Download Print this page

Polaris 2007 Sportsman 500 EF Service Manual

Atv polaris 2007 sportsman 450 / 500 efi / 500 x2 efi.
Hide thumbs
Table of Contents


2007 SPORTSMAN 450 / 500 EFI / 500 X2 EFI
This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with
service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper
tools as specified.
Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100
Hwy 55 Medina Minnesota 55340.
2007 Sportsman 450 / 500 EFI / 500 X2 EFI Service Manual PN 9920560
© Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting
or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.



   Related Manuals for Polaris 2007 Sportsman 500 EF

   Summary of Contents for Polaris 2007 Sportsman 500 EF

  • Page 1

    2007 Sportsman 450 / 500 EFI / 500 X2 EFI Service Manual PN 9920560 © Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 2

    Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries Some Polaris factory publications can be downloaded from, purchased from or by contacting the nearest Polaris dealer.

  • Page 3: Table Of Contents


  • Page 4


  • Page 5: General Information


  • Page 6: General, Model Number Information, Model Number, Engine Designation Numbers, Vehicle Identification Number (vin)

    GENERAL INFORMATION MODEL NUMBER INFORMATION Model Number The machine model number must be used with any correspondence regarding warranty or service. A 07 MN 50 AU Engine Designation Numbers EH50PLE - Single Cylinder, Liquid Cooled,4 Stroke, Electric Start Vehicle Identification Number (VIN) World Mfg.

  • Page 7: Paint Codes, Replacement Keys

    Sportsman X2 500 EFI 2007 A07MH46E 9920650 9920899 Quadricycle Paint Codes Table 1-2: Paint Codes COLOR DITZLER POLARIS PAINTED PART DESCRIPTION NUMBER NUMBER Sportsman Frame Black 9440 P-067 Replacement Keys Replacement keys can be made from the original key (Phoenix excluded). 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.

  • Page 8: Sportsman 'deluxe' And 'standard' Model Component Comparison

    GENERAL INFORMATION Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison For Model Year 2007, a Sportsman ‘Deluxe’ and ‘Standard’ model were offered. Use the following table as a guide: SPORTSMAN ‘DELUXE’ MODEL Item Location SPORTSMAN ‘STANDARD’ MODEL Winch No Winch PXT Tires Titan Tires PVT w/EBS Non-EBS (X2 excluded)

  • Page 9: Sportsman X2 'deluxe' And 'standard' Model Component, Sportsman X2 'deluxe' And 'standard' Model Component Comparison

    GENERAL INFORMATION Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison For Model Year 2007, an X2 ‘Deluxe’ and ‘Standard’ model were offered. Use the following table as a guide: X2 ‘DELUXE’ MODEL Item Location X2 ‘STANDARD’ MODEL Winch No Winch Rear Work Lights No Work Lights Front Drive w/ Active Descent Control (ADC)

  • Page 10: Sportsman 450, Model Number: A07mh46aa, Az

    GENERAL INFORMATION 2007 SPORTSMAN 450 Model Number: A07MH46AA, AZ Engine Model: EH46PLE Table 1-4: Sportsman 450 General Specifications Category Dimension / Capacity Length 83 in./211 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 50.5 in./128.3 cm Ground Clearance 11 in./27.94 cm Dry Weight 715 lbs./324 kg...

  • Page 11: Fuel System

    Rear Suspension / Shock Progressive Rate Independent - " w/ 2 Coil-over shock Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 ltr Rear Travel 9.5 in. / 24.13 cm Exhaust System Single Pipe USFS Approved Ground Clearance 11 in. / 27.94 cm...

  • Page 12: Sportsman 500 Efi

    GENERAL INFORMATION 2007 SPORTSMAN 500 EFI Model Number: A07MH50AX, AY, AZ, AQ / A07MN50AL, AF / A07MH50FC (Standard Models) (Deluxe Models) (International) Engine Model: EH50PLE Table 1-9: Sportsman 500 EFI General Specifications Category Dimension / Capacity Length 83 in./211 cm Width 48 in./122 cm Height...

  • Page 13: Fuel System

    Lubrication Pressurized Dry Sump Front Suspension / Shock A-arm / MacPherson Strut Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 ltr Front Travel 8.2 in. / 20.8 cm Exhaust System Single Pipe USFS Approved Rear Suspension / Shock...

  • Page 14: Sportsman X-2 500 Efi

    GENERAL INFORMATION 2007 SPORTSMAN X-2 500 EFI Model Number: A07TH50AU, AZ, AQ / A07TN50AF / A07TH50EA (Standard Models) (Deluxe Model) (Intl’ Quadricycle) Engine Model: EH50PLE Table 1-13: Sportsman X-2 500 EFI General Specifications Category Dimension / Capacity Length 93 in./236 cm Width 48 in./122 cm Height...

  • Page 15

    Lubrication Pressurized Dry Sump Front Travel 8.2 in. / 20.8 cm Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 ltr Rear Suspension / Shock Progressive Rate Independent - Coil - over shock Exhaust System Single Pipe USFS Approved Rear Travel 8.75 in.

  • Page 16: Misc. Numbers/charts, Standard Torque Specifications

    GENERAL INFORMATION MISC. NUMBERS/CHARTS 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. 1.12...

  • Page 17: Sae Tap Drill Sizes

    GENERAL INFORMATION SAE Tap Drill Sizes Decimal Equivalents 1/64 ....0156 Thread Size/ Drill Size Thread Size / Drill Size 1/32 ....0312 .

  • Page 18: 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 19: Glossary Of Terms

    Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8, or 1 cm). Polaris measures chain length in number of pitches. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase.

  • Page 20


  • Page 21: Table Of Contents


  • Page 22: Table Of Contents


  • Page 23: Maintenance Chart Key

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

  • Page 24

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

  • Page 25: Periodic Maintenance Chart

    620 (1000) Inspect routing, condition Valve clearance 100 H 12 M 620 (1000) Inspect; adjust Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.

  • Page 26

    Inspect periodically; adjust when parts are replaced Auxiliary brake Inspect daily; adjust as needed Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.

  • Page 27: Lubrication / Fluids

    MAINTENANCE LUBRICATION / FLUIDS SPORTSMAN Component Locations (Deluxe) (Sportsman Only)

  • Page 28: Sportsman X2 Component Locations

    MAINTENANCE SPORTSMAN X2 Component locations Instrument Cluster AWD/Turf Switch Brake Fluid Reservoir Worklight (Speedometer) Brake Lever Diagnostic Light Control Port (under access panel) & Run Switch Throttle Reverse Override Ignition/Key Front Storage Compartment & Rack Front Demand Drive Unit Rear Dump Box / Passenger Area (Behind Radiator) Battery (Under Tank) Oil Dipstick...

  • Page 29: Polaris Lubricants, Maintenance And Service Products

    MAINTENANCE Polaris Lubricants, Maintenance and Service Table 2-1: Products PART DESCRIPTION NUMBER Table 2-1: Coolant PART DESCRIPTION 2871323 60/40 Coolant (Gallon) (6 count) NUMBER 2871534 60/40 Coolant (Quart) (12 count) Engine Lubricant Additives / Sealants / Thread Locking Agents / Misc.

  • Page 30: Polaris Lubricant Symbol Identification, Pre-ride / Daily Inspection

    MAINTENANCE Polaris Lubricant Symbol Identification Pre-ride / Daily Inspection NOTE: The symbols used are for quick reference in identifying Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. which lubricant/grease to use on each component.

  • Page 31: Lubrication Components

    2 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) 3 Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special...

  • Page 32: Front Gearcase Lubrication

    • Be sure vehicle is level before proceeding and in PARK • Check vent hose to be sure it is routed properly and unobstructed • The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid. FRONT GEARCASE...

  • Page 33: Transmission Lubrication

    Clean around the drain plug and remove the drain plug and wipe the magnetic end clean to remove all accumulated metallic filings. Transmission - Specified Lubricant: Polaris AGL Gearcase Lubricant (Gallon - PN 2873603) (12 oz. - PN 2873602) Transmission - Capacity: 32 oz. (948 ml) Transmission Drain / Fill Plug Torque: 20-25 ft.lbs.

  • Page 34: Adc Differential Hydraulic Circuit Fluid Change, Vehicle Inspection, Shift Link Rod Inspection

    Shift Mount inadequate bleed of the hydraulic circuit. Begin the bleeding process by filling reservoir to ‘MAX’ line with clean Polaris ADC hyrdraulic fluid. (AW ISO 10 hydraulic fluid equivalent). Locate bleeder valves found on either side of differential Shifter and remove the protective caps.

  • Page 35: Throttle Inspection

    MAINTENANCE Throttle Inspection Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever Slide boot off throttle cable adjuster and jam nut. must return freely without binding.

  • Page 36: Fuel Lines, Vent Lines

    MAINTENANCE Fuel System Fuel Lines EFI Example WARNING Gasoline is extremely flammable and explosive under certain conditions. * EFI components are under high pressure. Verify system pressure has been relieved before disassembly. * Never drain the fuel system when the engine is hot.

  • Page 37: Fuel Filter, Compression Test, Engine Mounts

    MAINTENANCE Fuel Filter Compression Test NOTE: 450/500 4-Stroke engines are equipped with an The fuel filter should be replaced in accordance with the Periodic Maintenance Chart. automatic decompressor. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about 60-90 psi EFI Example during a compression test.

  • Page 38

    Check the level and verify it removed. is between the ‘MAX’ and ‘MIN’ lines. Add only Polaris ADC Remove spark plug. fluid when required.

  • Page 39: Cooling System Hoses, Liquid Cooling System Overview, Coolant Strength / Type, Radiator/grill Screen

    Overheating of engine could occur if air is not fully purged from system. Do not over-tighten hose clamps at radiator, Polaris Premium 60/40 is already premixed and ready to use. Do or radiator fitting may distort, not dilute with water.

  • Page 40: Cooling System Pressure Test, Coolant Level Inspection, Air Filter/pre-filter Service, Radiator Coolant Level Inspection

    Pull the seat back and free of the tabs. NOTE: When clear and open. reinstalling seat, make sure the slots in the seat engage the Fill reservoir to upper mark with Polaris Premium 60/40 tabs in the fuel tank. Anti Freeze / Coolant or 50/50 or 60/40 mixture of Remove clips (A) from air box cover and remove cover.

  • Page 41: Air Box Sediment Tube

    MAINTENANCE Loosen clamp and remove air filter assembly. Main Filter Proper Filter Placement Cover Filter Support Pre-Filter Gasket Air Box Main Element Front Carb Boot Cleaning: NOTE: The air filter should rest on the filter support. Slip the pre-filter element off of main element. Clean the Proper placement of the air filter is important to prevent rattles and air leaks.

  • Page 42: Recoil Housing, Breather Filter Inspection, Breather Hose

    MAINTENANCE Breather Filter Inspection Recoil Housing Four-cycle ATV engines are equipped with a breather filter. The in-line filter is similar in appearance to a fuel filter, and is visible on the left side (Location A). In-line breather filters can be installed in either direction. Typical Breather Filter Location Recoil Drain •...

  • Page 43: Engine Oil Level, Oil And Filter Change

    (PV-43527) Oil Tank Screen Fitting Torque: 25 ft-lb (34Nm) Recommended Engine Oil: Polaris Premium 4 All Season Synthetic, 0W-40 The oil tank is located on the left side of the vehicle. To check the oil level: Set machine on a level surface.

  • Page 44

    21. Remove dipstick and fill tank with 2 quarts (1.9 L) of Maximum torque for the screen fitting Polaris Premium 4 Synthetic Oil. is 25 ft-lb (34Nm), do not over tighten. 22. Place gear selector in Park and set parking brake.

  • Page 45: Valve Clearance

    MAINTENANCE Valve Clearance 23. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the Inspect and adjust valve clearance while the engine is cold and dipstick. the piston positioned at Top Dead Center (TDC) on compression 24.

  • Page 46: Intake Valve Clearance Adjustment, Exhaust Valve Clearance Adjustment

    Check routing of all cables, hoses, and wiring to be sure Repeat this step for the other intake valve. the steering mechanism is not restricted or limited. NOTE: Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts. INTAKE VALVE CLEARANCE WARNING .006” (.15 mm)

  • Page 47: Wheel Alignment, Tie Rod End/steering Inspection, Camber And Caster

    MAINTENANCE Tie Rod End/Steering Inspection Wheel Alignment • To check for play in the tie rod end, grasp the steering Place machine on a smooth level surface. tie rod, pull in all directions feeling for movement. Set handlebars in a straight ahead position and secure handlebars in this position.

  • Page 48: Brakes, Toe Alignment Adjustment, Exhaust Pipe

    MAINTENANCE Toe Alignment Adjustment Exhaust Pipe If toe alignment is incorrect, measure the distance between WARNING vehicle center and each wheel. This will tell you which tie rod needs adjusting. NOTE: Be sure handlebars are straight ahead before determining which tie rod(s) need adjustment. •...

  • Page 49: Brake System Inspection

    • Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir. • Use Polaris DOT 3 Brake Fluid Sight Glass If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front.

  • Page 50: Brake Pad Inspection, Auxiliary Brake Adjustment (hydraulic), Hose/fitting Inspection, Auxiliary Brake Testing

    MAINTENANCE Brake Pad Inspection While turning the rear wheels by hand, apply the auxiliary foot brake. This brake should not stop the wheels from Pads should be changed when the friction material is worn to turning until the lever is half way between its rest position .180”...

  • Page 51: Front Suspension, Suspension Spring Preload Adjustment, Cv Shaft Boot Inspection

    MAINTENANCE Suspension Spring Controls Preload Adjustment Center Spring Adjustment Ring Check controls for proper operation, positioning and adjustment. Shock Spanner Wrench Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch (PN 2871095) body.

  • Page 52: Wheel, Hub, And Spindle Torque Table, Wheel Installation, Wheel Removal Front Or Rear, Tire Pressure

    MAINTENANCE Wheel, Hub, And Spindle Wheel Installation Torque Table With the transmission in Park and the parking brake locked, place the wheel in the correct position on the wheel Item Specification hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.

  • Page 53: Frame, Nuts, Bolts, Fasteners

    MAINTENANCE Tire Inspection Storage Compartments • Improper tire inflation affect The storage compartments are easily accessible. To open the maneuverability. front compartment turn the latch handle to the horizontal position on both sides. To close the storage compartment turn • When replacing a tire always use original equipment the latch handles just past the vertical position.

  • Page 54: Winch Operation (if Equipped)

    MAINTENANCE Winch Operation (If Equipped) The mini-rocker (IN/OUT) control controls the direction of the cable for the winch. IN pulls the cable into the winch and OUT feeds the cable out of the winch. This information is for Sportsman models equipped with a winch in the front.

  • Page 55

    MAINTENANCE Yellow (6 Ga.) wires to the winch. Refer to the installation The Orange/White wires are located under the front cover instructions for more details. (under headlight pod). The Orange/White wires supply the control power to the winch. Winch Connector Winch Connecting Splash Guard for Contactor mount Harness...

  • Page 56: Atv Cleaning & Storage

    EFI sytem / carburetor. Turn the fuel valve off and drain the carburetor bowl (450 only). Polaris does not recommend the use of a high pressure type car wash system for washing the ATV. If a high pressure system is...

  • Page 57

    If Polaris fuel system additive is not used, fuel tank, and fuel lines should be completely drained of gasoline. Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant.

  • Page 58

    MAINTENANCE Maintenance Schedule Service Date Hours / Miles Service Performed Serviced By: 2.38...

  • Page 59: Table Of Contents


  • Page 60: Table Of Contents


  • Page 61: Specifications

    ENGINE SPECIFICATIONS Special Tools Torque Specifications PART NUMBER TOOL DESCRIPTION Valve Seat Reconditioning 2200634 TORQUE SPECIFICATIONS 2870390 Piston Support Block Fastener Size EH50PLE Ft. Lbs. (Nm) 2871043 Flywheel Puller Blind Plug (Oil 1/8 PT 6.5-11 (9-15 Nm) Crankshaft/Water Pump 2871283 Pressure) (28tpi) Seal Install Kit...

  • Page 62: Engine Service Data

    ENGINE Engine Service Data Cylinder Head / Valve EH50PLE Rocker Arm Rocker arm ID .8669-.8678" (22.020-22.041 mm) Rocker shaft OD .8656-.8661" (21.987-22.0 mm) Rocker shaft Oil Clearance Std .0008-.0021" (.020-.054 mm) Limit .0039" (.10 mm) Camshaft Cam lobe height 1.2884-1.2924” (32.726-32.826 mm) Limit 1.2766"...

  • Page 63

    ENGINE Engine Service Data Cylinder / Piston / Connecting Rod EH50PLE Cylinder Surface warpage limit (mating with cylinder .0020” (0.05 mm) head) Cylinder bore 3.6221-3.6228” (92.00-92.02 mm) Taper limit .0020” (0.05 mm) Out of round limit .0020” (0.05 mm) Piston clearance .0006-.0018"...

  • Page 64: General Engine Service, Cooling System Specifications, Piston Identification

    ENGINE GENERAL ENGINE SERVICE Cooling System Specifications Sensor Piston Identification 18.5 + ft. lbs. (25 Nm) The piston may have an identification mark or the piston may not have an identification mark for piston placement. If the piston has an identification mark, follow the directions for piston placement below.

  • Page 65: Cooling System

    ENGINE Cooling System System Pressure Test Remove radiator cap cover located in storage box. Remove recovery bottle hose from coolant filler. WARNING Connect a Mity Vac™ (PN 2870975) to radiator and pressurize system to 10 PSI (68.9 kpa). The system must Never remove radiator cap when engine is warm or hot.

  • Page 66: Engine Removal (typical), Accessible Components

    • Fuel Tank Cover / Front Cab (Refer to Chapter 5) engine damage. Polaris Premium 60/40 Antifreeze/ • Fuel Tank (Refer to Chapter 4) Coolant is recommended for use in all cooling systems, and comes pre-mixed, ready to use.

  • Page 67: Engine Installation Notes, Cylinder Hone Selection/ Honing Procedure, Honing To Oversize

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

  • Page 68: Electrical, Crankshaft Straightening, Cleaning The Cylinder After Honing

    Rinse thoroughly, dry with compressed air, and oil To correct a situation like the one shown in the illustration, the bore immediately with Polaris 2 Cycle Lubricant. strike the shaft at point A with a brass hammer. HIGH .002 (.05 mm) HIGH .005 (.13 mm)

  • Page 69: Oil Flow - Eh50pl, Oil Pressure Test - Eh 50pl

    The other oil path from the filter leads through a delivery pipe to the crankcase main oil gallery, which leads to the stator plate *Oil Pressure Specification...20 PSI @ 5500 RPM, Polaris oil passage. Here it passes through the slotted friction bearing 0W-40 Synthetic (Engine Hot) (located in the stator plate) into the crankshaft.

  • Page 70: Eh50pl Oil Flow Diagram

    ENGINE EH50PL Oil Flow Diagram Internal passage to camshaft (front left head bolt) Vent Hose Oil Filter Oil feed to filter From filter to crankshaft One way valve Bottom fitting is oil Oil Tank exhaust or return Top fitting is oil to tank feed or intake from bottom of tank...

  • Page 71

    ENGINE EH50PL Engine Exploded Views Cylinder/ Crankcase Cylinder Head Crankshaft Valvetrain and Piston 3.13...

  • Page 72: Engine Disassembly, Cam Chain Tensioner/rocker Arm/ Camshaft Removal, Cam Chain Tensioner Inspection

    ENGINE ENGINE DISASSEMBLY NOTE: The cam lobe should be pointing down and valves should have clearance at this point. Cam Chain Tensioner/ROCKER ARM/ CAMSHAFT Removal Remove ignition timing inspection plug from recoil housing. TDC “T” Mark Rotation Advance Marks Remove cam chain tensioner plug, sealing washer, and spring.

  • Page 73: Rocker Arm/shaft Inspection

    ENGINE Push ratchet pawl and hold it. The plunger should move Inspect each rocker arm cam follower surface. If there is smoothly in and out of the tensioner body. any damage or uneven wear, replace the rocker arm. NOTE: Always inspect camshaft lobe if rocker arms are Release ratchet pawl and push inward on plunger.

  • Page 74: Camshaft Removal

    ENGINE Measure I.D. of each rocker arm and compare to Loosen three camshaft sprocket bolts. specifications. Remove camshaft end cap and O-Ring. Rocker Shaft Oil Clearance: Std: .0008 - .0021 (.020-.054 mm) Limit: .0039” (.10 mm) Measure I.D. of both rocker arm shaft supports and visually inspect surface.

  • Page 75

    ENGINE Automatic Compression Release Removal/ Secure cam chain with a wire to prevent it from falling into Inspection the crankcase. NOTE: The automatic compression release mechanism can be inspected and serviced without removing the camshaft from Sprocket Teeth the cylinder head. The actuator ball (C) in the camshaft is not replaceable.

  • Page 76: Automatic Compression Release Installation, Camshaft Inspection

    ENGINE Automatic Compression Release Installation Camshaft Inspection Slide spring onto shaft. Visually inspect each cam lobe for wear, chafing or Apply engine oil to release lever shaft. damage. Thoroughly clean the cam shaft, making sure the oil feed The actuator ball must be held outward to allow installation holes are not obstructed.

  • Page 77: Cylinder Head Removal

    ENGINE Cylinder Head Removal Measure height of each cam lobe using a micrometer. Compare to specifications. Remove the two 6mm flange bolts (A) from cylinder head. Journal O.D See next exploded view on next page. Loosen each of the four cylinder head bolts (B) evenly 1/8 turn each time in a criss-cross pattern until loose.

  • Page 78

    ENGINE Cylinder Head Exploded View, EH50PL EH50PL 3.20...

  • Page 79: Cylinder Head Warp

    ENGINE Cylinder Head Inspection 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. Thoroughly clean cylinder head (A) surface to remove all traces of gasket material and carbon.

  • Page 80: Valve Inspection

    ENGINE Measure free length of spring with a Vernier caliper. Check seat area (B). NOTE: The valves cannot be re-faced or end spring for squareness. Compare to specifications. Replace ground. Valves must be replaced if worn, bent, or damaged. spring if either measurement is out of specification Measure valve stem in several places Valve Stem Diameter: Intake: .2343-.2348”...

  • Page 81: Combustion Chamber, Valve Seat Reconditioning

    ENGINE Combustion Chamber Heat cylinder head in an oven or use a hot plate to bring cylinder head temperature to 212 F (100 CAUTION Do not use a torch to heat cylinder head or warpage may result from uneven heating. Head temperature can be checked with a pyrometer or a welding temperature stick.

  • Page 82

    ENGINE Place cylinder head on cylinder head table. NOTE: Be sure Apply cutting oil to valve seat and cutter. cylinder head is still at 212 F (100 C) before installing new guides. Valve Guide Installed Height Place 46 cutter on the pilot and make a light cut. Valve Guide Height: 10.

  • Page 83

    ENGINE 13. Remove valve and check where the Prussian Blue™ NOTE: When using an interference angle, the seat contact point on the valve will be very narrow, and is a indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly normal condition.

  • Page 84: Cylinder Head Assembly, Valve Sealing Test, Valve Clearance Adjustment

    ENGINE Cylinder Head Assembly Valve Sealing Test Clean and dry the combustion chamber area. CAUTION Pour a small amount of clean, high flash point solvent into the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage. Wear eye protection during assembly.

  • Page 85

    ENGINE Cylinder/Piston Removal and Inspection Remove the two 6 mm cylinder base bolts. NOTE: Follow engine disassembly procedures to remove valve cover, camshaft and rocker arms, and cylinder head. 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 86: Piston Removal, Cylinder Inspection

    ENGINE Piston Removal *By hand: Placing both thumbs as shown, spread the ring open and push up on the opposite side. Do not scratch the ring lands. Remove circlip. Note piston directional arrow pointing Repeat procedure for second ring. toward the right (Mag) side of engine. Remove piston circlip and push piston pin out of piston.

  • Page 87: Piston/rod Inspection, Piston-to-cylinder Clearance

    ENGINE Inspect cylinder for wear, scratches, or damage. Subtract this measurement from the maximum cylinder measurement obtained in Step 5 above. 1/2” Down From Top of Cylinder Piston to Cylinder Clearance Std: .0006- .0018” (.015- .045 mm) Piston O.D.: Std: 3.6204- 3.6215” (91.970-91.985 mm) Piston/Rod Inspection 1/2”...

  • Page 88: Piston Ring Installed Gap, Crankcase Disassembly

    ENGINE Piston Ring Installed Gap Place each piston ring inside cylinder using piston to push ring squarely into place as shown at right. Feeler Gauge 25-50 mm Cylinder Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance. Piston Ring Measure connecting rod small end ID.

  • Page 89: Flywheel/stator Removal/inspection

    ENGINE Starter Drive Removal/Inspection Measure the ID of the bushing in the recoil housing (A) and in the crankcase and record. Measure in two directions 90 Remove recoil housing bolts and remove housing. apart to determine if bushing is out of round. Calculate bushing clearance.

  • Page 90: One Way Valve Removal, Cam Chain/tensioner Blade

    ENGINE Remove large sealing O-Ring from outer edge of stator section of chain. Replace if worn past service limit. plate. Chain Service Limit: 5.407” (13.7 cm) Using the special socket, remove the crankshaft slotted nut. NOTE: The crankshaft slotted nut is a left-hand thread. Remove cam chain drive sprocket and woodruff key from crankshaft.

  • Page 91: Crankcase Separation, Oil Pump Removal/inspection

    ENGINE Crankcase Separation Inspect drive gear teeth for cracks, damage or excessive wear. Remove flange bolts (10) from magneto side crankcase Remove three oil pump retaining bolts and pump. evenly in a criss-cross pattern. Inspect mating surface of crankcase and oil pump. Check Separate crankcase by tapping with a soft faced hammer in for nicks, burrs, or surface irregularities.

  • Page 92: Oil Pump Assembly

    ENGINE Oil Pump Assembly Measure pump end clearance using a feeler gauge and straight edge. Clean and dry all parts thoroughly. Apply clean engine oil to all parts. Do not use gasket sealer on the pump body mating surfaces or oil passages will become plugged. Install pump shaft and scavenge rotor drive pin.

  • Page 93: Crankshaft Removal/inspection

    ENGINE Turn the shaft until balancer counter weights clear the Support the PTO side crankcase and crankshaft; press the crankshaft and remove the balancer shaft from the crankshaft out. Be careful not to damage the crankcase crankcase. mating surface or connecting rod. Use a feeler gauge to measure the connecting rod big end Inspect the balancer drive gear and pump shaft drive gear.

  • Page 94: Crankcase Bearing Inspection, Crankcase Inspection

    ENGINE Crankcase Bearing Inspection Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal (Engine Disassembled) NOTE: The water pump mechanical seal can be removed without removing the engine. Refer to Water Pump Mechanical Seal Installation. Replace the pump shaft seal and water pump mechanical seal whenever the crankcase is disassembled.

  • Page 95: End Play Inspection/adjustment, Crankshaft End Play Adjustment

    ENGINE Bearing Installation Measure the distance from the PTO crankcase mating surface to the main bearing using a dial caliper and a NOTE: To ease bearing installation, warm straight edge. crankcase until hot to the touch. Place the bearings in a freezer.

  • Page 96: Counter Balancer Shaft End Play Adjustment

    ENGINE Measure the distance from the Magneto crankcase mating 10. Subtract the Crankshaft Width measured in Step 7 from the surface to the main bearing using the same method and Total Case Width recorded in Step 6, and record below. record.

  • Page 97: Oil Pump Shaft End Play Adjustment

    ENGINE 14. Measure the distance from the Mag crankcase mating Install the gear on the oil pump and measure the width of surface to the balance shaft bearing using a dial caliper and the pump and gear. Subtract this measurement from the a straight edge.

  • Page 98: Engine Reassembly, Crankshaft/counter Balance/oil Pump Installation, Pump Shaft Oil Seal Installation

    ENGINE ENGINE REASSEMBLY Crankshaft/Counter Balance/Oil Pump Installation Pump Shaft Oil Seal Installation Lubricate all bearings with clean engine oil before assembly. Use the Crankshaft/Water Pump Installation Kit (PN 2871283) to prevent damage to the crankshaft and main bearings during installation. Install the crankshaft into the PTO side crankcase.

  • Page 99: Crankcase Assembly, Water Pump Mechanical Seal Removal - Engine Installed, Water Pump Mechanical Seal Installation

    ENGINE Crankcase Assembly Water Pump Mechanical Seal Removal - Engine Installed Apply Crankcase Sealant (PN 2871557) to the crankcase mating surfaces. Be sure the alignment pins are in place. Water Pump Mechanical Seal Set the crankcase in position carefully to avoid damaging Puller: (PN 2872105) the pump shaft seal, and install the magneto end crankshaft installation tool (follow instructions provided with the...

  • Page 100: One Way Valve Installation

    ENGINE Slide the main puller body over the outer portion of the Tighten the hex socket screws on the puller legs sufficiently mechanical seal as shown in Ill. 2 and turn T-Handle so the lip of the puller legs will grasp the mechanical seal. clockwise until it contacts water pump shaft.

  • Page 101: Piston Ring Installation

    ENGINE Cam Chain Drive Sprocket Installation NOTE: The top rail has a locating tab to prevent rotation. The tab must be positioned in the notch on the Install the Woodruff key, drive sprocket, and slotted nut. side of the piston as shown (A). Tighten the nut to the specified torque.

  • Page 102: Piston Installation, Cylinder Installation

    ENGINE Piston Installation Cylinder Installation Clean the gasket surfaces on the cylinder and crankcase. Place the dowel pins in the crankcase and install a new Remove all traces of old gasket material. cylinder base gasket. Make sure the cylinder mounting bolt holes are clean and Position the Piston Support Block (PN 2870390) (A) free of debris.

  • Page 103: Cylinder Head Installation, Cam Chain/camshaft Installation

    ENGINE 10. Apply clean engine oil liberally to the cylinder bore and The following procedure must be used to torque the cylinder head properly: tapered area of the sleeve. Install the cylinder with a slight rocking motion until the rings are captive in the sleeve. Torque all bolts evenly in a criss- cross pattern *Torque bolts to 22 ft.

  • Page 104: Camshaft Timing

    Camshaft Timing Before positioning the sprocket on the camshaft, check the Apply Polaris Premium Starter Drive Grease (PN position of the cam sprocket alignment pin. When the cam 2871460) to the camshaft main journals and cam lobes.

  • Page 105

    ENGINE Install the sprocket on the camshaft. Apply Loctite™ 242 (PN 2871949) to the cam sprocket bolts and torque to specification. Cam Sprocket Bolt Torque: 6 ft. lbs. (8 Nm) Single (TDC) Mark Aligned Verify TDC mark in timing inspection hole and alignment pin is directly in line with crankshaft to camshaft centerline.

  • Page 106

    ENGINE CAMSHAFT TIMING Crankshaft to Camshaft Centreline Dots Sprocket Alignment Pin Single TDC Mark Aligned TDC Mark Rotation Do Not Use Advance Marks 3.48...

  • Page 107: Cam Chain Tensioner Installation, Stator, Flywheel And Starter Drive Installation

    ENGINE Cam Chain Tensioner Installation Apply 3 Bond 1215 (PN 2871557) or an equivalent sealer to the stator plate outer surface and install a new O-Ring. Release the ratchet pawl (A) and push the tensioner plunger (B) all the way into the tensioner body. Install the stator plate being careful not to damage the seal.

  • Page 108: Thermostat Installation, Oil Pipes, Rocker Shaft/rocker Arm Assembly Installation

    ENGINE gear. install the cover and bolts. Apply Starter Drive Rocker Cover Bolt Torque: Grease to Bushing 6 ft. lbs. (8 Nm) Thermostat Installation Apply starter drive grease to the drive bushing in the crankcase and all moving surfaces of the starter drive mechanism.

  • Page 109: Recoil Disassembly/inspection

    ENGINE RECOIL Inspect plate for wear or damage. Inspect plate friction spring for wear, damage, and proper tension. The spring should fit tightly on friction plate. Recoil Disassembly/Inspection CAUTION The recoil is under spring tension. A face shield and eye protection is required during this procedure. Replace any parts found to be worn or damaged.

  • Page 110: Recoil Assembly

    ENGINE Recoil Assembly post of the housing and the bushing. CAUTION Be sure to wear a face shield and eye protection when performing this procedure. Install reel into housing making sure the spring drive tab on the reel engages the spring and the reel is fully seated in the housing.

  • Page 111: Troubleshooting, Spark Plug Fouling

    ENGINE TROUBLESHOOTING Engine Does Not Turn Over • Dead battery Spark Plug Fouling • Starter motor does not turn • Spark plug cap loose or faulty • Engine seized, rusted, or mechanical failure • Choke cable adjustment or plunger/cable sticking Engine Runs But Will Not Idle •...

  • Page 112

    ENGINE Engine Has Low Power • Ignition system faulty: Spark plug cap cracked/broken • Spark plug fouled Ignition coil faulty Ignition or kill switch circuit faulty • Cylinder, piston, ring, or valve wear or damage Ignition timing incorrect (check compression) Sheared flywheel key •...

  • Page 113


  • Page 114


  • Page 115: Table Of Contents


  • Page 116


  • Page 117: Special Tools, Part Numbers / Descriptions

    • Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness Polaris EFI Diagnostic Software and death in a short time. Digital Wrench - PU-47063 •...

  • Page 118

    Polaris EFI systems. PU-47469 PU-47468 PU-47470 Throttle Position Sensor Tester - 2201519 This tester allows the use of a digital multi-meter to test TPS function as well perform initialization procedures. Polaris Dealers can order special tools from SPX.

  • Page 119: Efi Service Notes, General Service Information

    For more convenient and accurate testing of EFI components, it is recommended dealers utilize the • Polaris Diagnostic Software (dealer only), or limited testing may be done manually using the procedures provided. 80% of all EFI problems are caused by wiring harness connections. Follow a common sense •...

  • Page 120: Efi System Exploded View

    FUEL INJECTION EFI SYSTEM EXPLODED VIEW 1. Electronic Control Module (ECM) 2. Manifold Absolute Pressure Sensor (MAP) 3. Intake Air Temperature Sensor (IAT) 4. Idle Air Control (IAC) 5. Crankshaft Position Sensor (CPS - inside cover) 6. Fuel Injector 7. Fuel Rail 8.

  • Page 121: Efi System, Component Locations/identification

    FUEL INJECTION EFI SYSTEM Fuel Rail Component Locations/Identification Electronic Control Module (ECM) 9 & 10 Fuel Filters (1 located in tank, 1 under front cab) Manifold Absolute Pressure Sensor (MAP) 9 & 10 Fuel Pump / Regulator / Gauge Sender Assembly (located In tank as an assembly) Intake Air Temperature Sensor (IAT) 9 &...

  • Page 122: Fuel Tank, Electronic Fuel Injection

    FUEL INJECTION FUEL TANK ELECTRONIC FUEL INJECTION Exploded View General Information The Electronic Fuel Injection (EFI) system is a complete engine fuel and ignition management design. This system contains the following principal components: • Fuel Pump • Fuel Rail • Fuel Line(s) •...

  • Page 123: Initial Priming / Starting Procedure, Quick Connect Removal/installation

    Snap the fuel line back over the nipple, verify the connector NOTE: Accurate testing of EFI components is tabs snap back into place. recommended utilizing Polaris Diagnostic Software (dealer only). Squeeze Connector Tabs 4.11...

  • Page 124

    This process repeats itself in TPS must be re-initialized. rapid succession, limiting operation to the preset maximum. For the purpose of troubleshooting, a known-good ECM from a same-model Polaris 500 ATV EFI may be used without system or engine component damage. 4.12...

  • Page 125: Fuel Pump Assembly, Fuel Pump Test, Operation / Testing

    Regulator Insert the fuel test valve adapter PU-47476. Connect the pressure hose of the Polaris pressure tester (PN PU-43506) to the test valve. Route the clear hose into a portable Fuel Pump gasoline container or the equipment fuel tank.

  • Page 126: Fuel Pump / Tank Assembly Replacement

    FUEL INJECTION If the pump did not activate (Step 2), disconnect the plug Remove the clamps on the PVT intake duct and remove the from the fuel pump. Connect a DC voltmeter across PVT duct. terminals “A” and “C” in the plug, turn on the key switch and observe if a minimum of 7 volts is present.

  • Page 127: Fuel Pressure Regulator

    FUEL INJECTION Fuel Tank Installation Loosen the fuel tank hose and pull the fuel line from the tank. Reinstall the tank assembly. NOTE: A small amount of fuel may come out of the Reconnect the sender wiring harness and route the harness fuel line or tank.

  • Page 128: Fuel Filters, Fuel Injector

    FUEL INJECTION FUEL FILTERS FUEL INJECTOR General Information General Information NOTE: All EFI units utilize quick connect fuel lines. The fuel injector mounts into the intake manifold, and the fuel rail attaches at the top end. Replaceable O-Rings on both ends of the injector prevent external fuel leakage and also insulate it EFI Engines use a non-serviceable, high-volume, high- from heat and vibration.

  • Page 129: Crankshaft Position Sensor Test, Fuel Injector Replacement

    FUEL INJECTION CRANKSHAFT POSITION SENSOR Injector problems due to dirt or clogging are unlikely due to the design of the injectors, the high fuel pressure, the use of filters (CPS) and the detergent additives in the gasoline. Symptoms that could be caused by dirty/clogged injectors include rough idle, hesitation/stumble during acceleration, or triggering of fault General Information...

  • Page 130: Map Sensor Test And Replacement, Crankshaft Position Sensor Replacement, Map Sensor Replacement

    This sensor requires a 5 Vdc input to operate, specification and reverify air gap. therefore the MAP sensor should only be tested using Polaris Diagnostic Software (dealer only). Refer to the EFI Diagnostic 0.4 - 1.2 mm (0.015 - .047 in.) Software Manual for more information.

  • Page 131: Idle Air Control (iac), Intake Air Temperature Sensor Test, Intake Air Temperature Sensor Replacement

    FUEL INJECTION INTAKE AIR TEMPERATURE SENSOR IDLE AIR CONTROL (IAC) (IAT) General Information Operation Overview The Idle Air Control (IAC) is used to stabilize the idle quality of the engine at cold start-up and after warm-up operations. The intake air temperature sensor (IAT) is used to indicate charge air temperatures to the ECM.

  • Page 132: Throttle Position Sensor (tps), Throttle Position Sensor Test

    FUEL INJECTION THROTTLE POSITION SENSOR (TPS) Using TPS Test Adapter Harness 2201519- • Set up the TPS Test Harness 2201519 according to the Operation Overview instructions. Verify that the 9 volt battery is new. Figure The throttle position sensor (TPS), mounted to the throttle body, is used to indicate throttle plate angle to the ECM.

  • Page 133: Throttle Position Sensor (tps) Initialization, Throttle Position Sensor Replacement

    FUEL INJECTION Tps Tester - Correct Reference Voltage Remove the retaining screws and replace the sensor, but do not tighten the screws at this point. A 5 volt reference voltage signal from the test harness is Refer to “TPS Initialization” for setting the TPS voltage. required for the TPS test to be accurate.

  • Page 134: Engine Temperature Sensor, Engine Temperature Sensor Test, Engine Temperature Sensor Replacement

    FUEL INJECTION ENGINE TEMPERATURE SENSOR Engine Temperature Sensor Test Polaris dealers can test the sensor by using the Polaris Digital General Information ™ Wrench Software (dealer only). Refer to the Digital ™ Wrench Software Manual for more information. Mounted on the cylinder, the engine temperature sensor measures coolant temperature.

  • Page 135: Fuel System Troubleshooting

    FUEL INJECTION FUEL SYSTEM TROUBLESHOOTING POOR IDLE Symptom: Idle Too High (If greater than 1300 RPM when FUEL STARVATION / LEAN MIXTURE engine is warm) • Throttle stop screw tampering - replace throttle body The correct position of the throttle body idle •...

  • Page 136

    FUEL INJECTION EFI DIAGNOSTICS USING ‘BLINK NOTE: To clear codes manually, disconnect the positive battery lead for 20 seconds. CODES’ Blink Codes - Operation To enable the blink codes, turn the ignition from “OFF” to “ON” 3 times, leaving it 'on' the 3rd time, within 5 seconds. Any “blink codes”...

  • Page 137

    FUEL INJECTION Table 4-1: DIAGNOSTIC “BLINK CODES” CHART MIL L LINK IGHT BEGIN SEQUENCE Loss of Synchronization TPS Circuit: Sensor Low TPS Circuit: Sensor High System Voltage Low System Voltage High Air Temp Sensor (IAT): Low Voltage Air Temp Sensor (IAT): High Voltage Engine Temperature Sensor Circuit (ECT): Low Voltage Engine Temperature Sensor Circuit (ECT): High Voltage CPS Circuit Fault...

  • Page 138


  • Page 139

    FUEL INJECTION EFI CIRCUIT - Fuel Pump EFI CIRCUIT - Ignition Coil 4.27...

  • Page 140

    FUEL INJECTION EFI CIRCUIT - Idle Air Control EFI CIRCUIT - Throttle Position Sensor 4.28...

  • Page 141

    FUEL INJECTION EFI CIRCUIT - Manifold Absolute Pressure Sensor EFI CIRCUIT - Engine Coolant Temperature 4.29...

  • Page 142

    FUEL INJECTION EFI CIRCUIT - Air Temperature Sensor EFI CIRCUIT - Malfunction Indicator Light 4.30...

  • Page 143: Table Of Contents


  • Page 144: General Information And Specifications, Carburetor Jetting, Mikuni Jet Part Numbers, Carburetor Specifications

    Fuel Capacity / Requirement 4.25 gal US / 19.9 liters 87 Octane (minimum) of all Polaris ATVs. Carbon Clean stabilizes the fuel, or 89 Oxygenated preventing clogging of the small passages and orifices common to ATV carburetors, and ensures constant performance, reliability and easier starting.

  • Page 145: Bst 34 Carburetor Exploded View 1 Of

    CARBURETOR - SPORTSMAN 450 CARBURETION BST 34 Carburetor Exploded View 1 of 2 Table 4-1: Carburetor Components EFERENCE ESCRIPTION EFERENCE ESCRIPTION Jet Needle Throttle Control Cover Plate Diaphragm Assembly Carburetor Body Needle Jet Enrichment Plunger Jet Block Assembly Enrichment Spring Washer Cable guide Main jet...

  • Page 146: Bst 34 Carburetor Exploded View 2 Of

    CARBURETOR - SPORTSMAN 450 BST 34 Carburetor Exploded View 2 of 2 Table 4-2: Carburetor Components EFERENCE ESCRIPTION EFERENCE ESCRIPTION Throttle Plate Shaft Retaining Components Float Bowl O Ring Pilot Jet Float Bowl Needle Valve Assembly Float Bowl Drain Screw Throttle Plate Throttle Shaft Idle RPM Speed Adjustment Screw...

  • Page 147: Cv Carburetor System Function, Carburetor Venting, Mikuni Cv Carb Operation

    CARBURETOR - SPORTSMAN 450 CV Carburetor System Function Carburetor Venting The carburetor float bowl vent lines supply atmospheric Carburetor Component Function pressure to the float bowl. The lines must be free of kinks, restrictions and be properly routed. This allows fuel to flow in Main Main Main...

  • Page 148: Pilot (idle And Slow) System, Starter System (choke Or Enrichment)

    CARBURETOR - SPORTSMAN 450 Pilot (Idle and Slow) System When the pressure above and below the diaphragm are nearly equal, the slide moves downward under spring pressure. Raising or lowering the slide increases or decreases the cross sectional This system supplies fuel during engine operation with throttle area in the venturi, and therefore the air velocity in the venturi valve closed (1) or slightly opened.

  • Page 149: Main System, Float System

    CARBURETOR - SPORTSMAN 450 Main System Float System As throttle valve (1) is opened, engine speed rises, and this Fuel enters the float chamber (3) by means of the inlet pipe and increases negative pressure in the venturi. Consequently the passage, through a screen on the back of the inlet needle seat (4), vacuum slide (2) moves upward.

  • Page 150: Pilot Screw, Air/fuel Mixture Ratio

    CARBURETOR - SPORTSMAN 450 Pilot Screw Air/Fuel Mixture Ratio The pilot system supplies fuel during engine operation with the E-Clip Position vs. Fuel Flow throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet.

  • Page 151: Jet Needle, Throttle Opening Vs. Fuel Flow, Carburetor Disassembly – Mikuni Cv, Needle Jet

    CARBURETOR - SPORTSMAN 450 Jet Needle Throttle Opening vs. Fuel Flow The jet needle has five adjustment grooves cut into the upper In a full throttle condition the cross sectioned area between the portion, and is tapered from approximately the middle of the jet needle and the needle jet is larger than the cross sectioned needle to the lower end.

  • Page 152: Carburetor Cleaning

    CARBURETOR - SPORTSMAN 450 NOTE: The starter jet is removable. Upon disassembly, and float pin can be removed. place the parts in a container for safe keeping. Remove inlet needle seat retaining screw along with plate, and carefully remove needle seat. NOTE: Do not use a Carburetor Cleaning pliers to remove the seat or permanent damage may occur.

  • Page 153: Carburetor Inspection, Carburetor Assembly

    CARBURETOR - SPORTSMAN 450 Carburetor Inspection diaphragm should fit properly in the carburetor body. Replace diaphragm assembly if diaphragm is damaged. Inspect jet needle and needle jet for wear. Look for discoloration, shiny spots, or an area that looks different than the rest of the needle.

  • Page 154: Needle And Seat Leakage Test

    CARBURETOR - SPORTSMAN 450 the engine running. Refer to Page 2.10. float using Float Adjustment Tool (PN 2872314) or a vernier caliper. When measuring the height, be sure the inlet needle valve spring is not compressed. Pilot Screw Base Setting (Set at Factory) Float Bowl Height: 13-14 mm Factory Specification: 2.5 Turns Out...

  • Page 155: Fuel Level Test

    CARBURETOR - SPORTSMAN 450 Fuel Level Test 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 test. A fuel level test allows you to observe the height of the fuel in the float bowl without removing the carburetor.

  • Page 156


  • Page 157: Fuel Pump, Fuel Pump Testing, Fuel Pump Disassembly

    CARBURETOR - SPORTSMAN 450 FUEL PUMP This ATV is equipped with a pressure regulated fuel pump (1- 3 PSI). The pump is located under the left front fender of the machine. Fuel Pump Testing To test the fuel pump: Turn fuel off. Disconnect impulse line from pump.

  • Page 158: Fuel Pump Inspection And Reassembly, Fuel Gauge Sending Unit, Sending Unit Removal

    CARBURETOR - SPORTSMAN 450 Fuel Pump Inspection and Reassembly FUEL GAUGE SENDING UNIT Inspect inlet and outlet check valves for cracks, warping or Sending Unit Removal damage. Inspect the diaphragms for cracks, holes or swelling. Disconnect the negative battery cable. Remove the side panels and front cab assembly.

  • Page 159: Sending Unit Installation

    CARBURETOR - SPORTSMAN 450 TROUBLESHOOTING Remove the 5 screws that secure the fuel sender to the tank. 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.

  • Page 160

    CARBURETOR - SPORTSMAN 450 POOR IDLE Idle Too High • Idle adjusted improperly/idle mixture screw damaged • Sticky vacuum slide • Throttle cable sticking, improperly adjusted, routed incorrectly • Choke cable sticking, improperly adjusted, routed incorrectly • Plugged or restricted idle jet Idle Too Low •...

  • Page 161: Table Of Contents


  • Page 162

    BODY / STEERING / SUSPENSION GENERAL INFORMATION Special Tools Table 5-2: Torque Specifications Table 5-1: UMBER ESCRIPTION 2870871 Ball Joint Replacement Tool OMPONENT 2870872 Shock Spanner Wrench Front Hug Nut Shock Absorber Spring Compression 2870623 Tool Front A-Arm Attaching Bolt 2871572 Strut Rod Wrench Front A-Arm Ball Joint Stud Nut...

  • Page 163: Plastic Insert Removal / Installation

    To install the inserts, press outside insert (B) into the hole. Press inside insert (A) until it snaps into place. Some Polaris ATVs use a two piece plastic insert in place of a NOTE: The outside insert (B) should be flush metal screw.

  • Page 164: Side Panel Removal, Front Cover Removal / Installation

    BODY / STEERING / SUSPENSION BODY Reinstall the side panel by reversing the removal procedure. Step 3 Side Panel Removal Side panel removal is quick and easy, use the following instructions for removal and installation. Remove seat by releasing the latch and lifting up on the seat.

  • Page 165: Foot Well Removal / Installation, X2 Foot Well Removal / Installation

    BODY / STEERING / SUSPENSION Foot Well Removal / Installation X2 Foot Well Removal / Installation Remove the four plastic inserts (A) that secure the wheel Remove the four plastic inserts (A) that secure the wheel well to the front and rear cabs. (See “PLASTIC INSERT well to the front and rear cabs.

  • Page 166

    BODY / STEERING / SUSPENSION Front Storage Removal Remove the four bolts that secure the storage rack to the frame. Front Storage Remove Bolts Remove the two (T25) screws that secure the storage box to the front fender well areas (each side). Remove Bolts T-25 Screws Remove the front radiator cap cover (A) by lifting upward...

  • Page 167

    BODY / STEERING / SUSPENSION Winch Installation Area Remove the front headlights (C) or simply disconnect the electric connector (D) before removing the front plastic Remove the front cover piece by lifting up on sides of the bumper. two locking tabs as shown. Pull the tabs out of the notches and lift up on the cover piece.

  • Page 168: Front Storage Installation, Sportsman Rear Rack Removal / Installation

    BODY / STEERING / SUSPENSION Front Storage Installation Install the front radiator cap cover (E) . Front Storage Sportsman Rear Rack Removal / Installation inserts T-25 Screw A. 14 ft.lbs. (19 Nm) C. 10 in.lbs. (1.13 Nm) B. 10 in.lbs. (1.13 Nm) D.

  • Page 169: Front Cab/fender Removal/installation

    BODY / STEERING / SUSPENSION Place spacers on frame. Remove the two screws (B) that secure the front cab to the frame in the fuel tank mount area. Install rear rack onto rear frame and cab. Remove the side panels (D), refer to the “SIDE PANEL Install the two bolts (B) and six (A) T-27 screws.

  • Page 170: Sportsman Rear Cab / Fender Removal / Installation, X2 Rear Quarter Panel Removal / Installation

    BODY / STEERING / SUSPENSION Sportsman Rear Cab / Fender Removal / Disconnect the rear lights by pulling the locks on each side Installation and removing the connectors. Lift the rear cab from the frame. Follow the “REAR RACK REMOVAL” procedure to remove the rear rack.

  • Page 171: Radiator Screen Removal

    BODY / STEERING / SUSPENSION Sportsman Rear Storage Removal / Radiator Screen Removal Installation Pull out slightly on the top of the radiator screen. Follow the “REAR RACK REMOVAL” and “REAR With the top free, pull out on the bottom of the screen to CAB REMOVAL”...

  • Page 172

    BODY / STEERING / SUSPENSION Sportsman Body Assembly Exploded View Rear Cab Assembly Pull UP on rear of seat and back to disengage tabs at front of seat. Seat Latch Rear Cab Wheelwell Storage Frame Front Cab Assembly Side Cover Frame Front Cover Front Brush Guard...

  • Page 173

    BODY / STEERING / SUSPENSION X2 Body Assembly Exploded View Rear Cab Assembly Footwell RH Rear Cab Frame Footwell Support Front Cab Assembly Side Cover Frame Front Cover Front Brush Guard Support Front Cab Splash Shields 5.13...

  • Page 174

    BODY / STEERING / SUSPENSION Body / Rack Exploded Views Rack Rails Sportsman Only Rear Rack Rear Rack Support Rack Rails Frame Box Assembly Cover Front Brush Guard Panel Radiator Shield Grill Radiator Screen Front Bumper 5.14...

  • Page 175: Headlight Pod Exploded View

    BODY / STEERING / SUSPENSION Headlight Pod Exploded View Worklight Switch Instrument Cluster Brake Clean knurling when repositioning handlebars Wheel Speed Sensor - Sportsman (X2 Speed Sensor Located on Transmission) Disassembly Assembly • Remove two side Phillips screws (A) • Install bottom of pod onto handlebar and secure to brackets •...

  • Page 176: Handlebar Block Installation Procedure

    BODY / STEERING / SUSPENSION STEERING Handlebar Block Installation Procedure Clean knurling when repositioning handlebars The pin (A) on the bottom side of the top handlebar block faces down and to the front of the ATV. The bottom handle bar block has a side with 3 holes, the side with 3 holes faces up and to the front of the ATV. Align the pin (A) in the top block with the middle hole (B) in the bottom block for proper installation.

  • Page 177: Steering / A-arm Exploded View

    BODY / STEERING / SUSPENSION Steering / A-arm Exploded View 30 ft.lbs. (41 Nm) Steering Post 25-30 ft.lbs. (35-41 Nm) 30 ft.lbs. (41 Nm) Steering Post Arm 8 ft.lbs. (11 Nm) 25 ft.lbs. (35 Nm) 12-14 ft.lbs. (17-19 Nm) 40-45 ft.lbs. (54-61 Nm) Always use new cotter pins upon ™...

  • Page 178: A-arm Replacement

    BODY / STEERING / SUSPENSION A-Arm Replacement Vehicle Frame Bolt - 30 ft.lbs. (41 Nm) ™ Apply Loctite to the bolt threads. Ball Joint Stud Bushing 8 ft.lbs. (11 Nm) A-Arm Tube 30 ft.lbs. (41 Nm) A-arm Shaft 25 ft.lbs. (35 Nm) Cotter Pin - (Install New) Elevate and safely support vehicle with weight removed from front wheel(s).

  • Page 179: Ball Joint Replacement

    BODY / STEERING / SUSPENSION Ball Joint Replacement Install puller guide (G) with extension cap (H). Apply grease to extension cap and threads of puller bolt to NOTE: Refer to the illustration on the previous page ease removal. for this procedure. 10.

  • Page 180: Steering Post Removal, Front Strut Cartridge Replacement, Steering Post Assembly

    BODY / STEERING / SUSPENSION Steering Post Removal SUSPENSION Remove the front cab. Front Strut Cartridge Replacement Remove the handle bar pod. NOTE: Refer to illustration on following page. Remove the handle bar. Remove the fuel tank bracket assembly. Hold strut rod and remove top nut. Remove the steering tie rod ends from the steering bracket.

  • Page 181: Strut Assembly

    BODY / STEERING / SUSPENSION Strut Assembly Nut - 15 ft.lbs. (21 Nm) Strut Bumper Spacer Rubber Washer Strut Upper Pivot Ball Spacer Nut Clamp Lower Pivot Ball Washer 18 ft.lbs. (25 Nm) Spring Retainer 15 ft.lbs. (21 Bolts Spring Brake Caliper Hubstrut Bearing Retaining Ring...

  • Page 182

    BODY / STEERING / SUSPENSION Sportsman Rear Suspension Assembly 17 ft.lbs. (24 Nm) Stabilizer Bar 35 ft.lbs. (48 Nm) ft.lbs. (48 Nm) ft.lbs. (41 Nm) 35 ft.lbs. (48 Nm) Bushings Upper Control Arm 50 ft.lbs. Rear Shock (68 Nm) Lower Control Arm 30 ft.lbs.

  • Page 183

    BODY / STEERING / SUSPENSION X2 Rear Suspension Exploded View Rear Compression Spring Preload Adjustment Cam Rear Shock Bushings Control Arm Pivot Bracket Upper Control Arm Boot Shield A-Arm Shaft Lower Control Arm Wheel Bearing Carrier Grease Zerk 5.23...

  • Page 184

    BODY / STEERING / SUSPENSION X2 Torsion Bar Exploded View Linkage Bushing Stabilizer Bar Stabilizer Bushing Bushing Torsion Mount Linkage Asm. 5.24...

  • Page 185

    BODY / STEERING / SUSPENSION X2 CARGO BOX Exploded View 5.25...

  • Page 186: Removal / Installation

    BODY / STEERING / SUSPENSION Removal / Installation Disconnect the two wire harnesses connected to each of the taillights. IMPORTANT: Before attempting to remove the cargo box, be sure that the cargo box is not set up for 2-UP riding. The passenger backrest should be face down in the cargo box and the driver seat backrest should be locked into position.

  • Page 187

    BODY / STEERING / SUSPENSION Lift up firmly in the cargo box release lever on either side Carefully remove the cargo box from the ATV. of the ATV. 10. Reverse the removal steps to reinstall the cargo box. Refer to the standard fastener torque values in Chapter 1 during Remove the four bolts attaching the rear of the cargo box assembly.

  • Page 188


  • Page 189: X2 Seat Operation - Configuring Cargo Box For Passenger Riding

    BODY / STEERING / SUSPENSION X2 Seat Operation - Configuring Cargo Box Fold the driver seat backrest down into place to serve as the For Passenger Riding passenger seat bottom. Passenger Backrest Unlatch the driver seat backrest by turning the engagement knobs on each side in the directions shown below.

  • Page 190: Driver Seat Backrest Removal / Installation, Passenger Seat Backrest Removal / Installation

    BODY / STEERING / SUSPENSION Driver Seat Backrest Removal / Installation Lift up on the latch for the passenger seat bottom and lock it in the upright position as shown below. Configure the seating for 2-UP riding. With the passenger seat bottom in place, remove the two screws retaining the seat bottom.

  • Page 191: Table Of Contents


  • Page 192

    CLUTCH SYSTEM SPECIAL TOOLS AND Component Fastener Torques SPECIFICATIONS Special Tools OMPONENT Drive Clutch Retaining Bolt ESCRIPTION UMBER Driven Clutch Retaining Clutch Puller 2870506 Bolt PVT Inner Cover Bolts Clutch Holding Wrench 9314177 Drive Clutch Spider EBS Clutch Holding Fixture 2871358 Clutch Spider Nut Socket...

  • Page 193: Pvt Exploded Views

    CLUTCH SYSTEM PVT EXPLODED VIEWS PVT Sealing And Ducting Components Clutch Inlet Duct Transmission Cover Seal Inner Clutch Cover Clamps Boot Duct Clutch Cover Seal Inner Seal Cover Seal Retainer Bracket Clutch Cover Drive Clutch Exploded Views (Standard and Deluxe) One Way Clutch “Deluxe”...

  • Page 194: Clutch System

    CLUTCH SYSTEM Driven Clutch Exploded Views (Standard and Deluxe) STANDARD - NON EBS DELUXE - EBS 1. Torx Screw 11. Moveable Sheave 2. Cam Assembly 12. Roller Pin 3. Retaining Ring 13. Spring Pin 4. E-clip 14. Stationary Sheave 5. Washer 15.

  • Page 195: Engine Braking System (ebs) Exploded View

    CLUTCH SYSTEM Engine Braking System (EBS) Exploded View One Way Clutch Drive Washer Drive Belt Washer Shift Weights Cam Assembly Roller/Bushing Retaining Ring Assembly - Torque 200 ft.lbs. Spacer Clutch Rollers Spider Assembly Spider Lock Nut Compression Spring Bushing Cover Clutch Shaft Coil Spring Spacer Washer...

  • Page 196: Pvt System, Driven Clutch Operation, Pvt Operation Overview, Drive Clutch Operation

    During the continually shifting to maintain optimum engine RPM. At full development of a Polaris ATV, the PVT system is matched first throttle a perfectly matched PVT system should hold engine to the engine power curve; then to average riding conditions and RPM at the peak of the power curve.

  • Page 197

    CLUTCH SYSTEM EBS Clutch Operation PVT Maintenance / Inspection This EBS driven clutch provides the same engine braking Under normal operation the PVT system will provide years of abilities as the EBS drive clutch. trouble free operation. Periodic inspection and maintenance is required to keep the system operating at peak performance.

  • Page 198: Drive Clutch Spring

    CLUTCH SYSTEM Drive Clutch Spring Measuring Spring Length: With the spring resting on a flat surface, measure its free length from the outer coil surfaces as shown. Refer to the spring specification chart for specific free length measurements and tolerances. Also check to see that spring coils are parallel to one another.

  • Page 199: Optional Shift Weights

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

  • Page 200: Pvt Drying, Pvt Disassembly

    CLUTCH SYSTEM PVT Drying PVT Disassembly IMPORTANT: If operating the ATV through water, be NOTE: Some fasteners and procedures will vary. sure to check the PVT cover and other ATV Refer to the appropriate parts manual for proper components for water ingestion. The ATV should be fasteners and fastener placement.

  • Page 201: Pvt Installation

    CLUTCH SYSTEM PVT Installation Remove driven clutch offset spacers from the transmission input shaft. NOTE: Remember to keep spacers in order for Inspect PVT inner cover-to-engine seal. Replace if proper clutch offset on reassembly. cracked or damaged. Align the alignment mark on the cover with the mark on the engine seal.

  • Page 202

    CLUTCH SYSTEM Drive Belt Removal / Inspection Install clutch offset spacer(s) on transmission input shaft. Remove outer PVT cover as described in PVT Offset Spacer Disassembly. Mark drive belt direction of rotation so that it can be installed in the same direction. The belt is normally positioned so part numbers are easily read.

  • Page 203: Drive Belt Installation

    CLUTCH SYSTEM DRIVE BELT INSTALLATION Measure the distance where the side straight edges intersect the top, as shown in the illustration. NOTE: Be sure to position belt so part number is easily read. Verify new belt is seated properly in the clutches before operating the ATV.

  • Page 204: Clutch Alignment, Clutch Offset

    CLUTCH SYSTEM Clutch Alignment Measure belt deflection and measure offset both above and below shaft centerlines. Adjust if necessary. Remove belt and install the Clutch Offset Alignment Tool (PN 2872292) as shown. Center Line Offset Alignment Tool (PN 2872292) Measure Above and Below Centerline 1/8”...

  • Page 205: Ebs Drive Clutch Service

    CLUTCH SYSTEM EBS DRIVE CLUTCH SERVICE Remove and inspect spring. See “Drive Clutch Spring Specifications” for spring inspection. Drive Clutch Disassembly Inspect Shaft Using a permanent marker, mark the cover, spider, and moveable and stationary sheaves for reference, as the cast- in “X's”...

  • Page 206

    CLUTCH SYSTEM NOTE: It is important that the same number and Inspect all rollers, bushings and roller pins by pulling a flat thickness of washers are reinstalled beneath the metal rod across the roller. Turn roller with your finger. If spider during assembly.

  • Page 207

    Never replace parts with used parts from another clutch assembly! All PVT maintenance or repairs should be performed only by a certified Polaris Master Service Dealer (MSD) technician who has received the proper training and understands the procedures Button to Tower Clearance: .000-.001 outlined in this manual.

  • Page 208

    CLUTCH SYSTEM Moveable Sheave Bushing Inspection Lift one-way clutch (3) and thrustwasher (4) off shaft. Replace as an assembly if worn, damaged, or if problems Inspect the Teflon™ coating (arrow) on the moveable sheave were noted. bushing. Inspect BOTH sheaves for signs of wear, grooving or cracking.

  • Page 209

    CLUTCH SYSTEM NOTE: Bushings are installed at the factory using Drive Clutch Bushing Installation ™ Loctite 609. In order to remove bushings it will be Place main adapter (Item 8) on puller. necessary to apply heat evenly to the area around ™...

  • Page 210: One-way Clutch Inspection (drive Clutch)

    CLUTCH SYSTEM One-Way Clutch Inspection (Drive Clutch) Cover Bushing Removal Install main adapter (Item 8) on puller. Rotate one-way clutch clockwise (as viewed from the cover plate side). The clutch should rotate on the shaft Removal Tool (3) with only slight amount of drag. Verify there is no binding Nut (C) or rough spots.

  • Page 211

    CLUTCH SYSTEM C) “X”, or the marks that were made earlier under weight Install limiter nut on top of spider using the Clutch Spider Nut Socket (PN 2870338). Torque to specification. Reinstall shift weights using new lock nuts on the bolts. Spider Nut Torque: 15 ft.

  • Page 212: Ebs Driven Clutch Service, Driven Clutch Disassembly

    CLUTCH SYSTEM EBS DRIVEN CLUTCH SERVICE Place the clutch into Clutch Compression Tool PN 8700220. Using Compression Extensions PN PS-45909, Press down on top of the spider assembly, compressing the Driven Clutch Disassembly spider onto the shaft. Remove snap ring (A) and slowly Remove driven clutch from the transmission input shaft.

  • Page 213

    CLUTCH SYSTEM Remove the inside spider plate (D) and spider dampener 10. Pull out the clutch roller pins (L) and rollers (M). (E). Inspect the spider dampener (E) for wear and replaced if needed. Remove the E-clip (F), washer (G), and the clutch rollers (H).

  • Page 214

    CLUTCH SYSTEM Table 6-1: 12. Inspect the bearing for wear. Spin the bearing, if the bearing does not spin smoothly replace as needed. To remove the bearing, simply press the bearing from the shaft. ESCRIPTION 13. Inspect the bearing for wear. Spin the bearing, if the Bushing Replacement Kit 2871226 bearing does not spin smoothly replace as needed.

  • Page 215: Ebs Driven Clutch Reassembly

    CLUTCH SYSTEM Driven Clutch Bushing Installation EBS DRIVEN CLUTCH REASSEMBLY Install puller adapter (Item 10) onto puller. Press a new bearing onto the output shaft using a press. Install adapter (Item 9) onto puller. Install the shaft/bearing into the outer sheave. Apply Loctite™...

  • Page 216

    CLUTCH SYSTEM Install the small and large retaining rings into the outer Install the roller (A) onto the roller pin (B). (Both Sides). sheave above the bearing. Install the roller pin into the sheave assembly. (Both sides). The flat side of the roller pin faces downward when the shaft side is laying flat on the bench.

  • Page 217

    CLUTCH SYSTEM Install the spacer washer. 12. Install the spider assembly onto the shaft with the retaining ring on top of the spider. NOTE: Use the marks previously Install Spacer Washer made to align the skip tooth spider, or use the “X” on top of the spider and align it with the skip tooth on the shaft.

  • Page 218: Standard Drive Clutch

    CLUTCH SYSTEM STANDARD DRIVE CLUTCH 15. Install the cam assembly (helix) over the shaft. Line up the “X” on the cam, “X” on spider, and “X” on the stationary sheave or use the marks previously made before Drive Clutch Disassembly disassembly.

  • Page 219

    CLUTCH SYSTEM ™ Spider Removal Inspect the Teflon coating on the moveable sheave bushing. Remove the limiter nut using the Clutch Spider Nut Socket PN 2870338. Install clutch in holding fixture and loosen the spider (counterclockwise) using Clutch Spider Install Tool PN 2870341.

  • Page 220

    Button to Tower Clearance: .000-.001 All PVT maintenance or repairs should be performed only by a certified Polaris Master Service Inspect sheave surfaces. Replace the entire clutch as an Dealer (MSD) technician who has received the assembly if worn, damaged or cracked.

  • Page 221: Sheave / Bushing Inspection

    CLUTCH SYSTEM Sheave / Bushing Inspection NOTE: Bushings are installed at the factory using ™ Loctite 609. In order to remove bushings it will be Inspect the Teflon™ coating on the sheave bushings and cover necessary to apply heat evenly to the area around bushing.

  • Page 222: Drive Clutch Reassembly

    CLUTCH SYSTEM Drive Clutch Reassembly Drive Clutch Bushing Installation Place main adapter on puller. NOTE: It is important that the same number and Apply Loctite™ 609 evenly to bushing bore inside thickness of washers are reinstalled beneath the moveable sheave. spider during assembly.

  • Page 223

    CLUTCH SYSTEM Reinstall cover, aligning bosses on the tower and cover. Torque cover bolts evenly to specification. Spacer Washers Spider Torque: 200 ft. lbs. (271 Nm) CAUTION Verify spider spacer washers are fully seated in the recessed area of the spider. Any misalignment will alter clutch balance.

  • Page 224: Standard Driven Clutch

    CLUTCH SYSTEM STANDARD DRIVEN CLUTCH Separate the clutch sheaves by pulling upward while rotating the inner sheave. Disassembly Using special tool PN 8700220, apply and hold downward pressure on the outer spring retainer and remove the snap ring (A). Inspection Inspect both the inner and outer sheave surfaces.

  • Page 225

    CLUTCH SYSTEM Assembly Inspect the rollers in the stationary sheave for signs of wear. Install inner spring retainer (if removed). Install the inner sheave onto the outer sheave. NOTE: Verify ‘X’ marks on each side of the sheaves are aligned upon reassembly of sheaves. NOTE: Rollers and helix are non-serviceable items.

  • Page 226: Pvt Troubleshooting

    During this procedure, the throttle should not be held at the full position for more than 10 seconds. PVT seals should be inspected for damage if repeated leaking occurs. Inspection/repair of clutch components should be performed by a certified Polaris MSD Clutch malfunction.

  • Page 227: Problem, Cause And Remedy Chart

    CLUTCH SYSTEM Problem, Cause and Remedy Chart Table 6-2: Problem, Cause and Remedy ITUATION OSSIBLE AUSE EMEDY -Wrong or broken drive clutch spring. -Replace with recommended spring. Engine RPM below specified operating range -Install correct shift weight kit to match engine -Drive clutch shift weight too heavy.

  • Page 228

    CLUTCH SYSTEM Table 6-2: Problem, Cause and Remedy ITUATION OSSIBLE AUSE EMEDY -Abuse (continued throttle application when -Caution operator to operate machine within vehicle is stationary, excess load) guidelines. -Vehicle operated with park brake on. Inspect brake Belt burnt, thin spots -Dragging brake system.

  • Page 229: Table Of Contents


  • Page 230: Final Drive, Gearcase Fluid / Capacity, Front Drive Axle

    F/R Aluminum Wheel Nuts w/ ADC Premium Hub Fluid (Deluxe Models) 9.3 oz. (275 ml) Front Hub Nut ADC Gearcase Polaris ADC or AW ISO 10 Rear Hub Nut Pump Reservoir Hydraulic Fluid Front Gearcase Mount Bolts FRONT DRIVE AXLE Standard Gearcase Screws...

  • Page 231

    FINAL DRIVE Remove hub. 10. Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly. Remove cotter pin and nut from lower A-arm ball joint. Remove lower A-arm from ball joint. 11. Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly.

  • Page 232

    FINAL DRIVE Installation FRONT DRIVE SHAFT (CV) BOOT Install new spring ring on drive shaft. Apply an anti-seize Inspection compound to splines. Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft Check the front and rear driveshaft CV boots for any tears or leaking grease.

  • Page 233

    FINAL DRIVE Disconnect A-arm from ball joint using a tie rod fork. Remove small clamp and boot from driveshaft. NOTE: If the ATV has been operated with a damaged boot, the CV joint grease may be contaminated. Inspect the grease carefully for contamination, and clean the joint thoroughly if necessary.

  • Page 234: Front Hub

    FINAL DRIVE 13. Install the small clamp on the boot. punch in the reliefs as shown. Front Shaft NOTE: Drive bearing out evenly by tapping on outer FRONT HUB race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed.

  • Page 235: Prop Shaft - Front Or Rear, Removal And Installation

    FINAL DRIVE PROP SHAFT - FRONT OR REAR U-JOINT Removal and Installation Disassembly Using Roll Pin Removal Tool (PN 2872608), remove the CAUTION roll pin from prop shaft at rear of housing (front only) or transmission output shaft (rear only). Slide prop shaft back and away from housing, then pull sharply forward to Always wear eye protection when working with remove from transmission shaft.

  • Page 236

    FINAL DRIVE Assembly Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing ca Install new bearing caps in yoke by hand. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft. Take care not to dislodge needle bearings upon installation of cross joint.

  • Page 237

    FINAL DRIVE Install snap ring to contain bearing cap just installed. Repeat procedure for other side. Install snap ring to contain bearing cap just installed. Repeat procedure for other side. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown.

  • Page 238: Drive Axle Exploded Views

    FINAL DRIVE DRIVE AXLE EXPLODED VIEWS Drive Shafts and Propshafts NOTE: Refer to your parts manual for the proper replacement parts. Drive Axle Components Circlip Inner CV Joint Circlip Inner Boot Outer Boot Outer CV Joint Circlip Clamps Drive Boot Replacement Kits Clamp 3.5 oz.

  • Page 239: Front Gearcase - Centralized Hilliard (standard Models), Exploded View (standard Models)

    FINAL DRIVE FRONT GEARCASE - CENTRALIZED HILLIARD (STANDARD MODELS) Exploded View (Standard Models) Ref. # Description Ref. # Description Bolt Vent Tube Oil Seal Plug Input Cover Plate Asm. Gearcase Sub Asm. O-Ring Ring Gear / Clutch Housing Retaining Ring Output Hub Asm.

  • Page 240: Gearcase Removal

    FINAL DRIVE Operation Rollers Engaging front gearcase: The AWD switch may be turned on or off while the vehicle is moving. AWD will not enable until the engine rpm is below 3100 RPM. Once enabled, the AWD Ring Gear remains engaged while the front gearcase is moving and will not disengage until the rear wheels regain traction.

  • Page 241

    FINAL DRIVE Remove cotter pin, lower ball joint nut and A-arm from Remove bolts securing the bottom of housing to the skid ball joint. plate frame. Bolts and fluid drain plug are accessible through the skid plate. Pull the hub and strut assembly out and pull the drive-shaft out of the hub.

  • Page 242

    FINAL DRIVE Remove bolts retaining the outer cover plate assembly. Remove the armature plate and RH output hub assembly from the outer cover plate. Inspect the bearing and contact surfaces of the output hub for signs of wear or damage. Replace component if found to be worn or damaged Output Hub Assembly Armature Plate...

  • Page 243

    FINAL DRIVE Remove the LH output hub. Inspect the bearing and Inspect roll cage (B) sliding surface. This surface must be contact surfaces of the output hub for signs of wear or clean and free of nicks, burrs or scratches. Inspect the H- damage.

  • Page 244

    FINAL DRIVE 11. Inspect the magnetic coil (A) in the outer cover plate 13. Remove the snap ring retaining the input shaft assembly. assembly. Inspect the backlash pad (B) for excessive wear. 14. Remove the input shaft assembly. Inspect the pinion gear (C) for chipped, broken, or missing teeth.

  • Page 245

    FINAL DRIVE Reassembly / Inspection Install the LH output hub (A) into the gearcase housing. The output hub should spin freely. Replace all O-rings, seals, and worn components. Install the RH output hub (B) into the output cover. The Press the pinion shaft seal into the pinion cover, until the output hub should spin freely.

  • Page 246: Setting Ring Gear Backlash

    FINAL DRIVE Install the ring gear and roll cage assembly into the 11. Torque the cover plate bolts to specification. gearcase housing. Install the armature plate on top of the roll cage / ring gear assembly. Be sure that the armature plate tabs are fully engaged into the roll cage assembly.

  • Page 247: Front Gearcase Diagnosis

    FINAL DRIVE Using a 3/32 hex wrench, turn the back-lash screw out 3-4 NOTE: To test the gearcase coil resistance, use the ™ coil harness. The gearcase coil should measure turns. Re-apply Loctite 262 onto the bottom screw threads. between 22.8 ohms and 25.2 ohms. Turn the screw in until it is lightly seated, then turn the screw out 1/4 turn.

  • Page 248: Gearcase Installation

    FINAL DRIVE Gearcase Installation Check to make sure the coil is seated in the U-shaped insert that is pressed into the gearcase cover. The top of the coil To install gearcase, reverse removal procedures. Use new should be seated below the U-shaped insert. The U-shaped roll pin in front prop shaft.

  • Page 249: Front Gearcase - Active Descent Control (deluxe Models), Adc Gearcase Exploded View (deluxe Models)

    FINAL DRIVE FRONT GEARCASE - ACTIVE DESCENT CONTROL (DELUXE MODELS) ADC Gearcase Exploded View (Deluxe Models) Ref. # Description Ref. # Description O-ring Roll Cage Assembly " " Tubing 8-32 x 3/8 Screws 1/4-20 Screws Spacer, Gear Armature Plate Pump Assembly Clutch Assy Wire Connector - LH Exploded View...

  • Page 250

    FINAL DRIVE Operation ADC Engagement: When the AWD switch is activated, a 12 Vdc current is present at the input shaft coil (1). Operation is controlled by the ECU grounding and ungrounding the coil. The Engaging Front Gearcase: Active Descent Control (ADC) is coil’s magnetic field attracts a splined armature plate (2) on the controlled by the ECU and will not enable until the following pinion (input) shaft (4).

  • Page 251: Adc Coil Testing, Adc Differential Hydraulic Circuit Bleeding

    Replace as an Begin the bleeding process by filling reservoir to ‘MAX’ assembly if found to be damaged or non-working. line with clean Polaris ADC oil . (AW ISO 10 hydraulic Remove bolts (arrows) retaining the outer cover plate fluid equivalent).

  • Page 252

    FINAL DRIVE Remove the outer cover plate assembly. Remove and Remove the armature plate. Inspect the armature plate for inspect the cover o-ring (1). Inspect thrust bearing (2) for wear, distortion or other damage. Replace component as wear. Replace items as required. required.

  • Page 253

    FINAL DRIVE Remove the ring gear (1) and spacer (2). 12. Inspect roll cage sliding surface (2). This surface must be clean and free of nicks, burrs or scratches. Remove and inspect the H-springs (4). Replace any components as required. Remove and inspect the bearing surfaces of the output hub.

  • Page 254

    FINAL DRIVE 14. Inspect the magnetic coil (1) in the outer cover plate 16. Inspect the magnetic coil (1) and bushing in the input cover assembly. Inspect the backlash pad (2) for excessive wear. plate assembly. Replace the input cover seal. 17.

  • Page 255: Adc Gearcase Piston Replacement Procedure

    FINAL DRIVE ADC Gearcase Piston Replacement 19. Remove the snap ring retaining the input shaft assembly. Procedure CAUTION This repair procedure involves the use of compressed air. Safety glasses or a face shield are required. Place ADC Piston Tool PA-48542 on top of the piston. Using moderate hand pressure, hold the tool on top of the piston while using compressed air at the gearcase passage (circled) to force piston up and out of the case.

  • Page 256

    FINAL DRIVE Coat new piston and o-rings with a moderate amount of Place ADC Piston Tool PA-48542 on top of the piston and white lithium grease or assembly lube. Coat the edges of the verify alignment of the sight hole (circled) and piston mark piston cavities.

  • Page 257

    FINAL DRIVE Assembly Install the eccentric cam assembly (1). Thoroughly clean the gearcase components before beginning reassembly. Install a new seal in the main gearcase halve. Install the input shaft assembly. Install the pinion gear/ bearing assembly (1). Install a new seal and o-ring the input shaft cover (2) prior to reassembly.

  • Page 258

    FINAL DRIVE Install a new seal (1) in the outer cover plate assembly. 10. Install the clutch pack (1), spacer (2) and ring gear (3). Install a new o-ring on the backlash pad (2) stem . NOTE: Align locating pins / holes for installation. NOTE: Ring gear backlash (2) is set at the factory.

  • Page 259

    FINAL DRIVE 12. Install new cover o-ring (1) on the cover plate assembly 14. Place cover assembly on Install bolts (arrows) retaining the and a new passage o-ring (2) on the gear case. outer cover plate assembly and torque to specification. 13.

  • Page 260: Rear Hub

    FINAL DRIVE REAR HUB Remove hub nut, domed washer and flat washer. Removal Place the ATV in Park and lock the parking brake. Remove rear hub cap. Remove hub. Remove cotter pin (A). Loosen the hub retaining nut (B). Loosen the wheel nuts (C). Safely support the rear of the ATV.

  • Page 261

    FINAL DRIVE 11. Remove both lower control arm bolts. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown or press out using a hydraulic press. 12. Remove bearing carrier. NOTE: Drive bearing out evenly by tapping on outer Disassembly race only.

  • Page 262

    FINAL DRIVE Assembly Press bearing into place until outer race bottoms on housing. Support bottom of bearing carrier housing. Start bearing in housing. CAUTION Use an arbor press only on the outer race to avoid bearing damage. Install snap ring into groove. Installation Insert bearing carrier on drive shaft.

  • Page 263: Rear Drive (cv) Shaft

    FINAL DRIVE REAR DRIVE (CV) SHAFT Removal Lower Control Arm Bolt Torque: Remove rear hub, see “REAR HUB REMOVAL”. 50 ft. lbs. (68 Nm) Remove upper carrier bolt. Tip hub outward and remove Lift bearing carrier until top aligns with upper control arm. shaft from carrier.

  • Page 264

    FINAL DRIVE Service Open the snap ring using a snap ring pliers or small needle nose pliers. Tap CV housing off shaft with a soft faced Remove clamps from rubber boot(s) using the CV Boot hammer while holding snap ring open. Clamp Pliers (PN 8700226) (A).

  • Page 265: Cv Boot Replacement

    FINAL DRIVE CV Boot Replacement Refit CV joint on interconnecting shaft by tapping with a plastic hammer on the joint housing. Take care not to Remove CV joint from end of shaft. damage threads on the outboard CV joint. The joint is fully assembled when the snap ring is located in the groove on Remove boot from shaft.

  • Page 266

    FINAL DRIVE INSTALLATION While pulling out on the CV shaft, fully extend the CV joint and slide a straight O-ring pick or a small slotted screw Slide shaft assembly into bearing carrier hub. driver between the small end of the boot and the shaft. This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life.

  • Page 267: Drive Shaft And Cv Joint Handling Tips

    FINAL DRIVE Install rear wheel and torque wheel nuts to specification. 80 ft.lbs. (109 Nm) Refer to Page 7.2 for Wheel Nut Torque. Grease all fittings thoroughly with Premium U-Joint Lubricant (PN 2871551). Drive Shaft and CV Joint Handling Tips Care should be exercised during driveshaft removal or when servicing CV joints.

  • Page 268


  • Page 269


  • Page 270


  • Page 271: Torque Specifications

    GENERAL INFORMATION Torque Specifications Transmission Removal Place vehicle in “park”. Raise and securely support rear of COMPONENT FT. LBS. ATV at the frame. Remove both rear wheels. (IN.LBS.) Drain transmission lubricant (if required). Transmission Case Bolts 25-30 36-43 Remove seat, both side panels, both rear cab quarter panels and both footwells.

  • Page 272

    GENERAL INFORMATION 11. Remove all fasteners (X) attaching the torsion mount, and 14. Remove the middle transmission support bracket (K) completely remove the mount (Z) from the ATV. completely from the ATV. 12. Remove both upper control arms (I). Refer to Chapter 7 for more details.

  • Page 273: Transmission Installation

    Install the upper control arms. Refer to Chapter 5 for procedures and torque specifications. Apply Polaris Premium All Season Grease (PN 2871423) Reconnect the torsion bar to both lower control arms. to splines of front output shaft ,install new O–ring in prop Torque to 17 ft.lbs.

  • Page 274: Troubleshooting Checklist

    16. Install the rear wheel nuts and torque to specification. Rear Wheel Nut Torque Refer to Chapter 2 17. With the ATV on level ground, add Polaris AGL Gearcase Lubricant to the proper level. See Chapter 2 for proper fill procedures and Torque Specifications.

  • Page 275: Transmission Service


  • Page 276


  • Page 277: Transmission Disassembly

    GENERAL INFORMATION Transmission Disassembly Remove the compression spring (7). Place the transmission in the Neutral gear before disassembly. Drain and properly dispose of transmission oil. See Chapter Remove the bellcrank nut (1) and remove the bellcrank (2). Remove the c-clip (3) that holds the gear selector switch (4) onto the shaft and remove the selector switch.

  • Page 278

    GENERAL INFORMATION 10. Remove all cover bolts. Using suitable pry tools, remove 12. Remove the cam chain tensioner spring (14). Slide the cam the cover using the designated pry points. Tap cover with chain tensioner shoe (15), pins (16), and cam chain soft face hammer to remove.

  • Page 279

    GENERAL INFORMATION 15. Remove the T27 screws that secure the output gear (21) with a T27 hex socket or driver. Gear Cluster Disassembly 16. Remove the shift drum (22) from the gearcase by moving the drum up and to the right to clear the shift shaft. Reverse Shaft Needle...

  • Page 280

    GENERAL INFORMATION 22. The reverse shaft should slide out of the silent chain (4) to 26. To disassemble the shift fork rail remove the snap ring (10) separate the assembly. from the end of the shift rail on either side. CAUTION 23.

  • Page 281

    GENERAL INFORMATION 29. Use a 2 3/8” wrench to loosen and remove the front drive 30. If needed, remove the seal from the front of the snorkel shaft snorkel tube (11). tube. Remove the snap ring (12). 31. Remove the second snap ring (13) and spacer (14) from the Front Drive Snorkel Assembly snorkel shaft.

  • Page 282: Transmission Assembly

    GENERAL INFORMATION 33. To remove the remaining bearing on the snorkel shaft (15), Inspect the output gear assembly (1), replace bearings if remove the retaining ring and press the bearing off. needed. Inspect the 91T gear for nics, chips, or abnormal worn teeth.

  • Page 283

    GENERAL INFORMATION Install the output gear assembly. Be sure to properly mesh • Check the output shaft gear backlash again by feel. If the output shaft lash appears to be too tight, rotate the the snorkel shaft bevel gear with the output bevel gear. snorkel shaft counterclockwise to the next notch (or Install the 4 torx screws (2) to secure the output gear 8th) notch.

  • Page 284

    GENERAL INFORMATION Once the gear backlash is found, to install the snorkel lock Assemble the input shaft assembly if previously screw, you may have to rotate the snorkel tube clockwise disassembled. or counterclockwise slightly. This will allow the lock screw Input Shaft Assembly A.

  • Page 285

    GENERAL INFORMATION Inspect the shift drum for any damage or wear. Inspect the NOTE: To ease assembly use a plastic tie strap to hold the shift forks (D) and the shift drum (C) together during splines of the shift drum. Replace the O-rings on the end of the shift drum and lubricate them before assembly.

  • Page 286

    GENERAL INFORMATION 14. Lift the leg of the spring up and over the rear pin. The 11. Install the oil deflector shield into the gearcase. Apply tensioner cam will lift the shoe and tension chain. Loctite™ 242 to the threads of the screws. Torque the screws to 16-30 in.lbs.

  • Page 287

    GENERAL INFORMATION 15. Apply a continuous bead of Crankcase Sealant (3-Bond) 18. Install the O-ring (if not yet done) and lockout disc (H) onto (PN 2871557) to the LH gearcase mating surface and install the shift drum shaft. Be sure to install the lockout disc (H) the cover.

  • Page 288

    GENERAL INFORMATION 22. Install the bellcrank onto the shift shaft. Note the key splined on the bellcrank and shaft. Install the nut. Torque the nut to 12-18 ft.lbs. (16-26 Nm). 23. Install the transmission switch and secure the switch with the retaining ring.

  • Page 289: Table Of Contents


  • Page 290: Component Service Limits

    BRAKES SPECIFICATIONS Torque Table TORQUE SPECIFICATIONS (Sportsman and X2) ORQUE FT ORQUE Front / Rear Caliper Mounting Bolts Handlebar Master Cylinder Clamp Bolts (25 in.lbs.) Hand Master Cylinder Reservoir Cover Screws (7 in.lbs.) 0.79 Brake Line Banjo Bolt 15.0 Brake Line Flared Fittings 12-15 16-21 Brake Disc Bolts...

  • Page 291: Brake System Exploded Views, X2 System Component Exploded View

    BRAKES BRAKE SYSTEM EXPLODED VIEWS X2 System Component Exploded View 1) Master Cylinder Cover Screws: 7 in.lbs. (0.79 Nm) 2) Banjo Style Fitting: 15 ft.lbs. (21 Nm) 3) Flare Style Fittings: 12-15 ft.lbs. (16-21 Nm) 4) Brake Switch: 12-15 ft.lbs. (16-21 Nm) *Apply Pipe Sealant to Threads 5) Dual Input Master Cylinder and Bleed Screw: 25-30 in.

  • Page 292

    BRAKES Sportsman System Component Exploded View...

  • Page 293: Brake Caliper Exploded Views, Sportsman And X2 Front Caliper Assembly, X2 Rear Caliper Assembly

    BRAKES BRAKE CALIPER EXPLODED VIEWS Sportsman and X2 Front Caliper Assembly Apply Polaris DOT approved Brake Fluid to Component Apply Polaris All Purpose Grease A. Socket Set Screw B. Bleeder Screw C. Caliper Asm. D. Boot E. Square O-rings F. Piston G.

  • Page 294: Hydraulic Brake System, Sportsman Rear Caliper Assembly

    Never overfill the The Polaris disc brake system consists of the following reservoir! Fill to 1/4, - 5/16, (.64 - .80 cm) from top of the components or assemblies: brake lever;...

  • Page 295: Brake Noise Troubleshooting, Brake Bleeding / Fluid Change

    / park brake Educate operator to brake fail applied) When servicing Polaris ATV brake systems, use only Polaris Tighten wheel, hub nuts or DOT-approved brake fluid. Loose wheel hub or bearings replace bearings if worn...

  • Page 296

    25-30 in.lbs. (2.80-3.40 Nm) 10. Repeat procedure Steps 5-9 for the remaining caliper(s). Begin bleeding procedure with the caliper that is farthest 11. Add Polaris DOT-approved Brake Fluid to MAX level from the master cylinder. Install a box end wrench on inside reservoir.

  • Page 297: Front Master Cylinder

    BRAKES 12. Install diaphragm, sight glass, cap and screws. 15. Field test machine at low speed before putting into service. Check for proper braking action and lever reserve. With Master Cylinder Cap lever firmly applied, lever reserve should be no less than 1/ 2”, (1.3 cm) from handlebar.

  • Page 298: Front Brakes, Pad Removal

    BRAKES FRONT BRAKES Place new sealing washers on each side of banjo fitting on the brake line and torque banjo bolt to specification. Pad Removal Torque to 15 ft.lbs. (21 Nm) Sealing Washer Elevate and support the of the ATV. CAUTION Banjo Bolt Use care when supporting vehicle so that it does not...

  • Page 299

    Assembly edge. Remove inner pad. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. Measure the thickness of the pad material. Replace pads if worn beyond the service limit.

  • Page 300: Brake Burnishing Procedure, Front Brake Disc

    BRAKES Compress mounting bracket and make sure dust boots are Install the adjuster screw and turn clockwise until fully seated. Install pads with friction material facing each stationary pad contacts disc, then back off 1/2 turn other. (counterclockwise). Verify fluid level in reservoir is up to MAX line inside WARNING reservoir and install reservoir cap.

  • Page 301: Removal / Replacement

    BRAKES Removal / Replacement Measure the disc thickness at eight different points around the pad contact surface. Replace disc if worn beyond NOTE: To reduce the possibility of warping, service limit. removing the brake disc mounting bolts before applying heat to the bolts. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent.

  • Page 302: Front Caliper

    BRAKES FRONT CALIPER Remove mounting bracket, pin assembly and dust boot. Removal CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur. Loosen and remove brake line to caliper. Place a container under caliper to catch fluid draining from brake line.

  • Page 303

    Coat piston with clean Polaris DOT-approved Brake Fluid = In. / mm. (C). Install piston (D) with a twisting motion while pushing inward.

  • Page 304

    BRAKES Compress the mounting bracket and make sure the dust Install brake line and torque the banjo bolt to specification. seals are fully seated. Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease.

  • Page 305: Rear Brake Pad, X2 Pad Removal

    BRAKES REAR BRAKE PAD Push caliper piston into the caliper bore slowly using a C- clamp or locking pliers with pads installed. X2 Pad Removal Elevate and support the rear of the ATV. Remove the rear wheel Loosen pad adjuster screw 2-3 turns. NOTE: Brake fluid will...

  • Page 306: X2 Pad Installation

    Maintain at least 1/2, (12.7 mm) of brake fluid in the Lubricate mounting bracket pins with a light film of reservoir to prevent air from entering the brake system. Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. Install the adjuster screw and turn clockwise until the stationary pad contacts the disc, then back off 1/2 turn (counterclockwise).

  • Page 307: Sportsman Rear Pad Removal

    BRAKES Sportsman Rear Pad Removal NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink Support the machine. Remove the rear tire. or bend brake line. Remove the slide pin clips from the slide bolt. Push caliper pistons into caliper bore slowly with pads installed.

  • Page 308

    BRAKES Sportsman Rear Pad Installation Install the slide bolt snap ring. Torque the slide pin to specification. Install new brake pads in caliper body. Install Pads 30-35 ft.lbs. (41-48 Nm) WARNING Caliper Slide Bolt Torque: If the brake pads are contaminated with grease, 30-35 ft.lbs.

  • Page 309: X2 Rear Caliper

    BRAKES X2 REAR CALIPER Remove piston, dust seals and piston seals. Removal CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur. Clean caliper area before removal. Place a container below the caliper to catch brake fluid that will drain from the brake line.

  • Page 310

    Rear Caliper Piston Bore I.D. Service Limit: 1.193” (30.30 mm) Lubricate the mounting bracket pins with Polaris Premium All Season Grease (PN 2871423), and install the rubber Inspect piston for nicks, scratches, wear or damage. dust seal boots.

  • Page 311: Sportsman Rear Caliper, Removal And Inspection

    BRAKES Compress the mounting bracket and make sure the dust Remove the slide bolt snap rings (A), the slide pins (B), the seals are fully seated. Install the brake pads. Clean the disc bracket pad (C), and the brake pads (D). and pads with brake parts cleaner or denatured alcohol to Caliper remove any dirt, oil or grease.

  • Page 312

    BRAKES Assembly Measure the inside diameter of the rear caliper. The caliper body is a 2-step piston. The rear step is measured as well Install new O-rings in the slide bolt bushing holes. Be sure as the outside step. O-ring and seal grooves are thoroughly cleaned of all residue, or piston may bind in bore.

  • Page 313: Rear Brake Disc

    BRAKES REAR BRAKE DISC NOTE: The slide pins should be torqued when installed on caliper mount. Inspection Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. Use a micrometer and measure disc thickness at 8 different points around perimeter of disc.

  • Page 314: Rear Master Cylinder

    BRAKES REAR MASTER CYLINDER X2 Exploded View A. Master Cylinder Bolts B. Rear Brake Line C. Rear Master Cylinder D. Bushing(s) E. Washer(s) F. Cotter Pin G. Foot Pedal H. Spring I. Front Brake Line J. Banjo Fitting 9.26...

  • Page 315: X2 Rear Master Cylinder Removal And Installation

    If required, remove the rear brake line from the master cylinder. Use a suitable container to catch the brake fluid. Polaris disc brake systems are light weight, low maintenance Dispose of brake fluid properly. and perform well in the conditions ATV’s routinely encounter.

  • Page 316

    BRAKES Sportsman Rear Master Cylinder Removal / Reinstall the brake line and torque the banjo bolt to Installation specification depending on the style of fitting. Remove the RH footwell to gain access to the rear master cylinder. Remove the rear brake lines from the master cylinder. Use Banjo Bolt Torque: a suitable container to catch the brake fluid.

  • Page 317: Pedal Removal And Installation, Brakes Squeal, Poor Brake Performance, Lever Vibration, Caliper Overheats (brakes Drag)

    BRAKES Pedal Removal and Installation TROUBLESHOOTING Brakes Squeal • Dirty/contaminated friction pads • Improper alignment • Worn disc • Worn disc splines X2 Shown Poor Brake Performance • Air in system • Water in system (brake fluid contaminated) • Caliper/disc misaligned Remove the RH footwell to gain access to the rear master •...

  • Page 318

    BRAKES NOTES 9.30...

  • Page 319: Table Of Contents


  • Page 320: Table Of Contents


  • Page 321

    ELECTRICAL Ignition System / Basic Electrical Components GENERAL INFORMATION Special Tools Table 10-1: PART NUMBER TOOL DESCRIPTION ™ Fluke 77 Digital PV-43568 Multimeter 2870630 Timing Light 2870836 Battery Hydrometer 2460761 Hall Sensor Probe Harness 2871745 Static Timing Light Harness 10.3...

  • Page 322: Electrical Service Notes

    ELECTRICAL Electrical Service Notes Troubleshooting Keep the following notes in mind when diagnosing an electrical No Spark, Weak or Intermittent Spark problem: • Spark plug gap incorrect • Refer to wiring diagram for stator and electrical component resistance specifications. • Fouled spark plug •...

  • Page 323: Power Distribution Modules (pdm), Sportsman Efi Overview

    SPORTSMAN 500 EFI X2 SPORTSMAN 500 EFI The Power Distribution Module (PDM) integrates these electronic features found on Polaris 500 and 500 X2 EFI ATVs; rectifier/ regulator, main solid-state circuit breaker (SSCB) output, accessory power output, ignition relay output, fan relay controller, ECM relay output, ECM/cluster memory power, light output, starter lockout, active descent control (ADC) and differential solenoid drive (X2 ONLY).

  • Page 324

    ELECTRICAL Battery Protected Output micro-controller. If the over-current threshold is exceeded for The battery protected output (BAT_PROT) provides solid- the pre-programmed delay time, the output current will shut off. state-circuit-breaker (SSCB) outputs and enables most of the Exceeding the power switch maximum current limit shuts down functions on the PDM.

  • Page 325

    ELECTRICAL CONNECTOR 1 - PIN # SIGNAL NAME DESCRIPTION - IPS = Intelligent Power Switch J1-A ACC_PWR IPS that provides power to the accessories J1-B Unused J1-C TRANS Input signal from the transmission J1-D IDLE Input signal for Active Descent Control (ADC) High side enable to control differential solenoid.

  • Page 326

    ELECTRICAL CHARACTERISTIC PARAMETER UNIT NOTE Ambient temperatures at which module °C Operating Temperature -40 to +55 should remain within specified limits Ambient temperatures which should °C Storage Temperature -50 to +85 have no adverse effects on module operation CHARACTERISTIC MIN TYP MAX UNIT NOTE Battery Voltage 10.5...

  • Page 327

    ELECTRICAL CHARACTERISTIC MIN TYP MAX UNIT NOTE ECM_MEM OUTPUT (constant power for ECM and Instrument Cluster) MEM Circuit Limit Current capability of the output REVERSE POLARITY PROTECTION Battery Reverse Current Max reverse leakage current when connected in reverse Absolute maximum reverse voltage Reverse Bias Voltage before device breakdown.

  • Page 328: Sportsman 450 Overview

    ELECTRICAL Sportsman 450 Overview The Power Distribution Module (PDM) integrates these electronic features found on the Sportsman 450; rectifier/regulator, solid- state circuit breaker output, starter lockout output and engine temperature controller. There are no service parts in the PDM. If the PDM fails, it must be replaced.

  • Page 329

    ELECTRICAL the micro-controller will remain 'ON' until RUN input goes low thermally shuts down. ACC_PWR will automatically turn back by disconnection of the BAT_PROT via the key switch or on/off on when it has cooled, based on thermal recovery. Once tripped, switch.

  • Page 330

    ELECTRICAL CHARACTERISTIC PARAMETER UNIT NOTE ° Ambient temperatures at which module Operating Temperature -40 to +55 should remain within specified limits Ambient temperatures which should ° Storage Temperature -50 to +85 have no adverse effects on module operation CHARACTERISTIC MIN TYP MAX UNIT NOTE Battery Voltage 14.4...

  • Page 331

    Introduction Refer To Illustration 1: Overview The Polaris ATV Instrument Cluster is powered by battery (A) Needle (also flashes during warning condition) voltage (12 VDC) and requires inputs from the engine RPM, transmission gear, and transmission speed sensor for proper (B) Speedometer operation.

  • Page 332: Instrument Cluster Diagnostic Mode

    ELECTRICAL Instrument Cluster Diagnostic Mode 4. High/Low Battery Voltage • This warning usually indicates that the ATV is being NOTE: This gauge features auto shut-off protection operated at an RPM too low to keep the battery if the voltage on the DC bus is excessive. This is charged.

  • Page 333

    ELECTRICAL Screen 2: Tachometer (Ill. 3) indicates engine rpm. NOTE: 10-20% Variance from these reading is within normal parameters. Ill.3 23 Ohms in Park Screen 3: AWD diagnostic screen. This screen indicates whether or not current is flowing through the AWD coil on models with switchable AWD.

  • Page 334: Setting A New Service Interval

    ELECTRICAL Setting A New Service Interval While in the service interval mode, press and hold the mode/override button until the wrench icon flashes. When it begins to flash, release the button. The setting will increase by one hour each time the button is pressed.

  • Page 335: Efi Diagnostic Mode

    NOTE: The EFI diagnostic mode is intended to quickly view fault codes stored in the EFI module. The word “End” will display after all of the codes have been Polaris dealers are equipped with the proper displayed. diagnostic tools to further diagnose the blink codes.

  • Page 336

    ELECTRICAL Speedometer Removal Speedometer Installation Remove the three screws that secure the headlight pod Spray a soap and water mixture onto the outer surface area cover and disconnect the wire connectors from the of the instrument cluster. This will help the instrument instrument cluster.

  • Page 337


  • Page 338

    ELECTRICAL TEST 2 - No Speedometer Display TEST 3 - No Reverse Speed Limit 10.20...

  • Page 339

    ELECTRICAL TEST 4 - No AWD Hub Safety Limit 10.21...

  • Page 340

    ELECTRICAL TEST 5 - Reverse Speed Limiter Activated In Forward Gear TEST 6 - Wheel Speed Sensor 10.22...

  • Page 341

    ELECTRICAL TEST 7 - Fuel Gauge Display Not Working TEST 8 - Shift Indicator Not Working 10.23...

  • Page 342: Active Descent Control (adc) Coil, All Wheel Drive (awd) Coil, Diagnosing System Failures

    ELECTRICAL ACTIVE DESCENT CONTROL (ADC) ALL WHEEL DRIVE (AWD) COIL COIL Operation Overview Operation Overview • AWD switch must be ‘ON’. 12Vdc power is present at the ADC hub coil. • AWD switch must be ‘ON’. • The instrument cluster senses grounding at pin #16. •...

  • Page 343: Cooling System Components, Fan Motor Current Draw Test, Fan Control Circuit Operation

    ELECTRICAL COOLING SYSTEM COMPONENTS Fan Motor Current Draw Test A current draw test will provide a good indication of fan motor Fan Control Circuit Operation condition. A worn or damaged fan motor will draw more current, which causes a reduction in blade speed and reduced Power is supplied to the fan via the Orange/Black wire when the cooling.

  • Page 344: Coolant Temperature Sensor, Gear Position Indicator Switch, Test Diagram

    ELECTRICAL Coolant Temperature Sensor GEAR POSITION INDICATOR SWITCH The coolant temperature sensor can be tested using an ohmmeter Test Diagram or voltmeter. NOTE: Also see “INSTRUMENT CLUSTER TROUBLESHOOTING” for gear switch resistance. If the ECT circuit is open the engine Hot light and fan will both °...

  • Page 345: Etc Test

    ELECTRICAL ELECTRONIC THROTTLE CONTROL Hold throttle cable with fingers at point “A” as shown below and release throttle lever. If the ETC system is (ETC) SWITCH functioning properly, the engine will lose spark and stop. Operation Overview The Electronic Throttle Control (ETC) system is designed to stop the engine of an ATV in the event of a mechanical problem with the throttle mechanism.

  • Page 346: Ignition System

    ELECTRICAL IGNITION SYSTEM Overview The Sportsman has incorporated into it's design a DC/ CDI ignition system. The DC/ ignition system relies on battery power for ignition. EFI - Instead of generating DC voltage via flywheel magnetic induction, a 12 volt DC current is supplied directly from the battery to the PDM.

  • Page 347

    ELECTRICAL Components of EFI Alternator and DC / CDI Ignition System 10.29...

  • Page 348

    ELECTRICAL EFI Ignition System Testing Flow Chart 10.30...

  • Page 349: Crankshaft Position Sensor Gap, Ignition Output Test Using Gap Tester, Ignition Troubleshooting

    ELECTRICAL Crankshaft Position Sensor Gap Ignition Output Test Using Gap Tester Measure trigger coil gap with a feeler gauge. The gap should be Re-connect all wires. Disconnect spark plug wire from the spark 0.4 - 1.2 mm (0.015 - .047 in.). plug.

  • Page 350: Charging System, Current Draw - Key Off, Alternator Output Test, Break Even Test

    ELECTRICAL CHARGING SYSTEM Connect a tachometer to the engine. Using an inductive amperage metering device, (set to DC amps) connect to the negative battery cable. Current Draw - Key Off With engine off and the key, kill switch, and lights in the ON position, the ammeter should read negative amps CAUTION (battery discharge).

  • Page 351

    ELECTRICAL TEST 1: Resistance Value of Each Stator Leg Measure the resistance value of each of the three stator legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3. Each should measure 0.19 ± Ω 15 %. Table 10-2: ONNECT ETER EADING IN...

  • Page 352: Charging System Testing Diagrams

    ELECTRICAL Charging System Testing Diagrams Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not kinked or pinched. SPORTSMAN 500 / 500 X2 EFI SPORTSMAN 450 10.34...

  • Page 353

    ELECTRICAL (PDM) 10.35...

  • Page 354

    ELECTRICAL DIFFERENTIAL SOLENOID LIGHTING Testing High Beam Headlight Bulb Replacement Disconnect from the wire harness. Using a digital ohmmeter, test the solenoid at the connector leads and compare to the specification. Replacement of solenoid is required as it is not serviceable.

  • Page 355: Headlight Housing Relacement

    ELECTRICAL Turn the headlight lamp socket counter-clockwise and Unplug head lamp harness (C). remove. Turn Harness Assembly Loosen Tighten Remove O-Ring (D) from headlight pivot pins. (Both Carefully remove head lamp bulb from housing. Sides) Remove the head lamp and replace with a new head lamp. NOTE: Do not touch the lamp with bare fingers.

  • Page 356: High Beam Headlight Adjustment, Lower Headlamp Removal / Installation

    ELECTRICAL Reverse the steps to install the new housing and reassemble Place the vehicle on a level surface with the headlight the pod. approximately 25' (7.6 m) from a wall. 25’ (7.6 m) Lamp Center Height 2” (5.1 cm) 5 1/8” (13 cm) NOTE: he distance from the head lamp parting line to the end of the adjustment knob stop is 5 1/8”, (13 Measure the distance from the floor to the center of the...

  • Page 357: Low Beam Headlight Adjustment, Headlamp Switch Test

    ELECTRICAL Low Beam Headlight Adjustment Pull the harness assembly out from the headlight assembly. The low beam can be adjusted slightly upward or downward. Loosen Screw Remove the lamp and replace with a new head lamp. NOTE: Do not touch the new lamp with bare fingers. Hold the plastic part (1) of the lamp.

  • Page 358

    ELECTRICAL Work Light Switch Brake Light / Work Light Replacement Remove the headlight pod cover to locate the switch wires. The The brake light (A) and the work light (B) are both located in the switch (A) snaps out by pushing in on the tabs on both sides of rear tail lamp housing.

  • Page 359: Brake Light Switch Test

    ELECTRICAL Brake Light Switch Test X2 and Sportsman - Carefully pull out the red locking tab on the connector. Remove the front cover. Brake Lamp Switch X2 and Sportsman - Once the red tab is pulled out, press in on the black tab and pull out to disconnect harness. Black Tab Red Tab Brake Switch...

  • Page 360: Speed Sensor

    ELECTRICAL SPEED SENSOR FUEL SENDER Testing Testing Using the special tools listed, test the speed sensor according to Drain the fuel tank and remove it from the ATV. the tester instructions. Remove sensor and inspect the o-ring Set the fuel tank on a flat surface. seal for damage or wear and replace as required.

  • Page 361: Accessory Power, Wire Connections

    ELECTRICAL ACCESSORY POWER NOTE: Refer to the accessory instructions for accessory hook-up and installation. Wire Connections Winch Installation Orange/White Wires Located In This Area The Sportsman models have the main winch cables routed and installed from the factory. This enables quick installation. Refer to Chapter 2 for more information on winch installation and operation.

  • Page 362: Starter System, Starter Lockout Troubleshooting- Efi Models, Starter Lockout Troubleshooting- Sportsman, Voltage Drop Test

    ELECTRICAL STARTER SYSTEM Starter Lockout Troubleshooting- EFI Models Troubleshooting The starter lockout is controlled by the PDM. Pin 'C' on SSCB #1 of the PDM senses the transmission signal and determines if Starter Motor Does Not Run the switch is in Neutral or Park. When the conditions are met, the PDM will activate SSCB #2 Pin 'N' to ground the starter •...

  • Page 363

    ELECTRICAL Starter Lockout Diagram- EFI Starter Lockout Diagram- Sportsman 450 10.45...

  • Page 364: Starter Motor Removal / Disassembly, Brush Inspection / Replacement

    ELECTRICAL Starter Motor Removal / Disassembly O-rings located on the armature housing. NOTE: Use electrical contact cleaner to clean starter O-Rings motor parts. Some solvents may leave a residue or damage internal parts and insulation. Remove the starter from the engine. Remove the two bolts, washers, and sealing O-Rings.

  • Page 365: Armature Testing

    ELECTRICAL Armature Testing Inspect surface of commutator for wear or discoloration. See Steps 3-6 of ‘Armature Testing’. Remove armature from starter casing. NOTE: Note order of shims on drive end for reassembly. Brush Inspection Measure length of each carbon brush. Replace brush Inspect surface of commutator.

  • Page 366: Starter Solenoid Bench Test

    ELECTRICAL Starter Reassembly Starter Exploded View CAUTION Use care when handling starter housing. Do not drop or strike the housing as magnet damage is possible. If magnets are damaged, starter must be replaced. Inspect permanent magnets in starter housing. Make sure they are not cracked or separated from housing.

  • Page 367: Starter Drive, Pinion Gear - Anti-kick Out Shoe, Garter Spring Replacement

    ELECTRICAL STARTER DRIVE Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement If the garter spring is damaged, the overrun clutch may fail to return properly. Use either of the following methods to remove and install a new garter spring: A.

  • Page 368: Starter System Testing Flow Chart

    ELECTRICAL STARTER SYSTEM TESTING FLOW CHART Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test. This flow chart assumes that the starter lockout system is functional. With the tester on the VDC position, place the tester's black lead on the battery negative and the Remove battery and properly service.

  • Page 369

    ELECTRICAL BASIC WINCH WIRING Pre-wired Models 10.51...

  • Page 370

    ELECTRICAL TROUBLESHOOTING DIAGRAMS Power On - EFI To ECU Pin 12 Start Circuit - EFI 10.52...

  • Page 371

    ELECTRICAL Ignition Coil - EFI Fuel Pump - EFI 10.53...

  • Page 372

    ELECTRICAL Fan - EFI Charging System - EFI 10.54...

  • Page 373

    ELECTRICAL All Wheel Drive - EFI Transmission Switch - EFI 10.55...

  • Page 374

    ELECTRICAL Reverse Override - EFI Differential Solenoid - X2 10.56...

  • Page 375: Battery Activation, Battery Identification

    ELECTRICAL BATTERY Battery Activation Battery Identification WARNING NOTE: It is important to identify what type of battery you have installed in your ATV. Different types of Battery electrolyte is poisonous. It contains sulfuric batteries require different service procedures. acid. Serious burns can result from contact with Proper servicing and upkeep of your battery is very skin, eyes or clothing.

  • Page 376: Battery Removal, Battery Installation, Terminal Preparation

    1.270 or higher (excludes low maintenance batteries). Terminal Preparation Use Polaris corrosion resistant Nyogel grease (PN 2871329) on battery bolts and terminals when installing a battery. This will help to prevent corrosion and maintain good electrical connection.

  • Page 377: Low Maintenance Battery Off-season Storage, Off Season Storage, Battery Testing

    ELECTRICAL Low Maintenance Battery Off-Season Install clear battery vent tube from vehicle to battery vent. Storage WARNING Battery voltage should be checked with a digital multitester. Readings of 12.8 volts or less require further battery testing and Vent tube must be free from obstructions and kinks and charging.

  • Page 378: Battery Load Test

    ELECTRICAL Battery Load Test cell battery. Readings of 1.270 or greater should be observed in a fully charged battery. Differences of more than .025 between the lowest and highest cell readings indicate a need to replace CAUTION the battery. To prevent shock or component damage, remove spark plug high tension leads and connect securely to engine ground before proceeding.

  • Page 379: Low Maintenance Battery Check, Low Maintenance Battery Charging

    ELECTRICAL Install clear battery vent tube from vehicle to battery vent. Low Maintenance batteries are permanently sealed at the time of manufacture. The use of lead-calcium and AGM technology WARNING instead of lead-antimony allows the battery acid to be fully absorbed.

  • Page 380: Low Maintenance Battery Load Test, Low Maintenance Battery - Ocv- Open Circuit Voltage Test

    ELECTRICAL Table 10-1: LOW MAINTENANCE BATTERY Low Maintenance Battery Load Test CHARGING REFERENCE TABLE CAUTION TATE OF HARGE OLTAGE CTION HARGE To prevent shock or component damage, remove None, check spark plug high tension leads and connect securely voltage at 3 mos. None 100% 12.8-13 V...

  • Page 381: International


  • Page 382

    500 EFI INTERNATIONAL / QUADRICYCLE 500 EFI INTERNATIONAL / QUADRICYCLE BRAKE SYSTEM Overview The Sportsman International / Quadricycle brake system consists of a complete hydraulic brake system. All-wheel braking is integrated into the foot brake and hand brake systems and allows 4 wheel braking from either control separately, or at the same time. When the foot brake is applied, all brake calipers are active, as braking pressure is routed from the foot brake master cylinder through the proportioning valve and distribution block, exiting one line to the front calipers, while the other line exits the proportioning valve and feeds the outer line of the rear calipers.

  • Page 383

    500 EFI INTERNATIONAL / QUADRICYCLE Exploded View 11.3...

  • Page 384

    500 EFI INTERNATIONAL / QUADRICYCLE 500 EFI INTERNATIONAL / QUADRICYCLE STEERING POST AND LOCK Steering Assembly Exploded View The 500 EFI International / Quadricycle Sportsman is equipped with a steering locking mechanism to prevent theft or unauthorized use. Steering post removal may be required for lock service or repair. Lock System Item Number / Description: 11.

  • Page 385

    500 EFI INTERNATIONAL / QUADRICYCLE 500 EFI QUADRICYCLE EMISSIONS SYSTEM Overview 500 EFI Quadricycle model ATVs are equipped with an emissions system from the factory. The emission system is designed to meet the various international emissions standards. The emissions system consists of: •...

  • Page 386


  • Page 387

    Brake, Rear Auxiliary Master Cylinder ... . . 9.26 Brake, Torque Specifications ..... . 9.2 A-Arm Replacement .

  • Page 388

    Crankshaft Position Sensor Gap ....10.31 ETC Operation Test ......10.27 Crankshaft Straightening .

  • Page 389

    PVT, Drive Belt Installation ..... . 6.13 Lubricants/Fluids, Polaris Brand Part Numbers ..2.9 PVT, Drive Belt Removal/Inspection .

  • Page 390

    Special Tools, EFI .......4.5 Speedometer Troubleshooting Tests ....10.19 Special Tools, Engine .

  • Page 391

    Wheels, Removal ......2.32 Wheels, Tire Pressure ......2.32 Wheels, Torque Table .

  • Page 392


  • Page 393


  • Page 394


  • Page 395


  • Page 396


  • Page 397


  • Page 398


  • Page 399


  • Page 400


  • Page 401


  • Page 402


  • Page 403


  • Page 404


  • Page 405


  • Page 406


Comments to this Manuals

Symbols: 0
Latest comments: