Polaris Sportsma Manuals

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

Polaris Sportsma Service Manual (505 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 47 MB

Table of Contents
1
Quick Reference Data
5
Tire Inflation Pressure
5
Recommended Lubricants, Fluids and Capacities
5
Recommended Capacities
5
Maintenance and Tune-Up Torque Specifications
6
Maintenance and Tune-Up Specifications
6
Replacement Bulbs
6
General Information
7
Manual Organization
7
Chapter One
7
Notes, Cautions and Warnings
8
Safety First
8
Cleaning Parts
9
Handling Gasoline Safely
9
Service Hints
10
Torque Specifications
12
Fas Teners
12
ISO Metric Screw Threads
13
Machine Screws
13
Nuts
13
Self-Locking Fasteners
14
Washers
14
Cotter Pins
14
Circlips
14
Lubricants
15
Engine Oil
15
Threadlocking Compound
16
RTV Gasket Sealant
16
Expendable Supplies
16
Grease
16
Serial Numbers
17
Warning and Information Labels
18
Basic Hand Tools
18
Screwdrivers
18
Pliers
18
Locking Pliers
19
Circlip Pliers
19
Box, Open-End and Combination Wrenches
19
Adjustable Wrenches
19
Socket Wrenches
20
Allen Wrenches
20
Torque Wrench
20
Impact Driver
20
Precision Measuring Tools
21
Feeler Gauge
21
Vernier Caliper, Dial Caliper and Digital Electronic Caliper
21
Outside Micrometers
21
Micrometer Range
22
How to Read a Micrometer
22
Standard Inch Micrometer
22
Decimal Place Values
23
Vernier Inch Micrometer
24
Standard Metric Micrometer
25
Micrometer Accuracy Check
26
Proper Care of a Micrometer
28
Cylinder Bore Gauge
28
Small Hole Gauges
28
Telescoping Gauges
29
Multimeter
29
Voltage
29
Resistance
30
To Calibrate an Analog Ohmmeter
30
Continuity Test
30
Amperage
30
Special Tools
31
Fabricating Tools
31
Mechanic's Tips
31
Removing Frozen Nuts and Screws
31
Bearing Replacement
32
Bearing Removal
32
Removing Broken Screws and Bolts
32
Bearing Installation
34
Shrink Fit
34
Seals
35
Storage
36
Selecting a Storage Area
36
Preparing Vehicle for Storage
36
After Storage
37
Model Year and Number
37
General Dimensions
38
Vehicle Weight (DRY)
38
Decimal and Metric Equivalents
38
General Torque Specifications
39
Conversoin Tables
39
Technical Abbreviations
40
Metric Tap and Drill Sizes
41
Troubleshooting
42
Operating Requirements
42
Chapter Two
42
Troubleshooting Instruments
43
Starting the Engine
43
Starting a Cold Engine
43
Starting Difficulties
44
Starting a Warm or Hot Engine
44
Starting a Flooded Engine
44
Engine Fails to Start (Spark Test)
45
Engine Is Difficult to Start
46
Engine Starting System
47
Engine Compression
47
Poor Idle Speed Performance
47
Poor Medium - and High-Speed Performance
47
Charging System
48
Starter Troubleshooting
48
Ignition System
49
Ignition System Precautions
49
Switch Test
49
Ignition Coil Test
49
Ignition System
50
Electronic Throttle Control Switch Testing
51
Fuel System
52
Engine Overheating
52
Engine Preignition
52
Engine Detonation
52
Engine Noises
53
Cylinder Leakdown Test
53
Power Loss
53
Piston Seizure
53
Power Train
54
Low Engine Operating Speed
54
Engine Operating Speed too High
54
Engine Speed Erratic During Speed or Load Changes
54
Steering
55
Drive Belt Not Operating Smoothly in Primary Sheave
55
Glazed Drive Belt
55
Erratic Shifting
55
Disc Brake Troubleshooting
56
Frame Noise
57
Brakes
57
Generally Poor or Unpredictable Handling
57
Loose Steering
57
Electrical Specifications
58
Lubrication, Maintenance and Tune-Up
59
Pre-Ride Checklist
59
Tires and Wheels
61
Tire Pressure
61
Tire Inspection
61
Battery
62
Rim Inspection
62
Safety Precautions
62
Electrolyte Level Check
63
Battery Removal/Installation
63
Cleaning, Inspection and Adding Water
64
Battery Testing
65
Charging
66
New Battery Installation
66
Battery Electrical Cable Connectors
67
Periodic Lubrication
67
Engine Oil Level Check
67
Engine Oil and Filter Change
68
Engine Oil Pressure Test
70
Transmission Oil Level Check
71
Transmission Oil Change
71
Front Gearcase Oil Level Check
72
Front Gearcase Oil Change
72
Grease Service
73
Front Hub Oil Level Check
74
Front Hub Oil Change
74
Periodic Maintenance
76
Control Cable Lubrication
76
Drive Belt Inspection
76
Disc Brake System Inspection
76
Disc Brake Fluid Level Check and Fill
77
Disc Brake Hoses
77
Auxiliary Brake Testing and Adjustment
78
Throttle Cable/Electronic Throttle Control Adjustment
78
Throttle Cable Adjustment
79
Air Filter Element
80
Coolant Inspection
81
Coolant Change
82
Exhaust System
84
Fuel Hose Inspection
85
Fuel Filter Replacement
85
Steering System and Front Suspension Inspection
85
Front Wheel Toe-Out
86
Front Hub Wheel Bearings
87
Rear Suspension
87
Nuts, Bolts and Other Fasteners
87
Wire Harness, Control Cables and Hose Lines
87
Unscheduled Inspection and Maintenance
88
Recoil Starter
88
Body Fasteners
88
Fuel Tank and Lines
88
Valve Clearance Measurement
89
Valve Clearance Adjustment
90
Cam Chain Adjustment
91
Spark Plug Heat Range
91
Spark Plug Removal
91
Gapping and Installing the Spark Plug
92
Reading Spark Plugs
92
Normal Condition
93
Carbon-Fouled
93
Oil-Fouled
93
Gap Bridging
93
Spark Plug Condition
94
Worn out
95
Preignition
95
Checking Ignition Timing
95
Adjusting Ignition Timing
95
Carburetor Idle Mixture Adjustment
96
Idle Speed
97
Maintenance and Lubrication Schedule
97
Recommended Lubricants and Fluids
98
Capacities
99
Engine Top End
100
Engine Principles
100
Engine Cooling
100
Four-Stroke Operating Principles
101
Engine Lubrication
102
Servicing the Engine in the Frame
102
Cylinder Head Cover
105
Rocker Arm Assembly
105
Rocker Arm
107
Camshaft Removal
109
Camshaft Inspection
110
Automatic Compression Release Mechanism Testing
112
Camshaft Installation
113
Cylinder Head Removal
116
Cylinder Head Inspection
117
Cylinder Head Installation
118
Valves and Valve Components
119
Solvent Test
120
Valve Removal
120
Valve Inspection
121
Valve Troubleshooting
122
Valve Installation
123
Valve Guide Replacement
124
Valve Lapping
124
Cylinder Block Removal
125
Cylinder Block Inspection
126
Cylinder Block Installation
128
Spec Ial Tools
128
Piston and Piston Rings
130
Piston Removal
130
Piston Inspection
131
Piston Pin Inspection
133
Piston Clearance
133
Piston Installation
134
Piston Ring Inspection and Removal
134
Piston Ring Installation
136
Camshaft Chain and Sprockets Removal
137
Camshaft Chain and Sprockets Inspection
138
Camshaft Chain and Sprockets Installation
139
Camshaft Chain Wear
139
Break-In Procedure
140
General Engine Specifications
140
Engine Lubrication System
140
Engine Top End Tightening Torque Specifications
141
Engine Top End Specifications
141
Engine Lower End
143
Engine
143
Engine Removal
144
Flywheel and Stator Plate Removal
147
Flywheel and Stator Plate Installation
149
Recoil Starter Removal/Installation
150
Recoil Starter Disassembly and Starter Rope Removal
150
Recoil Starter Inspection and Assembly
150
Crankcase
152
Crankcase Separation
153
Crankcase Inspection
156
Crankshaft Seal Replacement
156
Crankcase Bearing Replacement
157
Seals
157
Water Pump Mechanical Seal and Bearing Replacement
161
Crankcase Assembly
162
Crankshaft Inspection
168
Crankshaft and Balancer
169
Balancer Shaft Inspection
169
Shaft End Float Measurement and Shim Selection
169
Crankshaft End Play
171
Balancer Shaft End Play
172
Oil Pump Removal/Disassembly
174
Oil Pump Inspection
174
Oil Pump Assembly/Installation
177
Oil System One-Way Check Valve
178
Oil System One-Way Check Valve Break-In Procedure
179
Engine Lower End Torque Specifications
180
Engine Lower End Specifications
180
Carburetor Operation
181
Carburetor Removal/Installation
182
Carburetor Disassembly
183
Mikuni Carburetor 34 MM
184
Carburetor Cleaning and Inspection
189
Carburetor Tests and Adjustments
192
Inlet Valve Seat Inspection
192
Float Level Height Adjustment
192
Jet Needle Adjustment
193
Main Jet Replacement
193
Throttle Cable Replacement
194
Starting Enrichment (Choke) Cable Removal/Installation
194
Fuel Tank Removal/Installation
196
Fuel Shutoff Valve
197
Air Filter Air Box Removal/Installation
198
Fuel Pump Testing
198
Fuel Pump Removal/Installation
202
Fuel Pump Disassembly/Assembly
203
Carburetor Specifications
203
Cooling Systems
204
Polaris Variable Transmission (PVT) Air Cooling System
204
PVT Cooling System
205
Clutch Outer and Inner Cover Ducting
205
Clutch Outer Cover Removal/Installation
205
Clutch Inner Cover Removal/Installation
206
Engine Cooling System
208
Liquid Cooling System (Typical)
209
Hoses and Hose Clamps
210
Engine Gaskets/Seals
210
Radiator Assembly
211
Cooling System Inspection
211
Radiator Removal/Installation
211
Radiator Inspection
214
Cooling Fan Removal/Installation
215
Thermostat Removal/Installation
217
Temperature Sensors
218
Cooling System Specifications
218
Clutch/Drive Belt System
219
Drive Unit
219
Drive Pulley
221
Fixed and Sliding Pulley Halves
221
Drive Pulley Spring
221
Eng Ine no Ises
221
Driven Pulley
222
Centrifugal Weight Levers
222
Release Spring
222
Power Tra in
222
Drive Belt
224
Torque Sensing Cam Angle
224
Drive Belt Deflection
226
Pulley Center-To-Center Distance
227
Drive Belt Alignment
227
Pulley Alignment
228
Pulley Offset
228
Drive Pulley Removal
230
Drive Pulley Bolt Inspection
241
Clutch Outer and Iinner Cover
252
Drive Belt and Pulley Specifications
253
Drive Pulley Spring Specifications
254
Shift Weights and Driven Pulley Specifications
254
Tightening Torque Specifications
254
Transmission
255
Transmission Service Notes
255
Transmission Removal/Installation
256
Transmission Case Disassembly
258
Transmission Case
259
Transmission Case Assembly
265
Transmission Shafts Disassembly
273
Transmission Shafts Assembly
273
Transmission Inspection
276
Gear Shafts and Shift Forks
277
Shift Shafts Removal/Inspection/Installation
280
Front Output Shaft
281
Output Shaft End Play Inspection and Adjustment
285
Output Shaft Gear Backlash Inspection and Adjustment
286
Transmission Gearcase Oil Seal Inspection and Replacement
287
Shift Selector Linkage
287
Checking and Preliminary Adjustment
287
Shift Selector Removal/Installation
289
Boot Replacement
290
Gearshift Selector
290
Transmission and Shift Linkage Torque Specifications
295
Transmission Specifications
295
Front Drive System
296
Front Hub and Hillard Clutch
296
Front Electric Hub Clutch
299
Hillard Clutch Testing
300
Front Hub Seal Replacement
302
Front Drive Axle, Boots and CV (Constant Velocity) Joints
304
Front Drive Shaft Removal/Installation
307
Front Drive Unit Removal/Installation
307
Tire Size and Inflation Pressure
308
Front Wheel Drive Hub Specifications
308
Electrical System
309
Basic Information
309
Electrical Component Resistance Testing
309
Negative Battery Terminal
310
Electrical Component Replacement
310
Electrical Connector Location
310
Charging System Output Test
310
Charging System Amperage Test
314
Alternator Stator
315
Exciter Coils Testing
315
Battery Charge Coils Testing
315
Alternator Output Test
315
Voltage Regulator/Rectifier
316
Capacitor Discharge Ignition
316
CDI Precautions
316
CDI Unit Replacement
316
Ignition Coil
320
Performance Test
320
Ignition Stator Coils
321
Electric Starting System
321
Starter Drive Gears
330
Starter Solenoid
330
Starter Solenoid Resistance Test
330
Lighting System
331
High-Beam Headlight
331
Bulb Replacement
331
Headlight and Pod
332
High-Beam Headlight Adjustment
334
High-Beam Headlight Case Removal/Installation
334
Grille-Mounted Low-Beam Headlight Bulb Replacement
334
Taillight/Brake Light Bulb and Lens Replacement
335
Indicator Lamp Replacement
335
Electrical Components
336
Speedometer Removal/Installation
336
Speed Sensor Removal/Installation
336
Switches
337
Testing
337
Right Handlebar Switch Housing Replacement
338
Left Handlebar Switch Housing Replacement
339
Key Switch or Ignition Switch Replacement
340
Transmission Switch
340
Wiring Diagrams
341
Electrical System Specifications
341
Front Suspension and Steering
343
Front Wheel Removal/Installation
343
Front Hub
344
Front Strut Cartridge and Spring
344
Front Strut/Spindle Removal/Installation
350
Ball Joint Inspection/Replacement
352
Control Arm
353
Handlebar Removal
355
Handlebar Installation
356
Tie Rods Removal
357
Steering Shaft Removal/Installation
362
Tire Changing
363
Rear Wheels Removal/Installation
368
Tire Changing and Tire Repairs
369
Shock Absorber
369
Shock Inspection
370
Spring Removal/Installation
370
Rear Hub and Bearing Carrier
371
Rear Axle Bearing Carrier Bearing Replacement
376
Rear Axles
377
Upper Control Arm
381
Lower Control Arm
381
Upper and Lower Control Arm Inspection
383
Stabilizer Linkage
384
Stabilizer Support
385
Rear Suspension Specifications
387
Rear Suspension Torque Specifications
387
Disc Brakes
388
Brake Service
388
Front Brake Pad Replacement
389
Front Brake Caliper
390
Front Caliper Removal/Installation
393
Front Caliper Disassembly
394
Output Shaft Brake Caliper
400
Output Shaft Brake Pad Replacement
403
Front Master Cylinder Removal/Installation
410
Front Caliper Brake Hoses
420
Output Shaft Caliper Brake Hoses
420
Rear Brake Pedal
421
Rear Brake Lever
423
Foot Brake
423
Bleeding the System
426
Brake Bleeder Process
426
Without a Brake Bleeder
428

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Polaris Sportsma Service Manual (505 pages)

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