rear wheels lose traction the front wheel rotational speed will decrease, causing the front drive axle speed to exceed front wheel speed.

  • Page 235

    - - FINAL DRIVE FRONT HUB REMOVAL (AWD) If an AWD problem is encountered, thoroughly inspect the electrical portion of the system as well as the front hub mechanism. Refer to the electrical chapter. 1. Carefully lift and support the front end of the machine as shown with the jack stands under the front end of the foot rests.

  • Page 236

    - - FINAL DRIVE HUB/WHEEL BEARING INSTALLATION 1. Thoroughly inspect the hub internally. If the hub bearing sleeve is damaged or shows signs of movement, the hub assembly must be replaced. When the sleeve is pressed into the hub it should be flush with the outside surface of the hub.

  • Page 237: Awd Front Hub Bearing Adjustment

    7. Remove fill check plug and rotate hole to either 4:00 or 8:00 position. 8. Fill with Polaris Premium Demand Drive Hub Fluid or Type F Automatic Transmission Fluid until fluid trickles out. NOTE: Do not force the oil into the hub under pressure.

  • Page 238: Awd Front Hub Exploded View

    - - FINAL DRIVE AWD FRONT HUB EXPLODED VIEW Garter Spring Brake Disc Armature Plate Seal Detail Bearing (1.000″ I.D.) DETAIL A Spacer Bearing Race Front Hub Clutch Front Hub Clutch Bearing (1.000″ I.D.) Cotter Pin ¡ Castle Nut (Use new cotter pin) O-Ring...

  • Page 239: Awd Hub Seal Replacement

    It is very important that the brake disc be free of any oil or solvents. 6. Reinstall the brake disc using genuine Polaris OEM bolts that have a pre-applied locking agent. Do not substitute bolts or use old ones.

  • Page 240

    - - FINAL DRIVE MAGNETIC COIL REMOVAL 1. Remove the front drive axle as described later in this chapter. 2. Remove the seal sleeve from the strut casting using a drift punch and hammer, tapping evenly on each side until the sleeve slides off. 3.

  • Page 241: Hilliard Clutch Disassembly/inspection

    - - FINAL DRIVE HILLIARD CLUTCH DISASSEMBLY/INSPECTION 1. Remove front hub. See page 7.3. 2. Remove Hilliard clutch assembly. 3. Disassemble the roller clutch and thoroughly clean all parts. CAUTION: Do not remove the garter spring. If the spring is removed, it will become over stressed and will require replacement. 4.

  • Page 242: Awd Armature Plate Inspection

    - - FINAL DRIVE AWD ARMATURE PLATE INSPECTION 1. As the armature plate is engaged, it should contact the outer magnet pole (seal sleeve) and the inner magnet pole. Also, the armature plate must be flat when placed on a flat surface. Bent armature plates should be replaced.

  • Page 243: Awd Front Drive Axle Removal

    - - FINAL DRIVE AWD FRONT DRIVE AXLE REMOVAL 1. Loosen front wheel nuts slightly. 2. Elevate and support machine under footrest/frame area with front wheels elevated. CAUTION: Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.

  • Page 244: Awd Front Drive Axle Installation

    - - FINAL DRIVE AWD FRONT DRIVE AXLE REMOVAL, CONT. 9. Remove cotter pin and nut from lower A-arm ball joint. Remove lower A-arm from ball joint. 10. Using roll pin remover P/N 2872608, remove roll pin at front housing. Roll Pin Remover Tool P/N 2872608 11.

  • Page 245

    - - FINAL DRIVE DRIVESHAFT AND CV JOINT HANDLING TIPS Care should be exercised during driveshaft removal or when servicing CV joints. Driveshaft components are precision parts. Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life.

  • Page 246

    - - FINAL DRIVE FRONT DRIVE SHAFT CV JOINT BOOT REPLACEMENT, CONT. 5. Remove clamps from rubber boot using the proper boot clamp pliers. Retaining ring 6. Remove the large end of the boot from the CV joint, slide the boot back and separate the wheel spindle and CV joint assembly from the axle shaft by pulling the shaft sharply outward, away from the CV joint.

  • Page 247: Awd Front Drive Axle Exploded View

    - - FINAL DRIVE AWD FRONT DRIVE AXLE EXPLODED VIEW Front Drive Axle Components Boot Drive Axle CV Joint Assy Clamps Circlip Yoke U--Joint Assy Front Prop Shaft Components O-Ring Propshaft Assembly Prop Shaft Cross and Bearing Kit Yoke, Propshaft to Transmission Spring Pin Yoke, Front Gearcase 7.15...

  • Page 248

    - - FINAL DRIVE AWD STRUT CASTING FRONT DRIVE AXLE SEAL REPLACEMENT 1. Disassemble front hub. Refer to page 7.3. 2. Remove the cotter pin and castle nut from the A- arm ball joint. Separate A-arm from ball joint. 3.

  • Page 249

    - - FINAL DRIVE SEAL SLEEVE REPLACEMENT Front Drive Axle Seal Sleeve 1. If front axle sleeves become damaged and leak fluid they are replaceable. Using a hammer and drift punch, remove the seal sleeve by driving it off evenly being careful not to nick or damage the sleeve mounting area (A).

  • Page 250: Awd Front Prop Shaft Removal

    - - FINAL DRIVE AWD FRONT PROP SHAFT REMOVAL 1. Using roll pin remover P/N 2872608, remove the roll pin from prop shaft at rear of housing. Slide prop shaft back and away from front housing. Pull sharply forward to remove from transmission shaft.

  • Page 251: U-joint Disassembly

    - - FINAL DRIVE U-JOINT DISASSEMBLY CAUTION: Always wear eye protection. 1. Remove internal or external snap ring from all bearing caps. NOTE:If yoke or bearing is removed, cross bearing must be replaced. Note orientation of grease fitting and mark inner and outer yoke for correct re-positioning dur- ing installation.

  • Page 252: U-joint Assembly

    - - FINAL DRIVE U-JOINT DISASSEMBLY CONT. 4. Force U-joint cross to one side and lift out of inner yoke. U-JOINT ASSEMBLY 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 253

    - - FINAL DRIVE U-JOINT ASSEMBLY, CONT. 4. Install outer yoke, aligning marks made before disassembly. 5. Repeat steps 1-3 to install bearing caps on outer yoke. 6. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown.

  • Page 254: Awd Front Housing Removal

    - - FINAL DRIVE AWD FRONT HOUSING REMOVAL 1. Stop engine, place machine in gear and set parking brake. 2. Loosen right front wheel nuts slightly. 3. Elevate support machine under footrest/frame area. CAUTION: Serious injury may result if machine tips or falls.

  • Page 255

    - - FINAL DRIVE AWD FRONT HOUSING DISASSEMBLY, CONT. 3. Remove output shaft assembly, large shim, and thrust button with its small shim. 4. Clean all parts and inspect spacers for wear. Inspect ring gear for chipped, broken, or missing teeth.

  • Page 256: Awd Front Housing Assembly

    - - FINAL DRIVE AWD FRONT HOUSING ASSEMBLY 1. Replace all O-rings, seals, and worn components. 2. Press pinion shaft seal into pinion cover until flush with sealing surface. 3. Inspect pinion and output shaft bushings. Bushings 4. Inspect bearings on output and pinion shafts. To replace, press new bearing on to shaft.

  • Page 257

    FRONT HOUSING INSTALLATION 1. To install housing, reverse removal procedure. Use new roll pins in drive shafts. 2. Add Polaris Premium Front Housing Lubricant or GL5 80-90 gear lube to front housing. Check drain plug for proper torque. Fill Plug...

  • Page 258: Awd Front Housing Exploded View

    - - FINAL DRIVE AWD FRONT HOUSING EXPLODED VIEW Vent Bushing Seal Output Shaft Pinion Shaft Pinion Cover Bearing Retaining Ring O-Ring Shim Output Cover Bearing O-Ring Thrust Button Seal Shim Seal 7.26...

  • Page 259: Rear Hub/bearing Carrier Removal

    - - FINAL DRIVE REAR HUB/BEARING CARRIER REMOVAL 1. Lock the parking brake. Remove rear hub cap. 2. Remove cotter pin. 3. Loosen the hub retaining nut. 4. Loosen the wheel nuts. 5. Safely support the rear of the ATV. CAUTION: Serious injury could occur if machine tips or falls.

  • Page 260

    - - FINAL DRIVE REAR HUB/BEARING CARRIER REMOVAL, CONT. 8. Remove hub. 9. Remove upper control arm bolt as shown. 10. Remove both lower control arm bolts. 11. Remove bearing carrier. 7.28...

  • Page 261: Rear Hub Installation

    - - FINAL DRIVE REAR HUB INSTALLATION 1. Start bearing carrier on drive shaft. 2. Align bottom of carrier housing and lower control arm. Grease and slide lower control arm bushings into place, securing corner housing. 3. Install and torque both lower control arm bolts. Lower Control Arm Bolt Torque: 30 ft.

  • Page 262: Rear Hub Disassembly

    - - FINAL DRIVE REAR HUB DISASSEMBLY 1. Remove outer snap ring. 2. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown. NOTE: Drive bearing out evenly by tapping on outer race only.

  • Page 263: Rear Hub Assembly

    - - FINAL DRIVE REAR HUB ASSEMBLY 1. Support bottom of bearing carrier housing. 2. Start bearing in housing. 3. Press bearing into place until outer race bottoms on housing. CAUTION: Use an arbor and press only on the outer race, as bear- ing damage may occur.

  • Page 264: Rear Drive Shaft Removal

    - - FINAL DRIVE REAR DRIVE SHAFT REMOVAL 1. Remove rear hub and bearing carrier. (See pages 7.27 - 7.28, steps 1- 9). 2. Tip hub outward and remove shaft from hub. 3. Pull sharply outward to remove shaft from transmission.

  • Page 265: Rear Drive Shaft Installation

    - - FINAL DRIVE REAR DRIVE SHAFT INSTALLATION 1. Slide shaft assembly into bearing carrier hub. 2. Apply anti-seize compound to splines of shaft. 3. Install a new lock ring and install the shaft. 4. Lift bearing carrier into place and install bolt to upper control arm.

  • Page 266: Rear Drive Shaft Service

    - - FINAL DRIVE REAR DRIVE SHAFT SERVICE 1. Remove clamps from rubber boot(s) using the proper boot clamp pliers. CV Boot Clamp Pliers: Earless Type 8700226 2. NOTE: Photo at right is shown without shaft for Snap ring located in clarity.

  • Page 267

    - - FINAL DRIVE REAR DRIVE SHAFT SERVICE, CONT. 4. Place a new snap ring in the groove of the CV joint inner hub, with tabs facing the shaft as shown. Tabs face shaft 5. Refit CV joint on interconnecting shaft by tapping Tap joint onto shaft with a plastic hammer on the joint housing.

  • Page 268

    - - FINAL DRIVE REAR DRIVE SHAFT SERVICE, CONT. (Boot Replacement) 1. Remove CV joint from end of shaft. (See page 7.34) 2. Remove boot from shaft. NOTE:When replacing a damaged boot, check the grease for contamination by rubbing it between two fingers. A gritty feeling indicates contamination.

  • Page 269: Table Of Contents

    - - CHAPTER 8 TRANSMISSION SERVICE Torque Specifications ......Gear Shift Selector Removal ....Gear Shift Selector Disassembly .

  • Page 270

    - - TRANSMISSION TORQUE SPECIFICATIONS Transmission Case Bolts ......... 12 ft.

  • Page 271: Gear Shift Selector Removal, Gear Shift Selector Disassembly

    - - TRANSMISSION GEAR SHIFT SELECTOR REMOVAL NOTE: To change fluid, remove selector box assembly, disassemble, clean, and assemble. 1. Remove parts that interfere with access to shift selector (seat, right side panel, and exhaust heat shield, etc.). 2. Disconnect the two linkage rods from gear shift selector slides.

  • Page 272

    - - TRANSMISSION GEAR SHIFT SELECTOR DISASSEMBLY, CONT. 2. Carefully pull the gear shift selector cover and rod from the gear shift selector body. 3. Set the cover/rod assembly aside. 4. Remove the three springs from gear shift selector. 5.

  • Page 273: Gear Shift Selector Assembly

    3. Clamp gear shift selector body lightly in a soft jawed vise. 4. Fill selector body with Polaris 0W-40 All Season Synthetic motor oil. The oil level should be at one half the height of the slides (approx. 1 oz.).

  • Page 274: Gear Shift Selector Installation, Boot Replacement

    - - TRANSMISSION GEAR SHIFT SELECTOR INSTALLATION 1. Place gear shift selector back into the mounting bracket and replace five bolts. 2. Reconnect linkage rods to gear shift selector slides. Adjust as required. See linkage adjustment procedures. 3. Replace remaining parts. BOOT REPLACEMENT NOTE: If moisture is found in the gear shift selector Screw...

  • Page 275: Transmission Removal

    - - TRANSMISSION TRANSMISSION REMOVAL All operations regarding transmission front output housing assembly can be performed with transmission installed in frame. 1. Remove the inner PVT cover. Refer to Clutch Chapter. 2. Remove complete airbox assembly transmission vent line. 3.

  • Page 276

    - - TRANSMISSION TRANSMISSION REMOVAL, CONT. 11. Disconnect the sway bar from both sides. Remove right side upper control arm. 12. Remove left side shock absorber. 13. Remove left rear drive shaft (see page 7.32). 14. Remove left side upper control arm. 15.

  • Page 277

    - - TRANSMISSION TRANSMISSION REMOVAL, CONT. 17. Remove front support bracket. Forward Front Transmission Support Bracket 18. Remove bottom transmission bolts as shown in illustration. 19. Lift and remove transmission out right side of frame. Remove bolts...

  • Page 278: Transmission Installation

    - - TRANSMISSION TRANSMISSION INSTALLATION 1. Apply Premium All Season grease to splines of front output shaft ,install new O-ring in prop shaft, insert output shaft into prop shaft. 2. Rotate transmission into place from right side of frame. 3.

  • Page 279

    9. Install PVT system. Refer to PVT section for procedure. 10. Install airbox assembly and transmission vent line. Be sure vent line is not kinked or pinched. 11. Add Polaris Premium Synthetic Gearcase Lubricant to the proper level on dipstick.

  • Page 280: Transmission Disassembly

    - - TRANSMISSION TRANSMISSION DISASSEMBLY 1. Remove gear indicator switches BEFORE disassembly. Remove switches 2. Drain and properly dispose of transmission oil. Drain 3. Remove all cover bolts. Tap cover with soft face Remove all bolts hammer to remove. Note 2 bolts in center of cover. CAUTION: Do not pry on case half sealing surfaces.

  • Page 281

    - - TRANSMISSION TRANSMISSION DISASSEMBLY, CONT. 4. Mark chain rotation direction for assembly. Note location of chain tensioner cam. If fully extended, chain is worn beyond service limit. Replace chain and chain tensioner shoe. 5. Remove chain tensioner along with mounting pins and spring.

  • Page 282

    - - TRANSMISSION TRANSMISSION DISASSEMBLY, CONT. 7. Remove oil deflector. Remove Screws 8. Make sure hole in oil deflector is clear and unobstructed. Be sure hole is clear 9. Using a puller remove Hi/Lo/Reverse (HLR) shaft bearing, and bearing thrust washer. 8.13...

  • Page 283

    - - TRANSMISSION TRANSMISSION DISASSEMBLY, CONT. 10. Turn transmission so shafts are pointing down. Slide the Low gear in and out until needle bearing slides out of gear and can be removed. Remove needle bearing, low gear, and inner thrust washer. 11.

  • Page 284

    - - TRANSMISSION TRANSMISSION DISASSEMBLY, CONT. 13. Inspect face of shift fork for excessive wear, discoloration, or bending. 14. Remove center shaft assembly by tapping on opposite side with a soft face hammer. 15. Remove the remaining gears and shafts as an assembly.

  • Page 285

    - - TRANSMISSION TRANSMISSION DISASSEMBLY, CONT. 16. Remove pinion gear retaining plate and pinion gear assembly. 17. Inspect pinion gear for broken, chipped, or worn teeth. Check bearing condition, and snap ring location. 18. Loosen front output housing pinch bolts. Loosen Pinch CAUTION: Do not lose pinch plate.

  • Page 286

    - - TRANSMISSION TRANSMISSION DISASSEMBLY, CONT. 19. Mark housing and casting for reference upon reassembly. 20. Using 2 1/8″ wrench (PN 2871701) unscrew the front drive housing from the transmission casting until O-ring is exposed 1/2″ (13mm). NOTE: Do not attempt to unscrew the front drive housing completely at this time.

  • Page 287

    - - TRANSMISSION TRANSMISSION DISASSEMBLY, CONT. 23. Using a strap wrench on splines to hold shaft, remove front output ring gear retaining bolt, lock tab washer, and flat washer. Ring Gear Flat Washer Lock Plate 24. Remove front output ring gear. Inspect for broken, chipped, or worn teeth.

  • Page 288

    - - TRANSMISSION TRANSMISSION DISASSEMBLY, CONT. 26. Using a brass hammer or a press, drive the shaft, bearing, retaining ring, and seal out of the housing from rear to front. Seal Retaining Ring Shim(s) Bearing Housing Shaft 27. Slide seal off shaft and remove snap ring and shims.

  • Page 289

    - - TRANSMISSION BUSHING INSTALLATION, TRANSMISSION CENTER SHAFT 1. Install center shaft (brake disc shaft) bushing using small end of bushing installation tool. Bushing Drive Tool PN 2871697 2. Apply Loctite t 243 (blue) to threads of screws and install center shaft cover.

  • Page 290

    - - TRANSMISSION FRONT OUTPUT HOUSING ASSEMBLY, CONT. 2. Install shaft with bearing in front output housing. Transmission Bearing End of Housing Shaft 3. Turn housing, shaft, and bearing assembly over and install front bearing until fully seated. 4. Front output shaft end play must be measured and adjusted if shaft or housing was replaced.

  • Page 291

    - - TRANSMISSION FRONT OUTPUT HOUSING (SNORKEL) INSTALLATION 6. Measured end play will be between .030″ -.070″. Shims must be added between bearing and circlip to reduce end play. To calculate proper end play, subtract total shim thickness from end play measured in step 8.

  • Page 292

    Apply Loctite™ 242 or 243 (Blue) FRONT OUTPUT HOUSING (SNORKEL) BACKLASH ADJUSTMENT 11. Lubricate front housing O-ring thoroughly with Polaris All Season grease. Continue to screw front housing in, making sure O-ring enters housing without damage. Be sure ring and pinion gear teeth mesh properly.

  • Page 293

    - - TRANSMISSION TRANSMISSION OUTPUT GEAR BACKLASH INSPECTION/ ADJUSTMENT 13. The following steps must be performed to obtain proper front output gear backlash adjustment: Front Gearcase Transmission The pinion gear must be held securely. Use This Mark Front Output Do not lubricate the gear teeth until backlash ad- Shaft Use justment is complete.

  • Page 294

    - - TRANSMISSION TRANSMISSION ASSEMBLY, CONT. 16. Make sure surface of access plate and transmission are clean and free of oil and grease. Apply 3Bondt 1215 to mating surface of transmission case. Install access plate with notch to front as shown, torque screws to specification. Access Plate Screws: 8 - 10 ft.

  • Page 295

    - - TRANSMISSION TRANSMISSION ASSEMBLY, CONT. 19. Stretch silent cluster chain tight on a flat surface and measure the length of 8 pitches in a minimum of three places on chain. Replace chain if measurement is longer than 3.0904I. Chain Stretch Limit 8 pitch length = 3.0904I Maximum 20.

  • Page 296

    - - TRANSMISSION TRANSMISSION ASSEMBLY, CONT. 23. Install center shaft assembly. 24. Install Low shift fork with sliding dog in place. Dogs must be positioned outward (toward you). Slide the shift dog over the spline and the low range shift shaft. 25.

  • Page 297

    - - TRANSMISSION TRANSMISSION ASSEMBLY, CONT. 26. Install outer thrust washer and bearing. 27. Install plastic oil deflector. Apply Loctite™ 242 or 243 (blue) to screw threads. Be sure deflector pin seats into case. NOTE: Do not over-tighten deflector screws, or deflector may crack.

  • Page 298

    - - TRANSMISSION TENSIONER INSTALLATION Tensioner Assembly - Top View Spring Leg Forward Tensioner Lock Cam With chain and sprockets installed: 1. Place tensioner cam on front spacer and tensioner shoe on rear spacer. 2. Insert pins through cam, and through shoe. 3.

  • Page 299

    - - TRANSMISSION TRANSMISSION ASSEMBLY, CONT. 30. Pre-lubricate all bearings with Polaris Premium Synthetic GearCase Lubricant before installing cover. 31. Place the bellcranks in neutral so shift fork shafts will engage into the spring loaded detents of case cover.

  • Page 300

    - - TRANSMISSION TRANSMISSION ASSEMBLY, CONT. 34. Apply grease to the lip of a new input shaft seal. Install the seal, being careful to work the lip of the seal over the step in the shaft before using installation tool. Install the seal flush with transmission housing.

  • Page 301: Transmission Exploded View

    - - TRANSMISSION TRANSMISSION EXPLODED VIEW Low Shift Shaft Forward Input Shaft HR Shift Shaft Low Shift Fork Low Gear HR Shift Fork Silent Chain Center Drive Interlock Pins Shaft Reverse Gear Spring Drive Chain High Gear Oil Deflector Retainer Bearings Shoe...

  • Page 302: Troubleshooting Checklist

    - - TRANSMISSION TROUBLESHOOTING CHECKLIST Check the following items when shifting difficulty is encountered. S Idle speed adjustment S Transmission oil type/quality S Transmission torque stop adjustment S Engine torque stop adjustment S Drive belt deflection S Loose fasteners on rod ends S Loose fasteners on selector box S Worn rod ends, clevis pins, or pivot arm bushings S Linkage rod adjustment and rod end positioning...

  • Page 303: Table Of Contents

    - - CHAPTER 9 BRAKES Specifications/Torques ......Brake System Service Notes ..... . Brake Pad Kits .

  • Page 304: Specifications

    - - BRAKES SPECIFICATIONS Front Brake Caliper Item Standard Service Limit Brake Pad Thickness .275″ / 7.0mm .150″ / 3.81mm Brake Disc Thickness .150-.164″ / 3.810-4.166mm .140″ / 3.556mm Brake Disc Thickness Variance Between .002″ / .051mm Measurements Brake Disc Runout .005″...

  • Page 305: Brake System Service Notes, Brake Pad Kits

    - - BRAKES BRAKE SYSTEM SERVICE NOTES Disc brake systems are light weight, low maintenance, and perform well in the conditions ATVs routinely en- counter. There are a few things to remember when replacing disc brake pads or performing brake system ser- vice to ensure proper system function and maximum pad service life.

  • Page 306: Brake Noise Troubleshooting

    - - BRAKES BRAKE NOISE TROUBLESHOOTING Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning does not reduce the occurrence of brake noise, Permatext Disc Brake Quiet (available from most auto parts stores) can be applied to the back of the pads.

  • Page 307: Hydraulic Brake System Operation

    When servicing Polaris ATV brake systems use only Polaris DOT 3 high temperature brake fluid (PN 2870990). Polaris brake fluid is sold in 5.5 oz. bottles. WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture.

  • Page 308: Dual Hydraulic Caliper Bleeding

    - - BRAKES DUAL HYDRAULIC CALIPER BLEEDING This caliper is a dual opposed piston design, with two independent hydraulic systems contained in the same cali- per body (see Ill.1). The caliper pistons are T-shaped, which allows both hand and foot brake to use the same caliper piston, but remain separated by seals.

  • Page 309

    - - BRAKES AUXILIARY BRAKE INSPECTION (HYDRAULIC) Use the following procedure to inspect the auxiliary 1/8″ to 1/4″ (foot) brake system and bleed if necessary. Free Play 1. First check foot brake effectiveness by applying a 1″ or greater 50 lbs 50 lb.

  • Page 310: Fluid Replacement/bleeding Procedure

    NOTE: Do not remove brake lever when reservoir fluid level is low. Mity Vac™ PN 2870975 5. Add brake fluid to the indicated MAX level inside reservoir. Polaris DOT 3 Brake Fluid PN 2870990 DH Caliper Hand Brake Line 6. Begin bleeding procedure with the caliper that is Forward farthest from the master cylinder.

  • Page 311

    - - BRAKES BRAKE BLEEDING - FLUID CHANGE CONT. 7. Slowly pump brake lever (D) until pressure builds and holds. 8. While maintaining lever pressure, open bleeder screw. Close bleeder screw and release brake lever. NOTE: Do not release lever before bleeder screw is tight or air may be drawn into caliper.

  • Page 312: Master Cylinder Disassembly

    - - BRAKES MASTER CYLINDER DISASSEMBLY 1. Clean master cylinder and reservoir assembly. Make sure you have a clean work area to disassemble brake components. 2. Place a shop towel under brake line connection at master cylinder. Loosen banjo bolt; remove bolt and sealing washers.

  • Page 313

    - - BRAKES MASTER CYLINDER DISASSEMBLY 1. Remove cover and diaphragm from master cylinder and dispose of the fluid properly. Vent Slots 2. Be sure vents in cover are clean and unobstructed. 3. Remove brake lever. Cover 4. Clean surfaces of the reservoir and master cylinder body.

  • Page 314: Master Cylinder Inspection, Master Cylinder Assembly

    - - BRAKES MASTER CYLINDER INSPECTION 1. Clean the master cylinder assembly with clean Dot 3 brake fluid, brake parts cleaner, or denatured alcohol. Dry thoroughly. Inspect the bore for nicks, scratches or wear. Replace if damage is evident or if worn. 2.

  • Page 315

    - - BRAKES MASTER CYLINDER ASSEMBLY, CONT. 3. Dip piston in clean DOT 3 brake fluid, attach spring to piston, and install assembly into installation tool. CAUTION: Do not attempt to install the piston without the required installation tool. Do not allow the lip of the seals to turn in- side out or fold.

  • Page 316: Master Cylinder Installation

    Sealing Washers 15 ft. lbs. (21 Nm) Brake Line 3. Fill reservoir with DOT 3 fluid. 4. Follow bleeding procedure on pages 9.7-9.8. Check all connections for leaks and repair if necessary. Polaris DOT 3 Brake Fluid PN 2870990 9.13...

  • Page 317: Front Pad Removal

    - - BRAKES FRONT PAD REMOVAL 1. Elevate and support front of machine. CAUTION: Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 2. Remove the front wheel. Loosen pad adjuster screw 2-3 turns.

  • Page 318: Front Pad Assembly

    - - BRAKES FRONT PAD ASSEMBLY 1. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots. Polaris Premium All Season Grease PN 2871423 2. Compress mounting bracket and make sure dust boots are fully seated.

  • Page 319: Front Disc Inspection

    - - BRAKES FRONT PAD ASSEMBLY, CONT. 7. Install wheels and torque wheel nuts. 8. It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise. Start machine and slowly increase speed to 30 mph.

  • Page 320

    - - BRAKES FRONT BRAKE DISC REMOVAL / REPLACEMENT 1. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent. 2. Remove bolts and disc. 3. Clean mating surface of disc and hub. 4.

  • Page 321: Front Caliper Removal, Front Caliper Disassembly

    - - BRAKES FRONT CALIPER REMOVAL CAUTION: Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 1. Remove brake pads. See page 9.14. 2. Using a line wrench, loosen and remove brake line to caliper.

  • Page 322: Front Caliper Inspection

    - - BRAKES FRONT CALIPER DISASSEMBLY, CONT. 4. Remove piston, dust seal and piston seal. 5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTE: Be sure to clean seal grooves in caliper body. FRONT CALIPER INSPECTION 1.

  • Page 323: Front Caliper Assembly

    Piston should slide in and out of bore smoothly, with light resistance. 3. Lubricate the mounting bracket pins with Polaris Premium All Season Grease, and install the rubber dust seal boots. Polaris Premium All Season Grease PN 2871423 4.

  • Page 324: Front Caliper Installation

    - - BRAKES FRONT CALIPER INSTALLATION 1. Install caliper on hub strut, and torque mounting bolts. Front Caliper Mounting Bolt Torque 18 ft. lbs. (25 Nm) 2. Install brake line and tighten securely with a line wrench. 3. Install the adjuster screw and turn until stationary pad contacts disc, then back off 1/2 turn.

  • Page 325

    - - BRAKES FRONT BRAKE CALIPER EXPLODED VIEW Adjuster Screw Square O--Rings Piston Pin Boot Pads Caliper Mount 9.22...

  • Page 326

    - - BRAKES REAR BRAKE PAD REMOVAL 1. Remove caliper mounting bolts and lift caliper off of disc. NOTE: When removing caliper, be careful not to dam- age brake line. Support caliper so as not to kink or bend brake line.

  • Page 327

    - - BRAKES REAR BRAKE PAD INSTALLATION 1. Install new pads in caliper body. Be sure to put aluminum spacer between pads. 2. Install caliper and torque mounting bolts. DH Brake Caliper Torque 18 ft. lbs. (24.9 Nm) Spacer 3.

  • Page 328

    - - BRAKES REAR CALIPER REMOVAL/INSPECTION 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. 3. Remove caliper. 4.

  • Page 329: Rear Caliper Assembly

    - - BRAKES REAR CALIPER REMOVAL/INSPECTION CONT. 8. Inspect caliper piston bore for scratches, severe corrosion, or galling and replace if necessary. 9. Inspect surface of caliper piston for nicks, scratches, or damage and replace if necessary. REAR CALIPER ASSEMBLY 1.

  • Page 330

    - - BRAKES REAR CALIPER ASSEMBLY CONT. 4. Install brake pads in caliper body with friction material facing each other. If equipped with a pad spacer, install the spacer between the pads. Install retaining pin through outer pad, pad spacer and inner pad. 5.

  • Page 331

    - - BRAKES REAR BRAKE DISC INSPECTION 1. Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. 2. Use a 0-1″ micrometer and measure disc thickness at 8 different points around perimeter of disc. Rear Brake Replace disc if worn beyond service limit.

  • Page 332

    - - BRAKES REAR AUXILIARY CALIPER/MASTER CYLINDER Auxiliary Reservoir Torque 18 ft./lbs DH Caliper 25 Nm Auxiliary Brake Line Hand Brake Line Hand Brake Bleed Auxiliary Brake Pads Auxilia- Brake Bleed Auxiliary Torque Brake 45 ft./lbs Disc 62 Nm Torque 8 ft./lbs 11 Nm...

  • Page 333

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

  • Page 334

    - - CHAPTER 10 ELECTRICAL Special Tools ........10.1 Headlamp Service .

  • Page 335: Special Tools, Electrical Service Notes

    - - ELECTRICAL SPECIAL TOOLS Fluke 73 Multitester or Tektronix DMM 155 . . . PN 2870659 Strobe Timing Light ..... . . PN 2870630 Hydrometer .

  • Page 336: High Beam Headlight Adjustment

    - - ELECTRICAL HIGH BEAM HEADLIGHT ADJUSTMENT The headlight beam can be adjusted to any position desired by turning the adjusting knob located on the bottom right side of the headlight pod. 1. Place the vehicle on a level surface with the headlight 25’...

  • Page 337: Indicator Lamp Replacement

    - - ELECTRICAL HEADLIGHT HOUSING REPLACEMENT 1. Remove three Phillips screws at back of headlight pod. 2. Remove Phillips screws from bottom of headlight pod at each front corner. NOTE: To aid in accessing these screws, it may be helpful to turn handlebars to left or right and use a short, stubby screwdriver.

  • Page 338

    - - ELECTRICAL TIMING CHECK PROCEDURE 1. The ignition timing check hole is in the starter recoil/magneto housing. Remove the check plug. NOTE: The ignition timing marks are stamped on the outside of the flywheel. Ignition timing must be inspected with the engine at room temperature (68°F / 20°...

  • Page 339

    - - ELECTRICAL TYPICAL IGNITION TIMING CURVE * Actual advance point may vary by several hundred RPM either above or below 3500. Use the point of maximum advance when checking ignition timing. MAXIMUM ADVANCE POINT (*) 1000 2500 3000 3500 4000 4500...

  • Page 340

    - - ELECTRICAL FLYWHEEL IDENTIFICATION Flywheel Identification Stamp Location The flywheel can be identified by the stamp mark in location A or B. Refer to “I.D.” location in chart below. Do not use the cast mark to determine flywheel application. Engine Application Cast Stamp...

  • Page 341

    - - ELECTRICAL COMPONENTS OF EH42PL/EH50PL 200/250 WATT ALTERNATOR NOTE: CDI boxes may look the same but have different internal circuitry. Be sure to always use Ignition Coil the correct CDI box part number. Primary Winding Resistor Ignition Kill Meter Wire .3 Ω...

  • Page 342: Ignition System

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

  • Page 343

    The following measurements are obtained when cranking the engine with the electric start- er, spark plug installed. The starter system must be in good condition and the battery fully charged. 200 Watt 4 Stroke (Sportsman 400) Coil...

  • Page 344

    - - ELECTRICAL IGNITION SYSTEM TROUBLESHOOTING No Spark, Weak or Intermittent Spark SSpark plug gap incorrect SFouled spark plug SFaulty spark plug cap or poor connection to high tension lead SRelated wiring loose, disconnected, shorted, or corroded SEngine Stop switch or ignition switch faulty SETC switch misadjusted or faulty STerminal board or connections wet, corroded SPoor ignition coil ground (e.g.

  • Page 345

    6. Check specific gravity of each cell with a hydrometer to assure each has a reading of 1.270 or higher. BATTERY TERMINALS/TERMINAL BOLTS Use Polaris corrosion resistant Nyogelt grease (PN 2871329) on battery bolts. See Battery Installation on page 10.12.

  • Page 346: Battery Installation

    - - ELECTRICAL BATTERY INSPECTION/REMOVAL The battery is located under the left rear fender. Inspect the battery fluid level. When the battery fluid nears the lower level, the battery should be removed and distilled water should be added to the upper level line. To remove the battery: 1.

  • Page 347: Load Test, Specific Gravity Test

    Differences of more than .025 between the lowest and highest cell readings indicate a need to replace the battery. OPEN CIRCUIT VOLTAGE State of Conventional YuMicron™ charge Lead-acid Type Polaris PN 2870876 100% Charged 12.60V 12.70V 75% Charged 12.40V 12.50V 1.10 50% Charged 12.10V...

  • Page 348: Off Season Storage, Charging Procedure

    - - ELECTRICAL OFF SEASON STORAGE To prevent battery damage during extended periods of non-use, the following basic battery maintenance items must be performed: SRemove the battery from the machine and wash the case and battery tray with a mild solution of baking soda and water.

  • Page 349

    - - ELECTRICAL CHARGING SYSTEM TESTING Whenever charging system problems are suspected, proceed with the following system check. Using a multitester set on D.C. volts, mea- sure the battery open circuit voltage (See Remove the battery and properly ser- page 10.12).

  • Page 350

    - - ELECTRICAL CURRENT DRAW - KEY OFF CAUTION: Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to light bulbs and speed limiter. Connect an ammeter in series with the negative battery cable. Check for current draw with the key off. If the draw is excessive, loads should be disconnected from the system one by one until the draw is eliminated.

  • Page 351

    - - ELECTRICAL ALTERNATOR OUTPUT TEST (AC AMP) This test measures AC amperage from the alternator. SMaximum alternator output will be indicated on the meter. It is not necessary to increase engine RPM above idle. SPlace the red lead on the tester in the 10A jack. STurn the selector dial to the AC amps (Aµ) position.

  • Page 352: Voltage Drop Test

    - - ELECTRICAL STARTER SYSTEM TROUBLESHOOTING Starter Motor Does Not Turn SBattery discharged - low specific gravity SLoose or faulty battery cables or corroded connections (see Voltage Drop Tests) SRelated wiring loose, disconnected, or corroded SPoor ground connections at battery cable, starter motor or starter solenoid (see Voltage Drop Tests) SFaulty starter button SFaulty ignition switch (Do other systems function?)

  • Page 353: Starter System

    - - ELECTRICAL STARTER SYSTEM Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test. With the tester on the VDC position, place the tes- ter’s black lead on the battery negative and the red Remove battery and properly service.

  • Page 354: Starter Motor Disassembly

    - - ELECTRICAL STARTER MOTOR DISASSEMBLY NOTE: Use electrical contact cleaner to clean starter motor parts. Some solvents may leave a residue or damage inter- nal parts and insulation. 1. Note the alignment marks on both ends of the starter motor casing.

  • Page 355

    - - ELECTRICAL STARTER MOTOR DISASSEMBLY, CONT. 4. Remove shims from armature shaft. NOTE: All shims must be replaced during reassembly. BRUSH INSPECTION/REPLACEMENT 1. Using a digital multitester, measure the resistance between the cable terminal and the insulated brush. The reading should be .3 ohms or less.

  • Page 356

    - - ELECTRICAL BRUSH INSPECTION/REPLACEMENT, CONT. 6. Place a wrap of electrical tape on the threads of the terminal bolt to prevent O-Ring damage during reinstallation. 7. Install the O-Ring over the bolt. Make sure the O-ring is fully seated. 8.

  • Page 357: Armature Testing

    - - ELECTRICAL ARMATURE TESTING 1. Remove armature from starter casing. Note order of shims on drive end for reassembly. 2. Inspect surface of commutator. Replace if excessively worn or damaged. 3. Using a digital multitester, measure the resistance between each of the commutator segments.

  • Page 358: Starter Assembly

    - - ELECTRICAL STARTER ASSEMBLY 1. Place armature in field magnet casing. 2. Place shims on drive end of armature shaft with phenolic washer outermost on shaft. Engage tabs of stationary washer in drive end housing, holding it in place with a light film of grease. 3.

  • Page 359: Starter Drive

    The replacement spring is PN 7042039. Use either of the following methods to remove and install a new garter spring. Polaris Premium Starter Drive Grease PN 2871460 1. Screw the overrun clutch out to the engaged Starter Motor Exploded View position on the pinion shaft assembly.

  • Page 360

    - - ELECTRICAL ELECTRONIC SPEEDOMETER TROUBLESHOOTING Overview of Operation The Polaris Electronic ATV speedometer is powered Engine Run Time Hour Meter by battery voltage (12 VDC) and requires engine If the engine is running, the hour meter is recording RPM, transmission gear, and wheel speed sensor the run time.

  • Page 361

    (6 Pin Connector) All tests done with key and engine stop switch “ON”. All voltages are with reference to pin B (ground). Polaris probe kit #2201209 will help in measurements but is not necessary if care is used when probing the connectors.

  • Page 362

    - - ELECTRICAL ELECTRONIC SPEEDOMETER TROUBLESHOOTING, CONT. TEST 1 NO ALL WHEEL DRIVE Note: If AWD light comes on, speedometer is O.K. Proceed to AWD system tests (in Service Manual). Check hub coils, related wiring, and mechanical system for fault and repair as necessary. Start Here REPLACE SPEEDOMETER...

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  • Page 365

    - - ELECTRICAL ELECTRONIC SPEEDOMETER TROUBLESHOOTING, CONT. TEST 7 RESET SPEEDOMETER If the key switch or engine stop switch is turned off with the vehicle in motion, the speedometer indicator needle may stick, indicating the speed at which the vehicle was traveling when the speedometer lost power. For example: If the ATV was traveling 30 mph when the engine stop switch is turned off, speedo may indicate 30 mph until reset.

  • Page 366

    - - ELECTRICAL 10.32...

  • Page 367

    - - ELECTRICAL COOLANT TEMPERATURE SENSOR TEST (HOT LIGHT) With the ignition switch (and engine stop switch) “ON”, power is delivered to the hot light via the Red/White wire. The Blue/White wire (ground) out of the light socket is connected to the coolant temperature sensor on the cylinder head.

  • Page 368

    - - ELECTRICAL FAN CONTROL CIRCUIT OPERATION / TESTING The fan switch is located on the radiator. Power is supplied to the fan switch via the Red/White wire when the ignition key and auxiliary shut off switch are ON. When the fan switch reaches the specified temperature, it be- comes conductive and sends power to the fan motor.

  • Page 369: Brake Light Switch

    - - ELECTRICAL FAN MOTOR CURRENT DRAW Fan Motor A current draw test will provide a good indication of fan motor condition. A worn or damaged fan motor will draw more current, which causes a reduction in blade speed and reduced cooling.

  • Page 370

    - - ELECTRICAL GEAR POSITION INDICATOR SWITCH TEST Switch Continuity Table High/Neutral/Reverse Switch Low/Neutral Switch High Range Reverse Neutral Low Range Switch Schematic L / N Switch H / N / R Switch 10.36...

  • Page 371: Etc Operation Test

    - - ELECTRICAL ELECTRONIC THROTTLE CONTROL (ETC) SWITCH The Electronic Throttle Control (ETC) system is designed to the engine of an ATV in the event of a mechanical problem with the throttle mechanism. The ETC switch is mounted independently of the throttle actuator lever inside the throttle block assembly.

  • Page 372

    - - ELECTRICAL NOTES 10.38...

  • Page 373

    - - INDEX Brake Light Switch Testing, 10.35 Brake Noise, 9.3 A-Arm Replacement, 5.7 Brake Pad Adjustment, Front, 9.15 Air Filter Service, 2.23 Brake Pad Application, 9.2 Alternator Output Test, 10.17 Brake Pad Assembly, Front, 9.15---9.16 Auxiliary Brake Testing, Mechanical, 9.6 Brake Pad Inspection, 2.35 AWD Armature Plate Inspection, 7.10 Brake Pad Installation, Rear, 9.24...

  • Page 374: Table Of Contents

    - - INDEX Carburetor Jet Part Numbers, 4.4 Crankshaft End Play Adjustment, 3.56---3.57 Carburetor Main System, 4.8 Crankshaft Removal/Inspection, 3.53 Carburetor Needle and Seat Testing, 4.16 Crankshaft Straightening, 3.12 Carburetor Operation, 4.6 Current Draw, 10.16 Carburetor Pilot System, 4.7 CV Joint Handling Tips, 7.13, 7.32 Carburetor Starter System, 4.7 Cylinder Cleaning, 3.11...

  • Page 375

    - - INDEX Fan Control Switch Testing, 10.34 Fan Motor Current Draw Test, 10.35 EBS Drive Clutch Bushing Service, 6.42---6.43 Fastener Torque, 2.18 EBS Drive Clutch Inspection, 6.37---6.38 Flywheel Identification, 10.6 EBS Driven Clutch Bushing Service, 6.44---6.45 Flywheel Installation, 3.72 EBS Driven Clutch Disassembly, 6.39---6.41 Flywheel Removal/Inspection, 3.45 EBS Exploded View, 6.36...

  • Page 376: Table Of Contents

    - - INDEX Gearcase Installation, Front, 7.25 Gearcase Lubrication, Front, 2.9 Machine Dimensions, 1.8---1.10 Gearcase Removal, Front, 7.22 Main Jet Selection, 4.1 Glossary of Terms, 1.24---1.25 Maintenance Chart, Periodic, 2.1---2.2 Master Cylinder Assembly, 9.11---9.12 Master Cylinder Disassembly, 9.9---9.10 Master Cylinder Inspection, 9.11 Headlamp Service, 10.2---10.3 Master Cylinder Installation, 9.13 Headlamp Switch Testing, 10.35...

  • Page 377: Table Of Contents

    - - INDEX Piston Ring Installation, 3.64 Piston Ring Installed Gap, 3.43 Sediment Tube, Maintenance, 2.24 Piston to Cylinder Clearance, 3.41 Shift Linkage Adjustment, 2.11---2.12 Piston/Rod Inspection, 3.42---3.43 Shift Weights, 6.11 Side Panel Removal, 5.5 Pre-Ride Inspection, 2.2 Spark Plug Maintenance, 2.20 Publication Numbers, 1.17 Special Tools, PVT, 6.1 Pump Shaft Oil Seal Installation, 3.59...

  • Page 378

    Wheel Installation, 2.39 Troubleshooting, Fuel System/Carb, 4.19---4.20 Wheel Removal Front or Rear, 2.39 Troubleshooting, Ignition System, 10.10 Wiring Diagram, 2001, Sportsman 400, 10.39 Troubleshooting, Spark Plug, 3.77 Wiring Diagram, 2001, Sportsman 500 Early, 10.40 Troubleshooting, Starter System, 10.18 Troubleshooting, Transmission, 8.33...

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Comments to this Manuals

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Latest comments:
  • Jerry Feb 17, 2019 06:09:
    I have a 2013 sportsman 500 h0, my about compressio​n release broke apart and cracked tge cover and I lost all my engine oil out threw the cover. What would cause this to happen
  • Jerry Feb 17, 2019 06:09:
    I have a 2013 sportsman 500 h0, my about compressio​n release broke apart and cracked tge cover and I lost all my engine oil out threw the cover. What would cause this to happen
  • Jerrison Jumbo Oct 06, 2018 03:22:
    Rpm runs high and low inter changes. Has a hard time starting. Seems like too much gas going into carburetor​. Trying to adjust the idle but sometimes it runs at normal idle, then rpm goes up at high idle. Stalls out. Seems like something clogs up.tryin to adjust lower idle screw type round adjuster. It's a 2014 Polaris sportsman 400ho atv
  • sherill calhoun Feb 13, 2017 10:16:
    can you show how to adjust the carborator