Page 1: Table Of Contents
GENERAL INFORMATION Specs Model Identification ..... . . Serial Number Location ....Replacement Keys .
Page 2: General Information
GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 0 9 C A 3 2 A A Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation ENGINE DESIGNATION NUMBERS ES32PFE...
Page 3: Replacement Keys
9921773 9921787 NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com or purchased from www.purepolaris.com. PAINT CODES FRAME COLOR - P067 Medium Gloss Black 9440 / 8520147.
Page 4 GENERAL INFORMATION 2009 TRAILBOSS 330 MODEL: ..MODEL NUMBER: A09CA32AA ENGINE MODEL: ES32PFE Category Dimension Length 75 in./191 cm Width 46 in./117 cm Height 46 in./117 cm Wheel Base 49.5 in./125.73 cm Ground Clearance 5.5./13.97 cm Dry Weight...
Page 5 Fuel Delivery Fuel Pump Brake - - Rear Single Hydraulic Disc Fuel Capacity / Requirement 3.25 gal. (12.3 L) Brake Fluid Polaris DOT 4 Brake Fluid 87 Octane (minimum) 89 Oxygenated AMBIENT TEMPERATURE JETTING CHART Electrical Below 40°F +40°F to +80°F Altitude Below 5°C...
Page 6 GENERAL INFORMATION 2009 TRAILBLAZER 330 MODEL: ..MODEL NUMBER: A09BA32AA ENGINE MODEL: ES32PFE Category Dimension Length 75 in./191 cm Width 46 in./117 cm Height 46 in./117 cm Wheel Base 48 in./121.9 cm Ground Clearance 5.5./13.97 cm Dry Weight...
Page 7 Fuel Delivery Fuel Pump Brake - - Rear Single Hydraulic Disc Fuel Capacity / Requirement 3.25 gal. (12.3 L) Brake Fluid Polaris DOT 4 Brake Fluid 87 Octane (minimum) 89 Oxygenated AMBIENT TEMPERATURE JETTING CHART Electrical Below 40°F +40°F to +80°F Altitude Below 5°C...
Page 8: Special Tools
Piston Pin Puller 8700220 Clutch Compression Tool 2871710 10” Center Distance Tool PV- -43568 Fluket77 Digital Multimeter 2870630 Timing Light 2870836 Battery Hydrometer 8712100 or 8712500 Tachometer NOTE: Polaris dealers can order the tools listed above through the SPX Service Tools catalog.
Page 9: Standard Torque Specifications
GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections. Bolt Size Threads/In Grade 2...
Page 10 GENERAL INFORMATION SAE TAP DRILL SIZES DECIMAL EQUIVALENTS 1/64 ....0156 Thread Size/Drill Size Thread Size/Drill Size 1/32 ... .0312 .
Page 11: 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 12: Glossary Of Terms
CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8″ or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.
Page 13 MAINTENANCE Periodic Maintenance Chart ....2.2-2.5 Recommended Maintenance Products ..2.6--2.7 Pre-Ride Inspection ..... . ATV Component Locations .
Page 14: Periodic Maintenance Chart
Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.) E= Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING: Improperly performing the procedures marked with a could result in component failure and lead...
Page 15: Maintenance And Lubrication
(if equipped) Transmission oil 25 H Monthly 155 (250) Inspect level; change yearly " " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.
Page 16 Inspect routing, condition " (1000) Valve clearance 100 H 12 M Inspect; adjust (1000) " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.
Page 17 Auxiliary brake Inspect daily; adjust as needed " Headlight aim Adjust as needed " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.
Page 18 MAINTENANCE POLARIS LUBES/FLUIDS FOR TRAILBOSS 330 MODELS Pure Polaris Lubricants and Maintenance Kits can be purchased at your local Polaris dealer.
Page 19 MAINTENANCE POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS Part No. Description Part No. Description Engine Lubricant Additives / Sealants / Thread Locking Agents / Misc. 2870791 Fogging Oil (12 oz. Aerosol) 2874275 Loctitet Primer N, Aerosol 2876244 Engine Oil (Quart) Premium 4 Synthetic...
Page 20: Pre-Ride Inspection
MAINTENANCE PRE-RIDE / DAILY INSPECTION Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. Tires - check condition and pressures Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank All brakes - check operation (includes auxiliary brake) Throttle - check for free operation Headlight/Taillight/Brakelight - check operation of all indicator lights and switches...
Page 21 MAINTENANCE TRAIL BOSS 330 COMPONENT LOCATIONS Brake Fluid Reservoir Display Brake Lever Light Control & Run Switch Reverse Override Throttle Choke Ignition/Key Fuel Valve Front Rack Rear Axle & Drive Sprocket PVT Cover Oil Dipstick Headlights Gear Shifter Front Rack Right Side View Transmission Muffler...
Page 22: Maintenance Quick Reference
Page 2.29. Drive Chain Polaris Chain Apply to chain link plates and roll- As required* Lube or O-Ring ers. chain lube NOTE: Refer to Page 2.6 for the Polaris Lubricant Identification table. Transmission Dipstick Dipstick 2W/50 Operating Full Range 2. Transmission 1.
Page 23 Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) ¡ Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) © Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or ¢ Mobilegrease Special 2.11...
Page 24: Transmission Lubrication
TRANSMISSION FLUID TRANSMISSION SPECIFICATIONS CHANGE/TORQUE STOP Specified Lubricant: ADJUSTMENT Polaris AGL Gearcase Lubricant: (PN 2873603) (Gallon) (PN 2873602) (12 oz.) 1. Remove skid plate (if necessary). Capacity: 11.3 oz. (335 ml) 2. Place a drain pan beneath the transmission oil drain plug area.
Page 25 MAINTENANCE LUBRICATION / GREASE TRANSMISSION GEARSHIFT POINTS LINKAGE ADJUSTMENT/ INSPECTION As shown on Page 2.8, there are only five grease zerks on the Trail Boss, two front ball joints, two on the swing are pivots, and one on the rear axle housing. Linkage rod will rotate 1/8 -1/4 turn if rod ends are tightened properly.
Page 26 MAINTENANCE SHIFT LINKAGE THROTTLE OPERATION - ALL ADJUSTMENT MODELS 1. Inspect shift linkage tie rod ends, clevis and pivot Check for smooth throttle opening and closing in all bushings and replace if worn or damaged. handlebar positions. Throttle lever operation should be smooth and lever must return freely without 2.
Page 27: Pilot Screw Adjustment
MAINTENANCE PILOT SCREW PILOT SCREW ADJUSTMENT The pilot system supplies fuel during engine operation with the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet. CAUTION: FRONT The pilot screw is calibrated at the factory to meet EPA / CARB...
Page 28: Throttle Operation / Choke Adjustment
MAINTENANCE 6. Slowly turn mixture screw counterclockwise until confirm adjustment. idle speed increases to maximum RPM. Continue turning counterclockwise until idle RPM begins to drop. 7. Center the pilot screw between the points in Step Lock- 5 and 6. Boot Boot 8.
Page 29: Fuel Lines
MAINTENANCE damaged. FUEL LINES Fuel Lines Fuel Pump Pulse Line NOTE: When replacing the cover, check for correct placement of cover O-ring. Ill.1 1. Check fuel lines for signs of wear, deterioration, FUEL SYSTEM damage or leakage. Replace if necessary. 2.
Page 30: Carburetor Draining
COMPRESSION TEST NOTE: This Polaris 4-Stroke engine is equipped with an automatic decompressor. Compression readings will vary in proportion to cranking speed during the test.
Page 31: Engine Mounts
MAINTENANCE ENGINE MOUNTS battery case is dark and the cell caps are not removable, since there is no need to check electrolyte level. Inspect rubber engine mounts for cracks or damage. NEVER attempt to add electrolyte or water to a Maintenance- -Free battery.
Page 32: Spark Plug
MAINTENANCE SPARK PLUG Recommended Spark Plug: 330 Engine NGK BKR6E Spark Plug Torque: 9- -11 Ft. Lbs. (12- -14 Nm) IGNITION TIMING Refer to Electrical chapter for ignition timing procedure. 1. Remove spark plug high tension lead. Clean plug area so no dirt and debris can fall into engine Ignition Timing: when plug is removed.
Page 33 MAINTENANCE Replace the air filter every 50 hours, 8. Inspect main filter and replace if necessary. If the and possibly more often in very dirty filter has been soaked with fuel or oil it must be conditions. replaced. Installation: AIR FILTER/PRE-FILTER 9.
Page 34: Air Box Sediment Tube Service
MAINTENANCE AIR BOX SEDIMENT TUBE recoil housing, especially when travelling in wet areas. If it is not sealed properly, water may enter the Periodically check the air box drain tube located recoil housing damage toward the rear of the machine. Drain whenever components.
Page 35: Engine Oil Level
If the oil level is over the full mark, change the oil. Crankcase Drain Recommended Engine Oil: Polaris Premium 4 All Season Synthetic, 2W- -50 Engine Sump Drain Plug - Bottom View 8. The oil filter is located on the right side of the machine.
Page 36: Valve Clearance
12. Remove dipstick and fill tank with 2 quarts (1.9 l) of Polaris Premium 4 Synthetic Oil (PN 2871281). 13. Place gear selector in neutral and set parking 5. Remove timing inspection plug from recoil brake.
Page 37: Intake Valve Clearance Adjustment
Use only genuine Polaris parts. WARNING NOTE: Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris Dealer. Only a qualified technician 3. Hold adjuster screw and tighten adjuster lock nut should replace worn or damaged steering parts.
Page 38: Camber And Caster
MAINTENANCE TIE ROD END / STEERING If abnormal movement is detected, inspect the hub and wheel assembly INSPECTION to determine the cause. Refer to the Body/Steering or Final To check for play in the tie rod end, grasp the steering Drive chapter for more information.
Page 39 MAINTENANCE WHEEL ALIGNMENT TOE ALIGNMENT METHOD 2: CHALK ADJUSTMENT 1. Place machine on a smooth level surface. If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell 2. Set handlebars in a straight ahead position and you which tie rod needs adjusting.
Page 40: Brake System Inspection
Keep fluid level in the master cylinder 2. Place the transmission in neutral and start the reservoir to the indicated level inside engine. Purge accumulated carbon from the reservoir. system by momentarily revving the engine Use Polaris DOT 4 Brake Fluid several times. (PN 2872189). 2.28...
Page 41: Brake Pad Inspection
Brake Chapter 9. DRIVE CHAIN AND 3/64″ SPROCKET INSPECTION (.1cm) Minimum Polaris ATV drive chains are equipped with O-ring Thickness sealed permanently greased pins and rollers. The sprockets outer rollers require periodic lubrication.
Page 42 Wear Limit: 12.875″ (32.7 cm) Service Limit: 1/4″ (6mm) Drive Chain Lubricant: DRIVE CHAIN ADJUSTMENT, Polaris O-Ring Chain Lubricant CONCENTRIC SWINGARM (PN 2872073) CAUTION: Never adjust or operate the vehicle with the rear drive chain too loose or too tight as...
Page 43: Rear Axle
MAINTENANCE any chain to have one or more tight spots in the chain. 2. Loosen two eccentric clamp bolts. Therefore, it is extremely important to check chain 3. 2004 Models -- Loosen caliper mounting bracket deflection in several areas of the chain to ensure bolts.
Page 44: Suspension Spring Preload Adjustment
MAINTENANCE chain has approximately 3/8 in. (10 mm) of Eccentric Clamp Without Hitch deflection. 11. Reinstall the chain guard (where applicable). Reposition chain guide to allow 1/8″ (.3 cm) clearance between sprocket and guide. 30 ft.lbs. (41 Nm) Without Trailer Hitch Eccentric Clamp With Hitch Chain Guide SUSPENSION SPRING...
Page 45: Wheel Removal / Installation
MAINTENANCE WHEEL REMOVAL FRONT OR Shock Spanner Wrench REAR (PN 2870872) 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. CONTROLS 3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame.
Page 46: Tire Pressure
MAINTENANCE 3. Lower the vehicle to the ground. 4. Securely tighten the wheel nuts to the proper torque listed in the table. Tread Depth 1/8I (3 mm) CAUTION: If wheels are improperly installed it could affect vehicle handling and tire wear. Be sure to properly torque and install all wheel nuts.
Page 47 ENGINE Engine Service Data ......3.2-3.3 Special Tools and Torque Specifications ..Torque Patterns .
Page 48: Engine Service Data
ENGINE ES32PFE10 ENGINE SERVICE DATA Cylinder Head / Valve ES32PFE10 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 .0008-.0021″ (.020-.054 mm) Limit .0039″ (.10 mm) Camshaft Cam lobe height 1.3001--1.3041″ (33.023-33.123 mm) Limit 1.2883″...
Page 49 ENGINE ES32PFE10 ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod ES32PFE10 Cylinder Surface warpage limit (mating with cylinder .0020″ (0.050 mm) head) Cylinder bore 3.0906-3.0913″ (78.50-78.520 mm) Taper limit .0020″ (0.050 mm) Out of round limit .0020″ (0.050 mm) Piston clearance .0015-.0032″...
Page 50: Torque Patterns
ENGINE SPECIAL TOOLS Oil Line Fitting 20 (27 Nm) Oil Pump Cov- 4-5 (5-7 Nm) PART NUMBER TOOL DESCRIPTION Oil Relief Valve 14mm 14.5-16.5 (20-23 Nm) 2200634 Valve Seat Plug Reconditioning Kit Recoil Housing 5-6.5 (7-9 Nm) 2870390 Piston Support Block Rocker Cover 7-8 (9-11 Nm)
Page 51: Piston Identification
ENGINE PISTON IDENTIFICATION The following components require engine removal for service: The piston may have an identification mark or the Camshaft piston may not have an identification mark for Connecting Rod piston placement. If the piston has an identification mark, follow the directions for piston placement Crankshaft below.
Page 52: Engine Installation Notes
Change break-in oil and filter at 20 areas. Rinse thoroughly, dry with compressed air, hours or 500 miles, whichever and oil the bore immediately with Polaris 4 Cycle comes first. Lubricant to prevent the formation of surface rust.
Page 53: Engine Lubrication
Rinse thoroughly, dry with compressed air, EXAMPLE OF CROSS HATCH PATTERN and oil the bore immediately with Polaris 4 Cycle Lubricant to prevent the formation of surface rust. HONING TO OVERSIZE...
Page 54 ENGINE 3. Start engine and allow it to reach operating NOTE: Use Polaris Premium 2W--50 Synthetic temperature while monitoring gauge indicator. Engine Lubricant. ES32PF10 Oil Pressure at 3000 RPM (Engine Hot): Standard: 71-99 PSI Minimum: 20 PSI at idle OIL COOLER ASSEMBLY...
Page 55 ENGINE OIL FLOW DIAGRAM - ES32PF Chain Room Small End Piston Bearing Rocker Arm / Rocker Shaft / Oil Jet Cylinder Sleeve Sprocket / (Fixed) Chain Connecting Rod Indirect Cam Shaft Lubrication Main Bearing Journal Cam Shaft Through Front Right Cam Lobe Large End Journal...
Page 56: Engine Exploded View
ENGINE ES32PFE ENGINE EXPLODED VIEW Cylinder/ Crankcase Cylinder Head ES32PF Valve Train Crankshaft and Piston 3.10...
Page 57: Cam Chain Tensioner Inspection
ENGINE ENGINE REMOVAL 5. Remove cam chain tensioner plug, sealing washer, spring and pin. CAUTION: The plug is REFER TO PAGE 3.5 - 3.6 FOR ENGINE under spring tension. Maintain inward pressure while removing. REMOVAL / INSTALLATION NOTES. 6. Remove the two 6x25 mm cam chain tensioner flange bolts.
Page 58 ENGINE 4. Measure free length of tensioner spring. Replace 4. Remove cylinder block plug using a 14 mm hex spring if excessively worn. head wrench. Cylinder block plug Tensioner Spring Free Length: 5. Measure O.D. of rocker shaft. Inspect it for wear or damage.
Page 59: Camshaft Removal
ENGINE CAMSHAFT REMOVAL 1. Remove cam shaft end plug (A). Rocker Arm & Support I.D.: .8669-.8678I (22.020-22.041 mm) 2. Remove camshaft sprocket flange bolt and washer. 7. Measure I.D. of both rocker arm shaft support areas and visually inspect surface. Compare to specifications.
Page 60: Automatic Compression Release Installation
ENGINE CAMSHAFT REMOVAL CONT’D 6. Inspect cam sprocket teeth for wear or damage. Replace if necessary. Lobe Inspect for Areas of Tooth Wear or Damage 2. Remove release lever shaft and return spring (spacer). 3. Inspect shaft for wear or galling. 7.
Page 61: Cylinder Head Removal
ENGINE 2. Thoroughly clean the cam shaft, making sure the CYLINDER HEAD REMOVAL oil feed holes are not obstructed. 3. Measure height of each cam lobe using a 1. Loosen each of the four cylinder head bolts micrometer. Compare to specifications. evenly 1/8 turn each time in a cross pattern until loose.
Page 62: Cylinder Head Warpage
ENGINE CYLINDER HEAD WARPAGE 2. Remove spring retainer and spring. 1. Lay a straight edge across the surface of the cylinder. head at several different points and measure warpage by inserting a feeler gauge between the straight edge and the cylinder head surface.
Page 63: Valve Inspection
ENGINE 5. Remove valve seals. CAUTION: Replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup. 4. Inspect split keeper groove for wear or flaring of the keeper seat area (B). NOTE: The valves cannot be re-faced or end ground.
Page 64: Valve Seat Reconditioning
ENGINE VALVE SEAT RECONDITIONING Valve Seat Inspection Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be reconditioned. See Valve Seat Reconditioning, Page 3.19--3.21. If the valve seat is cracked the cylinder head must be replaced.
Page 65 ENGINE 4. Follow the manufacturers instructions provided Reaming The Valve Guide with the valve seat cutters in the Valve Seat 9. Allow cylinder head to cool to room temperature. Reconditioning Kit (PN 2200634). Abrasive stone Apply cutting oil to the reamer. Guides should be seat reconditioning equipment can also be used.
Page 66 ENGINE VALVE SEAT RECONDITIONING CONT’D 6. Insert valve into guide and tap valve lightly into place a few times. 3. Place 46° cutter on the pilot and make a light cut. 7. Remove valve and check where the Prussian Bluet or black marker indicates seat contact on the valve face.
Page 67: Cylinder Head Assembly
ENGINE NOTE: When using an interference angle, the seat 12. Clean cylinder head, valves, and camshaft oil contact point on the valve will be very narrow, and is supply passage (A) thoroughly. a normal condition. Look for an even and continuous contact point on the black marker, all the way around the valve face.
Page 68: Engine Bottom End Disassembly
ENGINE CYLINDER HEAD ASSEMBLY CONT’D ENGINE BOTTOM END 5. Dip valve spring and retainer in clean engine oil DISASSEMBLY and install spring with closely spaced coils toward the cylinder head. Cylinder Removal Follow engine disassembly procedures to remove valve cover, camshaft and rocker arms, and cylinder head.
Page 69: Piston Removal
ENGINE PISTON REMOVAL 5. Remove the top rail first followed by the bottom rail. 1. Remove circlip. Note that opening for circlip 6. Remove the expander. access is on the intake side. CYLINDER INSPECTION 1. Remove all gasket material from the cylinder sealing surfaces.
Page 70 ENGINE CYLINDER INSPECTION CONT’D 3. Measure piston pin bore. 5. Record measurements. If cylinder is tapered or out of round beyond .002, the cylinder must be re-bored oversize, or replaced. Cylinder Taper Limit: .002 Max. Cylinder Out of Round Limit: .002 Max. Cylinder Standard Bore Size: 3.0906-3.0913I (78.50-78.520 mm) PISTON INSPECTION...
Page 71: Piston Ring Installed Gap
ENGINE 5. Measure connecting rod small end ID. PISTON RING INSTALLED 1. Place each piston ring inside cylinder using piston to push ring squarely into place as shown. Piston ring end gap installed Feeler Gauge Cylinder 25-50mm Connecting Rod Small End I.D. Piston Ring .7095-.7101I (18.007-18.023 mm) 2.
Page 72 ENGINE STARTER DRIVE Starter Drive Bushing Clearance: REMOVAL/INSPECTION Std: .0015″-.004″ (.038-.102 mm) Service Limit: 1. Remove recoil housing bolts and remove 008″ (.203 mm) housing. 6. Inspect gear teeth on starter drive. Replace starter drive if gear teeth are cracked, worn, or broken.
Page 73 ENGINE 5. Replace crankshaft seal. DRIVE SPROCKET REMOVAL 6. Remove large sealing O-Ring from outer edge of / INSPECTION stator plate. 1. Using the Slotted Nut Socket (PN 2871293), CAM CHAIN/TENSIONER remove the crankshaft slotted nut (A). NOTE: BLADE The slotted nut is a left hand thread. 1.
Page 74 ENGINE PRESSURE RELIEF VALVE The pressure relief valve opens to relieve any excess pressure from the oil pump if oil pressure reaches approximately 71 psi. It must be clean and have adequate spring pressure in order to seal properly. 1. Remove cap bolt, sealing washer, spring, and relief valve from MAG side crankcase.
Page 75: Oil Pump Assembly
ENGINE 5. Measure rotor tip clearance with a feeler gauge. 2. Separate crankcase by tapping with a soft faced hammer in reinforced areas. Rotor Tip Clearance: 3. Watch the gap along the crankcase mating Std: .005 (.127 mm) surface and separate the crankcase evenly. 4.
Page 76: Crankshaft Inspection
ENGINE 2. Use a feeler gauge to measure the connecting rod 2. Measure the width of the connecting rod at the big big end side clearance. end. Connecting Rod Width: Std: .8233-.8252I (20.88-20.93 mm) 3. Visually inspect bearing journal for scoring, damage or excessive wear.
Page 77: Crankcase & Bearing Assembly
ENGINE CRANKSHAFT MAIN BEARING INSPECTION 1. Inspect the crankshaft main bearings. NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. Look for signs of discoloration, scoring or galling. Turn the outer race of each bearing. The bearings should turn smoothly and quietly.
Page 78: Crankcase Inspection
ENGINE CRANKCASE INSPECTION 2. Measure the distance from the MAG side crankcase mating surface to the main bearing using a dial caliper and a straight edge. 1. Remove all traces of gasket sealer from the crankcase mating surfaces. Inspect the surfaces closely for nicks, burrs or damage.
Page 79: Crankshaft End Play Inspection
ENGINE 4. Measure the width of the crankshaft at the ENGINE ASSEMBLY/ bearing seats or, if PTO bearings are installed, the CONNECTING ROD width from MAG side bearing seat to the outside race of the PTO bearings with a micrometer or dial INSTALLATION caliper and record.
Page 80: Crankshaft Installation
ENGINE CRANKSHAFT 2. Install oil pump cover. Torque screws to specified torque. INSTALLATION Oil Pump Cover Screw Torque: Lubricate all bearings with clean engine oil before assembly. 4-5 ft. lbs. (5-7 Nm) 1. Install the crankshaft into the PTO side crankcase.
Page 81: Piston Ring Installation
ENGINE TENSIONER BLADE INSTALLATION Ring Profile 1. Install the tensioner blade and tighten the mounting bolt to specified torque. Tensioner Blade Mounting Bolt Torque: 5-6.5 ft. lbs. (7-9 Nm) “R1” Mark up OIL FILTER INSTALLATION 1. Apply clean engine oil to oil filter gasket. Install filter until gasket lightly touches seat and then tighten an additional 3/4 of a turn.
Page 82: Cylinder Head Installation
ENGINE 4. Apply clean engine oil to the piston rings, ring 2. Apply clean engine oil liberally to the cylinder bore lands, piston pin bore, piston pin, and piston skirt. and tapered area of the sleeve. Install the Lubricate the connecting rod (both ends) and cylinder with a slight rocking motion until the rings crankshaft main bearing area.
Page 83 ENGINE The following procedure must be used to torque the Install the cam chain over the crankshaft. cylinder head properly: Torque in cross Plated pattern per procedure Link Sprocket Mark Crankcase Projection IMPORTANT CAMSHAFT TIMING NOTE: In order to time the camshaft to the crankshaft, the piston must be precisely located at Top Dead Center (TDC).
Page 84 ENGINE 3. Apply Polaris Low Temp Grease (PN 2870577), Camshaft Installation - Timing Method 2 or engine assembly lubricant to the camshaft Refer to Page 3.40 main journals and cam lobes. Lubricate 1. Apply Polaris Low Temp Grease (PN 2870577),...
Page 85 ENGINE CAMSHAFT TIMING - METHOD 1 Method 1 - Camshaft Timing with Stator Removed Crankshaft to Camshaft Centerline Single Plated Sprocket marks aligned with gasket surface at TDC on Link and Dot on compression stroke (cam Cam Sprocket lobes facing downward) Single Plated Link and Rectangular...
Page 86 ENGINE CAMSHAFT TIMING - METHOD 2 Method 2 - Camshaft Timing Using Flywheel TDC Mark Crankshaft to Camshaft Centerline Do not use dot on sprocket for cam timing Decompressor arm stop pin UP (Cam lobes DOWN) Sprocket marks aligned with gasket surface at TDC on compression stroke (cam lobes facing downward, de-...
Page 87: Cam Chain Tensioner Installation
ENGINE CAM CHAIN TENSIONER 4. Slowly rotate engine two to three revolutions and re-check cam timing once chain is tight. INSTALLATION STATOR INSTALLATION 1. Release the ratchet pawl (A) and push the tensioner plunger (B) all the way into the NOTE: The stator, flywheel, starter drive, and recoil tensioner body.
Page 88 ENGINE FLYWHEEL INSTALLATION ROCKER SHAFT/ARM INSTALLATION 1. Install flywheel, washer, and nut. Torque flywheel to specification. 1. Assemble rocker arms, rocker shaft and wave washer into rocker cover. Flywheel Nut Torque: 2. Install and tighten rocker shaft block plug. 3. Apply engine assembly lube to the cam lobes and 58-72 ft.
Page 89 ENGINE INTAKE VALVE CLEARANCE ADJUSTMENT VALVE CLEARANCE 330 Engines 1. Insert a .006″ (.15mm) feeler gauge between end .006″ (.15 mm) of intake valve stem and clearance adjuster screw. 6. 330: Inspect o-rings on the plastic valve plugs, 2. Using Valve/Clutch Adjuster Tool...
Page 90 ENGINE RECOIL 5. Remove ratchet pawl with spring and inspect. Replace spring or ratchet pawl if worn, broken, or DISASSEMBLY/INSPECTION damaged. CAUTION: Recoil is under spring tension. A face shield or eye protection is required during this procedure. Replace any parts found to be worn or damaged. 1.
Page 91: Recoil Assembly
ENGINE 8. Slowly and carefully remove reel from recoil To reinstall an old spring: housing making sure the spring remains in the 1. Hook outer tab in place in recoil housing and wind housing. Inspect the reel hub and bushing (A) for spring in a counterclockwise direction one coil at a wear.
Page 92: Spark Plug Fouling Checklist
ENGINE SPARK PLUG FOULING Engine flooded Low compression (high cylinder TROUBLESHOOTING leakage) No spark (Spark plug fouled) Spark plug cap loose or faulty Engine Does Not Turn Over Choke cable adjustment or plunger/cable sticking Dead battery Foreign material on choke plunger Starter motor does not turn seat or plunger Engine seized, rusted, or...
Page 93 ENGINE TROUBLESHOOTING Piston Failure - Scoring Lack of lubrication Dirt entering engine through cracks in air filter or ducts Engine oil dirty or contaminated Excessive Smoke and Carbon Buildup Excessive piston-to-cylinder clearance Worn rings, piston, or cylinder Worn valves, guides or seals Restricted breather Air filter dirty or contaminated Low Compression...
Page 94 ENGINE NOTES 3.48...
Page 95 FUEL SYSTEM/CARBURETION Exploded View, Mikuni BST 34 Carburetor . . . Fuel Pump Exploded View ....Fuel Tank Asm. Exploded View ... . Fuel Flow Diagram .
Page 96 FUEL SYSTEM/CARBURETION 1. Carburetor Assembly BST 34 CARBURETOR EXPLODED VIEW 2. Screw 3. Throttle Valve 4. Cover, Diaphragm 5. Jet Block Assembly 6. Spring 7. Diaphragm Assembly 8. Ring 9. “E” Ring 10. Ring 11. Needle Jet 12. Cover 13. O-Ring 14.
Page 97: Fuel Pump Exploded View
FUEL SYSTEM/CARBURETION FUEL PUMP EXPLODED VIEW 1. Fuel Pump Assembly 2. Diaphragm, Gasket Set 3. Screw and Washer Assembly 4. Screw and Washer Assembly 5. Screw and Washer Assembly 6. Pressure Regulator 7. Fuel Inlet 8. Fuel Outlet...
Page 98: Fuel Flow Diagram
FUEL SYSTEM/CARBURETION FUEL TANK ASSEMBLY Vent line routed smoothly into center of steering post Forward Tank to fuel valve connection -- Gas Tank Mounting Gold fitting (tall stand pipe) to Hardware “ON” 90 Degree Fuel Reserve Outlet Fitting 90 Degree Fuel (Marked “2”...
Page 99: Jetting Guidelines
Never start the engine or let it run in an Polaris ATV Carburetors are calibrated for an altitude enclosed area. Gasoline powered engine 0-6000 ft. (0-1800 meters) and ambient exhaust fumes are poisonous and can temperatures between +40 and +80°...
Page 100: Carburetor Jetting
FUEL SYSTEM/CARBURETION / pilot screw adjustments and PVT adjustments may CV CARBURETOR SYSTEM be required to suit operating conditions. FUNCTION CARBURETOR JETTING Carburetor Component Function CAUTION: System Main Main Main Components Function Affect A main jet that is too small will cause a lean operating condition resulting in serious engine Float Inlet Pipe,...
Page 101: Assembly, Cv Carburetor
FUEL SYSTEM/CARBURETION VENT SYSTEMS - CV CARBURETOR OPERATION CONT’D CARBURETOR When the throttle plate is opened and engine speed begins to increase, the pressure in the venturi (and therefore in the chamber above the diaphragm) The carburetor float bowl vent lines supply becomes significantly lower than atmospheric.
Page 102: Float System
FUEL SYSTEM/CARBURETION FLOAT SYSTEM Fuel enters the float chamber (3) by means of the inlet pipe and passage, through a screen on the back of the inlet needle seat (4), and around the inlet needle (2). As the fuel fills the float chamber, the float (1) rises and forces the inlet needle against the seat, shutting off the orifice in the seat.
Page 103: Main System
FUEL SYSTEM/CARBURETION MAIN SYSTEM As throttle valve (1) is opened, engine speed rises, and this increases negative pressure in the venturi. Consequently the vacuum slide (2) moves upward. The fuel in float chamber (3) is metered by main jet (4), and the metered fuel enters needle jet (5), in which it mixes with the air admitted through main air jet (6) to form an emulsion.
Page 104 FUEL SYSTEM/CARBURETION CARBURETOR DISASSEMBLY - MIKUNI CV Use the following disassembly, assembly, and inspection techniques to service a CV carburetor. 1. Remove carburetor diaphragm chamber cover with a ratchet style screwdriver. DO NOT use an impact driver to remove the screws or carburetor may be permanently damaged.
Page 105: Carburetor Cleaning
FUEL SYSTEM/CARBURETION CARBURETOR CLEANING WARNING Jet Needle Needle Jet Protect eyes from contact with cleaner. Take appropriate safety measures during these procedures. Safety glasses and chemical resistant Inspect this area gloves are required. Should you get cleaner in your eyes or if you swallow cleaner, seek medical attention immediately.
Page 106: Carburetor Assembly
FUEL SYSTEM/CARBURETION CARBURETOR ASSEMBLY 3. Replace parts in proper order. The spring seat washer (B) is stepped and must be placed on TOP of “E” Clip (C). Spacer washer (D) must be Inspect the diaphragm (A) for holes, deterioration, or installed below the E-Clip.
Page 107: Float Height Adjustment
FUEL SYSTEM/CARBURETION FLOAT HEIGHT 3. If adjustment is necessary, bend the tongue slightly. Be sure float measurement is even on left ADJUSTMENT and right side. 1. Place the carburetor on a level surface as shown Float arms even at right to remove weight from float arm. In this position, the float tongue will rest lightly on the inlet needle valve pin without compressing the spring.
Page 108: Fuel Level
FUEL SYSTEM/CARBURETION FUEL LEVEL If fuel is present in the impulse line or vacuum chamber of the pump, the diaphragm is ruptured. The pump diaphragms must be replaced. A fuel level test can be performed on some models if the drain hose fitting is accessible. Be sure to re-attach the bowl drain hose after performing the Fuel Lines...
Page 109: Troubleshooting
FUEL SYSTEM/CARBURETION TROUBLESHOOTING Loose jets Worn jet needle/needle jet or other FUEL STARVATION/LEAN MIXTURE carburetor parts Dirty carburetor (air bleed Symptoms: Hard start or no start, bog, backfire, passages or jets) popping through intake / exhaust, hesitation, Weak or damaged vacuum piston detonation, low power, spark plug erosion, engine return spring runs hot, surging, high idle, idle speed erratic.
Page 110 FUEL SYSTEM/CARBURETION NOTES 4.16...
Page 111 BODY / STEERING / SUSPENSION Trail Boss Body Assembly, Exploded View ..Trail Blazer Body Assembly, Exploded View ..Steering Assembly, Exploded View ... . Torque Specifications and Special Tools .
Page 112: Trail Boss Body Assembly Exploded View
BODY / STEERING / SUSPENSION TRAIL BOSS BODY ASSEMBLY EXPLODED VIEW Rear Cab Assembly Seat Latch Retainer Seat Rear Cab Seat Latch Rear Rack Tool Box Clutch Guard Rock Guard Footwell Frame Front Cab Assembly Front Cover Fuel Tank Cover Front Cab Side Cover Front Rack...
Page 113: Trail Blazer Body Assembly Exploded View
BODY / STEERING / SUSPENSION TRAIL BLAZER BODY ASSEMBLY EXPLODED VIEW Rear Cab Assembly Seat Latch Retainer Seat Rear Cab Seat Latch Tool Box Clutch Guard Footwell Frame Front Cab Assembly Front Cover Panel or Headlight Cover Front Cab Mud Flap Foot Pad Rock Guard...
Page 114: Steering Assembly, Exploded View
BODY / STEERING / SUSPENSION STEERING ASSEMBLY, EXPLODED VIEW NOTE: Apply Loctitet 242 to To avoid damage to tie rods and other steering the bolt threads. components, be sure to install tie rod end bolts in the proper direction. The steering post arm bolt (B) points up; the rod end bolts (A) point down.
Page 115: Cover/Panel Removal
BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS COVER/PANEL REMOVAL Front A-Arm Attaching Bolt 30 ft. lbs. (41 Nm) To remove, perform these steps: Seat: Front A-Arm Ball Joint Stud Nut 25 ft. lbs. (35 Nm) Pull release lever at the rear of the seat Handlebar Adjuster Block 10-12 ft.
Page 116: Side Panel Removal
BODY / STEERING / SUSPENSION Front Rack SIDE PANEL REMOVAL Remove: 4 screws, lock washers, and 1. Remove seat. Grasp rear of panel near rear cab. flat washers With a quick and firm motion, pull panel forward Front Cab Assembly and outward to disengage the two rear tabs.
Page 117: A-Arm Replacement
BODY / STEERING / SUSPENSION A-ARM REPLACEMENT Apply Loctitet 242 to Vehicle Frame Bolt 30 ft. lbs. the bolt threads. (41 Nm) Bolt 30 ft. lbs. Ball Joint (41 Nm) Stud A-Arm Tube A-Arm Shaft 25 ft. lbs (35 Nm). Bushing Cotter Pin 8 ft.
Page 118: Concentric Swing Arm Removal
BODY / STEERING / SUSPENSION CONCENTRIC SWING ARM REMOVAL (2) Washer (3) Two-piece bushing (1) Nut (8) Pivot Bolt (4) Pivot Bushing, Right (7) Pivot Bushing, Left Place flats of pivot bushing in vise to hold while removing nut (5) Pivot Bolt (8) Pivot Bolt Retainer Refer to Maintenance section for chain adjustment information...
Page 119: Concentric Swing Arm Assembly/Installation
BODY / STEERING / SUSPENSION CONCENTRIC SWING ARM ASSEMBLY/INSTALLATION 150 ft. lbs. (207 Nm) (1) Nut 120 ft. lbs. (163 Nm) (2) Washer (8) Pivot Bolt (3) Two-piece bushing (7) Pivot Bushing, Left (4) Pivot Bushing, Right Place flats of pivot bushing in vise to hold while removing and installing nut 150 ft.
Page 120: Strut Assembly
BODY / STEERING / SUSPENSION STRUT ASSEMBLY 15 ft. lbs. (20 Nm) Spring Retainer Strut Bumper Spring Spring Retainer Strut Tie--Rod Bolt 15 ft. lbs. (21 Nm) Jam Nut 45 ft. lbs. 14 ft. lbs. (61 Nm) (19 Nm) Hub Nut 40 ft.
Page 121: Front Strut Cartridge Replacement
BODY / STEERING / SUSPENSION FRONT STRUT CARTRIDGE BALL JOINT REPLACEMENT REPLACEMENT REFER TO ILLUSTRATION ON PAGES REFER TO ILLUSTRATION ON PAGES 5.9. 5.9. 1. Loosen front wheel nuts slightly. 2. Elevate and safely support machine under 1. Hold strut rod and remove top nut. footrest/frame area.
Page 122 BODY / STEERING / SUSPENSION 8. To install new ball joint: NOTES Remove extension cap and attach puller guide using short bolts provided in the kit. Insert new ball joint (E) into driver (F). Slide ball joint/driver assembly into guide. Drive new joint into strut housing until fully seated.
Page 123: Steering Post Assembly
BODY / STEERING / SUSPENSION STEERING POST ASSEMBLY 12 ft. lbs. (16 Nm) 12 ft. lbs. (16 Nm) NOTE: Steering post bearing is shown in ex- ploded view form. This bearing is attached to the post using a radial riveting method and is a non--serviceable item.
Page 124 BODY / STEERING / SUSPENSION NOTES 5.14...
Page 125 CLUTCH Service Tools and Supplies ....PVT System Torques ..... PVT System Operation Overview .
Page 126: Special Tools And Supplies
(initial vehicle movement), clutch Tool Kit upshift and backshift. During the development of a Polaris ATV, the PVT system is matched first to the engine power curve; then to average riding conditions and the vehicle’s intended usage. Therefore,...
Page 127: Pvt Maintenance/Inspection
CLUTCH DRIVEN CLUTCH OPERATION CONT’D air ducts, as well as the inner and outer covers, must be properly sealed to ensure clean air is As engine RPM and horsepower increase, the load being used for cooling the PVT system. This also from the drive belt increases, resulting in the belt will prevent water and other contaminants from rotating up toward the outer diameter of the drive...
Page 128 10 seconds. PVT seals should be inspected for damage if repeated leaking occurs. Clutch malfunction. Inspection/repair of clutch components should be performed by a certified Polaris MSD techinician.
Page 129: Pvt Disassembly
CLUTCH PVT DISASSEMBLY 8. Remove driven clutch retaining bolt and driven clutch. Use the Driven Clutch Puller (PN 2870913) if necessary. NOTE: Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement. (See Page 6.7). Driven Clutch Puller (PN 2870913) 1.
Page 130: Pvt Assembly
CLUTCH PVT ASSEMBLY Inner Cover Bolt Torque (Rear): 12 ft. lbs. (16.6 Nm) Seal this edge to cover on engine side Driven Clutch Retaining Bolt Torque: 17 ft. lbs. (23.5 Nm) Drive Clutch Retaining Bolt Torque: 40 ft. lbs. (55 Nm) 1.
Page 131: Pvt Sealing And Ducting Components
CLUTCH PVT SEALING AND DUCTING COMPONENTS Inner Cover Outer Cover Seal Cover Screws (9) Inlet Duct Drain Plug Exhaust Duct Inner Cover Seal Retainer Outer Cover DRIVE CLUTCH EXPLODED VIEW Drive Clutch Teflont coated brass bushing Teflont coated brass bushing Mark with permanent marker before disassembly...
Page 132: Drive Clutch Spring Specifications
CLUTCH DRIVE CLUTCH SPRING SPECIFICATIONS FULL UPSHIFT NEUTRAL The drive clutch spring has two primary functions: ATV TRAVEL 1. To control clutch engagement RPM. The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM.
Page 133: Shift Weights
CLUTCH SHIFT WEIGHTS Shown below are the shift weights which have been designed for, or which may be used in the PVT system. These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern.
Page 134: Drive Clutch Inspection
REMOVAL” Page 6.11. clutch assembly! All PVT system maintenance repairs must be performed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this manual. Because of...
Page 135 CLUTCH 2. Remove cover bolts evenly in a cross pattern, and SPIDER REMOVAL remove cover plate. Cover Bushing Inspection: Replace the cover bushing if more brass than Teflont is visible on Clutch Holding Fixture: (PN 2871358) the bushing. Refer to bushing re- placement in this chapter.
Page 136: Drive Clutch Assembly
CLUTCH ROLLER, PIN AND THRUST DRIVE CLUTCH ASSEMBLY WASHER INSPECTION NOTE: It is important that the same number and 1. Inspect all rollers, bushings and roller pins by thickness of washers are reinstalled beneath the pulling a flat metal rod across the roller. Turn roller spider during assembly.
Page 137: Drive Belt Tension
CLUTCH 5. Torque spider to specification using the holding 8. Reinstall cover, aligning bosses on the tower and fixture and spider tool. Torque with smooth cover. Torque cover bolts evenly to specification. motion to avoid damage to the stationary sheave. Refer to Page 6.2 for torque specification.
Page 138: Drive Belt Removal/Inspection
CLUTCH NOTE: At least one shim must remain between the Projected inner and outer sheave of the driven clutch. If proper Belt belt deflection cannot be obtained, measure drive belt Width width, length, and center distance of drive and driven clutch, outlined in this section;...
Page 139: Drive Belt Installation
CLUTCH measure longer than nominal length may require CLUTCH ALIGNMENT driven shimming or engine adjustment for a longer center distance to obtain proper belt deflection. Belts which measure shorter than Offset Alignment Tool nominal length may require driven shimming or a should contact rear edge of shorter center distance.
Page 140: Clutch Offset
CLUTCH CLUTCH OFFSET P--90 Driven Clutch 5020631 Cover Bushing Re- moval Tool Offset Alignment Tool Main Puller Adapter 5020632 (PN 2870654) Adapter Reducer 5010279 Number Two Puller 5020633 Adapter DRIVE CLUTCH MOVEABLE SHEAVE - BUSHING 1/8I +0 / -- 1/16 REMOVAL 3.2mm +0 / -- 1.6 mm) Important:...
Page 141 CLUTCH 3. Install the Main Puller Adapter (#8) (PN 5020632) 2. Apply Loctitet 680 (PN 2870584) to the back onto the Piston Pin Puller (PN 2870386). side of new bushing. Push bushing into center of sheave on tower side by hand. Bushing (PN 3576504) Loctitet 680 (PN 2870584) 3.
Page 142 CLUTCH 1. Install the Main Puller Adapter (#8) (PN 5020632) onto the Piston Pin Puller (PN 2870386). Bushing (PN 3576510) Loctitet 680 (PN 2870584) 2. From outside of clutch cover, insert the Drive Cover Bushing Remover (#3) (PN 5020629) into 2.
Page 143: Driven Clutch Disassembly/Inspection
CLUTCH DRIVEN CLUTCH 2. Remove snap ring retainer. DISASSEMBLY/INSPECTION Note hole location of spring in helix and sheave 3. Note the location of the spring and remove helix. 4. Note the location of the spring in the moveable Used to adjust sheave, and remove the spring.
Page 144: Driven Clutch Assembly
CLUTCH 7. Remove moveable sheave and note the number 1. Install moveable sheave with spacer washers. of spacer washers. One spacer must remain Important: At least one spacer washer must be between the sheaves when adjusting belt installed. Teflont bushings are self-lubricating. deflection.
Page 145 CLUTCH 3. Remove ramp buttons from moveable sheave. turn 5. While holding downward pressure on helix, wind moveable sheave counterclockwise 4. Using an electric or hand held propane torch, approximately 1/3 turn (120°). apply heat directly on bushing until tiny smoke 6.
Page 146 CLUTCH 9. Remove nut from puller rod and set aside. 10. Remove adapters from puller. 11. Remove bushing and removal tool from adapters. Discard bushing. DRIVEN CLUTCH MOVEABLE SHEAVE - BUSHING INSTALLATION 6. Install sheave onto puller. 7. Install nut onto puller rod and tighten by hand. Turn puller barrel for further tension if needed.
Page 147: Troubleshooting
CLUTCH 6. Remove nut from puller rod and set aside. 7. Remove installation tool and clutch sheave from puller. 4. Install nut onto puller rod and hand tighten against installation tool. 5. Turn clutch sheave counterclockwise until 8. Repeat installation procedure for other moveable bushing is seated.
Page 148 CLUTCH Harsh drive -Drive belt worn too narrow. -Replace belt. clutch engage- ment. -Excessive belt/sheave clearance with new -Perform belt/sheave clearance adjustment with shim wash- belt. ers beneath spider. Drive belt turns -Wrong belt for application. -Replace with correct belt. over -Clutch alignment out of spec.
Page 149 FINAL DRIVE Special Tools / Torque Specifications ..Front Hub Disassembly/Inspection ..7.2-7.3 Front Hub Assembly ..... . Front Hub Installation .
Page 150: Front Hub Disassembly/Inspection
FINAL DRIVE SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2870872 Shock Spanner Wrench 2870871 Ball Joint Replacement Tool 2870623 Shock Absorber Spring Compression Tool 2871572 Strut Rod Wrench 2871573 LH Strut Spring Compressor 2871574 RH Strut Spring Compressor 2871199 Seal Sleeve Installation Tool Kit 3.
Page 151 FINAL DRIVE 6. Rotate each bearing by hand and check for Tap spacer to side smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 9. Remove spacer. Drive other bearing out and discard.
Page 152: Front Hub Assembly
FINAL DRIVE FRONT HUB ASSEMBLY 3. Install seal into hub backside (numbers facing out) until flush with end of seal bore. Apply grease 1. Insert spacer (D), small end facing, into backside to the seal lip before mounting to spindle. of hub.
Page 153 FINAL DRIVE 3. Install spindle nut and tighten to specification. 9. Install wheel and wheel nuts and tighten evenly in a crossing pattern to specified torque. 2 x 4 Spindle Nut Torque: 40 ft. lbs. Flange Nuts: (55.0 Nm) Flat side against wheel 2 x 4 Wheel Nut Torque: 27 ft.
Page 154: Front Hub Exploded View
FINAL DRIVE FRONT HUB EXPLODED VIEW Strut Housing Spindle Brake Disc Wheel Stud Seal Bearing Wheel Nut 18 ft. lbs. (24.9 Nm) 27 ft. lbs. Use new bolts with pre-applied (37 Nm) locking agent. Cotter Pin Spacer Bearing Washer Hub Cap Spindle Nut 40 ft.
Page 155: Rear Axle Removal
FINAL DRIVE CONCENTRIC SWINGARM REAR AXLE REMOVAL 1. Securely support rear of machine with rear wheels off the floor. Remove rear wheels. 2. Removing the cotter pin, hub nut, and washer, Pull off the left side hub. 6. Loosen the hex screw (A) to loosen the axle nut. 3.
Page 156 FINAL DRIVE 11. Remove the O--rings from left side of the axle. Brake Disc 9. Remove the three bolts that secure the sprocket 12. Slide the axle out the right side of the axle guard (C) on the other side of the axle. housing.
Page 157 FINAL DRIVE should still be visible under the axle nut from an angle. Torque to 8- -10 ft.lbs. (11--14 Nm) 16--19 ft.lbs. NOTE: The chain maybe installed at this point or later in the procedure. 7. Torque the axle nut pinch bolt to 50 in.lbs. (6 Nm). 3.
Page 158: Rear Housing Removal
Rear Hub Nut 80 ft. lbs. (108 Nm) 15. Lubricate the axle housing through the grease fitting with Polaris All Season Grease (PN 2871423). 12. Apply Anti--Seize lube to the axle splines. Install the rear wheel hubs on both sides.
Page 159: Rear Housing Disassembly
FINAL DRIVE REAR HOUSING CONCENTRIC SWINGARM DISASSEMBLY/BEARING REAR HOUSING SERVICE INSTALLATION 1. Remove seals from housing. 1. Re--install the housing (A) into the swing arm mounts. Re--install the brake caliper mounting bracket (B) onto the housing. Seal Bearing Swing arm Seal Bearing Race 2.
Page 160 FINAL DRIVE CONCENTRIC SWINGARM REAR AXLE ASSY, EXPLODED VIEW 11 12 1 Ring, Retaining 1 Housing, Axle, Rear 1 Screw 1 Fitting, Lubrication 1 Nut, Axle 1 Link, Connector, 520 3 Nut, Nylok 1 Axle, Rear 1 Disc, Brake 1 Chain, 520 O-Ring 1 Hub, Brake Disc 6 Nut, Nylok 3 Screw...
Page 161 TRANSMISSION Special Tools ......Torque Specifications ..... Transmission Remove/Install .
Page 162: Special Tools
TRANSMISSION SPECIAL TOOLS 6. Disconnect harness from gear position switch. 7. Remove drive chain and sprocket. PART NUMBER TOOL 8. Remove mounting bolts and brackets as shown. DESCRIPTION 9. Remove through-bolt from bottom 2871710 10” Center transmission. Distance Tool 10. Remove transmission from right side of frame. TRANSMISSION TORQUE SPECIFICATIONS INSTALLATION...
Page 163 TRANSMISSION 9. Inspect shift fork surface for wear or damage. Replace if necessary. 7. Using a wrench on the nut of the bellcrank, turn in a clockwise direction to assist with removal of 10. Remove shift fork guide pin. shift assembly and drive gear. 11.
Page 164 TRANSMISSION 15. Remove input shaft bearing. 13. Remove snap ring and washer. Pull down and rotate shift fork shaft back and forth to remove. 16. Inspect gears for galling and wear on teeth and bearing surface. Replace if necessary. 14. Inspect shift fork shaft O-ring. Replace if necessary.
Page 165: Transmission Assembly
TRANSMISSION 18. Inspect gear bushing. Replace if half of teflon NOTE: Input gear cogs face inward on input shaft. surface is gone. Sprocket Dog Gear Input Shaft Thrust Washer Input Gear Bushing 19. Inspect output shaft gear, sprocket and bearing. Replace if necessary.
Page 166 TRANSMISSION 6. Insert fork guide pin. 11. Install transmission and add Polaris AGL 7. Prior to reinstalling the cover make sure the Gearcase Lubricant (PN 2873602) in the mating cover surfaces are clean and dry. Apply recommended amount. Refer to Maintenance Crankcase Sealant (PN 2871557) to mating Chapter 2.
Page 167: Troubleshooting
TRANSMISSION TROUBLESHOOTING Linkage rod adjustment and rod end positioning CHECKLIST *Worn, broken or damaged internal transmission components Check the following items when shifting difficulty is *NOTE: To determine if shifting difficulty or problem encountered. is caused by an internal transmission problem, isolate Idle speed adjustment the transmission by disconnecting linkage rods from transmission bellcranks.
Page 168 TRANSMISSION TRANSMISSION EXPLODED VIEW 2 3 4 9 10...
Page 169 BRAKES Special Tools/Specifications/Torques ... Hydraulic Brake System Overview ... . . Brake System Service Notes ....Brake Noise Troubleshooting .
Page 170 BRAKES SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2870975 Mity Vact Test Tool SPECIFICATIONS Front Brake Caliper Item Standard Service Limit .298 ± .0073″ (7.6mm ± .185 mm) Brake Pad Thickness .180″ (4.6mm) Brake Disc Thickness .150--.165” (3.81mm 4.191 mm) .140″ (3.556mm) Brake Disc Thickness Variance Between .002″...
Page 171: Hydraulic Brake System Operation
When servicing Polaris ATV brake systems use only Polaris DOT 4 Brake Fluid. WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid.
Page 172: Brake System Service Notes
NOTES cause if brake drag is evident. Make sure caliper moves freely on Polaris disc brake systems are light weight, low guide pins (where applicable). maintenance and perform well in the conditions ATVs Inspect caliper piston seals for routinely encounter.
Page 173: Brake Noise Troubleshooting
BRAKES BRAKE NOISE Noise is from other If noise does not source (chain, axle, change when brake is TROUBLESHOOTING hub, disc or wheel) applied check other sources. Inspect and Dirt or dust buildup on the brake pads and disc is the repair as necessary most common cause of brake noise (squeal caused Wrong pad for...
Page 174: Brake Bleeding / Fluid Change
NOTE: Do not remove brake lever when reservoir fluid level is low. This procedure should be used to change fluid or bleed brakes during regular maintenance. Polaris DOT 3 Brake Fluid 1. Clean reservoir cover thoroughly. 2. Remove screws, cover and diaphragm (C) from (PN 2870990) reservoir.
Page 175 Illustration 1. 12. Repeat Steps 7-10 for the remaining caliper(s). 7. Slowly pump brake lever (D) until pressure builds 13. Add Polaris Dot 4 Brake Fluid to MAX level inside and holds. reservoir. 8. While maintaining lever pressure, hold the banjo bolt (E) with the wrench and open the top bleeder screw (F).
Page 176: Master Cylinder Removal
BRAKES MASTER CYLINDER REMOVAL 1. Clean master cylinder and reservoir assembly. Make sure you have a clean work area to disassemble brake components. Cap is Even 5 in. lbs. (0.56 Nm) Torque Outer Nut First 2. Place a shop towel under brake line connection at master cylinder.
Page 177: Master Cylinder Installation
(21 Nm) assembly or master cylinder parts, use the correct parts. There are different brake master cylinders for the different Polaris ATV models. Refer to your parts manual or guide for the correct parts. The master Banjo Bolt cylinder is not serviceable and is replaced as a unit.
Page 178: Front Pad Removal
BRAKES FRONT PAD REMOVAL 5. Push mounting bracket inward and slip outer brake pad past edge. Remove inner pad. 1. Elevate and support front of machine. 6. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. CAUTION: Use care when supporting vehicle so that it does not tip or fall.
Page 179: Front Pad Installation
1/2 turn (counterclockwise). 1. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots. 6. Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap.
Page 180: Front Disc Inspection
BRAKES FRONT DISC INSPECTION FRONT BRAKE DISC REMOVAL / REPLACEMENT 1. Visually inspect the brake disc for nicks, scratches, or damage. NOTE: To reduce the possibility of warpage, try 2. Measure the disc thickness at eight different removing the brake disc mounting bolts before points around the pad contact surface using a applying heat to the bolts.
Page 181: Front Caliper Removal
BRAKES FRONT CALIPER REMOVAL 2. Push upper pad retainer pin inward and slip brake pads past edge. CAUTION: Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 1.
Page 182: Front Caliper Inspection
Front Caliper Piston Bore I.D. Std. 1.191-1.192″ (30.25-30.28 mm) Service Limit 1.193″ (30.30 mm) 2. Coat piston with clean Polaris DOT 3 Brake Fluid (C). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.
Page 183: Front Caliper Installation
BRAKES 3. Lubricate the mounting bracket pins with Polaris FRONT CALIPER Premium All Season Grease, and install the INSTALLATION rubber dust seal boots. 1. Install caliper on hub strut, and torque mounting bolts. 15 ft. lbs. (21 Nm) 18 ft. lbs.
Page 184 BRAKES FRONT BRAKE CALIPER EXPLODED VIEW APPLY POLARIS DOT 4 BRAKE FLUID TO COMPONENT APPLY POLARIS ALL PURPOSE GREASE 35--60 IN. LBS. (4--6.5 NM) 1. Caliper Mount 2. Brake Pads 3. Piston 4. Brake Caliper Body 5. Boot Seal 6. Pin Bushing Seal 7.
Page 185 BRAKES REAR BRAKE PAD REMOVAL 4. Remove the loose slide pin (A). The brake pad will now slide out. 1. Remove the snap ring (B) from the bottom slide pin (A). 5. Clean the caliper with brake cleaner or alcohol. 6.
Page 186: Brake Burnishing Procedure
BRAKES REAR BRAKE PAD 5. Install the snap ring. INSTALLATION 30--35 ft.lbs. (41--48 Nm) 1. Insert new brake pads into the caliper. NOTE: If pads are greasy, dirty, oily, or fluid soaked DO NOT use the pads, use only new clean pads. 6.
Page 187: Rear Caliper Removal/Inspection
BRAKES REAR CALIPER Caliper REMOVAL/INSPECTION 1. Clean caliper area before removal. 2. Remove hand brake (inner) and auxiliary brake (outer) lines. Place a container to catch brake fluid draining from brake lines. 5. Remove the anvil bolts and separate caliper halves and remove pistons with piston pliers.
Page 188: Rear Caliper Assembly
BRAKES 9. Inspect caliper piston bore for scratches, severe corrosion, or galling and replace if necessary. Inspect 16--18 ft.lbs. (22--25 Nm) Caliper Anvil Bolt Torque: 10. Inspect surface of caliper piston for nicks, scratches, or damage and replace if necessary. 16- -18 ft.
Page 189 BRAKES 4. Install caliper and tighten mounting bolts, then REAR BRAKE DISC torque mounting bolts to 18 ft.lbs (25 Nm). INSPECTION 1. Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. 2. Use a 0-1″ micrometer and measure disc 18 ft.lbs.
Page 190: Rear Caliper Exploded View
BRAKES REAR CALIPER EXPLODED VIEW APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT 1. Snap Ring 2. Outboard Anvil Body 3. Slide Pin Bushing 4. Brake Pad 5. Caliper Bracket 6. Dust Boot 7. Dust Boot 8. Pin Sleeve 9. Piston Ring 10.
Page 191 BRAKES AUXILIARY BRAKE Rear Brake Master Cylinder Removal / Install REMOVAL / INSTALL 1. If necessary, remove the rear brake line from the master cylinder. Use a suitable container to catch Brake Pedal Removal / Install the brake fluid. Dispose of brake fluid properly. 1.
Page 192: Troubleshooting
BRAKES REAR BRAKE CALIPER EXPLODED VIEW TROUBLESHOOTING Brakes Squeal S Dirty/contaminated friction pads S Improper alignment S Worn disc S Worn disc splines Poor Brake Performance S Air in system S Water in system (brake fluid contaminated) S Caliper/disc misaligned S Caliper dirty or damaged S Brake line damaged or lining ruptured S Worn disc and/or friction pads...
Page 193 ELECTRICAL Special Tools and Electrical Service Notes ..10.2 Timing Check Procedure ..... 10.2 Transmission Gear Position Switch Testing .
Page 194: Electrical Service Notes
ELECTRICAL SPECIAL TOOLS TIMING CHECK PROCEDURE PART NUMBER TOOL 1. The ignition timing check hole is in the starter DESCRIPTION recoil/magneto housing. Remove the check plug. PV- -43568 Fluket77 Digital NOTE: The ignition timing marks are stamped on the Multimeter outside of the flywheel.
Page 195: Gear Position Indicator
ELECTRICAL GEAR POSITION INDICATOR LIMITER SPECIFICATIONS SWITCH TEST NOTE: The part number is printed on some late model LR modules. Whenever possible, use part Switch Continuity Table number to identify the module. Modules may have same “LR” I.D. number, with different part numbers, terminals, and internal function.
Page 196 ELECTRICAL REVERSE LIMIT SYSTEM 10.4...
Page 197 ELECTRICAL REVERSE SPEED LIMIT SYSTEM APPLY PARKING BRAKE. START ENGINE. NO REVERSE SPEED LIMIT SHIFT TO REVERSE GEAR (LR44 Limit Module) TEST GEAR POSITION INDICA- REVERSE LAMP TOR SWITCH AND INDICATOR LAMP MEASURE DC VOLTS ON TEST WIRING GRY/OR WIRE. TO GROUND AT LR MODULE 12 VOLTS MEASURE AC VOLTS ON...
Page 198 PDM Control Circuit The Power Distribution Module (PDM) integrates Regulator these electronic features found on Polaris ATVs; The rectifier converts the the output of the 3--phase Rectifier/regulator, Solid- -state circuit breaker alternator (COIL 1,2,3) and applies it to the battery output, Starter Lockout output and Engine and the PDM loads.
Page 199 ELECTRICAL condition then the regulator will remain off, as the thermistor. A thermistor fault will cause the engine hot minimum battery requirement will not be met. The indicator and FAN output to activate. regulator will not turn on unless there exists battery voltage in excess of the minimum battery voltage Accessory Power: requirement.
Page 200 ELECTRICAL Connector 1 Signal Name Description Pin # IPS = Intelligent Power Switch J1--A STARTER Starter output provides ground path when active. J1--B BRAKE Brake input for starter lockout. Active high. J1--C PDM enable input. Connected to BAT_PROT via ignition and run switches.
Page 201 ELECTRICAL PDM SPECIFICATIONS Characteristic Parameter Unit Note Operating Temperature --40 to +55 Ambient temperatures at which module should remain within specified limits Storage Temperature --50 to +85 Ambient temperatures which should have no adverse ef- fects on module operation Characteristic UNIT Note Battery Voltage...
Page 202 ELECTRICAL Characteristic UNIT Note STARTER Output Current Current capability of the STARTER output TRANS Neutral Voltage BRAKE On Input Voltage Voltage on BRAKE input to activate the STARTER output REVERSE POLARITY PROTECTION Battery Reverse Current Max reverse leakage current when connected in reverse Reverse Bias Voltage --55...
Page 203: Fan Motor Current Draw
ELECTRICAL FAN MOTOR CURRENT DRAW THERMISTOR RESISTANCE VS. TEMPERATURE Resistance Hot Light Ammeter Temperature ON/OFF ON/OFF Connect ammeter leads ± 20% between exposed Orange/Black terminals at 77° F 100KΩ fan connection. (25° C) 240° F 3.5KΩ (116° C) 260° F 2.5KΩ...
Page 204: Etc Operation Test
ELECTRICAL ELECTRONIC THROTTLE CONTROL (ETC) SWITCH (COMPOSITE THROTTLE HOUSING) 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. The ETC switch is mounted independently of the throttle actuator lever inside the throttle block assembly.
Page 205 ELECTRICAL FLYWHEEL IDENTIFICATION Flywheel Identification Stamp Location The flywheel can be identified by the stamp mark in location A. Refer to “I.D.” location in chart below. Do not use the cast mark to determine flywheel application. Engine Application Type Cast Stamp Comment I.D.
Page 206 ELECTRICAL COMPONENTS OF ES32PF / 210 WATT ALTERNATOR Note: DC/CDI components are not compatible with any other type of ignition Ω Ignition Coil Refer To Wiring Diagrams For Meter Primary Specified Stator Coil Resistance .3 Ω Coil Lead Winding Ignition Kill Wire (Black) Resistor...
Page 207 ELECTRICAL IGNITION SYSTEM TESTING Whenever troubleshooting an electrical problem you should first check all terminal connections to be sure they are clean and tight. Also be sure that colors match when wires are connected. Use the following pages as a guide for troubleshooting.
Page 208 ELECTRICAL IGNITION SYSTEM CDI OUTPUT TEST USING TROUBLESHOOTING PEAK READING ADAPTOR Re-connect all CDI wires to stator wires. Disconnect No Spark, Weak or Intermittent Spark CDI module wire from ignition coil primary terminal. GNo 12 volt power or ground to CDI Connect one meter lead to engine ground and the GSpark plug gap incorrect other to the ignition coil primary wire leading from the...
Page 209 ELECTRICAL CHARGING SYSTEM TESTING Whenever charging system problems are suspected, proceed with the following system checks: Using a multitester set on D.C. volts, mea- sure the battery open circuit voltage (see Remove the battery and properly ser- procedure later in chapter). It should be vice.
Page 210: Alternator Output Test
ELECTRICAL CURRENT DRAW - KEY OFF GWith engine off and the key and kill switch in the ON position, the ammeter should read negative amps (battery discharge). Reverse CAUTION: Do not connect or disconnect the battery meter leads if a positive reading is indicated. cable or ammeter with the engine running.
Page 211: Battery Identification
ELECTRICAL BATTERY IDENTIFICATION SEALED LOW MAINTENANCE BATTERY NOTICE: It is important to identify what type of battery you have installed in your ATV. Different types of batteries require different service procedures. NOTE: All Low Maintenance batteries are fully Proper servicing and upkeep of your battery is very charged and tested at the factory before important for maintaining long battery life.
Page 212: Battery Charging
ELECTRICAL 9917987) for proper instruction on servicing Low SEALED LOW MAINTENANCE Maintenance batteries. BATTERY INSPECTION/ NEVER attempt to add electrolyte or water to a Low REMOVAL Maintenance battery. Doing so will damage the case and shorten the life of the battery. Refer to the Battery Maintenance Video (PN 9917987) for proper The battery is located under the seat and right rear instruction...
Page 213: Battery Testing
ELECTRICAL 3. Reinstall battery, attaching positive (+) (red) cable SEALED LOW MAINTENANCE first and then the negative (-) (black) cable. Coat BATTERY LOAD TEST terminals and bolt threads with Nyogelt Grease (PN 2871329). CAUTION: To prevent shock or component 4. Reinstall the holder strap. damage, remove spark plug high tension leads and connect securely to engine ground before SEALED LOW MAINTENANCE...
Page 214 ELECTRICAL NOTE: Stored batteries lose their charge at the rate Conventional Lead--Acid batteries and Sealed Low of up to 1% per day. Recharge to full capacity every Maintenance batteries. Before service, identify the 30 to 60 days during a non-use period. If the battery battery type in the vehicle.
Page 215: Conventional Battery Installation
4. Remove the filler caps and add distilled water only as needed to bring each cell to the proper TERMINALS/TERMINAL BOLTS level. Do not overfill the battery. Use Polaris corrosion resistant Nyogelt grease (PN Refill using only distilled water. Tap water 2871329) on battery bolts. See Battery Installation.
Page 216: Conventional Battery Specific Gravity Test
ELECTRICAL CONVENTIONAL BATTERY OPEN CIRCUIT VOLTAGE OCV - OPEN CIRCUIT State of Conventional charge Lead-acid VOLTAGE TEST 100% 12.60V Charged 12.40V Battery voltage should be checked with a digital 75% Charged 12.10V multitester. Readings of 12.6 volts or less require 50% Charged 11.90V further battery testing and charging.
Page 217 ELECTRICAL CONVENTIONAL BATTERY CONVENTIONAL BATTERY OFF SEASON STORAGE CHARGING PROCEDURE To prevent battery damage during extended periods 1. Remove the battery from the ATV to prevent of non-use, the following basic battery maintenance damage from leaking or spilled acid during items must be performed: charging.
Page 218: Headlight Adjustment
ELECTRICAL HEADLIGHT ADJUSTMENT 1. With the headlight assembly in place, unsnap the electrical harness from the back the headlight assembly. The headlight beam can be adjusted up and down and side to side. 2. Turn and pull out the connector on the back of the headlight assembly.
Page 219: Brake Light Switch
ELECTRICAL 2. Disconnect indicator light panel from harness, by NEUTRAL LIGHT CIRCUIT lifting the retaining latch from the wire connector. OPERATION NOTE: The indicator panel (C) does not have to be remove from the pod to replace an indicator light. Power is supplied to the transmission switch from the Red/White wire when the key and engine stop switch 3.
Page 220 ELECTRICAL STARTER SYSTEM TESTING Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test. With the tester on the VDC position, place the tes- ter’s black lead on the battery negative and the red Remove battery and properly service.
Page 221: Voltage Drop Test
ELECTRICAL STARTER SYSTEM VOLTAGE DROP TEST TROUBLESHOOTING The Voltage Drop Test is used to test for bad connections. When performing the test, you are Starter Motor Does Not Turn testing the amount of voltage drop through the connection. A poor or corroded connection will GBattery discharged - low specific gravity appear as a high voltage reading.
Page 222: Starter Motor Disassembly
ELECTRICAL STARTER MOTOR DISASSEMBLY NOTE: Use electrical contact cleaner to clean starter motor parts. Some solvents may leave a residue or damage internal parts and insulation. 3. Remove brush terminal end of housing while holding other two sections together. 1. Note the alignment marks on both ends of the starter motor casing.
Page 223 ELECTRICAL BRUSH 4. Inspect surface of commutator for wear or discoloration. See Steps 3-6 of armature testing INSPECTION/REPLACEMENT on Page 10.32. 5. Install a new carbon brush assembly in the brush housing. NOTE: Be sure that the terminal bolt insulating washer is properly seated in the Brush Set housing, and the tab on the brush plate engages the notch in the brush plate housing.
Page 224: Armature Testing
ELECTRICAL ARMATURE TESTING STARTER ASSEMBLY 1. Remove armature from starter casing. Note order of shims on drive end for reassembly. 2. Inspect surface of commutator. Replace if excessively worn or damaged. 1. Place armature in field magnet casing. 2. Place shims on drive end of armature shaft with phenolic washer outermost on shaft.
Page 225: Starter Drive
Pinion Gear - Anti Kick-out Shoe, Garter Spring Replacement If the garter spring is damaged, the overrun clutch Polaris Premium Starter Drive Grease may fail to return properly. The replacement spring is (PN 2871460) (PN 7042039). Use either of the following methods to remove and install a new garter spring.
Page 226 ELECTRICAL NOTES 10.34...
Page 227 ELECTRICAL WIRING DIAGRAM 2009 TRAIL BOSS...
Page 228 ELECTRICAL WIRING DIAGRAM 2009 TRAIL BOSS...
Page 229 ELECTRICAL WIRING DIAGRAM 2009 TRAIL BLAZER...
Page 230 ELECTRICAL WIRING DIAGRAM 2009 TRAIL BLAZER...

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2009 trail blazer 330

Polaris 2009 Trail Boss 330 Service Manual

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