Polaris A09BG50AA Manuals

Manuals and User Guides for Polaris A09BG50AA. We have 1 Polaris A09BG50AA manual available for free PDF download: User Manual

Polaris A09BG50AA User Manual

Polaris A09BG50AA User Manual (256 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 5.67 MB

Table of Contents

Table of Contents

1
- Model Identification
  2
- Engine Serial Number Location
  2
- General Information
  2
- Replacement Keys
  3
- Publication Numbers
  3
- Paint Codes
  3
- Standard Torque Specifications
  6
  - Conversion Table
    8
- Glossary of Terms
  9
Table of Contents

11
- Periodic Maintenance Chart
  12
  - Maintenance and Lubrication
    13
- Pre-Ride Inspection
  17
- Front Gearcase Lubrication
  21
- Lubrication Charts
  21
- Transmission Lubrication 4X4
  22
- Throttle Operation / Choke Adjustment
  24
  - Pilot Screw Adjustment
    25
  - Idle Speed Adjustment
    25
- Fuel System
  27
  - Fuel Lines
    27
  - Vent Lines
    28
  - Fuel Filter
    28
  - Carburetor Draining
    28
- Battery Maintenance
  29
  - Engine Mounts
    29
  - Spark Plug
    31
  - Ignition Timing
    32
  - Liquid Cooling System Overview
    32
  - Cooling System Hoses
    32
  - Cooling System Pressure Test
    33
  - Radiator Coolant Level Inspection
    33
- Compression Test
  29
- Air Box Sediment Tube Service
  35
- Breather Filter
  35
  - Breather Hose
    36
- Recoil Housing
  36
  - Engine Oil Level
    36
- Oil Change/Filter
  37
- Valve Clearance
  39
  - Exhaust Valve Clearance Adjustment
    40
  - Camber and Caster
    41
  - Exhaust Pipe
    43
  - Brake Pad Inspection
    44
  - Brake System Inspection
    44
  - Rear Axle
    47
  - Suspension Spring Preload Adjustment
    48
  - Front Suspension
    48
  - Rear Suspension
    48
  - CV Shaft Boot Inspection
    49
  - Wheel Removal Front or Rear
    49
- Tire Inspection
  50
  - Piston Identification
    55
  - Engine Fastener Torque Patterns
    55
  - Cooling System
    55
  - Cooling System Specifications
    57
  - Honing to Oversize
    59
  - Cleaning the Cylinder after Honing
    59
  - Crankshaft Straightening
    60
  - Eh50Pl Oil Flow Diagram
    62
  - Engine Disassembly
    64
  - Cam Chain Tensioner Inspection
    65
  - Camshaft Removal
    66
  - Camshaft Inspection
    68
  - Automatic Compression Release Installation
    68
  - Cylinder Head Removal
    69
  - Cylinder Head Inspection
    71
  - Cylinder Head Disassembly
    71
  - Cylinder Head Warpage
    71
  - Valve Inspection
    72
  - Combustion Chamber
    73
  - Valve Seat Reconditioning
    73
  - Cylinder Head Assembly
    76
  - Valve Sealing Test
    76
  - Piston Removal
    78
  - Cylinder Inspection
    79
  - Piston Ring Installed Gap
    81
  - Crankcase Disassembly
    81
  - Crankcase Separation
    83
  - Oil Pump Assembly
    85
  - Bearing Installation
    88
  - Crankshaft End Play Adjustment
    88
  - Oil Pump Shaft End Play Adjustment
    90
  - Pump Shaft Oil Seal Installation
    91
  - Crankcase Assembly
    91
  - Water Pump Mechanical Seal Installation
    92
  - Piston Ring Installation
    94
  - Piston Installation
    94
  - Cylinder Installation
    95
  - Cylinder Head Installation
    96
  - Cam Chain Tensioner Installation
    99
  - Thermostat Installation
    100
  - Oil Pipes
    101
  - Recoil Assembly
    102
- Wheel Removal / Installation
  50
  - Tire Pressure
    50
Table of Contents

105
- Fuel Flow Diagram
  107
  - Jetting Guidelines
    108
- Carburetor Jetting
  109
  - Mikuni Jet Part Numbers
    109
- Assembly, CV Carburetor
  110
  - Mikuni CV Carb Operation
    110
  - Float System
    112
  - Main System
    112
  - Carburetor Cleaning
    113
  - Carburetor Inspection
    114
  - Carburetor Assembly
    114
- CV Carburetor System Function (4 Cycle)
  110
- Fuel Level
  116
- Needle and Seat Leakage Test
  116
- Pilot Screw
  116
- Fuel Pump Service
  117
  - Fuel Pump Disassembly
    117
- Troubleshooting
  119
Fuel System/Carburetion Notes

121
- Body Assembly Exploded View
  123
- Steering Assembly, Exploded View
  124
- A-Arm Replacement
  125
- Concentric Swing Arm Removal
  126
- Concentric Swing Arm Assembly/Installation
  127
- Decal Replacement
  132
- Steering Post Assembly
  132
Table of Contents

133
- Drive Clutch Operation
  134
- Driven Clutch Operation
  134
- Pvt System Fastener Torques
  134
- Special Tools and Supplies
  134
- PVT Maintenance/Inspection
  135
  - Pvt Drying
    135
- PVT Disassembly
  137
- PVT Assembly
  138
- Drive Clutch Exploded View
  139
- PVT Sealing and Ducting Components
  139
- Drive Clutch Spring Specifications
  140
- Shift Weights
  141
  - Shift Weight Inspection
    142
  - Button to Tower Clearance Inspection
    142
- Drive Clutch Disassembly/Inspection
  143
  - Spider Removal
    143
- Drive Clutch Assembly
  144
- Drive Belt Tension
  145
- Drive Belt Removal/Inspection
  146
- Clutch Alignment /Offset
  147
  - Clutch Offset
    148
- Drive Belt Installation
  147
- Drive Clutch Bushing Service
  148
- Driven Clutch Disassembly/Inspection
  151
- Driven Clutch Assembly
  153
- Troubleshooting
  157
Table of Contents

159
- AWD Front Hub Exploded View
  160
- Final Drive
  160
- AWD Operation Overview
  161
- AWD Front Hub Bearing Adjustment
  163
- AWD Hub Seal Replacement
  164
- AWD Armature Plate Inspection
  166
- AWD Front Drive Axle Removal
  167
- AWD Front Drive Axle Installation
  168
- AWD Front Drive Axle Exploded View
  171
- AWD Front Prop Shaft Removal
  173
- U-Joint Assembly
  174
- U-Joint Disassembly
  174
- AWD Front Housing Removal
  175
- AWD Front Housing Assembly
  176
- AWD Front Housing Exploded View
  178
- Rear Axle Removal
  179
Table of Contents

185
- Torque Specifications
  186
- Transmission Removal / Installation
  186
- Transmission Disassembly
  187
- Transmission Reassembly
  190
- Troubleshooting
  192
  - Troubleshooting Checklist
    192
Table of Contents

193
- Hydraulic Brake System Operation
  195
- Brake Noise Troubleshooting
  196
- Brake System Main Components
  196
- Brake System Service Notes
  196
- Brake Bleeding / Fluid Change
  197
- Hydraulic Caliper Bleeding
  197
- Master Cylinder Installation
  200
- Master Cylinder Removal
  200
- Front Pad Removal
  201
- Front Pad Installation
  202
- Brake Burnishing
  203
- Front Disc Inspection
  203
- Front Caliper Disassembly
  204
- Front Caliper Removal
  204
- Front Caliper Inspection
  205
- Front Caliper Reassembly
  205
- Front Caliper Installation
  206
- Rear Caliper Removal/Inspection
  210
- Rear Caliper Assembly
  211
- Rear Caliper Exploded View
  213
- Troubleshooting
  215
  - Electrical Service Notes
    219
  - Fan Motor Current Draw
    226
  - Etc Operation Test
    227
  - Alternator Output Test
    238
  - Battery Testing
    241
  - Conventional Battery Installation
    243
  - Conventional Battery Testing
    244
  - Conventional Battery Specific Gravity Test
    244
  - Headlight Adjustment
    246
  - Brake Light Switch
    247
  - Indicator Lamp Replacement
    247
  - Headlamp Switch
    247
  - Starter System
    248
  - Voltage Drop Test
    249
  - Starter Motor Disassembly
    250
  - Armature Testing
    252
  - Starter Drive
    253

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