Académique Documents
Professionnel Documents
Culture Documents
CHAPTER 1
GENERAL INFORMATION
1
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2007 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2007 HAWKEYE 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2007 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MODEL: 2007 HAWKEYE 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
VEHICLE IDENTIFICATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.
}
}
1.1
GENERAL INFORMATION
Vehicle Identification Number (VIN)
World
Mfg. ID
Vehicle Descriptor Vehicle Identifier
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A L H 2 7 A * 5 P 0 0 0 0 0 0
}
Engine Model
Year Individual Serial Number
Body Style
Emissions Plant No
Powertrain * This could be either
Check Digit a number or a letter
1.2
GENERAL INFORMATION
SPECIFICATIONS
MODEL: 2007 HAWKEYE 2x4
1
MODEL NUMBER: . . . . . . . . .A07LB27AA, A07LB27AC
A07LB27FA (International)
ENGINE MODEL: . . . . . . . . . .ES30PFE
Category Dimension
Length 74 in./188 cm
Width 42 in./107 cm
Height 45.5 in./116 cm
Wheel Base 46 in./117 cm
Ground Clearance 8 in./20.3 cm
Dry Weight 525 lbs./238 kg
Gross Vehicle Weight 930 lbs./422 kg
Front Rack Capacity 70 lbs./31.75 kg
Rear Rack Capacity 100 lbs./45 kg
Towing Capacity 750 lbs./340 kg
Hitch Tongue Weight 75 lbs./34 kg
Body Style Recreational/Utility
1.3
GENERAL INFORMATION
MODEL: 2007 HAWKEYE 2x4 Drivetrain
Transmission Type H-N-R
MODEL NUMBER: A07LB27
ENGINE MODEL: ES30PFE Transmission Capacity Level with fill plug
Gear Ratio : Foward 15.18:1
Engine Reverse 14.05:1
Platform Fuji 4 stroke, Single Cylinder Clutch Type CVT w/EBS
Engine Model Number ES300PFE010 Belt 3211108
Engine Displacement 299cc
Steering / Suspension
Number of Cylinders 1
Front Suspension / Shock Mac Pherson Strut
Bore & Stroke (mm) 78.5 x 68 mm
Front Travel 7 in. / 17.8 cm
Compression Ratio 9.2:1 Full Stroke
Rear Suspension Independent
Compression Pressure 120-140 psi Style / Shock Coil-over Adjustable
Engine Idle Speed 1400 RPM Rear Travel 8 in. / 20.3 cm
Cooling System/Capacity Air/Oil Cooled Ground Clearance 8 in. / 20.3 cm
Overheat Warning None Shock Preload Adjustment Front - Cam
Lubrication Wet Sump Front / Rear Rear - Cam
Oil Requirements Polaris 0W-50 / 1.7 qts (1.6L) Turning Radius 62.5 in. (159 cm) unloaded
Exhaust System Single Pipe - USFS Approved Toe Out 0-1/16 in. (0-.159 mm)
Carburetion Wheels / Brakes
Carburetor model Mikuni BST 34mm Tire/Rim Size - Front 22 x 7-12
Main Jet 140 Tire/Rim Size - Rear 22 x 10-12
Pilot Jet 45 Air Press. F/R Tires 3-5 psi
Jet Needle 4HC57-3 Brake - Front Single Control Hydraulic Disc
Needle Jet 05-m Brake - Rear Single Control Hydraulic Disc
Pilot/Air Screw 2.5 Turns Out (Initial setting) Brake Fluid Polaris DOT 3 or 4 Brake Fluid
Spark plug / Gap NGK CR8EB Note: Remove opposite rollers to retain proper clutch balance
.031 in. / .8 mm
Battery / Model / Amp Hr Conventional 14 Amp/hr
Circuit Breakers Fusible Link / 15 amp Main / 15 Amp Accsy
1.4
GENERAL INFORMATION
MODEL: 2007 HAWKEYE 4x4 Drivetrain
Exhaust System Single Pipe - USFS Approved Turning Radius 62.5 in. (159 cm) unloaded
Carburetion Toe Out 0-1/16 in. (0-.159 mm)
Carburetor model Mikuni BST 34mm Wheels / Brakes
Main Jet 140 Tire/Rim Size - Front 22 x 7-12
Pilot Jet 45 Tire/Rim Size - Rear 22 x 10-12
Jet Needle 4HC57-3 Air Press. F/R Tires 3-5 psi
Needle Jet 05-m Brake - Front Single Control Hydraulic Disc
Pilot/Air Screw 2.5 Turns Out (Initial setting) Brake - Rear Single Control Hydraulic Disc
Brake Fluid Polaris DOT 3 or 4 Brake Fluid
Float Height 13mm from carburetor body
Fuel Delivery Fuel Pump JETTING CHART
Fuel Capacity / 4.5 gal. (17 L) AMBIENT TEMPERATURE
Requirement 87 Octane (minimum) Altitude Below 40oo F Above +40oo F
89 Oxygenated Below 5 C Above +5 C
0-1800 145 140
Electrical Meters (0-6000)
(Feet) 1800-3700 140 135
Alternator Output 250 watt / 18.6 Amp @ 6000 (6000-12000)
Voltage Regulator 3-phase
CLUTCH CHART
Lights : High Beam --
Low Beam 37.5 watts Altitude Shift Weight Number Installed
Brake 12V / 26.9 watts 0-5000 13 g
(0-1534) 8
Tail 12V / 8.26 watts 5412988
1.5
GENERAL INFORMATION
GENERAL INFORMATION
Publication Numbers
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.
Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key
and refer to the chart to for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is
necessary.
Series # Part Number
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
1.6
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 the
1
exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections.
Metric / Torque
6 x 1.0. . . . . . . . . . 72-78 In.lbs. . . . . . . . . .8 x 1.25 14-18 ft.lbs . . . . 10 x 1.25 26-30 ft.lbs.
1.7
GENERAL INFORMATION
Sae Tap Drill Sizes Decimal Equivalents
Thread Size/ Drill Size Thread Size / Drill Size 1/64 ................. .0156
1/32 . . . . . . . . . . . . . .0312. . . 1 mm= .0394"
#0-80 3/64 1/2-13 27/64 3/64 ................. .0469
#1-64 53 1/2-20 29/64 1/16 . . . . . . . . . . . . . .0625
#1-72 53 9/16-12 31/64 5/64 ................. .0781. . . 2 mm = .0787"
3/32 . . . . . . . . . . . . . .0938
#2-56 51 9/16-18 33/64 7/64 ................. .1094. . . 3 mm =.1181"
#2-64 50 5/8-11 17/32 1/8 . . . . . . . .1250
#3-48 5/64 5/8-18 37/64 9/64 ................. .1406
5/32 . . . . . . . . . . . . . .1563. . . 4 mm = .1575"
#3-56 45 3/4-10 21/32 11/64 ................. .1719
#4-40 43 3/4-16 11/16 3/16 . . . . . . . . . . . . . .1875. . . 5mm= .1969"
13/64 ................. .2031
#4-48 42 7/8-9 49/64
7/32 . . . . . . . . . . . . . .2188
#5-40 38 7/8-14 13/16 15/64 ................. .2344. . . 6 mm = .2362"
#5-44 37 1-8 7/8 1/4 . . . . . . . .25
17/64 ................. .2656. . . 7 mm = .2756"
#6-32 36 1-12 59/64 9/32 . . . . . . . . . . . . . .2813
#6-40 33 1 1/8-7 63/64 19/64 ................. .2969
#8-32 29 1 1/8-12 1 3/64 5/16 . . . . . . . . . . . . . .3125. . . 8mm= .3150"
21/64 ................. .3281
#8-36 29 1 1/4-7 1 7/64 11/32 . . . . . . . . . . . . .3438. . . 9 mm = .3543"
#10-24 24 1 1/4-12 1 11/64 23/64 ................. .3594
#10-32 21 1 1/2-6 1 11/32 3/8 . . . . . . . .375
25/64 ................. .3906. . . 10 mm = .3937"
#12-24 17 1 1/2-12 1 27/64 13/32 . . . . . . . . . . . . .4063
#12-28 4.6mm 1 3/4-5 1 9/16 27/64 ................. .4219. . . 11 mm =.4331"
1/4-20 7 1 3/4-12 1 43/64 7/16 . . . . . . . . . . . . . .4375
29/64 ................. .4531
1/4-28 3 2-4 1/2 1 25/32 15/32 . . . . . . . . . . . . .4688. . . 12 mm = .4724"
5/16-18 F 2-12 1 59/64 31/64 ................. .4844
1/2 . . . . . . . .5 ..... . . . . . . . 13mm = .5118"
5/16-24 I 2 1/4-4 1/2 2 1/32
33/64 ................. .5156
3/8-16 O 2 1/2-4 2 1/4 17/32 . . . . . . . . . . . . .5313
3/8-24 Q 2 3/4-4 2 1/2 35/64 ................. .5469. . . 14 mm = .5512"
9/16 . . . . . . . . . . . . . .5625
7/16-14 U 3-4 2 3/4 37/64 ................. .5781. . . 15 mm = .5906"
7/16-20 25/64 19/32 . . . . . . . . . . . . .5938
39/64 ................. .6094
Metric Tap Drill Sizes 5/8 . . . . . . . .625 ... . . . . . . . 16mm=. 6299"
41/64 ................. .6406
21/32 . . . . . . . . . . . . .6563. . . 17 mm =.6693"
Tap Size Drill Size Decimal Nearest 43/64 ................. .6719
Equivalent Fraction 11/16 . . . . . . . . . . . . .6875
3x.50 #39 0.0995 3/32 45/64 ................. .7031. . . 18 mm = .7087"
3x.60 3/32 0.0937 3/32 23/32 . . . . . . . . . . . . .7188
47/64 ................. .7344. . . 19 mm = .7480"
4x.70 #30 0.1285 1/8 3/4 . . . . . . . .75
4x.75 1/8 0.125 1/8 49/64 ................. .7656
5x.80 #19 0.166 11/64 25/32 . . . . . . . . . . . . .7813. . . 20 mm = .7874"
51/64 ................. .7969
5x.90 #20 0.161 5/32 13/16 . . . . . . . . . . . . .8125. . . 21 mm =.8268"
6x1.00 #9 0.196 13/64 53/64 ................. .8281
27/32 . . . . . . . . . . . . .8438
7x1.00 16/64 0.234 15/64 55/64 ................. .8594. . . 22 mm = .8661"
8x1.00 J 0.277 9/32 7/8 . . . . . . . .875
8x1.25 17/64 0.265 17/64 57/64 ................. .8906. . . 23 mm = .9055"
29/32 . . . . . . . . . . . . .9063
9x1.00 5/16 0.3125 5/16 59/64 ................. .9219
9x1.25 5/16 0.3125 5/16 15/16 . . . . . . . . . . . . .9375. . . 24 mm = .9449"
10x1.25 11/32 0.3437 11/32 61/64 ................. .9531
31/32 . . . . . . . . . . . . .9688. . . 25 mm = .9843"
10x1.50 R 0.339 11/32 63/64 ................. .9844
11x1.50 3/8 0.375 3/8 1 . . . . . . . . . 1.0
12x1.50 13/32 0.406 13/32
12x1.75 13/32 0.406 13/32
1.8
GENERAL INFORMATION
Conversion Table
1.9
GENERAL INFORMATION
Glossary Of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
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.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and
grip the drive belt.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V
blocks or resting in crankcase. Measure at various points especially at PTO.
CVT: Centrifugal Variable Transmission (Drive Clutch System)
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore.
Electrical Open: Open circuit. An electrical circuit which isn't complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching
the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm2: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in2: Pounds per square inch.
Left or Right Side: Always referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy
is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040".
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
1.10
MAINTENANCE
CHAPTER 2
MAINTENANCE
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2
LUBRICANTS / FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS. . . . . . . . . . . . . 2.6
POLARIS LUBRICANT SYMBOL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
VEHICLE INSPECTION / MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
HAWKEYE HANDLEBAR COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
FRONT GEARCASE LUBRICATION (4X4 ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
LUBRICATION / GREASE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
THROTTLE OPERATION - ALL MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
CHOKE (ENRICHER) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
PILOT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
PILOT SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
ELECTRONIC THROTTLE CONTROL / THROTTLE CABLE ADJUSTMENT . . . . . . . 2.12
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
ENGINE FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
MAIN AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
AIR FILTER/PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
AIR BOX SEDIMENT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
CVT DRAIN PLUG & DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
TIE ROD END/STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
TOE ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
TOE ALIGNMENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
EXHAUST CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
BRAKE SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
HOSE/FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
BRAKE FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
SUSPENSION SPRING FRONT / REAR PRELOAD ADJUSTMENT. . . . . . . . . . . . . . 2.22
FRONT SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
REAR SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
WHEEL REMOVAL/INSTALLATION- FRONT OR REAR . . . . . . . . . . . . . . . . . . . . . . . 2.22
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
2.1
MAINTENANCE
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubri-
cation of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genu-
ine Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately
10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition:
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use
and determine the cause or see your dealer.
WARNING
2.2
MAINTENANCE
Maintenance And Lubrication
Periodic Maintenance Chart
Middle gearcase oil (if 25 H Monthly 250 (400) Inspect level; change yearly
equipped)
Rear gearcase oil
(if equipped)
25 H Monthly 250 (400) Inspect level; change yearly
2.3
MAINTENANCE
Item Maintenance Interval Remarks
(whichever comes first)
Hours Calendar Miles
(KM)
Engine breather 25 H Monthly 250 (400) Inspect; replace if necessary
E filter (if equipped)
Engine breather
100 H 6M 1000 (1600) Inspect
hose
General Lubricate all grease fittings, pivots,
lubrication
50 H 3M 500 (800)
cables, etc.
Shift Linkage 50 H 6M 500 (800) Inspect, lubricate, adjust
Steering 50 H 6M 500 (800) Inspect daily, Lubricate
Front suspension 50 H 6M 500 (800) Inspect, Lubricate, Tighten Fasteners
Rear suspension 50 H 6M 500 (800) Inspect, Lubricate, Tighten Fasteners
Carburetor float Drain bowl periodically and prior to
50 H 6M 500 (800)
bowl storage
Throttle Cable/ Inspect; adjust; lubricate; replace if
50 H 6M 500 (800)
E ETC Switch necessary
Inspect; adjust; lubricate; replace if
Choke cable 50 H 6M 500 (800)
E necessary
Carburetor air Inspect ducts for proper sealing/air
E 50 H 6M 500 (800)
intake ducts/flange leaks
Drive belt 100 H 12 M 1000 (1600) Inspect; adjust; replace as needed
Cooling system Inspect coolant strength seasonally;
50 H 6M 500 (800)
(if applicable) pressure test system yearly
Engine oil change 500 Perform a break-in oil change at 20
*Severe Duty 25 H 6M (800) hours/one month, change more
frequently during cold weather
E **Normal Duty 50 H 12 M 1000
(1600)
Engine oil change 500 Replace at oil change
*Severe Duty 25 H 6M (800)
2.4
MAINTENANCE
Item Maintenance Interval Remarks
(whichever comes first)
Hours Calendar Miles
(Km)
1000 Check for leaks at tank cap, lines, fuel valve, filter,
Fuel system 100 H 12M
E (1600) pump, carburetor, replace lines every two years
E
Fuel Filter 100 H 12M
1000
(1600)
Replace yearly
2
Radiator 1000
(if applicable) 100 H 12M
(1600)
Inspect; clean external surfaces
Cooling hoses 1000
(if applicable) 100 H 12M
(1600)
Inspect for leaks
1000
Engine mounts 100 H 12M
(1600)
Inspect
Exhaust muffler / 1000
100 H 12M Inspect
pipe (1600)
1000
Spark plug 100 H 12M Inspect; replace as needed
E (1600)
1000
Ignition Timing 100 H 12M Inspect
E (1600)
1000 Inspect for wear, routing, security; apply dielectric
Wiring 100 H 12M
(1600) grease to connectors subjected to water, mud, etc.
Clutches (drive 1000
100 H 12M Inspect;clean; replace worn parts
and driven) (1600)
Front wheel 1000
100 H 12M Inspect; replace as needed
bearings (1600)
2000
Brake fluid 200 H 24M Change every two years
(3200)
3000
Spark arrestor 300 H 36M Clean out
(4800)
E Idle Speed - Adjust as needed
Toe adjustment - Inspect periodically; adjust when parts are replaced
Auxiliary brake Pre- Ride Inspect daily; adjust as needed
Headlight aim - Adjust as needed
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
Have an authorized Polaris dealer perform these services.
2.5
MAINTENANCE
NOTE: The number count indicated by each part number in the table above indicates the number of units that are
shipped with each order.
Polaris Lubricant Symbol Identification
NOTE: The symbols are used to properly identify the correct lube or grease to use in the maintenance section.
Polaris DOT Polaris Synthetic Polaris Synthetic Polaris All Season Grease Polaris ATV
Brake Fluid Gearcase Lube OW-50 Oil Demand Drive Hub Fluid
2.6
MAINTENANCE
VEHICLE 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 - fill both to their proper level; Do not overfill
2
• All brakes - check operation(includes auxiliary brake)
• Throttle - check for free operation
• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
• Engine stop switch - check for proper function
• Wheels - check for loose wheel nuts
• Air cleaner element - check for dirt or water; clean or replace
• Steering - check for free operation, noting any unusual looseness in any area
• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
• Engine coolant(if applicable) - check for proper level at the recovery bottle
Choke
Ignition/Start Key
Reverse
Override
2.7
MAINTENANCE
Maintenance quick reference
Polaris AGL
2 Transmission See procedure. Change annually o
Lubricant
* More often under severe use, such as operated in water or under severe loads.
o Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
p Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special.
NOTE: Refer to Polaris lubricant Identification table for.
3. Brake Fluid
4. Front Gearcase Oil
2.8
MAINTENANCE
Transmission Lubrication Front Gearcase Lubrication (4x4 Only)
The transmission lubricant level should be checked and changed The front gearcase lubricant level should be checked and
in accordance with the maintenance schedule. changed in accordance with the maintenance schedule.
• Be sure vehicle is level before proceeding. • Be sure vehicle is level before proceeding.
• Check vent hose to be sure it is routed properly • Check vent hose to be sure it is routed properly
and unobstructed. and unobstructed. 2
TRANSMISSION SPECIFICATIONS FRONT GEARCASE SPECIFICATIONS
Specified Lubricant: Specified Lubricant:
Polaris AGL Gearcase Lubricant: Polaris Demand Drive LT Premium Hub Fluid:
(PN 2873603) (Gallon) (PN 2873602) (12 oz.) (PN 2876251) (8 oz.)
Capacity: Capacity:
Even with fill plug Even with fill plug
Drain Plug and Fill Plug Torque: Drain Plug Torque:
15 ft. lbs. (20 Nm) 8-10 ft. lbs. (11-13 Nm)
Fill / Check Plug Torque:
To change / check transmission fluid: 8-10 ft. lbs. (11-13 Nm)
1. Place a drain pan beneath oil pan and remove drain plug
from the crankcase. Allow oil to drain completely.
2. Reinstall the drain plug. Tighten to specification.
3. Add the proper amount of lubricant to bring level into A
operating range as shown. Do not over fill.
2.9
MAINTENANCE
Change Carburetor Draining
1. Remove the drain plug (C). Drain the oil into an The carburetor float bowl should be drained periodically to
appropriate container. Discard used oil properly remove moisture or sediment from the bowl, or before extended
2. Clean and reinstall the drain plug with a new sealing periods of storage.
washer. Torque to specification. NOTE: The bowl drain screw is located on the bottom
3. Remove the fill plug (A) and add a pre-measured amount left side of the float bowl.
of Polaris Angle Drive Fluid. The fluid should not be above
the bottom of the check plug (B) threads. 1. Turn fuel valve to the OFF position.
2. Place a clean container beneath the bowl drain spigot or
4. Reinstall the fill plug (A). Torque to specification.
bowl drain hose.
5. Check for leaks.
3. Turn drain screw out two turns and allow fuel in the float
bowl and fuel line to drain completely.
Lubrication / Grease points 4. Inspect the drained fuel for water or sediment.
There are grease zerks rear lower control arm inner pivots, lower 5. Tighten drain screw.
rear bearing carrier pivots, and the prop shaft. Apply grease until 6. Turn fuel valve to “ON”.
it is visible on the ends of the pivot points.
7. Start machine and check for leaks.
Throttle Operation - All Models NOTE: All tubes attached to the carburetor must be
Check for smooth throttle opening and closing in all handlebar check for pinching or blockage, as this will effect engine
positions. Throttle lever operation should be smooth and lever performance
must return freely without binding.
1. Place the gear selector in neutral.
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle speed
increases at any point in the turning range, inspect throttle
cable routing and condition. If cable is routed properly and
in good condition, repeat adjustment procedure.
5. Replace the throttle cable if worn, kinked, or damaged.
CHOKE
= In. / mm.
2.10
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 2
FRONT
The pilot screw is calibrated at the factory to meet (Engine)
EPA / CARB regulations for air quality standards and
is sealed with a brass plug to prevent tampering.
Removal of the tamper proof plug is not permitted. Pilot Screw
For service purposes, cleaning of the pilot circuit can
be done only by a certified repair shop to ensure air
quality standards are not exceeded.
2.11
MAINTENANCE
Electronic Throttle Control (ETC Switch)/ Fuel System
Throttle Cable Adjustment
1. Slide the boots off inline cable adjuster sleeve. Loosen WARNING
adjuster locknut.
2. With handlebars centered and wheels pointing forward, Gasoline is extremely flammable and explosive
turn adjuster sleeve until 1/16” - 1/8” freeplay is achieved under certain conditions.
at the thumb lever. After making any adjustment, “flip” the
lever slightly to confirm adjustment. • Always stop the engine and refuel outdoors or in a
well ventilated area.
• Do not smoke or allow open flames or sparks in or
near the area where refueling is performed or
where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
CAUTION
2.12
MAINTENANCE
Fuel Filter Engine Mounts
The fuel filter should be replaced in accordance with the Inspect rubber engine mounts for cracks or damage.
Periodic Maintenance Chart. The fuel filter is located between
the fuel tank and carburetor. Engine Fastener Torque
1. Clamp fuel lines
Check engine fasteners and ensure they are tight
2.
3.
Remove line clamps at both ends of the filter.
Remove fuel lines from filter. Battery Maintenance
2
4. Install new filter and clamps onto fuel lines with arrow
pointed in direction of fuel flow.
WARNING
2.13
MAINTENANCE
The battery is located under front rack. Spark Plug
To remove the battery: 1. Remove the seat and left hand side panel.
1. Disconnect holder strap. 2. Remove spark plug high tension lead. Clean plug area so
2. Disconnect battery negative (-) (black) cable first, followed no dirt and debris can fall into engine when plug is
by the positive (+) (red) cable. removed.
3. Remove spark plug.
CAUTION 4. Inspect electrodes for wear and carbon buildup. Look for a
sharp outer edge with no rounding or erosion of the
To reduce the chance of sparks: Whenever electrodes.
removing the battery, disconnect the negative Inspect electrode for wear and buildup
(black) cable first. When reinstalling the battery,
install the negative cable last. Spark Plug Gap
3. Remove the battery.
4. Clean battery cables and terminals with a stiff wire brush.
Corrosion can be removed using a solution of one cup water
and one tablespoon baking soda. Rinse well with clean
water and dry thoroughly.
5. Reinstall battery, attaching positive (+) (red) cable first and 5. Clean with electrical contact cleaner or a glass bead spark
then the negative (-) (black) cable. plug cleaner only. CAUTION: A wire brush or coated
6. Coat terminals and bolt threads with Dielectric Grease (PN abrasive should not be used.
2871329). 6. Measure gap with a wire gauge. Refer to specifications for
7. Reinstall battery cover and holder strap. proper spark plug type and gap. Adjust gap if necessary by
bending the side electrode carefully.
7. If necessary, replace spark plug with proper type.
CAUTION: Severe engine damage may occur if the
incorrect spark plug is used.
8. Apply a small amount of anti-seize compound to the spark
plug threads.
9. Install spark plug and torque to 9-11 ft. lbs (12-14 Nm).
10. Replace side panel and seat.
2.14
MAINTENANCE
Ignition Timing Cleaning:
Timing is CDI controlled and has no adjustment procedure. 5. Slip the pre-filter element off of main element. Clean the
pre filter with hot soapy water.
6. Rinse and dry thoroughly.
Ignition Timing:
7. Inspect element for tears or damage.
30o + 2o BTDC @ 5000RPM 8. Inspect main filter and replace if necessary. If the filter has
been soaked with fuel or oil it must be replaced.
2
Main Air Filter Cleaning Installation:
It is advisable to replace the filter when it is dirty. However, in 9. Reinstall pre-filter element over main filter. Be sure the
an emergency it is permissible to clean the main filter if you
observe the following practices. element covers entire surface of main filter without folds,
creases, or gaps.
• Never immerse the filter in water since dirt can be
transferred to the clean air side of the filter. 10. Reinstall filter on main filter mount. Place filter clamp over
the assembly and tighten.
• If compressed air is used never exceed a NOTE: Apply a small amount of general purpose grease
pressure of 40 PSI. Always use a dispersion type
nozzle to prevent filter damage and clean from the to the sealing edges of the filter before reinstalling.
inside to the outside.
• Replace the air filter every 50 hours, and possibly
more often in very dirty conditions.
Air Box
3. Inspect the gasket. It should adhere tightly to the cover and III. 3 Rear
seal all the way around.
4. Remove air filter assembly. NOTE: The air filter should rest on the filter support.
Proper placement of the air filter is important to prevent
rattles and air leaks. See Illustration above.
11. Install air box cover and secure with clips.
2.15
MAINTENANCE
Air Box Sediment Tube Engine Oil Level
Periodically check the air box drain tube located toward the rear To check the oil level:
of the machine. Drain whenever deposits are visible in the clear
tube. 1. Set machine on a level surface.
2. Place the transmission in neutral.
3. Lock the parking brake.
Sediment Tube
2. To further expel water from the cover and to dry out the
CVT system, shift the transmission to neutral and rev
engine slightly to expel the moisture and air-dry the belt and
clutches. Allow engine RPM to settle to idle speed, shift
transmission to lowest available range and test for belt
slippage. Operate ATV in lowest available range for a short
period of time until CVT system is dry.
2.16
MAINTENANCE
Oil and Filter Change 12. Place towels under the oil filter.
13. Using an oil filter wrench, turn the filter counter clockwise
1. Set machine on a level surface.
to remove it.
2. Place the transmission in neutral.
3. Lock the parking brake.
16. Install the new oil filter, After the filter contacts the engine
surface turn it 1/2 turn by hand.
CAUTION
2.17
MAINTENANCE
22. Verify the oil level. Add oil as needed to bring the level Steering
between the min. and max marks. Do not overfill.
The steering components should be checked periodically for
loose fasteners, worn tie rod ends, and damage. Also check to
make sure all cotter pins are in place. If cotter pins are removed,
they must not be re-used. Always use new cotter pins.
Replace any worn or damaged steering components. Steering
should move freely through entire range of travel without
23. Discard used oil and filter properly. binding. Check routing of all cables, hoses, and wiring to be sure
the steering mechanism is not restricted or limited. NOTE:
Whenever steering components are replaced, check front end
Valve Clearance Adjustment alignment. Use only genuine Polaris parts.
WARNING
2.18
MAINTENANCE
• Elevate front end of machine so front wheels are 6. Again measure the distance between the marks and record.
off the ground. Check for any looseness in front Call this measurement “B”. Subtract measurement “B”
hub / wheel assembly by grasping the tire firmly at
top and bottom first, and then at front and rear. Try from measurement “A”. The difference between
to move the wheel and hub by pushing inward and measurements “A” and “B” is the vehicle toe alignment.
pulling outward. The recommended vehicle toe tolerance is 1/8” to 1/4” (.3
to.6 cm) toe out. This means the measurement at the front
of the tire (A) is 1/8” to 1/4” (.3 to.6 cm) wider than the
measurement at the rear (B).
2
2.19
MAINTENANCE
• Important: When tightening the tie rod end jam 2. Place the transmission in Park and start the engine. Purge
nuts, the rod ends must be held parallel to prevent accumulated carbon from the system by momentarily
rod end damage and premature wear. Damage
may not be immediately apparent if done revving the engine several times.
incorrectly. See illustration. 3. If some carbon is expelled, cover the exhaust outlet and
lightly tap on the pipe around the clean out plugs with a
Hold Tie-Rod End Parallel
rubber mallet while revving the engine several more times.
x
Correctly Incorrectly
Tightened Tightened
Jam Nut Jam Nut
4. If particles are still suspected to be in the muffler, back the
machine onto an incline so the rear of the machine is one
Exhaust Pipe Cleaning foot higher than the front. Set the hand brake and block the
wheels. Make sure the machine is in Park and repeat Steps
WARNING
2 and 3. SEE WARNING
5. If particles are still suspected to be in the muffler, drive the
machine onto the incline so the front of the machine is one
• Do not perform clean out immediately after the
engine has been run, as the exhaust system foot higher than the rear. Set the hand brake and block the
becomes very hot. Serious burns could result wheels. Make sure the machine is in Park and repeat Steps
from contact with exhaust components. 2 and 3. SEE WARNING
• To reduce fire hazard, make sure that there are no
combustible materials in the area when purging
the spark arrestor.
• Wear eye protection.
• Do not stand behind or in front of the vehicle
while purging the carbon from the spark arrestor.
• Never run the engine in an enclosed area.Exhaust
contains poisonous carbon monoxide gas.
• Do not go under the machine while it is
inclined.Set the hand brake and block the wheels 1 ft.
to prevent roll back.
Failure to heed these warnings could result in serious
personal injury or death. 6. Repeat steps 2 through 5 until no more particles are
expelled when the engine is revved.
The exhaust pipe must be periodically purged of accumulated
carbon as follows: 7. Stop the engine and allow the arrestor to cool.
1. Remove the clean out plugs located on the bottom of the 8. Reinstall the clean out plugs.
muffler.
Brake System Inspection
The following checks are recommended to keep the brake
system in good operating condition. Service life of brake system
components depends on operating conditions. Inspect brakes in
accordance with the maintenance schedule and before each ride.
• Keep fluid level in the master cylinder reservoir to
the indicated level inside reservoir.
Clean Out Plug
III. 1
2.20
MAINTENANCE
• Check the fluid level “eye”. If it is clear, it is an 3. If excessive free play exists, inspect brake pads, pedal,
indication that fluid is needed or the brake pads linkage springs, and hoses for wear or damage and replace
may be worn, which can reduce the fluid level.
any parts as needed.
• Use Polaris DOT 3 or DOT 4 Brake Fluid
Rear Brake
Hose/Fitting Inspection
Check brake system hoses and fittings for cracks, deterioration,
abrasion, and leaks.Tighten any loose fittings and replace any Floorboard
worn or damaged parts.
Brake Freeplay
5. If more than one inch, two things must be examined:
Hand Brake Lever
• Free play of the brake pedal should be 1/8 - 1/4
1. Check the brake lever, and foot brake for loose inch (3.2 - 6.35 mm).
connections, free play, and damage.
2. Measure the hand brake lever freeplay. Freeplay should be • If free play is excessive: Inspect brake pads,
pedal, linkage springs, and hoses for wear or
0.40-0.80 in. (10-20 mm). damage and replace any parts as needed.
2.21
MAINTENANCE
Suspension Spring FRONT / REAR Preload Wheel Removal/Installation- Front or Rear
Adjustment
Wheel Removal
Operator weight and vehicle loading affect suspension spring
preload requirements. Using Spanner Wrench (PN 2870872) 1. Stop the engine, place the transmission in gear and lock the
adjust as necessary to avoid bottoming of the shocks. parking brake.
2. Loosen the wheel nuts slightly.
Shock Spanner Wrench 3. Elevate the side of the vehicle by placing a suitable stand
under the footrest frame.
(PN 2870872)
4. Remove the wheel nuts and remove the wheel.
Controls
Cotter
Check controls for proper operation, positioning and Key
adjustment.
• Brake control and switch must be positioned to
allow brake lever to travel throughout entire range
without contacting switch body.
2.22
MAINTENANCE
Tire Pressure Frame, Nuts, Bolts, Fasteners
Periodically inspect the torque of all fasteners in accordance
Tire Pressure Inspection (PSI - Cold) with the maintenance schedule. Check that all cotter pins are in
place. Refer to specific fastener torques listed in each chapter.
Front Rear
4 4
2
Tire Inspection
WARNING
CAUTION
Tread
Depth 1/8” (3 mm)
2.23
MAINTENANCE
NOTES
2.24
ENGINE
CHAPTER 3
ENGINE
TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3
OIL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
PISTON RING IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
TRANSMISSION INSTALLATION NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
OIL FLOW / PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
ENGINE BREATHER / OIL SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
CAM CHAIN TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
ROCKER ARM/SHAFT DISASSEMBLY AND INSPECTION. . . . . . . . . . . . . . . . . . . . . 3.16
CAMSHAFT REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
COMBUSTION CHAMBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
ENGINE BOTTOM END DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CAM CHAIN GUIDE AND TENSIONER BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
CYLINDER HONE SELECTION/ HONING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . 3.26
HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
FLYWHEEL REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
STARTER DRIVE CLUTCH REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
CAM CHAIN DRIVE SPROCKET REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . 3.29
OIL PUMP INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
STARTING CLUTCH AND ENGINE BRAKING CLUTCH REMOVAL /INSPECTION . . 3.30
STARTING CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION. . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKCASE OIL PASSAGES & PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . 3.33
3.1
ENGINE
CAMSHAFT CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
BALANCE SHAFT BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
CRANKCASE OIL PICKUP STRAINER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
BEARING /SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
END PLAY INSPECTION/ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
CRANKSHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
BALANCER SHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
CAM CHAIN, OIL PUMP, & TENSIONER BLADE INSTALLATION. . . . . . . . . . . . . . . . 3.37
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
CYLINDER HEAD AND CAMSHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
CAMSHAFT INSTALLATION & TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
ROCKER ARM INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
STARTER DRIVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
SPARK PLUG FOULING TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
ENGINE TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
3.2
ENGINE
TOOLS Oil Pressure Relief
14 mm 15-17 (20-23 Nm)
Valve Plug
Special Tools
Recoil Housing 6mm 7-8 (9-11 Nm)
PART NUMBER TOOL DESCRIPTION
Rocker Adjuster Screw 5mm 3.5-5 (5-7 Nm)
Valve Seat Reconditioning
2200634
Kit Rocker Cover 6mm 5-6.5 (7-9 Nm)
2870390 Piston Support Block
Rocker Adjuster Screw
PA-47308 Flywheel Puller 5mm 3.7-5.0 (5-7 Nm)
Lock Nut
PA-47457 Starting Clutch Holder
2871293-B
Crankshaft Slotted Nut
Socket
Stator Plate to
Crankcase
6mm 7-8 (9-11 Nm) 3
Stator to Stator Plate
5mm 5-6.5 (7-9 Nm)
Screws
TORQUE SPECIFICATIONS
Starter Motor 6mm 5-6.5 (7-9 Nm)
Engine Torque Specifications
Starting Clutch Cover 8mm 14-15.5 (19-21Nm)
ENGINE TORQUE SPECIFICATIONS 103-118
Starting Clutch Nut 16mm
(140-160 Nm)
Thread ES300PFE010
Fastener
Size Ft. Lbs. (Nm) Spark Plug (New) 12mm 7.5-9 (10-12 Nm)
Camshaft Chain Tighten 30-45
6mm 5-6.5 (7-9 Nm)
Tensioner Lever Spark Plug (Used) 12mm degrees after
Camshaft Chain gasket contact
6mm 6.5-8.0 (9-11 Nm)
Tensioner Body
Torque Patterns
Camshaft Chain
8mm 6-7.5 (8-10 Nm)
Tensioner Cap Tightening method for cylinder head nuts:
Camshaft Sprocket
6mm 6.5-8.0 (9-11 Nm) 1) Apply engine oil to washer and threads of 10mm bolts.
Cover
2) Tighten 10mm bolts in pattern below to 18.5 ft. lbs. (25 Nm)
Camshaft Sprocket Bolt 10mm 30-34 (40-46 Nm)
3) Loosen 180 degrees
Carburetor
8mm 12-14 (16-20 Nm)
Adaptor 4) Tighten to 11 ft. lbs. (15 Nm)
Refer to Torque
Cylinder Head Bolts 10mm 5) Tighten 90 degrees
Procedure
Cylinder & Head 6mm 6) Tighten 60 degrees
6mm 5-7 (7-9 Nm)
Bolts
Crankcase 6mm 6.5-8.0 (9-11 Nm) 7) Tighten 6mm head and base bolts to 8 ft. lbs. (11 Nm)
Crankshaft Sprocket
25mm 34 (46 Nm) Cylinder Head / Cylinder Base
Slotted Nut
Flywheel Nut 16mm 66-81 (90-110 Nm) 2
3
5
Oil Drain Bolt 6 mm
14mm 13-16 (18-22 Nm)
(Crankcase)
6
Oil Filter Pipe Fitting 4
20mm 9.5-12 (13-16 Nm) 1
(Crankcase)
3.3
ENGINE
GENERAL ENGINE SERVICE
Engine Exploded View
Crankcase Cylinder/
Cylinder Head
6 ft. lbs.
8 ft. lbs.
15 ft. lbs.
16 ft. lbs.
6 ft. lbs.
6 ft. lbs.
3.4
ENGINE
Engine Service Data
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off
3.5
ENGINE
Engine Service Data
3.6
ENGINE
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off.
3.7
ENGINE
Oil Flow Diagram
Rocker Arm
Rocker Shaft
Valve Springs
ES300PFE010
Chain Room
MAG SIDE
Starting Clutch
One Way Clutch Crankcase
Stator Plate
Oil Passage
Crankcase
Oil Cooler / Filter
Main Bearing Oil Passage
Oil Pump
Direct
Indirect
3.8
ENGINE
Piston Identification Accessible Components
Piston is identified by the marking ES30A. The following components can be serviced or removed with
the engine installed in the frame:
Note the directional and identification marks when viewing the
pistons from the top. The letters “IN” must always be toward the • Flywheel
intake side of the engine. • Alternator/Stator
Piston rings must be installed correctly to ensure engine • Starter Motor/Starter Drive
performance. The numbers or letters on all rings (except oil
• Oil pump
control rings) must be positioned upward. See text for oil control
ring upper rail installation. Use the information below to
identify pistons and rings.
• Rocker Arms / Rocker Shaft
• Camshaft
3
Engine Model Oversize Standard Piston • Cam Chain and Sprockets
No. Available (mm) Identification
• Cylinder
Valve Pocket to
.25mm • Cylinder Head
ES300PFE010 Rear
.50mm
(Intake Side) • Valves
• Carburetor
Piston Ring Identification
• Piston/RIngs
The piston ring profile is shown below. Install top and second
ring with marking UP. Refer to text for oil control ring The following components require engine removal for
installation. service:
3.9
ENGINE
ENGINE SERVICE 10. Disconnect gear indicator switch harness (at transmission)
Engine Removal
NOTE: The engine removal procedure described
A
below removes the engine and transmission as an
assembly, and the engine is then removed from the
transmission case. The transmission can be
removed separately from the engine (see
Transmission Removal procedure in this chapter).
• Seat
• Left and Right Side Covers
• Rear cab
7. Remove CVT cover and both clutches (refer to CVT
Chapter 8)
3.10
ENGINE
NOTE: If front cab is already removed, the stator 25. Lower the jack and pull engine / transmission assembly out
wires can be disconnected. Disregard the steps to the rear.
remove recoil cover, flywheel, and stator from the
engine.
3.11
ENGINE
26. Support engine and remove (9) transmission-to- Engine Break In Period
engine bolts.
4 Cycle Engine Break-In Period is defined as the first 10 hours
of engine operation or 2 full tanks of fuel.
General Items
CVT System
3.12
ENGINE
Transmission Removal 9. Disconnect gear indicator switch harness (at transmission)
8. Remove transmission linkage rod (A) and vent hose (B) 15. Remove rear plate (lower control arm bolts) and upper
control arm bolts.
3.13
ENGINE
16. Remove rear shocks. 24. Remove the top 2 rear bracket bolts.
25. Carefully lower the transmission jack until rear bracket is
clear of frame.
26. Slide transmission to the left until alignment pins in cover
are release from engine case.
27. Remove transmission out to the left side.
28. Remove sway bar bracket from transmission.
29. Refer to transmission disassembly in CVT/Transmission
Chapter 8.
Rear mount
A
22. Loosen, but do not remove the 4 bolts from the rear
transmission hanger bracket.
23. Remove (9) transmission-to-engine bolts.
3.14
ENGINE
Engine Lubrication Cam Chain Tensioner Removal
Oil Type:Polaris Premium 0W-50 Synthetic To position crankshaft at Top Dead Center (TDC) on
compression stroke:
Capacity (DRY):
1.64-1.95 U.S. Quarts (1.55-1.85 l) 4. Remove the valve cover.
Capacity (OIL/FILTER/COOLING BLOCK CHANGE): 5. Rotate engine in normal direction and watch the intake
1.4-1.7 U.S. Quarts (1.3-1.6 l) valve open and begin to close.
6. Continue to rotate engine slowly while watching camshaft
Drain Plug:14-18 ft. lbs. (19-24.4 Nm) sprocket marks and the mark in the timing inspection hole.
Oil Pressure Specification:
(Using Polaris 0W-50 Synthetic @ Operating Temperature @
Single TDC Mark Aligned 3
Idle) Any pressure reading above 9 PSI. TDC Mark
3.15
ENGINE
10. Tap lightly on tensioner body with a soft face hammer to Rocker Arm/Shaft Disassembly and
loosen and remove tensioner if required. Inspection
NOTE: Orientation of the components is important for
reassembly. Mark all components before disassembly.
2. Hold the ratchet open and slide the plunger in and out of
the tensioner body. The plunger should move smoothly
throughout the travel range.
3. Replace entire tensioner assembly if any part is worn or
damaged.
4. Inspect each rocker arm cam follower surface. If there is
any damage or uneven wear, replace the rocker arm.
NOTE: Always replace camshaft if lobe of either rocker
arm is worn or damaged.
5. Inspect the rocker arm shaft and the shaft bore in the
cylinder head for wear or signs of scoring.
3.16
ENGINE
6. Measure I.D. of each rocker arm (A) for out-of-round and 4. If not removing the cylinder for other service, secure the
visually inspect the I.D. surface. Replace arm if excessive cam chain with a wire to prevent it from falling into the
wear is evident. crankcase.
7. Inspect rocker adjuster screws (B) for wear, pitting, or
damage to threads of the adjuster or locknut. Replace all
worn or damaged parts. NOTE: The end of the adjuster is
hardened and cannot be ground or re-faced.
Camshaft Inspection
1. Thoroughly clean the camshaft.
2. Visually inspect each cam lobe and bearing journal for
wear, scoring, or damage. Verify oil delivery passages are
clean.
3. Check the automatic decompressor spring legs and replace
if broken. Spring preload is very light (about 45 degrees).
3.17
ENGINE
4. Measure the height of the cam lobes with a micrometer and 1/4 turn each time in a cross pattern until loose.
compare to specification. Replace cam if worn below
minimum height (service limit).
3. Remove bolts (A) and tap the cam support tower with a
plastic hammer until loose. Remove.
4. After removing the camshaft and securing the cam chain,
tap cylinder head lightly with a plastic hammer until loose.
= In. / mm. CAUTION: Tap only in reinforced areas or on thick parts
of cylinder head casting.
Cam Lobe Height - Intake & Exhaust
5. Remove cylinder head, gasket, front chain guide and dowel
Std: 1.2938”-1.2977 (32.863-32.963 mm)
pins.
Limit: 1.2820” (32.563 mm)
CAUTION
2. Loosen each of the four cylinder head bolts evenly.
Use care not to damage sealing surface. If there is
damage found on the cylinder head combustion
chamber, it is recommended the component be
replaced.
3.18
ENGINE
Cylinder Head Warp Inspection Cylinder Head Disassembly
1. Lay a straight edge across the surface of the head at several
different points and measure warpage by inserting a feeler WARNING
gauge between the straight edge and the cylinder head
surface. If warpage exceeds the service limit, replace the Wear eye protection or a face shield during cylinder
cylinder head. head disassembly and reassembly. Cylinder head
service should be performed by a technician
knowledgeable in cylinder head reconditioning in a
properly equipped shop.
= In. / mm.
3.19
ENGINE
3. Push valve out, keeping it in order for reassembly in the Valve Inspection
same guide.
1. Remove all carbon from valve with a soft wire wheel.
4. Measure free length of the inner and outer springs with a
Vernier caliper, Ill.1. Check spring for squareness as shown 2. Check valve face for runout, pitting, and burnt spots. To
in Ill.2. Replace spring if measurements are out of check for bent valve stems, mount valve in a drill or use “V”
specification. blocks and use a dial indicator.
A
Valve Spring
Free Length
III.1 3. Check end of valve stem for flaring, pitting, wear or damage
(A).
Coil fatigue/
Squareness
3.20
ENGINE
Measure in two directions, front to back and side to side. provided in the Valve Seat Reconditioning Kit (PN
2200634).
CAUTION
7. Subtract valve stem measurement to obtain stem to guide NOTE: Valve seat width and point of contact on the
clearance. NOTE: Be sure to measure each guide and valve valve face is very important for proper sealing. The valve
combination individually. must contact the valve seat over the entire
circumference of the seat, and the seat must be the
8. Replace valve and/or guide if clearance is excessive.
proper width all the way around. If the seat is uneven,
NOTE: If valve guides are replaced, valve seats must be compression leakage will result. If the seat is too wide,
reconditioned. Refer to Valve Seat Reconditioning for seat pressure is reduced, causing carbon accumulation
procedure. and possible compression loss. If the seat is too narrow,
heat transfer from valve to seat is reduced and the valve
Valve Seat Reconditioning may overheat and warp, resulting in burnt valves.
3.21
ENGINE
4. Inspect the cut area of the seat. • If the indicated seat contact is at the top edge of
the valve face and contacts the margin area(B) it is
• If the contact area is less than 75% of the too high on the valve face. Use the 30o cutter to
circumference of the seat, rotate the pilot 180o and lower the valve seat.
make another light cut.
• If too low use the 60o or 75o cutter to raise the
• If the cutter now contacts the uncut portion of the seat. When contact area is centered on the valve
seat, check the pilot. Look for burrs, nicks, or face, measure seat width.
runout. If the pilot is bent it must be replaced.
• If the seat is too wide or uneven, use both top and
• If the contact area of the cutter is in the same bottom cutters to narrow the seat.
place, the valve guide is distorted from improper
installation and must be replaced. Be sure the • If the seat is too narrow, widen using the 45o cutter
cylinder head is at the proper temperature and and re-check contact point on the valve face and
replace the guide. seat width after each cut.
• If the contact area of the initial cut is greater than Bottom 60o or 75o Seat - 45o or 46o
75%, continue to cut the seat until all pits are
removed and a new seat surface is evident. Top - 30o
NOTE: Remove only the amount of material
necessary to repair the seat surface.
5. To check the contact area of the seat on the valve face, apply
a thin coating of Prussian Blue™ paste to the valve seat. If
using an interference angle (46o)apply black marker to the
entire valve face (A).
(A)
NOTE: When using an interference angle, the seat
contact point on the valve will be very narrow, and is a
normal condition. Look for an even and continuous
contact point on the black marker, all the way around the
valve face.
6. Insert valve into guide and tap valve lightly into place a few
times.
7. Remove valve and check where the Prussian Blue™ or
black marker indicates seat contact on the valve face. The Seat
valve seat should contact the middle of the valve face or Width
slightly above, and must be the proper width (A).
(B)
(A)
8. Clean all filings from the area with hot soapy water, rinse,
and dry with compressed air.
9. Lubricate the valve guides with clean engine oil, and apply
oil or water based lapping compound to the face of the
valve. Lapping is not required with an interference angle.
10. Insert the valve into its respective guide and lap using a
Proper Seat Contact On Valve Face lapping tool or a section of fuel line connected to the valve
stem.
3.22
ENGINE
11. Rotate the valve rapidly back and forth until the cut sounds Cylinder Head Assembly
smooth. Lift the valve slightly off of the seat, rotate 1/4 turn,
and repeat the lapping process. Do this four to five times
until the valve is fully seated, and repeat process for the CAUTION
other valve.
12. Clean cylinder head, valves, and camshaft oil supply Wear eye protection during assembly.
passages thoroughly.
NOTE: Assemble the valves one at a time to maintain
13. Spray electrical contact cleaner into oil passages and dry proper order.
using compressed air.
1. Install new valve seals on valve guides.
Closely spaced
coils toward
cylinder head
3.23
ENGINE
6. Place retainer on springs and install valve spring Cam Chain Guide And Tensioner Blade
compressor. Compress spring only enough to allow split
keeper installation and prevent loss of spring tension. 1. The guide can be removed after cylinder head is removed
Install split keepers with the gap even on both sides. by pulling it upward out of the channel in the crankcase.
7. Repeat procedure for remaining valve. 2. Remove blade and inspect. Replace if worn., cracked, or
damaged.
8. When all valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the Split keepers. 3. Tensioner blade removal requires recoil, flywheel, and
stator plate removal. Refer to lower end service procedures
Valve Sealing Test to access the bolt securing the tensioner blade to the
crankcase.
1. Clean and dry the combustion chamber area.
2. Pour a small amount of cleaning solvent into each port and
check for leakage around each valve. The valve seats
should hold fluid with no seepage.
3.24
ENGINE
Piston Removal Cylinder Inspection
1. Remove one circlip. Note valve pocket on intake side of 1. Remove all gasket material from the cylinder sealing
piston for installation. surfaces.
2. Remove piston circlip and push piston pin out of piston. If 2. Inspect the top of the cylinder for warpage using a straight
necessary, heat the crown of the piston slightly with a edge and feeler gauge.
propane torch. CAUTION: Do not apply heat to the piston
rings. The ring may lose radial tension.
= In. / mm.
3. Remove the compression rings, starting with the top ring. Cylinder Warp:
.002” (.05 mm) MAX
*Using a piston ring pliers: Carefully expand ring and
lift it off the piston. CAUTION: Do not expand the ring 3. Inspect cylinder for wear, scratches, or damage.
more than the amount necessary to remove it from the 4. Inspect cylinder for taper and out of round with a
piston, or the ring may break. telescoping gauge or a dial bore gauge. Measure in two
different directions, front to back and side to side, on three
*By hand: Placing both thumbs at end gap, carefully spread the different levels (1/2” down from top, in the middle, and 1/
ring open and lift ring over piston at the opposite side. Use care 2” up from bottom).
to not scratch the ring lands. 1/2” Down From Top of Cylinder
4. Repeat procedure for second ring. X Y
5. The oil control ring is a three piece design consisting of a
top and bottom steel rail and a center expander section.
Remove the top rail first followed by the bottom rail and Y
expander. X
Y
X
= In. / mm.
3.25
ENGINE
Cylinder Hone Selection/ Honing Procedure If cylinder wear or damage is excessive, it will be necessary to
replace the cylinder. Hone only enough to deglaze the outer
layer of the cylinder bore.
CAUTION
3.26
ENGINE
4. Measure piston pin O.D. Replace piston pin if out-of-round. Piston Ring Installed Gap
1. Place each piston ring inside cylinder using piston to push
ring squarely into place as shown.
Piston ring installed end gap
Feeler Gauge
= In. / mm.
Top Ring
Std: .008- .012” (.2- .3 mm)
Limit: .032” (0.8 mm)
Second Ring
6. Measure piston ring to groove clearance by placing the ring Std: .014- .020” (0.35- 0.50 mm)
in the ring land and measuring with a thickness gauge. Limit: .039” (1.0 mm)
Replace piston and rings if ring-to-groove clearance Oil Ring
exceeds service limits. Std: .008- .028” (0.2- 0.7 mm)
Limit: .059” (1.5 mm)
Piston 2. Measure the gap with a feeler gauge at both the top and
bottom of the cylinder.
Ring
NOTE: Measure at two points in the cylinder A
difference in end gap indicates cylinder taper. The
cylinder should be measured for excessive taper and out
of round.
Feeler Gauge
3. If the installed gap measurement exceeds the limit, replace
the rings. If using new rings and the measurement is too
small, file the ring ends to achieve the proper gap.
NOTE: Always check piston ring installed gap after re-
boring a cylinder or when installing new rings. A re-bored
cylinder should always be scrubbed thoroughly with hot
soapy water, rinsed, and dried completely. Wipe cylinder
bore with an oil rag immediately to remove residue and
prevent rust.
3.27
ENGINE
Flywheel Removal / Inspection Starter Drive Clutch Removal/Inspection
1. Remove the recoil housing, recoil hub, and flywheel nut. 1. Remove recoil housing bolts and remove housing.
2. Remove the starter drive clutch and washer by pulling the
shaft and tilting the gear slightly.
3. Measure the O.D. of the starter drive shaft on both ends for
out-of-round.
4. Measure the I.D. of the bushings in the recoil housing and
in the crankcase (A) in two directions 90o apart to determine
if out-of-round. Replace worn bushings.
3.28
ENGINE
Cam Chain Drive Sprocket Removal / Oil Pump Inspection / Removal
Inspection
NOTE: Mark the oil pump geroters to keep parts mated
1. Remove recoil housing, flywheel, flywheel key, and for assembly.
stator.
1. Remove recoil housing, flywheel, flywheel key, and
stator.
2. Use a feeler gauge to check oil pump rotor tip clearance at
“A”, and pump body clearance at “B”. Compare to
specifications. Replace the oil pump assembly if any parts
are damaged, scored, or measure beyond the service limit.
3
A
B
2. Using the Slotted Nut Socket, remove the crankshaft slotted
nut by turning it clockwise. NOTE: Slotted nut is left hand
thread.
3. Mark the oil pump geroters and shaft and carefully lift the
geroters from the housing.
REMOVE
3.29
ENGINE
Starting Clutch And Engine Braking Clutch 5. Open the staked portion of the nut (A) with a center punch.
Removal /Inspection Inspect the one-way clutch hub surface on the starting
clutch (B). The hub must be smooth without any nicks or
NOTE: The transmission must be removed from the burrs. Replace the starting clutch assembly if the one-way
engine to access the starting clutch and one-way clutch hub is uneven or damaged
engine braking clutch.
Inspect entire surface of
1. Inspect the starting clutch drum bearing in the housing. one-way clutch hub.
The shaft must turn smoothly (by hand) without binding B
in the clockwise direction, and should not turn by hand in
the counter clockwise direction. Minimal movement in the
shaft is NORMAL with engine removed due to the lack of
clutch cover bearing support on the free end of the shaft
(approximately 0-.060” (0-1.5mm). Press the shaft out of A
the housing and replace the bearing if worn or rough.
DO NOT LIFT ENGINE WITH
CLUTCH SHAFT
3.30
ENGINE
thinnest point. 9. Install one-way clutch in starting clutch drum with the
flanged side toward the hub, using a rotating motion.
Standard Thickness: .100” (2.54mm)
LIMIT: .039” (1.00mm)
Crankcase Disassembly
7. If drum bearing was replaced in the starting clutch housing, NOTE: Engine must be removed from the frame to
press the drum/shaft into the housing until fully seated. perform any crankcase or crankshaft removal.
8. Clean the inside of the starting clutch drum and lubricate NOTE: The starter, starter drive, flywheel, stator, oil
the drum and one-way clutch with engine oil. pump and transmission can be serviced with the
engine in the frame.
3.31
ENGINE
Crankcase Separation crankshaft, or balance shaft. See procedure this
chapter.
NOTE: Stator housing, flywheel and gears have are
previously removed for this procedure. Use care during
the removal process to avoid damage to the cam chain.
1. Remove all bolts and the pressure relief valve (A) from the
magneto side crankcase.
2. Note the number and thickness of any shims installed on 3. The connecting rod utilizes a roller bearing. Clearance can
either shaft. be measured with a dial indicator to check radial clearance.
Visually inspect the connecting rod, crank pin, and thrust
NOTE: Crankshaft and balance shaft end play must washers for scoring, damage, excessive wear, or signs of
be measured and adjusted with shims if any new overheating. Check for roughness or noise when rotating
components are installed (bearings, crankcase, the connecting rod on the crank pin. Replace crankshaft if
it fails visual inspection, or if any up and down movement
3.32
ENGINE
is detectable in the connecting rod. Camshaft Chain
1. Replace the cam chain as part of any crankshaft repair.
2. The cam chain can be removed by removing the engine top
end, the recoil assembly, flywheel and flywheel key, stator
plate, and slotted nut.
3. Lift the sprocket slightly until chain clears the crankcase to
remove.
Connecting Rod Side Clearance: 1. Inspect the balance shaft bearings in the crankcase.
.0035-.0196” (.09-.50mm) NOTE: Due to extremely close tolerances and minimal
Limit: .023” (.60mm) movement, the bearing must be inspected visually and
by feel. Look for signs of discoloration, scoring or galling.
6. Clean crankshaft oil passages by running a stream of clean Turn the inner race of bearing. The bearing should turn
solvent through the crankshaft. Be sure all passages are smoothly and quietly. The outer race should fit tightly in
clear and free of nicks or scratches. the crankcase. The inner race should be firm with
minimal side to side movement and no detectable up and
Crankcase Oil Passages & Pressure Relief down movement.
Valve
2. To remove balance shaft bearings, use a blind hole bearing
1. Remove the pressure relief valve assembly from the case.
puller.
NOTE: Bearings are stressed during the removal
procedure and should not be re-used.
3.33
ENGINE
Crankcase Oil Pickup Strainer Inspection End Play Inspection/Adjustment
Before reassembling the crankcase, the following steps should
be performed to determine the amount of crankshaft, counter
balancer shaft, and pump shaft end play. Excessive end play may
cause engine noise at idle and slow speeds. Too little play will
side load the bearings which may lead to premature bearing
failure.
CAUTION
3.34
ENGINE
3. Subtract the thickness of the straightedge from the 6. Add the readings recorded in Step 3 and Step 5 and record
measurement obtained in Step 2 and record. below.
= In. / mm.
3.35
ENGINE
Balancer Shaft End Play Adjustment 7. Subtract the thickness of the existing shim from the result
of Step 6 to determine if a different shim is needed. The
NOTE: The balancer shaft end play measurement result must be within the specified range listed at below.
procedure is the same as that outlined for the
crankshaft. The exception is that measurements are 8. Add or subtract shims or change shim thickness as required
taken to the balancer shaft bearings in the case, and install them upon assembly.
rather than the crankshaft main bearings, and the
width of the balancer shaft is measured, not the
crankshaft. = In. / mm.
1. Make sure the counter balance shaft bearings are firmly
Counter Balance Shaft End Play:
seated in each crankcase.
.004”-.029” (.1-.74 mm)
Measure to balance shaft bearing race
Crankcase Reassembly
Crankshaft Installation
3.36
ENGINE
3. Be sure balance dots on gear teeth are aligned. Cam Chain, Oil Pump, & Tensioner Blade
Installation
1. Install the cam chain over the drive sprocket.
2. Lubricate and install the oil pump geroters, aligning the
marks made during disassembly. Clean the marks off the
geroters.
Crankcase Sealant
PN 2871557
5. Install the mag side case and tap with a soft faced hammer
to seat.
6. Install case screws and torque in a cross pattern to
specification. =T
Tensioner Blade Mounting Bolt Torque:
5-6.5 ft. lbs. (7-9 Nm)
=T
Crankcase Bolt Torque:
6.5-8.0 ft. lbs. (9-11 Nm)
3.37
ENGINE
6. IMPORTANT! Be sure the sealed screw is placed in the 5. Install the top ring with the marking facing up. The top ring
hole that aligns with the cam chain cavity or an oil leak may has an inner bevel with a barrel face.
result. If you are installing the old screw, seal it with Loctite Top Ring:
242 (blue) before installation. Bevel on Inner Edge Install with
mark UP
This screw must be sealed
Second Ring
Mark Faces UP
Flywheel Nut: 1. Install a new circlip on one side of the piston with the end
67-81 ft. lbs. (90-110 Nm) gap facing up or down.
Recoil Drive Hub: 2. Apply clean engine oil to the piston rings, ring lands, piston
12-14 ft. lbs. (17-19 Nm) pin bore, piston pin, and piston skirt. Lubricate the
connecting rod (both ends) and crankshaft main bearing
Piston Ring Installation area.
NOTE: Apply clean engine oil to all ring surfaces and 3. IMPORTANT- Install the piston on the connecting rod
ring lands. Always check piston ring installed gap before with the valve pocket facing the intake side of engine.
rings are installed on piston. If the piston has been in The piston pin should be a push fit into the piston.
service, clean any accumulated carbon from the ring Pocket
grooves and oil control ring holes.
1. Place the oil control ring expander in oil ring groove with
the end gap facing forward. The expander has no up or
down marking and can be installed either way. The ends
should butt squarely together and must not overlap.
2. Install the oil ring top rail with the end gap at least 30o from
the end of the expander.
3. Install the bottom rail with the gap at least 30o from the end
of the expander on the side opposite the top rail gap.
4. Install the second ring with the mark facing up. The second 4. Install the other circlip with the gap facing up or down. Push
ring has an undercut with a tapered face. Position the end the piston pin in both directions to make sure the clips are
gap toward the rear (intake) side of the piston. properly seated in the groove.
3.38
ENGINE
5. Lubricate the piston and rings with engine oil and install a 5. Loop the cam chain through the cylinder chain room and
ring compressor on the piston assembly. Verify that the ring secure with mechanic’s wire.
gaps are 120o - 180o apart from each other before
installation.
Cylinder Installation
NOTE: Clean the gasket surfaces on the crankcase and
cylinder. Remove all traces of old gasket material or
sealant. The surfaces must be oil-free!
3.39
ENGINE
Cylinder Head and Camshaft Installation 6. Torque the cylinder head following the procedure and
pattern below.
NOTE: Clean the gasket surfaces on the cylinder head
and cylinder. Remove all traces of old gasket material. Cylinder Head / Cylinder Base
The surfaces must be oil-free!
4. Install the two 6 mm bolts on cylinder base and on the head, Forward
but do not tighten.
=T
Cylinder Gasket Torque Sequence:
Tighten M10 bolts to 18.5 ft. lbs. (25 Nm)
Loosen 180 degrees
Tighten to 11 ft. lbs. (15 Nm)
Tighten M10 bolts 90 degrees
Tighten M10 bolts another 60 degrees
Tighten 6mm bolts to 8 ft.lbs.(11 Nm)
CAUTION
5. Lubricate the washers and the threads of the cylinder head
bolts and install the bolts with washers. Serious engine damage will result if the camshaft is
not properly timed to the crankshaft.
3.40
ENGINE
2. Apply engine oil or starter drive grease (molybdenum 8. Verify all marks are aligned. Install the cam sprocket bolt
disulfide paste) to the camshaft main journals and cam and torque to specification.
lobes. Lubricate automatic compression release
mechanism with clean engine oil.
=T
Starter Drive Grease: Camshaft Sprocket Bolt
(PN 2871460) 35.5-50 ft. lbs. (48-70 Nm)
3. Orient the camshaft with the lobes facing downward, and Cam Chain Tensioner Installation
install the cam into the cylinder head.
1. Hold the tensioner ratchet pawl (A) open and push the
plunger (B) in to the fully retracted position. 3
A
B
4. Disconnect the wire or tie strap securing the cam chain (if
used).
5. Be sure the pin on the camshaft is pointing DOWN. 2. With the plunger retracted, install the tensioner assembly
with a new gasket and tighten the bolts to specification.
6. Loop the cam chain over the sprocket and shift the chain
on the sprocket until it can be installed onto the camshaft.
A
B
B
A
=T
7. VERIFY the following: Tensioner Bolt Torque: 5-6.5 ft. lbs. (7-9 Nm)
• “T” Mark on flywheel is aligned with the 3. Install the pin, spring, and tensioner cap with a new sealing
projection in the timing hole of the recoil
housing. washer. Torque cap to specification.
3.41
ENGINE
4. Slowly rotate engine two to three revolutions in the Starter Drive Assembly
direction of rotation and re-check cam timing.
1. Be sure the washer is positioned on the back of the drive
Rocker Arm Installation gear.
1. Lubricate the rocker arms and shaft with engine oil. Apply
a light film of starter grease (moly grease) to the cam
follower pad on the rocker arms.
2. Slide the shaft through the tower just enough to install the
wave washer (A).
NOTE: The flats of the wave washer are positioned
against the intake rocker arm.
3.42
ENGINE
TROUBLESHOOTING Engine Does Not Turn Over
• Restricted air filter (main or pre-cleaner), or air • Starter motor does not turn
inlet ducts. • Engine seized, rusted, or mechanical failure
• Choke cable adjustment or plunger/cable sticking
Engine Runs But Will Not Idle
• Foreign material on choke plunger seat or plunger
• Idle speed set too low
• Incorrect spark plug heat range or gap
• Faulty ETC system
• Jet needle and/or needle jet worn or improperly
adjusted • Restricted carburetor pilot system 3
• Excessive carburetor vibration (check all engine • Carburetor misadjusted
and carburetor mounts)
• Choke not adjusted properly or sticking plunger
• Oil contaminated with fuel
• Low compression
• ETC switch mis-adjusted
• Crankcase breather restricted
• Low compression
• Air filter restriction
• Spark plug cap loose or faulty
Engine Idles But Will Not Rev Up
• Loose jets in carburetor or calibration incorrect for
altitude/temperature
• Spark plug fouled/weak spark
• Incorrect float level setting
• Broken throttle cable
• Carburetor inlet needle and seat worn
• Obstruction in air intake
• CVT system calibrated incorrectly or components
worn or mis-adjusted • Air box removed (reinstall all intake components)
• Weak ignition (loose coil ground, faulty coil, stator, • Carburetor vacuum slide sticking/diaphragm
engine to chassis ground, or ETC switch) damaged
3.43
ENGINE
Piston Failure - Scoring Backfiring
3.44
FUEL / AIR / EXHAUST
CHAPTER 4
FUEL / AIR / EXHAUST
GENERAL INFORMATION AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
CARBURETOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
CARBURETOR JETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
MIKUNI JET PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
CARBURETION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
BST 34 CARBURETOR EXPLODED VIEW 1 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
BST 34 CARBURETOR EXPLODED VIEW 2 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
CARBURETOR VENTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
CV CARBURETOR SYSTEM FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
CARBURETOR VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
MIKUNI CV CARB OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
STARTER SYSTEM (CHOKE OR ENRICHMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
PILOT (IDLE AND SLOW) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4
MAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
FLOAT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
PILOT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
AIR/FUEL MIXTURE RATIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
NEEDLE JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
THROTTLE OPENING VS. FUEL FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
CARBURETOR DISASSEMBLY – MIKUNI CV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
CARBURETOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
CARBURETOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
FLOAT HEIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
NEEDLE AND SEAT LEAKAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL LEVEL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
FUEL TANK/FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
FUEL TANK / FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
4.1
FUEL / AIR / EXHAUST
GENERAL INFORMATION AND Carburetor Specifications
SPECIFICATIONS
2007 Hawkeye 2x4 / 4x4
Special Tools (Domestic and International)
Never start the engine or let it run in an A main jet that is too small will cause a lean
enclosed area. Gasoline powered engine operating condition resulting in serious engine
exhaust fumes are poisonous and can cause damage. Select the correct main jet carefully for
loss of consciousness and death in a short elevation and temperature according to the charts in
time. the Specifications section or in the Owner’s Safety
and Maintenance Manual for each particular model.
Never drain the float bowl when the engine is
hot. Severe burns may result.
Mikuni Jet Part Numbers
Do not smoke or allow open flames or sparks Main Jets Pilot Jets
in or near the area where refueling is Jet Number Part Number Jet Number Part Number
performed or where gasoline is stored. 130 3130561 25 n/a
132.5 3130562 27.5 n/a
If you get gasoline in your eyes or if you 135 3130563 30 n/a
137.5 3130564 32.5 n/a
should swallow gasoline, seek medical 140 3130527 35 n/a
attention immediately. 142.5 3130566 37.5 n/a
145 3130567 40 3130624
147.5 3130568 42.5 3130526
If you spill gasoline on your skin or clothing, 152.5 3130570 45 3131397
immediately wash with soap and water and 155 3130571 47.5 3131226
change clothing. 157.5 3130572 50 3131132
160 3131141 55 n/a
NOTE: It is strongly recommended that Polaris Carbon 162.5 3131142 57.5 n/a
165 3131143 60 n/a
Clean be added regularly as directed to the fuel systems 167.5 3131144 65 n/a
of all Polaris ATVs. Carbon Clean stabilizes the fuel, 170 3131145 70 n/a
preventing clogging of the small passages and orifices
common to ATV carburetors, and ensures constant
performance, reliability and easier starting.
4.2
FUEL / AIR / EXHAUST
CARBURETION
BST 34 Carburetor Exploded View 1 of 2
A
G
H
4
C
N
M
P L
D
J
E
F
G Cover
H Spring
4.3
FUEL / AIR / EXHAUST
BST 34 Carburetor Exploded View 2 of 2
A D
B F
C
E
J
K
F Spring
H Floats
4.4
FUEL / AIR / EXHAUST
Carburetor Venting System
D
B
E
C
C Hose (Vents)
D Tee Fitting
E Filter
4.5
FUEL / AIR / EXHAUST
CV Carburetor System Function Carburetor Venting
The carburetor float bowl vent lines supply atmospheric
Carburetor Component Function pressure to the float bowl. The lines must be free of kinks,
Main Main Main restrictions and be properly routed. This allows fuel to flow in
System the proper amount and prevents contaminants from entering the
Components Function Affect carburetor.
Float Inlet Pipe, Maintains All systems
System Needle and specified fuel All throttle Mikuni CV Carb Operation
(Level Seat, Float, level in float ranges
Control) Float Pin chamber The constant velocity carburetor incorporates a mechan-
(carburetor float ically operated throttle plate and a vacuum controlled
bowl) slide valve (vacuum slide). The venturi cross–sectional
Venting Passages in Supplies All systems area in the carburetor bore is increased or decreased
Carburetor, Vent atmospheric All throttle automatically by the vacuum slide, which moves accord-
lines pressure to float ranges ing to the amount of negative pressure (less than atmo-
to frame chamber spheric) present in the venturi.
A diaphragm attached to the top of the vacuum slide is sealed to
Starter Choke Lever, Supplies All throttle the slide and to the carburetor body forming two chambers. The
chamber above the diaphragm is connected to the venturi area
(Choke/ Cable, Plunger, additional fuel ranges by a drilled orifice in the center of the vacuum slide. The
Enrichment) Return Spring, air mixture Greatest chamber below the diaphragm is vented to atmospheric pressure
Carb Passages necessary for effect at low by a passage on the air box side of the carburetor. A spring,
installed in the center of the vacuum slide, dampens the slide
(Starter Jet, cold starting throttle movement and assists the return of the slide.
Starter Bleed settings and
Pipe) idle
Low Pressure
Diaphragm
From Venturi
4.6
FUEL / AIR / EXHAUST
When the throttle plate is opened and engine speed begins to Starter System (Choke or Enrichment)
increase, the pressure in the venturi (and therefore in the
chamber above the diaphragm) becomes significantly lower When the choke cable (1) is activated, the starter plunger (5) is
than atmospheric. Atmospheric pressure in the chamber below lifted off the seat.
the diaphragm forces the diaphragm upward, raising the slide
against spring pressure. When the pressure above and below the 8
diaphragm are nearly equal, the slide moves downward under 5 1
spring pressure. Raising or lowering the slide increases or
decreases the cross sectional area in the venturi, and therefore
the air velocity in the venturi is kept relatively constant. This
provides improved fuel atomization and optimum fuel/air ratio.
7 6
2
3 4
Fuel is drawn into the starter circuit from the float chamber (2)
through the starter jet (3). Starter jet meters this fuel, which then
flows into starter pipe (4) and mixes with the air (7) coming from
the float chamber. The mixture, rich in fuel content, reaches
starter plunger and mixes again with the air coming through a
passage (8) extending from underneath the diaphragm. The rich
fuel/air mixture for starting is discharged through starter outlet
(6) in the main bore.
Note: Diagrams are for explanation of theory only, and are not true
representations of Mikini BST carburetor.
4.7
FUEL / AIR / EXHAUST
Pilot (Idle and Slow) System Main System
This system supplies fuel during engine operation with throttle As throttle valve (1) is opened, engine speed rises, and this
valve closed (1) or slightly opened. The fuel from float chamber increases negative pressure in the venturi. Consequently the
(2) is metered by pilot jet (3) where it mixes with air coming in vacuum slide (2) moves upward. The fuel in float chamber (3)
through pilot air jet (4). The mixture then goes up through pilot is metered by main jet (4), and the metered fuel enters needle jet
passage to pilot screw (5). A part of the mixture is discharged (5), in which it mixes with the air admitted through main air jet
into the main bore out of bypass ports (6). The remainder is then (6) to form an emulsion. The emulsified fuel then passes through
metered by pilot screw and discharged into the main bore the clearance between needle jet (5) and jet needle (7), and is
through pilot outlet (7). discharged into the venturi (A). Mixture proportioning is
accomplished in needle jet (5); the clearance through which the
emulsified fuel must flow is determined ultimately by throttle
position and vacuum slide height.
1
1
A
6
5
2
3
5 3
4.8
FUEL / AIR / EXHAUST
Float System Pilot Screw
Fuel enters the float chamber (3) by means of the inlet pipe and The pilot system supplies fuel during engine operation with the
passage, through a screen on the back of the inlet needle seat (4), throttle valve closed or slightly opened. The fuel/air mixture is
and around the inlet needle (2). As the fuel fills the float metered by pilot screw and discharged into the main bore
chamber, the float (1) rises and forces the inlet needle against the through the pilot outlet.
seat, shutting off the orifice in the seat. When fuel level is up in
float chamber, floats are up and needle valve remains pushed up
against valve seat. Under this condition, no fuel enters the float CAUTION
chamber. As the fuel level falls, floats go down and needle valve
unseats itself to allow fuel into the chamber. In this manner, the
needle valve releases and shuts off fuel alternately to maintain The pilot screw is calibrated at the factory to meet
a constant fuel level inside the float chamber. EPA / CARB regulations for air quality standards
and is sealed with a brass plug to prevent tampering.
Removal of the tamper proof plug is not permitted.
For service purposes, cleaning of the pilot circuit can
be done only by a certified repair shop to ensure air
quality standards are not exceeded.
4
Inlet
Pipe
Pilot Screw Location
4 2
4.9
FUEL / AIR / EXHAUST
Air/Fuel Mixture Ratio higher produces a leaner mixture. If the taper is worn due to
vibration, fuel flow may be significantly affected.
E-Clip Position vs. Fuel Flow Jet Needle
2
3 Leaner
4
Position#
4
Richer
Needle Jet
15 50 75 100% The needle jet works in conjunction with the jet needle to
Throttle Valve Opening regulate fuel flow rate. An air bleed opening in the side of the
needle jet brings in air measured by the air jet. This air initiates
the mixing and atomizing process inside the needle jet.
A carburetor with a slide type throttle valve is also called a
variable venturi type carburetor. In this type of carburetor, the
needle jet and jet needle serve to control proper air/fuel mixture
ratio at the medium throttle valve opening (between 1/4 and 3/ Needle Jet
4 opening).
Having the proper needle jet and jet needle has a major impact
on engine performance at partial load. The jet needle tapers off
at one end and the clearance between the jet needle and the
needle jet increases as the throttle valve opening gets wider. The
air/fuel mixture ratio is controlled by the height of the “E” clip
inserted into one of the five slots provided in the head of the jet
needle. The previous chart shows the variation of fuel flow
based on the height of the “E” clip. Main Jet
Jet Needle
The jet needle has five adjustment grooves cut into the upper
portion, and is tapered from approximately the middle of the
needle to the lower end. The top is fixed to the center of the
throttle valve by the needle clip, and the tapered end extends into
the needle jet. Fuel flows through the space between the needle
jet and jet needle. This space does not vary until the throttle
reaches the 1/4 open point. At that time the tapered portion of the
needle begins to move out of the jet, affecting fuel flow as the
opening enlarges. If the needle clip is changed from the standard
position to a lower groove, the needle taper starts coming out of
the jet sooner, resulting in a richer mixture. Moving the clip
4.10
FUEL / AIR / EXHAUST
Throttle Opening vs. Fuel Flow 2. Remove float bowl. Remove the float pin screw. The float
and float pin can be removed.
In a full throttle condition the cross sectioned area between the
jet needle and the needle jet is larger than the cross sectioned
area of the main jet. The main jet therefore has greater control
over fuel flow.
Small Medium Large
Clearance Clearance Clearance
4
3. Remove inlet needle seat retaining screw along with plate,
and carefully remove needle seat. NOTE: Do not use a
pliers to remove the seat or permanent damage may occur.
O-Ring
Washer
Spring
Pilot Screw
4.11
FUEL / AIR / EXHAUST
NOTE: The starter jet is removable. Upon disassembly, Carburetor Inspection
place the parts in a container for safe keeping.
1. Inspect jet needle and needle jet for wear. Look for
discoloration, shiny spots, or an area that looks different
than the rest of the needle. The middle to upper portion of
the needle contacts the needle jet and is the most likely
wear point. If jet needle shows signs of wear replace both
the needle and needle jet to prevent a rich condition. TIP:
A worn needle jet is difficult to spot. To check, slide a
slightly larger new jet needle into the needle jet and hold it
to a light source. Light will be visible between the needle
and needle jet if it is worn.
Needle Jet
Jet Needle
Carburetor Cleaning
Inspect this
WARNING area
4.12
FUEL / AIR / EXHAUST
Carburetor Assembly the engine running. Refer to Chapter 2.
2. With the carburetor still resting on the level surface, use one
hand to slightly tilt the carburetor back. The float will then
1. Replace parts in proper order. The spring seat (B) is fall into the correct position, with the float tongue resting
stepped and must be placed on TOP of “E” Clip (C). lightly on the inlet needle valve pin without compressing
Spacer washer (D) must be installed below the E–Clip. the spring. The bottom of the float should be parallel with
Refer to parts manual for more information. the float bowl mating surface. NOTE: If the float is past
2. Be sure the tab (E) on outer edge of diaphragm is positioned parallel with the mating surface, the carburetor has been
properly in the carburetor body. tilted back too far and the float tongue is likely compressing
the needle valve pin.
FRONT
(Engine)
Pilot Screw
4.13
FUEL / AIR / EXHAUST
3. Measure the height from the float bowl mating surface to Fuel Level test
the top of step of the float as shown in Illustration 2. Both
sides of float should be parallel to each other. The A fuel level test can be performed on some models if the drain
measurement should be made at the mid–point on top of the hose fitting is accessible. Be sure to re–attach the bowl drain
float using Float Adjustment Tool (PN 2872314) or a hose after performing the test. A fuel level test allows you to
vernier caliper. When measuring the height, be sure the observe the height of the fuel in the float bowl without removing
inlet needle valve spring is not compressed. the carburetor. The fuel level can be observed with the engine
either running or shut off, however, engine must run briefly to
allow fuel level to stabilize.
Float Bowl Height: 13-14 mm
1. Attach a clear line to drain fitting. Be sure line fits tightly
4. If adjustment is necessary, bend the tongue slightly. Be sure on fitting. Position hose along side of carburetor as shown.
float measurement is even on left and right side.
1.5 mm
.060 in. Bowl Mating
Surface
4.14
FUEL / AIR / EXHAUST
Troubleshooting POOR IDLE
4.15
FUEL / AIR / EXHAUST
AIR INTAKE SYSTEM
Air Intake System
G H
4.16
FUEL / AIR / EXHAUST
FUEL TANK/FUEL DELIVERY SYSTEM
Fuel Tank / Fuel Delivery System
B D
E 4
F
N
J
G
K
4.17
FUEL / AIR / EXHAUST
EXHAUST SYSTEM
Exhaust System
2 Muffler
3 Gasket - Plug
4 Gasket - Muffler
5 Head Pipe
6 Nut
7 Washer
8 Flange Gasket
9 Bolt
10 Nut
11 Springs
4.18
BODY / STEERING / SUSPENSION
CHAPTER 5
BODY / STEERING / SUSPENSION
PLASTIC RETAINER INSERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SEAT / SIDE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
FRONT CAB/FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
FRONT CAB/FENDER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
FRONT CAB/FENDER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
REAR CAB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
FOOTWELL REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
BODY RACK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
REAR RACK REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
POD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
POD/KEY SWITCH/CHOKE/SPEEDO CONNECTION REMOVAL/INSTALLATION. . . . 5.9
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
HANDLEBAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
HANDLEBAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5
STEERING POST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
STEERING POST BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
STEERING POST INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
A-ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
A-ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
FRONT STRUT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
FRONT STRUT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
FRONT STRUT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
BALL JOINT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
REAR CONTROL ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
UPPER AND LOWER REAR CONTROL ARM REMOVAL/INSTALLATION . . . . . . . . . 5.19
5.1
BODY / STEERING / SUSPENSION
PLASTIC RETAINER INSERTS 3. To install the inserts, press outside insert (B) into the hole.
Press inside insert (A) until it snaps into place.
Removal / Installation NOTE: The outside insert (B) should be flush
surface after installation.
Some Polaris ATVs use a two piece plastic insert in place of a
metal screw. The plastic inserts are simple to remove and install.
1. Use a a pair of diagonal side cutters to lift the plastic insert
(A) until you feel some slight pressure or lift the insert
approximately 1/4" (6.35 mm). Apply just enough pressure
on the side cutters to lift up on the insert. DO NOT apply
too much pressure on the side cutters, or damage to the
insert will occur.
A
The inside insert (A) should be flush with the top of the outside
insert (B).
A
B
2. Next, use the diagonal side cutters under outside insert (B)
to completely remove the assembly. NOTE: The inside
insert (A) will still be installed in the outside insert (B).
5.2
BODY / STEERING / SUSPENSION
SEAT / SIDE PANEL 3. Reinstall the side panel by reversing the removal procedure.
Step 3
Removal / Installation
Use the following instructions for removal and installation:
1. Remove seat by releasing the latch and lifting up on the
seat.
Step 1
5
2. Grasp the rear of the side panel near the rear cab. With a
firm motion, pull the panel outward to disengage the side
panel from the grommet. Pull the panel downward and
rearward to remove it from the ATV.
Step 2
5.3
BODY / STEERING / SUSPENSION
FRONT CAB/FENDER
5.4
BODY / STEERING / SUSPENSION
Front Cab/Fender Removal
For this procedure please refer to the diagram on 5.4.
1. Remove the seat.
2. Remove the fuel tank cover (4).
3. Remove the side panels (1,3).
4. Remove the plastic rivets on the mud guards (below) and remove them from the front cab assembly.
5
5. Remove the battery connections (negative first).
6. Remove the battery from the battery compartment.
7. Route the battery cables through the front compartment.
8. Remove the front cab fasteners (8).
9. Remove the plastic rivets from the footwells.
10. Carefully lift off the front cab.
5.5
BODY / STEERING / SUSPENSION
BODY ASSEMBLY
Exploded View
5.6
BODY / STEERING / SUSPENSION
Rear Cab Removal/Installation
1. Follow the procedure to remove the rear rack. See “Rear Rack Removal/installation” on page 5.8.
2. Remove the screws (1,19) that secure the rear cab to the frame.
3. Remove the plastic inserts (9) that secure the rear cab to the frame footwells (11,14).
4. Disconnect the rear lights.
5. Lift the rear cab (4) from the frame.
6. Reverse the removal steps for installation.
Footwell Removal/Installation
1. Remove the plastic inserts (A) that secure the wheel well to the front and rear cabs. See “PLASTIC RETAINER INSERTs”
on page 5.2.
2. Remove the screws (B) from the bottom of the foot well. Remove the footwell.
3. Reverse the removal procedures to install the foot well.
NOTE: Be sure to properly align the cab ends into the footwells upon reassembly.
B
5.7
BODY / STEERING / SUSPENSION
BODY RACK EXPLODED VIEW
5.8
BODY / STEERING / SUSPENSION
POD EXPLODED VIEW
1. The pin (A) on the bottom side of the top handlebar block faces down and to the front of the ATV.
2. The bottom handle bar block has a side with 3 holes, the side with 3 holes faces up and to the front of the ATV.
3. Align the pin (A) in the top block with the middle hole (B) in the bottom block for proper installation. The pin (A) and middle
hole (B) should face the front of the ATV.
4. Install the pin side bolts first and evenly tighten the bolts down. Torque the 2 front bolts to specification.
=T
Handle Bar Bolt Torque
11-13 ft.lbs.(15-18 Nm)
5. Install the rear bolts and tighten evenly. Evenly torque the 2 rear bolts to specification.
NOTE: Pod bracket installation required (Refer to page 5.9). There will also be a slight gap on the backside of
the blocks after the procedure is performed.
5.10
BODY / STEERING / SUSPENSION
Steering Post Removal 9. Remove the steering tie rod ends (D) from the steering
bracket (E). Note the orentation of the fasteners and bracket
1. Remove the front cab. See “FRONT CAB/FENDER” on on the steering assembly.
page 5.4.
2. Remove the handle bar pod. See “Pod/Key Switch/Choke/
Speedo Connection Removal/Installation” on page 5.9.
E
3. Remove the handle bar. See “POD EXPLODED VIEW” on
page 5.9. D
4. Remove the fuel tank bracket (A).
10. Remove the steering post bracket (F) at the front gear case
(4x4 shown)/plate (2x4).
F
5
5. Turn the fuel valve to the “OFF” position
6. Remove the fuel line (B) from the fuel pump (C).
C
11. Remove the top steering bracket (G).
B G
7. Remove the vent line from the frame that comes from the
top of the fuel tank. Note the vent line routing.
8. Remove the fuel tank from the frame.
5.11
BODY / STEERING / SUSPENSION
Steering Post Bearing Replacement Steering Post Installation
1. Remove the steering post. 1. Insert the steering post assembly into the chassis.
2. Press out the steering post cotter pin (A). 2. Place the lower bracket (F) into the front gear case on the
3. Remove the steering post nut (B), bushing (C). 4x4 units, and into the bracket on the 2x4 units.
4. Inspect the bushings 3. Apply blue Loctite to the threads of the bracket bolts.
5. Remove and replace the bearing (D). 4. Torque the bolts to specification.
6. Install the bearing as shown in the image.
7. Torque the steering post nut (B) to specification. F
8. Install a new cotter pin (A).
NOTE: Make sure that the cotter pin is not
obstructing steering movement.
B
=T
A
2x4 4x4 Steering Post Bearing Bracket
19-22 ft-lb (26-30Nm)
=T
Upper Steering Post Bracket
22 ft-lb (30Nm)
6. Place the tie rod retainer (H) on to a tie rod bolt (I).
7. Insert the tie rod bolts from the bottom of the tie rod, and
line up the retainer to the bottom of the tie rods.
5.12
BODY / STEERING / SUSPENSION
8. Torque the tie rod fasteners to specification. 13. Hook up the fuel line to the fuel pump and move the clamp
to the correct area.
I H
=T 5
Tie Rod Fasteners
40 ft-lb (54Nm)
11. Place the fuel tank bracket in place. Note to get the routing
of the throttle cable and carburetor venting correct.
12. Tighten the fuel tank bracket fasteners.
5.13
BODY / STEERING / SUSPENSION
FRONT SUSPENSION
Exploded View
NOTE: To avoid damage to tie rods and other steering 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. Be sure inner rod
ends are placed between the steering post arms. Replace all cotter pins if removed (4,11).
5.14
BODY / STEERING / SUSPENSION
A-arm Removal
Refer to drawing on page 5.14
1. Apply parking brake and loosen the lug nuts.
2. Elevate the front of the machine and secure it with jack stands.
3. Remove the rim from the hub and release the parking brake.
4. Remove the pinch bolt (10) and nut (9) that hold the A-Arm ball joint (13) to the carrier bearing assembly.
5. Remove the flange bolt (19) and flange nut (3) from the frame.
6. Remove A-Arm.
WARNING
A-Arm Assembly
Refer to drawing on page 5.14 5
1. Assemble A-Arm with all bushings (17), pivot tube (18), ball joint (12,13), and brush guard (15) (if applicable).
2. Place the A-Arm to the frame and insert the flange bolt (19) with the head toward the front of the machine and the flange nut
(3) toward the rear.
3. Torque the flange bolt (19) to specification.
=T
A-Arm Flange Bolt
40 ft-lb (54Nm)
4. Insert the ball joint (13) far enough into the carrier bearing assembly so that the pinch bolt (10) can be inserted.
5. Insert the pinch bolt (10) so that the flange head is at the front of the machine and the flange nut (9) is at the rear.
6. Torque the pinch bolt to specification.
=T
Pinch Bolts
20 ft-lb (27Nm)
WARNING
5.15
BODY / STEERING / SUSPENSION
FRONT STRUT SERVICE
5.16
BODY / STEERING / SUSPENSION
Front Strut Removal BALL JOINT
Refer to drawing on page 5.16
Replacement
1. Remove the wheel on the side of the strut that is to be
replaced.
2. Remove the front cab.
3. With an open end wrench hold the shock tower nut (16) and
with a socket turn the shock rod.
4. Remove the screw that holds on the brake line to the strut. 1
5. Remove the carrier bearing assembly fasteners (4,7).
6. Remove the strut from the vehicle.
=T
Carrier Bearing Fasteners
37 ft-lb (50Nm)
5. Replace the torx fastener that holds the brake line in place.
6. Replace front cab.
Bearing Replacement
Refer to drawing on page 5.16
1. Remove the front bearing carrier (1).
2. Remove the snap ring (3) from the bearing carrier.
3. Press out the bearing (2).
4. Press in new bearing.
5. Replace the snap ring
6. Install bearing carrier.
7. Torque the bearing carrier to strut mounting fasteners to
specification.
5.17
BODY / STEERING / SUSPENSION
REAR CONTROL ARMS
Exploded View
5.18
BODY / STEERING / SUSPENSION
Upper And Lower Rear Control Arm Removal/Installation
Described in this section is for one side of the machine. Duplicate this process for the other side.
1. Raise and secure the rear of the machine.
2. Remove the rear wheel.
3. Remove the rear shock.
4. Remove the Upper Control Arm (UCA) (15) fasteners (1,4,12) from the transmission and bearing carrier. Note the long (12,14)
and short (1,3) fasteners and pivot shaft locations.
5. Remove the x short grey bushings (2) and pivot shafts (3,14).
6. Remove the Lower Control Arm (LCA) (11) fasteners (4,5,12) from the frame and bearing carrier. Note the long (5,8) and
short (12,14) fasteners and pivot shaft locations.
7. Remove the long grey bushings (9) and pivot shaft (8) from the frame.
8. Remove the short bushings (13) and pivot shaft (14) from the bearing carrier.
9. Remove the LCA (11) from the unit.
10. Replace in reverse order with the following torque values.
=T
• LCA to Bearing Carrier 40 ft-lb (54Nm) 5
• LCA to Frame 40 ft-lb (54Nm)
• UCA to Bearing Carrier 40 ft-lb (54Nm)
• UCA to Transmission 40 ft-lb (54Nm)
• Shock Mounts (top and bottom) 40 ft-lb (54Nm)
• Wheel Lug Nuts 27 ft-lb (37Nm)
5.19
BODY / STEERING / SUSPENSION
NOTES
5.20
BRAKES
CHAPTER 6
BRAKES
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
BRAKES / TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
BRAKE NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
BRAKE SYSTEM MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
REAR MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
HAND BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
FRONT CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
THICKNESS / RUNOUT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
WEAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
FOOT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
FOOT PEDAL REMOVAL / INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
FOOT BRAKE MASTER CYLINDER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . 6.18
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
BRAKE SQUEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
6.1
BRAKES
SPECIFICATIONS
Brakes / Torque
NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures
are used when torquing certain bolts and fasteners. Do not re-use fasteners that have pre-applied locking
agents.
6.2
BRAKES
TROUBLESHOOTING
Brake Noise
Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning
does not reduce the occurrence of brake noise, a product such as Permatex™ Disc Brake Quiet or an equivalent can be applied to
the back of the pads. Follow directions on the package. This will keep pads in contact with caliper piston(s) to reduce the chance
of squeaks caused by dirt or dust.
6.3
BRAKES
Apply a Light
Amount of Pipe
Sealant to Threads
6.4
BRAKES
BRAKE CALIPER
Exploded View
A.Bleeder Screw C A
B. Caliper Body
C. Internal Caliper Slide Pin O-rings (small) B
D. Square Seals
E. Piston
F. Caliper Mount
G. Brake Pads D
H. Internal Caliper Slide Pin O-rings (large)
I. Caliper mount O-ring
E
H
6
F
6.5
BRAKES
HYDRAULIC BRAKE SYSTEM master cylinder piston is outward. As the temperature within the
hydraulic system changes, this port compensates for fluid
Operation Overview expansion (heated fluid) or contraction (cooled fluid). During
system service, be sure this port is open. Due to the high
Must be clear to Compensating port temperatures created within the system during heavy braking, it
allow proper E compensates for is very important that the master cylinder reservoir have
diaphragm temperature changes adequate space to allow for fluid expansion. Never overfill the
by allowing fluid back reservoir! Fill to 1/4, - 5/16, (.64 - .80 cm) from top of the
to master cylinder cylinder.
WARNING
The Polaris disc brake system consists of the following Once a bottle is opened, use what is necessary and
components or assemblies: hand brake lever; foot brake lever, discard the rest in accordance with local laws. Do
hand and foot brake master cylinders; hydraulic hoses; brake not store or use a partial bottle of brake fluid. Brake
calipers (slave cylinders); brake pads; and brake discs, which fluid is hygroscopic, meaning it rapidly absorbs
are secured to the drivetrain. moisture. This causes the boiling temperature of
the brake fluid to drop, which can lead to brake fade
When the hand activated brake lever (A) is applied it contacts
and the possible loss of control.
piston (B) within the master cylinder. As the master cylinder
piston moves inward it closes a small opening (compensating
port C) within the cylinder and starts to build pressure within the
brake system. As the pressure within the system is increased,
the piston (D) located in the brake caliper moves outward and
applies pressure to the brake pad. This pad contacts the brake
disc and moves the caliper in its floating bracket, pulling the
stationary side pad into the brake disc. The resulting friction
reduces brake disc and vehicle speed. As the lever pressure is
increased, the braking affect is also increased.
The friction applied to the brake pads will cause the pads to
wear. As these pads wear, the piston within the caliper moves
further outward and becomes self adjusting. Fluid from the
reservoir fills the additional area created when the caliper piston
moves outward.
6.6
BRAKES
REAR MASTER CYLINDER • Make sure the brake lever and pedal returns freely and
completely.
Operation Overview • Adjust stop pin on front caliper after pad service.
Brake Fluid Reservoir • Check and adjust master cylinder reservoir fluid level
after pad service.
• Make sure atmospheric vent on reservoir is
unobstructed.
• Test for brake drag after any brake system service and
investigate cause if brake drag is evident.
• Make sure caliper moves freely on guide pins (where
Rear Brake MC applicable).
Frame • Inspect caliper piston seals for foreign material that
could prevent caliper pistons from returning freely.
Rear Brake Line
CAUTION
Spring
Use only DOT 3 or 4 brake fluid as an assembly aid
for all procedures described in this chapter to
Brake Mount prevent brake system contamination. DO NOT USE
LUBRICANTS OF ANY KIND FOR ASSEMBLY, AS
THEIR USE CAN CAUSE RUBBER
Brake Lever COMPONENTS TO SWELL.
6
When the foot activated brake lever is applied it contacts piston
of the master cylinder. As the pressure within the system is
increased, the piston located in the brake calipers move outward
and apply equal pressure to the brake pads.
6.7
BRAKES
BRAKE BLEEDING bleeder until the fluid runs clear.
Sight Glass
Fluid Change C
CAUTION
6.8
BRAKES
Bleeding Procedure 9. Install diaphragm, cover and screws. Align any marks (if
present) into the proper holes in the master cylinder.
1. Begin bleeding procedure with the caliper that is farthest Wiggle and press down on the cap to be sure it fits evenly
from the master cylinder. Install a box end wrench on and snug. Torque the screw to 7 in.lbs. (0.79 Nm).
caliper bleeder screw. Attach a clean, clear hose to fitting
and place the other end in a container. Be sure the hose fits
tightly on fitting.
NOTE: Fluid may be forced from supply port (B) if
brake lever is pumped. Place diaphragm (C) in
reservoir to prevent spills. Do not install cover tight.
See Illustration above.
Maintain at least 1/2, (1.27 cm) of brake fluid 7 in.lbs. (0.79 Nm)
in the reservoir to prevent air from
entering the master cylinder.
10. Field test machine at low speed before putting into service.
Check for proper braking action and lever reserve. With
lever firmly applied, lever reserve should be no less than 1/
2”, (1.3 cm) from handlebar.
11. Check brake system for fluid leaks and inspect all hoses and
lines for wear or abrasion. Replace hose if wear or abrasion
is found.
6.9
BRAKES
HAND BRAKE MASTER CYLINDER Installation
NOTE: When replacing the brake master cylinder
Removal
assembly or master cylinder parts, use the correct
1. Clean master cylinder and reservoir assembly. Make sure parts. There are different brake master cylinders for
you have a clean work area to disassemble brake the different Polaris ATV models. Refer to your parts
components. manual or guide for the correct parts. Some master
cylinders are not serviceable and are replaced as an
assembly.
2. Remove the banjo bolt that connects the brake line to the
master cylinder. Discard the copper washers.
6.10
BRAKES
2. Place NEW sealing washers on each side of banjo line and BRAKE PADS
torque banjo bolt to specification.
Torque to specification (15 ft.lbs.) Removal
Sealing Washer 1. Loosen the wheel nuts. Elevate and support front of
machine and remove the tire(s).
CAUTION
Banjo Bolt
Use care when supporting vehicle so that it does not
tip or fall. Severe injury may occur if machine tips
or falls.
6.11
BRAKES
4. Push mounting bracket inward and slip outer brake pad past Installation
edge. Remove inner pad.
1. Lubricate mounting bracket pins and external slide pin O-
ring with a light film of Polaris Premium All Season
Grease (PN 2871423).
WARNING
Measure Pad
6.12
BRAKES
3. Install caliper on hub strut, and torque mounting bolts. FRONT CALIPER
Removal
CAUTION
4. Slowly pump the brake lever until pressure has been built
up. Maintain at least 1/2, (12.7 mm) of brake fluid in the
reservoir to prevent air from entering the brake system.
5. Verify fluid level in reservoir is up to MAX line inside
reservoir and install reservoir cap.
6. Install wheels and torque wheel nuts to specification.
NOTE: Front Wheel Nut Torque: Refer to Torque
Table at beginning of chapter. 6
2. Push pad retainer pin inward and slip brake pads past the
pin edges. A pliers may be used to compress the pad retainer
for removal if the pads are too thick. Use caution not to bend
or damage the retainer or the brake pad ears.
6.13
BRAKES
3. Remove mounting bracket pin assembly . 5. Remove the four (4) O-rings from the caliper body. Note
the orientation of the O-rings for reassembly. Clean the
caliper body, piston, and retaining bracket with brake
cleaner or alcohol.
NOTE: Be sure to clean grooves in caliper body. Do
not use a petroleum based spray to clean the caliper.
4. Remove piston using a twisting, pulling motion. Remove NOTE: O-ring grooves are size-specific
the piston square seals using a wooden or plastic pick. Use
caution not to scratch or damage the piston or the bore of
the caliper.
NOTE: Do not use a metal pick or awl to remove the
Clean Components
square seals.
CAUTION
6.14
BRAKES
Inspection Reassembly
1. Inspect caliper body for nicks, scratches or wear. Measure 1. Install new piston square seals (A) in the caliper body (B).
bore size and check for out of round. Replace if damage is Be sure groove is clean and free of residue or brakes may
evident or if worn. drag upon assembly.
C
B
2. Inspect piston for nicks, scratches, wear or damage. 2. Coat piston with clean Polaris DOT 3 or DOT 4 Brake Fluid
Measure diameter and replace if damaged or worn beyond (C). Install piston (D) with a twisting motion while pushing
service limit. inward. Piston should slide in and out of bore smoothly,
with light resistance.
3. Install new slide pin O-rings in the caliper body for the 6
Lubricate the mounting bracket pins with Polaris Premium
All Season Grease (PN 2871423), and install..
NOTE: Do not use grease on the square seals.
Petroleum based lubricants will cause the square
seals to swell. Lubricate with brake fluid only.
3. Inspect the brake disc and pads as outlined for brake pad
replacement this section. See “BRAKE PAD
INSPECTION” in this chapter.
6.15
BRAKES
4. Compress the mounting bracket into the caliper and make BRAKE BURNISHING PROCEDURE
sure the O-rings are fully seated. Install the brake pads.
Clean the disc and pads with brake parts cleaner or Overview
denatured alcohol to remove any dirt, oil or grease.
It is required that a burnishing procedure be performed after
installation of new brake pads to extend service life and reduce
noise.
Installation
1. Install caliper on hub strut, and torque mounting bolts.
22 ft.lbs.
(30 Nm)
6.16
BRAKES
BRAKE DISC Wear Inspection
1. visually inspect disc for scoring, scratches, or gouges.
Thickness / Runout Inspection
replace the disc if any deep scratches are evident.
1. Visually inspect the brake disc for nicks, scratches, or 2. use a 0-1” micrometer and measure disc thickness at 8
damage. different points around perimeter of disc. replace disc if
2. Measure the disc thickness at eight different points around worn beyond service limit.
the pad contact surface using a 0-1, micrometer. Replace
disc if worn beyond service limit.
BRAKE DISC
Disc Thickness
6
= In. / mm.
6.17
BRAKES
Removal / Replacement FOOT BRAKE
NOTE: To reduce the possibility of warping, try
Foot Pedal Removal / Install
removing the brake disc mounting bolts before
applying heat to the bolts. 1. Remove the cotter key (A).
2. Remove the washers, bushings, and tension spring and
1. Apply heat to the hub in the area of the brake disc remove the brake lever (F).
mounting bolts to soften the bolt locking agent.
3. Reverse the steps for installation, using a new cotter key
during installation.
=T
2. Remove bolts and disc. Master Cylinder Fasteners: 8 ft.lbs. (11 Nm)
3. Clean mating surface of disc and hub.
4. Reinstall the brake line and torque the banjo bolt (with new
4. Install new disc on hub. copper washers installed) to specification. Torque the
5. Install NEW bolts and tighten to specification. flared fitting (if removed) to specification.
=T
Banjo Bolts: 22 ft.lbs. (30 Nm)
=T
Flare Fittings: 12-15 ft.lbs. (16-21Nm)
=T
C
Brake Rotor Fasteners: 18 ft.lbs. (24 Nm)
D
CAUTION
6.18
BRAKES
TROUBLESHOOTING
Brake Squeal
• Dirty/contaminated friction pads
• Improper alignment
• Worn disc
• Worn caliper
Brakes Lock
• Alignment of caliper to disc
• Compensating port plugged
• Parking brake left on
6.19
BRAKES
NOTES
6.20
FINAL DRIVE
CHAPTER 7
FINAL DRIVE
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
FRONT BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
BEARING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
PROPSHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
FRONT GEARCASE / CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
ALL WHEEL DRIVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
CENTRALIZED HILLIARD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
AWD DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
GEARCASE REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
REAR BEARING CARRIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
BEARING CARRIER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
BEARING CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
BEARING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
BEARING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
7
DRIVE SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
FRONT DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
REAR DRIVE SHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
OUTER CV JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
INNER PLUNGING JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
FRONT DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
REAR DRIVE SHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
7.1
FINAL DRIVE
GENERAL SPECIFICATIONS FRONT BEARING CARRIER
Torque Specifications Bearing Carrier Removal
1. Elevate front end and safely support machine under
Item Specification footrest / frame area.
Item Nut Type Specification 4. Remove the A-arm pinch bolt and remove the ball joint
from the bearing carrier (see Chapter 5 “A-arm Removal”).
Lug Nut
Aluminum Wheels 90 ft. lbs. (122 Nm) 5. Remove the steering tie rod from the front bearing carrier.
#1
Bolt
Steel Wheels Flange Nut
27 ft. lbs. (37 Nm)
(Black / Camo) #2 Tie Rod
Washer
#1 #2
Nut
Aluminum Wheel Steel Wheel Cotter Pin
90 ft. lbs. (122 Nm) 27 ft. lbs. (37 Nm)
Special Tools
Part Number Tool Description
7.2
FINAL DRIVE
7. Remove the cotter pin, wheel hub castle nut and washer. Bearing Removal
Then remove the front wheel hub assembly from the ATV.
1. Remove the inner snap ring retaining the bearing.
Wheel Hub
2. From the front side of the housing, tap on the outer bearing
race with a drift punch in the reliefs as shown.
Bearing
Washer
Snap Ring
Cotter Castle
Pin Nut
Bolts
4. Inspect the bearing housing for scratches, wear or damage.
Replace front bearing carrier if damaged.
7
Bearing Installation
1. Thoroughly clean the bearing housing and the outer race
on the new bearing. Be sure that all oil residue has been
9. Remove the front bearing carrier and rotate the bearing to removed from each surface.
check for smooth rotation. Visually inspect bearing for 2. Apply Loctite® RC™ 680 to the outer circumference of the
moisture, dirt, or corrosion. Replace bearing if any of these
new bearing race.
conditions exist.
NOTE: Use care to not allow any of the Loctite®
Bearing Carrier
compound to get in the bearing.
3. Support the bearing carrier in a press or suitable device.
CAUTION
Rotate
Bearing When using an arbor press be sure to press only
on the outer race, as bearing damage may occur.
7.3
FINAL DRIVE
Bearing Carrier Installation 6. Install a new cotter pin. Tighten nut slightly if necessary
to align cotter pin holes.
1. Install the front bearing carrier over the drive shaft and
reinstall the bearing carrier onto the strut. Torque strut 7. Install the front brake caliper and torque mounting bolts to
fasteners to specification. specification.
22 ft. lbs.
(30 Nm)
37 ft. lbs.
(50 Nm)
=T
Brake Caliper Mounting Bolts:
=T 22 ft. lbs. (30 Nm)
Front Strut to Bearing Carrier Bolts: 8. Attach the steering tie rod to the front bearing carrier and
37 ft. lbs. (50 Nm) torque the fastener to specification.
40 ft. lbs.
2. Place the A-arm ball joint into the lower portion of the (54 Nm)
bearing carrier and install the pinch bolt (see Chapter 5
“A-arm Installation”).
3. Apply grease to the drive shaft splines.
4. Install the front wheel hub onto the drive shaft and into the
front bearing carrier. Apply grease to the washer and install
the washer with the domed side facing out.
5. Install the castle nut and torque to specification.
NEW
Cotter Pin
NEW 80 ft. lbs.
Cotter Pin (108 Nm)
=T
Tie Rod Fasteners:
40 ft. lbs. (54 Nm)
7.4
FINAL DRIVE
PROPSHAFT SERVICE PROPSHAFT U-JOINT SERVICE
Removal Disassembly
1. Remove right-hand mud guard to allow access to the 1. Remove internal or external snap ring from bearing caps.
propshaft roll pin (see Chapter 5 “Front Cab Removal”).
2. Using Roll Pin Removal Tool (PN 2872608), remove the CAUTION
roll pin from the propshaft at the rear of the front gearcase.
Always wear eye protection.
Installation 2. Support inner yoke as shown and drive outer yoke down
(bearing cap out) with a soft face hammer. 7
1. Apply anti-seize compound to all splines. Slide propshaft
back onto the transmission output shaft, then slide it up
onto the front gearcase input shaft, verify pin holes are
aligned.
2. Using Roll Pin Tool (PN 2872608), install a NEW roll pin
(spring pin) into the prop shaft.
3. Reinstall the right-hand mud guard (see Chapter 5 “Front
Cab Installation”).
7.5
FINAL DRIVE
3. Support U-joint in vise as shown and drive inner yoke down 3. Using a suitable arbor, fully seat the bearing cap in one side.
to remove remaining bearing caps. Continually check for free movement of bearing cross as
bearing caps are assembled.
4. Force U-joint cross to one side and lift out of inner yoke.
4. Install snap ring to contain bearing cap just installed.
Repeat procedure for other side.
5. Install outer yoke, aligning marks made at disassembly and
repeat Steps 1-3 to install bearing caps on outer yoke.
6. Seat all bearing caps against snap rings by supporting cross
shaft and tapping on each corner as shown.
Assembly
1. Install new bearing caps in yoke by hand. Carefully install
U-joint cross with grease fitting properly positioned
inward toward center of shaft. Take care not to dislodge
needle bearings upon installation of cross joint.
7. When installation is complete, yokes must pivot freely in
2. Tighten vise to force bearing caps in.
all directions without binding. If the joint is stiff or binding,
tap the yoke lightly to center the joint until it pivots freely.
7.6
FINAL DRIVE
FRONT GEARCASE AWD Engagement: When the AWD switch is activated, the
AWD coil is powered by a 12 Vdc input which creates a
CENTRALIZED HILLIARD magnetic field. This magnetic field attracts an armature plate
that is keyed to the roll cage. When the ring gear and roll cage
All Wheel Drive Operation are spinning (vehicle is moving), the energized coil and
armature plate will apply drag to the roll cage that indexes the
The AWD switch may be turned on or off while the vehicle is rollers inside the ring gear to an engagement position. While in
moving, however, AWD will not enable until the engine RPM
drops below 3100. Once the AWD is enabled, it remains the engagement position, the front drive will be in an “over-
enabled until the switch is turned off. running” condition (not engaged), until the rear wheels lose
traction. Once the rear wheels begin to lose traction, the front
Engage the AWD switch before getting into conditions where
the front wheel drive may be needed. If the rear wheels are drive will engage by coupling the output hubs to the ring gear via
spinning, release the throttle before switching to AWD. the rollers. The front drive will remain engaged until the torque
requirement goes away (i.e. rear wheels regain traction).
With the AWD switch off, the vehicle drives through the
rearwheels only (2 wheel drive). When the AWD is enabled, the
front drive acts as an on-demand AWD system. This means, the
front drive will engage once the rear wheels have lost traction,
and will remain engaged until the torque requirement goes away Armature External Cam /
(i.e. rear wheels regain traction). Plate Ring Gear
7.7
FINAL DRIVE
Centralized Hilliard Exploded View
7.8
FINAL DRIVE
AWD Diagnosis 4. Check to make sure the coil is seated in the U-shaped insert
that is pressed into the gearcase housing. The top of the coil
Symptom: AWD Will Not Engage should be seated below the U-shaped insert. The U-shaped
1. Check the gearcase coil resistance. To test the gearcase insert controls the pole gap. If the top of the coil is above
coil resistance, use the coil harness. The gearcase coil the surface of the U-shaped insert it raises the armature
should measure between 21-24 Ohms and at 68 F (20 C). plate, thereby increasing pole gap. If the pole gap increases
the coil will not be strong enough to engage the AWD
system.
BN/WH to GY
Side Cutaway View of Gearcase Cover
Coil
U-Shaped Insert
5. Inspect the rollers for nicks and scratches. The rollers must
slide up and down, and in and out freely within the roll cage
2. Check the minimum battery voltage at the wire harness sliding surfaces.
connection that supplies voltage to the hub coil. There
should be a minimum of 11.80-12.0 Volts present for Rollers
proper operation.
Poor Condition:
(Wear from Coil on
Armature Plate)
7.9
FINAL DRIVE
Gearcase Removal 12. Remove the upper steering post bracket from the frame
bulkhead.
1. Stop engine, place machine in gear and set parking brake.
4. Elevate machine until the front wheels are off the ground
and support machine under footrest/frame area.
CAUTION
5. Remove hub retaining nuts, wheel nuts and wheels. 13. Remove the lower steering post bracket fasteners.
6. To remove the gearcase, the following items must be 14. Lift the steering post assembly from the front gearcase and
removed or disconnected so that the steering post brackets move it toward the center of the vehicle to allow enough
can be accessed and the post raised up: room for gearcase removal.
9. Remove the fuel tank cover (see Chapter 5). Place gas cap
back on tank to avoid spills.
10. Remove the front cab (see Chapter 5). 15. Remove cotter pin, ball joint pinch bolt, and remove the
A-arm from the front bearing carrier.
11. Remove the fuel tank (see Chapter 4).
7.10
FINAL DRIVE
16. Pull the strut assembly out and pull the drive-shaft out of Disassembly
the front bearing carrier.
1. Drain and properly dispose of used fluid. Remove any
17. Remove both front drive shafts from the front gearcase. metal particles from the drain plug magnet.
18. Remove the roll pin (spring pin) from the prop shaft. Use 2. Remove the T30 Torx screws and output cover.
the Roller Pin Removal Tool (PN 2872608).
21. Remove the front gearcase from either side of the frame.
4. Clean all parts and inspect for wear. Inspect ring gear
backlash pad (arrow) for wear or damage.
Vent Line
Route inside
steering column
Remove Bolts
NOTE: Backlash for the front gearcase is set at the
factory. No adjustment can be made.
7.11
FINAL DRIVE
5. Remove the output hub assembly from the left-hand 9. Inspect roll cage (B) sliding surface. This surface must be
gearcase half. Inspect surfaces for wear or signs of damage. clean and free of nicks, burrs or scratches. Inspect the H-
Replace component if found to worn or damaged. springs, but do not remove them. Replace any H-springs
that appear damaged or have lost radial tension.
B H-Spring
7. Thoroughly clean all parts. Inspect the rollers (A) for nicks
and scratches. The rollers must slide up and down freely
within the roller cage surfaces (B). 11. Inspect the output hub thrust bearing. Replace if wear or
damage is found.
B A
C E
8. Inspect the ring gear (C) for consistent wear patterns. The
surfaces should be free of nicks and scratches.
7.12
FINAL DRIVE
12. Inspect the output hub bearings (arrows). Replace bearings 14. Inspect the magnetic coil (I) in the output housing. Test the
if wear or damage is found. resistance of the coil using an ohmmeter. Replace case half
if coil is found to be non-functional or if the coil surface is
damaged.
E 15. Remove and inspect the input cover (M), bearing (N), and
the pinion gear (O). Inspect the pinion gear (O) for chipped,
7
broken, or missing teeth. Replace the input cover O-ring
and seal.
M
N
7.13
FINAL DRIVE
16. Inspect the output shaft bushing (arrow). Replace as Gearcase Reassembly
needed. Clean the inside surfaces of both gearcase halves.
1. Replace all O-rings, seals, and worn components as
previously mentioned.
2. Press the pinion shaft seal into the pinion cover, until the
seal is flush with the sealing surface.
17. Remove and replace the O-rings and seals (arrows) from
the gearcase halve assemblies.
=T
Gearcase T30 Torx Screws:
7-11 ft. lbs. (10-15 Nm)
4. Install the output hub (A) into the gearcase housing. Apply
a small amount of grease to the seal and seal surface as this
will aid assembly. The output hub should spin freely.
7.14
FINAL DRIVE
5. Install the rollers and roll cage into the ring gear. Insert the 8. Install the other output hub (B) and thrust bearing (C) into
rollers as the roll cage is installed, installing the lower row the output case half. Apply a small amount of grease onto
first and then the upper row. the seal surfaces to aid installation.
C B
6. Install the ring gear over the output hub and into the output 9. Install the left output case half onto the right-hand assembly
cover. Insert the backlash pad (G) and set assembly upright. by holding it as shown. Verify the backlash plate thrust
bearing and armature plate stay in place during assembly.
7. Install the armature plate (D) onto the ring gear. Verify the
plate tabs are places into the slots on the roller cage.
NOTE: Verify backlash plate stays in place.
7.15
FINAL DRIVE
10. Torque screws to specification. 2. Coat drive shaft splines with anti-seize compound. Install
both drive shafts into the gearcase. Light tapping may be
required to properly seat the splines into the gearcase.
3. Pull strut assembly out while pivoting the front drive shaft
upward until it enters the front bearing carrier assembly.
4. Install the lower A-arm ball joints into the front bearing
carriers.
=T
Lower A-arm Pinch Bolt:
20 ft. lbs. (27 Nm)
=T
6. Install the wheel hubs, washers and hub retaining nuts.
Torque the wheel hub nuts to specification.
Gearcase T30 Torx Screws:
7-11 ft. lbs. (10-15 Nm)
=T
Installation
Wheel Hub Retaining Nut:
1. Install gearcase into the frame. Torque mounting bolts to 80 ft. lbs. (109 Nm)
specification and reinstall the vent line.
7. Install new cotter pins into the wheel hub castle nuts.
11. Add the proper lubricant to the front gearcase. Check drain
plug for proper torque (see Chapter 2 “Maintenance” for
fluid fill and change information).
Vent Line
Route inside
steering column
=T
Front Gearcase Mounting Bolt:
30 ft. lbs. (41 Nm)
7.16
FINAL DRIVE
REAR BEARING CARRIER 8. Remove the wheel hub castle nut, washer, and remove the
wheel hub from the rear drive shaft and rear bearing carrier.
Bearing Carrier Inspection Wheel Hub
CAUTION
4. Elevate rear end and safely support machine under main Nut
frame area.
Bolt
Lower
Control Arm
Nut
LH Side Only
10. Remove the rear bearing carrier. Inspect the bearing for
smoothness and side to side movement, replace as needed.
7. Safely suspend the caliper from the frame with a piece of
wire. CAUTION: Do not hang the caliper by the brake
line. Use wire to hang the caliper to prevent possible
damage to the brake line.
7.17
FINAL DRIVE
Bearing Removal Bearing Carrier Installation
1. Remove the inner snap ring retaining the bearing. 1. Grease the bushings and pivot tubes and slide them into
place in the rear bearing carrier.
2. From the front side of the housing, tap on the outer bearing
race with a drift punch in the reliefs as shown. 2. Insert drive shaft into the back side of the rear bearing
carrier.
Snap Ring
3. Align bottom of rear bearing carrier and lower control arm.
Bearing
Bearing Carrier 4. Install and torque lower control arm bolt to specification.
Upper
Control Arm
Casting 40 ft. lbs.
Reliefs (54 Nm)
Bearing Installation
1. Thoroughly clean the bearing housing and the outer race
on the new bearing. Be sure that all oil residue has been
Lower
removed from each surface. Control Arm
When using an arbor press be sure to press only 6. Pull drive shaft outward and apply grease to the drive shaft
on the outer race, as bearing damage may occur. splines.
4. Carefully press the new bearing into the rear bearing carrier 7. Install the wheel hub onto the drive shaft splines.
until the outer race bottoms in the housing. 8. Install the washer with domed side facing outward.
5. Wipe the housing clean of any excess compound and install
the snap ring into the groove.
7.18
FINAL DRIVE
9. Install the wheel hub castle nut and torque to specification. DRIVE SHAFT SERVICE
Wheel Hub
Front Drive Shaft Removal
1. Remove the cotter pin from the wheel hub castle nut and
NEW Washer slightly loosen the nut.
Cotter Pin
2. Elevate front of vehicle and safely support machine under
80 ft. lbs. the frame area.
(108 Nm)
CAUTION
11. Install the rear brake caliper and torque mounting bolts to
specification (only if servicing the left-hand side).
LH Side Only
22 ft. lbs. 5. Remove the wheel hub castle nut and washer.
(30 Nm)
6. Pull front bearing carrier assembly out while pivoting front
drive shaft downward until it clears the bearing carrier.
=T 7. With short sharp jerks, remove drive shaft from front
gearcase.
Brake Caliper Mounting Bolts:
22 ft. lbs. (30 Nm)
7.19
FINAL DRIVE
Rear Drive Shaft Removal • Over-angling of joints beyond their capacity can result
in boot or joint damage.
1. Remove the rear bearing carrier (see “REAR BEARING
CARRIER - Bearing Carrier Removal”). • Make sure surface-ground areas and splines of shaft are
protected during handling to avoid damage.
NOTE: The rear bearing carrier does not need to be
completely removed. The lower control can remain • Do not allow boots to come into contact with sharp
attached to the rear bearing carrier during this edges or hot engine and exhaust components.
procedure. • Shafts should never be used as a lever arm to position
2. Tip the rear bearing carrier down and remove the drive shaft other suspension components.
from the bearing carrier. • Never use a hammer or sharp tools to remove or to
install boot clamps.
• Be sure joints are thoroughly clean and that the proper
amount and type of grease is used to refill when joint
boots are replaced and when joints are cleaned.
Circlip
Cleanliness and following these instructions is very important to 5. Make sure the circlip remains on the shaft and not left in
ensure proper shaft function and a normal service life. the joint.
• The complete drive shaft / joint should be handled by
the interconnecting shaft to avoid disassembly or
potential damage to the drive shaft joints.
7.20
FINAL DRIVE
6. Remove the boot from the drive shaft.
BOOT KIT PN: 2203170 Large
Clamp
CAUTION Small
Clamp Boot
Complete disassembly of the CV joint is NOT
recommended. The internal components are a
precision fit and develop their own characteristic
wear patterns. Intermixing the internal
components could result in looseness, binding,
and/or premature failure of the joint.
IMPORTANT: If the grease in the joint is obviously NOTE: The amount of grease that’s provided is pre-
contaminated with water and/or dirt, the joint should measured, so use all the grease.
be replaced.
13. Slide the joint onto the drive shaft splines and align the
7. Thoroughly clean the joint with an appropriate solvent and circlip with the lead-in chamfer on the inner race of the
dry the joint to prevent any residual solvent from being left joint.
in the joint upon reassembly.
14. Use a soft-faced hammer to tap the joint onto the drive shaft
8. Visually inspect the joint by tilting the inner race to one side until it locks into place.
to expose each ball. Severe pitting, galling, play between
the ball and its cage window, any cracking or damage to the 15. Pull on the joint to make sure it is securely locked into place.
cage, pitting or galling or chips in raceways call for joint 16. Remove excess grease from the CV joint’s external
replacement. surfaces and place the excess grease in the boot.
NOTE: Shiny areas in ball tracks and on the cage 17. Pull the boot over the joint and position the boot lips into
spheres are normal. Do not replace CV joints the grooves on the joint housing and shaft. Make sure the
because parts have polished surfaces. Replace CV boot is not dimpled or collapsed.
joint only if components are cracked, broken, worn
or otherwise unserviceable. 18. Install and secure the CV boot with the large clamp using
9. Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.
the “earless” clamp pliers.
7
CV Boot Clamp Pliers
10. Slide the small boot clamp and boot (small end first) onto Earless Type: 8700226
the drive shaft and position the boot in it’s groove machined
in the shaft.
19. While pulling out on the CV shaft, fully extend the CV joint
11. Install a NEW circlip on the end of the shaft. and slide a straight O-ring pick or a small slotted screw
12. Grease the joint with the special CV joint grease provided driver between the small end of the boot and the shaft. This
in the boot replacement kit. Fill the cavity behind the balls will allow the air pressure to equalize in the CV boot in the
and the splined hole in the joint’s inner race. Pack the ball position that the joint will spend most of its life. Before you
tracks and outer face flush with grease. Place any remove your instrument, be sure the small end of the boot
remaining grease into the boot. is in its correct location on the shaft.
CAUTION
7.21
FINAL DRIVE
20. Install and secure the small clamp on the boot using the 10. Slide the small boot clamp and boot (small end first) onto
“earless” clamp pliers. the drive shaft and position the boot in it’s groove machined
in the shaft.
CV Boot Clamp Pliers 11. Install a NEW circlip on the end of the shaft.
Earless Type: 8700226 12. Grease the joint with the special CV joint grease provided
in the boot replacement kit. Fill the cavity behind the balls
and the splined hole in the joint’s inner race. Pack the ball
tracks and outer face flush with grease. Place any
Inner Plunging Joint / Boot Replacement
remaining grease into the boot.
1. Remove the drive shaft from the vehicle (see “Front Drive
Shaft Removal” or “Rear Drive Shaft Removal”).
CAUTION
2. Remove and discard the boot clamps.
The grease provided in the replacement kit is
CV Boot Clamp Pliers specially formulated for wear resistance and
Earless Type: 8700226 durability. DO NOT use substitutes
or mix with other lubricants.
3. Remove the large end of the boot from the plunging joint
and slide the boot back. BOOT KIT PN: 2203170 Large
Clamp
4. Use a soft-faced hammer or brass drift to separate the Small
plunging joint from the drive shaft. Clamp Boot
13. Fully compress the joint and push the drive shaft firmly into
Complete disassembly of the plunging joint is
the inner race.
NOT recommended. The internal components
are a precision fit and develop their own 14. Align the circlip with the lead-in chamfer.
characteristic wear patterns. Intermixing the
internal components could result in looseness, 15. Use a soft-faced hammer to tap the joint onto the drive shaft
binding, and/or premature failure of the joint. until it locks into place.
16. Pull on the joint to make sure it is securely locked into place.
IMPORTANT: If the grease in the joint is obviously
contaminated with water and/or dirt, the joint should 17. Remove excess grease from the plunging joint’s external
be replaced. surfaces and place the excess grease in the boot.
7. Thoroughly clean the joint with an appropriate solvent and 18. Pull the boot over the joint and position the boot lips into
dry the joint to prevent any residual solvent from being left the grooves on the joint housing and shaft. Make sure the
in the joint upon reassembly. boot is not dimpled or collapsed.
8. Visually inspect the joint by tilting the inner race to one side 19. Install and secure the small clamp on the boot using the
to expose each ball. Severe pitting, galling, play between “earless” clamp pliers.
the ball and its cage window, any cracking or damage to the
cage, pitting or galling or chips in raceways call for joint
CV Boot Clamp Pliers
replacement.
Earless Type: 8700226
9. Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.
7.22
FINAL DRIVE
20. Pull out on the drive shaft to center the joint in the housing. Front Drive Shaft Installation
Slide a straight O-ring pick or a small slotted screw driver
between the large end of the boot and the joint housing and 1. Install a new circlip on the end of the plunging joint and
lift up to equalize the air pressure in the boot. apply an anti-seize compound to the drive shaft splines.
21. Position the boot lip in its groove. Install and secure the 2. Align drive shaft splines with front gearcase and install by
boot with the large clamp using the “earless” clamp pliers. lightly tapping on drive shaft with a rubber faced hammer.
3. Install drive shaft into the front bearing carrier.
CV Boot Clamp Pliers
4. Install lower A-arm ball joint into the front bearing carrier.
Earless Type: 8700226
5. Install the ball joint pinch bolt into the bearing carrier.
Torque to 20 ft. lbs. (27 Nm) and install a new cotter pin.
Exploded View
NOTE: Refer the “Electronic Parts Catalog” to
obtain the required parts to service the drive shaft.
20 ft. lbs.
(27 Nm)
CV Joint
NEW
Cotter Pin
Large Circlip
Clamp =T
Boot Lower A-arm Pinch Bolt:
20 ft. lbs. (27 Nm) 7
6. Install the washer and castle nut onto the wheel hub.
Tighten hub nut to specification and install new cotter pin.
Small
Clamps
Boot
Large
Clamp
Circlip
=T
Plunging Wheel Hub Retaining Nut:
Joint Circlip 80 ft. lbs. (109 Nm)
=T
Control Arm to Bearing Carrier Bolt:
40 ft. lbs. (54 Nm)
NEW Washer
Cotter Pin
80 ft. lbs.
(108 Nm)
RH Hub Shown
=T
Wheel Hub Retaining Nut:
80 ft. lbs. (109 Nm)
7.24
CVT / TRANSMISSION
CHAPTER 8
CVT / TRANSMISSION
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
CVT TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
GEAR SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SHIFT LINKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
GEAR SELECTOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
CLUTCH ROLLER WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
CVT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
CVT OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
STARTING CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
DRIVEN CLUTCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
ENGINE BRAKING CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
CVT MAINTENANCE/INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
CVT DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
CVT OVERHEATING/DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
CVT SYSTEM DISASSEMBLY / DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
CVT SYSTEM / DRIVEN CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
TRANSMISSION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
TRANSMISSION REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
4X4 TRANSMISSION OUTPUT EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
STARTING CLUTCH EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
8.1
CVT / TRANSMISSION
TORQUE SPECIFICATIONS
CVT Torque Specifications
8.2
CVT / TRANSMISSION
GEAR SELECTION SPECIAL TOOLS
Shift Linkage Inspection Special Tools
NOTE: Shift rod is preset at time of manufacture.
1. Inspect shift linkage rod bushing clips and replace if worn
or damaged. Lubrication of rod ends is not required.
Shown below are roller shift weights which may be used in the
8
CVT system. These shift weights control engagement RPM and Order tools from SPX Corp. 1-800-328-6657
shifting patterns. Shift weights should not be changed or altered
without first having a thorough understanding the effects they
have on clutch balance, engagement and shifting characteristics.
• 14 gram - PN 5412989
• 13 gram - PN 5412988
• 12 gram - PN 5412987
• 10 gram - PN 5412986
8.3
CVT / TRANSMISSION
CVT OPERATION Drive Clutch Operation
The CVT drive clutch, mounted on the starting clutch hub shaft,
CVT Operation Overview is RPM sensitive. The drive clutch basic components are the
inner (fixed) sheave, the outer (moveable) sheave, the rollers
(weights) and the cover plate.
WARNING
The drive clutch begins to rotate when engine RPM reaches
engagement speed and the starter clutch engages.
All CVT maintenance or repairs should be performed
only by a certified Polaris Master Service Dealer (MSD) At low RPM, the drive belt is located at the bottom (smallest
diameter) of the drive clutch sheaves resulting in a low “gear”
technician who has received the proper training and ratio. As engine RPM increases, centrifugal force moves the
understands the procedures outlined in this manual. drive clutch shift rollers outward in their respective tracks
Because of the critical nature and precision balance toward the outside of the drive clutch. This forces the moveable
sheave farther inward toward the fixed sheave. The inward
incorporated into the CVT components, it is movement of the sheave forces the drive belt farther upward in
absolutely essential that no disassembly or repair the sheaves toward progressively higher “gear” ratios (larger
be made without factory authorized special tools diameter).
and service procedures.
Driven Clutch Operation
The power of the engine is transferred to the wheels through the The driven clutch is connected to the drive clutch via the drive
following components: Starting Clutch, Drive Clutch, Drive belt and is mounted on the main gearcase input shaft. The CVT
Belt, Driven Clutch, Transmission, Drive shaft(s), and Rear driven clutch consists of a fixed sheave, a moveable sheave with
Gearcase (and Front Gearcase on 4x4 models). roller tracks, rollers, and a compression style return spring.
During the development of a Polaris ATV, the CVT system is The driven clutch is primarily torque sensitive, reacting to the
matched first to the engine power curve; then to average riding forces of engine power and vehicle load to control the upshift
conditions and the vehicle’s intended usage. Therefore, and downshift of the CVT system.
modifications or variations of components at random are never
recommended.
Engine power is sensed by the driven clutch via the drive belt.
Proper clutch setup and careful inspection of existing Vehicle loads are sensed by the driven clutch through the main
components must be the primary objective when gearcase input shaft.
troubleshooting and tuning.
If forces on the drive belt (engine power) exceed the forces on
The Continuously Variable Transmission (CVT) consists of the transmission shaft (vehicle loads) the drive clutch sheaves
four major assemblies: 1) Starting Clutch; 2) Drive Clutch; 3) move inward and the belt upward, which forces the sheaves of
Drive Belt; and 4) Driven Clutch. the driven clutch apart against spring pressure. The drive belt
moves downward into the sheaves of the driven clutch to a
smaller diameter (higher “gear” ratio), increasing the speed of
Starting Clutch Operation the driven clutch. This process is called upshifting.
The starting clutch is located on the left (CVT) side of the engine If the torque resistance at the transmission input shaft is greater
crankshaft. It is an RPM sensitive clutch that connects the than the force through the drive belt, the driven clutch spring
engine crankshaft to the CVT System. forces the moveable sheave inward, and the drive belt is forced
toward the outer diameter of the sheaves. This action, which
When engine RPM is below the factory determined engagement decreases the driven clutch speed, is called backshifting.
speed of the vehicle, return springs on the staring clutch shoes
hold the shoes inward away from the starter clutch hub. In situations where loads vary (such as uphill and downhill) and
throttle settings are constant, the drive and driven clutches
When engine RPM is increased, centrifugal force causes the upshift or backshift accordingly to maintain optimum engine
shoes to overcome the return spring force and swing outward. RPM.
When the shoes contact the surface of the starter clutch hub, the
hub rotates at engine speed. This causes the CVT drive clutch At full throttle a perfectly matched CVT maintains engine RPM
mounted on the shaft of the starting clutch hub to rotate at the at the peak of the power curve during upshift and backshift. In
same RPM. this respect, the CVT system is similar to a conventional power
governor, but it functions by varying the load rather than by
Refer to the ENGINE section for more information. varying throttle position.
8.4
CVT / TRANSMISSION
CVT Maintenance/Inspection CVT Drying
Periodic inspection and maintenance is required to keep the NOTE: If operating the ATV through water, be sure to
system operating at peak performance. The following list of check the CVT cover and other ATV components for
items should be inspected and maintained to ensure maximum
performance and service life of CVT components. Refer to the water ingestion. The ATV should be checked
troubleshooting checklist for more information. immediately. Refer to Owner’s Manual for Safe Riding
1. Drive and Driven Clutch Rollers (Weights), Buttons Tips.
and Bushings, and Driven Clutch Spring. Inspect for 1. To drain any water that may be trapped inside the CVT
wear. cover, remove the CVT drain plug located on the bottom
2. Drive Belt. Inspect condition and width of belt. of the CVT cover and let the water drain out. (The location
of the CVT drain plug is shown on the following page.)
3. Sheave Faces. Clean and inspect for wear.
4. CVT System Sealing. The CVT system is air cooled by fins NOTE: To further expel water in the CVT cover and to
on the drive clutch stationary sheave. The fins create a low dry out the CVT system, shift the transmission to neutral
pressure area in the CVT area, drawing fresh air into the and rev engine slightly to expel the moisture. This will
system through the intake air duct. The opening for this also air-dry the belt and clutches. Allow engine RPM to
intake duct is located at a high point on the vehicle. All settle to idle speed, shift transmission to lowest available
connecting air ducts and the outer cover must be properly range and test for belt slippage. Repeat as needed.
sealed to reduce the chance of water ingestion into the CVT Operate ATV in lowest available range for a short period
area. A sealed CVT is especially critical on units subjected of time until CVT system is dry.
to frequent water forging.
8.5
CVT / TRANSMISSION
CVT DUCTING
Clamps
8.6
CVT / TRANSMISSION
CVT Overheating/Diagnosis
During routine maintenance or whenever CVT system overheating is evident, it’s important to check the inlet and outlet ducting for
obstructions. Obstructions to air flow through the ducts will significantly increase CVT system operating temperatures. The ATV
should be operated in LOW RANGE (if equipped) when pulling or plowing heavy loads, or if extended low speed operation is
anticipated.
Low Range (if equipped): Heavy pulling, basic operational speeds less
GENERAL OPERATION RANGE than 7 MPH, riding through rough terrain (swamps, mountains, etc.), low
GUIDELINES: ground speeds.
High Range: High ground speeds, speeds above 7 MPH.
Diagnosis of Clutch Drive Belt & Cover Related Issues:
Possible Causes Solutions/What to do
Loading the ATV into a pickup or tall trailer Shift transmission to low range (if equipped) during loading of the ATV to
when in high range. prevent belt burning.
Starting out going up a steep incline. When starting out on an incline, use low range (if equipped), or perform
the “K” turn to turn around. Warning: Excessive throttle may cause
loss of control and vehicle overturn.
Driving at low RPM or low ground speed Drive at higher speed or use Low Range. (if equipped) The use of Low
(at approximately 3-7 MPH). Range is highly recommended for cooler CVT operating temperatures
and longer component life.
Insufficient warm-up of ATVs exposed to Warm engine at least 5 min., then with transmission in neutral, advance
low ambient temperatures. throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will
become more flexible and prevent belt burning.
Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement. Continuous
operation at the point of engagement (initial vehicle movement)
increases CVT temperatures and component wear.
Towing/Pushing at low RPM/low ground Use Low Range only. (if equipped)
speed.
Plowing snow, dirt, etc./utility use. Use Low Range only. (if equipped)
Stuck in mud or snow. Shift the transmission to Low Range (if equipped), carefully use fast,
aggressive throttle application to engage clutch. Warning: Excessive
8
throttle may cause loss of control and vehicle overturn.
Climbing over large objects from a Shift the transmission to Low Range (if equipped), carefully use fast,
stopped position. aggressive, throttle application to engage clutch. Warning: Excessive
throttle may cause loss of control and vehicle overturn.
Belt slippage from water or snow Shift the transmission to neutral. Using the throttle, vary engine rpm from
ingestion into the CVT system. idle to 3/4 throttle. Engage transmission in the lowest possible range (if
equipped) and test for belt slippage Repeat several times as required.
During this procedure, the throttle should not be held at the full
position. Inspect CVT system for sealing or damage if repeated water
ingestion occurs.
Clutch malfunction. Inspection/repair of clutch components should be performed by a
certified Polaris MSD technician.
8.7
CVT / TRANSMISSION
CVT System Disassembly / Drive Clutch 7. Before removing drive belt, install the tool 2875563 as
shown to prevent drive clutch moveable sheave from
NOTE: Do not lubricate drive clutch components. moving inward.
NOTE: If tool is not available, use two hands to hold
1. Remove seat, left side cover, left foot well, rear rack and
the cam plate and the primary sliding sheave
rear cab. (Rear tire removal not required but helpful.)
together when removing the primary sliding sheave
2. Remove all CVT cover screws and CVT cover. and the cam plate assembly. This prevents the
rollers from falling out of the assembly.
8. Separate driven clutch sheaves and force belt down into the
sheaves. Remove belt from driven, then from drive clutch.
8.8
CVT / TRANSMISSION
9. Measure belt width and compare to specification. Replace 11. Remove sleeve and fixed sheave. Inspect the cooling fins
if any area is worn below the minimum width, if belt is for damage, the sleeve for wear or rough spots, and the face
unevenly worn (hour glassed) or if damaged. of the fixed sheave for wear, grooving or rough surface.
Fixed Sheave
Sleeve
= In. / mm.
12. Remove the rollers from the primary sliding sheave. Check
Drive Belt Service Limit: the rollers for wear, deep scoring, or flat spots. Remove and
1.320” (33.52mm) inspect the slide bushings and cam plate. Replace any
components that found to be worn excessively or appears
10. Remove the primary sliding sheave and cam plate assembly abnormal.
as one assembly. Inspect the movable sheave for scoring,
grooving, or abnormal wear. Slide Bushings
NOTE: If tool is not installed, be sure to hold cam
plate and primary sliding sheave together to prevent Rollers
rollers from falling out of the assembly.
Wide Surface
Bushing
Threaded Hole
8.9
CVT / TRANSMISSION
16. Install the fixed sheave and spacer sleeve. CVT System / Driven Clutch Service
1. Remove retaining bolt.
2. Pull the clutch off the shaft using flywheel puller as shown.
2875563
3. Remove the puller and place the driven clutch spring side
up in the clutch spring compressor 8700220.
4. Install arm PA-47457-1 on the spring compressor.
5. Install adaptor PA-47457-2 on the arm.
6. Remove nut (counterclockwise) using tool PA-46076 or a
standard socket.
7. Compress spring enough to remove the chain lock and
slowly release spring tension.
18. Install the assembly, engaging the splines and install the
nut. Do not apply any lubricants to the components. Apply
Loctite 242 (Blue) to threads and torque the retaining nut
to specification.
IMPORTANT: Be sure splines of cam plate are fully
engaged on shaft spline before tightening the nut!
=T
CVT Drive Clutch Nut Torque
185 ft. lbs. (250 Nm)
Loctite 242 (Blue)
CAUTION
8.10
CVT / TRANSMISSION
8. Measure the free length of spring. Standard free length is 10. Remove roller pins using a needle-nose pliers and
7.52” (191.1mm). Replace spring if length is less than remove top and bottom O-rings.
standard or if spring coils are distorted.
11. Clean all parts to remove old grease before inspecting the
= In. / mm. components.
12. Carefully inspect the roller tracks in the hub of the
Driven Compression Spring moveable sheave. Replace clutch assembly if tracks are
Standard Length: visibly worn.
7.52” (191.1 mm) 13. Check the pin holes in the shaft of the fixed sheave. Pins
should be a firm fit in the holes.
9. Carefully pry up the roller cover to remove it. Inspect cover
for wear. 14. Inspect sheaves for wear, damage, or rough spots. Replace
the clutch assembly if sheaves are worn or damaged.
15. Apply a light film of moly grease to seal lips and to the
inside of the roller pin hub. Install the moveable sheave
over the shaft of the fixed sheave until the sheaves contact
each other.
16. Lift the moveable sheave enough to clean all excess grease
from the shaft and the sheave faces to prevent belt
contamination after assembly.
8.11
CVT / TRANSMISSION
18. Lubricate the roller pins with grease and install all pins until
fully seated. The surface of the pins must be approximately
flush with the surface of the roller pin hub.
19. Install new O-rings on top and bottom of roller pin hub.
20. Pack all roller tracks with grease.
21. Install the roller pin sleeve and push it down until fully
seated against moveable sheave.
22. Clean the threads of the shaft, and threads of the spring
retaining nut to remove all oil or grease.
23. Place the driven clutch assembly in the compressor tool.
24. Install spring.
25. Install spring retainer on spring, visually aligning the flats
of the retainer with the flats on the threaded shaft.
26. Install tool PA-47457-3
27. Retainer Alignment Tool onto spring retainer.
28. Compress the clutch spring slowly, turning the retainer with
the tool as required to align the flats.
29. When flats are aligned, fully compress the spring and
secure the compressor arm with the chain.
30. Apply Loctite™ 242 to threads of the nut and the shaft, and
install nut hand tight.
31. Release the tool and torque the nut to specification using
the same tools for removal of the nut.
=T
Driven Clutch Spring Retainer Nut Torque:
45 ft. lbs. (61 Nm)
Loctite™ 242 (Blue)
8.12
CVT / TRANSMISSION
TRANSMISSION
8.13
CVT / TRANSMISSION
Transmission Service 6. Remove input shaft, counter shaft, and shift drum as an
assembly.
1. Drain transmission fluid.
2. Remove Transmission. Refer to the Engine Section for
transmission removal procedure.
Transmission Disassembly
1. Clean the exterior of the transmission.
2. Remove all case screws.
3. Remove the left case from the right. Be sure shafts stay with
right case.
7. Clean all parts. Remove seals from gear case and install
new using an appropriate size seal driver.
8. Inspect all bearings, gear teeth, and splines for wear or
damage. Inspect gear dogs carefully and replace if the edge
of the dog is worn or rounded, chipped, or broken.
9. Inspect the reverse chain for damage.
Gear Teeth
Bearings Reverse Chain
4. Remove output gear and shaft and pull oil deflector from
right case. Note orientation for installation later.
Oil Deflector
Splines
Engagement Dogs
8.14
CVT / TRANSMISSION
11. Inspect the shift drum tracks for wear or damage. Inspect 2. Place fork shaft through guide with pointed end as shown.
shift fork for bending and the surface for wear, burning, or
scoring.
Shaft Support
Spring Collar
Small Spring
Large Spring
Fork
8
Transmission Reassembly
1. Reassemble the drum starting with shaft guide, detent cam DOT
(wide flange faces toward the threaded end of drum), the
flat washer, and snap ring.
8.15
CVT / TRANSMISSION
4. Install the detent ratchet with spring. Install the snap ring. 7. Apply 3-Bond 1215 sealant evenly to clean and oil-free
case sealing surfaces.
5. Assemble the shafts with chain and shift drum and install
the assembly into the case.
8. Install the left case and tap it into place until seated.
9. Install bolts and torque in two steps following a cross
pattern to specification.
=T
Gearcase Bolt Torque:
(18 ft. lbs. (24.5 Nm)
8.16
CVT / TRANSMISSION
4x4 Transmission Output Exploded View
8.17
CVT / TRANSMISSION
Starting Clutch Exploded View
Complete disassembly, inspection and installation procedures are located in Chapter 3.
8.18
ELECTRICAL
CHAPTER 9
ELECTRICAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
FUSIBLE LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
FUSE SPLICE SAVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
INSTRUMENT GAUGE POWER / FWD / NEUTRAL SWITCHES / RPM SIGNAL . . . . . 9.4
AWD CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
SPEED SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
GEAR POSITION INDICATOR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
GEAR POSITION SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
ETC / REVERSE RPM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
ETC / REVERSE RPM CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
IGNITION SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
RPM LIMIT MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
IGNITION COIL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
CDI OUTPUT TEST USING PEAK READING ADAPTOR OR VOLTMETER . . . . . . . . 9.10
CDI CRANKING OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
IGNITION SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
IGNITION SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
CHARGING SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
ALTERNATOR OUTPUT TEST (AC AMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
STATOR FUNCTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
VOLTAGE DROP TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
BRUSH INSPECTION & REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
ARMATURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
STARTER REASSEMBLY & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
9
STARTER SOLENOID BENCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
STARTER MOTOR EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
PINION GEAR - ANTI-KICK OUT SHOE, GARTER SPRING REPLACEMENT . . . . . . 9.23
STARTER SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
CONDITION: STARTER FAILS TO TURN MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.1
ELECTRICAL
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
BATTERY IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
CONVENTIONAL BATTERY ACTIVATION/ SVC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
BATTERY TERMINALS/TERMINAL BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CONVENTIONAL BATTERY INSPECTION/REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CONVENTIONAL BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CONVENTIONAL BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CONVENTIONAL BATTERY OCV - OPEN CIRCUIT VOLTAGE TEST . . . . . . . . . . . . 9.27
CONVENTIONAL BATTERY SPECIFIC GRAVITY TEST . . . . . . . . . . . . . . . . . . . . . . . 9.27
CONVENTIONAL BATTERY LOAD TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
CONVENTIONAL BATTERY OFF-SEASON STORAGE. . . . . . . . . . . . . . . . . . . . . . . . 9.28
CONVENTIONAL BATTERY CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 9.28
9.2
ELECTRICAL
GENERAL INFORMATION Fuse Splice Saver
Special Tools The fuse splice saver is near the battery under the front storage
compartment.
Fusible Link
A fusible link is installed on the battery voltage circuit that
9
supplies power to the main 15A fuse. The link is located at the
starter motor solenoid + post.
9.3
ELECTRICAL
Instrument Gauge Power / FWD / Neutral Switches / RPM Signal
The instrument gauge displays engine RPM via an A/C signal from the Y/RED of the voltage regulator.
The gauge is powered by switched R/BLK and switched R/WHT battery voltage. Both the key and the RUN switches have to be
closed to power-up the gauge.
The gear selector switch provides a ground path for the FWD (BLU/RED) or neutral (GRN/WHT) circuits.
9.4
ELECTRICAL
AWD Control System
The front differential coil is controlled by the speedometer the AWD switch, and the RUN/OFF switch.
Battery voltage is supplied to the AWD coil when the operator turns the key switch to RUN, moves the AWD switch to AWD and
moves the RUN/OFF switch to RUN.
The AWD coil ground circuit is supplied by the instrument gauge. The speedometer will not allow the AWD to engage when the
engine RPM is 3100 RPM or higher.
9.5
ELECTRICAL
SPEED SENSOR
Vehicle Speed Sensor
The vehicle speed sensor is mated to the transmission housing and reads the speed of the transmission output gear.
The instrument gauge supplies the sensor with battery voltage via the ORANGE circuit, a reference ground via the BRN/RED circuit
and receives a return signal via the GRN/RED circuit.
To test the circuit:
1. Turn the ignition key to the ON position and move the RUN/OFF switch to run.
2. Verify there is battery voltage present on the ORANGE circuit. If voltage is not found, inspect the wiring harness, or replace
the instrument gauge.
3. If voltage is found, test the BRN/RED ground circuit. Verify there is continuity between the circuit and chassis ground.
4. If all circuits function, remove the speed sensor from the transmission. Verify the sensor is not damaged.
5. Back-probe the GRN/RED and BRN/RED wires with the connector still connected to the sensor. Turn the multimeter to measure
vDC. Wave a screwdriver back in forth across the face of the sensor while monitoring the multimeter.
6. The multimeter display should flip between a voltage and 0vDC every time the screwdriver blade passes by the sensor face. If
this does not occur, replace the sensor.
9.6
ELECTRICAL
ELECTRONIC THROTTLE CONTROL GEAR POSITION INDICATOR SWITCH
(ETC) SWITCH
Gear Position Switch Test
Electronic Throttle Control (ETC) Switch
1. Locate the gear selector switch on the transmission.
The Electronic Throttle Control (ETC) switch is designed to Remove the wiring harness connector and insert the two
close in the event where the throttle cable sticks or breaks. multimeter probes into the switch.
2. Move the gear selector handle to each of the three drive
During normal operation, the ETC switch contacts are open (not positions (FWD, NEU, or REV).
touching). The contacts will close when slack is present in the
cable. 3. Using an ohmmeter, test for continuity between the switch
contacts and connector leads. Replace the switch if no
Electronic Throttle Control (ETC) Switch continuity or high resistance is found.
9
NOTE: The throttle cable must have the proper amount of
end-play adjustment. A cable that is too tight will cause ETC
interruption, resulting in false engine RPM limiting.
9.7
ELECTRICAL
ETC / REVERSE RPM CONTROL
ETC / Reverse RPM Control System
The instrumentation gauge will signal the CDI controller to limit engine RPM to approximately 3100 RPM (6.5 MPH) whenever
the transmission is in reverse gear. If the ETC switch connects to ground, the instrument gauge will shut the engine off.
The operator can override the RPM speed limit in reverse, but not the ETC RPM limit, by pressing and holding the reverse override
button located on the left handlebar.
The reverse override button also serves as the mode switch button for the instrumentation gauge. The mode button toggles between
the several function the gauge performs.
To rule out engine RPM limiting caused by the CDI or instrument gauge, disconnect the BLACK wire from the CDI controller.
9.8
ELECTRICAL
IGNITION
Ignition System Diagram
The ignition system consists of:.
• CDI Controller
• Battery
• Ignition Coil
• Stator - Pulse Coil
• ETC / Key / Run-Off Switches / Instrument Gauge
9.9
ELECTRICAL
RPM Limit Modes CDI Output Test Using Peak Reading
Adaptor or Voltmeter
Engine RPM is limited when:
Re-connect all CDI wires to stator wires. Disconnect CDI
• Operator selects reverse gear. The maximum vehicle module wire from ignition coil primary terminal. Connect one
speed when reverse gear is selected is 6.5 MPH meter lead to engine ground and the other to the ignition coil
primary wire leading from the CDI module. Crank engine and
• If the wheel speed sensor malfunctions, the check output of CDI wire to coil. Reconnect CDI wire to the coil.
speedometer will limit engine RPM to approximately
3500 RPM when the transmission is in reverse.
• Maximum engine RPM is reached.
The reverse engine RPM limit can be overridden when the
operator presses and holds the override button.
On AWD models, the speedometer also limits the maximum
engine RPM in which the operator can engage the AWD system.
The speedometer will not allow the AWD to engage when the
engine RPM is at or above 3100 RPM.
Connect Meter
Test Reading
Wires To:
200 - 250
CDI Output W/BLU to Ground
Volts DC
9.10
ELECTRICAL
CDI Cranking Output Test Ignition System Troubleshooting
The following peak voltage tests will measure the amount of No Spark, Weak or Intermittent Spark
output from each component. A peak reading voltmeter can be
used to perform the tests. A variety of peak reading adaptors are • No12 volt power or ground to CDI
commercially available for use with the Fluke™ 77 Digital
Multimeter (PV-43568) and other digital VOMs which will • Spark plug gap incorrect
allow peak voltage tests to be performed accurately. Follow the
directions provided with the adaptor. All measurements are • Fouled spark plug
indicated in Volts. Readings obtained without a peak reading
adaptor will be significantly different. • Faulty spark plug cap or poor connection to high
tension lead
Disconnect the stator connectors from the CDI module. Test
output from the detection and pulse (trigger) coil, and compare • Related wiring loose, disconnected, shorted, or
to the chart. The following measurements were obtained when corroded
cranking the engine with the electric starter, spark plug installed.
The starting system must be in good condition and the battery • Engine Stop switch or ignition switch faulty
fully charged.
• ETC switch misadjusted or faulty
Voltage Connect Reading Reading • Poor ignition coil ground (e.g. corroded)
Test Meter Wires (With VOM) (With Peak
To: Reading • Faulty stator (measure resistance of all ignition related
windings)
Adapter)
Pulse Coil W/R and B 0.15 Volts 5.3 - 5.4 • Incorrect wiring (inspect color coding in connectors
etc)
minimum AC Volts
@ cranking minimum DC • Faulty ignition coil winding (measure resistance of
RPM @ cranking primary and secondary)
RPM • Worn magneto (RH) end Crankshaft bearings
• Sheared flywheel key
Ohm Connect Reading Reading
Test Meter Wires (With Peak • Flywheel loose or damaged
To: Reading • Excessive crankshaft runout on magneto (RH)
Adapter) end - should not exceed .005”
Pulse Coil W/R and B 520 Ohms n/a • Faulty CDI module
W/R to
O.L.
Ground
9.11
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. The resistance
values are also given on the specification pages.
Disconnect the BLACK wire at the CDI -Test the ignition switch, engine stop
module to isolate the ignition from the switch, and speed limiter circuit for
over-ride systems, but verify the CDI has a Yes shorts to ground.
good ground (BROWN) for operation. - Check connectors for moisture,
wire color matching or corrosion.
Does it have spark?
No
Yes
Yes
Yes
If all of the above tests are within specifications, and all grounds, connections, and wire color coding
have been inspected, perform voltage output tests on following page or replace the CDI module.
9.12
ELECTRICAL
CHARGING SYSTEM
Charging System
The charging system consists of:.
• Stator
• Battery
• Regulator / Rectifier
The regulator / rectifier is responsible for converting AC voltage to DC voltage, and generating the tachometer pulse.
9.13
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- Remove the battery and properly ser-
sure the battery open circuit voltage (see No vice. Reinstall the fully charged battery
procedure later in chapter). It should be or a fully charged shop battery.
12.4 volts or more. Is it?
Yes
9.14
ELECTRICAL
Current Draw - Key Off Charging System “Break Even” Test
CAUTION CAUTION
Do not connect or disconnect the battery cable or Do not connect or disconnect the battery cable or
ammeter with the engine running. Damage will occur to ammeter with the engine running.
light bulbs and speed limiter.
Connect an ammeter in series with the negative battery cable.
Check for current draw with the key off. If the draw is excessive, CAUTION
loads should be disconnected from the system one by one until
the draw is eliminated. Check component wiring as well as the
component for partial shorts to ground to eliminate the draw. Never use the electric starter with an ammeter
connected in series, as damage to the meter or meter
fuse may result. Do not run test for extended period of
Current Draw - Key Off: time. Do not run test with high amperage accessories.
Maximum of .02 DCA (20mA)
The “break even” point of the charging system is the point at
which the alternator overcomes all system loads (lights, etc.)
and begins to charge the battery. Depending on battery condition
and system load, the break even point may vary slightly. The
battery should be fully charged before performing this test.
• Clamp an inductive ammeter or connect an ammeter
(set to DC amps) in series between the negative battery
cable and terminal.
Less Than 9 mA
Do not use electric start.
9.15
ELECTRICAL
Alternator Output Test (AC amp) Stator Function Test
This test measures AC amperage from the alternator. Three tests can be performed using a multimeter to determine
the condition of the stator.
CAUTION
I = Current in Amps
P = Power in Watts
E = Electromotive Force (Volts)
• Maximum alternator output will be indicated on the 1. Measure the resistance value of each of the three stator
meter. It is not necessary to increase engine RPM above legs: W1 to W2, W1 to W3, and W2 to W3. Each should
idle. measure 0.314ohms.
• Place the red lead on the tester in the 10A jack. 2. Measure each of the white wires to ground, the reading
should be (O.L.).
• Turn the selector dial to the AC amps (A~) position.
NOTE: Significant variations in resistance readings
• Connect the meter leads to the wires leading from the between each circuit is an indication that one of the three
alternator (see schematic for proper wiring colors). circuits may be weak or failed.
• Start the engine and let it idle. Reading should be a
minimum of 8A at idle. TEST 2: Stator Output.
1. Place the red lead on the tester in the 10A jack.
2. Turn the selector dial to the AC-AMPs position.
3. Start the engine and let it idle.
4. Separately test each leg of the stator by connecting the
meter leads to the wires leading from the alternator (W1 to
W2, W1 to W3, W2 to W3). Alternator Current Output
Reading should be no less than 8 AMPS.
NOTE: Use an inductive amp meter to test stator
amperage for engine speeds over 1200 RPM.
9.16
ELECTRICAL
STARTER
Starter / Starter Lockout System
The starter and starter lockout system consists of:
• Battery
• Key Switch / Run-Off Switch
• Solenoid
• Brake / Neutral Switches
• Diodes
• Starter Motor
9.17
ELECTRICAL
Troubleshooting Voltage Drop Testing
Starter Motor Does Not Run The Voltage Drop Test is used to test for bad connections. When
performing the test, you are testing the amount of voltage drop
• Battery discharged. Low specific gravity through the connection. A poor or corroded connection will
appear as a high voltage reading. Voltage shown on the meter
• Loose or faulty battery cables or corroded connections when testing connections should not exceed.1 VDC per
(see Voltage Drop Tests) connection or component.
• Related wiring loose, disconnected, or corroded To perform the test, place the meter on DC volts and place the
meter leads across the connection to be tested. Refer to the chart
• Failed Diode on 1.47 to perform voltage drop tests on the starter system.
• Poor wire connections: harness, grounds, at battery
cable, starter motor or starter solenoid (see Voltage
Drop Tests) Voltage should not exceed
.1 DC volts per connection
• Faulty key switch
• Faulty kill switch
Removal / Disassembly
• Faulty brake switch
NOTE: Use electrical contact cleaner to clean starter
• Faulty transmission switch motor parts. Some solvents may leave a residue or
• Faulty starter solenoid or starter motor. damage internal parts and insulation.
• Engine problem - seized or binding (Can engine be 1. Remove the starter from the engine.
rotated easily with recoil starter?) 2. Remove the two bolts, washers, and sealing O-Rings.
Inspect O-Rings and replace if damaged.
Starter Motor Turns Over Slowly
• Battery discharged - low specific gravity
• Excessive circuit resistance - poor connections (see
Voltage Drop Test below)
• Engine problem - seized or binding (Can engine be
rotated easily?)
• Faulty or worn brushes in starter motor
Starter Motor Turns - Engine Does Not Rotate
• Faulty starter drive
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel
9.18
ELECTRICAL
3. Remove the front bracket assembly and the rear bracket as necessary.
assembly. Remove the shims from the armature shaft and
inspect the O-rings located on the armature housing.
O-Rings
Shims
3. Slide positive brush springs to the side, pull brushes out of
their guides and remove brush plate. Slide brush end frame
off end of starter.
NOTE: The shims will be replaced during
reassembly. NOTE: The electrical input post must stay with the
field coil housing.
Brush Inspection & Replacement 4. Measure resistance between ground brush and brush plate.
Resistance should be .3 ohms or less.
1. Measure resistance between starter input terminal and
insulated brushes. The reading should be .3 ohms or less.
Remember to subtract meter lead resistance.
Brush Inspection
9
2. Measure resistance between insulated brush and starter
housing. Reading should be infinite. (OL). Inspect 1. Measure length of each carbon brush. Replace brush
insulation on brush wires for damage and repair or replace assembly when worn to 5/16” (8 mm) or less. The brushes
must slide freely in their holders.
Brush Length
9.19
ELECTRICAL
Brush Replacement 3. Using a digital multitester, measure the resistance between
each of the commutator segments. The reading should be
1. Remove terminal nut with lock washer, flat washer, large .3 ohms or less.
phenolic washer, the small phenolic spacers, and sealing
4. Measure the resistance between each commutator segment
O-ring. Inspect O-ring and replace if damaged.
and the armature shaft. The reading should be infinite (no
continuity).
CAUTION
CAUTION
9.20
ELECTRICAL
Starter Reassembly & Installation 9. Lightly grease pinion shaft and install pinion, spring
stopper, and snap ring.
1. Install brush plate to field magnet housing aligning index
tab.
9
6. Be sure wire insulation is in place around positive brush
wire and pushed completely into slot on phenolic plate.
7. Using Dielectric Grease (PN 2871329), lubricate brush end
bushing and install shims.
8. Align brush plate and install cover and screws.
9.21
ELECTRICAL
Starter Motor Exploded View
9.22
ELECTRICAL
STARTER DRIVE
Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement
If the garter spring is damaged, the overrun clutch may fail to return properly. Use either of the following methods to remove and
install a new garter spring:
H
G
A F
D
A. Gear Assembly E
B. Thrust Washer C
C. Bushing
D. Retaining Ring
E. Thrust Washer
F. Stopper
G. Cover
H. Spring
1. Screw the overrun clutch out to the engaged position on the pinion shaft assembly. Use a small piece of wire with the end bent
in a hook and pick the old spring out of its channel. Slide it off the end of the shaft. Slide the new spring over the overrun clutch
and into the spring groove. Make sure that the spring is positioned between the shoe alignment pins and the back flange of the
anti kick-out shoes.
2. Remove the retaining ring, thrust washer, spring retainers and clutch return spring. Screw the overrun clutch off the end of the
pinion shaft. Remove the old spring and install a new one. Lightly grease the pinion shaft and reinstall the clutch, spring,
retainers, end washer and lock ring in the reverse order. Make sure the end washer is positioned properly so that it will hold
the lock ring in its groove.
9.23
ELECTRICAL
STARTER SYSTEM TESTING FLOW CHART
Condition: Starter Fails To Turn Motor
NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester
must be used for this test.
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.
lead on the battery positive. No Install fully charged shop battery to
continue test.
Reading should be 12.4 volts or greater.
Yes
Test starter solenoid coil by connecting an ohmmeter between the coil leads
Yes Resistance should be 3.7Ω + 1. Check solenoid ground path between the
BLUE wire and battery NEG. with transmission in NEUTRAL and the hand
Voltage Drop Testing brake applied. Set the meter to check continuity of a diode.
See Page 9.22 for instructions.
Yes
Yes
Yes
If all of these indicate a good condition, yet the starter still fails to turn, the
starter must be removed for static testing and inspection.
9.24
ELECTRICAL
BATTERY battery type in the vehicle. Use the section that applies to
the battery.
Battery Identification
WARNING
NOTICE: It is important to identify what type of battery you
have installed in your ATV. Different types of batteries require
different service procedures. Proper servicing and upkeep of Battery electrolyte is poisonous. It contains sulfuric
your battery is very important for maintaining long battery life. acid. Serious burns can result from contact with
Your ATV may have a Conventional Battery or a Sealed Low skin, eyes or clothing. Antidote:
Maintenance Battery. To identify which type of battery your
ATV has, refer to the illustration below and follow the correct External: Flush with water.
service and charging procedures that follow in the manual.
CONVENTIONAL BATTERY Internal: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.
Removable
Caps
Eyes: Flush with water for 15 minutes and get
prompt medical attention.
WARNING
9.25
ELECTRICAL
NOTE: New Battery: Battery must be fully charged 2. Disconnect battery negative (-) (black) cable first, followed
before use or battery life will be significantly reduced 10- by the positive (+) (red) cable.
30% of the battery’s full potential.
CAUTION
To activate a new battery:
1. Remove vent plug from vent fitting. Remove cell caps. Whenever removing or reinstalling the battery,
2. Fill battery with electrolyte to upper level marks on case. disconnect the negative (black) cable first and
3. Set battery aside to allow for acid absorption and reinstall the negative cable last!
stabilization for 30 minutes.
3. Remove the battery.
4. Add electrolyte to bring level back to upper level mark on
4. Remove the filler caps and add distilled water only as
case. NOTE: This is the last time that electrolyte should be
needed to bring each cell to the proper level. Do not overfill
added. If the level becomes low after this point, add only
the battery.
distilled water.
5. Charge battery at 1/10 of its amp/hour rating. Examples: 1/ Refill using only distilled water. Tap water contains minerals
10 of 9 amp battery = .9 amp; 1/10 of 14 amp battery = 1.4 which are harmful to a battery.
amp; 1/10 of 18 amp battery = 1.8 amp (recommended
Do not allow cleaning solution or tap water inside the battery.
charging rates). Battery life may be reduced.Reinstall the battery caps.
6. Check specific gravity of each cell with a hydrometer to
assure each has a reading of 1.270 or higher. 5. Reinstall the battery caps.
9.26
ELECTRICAL
Conventional Battery OCV - Open Circuit Conventional Battery Specific Gravity Test
Voltage Test
A tool such as a Battery Hydrometer (PN 2870836) can be used
Battery voltage should be checked with a digital multitester. to measure electrolyte strength or specific gravity. As the battery
goes through the charge/discharge cycle, the electrolyte goes
Readings of 12.6 volts or less require further battery testing from a heavy (more acidic) state at full charge to a light (more
and charging. See charts and Load Test on below. water) state when discharged. The hydrometer can measure
state of charge and differences between cells in a multi-cell
NOTE: Lead-acid batteries should be kept at or near a battery. Readings of 1.270 or greater should be observed in a
full charge as possible. Electrolyte level should be kept fully charged battery. Differences of more than .025 between the
lowest and highest cell readings indicate a need to replace the
between the low and full marks. If the battery is stored or battery.
used in a partially charged condition, or with low
electrolyte levels, hard crystal sulfation will form on the
plates, reducing the efficiency and service life of the
battery.
SPECIFIC GRAVITY
State of charge* Conventional Lead-acid
100% Charged 1.265
75% Charged 1.210
50% Charged 1.160
25% Charged 1.120
0% Charged less than 1.100
* At 80oF
NOTE: Subtract .01 from the specific gravity reading at 40o F. 9
9.27
ELECTRICAL
Conventional Battery Load Test Electrolyte Freezing Points
A battery may indicate a full charge condition in the OCV test 1.100 +18o F
and the specific gravity test, but still may not have the storage
capacity necessary to properly function in the electrical system. 1.050 +27o F
For this reason, a battery capacity or load test should be
conducted whenever poor battery performance is encountered.
To perform this test, hook a multitester to the battery in the same Conventional Battery Charging Procedure
manner as was done in the OCV test. The reading should be 12.6
volts or greater. Engage the starter and observe the battery 1. Remove the battery from the ATV to prevent damage from
voltage while cranking the engine. Continue the test for 15
seconds. During cranking the observed voltage should not drop leaking or spilled acid during charging.
below 9.5 volts. If the beginning voltage is 12.6 volts or higher 2. Charge the battery with a charging output no larger than 1/
and the cranking voltage drops below 9.5 volts during the test, 10 of the battery’s amp/hr rating. Charge as needed to raise
replace the battery.
the specific gravity to 1.270 or greater.
Conventional Battery Off-Season Storage 3. Install battery in vehicle. Coat threads of battery bolt with
a corrosion resistant dielectric grease.
To prevent battery damage during extended periods of non-use,
the following basic battery maintenance items must be Dielectric Grease
performed:
(PN 2871329)
• Remove the battery from the machine and wash the
case and battery tray with a mild solution of baking
soda and water. Rinse with lots of fresh water after 4. Connect battery cables.
cleaning.NOTE: Do not get any of the baking soda into
the battery or the acid will be neutralized.
WARNING
• Using a wire brush or knife, remove any corrosion from
the cables and terminals.
To avoid the possibility of explosion, connect
• Make sure that the electrolyte is at the proper level. Add positive (red) cable first and negative (black)
distilled water if necessary. cable last.
• Charge at a rate no greater than 1/10 of the battery’s
amp/hr capacity until the electrolyte’s specific gravity 5. After connecting the battery cables, attach the hold down
reaches 1.270 or greater. strap.
6. Install clear battery vent tube from vehicle to battery vent.
• Store the battery either in the machine with the cables
disconnected, or store in a cool place. WARNING: Vent tube must be free from obstructions and
kinks and securely installed. If not, battery gases could
NOTE: Stored batteries lose their charge at the rate of accumulate and cause an explosion. Vent should be routed
up to 1% per day. Recharge to full capacity every 30 to away from frame and body to prevent contact with
60 days during a non-use period. If the battery is stored electrolyte. Avoid skin contact with electrolyte, as severe
during the winter months, electrolyte will freeze at higher burns could result. If electrolyte contacts the vehicle frame,
temperatures as the battery discharges. The chart below corrosion will occur.
indicates freezing points by specific gravity.
7. Route cables so they are tucked away in front and behind
battery.
9.28
QUADRICYCLE
CHAPTER 10
QUADRICYCLE
HAWKEYE QUADRICYCLE ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
TRANSMISSION SWITCH - BREAKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
FUSE HOLDER - BREAKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
FLASHER RELAY - BREAKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
HEADLIGHT / TAILLIGHT - EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
HAWKEYE QUADRICYCLE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
FOOT BRAKE SYSTEM - EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
AUXILIARY HAND BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
AUXILIARY HAND MASTER CYLINDER - EXPLODED VIEW . . . . . . . . . . . . . . . . . . . 10.6
NOTE: This chapter illustrates components that are unique to the Hawkeye 2x4 / 4x4 Quadricycle.
Except where noted, any servicing of these components or other components
on the ATV can be done using this service manual’s procedures and illustrations.
10
10.1
QUADRICYCLE
HAWKEYE QUADRICYCLE ELECTRICAL
Transmission Switch - Breakout
A mechanical PARK lock is built into
the transmission on quadricycle models
10.2
QUADRICYCLE
Flasher Relay - Breakout
RH Turn Indicator
LH Turn Indicator
LH Turn Indicator
Splice
RH Turn Indicator
10.3
QUADRICYCLE
HAWKEYE QUADRICYCLE BRAKE SYSTEM
Overview
The Hawkeye Quadricycle brake system consists of a complete hydraulic brake system. All-wheel braking is integrated into the
foot brake pedal. This allows brake control on three wheel discs.
When the foot brake is applied, the two front calipers and the LH rear caliper are used. When applied, the brake pressure is routed
from the foot brake master cylinder through one line to the junction block and front calipers, while the other line feeds the LH rear
caliper. The foot brake master cylinder is equipped with a dual banjo fitting allowing brake fluid to be forced down both lines to
the front and rear when the foot brake is applied.
When the hand brake is applied, only the rear RH brake caliper is active and under pressure. This allows for rear wheel braking
only. The handlebar master cylinder only allows fluid to flow to the RH rear brake caliper.
Controlled by the
Auxiliary Hand Brake
LH Rear Caliper
22 ft. lbs
(30 Nm)
22 ft. lbs
(30 Nm)
LH Front Caliper
RH Rear Caliper
22 ft. lbs
(30 Nm)
22 ft. lbs
(30 Nm)
RH Front Caliper
Controlled by the
Foot Brake
10.4
QUADRICYCLE
Foot Brake System - Exploded View
3
4 T
2
7
1 T
10
T
8
9
5
2
10.5
QUADRICYCLE
Auxiliary Hand Brake System
B D
F
15 ft. lbs.
(20 Nm)
15 ft. lbs.
(20 Nm)
C
E
A. Rear Brake Caliper
B. Handlebar Master Cylinder
C. Banjo Bolt
D. Brake Line - Front Master to Rear RH Caliper
A
E. Seals
F. Brake Pressure Switch
M
S
O
K
I
L
G. Reservoir Body Q
H. Brake Lever
I. Piston
J. Park Brake Lever
K. Primary Cup
L. O-Ring T
M. Cover
N. Park Lever Pivot Pin P H
O. Piston Return Spring N
P. Pivot Pin
Q. Dust Boot
R. Return Lever Spring
S. Clamp
T. Retaining Ring J
U. Push-On R
V. Torx Screws U
W. Cover Screws
10.6
WIRE DIAGRAM
WD-1
WIRE DIAGRAM
WD-2
WIRE DIAGRAM
WD-3
WIRE DIAGRAM
WD-4
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
1
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2007 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2007 HAWKEYE 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2007 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MODEL: 2007 HAWKEYE 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
VEHICLE IDENTIFICATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.
}
}
1.1
GENERAL INFORMATION
Vehicle Identification Number (VIN)
World
Mfg. ID
Vehicle Descriptor Vehicle Identifier
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A L H 2 7 A * 5 P 0 0 0 0 0 0
}
Engine Model
Year Individual Serial Number
Body Style
Emissions Plant No
Powertrain * This could be either
Check Digit a number or a letter
1.2
GENERAL INFORMATION
SPECIFICATIONS
MODEL: 2007 HAWKEYE 2x4
1
MODEL NUMBER: . . . . . . . . .A07LB27AA, A07LB27AC
A07LB27FA (International)
ENGINE MODEL: . . . . . . . . . .ES30PFE
Category Dimension
Length 74 in./188 cm
Width 42 in./107 cm
Height 45.5 in./116 cm
Wheel Base 46 in./117 cm
Ground Clearance 8 in./20.3 cm
Dry Weight 525 lbs./238 kg
Gross Vehicle Weight 930 lbs./422 kg
Front Rack Capacity 70 lbs./31.75 kg
Rear Rack Capacity 100 lbs./45 kg
Towing Capacity 750 lbs./340 kg
Hitch Tongue Weight 75 lbs./34 kg
Body Style Recreational/Utility
1.3
GENERAL INFORMATION
MODEL: 2007 HAWKEYE 2x4 Drivetrain
Transmission Type H-N-R
MODEL NUMBER: A07LB27
ENGINE MODEL: ES30PFE Transmission Capacity Level with fill plug
Gear Ratio : Foward 15.18:1
Engine Reverse 14.05:1
Platform Fuji 4 stroke, Single Cylinder Clutch Type CVT w/EBS
Engine Model Number ES300PFE010 Belt 3211108
Engine Displacement 299cc
Steering / Suspension
Number of Cylinders 1
Front Suspension / Shock Mac Pherson Strut
Bore & Stroke (mm) 78.5 x 68 mm
Front Travel 7 in. / 17.8 cm
Compression Ratio 9.2:1 Full Stroke
Rear Suspension Independent
Compression Pressure 120-140 psi Style / Shock Coil-over Adjustable
Engine Idle Speed 1400 RPM Rear Travel 8 in. / 20.3 cm
Cooling System/Capacity Air/Oil Cooled Ground Clearance 8 in. / 20.3 cm
Overheat Warning None Shock Preload Adjustment Front - Cam
Lubrication Wet Sump Front / Rear Rear - Cam
Oil Requirements Polaris 0W-50 / 1.7 qts (1.6L) Turning Radius 62.5 in. (159 cm) unloaded
Exhaust System Single Pipe - USFS Approved Toe Out 0-1/16 in. (0-.159 mm)
Carburetion Wheels / Brakes
Carburetor model Mikuni BST 34mm Tire/Rim Size - Front 22 x 7-12
Main Jet 140 Tire/Rim Size - Rear 22 x 10-12
Pilot Jet 45 Air Press. F/R Tires 3-5 psi
Jet Needle 4HC57-3 Brake - Front Single Control Hydraulic Disc
Needle Jet 05-m Brake - Rear Single Control Hydraulic Disc
Pilot/Air Screw 2.5 Turns Out (Initial setting) Brake Fluid Polaris DOT 3 or 4 Brake Fluid
Spark plug / Gap NGK CR8EB Note: Remove opposite rollers to retain proper clutch balance
.031 in. / .8 mm
Battery / Model / Amp Hr Conventional 14 Amp/hr
Circuit Breakers Fusible Link / 15 amp Main / 15 Amp Accsy
1.4
GENERAL INFORMATION
MODEL: 2007 HAWKEYE 4x4 Drivetrain
Exhaust System Single Pipe - USFS Approved Turning Radius 62.5 in. (159 cm) unloaded
Carburetion Toe Out 0-1/16 in. (0-.159 mm)
Carburetor model Mikuni BST 34mm Wheels / Brakes
Main Jet 140 Tire/Rim Size - Front 22 x 7-12
Pilot Jet 45 Tire/Rim Size - Rear 22 x 10-12
Jet Needle 4HC57-3 Air Press. F/R Tires 3-5 psi
Needle Jet 05-m Brake - Front Single Control Hydraulic Disc
Pilot/Air Screw 2.5 Turns Out (Initial setting) Brake - Rear Single Control Hydraulic Disc
Brake Fluid Polaris DOT 3 or 4 Brake Fluid
Float Height 13mm from carburetor body
Fuel Delivery Fuel Pump JETTING CHART
Fuel Capacity / 4.5 gal. (17 L) AMBIENT TEMPERATURE
Requirement 87 Octane (minimum) Altitude Below 40oo F Above +40oo F
89 Oxygenated Below 5 C Above +5 C
0-1800 145 140
Electrical Meters (0-6000)
(Feet) 1800-3700 140 135
Alternator Output 250 watt / 18.6 Amp @ 6000 (6000-12000)
Voltage Regulator 3-phase
CLUTCH CHART
Lights : High Beam --
Low Beam 37.5 watts Altitude Shift Weight Number Installed
Brake 12V / 26.9 watts 0-5000 13 g
(0-1534) 8
Tail 12V / 8.26 watts 5412988
1.5
GENERAL INFORMATION
GENERAL INFORMATION
Publication Numbers
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.
Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key
and refer to the chart to for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is
necessary.
Series # Part Number
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
1.6
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 the
1
exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections.
Metric / Torque
6 x 1.0. . . . . . . . . . 72-78 In.lbs. . . . . . . . . .8 x 1.25 14-18 ft.lbs . . . . 10 x 1.25 26-30 ft.lbs.
1.7
GENERAL INFORMATION
Sae Tap Drill Sizes Decimal Equivalents
Thread Size/ Drill Size Thread Size / Drill Size 1/64 ................. .0156
1/32 . . . . . . . . . . . . . .0312. . . 1 mm= .0394"
#0-80 3/64 1/2-13 27/64 3/64 ................. .0469
#1-64 53 1/2-20 29/64 1/16 . . . . . . . . . . . . . .0625
#1-72 53 9/16-12 31/64 5/64 ................. .0781. . . 2 mm = .0787"
3/32 . . . . . . . . . . . . . .0938
#2-56 51 9/16-18 33/64 7/64 ................. .1094. . . 3 mm =.1181"
#2-64 50 5/8-11 17/32 1/8 . . . . . . . .1250
#3-48 5/64 5/8-18 37/64 9/64 ................. .1406
5/32 . . . . . . . . . . . . . .1563. . . 4 mm = .1575"
#3-56 45 3/4-10 21/32 11/64 ................. .1719
#4-40 43 3/4-16 11/16 3/16 . . . . . . . . . . . . . .1875. . . 5mm= .1969"
13/64 ................. .2031
#4-48 42 7/8-9 49/64
7/32 . . . . . . . . . . . . . .2188
#5-40 38 7/8-14 13/16 15/64 ................. .2344. . . 6 mm = .2362"
#5-44 37 1-8 7/8 1/4 . . . . . . . .25
17/64 ................. .2656. . . 7 mm = .2756"
#6-32 36 1-12 59/64 9/32 . . . . . . . . . . . . . .2813
#6-40 33 1 1/8-7 63/64 19/64 ................. .2969
#8-32 29 1 1/8-12 1 3/64 5/16 . . . . . . . . . . . . . .3125. . . 8mm= .3150"
21/64 ................. .3281
#8-36 29 1 1/4-7 1 7/64 11/32 . . . . . . . . . . . . .3438. . . 9 mm = .3543"
#10-24 24 1 1/4-12 1 11/64 23/64 ................. .3594
#10-32 21 1 1/2-6 1 11/32 3/8 . . . . . . . .375
25/64 ................. .3906. . . 10 mm = .3937"
#12-24 17 1 1/2-12 1 27/64 13/32 . . . . . . . . . . . . .4063
#12-28 4.6mm 1 3/4-5 1 9/16 27/64 ................. .4219. . . 11 mm =.4331"
1/4-20 7 1 3/4-12 1 43/64 7/16 . . . . . . . . . . . . . .4375
29/64 ................. .4531
1/4-28 3 2-4 1/2 1 25/32 15/32 . . . . . . . . . . . . .4688. . . 12 mm = .4724"
5/16-18 F 2-12 1 59/64 31/64 ................. .4844
1/2 . . . . . . . .5 ..... . . . . . . . 13mm = .5118"
5/16-24 I 2 1/4-4 1/2 2 1/32
33/64 ................. .5156
3/8-16 O 2 1/2-4 2 1/4 17/32 . . . . . . . . . . . . .5313
3/8-24 Q 2 3/4-4 2 1/2 35/64 ................. .5469. . . 14 mm = .5512"
9/16 . . . . . . . . . . . . . .5625
7/16-14 U 3-4 2 3/4 37/64 ................. .5781. . . 15 mm = .5906"
7/16-20 25/64 19/32 . . . . . . . . . . . . .5938
39/64 ................. .6094
Metric Tap Drill Sizes 5/8 . . . . . . . .625 ... . . . . . . . 16mm=. 6299"
41/64 ................. .6406
21/32 . . . . . . . . . . . . .6563. . . 17 mm =.6693"
Tap Size Drill Size Decimal Nearest 43/64 ................. .6719
Equivalent Fraction 11/16 . . . . . . . . . . . . .6875
3x.50 #39 0.0995 3/32 45/64 ................. .7031. . . 18 mm = .7087"
3x.60 3/32 0.0937 3/32 23/32 . . . . . . . . . . . . .7188
47/64 ................. .7344. . . 19 mm = .7480"
4x.70 #30 0.1285 1/8 3/4 . . . . . . . .75
4x.75 1/8 0.125 1/8 49/64 ................. .7656
5x.80 #19 0.166 11/64 25/32 . . . . . . . . . . . . .7813. . . 20 mm = .7874"
51/64 ................. .7969
5x.90 #20 0.161 5/32 13/16 . . . . . . . . . . . . .8125. . . 21 mm =.8268"
6x1.00 #9 0.196 13/64 53/64 ................. .8281
27/32 . . . . . . . . . . . . .8438
7x1.00 16/64 0.234 15/64 55/64 ................. .8594. . . 22 mm = .8661"
8x1.00 J 0.277 9/32 7/8 . . . . . . . .875
8x1.25 17/64 0.265 17/64 57/64 ................. .8906. . . 23 mm = .9055"
29/32 . . . . . . . . . . . . .9063
9x1.00 5/16 0.3125 5/16 59/64 ................. .9219
9x1.25 5/16 0.3125 5/16 15/16 . . . . . . . . . . . . .9375. . . 24 mm = .9449"
10x1.25 11/32 0.3437 11/32 61/64 ................. .9531
31/32 . . . . . . . . . . . . .9688. . . 25 mm = .9843"
10x1.50 R 0.339 11/32 63/64 ................. .9844
11x1.50 3/8 0.375 3/8 1 . . . . . . . . . 1.0
12x1.50 13/32 0.406 13/32
12x1.75 13/32 0.406 13/32
1.8
GENERAL INFORMATION
Conversion Table
1.9
GENERAL INFORMATION
Glossary Of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
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.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and
grip the drive belt.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V
blocks or resting in crankcase. Measure at various points especially at PTO.
CVT: Centrifugal Variable Transmission (Drive Clutch System)
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore.
Electrical Open: Open circuit. An electrical circuit which isn't complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching
the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm2: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in2: Pounds per square inch.
Left or Right Side: Always referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy
is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040".
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
1.10
MAINTENANCE
CHAPTER 2
MAINTENANCE
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2
LUBRICANTS / FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS. . . . . . . . . . . . . 2.6
POLARIS LUBRICANT SYMBOL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
VEHICLE INSPECTION / MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
HAWKEYE HANDLEBAR COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
FRONT GEARCASE LUBRICATION (4X4 ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
LUBRICATION / GREASE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
THROTTLE OPERATION - ALL MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
CHOKE (ENRICHER) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
PILOT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
PILOT SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
ELECTRONIC THROTTLE CONTROL / THROTTLE CABLE ADJUSTMENT . . . . . . . 2.12
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
ENGINE FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
MAIN AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
AIR FILTER/PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
AIR BOX SEDIMENT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
CVT DRAIN PLUG & DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
TIE ROD END/STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
TOE ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
TOE ALIGNMENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
EXHAUST CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
BRAKE SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
HOSE/FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
BRAKE FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
SUSPENSION SPRING FRONT / REAR PRELOAD ADJUSTMENT. . . . . . . . . . . . . . 2.22
FRONT SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
REAR SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
WHEEL REMOVAL/INSTALLATION- FRONT OR REAR . . . . . . . . . . . . . . . . . . . . . . . 2.22
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
2.1
MAINTENANCE
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubri-
cation of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genu-
ine Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately
10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition:
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use
and determine the cause or see your dealer.
WARNING
2.2
MAINTENANCE
Maintenance And Lubrication
Periodic Maintenance Chart
Middle gearcase oil (if 25 H Monthly 250 (400) Inspect level; change yearly
equipped)
Rear gearcase oil
(if equipped)
25 H Monthly 250 (400) Inspect level; change yearly
2.3
MAINTENANCE
Item Maintenance Interval Remarks
(whichever comes first)
Hours Calendar Miles
(KM)
Engine breather 25 H Monthly 250 (400) Inspect; replace if necessary
E filter (if equipped)
Engine breather
100 H 6M 1000 (1600) Inspect
hose
General Lubricate all grease fittings, pivots,
lubrication
50 H 3M 500 (800)
cables, etc.
Shift Linkage 50 H 6M 500 (800) Inspect, lubricate, adjust
Steering 50 H 6M 500 (800) Inspect daily, Lubricate
Front suspension 50 H 6M 500 (800) Inspect, Lubricate, Tighten Fasteners
Rear suspension 50 H 6M 500 (800) Inspect, Lubricate, Tighten Fasteners
Carburetor float Drain bowl periodically and prior to
50 H 6M 500 (800)
bowl storage
Throttle Cable/ Inspect; adjust; lubricate; replace if
50 H 6M 500 (800)
E ETC Switch necessary
Inspect; adjust; lubricate; replace if
Choke cable 50 H 6M 500 (800)
E necessary
Carburetor air Inspect ducts for proper sealing/air
E 50 H 6M 500 (800)
intake ducts/flange leaks
Drive belt 100 H 12 M 1000 (1600) Inspect; adjust; replace as needed
Cooling system Inspect coolant strength seasonally;
50 H 6M 500 (800)
(if applicable) pressure test system yearly
Engine oil change 500 Perform a break-in oil change at 20
*Severe Duty 25 H 6M (800) hours/one month, change more
frequently during cold weather
E **Normal Duty 50 H 12 M 1000
(1600)
Engine oil change 500 Replace at oil change
*Severe Duty 25 H 6M (800)
2.4
MAINTENANCE
Item Maintenance Interval Remarks
(whichever comes first)
Hours Calendar Miles
(Km)
1000 Check for leaks at tank cap, lines, fuel valve, filter,
Fuel system 100 H 12M
E (1600) pump, carburetor, replace lines every two years
E
Fuel Filter 100 H 12M
1000
(1600)
Replace yearly
2
Radiator 1000
(if applicable) 100 H 12M
(1600)
Inspect; clean external surfaces
Cooling hoses 1000
(if applicable) 100 H 12M
(1600)
Inspect for leaks
1000
Engine mounts 100 H 12M
(1600)
Inspect
Exhaust muffler / 1000
100 H 12M Inspect
pipe (1600)
1000
Spark plug 100 H 12M Inspect; replace as needed
E (1600)
1000
Ignition Timing 100 H 12M Inspect
E (1600)
1000 Inspect for wear, routing, security; apply dielectric
Wiring 100 H 12M
(1600) grease to connectors subjected to water, mud, etc.
Clutches (drive 1000
100 H 12M Inspect;clean; replace worn parts
and driven) (1600)
Front wheel 1000
100 H 12M Inspect; replace as needed
bearings (1600)
2000
Brake fluid 200 H 24M Change every two years
(3200)
3000
Spark arrestor 300 H 36M Clean out
(4800)
E Idle Speed - Adjust as needed
Toe adjustment - Inspect periodically; adjust when parts are replaced
Auxiliary brake Pre- Ride Inspect daily; adjust as needed
Headlight aim - Adjust as needed
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
Have an authorized Polaris dealer perform these services.
2.5
MAINTENANCE
NOTE: The number count indicated by each part number in the table above indicates the number of units that are
shipped with each order.
Polaris Lubricant Symbol Identification
NOTE: The symbols are used to properly identify the correct lube or grease to use in the maintenance section.
Polaris DOT Polaris Synthetic Polaris Synthetic Polaris All Season Grease Polaris ATV
Brake Fluid Gearcase Lube OW-50 Oil Demand Drive Hub Fluid
2.6
MAINTENANCE
VEHICLE 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 - fill both to their proper level; Do not overfill
2
• All brakes - check operation(includes auxiliary brake)
• Throttle - check for free operation
• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
• Engine stop switch - check for proper function
• Wheels - check for loose wheel nuts
• Air cleaner element - check for dirt or water; clean or replace
• Steering - check for free operation, noting any unusual looseness in any area
• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
• Engine coolant(if applicable) - check for proper level at the recovery bottle
Choke
Ignition/Start Key
Reverse
Override
2.7
MAINTENANCE
Maintenance quick reference
Polaris AGL
2 Transmission See procedure. Change annually o
Lubricant
* More often under severe use, such as operated in water or under severe loads.
o Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
p Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special.
NOTE: Refer to Polaris lubricant Identification table for.
3. Brake Fluid
4. Front Gearcase Oil
2.8
MAINTENANCE
Transmission Lubrication Front Gearcase Lubrication (4x4 Only)
The transmission lubricant level should be checked and changed The front gearcase lubricant level should be checked and
in accordance with the maintenance schedule. changed in accordance with the maintenance schedule.
• Be sure vehicle is level before proceeding. • Be sure vehicle is level before proceeding.
• Check vent hose to be sure it is routed properly • Check vent hose to be sure it is routed properly
and unobstructed. and unobstructed. 2
TRANSMISSION SPECIFICATIONS FRONT GEARCASE SPECIFICATIONS
Specified Lubricant: Specified Lubricant:
Polaris AGL Gearcase Lubricant: Polaris Demand Drive LT Premium Hub Fluid:
(PN 2873603) (Gallon) (PN 2873602) (12 oz.) (PN 2876251) (8 oz.)
Capacity: Capacity:
Even with fill plug Even with fill plug
Drain Plug and Fill Plug Torque: Drain Plug Torque:
15 ft. lbs. (20 Nm) 8-10 ft. lbs. (11-13 Nm)
Fill / Check Plug Torque:
To change / check transmission fluid: 8-10 ft. lbs. (11-13 Nm)
1. Place a drain pan beneath oil pan and remove drain plug
from the crankcase. Allow oil to drain completely.
2. Reinstall the drain plug. Tighten to specification.
3. Add the proper amount of lubricant to bring level into A
operating range as shown. Do not over fill.
2.9
MAINTENANCE
Change Carburetor Draining
1. Remove the drain plug (C). Drain the oil into an The carburetor float bowl should be drained periodically to
appropriate container. Discard used oil properly remove moisture or sediment from the bowl, or before extended
2. Clean and reinstall the drain plug with a new sealing periods of storage.
washer. Torque to specification. NOTE: The bowl drain screw is located on the bottom
3. Remove the fill plug (A) and add a pre-measured amount left side of the float bowl.
of Polaris Angle Drive Fluid. The fluid should not be above
the bottom of the check plug (B) threads. 1. Turn fuel valve to the OFF position.
2. Place a clean container beneath the bowl drain spigot or
4. Reinstall the fill plug (A). Torque to specification.
bowl drain hose.
5. Check for leaks.
3. Turn drain screw out two turns and allow fuel in the float
bowl and fuel line to drain completely.
Lubrication / Grease points 4. Inspect the drained fuel for water or sediment.
There are grease zerks rear lower control arm inner pivots, lower 5. Tighten drain screw.
rear bearing carrier pivots, and the prop shaft. Apply grease until 6. Turn fuel valve to “ON”.
it is visible on the ends of the pivot points.
7. Start machine and check for leaks.
Throttle Operation - All Models NOTE: All tubes attached to the carburetor must be
Check for smooth throttle opening and closing in all handlebar check for pinching or blockage, as this will effect engine
positions. Throttle lever operation should be smooth and lever performance
must return freely without binding.
1. Place the gear selector in neutral.
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle speed
increases at any point in the turning range, inspect throttle
cable routing and condition. If cable is routed properly and
in good condition, repeat adjustment procedure.
5. Replace the throttle cable if worn, kinked, or damaged.
CHOKE
= In. / mm.
2.10
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 2
FRONT
The pilot screw is calibrated at the factory to meet (Engine)
EPA / CARB regulations for air quality standards and
is sealed with a brass plug to prevent tampering.
Removal of the tamper proof plug is not permitted. Pilot Screw
For service purposes, cleaning of the pilot circuit can
be done only by a certified repair shop to ensure air
quality standards are not exceeded.
2.11
MAINTENANCE
Electronic Throttle Control (ETC Switch)/ Fuel System
Throttle Cable Adjustment
1. Slide the boots off inline cable adjuster sleeve. Loosen WARNING
adjuster locknut.
2. With handlebars centered and wheels pointing forward, Gasoline is extremely flammable and explosive
turn adjuster sleeve until 1/16” - 1/8” freeplay is achieved under certain conditions.
at the thumb lever. After making any adjustment, “flip” the
lever slightly to confirm adjustment. • Always stop the engine and refuel outdoors or in a
well ventilated area.
• Do not smoke or allow open flames or sparks in or
near the area where refueling is performed or
where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
CAUTION
2.12
MAINTENANCE
Fuel Filter Engine Mounts
The fuel filter should be replaced in accordance with the Inspect rubber engine mounts for cracks or damage.
Periodic Maintenance Chart. The fuel filter is located between
the fuel tank and carburetor. Engine Fastener Torque
1. Clamp fuel lines
Check engine fasteners and ensure they are tight
2.
3.
Remove line clamps at both ends of the filter.
Remove fuel lines from filter. Battery Maintenance
2
4. Install new filter and clamps onto fuel lines with arrow
pointed in direction of fuel flow.
WARNING
2.13
MAINTENANCE
The battery is located under front rack. Spark Plug
To remove the battery: 1. Remove the seat and left hand side panel.
1. Disconnect holder strap. 2. Remove spark plug high tension lead. Clean plug area so
2. Disconnect battery negative (-) (black) cable first, followed no dirt and debris can fall into engine when plug is
by the positive (+) (red) cable. removed.
3. Remove spark plug.
CAUTION 4. Inspect electrodes for wear and carbon buildup. Look for a
sharp outer edge with no rounding or erosion of the
To reduce the chance of sparks: Whenever electrodes.
removing the battery, disconnect the negative Inspect electrode for wear and buildup
(black) cable first. When reinstalling the battery,
install the negative cable last. Spark Plug Gap
3. Remove the battery.
4. Clean battery cables and terminals with a stiff wire brush.
Corrosion can be removed using a solution of one cup water
and one tablespoon baking soda. Rinse well with clean
water and dry thoroughly.
5. Reinstall battery, attaching positive (+) (red) cable first and 5. Clean with electrical contact cleaner or a glass bead spark
then the negative (-) (black) cable. plug cleaner only. CAUTION: A wire brush or coated
6. Coat terminals and bolt threads with Dielectric Grease (PN abrasive should not be used.
2871329). 6. Measure gap with a wire gauge. Refer to specifications for
7. Reinstall battery cover and holder strap. proper spark plug type and gap. Adjust gap if necessary by
bending the side electrode carefully.
7. If necessary, replace spark plug with proper type.
CAUTION: Severe engine damage may occur if the
incorrect spark plug is used.
8. Apply a small amount of anti-seize compound to the spark
plug threads.
9. Install spark plug and torque to 9-11 ft. lbs (12-14 Nm).
10. Replace side panel and seat.
2.14
MAINTENANCE
Ignition Timing Cleaning:
Timing is CDI controlled and has no adjustment procedure. 5. Slip the pre-filter element off of main element. Clean the
pre filter with hot soapy water.
6. Rinse and dry thoroughly.
Ignition Timing:
7. Inspect element for tears or damage.
30o + 2o BTDC @ 5000RPM 8. Inspect main filter and replace if necessary. If the filter has
been soaked with fuel or oil it must be replaced.
2
Main Air Filter Cleaning Installation:
It is advisable to replace the filter when it is dirty. However, in 9. Reinstall pre-filter element over main filter. Be sure the
an emergency it is permissible to clean the main filter if you
observe the following practices. element covers entire surface of main filter without folds,
creases, or gaps.
• Never immerse the filter in water since dirt can be
transferred to the clean air side of the filter. 10. Reinstall filter on main filter mount. Place filter clamp over
the assembly and tighten.
• If compressed air is used never exceed a NOTE: Apply a small amount of general purpose grease
pressure of 40 PSI. Always use a dispersion type
nozzle to prevent filter damage and clean from the to the sealing edges of the filter before reinstalling.
inside to the outside.
• Replace the air filter every 50 hours, and possibly
more often in very dirty conditions.
Air Box
3. Inspect the gasket. It should adhere tightly to the cover and III. 3 Rear
seal all the way around.
4. Remove air filter assembly. NOTE: The air filter should rest on the filter support.
Proper placement of the air filter is important to prevent
rattles and air leaks. See Illustration above.
11. Install air box cover and secure with clips.
2.15
MAINTENANCE
Air Box Sediment Tube Engine Oil Level
Periodically check the air box drain tube located toward the rear To check the oil level:
of the machine. Drain whenever deposits are visible in the clear
tube. 1. Set machine on a level surface.
2. Place the transmission in neutral.
3. Lock the parking brake.
Sediment Tube
2. To further expel water from the cover and to dry out the
CVT system, shift the transmission to neutral and rev
engine slightly to expel the moisture and air-dry the belt and
clutches. Allow engine RPM to settle to idle speed, shift
transmission to lowest available range and test for belt
slippage. Operate ATV in lowest available range for a short
period of time until CVT system is dry.
2.16
MAINTENANCE
Oil and Filter Change 12. Place towels under the oil filter.
13. Using an oil filter wrench, turn the filter counter clockwise
1. Set machine on a level surface.
to remove it.
2. Place the transmission in neutral.
3. Lock the parking brake.
16. Install the new oil filter, After the filter contacts the engine
surface turn it 1/2 turn by hand.
CAUTION
2.17
MAINTENANCE
22. Verify the oil level. Add oil as needed to bring the level Steering
between the min. and max marks. Do not overfill.
The steering components should be checked periodically for
loose fasteners, worn tie rod ends, and damage. Also check to
make sure all cotter pins are in place. If cotter pins are removed,
they must not be re-used. Always use new cotter pins.
Replace any worn or damaged steering components. Steering
should move freely through entire range of travel without
23. Discard used oil and filter properly. binding. Check routing of all cables, hoses, and wiring to be sure
the steering mechanism is not restricted or limited. NOTE:
Whenever steering components are replaced, check front end
Valve Clearance Adjustment alignment. Use only genuine Polaris parts.
WARNING
2.18
MAINTENANCE
• Elevate front end of machine so front wheels are 6. Again measure the distance between the marks and record.
off the ground. Check for any looseness in front Call this measurement “B”. Subtract measurement “B”
hub / wheel assembly by grasping the tire firmly at
top and bottom first, and then at front and rear. Try from measurement “A”. The difference between
to move the wheel and hub by pushing inward and measurements “A” and “B” is the vehicle toe alignment.
pulling outward. The recommended vehicle toe tolerance is 1/8” to 1/4” (.3
to.6 cm) toe out. This means the measurement at the front
of the tire (A) is 1/8” to 1/4” (.3 to.6 cm) wider than the
measurement at the rear (B).
2
2.19
MAINTENANCE
• Important: When tightening the tie rod end jam 2. Place the transmission in Park and start the engine. Purge
nuts, the rod ends must be held parallel to prevent accumulated carbon from the system by momentarily
rod end damage and premature wear. Damage
may not be immediately apparent if done revving the engine several times.
incorrectly. See illustration. 3. If some carbon is expelled, cover the exhaust outlet and
lightly tap on the pipe around the clean out plugs with a
Hold Tie-Rod End Parallel
rubber mallet while revving the engine several more times.
x
Correctly Incorrectly
Tightened Tightened
Jam Nut Jam Nut
4. If particles are still suspected to be in the muffler, back the
machine onto an incline so the rear of the machine is one
Exhaust Pipe Cleaning foot higher than the front. Set the hand brake and block the
wheels. Make sure the machine is in Park and repeat Steps
WARNING
2 and 3. SEE WARNING
5. If particles are still suspected to be in the muffler, drive the
machine onto the incline so the front of the machine is one
• Do not perform clean out immediately after the
engine has been run, as the exhaust system foot higher than the rear. Set the hand brake and block the
becomes very hot. Serious burns could result wheels. Make sure the machine is in Park and repeat Steps
from contact with exhaust components. 2 and 3. SEE WARNING
• To reduce fire hazard, make sure that there are no
combustible materials in the area when purging
the spark arrestor.
• Wear eye protection.
• Do not stand behind or in front of the vehicle
while purging the carbon from the spark arrestor.
• Never run the engine in an enclosed area.Exhaust
contains poisonous carbon monoxide gas.
• Do not go under the machine while it is
inclined.Set the hand brake and block the wheels 1 ft.
to prevent roll back.
Failure to heed these warnings could result in serious
personal injury or death. 6. Repeat steps 2 through 5 until no more particles are
expelled when the engine is revved.
The exhaust pipe must be periodically purged of accumulated
carbon as follows: 7. Stop the engine and allow the arrestor to cool.
1. Remove the clean out plugs located on the bottom of the 8. Reinstall the clean out plugs.
muffler.
Brake System Inspection
The following checks are recommended to keep the brake
system in good operating condition. Service life of brake system
components depends on operating conditions. Inspect brakes in
accordance with the maintenance schedule and before each ride.
• Keep fluid level in the master cylinder reservoir to
the indicated level inside reservoir.
Clean Out Plug
III. 1
2.20
MAINTENANCE
• Check the fluid level “eye”. If it is clear, it is an 3. If excessive free play exists, inspect brake pads, pedal,
indication that fluid is needed or the brake pads linkage springs, and hoses for wear or damage and replace
may be worn, which can reduce the fluid level.
any parts as needed.
• Use Polaris DOT 3 or DOT 4 Brake Fluid
Rear Brake
Hose/Fitting Inspection
Check brake system hoses and fittings for cracks, deterioration,
abrasion, and leaks.Tighten any loose fittings and replace any Floorboard
worn or damaged parts.
Brake Freeplay
5. If more than one inch, two things must be examined:
Hand Brake Lever
• Free play of the brake pedal should be 1/8 - 1/4
1. Check the brake lever, and foot brake for loose inch (3.2 - 6.35 mm).
connections, free play, and damage.
2. Measure the hand brake lever freeplay. Freeplay should be • If free play is excessive: Inspect brake pads,
pedal, linkage springs, and hoses for wear or
0.40-0.80 in. (10-20 mm). damage and replace any parts as needed.
2.21
MAINTENANCE
Suspension Spring FRONT / REAR Preload Wheel Removal/Installation- Front or Rear
Adjustment
Wheel Removal
Operator weight and vehicle loading affect suspension spring
preload requirements. Using Spanner Wrench (PN 2870872) 1. Stop the engine, place the transmission in gear and lock the
adjust as necessary to avoid bottoming of the shocks. parking brake.
2. Loosen the wheel nuts slightly.
Shock Spanner Wrench 3. Elevate the side of the vehicle by placing a suitable stand
under the footrest frame.
(PN 2870872)
4. Remove the wheel nuts and remove the wheel.
Controls
Cotter
Check controls for proper operation, positioning and Key
adjustment.
• Brake control and switch must be positioned to
allow brake lever to travel throughout entire range
without contacting switch body.
2.22
MAINTENANCE
Tire Pressure Frame, Nuts, Bolts, Fasteners
Periodically inspect the torque of all fasteners in accordance
Tire Pressure Inspection (PSI - Cold) with the maintenance schedule. Check that all cotter pins are in
place. Refer to specific fastener torques listed in each chapter.
Front Rear
4 4
2
Tire Inspection
WARNING
CAUTION
Tread
Depth 1/8” (3 mm)
2.23
MAINTENANCE
NOTES
2.24
ENGINE
CHAPTER 3
ENGINE
TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3
OIL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
PISTON RING IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
TRANSMISSION INSTALLATION NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
OIL FLOW / PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
ENGINE BREATHER / OIL SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
CAM CHAIN TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
ROCKER ARM/SHAFT DISASSEMBLY AND INSPECTION. . . . . . . . . . . . . . . . . . . . . 3.16
CAMSHAFT REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
COMBUSTION CHAMBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
ENGINE BOTTOM END DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CAM CHAIN GUIDE AND TENSIONER BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
CYLINDER HONE SELECTION/ HONING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . 3.26
HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
FLYWHEEL REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
STARTER DRIVE CLUTCH REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
CAM CHAIN DRIVE SPROCKET REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . 3.29
OIL PUMP INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
STARTING CLUTCH AND ENGINE BRAKING CLUTCH REMOVAL /INSPECTION . . 3.30
STARTING CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION. . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKCASE OIL PASSAGES & PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . 3.33
3.1
ENGINE
CAMSHAFT CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
BALANCE SHAFT BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
CRANKCASE OIL PICKUP STRAINER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
BEARING /SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
END PLAY INSPECTION/ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
CRANKSHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
BALANCER SHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
CAM CHAIN, OIL PUMP, & TENSIONER BLADE INSTALLATION. . . . . . . . . . . . . . . . 3.37
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
CYLINDER HEAD AND CAMSHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
CAMSHAFT INSTALLATION & TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
ROCKER ARM INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
STARTER DRIVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
SPARK PLUG FOULING TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
ENGINE TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
3.2
ENGINE
TOOLS Oil Pressure Relief
14 mm 15-17 (20-23 Nm)
Valve Plug
Special Tools
Recoil Housing 6mm 7-8 (9-11 Nm)
PART NUMBER TOOL DESCRIPTION
Rocker Adjuster Screw 5mm 3.5-5 (5-7 Nm)
Valve Seat Reconditioning
2200634
Kit Rocker Cover 6mm 5-6.5 (7-9 Nm)
2870390 Piston Support Block
Rocker Adjuster Screw
PA-47308 Flywheel Puller 5mm 3.7-5.0 (5-7 Nm)
Lock Nut
PA-47457 Starting Clutch Holder
2871293-B
Crankshaft Slotted Nut
Socket
Stator Plate to
Crankcase
6mm 7-8 (9-11 Nm) 3
Stator to Stator Plate
5mm 5-6.5 (7-9 Nm)
Screws
TORQUE SPECIFICATIONS
Starter Motor 6mm 5-6.5 (7-9 Nm)
Engine Torque Specifications
Starting Clutch Cover 8mm 14-15.5 (19-21Nm)
ENGINE TORQUE SPECIFICATIONS 103-118
Starting Clutch Nut 16mm
(140-160 Nm)
Thread ES300PFE010
Fastener
Size Ft. Lbs. (Nm) Spark Plug (New) 12mm 7.5-9 (10-12 Nm)
Camshaft Chain Tighten 30-45
6mm 5-6.5 (7-9 Nm)
Tensioner Lever Spark Plug (Used) 12mm degrees after
Camshaft Chain gasket contact
6mm 6.5-8.0 (9-11 Nm)
Tensioner Body
Torque Patterns
Camshaft Chain
8mm 6-7.5 (8-10 Nm)
Tensioner Cap Tightening method for cylinder head nuts:
Camshaft Sprocket
6mm 6.5-8.0 (9-11 Nm) 1) Apply engine oil to washer and threads of 10mm bolts.
Cover
2) Tighten 10mm bolts in pattern below to 18.5 ft. lbs. (25 Nm)
Camshaft Sprocket Bolt 10mm 30-34 (40-46 Nm)
3) Loosen 180 degrees
Carburetor
8mm 12-14 (16-20 Nm)
Adaptor 4) Tighten to 11 ft. lbs. (15 Nm)
Refer to Torque
Cylinder Head Bolts 10mm 5) Tighten 90 degrees
Procedure
Cylinder & Head 6mm 6) Tighten 60 degrees
6mm 5-7 (7-9 Nm)
Bolts
Crankcase 6mm 6.5-8.0 (9-11 Nm) 7) Tighten 6mm head and base bolts to 8 ft. lbs. (11 Nm)
Crankshaft Sprocket
25mm 34 (46 Nm) Cylinder Head / Cylinder Base
Slotted Nut
Flywheel Nut 16mm 66-81 (90-110 Nm) 2
3
5
Oil Drain Bolt 6 mm
14mm 13-16 (18-22 Nm)
(Crankcase)
6
Oil Filter Pipe Fitting 4
20mm 9.5-12 (13-16 Nm) 1
(Crankcase)
3.3
ENGINE
GENERAL ENGINE SERVICE
Engine Exploded View
Crankcase Cylinder/
Cylinder Head
6 ft. lbs.
8 ft. lbs.
15 ft. lbs.
16 ft. lbs.
6 ft. lbs.
6 ft. lbs.
3.4
ENGINE
Engine Service Data
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off
3.5
ENGINE
Engine Service Data
3.6
ENGINE
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off.
3.7
ENGINE
Oil Flow Diagram
Rocker Arm
Rocker Shaft
Valve Springs
ES300PFE010
Chain Room
MAG SIDE
Starting Clutch
One Way Clutch Crankcase
Stator Plate
Oil Passage
Crankcase
Oil Cooler / Filter
Main Bearing Oil Passage
Oil Pump
Direct
Indirect
3.8
ENGINE
Piston Identification Accessible Components
Piston is identified by the marking ES30A. The following components can be serviced or removed with
the engine installed in the frame:
Note the directional and identification marks when viewing the
pistons from the top. The letters “IN” must always be toward the • Flywheel
intake side of the engine. • Alternator/Stator
Piston rings must be installed correctly to ensure engine • Starter Motor/Starter Drive
performance. The numbers or letters on all rings (except oil
• Oil pump
control rings) must be positioned upward. See text for oil control
ring upper rail installation. Use the information below to
identify pistons and rings.
• Rocker Arms / Rocker Shaft
• Camshaft
3
Engine Model Oversize Standard Piston • Cam Chain and Sprockets
No. Available (mm) Identification
• Cylinder
Valve Pocket to
.25mm • Cylinder Head
ES300PFE010 Rear
.50mm
(Intake Side) • Valves
• Carburetor
Piston Ring Identification
• Piston/RIngs
The piston ring profile is shown below. Install top and second
ring with marking UP. Refer to text for oil control ring The following components require engine removal for
installation. service:
3.9
ENGINE
ENGINE SERVICE 10. Disconnect gear indicator switch harness (at transmission)
Engine Removal
NOTE: The engine removal procedure described
A
below removes the engine and transmission as an
assembly, and the engine is then removed from the
transmission case. The transmission can be
removed separately from the engine (see
Transmission Removal procedure in this chapter).
• Seat
• Left and Right Side Covers
• Rear cab
7. Remove CVT cover and both clutches (refer to CVT
Chapter 8)
3.10
ENGINE
NOTE: If front cab is already removed, the stator 25. Lower the jack and pull engine / transmission assembly out
wires can be disconnected. Disregard the steps to the rear.
remove recoil cover, flywheel, and stator from the
engine.
3.11
ENGINE
26. Support engine and remove (9) transmission-to- Engine Break In Period
engine bolts.
4 Cycle Engine Break-In Period is defined as the first 10 hours
of engine operation or 2 full tanks of fuel.
General Items
CVT System
3.12
ENGINE
Transmission Removal 9. Disconnect gear indicator switch harness (at transmission)
8. Remove transmission linkage rod (A) and vent hose (B) 15. Remove rear plate (lower control arm bolts) and upper
control arm bolts.
3.13
ENGINE
16. Remove rear shocks. 24. Remove the top 2 rear bracket bolts.
25. Carefully lower the transmission jack until rear bracket is
clear of frame.
26. Slide transmission to the left until alignment pins in cover
are release from engine case.
27. Remove transmission out to the left side.
28. Remove sway bar bracket from transmission.
29. Refer to transmission disassembly in CVT/Transmission
Chapter 8.
Rear mount
A
22. Loosen, but do not remove the 4 bolts from the rear
transmission hanger bracket.
23. Remove (9) transmission-to-engine bolts.
3.14
ENGINE
Engine Lubrication Cam Chain Tensioner Removal
Oil Type:Polaris Premium 0W-50 Synthetic To position crankshaft at Top Dead Center (TDC) on
compression stroke:
Capacity (DRY):
1.64-1.95 U.S. Quarts (1.55-1.85 l) 4. Remove the valve cover.
Capacity (OIL/FILTER/COOLING BLOCK CHANGE): 5. Rotate engine in normal direction and watch the intake
1.4-1.7 U.S. Quarts (1.3-1.6 l) valve open and begin to close.
6. Continue to rotate engine slowly while watching camshaft
Drain Plug:14-18 ft. lbs. (19-24.4 Nm) sprocket marks and the mark in the timing inspection hole.
Oil Pressure Specification:
(Using Polaris 0W-50 Synthetic @ Operating Temperature @
Single TDC Mark Aligned 3
Idle) Any pressure reading above 9 PSI. TDC Mark
3.15
ENGINE
10. Tap lightly on tensioner body with a soft face hammer to Rocker Arm/Shaft Disassembly and
loosen and remove tensioner if required. Inspection
NOTE: Orientation of the components is important for
reassembly. Mark all components before disassembly.
2. Hold the ratchet open and slide the plunger in and out of
the tensioner body. The plunger should move smoothly
throughout the travel range.
3. Replace entire tensioner assembly if any part is worn or
damaged.
4. Inspect each rocker arm cam follower surface. If there is
any damage or uneven wear, replace the rocker arm.
NOTE: Always replace camshaft if lobe of either rocker
arm is worn or damaged.
5. Inspect the rocker arm shaft and the shaft bore in the
cylinder head for wear or signs of scoring.
3.16
ENGINE
6. Measure I.D. of each rocker arm (A) for out-of-round and 4. If not removing the cylinder for other service, secure the
visually inspect the I.D. surface. Replace arm if excessive cam chain with a wire to prevent it from falling into the
wear is evident. crankcase.
7. Inspect rocker adjuster screws (B) for wear, pitting, or
damage to threads of the adjuster or locknut. Replace all
worn or damaged parts. NOTE: The end of the adjuster is
hardened and cannot be ground or re-faced.
Camshaft Inspection
1. Thoroughly clean the camshaft.
2. Visually inspect each cam lobe and bearing journal for
wear, scoring, or damage. Verify oil delivery passages are
clean.
3. Check the automatic decompressor spring legs and replace
if broken. Spring preload is very light (about 45 degrees).
3.17
ENGINE
4. Measure the height of the cam lobes with a micrometer and 1/4 turn each time in a cross pattern until loose.
compare to specification. Replace cam if worn below
minimum height (service limit).
3. Remove bolts (A) and tap the cam support tower with a
plastic hammer until loose. Remove.
4. After removing the camshaft and securing the cam chain,
tap cylinder head lightly with a plastic hammer until loose.
= In. / mm. CAUTION: Tap only in reinforced areas or on thick parts
of cylinder head casting.
Cam Lobe Height - Intake & Exhaust
5. Remove cylinder head, gasket, front chain guide and dowel
Std: 1.2938”-1.2977 (32.863-32.963 mm)
pins.
Limit: 1.2820” (32.563 mm)
CAUTION
2. Loosen each of the four cylinder head bolts evenly.
Use care not to damage sealing surface. If there is
damage found on the cylinder head combustion
chamber, it is recommended the component be
replaced.
3.18
ENGINE
Cylinder Head Warp Inspection Cylinder Head Disassembly
1. Lay a straight edge across the surface of the head at several
different points and measure warpage by inserting a feeler WARNING
gauge between the straight edge and the cylinder head
surface. If warpage exceeds the service limit, replace the Wear eye protection or a face shield during cylinder
cylinder head. head disassembly and reassembly. Cylinder head
service should be performed by a technician
knowledgeable in cylinder head reconditioning in a
properly equipped shop.
= In. / mm.
3.19
ENGINE
3. Push valve out, keeping it in order for reassembly in the Valve Inspection
same guide.
1. Remove all carbon from valve with a soft wire wheel.
4. Measure free length of the inner and outer springs with a
Vernier caliper, Ill.1. Check spring for squareness as shown 2. Check valve face for runout, pitting, and burnt spots. To
in Ill.2. Replace spring if measurements are out of check for bent valve stems, mount valve in a drill or use “V”
specification. blocks and use a dial indicator.
A
Valve Spring
Free Length
III.1 3. Check end of valve stem for flaring, pitting, wear or damage
(A).
Coil fatigue/
Squareness
3.20
ENGINE
Measure in two directions, front to back and side to side. provided in the Valve Seat Reconditioning Kit (PN
2200634).
CAUTION
7. Subtract valve stem measurement to obtain stem to guide NOTE: Valve seat width and point of contact on the
clearance. NOTE: Be sure to measure each guide and valve valve face is very important for proper sealing. The valve
combination individually. must contact the valve seat over the entire
circumference of the seat, and the seat must be the
8. Replace valve and/or guide if clearance is excessive.
proper width all the way around. If the seat is uneven,
NOTE: If valve guides are replaced, valve seats must be compression leakage will result. If the seat is too wide,
reconditioned. Refer to Valve Seat Reconditioning for seat pressure is reduced, causing carbon accumulation
procedure. and possible compression loss. If the seat is too narrow,
heat transfer from valve to seat is reduced and the valve
Valve Seat Reconditioning may overheat and warp, resulting in burnt valves.
3.21
ENGINE
4. Inspect the cut area of the seat. • If the indicated seat contact is at the top edge of
the valve face and contacts the margin area(B) it is
• If the contact area is less than 75% of the too high on the valve face. Use the 30o cutter to
circumference of the seat, rotate the pilot 180o and lower the valve seat.
make another light cut.
• If too low use the 60o or 75o cutter to raise the
• If the cutter now contacts the uncut portion of the seat. When contact area is centered on the valve
seat, check the pilot. Look for burrs, nicks, or face, measure seat width.
runout. If the pilot is bent it must be replaced.
• If the seat is too wide or uneven, use both top and
• If the contact area of the cutter is in the same bottom cutters to narrow the seat.
place, the valve guide is distorted from improper
installation and must be replaced. Be sure the • If the seat is too narrow, widen using the 45o cutter
cylinder head is at the proper temperature and and re-check contact point on the valve face and
replace the guide. seat width after each cut.
• If the contact area of the initial cut is greater than Bottom 60o or 75o Seat - 45o or 46o
75%, continue to cut the seat until all pits are
removed and a new seat surface is evident. Top - 30o
NOTE: Remove only the amount of material
necessary to repair the seat surface.
5. To check the contact area of the seat on the valve face, apply
a thin coating of Prussian Blue™ paste to the valve seat. If
using an interference angle (46o)apply black marker to the
entire valve face (A).
(A)
NOTE: When using an interference angle, the seat
contact point on the valve will be very narrow, and is a
normal condition. Look for an even and continuous
contact point on the black marker, all the way around the
valve face.
6. Insert valve into guide and tap valve lightly into place a few
times.
7. Remove valve and check where the Prussian Blue™ or
black marker indicates seat contact on the valve face. The Seat
valve seat should contact the middle of the valve face or Width
slightly above, and must be the proper width (A).
(B)
(A)
8. Clean all filings from the area with hot soapy water, rinse,
and dry with compressed air.
9. Lubricate the valve guides with clean engine oil, and apply
oil or water based lapping compound to the face of the
valve. Lapping is not required with an interference angle.
10. Insert the valve into its respective guide and lap using a
Proper Seat Contact On Valve Face lapping tool or a section of fuel line connected to the valve
stem.
3.22
ENGINE
11. Rotate the valve rapidly back and forth until the cut sounds Cylinder Head Assembly
smooth. Lift the valve slightly off of the seat, rotate 1/4 turn,
and repeat the lapping process. Do this four to five times
until the valve is fully seated, and repeat process for the CAUTION
other valve.
12. Clean cylinder head, valves, and camshaft oil supply Wear eye protection during assembly.
passages thoroughly.
NOTE: Assemble the valves one at a time to maintain
13. Spray electrical contact cleaner into oil passages and dry proper order.
using compressed air.
1. Install new valve seals on valve guides.
Closely spaced
coils toward
cylinder head
3.23
ENGINE
6. Place retainer on springs and install valve spring Cam Chain Guide And Tensioner Blade
compressor. Compress spring only enough to allow split
keeper installation and prevent loss of spring tension. 1. The guide can be removed after cylinder head is removed
Install split keepers with the gap even on both sides. by pulling it upward out of the channel in the crankcase.
7. Repeat procedure for remaining valve. 2. Remove blade and inspect. Replace if worn., cracked, or
damaged.
8. When all valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the Split keepers. 3. Tensioner blade removal requires recoil, flywheel, and
stator plate removal. Refer to lower end service procedures
Valve Sealing Test to access the bolt securing the tensioner blade to the
crankcase.
1. Clean and dry the combustion chamber area.
2. Pour a small amount of cleaning solvent into each port and
check for leakage around each valve. The valve seats
should hold fluid with no seepage.
3.24
ENGINE
Piston Removal Cylinder Inspection
1. Remove one circlip. Note valve pocket on intake side of 1. Remove all gasket material from the cylinder sealing
piston for installation. surfaces.
2. Remove piston circlip and push piston pin out of piston. If 2. Inspect the top of the cylinder for warpage using a straight
necessary, heat the crown of the piston slightly with a edge and feeler gauge.
propane torch. CAUTION: Do not apply heat to the piston
rings. The ring may lose radial tension.
= In. / mm.
3. Remove the compression rings, starting with the top ring. Cylinder Warp:
.002” (.05 mm) MAX
*Using a piston ring pliers: Carefully expand ring and
lift it off the piston. CAUTION: Do not expand the ring 3. Inspect cylinder for wear, scratches, or damage.
more than the amount necessary to remove it from the 4. Inspect cylinder for taper and out of round with a
piston, or the ring may break. telescoping gauge or a dial bore gauge. Measure in two
different directions, front to back and side to side, on three
*By hand: Placing both thumbs at end gap, carefully spread the different levels (1/2” down from top, in the middle, and 1/
ring open and lift ring over piston at the opposite side. Use care 2” up from bottom).
to not scratch the ring lands. 1/2” Down From Top of Cylinder
4. Repeat procedure for second ring. X Y
5. The oil control ring is a three piece design consisting of a
top and bottom steel rail and a center expander section.
Remove the top rail first followed by the bottom rail and Y
expander. X
Y
X
= In. / mm.
3.25
ENGINE
Cylinder Hone Selection/ Honing Procedure If cylinder wear or damage is excessive, it will be necessary to
replace the cylinder. Hone only enough to deglaze the outer
layer of the cylinder bore.
CAUTION
3.26
ENGINE
4. Measure piston pin O.D. Replace piston pin if out-of-round. Piston Ring Installed Gap
1. Place each piston ring inside cylinder using piston to push
ring squarely into place as shown.
Piston ring installed end gap
Feeler Gauge
= In. / mm.
Top Ring
Std: .008- .012” (.2- .3 mm)
Limit: .032” (0.8 mm)
Second Ring
6. Measure piston ring to groove clearance by placing the ring Std: .014- .020” (0.35- 0.50 mm)
in the ring land and measuring with a thickness gauge. Limit: .039” (1.0 mm)
Replace piston and rings if ring-to-groove clearance Oil Ring
exceeds service limits. Std: .008- .028” (0.2- 0.7 mm)
Limit: .059” (1.5 mm)
Piston 2. Measure the gap with a feeler gauge at both the top and
bottom of the cylinder.
Ring
NOTE: Measure at two points in the cylinder A
difference in end gap indicates cylinder taper. The
cylinder should be measured for excessive taper and out
of round.
Feeler Gauge
3. If the installed gap measurement exceeds the limit, replace
the rings. If using new rings and the measurement is too
small, file the ring ends to achieve the proper gap.
NOTE: Always check piston ring installed gap after re-
boring a cylinder or when installing new rings. A re-bored
cylinder should always be scrubbed thoroughly with hot
soapy water, rinsed, and dried completely. Wipe cylinder
bore with an oil rag immediately to remove residue and
prevent rust.
3.27
ENGINE
Flywheel Removal / Inspection Starter Drive Clutch Removal/Inspection
1. Remove the recoil housing, recoil hub, and flywheel nut. 1. Remove recoil housing bolts and remove housing.
2. Remove the starter drive clutch and washer by pulling the
shaft and tilting the gear slightly.
3. Measure the O.D. of the starter drive shaft on both ends for
out-of-round.
4. Measure the I.D. of the bushings in the recoil housing and
in the crankcase (A) in two directions 90o apart to determine
if out-of-round. Replace worn bushings.
3.28
ENGINE
Cam Chain Drive Sprocket Removal / Oil Pump Inspection / Removal
Inspection
NOTE: Mark the oil pump geroters to keep parts mated
1. Remove recoil housing, flywheel, flywheel key, and for assembly.
stator.
1. Remove recoil housing, flywheel, flywheel key, and
stator.
2. Use a feeler gauge to check oil pump rotor tip clearance at
“A”, and pump body clearance at “B”. Compare to
specifications. Replace the oil pump assembly if any parts
are damaged, scored, or measure beyond the service limit.
3
A
B
2. Using the Slotted Nut Socket, remove the crankshaft slotted
nut by turning it clockwise. NOTE: Slotted nut is left hand
thread.
3. Mark the oil pump geroters and shaft and carefully lift the
geroters from the housing.
REMOVE
3.29
ENGINE
Starting Clutch And Engine Braking Clutch 5. Open the staked portion of the nut (A) with a center punch.
Removal /Inspection Inspect the one-way clutch hub surface on the starting
clutch (B). The hub must be smooth without any nicks or
NOTE: The transmission must be removed from the burrs. Replace the starting clutch assembly if the one-way
engine to access the starting clutch and one-way clutch hub is uneven or damaged
engine braking clutch.
Inspect entire surface of
1. Inspect the starting clutch drum bearing in the housing. one-way clutch hub.
The shaft must turn smoothly (by hand) without binding B
in the clockwise direction, and should not turn by hand in
the counter clockwise direction. Minimal movement in the
shaft is NORMAL with engine removed due to the lack of
clutch cover bearing support on the free end of the shaft
(approximately 0-.060” (0-1.5mm). Press the shaft out of A
the housing and replace the bearing if worn or rough.
DO NOT LIFT ENGINE WITH
CLUTCH SHAFT
3.30
ENGINE
thinnest point. 9. Install one-way clutch in starting clutch drum with the
flanged side toward the hub, using a rotating motion.
Standard Thickness: .100” (2.54mm)
LIMIT: .039” (1.00mm)
Crankcase Disassembly
7. If drum bearing was replaced in the starting clutch housing, NOTE: Engine must be removed from the frame to
press the drum/shaft into the housing until fully seated. perform any crankcase or crankshaft removal.
8. Clean the inside of the starting clutch drum and lubricate NOTE: The starter, starter drive, flywheel, stator, oil
the drum and one-way clutch with engine oil. pump and transmission can be serviced with the
engine in the frame.
3.31
ENGINE
Crankcase Separation crankshaft, or balance shaft. See procedure this
chapter.
NOTE: Stator housing, flywheel and gears have are
previously removed for this procedure. Use care during
the removal process to avoid damage to the cam chain.
1. Remove all bolts and the pressure relief valve (A) from the
magneto side crankcase.
2. Note the number and thickness of any shims installed on 3. The connecting rod utilizes a roller bearing. Clearance can
either shaft. be measured with a dial indicator to check radial clearance.
Visually inspect the connecting rod, crank pin, and thrust
NOTE: Crankshaft and balance shaft end play must washers for scoring, damage, excessive wear, or signs of
be measured and adjusted with shims if any new overheating. Check for roughness or noise when rotating
components are installed (bearings, crankcase, the connecting rod on the crank pin. Replace crankshaft if
it fails visual inspection, or if any up and down movement
3.32
ENGINE
is detectable in the connecting rod. Camshaft Chain
1. Replace the cam chain as part of any crankshaft repair.
2. The cam chain can be removed by removing the engine top
end, the recoil assembly, flywheel and flywheel key, stator
plate, and slotted nut.
3. Lift the sprocket slightly until chain clears the crankcase to
remove.
Connecting Rod Side Clearance: 1. Inspect the balance shaft bearings in the crankcase.
.0035-.0196” (.09-.50mm) NOTE: Due to extremely close tolerances and minimal
Limit: .023” (.60mm) movement, the bearing must be inspected visually and
by feel. Look for signs of discoloration, scoring or galling.
6. Clean crankshaft oil passages by running a stream of clean Turn the inner race of bearing. The bearing should turn
solvent through the crankshaft. Be sure all passages are smoothly and quietly. The outer race should fit tightly in
clear and free of nicks or scratches. the crankcase. The inner race should be firm with
minimal side to side movement and no detectable up and
Crankcase Oil Passages & Pressure Relief down movement.
Valve
2. To remove balance shaft bearings, use a blind hole bearing
1. Remove the pressure relief valve assembly from the case.
puller.
NOTE: Bearings are stressed during the removal
procedure and should not be re-used.
3.33
ENGINE
Crankcase Oil Pickup Strainer Inspection End Play Inspection/Adjustment
Before reassembling the crankcase, the following steps should
be performed to determine the amount of crankshaft, counter
balancer shaft, and pump shaft end play. Excessive end play may
cause engine noise at idle and slow speeds. Too little play will
side load the bearings which may lead to premature bearing
failure.
CAUTION
3.34
ENGINE
3. Subtract the thickness of the straightedge from the 6. Add the readings recorded in Step 3 and Step 5 and record
measurement obtained in Step 2 and record. below.
= In. / mm.
3.35
ENGINE
Balancer Shaft End Play Adjustment 7. Subtract the thickness of the existing shim from the result
of Step 6 to determine if a different shim is needed. The
NOTE: The balancer shaft end play measurement result must be within the specified range listed at below.
procedure is the same as that outlined for the
crankshaft. The exception is that measurements are 8. Add or subtract shims or change shim thickness as required
taken to the balancer shaft bearings in the case, and install them upon assembly.
rather than the crankshaft main bearings, and the
width of the balancer shaft is measured, not the
crankshaft. = In. / mm.
1. Make sure the counter balance shaft bearings are firmly
Counter Balance Shaft End Play:
seated in each crankcase.
.004”-.029” (.1-.74 mm)
Measure to balance shaft bearing race
Crankcase Reassembly
Crankshaft Installation
3.36
ENGINE
3. Be sure balance dots on gear teeth are aligned. Cam Chain, Oil Pump, & Tensioner Blade
Installation
1. Install the cam chain over the drive sprocket.
2. Lubricate and install the oil pump geroters, aligning the
marks made during disassembly. Clean the marks off the
geroters.
Crankcase Sealant
PN 2871557
5. Install the mag side case and tap with a soft faced hammer
to seat.
6. Install case screws and torque in a cross pattern to
specification. =T
Tensioner Blade Mounting Bolt Torque:
5-6.5 ft. lbs. (7-9 Nm)
=T
Crankcase Bolt Torque:
6.5-8.0 ft. lbs. (9-11 Nm)
3.37
ENGINE
6. IMPORTANT! Be sure the sealed screw is placed in the 5. Install the top ring with the marking facing up. The top ring
hole that aligns with the cam chain cavity or an oil leak may has an inner bevel with a barrel face.
result. If you are installing the old screw, seal it with Loctite Top Ring:
242 (blue) before installation. Bevel on Inner Edge Install with
mark UP
This screw must be sealed
Second Ring
Mark Faces UP
Flywheel Nut: 1. Install a new circlip on one side of the piston with the end
67-81 ft. lbs. (90-110 Nm) gap facing up or down.
Recoil Drive Hub: 2. Apply clean engine oil to the piston rings, ring lands, piston
12-14 ft. lbs. (17-19 Nm) pin bore, piston pin, and piston skirt. Lubricate the
connecting rod (both ends) and crankshaft main bearing
Piston Ring Installation area.
NOTE: Apply clean engine oil to all ring surfaces and 3. IMPORTANT- Install the piston on the connecting rod
ring lands. Always check piston ring installed gap before with the valve pocket facing the intake side of engine.
rings are installed on piston. If the piston has been in The piston pin should be a push fit into the piston.
service, clean any accumulated carbon from the ring Pocket
grooves and oil control ring holes.
1. Place the oil control ring expander in oil ring groove with
the end gap facing forward. The expander has no up or
down marking and can be installed either way. The ends
should butt squarely together and must not overlap.
2. Install the oil ring top rail with the end gap at least 30o from
the end of the expander.
3. Install the bottom rail with the gap at least 30o from the end
of the expander on the side opposite the top rail gap.
4. Install the second ring with the mark facing up. The second 4. Install the other circlip with the gap facing up or down. Push
ring has an undercut with a tapered face. Position the end the piston pin in both directions to make sure the clips are
gap toward the rear (intake) side of the piston. properly seated in the groove.
3.38
ENGINE
5. Lubricate the piston and rings with engine oil and install a 5. Loop the cam chain through the cylinder chain room and
ring compressor on the piston assembly. Verify that the ring secure with mechanic’s wire.
gaps are 120o - 180o apart from each other before
installation.
Cylinder Installation
NOTE: Clean the gasket surfaces on the crankcase and
cylinder. Remove all traces of old gasket material or
sealant. The surfaces must be oil-free!
3.39
ENGINE
Cylinder Head and Camshaft Installation 6. Torque the cylinder head following the procedure and
pattern below.
NOTE: Clean the gasket surfaces on the cylinder head
and cylinder. Remove all traces of old gasket material. Cylinder Head / Cylinder Base
The surfaces must be oil-free!
4. Install the two 6 mm bolts on cylinder base and on the head, Forward
but do not tighten.
=T
Cylinder Gasket Torque Sequence:
Tighten M10 bolts to 18.5 ft. lbs. (25 Nm)
Loosen 180 degrees
Tighten to 11 ft. lbs. (15 Nm)
Tighten M10 bolts 90 degrees
Tighten M10 bolts another 60 degrees
Tighten 6mm bolts to 8 ft.lbs.(11 Nm)
CAUTION
5. Lubricate the washers and the threads of the cylinder head
bolts and install the bolts with washers. Serious engine damage will result if the camshaft is
not properly timed to the crankshaft.
3.40
ENGINE
2. Apply engine oil or starter drive grease (molybdenum 8. Verify all marks are aligned. Install the cam sprocket bolt
disulfide paste) to the camshaft main journals and cam and torque to specification.
lobes. Lubricate automatic compression release
mechanism with clean engine oil.
=T
Starter Drive Grease: Camshaft Sprocket Bolt
(PN 2871460) 35.5-50 ft. lbs. (48-70 Nm)
3. Orient the camshaft with the lobes facing downward, and Cam Chain Tensioner Installation
install the cam into the cylinder head.
1. Hold the tensioner ratchet pawl (A) open and push the
plunger (B) in to the fully retracted position. 3
A
B
4. Disconnect the wire or tie strap securing the cam chain (if
used).
5. Be sure the pin on the camshaft is pointing DOWN. 2. With the plunger retracted, install the tensioner assembly
with a new gasket and tighten the bolts to specification.
6. Loop the cam chain over the sprocket and shift the chain
on the sprocket until it can be installed onto the camshaft.
A
B
B
A
=T
7. VERIFY the following: Tensioner Bolt Torque: 5-6.5 ft. lbs. (7-9 Nm)
• “T” Mark on flywheel is aligned with the 3. Install the pin, spring, and tensioner cap with a new sealing
projection in the timing hole of the recoil
housing. washer. Torque cap to specification.
3.41
ENGINE
4. Slowly rotate engine two to three revolutions in the Starter Drive Assembly
direction of rotation and re-check cam timing.
1. Be sure the washer is positioned on the back of the drive
Rocker Arm Installation gear.
1. Lubricate the rocker arms and shaft with engine oil. Apply
a light film of starter grease (moly grease) to the cam
follower pad on the rocker arms.
2. Slide the shaft through the tower just enough to install the
wave washer (A).
NOTE: The flats of the wave washer are positioned
against the intake rocker arm.
3.42
ENGINE
TROUBLESHOOTING Engine Does Not Turn Over
• Restricted air filter (main or pre-cleaner), or air • Starter motor does not turn
inlet ducts. • Engine seized, rusted, or mechanical failure
• Choke cable adjustment or plunger/cable sticking
Engine Runs But Will Not Idle
• Foreign material on choke plunger seat or plunger
• Idle speed set too low
• Incorrect spark plug heat range or gap
• Faulty ETC system
• Jet needle and/or needle jet worn or improperly
adjusted • Restricted carburetor pilot system 3
• Excessive carburetor vibration (check all engine • Carburetor misadjusted
and carburetor mounts)
• Choke not adjusted properly or sticking plunger
• Oil contaminated with fuel
• Low compression
• ETC switch mis-adjusted
• Crankcase breather restricted
• Low compression
• Air filter restriction
• Spark plug cap loose or faulty
Engine Idles But Will Not Rev Up
• Loose jets in carburetor or calibration incorrect for
altitude/temperature
• Spark plug fouled/weak spark
• Incorrect float level setting
• Broken throttle cable
• Carburetor inlet needle and seat worn
• Obstruction in air intake
• CVT system calibrated incorrectly or components
worn or mis-adjusted • Air box removed (reinstall all intake components)
• Weak ignition (loose coil ground, faulty coil, stator, • Carburetor vacuum slide sticking/diaphragm
engine to chassis ground, or ETC switch) damaged
3.43
ENGINE
Piston Failure - Scoring Backfiring
3.44
FUEL / AIR / EXHAUST
CHAPTER 4
FUEL / AIR / EXHAUST
GENERAL INFORMATION AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
CARBURETOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
CARBURETOR JETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
MIKUNI JET PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
CARBURETION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
BST 34 CARBURETOR EXPLODED VIEW 1 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
BST 34 CARBURETOR EXPLODED VIEW 2 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
CARBURETOR VENTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
CV CARBURETOR SYSTEM FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
CARBURETOR VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
MIKUNI CV CARB OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
STARTER SYSTEM (CHOKE OR ENRICHMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
PILOT (IDLE AND SLOW) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4
MAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
FLOAT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
PILOT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
AIR/FUEL MIXTURE RATIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
NEEDLE JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
THROTTLE OPENING VS. FUEL FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
CARBURETOR DISASSEMBLY – MIKUNI CV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
CARBURETOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
CARBURETOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
FLOAT HEIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
NEEDLE AND SEAT LEAKAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL LEVEL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
FUEL TANK/FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
FUEL TANK / FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
4.1
FUEL / AIR / EXHAUST
GENERAL INFORMATION AND Carburetor Specifications
SPECIFICATIONS
2007 Hawkeye 2x4 / 4x4
Special Tools (Domestic and International)
Never start the engine or let it run in an A main jet that is too small will cause a lean
enclosed area. Gasoline powered engine operating condition resulting in serious engine
exhaust fumes are poisonous and can cause damage. Select the correct main jet carefully for
loss of consciousness and death in a short elevation and temperature according to the charts in
time. the Specifications section or in the Owner’s Safety
and Maintenance Manual for each particular model.
Never drain the float bowl when the engine is
hot. Severe burns may result.
Mikuni Jet Part Numbers
Do not smoke or allow open flames or sparks Main Jets Pilot Jets
in or near the area where refueling is Jet Number Part Number Jet Number Part Number
performed or where gasoline is stored. 130 3130561 25 n/a
132.5 3130562 27.5 n/a
If you get gasoline in your eyes or if you 135 3130563 30 n/a
137.5 3130564 32.5 n/a
should swallow gasoline, seek medical 140 3130527 35 n/a
attention immediately. 142.5 3130566 37.5 n/a
145 3130567 40 3130624
147.5 3130568 42.5 3130526
If you spill gasoline on your skin or clothing, 152.5 3130570 45 3131397
immediately wash with soap and water and 155 3130571 47.5 3131226
change clothing. 157.5 3130572 50 3131132
160 3131141 55 n/a
NOTE: It is strongly recommended that Polaris Carbon 162.5 3131142 57.5 n/a
165 3131143 60 n/a
Clean be added regularly as directed to the fuel systems 167.5 3131144 65 n/a
of all Polaris ATVs. Carbon Clean stabilizes the fuel, 170 3131145 70 n/a
preventing clogging of the small passages and orifices
common to ATV carburetors, and ensures constant
performance, reliability and easier starting.
4.2
FUEL / AIR / EXHAUST
CARBURETION
BST 34 Carburetor Exploded View 1 of 2
A
G
H
4
C
N
M
P L
D
J
E
F
G Cover
H Spring
4.3
FUEL / AIR / EXHAUST
BST 34 Carburetor Exploded View 2 of 2
A D
B F
C
E
J
K
F Spring
H Floats
4.4
FUEL / AIR / EXHAUST
Carburetor Venting System
D
B
E
C
C Hose (Vents)
D Tee Fitting
E Filter
4.5
FUEL / AIR / EXHAUST
CV Carburetor System Function Carburetor Venting
The carburetor float bowl vent lines supply atmospheric
Carburetor Component Function pressure to the float bowl. The lines must be free of kinks,
Main Main Main restrictions and be properly routed. This allows fuel to flow in
System the proper amount and prevents contaminants from entering the
Components Function Affect carburetor.
Float Inlet Pipe, Maintains All systems
System Needle and specified fuel All throttle Mikuni CV Carb Operation
(Level Seat, Float, level in float ranges
Control) Float Pin chamber The constant velocity carburetor incorporates a mechan-
(carburetor float ically operated throttle plate and a vacuum controlled
bowl) slide valve (vacuum slide). The venturi cross–sectional
Venting Passages in Supplies All systems area in the carburetor bore is increased or decreased
Carburetor, Vent atmospheric All throttle automatically by the vacuum slide, which moves accord-
lines pressure to float ranges ing to the amount of negative pressure (less than atmo-
to frame chamber spheric) present in the venturi.
A diaphragm attached to the top of the vacuum slide is sealed to
Starter Choke Lever, Supplies All throttle the slide and to the carburetor body forming two chambers. The
chamber above the diaphragm is connected to the venturi area
(Choke/ Cable, Plunger, additional fuel ranges by a drilled orifice in the center of the vacuum slide. The
Enrichment) Return Spring, air mixture Greatest chamber below the diaphragm is vented to atmospheric pressure
Carb Passages necessary for effect at low by a passage on the air box side of the carburetor. A spring,
installed in the center of the vacuum slide, dampens the slide
(Starter Jet, cold starting throttle movement and assists the return of the slide.
Starter Bleed settings and
Pipe) idle
Low Pressure
Diaphragm
From Venturi
4.6
FUEL / AIR / EXHAUST
When the throttle plate is opened and engine speed begins to Starter System (Choke or Enrichment)
increase, the pressure in the venturi (and therefore in the
chamber above the diaphragm) becomes significantly lower When the choke cable (1) is activated, the starter plunger (5) is
than atmospheric. Atmospheric pressure in the chamber below lifted off the seat.
the diaphragm forces the diaphragm upward, raising the slide
against spring pressure. When the pressure above and below the 8
diaphragm are nearly equal, the slide moves downward under 5 1
spring pressure. Raising or lowering the slide increases or
decreases the cross sectional area in the venturi, and therefore
the air velocity in the venturi is kept relatively constant. This
provides improved fuel atomization and optimum fuel/air ratio.
7 6
2
3 4
Fuel is drawn into the starter circuit from the float chamber (2)
through the starter jet (3). Starter jet meters this fuel, which then
flows into starter pipe (4) and mixes with the air (7) coming from
the float chamber. The mixture, rich in fuel content, reaches
starter plunger and mixes again with the air coming through a
passage (8) extending from underneath the diaphragm. The rich
fuel/air mixture for starting is discharged through starter outlet
(6) in the main bore.
Note: Diagrams are for explanation of theory only, and are not true
representations of Mikini BST carburetor.
4.7
FUEL / AIR / EXHAUST
Pilot (Idle and Slow) System Main System
This system supplies fuel during engine operation with throttle As throttle valve (1) is opened, engine speed rises, and this
valve closed (1) or slightly opened. The fuel from float chamber increases negative pressure in the venturi. Consequently the
(2) is metered by pilot jet (3) where it mixes with air coming in vacuum slide (2) moves upward. The fuel in float chamber (3)
through pilot air jet (4). The mixture then goes up through pilot is metered by main jet (4), and the metered fuel enters needle jet
passage to pilot screw (5). A part of the mixture is discharged (5), in which it mixes with the air admitted through main air jet
into the main bore out of bypass ports (6). The remainder is then (6) to form an emulsion. The emulsified fuel then passes through
metered by pilot screw and discharged into the main bore the clearance between needle jet (5) and jet needle (7), and is
through pilot outlet (7). discharged into the venturi (A). Mixture proportioning is
accomplished in needle jet (5); the clearance through which the
emulsified fuel must flow is determined ultimately by throttle
position and vacuum slide height.
1
1
A
6
5
2
3
5 3
4.8
FUEL / AIR / EXHAUST
Float System Pilot Screw
Fuel enters the float chamber (3) by means of the inlet pipe and The pilot system supplies fuel during engine operation with the
passage, through a screen on the back of the inlet needle seat (4), throttle valve closed or slightly opened. The fuel/air mixture is
and around the inlet needle (2). As the fuel fills the float metered by pilot screw and discharged into the main bore
chamber, the float (1) rises and forces the inlet needle against the through the pilot outlet.
seat, shutting off the orifice in the seat. When fuel level is up in
float chamber, floats are up and needle valve remains pushed up
against valve seat. Under this condition, no fuel enters the float CAUTION
chamber. As the fuel level falls, floats go down and needle valve
unseats itself to allow fuel into the chamber. In this manner, the
needle valve releases and shuts off fuel alternately to maintain The pilot screw is calibrated at the factory to meet
a constant fuel level inside the float chamber. EPA / CARB regulations for air quality standards
and is sealed with a brass plug to prevent tampering.
Removal of the tamper proof plug is not permitted.
For service purposes, cleaning of the pilot circuit can
be done only by a certified repair shop to ensure air
quality standards are not exceeded.
4
Inlet
Pipe
Pilot Screw Location
4 2
4.9
FUEL / AIR / EXHAUST
Air/Fuel Mixture Ratio higher produces a leaner mixture. If the taper is worn due to
vibration, fuel flow may be significantly affected.
E-Clip Position vs. Fuel Flow Jet Needle
2
3 Leaner
4
Position#
4
Richer
Needle Jet
15 50 75 100% The needle jet works in conjunction with the jet needle to
Throttle Valve Opening regulate fuel flow rate. An air bleed opening in the side of the
needle jet brings in air measured by the air jet. This air initiates
the mixing and atomizing process inside the needle jet.
A carburetor with a slide type throttle valve is also called a
variable venturi type carburetor. In this type of carburetor, the
needle jet and jet needle serve to control proper air/fuel mixture
ratio at the medium throttle valve opening (between 1/4 and 3/ Needle Jet
4 opening).
Having the proper needle jet and jet needle has a major impact
on engine performance at partial load. The jet needle tapers off
at one end and the clearance between the jet needle and the
needle jet increases as the throttle valve opening gets wider. The
air/fuel mixture ratio is controlled by the height of the “E” clip
inserted into one of the five slots provided in the head of the jet
needle. The previous chart shows the variation of fuel flow
based on the height of the “E” clip. Main Jet
Jet Needle
The jet needle has five adjustment grooves cut into the upper
portion, and is tapered from approximately the middle of the
needle to the lower end. The top is fixed to the center of the
throttle valve by the needle clip, and the tapered end extends into
the needle jet. Fuel flows through the space between the needle
jet and jet needle. This space does not vary until the throttle
reaches the 1/4 open point. At that time the tapered portion of the
needle begins to move out of the jet, affecting fuel flow as the
opening enlarges. If the needle clip is changed from the standard
position to a lower groove, the needle taper starts coming out of
the jet sooner, resulting in a richer mixture. Moving the clip
4.10
FUEL / AIR / EXHAUST
Throttle Opening vs. Fuel Flow 2. Remove float bowl. Remove the float pin screw. The float
and float pin can be removed.
In a full throttle condition the cross sectioned area between the
jet needle and the needle jet is larger than the cross sectioned
area of the main jet. The main jet therefore has greater control
over fuel flow.
Small Medium Large
Clearance Clearance Clearance
4
3. Remove inlet needle seat retaining screw along with plate,
and carefully remove needle seat. NOTE: Do not use a
pliers to remove the seat or permanent damage may occur.
O-Ring
Washer
Spring
Pilot Screw
4.11
FUEL / AIR / EXHAUST
NOTE: The starter jet is removable. Upon disassembly, Carburetor Inspection
place the parts in a container for safe keeping.
1. Inspect jet needle and needle jet for wear. Look for
discoloration, shiny spots, or an area that looks different
than the rest of the needle. The middle to upper portion of
the needle contacts the needle jet and is the most likely
wear point. If jet needle shows signs of wear replace both
the needle and needle jet to prevent a rich condition. TIP:
A worn needle jet is difficult to spot. To check, slide a
slightly larger new jet needle into the needle jet and hold it
to a light source. Light will be visible between the needle
and needle jet if it is worn.
Needle Jet
Jet Needle
Carburetor Cleaning
Inspect this
WARNING area
4.12
FUEL / AIR / EXHAUST
Carburetor Assembly the engine running. Refer to Chapter 2.
2. With the carburetor still resting on the level surface, use one
hand to slightly tilt the carburetor back. The float will then
1. Replace parts in proper order. The spring seat (B) is fall into the correct position, with the float tongue resting
stepped and must be placed on TOP of “E” Clip (C). lightly on the inlet needle valve pin without compressing
Spacer washer (D) must be installed below the E–Clip. the spring. The bottom of the float should be parallel with
Refer to parts manual for more information. the float bowl mating surface. NOTE: If the float is past
2. Be sure the tab (E) on outer edge of diaphragm is positioned parallel with the mating surface, the carburetor has been
properly in the carburetor body. tilted back too far and the float tongue is likely compressing
the needle valve pin.
FRONT
(Engine)
Pilot Screw
4.13
FUEL / AIR / EXHAUST
3. Measure the height from the float bowl mating surface to Fuel Level test
the top of step of the float as shown in Illustration 2. Both
sides of float should be parallel to each other. The A fuel level test can be performed on some models if the drain
measurement should be made at the mid–point on top of the hose fitting is accessible. Be sure to re–attach the bowl drain
float using Float Adjustment Tool (PN 2872314) or a hose after performing the test. A fuel level test allows you to
vernier caliper. When measuring the height, be sure the observe the height of the fuel in the float bowl without removing
inlet needle valve spring is not compressed. the carburetor. The fuel level can be observed with the engine
either running or shut off, however, engine must run briefly to
allow fuel level to stabilize.
Float Bowl Height: 13-14 mm
1. Attach a clear line to drain fitting. Be sure line fits tightly
4. If adjustment is necessary, bend the tongue slightly. Be sure on fitting. Position hose along side of carburetor as shown.
float measurement is even on left and right side.
1.5 mm
.060 in. Bowl Mating
Surface
4.14
FUEL / AIR / EXHAUST
Troubleshooting POOR IDLE
4.15
FUEL / AIR / EXHAUST
AIR INTAKE SYSTEM
Air Intake System
G H
4.16
FUEL / AIR / EXHAUST
FUEL TANK/FUEL DELIVERY SYSTEM
Fuel Tank / Fuel Delivery System
B D
E 4
F
N
J
G
K
4.17
FUEL / AIR / EXHAUST
EXHAUST SYSTEM
Exhaust System
2 Muffler
3 Gasket - Plug
4 Gasket - Muffler
5 Head Pipe
6 Nut
7 Washer
8 Flange Gasket
9 Bolt
10 Nut
11 Springs
4.18
BODY / STEERING / SUSPENSION
CHAPTER 5
BODY / STEERING / SUSPENSION
PLASTIC RETAINER INSERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SEAT / SIDE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
FRONT CAB/FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
FRONT CAB/FENDER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
FRONT CAB/FENDER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
REAR CAB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
FOOTWELL REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
BODY RACK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
REAR RACK REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
POD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
POD/KEY SWITCH/CHOKE/SPEEDO CONNECTION REMOVAL/INSTALLATION. . . . 5.9
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
HANDLEBAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
HANDLEBAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5
STEERING POST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
STEERING POST BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
STEERING POST INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
A-ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
A-ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
FRONT STRUT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
FRONT STRUT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
FRONT STRUT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
BALL JOINT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
REAR CONTROL ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
UPPER AND LOWER REAR CONTROL ARM REMOVAL/INSTALLATION . . . . . . . . . 5.19
5.1
BODY / STEERING / SUSPENSION
PLASTIC RETAINER INSERTS 3. To install the inserts, press outside insert (B) into the hole.
Press inside insert (A) until it snaps into place.
Removal / Installation NOTE: The outside insert (B) should be flush
surface after installation.
Some Polaris ATVs use a two piece plastic insert in place of a
metal screw. The plastic inserts are simple to remove and install.
1. Use a a pair of diagonal side cutters to lift the plastic insert
(A) until you feel some slight pressure or lift the insert
approximately 1/4" (6.35 mm). Apply just enough pressure
on the side cutters to lift up on the insert. DO NOT apply
too much pressure on the side cutters, or damage to the
insert will occur.
A
The inside insert (A) should be flush with the top of the outside
insert (B).
A
B
2. Next, use the diagonal side cutters under outside insert (B)
to completely remove the assembly. NOTE: The inside
insert (A) will still be installed in the outside insert (B).
5.2
BODY / STEERING / SUSPENSION
SEAT / SIDE PANEL 3. Reinstall the side panel by reversing the removal procedure.
Step 3
Removal / Installation
Use the following instructions for removal and installation:
1. Remove seat by releasing the latch and lifting up on the
seat.
Step 1
5
2. Grasp the rear of the side panel near the rear cab. With a
firm motion, pull the panel outward to disengage the side
panel from the grommet. Pull the panel downward and
rearward to remove it from the ATV.
Step 2
5.3
BODY / STEERING / SUSPENSION
FRONT CAB/FENDER
5.4
BODY / STEERING / SUSPENSION
Front Cab/Fender Removal
For this procedure please refer to the diagram on 5.4.
1. Remove the seat.
2. Remove the fuel tank cover (4).
3. Remove the side panels (1,3).
4. Remove the plastic rivets on the mud guards (below) and remove them from the front cab assembly.
5
5. Remove the battery connections (negative first).
6. Remove the battery from the battery compartment.
7. Route the battery cables through the front compartment.
8. Remove the front cab fasteners (8).
9. Remove the plastic rivets from the footwells.
10. Carefully lift off the front cab.
5.5
BODY / STEERING / SUSPENSION
BODY ASSEMBLY
Exploded View
5.6
BODY / STEERING / SUSPENSION
Rear Cab Removal/Installation
1. Follow the procedure to remove the rear rack. See “Rear Rack Removal/installation” on page 5.8.
2. Remove the screws (1,19) that secure the rear cab to the frame.
3. Remove the plastic inserts (9) that secure the rear cab to the frame footwells (11,14).
4. Disconnect the rear lights.
5. Lift the rear cab (4) from the frame.
6. Reverse the removal steps for installation.
Footwell Removal/Installation
1. Remove the plastic inserts (A) that secure the wheel well to the front and rear cabs. See “PLASTIC RETAINER INSERTs”
on page 5.2.
2. Remove the screws (B) from the bottom of the foot well. Remove the footwell.
3. Reverse the removal procedures to install the foot well.
NOTE: Be sure to properly align the cab ends into the footwells upon reassembly.
B
5.7
BODY / STEERING / SUSPENSION
BODY RACK EXPLODED VIEW
5.8
BODY / STEERING / SUSPENSION
POD EXPLODED VIEW
1. The pin (A) on the bottom side of the top handlebar block faces down and to the front of the ATV.
2. The bottom handle bar block has a side with 3 holes, the side with 3 holes faces up and to the front of the ATV.
3. Align the pin (A) in the top block with the middle hole (B) in the bottom block for proper installation. The pin (A) and middle
hole (B) should face the front of the ATV.
4. Install the pin side bolts first and evenly tighten the bolts down. Torque the 2 front bolts to specification.
=T
Handle Bar Bolt Torque
11-13 ft.lbs.(15-18 Nm)
5. Install the rear bolts and tighten evenly. Evenly torque the 2 rear bolts to specification.
NOTE: Pod bracket installation required (Refer to page 5.9). There will also be a slight gap on the backside of
the blocks after the procedure is performed.
5.10
BODY / STEERING / SUSPENSION
Steering Post Removal 9. Remove the steering tie rod ends (D) from the steering
bracket (E). Note the orentation of the fasteners and bracket
1. Remove the front cab. See “FRONT CAB/FENDER” on on the steering assembly.
page 5.4.
2. Remove the handle bar pod. See “Pod/Key Switch/Choke/
Speedo Connection Removal/Installation” on page 5.9.
E
3. Remove the handle bar. See “POD EXPLODED VIEW” on
page 5.9. D
4. Remove the fuel tank bracket (A).
10. Remove the steering post bracket (F) at the front gear case
(4x4 shown)/plate (2x4).
F
5
5. Turn the fuel valve to the “OFF” position
6. Remove the fuel line (B) from the fuel pump (C).
C
11. Remove the top steering bracket (G).
B G
7. Remove the vent line from the frame that comes from the
top of the fuel tank. Note the vent line routing.
8. Remove the fuel tank from the frame.
5.11
BODY / STEERING / SUSPENSION
Steering Post Bearing Replacement Steering Post Installation
1. Remove the steering post. 1. Insert the steering post assembly into the chassis.
2. Press out the steering post cotter pin (A). 2. Place the lower bracket (F) into the front gear case on the
3. Remove the steering post nut (B), bushing (C). 4x4 units, and into the bracket on the 2x4 units.
4. Inspect the bushings 3. Apply blue Loctite to the threads of the bracket bolts.
5. Remove and replace the bearing (D). 4. Torque the bolts to specification.
6. Install the bearing as shown in the image.
7. Torque the steering post nut (B) to specification. F
8. Install a new cotter pin (A).
NOTE: Make sure that the cotter pin is not
obstructing steering movement.
B
=T
A
2x4 4x4 Steering Post Bearing Bracket
19-22 ft-lb (26-30Nm)
=T
Upper Steering Post Bracket
22 ft-lb (30Nm)
6. Place the tie rod retainer (H) on to a tie rod bolt (I).
7. Insert the tie rod bolts from the bottom of the tie rod, and
line up the retainer to the bottom of the tie rods.
5.12
BODY / STEERING / SUSPENSION
8. Torque the tie rod fasteners to specification. 13. Hook up the fuel line to the fuel pump and move the clamp
to the correct area.
I H
=T 5
Tie Rod Fasteners
40 ft-lb (54Nm)
11. Place the fuel tank bracket in place. Note to get the routing
of the throttle cable and carburetor venting correct.
12. Tighten the fuel tank bracket fasteners.
5.13
BODY / STEERING / SUSPENSION
FRONT SUSPENSION
Exploded View
NOTE: To avoid damage to tie rods and other steering 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. Be sure inner rod
ends are placed between the steering post arms. Replace all cotter pins if removed (4,11).
5.14
BODY / STEERING / SUSPENSION
A-arm Removal
Refer to drawing on page 5.14
1. Apply parking brake and loosen the lug nuts.
2. Elevate the front of the machine and secure it with jack stands.
3. Remove the rim from the hub and release the parking brake.
4. Remove the pinch bolt (10) and nut (9) that hold the A-Arm ball joint (13) to the carrier bearing assembly.
5. Remove the flange bolt (19) and flange nut (3) from the frame.
6. Remove A-Arm.
WARNING
A-Arm Assembly
Refer to drawing on page 5.14 5
1. Assemble A-Arm with all bushings (17), pivot tube (18), ball joint (12,13), and brush guard (15) (if applicable).
2. Place the A-Arm to the frame and insert the flange bolt (19) with the head toward the front of the machine and the flange nut
(3) toward the rear.
3. Torque the flange bolt (19) to specification.
=T
A-Arm Flange Bolt
40 ft-lb (54Nm)
4. Insert the ball joint (13) far enough into the carrier bearing assembly so that the pinch bolt (10) can be inserted.
5. Insert the pinch bolt (10) so that the flange head is at the front of the machine and the flange nut (9) is at the rear.
6. Torque the pinch bolt to specification.
=T
Pinch Bolts
20 ft-lb (27Nm)
WARNING
5.15
BODY / STEERING / SUSPENSION
FRONT STRUT SERVICE
5.16
BODY / STEERING / SUSPENSION
Front Strut Removal BALL JOINT
Refer to drawing on page 5.16
Replacement
1. Remove the wheel on the side of the strut that is to be
replaced.
2. Remove the front cab.
3. With an open end wrench hold the shock tower nut (16) and
with a socket turn the shock rod.
4. Remove the screw that holds on the brake line to the strut. 1
5. Remove the carrier bearing assembly fasteners (4,7).
6. Remove the strut from the vehicle.
=T
Carrier Bearing Fasteners
37 ft-lb (50Nm)
5. Replace the torx fastener that holds the brake line in place.
6. Replace front cab.
Bearing Replacement
Refer to drawing on page 5.16
1. Remove the front bearing carrier (1).
2. Remove the snap ring (3) from the bearing carrier.
3. Press out the bearing (2).
4. Press in new bearing.
5. Replace the snap ring
6. Install bearing carrier.
7. Torque the bearing carrier to strut mounting fasteners to
specification.
5.17
BODY / STEERING / SUSPENSION
REAR CONTROL ARMS
Exploded View
5.18
BODY / STEERING / SUSPENSION
Upper And Lower Rear Control Arm Removal/Installation
Described in this section is for one side of the machine. Duplicate this process for the other side.
1. Raise and secure the rear of the machine.
2. Remove the rear wheel.
3. Remove the rear shock.
4. Remove the Upper Control Arm (UCA) (15) fasteners (1,4,12) from the transmission and bearing carrier. Note the long (12,14)
and short (1,3) fasteners and pivot shaft locations.
5. Remove the x short grey bushings (2) and pivot shafts (3,14).
6. Remove the Lower Control Arm (LCA) (11) fasteners (4,5,12) from the frame and bearing carrier. Note the long (5,8) and
short (12,14) fasteners and pivot shaft locations.
7. Remove the long grey bushings (9) and pivot shaft (8) from the frame.
8. Remove the short bushings (13) and pivot shaft (14) from the bearing carrier.
9. Remove the LCA (11) from the unit.
10. Replace in reverse order with the following torque values.
=T
• LCA to Bearing Carrier 40 ft-lb (54Nm) 5
• LCA to Frame 40 ft-lb (54Nm)
• UCA to Bearing Carrier 40 ft-lb (54Nm)
• UCA to Transmission 40 ft-lb (54Nm)
• Shock Mounts (top and bottom) 40 ft-lb (54Nm)
• Wheel Lug Nuts 27 ft-lb (37Nm)
5.19
BODY / STEERING / SUSPENSION
NOTES
5.20
BRAKES
CHAPTER 6
BRAKES
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
BRAKES / TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
BRAKE NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
BRAKE SYSTEM MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
REAR MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
HAND BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
FRONT CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
THICKNESS / RUNOUT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
WEAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
FOOT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
FOOT PEDAL REMOVAL / INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
FOOT BRAKE MASTER CYLINDER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . 6.18
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
BRAKE SQUEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
6.1
BRAKES
SPECIFICATIONS
Brakes / Torque
NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures
are used when torquing certain bolts and fasteners. Do not re-use fasteners that have pre-applied locking
agents.
6.2
BRAKES
TROUBLESHOOTING
Brake Noise
Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning
does not reduce the occurrence of brake noise, a product such as Permatex™ Disc Brake Quiet or an equivalent can be applied to
the back of the pads. Follow directions on the package. This will keep pads in contact with caliper piston(s) to reduce the chance
of squeaks caused by dirt or dust.
6.3
BRAKES
Apply a Light
Amount of Pipe
Sealant to Threads
6.4
BRAKES
BRAKE CALIPER
Exploded View
A.Bleeder Screw C A
B. Caliper Body
C. Internal Caliper Slide Pin O-rings (small) B
D. Square Seals
E. Piston
F. Caliper Mount
G. Brake Pads D
H. Internal Caliper Slide Pin O-rings (large)
I. Caliper mount O-ring
E
H
6
F
6.5
BRAKES
HYDRAULIC BRAKE SYSTEM master cylinder piston is outward. As the temperature within the
hydraulic system changes, this port compensates for fluid
Operation Overview expansion (heated fluid) or contraction (cooled fluid). During
system service, be sure this port is open. Due to the high
Must be clear to Compensating port temperatures created within the system during heavy braking, it
allow proper E compensates for is very important that the master cylinder reservoir have
diaphragm temperature changes adequate space to allow for fluid expansion. Never overfill the
by allowing fluid back reservoir! Fill to 1/4, - 5/16, (.64 - .80 cm) from top of the
to master cylinder cylinder.
WARNING
The Polaris disc brake system consists of the following Once a bottle is opened, use what is necessary and
components or assemblies: hand brake lever; foot brake lever, discard the rest in accordance with local laws. Do
hand and foot brake master cylinders; hydraulic hoses; brake not store or use a partial bottle of brake fluid. Brake
calipers (slave cylinders); brake pads; and brake discs, which fluid is hygroscopic, meaning it rapidly absorbs
are secured to the drivetrain. moisture. This causes the boiling temperature of
the brake fluid to drop, which can lead to brake fade
When the hand activated brake lever (A) is applied it contacts
and the possible loss of control.
piston (B) within the master cylinder. As the master cylinder
piston moves inward it closes a small opening (compensating
port C) within the cylinder and starts to build pressure within the
brake system. As the pressure within the system is increased,
the piston (D) located in the brake caliper moves outward and
applies pressure to the brake pad. This pad contacts the brake
disc and moves the caliper in its floating bracket, pulling the
stationary side pad into the brake disc. The resulting friction
reduces brake disc and vehicle speed. As the lever pressure is
increased, the braking affect is also increased.
The friction applied to the brake pads will cause the pads to
wear. As these pads wear, the piston within the caliper moves
further outward and becomes self adjusting. Fluid from the
reservoir fills the additional area created when the caliper piston
moves outward.
6.6
BRAKES
REAR MASTER CYLINDER • Make sure the brake lever and pedal returns freely and
completely.
Operation Overview • Adjust stop pin on front caliper after pad service.
Brake Fluid Reservoir • Check and adjust master cylinder reservoir fluid level
after pad service.
• Make sure atmospheric vent on reservoir is
unobstructed.
• Test for brake drag after any brake system service and
investigate cause if brake drag is evident.
• Make sure caliper moves freely on guide pins (where
Rear Brake MC applicable).
Frame • Inspect caliper piston seals for foreign material that
could prevent caliper pistons from returning freely.
Rear Brake Line
CAUTION
Spring
Use only DOT 3 or 4 brake fluid as an assembly aid
for all procedures described in this chapter to
Brake Mount prevent brake system contamination. DO NOT USE
LUBRICANTS OF ANY KIND FOR ASSEMBLY, AS
THEIR USE CAN CAUSE RUBBER
Brake Lever COMPONENTS TO SWELL.
6
When the foot activated brake lever is applied it contacts piston
of the master cylinder. As the pressure within the system is
increased, the piston located in the brake calipers move outward
and apply equal pressure to the brake pads.
6.7
BRAKES
BRAKE BLEEDING bleeder until the fluid runs clear.
Sight Glass
Fluid Change C
CAUTION
6.8
BRAKES
Bleeding Procedure 9. Install diaphragm, cover and screws. Align any marks (if
present) into the proper holes in the master cylinder.
1. Begin bleeding procedure with the caliper that is farthest Wiggle and press down on the cap to be sure it fits evenly
from the master cylinder. Install a box end wrench on and snug. Torque the screw to 7 in.lbs. (0.79 Nm).
caliper bleeder screw. Attach a clean, clear hose to fitting
and place the other end in a container. Be sure the hose fits
tightly on fitting.
NOTE: Fluid may be forced from supply port (B) if
brake lever is pumped. Place diaphragm (C) in
reservoir to prevent spills. Do not install cover tight.
See Illustration above.
Maintain at least 1/2, (1.27 cm) of brake fluid 7 in.lbs. (0.79 Nm)
in the reservoir to prevent air from
entering the master cylinder.
10. Field test machine at low speed before putting into service.
Check for proper braking action and lever reserve. With
lever firmly applied, lever reserve should be no less than 1/
2”, (1.3 cm) from handlebar.
11. Check brake system for fluid leaks and inspect all hoses and
lines for wear or abrasion. Replace hose if wear or abrasion
is found.
6.9
BRAKES
HAND BRAKE MASTER CYLINDER Installation
NOTE: When replacing the brake master cylinder
Removal
assembly or master cylinder parts, use the correct
1. Clean master cylinder and reservoir assembly. Make sure parts. There are different brake master cylinders for
you have a clean work area to disassemble brake the different Polaris ATV models. Refer to your parts
components. manual or guide for the correct parts. Some master
cylinders are not serviceable and are replaced as an
assembly.
2. Remove the banjo bolt that connects the brake line to the
master cylinder. Discard the copper washers.
6.10
BRAKES
2. Place NEW sealing washers on each side of banjo line and BRAKE PADS
torque banjo bolt to specification.
Torque to specification (15 ft.lbs.) Removal
Sealing Washer 1. Loosen the wheel nuts. Elevate and support front of
machine and remove the tire(s).
CAUTION
Banjo Bolt
Use care when supporting vehicle so that it does not
tip or fall. Severe injury may occur if machine tips
or falls.
6.11
BRAKES
4. Push mounting bracket inward and slip outer brake pad past Installation
edge. Remove inner pad.
1. Lubricate mounting bracket pins and external slide pin O-
ring with a light film of Polaris Premium All Season
Grease (PN 2871423).
WARNING
Measure Pad
6.12
BRAKES
3. Install caliper on hub strut, and torque mounting bolts. FRONT CALIPER
Removal
CAUTION
4. Slowly pump the brake lever until pressure has been built
up. Maintain at least 1/2, (12.7 mm) of brake fluid in the
reservoir to prevent air from entering the brake system.
5. Verify fluid level in reservoir is up to MAX line inside
reservoir and install reservoir cap.
6. Install wheels and torque wheel nuts to specification.
NOTE: Front Wheel Nut Torque: Refer to Torque
Table at beginning of chapter. 6
2. Push pad retainer pin inward and slip brake pads past the
pin edges. A pliers may be used to compress the pad retainer
for removal if the pads are too thick. Use caution not to bend
or damage the retainer or the brake pad ears.
6.13
BRAKES
3. Remove mounting bracket pin assembly . 5. Remove the four (4) O-rings from the caliper body. Note
the orientation of the O-rings for reassembly. Clean the
caliper body, piston, and retaining bracket with brake
cleaner or alcohol.
NOTE: Be sure to clean grooves in caliper body. Do
not use a petroleum based spray to clean the caliper.
4. Remove piston using a twisting, pulling motion. Remove NOTE: O-ring grooves are size-specific
the piston square seals using a wooden or plastic pick. Use
caution not to scratch or damage the piston or the bore of
the caliper.
NOTE: Do not use a metal pick or awl to remove the
Clean Components
square seals.
CAUTION
6.14
BRAKES
Inspection Reassembly
1. Inspect caliper body for nicks, scratches or wear. Measure 1. Install new piston square seals (A) in the caliper body (B).
bore size and check for out of round. Replace if damage is Be sure groove is clean and free of residue or brakes may
evident or if worn. drag upon assembly.
C
B
2. Inspect piston for nicks, scratches, wear or damage. 2. Coat piston with clean Polaris DOT 3 or DOT 4 Brake Fluid
Measure diameter and replace if damaged or worn beyond (C). Install piston (D) with a twisting motion while pushing
service limit. inward. Piston should slide in and out of bore smoothly,
with light resistance.
3. Install new slide pin O-rings in the caliper body for the 6
Lubricate the mounting bracket pins with Polaris Premium
All Season Grease (PN 2871423), and install..
NOTE: Do not use grease on the square seals.
Petroleum based lubricants will cause the square
seals to swell. Lubricate with brake fluid only.
3. Inspect the brake disc and pads as outlined for brake pad
replacement this section. See “BRAKE PAD
INSPECTION” in this chapter.
6.15
BRAKES
4. Compress the mounting bracket into the caliper and make BRAKE BURNISHING PROCEDURE
sure the O-rings are fully seated. Install the brake pads.
Clean the disc and pads with brake parts cleaner or Overview
denatured alcohol to remove any dirt, oil or grease.
It is required that a burnishing procedure be performed after
installation of new brake pads to extend service life and reduce
noise.
Installation
1. Install caliper on hub strut, and torque mounting bolts.
22 ft.lbs.
(30 Nm)
6.16
BRAKES
BRAKE DISC Wear Inspection
1. visually inspect disc for scoring, scratches, or gouges.
Thickness / Runout Inspection
replace the disc if any deep scratches are evident.
1. Visually inspect the brake disc for nicks, scratches, or 2. use a 0-1” micrometer and measure disc thickness at 8
damage. different points around perimeter of disc. replace disc if
2. Measure the disc thickness at eight different points around worn beyond service limit.
the pad contact surface using a 0-1, micrometer. Replace
disc if worn beyond service limit.
BRAKE DISC
Disc Thickness
6
= In. / mm.
6.17
BRAKES
Removal / Replacement FOOT BRAKE
NOTE: To reduce the possibility of warping, try
Foot Pedal Removal / Install
removing the brake disc mounting bolts before
applying heat to the bolts. 1. Remove the cotter key (A).
2. Remove the washers, bushings, and tension spring and
1. Apply heat to the hub in the area of the brake disc remove the brake lever (F).
mounting bolts to soften the bolt locking agent.
3. Reverse the steps for installation, using a new cotter key
during installation.
=T
2. Remove bolts and disc. Master Cylinder Fasteners: 8 ft.lbs. (11 Nm)
3. Clean mating surface of disc and hub.
4. Reinstall the brake line and torque the banjo bolt (with new
4. Install new disc on hub. copper washers installed) to specification. Torque the
5. Install NEW bolts and tighten to specification. flared fitting (if removed) to specification.
=T
Banjo Bolts: 22 ft.lbs. (30 Nm)
=T
Flare Fittings: 12-15 ft.lbs. (16-21Nm)
=T
C
Brake Rotor Fasteners: 18 ft.lbs. (24 Nm)
D
CAUTION
6.18
BRAKES
TROUBLESHOOTING
Brake Squeal
• Dirty/contaminated friction pads
• Improper alignment
• Worn disc
• Worn caliper
Brakes Lock
• Alignment of caliper to disc
• Compensating port plugged
• Parking brake left on
6.19
BRAKES
NOTES
6.20
FINAL DRIVE
CHAPTER 7
FINAL DRIVE
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
FRONT BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
BEARING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
PROPSHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
FRONT GEARCASE / CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
ALL WHEEL DRIVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
CENTRALIZED HILLIARD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
AWD DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
GEARCASE REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
REAR BEARING CARRIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
BEARING CARRIER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
BEARING CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
BEARING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
BEARING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
7
DRIVE SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
FRONT DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
REAR DRIVE SHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
OUTER CV JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
INNER PLUNGING JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
FRONT DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
REAR DRIVE SHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
7.1
FINAL DRIVE
GENERAL SPECIFICATIONS FRONT BEARING CARRIER
Torque Specifications Bearing Carrier Removal
1. Elevate front end and safely support machine under
Item Specification footrest / frame area.
Item Nut Type Specification 4. Remove the A-arm pinch bolt and remove the ball joint
from the bearing carrier (see Chapter 5 “A-arm Removal”).
Lug Nut
Aluminum Wheels 90 ft. lbs. (122 Nm) 5. Remove the steering tie rod from the front bearing carrier.
#1
Bolt
Steel Wheels Flange Nut
27 ft. lbs. (37 Nm)
(Black / Camo) #2 Tie Rod
Washer
#1 #2
Nut
Aluminum Wheel Steel Wheel Cotter Pin
90 ft. lbs. (122 Nm) 27 ft. lbs. (37 Nm)
Special Tools
Part Number Tool Description
7.2
FINAL DRIVE
7. Remove the cotter pin, wheel hub castle nut and washer. Bearing Removal
Then remove the front wheel hub assembly from the ATV.
1. Remove the inner snap ring retaining the bearing.
Wheel Hub
2. From the front side of the housing, tap on the outer bearing
race with a drift punch in the reliefs as shown.
Bearing
Washer
Snap Ring
Cotter Castle
Pin Nut
Bolts
4. Inspect the bearing housing for scratches, wear or damage.
Replace front bearing carrier if damaged.
7
Bearing Installation
1. Thoroughly clean the bearing housing and the outer race
on the new bearing. Be sure that all oil residue has been
9. Remove the front bearing carrier and rotate the bearing to removed from each surface.
check for smooth rotation. Visually inspect bearing for 2. Apply Loctite® RC™ 680 to the outer circumference of the
moisture, dirt, or corrosion. Replace bearing if any of these
new bearing race.
conditions exist.
NOTE: Use care to not allow any of the Loctite®
Bearing Carrier
compound to get in the bearing.
3. Support the bearing carrier in a press or suitable device.
CAUTION
Rotate
Bearing When using an arbor press be sure to press only
on the outer race, as bearing damage may occur.
7.3
FINAL DRIVE
Bearing Carrier Installation 6. Install a new cotter pin. Tighten nut slightly if necessary
to align cotter pin holes.
1. Install the front bearing carrier over the drive shaft and
reinstall the bearing carrier onto the strut. Torque strut 7. Install the front brake caliper and torque mounting bolts to
fasteners to specification. specification.
22 ft. lbs.
(30 Nm)
37 ft. lbs.
(50 Nm)
=T
Brake Caliper Mounting Bolts:
=T 22 ft. lbs. (30 Nm)
Front Strut to Bearing Carrier Bolts: 8. Attach the steering tie rod to the front bearing carrier and
37 ft. lbs. (50 Nm) torque the fastener to specification.
40 ft. lbs.
2. Place the A-arm ball joint into the lower portion of the (54 Nm)
bearing carrier and install the pinch bolt (see Chapter 5
“A-arm Installation”).
3. Apply grease to the drive shaft splines.
4. Install the front wheel hub onto the drive shaft and into the
front bearing carrier. Apply grease to the washer and install
the washer with the domed side facing out.
5. Install the castle nut and torque to specification.
NEW
Cotter Pin
NEW 80 ft. lbs.
Cotter Pin (108 Nm)
=T
Tie Rod Fasteners:
40 ft. lbs. (54 Nm)
7.4
FINAL DRIVE
PROPSHAFT SERVICE PROPSHAFT U-JOINT SERVICE
Removal Disassembly
1. Remove right-hand mud guard to allow access to the 1. Remove internal or external snap ring from bearing caps.
propshaft roll pin (see Chapter 5 “Front Cab Removal”).
2. Using Roll Pin Removal Tool (PN 2872608), remove the CAUTION
roll pin from the propshaft at the rear of the front gearcase.
Always wear eye protection.
Installation 2. Support inner yoke as shown and drive outer yoke down
(bearing cap out) with a soft face hammer. 7
1. Apply anti-seize compound to all splines. Slide propshaft
back onto the transmission output shaft, then slide it up
onto the front gearcase input shaft, verify pin holes are
aligned.
2. Using Roll Pin Tool (PN 2872608), install a NEW roll pin
(spring pin) into the prop shaft.
3. Reinstall the right-hand mud guard (see Chapter 5 “Front
Cab Installation”).
7.5
FINAL DRIVE
3. Support U-joint in vise as shown and drive inner yoke down 3. Using a suitable arbor, fully seat the bearing cap in one side.
to remove remaining bearing caps. Continually check for free movement of bearing cross as
bearing caps are assembled.
4. Force U-joint cross to one side and lift out of inner yoke.
4. Install snap ring to contain bearing cap just installed.
Repeat procedure for other side.
5. Install outer yoke, aligning marks made at disassembly and
repeat Steps 1-3 to install bearing caps on outer yoke.
6. Seat all bearing caps against snap rings by supporting cross
shaft and tapping on each corner as shown.
Assembly
1. Install new bearing caps in yoke by hand. Carefully install
U-joint cross with grease fitting properly positioned
inward toward center of shaft. Take care not to dislodge
needle bearings upon installation of cross joint.
7. When installation is complete, yokes must pivot freely in
2. Tighten vise to force bearing caps in.
all directions without binding. If the joint is stiff or binding,
tap the yoke lightly to center the joint until it pivots freely.
7.6
FINAL DRIVE
FRONT GEARCASE AWD Engagement: When the AWD switch is activated, the
AWD coil is powered by a 12 Vdc input which creates a
CENTRALIZED HILLIARD magnetic field. This magnetic field attracts an armature plate
that is keyed to the roll cage. When the ring gear and roll cage
All Wheel Drive Operation are spinning (vehicle is moving), the energized coil and
armature plate will apply drag to the roll cage that indexes the
The AWD switch may be turned on or off while the vehicle is rollers inside the ring gear to an engagement position. While in
moving, however, AWD will not enable until the engine RPM
drops below 3100. Once the AWD is enabled, it remains the engagement position, the front drive will be in an “over-
enabled until the switch is turned off. running” condition (not engaged), until the rear wheels lose
traction. Once the rear wheels begin to lose traction, the front
Engage the AWD switch before getting into conditions where
the front wheel drive may be needed. If the rear wheels are drive will engage by coupling the output hubs to the ring gear via
spinning, release the throttle before switching to AWD. the rollers. The front drive will remain engaged until the torque
requirement goes away (i.e. rear wheels regain traction).
With the AWD switch off, the vehicle drives through the
rearwheels only (2 wheel drive). When the AWD is enabled, the
front drive acts as an on-demand AWD system. This means, the
front drive will engage once the rear wheels have lost traction,
and will remain engaged until the torque requirement goes away Armature External Cam /
(i.e. rear wheels regain traction). Plate Ring Gear
7.7
FINAL DRIVE
Centralized Hilliard Exploded View
7.8
FINAL DRIVE
AWD Diagnosis 4. Check to make sure the coil is seated in the U-shaped insert
that is pressed into the gearcase housing. The top of the coil
Symptom: AWD Will Not Engage should be seated below the U-shaped insert. The U-shaped
1. Check the gearcase coil resistance. To test the gearcase insert controls the pole gap. If the top of the coil is above
coil resistance, use the coil harness. The gearcase coil the surface of the U-shaped insert it raises the armature
should measure between 21-24 Ohms and at 68 F (20 C). plate, thereby increasing pole gap. If the pole gap increases
the coil will not be strong enough to engage the AWD
system.
BN/WH to GY
Side Cutaway View of Gearcase Cover
Coil
U-Shaped Insert
5. Inspect the rollers for nicks and scratches. The rollers must
slide up and down, and in and out freely within the roll cage
2. Check the minimum battery voltage at the wire harness sliding surfaces.
connection that supplies voltage to the hub coil. There
should be a minimum of 11.80-12.0 Volts present for Rollers
proper operation.
Poor Condition:
(Wear from Coil on
Armature Plate)
7.9
FINAL DRIVE
Gearcase Removal 12. Remove the upper steering post bracket from the frame
bulkhead.
1. Stop engine, place machine in gear and set parking brake.
4. Elevate machine until the front wheels are off the ground
and support machine under footrest/frame area.
CAUTION
5. Remove hub retaining nuts, wheel nuts and wheels. 13. Remove the lower steering post bracket fasteners.
6. To remove the gearcase, the following items must be 14. Lift the steering post assembly from the front gearcase and
removed or disconnected so that the steering post brackets move it toward the center of the vehicle to allow enough
can be accessed and the post raised up: room for gearcase removal.
9. Remove the fuel tank cover (see Chapter 5). Place gas cap
back on tank to avoid spills.
10. Remove the front cab (see Chapter 5). 15. Remove cotter pin, ball joint pinch bolt, and remove the
A-arm from the front bearing carrier.
11. Remove the fuel tank (see Chapter 4).
7.10
FINAL DRIVE
16. Pull the strut assembly out and pull the drive-shaft out of Disassembly
the front bearing carrier.
1. Drain and properly dispose of used fluid. Remove any
17. Remove both front drive shafts from the front gearcase. metal particles from the drain plug magnet.
18. Remove the roll pin (spring pin) from the prop shaft. Use 2. Remove the T30 Torx screws and output cover.
the Roller Pin Removal Tool (PN 2872608).
21. Remove the front gearcase from either side of the frame.
4. Clean all parts and inspect for wear. Inspect ring gear
backlash pad (arrow) for wear or damage.
Vent Line
Route inside
steering column
Remove Bolts
NOTE: Backlash for the front gearcase is set at the
factory. No adjustment can be made.
7.11
FINAL DRIVE
5. Remove the output hub assembly from the left-hand 9. Inspect roll cage (B) sliding surface. This surface must be
gearcase half. Inspect surfaces for wear or signs of damage. clean and free of nicks, burrs or scratches. Inspect the H-
Replace component if found to worn or damaged. springs, but do not remove them. Replace any H-springs
that appear damaged or have lost radial tension.
B H-Spring
7. Thoroughly clean all parts. Inspect the rollers (A) for nicks
and scratches. The rollers must slide up and down freely
within the roller cage surfaces (B). 11. Inspect the output hub thrust bearing. Replace if wear or
damage is found.
B A
C E
8. Inspect the ring gear (C) for consistent wear patterns. The
surfaces should be free of nicks and scratches.
7.12
FINAL DRIVE
12. Inspect the output hub bearings (arrows). Replace bearings 14. Inspect the magnetic coil (I) in the output housing. Test the
if wear or damage is found. resistance of the coil using an ohmmeter. Replace case half
if coil is found to be non-functional or if the coil surface is
damaged.
E 15. Remove and inspect the input cover (M), bearing (N), and
the pinion gear (O). Inspect the pinion gear (O) for chipped,
7
broken, or missing teeth. Replace the input cover O-ring
and seal.
M
N
7.13
FINAL DRIVE
16. Inspect the output shaft bushing (arrow). Replace as Gearcase Reassembly
needed. Clean the inside surfaces of both gearcase halves.
1. Replace all O-rings, seals, and worn components as
previously mentioned.
2. Press the pinion shaft seal into the pinion cover, until the
seal is flush with the sealing surface.
17. Remove and replace the O-rings and seals (arrows) from
the gearcase halve assemblies.
=T
Gearcase T30 Torx Screws:
7-11 ft. lbs. (10-15 Nm)
4. Install the output hub (A) into the gearcase housing. Apply
a small amount of grease to the seal and seal surface as this
will aid assembly. The output hub should spin freely.
7.14
FINAL DRIVE
5. Install the rollers and roll cage into the ring gear. Insert the 8. Install the other output hub (B) and thrust bearing (C) into
rollers as the roll cage is installed, installing the lower row the output case half. Apply a small amount of grease onto
first and then the upper row. the seal surfaces to aid installation.
C B
6. Install the ring gear over the output hub and into the output 9. Install the left output case half onto the right-hand assembly
cover. Insert the backlash pad (G) and set assembly upright. by holding it as shown. Verify the backlash plate thrust
bearing and armature plate stay in place during assembly.
7. Install the armature plate (D) onto the ring gear. Verify the
plate tabs are places into the slots on the roller cage.
NOTE: Verify backlash plate stays in place.
7.15
FINAL DRIVE
10. Torque screws to specification. 2. Coat drive shaft splines with anti-seize compound. Install
both drive shafts into the gearcase. Light tapping may be
required to properly seat the splines into the gearcase.
3. Pull strut assembly out while pivoting the front drive shaft
upward until it enters the front bearing carrier assembly.
4. Install the lower A-arm ball joints into the front bearing
carriers.
=T
Lower A-arm Pinch Bolt:
20 ft. lbs. (27 Nm)
=T
6. Install the wheel hubs, washers and hub retaining nuts.
Torque the wheel hub nuts to specification.
Gearcase T30 Torx Screws:
7-11 ft. lbs. (10-15 Nm)
=T
Installation
Wheel Hub Retaining Nut:
1. Install gearcase into the frame. Torque mounting bolts to 80 ft. lbs. (109 Nm)
specification and reinstall the vent line.
7. Install new cotter pins into the wheel hub castle nuts.
11. Add the proper lubricant to the front gearcase. Check drain
plug for proper torque (see Chapter 2 “Maintenance” for
fluid fill and change information).
Vent Line
Route inside
steering column
=T
Front Gearcase Mounting Bolt:
30 ft. lbs. (41 Nm)
7.16
FINAL DRIVE
REAR BEARING CARRIER 8. Remove the wheel hub castle nut, washer, and remove the
wheel hub from the rear drive shaft and rear bearing carrier.
Bearing Carrier Inspection Wheel Hub
CAUTION
4. Elevate rear end and safely support machine under main Nut
frame area.
Bolt
Lower
Control Arm
Nut
LH Side Only
10. Remove the rear bearing carrier. Inspect the bearing for
smoothness and side to side movement, replace as needed.
7. Safely suspend the caliper from the frame with a piece of
wire. CAUTION: Do not hang the caliper by the brake
line. Use wire to hang the caliper to prevent possible
damage to the brake line.
7.17
FINAL DRIVE
Bearing Removal Bearing Carrier Installation
1. Remove the inner snap ring retaining the bearing. 1. Grease the bushings and pivot tubes and slide them into
place in the rear bearing carrier.
2. From the front side of the housing, tap on the outer bearing
race with a drift punch in the reliefs as shown. 2. Insert drive shaft into the back side of the rear bearing
carrier.
Snap Ring
3. Align bottom of rear bearing carrier and lower control arm.
Bearing
Bearing Carrier 4. Install and torque lower control arm bolt to specification.
Upper
Control Arm
Casting 40 ft. lbs.
Reliefs (54 Nm)
Bearing Installation
1. Thoroughly clean the bearing housing and the outer race
on the new bearing. Be sure that all oil residue has been
Lower
removed from each surface. Control Arm
When using an arbor press be sure to press only 6. Pull drive shaft outward and apply grease to the drive shaft
on the outer race, as bearing damage may occur. splines.
4. Carefully press the new bearing into the rear bearing carrier 7. Install the wheel hub onto the drive shaft splines.
until the outer race bottoms in the housing. 8. Install the washer with domed side facing outward.
5. Wipe the housing clean of any excess compound and install
the snap ring into the groove.
7.18
FINAL DRIVE
9. Install the wheel hub castle nut and torque to specification. DRIVE SHAFT SERVICE
Wheel Hub
Front Drive Shaft Removal
1. Remove the cotter pin from the wheel hub castle nut and
NEW Washer slightly loosen the nut.
Cotter Pin
2. Elevate front of vehicle and safely support machine under
80 ft. lbs. the frame area.
(108 Nm)
CAUTION
11. Install the rear brake caliper and torque mounting bolts to
specification (only if servicing the left-hand side).
LH Side Only
22 ft. lbs. 5. Remove the wheel hub castle nut and washer.
(30 Nm)
6. Pull front bearing carrier assembly out while pivoting front
drive shaft downward until it clears the bearing carrier.
=T 7. With short sharp jerks, remove drive shaft from front
gearcase.
Brake Caliper Mounting Bolts:
22 ft. lbs. (30 Nm)
7.19
FINAL DRIVE
Rear Drive Shaft Removal • Over-angling of joints beyond their capacity can result
in boot or joint damage.
1. Remove the rear bearing carrier (see “REAR BEARING
CARRIER - Bearing Carrier Removal”). • Make sure surface-ground areas and splines of shaft are
protected during handling to avoid damage.
NOTE: The rear bearing carrier does not need to be
completely removed. The lower control can remain • Do not allow boots to come into contact with sharp
attached to the rear bearing carrier during this edges or hot engine and exhaust components.
procedure. • Shafts should never be used as a lever arm to position
2. Tip the rear bearing carrier down and remove the drive shaft other suspension components.
from the bearing carrier. • Never use a hammer or sharp tools to remove or to
install boot clamps.
• Be sure joints are thoroughly clean and that the proper
amount and type of grease is used to refill when joint
boots are replaced and when joints are cleaned.
Circlip
Cleanliness and following these instructions is very important to 5. Make sure the circlip remains on the shaft and not left in
ensure proper shaft function and a normal service life. the joint.
• The complete drive shaft / joint should be handled by
the interconnecting shaft to avoid disassembly or
potential damage to the drive shaft joints.
7.20
FINAL DRIVE
6. Remove the boot from the drive shaft.
BOOT KIT PN: 2203170 Large
Clamp
CAUTION Small
Clamp Boot
Complete disassembly of the CV joint is NOT
recommended. The internal components are a
precision fit and develop their own characteristic
wear patterns. Intermixing the internal
components could result in looseness, binding,
and/or premature failure of the joint.
IMPORTANT: If the grease in the joint is obviously NOTE: The amount of grease that’s provided is pre-
contaminated with water and/or dirt, the joint should measured, so use all the grease.
be replaced.
13. Slide the joint onto the drive shaft splines and align the
7. Thoroughly clean the joint with an appropriate solvent and circlip with the lead-in chamfer on the inner race of the
dry the joint to prevent any residual solvent from being left joint.
in the joint upon reassembly.
14. Use a soft-faced hammer to tap the joint onto the drive shaft
8. Visually inspect the joint by tilting the inner race to one side until it locks into place.
to expose each ball. Severe pitting, galling, play between
the ball and its cage window, any cracking or damage to the 15. Pull on the joint to make sure it is securely locked into place.
cage, pitting or galling or chips in raceways call for joint 16. Remove excess grease from the CV joint’s external
replacement. surfaces and place the excess grease in the boot.
NOTE: Shiny areas in ball tracks and on the cage 17. Pull the boot over the joint and position the boot lips into
spheres are normal. Do not replace CV joints the grooves on the joint housing and shaft. Make sure the
because parts have polished surfaces. Replace CV boot is not dimpled or collapsed.
joint only if components are cracked, broken, worn
or otherwise unserviceable. 18. Install and secure the CV boot with the large clamp using
9. Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.
the “earless” clamp pliers.
7
CV Boot Clamp Pliers
10. Slide the small boot clamp and boot (small end first) onto Earless Type: 8700226
the drive shaft and position the boot in it’s groove machined
in the shaft.
19. While pulling out on the CV shaft, fully extend the CV joint
11. Install a NEW circlip on the end of the shaft. and slide a straight O-ring pick or a small slotted screw
12. Grease the joint with the special CV joint grease provided driver between the small end of the boot and the shaft. This
in the boot replacement kit. Fill the cavity behind the balls will allow the air pressure to equalize in the CV boot in the
and the splined hole in the joint’s inner race. Pack the ball position that the joint will spend most of its life. Before you
tracks and outer face flush with grease. Place any remove your instrument, be sure the small end of the boot
remaining grease into the boot. is in its correct location on the shaft.
CAUTION
7.21
FINAL DRIVE
20. Install and secure the small clamp on the boot using the 10. Slide the small boot clamp and boot (small end first) onto
“earless” clamp pliers. the drive shaft and position the boot in it’s groove machined
in the shaft.
CV Boot Clamp Pliers 11. Install a NEW circlip on the end of the shaft.
Earless Type: 8700226 12. Grease the joint with the special CV joint grease provided
in the boot replacement kit. Fill the cavity behind the balls
and the splined hole in the joint’s inner race. Pack the ball
tracks and outer face flush with grease. Place any
Inner Plunging Joint / Boot Replacement
remaining grease into the boot.
1. Remove the drive shaft from the vehicle (see “Front Drive
Shaft Removal” or “Rear Drive Shaft Removal”).
CAUTION
2. Remove and discard the boot clamps.
The grease provided in the replacement kit is
CV Boot Clamp Pliers specially formulated for wear resistance and
Earless Type: 8700226 durability. DO NOT use substitutes
or mix with other lubricants.
3. Remove the large end of the boot from the plunging joint
and slide the boot back. BOOT KIT PN: 2203170 Large
Clamp
4. Use a soft-faced hammer or brass drift to separate the Small
plunging joint from the drive shaft. Clamp Boot
13. Fully compress the joint and push the drive shaft firmly into
Complete disassembly of the plunging joint is
the inner race.
NOT recommended. The internal components
are a precision fit and develop their own 14. Align the circlip with the lead-in chamfer.
characteristic wear patterns. Intermixing the
internal components could result in looseness, 15. Use a soft-faced hammer to tap the joint onto the drive shaft
binding, and/or premature failure of the joint. until it locks into place.
16. Pull on the joint to make sure it is securely locked into place.
IMPORTANT: If the grease in the joint is obviously
contaminated with water and/or dirt, the joint should 17. Remove excess grease from the plunging joint’s external
be replaced. surfaces and place the excess grease in the boot.
7. Thoroughly clean the joint with an appropriate solvent and 18. Pull the boot over the joint and position the boot lips into
dry the joint to prevent any residual solvent from being left the grooves on the joint housing and shaft. Make sure the
in the joint upon reassembly. boot is not dimpled or collapsed.
8. Visually inspect the joint by tilting the inner race to one side 19. Install and secure the small clamp on the boot using the
to expose each ball. Severe pitting, galling, play between “earless” clamp pliers.
the ball and its cage window, any cracking or damage to the
cage, pitting or galling or chips in raceways call for joint
CV Boot Clamp Pliers
replacement.
Earless Type: 8700226
9. Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.
7.22
FINAL DRIVE
20. Pull out on the drive shaft to center the joint in the housing. Front Drive Shaft Installation
Slide a straight O-ring pick or a small slotted screw driver
between the large end of the boot and the joint housing and 1. Install a new circlip on the end of the plunging joint and
lift up to equalize the air pressure in the boot. apply an anti-seize compound to the drive shaft splines.
21. Position the boot lip in its groove. Install and secure the 2. Align drive shaft splines with front gearcase and install by
boot with the large clamp using the “earless” clamp pliers. lightly tapping on drive shaft with a rubber faced hammer.
3. Install drive shaft into the front bearing carrier.
CV Boot Clamp Pliers
4. Install lower A-arm ball joint into the front bearing carrier.
Earless Type: 8700226
5. Install the ball joint pinch bolt into the bearing carrier.
Torque to 20 ft. lbs. (27 Nm) and install a new cotter pin.
Exploded View
NOTE: Refer the “Electronic Parts Catalog” to
obtain the required parts to service the drive shaft.
20 ft. lbs.
(27 Nm)
CV Joint
NEW
Cotter Pin
Large Circlip
Clamp =T
Boot Lower A-arm Pinch Bolt:
20 ft. lbs. (27 Nm) 7
6. Install the washer and castle nut onto the wheel hub.
Tighten hub nut to specification and install new cotter pin.
Small
Clamps
Boot
Large
Clamp
Circlip
=T
Plunging Wheel Hub Retaining Nut:
Joint Circlip 80 ft. lbs. (109 Nm)
=T
Control Arm to Bearing Carrier Bolt:
40 ft. lbs. (54 Nm)
NEW Washer
Cotter Pin
80 ft. lbs.
(108 Nm)
RH Hub Shown
=T
Wheel Hub Retaining Nut:
80 ft. lbs. (109 Nm)
7.24
CVT / TRANSMISSION
CHAPTER 8
CVT / TRANSMISSION
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
CVT TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
GEAR SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SHIFT LINKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
GEAR SELECTOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
CLUTCH ROLLER WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
CVT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
CVT OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
STARTING CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
DRIVEN CLUTCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
ENGINE BRAKING CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
CVT MAINTENANCE/INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
CVT DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
CVT OVERHEATING/DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
CVT SYSTEM DISASSEMBLY / DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
CVT SYSTEM / DRIVEN CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
TRANSMISSION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
TRANSMISSION REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
4X4 TRANSMISSION OUTPUT EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
STARTING CLUTCH EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
8.1
CVT / TRANSMISSION
TORQUE SPECIFICATIONS
CVT Torque Specifications
8.2
CVT / TRANSMISSION
GEAR SELECTION SPECIAL TOOLS
Shift Linkage Inspection Special Tools
NOTE: Shift rod is preset at time of manufacture.
1. Inspect shift linkage rod bushing clips and replace if worn
or damaged. Lubrication of rod ends is not required.
Shown below are roller shift weights which may be used in the
8
CVT system. These shift weights control engagement RPM and Order tools from SPX Corp. 1-800-328-6657
shifting patterns. Shift weights should not be changed or altered
without first having a thorough understanding the effects they
have on clutch balance, engagement and shifting characteristics.
• 14 gram - PN 5412989
• 13 gram - PN 5412988
• 12 gram - PN 5412987
• 10 gram - PN 5412986
8.3
CVT / TRANSMISSION
CVT OPERATION Drive Clutch Operation
The CVT drive clutch, mounted on the starting clutch hub shaft,
CVT Operation Overview is RPM sensitive. The drive clutch basic components are the
inner (fixed) sheave, the outer (moveable) sheave, the rollers
(weights) and the cover plate.
WARNING
The drive clutch begins to rotate when engine RPM reaches
engagement speed and the starter clutch engages.
All CVT maintenance or repairs should be performed
only by a certified Polaris Master Service Dealer (MSD) At low RPM, the drive belt is located at the bottom (smallest
diameter) of the drive clutch sheaves resulting in a low “gear”
technician who has received the proper training and ratio. As engine RPM increases, centrifugal force moves the
understands the procedures outlined in this manual. drive clutch shift rollers outward in their respective tracks
Because of the critical nature and precision balance toward the outside of the drive clutch. This forces the moveable
sheave farther inward toward the fixed sheave. The inward
incorporated into the CVT components, it is movement of the sheave forces the drive belt farther upward in
absolutely essential that no disassembly or repair the sheaves toward progressively higher “gear” ratios (larger
be made without factory authorized special tools diameter).
and service procedures.
Driven Clutch Operation
The power of the engine is transferred to the wheels through the The driven clutch is connected to the drive clutch via the drive
following components: Starting Clutch, Drive Clutch, Drive belt and is mounted on the main gearcase input shaft. The CVT
Belt, Driven Clutch, Transmission, Drive shaft(s), and Rear driven clutch consists of a fixed sheave, a moveable sheave with
Gearcase (and Front Gearcase on 4x4 models). roller tracks, rollers, and a compression style return spring.
During the development of a Polaris ATV, the CVT system is The driven clutch is primarily torque sensitive, reacting to the
matched first to the engine power curve; then to average riding forces of engine power and vehicle load to control the upshift
conditions and the vehicle’s intended usage. Therefore, and downshift of the CVT system.
modifications or variations of components at random are never
recommended.
Engine power is sensed by the driven clutch via the drive belt.
Proper clutch setup and careful inspection of existing Vehicle loads are sensed by the driven clutch through the main
components must be the primary objective when gearcase input shaft.
troubleshooting and tuning.
If forces on the drive belt (engine power) exceed the forces on
The Continuously Variable Transmission (CVT) consists of the transmission shaft (vehicle loads) the drive clutch sheaves
four major assemblies: 1) Starting Clutch; 2) Drive Clutch; 3) move inward and the belt upward, which forces the sheaves of
Drive Belt; and 4) Driven Clutch. the driven clutch apart against spring pressure. The drive belt
moves downward into the sheaves of the driven clutch to a
smaller diameter (higher “gear” ratio), increasing the speed of
Starting Clutch Operation the driven clutch. This process is called upshifting.
The starting clutch is located on the left (CVT) side of the engine If the torque resistance at the transmission input shaft is greater
crankshaft. It is an RPM sensitive clutch that connects the than the force through the drive belt, the driven clutch spring
engine crankshaft to the CVT System. forces the moveable sheave inward, and the drive belt is forced
toward the outer diameter of the sheaves. This action, which
When engine RPM is below the factory determined engagement decreases the driven clutch speed, is called backshifting.
speed of the vehicle, return springs on the staring clutch shoes
hold the shoes inward away from the starter clutch hub. In situations where loads vary (such as uphill and downhill) and
throttle settings are constant, the drive and driven clutches
When engine RPM is increased, centrifugal force causes the upshift or backshift accordingly to maintain optimum engine
shoes to overcome the return spring force and swing outward. RPM.
When the shoes contact the surface of the starter clutch hub, the
hub rotates at engine speed. This causes the CVT drive clutch At full throttle a perfectly matched CVT maintains engine RPM
mounted on the shaft of the starting clutch hub to rotate at the at the peak of the power curve during upshift and backshift. In
same RPM. this respect, the CVT system is similar to a conventional power
governor, but it functions by varying the load rather than by
Refer to the ENGINE section for more information. varying throttle position.
8.4
CVT / TRANSMISSION
CVT Maintenance/Inspection CVT Drying
Periodic inspection and maintenance is required to keep the NOTE: If operating the ATV through water, be sure to
system operating at peak performance. The following list of check the CVT cover and other ATV components for
items should be inspected and maintained to ensure maximum
performance and service life of CVT components. Refer to the water ingestion. The ATV should be checked
troubleshooting checklist for more information. immediately. Refer to Owner’s Manual for Safe Riding
1. Drive and Driven Clutch Rollers (Weights), Buttons Tips.
and Bushings, and Driven Clutch Spring. Inspect for 1. To drain any water that may be trapped inside the CVT
wear. cover, remove the CVT drain plug located on the bottom
2. Drive Belt. Inspect condition and width of belt. of the CVT cover and let the water drain out. (The location
of the CVT drain plug is shown on the following page.)
3. Sheave Faces. Clean and inspect for wear.
4. CVT System Sealing. The CVT system is air cooled by fins NOTE: To further expel water in the CVT cover and to
on the drive clutch stationary sheave. The fins create a low dry out the CVT system, shift the transmission to neutral
pressure area in the CVT area, drawing fresh air into the and rev engine slightly to expel the moisture. This will
system through the intake air duct. The opening for this also air-dry the belt and clutches. Allow engine RPM to
intake duct is located at a high point on the vehicle. All settle to idle speed, shift transmission to lowest available
connecting air ducts and the outer cover must be properly range and test for belt slippage. Repeat as needed.
sealed to reduce the chance of water ingestion into the CVT Operate ATV in lowest available range for a short period
area. A sealed CVT is especially critical on units subjected of time until CVT system is dry.
to frequent water forging.
8.5
CVT / TRANSMISSION
CVT DUCTING
Clamps
8.6
CVT / TRANSMISSION
CVT Overheating/Diagnosis
During routine maintenance or whenever CVT system overheating is evident, it’s important to check the inlet and outlet ducting for
obstructions. Obstructions to air flow through the ducts will significantly increase CVT system operating temperatures. The ATV
should be operated in LOW RANGE (if equipped) when pulling or plowing heavy loads, or if extended low speed operation is
anticipated.
Low Range (if equipped): Heavy pulling, basic operational speeds less
GENERAL OPERATION RANGE than 7 MPH, riding through rough terrain (swamps, mountains, etc.), low
GUIDELINES: ground speeds.
High Range: High ground speeds, speeds above 7 MPH.
Diagnosis of Clutch Drive Belt & Cover Related Issues:
Possible Causes Solutions/What to do
Loading the ATV into a pickup or tall trailer Shift transmission to low range (if equipped) during loading of the ATV to
when in high range. prevent belt burning.
Starting out going up a steep incline. When starting out on an incline, use low range (if equipped), or perform
the “K” turn to turn around. Warning: Excessive throttle may cause
loss of control and vehicle overturn.
Driving at low RPM or low ground speed Drive at higher speed or use Low Range. (if equipped) The use of Low
(at approximately 3-7 MPH). Range is highly recommended for cooler CVT operating temperatures
and longer component life.
Insufficient warm-up of ATVs exposed to Warm engine at least 5 min., then with transmission in neutral, advance
low ambient temperatures. throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will
become more flexible and prevent belt burning.
Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement. Continuous
operation at the point of engagement (initial vehicle movement)
increases CVT temperatures and component wear.
Towing/Pushing at low RPM/low ground Use Low Range only. (if equipped)
speed.
Plowing snow, dirt, etc./utility use. Use Low Range only. (if equipped)
Stuck in mud or snow. Shift the transmission to Low Range (if equipped), carefully use fast,
aggressive throttle application to engage clutch. Warning: Excessive
8
throttle may cause loss of control and vehicle overturn.
Climbing over large objects from a Shift the transmission to Low Range (if equipped), carefully use fast,
stopped position. aggressive, throttle application to engage clutch. Warning: Excessive
throttle may cause loss of control and vehicle overturn.
Belt slippage from water or snow Shift the transmission to neutral. Using the throttle, vary engine rpm from
ingestion into the CVT system. idle to 3/4 throttle. Engage transmission in the lowest possible range (if
equipped) and test for belt slippage Repeat several times as required.
During this procedure, the throttle should not be held at the full
position. Inspect CVT system for sealing or damage if repeated water
ingestion occurs.
Clutch malfunction. Inspection/repair of clutch components should be performed by a
certified Polaris MSD technician.
8.7
CVT / TRANSMISSION
CVT System Disassembly / Drive Clutch 7. Before removing drive belt, install the tool 2875563 as
shown to prevent drive clutch moveable sheave from
NOTE: Do not lubricate drive clutch components. moving inward.
NOTE: If tool is not available, use two hands to hold
1. Remove seat, left side cover, left foot well, rear rack and
the cam plate and the primary sliding sheave
rear cab. (Rear tire removal not required but helpful.)
together when removing the primary sliding sheave
2. Remove all CVT cover screws and CVT cover. and the cam plate assembly. This prevents the
rollers from falling out of the assembly.
8. Separate driven clutch sheaves and force belt down into the
sheaves. Remove belt from driven, then from drive clutch.
8.8
CVT / TRANSMISSION
9. Measure belt width and compare to specification. Replace 11. Remove sleeve and fixed sheave. Inspect the cooling fins
if any area is worn below the minimum width, if belt is for damage, the sleeve for wear or rough spots, and the face
unevenly worn (hour glassed) or if damaged. of the fixed sheave for wear, grooving or rough surface.
Fixed Sheave
Sleeve
= In. / mm.
12. Remove the rollers from the primary sliding sheave. Check
Drive Belt Service Limit: the rollers for wear, deep scoring, or flat spots. Remove and
1.320” (33.52mm) inspect the slide bushings and cam plate. Replace any
components that found to be worn excessively or appears
10. Remove the primary sliding sheave and cam plate assembly abnormal.
as one assembly. Inspect the movable sheave for scoring,
grooving, or abnormal wear. Slide Bushings
NOTE: If tool is not installed, be sure to hold cam
plate and primary sliding sheave together to prevent Rollers
rollers from falling out of the assembly.
Wide Surface
Bushing
Threaded Hole
8.9
CVT / TRANSMISSION
16. Install the fixed sheave and spacer sleeve. CVT System / Driven Clutch Service
1. Remove retaining bolt.
2. Pull the clutch off the shaft using flywheel puller as shown.
2875563
3. Remove the puller and place the driven clutch spring side
up in the clutch spring compressor 8700220.
4. Install arm PA-47457-1 on the spring compressor.
5. Install adaptor PA-47457-2 on the arm.
6. Remove nut (counterclockwise) using tool PA-46076 or a
standard socket.
7. Compress spring enough to remove the chain lock and
slowly release spring tension.
18. Install the assembly, engaging the splines and install the
nut. Do not apply any lubricants to the components. Apply
Loctite 242 (Blue) to threads and torque the retaining nut
to specification.
IMPORTANT: Be sure splines of cam plate are fully
engaged on shaft spline before tightening the nut!
=T
CVT Drive Clutch Nut Torque
185 ft. lbs. (250 Nm)
Loctite 242 (Blue)
CAUTION
8.10
CVT / TRANSMISSION
8. Measure the free length of spring. Standard free length is 10. Remove roller pins using a needle-nose pliers and
7.52” (191.1mm). Replace spring if length is less than remove top and bottom O-rings.
standard or if spring coils are distorted.
11. Clean all parts to remove old grease before inspecting the
= In. / mm. components.
12. Carefully inspect the roller tracks in the hub of the
Driven Compression Spring moveable sheave. Replace clutch assembly if tracks are
Standard Length: visibly worn.
7.52” (191.1 mm) 13. Check the pin holes in the shaft of the fixed sheave. Pins
should be a firm fit in the holes.
9. Carefully pry up the roller cover to remove it. Inspect cover
for wear. 14. Inspect sheaves for wear, damage, or rough spots. Replace
the clutch assembly if sheaves are worn or damaged.
15. Apply a light film of moly grease to seal lips and to the
inside of the roller pin hub. Install the moveable sheave
over the shaft of the fixed sheave until the sheaves contact
each other.
16. Lift the moveable sheave enough to clean all excess grease
from the shaft and the sheave faces to prevent belt
contamination after assembly.
8.11
CVT / TRANSMISSION
18. Lubricate the roller pins with grease and install all pins until
fully seated. The surface of the pins must be approximately
flush with the surface of the roller pin hub.
19. Install new O-rings on top and bottom of roller pin hub.
20. Pack all roller tracks with grease.
21. Install the roller pin sleeve and push it down until fully
seated against moveable sheave.
22. Clean the threads of the shaft, and threads of the spring
retaining nut to remove all oil or grease.
23. Place the driven clutch assembly in the compressor tool.
24. Install spring.
25. Install spring retainer on spring, visually aligning the flats
of the retainer with the flats on the threaded shaft.
26. Install tool PA-47457-3
27. Retainer Alignment Tool onto spring retainer.
28. Compress the clutch spring slowly, turning the retainer with
the tool as required to align the flats.
29. When flats are aligned, fully compress the spring and
secure the compressor arm with the chain.
30. Apply Loctite™ 242 to threads of the nut and the shaft, and
install nut hand tight.
31. Release the tool and torque the nut to specification using
the same tools for removal of the nut.
=T
Driven Clutch Spring Retainer Nut Torque:
45 ft. lbs. (61 Nm)
Loctite™ 242 (Blue)
8.12
CVT / TRANSMISSION
TRANSMISSION
8.13
CVT / TRANSMISSION
Transmission Service 6. Remove input shaft, counter shaft, and shift drum as an
assembly.
1. Drain transmission fluid.
2. Remove Transmission. Refer to the Engine Section for
transmission removal procedure.
Transmission Disassembly
1. Clean the exterior of the transmission.
2. Remove all case screws.
3. Remove the left case from the right. Be sure shafts stay with
right case.
7. Clean all parts. Remove seals from gear case and install
new using an appropriate size seal driver.
8. Inspect all bearings, gear teeth, and splines for wear or
damage. Inspect gear dogs carefully and replace if the edge
of the dog is worn or rounded, chipped, or broken.
9. Inspect the reverse chain for damage.
Gear Teeth
Bearings Reverse Chain
4. Remove output gear and shaft and pull oil deflector from
right case. Note orientation for installation later.
Oil Deflector
Splines
Engagement Dogs
8.14
CVT / TRANSMISSION
11. Inspect the shift drum tracks for wear or damage. Inspect 2. Place fork shaft through guide with pointed end as shown.
shift fork for bending and the surface for wear, burning, or
scoring.
Shaft Support
Spring Collar
Small Spring
Large Spring
Fork
8
Transmission Reassembly
1. Reassemble the drum starting with shaft guide, detent cam DOT
(wide flange faces toward the threaded end of drum), the
flat washer, and snap ring.
8.15
CVT / TRANSMISSION
4. Install the detent ratchet with spring. Install the snap ring. 7. Apply 3-Bond 1215 sealant evenly to clean and oil-free
case sealing surfaces.
5. Assemble the shafts with chain and shift drum and install
the assembly into the case.
8. Install the left case and tap it into place until seated.
9. Install bolts and torque in two steps following a cross
pattern to specification.
=T
Gearcase Bolt Torque:
(18 ft. lbs. (24.5 Nm)
8.16
CVT / TRANSMISSION
4x4 Transmission Output Exploded View
8.17
CVT / TRANSMISSION
Starting Clutch Exploded View
Complete disassembly, inspection and installation procedures are located in Chapter 3.
8.18
ELECTRICAL
CHAPTER 9
ELECTRICAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
FUSIBLE LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
FUSE SPLICE SAVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
INSTRUMENT GAUGE POWER / FWD / NEUTRAL SWITCHES / RPM SIGNAL . . . . . 9.4
AWD CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
SPEED SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
GEAR POSITION INDICATOR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
GEAR POSITION SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
ETC / REVERSE RPM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
ETC / REVERSE RPM CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
IGNITION SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
RPM LIMIT MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
IGNITION COIL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
CDI OUTPUT TEST USING PEAK READING ADAPTOR OR VOLTMETER . . . . . . . . 9.10
CDI CRANKING OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
IGNITION SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
IGNITION SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
CHARGING SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
ALTERNATOR OUTPUT TEST (AC AMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
STATOR FUNCTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
VOLTAGE DROP TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
BRUSH INSPECTION & REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
ARMATURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
STARTER REASSEMBLY & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
9
STARTER SOLENOID BENCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
STARTER MOTOR EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
PINION GEAR - ANTI-KICK OUT SHOE, GARTER SPRING REPLACEMENT . . . . . . 9.23
STARTER SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
CONDITION: STARTER FAILS TO TURN MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.1
ELECTRICAL
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
BATTERY IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
CONVENTIONAL BATTERY ACTIVATION/ SVC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
BATTERY TERMINALS/TERMINAL BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CONVENTIONAL BATTERY INSPECTION/REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CONVENTIONAL BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CONVENTIONAL BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CONVENTIONAL BATTERY OCV - OPEN CIRCUIT VOLTAGE TEST . . . . . . . . . . . . 9.27
CONVENTIONAL BATTERY SPECIFIC GRAVITY TEST . . . . . . . . . . . . . . . . . . . . . . . 9.27
CONVENTIONAL BATTERY LOAD TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
CONVENTIONAL BATTERY OFF-SEASON STORAGE. . . . . . . . . . . . . . . . . . . . . . . . 9.28
CONVENTIONAL BATTERY CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 9.28
9.2
ELECTRICAL
GENERAL INFORMATION Fuse Splice Saver
Special Tools The fuse splice saver is near the battery under the front storage
compartment.
Fusible Link
A fusible link is installed on the battery voltage circuit that
9
supplies power to the main 15A fuse. The link is located at the
starter motor solenoid + post.
9.3
ELECTRICAL
Instrument Gauge Power / FWD / Neutral Switches / RPM Signal
The instrument gauge displays engine RPM via an A/C signal from the Y/RED of the voltage regulator.
The gauge is powered by switched R/BLK and switched R/WHT battery voltage. Both the key and the RUN switches have to be
closed to power-up the gauge.
The gear selector switch provides a ground path for the FWD (BLU/RED) or neutral (GRN/WHT) circuits.
9.4
ELECTRICAL
AWD Control System
The front differential coil is controlled by the speedometer the AWD switch, and the RUN/OFF switch.
Battery voltage is supplied to the AWD coil when the operator turns the key switch to RUN, moves the AWD switch to AWD and
moves the RUN/OFF switch to RUN.
The AWD coil ground circuit is supplied by the instrument gauge. The speedometer will not allow the AWD to engage when the
engine RPM is 3100 RPM or higher.
9.5
ELECTRICAL
SPEED SENSOR
Vehicle Speed Sensor
The vehicle speed sensor is mated to the transmission housing and reads the speed of the transmission output gear.
The instrument gauge supplies the sensor with battery voltage via the ORANGE circuit, a reference ground via the BRN/RED circuit
and receives a return signal via the GRN/RED circuit.
To test the circuit:
1. Turn the ignition key to the ON position and move the RUN/OFF switch to run.
2. Verify there is battery voltage present on the ORANGE circuit. If voltage is not found, inspect the wiring harness, or replace
the instrument gauge.
3. If voltage is found, test the BRN/RED ground circuit. Verify there is continuity between the circuit and chassis ground.
4. If all circuits function, remove the speed sensor from the transmission. Verify the sensor is not damaged.
5. Back-probe the GRN/RED and BRN/RED wires with the connector still connected to the sensor. Turn the multimeter to measure
vDC. Wave a screwdriver back in forth across the face of the sensor while monitoring the multimeter.
6. The multimeter display should flip between a voltage and 0vDC every time the screwdriver blade passes by the sensor face. If
this does not occur, replace the sensor.
9.6
ELECTRICAL
ELECTRONIC THROTTLE CONTROL GEAR POSITION INDICATOR SWITCH
(ETC) SWITCH
Gear Position Switch Test
Electronic Throttle Control (ETC) Switch
1. Locate the gear selector switch on the transmission.
The Electronic Throttle Control (ETC) switch is designed to Remove the wiring harness connector and insert the two
close in the event where the throttle cable sticks or breaks. multimeter probes into the switch.
2. Move the gear selector handle to each of the three drive
During normal operation, the ETC switch contacts are open (not positions (FWD, NEU, or REV).
touching). The contacts will close when slack is present in the
cable. 3. Using an ohmmeter, test for continuity between the switch
contacts and connector leads. Replace the switch if no
Electronic Throttle Control (ETC) Switch continuity or high resistance is found.
9
NOTE: The throttle cable must have the proper amount of
end-play adjustment. A cable that is too tight will cause ETC
interruption, resulting in false engine RPM limiting.
9.7
ELECTRICAL
ETC / REVERSE RPM CONTROL
ETC / Reverse RPM Control System
The instrumentation gauge will signal the CDI controller to limit engine RPM to approximately 3100 RPM (6.5 MPH) whenever
the transmission is in reverse gear. If the ETC switch connects to ground, the instrument gauge will shut the engine off.
The operator can override the RPM speed limit in reverse, but not the ETC RPM limit, by pressing and holding the reverse override
button located on the left handlebar.
The reverse override button also serves as the mode switch button for the instrumentation gauge. The mode button toggles between
the several function the gauge performs.
To rule out engine RPM limiting caused by the CDI or instrument gauge, disconnect the BLACK wire from the CDI controller.
9.8
ELECTRICAL
IGNITION
Ignition System Diagram
The ignition system consists of:.
• CDI Controller
• Battery
• Ignition Coil
• Stator - Pulse Coil
• ETC / Key / Run-Off Switches / Instrument Gauge
9.9
ELECTRICAL
RPM Limit Modes CDI Output Test Using Peak Reading
Adaptor or Voltmeter
Engine RPM is limited when:
Re-connect all CDI wires to stator wires. Disconnect CDI
• Operator selects reverse gear. The maximum vehicle module wire from ignition coil primary terminal. Connect one
speed when reverse gear is selected is 6.5 MPH meter lead to engine ground and the other to the ignition coil
primary wire leading from the CDI module. Crank engine and
• If the wheel speed sensor malfunctions, the check output of CDI wire to coil. Reconnect CDI wire to the coil.
speedometer will limit engine RPM to approximately
3500 RPM when the transmission is in reverse.
• Maximum engine RPM is reached.
The reverse engine RPM limit can be overridden when the
operator presses and holds the override button.
On AWD models, the speedometer also limits the maximum
engine RPM in which the operator can engage the AWD system.
The speedometer will not allow the AWD to engage when the
engine RPM is at or above 3100 RPM.
Connect Meter
Test Reading
Wires To:
200 - 250
CDI Output W/BLU to Ground
Volts DC
9.10
ELECTRICAL
CDI Cranking Output Test Ignition System Troubleshooting
The following peak voltage tests will measure the amount of No Spark, Weak or Intermittent Spark
output from each component. A peak reading voltmeter can be
used to perform the tests. A variety of peak reading adaptors are • No12 volt power or ground to CDI
commercially available for use with the Fluke™ 77 Digital
Multimeter (PV-43568) and other digital VOMs which will • Spark plug gap incorrect
allow peak voltage tests to be performed accurately. Follow the
directions provided with the adaptor. All measurements are • Fouled spark plug
indicated in Volts. Readings obtained without a peak reading
adaptor will be significantly different. • Faulty spark plug cap or poor connection to high
tension lead
Disconnect the stator connectors from the CDI module. Test
output from the detection and pulse (trigger) coil, and compare • Related wiring loose, disconnected, shorted, or
to the chart. The following measurements were obtained when corroded
cranking the engine with the electric starter, spark plug installed.
The starting system must be in good condition and the battery • Engine Stop switch or ignition switch faulty
fully charged.
• ETC switch misadjusted or faulty
Voltage Connect Reading Reading • Poor ignition coil ground (e.g. corroded)
Test Meter Wires (With VOM) (With Peak
To: Reading • Faulty stator (measure resistance of all ignition related
windings)
Adapter)
Pulse Coil W/R and B 0.15 Volts 5.3 - 5.4 • Incorrect wiring (inspect color coding in connectors
etc)
minimum AC Volts
@ cranking minimum DC • Faulty ignition coil winding (measure resistance of
RPM @ cranking primary and secondary)
RPM • Worn magneto (RH) end Crankshaft bearings
• Sheared flywheel key
Ohm Connect Reading Reading
Test Meter Wires (With Peak • Flywheel loose or damaged
To: Reading • Excessive crankshaft runout on magneto (RH)
Adapter) end - should not exceed .005”
Pulse Coil W/R and B 520 Ohms n/a • Faulty CDI module
W/R to
O.L.
Ground
9.11
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. The resistance
values are also given on the specification pages.
Disconnect the BLACK wire at the CDI -Test the ignition switch, engine stop
module to isolate the ignition from the switch, and speed limiter circuit for
over-ride systems, but verify the CDI has a Yes shorts to ground.
good ground (BROWN) for operation. - Check connectors for moisture,
wire color matching or corrosion.
Does it have spark?
No
Yes
Yes
Yes
If all of the above tests are within specifications, and all grounds, connections, and wire color coding
have been inspected, perform voltage output tests on following page or replace the CDI module.
9.12
ELECTRICAL
CHARGING SYSTEM
Charging System
The charging system consists of:.
• Stator
• Battery
• Regulator / Rectifier
The regulator / rectifier is responsible for converting AC voltage to DC voltage, and generating the tachometer pulse.
9.13
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- Remove the battery and properly ser-
sure the battery open circuit voltage (see No vice. Reinstall the fully charged battery
procedure later in chapter). It should be or a fully charged shop battery.
12.4 volts or more. Is it?
Yes
9.14
ELECTRICAL
Current Draw - Key Off Charging System “Break Even” Test
CAUTION CAUTION
Do not connect or disconnect the battery cable or Do not connect or disconnect the battery cable or
ammeter with the engine running. Damage will occur to ammeter with the engine running.
light bulbs and speed limiter.
Connect an ammeter in series with the negative battery cable.
Check for current draw with the key off. If the draw is excessive, CAUTION
loads should be disconnected from the system one by one until
the draw is eliminated. Check component wiring as well as the
component for partial shorts to ground to eliminate the draw. Never use the electric starter with an ammeter
connected in series, as damage to the meter or meter
fuse may result. Do not run test for extended period of
Current Draw - Key Off: time. Do not run test with high amperage accessories.
Maximum of .02 DCA (20mA)
The “break even” point of the charging system is the point at
which the alternator overcomes all system loads (lights, etc.)
and begins to charge the battery. Depending on battery condition
and system load, the break even point may vary slightly. The
battery should be fully charged before performing this test.
• Clamp an inductive ammeter or connect an ammeter
(set to DC amps) in series between the negative battery
cable and terminal.
Less Than 9 mA
Do not use electric start.
9.15
ELECTRICAL
Alternator Output Test (AC amp) Stator Function Test
This test measures AC amperage from the alternator. Three tests can be performed using a multimeter to determine
the condition of the stator.
CAUTION
I = Current in Amps
P = Power in Watts
E = Electromotive Force (Volts)
• Maximum alternator output will be indicated on the 1. Measure the resistance value of each of the three stator
meter. It is not necessary to increase engine RPM above legs: W1 to W2, W1 to W3, and W2 to W3. Each should
idle. measure 0.314ohms.
• Place the red lead on the tester in the 10A jack. 2. Measure each of the white wires to ground, the reading
should be (O.L.).
• Turn the selector dial to the AC amps (A~) position.
NOTE: Significant variations in resistance readings
• Connect the meter leads to the wires leading from the between each circuit is an indication that one of the three
alternator (see schematic for proper wiring colors). circuits may be weak or failed.
• Start the engine and let it idle. Reading should be a
minimum of 8A at idle. TEST 2: Stator Output.
1. Place the red lead on the tester in the 10A jack.
2. Turn the selector dial to the AC-AMPs position.
3. Start the engine and let it idle.
4. Separately test each leg of the stator by connecting the
meter leads to the wires leading from the alternator (W1 to
W2, W1 to W3, W2 to W3). Alternator Current Output
Reading should be no less than 8 AMPS.
NOTE: Use an inductive amp meter to test stator
amperage for engine speeds over 1200 RPM.
9.16
ELECTRICAL
STARTER
Starter / Starter Lockout System
The starter and starter lockout system consists of:
• Battery
• Key Switch / Run-Off Switch
• Solenoid
• Brake / Neutral Switches
• Diodes
• Starter Motor
9.17
ELECTRICAL
Troubleshooting Voltage Drop Testing
Starter Motor Does Not Run The Voltage Drop Test is used to test for bad connections. When
performing the test, you are testing the amount of voltage drop
• Battery discharged. Low specific gravity through the connection. A poor or corroded connection will
appear as a high voltage reading. Voltage shown on the meter
• Loose or faulty battery cables or corroded connections when testing connections should not exceed.1 VDC per
(see Voltage Drop Tests) connection or component.
• Related wiring loose, disconnected, or corroded To perform the test, place the meter on DC volts and place the
meter leads across the connection to be tested. Refer to the chart
• Failed Diode on 1.47 to perform voltage drop tests on the starter system.
• Poor wire connections: harness, grounds, at battery
cable, starter motor or starter solenoid (see Voltage
Drop Tests) Voltage should not exceed
.1 DC volts per connection
• Faulty key switch
• Faulty kill switch
Removal / Disassembly
• Faulty brake switch
NOTE: Use electrical contact cleaner to clean starter
• Faulty transmission switch motor parts. Some solvents may leave a residue or
• Faulty starter solenoid or starter motor. damage internal parts and insulation.
• Engine problem - seized or binding (Can engine be 1. Remove the starter from the engine.
rotated easily with recoil starter?) 2. Remove the two bolts, washers, and sealing O-Rings.
Inspect O-Rings and replace if damaged.
Starter Motor Turns Over Slowly
• Battery discharged - low specific gravity
• Excessive circuit resistance - poor connections (see
Voltage Drop Test below)
• Engine problem - seized or binding (Can engine be
rotated easily?)
• Faulty or worn brushes in starter motor
Starter Motor Turns - Engine Does Not Rotate
• Faulty starter drive
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel
9.18
ELECTRICAL
3. Remove the front bracket assembly and the rear bracket as necessary.
assembly. Remove the shims from the armature shaft and
inspect the O-rings located on the armature housing.
O-Rings
Shims
3. Slide positive brush springs to the side, pull brushes out of
their guides and remove brush plate. Slide brush end frame
off end of starter.
NOTE: The shims will be replaced during
reassembly. NOTE: The electrical input post must stay with the
field coil housing.
Brush Inspection & Replacement 4. Measure resistance between ground brush and brush plate.
Resistance should be .3 ohms or less.
1. Measure resistance between starter input terminal and
insulated brushes. The reading should be .3 ohms or less.
Remember to subtract meter lead resistance.
Brush Inspection
9
2. Measure resistance between insulated brush and starter
housing. Reading should be infinite. (OL). Inspect 1. Measure length of each carbon brush. Replace brush
insulation on brush wires for damage and repair or replace assembly when worn to 5/16” (8 mm) or less. The brushes
must slide freely in their holders.
Brush Length
9.19
ELECTRICAL
Brush Replacement 3. Using a digital multitester, measure the resistance between
each of the commutator segments. The reading should be
1. Remove terminal nut with lock washer, flat washer, large .3 ohms or less.
phenolic washer, the small phenolic spacers, and sealing
4. Measure the resistance between each commutator segment
O-ring. Inspect O-ring and replace if damaged.
and the armature shaft. The reading should be infinite (no
continuity).
CAUTION
CAUTION
9.20
ELECTRICAL
Starter Reassembly & Installation 9. Lightly grease pinion shaft and install pinion, spring
stopper, and snap ring.
1. Install brush plate to field magnet housing aligning index
tab.
9
6. Be sure wire insulation is in place around positive brush
wire and pushed completely into slot on phenolic plate.
7. Using Dielectric Grease (PN 2871329), lubricate brush end
bushing and install shims.
8. Align brush plate and install cover and screws.
9.21
ELECTRICAL
Starter Motor Exploded View
9.22
ELECTRICAL
STARTER DRIVE
Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement
If the garter spring is damaged, the overrun clutch may fail to return properly. Use either of the following methods to remove and
install a new garter spring:
H
G
A F
D
A. Gear Assembly E
B. Thrust Washer C
C. Bushing
D. Retaining Ring
E. Thrust Washer
F. Stopper
G. Cover
H. Spring
1. Screw the overrun clutch out to the engaged position on the pinion shaft assembly. Use a small piece of wire with the end bent
in a hook and pick the old spring out of its channel. Slide it off the end of the shaft. Slide the new spring over the overrun clutch
and into the spring groove. Make sure that the spring is positioned between the shoe alignment pins and the back flange of the
anti kick-out shoes.
2. Remove the retaining ring, thrust washer, spring retainers and clutch return spring. Screw the overrun clutch off the end of the
pinion shaft. Remove the old spring and install a new one. Lightly grease the pinion shaft and reinstall the clutch, spring,
retainers, end washer and lock ring in the reverse order. Make sure the end washer is positioned properly so that it will hold
the lock ring in its groove.
9.23
ELECTRICAL
STARTER SYSTEM TESTING FLOW CHART
Condition: Starter Fails To Turn Motor
NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester
must be used for this test.
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.
lead on the battery positive. No Install fully charged shop battery to
continue test.
Reading should be 12.4 volts or greater.
Yes
Test starter solenoid coil by connecting an ohmmeter between the coil leads
Yes Resistance should be 3.7Ω + 1. Check solenoid ground path between the
BLUE wire and battery NEG. with transmission in NEUTRAL and the hand
Voltage Drop Testing brake applied. Set the meter to check continuity of a diode.
See Page 9.22 for instructions.
Yes
Yes
Yes
If all of these indicate a good condition, yet the starter still fails to turn, the
starter must be removed for static testing and inspection.
9.24
ELECTRICAL
BATTERY battery type in the vehicle. Use the section that applies to
the battery.
Battery Identification
WARNING
NOTICE: It is important to identify what type of battery you
have installed in your ATV. Different types of batteries require
different service procedures. Proper servicing and upkeep of Battery electrolyte is poisonous. It contains sulfuric
your battery is very important for maintaining long battery life. acid. Serious burns can result from contact with
Your ATV may have a Conventional Battery or a Sealed Low skin, eyes or clothing. Antidote:
Maintenance Battery. To identify which type of battery your
ATV has, refer to the illustration below and follow the correct External: Flush with water.
service and charging procedures that follow in the manual.
CONVENTIONAL BATTERY Internal: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.
Removable
Caps
Eyes: Flush with water for 15 minutes and get
prompt medical attention.
WARNING
9.25
ELECTRICAL
NOTE: New Battery: Battery must be fully charged 2. Disconnect battery negative (-) (black) cable first, followed
before use or battery life will be significantly reduced 10- by the positive (+) (red) cable.
30% of the battery’s full potential.
CAUTION
To activate a new battery:
1. Remove vent plug from vent fitting. Remove cell caps. Whenever removing or reinstalling the battery,
2. Fill battery with electrolyte to upper level marks on case. disconnect the negative (black) cable first and
3. Set battery aside to allow for acid absorption and reinstall the negative cable last!
stabilization for 30 minutes.
3. Remove the battery.
4. Add electrolyte to bring level back to upper level mark on
4. Remove the filler caps and add distilled water only as
case. NOTE: This is the last time that electrolyte should be
needed to bring each cell to the proper level. Do not overfill
added. If the level becomes low after this point, add only
the battery.
distilled water.
5. Charge battery at 1/10 of its amp/hour rating. Examples: 1/ Refill using only distilled water. Tap water contains minerals
10 of 9 amp battery = .9 amp; 1/10 of 14 amp battery = 1.4 which are harmful to a battery.
amp; 1/10 of 18 amp battery = 1.8 amp (recommended
Do not allow cleaning solution or tap water inside the battery.
charging rates). Battery life may be reduced.Reinstall the battery caps.
6. Check specific gravity of each cell with a hydrometer to
assure each has a reading of 1.270 or higher. 5. Reinstall the battery caps.
9.26
ELECTRICAL
Conventional Battery OCV - Open Circuit Conventional Battery Specific Gravity Test
Voltage Test
A tool such as a Battery Hydrometer (PN 2870836) can be used
Battery voltage should be checked with a digital multitester. to measure electrolyte strength or specific gravity. As the battery
goes through the charge/discharge cycle, the electrolyte goes
Readings of 12.6 volts or less require further battery testing from a heavy (more acidic) state at full charge to a light (more
and charging. See charts and Load Test on below. water) state when discharged. The hydrometer can measure
state of charge and differences between cells in a multi-cell
NOTE: Lead-acid batteries should be kept at or near a battery. Readings of 1.270 or greater should be observed in a
full charge as possible. Electrolyte level should be kept fully charged battery. Differences of more than .025 between the
lowest and highest cell readings indicate a need to replace the
between the low and full marks. If the battery is stored or battery.
used in a partially charged condition, or with low
electrolyte levels, hard crystal sulfation will form on the
plates, reducing the efficiency and service life of the
battery.
SPECIFIC GRAVITY
State of charge* Conventional Lead-acid
100% Charged 1.265
75% Charged 1.210
50% Charged 1.160
25% Charged 1.120
0% Charged less than 1.100
* At 80oF
NOTE: Subtract .01 from the specific gravity reading at 40o F. 9
9.27
ELECTRICAL
Conventional Battery Load Test Electrolyte Freezing Points
A battery may indicate a full charge condition in the OCV test 1.100 +18o F
and the specific gravity test, but still may not have the storage
capacity necessary to properly function in the electrical system. 1.050 +27o F
For this reason, a battery capacity or load test should be
conducted whenever poor battery performance is encountered.
To perform this test, hook a multitester to the battery in the same Conventional Battery Charging Procedure
manner as was done in the OCV test. The reading should be 12.6
volts or greater. Engage the starter and observe the battery 1. Remove the battery from the ATV to prevent damage from
voltage while cranking the engine. Continue the test for 15
seconds. During cranking the observed voltage should not drop leaking or spilled acid during charging.
below 9.5 volts. If the beginning voltage is 12.6 volts or higher 2. Charge the battery with a charging output no larger than 1/
and the cranking voltage drops below 9.5 volts during the test, 10 of the battery’s amp/hr rating. Charge as needed to raise
replace the battery.
the specific gravity to 1.270 or greater.
Conventional Battery Off-Season Storage 3. Install battery in vehicle. Coat threads of battery bolt with
a corrosion resistant dielectric grease.
To prevent battery damage during extended periods of non-use,
the following basic battery maintenance items must be Dielectric Grease
performed:
(PN 2871329)
• Remove the battery from the machine and wash the
case and battery tray with a mild solution of baking
soda and water. Rinse with lots of fresh water after 4. Connect battery cables.
cleaning.NOTE: Do not get any of the baking soda into
the battery or the acid will be neutralized.
WARNING
• Using a wire brush or knife, remove any corrosion from
the cables and terminals.
To avoid the possibility of explosion, connect
• Make sure that the electrolyte is at the proper level. Add positive (red) cable first and negative (black)
distilled water if necessary. cable last.
• Charge at a rate no greater than 1/10 of the battery’s
amp/hr capacity until the electrolyte’s specific gravity 5. After connecting the battery cables, attach the hold down
reaches 1.270 or greater. strap.
6. Install clear battery vent tube from vehicle to battery vent.
• Store the battery either in the machine with the cables
disconnected, or store in a cool place. WARNING: Vent tube must be free from obstructions and
kinks and securely installed. If not, battery gases could
NOTE: Stored batteries lose their charge at the rate of accumulate and cause an explosion. Vent should be routed
up to 1% per day. Recharge to full capacity every 30 to away from frame and body to prevent contact with
60 days during a non-use period. If the battery is stored electrolyte. Avoid skin contact with electrolyte, as severe
during the winter months, electrolyte will freeze at higher burns could result. If electrolyte contacts the vehicle frame,
temperatures as the battery discharges. The chart below corrosion will occur.
indicates freezing points by specific gravity.
7. Route cables so they are tucked away in front and behind
battery.
9.28
QUADRICYCLE
CHAPTER 10
QUADRICYCLE
HAWKEYE QUADRICYCLE ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
TRANSMISSION SWITCH - BREAKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
FUSE HOLDER - BREAKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
FLASHER RELAY - BREAKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
HEADLIGHT / TAILLIGHT - EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
HAWKEYE QUADRICYCLE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
FOOT BRAKE SYSTEM - EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
AUXILIARY HAND BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
AUXILIARY HAND MASTER CYLINDER - EXPLODED VIEW . . . . . . . . . . . . . . . . . . . 10.6
NOTE: This chapter illustrates components that are unique to the Hawkeye 2x4 / 4x4 Quadricycle.
Except where noted, any servicing of these components or other components
on the ATV can be done using this service manual’s procedures and illustrations.
10
10.1
QUADRICYCLE
HAWKEYE QUADRICYCLE ELECTRICAL
Transmission Switch - Breakout
A mechanical PARK lock is built into
the transmission on quadricycle models
10.2
QUADRICYCLE
Flasher Relay - Breakout
RH Turn Indicator
LH Turn Indicator
LH Turn Indicator
Splice
RH Turn Indicator
10.3
QUADRICYCLE
HAWKEYE QUADRICYCLE BRAKE SYSTEM
Overview
The Hawkeye Quadricycle brake system consists of a complete hydraulic brake system. All-wheel braking is integrated into the
foot brake pedal. This allows brake control on three wheel discs.
When the foot brake is applied, the two front calipers and the LH rear caliper are used. When applied, the brake pressure is routed
from the foot brake master cylinder through one line to the junction block and front calipers, while the other line feeds the LH rear
caliper. The foot brake master cylinder is equipped with a dual banjo fitting allowing brake fluid to be forced down both lines to
the front and rear when the foot brake is applied.
When the hand brake is applied, only the rear RH brake caliper is active and under pressure. This allows for rear wheel braking
only. The handlebar master cylinder only allows fluid to flow to the RH rear brake caliper.
Controlled by the
Auxiliary Hand Brake
LH Rear Caliper
22 ft. lbs
(30 Nm)
22 ft. lbs
(30 Nm)
LH Front Caliper
RH Rear Caliper
22 ft. lbs
(30 Nm)
22 ft. lbs
(30 Nm)
RH Front Caliper
Controlled by the
Foot Brake
10.4
QUADRICYCLE
Foot Brake System - Exploded View
3
4 T
2
7
1 T
10
T
8
9
5
2
10.5
QUADRICYCLE
Auxiliary Hand Brake System
B D
F
15 ft. lbs.
(20 Nm)
15 ft. lbs.
(20 Nm)
C
E
A. Rear Brake Caliper
B. Handlebar Master Cylinder
C. Banjo Bolt
D. Brake Line - Front Master to Rear RH Caliper
A
E. Seals
F. Brake Pressure Switch
M
S
O
K
I
L
G. Reservoir Body Q
H. Brake Lever
I. Piston
J. Park Brake Lever
K. Primary Cup
L. O-Ring T
M. Cover
N. Park Lever Pivot Pin P H
O. Piston Return Spring N
P. Pivot Pin
Q. Dust Boot
R. Return Lever Spring
S. Clamp
T. Retaining Ring J
U. Push-On R
V. Torx Screws U
W. Cover Screws
10.6
WIRE DIAGRAM
WD-1
WIRE DIAGRAM
WD-2
WIRE DIAGRAM
WD-3
WIRE DIAGRAM
WD-4