Polaris Trail Boss 330 2003 Service Manual
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Polaris Trail Boss 330 2003 Service Manual

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2003 TRAIL BOSS
SERVICE MANUAL
PN 9918061
PN 9918061
Printed in USA

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July 22, 2025

Part # and how to replace PCV valve

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Summary of Contents for Polaris Trail Boss 330 2003

  • Page 1 2003 TRAIL BOSS SERVICE MANUAL PN 9918061 PN 9918061 Printed in USA...
  • Page 2 2003 Trail Boss 330 ATV Service Manual (PN 9918061) ECopyright 2002 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improcvements in the design and quality of production components, some minor descrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 3 NOTE: A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm.
  • Page 4 CHAPTER INDEX CHAPTER 1 GENERAL CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE CHAPTER 4 FUEL SYSTEM CHAPTER 5 BODY/SUSPENSION CHAPTER 6 PVT SYSTEM CHAPTER 7 FINAL DRIVE CHAPTER 8 TRANSMISSION CHAPTER 9 BRAKES CHAPTER 10 ELECTRICAL...

  • Page 6: Table Of Contents

    GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION/ MAINTENANCE 2003 Model Identification ....Serial Number Location ....2003 Trailboss Model .

  • Page 7: Model Identification

    GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 0 3 C A 3 2 A A Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation ENGINE DESIGNATION NUMBERS 32 ES32PFE10...

  • Page 8: 2003 Trailboss Model

    GENERAL INFORMATION 2003 TRAILBOSS MODEL 2003 TRAILBOSS 330...

  • Page 9: 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. Should both keys become lost, ignition switch replacement is required.

  • Page 10: Machine Dimensions

    GENERAL INFORMATION MACHINE DIMENSIONS 46 in 117 cm FRONT 46 in 117 cm 75 in 191 cm 34 in 86 cm SIDE 49.5 in 126 cm...

  • Page 11: General Information

    GENERAL INFORMATION 2003 TRAIL BOSS 330 MODEL: ..MODEL NUMBER: A03CA32 ENGINE MODEL: ES32PFE10 JETTING CHART CARBURETION AMBIENT TEMPERATURE Type ....BST 34 Mikuni Altitude Altitude...
  • Page 12 ..Standard Electronic Speedo Polaris Lubricants *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 13: Publication Numbers

    A03CA32AA 9917492 9917492 9917862 9917862 9917863 9917863 NOTE: When ordering service parts be sure to use the correct parts manual. PAINT CODES PAINTED PART COLOR DITZLER POLARIS DESCRIPTION NUMBER NUMBER Springs Silver ---- P-385 Rims Bright White 2185 P-133 Rack(s)
  • Page 14 GENERAL INFORMATION SAE TAP DRILL SIZES DECIMAL EQUIVALENTS 1/64 ....0156 Thread Size/Drill Size Thread Size/Drill Size 1/32 ... .0312 .

  • Page 15: Conversion Table

    GENERAL INFORMATION CONVERSION TABLE Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m x .7376 = ft.lbs. kg-m x 7.233 = ft.

  • Page 16: 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 = 3/8² or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.
  • Page 17 GENERAL INFORMATION NOTES 1.12...
  • Page 18 MAINTENANCE CHAPTER 2 MAINTENANCE Periodic Maintenance Chart ....2.2-2.3 Pre-Ride Inspection ..... . Recommended Maintenance Products .

  • Page 19: Periodic Maintenance Chart

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

  • Page 20: Pre-Ride Inspection

    MAINTENANCE PERIODIC MAINTENANCE CHART, CONT. CHASSIS Frequency (Whichever comes first) Item Hours Calendar Miles Remarks (Km) " General Lubrication 50 hrs 3 months 500 (800) Lubricate All Fittings, Pivots, Cables, Etc. " Front Hubs/Fluid Check 50 hrs 6 months 500 (800) Check monthly "...
  • Page 21 MAINTENANCE POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS Part No. Description 2870584 Loctite 680-Retaining Compound (10 ml.) Engine Lubricant 2870587 Loctite 518 Gasket Eliminator / Flange 2870791 Fogging Oil (12 oz. Aerosol) Sealant (50 ml.) (10 Count) 2871281 Engine Oil (Quart) Premium 4 Synthetic 2872113 Disk Brake Quiet (12 oz.) (12 Count)

  • Page 22: Recommended Maintenance Products

    2.17-2.18 Synthetic, 0W--40 Transmission Polaris Synthetic Gear Refer to procedures outlined later in this Case Lubricant chapter. Brake Fluid Polaris DOT 3 Brake Fluid Fill to indicated level inside reservoir. 2.23 MAINTENANCE QUICK REFERENCE Ill. Item Lube Rec. Method Frequency*...
  • Page 23 Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special...

  • Page 24: Special Tools

    8700220 Clutch Compression Tool 2871710 10” Center Distance Tool PV- -43568 Fluke 77 Digital Multimeter 2870630 Timing Light 2870836 Battery Hydrometer 8712100 or 8712500 Tachometer NOTE: Polaris dealers can order the tools listed above through the SPX Service Tools catalog.

  • Page 25: Transmission Lubrication

    Torque Specified Lubricant: to 14 ft. lbs. (19.3 Nm). Polaris Premium Synthetic Gearcase Lubricant (PN 2871477) (Gallon) (PN 2871478) (12 oz.) 7. Turn adjuster bolt (B) out until it touches the frame, and then an additional 1/2 turn.
  • Page 26 MAINTENANCE TRANSMISSION GEARSHIFT SHIFT LINKAGE LINKAGE ADJUSTMENT/ ADJUSTMENT INSPECTION 1. Inspect shift linkage tie rod ends, clevis and pivot bushings and replace if worn or damaged. Linkage rod will rotate 2. Place gear selector in neutral. 1/8 -1/4 turn if rod ends 3.
  • Page 27 MAINTENANCE THROTTLE OPERATION - ALL PILOT SCREW (IDLE MODELS MIXTURE) ADJUSTMENT Check for smooth throttle opening and closing in all NOTE: These procedures are intended as reference handlebar positions. Throttle lever operation should only. Actual final settings may be different depending be smooth and lever must return freely without on the atmospheric conditions in your area.

  • Page 28: Throttle Operation / Choke Adjustment

    MAINTENANCE IDLE SPEED ADJUSTMENT 3. Tighten locknut and slide boots over cable adjuster until they touch at the middle point of the adjuster. 1. Start engine and warm it up thoroughly. 4. With engine running, turn the handlebars from full left to full right with transmission in neutral.

  • Page 29: Fuel System

    MAINTENANCE FUEL SYSTEM VENT LINES 1. Check fuel tank, oil tank, carburetor, battery and WARNING transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every Gasoline is extremely flammable and explosive two years. under certain conditions. 2. Be sure vent lines are routed properly and Always stop the engine and refuel secured with cable ties.

  • Page 30: Compression Test

    Serious burns can result from contact with skin, eyes or clothing. Anti- dote: NOTE: This Polaris 4-Stroke engine is equipped with an automatic decompressor. Compression readings External: Flush with water. will vary in proportion to cranking speed during the Internal: Drink large quantities of water or test.

  • Page 31: Spark Plug

    MAINTENANCE SPARK PLUG Maintenance- -Free batteries are permanently sealed at the time of manufacture. The use of lead- -calcium and AGM technology instead of 1. Remove spark plug high tension lead. Clean plug lead- -antimony allows the battery acid to be fully area so no dirt and debris can fall into engine absorbed.
  • Page 32 MAINTENANCE ENGINE-TO-FRAME GROUND AIR FILTER/PRE-FILTER SERVICE Inspect engine-to-frame ground cable connection. Be sure it is clean and tight. It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty Engine Ground Strap conditions, replacement is required more often. The pre filter should be cleaned before each ride using the following procedure: 1.

  • Page 33: Air Box Sediment Tube Service

    MAINTENANCE NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling. Filter Clamp Sediment Tube NOTE: The sediment tube will require more frequent ILL.1 service if the vehicle is operated in wet conditions or at high throttle openings for extended periods.

  • Page 34: Engine Oil Level

    Ill.3 Recommended Engine Oil: 2. To further expel water from the cover and to dry Polaris Premium 4 All Season out the PVT system, shift the transmission to Synthetic, 0W-40 (PN 2871281) neutral and rev engine slightly to expel the moisture and air-dry the belt and clutches.

  • Page 35: Oil And Filter Change

    12. Remove dipstick and fill tank with 2 quarts (1.9 l) of Polaris Premium 4 Synthetic Oil (PN 2871281). 13. Place gear selector in neutral and set parking brake.

  • Page 36: 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. 3.

  • Page 37: Steering

    NOTE: Due to the critical nature of the procedures front and rear. Try to move the wheel outlined in this chapter, Polaris recommends steering and hub by pushing inward and component repair and adjustment be performed by an pulling outward.

  • Page 38: Camber And Caster

    MAINTENANCE WHEEL ALIGNMENT If abnormal movement is detected, inspect the hub and wheel assembly METHOD 2: CHALK to determine the cause. Refer to the Body/Steering or Final 1. Place machine on a smooth level surface. Drive chapter for more information. 2.

  • Page 39: Toe Alignment

    MAINTENANCE TOE ALIGNMENT EXHAUST CLEANING ADJUSTMENT WARNING If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell G Do not perform clean out immediately you which tie rod needs adjusting. NOTE: Be sure after the engine has been run, as the ex- handlebars are straight ahead before determining haust system becomes very hot.

  • Page 40: Brake Pad Inspection

    Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose Use Polaris DOT 3 Brake Fluid (PN fittings and replace any worn or damaged parts. 2870990). Sight AUXILIARY BRAKE...

  • Page 41: Drive Chain Inspection

    DRIVE CHAIN AND the closed end leading in forward operation. SPROCKET INSPECTION Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers. The sprockets outer...
  • Page 42 MAINTENANCE After inspection, again slowly move the ATV forward Loosen Eccentric until all the chain slack is on the top side of the chain clamp bolts (Step 2) and inspect the deflection. Repeat this procedure several times to check different spots on the chain. The chain is correctly adjusted when the tightest portion of the chain itself has approximately 3/8 in., (10 mm) of deflection.

  • Page 43: Shock Spanner Wrench 2

    MAINTENANCE CAUTION: DO NOT OVER-TIGHTEN ECCENTRIC CLAMP BOLTS. PRE-MATURE BEARING Loosen FAILURE MAY RESULT. Eccentric Clamp Without Hitch Tighten SUSPENSION SPRING Torque the nut PRELOAD ADJUSTMENT WITHOUT TRAILER HITCH - 30 ft. lbs. (41 Nm) Operator weight and vehicle loading affect 7.

  • Page 44: Wheel Removal / Installation

    MAINTENANCE CONTROLS 4. Remove the wheel nuts and remove the wheel. Check controls for proper operation, positioning and adjustment. Tapered nuts - install with tapered side against wheel Brake control and switch must be positioned to allow brake lever to travel throughout entire...

  • Page 45: Tire Inspection

    MAINTENANCE TIRE PRESSURE FRAME, NUTS, BOLTS, FASTENERS Tire Pressure Inspection (PSI - Cold) Periodically inspect the tightness of all fasteners in Front Rear accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter. TIRE INSPECTION WARNING Operating an ATV with worn tires will increase...
  • Page 46 ENGINE CHAPTER 3 ENGINE Engine Service Data ......3.2-3.3 Special Tools and Torque Specifications ..Torque Patterns .

  • Page 47: Engine

    ENGINE ES32PFE10 ENGINE SERVICE DATA Cylinder Head / Valve ES32PFE10 Rocker Arm Rocker arm ID .8669-.8678² (22.020-22.041 mm) Rocker shaft OD .8656-.8661² (21.987-22.0 mm) Rocker shaft Oil Clearance .0008-.0021² (.020-.054 mm) Limit .0039² (.10 mm) Camshaft Cam lobe height 1.3001--1.3041² (33.023-33.123 mm) Limit 1.2883²...
  • Page 48 ENGINE ES32PFE10 ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod ES32PFE10 Cylinder Surface warpage limit (mating with cylinder .0020² (0.050 mm) head) Cylinder bore 3.0906-3.0913² (78.50-78.520 mm) Taper limit .0020² (0.050 mm) Out of round limit .0020² (0.050 mm) Piston clearance .0015-.0032²...

  • Page 49: Torque Patterns

    ENGINE SPECIAL TOOLS Oil Line Fitting 20 (27 Nm) Oil Pump Cov- 4-5 (5-7 Nm) PART NUMBER TOOL DESCRIPTION Oil Relief Valve 14mm 14.5-16.5 (20-23 Nm) 2200634 Valve Seat Plug Reconditioning Kit Recoil Housing 5-6.5 (7-9 Nm) 2870390 Piston Support Block Rocker Cover 7-8 (9-11 Nm)

  • Page 50: Piston Identification

    ENGINE PISTON IDENTIFICATION The following components require engine removal for service: The piston may have an identification mark or the Camshaft piston may not have an identification mark for Connecting Rod piston placement. If the piston has an identification mark, follow the directions for piston placement Crankshaft below.

  • Page 51: Engine Installation Notes

    Change break-in oil and filter at 20 areas. Rinse thoroughly, dry with compressed air, hours or 500 miles, whichever and oil the bore immediately with Polaris 4 Cycle comes first. Lubricant to prevent the formation of surface rust.

  • Page 52: Honing To Oversize

    Rinse thoroughly, dry with compressed air, EXAMPLE OF CROSS HATCH PATTERN and oil the bore immediately with Polaris 4 Cycle Lubricant to prevent the formation of surface rust. HONING TO OVERSIZE...

  • Page 53: Oil Cooler Assembly

    ENGINE 3. Start engine and allow it to reach operating NOTE: Use Polaris Premium 0--40W Synthetic temperature while monitoring gauge indicator. Engine Lubricant (PN 2871281). ES32PF10 Oil Pressure at 3000 RPM (Engine Hot): Standard: 71-99 PSI Minimum: 20 PSI at idle...
  • Page 54 ENGINE OIL FLOW DIAGRAM - ES32PF Chain Room Small End Piston Bearing Rocker Arm / Rocker Shaft / Oil Jet Cylinder Sleeve Sprocket / (Fixed) Chain Connecting Rod Indirect Cam Shaft Lubrication Main Bearing Journal Cam Shaft Through Front Right Cam Lobe Large End Journal...

  • Page 55: Engine Exploded View

    ENGINE ES32PFE ENGINE EXPLODED VIEW Cylinder/ Crankcase Cylinder Head ES32PF Valve Train Crankshaft and Piston 3.10...
  • Page 56 ENGINE ENGINE REMOVAL 5. Remove cam chain tensioner plug, sealing washer, spring and pin. CAUTION: The plug is REFER TO PAGE 3.5 - 3.6 FOR ENGINE under spring tension. Maintain inward pressure while removing. REMOVAL / INSTALLATION NOTES. 6. Remove the two 6x25 mm cam chain tensioner flange bolts.

  • Page 57: Rocker Arm/Shaft Inspection

    ENGINE 4. Measure free length of tensioner spring. Replace 4. Remove cylinder block plug using a 14 mm hex spring if excessively worn. head wrench. Cylinder block plug Tensioner Spring Free Length: 5. Measure O.D. of rocker shaft. Inspect it for wear or damage.

  • Page 58: Camshaft Removal

    ENGINE CAMSHAFT REMOVAL 1. Remove cam shaft end plug (A). Rocker Arm & Support I.D.: .8669-.8678I (22.020-22.041 mm) 2. Remove camshaft sprocket flange bolt and washer. 7. Measure I.D. of both rocker arm shaft support areas and visually inspect surface. Compare to specifications.

  • Page 59: Automatic Compression Release Installation

    ENGINE CAMSHAFT REMOVAL CONT’D 6. Inspect cam sprocket teeth for wear or damage. Replace if necessary. Lobe Inspect for Areas of Tooth Wear or Damage 2. Remove release lever shaft and return spring (spacer). 3. Inspect shaft for wear or galling. 7.

  • Page 60: Cylinder Head

    ENGINE CYLINDER HEAD REMOVAL 2. Thoroughly clean the cam shaft, making sure the oil feed holes are not obstructed. 3. Measure height of each cam lobe using a 1. Loosen each of the four cylinder head bolts micrometer. Compare to specifications. evenly 1/8 turn each time in a cross pattern until loose.

  • Page 61: Cylinder Head Warpage

    ENGINE CYLINDER HEAD WARPAGE 2. Remove spring retainer and spring. 1. Lay a straight edge across the surface of the cylinder. head at several different points and measure warpage by inserting a feeler gauge between the straight edge and the cylinder head surface.

  • Page 62: Valve Inspection

    ENGINE 5. Remove valve seals. CAUTION: Replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup. 4. Inspect split keeper groove for wear or flaring of the keeper seat area (B). NOTE: The valves cannot be re-faced or end ground.

  • Page 63: Valve Seat

    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 3.19--3.21. If the valve seat is cracked the cylinder head must be replaced.
  • Page 64 ENGINE 4. Follow the manufacturers instructions provided Reaming The Valve Guide with the valve seat cutters in the Valve Seat 9. Allow cylinder head to cool to room temperature. Reconditioning Kit (PN 2200634). Abrasive stone Apply cutting oil to the reamer. Guides should be seat reconditioning equipment can also be used.
  • Page 65 ENGINE VALVE SEAT RECONDITIONING CONT’D 6. Insert valve into guide and tap valve lightly into place a few times. 3. Place 46° cutter on the pilot and make a light cut. 7. Remove valve and check where the Prussian Bluet or black marker indicates seat contact on the valve face.

  • Page 66: Cylinder Head Assembly

    ENGINE NOTE: When using an interference angle, the seat 12. Clean cylinder head, valves, and camshaft oil contact point on the valve will be very narrow, and is supply passage (A) thoroughly. a normal condition. Look for an even and continuous contact point on the black marker, all the way around the valve face.

  • Page 67: Engine Bottom End Disassembly

    ENGINE ENGINE BOTTOM END CYLINDER HEAD ASSEMBLY CONT’D 5. Dip valve spring and retainer in clean engine oil DISASSEMBLY and install spring with closely spaced coils toward the cylinder head. Cylinder Removal Follow engine disassembly procedures to remove valve cover, camshaft and rocker arms, and cylinder head.

  • Page 68: Piston Removal

    ENGINE PISTON REMOVAL 5. Remove the top rail first followed by the bottom rail. 6. Remove the expander. 1. Remove circlip. Note that opening for circlip access is on the intake side. CYLINDER INSPECTION 1. Remove all gasket material from the cylinder sealing surfaces.

  • Page 69: Piston Inspection

    ENGINE CYLINDER INSPECTION CONT’D 3. Measure piston pin bore. 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: 3.0906-3.0913I (78.50-78.520 mm) PISTON INSPECTION...

  • Page 70: Crankcase Disassembly

    ENGINE PISTON RING INSTALLED 5. Measure connecting rod small end ID. 1. Place each piston ring inside cylinder using piston to push ring squarely into place as shown. Piston ring end gap installed Feeler Gauge Cylinder 25-50mm Connecting Rod Small End I.D. Piston Ring .7095-.7101I (18.007-18.023 mm) 2.

  • Page 71: Starter Drive Removal/Inspection

    ENGINE STARTER DRIVE Starter Drive Bushing Clearance: REMOVAL/INSPECTION Std: .0015²-.004² (.038-.102 mm) Service Limit: 1. Remove recoil housing bolts and remove 008² (.203 mm) housing. 6. Inspect gear teeth on starter drive. Replace starter drive if gear teeth are cracked, worn, or broken.
  • Page 72 ENGINE DRIVE SPROCKET REMOVAL 5. Replace crankshaft seal. 6. Remove large sealing O-Ring from outer edge of / INSPECTION stator plate. CAM CHAIN/TENSIONER 1. Using the Slotted Nut Socket (PN 2871293), remove the crankshaft slotted nut (A). NOTE: BLADE The slotted nut is a left hand thread. 1.

  • Page 73: Oil Pump

    ENGINE PRESSURE RELIEF VALVE The pressure relief valve opens to relieve any excess pressure from the oil pump if oil pressure reaches approximately 71 psi. It must be clean and have adequate spring pressure in order to seal properly. 1. Remove cap bolt, sealing washer, spring, and relief valve from MAG side crankcase.

  • Page 74: Oil Pump Assembly

    ENGINE 5. Measure rotor tip clearance with a feeler gauge. 2. Separate crankcase by tapping with a soft faced hammer in reinforced areas. Rotor Tip Clearance: 3. Watch the gap along the crankcase mating Std: .005 (.127 mm) surface and separate the crankcase evenly. 4.

  • Page 75: Crankshaft Inspection

    ENGINE 2. Use a feeler gauge to measure the connecting rod 2. Measure the width of the connecting rod at the big big end side clearance. end. Connecting Rod Width: Std: .8233-.8252I (20.88-20.93 mm) 3. Visually inspect bearing journal for scoring, damage or excessive wear.

  • Page 76: Crankcase & Bearing Assembly

    ENGINE CRANKSHAFT MAIN BEARING INSPECTION 1. Inspect the crankshaft main bearings. NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. Look for signs of discoloration, scoring or galling. Turn the outer race of each bearing. The bearings should turn smoothly and quietly.

  • Page 77: Crankcase Inspection

    ENGINE CRANKCASE INSPECTION 2. Measure the distance from the MAG side crankcase mating surface to the main bearing using a dial caliper and a straight edge. 1. Remove all traces of gasket sealer from the crankcase mating surfaces. Inspect the surfaces closely for nicks, burrs or damage.

  • Page 78: Crankshaft End Play Inspection

    ENGINE ENGINE ASSEMBLY/ 4. Measure the width of the crankshaft at the bearing seats or, if PTO bearings are installed, the CONNECTING ROD width from MAG side bearing seat to the outside race of the PTO bearings with a micrometer or dial INSTALLATION caliper and record.

  • Page 79: Crankcase Reassembly

    ENGINE CRANKSHAFT 2. Install oil pump cover. Torque screws to specified torque. INSTALLATION Oil Pump Cover Screw Torque: Lubricate all bearings with clean engine oil before assembly. 4-5 ft. lbs. (5-7 Nm) 1. Install the crankshaft into the PTO side crankcase.

  • Page 80: Piston Ring Installation

    ENGINE TENSIONER BLADE INSTALLATION Ring Profile 1. Install the tensioner blade and tighten the mounting bolt to specified torque. Tensioner Blade Mounting Bolt Torque: 5-6.5 ft. lbs. (7-9 Nm) “R1” Mark up OIL FILTER INSTALLATION 1. Apply clean engine oil to oil filter gasket. Install filter until gasket lightly touches seat and then tighten an additional 3/4 of a turn.

  • Page 81: Cylinder Head Installation

    ENGINE 4. Apply clean engine oil to the piston rings, ring 2. Apply clean engine oil liberally to the cylinder bore lands, piston pin bore, piston pin, and piston skirt. and tapered area of the sleeve. Install the Lubricate the connecting rod (both ends) and cylinder with a slight rocking motion until the rings crankshaft main bearing area.
  • Page 82 ENGINE The following procedure must be used to torque the Install the cam chain over the crankshaft. cylinder head properly: Torque in cross Plated pattern per procedure Link Sprocket Mark Crankcase Projection IMPORTANT CAMSHAFT TIMING NOTE: In order to time the camshaft to the crankshaft, the piston must be precisely located at Top Dead Center (TDC).
  • Page 83 ENGINE 3. Apply Polaris Low Temp Grease (PN 2870577), Camshaft Installation - Timing Method 2 or engine assembly lubricant to the camshaft Refer to Page 3.40 main journals and cam lobes. Lubricate 1. Apply Polaris Low Temp Grease (PN 2870577),...
  • Page 84 ENGINE CAMSHAFT TIMING - METHOD 1 Method 1 - Camshaft Timing with Stator Removed Crankshaft to Camshaft Centerline Single Plated Sprocket marks aligned with gasket surface at TDC on Link and Dot on compression stroke (cam Cam Sprocket lobes facing downward) Single Plated Link and Rectangular...
  • Page 85 ENGINE CAMSHAFT TIMING - METHOD 2 Method 2 - Camshaft Timing Using Flywheel TDC Mark Crankshaft to Camshaft Centerline Do not use dot on sprocket for cam timing Decompressor arm stop pin UP (Cam lobes DOWN) Sprocket marks aligned with gasket surface at TDC on compression stroke (cam lobes facing downward, de-...
  • Page 86 ENGINE CAM CHAIN TENSIONER 4. Slowly rotate engine two to three revolutions and re-check cam timing once chain is tight. INSTALLATION STATOR INSTALLATION 1. Release the ratchet pawl (A) and push the tensioner plunger (B) all the way into the NOTE: The stator, flywheel, starter drive, and recoil tensioner body.

  • Page 87: Flywheel Installation

    ENGINE FLYWHEEL INSTALLATION ROCKER SHAFT/ARM INSTALLATION 1. Install flywheel, washer, and nut. Torque flywheel to specification. 1. Assemble rocker arms, rocker shaft and wave washer into rocker cover. Flywheel Nut Torque: 2. Install and tighten rocker shaft block plug. 3. Apply engine assembly lube to the cam lobes and 58-72 ft.
  • Page 88 ENGINE 3. Remove center bolt from recoil friction plate (A). NOTE: Long arm of spring engages reel. Short end rests against pawl. 6. Hold reel firmly in housing. Pull rope handle until 12-18² of rope is exposed, and hold reel in place. 4.

  • Page 89: Recoil Assembly

    ENGINE RECOIL ASSEMBLY Open end here CAUTION: Recoil is under spring tension. A face shield or eye protection is required during 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.

  • Page 90: Spark Plug Fouling Checklist

    ENGINE SPARK PLUG FOULING Engine Does Not Turn Over TROUBLESHOOTING Dead battery Starter motor does not turn Spark plug cap loose or faulty Engine seized, rusted, or mechanical failure Choke cable adjustment or plunger/cable sticking Recoil components damaged Foreign material on choke plunger Engine Runs But Will Not Idle seat or plunger Restricted carburetor pilot system...
  • Page 91 ENGINE TROUBLESHOOTING Piston Failure - Scoring Lack of lubrication Dirt entering engine through cracks in air filter or ducts Engine oil dirty or contaminated Excessive Smoke and Carbon Buildup Excessive piston-to-cylinder clearance Worn rings, piston, or cylinder Worn valves, guides or seals Restricted breather Air filter dirty or contaminated Low Compression...
  • Page 92 FUEL SYSTEM/CARBURETION CHAPTER 4 FUEL SYSTEM/CARBURETION Exploded View, Mikuni BST 34 Carburetor . . . Fuel Pump Exploded View ....Fuel Tank Asm. Exploded View .
  • Page 93 FUEL SYSTEM/CARBURETION 1. Carburetor Assembly BST 34 CARBURETOR EXPLODED VIEW 2. Screw 3. Throttle Valve 4. Cover, Diaphragm 5. Jet Block Assembly 6. Spring 7. Diaphragm Assembly 8. Ring 9. “E” Ring 10. Ring 11. Needle Jet 12. Cover 13. O-Ring 14.

  • Page 94: Fuel Pump Exploded View

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

  • Page 95: Fuel Flow Diagram

    FUEL SYSTEM/CARBURETION FUEL TANK ASSEMBLY Vent line routed smoothly into center of steering post Forward Tank to fuel valve connection -- Gas Tank Mounting Gold fitting (tall stand pipe) to Hardware “ON” 90 Degree Fuel Reserve Outlet Fitting 90 Degree Fuel (Marked “2”...

  • Page 96: Carburetor Jetting

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

  • Page 97: Cv Carburetor System Function (4 Cycle)

    FUEL SYSTEM/CARBURETION CV CARBURETOR SYSTEM VENT SYSTEMS - CV FUNCTION CARBURETOR The carburetor float bowl vent lines supply atmospheric pressure to the float bowl. The lines Carburetor Component Function must be free of kinks, restrictions and be properly System Main Main Main routed.
  • Page 98 FUEL SYSTEM/CARBURETION CARBURETOR OPERATION CONT’D When the throttle plate is opened and engine speed begins to increase, the pressure in the venturi (and therefore in the chamber above the diaphragm) becomes significantly lower than atmospheric. Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward, raising the slide against spring pressure.

  • Page 99: Float System

    FUEL SYSTEM/CARBURETION FLOAT SYSTEM Fuel enters the float chamber (3) by means of the inlet pipe and passage, through a screen on the back of the inlet needle seat (4), and around the inlet needle (2). As the fuel fills the float chamber, the float (1) rises and forces the inlet needle against the seat, shutting off the orifice in the seat.

  • Page 100: Carburetor Cleaning

    FUEL SYSTEM/CARBURETION CARBURETOR DISASSEMBLY CONT’D NOTE: The starter jet is not removeable. Upon disassembly, place the parts in a container for safe 2. Remove float bowl and carefully remove the keeping. pressed float pin. Support Here Pilot Screw Starter Jet NOTE: Be careful not to damage the float pin tower during the float pin removal.
  • Page 101 FUEL SYSTEM/CARBURETION CARBURETOR INSPECTION CARBURETOR ASSEMBLY 1. Inspect jet needle and needle jet for wear. Look Inspect the diaphragm (A) for holes, deterioration, or for discoloration, shiny spots, or an area that damage. Make sure the diaphragm is pliable but not looks different than the rest of the needle.

  • Page 102: Needle & Seat Leakage Test

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

  • Page 103: Fuel Level

    FUEL SYSTEM/CARBURETION FUEL LEVEL If fuel is present in the impulse line or vacuum chamber of the pump, the diaphragm is ruptured. The pump diaphragms must be replaced. A fuel level test can be performed on some models if the drain hose fitting is accessible. Be sure to re-attach the bowl drain hose after performing the Fuel Pump...

  • Page 104: Troubleshooting

    FUEL SYSTEM/CARBURETION TROUBLESHOOTING Loose jets Worn jet needle/needle jet or other carburetor parts FUEL STARVATION/LEAN MIXTURE Dirty carburetor (air bleed Symptoms: Hard start or no start, bog, backfire, passages or jets) popping through intake / exhaust, hesitation, Weak or damaged vacuum piston detonation, low power, spark plug erosion, engine return spring runs hot, surging, high idle, idle speed erratic.
  • Page 105 FUEL SYSTEM/CARBURETION NOTES 4.14...
  • Page 106 BODY / STEERING / SUSPENSION CHAPTER 5 BODY AND STEERING Body Assembly, Exploded View ....Steering Assembly, Exploded View ... . Torque Specifications and Special Tools .

  • Page 107: Body Assembly Exploded View

    BODY / STEERING / SUSPENSION BODY ASSEMBLY EXPLODED VIEW Rear Cab Assembly Seat Latch Seat Retainer Rear Cab Seat Latch Tool Box Clutch Gaurd Footwell Rock Gaurd Frame Front Cab Assembly Front Cover Fuel Tank Cover Front Cab Side Cover Footwell Frame Deflector...

  • Page 108: Steering Assembly, Exploded View

    BODY / STEERING / SUSPENSION STEERING ASSEMBLY, EXPLODED VIEW NOTE: To avoid damage to tie rods and other steering Apply Loctitet 242 to components, be sure to install tie rod end bolts in the the bolt threads. proper direction. The steering post arm bolt (B) points up; the rod end bolts (A) point down.

  • Page 109: Ball Joint Replacement Tool

    BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS Front A-Arm Attaching Bolt 30 ft. lbs. (41 Nm) Front A-Arm Ball Joint Stud Nut 25 ft. lbs. (35 Nm) Handlebar Adjuster Block 10-12 ft. lbs. (14-17 Nm) Master Cylinder 45-55 in. lbs. (5.2-6.3 Nm) Rear Axle Nut - (Tapered Roller Bearings) (Left side) 120 ft.

  • Page 110: Cover/Panel Removal

    BODY / STEERING / SUSPENSION COVER/PANEL REMOVAL 1 inner screw from front cab to foot rest on each side To remove, perform these steps: 2 screws under front panel Seat: SIDE PANEL REMOVAL Pull release lever at the rear of the seat Lift and pull seat rearward, disengaging 1.

  • Page 111: A-Arm Replacement

    BODY / STEERING / SUSPENSION A-ARM REPLACEMENT Apply Loctitet 242 to Vehicle Frame Bolt 30 ft. lbs. the bolt threads. (41 Nm) Bolt 30 ft. lbs. (41 Nm) Ball Joint Stud Washer A-Arm Tube 8 ft. lbs. A-Arm Shaft (11 Nm) 25 ft.

  • Page 112: Concentric Swing Arm Removal

    BODY / STEERING / SUSPENSION CONCENTRIC SWING ARM REMOVAL (2) Washer (3) Two-piece bushing (1) Nut (8) Pivot Bolt (4) Pivot Bushing, Right (7) Pivot Bushing, Left Place flats of pivot bushing in vise to hold while removing nut (5) Pivot Bolt Eccentric clamp bolt torque: Models with trailer hitch - 40 ft.

  • Page 113: Concentric Swing Arm Assembly/Installation

    BODY / STEERING / SUSPENSION CONCENTRIC SWING ARM ASSEMBLY/INSTALLATION Apply Loctitet 262 to the bolt threads. 150 ft. lbs. (207 Nm) (1) Nut 120 ft. lbs. (163 Nm) (2) Washer (8) Pivot Bolt (3) Two-piece bushing (7) Pivot Bushing, Left (4) Pivot Bushing, Right Place flats of pivot bushing in vise to hold while removing and installing nut...

  • Page 114: Strut Assembly

    BODY / STEERING / SUSPENSION STRUT ASSEMBLY Nut - 15 ft. lbs. (21 Nm) Washer Spacer Rubber Upper Pivot Ball Lower Pivot Ball Spacer Nut Spring Retainer Strut Bumper Spring Strut Cartridge Clamp Spring Retainer Washer Lock Nut 15 ft. lbs. (21 Nm) Strut Housing Washer Washer...

  • Page 115: Ball Joint Replacement

    BODY / STEERING / SUSPENSION FRONT STRUT CARTRIDGE BALL JOINT REPLACEMENT REPLACEMENT REFER TO ILLUSTRATION ON PAGES REFER TO ILLUSTRATION ON PAGES 5.9. 5.9. 1. Loosen front wheel nuts slightly. 2. Elevate and safely support machine under 1. Hold strut rod and remove top nut. footrest/frame area.
  • Page 116 BODY / STEERING / SUSPENSION 8. To install new ball joint: Remove extension cap and attach puller guide using short bolts provided in the kit. Insert new ball joint (E) into driver (F). Slide ball joint/driver assembly into guide. Drive new joint into strut housing until fully seated.

  • Page 117: Steering Post Assembly

    BODY / STEERING / SUSPENSION STEERING POST ASSEMBLY 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 oppo- site directions. 4. Check steering, must move freely and easily from full left to full right without binding.
  • Page 118 CLUTCH CHAPTER 6 PVT SYSTEM Service Tools and Supplies ....PVT System Torques ..... PVT System Operation Overview .

  • Page 119: Clutch Puller

    Clutch Bushing Replacement control engagement (initial vehicle movement), clutch Tool Kit upshift and backshift. During the development of a Polaris ATV, the PVT system is matched first to the engine power curve; then to average riding conditions SPECIAL SUPPLIES PART NUMBER and the vehicle’s intended usage.

  • Page 120: Pvt Maintenance/Inspection

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

  • Page 121: Pvt Over Heating

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

  • Page 122: Pvt Disassembly

    CLUTCH PVT DISASSEMBLY 8. Remove driven clutch retaining bolt and driven clutch. Use the Driven Clutch Puller (PN 2870913) if necessary. NOTE: Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement. (See Page 6.7). Driven Clutch Puller (PN 2870913) 1.

  • Page 123: Pvt Assembly

    CLUTCH PVT ASSEMBLY Inner Cover Bolt Torque (Rear): 12 ft. lbs. (16.6 Nm) Seal this edge to cover on engine side Driven Clutch Retaining Bolt Torque: 17 ft. lbs. (23.5 Nm) Drive Clutch Retaining Bolt Torque: 40 ft. lbs. (55 Nm) 1.

  • Page 124: 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 DRIVE CLUTCH EXPLODED VIEW Drive Clutch Teflont coated brass bushing Teflont coated brass bushing Mark with permanent marker before disassembly...

  • Page 125: Drive Clutch Spring Specifications

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

  • Page 126: 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 127: Drive Clutch Inspection

    REMOVAL” Page 6.11. clutch assembly! 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 the proper procedures as outlined in this manual. Because of...

  • Page 128: Spider Removal

    CLUTCH SPIDER REMOVAL 2. Remove cover bolts evenly in a cross pattern, and remove cover plate. Cover Bushing Inspection: Replace the cover bushing if more brass than Teflont is visible on Clutch Holding Fixture: the bushing. Refer to bushing re- (PN 2871358) placement in this chapter.

  • Page 129: Drive Clutch Assembly

    CLUTCH ROLLER, PIN AND THRUST DRIVE CLUTCH ASSEMBLY WASHER INSPECTION NOTE: It is important that the same number and 1. Inspect all rollers, bushings and roller pins by thickness of washers are reinstalled beneath the pulling a flat metal rod across the roller. Turn roller spider during assembly.

  • Page 130: Drive Belt Tension

    CLUTCH DRIVE BELT TENSION 5. Torque spider to specification using the holding fixture and spider tool. Torque with smooth motion to avoid damage to the stationary sheave. Straight Edge Refer to Page 6.1 for torque specification. 1 1/8² (28.5 mm) CAUTION: Be sure the spider spacer washers are fully seated in the recessed area in the spider.

  • Page 131: Drive Belt Removal/Inspection

    CLUTCH DRIVE BELT 4. Measure belt width and replace if worn severely. Generally, belt should be replaced if clutches can REMOVAL/INSPECTION no longer be adjusted to provide proper belt deflection. 1. Remove outer PVT cover as described in PVT The top edges have been trimmed on Disassembly.

  • Page 132: Drive Belt Installation

    CLUTCH 8. Replace belt if worn past the service limit. Belts 1. Remove belt and install the Clutch Offset with thin spots, burn marks, etc., should be Alignment Tool (PN 2870654) as shown. replaced to eliminate noise, vibration, or erratic 2.

  • Page 133: Clutch Bushing Replacement Tool Kit

    CLUTCH CLUTCH OFFSET P--90 Driven Clutch 5020631 Cover Bushing Re- moval Tool Offset Alignment Tool Main Puller Adapter 5020632 (PN 2870654) Adapter Reducer 5010279 Number Two Puller 5020633 Adapter DRIVE CLUTCH MOVEABLE SHEAVE - BUSHING REMOVAL 1/8I +0 / -- 1/16 3.2mm +0 / -- 1.6 mm) Important: Inspect clutch alignment and center...
  • Page 134 CLUTCH 3. Install the Main Puller Adapter (#8) (PN 5020632) 2. Apply Loctitet 680 (PN 2870584) to the back onto the Piston Pin Puller (PN 2870386). side of new bushing. Push bushing into center of sheave on tower side by hand. Bushing (PN 3576504) Loctitet 680 (PN 2870584) 3.
  • Page 135 CLUTCH 1. Install the Main Puller Adapter (#8) (PN 5020632) onto the Piston Pin Puller (PN 2870386). Bushing (PN 3576510) Loctitet 680 (PN 2870584) 2. From outside of clutch cover, insert the Drive Cover Bushing Remover (#3) (PN 5020629) into 2.

  • Page 136: Clutch Compression Tool

    CLUTCH DRIVEN CLUTCH 2. Remove snap ring retainer. DISASSEMBLY/INSPECTION Note hole location of spring in helix and sheave 3. Note the location of the spring and remove helix. 4. Note the location of the spring in the moveable Used to adjust sheave, and remove the spring.

  • Page 137: Driven Clutch Assembly

    CLUTCH 7. Remove moveable sheave and note the number 1. Install moveable sheave with spacer washers. of spacer washers. One spacer must remain Important: At least one spacer washer must be between the sheaves when adjusting belt installed. Teflont bushings are self-lubricating. deflection.
  • Page 138 CLUTCH DRIVEN CLUTCH MOVEABLE SHEAVE - BUSHING REMOVAL NOTE: Bushings are installed at the factory using Loctitet. 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. Be sure to support the sheave or cover as close as possible to Clutch Bushing the bushing bore when using a press.
  • Page 139 CLUTCH 9. Remove nut from puller rod and set aside. 10. Remove adapters from puller. 11. Remove bushing and removal tool from adapters. Discard bushing. DRIVEN CLUTCH MOVEABLE SHEAVE - BUSHING INSTALLATION 4. Install nut onto puller rod and hand tighten against installation tool.

  • Page 140: Troubleshooting

    CLUTCH TROUBLESHOOTING Situation Probable Cause Remedy Engine RPM -Wrong or broken drive clutch spring. -Replace with recommended spring. below specified operating -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine application. range, although engine is prop- -Driven clutch spring broken or installed in -Replace spring;...
  • Page 141 CLUTCH TROUBLESHOOTING Situation Probable Cause Remedy Belt slippage -Belt worn out -Replace belt. -Water ingestion -Inspect and seal PVT system. -Belt contaminated with oil or grease -Inspect and clean. Belt burnt, thin -Abuse (continued throttle application when -Caution operator to operate machine within guidelines. spots vehicle is stationary, excess load) -Dragging brake...
  • Page 142 FINAL DRIVE CHAPTER 7 FINAL DRIVE Torque Specifications ..... Front Hub Disassembly/Inspection ..7.2-7.3 Front Hub Assembly .

  • Page 143: Front Hub Disassembly/Inspection

    FINAL DRIVE WHEEL, HUB, AND SPINDLE 4. Remove the two brake caliper bolts and the brake caliper. TORQUE TABLE Item Specification Front Wheel Nuts 20 Ft. Lbs. (27 Nm) Rear Wheel Nuts 50 Ft. Lbs. (68 Nm) Front Spindle Nut 40 Ft.

  • Page 144: Front Hub Assembly

    FINAL DRIVE FRONT HUB ASSEMBLY 8. Using a brass drift, tap bearing spacer to one side to expose inner bearing race. Drive bearing out using a drift through opposite side of hub and Hub assembly view discard. Tap spacer to side Seal 1.

  • Page 145: Front Hub Installation

    FINAL DRIVE 3. Install seal into hub (with numbers facing out) until 5. Install spindle nut and tighten to specification. flush with end of seal bore. Seal 2 x 4 Spindle Nut Torque: 40 ft. lbs. (55.0 Nm) FRONT HUB INSTALLATION 1.

  • Page 146: Front Hub Exploded View

    FINAL DRIVE FRONT HUB EXPLODED VIEW Strut Housing Spindle Bearing Brake Disc Seal Washer (domed side out) 18 ft. lbs. (24.9 Nm) Use new bolts with pre-applied Spacer locking agent. Bearing Cotter Pin Wheel Nut O-Ring Hub Cap 40 ft. lbs. (55.3 Nm)

  • Page 147: Rear Axle Removal

    FINAL DRIVE CONCENTRIC SWINGARM REAR AXLE REMOVAL Remove Rear Caliper 1. Securely support rear of machine with rear wheels off the floor. Remove rear wheels and hubs. 2. Remove drive chain. 3. Remove snap ring (A), lock sleeve (B) and foam seal (C) from axle.

  • Page 148: Rear Axle Disassembly

    FINAL DRIVE CONCENTRIC SWINGARM 2. Install disc hub assembly on axle. Be sure hub covers stop ring. Install disc in soft jawed vise. REAR AXLE DISASSEMBLY Apply Never Seize to threads, install left axle nut and tighten to 120 ft. lbs (166 Nm). Keep 1.

  • Page 149: Rear Axle Installation

    If axle movement (up and down or side to side) is detected, axle is too loose. 8. Lubricate eccentric housing through grease fitting with Polaris Premium All Season Grease until grease is purged on each side of eccentric. Axle Nut (Sprocket Side) Torque: 8-10 ft.

  • Page 150: Rear Axle Exploded View

    FINAL DRIVE CONCENTRIC SWINGARM REAR AXLE EXPLODED VIEW Left Axle Nut (120 ft. lbs.)(163 Nm) Foam Seal Brake Disc Snap Ring Disc Hub Lock Collar Stop Ring Seal Sleeve O-Ring Bearing Seal Bearing Race Eccentric Housing Grease Fitting Left side of axle identified by groove in spline Axle Bearing Race...

  • Page 151: Rear Housing Removal

    FINAL DRIVE CONCENTRIC SWINGARM 5. Remove the rear housing from the swingarm. REAR HOUSING REMOVAL 1. Remove rear axle. (See Page 7.6) 2. Remove sprocket hub. Note sealing O-ring between sprocket hub and bearing. REAR HOUSING DISASSEMBLY/BEARING SERVICE 3. Remove brake caliper mounting bracket from the 1.

  • Page 152: Rear Housing Installation

    FINAL DRIVE CONCENTRIC SWINGARM REAR HOUSING INSTALLATION 1. Place brake caliper pivot bushing on stud with flange inward as shown. Caliper Mount Bushing Upper Mounting Bracket Rear Housing 2. Loosely assemble upper and lower brake caliper mount. Do not tighten at this time. Upper Mounting Bracket Brake Disc...
  • Page 153 FINAL DRIVE NOTES 7.12...
  • Page 154 TRANSMISSION CHAPTER 8 TRANSMISSION SERVICE Special Tools ......Torque Specifications ..... Transmission Remove/Install .

  • Page 155: Special Tools

    TRANSMISSION SPECIAL TOOLS 6. Disconnect harness from gear position switch. 7. Remove drive chain and sprocket. PART NUMBER TOOL 8. Remove mounting bolts and brackets as shown. DESCRIPTION 9. Remove through-bolt from bottom 2871710 10” Center transmission. Distance Tool 10. Remove transmission from right side of frame. TRANSMISSION TORQUE SPECIFICATIONS INSTALLATION...
  • Page 156 TRANSMISSION 9. Inspect shift fork surface for wear or damage. Replace if necessary. 7. Using a wrench on the nut of the bellcrank, turn in a clockwise direction to assist with removal of 10. Remove shift fork guide pin. shift assembly and drive gear. 11.
  • Page 157 TRANSMISSION 15. Remove input shaft bearing. 13. Remove snap ring and washer. Pull down and rotate shift fork shaft back and forth to remove. 16. Inspect gears for galling and wear on teeth and bearing surface. Replace if necessary. 14. Inspect shift fork shaft O-ring. Replace if necessary.

  • Page 158: Transmission Assembly

    TRANSMISSION 18. Inspect gear bushing. Replace if half of teflon surface is gone. Measure 8 pitches TRANSMISSION ASSEMBLY 19. Inspect output shaft gear, sprocket and bearing. 1. Assemble input shaft assembly. Replace if necessary. NOTE: Install bearings with numbers and letters facing out so they can be read after assembly.
  • Page 159 10. Insert shifting bullet with tip in position as shown. Insert spring and plug. Torque plug to 14 ft. lbs. (19 Nm). 6. Insert fork guide pin. 11. Install transmission and add Polaris Premium Synthetic Gear Case Lubricant (PN 2871477) in the recommended amount. Refer to Maintenance Chapter 2.

  • Page 160: Transmission Exploded View

    TRANSMISSION TROUBLESHOOTING Linkage rod adjustment and rod end positioning CHECKLIST *Worn, broken or damaged internal transmission components Check the following items when shifting difficulty is *NOTE: To determine if shifting difficulty or problem encountered. is caused by an internal transmission problem, isolate Idle speed adjustment the transmission by disconnecting linkage rods from transmission bellcranks.
  • Page 161 TRANSMISSION TRANSMISSION EXPLODED VIEW 2 3 4 9 10...
  • Page 162 BRAKES CHAPTER 9 BRAKES Specifications/Torques ....Special Tools ..... . Brake System Service Notes .

  • Page 163: Specifications

    BRAKES SPECIFICATIONS Front Brake Caliper Item Standard Service Limit .298 ± .0073² / 7.56 ± .185 mm Brake Pad Thickness .150² / 3.81 mm Brake Disc Thickness .150-.165² / 3.810-4.191 mm .140² / 3.556 mm Brake Disc Thickness Variance Between .002²...

  • Page 164: Special Tools

    BRAKES SPECIAL TOOLS Test for brake drag after any brake system service and investigate cause if brake drag is evident. PART NUMBER TOOL DESCRIPTION Make sure caliper moves freely on guide pins. 2870975 Mity Vac Pressure Test Tool Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely.

  • Page 165: 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 166: Brake System Main Components

    BRAKES BRAKE SYSTEM MAIN COMPONENTS TOP VIEW MASTER CYLINDER RIGHT BRAKE CALIPER LEFT BRAKE CROSS FITTING CALIPER BRAKE SWITCH REAR BRAKE REAR BRAKE RESERVOIR CALIPER DUAL HYDRAULIC CALIPER caliper piston, but remain separated by seals. The left hand brake system applies hydraulic pressure to both BLEEDING front calipers and only the outer diameter of the rear caliper piston.

  • Page 167: Fluid Replacement/Bleeding Procedure

    5. Add brake fluid to the upper level mark on reservoir. CAUTION: Brake fluid will damage finished surfaces. Do not Polaris DOT 3 Brake Fluid allow brake fluid to come in contact with finished surfaces. (PN 2870990) BRAKE BLEEDING - FLUID...

  • Page 168: Master Cylinder Disassembly

    BRAKES 9. Repeat procedure until clean fluid appears in 13. Install diaphragm, cover, and screws. Torque the bleeder hose and all air has been purged. Add screws to 5 in.lbs. (0.56 Nm). fluid as necessary to maintain level in reservoir. Reservoir Cover Torque - CAUTION: 5 in.

  • Page 169: Master Cylinder Installation

    3. Install brake line on master cylinder hand tight. use the correct assembly. There are different brake master cylinders for the different Polaris ATV models. 4. Fill reservoir with DOT3 Brake Fluid (PN Refer to your parts manual or guide for the correct 2870990).

  • Page 170: Front Pad Removal

    BRAKES 3. Remove caliper from mounting bracket. Polaris DOT 3 Brake Fluid 4. Push caliper piston into caliper bore slowly using a C-clamp or locking pliers with pads installed. (PN 2870990) 5. Follow bleeding procedure on Pages 9.6-9.7. Check all connections for leaks and repair if necessary.

  • Page 171: Front Pad Assembly

    New .298²/7.6 mm Service Limit .180² / 4.0 mm FRONT PAD ASSEMBLY 1. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots. 18 ft. lbs. (25 Nm) Front Caliper Mounting Bolts Torque: 18 ft.

  • Page 172: Front Disc Inspection

    BRAKES 5. Install the adjuster screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise). Brake Disc Thickness .150- -.165² (3.81- -4.19 mm) Service Limit .140² / 3.556 mm 6. Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap.

  • Page 173: Front Caliper Removal

    BRAKES 1. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent. 18 ft. lbs. (25 Nm) new bolts have pre-applied locking agent. 2. Remove bolts and disc. 3. Remove brake caliper and drain fluid into 3.

  • Page 174: Front Caliper Inspection

    BRAKES 5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTE: Be sure to clean seal grooves in caliper body. Clean Components 3. Remove mounting bracket, pin assembly and dust boot. FRONT CALIPER INSPECTION Remove Mounting Bracket 1.

  • Page 175: Front Caliper Reassembly

    2. Coat piston with clean Polaris DOT 3 Brake Fluid (C). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.

  • Page 176: Front Caliper Installation

    BRAKES FRONT CALIPER INSTALLATION Front Wheel Nut Torque 20 ft. lbs. (27 Nm). 1. Install caliper on hub strut, and torque mounting bolts. 18 ft. lbs. (25 Nm) Front Caliper Mounting Bolt Torque 18 ft. lbs. (25 Nm) 2. Install brake line and tighten securely with a line wrench.
  • Page 177 BRAKES FRONT BRAKE CALIPER EXPLODED VIEW APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT APPLY POLARIS ALL PURPOSE GREASE Socket Set Screw Bushing Boot Piston Square O--Rings Brake Pads Bleeder Screw 35--60 IN. LBS. (4--6.5 NM) Caliper Assembly Boot Bushing Caliper Mount 9.16...

  • Page 178: Rear Brake Pad

    BRAKES REAR BRAKE PAD REMOVAL 4. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. 1. Remove caliper mounting bolts and lift caliper off of disc. Support Caliper from Frame Measure Thickness Rear Brake Pad Thickness .298 ±...

  • Page 179: Rear Caliper Removal/Inspection

    BRAKES 3. Remove the caliper and pads from the caliper. Auxiliary Brake Master Cylinder Fluid Level Between MIN and MAX lines Retaining Pin 4. It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise.

  • Page 180: Rear Caliper Assembly

    BRAKES Caliper Halves Bolt Torque: 10. Inspect surface of caliper piston for nicks, 18 ft. lbs. (25 Nm) scratches, or damage and replace if necessary. REAR CALIPER ASSEMBLY 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.

  • Page 181: Rear Brake Disc

    BRAKES REAR BRAKE DISC 6. Install brake lines and tighten to specified torque. INSPECTION Hand Brake Line 1. Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. Rear Brake Disc Auxiliary Brake Line Measure Banjo Bolt Torque...

  • Page 182: Troubleshooting

    BRAKES TROUBLESHOOTING Brakes Squeal Dirty/contaminated friction pads Improper alignment Worn disc Worn disc splines Poor Brake Performance Air in system Water system (brake fluid contaminated) Caliper/disc misaligned Caliper dirty or damaged Brake line damaged lining ruptured Worn disc and/or friction pads Incorrectly adjusted lever Incorrectly adjusted stationary pad Worn or damaged master cylinder or...
  • Page 183 BRAKES DH (REAR AXLE MOUNTED) CALIPER/MASTER CYLINDER Torque 28 ft. lbs. (38 Nm) Caliper Hand Brake Bleed Hand Brake Line Auxiliary Brake Line Torque 15 ft. lbs. (20.7 Nm) Auxiliary Spacer Brake Pads Auxiliary Brake Bleed Torque Auxiliary Brake Torque 8 ft.
  • Page 184 ELECTRICAL CHAPTER 10 ELECTRICAL Special Tools and Electrical Service Notes ..10.2 Timing Check Procedure ..... 10.2 Transmission Gear Position Switch Testing .

  • Page 185: Timing Check Procedure

    ELECTRICAL SPECIAL TOOLS TIMING CHECK PROCEDURES PART NUMBER TOOL DESCRIPTION 1. The ignition timing check hole is in the starter PV- -43568 Fluke 77 Digital recoil/magneto housing. Remove the check plug. Multimeter 2870836 Battery NOTE: The ignition timing marks are stamped on the Hydrometer outside of the flywheel.

  • Page 186: Gear Position Indicator

    ELECTRICAL GEAR POSITION INDICATOR LIMITER SPECIFICATIONS SWITCH TEST NOTE: The part number is printed on some late model LR modules. Whenever possible, use part Switch Continuity Table number to identify the module. Modules may have same “LR” I.D. number, with different part numbers, terminals, and internal function.

  • Page 187: Reverse Limit System

    ELECTRICAL REVERSE LIMIT SYSTEM Gry/Or 10.4...
  • Page 188 ELECTRICAL REVERSE SPEED LIMIT SYSTEM APPLY PARKING BRAKE. START ENGINE. NO REVERSE SPEED LIMIT SHIFT TO REVERSE GEAR (LR44- - 3 Limit Module) TEST GEAR POSITION INDICA- REVERSE LAMP TOR SWITCH AND INDICATOR LAMP MEASURE DC VOLTS ON TEST WIRING GRY/OR WIRE.

  • Page 189: Thermistor / Fan Control Testing

    ELECTRICAL OIL COOLER FAN CONTROL FAN MOTOR CURRENT DRAW TEST OIL COOLER FAN CIRCUIT Hot light and fan “on” with leads connected Connect ammeter leads Battery Voltage between exposed Orange/Black terminals at fan connection. Electronic Module Connect only the Red/White GThermistor resistance decreases as terminals at fan connection.
  • Page 190 ELECTRICAL ELECTRONIC THROTTLE Test the ETC switch at the harness connector. NOTE: Adjust throttle cable freeplay (ETC switch) and make CONTROL (ETC) SWITCH sure throttle mechanism is functioning properly before testing the switch. Refer to Maintenance Chapter 2 (COMPOSITE THROTTLE for cable adjustment procedure.

  • Page 191: Flywheel Identification

    ELECTRICAL FLYWHEEL IDENTIFICATION Flywheel Identification Stamp Location The flywheel can be identified by the stamp mark in location A. Refer to “I.D.” location in chart below. Do not use the cast mark to determine flywheel application. 2003 Engine Application Type Cast Stamp Comment...

  • Page 192: Components Of Es32Pf/200 Watt Alternator

    ELECTRICAL COMPONENTS OF ES32PF / 200 WATT ALTERNATOR Note: DC/CDI components are not compatible with any other type of ignition Ignition Coil Refer To Wiring Diagrams For Meter Primary Specified Stator Coil Resistance .3 W Coil Lead Winding Ignition Kill Wire (Black) Resistor...

  • Page 193: Ignition System Testing

    ELECTRICAL IGNITION SYSTEM TESTING 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 194: Ignition System Troubleshooting

    ELECTRICAL IGNITION SYSTEM Test output from the CDI and pulse (trigger) coil and compare to the table. The following measurements TROUBLESHOOTING are obtained when cranking the engine with the electric starter, spark plug installed. The starter No Spark, Weak or Intermittent Spark system must be in good condition and the battery fully charged.

  • Page 195: Charging System Testing

    ELECTRICAL CHARGING SYSTEM TESTING Whenever charging system problems are suspected, proceed with the following system checks: Using a multitester set on D.C. volts, mea- sure the battery open circuit voltage (See Remove the battery and properly ser- Page 10.15). It should be 12.4 volts or vice.

  • Page 196: Alternator Output Test

    ELECTRICAL CURRENT DRAW - KEY OFF GWith engine off and the key and kill switch in the ON position, the ammeter should read negative amps CAUTION: Do not connect or disconnect the battery (battery discharge). Reverse meter cable or ammeter with the engine running. Damage leads if a positive reading is will occur to light bulbs and speed limiter.

  • Page 197: Battery Service

    BATTERY INSPECTION The battery is located under the left rear fender. BATTERY TERMINALS/BOLTS Use Polaris corrosion resistant Dielectric Grease (PN 2871329) on battery bolts. See Battery Installation on Maintain Page 10.15. between upper...

  • Page 198: Battery Installation

    ELECTRICAL To remove the battery: 2. Reinstall battery, attaching positive (+) (red) cable first and then the negative (-) (black) cable. Coat 1. Disconnect holder strap and remove cover. terminals and bolt threads with Dielectric Grease 2. Disconnect battery negative (-) (black) cable first, (PN 2871329).

  • Page 199: Load Test

    ELECTRICAL SPECIFIC GRAVITY TEST LOAD TEST CAUTION: Remove spark plug high tension leads and NOTE: This test is for Conventional Lead--acid connect securely to engine ground before proceeding. batteries only. Maintenance--Free batteries cannot be opened. NOTE: This test can only be performed on engines with electric starters.

  • Page 200: Headlight Adjustment

    ELECTRICAL NOTE: Stored batteries lose their charge at the rate 1. Place the vehicle on a level surface with the of 1% per day. They should be recharged to a full headlight approximately 25’ (7.6 m) from a wall. charge every 30 to 60 days during a non-use period. If the battery is stored during the winter months the Lamp Center Height electrolyte will freeze at a higher temperature as the...

  • Page 201: Headlamp Replacement

    ELECTRICAL POD ASSEMBLY REMOVAL / Headlamp Replacement INDICATOR LAMP 1. With the headlight assembly in place, unsnap the electrical harness from the back the headlight REPLACEMENT assembly. 2. Turn and pull out the connector on the back of the 1. Remove the two screw covers (A) and screws headlight assembly.

  • Page 202: Brake Light Switch

    ELECTRICAL HEADLAMP SWITCH NOTES Follow procedure, Headlight Lamp Replacement, on Page 10.17--10.18 to access connector. Probe the headlamp plug wires (Brown, Green, Yellow) at back of connector. Turn headlight on. Test for battery voltage across the connections. Check continuity across pins of the left handle bar switch assembly.

  • Page 203: Starter System Testing

    ELECTRICAL STARTER SYSTEM TESTING 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 204: Starter System Troubleshooting

    ELECTRICAL STARTER SYSTEM voltage drop tests on the starter system. TROUBLESHOOTING Voltage should not exceed: Starter Motor Does Not Turn 1 DC volts per connection GBattery discharged - low specific gravity GLoose or faulty battery cables or corroded STARTER MOTOR connections (see Voltage Drop Tests) DISASSEMBLY GRelated wiring loose, disconnected, or...
  • Page 205 ELECTRICAL cable terminal and brush housing. Make sure the brush is not touching the case. The reading should be infinite. 2. Remove nut, flat washer, large phenolic washer, two small phenolic washers, and O-Ring from brush terminal. Inspect the O-Ring and replace if damaged.

  • Page 206: Armature Testing

    ELECTRICAL ARMATURE TESTING STARTER ASSEMBLY 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. 1. Place armature in field magnet casing. 2. Place shims on drive end of armature shaft with phenolic washer outermost on shaft.

  • Page 207: Starter Drive

    Pinion Gear - Anti Kick-out Shoe, Garter Spring Replacement If the garter spring is damaged, the overrun clutch Polaris Premium Starter Drive Grease may fail to return properly. The replacement spring is (PN 2871460) (PN 7042039). Use either of the following methods to remove and install a new garter spring.
  • Page 208 Brake Pad Removal, Front, 9.9 Brake Pad Removal, Rear, 9.17 A-Arm Replacement, 5.6 Brake System Inspection, 2.23 Air Filter Cleaning, 2.15 Brake System Main Components, 9.5 Air Filter Service, 2.15 Brake System Operation, 9.4 Alternator Output Test, 10.13 Brake System Service Notes, 9.3 Alternator, Exploded View, 10.9 Brake, Auxiliary, Hydraulic, 2.23 Brakelight Lamp Replacement, 10.18...
  • Page 209 Clutch Offset, 6.16 Combustion Chamber, 3.18 Decal Replacement, 5.12 Compression Release Installation, 3.14 Decimal Equivalents, 1.9 Compression Release Removal/Inspection, 3.14 Draining Recoil Housing, 2.16 Compression Test, 2.13 Drive Belt Removal/Inspection, 6.14 Concentric Swing Arm Installation, 5.8 Drive Belt Tension, 6.13 Concentric Swing Arm Removal, 5.7 Drive Chain Adjustment, 2.24 Connecting Rod Bearing Clearance Inspection,...
  • Page 210 Engine Top End Disassembly, 3.11, 3.12, 3.13, Headlight Lamp Replacement, 10.17 3.14, 3.15, 3.16, 3.17 Honing to Oversize, 3.6, 3.7 ETC Switch Adjustment, 2.11 ETC Switch Testing, 10.7 Exhaust System, Maintenance, 2.22 Idle Speed Adjustment, 2.11 Exhaust Valve Adjustment, 2.19 Ignition System Testing, 10.10 Ignition Timing, 2.14 Indicator Lamp Replacement, 10.18...
  • Page 211 Oil Cooler Assembly, 3.8 Rear Housing Bearing Service, 7.10 Rear Housing Installation, 7.11 Oil Filter Installation, 3.35 Rear Housing Removal, 7.10 Oil Flow, ES32PF, 3.9 Recoil Assembly, 3.44 Oil Pressure Test, 3.7 Recoil Disassembly/Inspection, 3.42 Oil Pump Assembly, 3.29 Recoil Draining, 2.16 Oil Pump Installation, 3.34 Reverse Limit System, 10.4, 10.5 Oil Pump Removal/Inspection, 3.28...
  • Page 212 Starter System Test, 10.20 Transmission Exploded View, 8.7, 8.8 Stator Installation, 3.41 Transmission I.D. Location, 1.2 Stator Removal/Inspection, 3.26 Transmission Installation, 8.2 Steering Assembly, Exploded View, 4x4, 5.3 Transmission Linkage Adjustment, 2.9 Steering Maintenance, 2.20 Transmission Removal, 8.2 Steering Post Assembly, 5.12 Troubleshooting, Brakes, 9.21 Suspension Preload Adjustment, 2.26 Troubleshooting, Engine, 3.45, 3.46...

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