Polaris 6X6 Manuals

Manuals and User Guides for Polaris 6X6. We have 5 Polaris 6X6 manuals available for free PDF download: Service Manual, Manual, Owner's Manual For Maintenance And Safety, Owner's Manual

Polaris 6X6 Service Manual (666 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 15.13 MB

Table of Contents
2
General Information / Specifications
2
Chapter 1 General Information / Specifications

4
- Engine Serial Number Location
  4
- Machine Model Number and VIN Number Location
  4
- Model / VIN Identification
  4
- 1999 Publication Part Numbers
  6
- Standard Torque Specifications
  8
- Conversion Table
  10
  - Metric Tap Drill Sizes
    11
  - SAE Tap Drill Sizes
    11
- Tap Drill Charts
  11
- Service Tips
  12
- Glossary of Terms
  13
- Glossary of Terms
  14
- Special Tools
  16
- 1999 Model Specifications
  17
  - Trail Blazer
    17
  - Trail Boss 250
    19
  - Xpress 300
    21
  - Xplorer 300
    23
  - Sportsman 335
    25
  - Sport 400
    28
  - Scrambler 400
    29
  - Scrambler 500
    30
  - Magnum 500
    36
- 1999 Model Specifications
  36
  - Trail Blazer
    41
  - Xplorer 4X4
    43
  - Trail Boss 325
    45
  - Xpedition 325
    51
  - Sportsman 335
    53
  - Xplorer 400
    55
  - Scrambler 400 2X4
    57
  - Scrambler 400 4X4
    59
  - Xpedition 425
    61
  - Magnum 500
    63
  - Scrambler 500
    65
  - Sportsman 6X6
    69
  - Maintenance
    72
Chapter 2 Maintenance

74
- Periodic Maintenance Chart
  74
  - Pre-Ride / Daily Inspection
    75
  - Recommended Lubricants - Quick Reference
    76
  - Polaris Premium Lubricant and Maintenance Product Part Numbers
    77
  - Lubrication
    79
  - Lubrication - Shaft Drive Models
    81
  - Lubrication Chart - Shaft Drive Models
    82
  - Gearcase Lubrication - Quick Reference
    83
  - Front Gearcase Lubrication
    84
  - Rear Gearcase Lubrication
    86
    
    Dipstick Models
    87
    
    Transmission Lubrication
    87
    
    Shaft / Chain Models Without Dipstick
    88
    
    Counter Balance Oil Changing Procedure
    89
    
    Counter Balancer Lubrication (400Cc Engines)
    89
    
    Procedure for Adding Oil (400)
    89
    
    Torque Stop Adjustment
    90
    
    Transmission Gearshift Linkage Adjustment, Preliminary Inspection
    90
    
    Shift Linkage Adjustment -High/Low/Reverse Transmissions
    91
    
    Shift Linkage Adjustment (High/Reverse Transmissions)
    93
  - Carburetor Adjustments
    94
    
    Choke (Enricher) Adjustment
    94
    
    Throttle Operation - All Models
    94
    
    Air Screw Adjustment
    95
    
    Pilot Screw Anti-Tamper Plug Removal
    96
    
    Pilot Screw (Idle Mixture) Adjustment Notes
    97
    
    Pilot Screw Adjustment - 335 4- -Stroke Models
    97
    
    Pilot Screw Adjustment - 425 / 500 4- -Stroke Models
    97
    
    Idle Speed Adjustment
    98
    
    Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment
    99
    
    Oil Pump Adjustment Procedure
    100
    
    Oil Pump Bleeding Procedure
    102
    
    Oil Pump Troubleshooting Procedure
    102
    
    Oil Filter (2 Strokes)
    103
    
    Fuel Filter
    104
    
    Fuel Lines
    104
  - Fuel System
    104
    
    Vent Lines
    104
    
    Carburetor Draining
    105
    
    Compression Test - 2 Stroke
    106
    
    Compression Test - 4 Stroke
    106
    
    Engine Mounts
    106
    
    Fastener Torque - Engine
    106
  - Battery Maintenance
    107
  - Electrical
    107
  - Electrical
    108
    
    Engine-To-Frame Ground
    108
    
    Ignition Timing
    108
    
    Spark Plug
    108
    
    Coolant Strength / Type
    109
    
    Cooling System Hoses
    109
    
    Liquid Cooling System Overview
    109
    
    Radiator
    109
    
    Coolant Level Inspection
    110
    
    Engine Cooling System
    111
    
    Radiator Coolant Level Inspection
    111
    
    Air Filter Service (Trail Blazer Style)
    112
    
    Dual Stage Air Cleaner - 300 Style
    113
    
    Primary Pre-Cleaner Foam Boot
    113
    
    Cleaning the Main Filter
    114
    
    Secondary (Main) Filter
    114
    
    Secondary Filter Removal and Installation
    114
  - Air Filter Service, 2 Stroke
    116
  - Air Filter Service, 4 Stroke
    116
  - Breather Filter
    116
    
    Air Box Sediment Tube
    117
    
    Breather Filter Inspection
    118
    
    Breather Hose
    118
  - Recoil Housing
    119
    
    Engine Oil Level (4 Stroke)
    120
    
    Oil and Filter Change (4 Stroke)
    120
    
    Valve Clearance - 335, 425, 500Cc Engines
    122
    
    Exhaust Valve Clearance Adjustment
    123
    
    Intake Valve Clearance Adjustment
    123
    
    Steering & Toe Alignment Inspection
    125
    
    Tie Rod End / Steering Inspection
    125
    
    Straightedge or String
    126
    
    Chalk
    127
    
    Toe Alignment Adjustment
    127
    
    Front Hub Fluid Change (AWD Models)
    128
    
    Front Hub Fluid Level Inspection (AWD Models)
    128
    
    Exhaust Pipe
    129
    
    Brake Pad Inspection
    130
    
    Brake System Inspection
    130
  - Brake System Service
    130
    
    Hose/Fitting Inspection
    130
    
    Auxiliary Brake Adjustment (Hydraulic)
    131
    
    Auxiliary Brake Adjustment - Mechanical
    132
    
    Auxiliary Brake Testing
    132
    
    Auxiliary Mechanical Brake System
    132
    
    Drive Chain and Sprocket Inspection
    133
    
    Drive Chain Inspection
    133
    
    Sprocket Inspection
    133
    
    Rear Drive Chain Tension Adjustment - Standard Swingarm
    134
    
    Rear Drive Chain Tension Inspection - Standard Swingarm
    134
    
    Adjustment Procedure - Concentric Swingarm Rear Axles (Tapered Roller Bearings)
    135
    
    Drive Chain Adjustment, Concentric Swingarm
    135
    
    Center/Front Drive Chain Inspection/Adjustment
    138
    
    Center/Front Drive Chain Slack Adjustment
    138
    
    6X6 Chain Inspection
    139
    
    6X6 Middle Axle Chain Adjustment
    139
    
    6X6 Rear Axle Drive Chain Adjustment
    139
    
    Drive Chain Inspection/Adjustment - 6X6
    139
    
    Controls
    140
    
    Front Suspension
    140
    
    Rear Suspension
    140
    
    Suspension Spring Preload Adjustment
    140
    
    Chassis Maintenance
    141
    
    Wheel Removal Front or Rear
    141
    
    Wheel, Hub, and Spindle Torque Table
    141
    
    Wheels
    141
    
    Frame, Nuts, Bolts, Fasteners
    142
  - Tire Inspection
    142
  - Tire Pressure
    142
  - Tire Tread Depth
    142
  - Engine
    144
  - Torque Specifications
    146
  - Engine Fastener Torque Patterns
    148
  - Piston Clearance Specifications (2 Stroke Engines)
    149
  - Piston Identification
    149
  - ES33PFE01 / 02 Engine Service Data
    150
  - EH42PLE02 / EH50PLE04, 06, 08, 09 Engine Service Data
    152
  - Bleed Hole Inspection
    154
  - Radiator Cap Pressure Test
    154
  - System Pressure Test
    154
CHAPTER 3 ENGINE Torque Specifications - 2 Stroke

155
- Cooling System Specifications
  155
  - Recommended Coolant
    155
  - Accessible Components - All Models
    156
  - Engine Removal
    156
    
    Engine Removal
    157
    
    Bleed Cooling System
    158
  - Engine Installation Notes
    158
    
    General Items
    158
    
    PVT System
    158
    
    EC25PF / EC28PF Engine Disassembly
    159
    
    Connecting Rod Side Clearance
    160
    
    Crankshaft Main Bearing Inspection
    160
    
    EC25PF/EC28PF Engine Assembly
    161
    
    Measure Crankshaft Width - - Bearings Installed
    161
    
    Oil Pump End Play Adjustment
    166
    
    Oil Check Valve Testing (EC25PF)
    167
    
    Oil Check Valve Testing (EC28PF)
    167
    
    Recoil Disassembly
    168
  - EC25PF Recoil Assembly
    169
  - EC38PL Engine Disassembly
    171
  - EC38PL Engine Inspection
    172
    
    Connecting Radial Clearance
    177
    
    Reed Valve Inspection
    178
    
    Water Pump Impeller Clearance
    178
    
    Impeller Spacer Shim Part Numbers
    179
    
    Oil Check Valve Testing (EC38PL)
    180
    
    Cylinder Inspection/Measurement
    181
    
    Piston Inspection/Measurement (2 Stroke)
    181
    
    Piston Ring Installed Gap
    182
    
    Cleaning the Cylinder after Honing
    183
    
    Cylinder Hone Selection/Honing Procedure
    183
    
    Honing to Oversize
    183
    
    Connecting Rod Small End Bearing Inspection
    184
  - Crankshaft Runout Inspection - 2 Stroke
    185
    
    Crankshaft Straightening
    185
    
    4 Stroke Engine Service
    186
    
    Engine Lubrication - ES33PF / EH50PL
    188
    
    Oil Pressure Test - ES33PF / EH50PL
    188
    
    Oil Flow -- ES33PF
    189
    
    335 (ES33PFE) Oil Flow Chart
    190
  - ES50PL Lubrication/Oil Flow
    191
  - EH50PL Oil Flow Chart
    192
  - Es33Pfengine Exploded View
    193
  - EH50PL Engine Exploded View
    194
    
    Cam Chain Tensioner/Rocker Arm/Camshaft Removal
    195
    
    Engine Disassembly / Inspection
    195
    
    To Position Crankshaft at Top Dead Center (TDC) on Compression Stroke
    195
    
    Cam Chain Tensioner Inspection
    196
  - ES33PF / EH50PL Engine Removal
    196
    
    Rocker Arm/Shaft Removal
    197
    
    Rocker Arm/Shaft Inspection
    198
    
    Camshaft Removal
    200
    
    Automatic Compression Release Installation
    202
    
    Automatic Compression Release Removal/Inspection
    202
    
    If Camshaft Is Installed in the Engine
    202
    
    If Camshaft Is Removed from Engine
    202
    
    Camshaft Inspection
    203
    
    Cylinder Head Exploded View, ES33PF
    204
    
    Cylinder Head Exploded View, EH50PL
    205
    
    Cylinder Head Inspection
    206
    
    Cylinder Head Disassembly
    207
    
    Cylinder Head Warpage
    207
    
    Valve Inspection
    209
    
    Combustion Chamber
    210
    
    Cylinder Head Reconditioning
    211
    
    Valve Guide Removal/Installation
    211
    
    Valve Seat Inspection
    211
    
    Reaming the Valve Guide
    212
    
    Valve Seat Reconditioning
    212
    
    Cylinder Head Assembly
    215
    
    Valve Sealing Test
    216
    
    Cylinder/Piston Removal and Inspection
    217
  - ES33PF / EH50PL Engine Bottom End Disassembly
    217
    
    Piston Removal
    219
    
    Cylinder Inspection
    220
    
    Piston-To-Cylinder Clearance
    221
    
    Crankcase Disassembly
    224
    
    Starter Drive Removal/Inspection
    224
    
    Flywheel/Stator Removal/Inspection
    225
    
    Cam Chain/Tensioner Blade
    226
    
    One Way Valve
    227
    
    Crankcase Separation
    228
    
    Oil Pump Removal/Inspection
    229
    
    Oil Pump Assembly
    231
    
    Counter Balancer Shaft Removal/Inspection
    232
    
    Crankshaft Removal/Inspection
    233
    
    Crankcase Bearing Inspection
    234
    
    Pump Shaft Oil Seal/ Water Pump Mechanical Seal Removal (Engine Disassembled)
    234
    
    Bearing Installation
    235
    
    Crankcase Assembly
    235
    
    Crankshaft End Play Adjustment
    236
    
    End Play Inspection/Adjustment
    236
    
    Counter Balancer Shaft End Play Adjustment
    238
    
    Pump Shaft
    239
    
    Pump Shaft Oil Seal Installation
    239
    
    Crankshaft, Counter Balancer, and Oil Pump Installation
    240
    
    Water Pump Mechanical Seal Installation (EH50PL)
    241
    
    Water Pump Mechanical Seal Removal - Engine Installed (EH50PL)
    241
    
    Cam Chain Drive Sprocket Installation
    243
    
    One Way Valve Installation
    243
    
    Tensioner Blade Installation
    243
    
    Piston Ring Installation
    244
    
    Piston Installation
    245
    
    Cylinder Installation
    246
    
    Cylinder Head Installation
    248
    
    Cam Chain/Camshaft Installation
    249
    
    Camshaft Timing
    249
  - ES33PF / EH50PL Engine Assembly/Inspection
    251
    
    Cam Chain Tensioner Installation
    252
    
    Stator, Flywheel and Starter Drive Installation
    252
    
    Flywheel
    253
    
    Starter Drive
    253
    
    Oil Pipes
    254
    
    Rocker Shaft/Rocker Arm Assembly Installation
    254
    
    Thermostat Installation
    254
    
    Recoil Disassembly/Inspection
    255
    
    To Complete Recoil Assembly
    257
    
    To Install a New Spring
    257
    
    To Reinstall an Old Spring
    257
    
    Spark Plug Fouling - 2 Stroke Engines
    258
    
    Spark Plug Fouling - 4 Stroke Engines
    258
  - Spark Plug Fouling Checklist
    258
    
    2 Stroke Engine Troubleshooting
    259
    
    Engine Does Not Turn over
    261
    
    Engine Idles but will Not Rev up
    261
    
    Engine Runs but will Not Idle
    261
    
    Engine Turns over but Fails to Start
    261
    
    Backfiring
    262
    
    Excessive Smoke and Carbon Buildup
    262
    
    Low Compression
    262
    
    EH42PL/EH50PL Cooling System Troubleshooting
    263
    
    Leak at Water Pump Weep Hole
    263
    
    Overheating
    263
    
    Temperature too Low
    263
    
    Fuel System/Carburetion
    264
    
    Air Screw (2 Cycle) / Pilot Screw (4 Cycle) Adjustment
    266
  - Main Jet Selection
    266
Chapter 4 Fuel System/Carburetion

266
- Jetting Guidelines
  266
  - Fuel Tank Assembly / Oil Tank Assembly
    267
  - Fuel Flow Diagrams
    269
    
    Fuel System Diagram - 2 Stroke Models
    269
    
    Fuel System Diagram - 4 Stroke Models
    269
    
    Air/Fuel Mixture Ratio
    272
    
    E-Clip Position Vs. Fuel Flow
    272
    
    Pilot Air Screw
    272
    
    Pilot Jet
    272
    
    Jet Needle
    273
    
    Needle Jet
    273
    
    Throttle Opening Vs. Fuel Flow
    273
  - Main Jet / Pilot Jet Part Numbers
    274
    
    Throttle Valve
    274
    
    Starter System - Closed Throttle (2 Cycle)
    275
    
    Pilot System (0-3/8 Throttle) (2 Cycle)
    276
    
    Slide Cutaway (1/8-3/8 Throttle) (2 Cycle)
    277
    
    Jet Needle/Needle Jet (3/8-3/4 Throttle) (2 Cycle)
    278
    
    Main System (3/4 to Full Throttle) (2 Cycle)
    279
  - Carburetor Component Function (2 Cycle)
    280
    
    Component Effect Vs. Throttle Opening (2 Cycle)
    280
    
    Mikuni Fuel Delivery (2 Cycle)
    280
  - Assembly, CV Carburetor
    281
  - Float Height Adjustment (2 Cycle)
    281
  - Needle and Seat Leakage Test - 2 Cycle
    281
  - Vent Systems (2 Cycle)
    281
  - Mikuni VM30SS / VM34SS Carburetor Exploded View
    282
  - 4 Cycle CV Carburetor System Function
    283
  - Vent Systems - 4 Cycle CV Carburetor
    283
  - Mikuni CV Carb Operation
    284
  - Pilot (Idle and Slow) System
    285
  - Starter System (Choke or Enrichment)
    285
  - Float System
    286
  - Main System
    286
  - Mikuni BST 34 Carburetor Exploded View
    287
  - Mikuni BST 40 Carburetor Exploded View
    288
  - Carburetor Disassembly Notes- Mikuni CV
    289
  - Carburetor Cleaning - Mikuni CV
    291
  - Carburetor Inspection - Mikuni CV
    292
  - Carburetor Assembly - Mikuni CV
    293
  - Carburetor Adjustment - Mikuni CV
    294
  - Float Height Adjustment
    294
  - Fuel Level
    295
Fuel Pump

296
- Needle and Seat Leakage Test
  295
- Fuel Pump Disassembly
  296
- Fuel Pump Inspection/Assembly
  296
- Fuel Pump Exploded View
  297
  - Fuel Starvation/Lean Mixture
    298
  - Poor Idle
    298
  - Troubleshooting
    298
  - Rich Mixture
    298
  - Erratic Idle
    299
  - Idle too Low
    299
  - Body / Steering / Suspension
    300
  - Torque Specifications, Special Tools
    302
  - Body Assembly Exploded View (Gen Ll - Typical)
    303
  - Front Cab Assembly
    303
  - Rear Cab Assembly
    303
  - Cover/Panel Removal (Gen Ll - Typical)
    304
  - Body Assembly Exploded View (Gen Lll - Typical)
    305
  - Cover/Panel Removal (Gen Lli - Typical)
    306
  - Body Assembly Exploded View (Gen Lv - Typical)
    307
  - Cover/Panel Removal (Gen Lv - Typical)
    308
  - Headlight Pod Exploded View (Gen Lv - Typical)
    309
  - Side Panel Removal (Gen Lv - Typical)
    310
  - Typical Steering Assembly, Exploded View, ’99 Trail Boss 250
    311
  - Steering Assembly, Exploded View, - 2X4 Models (Except ’99 Trail Boss 250)
    312
  - Steering Assembly, Exploded View All 4X4 and 6X6 Models
    313
  - A-Arm Replacement
    314
  - Concentric Swing Arm Removal
    315
  - Standard Swing Arm and Rear Suspension Exploded View
    317
  - Shaft Ride Swingarm Exploded View
    318
  - Shaft Ride Swingarm
    319
  - Swingarm Installation
    319
  - Rear Suspension Assembly, - Shaft Drive Models
    320
  - Rear Strut Stabilizer, 6X6 Models
    321
  - Rear Swing Arm Weldment, 6X6 Models
    322
  - Front Swing Arm Weldment, 6X6 Models
    323
  - Strut Assembly Exploded View - 2X4 Models
    324
  - Strut Assembly - AWD Models
    325
  - Front Strut Cartridge Replacement
    326
  - Front Strut Weldment Replacement
    326
  - Ball Joint Replacement
    327
  - Front Strut Ball Joint Replacement
    327
  - Decal Replacement
    330
  - Clutches
    332
  - Clutch Specifications
    334
  - PVT System Fastener Torques
    334
  - Special Service Tools and Supplies
    334
  - Drive Clutch Operation
    335
  - Driven Clutch Operation
    335
  - PVT Operation
    335
  - Standard PVT System Introduction
    335
CHAPTER 6 CLUTCHES Service Tools and Supplies

336
- PVT Maintenance/Inspection
  336
  - PVT Drying
    336
  - PVT Overheating
    336
  - PVT Sealing and Ducting Components
    336
  - PVT Disassembly
    337
  - PVT Assembly
    339
  - PVT Sealing and Ducting Components
    340
    
    Relationship of Drive Clutch Weights and Spring in Maintaining Operating RPM
    343
    
    Drive Clutch Spring Specifications
    344
  - Shift Weights
    345
  - Button to Tower Clearance Inspection
    346
  - Drive Clutch Inspection
    346
  - Shift Weight Inspection
    346
  - Drive Clutch & EBS Exploded View
    347
  - Drive Clutch Disassembly/Inspection
    348
    
    Moveable Sheave Bushing Inspection
    349
    
    Spider Removal
    349
    
    Roller, Pin and Thrust Washer Inspection
    350
  - Drive Clutch Assembly
    351
  - Standard P-90 (Non-EBS) Clutch
    353
  - Drive Belt Tension
    355
  - Drive Belt Removal/Inspection
    356
  - Clutch Alignment/Offset
    357
  - Drive Clutch Bushing Service
    359
    
    Drive Clutch Moveable Sheave - Bushing Removal
    359
    
    Polaris Kit PN 2871226
    359
    
    Drive Clutch Moveable Sheave - Bushing Installation
    360
    
    Drive Clutch Cover - Bushing Removal
    361
    
    Drive Clutch Cover - Bushing Installation
    362
  - Driven Clutch Disassembly/Inspection
    363
  - Driven Clutch Assembly
    366
  - Driven Clutch Bushing Service
    367
    
    Driven Clutch Moveable Sheave - Bushing Installation
    369
    
    Engine Braking System (EBS) Clutch
    372
    
    EBS Theory of Operation
    373
    
    Operation Guidelines for Ebs Clutches
    374
  - EBS Exploded View
    375
  - One-Way Clutch Inspection (Drive Clutch)
    376
  - Driven Clutch Disassembly/Inspection - EBS
    379
  - One-Way Clutch Preliminary Inspection (Driven)
    379
  - Ebs Clutch Bushing Removal and Installation
    383
  - Ebs Drive Clutch Moveable Sheave - Bushing Removal
    383
  - Removal and Installation Instructions
    383
  - EBS Clutch Cover - Bushing Installation
    384
  - EBS Clutch Cover - Bushing Removal
    384
  - EBS Drive Moveable - Bushing Installation
    384
  - EBS Driven - Bushing Installation
    385
  - EBS Driven - Bushing Removal
    385
  - EBS Driven - Backside (Outer) Bushing Installation
    386
  - EBS Driven - Backside (Outer) Bushing Removal
    386
  - Clutch Troubleshooting
    387
  - Final Drive
    390
  - Final Drive
    392
  - 2X4 Hub Bearing / Seal Replacement
    393
CHAPTER 7 FINAL DRIVE Final Drive Torque Specifications

393
- 2X4 Front Hub Disassembly/Inspection
  393
- 2X4 Front Hub Installation
  396
  - 2X4 Front Hub Assembly
    397
  - 2X4 Front Hub Exploded View
    397
  - AWD Operation Overview
    399
  - Electric Hub Engagement (AWD)
    399
  - AWD Front Hub Disassembly
    400
    
    Front Hub Removal (AWD)
    400
    
    Hub/Wheel Bearing Installation
    401
  - AWD Front Hub Bearing Adjustment
    402
  - AWD Front Hub Exploded View
    403
  - AWD Hub Seal Replacement
    405
  - AWD Magnetic Coil Service
    406
    
    Magnetic Coil Installation
    406
    
    Magnetic Coil Removal
    406
  - AWD Hilliard Clutch Disassembly/Inspection
    407
  - AWD Armature Plate Inspection
    408
  - AWD Front Drive Axle Removal
    409
  - AWD Front Drive Axle Installation
    410
    
    Driveshaft and CV Joint Handling Tips
    411
    
    Front Drive Shaft CV Joint Boot Replacement
    411
  - AWD Front Drive Axle Exploded View
    413
    
    Front Drive Axle Components
    413
    
    Front Prop Shaft Components
    413
    
    AWD Strut Casting Front Drive Axle Seal Replacement
    414
    
    Bearing Replacement Note for Front Drive Axle and Front Hub
    414
    
    Seal Sleeve Replacement
    415
    
    Seal Sleeve Tool
    415
  - AWD Front Prop Shaft Removal
    416
    
    U-Joint Disassembly (Typical)
    417
    
    U-Joint Service
    417
  - U-Joint Assembly
    418
  - AWD Front Housing Removal
    420
    
    Front Housing Disassembly
    420
    
    AWD Front Housing Identification
    421
  - AWD Front Housing Disassembly
    422
  - AWD Front Housing Identification
    422
  - AWD Front Housing Assembly
    424
  - AWD Front Housing Installation
    424
  - Front Housing Installation
    427
  - AWD Front Housing Exploded View
    428
    
    Rear Drive
    429
    
    Rear Axle Bend
    430
    
    Rear Drive Axle Service - Xpress / Xplorer 300
    430
    
    Rear Axle Installation
    431
    
    Rear Axle Removal
    431
    
    Concentric Swingarm Rear Axle Removal
    432
    
    Concentric Swingarm Rear Axle Installation
    434
    
    Concentric Swingarm Rear Axle Assembly, Exploded View
    435
    
    Concentric Swingarm Rear Axle Disassembly
    436
    
    Concentric Swingarm Rear Axle Assembly
    437
    
    Concentric Swingarm Rear Housing Removal
    438
    
    Concentric Swingarm Rear Housing Installation
    440
    
    Concentric Swingarm Rear Housing Service
    440
    
    Rear Housing Assembly/Bearing Service
    440
    
    Rear Housing Disassembly/Bearing Service
    440
    
    Rear Hub Inspection
    441
    
    Rear Axle Bearing Removal
    445
    
    Rear Axle Bearing Installation
    446
    
    Rear Hub/Bearing Carrier Removal
    447
  - Rear Hub Installation - Independent
    449
  - Rear Hub Disassembly - Independent
    450
  - Rear Hub Assembly - Independent
    451
  - Rear Drive Shaft Removal - Independent
    452
  - Rear Drive Shaft Installation
    454
  - Rear Drive Shaft Disassembly (U-Joint Style)
    455
    
    U-Joint Inspection - Rear Drive Shafts
    455
    
    Rear Drive Shaft Disassembly (Dual CV Joint Style)
    456
    
    CV Joint Assembly Procedure
    457
    
    Boot Installation
    458
    
    Boot Replacement
    458
    
    CV Joint Cleaning / Replacement
    458
    
    Independent Rear Suspension Exploded View
    459
  - Center Eccentric Housing Service
    460
    
    Tapered Bearing Center Eccentric Assembly Procedure
    460
    
    Front Eccentric Disassembly / Assembly Procedure
    461
  - Front Eccentric Housing Service
    461
    
    Front Eccentric Removal / Installation Procedure
    461
    
    Center / Front Chain Tightener Exploded View
    462
    
    Transmission Service
    464
  - Transmission Type Identification
    466

Polaris 6X6 Manual (292 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 4.8 MB

Chapter 1 General Information

1
- Table of Contents
  1
- General Information
  2
- Model Identification
  2
- Serial Number Location
  2
- Machine Dimensions
  4
- Publication Numbers
  12
- Paint Codes
  12
- Starting the RANGER
  12
General Information Chapter 2 Maintenance

13
- Periodic Maintenance Chart
  14
- Pre-Ride Inspection
  17
- Special Tools
  17
- Front Gearcase Lubrication
  21
- Middle Gearcase Lubrication
  21
- Rear Gearcase Lubrication
  22
- Transmission Lubrication
  23
- Shift Linkage Adjustment
  25
- Throttle Pedal Inspection
  26
- Fuel System
  28
- Battery Maintenance
  29
- Spark Plug / Electrical
  30
- Air Filter / Breather Filter
  34
- Flywheel Housing
  36
- Oil Level and Filter Change
  37
- Oil Pump Priming Procedure
  38
- Valve Adjustment
  39
- Exhaust Pipe
  42
- Suspension
  44
Chapter 3 Engine

47
- Special Tools
  48
- Torque Specifications
  48
- Service Data
  49
- Piston Identification
  51
- Torque Patterns
  51
- Cooling System Specifications
  53
- Engine Removal
  53
- Engine Installation Notes
  54
- Engine Lubrication
  56
- Oil Pump Priming Procedure
  56
- Engine Exploded View
  59
- Valve Seat Service
  69
- Cylinder Head Assembly
  72
- Crankshaft End Play Inspection
  84
- Oil Pump Shaft End Play Inspection
  86
- Spark Plug Fouling Checklist
  99
- Troubleshooting
  99
Chapter 4 Fuel System/Carburetion

101
- Fuel Flow Diagram
  103
- Carburetor Jetting
  104
- Assembly, CV Carburetor
  105
- CV Carburetor System Function (4 Cycle)
  105
- Needle & Seat Leakage Test
  111
- Fuel Level
  112
- Fuel Pump Service
  112
- Fuel Tank Removal/Installation
  112
- Troubleshooting
  113
Body/Steering/Suspension Chapter 5 Body and Steering

115
- Body/Panel Removal
  117
- Cab Frame & Seat Exploded View
  118
- Frame/Body Assembly Exploded View
  119
- Body Molding Exploded View
  120
- Hood Exploded View
  121
- Cargo Box Exploded View
  122
- Dash Instruments & Controls
  123
- Steering Assembly Exploded View
  124
- A-Arm Replacement
  126
- Rear Axle & Swingarm
  129
- Swing Arm Removal & Installation
  129
- Front Strut Cartridge Replacement
  131
- Box Removal / Installation
  133
- Decal Replacement
  134
Clutch Chapter 6 Pvt System

135
- PVT System Torques
  136
- Service Tools and Supplies
  136
- PVT Maintenance/Inspection
  137
- PVT Disassembly
  139
- PVT Assembly
  140
- Drive Clutch Exploded View
  141
- PVT Sealing and Ducting Components
  141
- Drive Clutch Spring Specifications
  142
- Shift Weights
  143
- Drive Clutch Disassembly/Inspection
  144
- Drive Clutch Inspection
  144
- Drive Clutch Assembly
  146
- Drive Belt Tension
  147
- Drive Belt Removal/Inspection
  148
- Drive Belt Installation
  149
- Drive Clutch Bushing Service
  150
- Driven Clutch Disassembly/Inspection
  152
- Driven Clutch Assembly
  154
- Driven Clutch Bushing Service
  154
- Troubleshooting
  157

Polaris 6X6 Owner's Manual For Maintenance And Safety (136 pages)

Polaris Offroad Vehicle User Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 4.78 MB

Table of Contents
6
Vehicle Identification Numbers
7
Age Restrictions
8
Safety
8
- Safety Training
  9
- Operator Safety
  10
- Equipment Modifications
  14
- Safety Decals and Locations
  30
- Safe Riding Gear
  34
Features and Controls
35
- Throttle Lever
  37
- Service Brakes
  38
- Auxiliary Brakes
  38
- Master Cylinders
  39
- Parking Brake
  40
- Setting the Parking Brake
  40
- Fuel Tank
  41
- Gear Selector
  42
- Belt Life
  42
- Recoil Starter
  43
- Disengaging Wheel Hubs
  46
- Instrument Cluster
  47
- Rider Information Center
  48
- Diagnostic Mode
  50
Operation
52
- Break-In Period
  53
- Starting a Cold Engine
  55
- Starting a Warm Engine
  56
- Hauling Cargo
  57
- Dumping Cargo
  58
- Load Distribution
  59
- Driving Safely
  59
- Driving Procedures
  60
- Making Turns
  61
- Driving Downhill
  63
- Driving Uphill
  64
- Turning Around on a Hill
  65
- Driving on Slippery Surfaces
  66
- Driving through Water
  67
- Driving in Reverse
  68
- Parking on an Incline
  69
- Driving over Obstacles
  70
- Exhaust Emission Control System
  71
- Noise Emission Control System
  71
- Crankcase Emission Control System
  71
Emission Control Systems
71
Tool Kit
72
Maintenance and Lubrication
72
- Periodic Maintenance Chart
  73
- Severe Use Definition
  73
- Maintenance Chart Key
  74
- Lubrication Recommendations
  77
- Oil Change
  79
- Transmission Lubrication
  79
- Front Gearcase Lubrication
  80
- Premium 4 Synthetic Lubricant
  81
- Oil Level
  82
- Oil and Filter Change
  83
- Engine Cooling System
  85
- Radiator Coolant Level
  85
- Recovery Bottle Coolant Level
  86
- Cooling System Operation
  86
- Filter Systems
  87
- Air Box Drain
  88
- Breather Filter
  88
- Toe Alignment
  89
- Steering Inspection
  90
- Handlebar Adjustment
  90
- Camber and Caster
  90
- Front Wheel and Middle Axle Brake
  91
- Front Brake
  91
- Rear Brake
  92
- Front Wheel Hub Tightening
  92
- Oil Pump Priming
  95
- Side Panel Removal
  96
- Wheel Removal
  97
- Wheel Installation
  97
- Tire Tread Depth
  98
- Tire Specifications
  99
- Spark Plugs
  100
- Pvt System
  101
- Low Range
  101
- High Range
  101
- Pvt Drying
  102
- Spark Arrestor
  103
- Recoil Housing
  104
- Battery Removal
  105
- Battery Installation
  105
- Battery Charging
  106
- Battery Storage
  106
- Headlight Lamp Replacement
  108
- High Beam Headlight Adjustment
  109
- Headlight Housing Replacement
  110
- Cleaning and Storage
  112
- Cleaning the Atv
  112
- Washing the Atv
  112
- Waxing the Atv
  112
- Fluid Levels
  113
- Storage Tips
  114
- Transporting the Vehicle
  116

Polaris 6X6 Owner's Manual (116 pages)

Polaris 2014 ATV Owner's manual

Brand: Polaris | Category: Offroad Vehicle | Size: 5.72 MB

Table of Contents
5
Introduction
6
- Vehicle Identification Numbers
  8
Safety
10
- Safe Riding Gear
  11
- Clutch Cover Warning
  14
- Operator Safety
  15
- Equipment Modifications
  17
- Seat Belts
  18
- Using Alcohol or Drugs
  18
- Protective Apparel
  18
- Operating Without Instruction
  18
- Age Restrictions
  18
- Cab Nets
  19
- Handling Gasoline
  20
- Exposure to Exhaust
  20
- Operating a Damaged Vehicle
  20
- Operating at Excessive Speeds
  20
- Operating on Pavement
  20
- Operating on Public Roads
  20
- Stalling While Climbing a Hill
  21
- Descending Hills Improperly
  21
- Improper Hill Climbing
  21
- Jumps and Stunts
  21
- Operating in Unfamiliar Terrain
  21
- Turning Improperly
  21
- Improper Tire Maintenance
  22
- Operating on Slippery Terrain
  22
- Hot Exhaust Systems
  22
- Component Locations
  23
Features and Controls
23
- Auxiliary Outlets
  24
- Light Switch
  25
- Mode Button
  25
- Throttle Pedal
  26
  - Trailer Hitch Bracket
    26
  - Park Brake Lever
    27
  - Seat Belts
    29
- Seat Removal
  29
- Storage Compartments
  30
  - Indicator Lamps
    31
  - Instrument Cluster
    31
  - Instrument Cluster
    33
- Rider Information Center
  33
- Break-In Period
  36
- Pre-Ride Inspection
  37
- Starting the Engine
  38
- Stopping the Engine
  38
Operation
36
- Driving Procedure
  39
- Driving with a Passenger
  40
- Driving on Slippery Surfaces
  41
- Driving over Obstacles
  42
- Driving Downhill
  43
- Driving Uphill
  43
- Driving through Water
  44
- Driving in Reverse
  45
- Parking on an Incline
  45
- Hauling Cargo
  46
- Towing Loads
  47
- Belt Life
  47
- Dumping the Cargo Box
  48
- Engaging Awd
  49
- All Wheel Drive (AWD)
  49
- Disengaging Awd
  49
- Locking the Differential
  50
Winch Guide
51
- Winch Safety Precautions
  52
- Winch Operation
  53
- Winch Cable Care
  57
- Winch Maintenance and Service Safety
  59
- Crankcase Emission Control System
  60
- Exhaust Emission Control System
  60
Emission Control Systems
60

Polaris 6X6 Owner's Manual (131 pages)

Polaris 2002 ATV Owner's Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 1.51 MB

Safety Training
6
Table of Contents
7
Vehicle Identification Numbers

9
Safety

10
- Understanding Warnings
  10
- Key Safety Issues
  11
  - Safe Riding Gear
    15
  - Eye Protection
    15
- Decals and Locations
  16
- Safety Decals and Locations
  17
- Safety
  23
- Operator Safety
  24
- Controls and Features
  40
- Controls
  40
- Main Switch
  41
- Engine Electrical Switches
  41
- Throttle Lever
  42
- Front and Rear Brakes
  43
Controls and Features

44
- Parking Brake
  45
- Transmission Gear Selector Operation
  48
- Recoil Starter
  49
- Features
  50
- Disengaging Wheel Hubs
  52
Operation

53
- Pre Ride
  53
- Vehicle Break-In Period
  54
- Starting the Engine
  55
- Starting a Cold Engine
  55
- Starting a Warm Engine
  56
- Carrying Loads
  57
- Operation
  59
Noise Emission Control System

60
Riding

61
- Pre Ride Inspection
  61
- Riding Safely
  62
- Load Distribution
  62
- Making Turns
  64
- Riding on Slippery Surfaces
  66
- Traveling Downhill
  68
- Traveling Uphill
  69
- Turning Around on a Hill
  70
- Crossing Streams
  71
- Trail Obstacles
  74
- Riding
  75
- Parking on an Incline
  75
Maintenance and Lubrication

76
- Tools
  76
- Tool Kit
  76
- Periodic Maintenance Schedule
  77
- Lubrication Recommendations
  80
- Transmission Lubrication
  83
- Front Gearcase Lubrication
  84
- Premium 4 Synthetic Lubricant
  85
- Oil System
  85
- Maintenance Record
  88
- Cooling System
  89
- Coolant Level
  90
- Filter Systems
  91
- Air Box Drain
  92
- Adjustments
  93
- Toe Alignment
  93
- Steering Inspection
  94
- Handlebar Adjustment
  94
- Camber and Caster
  94
  - Front Brake
    95
  - Wheel Installation
    98
- Tire Inspection
  99
- Tire Specifications
  100
- Front Wheel Hub Tightening
  100
- Front Drive Chain Adjustment
  101
- Carburetor Adjustments
  104
- Jetting Chart
  104
- Side Panel Removal
  105
- Spark Plugs
  106
- Spark Arrestor
  107
- Recoil Housing
  109
- Pvt
  110
- Battery
  111
- Battery Removal
  112
- Lights
  114
- High Beam Headlight Adjustment
  115
- Headlight Housing Replacement
  116
- Indicator Lamp Replacement
  117
- Cleaning and Storage
  118
- Storage of the 6X
  119
- Maintenance and Lubrication
  120
- Transporting the 6X
  120

Polaris Categories

Offroad Vehicle Swimming Pool Vacuum Utility Vehicle Automobile Accessories Snowmobiles

More Polaris Manuals

Polaris 6X6 Manuals

Polaris 6X6 Service Manual (666 pages)

Table of Contents

Chapter 1 General Information / Specifications

Chapter 2 Maintenance

CHAPTER 3 ENGINE Torque Specifications - 2 Stroke

Chapter 4 Fuel System/Carburetion

Fuel Pump

CHAPTER 6 CLUTCHES Service Tools and Supplies

CHAPTER 7 FINAL DRIVE Final Drive Torque Specifications

Polaris 6X6 Manual (292 pages)

Table of Contents

Chapter 1 General Information

General Information Chapter 2 Maintenance

Chapter 3 Engine

Chapter 4 Fuel System/Carburetion

Body/Steering/Suspension Chapter 5 Body and Steering

Clutch Chapter 6 Pvt System

Polaris 6X6 Owner's Manual For Maintenance And Safety (136 pages)

Table of Contents

Polaris 6X6 Owner's Manual (116 pages)

Table of Contents

Polaris 6X6 Owner's Manual (131 pages)

Table of Contents

Vehicle Identification Numbers

Safety

Controls and Features

Operation

Noise Emission Control System

Riding

Maintenance and Lubrication

Related Products

Polaris Categories