2005 Sportsman 6x6

SPORTSMAN
SPORTSMAN 6X6
6X6
6(59,&(0$18$/
6(59,&(0$18$/
31504
31504
2004--2005 SPORTSMAN 6x6
SERVICE MANUAL
Foreword
This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle
are from the operator’s perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar
with service procedures before starting the work. Certain procedures require the use of special tools. Use
only the proper tools as specified.
This manual includes procedures for maintenance operations, component identification and unit repair, along
with service specifications for Polaris Sportsman 6x6 ATVs. Comments or suggestions about this manual
may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.
Some Polaris factory publications can be downloaded from www.polarisindustries.com or purchased from
www.purepolaris.com or contact your nearest Polaris dealer.
2004--2005 Sportsman 6x6 ATV Service Manual (PN 9919504)
ECopyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the
time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may
result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are
intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions
and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
Throughout these instructions, important information is brought to your attention by the following symbols:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
DANGER
Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person
inspecting or servicing the ATV.
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or
person inspecting or servicing the ATV.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property
damage.
NOTE:
A NOTE provides key information to clarify instructions.
Trademarks
Polaris acknowledges the following products mentioned in this manual:
FLEXLOC, Registered Trademark of SPS Technologies

Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
GENERAL
MAINTENANCE
ENGINE
CARBURETION
BODY AND STEERING
CLUTCHING
FINAL DRIVE
TRANSMISSION
BRAKES
ELECTRICAL
GENERAL INFORMATION
Specs
Model Identification . . . . . . . . . . . . . . . . . . . . . . . 1.2

Serial Number Location . . . . . . . . . . . . . . . . . . . 1.2
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . 1.3
Specifications -- Sportsman 6x6 . . . . . . . . . . . . 1.3--1.5
Optional Springs . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Publication Numbers . . . . . . . . . . . . . . . . . . . . . 1.6
Replacement Keys . . . . . . . . . . . . . . . . . . . . . . . 1.6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7--1.12
Standard Torque Specifications . . . . . . . . . . . . 1.13
Decimal Equivalent / Tap Drill Chart . . . . . . . . 1.14
Unit of Measure Conversion Chart . . . . . . . . . . 1.15
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . 1.16
1.1
GENERAL INFORMATION
MODEL IDENTIFICATION
The machine model number must be used with any correspondence regarding warranty or service.
Machine Model Number Identification

A 05 CL 50 AA
Emissions &
Year Designation Basic Chassis Model Option
Designation Engine Designation
ENGINE DESIGNATION NUMBERS

EH500PLE104 . . . . . . . . . . . . . . Single, L/C. SOHC 4 Stroke, Electric Start
VIN IDENTIFICATION
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 C L 5 0 A * Y P 0 0 0 0 0 0
Body Style Emissions Model * This could be either

Engine Year Individual Serial No. a number or a letter
Powertrain Check Digit Plant No.
ENGINE SERIAL NUMBER LOCATION

Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This
information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional
number is stamped on the center top of crankcase beneath the cylinder coolant elbow.
MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION

The machine model number and serial number are A
important for vehicle identification. The machine
serial number is stamped on the lower left side of
the frame tube.(B)
TRANSMISSION I.D. NUMBER

LOCATION
The transmission I.D. number is located
on top of the transmission, right side of
machine.
Front
B
1.2
GENERAL INFORMATION
MODEL: . . . . . . . . . . Sportsman 500 6x6

MODEL NUMBER: . A04CL50AA, A05CL50AA
ENGINE MODEL: . . EH500PLE104
Category Dimension
Length 105 in./266.7 cm
Width 46 in./116.8 cm
Height 48 in./121.9 cm
Wheel Base 77 in./195.6 cm
Ground Clearance 5.5 in./14 cm
Gross Vehicle Weight 1965 lbs./891 kg
Dry Weight 895 lbs./406 kg
Oil Capacity 2.0 qts./1.9 ltr
Coolant Capacity 2.25 qts./2.1 ltr
Front Rack Capacity 75 lbs./40.8 kg
Cargo Box Capacity 800 lbs./362.8 kg
Towing Capacity 1500 lbs./681 kg
Hitch Tongue Weight 150 lbs./68.1 kg
Body Style Gen VI
2004 SPORTSMAN 6X6
2005 SPORTSMAN 6X6
1.3
GENERAL INFORMATION
MODEL: . . . . . . . . . . 2004 SPORTSMAN 500 6x6

MODEL NUMBER: . A04CL50AA
Engine Drivetrain
Platform Fuji 4 stroke, Single Cylinder Transmission Type H--Pattern H/L/N/R
Engine Model Number EH500PLE104 Transmission Fluid Capacity 32 oz.
Engine Displacement 499cc Front Gearcase Capacity 4 oz. (120 ml)
Number of Cylinders 1 Front Hub Capacity 2.5 oz. (75 ml)
Bore & Stroke (mm) 92 x 75 mm Gear Ratio : Low 6.69/1
High 3.34/1
Compression Ratio 10:2
Rev. 5.17/1
Compression Pressure 50--90 psi
Final 12/38 80 P chain
Engine Idle Speed 1200 ± 200 Rpm
Clutch Type PVT
Cooling System/Capacity Liquid / 2.25 qts. (2.1 L)
Belt 3211077
Overheat Warning HOT on Instrument Cluster
Lubrication Pressurized Dry Sump Steering / Suspension
Oil Requirements Polaris 0W--40 Front Suspension / Shock A--arm / MacPherson Strut
Exhaust System Single Pipe Front Travel 6.7 in. / 17.02 cm

Rear Suspension
Carburetion Style / Shock
Progressive Rate Single
Carburetor model Mikuni BST 34mm
Rear Travel Center 6.5 in. / 16.5 cm
Main Jet 142.5 Rear 7.5 in / 19.1 cm
Pilot Air Jet 160 Ground Clearance 5.5 in. / 14 cm
Jet Needle--clip position 4HB41--3 Shock Preload Adjustment F --Spring tension -- Std.
Needle Jet Q--4M (829) Front / Rear R -- Cam Adjustment
Pilot Screw 3 Turns Out Turning Radius 119 in. / 302 cm unloaded
Float Height 13 ± 1 mm (0.51 ± 0.40“) Toe Out 0 -- 1/16 in / .0 -- .159 mm
Fuel Delivery/Tank Capacity Fuel Pump Wheels / Brakes
Fuel Capacity / Requirement 4.25 gal. (16.09L) Wheel Size -- Front 25 x 8 -- 12 / 4--156
87 Octane (minimum)
89 Oxygenated Wheel Size -- Center / Rear 25 x 11 -- 10 / 4--156
Air Press. F/R Tires 5 psi Front / 5 psi Rear
Electrical
Brake -- Front Dual Hydraulic Disc
Alternator Output 250 w @ 5000 RPM
Brake -- Rear Hydraulic Disc
Voltage Regulator 3--Phase
Brake Fluid Polaris DOT 3 Brake Fluid
Lights : High Beam 50 watts
Low Beam 27 watts
JETTING CHART AMBIENT TEMPERATURE
Brake 26.9 watts Below 40°F Above 40°F
Altitude Below 5°C Above 5°C
Tail 8.26 watts
Meters 0--1800
147.5 142.5
Ignition System DC/CDI Ignition (Feet) (0--6000)
Ignition Timing 30° ± 2° BTDC @ 5000 RPM above 1800

140 135
(above 6000)
Spark plug / Gap NGK BKR5E/ .036 in./ 0.9 mm
CLUTCH CHART Shift Drive Driven Driven
Battery / Model / Amp Hr Sealed Low Maintenance -- Weight Spring Helix
Altitude Spring
14 Amp Hr
10 MH Blu/Grn Red 40°
0--1800
Circuit Breakers Solid State in ECM (5630513) (7041157) (7041198)
(5131446)
(0--6000) 2--2
Meters
Starting Electric / Recoil Backup (Feet) 40°
1800--3700 10 WH Blu/Grn Red (5131446)
Instrument Cluster LCD (6000--12000) (5630710) (7041157) (7041198) 2--2
1.4
GENERAL INFORMATION
MODEL: . . . . . . . . . . 2005 SPORTSMAN 500 6x6

MODEL NUMBER: . A05CL50AA
Engine Drivetrain
Platform Fuji 4 stroke, Single Cylinder Transmission Type H--Pattern H/L/N/R
Engine Model Number EH500PLE106 Transmission Fluid Capacity 32 oz.
Engine Displacement 499cc Front Gearcase Capacity 4 oz. (120 ml)
Number of Cylinders 1 Front Hub Capacity 2.5 oz. (75 ml)
Bore & Stroke (mm) 92 x 75 mm Gear Ratio : Low 6.69/1
High 3.34/1
Compression Ratio 10:2
Rev. 5.17/1
Compression Pressure 50--90 psi
Final 12/38 80 P chain
Engine Idle Speed 1200 ± 200 Rpm
Clutch Type PVT
Cooling System/Capacity Liquid / 2.25 qts. (2.1 L)
Belt 3211077
Overheat Warning HOT on Instrument Cluster
Lubrication Pressurized Dry Sump Steering / Suspension
Oil Requirements Polaris 0W--40 Front Suspension / Shock A--arm / MacPherson Strut
Exhaust System Single Pipe Front Travel 6.7 in. / 17.02 cm

Rear Suspension
Carburetion Style / Shock
Progressive Rate Single
Carburetor model Mikuni BST 34mm
Rear Travel Center 6.5 in. / 16.5 cm
Main Jet 142.5 Rear 7.5 in / 19.1 cm
Pilot Air Jet 160 Ground Clearance 5.5 in. / 14 cm
Jet Needle--clip position 4HB41--3 Shock Preload Adjustment F --Spring tension -- Std.
Needle Jet Q--4M (829) Front / Rear R -- Cam Adjustment
Pilot Screw 3 Turns Out Turning Radius 119 in. / 302 cm unloaded
Float Height 13 ± 1 mm (0.51 ± 0.40“) Toe Out 0 -- 1/16 in / .0 -- .159 mm
Fuel Delivery/Tank Capacity Fuel Pump Wheels / Brakes
Fuel Capacity / Requirement 4.25 gal. (16.09L) Wheel Size -- Front 25 x 8 -- 12 / 4--156
87 Octane (minimum)
89 Oxygenated Wheel Size -- Center / Rear 25 x 11 -- 10 / 4--156
Air Press. F/R Tires 5 psi Front / 5 psi Rear
Electrical
Brake -- Front Dual Hydraulic Disc
Alternator Output 250 w @ 5000 RPM
Brake -- Rear Hydraulic Disc
Voltage Regulator 3--Phase
Brake Fluid Polaris DOT 3 Brake Fluid
Lights : High Beam 50 watts
Low Beam 27 watts
JETTING CHART AMBIENT TEMPERATURE
Brake 26.9 watts Below 40°F Above 40°F
Altitude Below 5°C Above 5°C
Tail 8.26 watts
Meters 0--1800
147.5 142.5
Ignition System DC/CDI Ignition (Feet) (0--6000)
Ignition Timing 30° ± 2° BTDC @ 5000 RPM above 1800

140 135
(above 6000)
Spark plug / Gap NGK BKR5E/ .036 in./ 0.9 mm
CLUTCH CHART Shift Drive Driven Driven
Battery / Model / Amp Hr Sealed Low Maintenance -- Weight Spring Helix
Altitude Spring
14 Amp Hr
10 MH Blu/Grn Red 40°
0--1800
Circuit Breakers Solid State in ECM (5630513) (7041157) (7041198)
(5131446)
(0--6000) 2--2
Meters
Starting Electric / Recoil Backup (Feet) 40°
1800--3700 10 WH Blu/Grn Red (5131446)
Instrument Cluster LCD (6000--12000) (5630710) (7041157) (7041198) 2--2
1.5
GENERAL INFORMATION
OPTIONAL SPRINGS
SPRING TYPE SOFT STANDARD FIRM
7041880-067
Rear Compression Spring N/A N/A
Standard 210/250 lb/in.
7041987-067
Mid Compression Spring N/A N/A
Standard 100/160 lb/in.
7041375-067 7041450-067 7041696-067
Front Strut Spring
Option 64/113 lb/in. Standard 101 lb/in. Option 140/190 lb/in.
PUBLICATION NUMBERS
Year Model Model No. Owner’s Manual Parts Parts
PN Manual PN Micro Fiche PN
2004 Sportsman 500 6x6 A04CL50AA 9918775 9918628 9918629
2005 Sportsman 500 6x6 A05CL50AA 9919500 9919501 9919502
NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com

PAINT CODES
FRAME COLOR - (All) P067 Medium Gloss Black
COLD WEATHER KITS FOR 4 CYCLE ATVS
Engine Heater -- (PN 2871507)
ACCESSORY ENGINE HEATER

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 the right for the proper part
number.NOTE: Should both keys become lost,
ignition replacement is necessary.
Series # Part Number
20 4010278
31XX 21 4010278
22 4010321
Key Series
Number 23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
1.6
GENERAL INFORMATION
SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN
PA--44689 Valve Clutch Adjuster 2
2872105 Water Pump Mechanical Seal Puller 2
PV--43527 Oil Filter Wrench 2,3
8712100 or 8712500 Tachometer 2,10
2200634 Valve Seat Reconditioning Kit 3
2870390 Piston Support Block 3
2871043 Flywheel Puller 3
2871283 Crankshaft/Water Pump Seal Install Kit 3
5131135 Water Pump Install Kit 3
2870569 Crankshaft Truing Stand 3
2870975 Mity Vact Pressure Test Tool 3, 4, 9
2872314 Carburetor Float Adjustment Tool 4
2870871 Ball Joint Replacement Tool 5
2870872 Shock Spanner Wrench 2, 5
2870623 Shock Absorber Spring Compression Tool 5
2871572 Strut Rod Wrench 5
2871573 LH Strut Spring Compressor 5
2871574 RH Strut Spring Compressor 5
2870506 Clutch Puller 6
9314177 Clutch Holding Wrench 6
2871358 Clutch Holding Fixture 6
2870341 Drive Clutch Spider Removal and Install Tool 6
2870654 Clutch Offset Alignment Tool 6
2870913 Driven Clutch Puller 6
2870910 Roller Pin Tool 6
2871226 Clutch Bushing Replacement Tool Kit 6
2870386 Piston Pin Puller 6
8700220 Clutch Compression Tool 6
2871025 Clutch Bushing Replacement Tool Kit 6
2871199 Seal Sleeve Installation Tool Kit 5, 7
2870888 Hilliard Clutch Garter Spring Installation Tool 7
2872608 Roller Pin Removal Tool 7
2870772 1 3/4 Straight Wrench 7
8700226 CV Boot Clamp Pliers 7
2871710 10” Center Distance Tool 8
PV--43568 Fluket77 Digital Multimeter 10
2870630 Timing Light 10
2870836 Battery Hydrometer 10
2460761 Hall Sensor Probe Harness 10
2871745 Static Timing Light Harness 10
NOTE: Polaris dealers can order the tools listed above through the Polaris Special Service Tools catalog.
1.7
GENERAL INFORMATION
SPECIAL TOOLS
Special Tools maybe required while servicing your
machine. Some of the tools listed are mandatory and Standard Tools and Engine Tools
other tools maybe substituted with a similar tool, if
available. Polaris reccommends the use of Polaris
special tools when servicing any Polaris product.
Standard Tools and Engine Tools
2870569 -- Crankshaft True Kit

PU--45432 -- Caliper or
A Basic Caliper
2870386 -- Piston Pin Puller
Basic Micrometer
2871445 -- Piston Pin Puller Adapter
2871043 -- Flywheel Puller 2870968 -- Counter Balance Puller
2870773 -- C--Clip Install Tool

PV--43527 Oil Filter Wrench
2870967 -- Slotted Nut Socket

PA--44689 -- Valve/Clutch Adjuster
2870390 -- Piston Support Block

8700229 -- Flywheel Holder & Adapter
1.8
GENERAL INFORMATION
Standard Tools and Engine Tools
2870303 -- Hone Kit 2871283 -- Crank/Water Pump Seal

Install Kit
Clutch (PVT) Tools
2870305 -- Stone Replacement Kit

2870506 -- Drive Clutch Puller
2870588 -- Hone Oil (12 oz.) 2870913 -- Driven Clutch Puller
2200634 -- Valve Seat

Reconditioning Kit
2870654 -- ATV Clutch Align Tool
2870459 -- Dial Indicator
9914177--A -- Drive Clutch Holding Tool

PV--35667--A -- Cylinder Leak
down Tester
2872105 -- Water Pump Seal Puller 8700220 -- Clutch Compression Tool
1.9
GENERAL INFORMATION
Clutch (PVT) Tools Suspension Tools
2870341 -- Drive Clutch Spider

Removal Tool
2870871 -- ATV Ball Joint Tool Kit
2870910 -- Roll Pin Tool
2871025 -- Clutch Bushing Replace 2871071 -- Shock Body Holding Tool

Tool Kit
2871226 -- Clutch Bushing

Replacement Kit 2870623 -- Shock Spring Compressor
2871572 -- Strut Rod Wrench
2870338 -- Spider Nut Socket

2871573 & 2871574 -- Strut
Spring Compressor
8700225 & 8700226 -- CV Boot

Clamp Pliers
2871358 -- Clutch Holding Fixture
1.10
GENERAL INFORMATION
Suspension Tools Fuel & Brake Systems
2870872 -- Shock Spanner Wrench
2872608 -- Roll Pin Removal Tool 2870975 -- Mity Vac
Electrical Tools
2871351 -- Shock IFP Depth Tool
PV--43568 --Fluke 77 Multimeter
2870772 -- 1.75” Wrench
Transmission Tools
PV--39617 -- Current Clamp
2871702 -- Shaft Drive Transmission

& Front Gearcase Tool Kit
2870836 -- Battery Hydrometer
RPM
8712500 -- PV--39951--A --
Tachometer Tachometer
2871282 -- Bearing/Seal Driver
(50 mm)
1.11
GENERAL INFORMATION
Electrical Tools
2870630 -- Timing Light
2871745 --Static Timing Light Harness
2460761 -- Hall Sensor Probe Harness
PV--39991 -- Peak Reading Adapter
PV--37453 -- Christie De--Sulfating

Multi--Battery Charger
PV--63070 -- Christie Multi--Battery

Charger
1.12
GENERAL INFORMATION
STANDARD TORQUE SPECIFICATIONS

The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF
FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering,
suspension, and engine sections.
Bolt Size Threads/In Grade 2 Grade 5 Grade 8

Torque in. lbs. (Nm)
#10 - 24 . . . . . . . . . . . . . . 27 (3.1) . . . . . . . . . . . . . . . . 43 (5.0) . . . . . . . . . . . . . . 60 (6.9)
#10 - 32 . . . . . . . . . . . . . . 31 (3.6) . . . . . . . . . . . . . . . . 49 (5.6) . . . . . . . . . . . . . . 68 (7.8)
Torque ft. lbs. (Nm)*
1/4 - 20 . . . . . . . . . . . . . . 5 (7) . . . . . . . . . . . . . . . . . . 8 (11) . . . . . . . . . . . . . . . . 12 (16)
1/4 - 28 . . . . . . . . . . . . . . 6 (8) . . . . . . . . . . . . . . . . . . 10 (14) . . . . . . . . . . . . . . 14 (19)
5/16 - 18 . . . . . . . . . . . . . . 11 (15) . . . . . . . . . . . . . . . . 17 (23) . . . . . . . . . . . . . . 25 (35)
5/16 - 24 . . . . . . . . . . . . . . 12 (16) . . . . . . . . . . . . . . . . 19 (26) . . . . . . . . . . . . . . 29 (40)
3/8 - 16 . . . . . . . . . . . . . . 20 (27) . . . . . . . . . . . . . . . . 30 (40) . . . . . . . . . . . . . . 45 (62)
3/8 - 24 . . . . . . . . . . . . . . 23 (32) . . . . . . . . . . . . . . . . 35 (48) . . . . . . . . . . . . . . 50 (69)
7/16 - 14 . . . . . . . . . . . . . . 30 (40) . . . . . . . . . . . . . . . . 50 (69) . . . . . . . . . . . . . . 70 (97)
7/16 - 20 . . . . . . . . . . . . . . 35 (48) . . . . . . . . . . . . . . . . 55 (76) . . . . . . . . . . . . . . 80 (110)
1/2 - 13 . . . . . . . . . . . . . . 50 (69) . . . . . . . . . . . . . . . . 75 (104) . . . . . . . . . . . . . 110 (152)
1/2 - 20 . . . . . . . . . . . . . . 55 (76) . . . . . . . . . . . . . . . . 90 (124) . . . . . . . . . . . . . 120 (166)
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.
1.13
GENERAL INFORMATION
SAE TAP DRILL SIZES DECIMAL EQUIVALENTS

1/64 . . . . . . . . . . . . . . . . .0156
Thread Size/Drill Size Thread Size/Drill Size 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
5/64 . . . . . . . . . . . . . . . . .0781 . . . 2 mm = .0787″
#1-72 53 9/16-12 31/64 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 9/64 . . . . . . . . . . . . . . . . .1406
5/8-18 37/64 5/32 . . . . . . . . . . . .1563 . . . 4 mm = .1575″
#3-56 45
#4-40 43 3/4-10 21/32 11/64 . . . . . . . . . . . . . . . .1719
3/4-16 11/16 3/16 . . . . . . . . . . . .1875 . . . 5 mm = .1969″
#4-48 42 13/64 . . . . . . . . . . . . . . . .2031
#5-40 38 7/8-9 49/64
7/32 . . . . . . . . . . . .2188
#5-44 37 7/8-14 13/16 15/64 . . . . . . . . . . . . . . . .2344 . . . 6 mm = .2362″
#6-32 36 1-8 7/8 1/4 . . . . .25
#6-40 33 1-12 59/64 17/64 . . . . . . . . . . . . . . . .2656 . . . 7 mm = .2756″
#8-32 29 9/32 . . . . . . . . . . . .2813
1 1/8-7 63/64 19/64 . . . . . . . . . . . . . . . .2969
#8-36 29 1 1/8-12 1 3/64 5/16 . . . . . . . . . . . .3125 . . . 8 mm = .3150″
#10-24 24 1 1/4-7 1 7/64 21/64 . . . . . . . . . . . . . . . .3281
#10-32 21 11/32 . . . . . . . . . . .3438 . . . 9 mm = .3543″
1 1/4-12 1 11/64
#12-24 17 23/64 . . . . . . . . . . . . . . . .3594
#12-28 4.6mm 1 1/2-6 1 11/32 3/8 . . . . .375
1/4-20 7 1 1/2-12 1 27/64 25/64 . . . . . . . . . . . . . . . .3906 . . . 10 mm = .3937″
1 3/4-5 1 9/16 13/32 . . . . . . . . . .4063
1/4-28 3
27/64 . . . . . . . . . . . . . . . .4219 . . . 11 mm = .4331″
5/16-18 F 1 3/4-12 1 43/64 7/16 . . . . . . . . . . . .4375
5/16-24 I 2-4 1/2 1 25/32 29/64 . . . . . . . . . . . . . . . .4531
3/8-16 O 2-12 1 59/64 15/32 . . . . . . . . . .4688 . . . 12 mm = .4724″
3/8-24 Q 2 1/4-4 1/2 2 1/32 31/64 . . . . . . . . . . . . . . . .4844
7/16-14 U 1/2 . . . . .5 . . . . . . . . . . . . . . 13 mm = .5118
2 1/2-4 2 1/4 33/64 . . . . . . . . . . . . . . . .5156
7/16-20 25/64 2 3/4-4 2 1/2 17/32 . . . . . . . . . .5313
3-4 2 3/4 35/64 . . . . . . . . . . . . . . . .5469 . . . 14 mm = .5512″
9/16 . . . . . . . . . . . .5625
37/64 . . . . . . . . . . . . . . . .5781 . . . 15 mm = .5906″
19/32 . . . . . . . . . .5938
METRIC TAP DRILL SIZES 39/64 . . . . . . . . . . . . . . . .6094
5/8 . . . . .625 . . . . . . . . . . . . 16 mm = .6299″
41/64 . . . . . . . . . . . . . . . .6406
Tap Size Drill Size Decimal Nearest 21/32 . . . . . . . . . .6563 . . . 17 mm = .6693″
Equiva- Fraction 43/64 . . . . . . . . . . . . . . .6719
lent 11/16 . . . . . . . . . . .6875
3 x .50 #39 0.0995 3/32 45/64 . . . . . . . . . . . . . . . .7031 . . . 18 mm = .7087″
3 x .60 3/32 0.0937 3/32 23/32 . . . . . . . . . .7188
47/64 . . . . . . . . . . . . . . . .7344 . . . 19 mm = .7480″
4 x .70 #30 0.1285 1/8 3/4 . . . . .75
4 x .75 1/8 0.125 1/8 49/64 . . . . . . . . . . . . . . . .7656
5 x .80 #19 0.166 11/64 25/32 . . . . . . . . . .7813 . . . 20 mm = .7874″
5 x .90 #20 0.161 5/32 51/64 . . . . . . . . . . . . . . . .7969
6 x 1.00 #9 0.196 13/64 13/16 . . . . . . . . . .8125 . . . 21 mm = .8268″
7 x 1.00 16/64 0.234 15/64 53/64 . . . . . . . . . . . . . . . .8281
8 x 1.00 J 0.277 9/32 27/32 . . . . . . . . . .8438
8 x 1.25 17/64 0.265 17/64 55/64 . . . . . . . . . . . . . . . .8594 . . . 22 mm = .8661″
9 x 1.00 5/16 0.3125 5/16 7/8 . . . . .875
9 x 1.25 5/16 0.3125 5/16 57/64 . . . . . . . . . . . . . . . .8906 . . . 23 mm = .9055″
29/32 . . . . . . . . . .9063
10 x 1.25 11/32 0.3437 11/32 59/64 . . . . . . . . . . . . . . .9219
10 x 1.50 R 0.339 11/32 15/16 . . . . . . . . . .9375 . . . 24 mm = .9449″
11 x 1.50 3/8 0.375 3/8 61/64 . . . . . . . . . . . . . . . .9531
12 x 1.50 13/32 0.406 13/32 31/32 . . . . . . . . . .9688 . . . 25 mm = .9843
12 x 1.75 13/32 0.406 13/32 63/64 . . . . . . . . . . . . . . . .9844
1 . . . . . 1.0
1.14
GENERAL INFORMATION
CONVERSION TABLE
Unit of Measure Multiplied by Converts to
ft. lbs. x 12 = in. lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.356 = Nm
in. lbs. x .0115 = kg-m
Nm x .7376 = ft.lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 = in. lbs.
kg-m x 10 = Nm
in. x 25.4 =mm
mm x .03937 = in.
in. x 2.54 = cm
mile (mi.) x 1.6 = km
km x .6214 = mile (mi.)
Ounces (oz) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x 0.035 = Ounces (oz)
lb. x .454 = kg
kg x 2.2046 = lb.
Cubic inches (cu in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = Cubic inches (cu in)
Imperial pints (Imp pt) x 0.568 = Liters (l)
Liters (l) x 1.76 = Imperial pints (Imp pt)
Imperial quarts (Imp qt) x 1.137 = Liters (l)
Liters (l) x 0.88 = Imperial quarts (Imp qt)
Imperial quarts (Imp qt) x 1.201 = US quarts (US qt)
US quarts (US qt) x 0.833 = Imperial quarts (Imp qt)
US quarts (US qt) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt)
US gallons (US gal) x 3.785 =Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x 0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)
π (3.14) x R2 x H (height) = Cylinder Volume
°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F
°F to °C: 5 (°F + 40) ÷ 9 - 40 = °C
1.15
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.
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.
2
kg/cm : 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.
2
lbs/in : 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. 1mm = 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.
PVT: Polaris Variable Transmission (Drive Clutch System)
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.
1.16
MAINTENANCE
Periodic Maintenance Chart . . . . . . . . . . . . . . . 2.2-2.5

Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . 2.6
Recommended Lubricants and Capacities . . . 2.6
Lubricant and Maintenance Service Products 2.7--2.8
Lubrication Charts . . . . . . . . . . . . . . . . . . . . . . . . 2.9-2.11
Transmission Lubrication . . . . . . . . . . . . . . . . . . 2.12
Front Gearcase Lubrication . . . . . . . . . . . . . . . . 2.13
Transmission Linkage Adjustment . . . . . . . . . . 2.13-2.14
Carburetor Adjustments . . . . . . . . . . . . . . . . . . . 2.15-2.17
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17--2.18
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . 2.19
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . 2.19--2.20
Ignition / Sparkplug . . . . . . . . . . . . . . . . . . . . . . . 2.20
Coolant System Maintenance . . . . . . . . . . . . . . 2.21-2.22
Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . 2.22-2.24
Air Box Sediment Tube Service . . . . . . . . . . . . 2.24
Breather Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
Recoil Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24--2.45
Engine Oil Service . . . . . . . . . . . . . . . . . . . . . . . . 2.25-2.27
Valve Clearance / Adjustment . . . . . . . . . . . . . . 2.27
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28-2.31
Front Hub Maintenance . . . . . . . . . . . . . . . . . . . 2.31
Exhaust System Maintenance . . . . . . . . . . . . . 2.32
Brake System Inspection . . . . . . . . . . . . . . . . . . 2.32-2.34
Drive Chain Service . . . . . . . . . . . . . . . . . . . . . . 2.34-2.35
Suspension Service . . . . . . . . . . . . . . . . . . . . . . 2.35-2.36
Wheel Removal/Installation . . . . . . . . . . . . . . . . 2.36-2.37
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
2.1
MAINTENANCE
PERIODIC MAINTENANCE CHART

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection,
adjustment and lubrication 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 genuine 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
G Frequent immersion in mud, water or sand
G Racing or race-style high RPM use
G Prolonged low speed, heavy load operation
G Extended idle
G 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.
Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:
H= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed
by an authorized Polaris dealer.
"= SEVERE USE ITEM ----If vehicle is subjected to severe use, decrease interval by 50%
(Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race- style high rpm
use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is
required under these conditions. Fluid changes, cable, chain and chassis lubrication are required more
frequently. For engine oil, short trip cold weather riding also constitutes severe use. Pay special attention
to oil level. A rising oil level in cold weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately and monitor level. If oil level begins to rise, discontinue use and
determine cause.)
E= Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
WARNING: Improperly performing the procedures marked with a J could result in component failure and lead
to serious injury or death. Have an authorized Polaris dealer perform these services.
2.2
MAINTENANCE
MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart
Item Maintenance Interval Remarks
(whichever comes first)
Hours Calendar Miles
(Km)
J Steering -- Pre-Ride -- Make adjustments
j as needed. See Pre-Ride
" Front suspension -- Pre-Ride -- Ch kli t on Page
Checklist P 1.7.
17
" Rear suspension -- Pre-Ride --
Tires -- Pre-Ride --
" Brake fluid level -- Pre-Ride --
" Brake lever travel -- Pre-Ride --
Brake systems -- Pre-Ride --
Wheels/fasteners -- Pre-Ride --
Frame fasteners -- Pre-Ride --

" Engine oil level -- Pre-Ride --
E
" Air filter, pre-filter -- Daily -- Inspect; clean often
E
" Air box sediment -- Daily -- Drain deposits when visible
E tube
Coolant -- Daily -- Check level daily, change coolant every 2 years
(if applicable)
Headlamp/tail -- Daily -- Check operation; apply dielectric grease if re-
lamp placing
" Air filter, -- Weekly -- Inspect; replace as needed
E main element
Recoil housing -- Weekly -- Drain water as needed, check often if operating
in wet conditions
" Brake pad wear 10 H Monthly 60 (100) Inspect periodically
J
Battery 20 H Monthly 125 (200) Check terminals; clean; test
" Front gearcase oil 25 H Monthly 155 (250) Inspect level; change yearly
(if equipped)
" Middle gearcase 25 H Monthly 155 (250) Inspect level; change yearly
oil (if equipped)
" Rear gearcase oil 25 H Monthly 155 (250) Inspect level; change yearly
(if equipped)
" Transmission oil 25 H Monthly 155 (250) Inspect level; change yearly
" Perform these procedures more often for vehicles
subjected to severe use.
E Emission Control System Service (California)
J Have an authorized Polaris dealer perform these
services.
2.3
MAINTENANCE

(Km)
" Engine breather 25 H Monthly 155 (250) Inspect; replace if necessary
E filter (if equipped)
" Engine oil change 25 H 1M 155 (250) Perform a break-in oil change at one month
E (break-in)
" General 50 H 3M 310 (500) Lubricate all fittings, pivots, cables, etc.
lubrication
Shift Linkage 50 H 6M 310 (500) Inspect, lubricate, adjust
J Steering 50 H 6M 310 (500) Lubricate
" Front suspension 50 H 6M 310 (500) Lubricate
" Rear suspension 50 H 6M 310 (500) Lubricate
Carburetor float 50 H 6M 310 (500) Drain bowl periodically and prior to storage
bowl
J Throttle Cable/ 50 H 6M 310 (500) Inspect; adjust; lubricate; replace if necessary
E ETC Switch
J Choke cable 50 H 6M 310 (500) Inspect; adjust; lubricate; replace if necessary
E
E Carburetor air 50 H 6M 310 (500) Inspect ducts for proper sealing/air leaks
intake ducts/
flange
Drive belt 50 H 6M 310 (500) Inspect; adjust; replace as needed
Cooling system 50 H 6M 310 (500) Inspect coolant strength
(if applicable) seasonally; pressure test
system yearly
" Engine oil change 100 H 6M 620 Perform a break-in oil change at 25 hours/one
E (1000) month
" Oil filter change 100 H 6M 620 Replace with oil change
E (1000)
" Oil tank vent hose 100 H 12 M 620 Inspect routing, condition
E (1000)
J Valve clearance 100 H 12 M 620 Inspect; adjust
E (1000)
services.
2.4
MAINTENANCE

(Km)
J Fuel system 100 H 12 M 620 Check for leaks at tank cap, lines, fuel valve, fil-
E (1000) ter, pump, carburetor; replace lines every two
years
J Fuel filter 100 H 12 M 620 Replace yearly
E (1000)
" Radiator 100 H 12 M 620 Inspect; clean external
(if applicable) (1000) surfaces
" Cooling hoses 100 H 12 M 620 Inspect for leaks
(if applicable) (1000)
" Engine mounts 100 H 12 M 620 Inspect
(1000)
Exhaust muffler/ 100 H 12 M 620 Inspect
pipe (1000)
J Spark plug 100 H 12 M 620 Inspect; replace as needed
E (1000)
J Ignition Timing 100 H 12 M 620 Inspect
E (1000)
" Wiring 100 H 12 M 620 Inspect for wear, routing,
(1000) security; apply dielectric grease to connectors
subjected to water, mud, etc.
J Clutches (drive 100 H 12 M 620 Inspect; clean; replace worn parts
and driven) (1000)
J Front wheel 100 H 12 M 1000 Inspect; replace as needed
bearings (1600)
J Brake fluid 200 H 24 M 1240 Change every two years
(2000)
Spark arrestor 300 H 36 M 1860 Clean out
(3000)
E Idle speed -- Adjust as needed
J Toe adjustment -- Inspect periodically; adjust when parts are re-
placed
" Auxiliary brake -- Inspect daily; adjust as needed
J
Headlight aim -- Adjust as needed
services.
2.5
MAINTENANCE
PRE-RIDE / DAILY INSPECTION

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
G Tires - check condition and pressures
G Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank
G All brakes - check operation and adjustment (includes auxiliary brake)
G Throttle - check for free operation
G Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
G Engine stop switch - check for proper function
G Wheels - check for loose wheel nuts
G Air cleaner element - check for dirt or water; clean or replace
G Steering - check for free operation, noting any unusual looseness in any area
G Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
G Engine coolant - check for proper level at the recovery bottle
COLD WEATHER KITS FOR 4 STROKE ATVS

Engine Heater -- (PN 2871507)
ACCESSORY ENGINE HEATER
RECOMMENDED LUBRICANTS - QUICK REFERENCE

LUBRICANTS AND MAINTENANCE PRODUCT PART NUMBERS ARE LISTED ON PAGE 2.5
Item Type Notes See

Pages
Engine Oil Polaris Premium 4 Add to proper level on dipstick. 2.25
Synthetic, 0W--40 (PN
2871567)
Transmission Polaris AGL Gearcase Lu- Refer to procedures outlined later in this 2.12
bricant (PN 2873602) chapter.
Front Gear Case ATV Angle Drive Fluid Refer to procedures outlined later in this 2.13
(PN2871653) chapter.
Gear Shift Selector Polaris 0W--40 Synthetic Oil in selector box should be at the center 8.2
Box Engine Lubricant (PN line of the shift selector plungers. Do not
2871281) overfill or the selector may hydro-lock.
Coolant Level Polaris Premium 60/40 Fill reservoir tank to full line. Add if neces- 2.21
Pre-mixed Antifreeze/ sary. If reservoir was empty or extremely
Coolant (PN 2871323) or low, allow engine and cooling system to
a 50/50 mixture high quali- cool completely and check level in radia-
ty antifreeze/coolant and tor. Fill to top of filler neck.
distilled water
Front Hubs Premium Demand Drive Fill hub at 4:00 or 8:00 position until fluid 2.31
Hub Fluid (PN 2871654) trickles out. Do not force fluid into hub.
Brake Fluid Polaris DOT 3 Brake Fluid -Fill to indicated level inside reservoir. 2.33
(PN 2870990)
2.6
MAINTENANCE
POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS

Part No. Description Part No. Description
Engine Lubricant Additives / Sealants / Thread Locking Agents /
2870791 Fogging Oil (12 oz. Aerosol) Misc.
2871098 Premium 2 Cycle Engine Oil (Quart) (12 2870585 Loctitet Primer N, Aerosol, 25 g
Count) 2871956 Loctitet Thread Sealant 565
2871281 Engine Oil (Quart) Premium 4 Synthetic (50 ml.) (6 Count)
0W--40 (4--Cycle) (12 Count) 2871949 Loctitet Threadlock 242
2871844 Engine Oil (Gallon) Premium 4 Synthetic (50 ml.) (10 Count)
0W--40 (4--Cycle) (4 Count) 2871950 Loctitet Threadlock 242
2871567 Engine Oil (16 Gallon) Premium 4 (6 ml.) (12 Count)
Synthetic 0W--40 (4--Cycle)
2871951 Loctitet Threadlock 262
Gearcase / Transmission Lubricants (50 ml.) (10 Count)
2873602 Premium Synthetic AGL Gearcase Lube 2871952 Loctitet Threadlock 262
(12 oz. bottle) (12 Count) (6 ml.) (12 Count)
2873603 Premium Synthetic AGL Gearcase Lube
2871953 Loctitet Threadlock 271
(1 Gal.) (4 Count)
(6 ml.) (12 Count)
2871653 Premium ATV Angle Drive Fluid
(8 oz.) (12 Count) 2871954 Loctitet Threadlock 271
(36 ml.) (6 Count)
2872276 Premium ATV Angle Drive Fluid
(2.5 Gal) (2 Count) 2870584 Loctitet 680-Retaining Compound
(10 ml.)
2870465 Oil Pump for 1 Gallon Jug
2870587 Loctitet 518 Gasket Eliminator / Flange
2871654 Premium Demand Drive Hub Fluid
Sealant (50 ml.) (10 Count)
(8 oz.) (12 Count)
2871326 Premium Carbon Clean
2872277 Premium Demand Drive Hub Fluid (12 oz.) (12 Count)
(2.5 gal.) (2 Count)
2870652 Fuel Stabilizer (16 oz.) (12 Count)
Grease / Specialized Lubricants
2871957 Black RTV Silicone Sealer
2871322 Premium All Season Grease (3 oz. tube) (12 Count)
(3 oz. cartridge) (24 Count)
2871958 Black RTV Silicone Sealer
2871423 Premium All Season Grease
(14 oz. cartridge) (10 Count) (11 oz. cartridge) (12 Count)
2871460 Starter Drive Grease (12 Count) 2870990 DOT3 Brake Fluid (12 Count)
2871515 Premium U-Joint Lube (3 oz.) (24 Count) 2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)
2871551 Premium U-Joint Lube (14 oz.) (10 Count) 2872893 Engine Degreaser (12oz.) (12 Count)
2871312 Grease Gun Kit
NOTE: The number count indicated by each part
2871329 Dielectric Grease (Nyogelt) number in the table above indicates the number of
Coolant units that are shipped with each order.
2871323 60/40 Coolant (Gallon) (6 Count)
2871534 60/40 Coolant (Quart) (12 Count)
NOTE: Each item can be purchased separately at
your local Polaris dealer.
POLARIS LUBRICANT SYMBOL IDENTIFICATON
AGL 0W/40 DHF ADF
Polaris DOT 3 Polaris Sythetic Polaris Sythetic Polaris Demand Polaris ATV
Gearcase Lube OW--40 Oil Drive Hub Fluid Angle Drive Fluid
Brake Fluid AGL
U--Joint
Polaris U--Joint Lube Polaris All Season Grease
2.7
MAINTENANCE
POLARIS LUBES/FLUIDS FOR SPORTSMAN 6X6 MODELS

Pure Polaris Lubricants and Maintenance Kits can be purchased at your local Polaris dealer.
ATV Angle Drive Fluid
2873554 -- ATV Oil Change Kit

-- Oil Filter & 3 Qts. of 0W--40 oil
-- Reservoir Gasket
-- Drain Plug Gasket
-- Instruction Sheet
2.8
MAINTENANCE
LUBRICATION
Ill. Item Lube Method Frequency*
# Required
1 Engine Oil Polaris 0W--40 Add oil to proper level. Change after 1st month, 6 months or 100
Synthetic hours thereafter; Change more often (25-50
(PN 2871567) hours) in extremely dirty conditions, or short
trip cold weather operation.
2 Transmis- AGL Gearcase Add to bottom of fill hole. Change annually ©
sion Lubricant Approx. 27 oz. at change
(PN 2873602)
3 Brake Fluid Polaris DOT 3 Fill master cylinder reservoirs to As required. Change fluid every 2 years.
Brake Fluid 1/4″ (6.4mm) from top, or between
(PN 2870990) indicated lines. See Page 2.29.
4 Drive Chain Polaris Chain Apply to chain link plates and roll- As required*
Lube ers
ers.
5 Middle (PN 2872073)
Chain
* More often under severe use, such as operated in water or under severe loads.
© Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
More often under severe conditions (operating in water or hauling heavy
loads)
0W/40
Dipstick
Filter
1. Engine Oil and Filter AGL 2. Transmission Fill Plug
Master Cylinder
Reservoir
3. Brake Fluid
4. Rear Drive Chain

5. Middle Drive
Chain
2.9
MAINTENANCE
LUBRICATION, CONT.
7. Propshaft Yoke
(3 pumps max.)
6. Front Gear Case Fill Plug

Fill Plug
DHF ADF
8. Demand 4 Hubs
4 or 8 O’clock position-
(end view)
9. Strut Assembly
(Bottom Side)
Ill. Item Lube Required Method Frequency*

#
6 Front Gearcase ATV Angle Drive Fluid Add to bottom of fill plug threads. See Page 2.11. Annually©
(PN 2871653)
7 Propshaft Yoke Premium U-Joint Locate fittings and grease - 3 pumps maximum Annually©
Grease (PN 2871551)
8 Demand 4 Hubs Polaris Demand Drive Remove filler hole screw in hubs. Rotate wheels to Semi-annually
Hub Fluid 4 or 8 O’clock position. If lubricant is not visible add ¡
(PN 2871654) until it flows from filler hole. Reinstall screw.
9 Strut Assembly Polaris All Season Locate grease fitting and grease with grease gun. Semi-annually
Grease¢ ¡
(PN 2871423)
¡ Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)

More often under severe conditions (operating in water or hauling heavy loads)
¢ Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or
Mobilegrease Special
2.10
MAINTENANCE
LUBRICATION, CONT.
10. Middle Axle Bearings 12. Rear Scissors and Lower Rear Shock Bushings
11. Center Swing Arm Housing
10. Rear Axle

Bearing
Ill. Item Lube Required Method Frequency*

#
10 Rear and Middle Polaris All Season Locate grease fitting on eccentric and grease with Semi-
Axle Bearings Grease¢ grease gun. annually ¡
(PN 2871423)
11 Center Swing Polaris All Season Locate grease fitting on swing arm and grease with Semi-
Arm Housing Grease¢ grease gun. annually ¡
(PN 2871423)
12 Rear Scissors and Polaris All Season Locate and grease. Semi-
Lower Rear Shock Grease¢ annually ¡
Bushings (PN 2871423)
¡ Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)

¢ Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or
Mobilegrease Special
2.11
MAINTENANCE
TRANSMISSION TRANSMISSION SPECIFICATIONS

LUBRICATION Specified Lubricant:
Polaris AGL Gearcase Lubricant (PN 2873603)
The transmission lubricant level should be checked (Gallon) (PN 2873602) (12 oz.)
and changed in accordance with the maintenance
schedule. Capacity: . . . . 32 ± 1.6 oz. / 946 ml
G -- Check vent hose to be sure it is routed properly and Drain Plug / Fill Plug Torque:
unobstructed.
G -- Follow instructions on following pages to check / 14 ft. lbs. (19.4 Nm)
change transmission lubricant.
G -- Be sure vehicle is on a level surface.
Drain Plug
To check the level: (Opposite Side)
1. Remove footwell from the right side of the vehicle.
2. Remove fill plug and visually inspect the oil level. Fill Plug
Level is correct when it reaches the bottom of the fill
hole as shown at right.
To change lubricant:
1. Remove footwell from the right side of the vehicle.
2. Remove transmission drain plug drain the oil. Catch

and discard used oil properly.
3. Clean and reinstall the drain plug with a new sealing

washer. Torque to specification.
4. Remove fill plug.
5. Add Polaris AGL Gearcase Lubricant to proper level

as described above.
Correct Fluid Level: AGL
6. Check for leaks. Bottom Fill Plug Threads
7. Reinstall propshaft shield.
Fill to bottom of fill plug threads
View
Transmission Fill Plug
2.12
MAINTENANCE
FRONT GEARCASE 5. Install fill plug. Check for leaks.
LUBRICATION Make sure vent

is unobstructed
Fill plug
The gearcase lubricant level should be checked and
changed in accordance with the maintenance
schedule.
ADF
G -- Be sure vehicle is level before proceeding.

G -- Check vent hose to be sure it is routed
properly and unobstructed.
G -- The correct gearcase lubricant to use is Drain Plug
ATV Angle Drive Fluid (PN 2871653).
TRANSMISSION GEARSHIFT
LINKAGE ADJUSTMENT,
FRONT GEARCASE SPECIFICATIONS
Specified Lubricant:
PRELIMINARY INSPECTION
ATV Angle Drive Fluid (PN 2871653)
Linkage rod will rotate
1/8 -1/4 turn if rod ends
Capacity: . . . . . . . . . . . 4.0 Oz. are tightened properly.
(120ml.)
Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)
Parallel
To check the level:
Correctly Tightened Incorrectly Tightened

1. The front gearcase lubricant level cannot be Jam Nut
Jam Nut
checked with a dipstick or by visual reference.
The gearcase must be drained and re-filled with
G If shifting problems are encountered, the
the proper amount of lubricant. Refer to
transmission linkage can be adjusted.
procedure below.
G Tighten shift linkage rod end jam nuts
To change lubricant: properly after adjustment. You
should be able to rotate the linkage
1. Remove gearcase drain plug located on the rod between 1/8 and 1/4 turn after
bottom and drain oil. Catch and discard used oil both jam nuts are tight.
properly. G The transmission shift linkage should
be periodically inspected for wear
2. Clean and reinstall drain plug using a new sealing and parts replaced as required to
washer. remove excess play from shift
linkage.
3. Remove fill plug.
G Refer to Transmission chapter for more
4. Add proper amount of lubricant. information.
2.13
MAINTENANCE
SHIFT LINKAGE 5. Place gear selector in neutral. Make sure the

transmission bell cranks are engaged in the
ADJUSTMENT neutral position detents.
Linkage rod adjustment is necessary when

Adjust to align linkage rod end studs
symptoms include:
with holes in bellcrank(s).
G No All Wheel Drive light

G Noise on deceleration
G Inability to engage a gear
35 in. lbs.
G Excessive gear clash (noise) (4 Nm)
35 in. lbs.
G Shift selectors moving out of desired range (4 Nm)
Ill. 2
NOTE: When adjusting linkage, always adjust both
linkage rods. The adjustment of one rod can prevent
proper adjustment of the other rod. Remove 6. Be sure the shift linkage rod ends are firmly
necessary components to gain access to shift linkage attached to the gear selector slides. Adjust the
rod ends (i.e. exhaust heat shield, exhaust pipe, etc.). low range (inside) rod so the rod end is centered
on the transmission bell crank. Install the lock nut
to the rod end and torque to 35 in. lbs. (4 Nm).
Gear Selector
Low Range Slides S Rotate rod both directions to
Jam find points where resistance
Jam Nut Nut is felt.
S Center the rod between the
points.
Place
mark S Hold rod end parallel to
on rod mounting surface and
tighten jam nut.
NOTE: Rod end orientation, rod ends are
both down. Parallel
Ill. 1
Ill. 3
1. Inspect shift linkage tie rod ends, clevis pins, and 7. Rotate the linkage rod clockwise until resistance
pivot bushings and replace if worn or damaged. is felt. Mark the rod so revolutions can be easily
Lubricate the tie rod ends with a light aerosol counted. See Ill. 3 at right.
lubricant or grease. 8. Rotate the linkage rod counterclockwise until the
same resistance is felt, counting the revolutions
2. Loosen all rod end adjuster jam nuts see Ill. 1.
as the rod is turned.
3. Note orientation of tie rod end studs with stud up 9. Turn the rod clockwise again one half of the
or down. Remove both rod end studs from revolutions counted in Step 9.
transmission bell cranks.
10. Tighten the rod end jam nuts securely while
4. Be sure idle speed is adjusted properly. holding the rod end. The jam nuts must be
tightened with both front and rear rod ends
parallel to each other. If jam nuts are properly
NOTE: It is important to disconnect both rod ends
tightened, the rod should rotate freely 1/4 turn
from the transmission bell cranks. If one linkage rod
without binding.
is incorrectly adjusted, it can affect the adjustment of
the other rod. 11. Repeat Steps 7-10 for the High/Reverse rod.
2.14
MAINTENANCE
CARBURETOR/THROTTLE CHOKE (ENRICHER)

INSPECTION ADJUSTMENT
Check for smooth throttle opening and closing in all

handlebar positions. Throttle lever operation should
be smooth and lever 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 Boot
speed increases at any point in the turning range,
inspect throttle cable routing and condition. If the choke knob does not stay out when pulled, adjust
Adjust cable tension as needed until lock--to--lock the choke tension by tightening (clockwise) the jam nut
turning can be accomplished with no rise in under the rubber boot between the choke knob and nut.
engine rpm. Firmly grasp the rubber boot and tighten until the choke
slides freely but stays out when pulled.
5. Replace the throttle cable if worn, kinked, or
damaged.
To remove the ETC cover: IDLE SPEED ADJUSTMENT

1. Use a medium flat blade screwdriver and insert CV Carburetor
blade into the pocket of the cover starting on the
#1 position.
2. Twist screwdriver slightly while lifting on the cover

to release snap.
3. Repeat procedure at the other five locations as

shown.
NOTE: Do not attempt to remove cover until all
latch points are released.
Ill.3 Idle Screw
1. Start engine and warm it up thoroughly.

2 2. Adjust idle speed by turning the idle adjustment
3
1 screw in (clockwise) to increase or out
(counterclockwise) to decrease RPM. (Ill.3)
NOTE: Adjusting the idle speed affects throttle cable
6 freeplay and electronic throttle control (ETC)
5 4 adjustment. Always check throttle cable freeplay
after adjusting idle speed and adjust if necessary.
ETC Cover Idle Speed:

Ill. 1 Removal Sequence
1200 +/-- 100 RPM
2.15
MAINTENANCE
PILOT SCREW PILOT SCREW ADJUSTMENT
The pilot system supplies fuel during engine operation

with the throttle valve closed or slightly opened. The
fuel/air mixture is metered by pilot screw and
discharged into the main bore through the pilot outlet.
CAUTION: FRONT
(Engine)
The pilot screw is calibrated at the factory to meet 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 Pilot Screw
circuit can be done only by a certified repair shop to ensure air
quality standards are not exceeded.
View -- Right Cover Panel Removed
Pilot Screw
1. Start engine and warm it up to operating

Pilot Screw location temperature (about 10 minutes).
2. Turn pilot screw in (clockwise) until lightly seated.
Turn screw out the specified number of turns.
NOTE: Do not tighten the pilot screw forcefully
against the seat or the screw and/or seat will be
permanently damaged.
Brass Plug Installed

The pilot screw is set at the factory.
Each carburetor will have a slightly differ-
ent pilot screw setting, the adjustments
below are the recommended settings, the
settings may differ from these recommen-
dations.
Pilot Screw Adjustment:

Sportsman 6x6 500 -- 2 Turns Out
Brass Plug Removed
3. Connect an accurate tachometer that will read in

increments of + or -- 50 RPM such as the PET
2100DX (PN 8712100DX) or the PET 2500 (PN
8712500).
4. Set idle speed to 1200 RPM. Always check
throttle cable freeplay after adjusting idle speed
and adjust if necessary.
2.16
MAINTENANCE
5. Slowly turn mixture screw clockwise using the

pilot screw wrench until engine begins to miss.
6. Slowly turn mixture screw counterclockwise until
idle speed increases to maximum RPM.
Continue turning counterclockwise until idle RPM
begins to drop.
7. Center the pilot screw between the points in Step
5 and 6.
8. Re adjust idle speed if not within specification.
Direction
of travel
1/16″ - 1/8″
Ill. 2 Freeplay
6. Tighten lock nut securely and slide boot

completely in place to ensure a water-tight seal.
THROTTLE CABLE / 7. Turn handlebars from left to right through the
ELECTRONIC THROTTLE entire turning range. If idle speed increases,
check for proper cable routing. If cable is routed
CONTROL (ETC SWITCH) properly and in good condition, repeat adjustment
procedure.
ADJUSTMENT
1. Slide boot off throttle cable adjuster and jam nut.

2. Place shift selector in neutral and set parking
brake. FUEL SYSTEM
3. Start engine and set idle to specified RPM. WARNING
Gasoline is extremely flammable and explosive

under certain conditions.
G Always stop the engine and refuel
Boot Adjuster outdoors or in a well ventilated
Lock- Boot
Sleeve nut area.
G Do not smoke or allow open flames
or sparks in or near the area where
refueling is performed or where
gasoline is stored.
G Do not overfill the tank. Do not fill
the tank neck.
G If you get gasoline in your eyes or if
you swallow gasoline, seek
Ill. 1 medical attention immediately.
G If you spill gasoline on your skin or
clothing, immediately wash it off
with soap and water and change
NOTE: Be sure the engine is at operating clothing.
temperature. See Idle Speed Adjustment. G Never start the engine or let it run in
an enclosed area. Engine exhaust
fumes are poisonous and can
4. Loosen lock nut on in-line cable adjuster (Ill. 1).
result loss of consciousness or
5. Turn adjuster until 1/16″ to 1/8″ freeplay is death in a short time.
achieved at thumb lever. (Ill. 2). After making G Never drain the float bowl when the
adjustments, quickly actuate the thumb lever engine is hot. Severe burns may
several times and reverify freeplay. result.
2.17
MAINTENANCE
FUEL LINES CARBURETOR DRAINING

1. Check fuel lines for signs of wear, deterioration, The carburetor float bowl should be drained
damage or leakage. Replace if necessary. periodically to remove moisture or sediment from the
2. Be sure fuel lines are routed properly and secured bowl, or before extended periods of storage.
with cable ties. CAUTION: Make sure lines are
not kinked or pinched. NOTE: The bowl drain screw is located on the bottom
left side of the float bowl.
3. Replace all fuel lines every two years.
1. Turn fuel valve to the off position.
2. Place a clean container beneath the bowl drain
VENT LINES spigot or bowl drain hose.
Check fuel tank, oil tank, carburetor, battery and 3. Turn drain screw out two turns and allow fuel in
transmission vent lines for signs of wear, the float bowl and fuel line to drain completely.
deterioration, damage or leakage. Replace every two 4. Inspect the drained fuel for water or sediment.
years. 5. Tighten drain screw.
Be sure vent lines are routed properly and secured 6. Turn fuel valve to “ON”.
with cable ties. CAUTION: Make sure lines are not 7. Start machine and check for leaks.
kinked or pinched.
NOTE: All tubes attached to the carburetor must be
check for pinching or blockage, as this will effect
FUEL FILTER engine performance.
The fuel filter should be replaced in accordance with

the Periodic Maintenance Chart or whenever
sediment is visible in the filter.
Fuel Filter Located Close to Carburetor

Drain tube
attached
here
Arrow Indicates Direction of Flow
Drain Screw
Ill. 1
RES
To Carburetor
1. Shut off fuel supply at fuel valve.

2. Remove line clamps at both ends of the filter. OFF
3. Remove fuel lines from filter.
4. Install new filter and clamps onto fuel lines with
arrow pointed in direction of fuel flow.
5. Install clamps on fuel line.
ON
6. Turn fuel valve “ON”.
Ill. 2
7. Start engine and inspect for leaks.
2.18
MAINTENANCE
COMPRESSION TEST BATTERY MAINTENANCE

NOTE: 4-Stroke engines are equipped with an
automatic decompressor. Compression readings will
vary in proportion to cranking speed during the test.
Average compression (measured) is about 50-90 psi
WARNING
during a compression test.
Smooth idle generally indicates good compression.
Low engine compression is rarely a factor in running
condition problems above idle speed. Abnormally Battery electrolyte is poisonous. It contains
high compression can be caused by a decompressor sulfuric acid. Serious burns can result from
malfunction, or worn or damaged exhaust cam lobes. contact with skin, eyes or clothing. Anti-
Inspect camshaft and automatic decompression dote:
mechanism if compression is abnormally high.
External: Flush with water.
A cylinder leakage test is the best indication of engine
condition on models with automatic decompression. Internal: Drink large quantities of water or
Follow manufacturer’s instructions to perform a milk. Follow with milk of magnesia, beaten
cylinder leakage test. (Never use high pressure egg, or vegetable oil. Call physician im-
leakage tester as crankshaft seals may dislodge and mediately.
leak). Eyes: Flush with water for 15 minutes and
get prompt medical attention.
Cylinder Compression Batteries produce explosive gases. Keep
Standard 50-90 PSI sparks, flame, cigarettes, etc. away. Venti-
late when charging or using in an enclosed
Cylinder Leakage space. Always shield eyes when working
Service Limit 10 % near batteries. KEEP OUT OF REACH OF
(Inspect for cause if leakage exceeds 10%) CHILDREN.
ENGINE MOUNTS
The battery is located under the left rear fender.
Inspect rubber engine mounts (A) for cracks or
damage. Check engine fasteners and ensure they
are tight. Battery Location:
Left Rear Fender
View With Seat Removed
NOTE: All Sportsman 6x6 ATV batteries are Low

Maintenance in design and construction. All Low
Maintenance batteries are fully charged and
A tested at the factory before installation. Expected
shelf life is 6--8 months depending on storage
A conditions. As a general rule before placing the
battery into service, check the battery condition
and charge accordingly.
2.19
MAINTENANCE
New Batteries: Batteries must be fully charged

before use or battery life can be reduced by
SPARK PLUG
10-30% of full potential. Charge battery for 3--5 1. Remove spark plug high tension lead. Clean plug
hours at a current equivalent of 1/10 of the area so no dirt and debris can fall into engine
battery’s rated amp/hour capacity (i.e. 12amp hr when plug is removed.
x .10 = 1.2 amp charging). Do not use the 2. Remove spark plug.
alternator to charge a new battery.
3. Inspect electrodes for wear and carbon buildup.
Low--Maintenance batteries are permanently Look for a sharp outer edge with no rounding or
sealed at the time of manufacture. The use of erosion of the electrodes.
lead--calcium and AGM technology instead of
lead--antimony allows the battery acid to be fully
absorbed. For this reason, a Low--Maintenance
battery case is dark and the cell caps are not
removable, since there is no need to check
electrolyte level.
NEVER attempt to add electrolyte or water to a
Low--Maintenance battery. Doing so will damage
the case and shorten the life of the battery. Refer
to the Battery Maintenance Video (PN 9917987) for 4. Clean with electrical contact cleaner or a glass
proper instruction on servicing batteries. bead spark plug cleaner only. CAUTION: A wire
brush or coated abrasive should not be used.
IGNITION TIMING 5. Measure gap with a wire gauge. Refer to
specifications for proper spark plug type and gap.
Refer to Chapter 10 for ignition timing procedures. Adjust gap if necessary by bending the side
electrode carefully. (Ill. 1)
6. If necessary, replace spark plug with proper type.
Ignition Timing 500 Engines:
CAUTION: Severe engine damage may occur if
30°±2° BTDC@5000RPM the incorrect spark plug is used.
7. Apply a small amount of anti-seize compound to
the spark plug threads.
Engine-To-Frame Ground 8. Install spark plug and torque to specification.
Inspect engine-to-frame ground cable connection. Be
sure it is clean and tight. Recommended Spark Plug:
Refer to Specifications
Spark Plug Torque:

14 Ft. Lbs. (19 Nm)
Spark Plug Gap
.036″ (0.9 mm)
2.20
MAINTENANCE
LIQUID COOLING SYSTEM COOLING SYSTEM HOSES

OVERVIEW
The engine coolant level is controlled or maintained
by the recovery system. The recovery system
components are the recovery bottle, radiator filler
neck, radiator pressure cap and connecting hose.
As coolant operating temperature increases, the

expanding(heated)excesscoolantisforcedoutofthe
radiator past the pressure cap and into the recovery
bottle. Asenginecoolant temperature decreasesthe
contracting(cooled)coolantisdrawnbackupfromthe
tank past the pressure cap and into the radiator.
Some coolant level drop on new machines is normal

as the system is purging itself of trappedair. Observe
coolant levels often during the break-in period. 1. Inspect all hoses for cracks, deterioration,
abrasion or leaks. Replace if necessary.
Overheating of engine could occur if air is not fully 2. Check tightness of all hose clamps.
purged from system.
PolarisPremium60/40isalreadypremixedandready CAUTION:
to use. Do not dilute with water.
Do not over-tighten hose clamps at radiator, or radiator
fitting may distort, causing a restriction to coolant flow.
Radiator hose clamp torque is 36 in. lbs. (4 Nm).
COOLANT STRENGTH / TYPE

RADIATOR
Test the strength of the coolant using an antifreeze
hydrometer.
Antifreeze Hydrometer
G A 50/50 or 60/40 mixture of antifreeze and

distilled water will provide the optimum
cooling, corrosion protection, and
antifreeze protection.
G Do not use tap water, straight antifreeze, or
straight water in the system. Tap water 1. Check radiator (A) air passages for restrictions or
contains minerals and impurities which damage.
build up in the system. 2. Carefully straighten any bent radiator fins.
G Straight water or antifreeze may cause the 3. Remove any obstructions with compressed air or
system to freeze, corrode, or overheat. low pressure water.
Polaris 60/40 Anti-Freeze / Coolant COOLING SYSTEM

(PN 2871323) PRESSURE TEST
Refer to Page 3.5 for pressure test procedure.
2.21
MAINTENANCE
COOLANT LEVEL RADIATOR COOLANT LEVEL

INSPECTION INSPECTION
The recovery bottle, located on the left side of the NOTE: This procedure is only required if the cooling
machine, must be maintained between the minimum system has been drained for maintenance and/or
andmaximumlevelsindicatedontherecoverybottle. repair. However, if the recovery bottle has run dry, or
if overheating is evident, the level in the radiator
should be inspected and coolant added if necessary.
WARNING Never remove the pressure cap

Recovery when the engine is warm or hot. Escaping steam can
Bottle cause severe burns. The engine must be cool before
Accessible removing the pressure cap.
Under Side NOTE: Use of a non-standard pressure cap will not
Panel allow the recovery system to function properly.
Front
Cover
With the engine at operating temperature, the coolant
level should be between the upper and lower marks
on the coolant reservoir. If not:
1. Remove reservoir cap. Inner splash cap vent Rack
hole must be clear and open.
2. Fill reservoir to upper mark with Polaris Premium
60/40 Anti Freeze / Coolant or 50/50 or 60/40
mixture of antifreeze and distilled water as
required for freeze protection in your area.
To access the radiator pressure cap:
3. Reinstall cap. Remove the screws securing front rack. Turn handle
NOTE: If overheating is evident, allow system to cool bars full left or right to provide more clearance.
completely and check coolant level in the radiator and Remove front cover by placing your fingers under the
inspect for signs of trapped air in system. front of the cover and pulling upward.
AIR FILTER/PRE-FILTER
SERVICE
It is recommended that the air filter and pre filter be
replaced annually. When riding in extremely dusty
conditions, replacement is required more often.
The pre filter should be cleaned before each ride using
the following procedure:
1. Lift up on the rear of the seat.
2. Pull the seat back and free of the tabs. NOTE:
When reinstalling seat, make sure the slots in the
seat engage the tabs in the fuel tank.
3. Remove clips (6) from air box cover and remove
cover. Inspect the gasket. It should adhere tightly
2.22
MAINTENANCE
to the cover and seal all the way around. filter without folds, creases, or gaps.
Proper Filter Placement
Main Filter
Filter Support
A
Air Box
4. Loosen clamp and remove air filter

assembly. Ill.2 Front
10. Reinstall filter on main filter mount. Place filter

Cover clamp over the assembly and tighten.
Gasket
Filter Clamp
Pre-filter
Main Element
Ill.1
Ill.3
Cleaning:
5. Slip the pre-filter element off of main element.
Clean the pre filter with hot soapy water. NOTE: The air filter should rest on the filter support.
Proper placement of the air filter is important to
6. Rinse and dry thoroughly.
prevent rattles and air leaks. See Illustration 2.
7. Inspect element for tears or damage.
8. Inspect main filter and replace if necessary. If the 11. Install air box cover and secure with clips.
filter has been soaked with fuel or oil it must be
replaced.
Installation:
NOTE: Apply a small amount of general purpose
grease to the sealing edges of the filter before
reinstalling.
9. Reinstall pre-filter element over main filter. Be
sure the element covers entire surface of main
2.23
MAINTENANCE
AIR BOX SEDIMENT TUBE

Periodically check the air box drain tube located Typical Breather Filter Location
toward the rear of the machine. Drain whenever
deposits are visible in the clear tube.
1. Remove drain plug from end of sediment tube.
2. Drain tube.
3. Reinstall drain plug.
In-Line Breather Filter

Location A
BREATHER HOSE
1. Be sure breather line is routed properly and
secured in place.
CAUTION: Make sure lines are not kinked or
Sediment Tube
pinched.
Ill.1 RECOIL HOUSING
NOTE: The sediment tube will require more frequent
service if the vehicle is operated in wet conditions or
at high throttle openings for extended periods. Crankcase Drain
BREATHER FILTER
INSPECTION
Four cycle ATV engines are equipped with a breather
filter. The in-line filter is similar in appearance to a fuel
filter, and is visible on the left side (Location A).
In-line breather filters can be installed with the arrow
pointing in either direction. Recoil Drain
G -- Drain the housing periodically to remove

moisture.
G -- Drain the recoil housing after operating the
ATV in very wet conditions. This should
also be done before storing the ATV. The
drain screw is located at the bottom of the
recoil housing. Remove the screw with a
10 mm wrench. Reinstall screw once
housing has been drained.
G CAUTION: Make sure the manual start
handle is fully seated on the recoil
housing, especially when travelling in wet
areas. If it is not sealed properly, water
may enter the recoil housing and damage
components.
2.24
MAINTENANCE
G -- Water will enter the recoil housing if the between the top line and the bottom line on the
starter handle is disengaged from the rope dipstick. Add oil as indicated by the level on the
guide when under water. dipstick. Do not overfill.
G -- After travelling in wet areas the recoil
housing and starter should always be NOTE: A rising oil level between checks in cool
drained completely by removing the weather driving can indicate contaminants collecting
recoil. in the oil reservoir. If the oil level is over the full mark,
change the oil.
G -- Do not open the crankcase drain unless
the engine has ingested water. Some
engine oil will be lost if crankcase drain is OIL AND FILTER CHANGE
opened.
G -- If recoil handle seal has been damaged,
the handle should be replaced.
WARNING
Personal injury can occur when han-
dling used oil. Hot oil can cause burns
ENGINE OIL SERVICE or skin damage.
NOTICE:
Care must be taken to ensure that fluids are
contained. Be prepared to collect the fluid
with suitable containers before opening any
compartment or disassembly any component
containing fluids.
1. Place vehicle on a level surface.

2. Run engine two to three minutes until warm. Stop
engine.
A 3. Clean area around drain plug (B) at bottom of oil
tank. Remove drain plug (B).
4. Place a drain pan beneath oil tank and remove
drain plug. CAUTION: Oil may be hot. Do not
allow hot oil to come into contact with skin as
The oil tank is located on the left side of the vehicle. serious burns may result.
To check the oil level:
1. Set machine on a level surface.
2. Start and run engine for 20-30 seconds. This will
return oil to its true level in the oil tank. D
3. Stop engine, remove dipstick (A) and wipe dry
with a clean cloth.
4. Reinstall dipstick, screw the dipstick into place.
A
NOTE: The dipstick must be screwed completely in B C
to ensure accurate measurement.
5. Allow oil to drain completely.

6. Replace sealing washer (A) on drain plug (B).
ADD 8 OZ. NORMAL FULL NOTE: The sealing surfaces on drain plug and oil
tank should be clean and free of burrs, nicks or
scratches.
7. Reinstall drain plug (B) and torque to 14 ft. lbs. (19
Maintain Oil Level In Normal Range Nm).
0W/40 8. Loosen clamp (D).
Screw Dipstick in completely to check
9. Remove oil hose from screen fitting (C) on bottom
5. Remove dipstick and check to see that the oil of oil tank.
level is in the normal range. The oil should be 10. Remove screen fitting (C) and clean the screen.
2.25
MAINTENANCE
11. Apply Loctitet Thread Sealant 565 (PN

2871956) or an equivalent pipe thread sealant or
PTFE sealant tape to clean, oil free threads of Crankcase Drain
fitting (C).
12. Install fitting (C) and torque to 14-17 ft.lbs. (19--23
Nm).
13. Install oil hose on fitting (C) and re--install clamp
(D).
D Engine Sump Drain Plug - Bottom View
18. Approximately 1 cup of engine oil will remain in

the crankcase. To drain, remove drain plug found
on lower right side of crankcase.
NOTE: The sealing surfaces on the drain plug and
C crankcase should be clean and free of burrs, nicks or
scratches.
19. Reinstall drain plug.
20. Remove dipstick and fill tank with 2 quarts (1.9 L)
14. Place shop towels beneath oil filter (E) . Use Oil of Polaris Premium 4 Synthetic Oil (PN 2871844).
Filter Wrench (PV--43527), turn filter
counterclockwise to remove. 21. Place gear selector in Park and set parking brake.
NOTE: Clamp or pinch off the vent line 2” from the oil
tank as shown below in the Oil Pump Priming
Procedure for the 400/500 engine.
22. Re-check the oil level on the dipstick and add oil
as necessary to bring the level to the upper mark
on the dipstick.
15. Using a clean dry cloth, clean filter sealing surface

on crankcase.
16. Lubricate O-ring on new filter with a film of engine
oil. Check to make sure the O-ring is in good
condition.
17. Install new filter and turn by hand until filter gasket
contacts the sealing surface, then turn and
additional 1/2 turn.
2.26
MAINTENANCE
23. Dispose of used filter and oil properly.
(A) Vent Hose to Air Box

Oil Tank Drain Plug Torque:
14 ft. lbs. (19 Nm) Oil Lines
To Engine
Crankcase Drain Plug Torque:
14 ft. lbs. (19 Nm)
Oil Filter Torque:

Turn by hand until filter gasket
contacts sealing surface, then
turn an additional 1/2 turn
Oil Filter Wrench:

(PV--43527)
To Air Box
Approx.
Oil Tank Screen Fitting Torque: 2I
14-17 ft. lbs. (19 Nm --23 Nm)
Recommended Engine Oil:
Polaris Premium 4 All Season

Synthetic, 0W--40, (PN 2871281) Slit
Oil Tank Pinch Off
Ambient Temperature Range:
-40° F to 120° F (A) Vent Hose
VALVE CLEARANCE
OIL PUMP PRIMING Inspect and adjust valve clearance while the engine
is cold and the piston positioned at Top Dead Center
PROCEDURE (TDC) on compression stroke.
1. Remove the seat.
NOTE: This priming procedure must be 2. Remove body panels and fuel tank as necessary
performed whenever the oil hose connection to gain access to valve cover.
between the oil tank and pump inlet has been 3. Remove the spark plug high tension lead and
disconnected. remove the spark plug. CAUTION: Place a clean
shop towel into the spark plug cavity to prevent
1. Clamp or pinch off vent line (A) approximately 2I dirt from entering.
from oil tank to avoid the end of oil tank vent fitting, 4. Remove rocker cover bolts, cover and gasket.
and the vent line’s pressure relief slit
2. Run engine at idle for 10--20 seconds. NOTE: It may be necessary to tap cover lightly
with a soft-faced hammer to loosen it from the
3. Shut engine off. Remove the vent line clamp. A
cylinder head.
rush of air should be heard, indicating the oil pump
is properly primed and ready for field operation. 5. Remove timing inspection plug from recoil
Note: If the system is primed properly you should housing.
hear some air release. If you do not, the system CAUTION: Failure to position the crankshaft at TDC
has not primed. Repeat the process if necessary. on compression stroke will result in improper valve
adjustment.
2.27
MAINTENANCE
6. Repeat this step for the other intake valve.
Sprocket alignment pin facing up

INTAKE VALVE CLEARANCE
.006″ (.15 mm)
EXHAUST VALVE
CLEARANCE ADJUSTMENT
500 Engine
Crankshaft-to-Camshaft Centerline
6. Rotate engine slowly with recoil rope, watching

the intake valve(s) open and close.
NOTE: At this point watch the camshaft sprocket
locating pin and slowly rotate engine until locating pin
is facing upward, directly in line with the crankshaft to
camshaft center line as shown. The camshaft lobes
should be pointing downward.
Feeler Gauge for Both Valves
NOTE: The exhaust valves share a common rocker

arm, and must be adjusted using two feeler gauges.
1. Insert .006 feeler gauge(s) between end of
exhaust valve stem and adjuster screw(s).
2. Loosen locknut(s) and turn adjuster screw(s) until
there is a slight drag on feeler gauge(s). The
Valve/Clutch Adjuster Tool (PA--44689) can be
7. Verify accurate TDC positioning by observing the used to adjust the 500 engines valves. NOTE:
“T” mark aligned with the pointer in the timing Both feeler gauges should remain inserted during
inspection hole. In this position there should be adjustment of each valve.
clearance on all valves.
EXHAUST VALVE CLEARANCE
INTAKE VALVE CLEARANCE .006″ (.15 mm)
ADJUSTMENT
3. When clearance is correct, hold adjuster screw
1. Insert a .006″ (.15mm) feeler gauge between end and tighten locknut securely
of intake valve stem and clearance adjuster 4. Re-check the valve clearance.
screw. 5. Repeat adjustment procedure if necessary until
2. Using a 10 mm wrench and a screwdriver, loosen clearance is correct with locknut secured.
adjuster lock nut and turn adjusting screw until
there is a slight drag on the feeler gauge. STEERING
3. Hold adjuster screw and tighten adjuster lock nut
securely. The steering components should be checked
periodically for loose fasteners, worn tie rod ends, and
4. Re-check the valve clearance. damage. Also check to make sure all cotter pins are
5. Repeat adjustment procedure if necessary until in place. If cotter pins are removed, they must not be
clearance is correct with locknut secured. re-used. Always use new cotter pins.
2.28
MAINTENANCE
Replace any worn or damaged steering components. and hub by pushing inward and
Steering should move freely through entire range of pulling outward.
travel without binding. Check routing of all cables, G -- If abnormal movement is detected,
hoses, and wiring to be sure the steering mechanism inspect the hub and wheel assembly
is not restricted or limited. NOTE: Whenever steering to determine the cause ( possible
components are replaced, check front end alignment. loose wheel nuts or loose front hub
Use only genuine Polaris parts. components).
WARNING
Due to the critical nature of the procedures out-
lined in this chapter, Polaris recommends
steering component repair and adjustment be
performed by an authorized Polaris MSD--certi-
fied technician when replacing worn or dam-
aged steering parts. Use only genuine Polaris
replacement parts.
One of two methods can be used to measure toe

alignment. The string method and the chalk method.
If adjustment is required, refer to following pages for
procedure.
Check for Loose Wheel or Hub

TIE ROD END / STEERING
INSPECTION G -- Refer to the Body/Steering Chapter
5 or Final Drive Chapter 7 for service
G -- To check for play in the tie rod end, procedures.
grasp the steering tie rod, pull in all
directions feeling for movement.
G -- Repeat inspection for inner tie rod CAMBER AND CASTER
end on steering post.
The camber and caster are non-adjustable.
FRAME, NUTS, BOLTS,

FASTENERS
Periodically inspect the torque of all fasteners in
accordance with the maintenance schedule. Check
that all cotter pins are in place. Refer to specific
fastener torques listed in each chapter.
G -- Replace any worn steering

components. Steering should move
freely through entire range of travel
without binding.
G -- Elevate front end of machine so front
wheels are off the ground. Check for
any looseness in front hub / wheel
assembly by grasping the tire firmly
at top and bottom first, and then at
front and rear. Try to move the wheel
2.29
MAINTENANCE
WHEEL ALIGNMENT WHEEL ALIGNMENT

METHOD 1: METHOD 2: CHALK
STRAIGHTEDGE OR STRING 1. Place machine on a smooth level surface.
Be sure to keep handlebars centered. See notes 2. Set handlebars in a straight ahead position and
below. secure handlebars in this position. NOTE: The
steering arm “frog” can be used as an indicator of
whether the handlebars are straight. The frog
NOTE: String should just touch side sur- should always point straight back from the
face of rear tire on each side of machine. steering post.
3. Place a chalk mark on the center line of the front
tires approximately 10″ (25.4 cm) from the floor or
as close to the hub/axle center line as possible.
NOTE: It is important that the height of both
marks be equally positioned in order to get an
accurate measurement.
4. Measure the distance between the marks and
record the measurement. Call this measurement
“A”.
5. Rotate the tires 180° by moving vehicle forward or
Rear rim backward. Position chalk marks facing rearward,
Measure measure- even with the hub/axle centerline.
from string ment should 6. Again measure the distance between the marks
to rim at be 1/16″ to and record. Call this measurement “B”. Subtract
front and 1/8″ (.2 to .3 measurement “B” from measurement “A”. The
rear of rim. cm) more difference between measurements “A” and “B” is
than front rim the vehicle toe alignment. The recommended
measure- vehicle toe tolerance is 1/8″ to 1/4″ (.3 to .6 cm)
ment. 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)
TOE ALIGNMENT
ADJUSTMENT
If toe alignment is incorrect, measure the distance
between vehicle center and each wheel. This will tell
you which tie rod needs adjusting. NOTE: Be sure
handlebars are straight ahead before determining
which tie rod(s) need adjustment.
NOTE: The steering post arm can be used

as an indicator of whether the handlebars
are straight. The arm should always point
straight back from the steering post.
2.30
MAINTENANCE
CAUTION: During tie rod adjustment, it is very To check front hub fluid:
important that the following precautions be taken
when tightening tie rod end jam nuts. If the rod end 1. Place vehicle on a level surface.
is positioned incorrectly it will not pivot, and may
2. Turn wheel until front hub fill/check plug is in either
break.
the 4 o’clock or 8 o’clock position.
3. Remove fill/check plug.
Hold
4. Add Polaris Demand Drive Hub Fluid if necessary
Rod End
until fluid trickles out. NOTE: Do not force the
fluid into the hub under pressure or seal damage
may occur.
5. Reinstall plug.
6. Repeat procedure for other hub.
Correctly Incorrectly
Tightened Tightened
Jam Nut Jam Nut
Ill.2 FRONT HUB FLUID CHANGE
To adjust toe alignment:

G -- Hold tie rod end to keep it from rotating.
G -- Loosen jam nuts at both end of the tie rod.
G -- Shorten or lengthen the tie rod until
alignment is as required to achieve the
proper toe setting as specified in
Method 1 or Method 2.
G IMPORTANT: When tightening the tie rod
end jam nuts, the rod ends must be held
parallel to prevent rod end damage and
premature wear. Damage may not be
immediately apparent if done incorrectly.
See illustration 2.
G -- After alignment is complete, torque jam
nuts to 12-14 ft. lbs. (16-19 Nm).
1. Place a drain pan beneath the hub.
FRONT HUB FLUID LEVEL 2. Remove check/fill plug.
INSPECTION 3. Turn the hub to the 6 o’clock position and drain the
fluid
into the drain pan.
4. Turn wheel until front hub fill/check plug is in either
the 4 or 8 o’clock position.
5. Add Polaris Demand Drive Hub Fluid (PN
2871654) until fluid trickles out. NOTE: Do not
force the fluid into the hub under pressure or seal
damage may occur.
Polaris Demand Drive Hub Fluid:

(PN 2871654) - 8 oz.
(PN 2872277) - 2.5 gallon
2.31
MAINTENANCE
EXHAUST PIPE
WARNING
G Do not perform clean out immediately af-
ter the engine has been run, as the ex-
haust system becomes very hot. Serious
burns could result from contact with ex-
haust components.
G To reduce fire hazard, make sure that
there are no combustible materials in the
area when purging the spark arrestor.
4. If particles are still suspected to be in the muffler,
G Wear eye protection. back the machine onto an incline so the rear of the
G Do not stand behind or in front of the ve- machine is one foot higher than the front. Set the
hicle while purging the carbon from the hand brake and block the wheels. Make sure the
spark arrestor. machine is in neutral and repeat Steps 2 and 3.
G Never run the engine in an enclosed SEE WARNING
area. Exhaust contains poisonous car-
bon monoxide gas. 5. If particles are still suspected to be in the muffler,
drive the machine onto the incline so the front of
G Do not go under the machine while it is the machine is one foot higher than the rear. Set
inclined. Set the hand brake and block the hand brake and block the wheels. Make sure
the wheels to prevent roll back.
the machine is in neutral and repeat Steps 2 and
Failure to heed these warnings could result in 3. SEE WARNING
serious personal injury or death.
The exhaust pipe must be periodically purged of

accumulated carbon as follows: 1 ft.
1. Remove the clean out plugs located on the

bottom of the muffler as shown in illustration 1.
6. Repeat steps 2 through 5 until no more particles
are expelled when the engine is revved.
7. Stop the engine and allow the arrestor to cool.
8. Reinstall the clean out plugs.
Ill.1 Clean Out Plug BRAKE SYSTEM INSPECTION

2. Place the transmission in neutral and start the The following checks are recommended to keep the
engine. Purge accumulated carbon from the brake system in good operating condition. Service life
system by momentarily revving the engine of brake system components depends on operating
several times. conditions. Inspect brakes in accordance with the
maintenance schedule and before each ride.
3. If some carbon is expelled, cover the exhaust
outlet and rap on the pipe around the clean out G -- Keep fluid level in the master cylinder
plugs while revving the engine several more reservoir to the indicated level inside
times. reservoir.
2.32
MAINTENANCE
G -- Use Polaris DOT 3 Brake Fluid (PN

2870990).
BRAKE PAD INSPECTION
Sight Pads should be changed when the friction material is
Parking Brake worn to 3/64″ (.1 cm), or about the thickness of a dime.
Glass Lock
3/64″
(.1cm)
Minimum
Rear Master Cylinder Reservoir Thickness
HOSE/FITTING INSPECTION
Max
Min Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
fittings and replace any worn or damaged parts.
AUXILIARY BRAKE TESTING

The auxiliary brake should be checked for proper
G -- Check brake system for fluid leaks. function.
G -- Check brake for excessive travel or
spongy feel.
G -- Check friction pads for wear, damage
or looseness.
Auxiliary Brake
G -- Check surface condition of the disc.
G -- Inspect thickness of brake pad friction
material.
Support the rear wheels off the ground.

While turning the rear wheels by hand, apply the
auxiliary foot brake. This brake should not stop the
wheels from turning until the lever is half way between
its rest position and bottoming on the footrest.
AUXILIARY BRAKE
ADJUSTMENT (HYDRAULIC)
Use the following procedure to inspect the hydraulic
auxiliary (foot) brake system and adjust or bleed if
necessary:
2.33
MAINTENANCE
First, check foot brake effectiveness by applying 50 lb. within specification, adjust the chains. If the chains
(approx.) downward force on the pedal. The top of the appear dry (no sign of lubrication), apply Chain Lube
pedal should be at least 1 inch, (25.4mm) above the (PN 2872073), coating the plates and rollers as often
surface of the footrest. as needed.
1/8, to 1/4, MIDDLE AXLE CHAIN

Free Play ADJUSTMENT
50 lbs 1″ or greater
Drive Chain Adjustment
Floorboard
If less than one inch, two things must be examined:

Free Play:
Free play of the brake pedal should be 1/8 - 1/4 A
inch (3.2 - 6.35 mm).
If free play is excessive, inspect pedal, linkage, and 1. Loosen chain guard.
master cylinder for wear or damage and replace any 2. Loosen two eccentric locking bolts (A).
parts as needed. 3. Insert a pin punch (B) through the sprocket hub
Bleeding: and into the eccentric axle housing.
4. Roll the vehicle ahead or back to adjust chain
If free play is correct and brake pedal travel is still slack to the proper dimension. Correct chain
excessive, air may be trapped somewhere in the slack adjustment is 3/8”″ to 1/2″ (6.77--12.70
system. Bleed the hydraulic auxiliary brake system in mm) at the tightest point in the chain.
a conventional manner, following the procedure
outlined in Brake Chapter 9. 5. Roll the vehicle ahead and check tension in
several places around the chain.
DRIVE CHAIN 6. Tighten the eccentric locking bolts to 40 ft. lbs. (54
Nm).
INSPECTION/ADJUSTMENT 7. Reinstall chain guard.
NOTE: Reposition chain guide to allow 1/8″ (.3 cm)
CAUTION: clearance between sprocket and guide.
Never adjust or operate the vehicle with the rear drive
chain slack out of the specified range, as severe
damage to the transmission and drive components can
REAR AXLE DRIVE CHAIN
result. ADJUSTMENT
CHAIN INSPECTION To adjust the rear axle drive chain on 6x6 models,
loosen the rear most eccentric and rotate using the
Check the amount of chain slack by moving the same method as outlined for the middle axle chain.
vehicle slightly forward to gain slack at the top side of Total slack, however, should be adjusted to 3/8″ to
the chain. Then pull up and down on the chain. Total 1/2” (6.77--12.70 mm) at the tightest point on the
slack should be as specified below. If slack is not chain.
2.34
MAINTENANCE
Chain Deflection FRONT SUSPENSION

Middle Axle: G Compress and release front suspension.
3/8”--1/2” (6.77--12.70 mm) Damping should be smooth throughout
the range of travel.
G Check all front suspension components for
wear or damage.
G Inspect front strut cartridges for leakage.
CENTER/REAR SUSPENSION
G Compress and release rear suspension.
Damping should be smooth throughout
the range of travel.
Rear Axle:
3/8”--1/2” (6.77--12.70 mm) G Check all rear suspension components for
wear or damage.
G Inspect shock for leakage.
Chain Deflection
Shock Spanner Wrench
Middle Axle:
3/8” -- 1/2 “ (6.77--12.70 mm) (PN 2870872)
Rear Axle:
3/8” -- 1/2 “ (6.77--12.70 mm)
CV SHAFT BOOT
INSPECTION
SUSPENSION SPRING Inspect the cv shaft boots in the front of the ATV for
damage, tears, wear, or leaking grease. If the rubber
PRELOAD ADJUSTMENT boot exhibits any of these symptoms, replace the
boot. Refer to Chapter 7 for CV boot replacement, or
have you Polaris dealer replace the boot.
Center Spring
Adjustment Ring
1 2
Operator weight and vehicle loading affect

suspensionspringpreloadrequirements. Adjustas Inspect Boots
necessary, using the spanner wrench (2) supplied
in your ATV tool kit to turn the adjustment cam (1).
2.35
MAINTENANCE
CONTROLS WHEEL, HUB, AND SPINDLE

TORQUE TABLE
Item Specification
Front Wheel Nuts 27 Ft. Lbs. (27 Nm)
Mid / Rear Wheel Nuts 50 Ft. Lbs.(68 Nm)
Front Spindle Nut Refer to procedure listed in
Chapter 7
Rear Hub Retaining Nut 80 Ft. Lbs. (109 Nm)
WHEEL REMOVAL FRONT OR

REAR
Front Wheel
Check controls for proper operation, positioning See Chapter 7

and adjustment. for Hub Nut
Brake control and switch must be positioned to allow

brake lever to travel throughout entire range without
contacting switch body.
27 ft.lbs.
Throttle Rear Wheel

assembly
clamp Tapered nuts - install with
tapered side against wheel
50 ft.lbs.
Align clamp
edge with 80 ft.lbs.
knurl
1. Stop the engine, place the transmission in gear
and lock the parking brake.
2. Loosen the wheel nuts slightly.
Align throttle control assembly clamp with knurl on
handlebar 3. Elevate the side of the vehicle by placing a
suitable stand under the footrest frame.
4. Remove the wheel nuts and remove the wheel.
WHEEL INSTALLATION
WHEELS 1. With the transmission in gear and the parking
brake locked, place the wheel in the correct
Inspect all wheels for runout or damage. Check wheel position on the wheel hub. Be sure the valve stem
nuts and ensure they are tight. Do not over tighten the is toward the outside and rotation arrows on the
wheel nuts. tire point toward forward rotation.
2.36
MAINTENANCE
2. Attach the wheel nuts and finger tighten them. Tire Tread Depth
3. Lower the vehicle to the ground.
4. Securely tighten the wheel nuts to the proper Always replace tires when tread depth is worn to
torque listed in the table above. 1/8″ (3 mm) or less.
CAUTION:
If wheels are improperly installed it could affect
Tread
vehicle handling and tire wear. On vehicles with Depth 1/8I (3 mm)
tapered rear wheel nuts, make sure tapered end of nut
goes into taper on wheel.
TIRE PRESSURE
CAUTION:
Maintain proper tire pressure. Refer to the warning
tire pressure decal applied to the vehicle.
Tire Pressure Inspection (PSI - Cold)

Center Front Center
5 PSI 5 PSI 5 PSI
WARNING
TIRE INSPECTION Operating an ATV with worn tires will in-
crease the possibility of the vehicle skid-
G Improper tire inflation may affect ATV ding easily with possible loss of control.
maneuverability. Worn tires can cause an accident.
G When replacing a tire always use original
Always replace tires when the tread
equipment size and type. depth measures 1/8″ (.3 cm) or less.
G The use of non-standard size or type
tires may affect ATV handling.
2.37
MAINTENANCE
NOTES
2.38
GENERAL INFORMATION
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3.2

EH50PL Service Data . . . . . . . . . . . . . . . . . . . . . . . . 3.3-3.4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Torque Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Piston Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Cooling System Bleeding Procedure . . . . . . . . . . . 3.6
Cooling System Tests/Routing/Specifications . . . 3.7
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . 3.8-3.9
Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Crankshaft Runout Inspection/Straightening . . . . 3.10
EH50PL Engine Lubrication . . . . . . . . . . . . . . . . . . 3.10
EH50PL Oil Pump Priming Procedure . . . . . . . . . . 3.11
EH50PL Lubrication/Oil Flow . . . . . . . . . . . . . . . . . 3.11
EH50PL Engine Oil Flow charts . . . . . . . . . . . . . . . 3.12
EH50PL Engine Exploded Views . . . . . . . . . . . . . . 3.13
EH50PL Engine Top End Disassembly . . . . . . . . . 3.14-3.23
EH50PL Valve Seat Service . . . . . . . . . . . . . . . . . . 3.23-3.26
EH50PL Cylinder Head Assembly . . . . . . . . . . . . . 3.26-3.27
EH50PL Cylinder Service . . . . . . . . . . . . . . . . . . . . 3.27-3.31
EH50PL Engine Bottom End Disassembly . . . . . . 3.31-3.37
EH50PL Crankcase & Bearing Assembly . . . . . . . 3.37--3.38
EH50PL Crankshaft End Play Inspection . . . . . . . 3.38-3.39
EH50PL Counter Balancer End Play Inspection. . 3.40
EH50PL Oil Pump Shaft End Play Inspection . . . 3.40--3.41
EH50PL Engine Assembly/Inspection . . . . . . . . . . 3.41-3.51
Sealed Recoil Disassembly/Inspection . . . . . . . . . 3.51--3.52
Sealed Recoil Assembly . . . . . . . . . . . . . . . . . . . . . 3.52
Spark Plug Fouling Checklist . . . . . . . . . . . . . . . . . 3.53
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53--3.54
3.1
GENERAL INFORMATION
TORQUE SPECIFICATIONS
Fastener Size EH50PLE
Ft. Lbs. (Nm)
Blind Plug (Oil Pressure) 1/8 Pipe 6.5-11 (9-15 Nm)
Thread
Camshaft Sprocket 6mm 5-6.5 (7-9 Nm)
Camshaft Chain Tensioner Lever 6mm 5-6.5 (7-9 Nm)
Camshaft Chain Tensioner 6mm 5-6.5 (7-9 Nm)
Camshaft Chain Tensioner Cap 11mm 14-19 (20-25 Nm)
Carburetor Adaptor 8mm 12-14 (16-20 Nm)
Crankcase 8mm 14-15 (19-21 Nm)
Crankshaft Slotted Nut (Cam Chain Drive Sprocket) 28mm 35-51 (47-69 Nm)
Cylinder Base Bolts 10mm 45-49 (61-67 Nm)
6mm 6-8 (9-11 Nm)
Cylinder Head Bolts 11mm Refer to Engine
6mm Assembly for
torque procedure
Drive Clutch Bolt 7/16 - 20 40 (55 Nm)
Flywheel 16mm 58-72 (78-98 Nm)
Oil Delivery Pipe 12mm 11-15 (15-21 Nm)
Oil Drain Bolt (Crankcase) 14mm 14-17 (19-23 Nm)
Oil Filter Pipe Fitting 20mm 36-43 (49-59 Nm)
Oil Hose Fitting 1/8 Pipe 6.5-11 (9-15 Nm)
Thread
Hard Metal Oil Line Banjo Fitting N/A 11--16 ft. lbs.
(15--21 Nm)
Oil Pump 6mm 5-6.5 (7-9 Nm)
Oil Pump Case Screw 5mm 1.5-2 (2-3 Nm)
One Way Valve 11mm 14-19 (20-25 Nm)
Recoil Housing 6mm 5-6.5 (7-9 Nm)
Rocker Cover 6mm 7-8 (9-11 Nm)
Rocker Support 8mm 8-10 (11-13 Nm)
Rocker Adjuster Screw 6mm 6-7 (8-10 Nm)
Water Pump Impeller Nut 6mm 5-6.5 (7-9 Nm)
Water Pump Housing Cover 6mm 5-6.5 (7-9 Nm)
Stator Plate 6mm 5-6.5 (7-9 Nm)
Starter Motor 6mm 5-6.5 (7-9 Nm)
Spark Plug 14mm 9-11 (12-15 Nm)
Thermistor ---- 26 ± 2.1 (35 ± 3
Nm)
3.2
GENERAL INFORMATION
EH50PLE10 ENGINE SERVICE DATA

Cylinder Head / Valve EH50PLE10
Rocker Arm Rocker arm ID .8669-.8678″ (22.020-22.041 mm)
Rocker shaft OD .8656-.8661″ (21.987-22.0 mm)
Rocker shaft Oil Clear- Std .0008-.0021″ (.020-.054 mm)
ance Limit .0039″ (.10 mm)
Camshaft Cam lobe height
g In Std 1.2884-1.2924″ (32.726-32.826 mm)
Limit 1.2766″ (32.426 mm)
Ex Std 1.2884-1.2924″ (32.726-32.826 mm)
Limit 1.2766″ (32.426 mm)
Camshaft jjournal OD Mag 1.4935-1.4941″ (37.935-37.950 mm)
PTO 1.4935-1.4941″ (37.935-37.950 mm)
Camshaft jjournal bore ID Mag 1.4963-1.4970″ (38.005-38.025 mm)
PTO 1.4963-1.4970″ (38.005-38.025 mm)
Camshaft Oil clearance Std .0022-.0035″ (.055-.090 mm)
Limit .0039″ (.10 mm)
Cylinder
y Head Surface warpage limit .0020″ (.05 mm)
Standard height 3.870″ (98.3 mm)
Valve Seat Contactingg width In Std .028″ (.7 mm)
Limit .055″ (1.4 mm)
Ex Std .039″ (1.0 mm)
Limit .071″ (1.8 mm)
Valve Guide Inner diameter .2362-.2367″ (6.0-6.012 mm)
Protrusion above head .689-.709″ (17.5-18.0 mm)
Valve Margin
g thickness In Std .039″ (1.0 mm)
Limit .031″ (.8 mm)
Ex Std .047″ (1.2 mm)
Limit .031″ (.8 mm)
Valve Stem diameter In .2343-.2348″ (5.950-5.965 mm)
Ex .2341-.2346″ (5.945-5.960 mm)
Stem oil clearance Std In .0014-.0024″ (.035-.062 mm)
Ex .0016-.0026″ (.040-.067 mm)
Limit .0059″ (.15 mm)
Overall length
g In 3.976″ (101.0 mm)
Ex 3.984″ (101.2 mm)
Valve Spring
p g Overall length
g Std 1.654″ (42.0 mm)
Limit 1.575″ (40.0 mm)
Squareness .075″ (1.9 mm)
3.3
GENERAL INFORMATION
EH50PLE10 ENGINE SERVICE DATA

Cylinder / Piston / Connecting Rod EH50PLE10
Cylinder Surface warpage limit (mating with .0020″ (.05 mm)
cylinder head)
Cylinder bore Std 3.6221-3.6228″ (92.00-92.02 mm)
Taper limit .0020″ (.050 mm)
Out of round limit .0020″ (.050 mm)
Piston clearance Std .0006-.0018″ (.015-.045 mm)
Limit .0024″ (.060 mm)
Boring limit .020″ (.5 mm)
Piston Outer diameter Std 3.6204-3.6215″ (91.970-91.985 mm)
.0098″ (.25 3.6304-3.6310 (92.21-92.23 mm)
mm) OS
.0197″ (.50 3.6403-3.6407 (92.46-92.47 mm)
mm) OS
Standard inner diameter of piston .9055-.9057″ (23.0-23.006 mm)
pin bore
Piston Pin Outer diameter .9053-.9055″ (22.994-23.0 mm)
Standard clearance-piston pin to pin .0002-.0003″ (.004-.008 mm)
bore
Degree of fit Piston pin must be a push (by hand) fit
at 68° F (20° C)
Piston Ring
g Piston ring
g installed Topp Std .0079-.0138″ (.20-.36 mm)
gap ring Limit .039″ (1.0 mm)
Second Std .0079-.0138″ (.20-.36 mm)
ring Limit .039″ (1.0 mm)
Oil ring
g Std .0079-.0276″ (.20-.70 mm)
Limit .059″ (1.5 mm)
Piston Ring
g Standard clearance Top p Std .0016-.0031″ (.040-.080 mm)
- ring Limit .0059″ (.15 mm)
piston ring to ring
Second Std .0012-.0028″ (.030-.070 mm)
groove
ring Limit .0059″ (.15 mm)
Connecting
g Connecting rod small end ID .9058-.9063″ (23.007-23.020 mm)
Rod Connecting g rod small end ra- Std .0003-.0010″ (.007-.026 mm)
dial clearance Limit .0020″ (.05 mm)
Connecting g rod bigg end side Std .0039-.0256″ (.1-.65 mm)
clearance Limit .0315″ (.80 mm)
Connecting g rod bigg end radial Std .0004-.0015″ (.011-.038 mm)
clearance Limit .0020″ (.05 mm)
Crankshaft Crankshaft runout limit .0024″ (.06 mm)
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter;
OD: Outer Diameter; Mag: Magneto Side; PTO: Power
Take Off Side
3.4
GENERAL INFORMATION
SPECIAL TOOLS PISTON IDENTIFICATION

PART NUMBER TOOL The piston may have an identification mark or the
DESCRIPTION piston may not have an identification mark for
2872105 Water Pump piston placement. If the piston has an identification
Mechanical Seal mark, follow the directions for piston placement
Puller
below. If the piston does not have an identification
2200634 Valve Seat mark, the direction for placement of the piston does
Reconditioning Kit
not matter.
2870390 Piston Support
Block Note the directional and identification marks when
2871043 Flywheel Puller viewing the pistons from the top. The letter “F”, “ !
2871283 Crankshaft/Water
”, “ "” or : must always be toward the flywheel side
Pump Seal Install of the engine. The other numbers are used for
Kit identification as to diameter, length and design. Four
5131135 Water Pump stroke engine rings are rectangular profile. See text
Install Kit for oil control ring upper rail installation. Use the
information below to identify pistons and rings.
Engine Oversize Piston Standard

Model No. Available* Length Piston
ENGINE FASTENER TORQUE Identifier
(mm)
PATTERNS EH50PLE10 .25 72mm C
Tighten cylinder head, cylinder base, and crankcase .50
fasteners in 3 steps following the sequence outlined
below. *Pistons and rings marked 25 equal .25mm (.010I)
oversized
Pistons and rings marked 50 equal .50mm (.020I)
6mm oversized
3 2
5 COOLING SYSTEM
6 WARNING: Never remove radiator cap when engine
1 4
is warm or hot. The cooling system is under pressure
and serious burns may result. Allow the engine and
Cylinder Head cooling system to cool before servicing.
Cylinder Base
Pattern FLOW
Radiator
7 5 9 10
3 1
8 Thermostat Water
Pump
2
4 6
Crankcase Cylinder Cylinder

Pattern Head
3.5
GENERAL INFORMATION
COOLING SYSTEM -- 4--STROKE BLEEDING PROCEDURE
Use this procedure when a unit overheats and no appar-

ent leaks in the cooling system are found.
Pump hose by
Note: If the coolant level is LOW in the radiator, or if there hand to help
are leaks in the system, the coolant system will not draw purge system
coolant from the reservoir tank.
1. Park Machine on a flat surface. Remove radiator cap and
top off coolant. Leave the cap off of the radiator. Start and idle
machine for 5-10 minutes until steam is visible in the radiator Squeeze Hose
cap area. Here to Help
2. Stop the engine and let cool for a few minutes or until a Purge Air From
System
“glug” is seen at the filler neck or there is a dropping of the
coolant level, indicating that coolant has been pulled into the
system.
Important Tips: Slowly squeezing the hose after the bend
below the filler neck will aid in purging the system of air.
Pump the hose using your hand several times as shown in
the diagram. Elevating the rear of the ATV with a floor jack
(rear tires 4-6, off the ground) also aids the purging of air from
the system.
3. Always add coolant to the radiator first, filling to the top of Remote Filler Cooling System
the neck to replace air that has been purged from the system.
Fill the reservoir only after you have completely filled the cool-
Polaris Premium Antifreeze
2871534 Quart
ing system at the radiator filler neck.
2871323 Gallon
4. Repeat Steps 1 and 2 four or five times or until no more
coolant is pulled into the system.
5. In some instances, Steps 1 and 2 may have to be per-
formed with the radiator cap on to prevent coolant loss.
6. To test, install the radiator cap and idle machine until fan
comes on. Make sure the fan comes on before the hot light.
3.6
GENERAL INFORMATION
RADIATOR CAP / SYSTEM COOLING SYSTEM

PRESSURE TEST SPECIFICATIONS
1. Remove radiator cap and test using a cap tester
(commercially available).
2. The radiator cap relief pressure is 13 lbs. for all Thermistor
models. 26 ± 2.1 ft.lbs.
(35 ± 3 Nm)
COOLING SYSTEM
Pressure test
here with cap
in place
Radiator
Front THERMISTOR READING DURING OPERATION
View Condition Approx. Reading Temperature
(Min--Max)
Hot Light 178Ω -- 190Ω 215° F
On (102° C)
Fan Off 296Ω -- 316Ω 180° F (82° C)
Fan On 236Ω -- 251Ω 195° F (91° C)
System 2.25 Quarts
Capacity (2.13L)
Radiator
Cap Relief 13 PSI
Pressure
RECOMMENDED COOLANT
Use only high quality antifreeze/coolant mixed with

distilled water in a 50/50 or 60/40 ratio, depending on
freeze protection required in your area. CAUTION:
Using tap water in the cooling system will lead to a
Vent hole inside cap buildup of deposits which may restrict coolant flow and
liner must be clear. reduce heat dissipation, resulting in possible engine
damage. Polaris Premium 60/40 Antifreeze/Coolant is
recommended for use in all cooling systems, and comes
pre-mixed and ready to use.
3.7
GENERAL INFORMATION
ACCESSIBLE COMPONENTS 12. Remove center drive and driven sprocket bolts
and remove chain and sprockets as an assembly.
The following components can be serviced or 13. Refer to PVT System to remove outer clutch
removed with the engine installed in the frame: cover, drive belt, drive clutch, driven clutch, and
S Flywheel inner cover.
S Alternator/Stator 14. Starter motor. Note ground cable location. Mark
S Starter Motor/Starter Drive positive (+) cable mounting angle and remove
S Cylinder Head cable.
S Cylinder 15. Remove transmission linkage rod(s) from gear
S Piston/Rings selector and secure out of the way.
S Camshaft
16. Disconnect coolant temperature sensor wire.
S Rocker Arms
S Cam Chain and Sprockets 17. Remove engine to chassis ground cable.
S Water Pump / Water Pump 18. Remove all engine mount nuts and / or engine
Mechanical Seal* mount plates.
The following components require engine 19. Remove engine through right side of frame.
removal for service:
S Oil pump / Oil Pump Drive Gear
S Counterbalance Shaft or Bearing(s) ENGINE INSTALLATION
S Connecting Rod
S Crankshaft
NOTES
S Crankshaft Main Bearings After the engine is installed in the frame, review this
S Crankcase checklist and perform all steps that apply.
*It may be necessary to loosen engine mounts and
move engine slightly to access water pump. Use the General Items
Water Pump Mechanical Seal Puller (PN 2872105) to 1. Install previously removed components using
replace mechanical seal with engine in frame. new gaskets, seals, and fasteners where
applicable.
2. Perform regular checks on fluid levels, controls,
ENGINE REMOVAL and all important areas on the vehicle as outlined
in the daily pre-ride inspection checklist (refer to
1. Clean work area. Chapter 2 or the Owner’s Safety and
2. Thoroughly clean the ATV engine and chassis. Maintenance Manual).
3. Disconnect battery negative (-) cable. PVT System
4. Remove the following parts as required. 1. Adjust center distance of drive and driven clutch.
S Seat (Chapter 6)
S Left and Right Side Covers (Refer to 2. Adjust clutch offset, alignment, and belt
Chapter 5) deflection. (Chapter 6)
S Fuel Tank Cover / Front Cab (Refer to 3. Clean clutch sheaves thoroughly and inspect inlet
Chapter 5) and outlet ducts for proper routing and sealing.
S Fuel Tank (Refer to Chapter 4) (Chapter 6)
5. Disconnect spark plug high tension lead. Transmission
6. Remove springs from exhaust pipe and remove 1. Inspect transmission operation and adjust linkage
pipe. if necessary. Refer to Chapter 2 and Chapter 8.
7. Drain coolant and engine oil. Exhaust
8. Remove air pre-cleaner and duct. 1. Replace exhaust gaskets. Seal connections with
9. Remove airbox. high temp silicone sealant.
10. Remove carburetor. Insert a shop towel into the 2. Check to be sure all springs are in good condition.
carburetor flange to prevent dirt from entering the Bleed Cooling System
intake port.
11. Remove center chain guard on chain drive AWD 1. Remove radiator cap and slowly add coolant to
models. top of filler neck.
2. Fill coolant reservoir tank to full mark.
3.8
GENERAL INFORMATION
3. Install radiator cap and squeeze coolant lines to piston-to-cylinder clearance specifications on Page
force air out of system. 3.4 before honing. Complete the sizing with fine grit
4. Again remove radiator cap and slowly add coolant stones to provide the proper cross-hatch finish and
to top of fill neck. required piston clearance.
5. Start engine and observe coolant level in the
radiator. Allow air to purge and top off as
necessary. Reinstall radiator cap and bring
engine to operating temp. Check level in
reservoir tank after engine is cool and add coolant
if necessary.
Engine Break In Period
4 Cycle Engine Break-In Period is defined as the first
10 hours of engine operation, or 2 full tanks of fuel.
1. Use only Polaris Premium 4 All Season synthetic
oil, or API certified “SH” oil. Never substitute or mix EXAMPLE OF CROSS HATCH PATTERN
oil brands. Serious engine damage can result.
A finished cylinder should have a cross-hatch pattern
2. Use fuel with a minimum octane of 87 (R+M)/2
to ensure piston ring seating and to aid in the retention
method.
of the fuel/oil mixture during initial break in. Hone
3. Change break-in oil and filter at 20 hours or 500 cylinder according to hone manufacturer’s
miles, whichever comes first. instructions, or these guidelines:
Use a motor speed of approximately
CYLINDER HONE S
300-500 RPM, run the hone in and out of
SELECTION/HONING the cylinder rapidly until cutting tension
decreases. Remember to keep the hone
PROCEDURE drive shaft centered (or cylinder centered
on arbor) and to bring the stone
approximately 1/2″ (1.3 cm) beyond the
CAUTION: bore at the end of each stroke.
Selecting a hone which will straighten as well as S Release the hone at regular intervals and
remove material from the cylinder is very important. inspect the bore to determine if it has been
Using a common spring loaded finger type glaze cleared, and to check piston fit. NOTE: Do
breaker for honing is never advised. Polaris not allow cylinder to heat up during honing.
recommends using a rigid hone or arbor honing The thinner areas of the liner around the
machine which also has the capability of oversizing. ports will expand causing uneven bore.
S After honing has been completed inspect
Cylinders may be wet or dry honed depending upon all port opening areas for rough or sharp
the hone manufacturer’s recommendations. Wet edges. Apply a slight chamfer to all ports
honing removes more material faster and leaves a to remove sharp edges or burrs, paying
more distinct pattern in the bore. particular attention to the corners of the
intake and exhaust ports.
HONING TO OVERSIZE CLEANING THE CYLINDER

CAUTION: If cylinder wear or damage is excessive, it
will be necessary to oversize the cylinder using a new
AFTER HONING
oversize piston and rings. This may be accomplished It is very important that the cylinder be thoroughly
by either boring the cylinder and then finish honing to the cleaned after honing to remove all grit material. Wash
final bore size, or by rough honing followed by finish the cylinder in a solvent, then in hot, soapy water. Pay
honing. close attention to areas where the cylinder sleeve
CAUTION: For oversize honing always wet hone meets the aluminum casting (transfer port area). Use
using honing oil and a coarse roughing stone. electrical contact cleaner if necessary to clean these
Measure the piston (see piston measurement) and areas. Rinse thoroughly, dry with compressed air,
rough hone to the size of the piston. Always leave and oil the bore immediately with Polaris 4 Cycle
.002 - .003″ (.05 - .07 mm) for finish honing. Refer to Lubricant.
3.9
GENERAL INFORMATION
CRANKSHAFT
STRAIGHTENING HIGH .002 (.05mm)
Lubricate the bearings and clamp the crankshaft A A HIGH .005 (.13mm)
securely in the Crankshaft Truing Stand (PN
2870569). Refer to the illustrations below.
Crankshaft Truing Stand

(PN 2870569)
NOTE: The rod pin position in relation to the dial 3. If the crank rod pin location is 180_ from the dial
indicator position tells you what action is required to indicator (opposite that shown above), it will be
straighten the shaft. necessary to spread the crankshaft at position A
as shown in the illustration at right. When
HIGH .004 (.1mm) rebuilding and straightening a crankshaft, runout
must be as close to zero as possible.
A HIGH .004 (.1mm)
NOTE: Maximum allowable runout is .0024I.
ENGINE LUBRICATION -
EH50PL
B
SUPPORT CRANKSHAFT Oil Type . . . . . . . . . . . . . Polaris Premium 4 Synthetic
HERE. (PN 2871281)
Capacity . . . . . . . . . . . . Approximately 2 U.S.
1. To correct a situation like the one shown in the Quarts (1.9 l)
illustration at right, strike the shaft at point A with a
brass hammer. Filter . . . . . . . . . . . . . . . . (PN 3084963)
Filter Wrench . . . . . . . . (PV--43527)
HIGH .002 (.05mm) *Drain Plug / Screen Fitting . . 14 ft. lbs. (19 Nm) (If
fitting is removed, follow oil pump priming procedure).
HIGH .005 (.13mm)
*Oil Pressure Specification . . . 20 PSI @ 5500
RPM, Polaris 0W--40 Synthetic (Engine Hot)
A A
2. To correct a situation like the one shown in the

illustration at right, squeeze the crankshaft at
point A. (Use tool from alignment kit).
3.10
GENERAL INFORMATION
OIL PRESSURE TEST - OIL FLOW -- EH50PL

EH50PL The chart on Page 3.12 describes the flow of oil
through the EH50PL engine. Beginning at the oil tank,
1. Remove blind plug on front left cylinder head. the oil flows through a screen fitting in the bottom of
2. Insert a 1/8 NPT oil pressure gauge adaptor into the tank and into the oil supply hose. The feed side
the cylinder head and attach the gauge. of the oil pump draws oil through the hose and into the
3. Start engine and allow it to reach operating crankcase oil gallery, and then pumps the oil through
temperature, monitoring gauge indicator. another passage to the one way valve. (When the
engine is off, the one way valve closes to prevent oil
NOTE: Use Polaris Premium 4 Synthetic Engine in the tank from draining into the crankcase.) The oil
Lubricant (PN 2871281). is pumped through a delivery pipe to the oil filter. If the
oil filter is obstructed, a bypass valve contained in the
filter allows oil to bypass the filter element.
Oil Pressure at 5500 RPM (Engine Hot): At this point, the oil is diverted in two directions. Oil
Standard: 20 PSI is supplied to the camshaft through the left front
Minimum: 12 PSI
cylinder stud, and an oil passage in the head. Oil
enters the camshaft through the PTO (L) journal. The
camshaft journals, cam lobes, and rocker arms are
OIL PUMP PRIMING lubricated through holes in the camshaft. The oil
lubricates the cam chain and sprocket and drains to
PROCEDURE the sump.
The other oil path from the filter leads through a
NOTE: This priming procedure must be delivery pipe to the crankcase main oil gallery, which
performed whenever the oil hose connection leads to the stator plate oil passage. Here it passes
between the oil tank and pump inlet has been through the slotted friction bearing (located in the
disconnected. stator plate) into the crankshaft. An oil seal on the
stator plate prevents oil from entering the
To Air Box stator/flywheel area. Oil travels through the
Approx. crankshaft to the crank pin, lubricating the connecting
2I rod large end bearing directly. Oil also passes through
an oil jet (drilled orifice) in the end of the crank pin to
the PTO end main bearings and counterbalancer
gears.
Residual oil from the lubrication of the crankshaft and
connecting rod indirectly lubricates the cylinder wall,
Oil Tank Slit piston, rings, connecting rod small end bearing, piston
pin, oil/water pump drive gears, cam chain and drive
Pinch Off sprocket, and Magneto end crankshaft main bearing.
Vent Hose The one-way valve is located on the front left (PTO)
side of the crankcase. The valve prevents oil in the
1. Clamp or pinch off vent line approximately 2I
tank from draining into the engine sump when the
from oil tank to avoid the end of oil tank vent fitting,
engine is off. The valve mechanism consists of a
and the vent line’s pressure relief slit
plunger, return spring, guide plug, and sealing
2. Run engine for 10--20 seconds. washer. When the engine is running, oil pressure lifts
3. Shut engine off. Remove the vent line clamp. A the plunger off the seat, allowing oil flow. When the
rush of air should be heard, indicating the oil pump engine is off, spring pressure forces the plunger
is properly primed and ready for field operation. against the oil passage seat, preventing oil flow from
Note: If the system is primed properly you should the tank to the sump. The one-way valve requires
hear some air release. If you do not, the system very little maintenance. If engine oil drains into the
has not primed. Repeat the process if necessary. sump when the engine is off, inspect the valve sealing
surface for debris or damage. Inspect the return
spring for distortion or damage.
3.11
GENERAL INFORMATION
EH50PL OIL FLOW DIAGRAM
Internal passage to
camshaft (front left
head bolt)
Oil filter
Oil feed to
filter
From filter
to crankshaft
One way valve
Top fitting is oil

Bottom fitting is oil feed or intake
Oil Tank exhaust or return from bottom of
to tank tank
EH50PL Oil Flow Chart

Top of Oil Tank Union Fitting (Lower)
Oil Tank
Oil Hose Crankcase Oil Pump Oil Strainer
Oil Gallery (Scavenging)
Union Fitting Screen Fitting
(Upper) (Bottom of Tank)
Oil Hose Crankcase
Small End
Chain Room Sprocket
Crankcase Bearing
Chain
Oil Gallery
Cylinder Sleeve
Oil Pump Cam Shaft Rocker Arm

Prevents oil (Feed) Journal Rocker Shaft
Indirect Main Bearing
from draining (PTO)
into crankcase Lubrication
with engine off
One Way Valve
Cam Lobe Large End
Bearing
Delivery Pipe Cam Shaft Metal

Journal Oil Jet
Crank Pin
Bypass Oil Filter Through Cylinder
Stud Front Left
Delivery Pipe Crankshaft
Crankcase
Delivery Pipe Oil Gallery
3.12
GENERAL INFORMATION
EH50PL ENGINE EXPLODED VIEW
Crankcase Cylinder/
Cylinder
Head
Crankshaft Valve Train

and Piston
3.13
GENERAL INFORMATION
ENGINE DISASSEMBLY should have clearance at this point.
REFER TO PAGE 3.7 FOR ENGINE

REMOVAL / INSTALLATION NOTES.
CAM CHAIN
TENSIONER/ROCKER
ARM/CAMSHAFT REMOVAL
1. Remove ignition timing inspection plug from recoil
housing.
TDC “T” Mark 5. Remove cam chain tensioner plug, sealing

washer, and spring. CAUTION: The plug is
under spring tension. Maintain inward pressure
while removing.
6. Remove the two 6x25 mm cam chain tensioner
Rotation flange bolts.
7. Tap lightly on tensioner body with a soft face
hammer and remove tensioner.
Advance Marks
To position crankshaft at Top Dead Center (TDC)

on compression stroke:
2. Rotate engine slowly in the direction of rotation
watching intake valves open and start to close.
3. Continue to rotate engine slowly, watching
camshaft sprocket marks and the mark in the
timing inspection hole.
4. Align single (TDC) mark on flywheel with

projection in inspection hole, and the cam
sprocket pin (facing upward) aligned with the
camshaft to crankshaft center line. NOTE: The
cam lobe should be pointing down and valves
3.14
GENERAL INFORMATION
CAM CHAIN TENSIONER ROCKER ARM/SHAFT

INSPECTION INSPECTION
B
A
1. Pull cam chain tensioner plunger outward to the 1. Mark or tag rocker arms to keep them in order for
end of its travel. Inspect teeth on ratchet pawl (A) assembly.
and plunger teeth (B) for wear or damage. 2. Inspect each rocker arm cam follower surface. If
2. Push ratchet pawl and hold it. The plunger should there is any damage or uneven wear, replace the
move smoothly in and out of the tensioner body. rocker arm. NOTE: Always inspect camshaft
3. Release ratchet pawl and push inward on plunger. lobe if rocker arms are worn or damaged.
It should remain locked in position and not move
inward.
3. Measure O.D. of rocker shaft. Inspect it for wear

or damage. Compare to specifications.
Tensioner Spring Free Length: Rocker Shaft O.D.:

2.320I (5.9 cm) .8656-.8661I (21.987-22.0 mm)
4. Measure free length of tensioner spring. Replace

spring if excessively worn. Compare to
specifications.
5. Replace entire tensioner assembly if any part is
worn or damaged.
3.15
GENERAL INFORMATION
ROCKER ARM/SHAFT
INSPECTION, CONT. Rocker Shaft Oil Clearance:
Std: .0008-.0021I (.020-.054 mm)
Limit: .0039I (.10 mm)
5. Measure I.D. of both rocker arm shaft supports

and visually inspect surface. Compare to
specifications.
6. Subtract rocker shaft O.D. from rocker arm &
shaft support I.D. This is the oil clearance.
Compare to specifications.
7. Inspect rocker adjuster screws for wear, pitting, or

damage to threads of the adjuster or locknut.
Replace all worn or damaged parts. NOTE: The
end of the adjuster screw is hardened and cannot
be ground or re-faced.
Rocker Arm & Support I.D.:

CAMSHAFT REMOVAL
.8669-.8678I (22.020-22.041 mm)
4. Measure I.D. of each rocker arm and compare to

specifications.
1. Remove thermostat housing.

2. Remove camshaft sprocket inspection cover.
3.16
GENERAL INFORMATION
3. Loosen three camshaft sprocket bolts. 7. Slide camshaft inward to allow removal of cam
sprocket and remove sprocket from camshaft and
chain.
8. Secure cam chain with a wire to prevent it from
falling into the crankcase.
Sprocket Teeth
4. Remove camshaft end cap and O-Ring.

Inspect for Areas of Tooth
Wear or Damage
9. Inspect cam sprocket teeth for wear or damage.

Replace if necessary.
Decompressor Shaft
Decompressor Ball
5. Inspect camshaft end cap (thrust face) for wear.
Replace if worn or damaged.
6. Place a clean shop towel in the area below cam Retainer Sleeve
chain sprocket and remove sprocket retaining
bolts.
10. Slide camshaft out the PTO side of the cylinder
head.
AUTOMATIC COMPRESSION
RELEASE
REMOVAL/INSPECTION
NOTE: The automatic compression release
mechanism can be inspected and serviced without
removing the camshaft from the cylinder head. The
actuator ball in the camshaft is not replaceable.
Replace the camshaft as an assembly if the actuator
ball is worn or damaged.
3.17
GENERAL INFORMATION
If Camshaft Is Removed From Engine:

3. Turn the camshaft until the actuator ball is in the
lowest position and install the release lever shaft.
C If Camshaft Is Installed In The Engine:
4. Use a small magnet to draw the actuator ball
outward, or rotate the engine until the cam lobes
face upward and install release lever shaft.
5. Position camshaft as shown at bottom of
A illustration at right.
6. Place arm of spring under stop pin as shown and
push release lever inward until fully seated. Do
not pre-wind the spring one full turn or the
B compression release will not disengage when the
engine starts. Check operation of mechanism as
outlined in Step 1 of Removal (above).
1. Check release lever shaft (A) for smooth NOTE: When shaft is properly installed, actuator
operation throughout the entire range of rotation. ball will be held in the “out” position. It is important
The spring (B) should hold the shaft weight to note that spring pressure is very light.
against the stop pin. In this position, the actuator
ball (C) will be held outward in the compression
release mode. CAMSHAFT INSPECTION
2. Remove release lever shaft and return spring.
1. Visually inspect each cam lobe for wear, chafing
3. Inspect shaft for wear or galling. or damage.
4. Inspect lobe on end of release lever shaft and 2. Thoroughly clean the cam shaft, making sure
actuator ball for wear and replace if necessary. the oil feed holes are not obstructed.
AUTOMATIC COMPRESSION
RELEASE INSTALLATION
1. Slide spring onto shaft.
2. Apply engine oil to release lever shaft. Lubrication holes
The actuator ball must be held outward to allow
installation of the release lever shaft.
Lobe height
Stop pin
Cam Lobe Height (Intake & Exhaust):

Std: 1.2884-1.2924I (32.726-32.826 mm)
Limit: 1.2766I (32.426 mm)
Spring in relaxed position
3.18
GENERAL INFORMATION
3. Measure height of each cam lobe using a

micrometer. Compare to specifications.
CYLINDER HEAD REMOVAL
1. Remove the two 6mm flange bolts (A) from
Journal O.D. cylinder head. See next exploded view on next
page to view item A.
2. Loosen each of the four cylinder head bolts
evenly 1/8 turn each time in a criss-cross pattern
until loose.
Journal
Camshaft Journal O.D.:

Mag & PTO End: 1.4935-1.4941I
(37.935-37.950 mm)
4. Measure camshaft journal outside diameter

(O.D.)
5. Measure ID of camshaft journal bore.
3. Remove bolts (B) and tap cylinder head lightly
with a plastic hammer until loose. CAUTION:
Camshaft Journal I.D.: Tap only in reinforced areas or on thick parts of
Mag & PTO End: 1.4963-1.4970I cylinder head casting to avoid damaging the
(38.005-38.025 mm) thread.
4. Remove cylinder head and head gasket.
Calculate oil clearance by subtracting journal OD

from journal bore ID. Compare to specifications.
Camshaft Oil Clearance:

Std: .0022-.0035I (.055-.090 mm)
Limit: .0039I (.10 mm)
NOTE: Replace camshaft if damaged or if any part

is worn past the service limit.
NOTE: Replace cylinder head if camshaft journal
bore is damaged or worn excessively.
3.19
GENERAL INFORMATION
CYLINDER HEAD EXPLODED VIEW, EH50PL
EH50PL
3.20
GENERAL INFORMATION
CYLINDER HEAD CYLINDER HEAD

INSPECTION DISASSEMBLY
WARNING: Wear eye protection or a face shield
during cylinder head disassembly and reassembly.
NOTE: Keep all parts in order with respect to their
location in the cylinder head.
(A)
1. Thoroughly clean cylinder head (A) surface to

remove all traces of gasket material and carbon.
CAUTION: Use care not to damage sealing
surface.
CYLINDER HEAD WARPAGE
1. Using a valve spring compressor (A), compress

the valve spring and remove the split keeper.
NOTE: To prevent loss of tension, do not
compress the valve spring more than necessary.
Cylinder Head Warpage Limit:
.002″ (.05 mm)
1. Lay a straight edge across the surface of the 2. Remove spring retainer and spring.
cylinder head at several different points and NOTE: The valve springs should be positioned with
measure warpage by inserting a feeler gauge the tightly wound coils against the cylinder head on
between the straight edge and the cylinder head progressively wound springs (A).
surface. If warpage exceeds the service limit,
3. Push valve out, keeping it in order for reassembly
replace the cylinder head.
in the same guide.
4. Measure free length of spring with a Vernier
caliper. Check spring for squareness. Compare
3.21
GENERAL INFORMATION
to specifications. Replace spring if either indicator.

measurement is out of specification
A
3. Check end of valve stem for flaring, pitting, wear

or damage (A).
4. Inspect split keeper groove for wear or flaring of
the keeper seat area (B). NOTE: The valves
cannot be re-faced or end ground. They must be
5. Remove valve seals. CAUTION: Replace seals replaced if worn, bent, or damaged.
whenever the cylinder head is disassembled.
Hardened, cracked or worn valve seals will cause
excessive oil consumption and carbon buildup.
Measure valve stem in
several places.
VALVE INSPECTION
1. Remove all carbon from valve with a soft wire
wheel.
Valve Stem Diameter:

Intake: .2343-.2348I (5.950-5.965 mm)
Exhaust: .2341-.2346I (5.945-5.960 mm)
5. Measure diameter of valve stem with a

micrometer in three places and in two different
directions (six measurements total). Compare to
specifications.
2. Check valve face for runout, pitting, and burnt

spots. To check for bent valve stems, mount
valve in a drill or use “V” blocks and a dial
3.22
GENERAL INFORMATION
VALVE SEAT SERVICE

Valve Seat Inspection
Inspect valve seat in cylinder head for pitting, burnt
spots, roughness, and uneven surface. If any of the
above conditions exist, the valve seat must be
reconditioned. See Valve Seat Reconditioning, Page
3.25. If the valve seat is cracked the cylinder head
must be replaced.
Cylinder Head Reconditioning
NOTE: Servicing the valve guides and valve seats
requires special tools and a thorough knowledge of
reconditioning techniques. Follow the instructions
provided in the cylinder head service tool kit.
CAUTION: Wear eye protection when performing
Valve Guide I.D.: cylinder head service. Valve guide replacement will
.2362-.2367I (6.0-6.012 mm) require heating of the cylinder head. Wear gloves to
prevent burns.
6. Measure valve guide inside diameter at the top Valve Guide Removal/Installation
middle and end of the guide using a small hole 1. Remove all carbon deposits from the combustion
gauge and a micrometer. Measure in two chamber, valve seat and valve guide area before
directions, front to back and side to side. attempting to remove valve guides. CAUTION:
7. Subtract valve stem measurement to obtain stem Carbon deposits are extremely abrasive and may
to guide clearance. NOTE: Be sure to measure damage the valve guide bore when guides are
each guide and valve combination individually. removed.
8. Replace valve and/or guide if clearance is 2. Place new valve guides in a freezer for at least 15
excessive. Compare to specifications. minutes while heating cylinder head.
NOTE: If valve guides are replaced, valve seats 3. Heat cylinder head in an oven or use a hot plate to
must be reconditioned. Refer to Valve Seat bring cylinder head temperature to 212° F (100°
Reconditioning for procedure. C). CAUTION: Do not use a torch to heat
cylinder head or warpage may result from uneven
heating. Head temperature can be checked with
COMBUSTION CHAMBER a pyrometer or a welding temperature stick.
VALVE SEAT
RECONDITIONING
Follow the manufacturers instructions provided with
the valve seat cutters in the Valve Seat
Reconditioning Kit (PN 2200634). Abrasive stone
seat reconditioning equipment can also be used.
Keep all valves in order with their respective seat.
Clean all accumulated carbon deposits from

combustion chamber and valve seat area with a soft
wire brush.
3.23
GENERAL INFORMATION
Reaming The Valve Guide
Too Uneven Good Too

Wide Narrow
NOTE: Valve seat width and point of contact on the

valve face is very important for proper sealing. The
valve must contact the valve seat over the entire
circumference of the seat, and the seat must be the
proper width all the way around. If the seat is uneven,
compression leakage will result. If the seat is too
wide, seat pressure is reduced, causing carbon
accumulation and possible compression loss. If the 5. Allow cylinder head to cool to room temperature.
seat is too narrow, heat transfer from valve to seat is Apply cutting oil to the reamer. Guides should be
reduced and the valve may overheat and warp, reamed from the valve spring side of the cylinder
resulting in burnt valves. head. Ream each guide to size by turning the
reamer clockwise continually. Continue to rotate
1. When thoroughly heated, place cylinder head on reamer clockwise during removal of the tool.
blocks of wood which will allow the old guides to 6. Clean guides thoroughly with hot soapy water and
be removed. a nylon brush. Rinse and dry with compressed
2. Using valve guide driver, drive guides out of the air. Apply clean engine oil to guides.
cylinder head from the combustion chamber side. 7. Install pilot into valve guide.
Be careful not to damage guide bore or valve seat
when removing guides.
8. Apply cutting oil to valve seat and cutter.
3. Place cylinder head on cylinder head table.
NOTE: Be sure cylinder head is still at 212° F
(100° C) before installing new guides.
Valve Guide Installed Height
Valve Guide Height:

.689-.709I (17.5-18.0 mm)
9. Place 46° cutter on the pilot and make a light cut.
4. Place a new guide in the valve guide installation
tool and press guide in to proper depth. Check 10. Inspect the cut area of the seat.
height of each guide above the cylinder head (A). S If the contact area is less than 75% of the
NOTE: The guide can also be driven in to the circumference of the seat, rotate the pilot
proper depth. Inspect the guide closely for cracks 180° and make another light cut.
or damage if a driver is used. S If the cutter now contacts the uncut
portion of the seat, check the pilot. Look
for burrs, nicks, or runout. If the pilot is
bent it must be replaced.
3.24
GENERAL INFORMATION
S If the contact area of the cutter is in the

same place, the valve guide is distorted
from improper installation and must be
replaced. Be sure the cylinder head is at Valve Seat Width:
the proper temperature and replace the
guide. Intake Std: .028I (.7 mm)
Limit: .055I (1.4 mm)
S If the contact area of the initial cut is
Exhaust Std: .039I (1.0 mm)
greater than 75%, continue to cut the Limit: .071I (1.8 mm)
seat until all pits are removed and a new
seat surface is evident. NOTE: Remove
only the amount of material
necessary to repair the seat surface.
Seat
Width
(A)
Bottom - 60° or 75° Seat - 45° or 46°

Top - 30°
11. To check the contact area of the seat on the valve
face, apply a thin coating of Prussian Bluet paste
to the valve seat. If using an interference angle
(46°) apply black permanent marker to the entire
valve face (A).
12. Insert valve into guide and tap valve lightly into
place a few times.
13. Remove valve and check where the Prussian NOTE: When using an interference angle, the seat
Bluet indicates seat contact on the valve face. contact point on the valve will be very narrow, and is
The valve seat should contact the middle of the a normal condition. Look for an even and continuous
valve face or slightly above, and must be the contact point on the black marker, all the way around
proper width. the valve face.
S If the indicated seat contact is at the 14. Clean all filings from the area with hot soapy
top edge of the valve face and water, rinse, and dry with compressed air.
contacts the margin area(B) it is too 15. Lubricate the valve guides with clean engine oil,
high on the valve face. Use the 30° and apply oil or water based lapping compound to
cutter to lower the valve seat. the face of the valve. Lapping is not required with
S If too low use the 60° or 75° cutter to an interference angle.
raise the seat. When contact area is 16. Insert the valve into its respective guide and lap
centered on the valve face, measure using a lapping tool or a section of fuel line
seat width. connected to the valve stem.
S If the seat is too wide or uneven, use 17. Rotate the valve rapidly back and forth until the
both top and bottom cutters to cut sounds smooth. Lift the valve slightly off of the
narrow the seat. seat, rotate 1/4 turn, and repeat the lapping
S If the seat is too narrow, widen using process. Do this four to five times until the valve is
the 45° cutter and re-check contact fully seated, and repeat process for the other
point on the valve face and seat width valve(s).
after each cut.
3.25
GENERAL INFORMATION
1. Install new valve seals on valve guides.

2. Apply engine oil to valve guides and seats.
A 3. Coat valve stem with molybdenum disulfide
grease.
4. Install valve carefully with a rotating motion to
avoid damaging valve seal.
5. Dip valve spring and retainer in clean engine oil
and install spring with closely spaced coils toward
the cylinder head.
18. Clean cylinder head, valves, and camshaft oil

supply passage (A) thoroughly.
19. If oil passage blind plug was removed, apply
Crankcase Sealant (PN 2871557) or equivalent
sealer to the threads and install, torquing to 8 ft.
lbs. (11 Nm). CAUTION: Do not allow sealant to
enter oil passage.
20. Spray electrical contact cleaner into oil passage
and dry using compressed air.
6. Place retainer on spring and install valve spring
compressor. Compress spring only enough to
CYLINDER HEAD ASSEMBLY allow split keeper installation to prevent loss of
spring tension. Install split keepers with the gap
CAUTION: Wear eye protection during assembly. even on both sides.
NOTE: Assemble the valves one at a time to 7. Repeat procedure for remaining valve.
maintain proper order. 8. When all valves are installed, tap lightly with soft
faced hammer on the end of the valves to seat the
split keepers.
VALVE SEALING TEST

1. Clean and dry the combustion chamber area.
2. Pour a small amount of clean, high flash point
solvent into the intake port and check for leakage
around each intake valve. The valve seats should
hold fluid with no seepage.
3. Repeat for exhaust valves by pouring fluid into
exhaust port.
3.26
GENERAL INFORMATION
EXHAUST VALVE CYLINDER/PISTON REMOVAL

CLEARANCE ADJUSTMENT AND INSPECTION
500 Engine NOTE: Follow engine disassembly procedures to
remove valve cover, camshaft and rocker arms, and
cylinder head.
Feeler Gauge for Both Valves
NOTE: The exhaust valves share a common rocker

arm, and must be adjusted using two feeler gauges.
1. Insert .006 feeler gauge(s) between end of
exhaust valve stem and adjuster screw(s). 1. Remove cam chain guide at front of cylinder.
2. Loosen locknut(s) and turn adjuster screw(s) until
there is a slight drag on feeler gauge(s). The
Valve/Clutch Adjuster Tool (PA--44689) can be
used to adjust the 500 engine valves. NOTE:
Both feeler gauges should remain inserted during
adjustment of each valve.
EXHAUST VALVE CLEARANCE

.006″ (.15 mm)
3. When clearance is correct, hold adjuster screw

and tighten locknut securely
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until
clearance is correct with locknut secured. 2. Loosen all four oil pipe banjo bolts and then
remove the bolts and eight sealing washers.
Remove the pipes.
3.27
GENERAL INFORMATION
3. Loosen hose clamps and remove coolant inlet

hose.
PISTON REMOVAL
4. Remove the two 6 mm cylinder base bolts.
1. Remove circlip. Note piston directional arrow

pointing toward the right (Mag) side of engine.
5. Loosen each of the four large cylinder base bolts
2. Remove piston circlip and push piston pin out of
1/4 turn at a time in a criss-cross pattern until
piston. If necessary, heat the crown of the piston
loose and remove bolts.
slightly with a propane torch. CAUTION: Do not
NOTE: The bolts are inside the water jacket. apply heat to the piston rings. The ring may lose
radial tension.
6. Tap cylinder lightly with a plastic hammer in the

reinforced areas only until loose.
7. Rock cylinder forward and backward and lift it
from the crankcase, supporting piston and
connecting rod. Support piston with Piston
Support Block (PN 2870390).
8. Remove dowel pins from crankcase.
3.28
GENERAL INFORMATION
3. Remove top compression ring.

*Using a piston ring pliers: Carefully expand ring
and lift it off the piston. CAUTION: Do not expand the 2. Inspect the top of the cylinder for warpage using a
ring more than the amount necessary to remove it straight edge and feeler gauge.
from the piston, or the ring may break.
*By hand: Placing both thumbs as shown, spread the
ring open and push up on the opposite side. Do not Cylinder Warpage:
scratch the ring lands.
.002″ (.05 mm)
3. Inspect cylinder for wear, scratches, or damage.
A
1/2″ Down From Top of Cylinder
Y
X
X
4. Repeat procedure for second ring.
The oil control ring is a three piece design consisting
of a top and bottom steel rail and a center expander
section. The top rail has a locating tab on the end Y
which fits into a notch (A) in the upper oil ring land of
the piston. X
5. Remove the top rail first followed by the bottom
rail. 1/2″ Up From Bottom
6. Remove the expander.
4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure
in two different directions, front to back and side to
CYLINDER INSPECTION side, on three different levels (1/2″ down from top,
in the middle, and 1/2″ up from bottom).
1. Remove all gasket material from the cylinder
sealing surfaces. 5. Record measurements. If cylinder is tapered or
out of round beyond .002, the cylinder must be
re-bored oversize, or replaced.
Cylinder Taper
Limit: .002 Max.
Cylinder Out of Round
Limit: .002 Max.
Standard Bore Size:
3.6221-3.6228I (92.00-92.012mm)
3.29
GENERAL INFORMATION
PISTON-TO-CYLINDER 1. Measure piston pin bore.
CLEARANCE
Piston
40 mm
Piston Pin Measurement Locations

Piston Pin
Piston Pin O.D.
1. Measure piston outside diameter at a point 40 mm .9053-.9055I (22.994-23.0 mm)
down from the top of the piston at a right angle to
the direction of the piston pin.
2. Measure piston pin O.D. Replace piston and/or
2. Subtract this measurement from the maximum
piston pin if out of tolerance.
cylinder measurement obtained in Step 5 above.
Piston to Cylinder Clearance
Std: .0006-.0018I (.015-.045 mm)

Piston O.D.:
Std: 3.6204-3.6215I (91.970-91.985 mm)
3. Measure connecting rod small end ID.
PISTON/ROD INSPECTION Piston
Ring
Feeler Gauge
Piston Pin Bore
Piston Ring-to-Groove Clearance

Piston Pin Bore:
Top Ring Std: .0016-.0031I (.040-.080 mm)
.9055-.9057I (23.0-23.006 mm) Limit: .0059I (15 mm)
Second Ring Std: .0012-.0028I (.030-.070 mm)
Limit: .0059I (15 mm)
4. Measure piston ring to groove clearance by

placing the ring in the ring land and measuring
with a thickness gauge. Replace piston and rings
if ring-to-groove clearance exceeds service
limits.
3.30
GENERAL INFORMATION
PISTON RING INSTALLED STARTER DRIVE

GAP REMOVAL/INSPECTION
1. Place each piston ring inside cylinder using piston 1. Remove recoil housing bolts and remove
to push ring squarely into place as shown at right. housing.
Feeler Gauge
Cylinder
25-50mm
Piston Ring
Piston Ring Installed Gap 2. Remove starter drive assembly. Note the thrust
washer located at the rear of the drive
Top Ring mechanism.
Std: .0079-.0138I (.20-.36 mm) 3. Inspect the thrust washer for wear or damage and
Limit: .039I (1.0 mm) replace if necessary.
Second Ring
Std: .0079-.0138I (.20-.36 mm)
Limit: .039I (1.0 mm)
Oil Ring A
Std: .0079-.0276I (.20-.70 mm)
Limit: .059I (1.5 mm)
2. Measure installed gap with a feeler gauge at both

the top and bottom of the cylinder. NOTE: A
difference in end gap indicates cylinder taper.
The cylinder should be measured for excessive
taper and out of round.
3. If the bottom installed gap measurement exceeds
the service limit, replace the rings. If ring gap is
below specified limit, file ring ends until gap is Std. Bushing ID:
within specified range. .4735″-.4740″ (11.11-12.04 mm)
NOTE: Always check piston ring installed gap after
re-boring a cylinder or when installing new rings. A Std. Shaft OD:
re-bored cylinder should always be scrubbed .470″-.472″ (11.93-11.99 mm)
thoroughly with hot soapy water, rinsed, and dried
completely. Wipe cylinder bore with an oil rag
immediately to remove residue and prevent rust. Starter Drive Bushing Clearance:
Std: .0015″-.004″ (.038-.102 mm)
CRANKCASE DISASSEMBLY
Service Limit:
NOTE: The recoil starter, starter motor, starter drive, .008″ (.203 mm)
flywheel, stator, cam chain and sprockets can be
serviced with the engine in the frame. 4. Measure the OD of the starter drive shaft on both
ends and record.
3.31
GENERAL INFORMATION
5. Measure the ID of the bushing in the recoil 6. Remove oil passage O-Ring (B).
housing (A) and in the crankcase and record.
Measure in two directions 90° apart to determine
if bushing is out of round. Calculate bushing
clearance. Replace bushing if clearance exceeds
the service limit.
6. Inspect gear teeth on starter drive. Replace
starter drive if gear teeth are cracked, worn, or
broken.
FLYWHEEL/STATOR
REMOVAL/INSPECTION
1. Remove flywheel nut and washer.
2. Install Flywheel Puller (PN 2871043) and remove
flywheel. CAUTION: Do not thread the puller
bolts into the flywheel more than 1/4″ or stator
coils may be damaged. 7. Remove large sealing O-Ring from outer edge of
stator plate.
3. Mark or note position of stator plate on crankcase.
4. Remove bolts and carefully remove stator
assembly, being careful not to damage crankshaft CAM CHAIN/TENSIONER
bushing on stator plate.
BLADE
1. Remove bolt securing tensioner blade to

crankcase (A).
5. Replace crankshaft seal (A).
2. Remove blade and inspect for cracks, wear, or
damage.
B
B
3.32
GENERAL INFORMATION
3. Remove cam chain (B). Inspect chain for worn or

missing rollers or damage. Stretch chain tight on
a flat surface and apply a 10 lb. (4.53 kg) load. One Way Valve Spring Free Length:
Measure length of a 20 pitch section of chain.
Replace if worn past service limit. Std: 1.450″ (3.68 cm)
Chain Service Limit:

5.407″ (13.7 cm)
3. Inspect valve for wear.

4. Using the special socket, remove the crankshaft 4. Check seat area for nicks or foreign material that
slotted nut (A). NOTE: The slotted nut is a left may prevent proper sealing of valve.
hand thread.
5. Remove cam chain drive sprocket (B) and
Woodruff key from crankshaft. CRANKCASE SEPARATION
6. Inspect sprocket teeth for wear or damage.
7. Inspect Woodruff key for wear.
8. Replace any worn or damaged parts.
ONE WAY VALVE

The one way valve prevents oil from draining out of the
oil tank and into the crankcase when the engine is off.
It must be clean and have adequate spring pressure
in order to seal properly.
B A
D C 1. Remove flange bolts (10) from magneto side
crankcase evenly in a criss-cross pattern.
2. Separate crankcase by tapping with a soft faced
hammer in reinforced areas.
3. Tap lightly on balancer gear with a brass drift
through the hole in the crankcase if necessary, to
ensure the balancer shaft stays in the PTO side
crankcase. Watch the gap along the crankcase
mating surface and separate the crankcase
evenly. It may also be necessary to tap the oil
pump shaft lightly to separate the crankcase.
1. Remove cap bolt (A), sealing washer (B), spring CAUTION: Do not strike the oil pump shaft at an
(C), and one way valve (D) from PTO side angle or the shaft may bend, causing irreparable
crankcase. damage. Tap only lightly on the pump shaft if
necessary.
2. Inspect free length of spring and check coils for
distortion. 4. Remove the Mag (RH) crankcase from the PTO
case.
3.33
GENERAL INFORMATION
OIL PUMP 4. Remove three oil pump retaining bolts and pump.
REMOVAL/INSPECTION
C A 5. Inspect mating surface of crankcase and oil

B
pump. Check for nicks, burrs, or surface
1. Remove pump shaft bearing (A) and thrust irregularities.
washer (B) from pump shaft. 6. Remove the three screws and strainer screen
2. Remove (2) bolts holding pump drive gear (C). from pump.
3. Inspect drive gear teeth for cracks, damage or 7. Clean screen thoroughly.
excessive wear.
8. Remove pump body screw and feed chamber

cover.
3.34
GENERAL INFORMATION
5. Install inner feed rotor and feed chamber cover

with screw.
9. Measure pump end clearance using a feeler 6. Tighten screw securely.
gauge and straight edge. 7. Install screen on pump body.
8. Install oil pump on crankcase and torque bolts to 6
Pump End Clearance: ft. lbs. (8 Nm).
Std: .001-.003 (.0254-.0762 mm)

Oil Pump Attaching Bolt Torque:
Wear Limit: .004 (.1016 mm) 6 ft. lbs. (8 Nm)
10. Measure clearance between outer feed rotor and

pump body with a feeler gauge.
COUNTER BALANCER
SHAFT
REMOVAL/INSPECTION
Rotor Tip Clearance:
Std: .005 (.127 mm)

1. Remove the shim washer (A) from the counter
Wear Limit: .008 (.2032 mm) balancer shaft.
11. Measure rotor tip clearance with a feeler gauge.

12. Remove inner and outer feed rotor and pump
chamber body.
13. Repeat measurements for scavenge rotor.
14. Remove inner and outer scavenge rotor and
inspect pump shaft for wear.
OIL PUMP ASSEMBLY

1. Clean and dry all parts thoroughly. Apply clean
engine oil to all parts. Do not use gasket sealer on
the pump body mating surfaces or oil passages
will become plugged.
2. Install pump shaft and scavenge rotor drive pin.
3. Install outer scavenge rotor, inner scavenge rotor,
and scavenge casing.
4. Install outer feed rotor and inner feed rotor drive
pin.
3.35
GENERAL INFORMATION
2. Note the alignment dots on the balancer and

crankshaft gears, the marks must be aligned
CRANKSHAFT
during reassembly. REMOVAL/INSPECTION
A
3. Turn the shaft until balancer counter weights clear 1. Remove the shim washer (A) from the crankshaft.
the crankshaft and remove the balancer shaft 2. Support the PTO side crankcase and crankshaft;
from the crankcase. press the crankshaft out. Be careful not to
4. Inspect the balancer drive gear and pump shaft damage the crankcase mating surface or
drive gear. connecting rod.
5. Replace the shaft if gear teeth are abnormally
worn or damaged.
6. Inspect the balancer shaft bearings.
NOTE: Due to extremely close tolerances and
minimal wear, the balancer shaft ball bearings must
be inspected visually and by feel. Look for signs of
discoloration, scoring or galling. Turn the inner race
of each bearing. The bearings should turn smoothly
and quietly. The outer race of each bearing should fit
tightly in the crankcase. The inner race should be firm
with minimal side to side movement and no detectable
up and down movement.
3. Use a feeler gauge to measure the connecting rod

big end side clearance.
Connecting Rod Big End Side Clearance:
Std: .0039-.0256I (.1-.65 mm)

Limit: .0315I (.80 mm)
4. Place the crankshaft in a truing stand or V-blocks

and measure the runout on both ends with a dial
indicator.
Max Runout: .0024″ (.06 mm)
3.36
GENERAL INFORMATION
5. Measure the connecting rod big end radial

clearance.
PUMP SHAFT OIL SEAL/
WATER PUMP MECHANICAL
Big End Radial Clearance: SEAL REMOVAL (ENGINE
Std: .0004-.0015I (.011-.038 mm) DISASSEMBLED)
Limit: .0020I (.05 mm)
NOTE: The water pump mechanical seal can be
removed without removing the engine. Refer to Water
Pump Mechanical Seal Installation.
6. Inspect the crankshaft main bearing journals for
scoring and abnormal wear. Replace the pump shaft seal and water pump
mechanical seal whenever the crankcase is
CRANKCASE BEARING disassembled.
INSPECTION
1. Remove the pump shaft bearing from the

Magneto (right hand) side crankcase.
1. Remove the seal from the PTO side crankcase. 2. Pry out the oil seal, noting the direction of
2. Inspect the crankshaft main bearings, balancer installation with the spring side facing IN (toward
shaft bearings, and pump shaft bearing. inside of case).
NOTE: Due to extremely close tolerances and 3. Drive the water pump mechanical seal out of the
minimal wear, the bearings must be inspected crankcase from inside to outside. Note: The new
visually, and by feel. Look for signs of discoloration, mechanical seal must be installed after the
scoring or galling. Turn the inner race of each bearing. crankcases are assembled, using a special tool.
The bearings should turn smoothly and quietly. The See Mechanical Seal Installation.
outer race of each bearing should fit tightly in the
crankcase. The inner race should be firm with
minimal side to side movement and no detectable up
and down movement. CRANKCASE INSPECTION
3. Support the crankcase and drive or press the
1. Remove all traces of gasket sealer from the
main bearings out of each crankcase.
crankcase mating surfaces. Inspect the surfaces
4. To remove balancer shaft bearings and pump closely for nicks, burrs or damage.
shaft bearing use a blind hole bearing puller.
2. Check the oil pump and oil passage mating
NOTE: Bearings are stressed during the removal surfaces to be sure they are clean and not
process and should not be re-used! damaged.
3.37
GENERAL INFORMATION
BEARING INSTALLATION
NOTE: To ease bearing installation, warm the
crankcase until hot to the touch. Place the bearings in
a freezer.
1. Install the bearings so the numbers are visible.
2. Drive or press new bearings into the crankcases,
using the proper driver. CAUTION: Press only on
outer race of bearing to prevent bearing damage.
S 70 mm (2.755″) driver- For
crankshaft main bearings.
S 46 mm (1.810″) For counter balancer
bearings.
S 28 mm (1.100″) For pump shaft
bearing.
2. Measure the distance from the PTO crankcase
mating surface to the main bearing using a dial
END PLAY caliper and a straight edge.
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.
CRANKSHAFT END PLAY

ADJUSTMENT
3. Subtract the thickness of the straightedge from

the measurement obtained in Step 2 and record.
PTO Case Depth
1. Make sure all bearings are firmly seated in the

both Mag and PTO crankcase.
3.38
GENERAL INFORMATION
4. Measure the distance from the Magneto 7. Measure the width of the crankshaft at the
crankcase mating surface to the main bearing bearing seats with a micrometer or dial caliper
using the same method and record. and record.
Crankshaft Width
8. Subtract the Crankshaft Width measured in Step
7 from the Total Case Width recorded in Step 6,
and record below.
Total End Play

9. Subtract the thickness of the existing shim from
the result of Step 8 to determine if a different shim
is required. The result must be within the
specified range listed at right.
Crankshaft End Play:

5. Subtract the thickness of the straightedge from .008″-.016″ (.02-.04 cm)
the measurement obtained in Step 4 and record.
Mag Case Depth
6. Add the readings recorded in Step 3 and Step 5

and record below.
Total Case Width
3.39
GENERAL INFORMATION
COUNTER BALANCER
SHAFT END PLAY ADJUST. Counter Balancer Shaft End Play:
Step 2 .008″-.016″ (.02-.04 cm)
OIL PUMP SHAFT END PLAY

ADJUSTMENT
1. Make sure the pump shaft bearing is firmly seated
in the Magneto side crankcase.
1. Make sure all bearings are firmly seated in the

crankcase.
2. Measure the width of the counter balancer shaft
at the bearing seats with a dial caliper or
micrometer, and record reading.
Step 3 / 4
2. Measure the distance from the magneto

crankcase mating surface to the bearing using a
dial caliper and a straight edge. Subtract the
thickness of the straightedge and record.
3. Measure the distance from the Mag crankcase

mating surface to the balance shaft bearing using
a dial caliper and a straight edge. Subtract the
thickness of the straightedge and record.
4. Measure the distance from the PTO crankcase
mating surface to the bearing using the same
method outlined in Step 1, 2, and-3.
5. Add the readings obtained in Step 3 and Step 4.
3. Install the gear on the oil pump and measure the
6. Subtract the counter balancer shaft width
measured in Step 2 from the figure obtained in Step width of the pump and gear. Subtract this
5. measurement from the measurement recorded in
Step 2.
7. Subtract the thickness of the existing shim from
the result of Step 6 to determine if a different shim 4. Subtract the thickness of the existing shim from
the result of Step 3 to determine if a different shim
is needed. The result must be within the specified
is needed. See Shaft End Play Spec. next page.
range listed at below.
3.40
GENERAL INFORMATION
difficult, install two nuts on the end of the threaded

rod and tighten against each other.
Pump Shaft End Play:
3. Install the proper shim on the magneto end of the
.008″-.016″ (.02-.04 cm) crankshaft.
4. Place the balancer shaft in the PTO crankcase
aligning the timing marks on the crankshaft and
balancer gears. Install the proper shim washer on
PUMP SHAFT OIL SEAL the shaft.
5. Inspect the oil pump sealing surface on the
INSTALLATION crankcase. Apply a light film of engine oil to the
surface and install the oil pump.
NOTE: Do not use gasket sealer on the pump mating
surfaces.
NOTE: After engine is assembled and machine is
readied for field operation, oil pump MUST be primed.
Follow oil pump priming procedure on Page 3.10.
Oil Pump Bolt Torque:
6. ft. lbs. (8 Nm)
6. Align the drive gear with the drive pin on the pump
shaft and install the gear. Be sure the gear is fully
seated and properly engaged.
1. Install the seal from the outside of the crankcase
7. Install the proper shim washer on the pump shaft.
(water pump side) with the spring facing inward,
toward the pump shaft bearing.
2. Drive or press the seal into place using a 25 mm CRANKCASE ASSEMBLY
(.985″) seal driver, until flush with the outer edge
of the seal bore. 1. Apply Crankcase Sealant (PN 2871557) to the
3. Lubricate the seal lip with grease. crankcase mating surfaces. Be sure the
alignment pins are in place.
2. Set the crankcase in position carefully to avoid
CRANKSHAFT/COUNTER damaging the pump shaft seal, and install the
magneto end crankshaft installation tool (follow
BALANCE/OIL PUMP instructions provided with the Crankshaft/Water
INSTALLATION Pump Installation Kit (PN 2871283). Draw the
crankcase halves together by tightening the nut
Lubricate all bearings with clean engine oil before on the tool and tapping lightly in the pump shaft
assembly. area with a soft faced hammer to maintain
alignment. Continually check alignment of the
Use the Crankshaft/Water Pump Installation Kit (PN cases during installation, closing the gap equally
2871283) to prevent damage to the crankshaft and until the surfaces are tightly seated.
main bearings during installation.
3. Remove the tool.
1. Install the crankshaft into the PTO side
crankcase. Screw the threaded rod into the
crankshaft until the threads are engaged a
minimum of one inch (25.4mm).
2. Install the collar, washer, and nut onto the
threaded rod. Hold the crankshaft and tighten the
nut to draw the crankshaft into the main bearings
until fully seated. Loosen the nut and remove the
threaded rod from the crankshaft. If removal is
3.41
GENERAL INFORMATION
4. Install the crankcase flange bolts and tighten in 3

steps following the pattern on Page 3.2 to Sealing Washer
specified torque. Sealing Washer
(Copper or Aluminum)
Crankcase Bolt Torque: Coolant Drain

Bolt
14 ft. lbs. (19 Nm) Oil
Seal
Crankcase Sealant: Impeller
(PN 2871557) Ill. 1 Mechanical Seal
1. After the coolant has been drained, remove the

water pump cover, impeller and the sealing
WATER PUMP MECHANICAL washer. (Ill. 1)
SEAL INSTALLATION
1. Clean the seal cavity to remove all traces of old
sealer.
2. Place a new mechanical seal in the seal drive
collar, and install on the pump shaft.
3. Screw the guide onto the end of the pump shaft.
4. Install the washer and nut and tighten to draw seal T-Handle
into place until fully seated.
5. Remove the guide adaptor using the additional
nut as a jam nut if necessary.
Main Puller Body
Ill. 2
WATER PUMP MECHANICAL
2. Slide the main puller body over the outer portion
SEAL REMOVAL - ENGINE of the mechanical seal as shown in Ill. 2 and turn
INSTALLED T-Handle clockwise until it contacts water pump
shaft. Continue rotating until outer portion of
mechanical seal is separated from the metal seal
Water Pump Mechanical Seal body.
Puller: (PN 2872105)
Replacement T--Handle: 3. Insert the puller legs between the water pump
(PN 2872106) drive shaft and the remaining portion of the
mechanical seal. Attach the puller legs to the
main puller body. Ill. 3
This tool allows a technician to replace the
mechanical water pump seal on EH50PL engines
without removing the engine and splitting the cases.
Main puller
body
CAUTION:
Improper or careless use of this tool or procedure can
result in a bent water pump shaft. Pump shaft
replacement requires engine removal and crankcase Position the split
separation. Use caution while performing this 90° to opening
procedure. Make sure that the puller is parallel to the on main puller
shaft at all times. Do not place side loads on the water Ill. 4 body
pump shaft or strike the puller or shaft in any way.
3.42
GENERAL INFORMATION
4. Ensure that the split between the puller legs is

fully supported by the main body of the tool (Ill 4).
ONE WAY VALVE
INSTALLATION
Hex Socket Screws Install the one way valve plunger, spring, and plug
using a new sealing washer.
Puller Legs
One Way Valve Plug Torque:
16 ft. lbs. (22 Nm)
Lip must grasp inside

of mechanical seal.
CAM CHAIN DRIVE
Ill. 5 SPROCKET INSTALLATION
5. Tighten the hex socket screws on the puller legs
sufficiently so the lip of the puller legs will grasp B
the mechanical seal. Ill. 5
Tighten
1. Install the Woodruff key, drive sprocket, and

Ill. 6 slotted nut. Tighten the nut to the specified
torque.
6. Turn the puller T-Handle clockwise until it
contacts the water pump shaft. Continue rotating
until the remaining portion of mechanical seal has Slotted Nut Torque:
been removed from the cases. Ill. 6 Pump shaft
oil seal can also be replaced at this time if 35-51 ft. lbs. (47-69 Nm)
necessary.
7. The Water Pump Install Kit (PN 5131135) is
required to install the new mechanical seal. This
tool is available separately and it is also included
in the Crankshaft/Water Pump Seal Installation
Kit (PN 2871283).
3.43
GENERAL INFORMATION
TENSIONER BLADE 5. Install the top ring (chrome faced) with the “R”
mark facing up and the end gap facing forward
INSTALLATION (toward the exhaust). (See ILL. 1).
6. Check to make sure the rings rotate freely in the
1. Install the tensioner blade and tighten the groove when
mounting bolt to specified torque. compressed.
Ring Profile
Tensioner Blade Mounting Bolt Torque:
6 ft. lbs. (8 Nm)
Top
PISTON RING INSTALLATION Mark up
NOTE: Apply clean engine oil to all ring surfaces and

ring lands. Always check piston ring installed gap
before rings are installed on piston. See Page 3.30.
If the piston has been in service clean any
accumulated carbon from the ring grooves and oil
control ring holes.
1. Place the oil control ring expander in oil ring
Second
groove with the end gap facing forward. The
expander has no up or down marking and can be Mark up
installed either way. The ends should butt
squarely together and must not overlap. ILL. 1
2. Install the oil ring top rail.
NOTE: The top rail has a locating tab to prevent
rotation. The tab must be positioned in the notch on
the side of the piston as shown (A).
PISTON INSTALLATION
1. Clean the gasket surfaces on the cylinder and
crankcase. Remove all traces of old gasket
material.
2. Make sure the cylinder mounting bolt holes are
clean and free of debris.
Tang Outward
3. Install the bottom rail with the gap at least 30°

from the end of the expander on the side opposite
the top rail gap.(See ILL. 1).
4. Install the second ring with the “R” mark facing up. 3. Install a new circlip on one side of the piston with
Position the end gap toward the rear (intake) side the end gap facing up or down, and tang outward.
of the piston.
CAUTION: Circlips become deformed during the
removal process. Do not re-use old circlips. Do not
3.44
GENERAL INFORMATION
compress the new clip more than necessary upon 3. Apply clean engine oil to the ring compressor
installation to prevent loss of radial tension. Severe (Snap Ont PN RCL30) and install the
engine damage may result if circlips are re-used or compressor following manufacturers
deformed during installation. instructions. CAUTION: Make sure the oil
control ring upper rail tab is positioned properly in
4. Apply clean engine oil to the piston rings, ring
the notch of the piston. Verify all ring end gaps are
lands, piston pin bore, piston pin, and piston skirt.
correctly located.
Lubricate the connecting rod (both ends),
balancer drive gear, and crankshaft main bearing
area.
Mag
or:
5. Install the piston on the connecting rod with the

arrow or : mark facing the magneto (RH) end of 4. Apply clean engine oil liberally to the cylinder bore
the crankshaft. The piston pin should be a push fit and tapered area of the sleeve. Install the
in the piston. cylinder with a slight rocking motion until the rings
6. Install the other circlip with the gap facing up or are captive in the sleeve.
down and tang outward. (See Caution with Step 3
above). Push the piston pin in both directions to
make sure the clips are properly seated in the
groove.
CYLINDER INSTALLATION
1. Place the dowel pins in the crankcase and install a
new cylinder base gasket.
5. Remove the ring compressor and support block.

6. Push the cylinder downward until fully seated on
the base gasket.
7. Apply a light film of oil to the threads and flange
surface of the cylinder mounting bolts.
8. Install all four bolts finger tight. Rotate the engine
and position the piston at BDC.
NOTE: If cam chain is installed, hold it up while
2. Position the Piston Support Block (PN 2870390) rotating the engine to avoid damage to the chain, drive
(A) beneath the piston skirt to support the piston sprocket teeth, or tensioner blade.
during cylinder installation.
3.45
GENERAL INFORMATION
9. Tighten the cylinder bolts in three steps in a criss

cross pattern and torque to specifications.
10. Install the two 6 mm bolts.
Cylinder Bolt Torque:
10mm - 46 ft. lbs. (62 Nm) Guide in

6mm - 6 ft. lbs. (8 Nm) recess
CYLINDER HEAD
INSTALLATION
Clean the gasket surfaces on the cylinder head and
cylinder. Remove all traces of old gasket material.
Refer to disassembly photos.
1. Install the cam chain tensioner guide. Be sure
bottom end of guide is located properly in
crankcase.
2. Install the two dowel pins and a new cylinder head
gasket.
3. Place the cylinder head on the cylinder. Apply a
film of engine oil to the cylinder head bolt threads
and washers, and hand tighten the bolts.
The following procedure must be used to torque the
cylinder head properly:
CAM CHAIN/CAMSHAFT
Torque all bolts evenly in a criss cross
pattern
INSTALLATION
Install the cam chain over the crankshaft.
*Torque bolts to 22 ft. lbs. (30 Nm)
CAUTION: Serious engine damage may result if the
*Torque bolts to 51 ft. lbs. (70 Nm) camshaft is not properly timed to the crankshaft.
IMPORTANT CAMSHAFT TIMING NOTE: In order
*Loosen bolts evenly 180° (1/2 turn)
to time the camshaft to the crankshaft, the piston must
*Loosen bolts again another 180° (1/2 be precisely located at Top Dead Center (TDC).
turn)
CAMSHAFT TIMING
*Torque bolts to 11 ft. lbs. (15 Nm)
*From this point, tighten bolts evenly

90° (1/4 turn)
*Finally, tighten another 90° (1/4 turn)
*Install two 6mm bolts and torque to 6

ft. lbs. (8 Nm)
3.46
GENERAL INFORMATION
1. Apply Polaris Premium Starter Drive Grease (PN

2871460) to the camshaft main journals and cam B
lobes. Lubricate automatic compression release A
mechanism with clean engine oil. (To install the
compression release mechanism, refer to Page
3.17).
2. Install the camshaft with the lobes facing
downward and the sprocket alignment pin facing
upward.
Single (TDC)
Mark Aligned
5. Before positioning the sprocket on the camshaft,

check the position of the cam sprocket alignment
pin. When the cam is positioned properly, the
cam sprocket alignment pin (A) is directly in line
with the crankshaft/camshaft centerline (B).
6. Install the sprocket on the camshaft. Apply
Loctitet 242 (PN 2871949) to the cam sprocket
3. Disconnect the wire from the cam chain and
bolts and torque to specifications.
rotate the engine to align the single (TDC ) timing
mark (Top Dead Center) on the flywheel with the
notch in the timing inspection window. Be sure to
use the single TDC mark when installing the cam. Cam Sprocket Bolt Torque:
Do not use the advance marks. See Ill. on next
page. 6 ft. lbs. (8 Nm)
A Single (TDC)
Mark Aligned
7. Verify TDC mark in timing inspection hole and

alignment pin is directly in line with crankshaft to
camshaft centerline. Refer to Ill. on following
4. Loop the cam chain on the cam sprocket with the page.
dots on the sprocket facing outward and the 8. Apply Crankcase Sealant (PN 2871557) to the
alignment pin notch facing directly upward. camshaft end cap and install using a new O-Ring.
9. Check all cam timing marks to verify proper cam

timing, and install the cam chain tensioner body
with a new gasket.
10. After tensioner installation, rotate engine at least
two revolutions and re-check marks/timing.
3.47
GENERAL INFORMATION
CAMSHAFT TIMING
Crankshaft to Camshaft Centerline

Dots
Sprocket Alignment Pin
Single TDC Mark Aligned

TDC Mark
Rotation
Do Not Use
Advance Marks
3.48
GENERAL INFORMATION
CAM CHAIN TENSIONER 2. Install a new O-Ring in the oil passage recess in
the crankcase.
INSTALLATION 3. Apply 3 Bond 1215 (PN 2871557) or an
equivalent sealer to the stator plate outer surface
and install a new O-Ring.
B
A
1. Release the ratchet pawl (A) and push the

tensioner plunger (B) all the way into the
tensioner body.
2. Install the tensioner body with a new gasket and 4. Install the stator plate being careful not to damage
tighten the bolts. the seal. Align timing reference marks on the
plate and crankcase. Be sure the plate is fully
seated.
Tensioner Bolt Torque:
NOTE: This is a static timing mark. Strobe timing
should be performed after start up.
6 ft. lbs. (8 Nm)
5. Torque bolts evenly to specification.
3. Install the spring, new sealing washer, and

tensioner plug. Stator Plate Bolt Torque:
5-6.5 ft. lbs. (7-9 Nm)

Tensioner Plug Torque:
6. Seal stator wire grommet with Crankcase Sealant
17 ft. lbs. (23 Nm) (PN 2871557) or equivalent sealer.
Flywheel
4. Slowly rotate engine two to three revolutions and
re-check cam timing. 1. Install flywheel, washer, and nut. Torque flywheel
to specification.
STATOR, FLYWHEEL AND Flywheel Nut Torque:

STARTER DRIVE 58-72 ft. lbs. (78-98 Nm)
INSTALLATION
NOTE: The stator, flywheel, starter drive, and recoil
can be assembled with the engine in the frame.
Stator
1. Apply a light film of grease to the crankshaft seal.
Apply molybdenum disulfide grease or assembly
lubricant to the crankshaft bushing.
3.49
GENERAL INFORMATION
Starter Drive 5. Be sure the dowel pins are in place and install the
rocker shaft assembly.
6. Apply a light film of engine oil to the threads of the
bolts and tighten evenly.
Rocker Shaft Support Tower Bolt Torque:
9 ft. lbs. (12 Nm)
Rocker Shaft Locating Bolt Torque:
6 ft. lbs. (8 Nm)
7. Adjust valves according to the valve adjustment

procedure found in Chapter 2, Maintenance.
1. Be sure the washer is positioned on the back of
the drive gear. 8. Apply clean engine oil liberally to the valve
springs, cam chain, rocker arms, and camshaft.
Apply Starter Drive 9. Place a new rocker cover gasket on the cylinder
Grease to Bushing head and install the cover and bolts.
Rocker Cover Bolt Torque:
6 ft. lbs. (8 Nm)
THERMOSTAT INSTALLATION
2. Apply starter drive grease to the drive bushing in
the crankcase and all moving surfaces of the
starter drive mechanism. Install the starter drive.
3. Install recoil housing gasket and recoil housing.
Starter Drive Grease:
(PN 2871460)
ROCKER SHAFT/ROCKER
ARM ASSEMBLY
INSTALLATION
Install the thermostat with one of the air bleed holes
1. Assemble rocker arms, rocker shaft, and shaft
positioned next to the upper thermostat cover bolt
supports.
hole as shown.
2. Install and tighten rocker arm shaft locating bolt.
3. Apply starter drive grease to the cam lobes and
cam follower surfaces.
4. Rotate the engine until the cam lobes are pointing
downward.
3.50
GENERAL INFORMATION
OIL PIPES 11. Remove center bolt from recoil friction plate (A).
Install the oil pipes with new sealing washers. Tighten

all bolts evenly to specified torque.
Oil Pipe Bolt Torque:
20 ft. lbs. (27 Nm)
RECOIL
DISASSEMBLY/INSPECTION
CAUTION: The recoil is under spring tension. A face
shield and eye protection is required during this
12. Inspect plate for wear or damage. Inspect plate
procedure.
friction spring for wear, damage, and proper
Replace any parts found to be worn or damaged. tension. The spring should fit tightly on friction
plate.
REMOVE BOLTS AND

RECOIL HOUSING
13. Remove ratchet pawl with spring and inspect.

Replace spring or ratchet pawl if worn, broken, or
damaged.
10. Pull recoil rope so it is extended approximately NOTE: Long arm of spring engages reel. Short end
12-18″. Check handle c-ring for proper tension, against pawl.
and the handle for cracks or damage which may 14. Hold reel firmly in housing. Pull rope handle until
allow water or dirt to enter the recoil housing 12-18″ of rope is exposed, and hold reel in place.
through the rope. NOTE: The handle must seal 15. Place rope in notch on outer edge of reel.
tightly on the recoil housing to prevent water from Release tension on hub and allow reel to unwind
entering. approximately 6-7 turns until spring tension is
released.
3.51
GENERAL INFORMATION
To reinstall an old spring:

A 1. Hook outer tab in place in recoil housing and wind
spring in a counterclockwise direction one coil at a
time while holding the installed coils in place.
2. Lubricate the spring with light lubricant such as
Premium All Season Grease (PN 2871423).
To complete recoil assembly:

1. Route rope through guide bushing in recoil
housing and into reel. Tie a secure knot in end of
the rope.
2. Wind rope counterclockwise onto the reel, as
viewed from ratchet side of reel.
3. Lock rope into notch on outer edge of reel.
16. Slowly and carefully remove reel from recoil 4. Apply a small amount of grease or equivalent to
housing making sure the spring remains in the the center post of the housing and the bushing.
housing. Inspect the reel hub and bushing (A) for
wear.
Open end here
17. Unwind rope and inspect for cuts or abrasions.
18. Inspect drive tab on hub return spring for damage.
To remove hub return spring, hold outer coils in
place with one hand and slowly remove spring
one coil at a time from the inside out.
19. Pull knot out of of recoil reel. Untie knot. Remove
rope from reel.
RECOIL ASSEMBLY
CAUTION: Be sure to wear a face shield and eye
protection when performing this procedure.
5. Install reel into housing making sure the spring
drive tab on the reel engages the spring and the
reel is fully seated in the housing.
6. Apply downward pressure on the reel and rotate
counterclockwise approximately 6-7 turns to
pre-wind the spring. Continue rotating
counterclockwise until rope on outer edge aligns
with rope guide bushing.
7. Release rope from notch and allow reel to rewind
completely. If more pre-wind is required, place rope
in notch and add additional turns of pre-wind.
8. Install ratchet pawl and return spring, with long leg
of spring engaged in reel.
9. Reinstall friction plate. NOTE: The friction plate
must be positioned with both end tabs of the
To install a new spring: friction spring opposite the ratchet pawl.
10. Torque friction plate retaining bolt to 5-6 ft. lbs.
1. Place spring in housing with the end positioned so
(7-9 Nm).
the spring spirals inward in a counterclockwise
direction. See photo at right. 11. Reinstall recoil housing using a new gasket. Seal
stator wire harness grommet with RTV silicone.
2. Hold spring in place and cut retaining wire.
3.52
GENERAL INFORMATION
SPARK PLUG FOULING S Dead battery

S Starter motor does not turn
S Spark plug cap loose or faulty S Engine seized, rusted, or
S Choke cable adjustment or mechanical failure
plunger/cable sticking Engine Runs But Will Not Idle
S Foreign material on choke plunger
S Restricted carburetor pilot system
seat or plunger
S Carburetor misadjusted
S Incorrect spark plug heat range or
gap S Choke not adjusted properly
S Carburetor inlet needle and seat S Low compression
worn S Crankcase breather restricted
S Jet needle and/or needle jet worn or Engine Idles But Will Not Rev Up
improperly adjusted
S Spark plug fouled/weak spark
S Excessive carburetor vibration
S Broken throttle cable
(loose or missing needle jet locating
pins) S Obstruction in air intake
S Loose jets in carburetor or calibration S Air box removed (reinstall all intake
incorrect for altitude/temperature components)
S Incorrect float level setting S Incorrect or restricted carburetor jetting
S PVT system calibrated incorrectly or S ETC switch limiting speed
components worn or mis-adjusted S Reverse speed limiter limiting speed
S Fuel quality poor (old) or octane too S Carburetor vacuum slide
high sticking/diaphragm damaged
S Low compression S Incorrect ignition timing
S Restricted exhaust S Restricted exhaust system
S Weak ignition (loose coil ground, Engine Has Low Power
faulty coil, stator, or ETC switch)
S Spark plug fouled
S ETC switch mis-adjusted
S Cylinder, piston, ring, or valve wear or
S Restricted air filter (main or damage (check compression)
pre-cleaner) or breather system
S PVT not operating properly
S Improperly assembled air intake
S Restricted exhaust muffler
system
S Carburetor vacuum slide
S Restricted engine breather system
sticking/diaphragm damaged
S Oil contaminated with fuel
S Dirty carburetor
S Restricted oil tank vent
Piston Failure - Scoring
S Lack of lubrication
TROUBLESHOOTING S Dirt entering engine through cracks in air
Engine Turns Over But Fails to Start filter or ducts
S Engine oil dirty or contaminated
S No fuel
S Dirt in fuel line or filter Excessive Smoke and Carbon Buildup
S Fuel will not pass through fuel valve S Excessive piston-to-cylinder clearance
S Fuel pump inoperative/restricted S Wet sumping
S Tank vent plugged S Worn rings, piston, or cylinder
S Carb starter circuit S Worn valve guides or seals
S Engine flooded S Restricted breather
S Low compression (high cylinder S Air filter dirty or contaminated
leakage) Low Compression
S No spark (Spark plug fouled)
S Decompressor stuck
Engine Does Not Turn Over
3.53
GENERAL INFORMATION
S Cylinder head gasket leak S Ignition timing misadjusted

S No valve clearance or incorrectly S Low oil level
adjusted S Spark plug incorrect heat range
S Cylinder or piston worn S Faulty hot light circuit
S Piston rings worn, leaking, broken, or S Thermostat stuck closed or not opening
sticking completely
S Bent valve or stuck valve Temperature Too Low
S Valve spring broken or weak
S Thermostat stuck open
S Valve not seating properly (bent or
Leak at Water Pump Weep Hole
carbon accumulated on sealing surface)
S Rocker arm sticking S Faulty water pump mechanical seal
(coolant leak)
Backfiring
S Faulty pump shaft oil seal (oil leak)
S ETC or speed limiter system malfunction
S Fouled spark plug or incorrect plug or
plug gap
S Carburetion faulty - lean condition
S Exhaust system air leaks
S Ignition system faulty:
Spark plug cap cracked/broken
Ignition coil faulty
Ignition or kill switch circuit faulty
Ignition timing incorrect
Sheared flywheel key
S Poor connections in ignition system
S System wiring wet
S Valve sticking
S Air leaks in intake
S Lean condition
COOLING SYSTEM
TROUBLESHOOTING
Overheating
S Low coolant level
S Air in cooling system
S Wrong type of coolant
S Faulty pressure cap or system leaks
S Restricted system (mud or debris in
radiator fins or restriction to air flow,
passages blocked in radiator, lines,
pump, or water jacket)
S Lean mixture (restricted jets, vents, fuel
pump or fuel valve)
S Fuel pump output weak
S Restricted radiator (internally or cooling
fins)
S Water pump failure
S Cooling system restriction
S Cooling fan inoperative or turning too
slowly (perform current draw test)
3.54
GENERAL INFORMATION
Exploded View, Mikuni BST 34 Carburetor . . . 4.2

Fuel Tank Asm. Exploded View . . . . . . . . . . . . 4.3
Fuel Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . 4.3
Special Tool & Jetting Guidelines . . . . . . . . . . 4.4
Carburetor Jetting . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Main Jet / Pilot Jet Part Numbers . . . . . . . . . . . 4.4
CV Carburetor System Function (4 Cycle) . . . 4.5
CV Carburetor Vent System (4 Cycle) . . . . . . . 4.5
CV Carburetor Operation . . . . . . . . . . . . . . . . . . 4.5-4.7
Disassembly Notes, CV Carburetor . . . . . . . . . 4.7-4.8
Cleaning, CV Carburetor . . . . . . . . . . . . . . . . . . 4.8
Inspection, CV Carburetor . . . . . . . . . . . . . . . . . 4.9
Assembly, CV Carburetor . . . . . . . . . . . . . . . . . 4.9-4.10
Float Adjustment, CV Carburetor . . . . . . . . . . . 4.10
Needle & Seat Leakage Test . . . . . . . . . . . . . . . 4.10
Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Fuel Pump Service . . . . . . . . . . . . . . . . . . . . . . . 4.11
Fuel Pump Exploded View . . . . . . . . . . . . . . . . . 4.12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
4.1
GENERAL INFORMATION
1. Carburetor Assembly
BST 34 CARBURETOR EXPLODED VIEW 2. Screw
3. Throttle Valve
4. Cover, Diaphragm
5. Jet Block Assembly
6. Spring
7. Diaphragm Assembly
8. Ring
9. “E” Ring
10. Ring
11. Needle Jet
12. Cover
13. O-Ring
14. Throttle Shaft Assembly
15. Ring
16. Seal
17. Spring
18. Packing
19. “E” Ring
20. Cap
21. Screw
22. Drain Screw
23. O-Ring
24. Washer
25. Adjuster
26. Spring
27. Pilot Jet
28. Main Jet
29. Washer
30. Jet Needle
31. Float Assembly
32. Float Body Assembly
33. Float Pin
34. Needle Valve
35. O-Ring
36. O-Ring
37. Filter
38. Screw
39. Screw
22
40. Screw
1 41. Guide Holder
2
42. Spring
3
4 43. Plunger Assembly
5 44. Spring Washer
45. Screw
46. Air Jet
47. Cable Guide
Jet Needle
Refer to Page 4.4 for Jet Part Numbers “E” Clip Position 48. Spring
49. Ring
50. Adjust Screw
51. Screw and Washer Assy.
4.2
GENERAL INFORMATION
FUEL TANK ASSEMBLY
Vent Line
Cap
Gasket
Seal Foam
Mounting Bracket
Forward
Foil
Fuel Valve
Fuel Valve Knob

Foil
Fuel Outlets
FUEL FLOW
Fuel Tank Vent Fuel Tank
Fitting Screens
L Fuel Pump Filter Fuel Valve
Carburetor Vent
Carburetor Engine
L Located Above Oil Tank
4.3
GENERAL INFORMATION
SPECIAL TOOLS outside this temperature and/or altitude range. The

jetting installed in production is not intended for all
PART NUMBER TOOL altitudes and/or temperatures. In addition, air screw
DESCRIPTION / pilot screw adjustments and PVT adjustments may
2870975 Mity Vact be required to suit operating conditions.
Pressure Test Tool
2872314 Carburetor Float
Adjustment Tool CARBURETOR JETTING
WARNING
CAUTION:
Gasoline is extremely flammable and explosive under
certain conditions. A main jet that is too small will cause a lean
operating condition resulting in serious engine
damage. Select the correct main jet carefully for
Always stop the engine and refuel elevation and temperature according to the
outdoors or in a well ventilated area. charts on page 1.4 or in the Owner’s Safety and
Maintenance Manual for each particular model.
Do not overfill the tank. The tank is at
IMPORTANT: The following guidelines must be
full capacity when the fuel reaches the
bottom of the filler neck. Leave room followed when establishing a main jet setting:
for expansion of fuel. 1. Select the lowest anticipated temperature at
which the machine will be operated.
Never start the engine or let it run in an 2. Determine the lowest approximate altitude at
enclosed area. Gasoline powered engine which the machine will be operated.
exhaust fumes are poisonous and can
cause loss of consciousness and death in 3. Select the correct main jet from the chart on page
a short time. 1.4.
4. Clutching changes may also be required for
changes in elevation. Refer to clutching chart on
Never drain the float bowl when the engine
is hot. Severe burns may result. page 1.4 for recommendations.
Do not smoke or allow open flames or

MIKUNI JET PART NUMBERS
sparks in or near the area where refueling
is performed or where gasoline is stored. Main Jets Pilot Jets
Jet Number Part Number Jet Number Part Number
112.5 3130554 40.0 3130624
If you get gasoline in your eyes or if you
115 3130555 42.5 3130526
should swallow gasoline, seek medical 117.5 3130556
attention immediately. 120 3130557
122.5 3130558
If you spill gasoline on your skin or clothing, 125 3130559
immediately wash with soap and water and 127.5 3130560
change clothing. 130 3130561
132.5 3130562
135 3130563
JETTING GUIDELINES 137.5
140
3130564
3130527
142.5 3130566
Changes in altitude and temperature affect air density,
145 3130567
which is essentially the amount of oxygen available for 147.5 3130568
combustion. In low elevations and cold temperatures, 150 3130569
the air is more dense and has more oxygen. In higher 152.5 3130570
elevations and higher temperatures, the air is less 155 3130571
dense with reduced oxygen. 157.5 3130572
160 3131141
Polaris ATV Carburetors are calibrated for an altitude 162.5 3131142
of 0-6000 ft. (0-1800 meters) and ambient 165 3131143
temperatures between +40 and +80° F (+5° to +26° 167.5 3131144
C). Carburetors must be re-calibrated if operated 170 3131145
4.4
GENERAL INFORMATION
CV CARBURETOR SYSTEM VENT SYSTEMS - CV

FUNCTION CARBURETOR
The carburetor float bowl vent lines supply
Carburetor Component Function
atmospheric pressure to the float bowl. The lines
must be free of kinks, restrictions and be properly
System Main Main Main routed. This allows fuel to flow in the proper amount
Components Function Affect and prevents contaminants from entering the
Float Inlet Pipe, Maintains All systems carburetor.
System Needle and specified All throttle
(Level Control) Seat, Float, fuel level in ranges MIKUNI CV CARB
Float Pin float cham-
ber (carbu- OPERATION
retor float
bowl)
The constant velocity carburetor incorporates a
Venting Passages in Supplies All systems mechanically operated throttle plate and a vacuum
Carburetor, atmospheric All throttle
Vent lines pressure to ranges
controlled slide valve (vacuum slide). The venturi
to frame float cham- cross-sectional area in the carburetor bore is
ber increased or decreased automatically by the vacuum
slide, which moves according to the amount of
Starter Choke Lever, Supplies All throttle
(Choke/En- Cable, Plung- additional ranges
negative pressure (less than atmospheric) present in
richment) er, Return fuel air mix- Greatest ef- the venturi.
Spring, Carb ture neces- fect at low
Passages sary for cold throttle set-
A diaphragm attached to the top of the vacuum slide
(Starter Jet, starting tings and is sealed to the slide and to the carburetor body
Starter Bleed idle forming two chambers. The chamber above the
Pipe) diaphragm is connected to the venturi area by a drilled
Pilot (Idle Pilot Jet/ Primarily Mainly idle orifice in the center of the vacuum slide. The chamber
System) Passage- supplies fuel to 1/4 below the diaphragm is vented to atmospheric
ways, Pilot- at idle and throttle pressure by a passage on the air box side of the
Mixture low throttle Minimal ef- carburetor. A spring, installed in the center of the
Screw with positions fect after 1/2 vacuum slide, dampens the slide movement and
Spring throttle assists the return of the slide.
Washer and
Sealing O-
Ring, By- Low Pressure
Diaphragm From Venturi
pass Ports Air Box
(Behind Pressure
Throttle
Plate), Pilot
Air Jet, Pilot
Outlet,
Throttle
Plate From
Air Box
Main Sys- Main Jet, Supplies 1/4 to full
tem Main Air Jet, fuel at mid- throttle
Main Air range and
Passage, high throttle Vacuum
Throttle Slide
Needle Jet, settings.
Plate
Jet Needle,
Vacuum
Slide,
Throttle
Plate
Venturi
= Air Flow = Low Pressure
4.5
GENERAL INFORMATION
CARBURETOR OPERATION CONT’D
When the throttle plate is opened and engine speed

begins to increase, the pressure in the venturi (and
therefore in the chamber above the diaphragm) 4
becomes significantly lower than atmospheric.
Atmospheric pressure in the chamber below the
diaphragm forces the diaphragm upward, raising the
slide against spring pressure. When the pressure 1
above and below the diaphragm are nearly equal, the
slide moves downward under spring pressure. 6
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.
7
This provides improved fuel atomization and optimum
fuel/air ratio.
5
2
Low Pressure
Diaphragm From Venturi 3
Vacuum
Slide
STARTER SYSTEM (CHOKE

From
Air Box
OR ENRICHMENT)
When the choke cable (1) is activated, the starter
plunger (5) is lifted off the seat.
8
5
Throttle 1
Plate
Venturi
6
7
= Low Pressure
4
= Air Flow
Note: Diagrams are for explanation of theory only, and are not true 2
representations of Mikuni BST carburetor.
PILOT (IDLE AND SLOW) Fuel is drawn into the starter circuit from the float
chamber (2) through the starter jet (3). Starter jet
SYSTEM meters this fuel, which then flows into starter pipe (4)
and mixes with the air (7) coming from the float
This system supplies fuel during engine operation
chamber. The mixture, rich in fuel content, reaches
with throttle valve closed (1) or slightly opened. The
starter plunger and mixes again with the air coming
fuel from float chamber (2) is metered by pilot jet (3)
through a passage (8) extending from underneath the
where it mixes with air coming in through pilot air jet
diaphragm. The rich fuel/air mixture for starting is
(4). The mixture then goes up through pilot passage
discharged through starter outlet (6) in the the main
to pilot screw (5). A part of the mixture is discharged
bore.
into the main bore out of bypass ports (6). The
remainder is then metered by pilot screw and
discharged into the main bore through pilot outlet (7).
4.6
GENERAL INFORMATION
FLOAT SYSTEM
Fuel enters the float chamber (3) by means of the inlet
pipe and passage, through a screen on the back of the
inlet needle seat (4), and around the inlet needle (2).
As the fuel fills the float chamber, the float (1) rises and 1
forces the inlet needle against the seat, shutting off 2
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 chamber. As the fuel level falls, 7
floats go down and needle valve unseats itself to
admit fuel into the chamber. In this manner, the
needle valve admits and shuts off fuel alternately to A
6
maintain a practically constant fuel level inside the
float chamber.
3
5
Inlet CARBURETOR
Pipe
DISASSEMBLY - MIKUNI CV
Use the following disassembly, assembly, and
inspection techniques to service a CV carburetor.
1. Remove carburetor diaphragm chamber cover
with a ratchet style screwdriver. DO NOT use an
1 3 impact driver to remove the screws or carburetor
may be permanently damaged.
4
2
MAIN SYSTEM
As throttle valve (1) is opened, engine speed rises,
and this increases negative pressure in the venturi.
Consequently the vacuum slide (2) moves upward.
The fuel in float chamber (3) is metered by main jet (4),
and the metered fuel enters needle jet (5), in which it
mixes with the air admitted through main air jet (6) to
form an emulsion. The emulsified fuel then passes
through the clearance between needle jet (5) and jet
needle (7), and is 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.
4.7
GENERAL INFORMATION
CARBURETOR DISASSEMBLY CONT’D NOTE: The starter jet is not removeable. Upon
disassembly, place the parts in a container for safe
2. Remove float bowl and carefully remove the
keeping.
pressed float pin.
Support Here
Pilot Screw
Starter Jet
NOTE: Be careful not to damage the float pin tower

during the float pin removal. Support the float pin
tower while removing the float pin. This helps to
prevent the float pin towers from breaking off. CARBURETOR CLEANING
3. Remove inlet needle seat retaining screw along WARNING
with plate, and carefully remove needle seat.
NOTE: Do not use a pliers to remove the seat or Protect eyes from contact with cleaner. Take
permanent damage may occur. appropriate safety measures during these
procedures. Safety glasses and chemical resistant
gloves are required. Should you get cleaner in your
eyes or if you swallow cleaner, seek medical attention
immediately.
Carburetor cleaners can be extremely caustic.
Extended periods of soaking can loosen the adhesive
sealer on the passage drill-way plugs. Do not soak
rubber or plastic components (such as the vacuum
slide diaphragm, needle seat screen, or O-Rings in
caustic cleaning solutions. Irreparable damage may
occur. Do not use agitator--type carburetor cleaning
equipment. Rubber parts must be cleaned with mild
detergent and hot water only.
1. Thoroughly clean the carburetor body, jets, and
all passages with carburetor cleaner or electrical
4. Remove the pilot mixture screw, spring, flat
contact cleaner.
washer, and O-Ring. If an anti-tamper plug is
installed over the pilot screw cavity, it must be 2. If the carburetor is extremely dirty or
removed for access. contaminated with fuel residue and varnish, soak
for short periods only in carburetor cleaner, and
rinse in hot water.
3. Replace the jets if they have a buildup of fuel
residue or bacterial growth that cannot be
O-Ring removed. Even a small amount of residue will
reduce the flow characteristics of the jet.
Washer
4. Verify all passages and jets are unobstructed by
Spring
spraying electrical contact cleaner through the
passages. CAUTION: Do not use wire or welding
tip cleaners as the orifice size may be altered.
Pilot Screw
5. Use low pressure air to dry carburetor body and
all components.
4.8
GENERAL INFORMATION
CARBURETOR INSPECTION CARBURETOR ASSEMBLY

1. Inspect jet needle and needle jet for wear. Look Inspect the diaphragm (A) for holes, deterioration, or
for discoloration, shiny spots, or an area that damage. Make sure the diaphragm is pliable but not
looks different than the rest of the needle. The swollen. The diaphragm should fit properly in the
middle to upper portion of the needle contacts the carburetor body. Replace diaphragm assembly if
needle jet and is the most likely wear point. If jet diaphragm is damaged.
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.
Jet Needle Needle Jet
Inspect this C
area B
D
A
E
2. Inspect the inlet needle tapered surface for any

sign of wear or damage. Be sure the spring
loaded pin is free moving and returns freely when
pushed. The inlet needle and seat should be
3. Replace parts in proper order. The spring seat
pressure tested after assembly.
washer (B) is stepped and must be placed on
TOP of “E” Clip (C). Spacer washer (D) must be
installed below the E-Clip. Refer to parts manual
for more information.
Good Condition Worn, Deposits
4. Be sure the tab (E) on outer edge of diaphragm is
positioned properly in the carburetor body.
Seat
Wear areas
Needle
Pilot Screw
4.9
GENERAL INFORMATION
CARBURETOR ASSEMBLY CONT’D 3. If adjustment is necessary, bend the tongue

slightly. Be sure float measurement is even on left
5. Install the pilot mixture screw, spring, washer, and
and right side.
O-ring as an assembly. Lubricate the O-Ring with
oil or light grease before installation. CAUTION:
Do not damage the O-ring during installation. Float arms even
Turn the screw in until it lightly contacts the seat.
Back out the specified number of turns. NOTE:
The final pilot (idle) mixture must be adjusted with
the engine running. Refer to Page 2.13.
Pilot Mixture Screw Base Setting

(Set at Factory)
Refer to Specifications Page 1.4

Bend to adjust
float
FLOAT HEIGHT
ADJUSTMENT
1. Place the carburetor on a level surface as shown
at right to remove weight from float arm. In this NEEDLE AND SEAT
position, the float tongue will rest lightly on the
inlet needle valve pin without compressing the LEAKAGE TEST
spring.
1. Install the float bowl. Invert the carburetor and
install a Mity-Vact (PN 2870975) to the fuel inlet
fitting. Apply 5 PSI pressure to inlet fitting. The
needle and seat should hold pressure indefinitely.
If not, inspect needle and seat and seat O-ring.
Float Height:
Std: BST 34 13--14 mm (.51--.55 inches)
2. Measure the height from the float bowl mating Mity Vact (PN 2870975)
surface to the top of step in float as shown. Both
sides of float should be parallel to each other. The
measurement should be made at the mid-point on
the top of the float using Float Adjustment Tool
(PN 2872314) or a vernier caliper. When
measuring the height be sure the inlet needle
valve spring is not compressed.
4.10
GENERAL INFORMATION
FUEL LEVEL If fuel is present in the impulse line or vacuum

chamber of the pump, the diaphragm is ruptured. The
A fuel level test can be performed on some models if pump diaphragms must be replaced.
the drain hose fitting is accessible. Be sure to
re-attach the bowl drain hose after performing the Fuel Pump
test. A fuel level test allows you to observe the height
of the fuel in the float bowl without removing 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..
Fuel Filter
1. Attach a clear line to drain fitting. Be sure line fits
tightly on fitting. Position hose along side of
carburetor as shown.
Impulse line
1.5 mm
FUEL PUMP DISASSEMBLY
.060″ 1. Remove the screws from the pump diaphragm
Bowl Mating cover. Note the location of the two longer screws.
Surface
2. Remove the diaphragm cover gasket,
diaphragm, and valve body gasket.
3. Remove the outlet check valve cover, diaphragm,
2. Open bowl drain screw by turning and gasket.
counterclockwise approximately two turns. Start
and run engine for 3 to 5 seconds to allow fuel
level to stabilize in the line. If level is out of FUEL PUMP
specification, remove carburetor and inspect inlet
needle and seat, float height, passages, etc. INSPECTION/ASSEMBLY
NOTE: If a line was removed to perform this 1. Inspect inlet and outlet check valves for cracks,
procedure, it must be replaced.
warpage or damage. Inspect the diaphragms for
cracks, holes or swelling.
FUEL PUMP 2. To clean the valves or pump body, remove the set
screw and washer. Remove the valve and wash
This Polaris ATV is equipped with a pressure with soap and water. Carburetor cleaner may be
regulated fuel pump (1-3 PSI). The pump is located used to clean the pump body when the check
under the left front fender of the machine. valves are removed. CAUTION: Some
carburetor cleaners are very caustic and should
To test the fuel pump: not be used to clean the non-metal parts of the
1. Turn fuel off. fuel pump.
2. Disconnect impulse line from pump. 3. Check the sealing surfaces of the pump body and
covers. Carefully remove all traces of old gasket
3. Connect Mity-Vact (PN 2870975) to the impulse
and check the surfaces for damage. Replace
line fitting on the pump.
diaphragms and gaskets as a set.
4. Apply 5 inches (Hg) vacuum to the pump fitting.
4. Reassemble the pump in the reverse order of
The diaphragm should hold vacuum indefinitely.
disassembly. Tighten all screws evenly.
4.11
GENERAL INFORMATION
FUEL PUMP EXPLODED VIEW
4 5
5 1. Fuel Pump Assembly

2. Diaphragm, Gasket Set
3. Screw and Washer Assembly
6. Pressure Regulator
7. Fuel Inlet
8. Fuel Outlet
3
2
8 1
4.12
GENERAL INFORMATION
TROUBLESHOOTING S Loose jets

S Worn jet needle/needle jet or other
FUEL STARVATION/LEAN MIXTURE carburetor parts
S Dirty carburetor (air bleed
Symptoms: Hard start or no start, bog, backfire, passages or jets)
popping through intake / exhaust, hesitation,
detonation, low power, spark plug erosion, engine S Weak or damaged vacuum piston
runs hot, surging, high idle, idle speed erratic. return spring
S No fuel in tank S Fouled spark plug
S Restricted tank vent, or routed
improperly POOR IDLE
S Fuel lines or fuel valve restricted Idle Too High
S Fuel filter plugged S Idle adjusted improperly/idle
S Carburetor vent line(s) restricted mixture screw damaged
S Plugged or restricted inlet needle S Sticky vacuum slide
and seat screen or inlet passage S Throttle cable sticking, improperly
S Clogged jets or passages adjusted, routed incorrectly
S Float stuck, holding inlet needle S Choke cable sticking, improperly
closed or inlet needle stuck adjusted, routed incorrectly
S Float level too low S Plugged or restricted idle jet
S Fuel pump inoperative
S Air leak at impulse line Idle Too Low
S Restricted impulse line (kinked, S Choke cable bending or incorrectly
pinched) adjusted
S Intake air leak (throttle shaft, intake S Idle speed set incorrectly
ducts, airbox or air cleaner cover) S Idle mixture screw misadjusted or
S Ruptured vacuum slide diaphragm, damaged
Vacuum slide stuck closed or sticky S Belt dragging
S Improper spring S Ignition timing incorrect
S Jet needle position incorrect S Worn jet needle/needle jet
S Incorrect pilot screw adjustment S Plugged or restricted idle jet
RICH MIXTURE Erratic Idle

Symptoms: Fouls spark plugs, black, sooty exhaust S Choke cable bending or incorrectly
smoke, rough idle, poor fuel economy, engine runs adjusted
rough/ misses, poor performance, bog, engine loads S Throttle cable incorrectly adjusted
up, backfire. S Air leaks, dirty carburetor passages
S Air intake restricted (inspect intake (pilot circuit)
duct) S Pilot mixture screw damaged or
S Air filter dirty/plugged adjusted incorrectly
S Choke plunger sticking, incorrectly S Tight valves
adjusted choke S Ignition timing incorrect
S Choke cable binding or improperly S Belt dragging
routed
S Dirty air cleaner
S Incorrect pilot air/fuel screw
adjustment S Engine worn
S Faulty inlet needle and seat S Spark plug fouled
S Faulty inlet needle seat O-Ring S Idle speed set incorrectly (speed
limiter)
S Float level too high
S Worn jet needle/needle jet
S Poor fuel quality (old fuel)
S Plugged or restricted idle jet
4.13
GENERAL INFORMATION
NOTES
4.14
GENERAL INFORMATION
Torque Specifications and Special Tools . . . . . . . . 5.2

Cover/Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Dump Box, Exploded View . . . . . . . . . . . . . . . . . . . 5.3
Body Assembly, Exploded View . . . . . . . . . . . . . . . 5.4
Headlight Pod Exploded View . . . . . . . . . . . . . . . . . 5.5
Side Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Steering Assembly, Exploded View . . . . . . . . . . . . 5.7
A-Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Concentric Swing Arm Removal . . . . . . . . . . . . . . . 5.9
Concentric Swing Arm Assembly/Installation . . . . 5.10
Rear Strut Stabilizer, Exploded View . . . . . . . . . . . 5.11
Rear Swing Arm Weldment . . . . . . . . . . . . . . . . . . . 5.12
Strut Assembly Exploded View . . . . . . . . . . . . . . . . 5.13
Front Strut Cartridge Replacement . . . . . . . . . . . . 5.14
Front Strut Ball Joint Replacement . . . . . . . . . . . . . 5.14--5.15
Steering Post Assembly . . . . . . . . . . . . . . . . . . . . . . 5.15
Decal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
5.1
GENERAL INFORMATION
TORQUE SPECIFICATIONS S Lift and pull seat rearward, disengaging

seat from tabs at the rear of the fuel tank
Item Specification Side Panels (See Page 5.6)
Front A-Arm Attaching Bolt 30 ft. lbs. (41 Nm) S Remove: Seat
Front A--Arm Ball JointStud 25 ft. lbs. (35 Nm) S Disengage tabs at front and rear
Nut
Headlight Pod (See Page 5.5)
Handlebar Adjuster Block 10-12 ft. lbs. (14-17 Nm)
Front Cover
Steering Post Nut 75 ft.lbs. (16 Nm)
Steering Post Bushing Nuts 12 ft. lbs. (17 Nm) S Remove: Front rack
Steering Post Retainer Nuts 12 ft. lbs. (17 Nm) S Disengage tabs at front and rear
S Lift panel out
Rear Axle Nut - 120 ft. lbs. (165 Nm)
(Tapered Roller Bearings) Cargo Box
(Left side)
S Place box in the down position
Rear Axle Nut - 8-10 ft. lbs. (11-14 Nm)
(Tapered Roller Bearings)
S Disconnect taillight harness
(Right Side) S Remove 6 bolts holding hinges to frame
Rear Shock Bolt (upper) 25 ft. lbs. (35 Nm) S Raise rear of box with assist from
Rear Shock Bolt (lower) 25 ft. lbs. (35 Nm)
dump box shock
S Remove bolt from shock at box
Rear Wheel Hub Nut 80 ft. lbs. (110 Nm)
S Lift box off frame with assistance
Rear Wheel Nut 50 ft. lbs. (69 Nm)
Rear Cab Assembly
Strut Rod Retaining Nut 15 ft. lbs. (21 Nm)
(Top) S Remove: Seat
Strut Casting Pinch Bolt 15 ft. lbs. (20 Nm) S Rear rack
Tie Rod End Jam Nut 12-14 ft. lbs. (17-19 Nm) S 1 screw, nut and washer at rear of inner
left footrest
Tie Rod End Castle Nut 23-24 ft. lbs. (32-33 Nm)
S 4 screws at bottom of left rear mud flap
Tie Rod End Attaching Bolt 25-30 ft. lbs. (35-41 Nm)
S 1 screw, nut and washer at rear of inner
NOTE: Refer to exploded views throughout this right footrest
chapter for identification and location of components. S 4 screws at bottom of right rear mud flap
S 4 bolts and flat washers from top of cab
SPECIAL TOOLS assembly, under seat
PART NUMBER TOOL S 2 screws at rear bottom of cab assembly
DESCRIPTION near tail light
2870871 Ball Joint Front Rack
Replacement Tool S Remove: 4 screws, lock washers, and
2870872 Shock Spanner flat washers
Wrench
Front Cab Assembly
2870623 Shock Absorber
Spring S Remove: Seat
Compression Tool S Side panels
2871572 Strut Rod Wrench S 2 screws at rear of cab at fuel tank
2871573 LH Strut Spring mount bracket
Compressor
S Front rack
2871574 RH Strut Spring
Compressor S Front bumper
2871199 Seal Sleeve S Front cover panel
Installation Tool Kit
S 3 screws from bottom left mud flap
S 3 screws from bottom right mud flap
COVER/PANEL REMOVAL S 1 inner screw from front cab to foot
To remove, perform these steps: rest on each side
Seat: S 2 screws under front panel
S Pull release lever at the rear of the seat
5.2
GENERAL INFORMATION
DUMP BOX EXPLODED VIEW
Paddle Latch Latch

Tailgate
Shaft Latch
Tailgate Cover
Rod Hinge
Reflector
Tailgate Cable
Box
Latch
Brackets
Headrest
Tail/Brake Light
Shock
Box Support
Box Latch
NOTE: All warning information labels must be in

place when body parts are assembled.
5.3
GENERAL INFORMATION
BODY ASSEMBLY EXPLODED VIEW
Rear Cab Seat

Rear Cab Assembly
Rear Mud Guard
Front Cover
Side Cover
Front Cab
Front Cab Assembly
Footrest
Front
Mud
Guard
NOTE: All warning information labels must be in

place when body parts are assembled.
5.4
GENERAL INFORMATION
HEADLIGHT POD Torque bolts evenly so gap

is equal at front and rear of
EXPLODED VIEW handlebar block
10--12 ft. lbs.
(14--17 Nm)
B A
Disassembly Clean knurling when

S Remove two side Phillips screws (A). E repositioning handlebars
S Remove one rear Phillips screw (B). Adjuster
S Lift top half of pod.
S Disconnect speedometer wire connectors. D
S Disconnect oil indicator light wires and gear
position indicator connector.
S Disconnect 12V power plug (where applicable).
S Disconnect headlight harness.
S Remove ignition switch (C) and choke cable (D). C
S Remove headlight with adjuster.
S Remove two screws securing bottom
half of pod (E).
Assembly
S Install bottom of pod onto handlebar and secure to brackets. Handlebar clamp torque:
S Install key switch, choke cable, and headlight. 10--12 ft. lbs. (14--17 Nm)
S Connect 12V power outlet (where applicable)
S Connect headlight.
S Connect speedometer connectors to speedometer.
S Install top of pod onto bottom half, making sure interlocking tabs mate properly.
S Install two side Phillips screws.
S Install one rear Phillips screw.
S To adjust headlight, refer to procedure outlined in Maintenance chapter.
S To apply decals, refer to Page 5.15.
5.5
GENERAL INFORMATION
SIDE PANEL REMOVAL
Side panel removal may be difficult until the locking

tabs and receivers have been snapped and
unsnapped a few times.
1. Remove the seat. Grasp rear of side panel near

rear cab. With a quick and firm motion, pull the Step 1.
panel forward and outward to disengage the two
rear tabs.
Pull forward and out to disengage

two rear tabs.
2. Place hand on top of side panel behind the fuel Step 2.

tank. With a quick and firm motion, push down
on the side panel to disengage the top rear two
tabs. Then pull up on side panel to disengage
front upper and lower tab.
Push down to disengage top rear

two tabs.
3. To reinstall side panel, align panel tabs with slots on

front cab. Push panel upward and forward until tabs Step 3.
lock. Bend rear of side panel and insert the two tabs
into the rear cab.
To reinstall, align panel tabs with

slots. Push upward and forward
until tabs lock.
5.6
GENERAL INFORMATION
STEERING ASSEMBLY, 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
25-30 ft. lbs. are positioned properly.
(35-41 Nm)
Steering Post
Steering Post
Arm (Frog)
Right Hand Tie

Rod End Positioned
Between Steering
Post Arms 12-14 ft. lbs.
(17-19 Nm)
A
B
1 40-45 ft. lbs.

(54-61 Nm)
30 ft. lbs.
(41 Nm)
1
30 ft. lbs.
(41 Nm)
2
25 ft. lbs.
(35 Nm) 8 ft. lbs.
242
(11 Nm)
Always use new bolts Always use new cotter pins upon
1 upon reassembly
2 reassembly. Install with open end
toward rear of machine. Apply Loctitet 242 to
the bolt threads.
242
5.7
GENERAL INFORMATION
A-ARM REPLACEMENT
1. Elevate and safely support vehicle with weight removed from front wheel(s).
2. Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud.
3. Using a soft face hammer, tap nut to loosen A-arm from bolt. Remove nut and A-arm from hub strut assembly.
4. Loosen two bolts on A-arm tube by alternating each about 1/3 of the way until A-arm can be removed.
5. Examine A-arm shaft. Replace if worn. Discard hardware.
6. Insert A-arm shaft into new A-arm. NOTE: On AWD models, install CV joint shields. See Ill.
Vehicle Frame Bolt 30 ft. lbs. Apply Loctitet 242 to
(41 Nm) the bolt threads.
242
Bolt 30 ft. lbs. Grease Fitting
(41 Nm) Ball Joint
Stud
Washer A-Arm Tube
8 ft. lbs.
242
A-Arm Shaft (11 Nm)
25 ft. lbs Nut
(35 Nm).
CV Joint Shield Cotter Pin
(AWD Models)
7. Install new A-arm assembly onto vehicle frame. Torque new bolts to 30 ft. lbs. (41 Nm).
WARNING
The locking features on the existing bolts were destroyed

during removal. DO NOT reuse old bolts. Serious injury
or death could result if fasteners come loose during
operation.
8. Attach A-arm to hub strut assembly. Tighten ball joint

A-arm Attaching Bolt Torque:
nut to 25 ft. lbs. (35 Nm). If cotter pin holes are not
aligned, tighten nut slightly to align. Install a new cotter 30 ft. lbs. (41 Nm)
pin with open ends toward rear of machine. Bend both
ends in opposite directions around nut. Ball Joint Stud Nut Torque:
9. Locate grease fitting in center of A-arm tube and pump
A-arm full of grease. 25 ft. lbs. (35 Nm)
WARNING
Upon A-arm installation completion, test vehicle at low speeds before putting into regular service.
5.8
GENERAL INFORMATION
CONCENTRIC SWING ARM REMOVAL

Removal / Disassembly
1. Lift rear of machine and support securely with wheels off the floor.
2. Remove drive chain.
3. Remove rear caliper.
CAUTION: Do not allow the caliper to hang by the brake line. Brake line damage may result.
4. Remove rear wheels and/or hubs.
5. Remove lower shock bolt.
6. Remove Pivot Bolt Retainers.
7. Loosen both swingarm pivot bolts (5 and 8) and then remove both bolts while supporting
swingarm.
8. Remove swingarm.
9. Remove LH pivot bushing (7) and swingarm bushing (6) from swingarm.
10. Place flats of right side pivot bushing (4) in a vise to hold while removing nut (1). Heat nut with a pro
pane torch to soften LocTitet.
11. Remove two-piece bushing (3) and RH pivot bushing (4) from swingarm.
12. Clean and inspect parts for wear. Replace worn parts.
(2) Washer
(1) Nut (3) Two-piece bushing
(8) Pivot Bolt
(7) Pivot Bushing, Left

(4) Pivot Bushing, Right
(6)
Place flats of pivot bushing in
vise to hold while removing nut
(5) Pivot Bolt
Eccentric clamp bolt torque:

Models with trailer hitch - 40 ft. lbs. (55 Nm)
Models without trailer hitch - 30 ft. lbs. (41 Nm)
Refer to Maintenance section for chain adjust-
ment information on Concentric swingarm models
(tapered rear axle bearings).
5.9
GENERAL INFORMATION
CONCENTRIC SWING ARM ASSEMBLY/INSTALLATION

Assembly / Installation
1. Install bushing (6) in left side of swingarm and two-piece bushings (3) in right side.
2. Clean threads of nut (1), and pivot bushings (4) with Loctitet Primer N (PN 2870585). Apply Loctitet 262
(PN 2871951) to threads of pivot bushing (4) and nut (1).
3. Install right pivot bushing (4) through the two-piece bushing (3).
4. Install washer (2) and nut (1). Hold pivot bushing (4) in vise and torque nut (1) to 120 ft. lbs. 163 Nm).
5. Install left pivot bushing (7).
Note: There are stop plates attached to the inside of the frame to prevent the pivot bushings from turning
when the pivot bolts are tightened. The flats of the pivot bushings must be oriented correctly to align with
the frame plate, or the pivot bolt holes will not be aligned. The top flat on the nut should be approximately
parallel with top surface of the swingarm.
6. Install swingarm assembly in frame.
7. Install and tighten pivot bolts slowly until the flats of the pivot bushings (4) and (7) engage the stop plate . . . . . .
on the frame.
8. Torque swing arm bolts (5) and (8) to 150 ft. lbs. (207 Nm).
9. Install pivot bolt retainer brackets in upper hole of bulkhead. Attach with self--tapping fasteners and torque
to 15--17 ft. lbs. (19--23 Nm).
9. Install lower rear shock bolt. Torque to 25 ft. lbs. (35 Nm). Assemble rear axle, brake caliper, caliper
mount, hubs, wheels and chain. (Refer to Chapter 7)
NOTE: Allow LocTitet to cure at least 24 hours before use. Chain Guide
(8) Swing Arm Bolt

150 ft. lbs. (207 Nm) (1) Nut
Washer
Pivot Bushing
(3) Bushing
(6) Swing Arm
Bushing (8) Pivot Bolt
150 ft. lbs.
(207 Nm)
Bushing
Rock Guard
Mount Bracket
(7) Left Pivot Bushing
262
Pivot Bolt
Retainer
15--17ft. lbs. (19--23 Nm)
Swing Arm
Assembly 150 ft. lbs. (207 Nm)
Swing Arm Guard Chain Guard

Apply Loctitet 262 to
262
the bolt threads.
5.10
GENERAL INFORMATION
REAR STRUT STABILIZER
30 ft. lbs.
(41 Nm)
Grease Fittings
Upper Stabilizer
30 ft. lbs.
(41 Nm)
Lower Stabilizer
30 ft. lbs.
(41 Nm)
Swingarm
40 ft. lbs.
(54 Nm)
5.11
GENERAL INFORMATION
REAR SWING ARM

WELDMENT
Chain Cover
55 ft. lbs.
30 ft. lbs. (76 Nm)
(48 Nm)
Swing Arm Chain Cover
Extension Mounts
Swing Arm Bracket
Hitch
50 ft. lbs.
Lower Chain Guard
(54 Nm)
Guide
5.12
GENERAL INFORMATION
STRUT ASSEMBLY
Nut
15 ft. lbs. Strut Bumper
(21 Nm)
Spring Retainer
Washer
Spacer Rubber
Clamp
Upper Pivot Ball 18 ft. lbs.
(25 Nm)
15 ft. lbs.
(21 Nm)
Washer Wire retainer

Bolt
1
Spacer
2
Lower Pivot Ball
Spring Retainer
Washer
Spring Hub Coil
Use the Seal Sleeve Installation

Tool (PN 2871199)
NOTE: Be sure steel insert notch (1) and strut casting notch are lined up and provide a channel for the
magnetic coil wires to lie in. If insert and strut do not match, strut replacement will be necessary.
Grease fitting (2) location. Check lubrication guide for recommended service intervals.
Specified pole gap is 0-.001″ (0-.0254mm)
5.13
GENERAL INFORMATION
FRONT STRUT CARTRIDGE 3. Remove wheel nuts and wheels.
REPLACEMENT
NOTE: Refer to the Illustration on the previous page
for this procedure.
1. Hold strut rod and remove top nut.
C F
2. Compress spring using strut spring compressor
tools. E
Strut Rod Wrench (PN 2871572) D

B
Strut Spring Compressor Tools A
(PN 2871573) and (PN 2871574)
4. Remove cotter pin (A) from ball joint castlenut.
5. Remove castle nut (B) and separate A-arm (C)
3. Remove upper strut pivot assembly. from ball joint stud.
4. Remove coil spring and collapse strut cartridge. 6. Remove screws (D) and ball joint retaining plate
5. Remove two pinch bolts from strut casting. plate (E).
6. Remove strut cartridge. 7. Use the Ball Joint Replacement Tool (PN
7. Install cartridge until bottomed in strut casting. 2870871), remove ball joint (F) from strut
housing. Refer to photos at right.
8. Install pinch bolts with wire clamp(s). Torque
pinch bolts to 15 ft. lbs. (21 Nm).
9. Reassemble spring and top pivot assembly. Be
sure all parts are installed properly and seated G
fully. H
10. Torque strut rod nut to specification. Do not over
torque the nut.
I
J
Strut Rod Nut Torque
15 ft. lbs. (21 Nm)
BALL JOINT REPLACEMENT.

NOTE: Refer to the illustration on the previous page
for this procedure. S Install puller guide (G) with extension cap
1. Loosen front wheel nuts slightly. (H).
2. Elevate and safely support machine under S Apply grease to extension cap and
footrest/frame area. threads of puller bolt to ease removal.
CAUTION: Serious injury may result if machine tips S Thread bolt (J) with nut (I) onto ball joint
or falls. Be sure machine is secure before beginning stud as shown.
this service procedure. S Apply heat to ease removal.
S Hold bolt (J) and turn nut (I) clockwise
until ball joint is removed from strut
housing.
5.14
GENERAL INFORMATION
flame treating. Do not hold the torch too close to

the surface. Keep the torch moving to prevent
damage.
A 2. Apply the decal.
B
K
STEERING POST ASSEMBLY
C
E
D
12 ft. lbs.
(16 Nm)
8. To install new ball joint:

S Remove extension cap and attach puller
guide using short bolts provided in the kit.
S Insert new ball joint (K) into driver (L).
S Slide ball joint/driver assembly into
guide.
S Apply heat to ease installation.
S Drive new joint into strut housing until
fully seated. 1. Torque to 75 ft. lbs.
2. Align cotter pin hole.
9. Apply Loctitet 242 (PN 2871949) to threads of 3. Install cotter pin. Bend both ends of cotter pin around
retaining plate screws or install new screws with nut in opposite directions.
pre-applied locking agent. Torque screws to 8 ft. 4. Check steering, must move freely and easily from full
left to full right without binding.
lbs. (11 Nm).
10. Install A-arm on ball joint and torque castle nut to 1. Torque steering post slotted nut (A).
25 ft. lbs. (35 Nm). 2. Align the cotter pin hole on the steering post
11. Reinstall cotter pin with open ends toward rear of slotted nut.
machine. 3. Install the cotter pin. Bend both ends of the cotter
DECAL REPLACEMENT pin around the slotted nut (A) in opposite
directions.
Plastic polyethylene material must be “flame treated” 4. Check the steering, the handle bars must move
prior to installing a decal to ensure good adhesion. freely and easily from full left to full right without
The flame treating procedure can often be used to binding.
reduce or eliminate the whitish stress marks that are
sometimes left after a fender or cab is bent, flexed, or
damaged.
WARNING
The following procedure involves the use of an
open flame. Perform this procedure in a well ventilated
area, away from gasoline or other flammable materials.
Be sure the area to be flame treated is clean and free
of gasoline or flammable residue.
To flame treat the decal area:
1. Pass the flame of a propane torch back and forth
quickly over the area where the decal is to be
applied until the surface appears slightly glossy.
This should occur after just a few seconds of
5.15
GENERAL INFORMATION
NOTES
5.16
CLUTCH
Service Tools and Supplies . . . . . . . . . . . . . . . . 6.2

PVT System Operation . . . . . . . . . . . . . . . . . . . 6.2
PVT Maintenance/Inspection . . . . . . . . . . . . . . 6.3--6.4
PVT Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
PVT Sealing and Ducting Components . . . . . . 6.7
Drive Clutch Exploded View . . . . . . . . . . . . . . . 6.7
Drive Clutch Spring Specifications . . . . . . . . . . 6.8
Shift Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
Drive Clutch Inspection . . . . . . . . . . . . . . . . . . . 6.10
Drive Clutch Disassembly/Inspection . . . . . . . 6.11-6.12
Drive Clutch Assembly . . . . . . . . . . . . . . . . . . . . 6.12-6.13
Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . 6.13
Drive Belt Removal/Inspection . . . . . . . . . . . . . 6.14-6.15
Drive Belt Installation . . . . . . . . . . . . . . . . . . . . . 6.15
Clutch Alignment /Offset . . . . . . . . . . . . . . . . . . 6.15--6.16
Drive Clutch Bushing Service . . . . . . . . . . . . . . 6.16-6.19
Driven Clutch Disassembly/Inspection . . . . . . 6.19-6.20
Driven Clutch Assembly . . . . . . . . . . . . . . . . . . . 6.20
Driven Clutch Bushing Service . . . . . . . . . . . . . 6.21-6.23
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24--6.26
6.1
CLUTCH
SPECIAL TOOLS AND PVT OPERATION OVERVIEW

SUPPLIES WARNING
PART NUMBER TOOL DESCRIPTION
2870506 Clutch Puller All PVT maintenance or repairs should be
9314177 Clutch Holding Wrench performed only by a certified Polaris Master Service
2871358 Clutch Holding Fixture Dealer (MSD) technician who has received the proper
2870341 Drive Clutch Spider Removal and training and understands the procedures outlined in
Install Tool this manual. Because of the critical nature and
2870654 Clutch Offset Alignment Tool precision balance incorporated into the PVT
components, it is absolutely essential that no
2870913 Driven Clutch Puller
disassembly or repair be made without factory
2870910 Roller Pin Tool authorized special tools and service procedures.
2871226 Clutch Bushing Replacement
Tool Kit The Polaris Variable Transmission (PVT) consists of
2870386 Piston Pin Puller three major assemblies: 1) The Drive Clutch; 2) The
8700220 Clutch Compression Tool Driven Clutch; and 3) The Drive Belt. The internal
2871025 Clutch Bushing Replacement
components of the drive clutch and driven clutch
Tool Kit control engagement (initial vehicle movement), clutch
upshift and backshift. During the development of a
Polaris ATV, the PVT system is matched first to the
engine power curve; then to average riding conditions
SPECIAL SUPPLIES PART NUMBER and the vehicle’s intended usage. Therefore,
modifications or variations of components at random
Loctitet 680 . . . . . . . . . . . . . . . . 2870584
are never recommended. Proper clutch setup and
RTV Silicone Sealer . . . . . . . . . 2870661 careful inspection of existing components must be the
primary objective when troubleshooting and tuning.
Loctitet Gasket Remover . . . . 2870601
PVT SYSTEM FASTENER DRIVE CLUTCH OPERATION

TORQUES Drive clutches primarily sense engine RPM. The two
major components which control its shifting function
Drive Clutch Retaining Bolt . . . 40 ft. lbs. (54 Nm) are the shift weights and the coil spring. Whenever
Driven Clutch Retaining Bolt . . 17 ft. lbs. (23 Nm) engine RPM is increased, centrifugal force is created,
causing the shift weights to push against rollers on the
PVT Inner Cover Bolts . . . . . . . 12 ft. lbs. (16 Nm) moveable sheave, which is held open by coil spring
Drive Clutch Spider (Standard Clutch) . 200 ft. lbs. preload. When this force becomes higher than the
(271 Nm) preload in the spring, the outer sheave moves inward
and contacts the drive belt. This motion pinches the
Drive Clutch Cover Plate . . . . . 90 in. lbs. (10 Nm) drive belt between the spinning sheaves and causes
it to rotate, which in turn rotates the driven clutch.
At lower RPM, the drive belt rotates low in the drive
clutch sheaves. As engine RPM increases,
centrifugal force causes the drive belt to be forced
upward on drive clutch sheaves.
DRIVEN CLUTCH OPERATION

Driven clutches primarily sense torque, opening and
closing according to the forces applied to it from the
drive belt and the transmission input shaft. If the
torque resistance at the transmission input shaft is
greater than the load from the drive belt, the drive belt
is kept at the outer diameter of the driven clutch
sheaves.
6.2
CLUTCH
DRIVEN CLUTCH OPERATION CONT’D air ducts, as well as the inner and outer covers,
must be properly sealed to ensure clean air is
As engine RPM and horsepower increase, the load being used for cooling the PVT system. This also
from the drive belt increases, resulting in the belt will prevent water and other contaminants from
rotating up toward the outer diameter of the drive entering the PVT area. A sealed PVT is
clutch sheaves and downward into the sheaves of the especially critical on units subjected to frequent
driven clutch. This action, which increases the driven water forging.
clutch speed, is called upshifting.
Should the throttle setting remain the same and the PVT DRYING
vehicle is subjected to a heavier load, the drive belt
rotates back up toward the outer diameter of the NOTE: If operating the ATV through water, be sure
driven clutch and downward into the sheaves of the to check the PVT cover and other ATV components
drive clutch. This action, which decreases the driven for water ingestion. The ATV should be checked
clutch speed, is called backshifting. immediately. Refer to Owner’s Manual for Safe
In situations where loads vary (such as uphill and Riding Tips.
downhill) and throttle settings are constant, the drive
and driven clutches are continually shifting to maintain
optimum engine RPM. At full throttle a perfectly PVT Drain Plug
matched PVT system should hold engine RPM at the
peak of the power curve. This RPM should be
maintained during clutch upshift and backshift. In this
respect, the PVT system is similar to a power
governor. Rather than vary throttle position, as a
conventional governor does, the PVT system
changes engine load requirements by either
upshifting or backshifting.
PVT
MAINTENANCE/INSPECTION
To drain any water that may be trapped inside the PVT
Under normal operation the PVT system will provide cover, simply remove the PVT drain plug and O--ring
years of trouble free operation. Periodic inspection located on the bottom of the PVT cover and let the
and maintenance is required to keep the system water drain out. The PVT drain plug is shown below.
operating at peak performance. The following list of
items should be inspected and maintained to ensure To further expel water in the PVT cover and to dry out
maximum performance and service life of PVT the PVT system, shift the transmission to neutral and
components. Refer to the troubleshooting checklist at rev engine slightly to expel the moisture. This will also
the end of this chapter for more information. air-dry the belt and clutches. Allow engine RPM to
settle to idle speed, shift transmission to lowest
1. Drive to Driven Clutch Offset, Belt Width. See available range and test for belt slippage. Repeat as
Page-6.16--6.18 needed. Operate ATV in lowest available range for a
2. Drive and Driven Clutch Buttons and short period of time until PVT system is dry.
Bushings, Drive Clutch Shift Weights and
Pins, Drive Clutch Spider Rollers and Roller
Pins, Drive and Driven Clutch Springs. See
Pages 6.11-6.12
3. Sheave Faces. Clean and inspect for wear.
4. PVT System Sealing. Refer to appropriate
illustrations and photos. The PVT system is air
cooled by fins on the drive clutch stationary
sheave. The fins create a low pressure area in the
crankcase casting, drawing air into the system
through an intake duct. The opening for this
intake duct is located at a high point on the vehicle
(location varies by model). The intake duct draws PVT Drain Plug & O--ring
fresh air through a vented cover. All connecting
6.3
CLUTCH
PVT OVERHEATING/DIAGNOSIS
During routine maintenance or whenever PVT 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 PVT
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.
GENERAL RANGE OPERATION Low Range: Heavy pulling, basic operational speeds less
GUIDELINES: than 7 MPH, riding through rough terrain (swamps, mountains,
etc.), low 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 during loading of the ATV to
when in high range. prevent belt burning. (if equipped)
Starting out going up a steep incline. When starting out on an incline, use low range, or dismount the
ATV after first applying the park brake and perform the “K”
turn.
Driving at low RPM or low ground speed Drive at higher speed or use Low Range. (if equipped) The use
(at approximately 3--7 MPH). of Low Range is highly recommended for cooler PVT operating
temperatures and longer component life.
Insufficient warm--up of ATVs exposed to Warm engine at least 5 min., then with transmission in neutral,
low ambient temperatures. advance 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 PVT 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 throttle may cause loss of control
and vehicle overturn.
Climbing over large objects from a Shift the transmission to Low Range (if equipped), carefully
stopped position. use fast, aggressive, throttle application to engage clutch.
Warning: Excessive throttle may cause loss of control
and vehicle overturn.
Belt slippage from water or snow ingestion Shift the transmission to neutral. Using the throttle, vary the
into the PVT system. engine rpm from idle to 3/4 throttle. Engage transmission in
the lowest possible range (if equipped) and test for belt slip-
page Repeat several times as required. During this proce-
dure, the throttle should not be held at the full position
for more than 10 seconds. PVT seals should be inspected
for damage if repeated leaking occurs.
Clutch malfunction. Inspection/repair of clutch components should be performed by
a certified Polaris MSD techinician.
6.4
CLUTCH
PVT DISASSEMBLY 8. Remove driven clutch retaining bolt and driven

clutch. Use the Driven Clutch Puller (PN
2870913) if necessary.
NOTE: Some fasteners and procedures will vary.
Refer to the appropriate parts manual for proper
fasteners and fastener placement. (See Page 6.6). Driven Clutch Puller (PN 2870913)
1. Remove seat.
2. Remove or loosen rear cab fasteners as
necessary to gain access to PVT outer cover.
3. Remove PVT air outlet duct hose. Keep Spacers In Order
4. Remove outer cover screws. Refer to Page 6.7.
5. Mark the drive belt direction of rotation and
remove drive belt. See Page 6.14 for drive belt
removal.
B
9. Remove driven clutch offset spacers from the
transmission input shaft.
6. Install the Drive Clutch Holder (PN 9314177) (A).

7. Remove drive clutch retaining bolt and remove
drive clutch using the Drive Clutch Holder (PN
9314177) (B).
Drive Clutch Puller (PN 2870506)
Drive Clutch Holder (PN 9314177)
10. Remove screws and retainer plate.

11. Remove inner cover retaining bolts at rear of
cover.
12. Remove cover along with foam seal on back of
cover or shaft.
6.5
CLUTCH
PVT ASSEMBLY Inner Cover Bolt Torque (Rear):

12 ft. lbs. (16.6 Nm)
Seal this edge to cover on engine side
Driven Clutch Retaining Bolt Torque:
17 ft. lbs. (23.5 Nm)
Drive Clutch Retaining Bolt Torque:

40 ft. lbs. (55 Nm)
1. Inspect PVT inner cover-to engine seal. Replace

if cracked or damaged. Offset
2. Place a new foam seal on transmission input Spacer
shaft.
3. Apply RTV silicone sealant to outside edge of
inner cover-to-engine seal, to ensure a water tight
fit between the seal and the cover. Surfaces must
be clean to ensure adhesion of silicone sealant. 7. Install clutch offset spacers on transmission input
shaft.
4. Reinstall cover and tighten rear cover bolts just
enough to hold it in place. 8. Clean splines inside driven clutch and on the
9. Apply a light film of grease to the splines on the
shaft.
10. Install the driven clutch, washer, lock washer, and
B C
retaining bolt. Torque to specification.
11. Clean end of taper on crankshaft and the taper
bore inside drive clutch.
12. Install drive clutch and torque retaining bolt to
specification.
13. Reinstall drive belt noting direction of rotation. If a
A
new belt is installed, install so numbers can be
easily read.
Seal outer edge to cover
with RTV silicone sealant Toward outer cover
5. Fit lip of inner cover seal (A) to engine. Install seal

retainer plate and tighten screws securely.
6. Torque rear inner cover bolts (B) to specification. PVT Cover Gasket
14. Replace PVT outer cover rubber gasket with the

narrow side out (C).
15. Reinstall PVT outer cover and secure with
screws.
16. Reinstall rear cab assembly and seat.
6.6
CLUTCH
PVT SEALING AND DUCTING COMPONENTS
Inner Cover Outer Cover Seal
Inlet duct Drain

Plug
Inlet Duct Inner Cover Seal
Retainer
Outer Cover
Cover Bolts
Exhaust Duct
DRIVE CLUTCH EXPLODED VIEW

Drive Clutch
Teflont coated
brass bushing
Teflont coated
brass bushing
Mark with permanent

marker before disassembly
6.7
CLUTCH
DRIVE CLUTCH SPRING SPECIFICATIONS

NEUTRAL FULL UPSHIFT
The drive clutch spring has two
300
primary functions: ATV TRAVEL
FORCE (POUNDS)
1. To control clutch engagement 280
RPM. The springs which have a
260
higher rate when the clutch is in
neutral will increase clutch 240
engagement RPM.
220
2. To control the rate at which the
drive belt moves upward in the 200
drive clutch sheaves. This is
referred to as drive clutch upshift. 180
There are other components which Green
160 7041168
control upshift, but the spring is one of Purple
7041063
the primary components in insuring 140 White
optimum performance. It is very 7041132
Plain
important that the spring is of the 120 7041021
correct design and is in good Blue/Green

7041157
condition. 100 Black

7041022
CAUTION: Never shim a drive clutch 80

spring to increase its compression
rate. This may result in complete 60
stacking of the coils and subsequent
40
clutch cover failure.
The drive clutch spring is one of the 20
most critical components of the PVT
0
system. It is also one of the easiest to 2.5 2.25 2.00 1.75 1.50 1.25 1.19
service. Due to the severe stress the
spring is subject to during operation, it COMPRESSED SPRING LENGTH (INCHES)
should always be inspected for
tolerance limits during any clutch
operation diagnosis or repair.
With the spring resting on a flat surface, measure its free
length from the outer coil surfaces as shown. Refer to
the spring specification chart for specific free length
measurements and tolerances. Also check to see that
spring coils are parallel to one another. Distortion of the
spring indicates stress fatigue, requiring replacement.
Primary Clutch Springs Secondary Clutch Springs

PART COLOR WIRE FREE LENGTH PART DESCRIPTION
NUMBER CODE DIAMETER ¦.125I NUMBER
7041021 Plain .157I 4.38I 7041198 Red
7041022 Black .140I 4.25I 7041782 Black 5--coil
7041063 Purple .168I 4.37I 7041501 Gold 6--coil
7041132 White .177I 2.92I 7041499 Silver
7041168 Green .177I 3.05I 7041296 Blue
7041157 Blue/Green .177I 2.53I 7041646 Silver/Blue
6.8
CLUTCH
SHIFT WEIGHTS
Shown below are the shift weights which have been designed for, or which may be used in the PVT system. These
shift weights have many factors designed into them for controlling engagement RPM and shifting patterns. Shift
weights should not be changed or altered without first having a thorough understanding of their positioning and
the effects they may have on belt to sheave clearance, clutch balance and shifting pattern.
16
53 55
PN 5630418
50 gr PN 5630279 PN 5630095 PN 5630509
43 gr 53 gr 55 gr
10 10 10
RH WH BH
PN 5630513 PN 5630709 PN 5630710 PN 5630711

50.5 gr 44 gr 46 gr 47gr
6.9
CLUTCH
SHIFT WEIGHT INSPECTION
Button to Tower Clearance:

1. Remove shift weight bolts and weights. Inspect .000 - .001I
as shown. The contact surface of the weight
should be smooth and free of dents or gall marks. 2. Inspect sheave surfaces. Replace the entire
Inspect the weight pivot bore and pivot bolts for service clutch if worn, damaged or cracked.
wear or galling. If weights or bolts are worn or
broken, replace in sets of three with new bolts.
WARNING
NOTE: A damaged shift weight is usually caused
by a damaged or stuck roller in the spider The clutch assembly is a precisely balanced unit.
assembly. See “ROLLER, PIN AND THRUST Never replace parts with used parts from another
WASHER INSPECTION”, Page 6.12. clutch assembly!
All PVT system maintenance repairs must be
performed only by an authorized Polaris service
technician who has attended a Polaris sponsored
service training seminar and understands the proper
procedures as outlined in this manual. Because of
the critical nature and precision balance
incorporated into the PVT system, it is absolutely
Broken Worn Good essential that no attempt at disassembly or repair
be made without factory authorized special tools
and service procedures.
BUTTON TO TOWER
CLEARANCE INSPECTION
1. Inspect for any clearance between spider button
to tower. If clearance exists, replace all buttons
and inspect surface of towers. See “SPIDER
REMOVAL” Page 6.11.
6.10
CLUTCH
DRIVE CLUTCH
DISASSEMBLY Inspect shaft
Mark
“X”
Mark
4. Inspect area on shaft where bushing rides for
wear, galling, nicks, or scratches. Replace clutch
1. Using a permanent marker, mark the cover, assembly if worn or damaged.
spider, moveable and stationary sheaves, and 5. Remove and inspect spring. (See Page 6.8)
steel post to the stationary sheave for reference.
The X’s may not have been in alignment before
disassembly. SPIDER REMOVAL
2. Remove cover bolts evenly in a cross pattern, and
remove cover plate.
Cover Bushing Inspection:

Clutch Holding Fixture:
Replace the cover bushing if more (PN 2871358)
brass than Teflont is visible on
the bushing. Refer to bushing re- Spider Removal Tool:
placement in this chapter. (PN 2870341)
1. Install clutch in holding fixture and loosen the

3. Inspect cover bushing (A). The outer cover spider (counterclockwise) using spider removal
bushing is manufactured with a Teflont coating. tool.
Bushing wear is determined by the amount of
Teflont remaining on the bushing. NOTE: It is important that the same number and
thickness of washers are reinstalled beneath the
spider during assembly. Be sure to note the number
and thickness of these washers.
6.11
CLUTCH
Moveable Sheave Bushing Inspection the new pin during installation.

2. Inspect the Teflont coating on the moveable
sheave bushing.
2. Rubber backed buttons can be used in all ATV

clutches if the hollow roller pin is changed to the
Teflont solid roller pin. NOTE: The rubber side of the
button is positioned toward the solid roller pin.
Moveable Sheave Bushing Inspection:

DRIVE CLUTCH ASSEMBLY
Replace the cover bushing if more
brass than Teflont is visible on the
bushing. Refer to bushing replace-
ment in this chapter.
ROLLER, PIN AND THRUST

WASHER INSPECTION
NOTE: It is important that the same number and

thickness of washers are reinstalled beneath the
spider during assembly. The Teflont bushings are
self-lubricating. Do not apply oil or grease to the
bushings.
1. Reassemble drive clutch in the following
sequence. Be sure the “X”, or the marks that were
1. Inspect all rollers, bushings and roller pins by made earlier, are aligned during each phase of
pulling a flat metal rod across the roller. Turn roller assembly)
with your finger. If you notice resistance, galling, a)“X”, or the marks that were made earlier, on
or flat spots, replace rollers, pins and thrust cover
washers in sets of three. Also inspect to see if b) spider, making sure spacer washers are
roller and bushing are separating. Bushing must installed underneath spider and
fit tightly in roller. Use the Roller Pin Tool (PN
positioned properly in recess
2870910) to replace rollers and pins. Take care
not to damage roller bushing or bearing surface of
6.12
CLUTCH
c) “X”, or the marks that were made earlier,

under weight
Spacer washers
Spider Torque:
200 ft. lbs. (276 Nm)
2. Install moveable sheave onto fixed sheave. Cover Screw Torque:
3. Install spider spacers. Use same quantity and 90 in. lbs. (10.4 Nm)
thickness as were removed.
4. Compress spider buttons for each tower and 8. Reinstall cover, aligning bosses on the tower and
install spider, making sure that “X”, or the marks cover. Torque cover bolts evenly to specification.
that were made earlier, on spider aligns with “X”,
or the marks that were made earlier, in moveable
sheave.
5. Torque spider to specification using the holding
fixture and spider tool. Torque with smooth
motion to avoid damage to the stationary sheave.
Refer to Page 6.2 for torque specification.
CAUTION:
Be sure the spider spacer washers are fully seated in

the recessed area in the spider. Any misalignment will
alter clutch balance. Inverting the clutch while initially
tightening the spider will help position the washers. DRIVE BELT TENSION
Straight Edge
1 1/8″ (28.5 mm)
Rotation
Nut on trailing side

Belt Deflection (Tension):
6. Install shift weights using new lock nuts on the 1 1/8″ (2.9 cm) - 1 1/4″ (3.2 cm)
bolts.
7. Reinstall clutch spring.
6.13
CLUTCH
NOTE: Pinch the sheaves lightly together with clamp

to prevent the belt from being pushed into the driven
sheave.
1. Place a straight edge on top of the belt between
drive and driven clutch.
2. Push down on drive belt until it is lightly tensioned.
3. Measure belt deflection as shown in photo.
NOTE: If belt deflection is out of specification, adjust

by removing or adding shims between the driven
clutch sheaves.
G Remove shims to decrease belt
deflection 3. To remove drive belt: apply brake, pull upward
G Add shims to increase belt deflection and rearward on belt to open driven clutch
See DRIVEN CLUTCH sheaves, pull out and down on belt to slip over the
DISASSEMBLY/INSPECTION, Pages 6.19 - 6.20. driven clutch outer sheave.
NOTE: At least one shim must remain between the

inner and outer sheave of the driven clutch. If proper Projected Belt
belt deflection cannot be obtained, measure drive belt Width
width, length, and center distance of drive and driven
clutch, outlined in this section; all have an effect on
belt deflection.
DRIVE BELT
REMOVAL/INSPECTION
1. Remove outer PVT cover as described in PVT Belt Width:
Disassembly.
2. Mark drive belt direction of rotation so that it can New 1.174 - 1.188″ (2.98-3.02 cm)
be installed in the same direction. NOTE:
Normally positioned so part numbers are easily Wear Limit 1.125″ (2.86 cm)
read.
4. Measure belt width and replace if worn severely.
Generally, belt should be replaced if clutches can
no longer be adjusted to provide proper belt
deflection.
G The top edges have been trimmed on
some drive belts. It will be necessary
to project the side profiles and
measure from corner to corner.
G Place a straight edge on each side of
the drive belt.
G Place another straight edge on top of
belt.
G Measure the distance where the side
straight edges intersect the top, as
shown in the illustration below.
6.14
CLUTCH
5. Inspect belt for loose cords, missing cogs, cracks,

abrasions, thin spots, or excessive wear.
DRIVE BELT INSTALLATION
6. Inspect belt for hour glassing (extreme circular
wear in at least one spot and on both sides of the
belt). Hour glassing occurs when the drive train
does not move and the drive clutch engages the
belt.
Center
Distance 1. Loop belt over drive and over top of driven
sheave.
Clutch Center Distance -
10″ +.1 / -.05 (254 +2.5 / -1.3mm) 2. While pushing down on top of belt, turn the back
Belt Nominal Length - 40.875″± 3/16 or moveable driven sheave clockwise.
(103.8 cm ± .48 cm) 3. The belt then should be able to be pushed down
into and between the sheaves.
7. Measure belt length with a tape measure around NOTE: Be sure to position belt so part number is
the outer circumference of the belt. Belts which easily read.
measure longer than nominal length may require
driven shimming or engine adjustment for a
longer center distance to obtain proper belt CLUTCH ALIGNMENT
deflection. Belts which measure shorter than
nominal length may require driven shimming or a
shorter center distance. Remember, proper belt Offset Alignment Tool
deflection is the desired goal -- not a specific should contact rear edge
center distance. of driven clutch sheave
8. Replace belt if worn past the service limit. Belts
with thin spots, burn marks, etc., should be
replaced to eliminate noise, vibration, or erratic
PVT operation. See Troubleshooting Chart at the Driven Clutch Offset
end of this chapter for possible causes. NOTE: If To adjust, add or remove
a new belt is installed, check belt deflection. washers from behind the
driven clutch
6.15
CLUTCH
1. Remove belt and install the Clutch Offset

Alignment Tool (PN 2870654) as shown.
CLUTCH OFFSET
2. With tool touching rear of driven clutch inner
sheave, the distance at point “A” should be 1/8″. Offset Alignment Tool
(PN 2870654)
If the distance is greater than 1/8″ or less than 1/16″,
clutch alignment must be adjusted as follows:
B
3. Remove drive and driven clutch. See PVT
Disassembly, Pages 6.5.
4. Remove PVT inner cover.
A
5. Loosen all engine mounts. Move front of engine
to the right or left slightly until alignment is correct.
6. Tighten engine mounts and verify alignment is 1/8I +0 / -- 1/16
correct. 3.2mm +0 / -- 1.6 mm)
Center line
Important: Inspect clutch alignment and center

distance before adjusting offset.
Measure offset above and below
centerline 1. Install offset alignment tool as shown.
7. Measure belt deflection and measure offset both Offset is correct when rear of tool contacts rear of
above and below sheave centerlines. Adjust if inner sheave with driven clutch pushed completely
inward on shaft and bolt torqued. Adjust offset by
necessary.
adding or removing spacer washers between back of
NOTE: On some models, minor adjustments can be driven clutch and spacer as shown.
made by adding shims between the frame and front
lower left engine mount to increase the distance at
point “A”. If a shim is present, it can be removed to Spacer Washer (PN 7556401)
decrease the distance at point “A”.
Shim Kit (PN 2200126)

DRIVE CLUTCH BUSHING
SERVICE
*Clutch Bushing Replacement Tool Kit (PN
2871226)
Stamp Qty. Part Description Part #

#2 1 P--90 Drive/Driven 5020628
Clutch Bushing
Install Tool
6.16
CLUTCH
#3 1 Drive Clutch Cover 5020629 2. Remove nut from puller rod and set aside.
Bushing Removal/
Installation Tool (all
clutches) Piston Pin Puller
#5 1 P--90 Driven Clutch 5020631 (PN 2870386)
Cover Bushing Re-
moval Tool
#8 1 Main Puller Adapter 5020632
#9 1 Adapter Reducer 5010279
#10 1 Number Two Puller 5020633 Main Puller Adaptor (#8)
Adapter
DRIVE CLUTCH MOVEABLE 3. Install the Main Puller Adapter (#8) (PN 5020632)
SHEAVE - BUSHING onto the Piston Pin Puller (PN 2870386).
REMOVAL
#3 #5
#2
#10 #9
4. Insert the Number Two Adapter (#10) (PN
#8
5020633) into the bushing from belt side as
shown. With towers pointing toward vise, slide
1. Install handle end of the Piston Pin Puller (PN sheave and bushing onto puller rod.
2870386) securely into bench vise and lightly 5. Install the nut removed in Step 2 onto end of puller
grease puller threads. rod and hand tighten. Turn puller barrel to
increase tension on sheave if needed. Nut is left
hand thread
Piston Pin Puller (PN 2870386)
6.17
CLUTCH
6. Turn sheave and puller barrel together

counterclockwise on puller rod until bushing is
DRIVE CLUTCH COVER -
removed. BUSHING REMOVAL
7. Remove nut from puller rod and set aside.
8. Pull bushing removal tool and adapter from puller
rod. Remove bushing from tool and discard.
Piston Pin Puller
(PN 2870386)
DRIVE CLUTCH MOVEABLE
SHEAVE - BUSHING
INSTALLATION
1. Place the Main Puller Adapter (#8) (PN 5020632)
Main Puller
onto the puller.
Adaptor (#8)
2. Apply Loctitet 680 (PN 2870584) to the back
side of new bushing. Push bushing into center of
sheave on tower side by hand.
1. Install the Main Puller Adapter (#8) (PN 5020632)
onto the Piston Pin Puller (PN 2870386).
Bushing (PN 3576504)
Loctitet 680 (PN 2870584)
3. Insert the Clutch Bushing Installation Tool (#2) (PN

5020628) into center of sheave and with towers
pointing away from vise, slide sheave onto puller
rod.
4. Install nut on puller rod and hand tighten. Turn
barrel to apply additional tension if needed.
2. From outside of clutch cover, insert the Drive

Cover Bushing Remover (#3) (PN 5020629) into
cover bushing.
3. With inside of cover toward vise, slide cover onto
puller.
4. Install nut onto puller rod and hand tighten. Turn
puller barrel to increase tension as needed.
5. Turn sheave and barrel together
counterclockwise until bushing is seated.
7. Remove sheave from puller.
8. Remove installation tool.
6.18
CLUTCH
2. With the Main Puller Adapter (#8) (PN 5020632)

5. Turn clutch cover counterclockwise on puller rod on the puller, insert cover onto puller rod, placing
until bushing is removed. outside of cover toward vise.
6. Remove nut from puller rod and set aside. 3. Install nut on rod and hand tighten. Turn puller
7. Remove bushing and bushing removal tool from barrel to apply more tension if needed.
puller. Discard bushing. 4. Turn clutch cover and barrel together
counterclockwise on puller rod until bushing is
DRIVE CLUTCH COVER - seated.
5. Remove nut from puller rod and take installation
BUSHING INSTALLATION tool and clutch cover off rod.
DRIVEN CLUTCH
DISASSEMBLY/INSPECTION
1. Apply Loctitet 680 (PN 2870584) to the back

side of new bushing. Working from inside of
cover, insert bushing and bushing installation tool
into center of clutch cover. Used to adjust
belt tension. One must
always be installed.
Bushing (PN 3576510)
Loctitet 680 (PN 2870584) CAUTION:
Wear eye protection when removing snap ring to

prevent serious personal injury.
6.19
CLUTCH
6. Inspect ramp buttons in the moveable sheave and

replace if worn. NOTE: The ramp buttons are
secured by Torxt screws (T20).
Belt deflection adjustment

washers
1. Apply and hold downward pressure on the helix,

or place driven clutch in the Clutch Compression
Tool (PN 8700220). 7. Remove moveable sheave and note the number
2. Remove snap ring retainer. of spacer washers. One spacer must remain
between the sheaves when adjusting belt
deflection.
Note hole location of spring
in helix and sheave
Inspect bushings for wear
3. Note the location of the spring and remove helix.

Moveable Sheave Bushing Inspection:
4. Note the location of the spring in the moveable
sheave, and remove the spring. Replace the bushing if more brass than
5. Check alignment of tabs on spring. Replace the Teflont is visible on the bushing. Re-
spring if tabs are misaligned or the spring coils are fer to bushing replacement in this
distorted. chapter.
8. Inspect the Teflont coating on the moveable

sheave bushing.
9. Inspect driven clutch faces for wear or damage.
10. Clean and inspect splines on helix and
11. Lube splines with a light film of grease. Do not
lubricate the bushings!
6.20
CLUTCH
DRIVEN CLUTCH ASSEMBLY
Driven Spring
Driven Clutch Sportsman 6X6 Driven

Ill. 2 Spring Placement: 2--2
Moveable Spring
Example: Helix Sheave Tension
2 -- 1 Heavy
Spring/ 2 -- 2
Position 1 -- 1
2 -- 3 Align boss spline
1 -- 2 to install helix
1 -- 3 Soft
Refer to General Information Chapter 1 for driv-
en clutch spring color and production setting.
1. Install moveable sheave with spacer washers.

Important: At least one spacer washer must be
installed. Teflont bushings are self-lubricating.
Do not apply oil or grease to the bushings.
2. Install spring, inserting spring tab into proper hole
in moveable sheave.
3. Insert spring tab into proper hole in helix. See
specifications in Chapter 1 or Illustration 2 above. 4. Line up boss spline and push helix down until it
engages the splines 1/2″ to 3/4″.
The driven clutch, helix/moveable assembly has
several different spring locations which affect clutch
shifting and RPMs. The greatest amount of spring
tension will raise engine RPMs during clutch upshift
and allow quicker backshift or downshift when pulling 1/3
turn
or negotiating a hill, for example. The least amount of
tension will create a slower downshift and a harder
upshift.
5. While holding downward pressure on helix, wind

moveable sheave counterclockwise
approximately 1/3 turn (120°).
6. Push helix into place and install snap ring.
6.21
CLUTCH
DRIVEN CLUTCH MOVEABLE

SHEAVE - BUSHING
REMOVAL
NOTE: Bushings are installed at the factory using
Loctitet. In order to remove the bushing it will be
necessary to apply heat. A press can be used to
remove and install some of the bushings. Be sure to
support the sheave or cover as close as possible to
the bushing bore when using a press. Clutch Bushing
Removal Tool (#5)
Main Puller Adapter (#8)

5. Working from the top, install Driven Clutch
Bushing Removal Tool (#5) (PN 5020631) into the
center of clutch sheave with smaller diameter
toward bushing to be removed. See illustration at
above.
Adapter
Reducer (#9)
Piston Pin Puller
(PN 2870386)
1. Install Main Puller Adapter (#8) (PN 5020632)

onto the Piston Pin Puller (PN 2870386).
2. Insert Adapter Reducer (#9) (PN 5010279) onto
the puller, sliding it inside the main adapter.
3. Remove ramp buttons from moveable sheave.
4. Using an electric or hand held propane torch,

apply heat directly on bushing until tiny smoke
tailings appear.
CAUTION:
Clutch components will be hot! In order to avoid

serious burns, wear some type of insulated gloves for
the rest of the removal process.
6.22
CLUTCH
6. Install sheave onto puller. 2. Start new bushing evenly in moveable sheave.
7. Install nut onto puller rod and tighten by hand. Apply Loctitet 680 (PN 2870584) to the back
Turn puller barrel for further tension if needed. side of new bushing.
8. Turn clutch sheave counterclockwise until

bushing is removed. Repeat Steps 5 - 8 for other 3. Install sheave onto puller with new bushing
bushing. upward as shown. Install the Number Two Puller
9. Remove nut from puller rod and set aside. Adapter (#10) (PN 5020633).
10. Remove adapters from puller.
11. Remove bushing and removal tool from adapters.
Discard bushing.
DRIVEN CLUTCH MOVEABLE

SHEAVE - BUSHING
INSTALLATION
4. Install nut onto puller rod and hand tighten against

installation tool.
Number Two Puller
Adapter (#10)
Piston Pin Puller
(PN 2870386)
1. Working from the top, insert Number Two Puller

Adapter (#10) (PN 5020633) onto the puller. See
illustration at above.
6.23
CLUTCH
5. Turn clutch sheave counterclockwise until

bushing is seated.
7. Remove installation tool and clutch sheave from
puller.
8. Repeat installation procedure for other moveable

bushing.
6.24
CLUTCH
TROUBLESHOOTING
Situation Probable Cause Remedy

Engine RPM -Wrong or broken drive clutch spring. -Replace with recommended spring.
below specified
operating -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine application.
range, although
engine is prop- -Driven clutch spring broken or installed in -Replace spring; refer to proper installation location.
erly tuned. wrong helix location.
Erratic engine -Drive clutch binding. a. Disassemble drive clutch; inspect shift weights for wear
operating RPM and free operation.
during accelera- b. Clean and polish stationary shaft hub; reassemble clutch
tion or load vari- without spring to determine problem area.
ations.
-Belt worn unevenly - thin/burnt spots Replace belt
-Driven clutch malfunction. a. Replace ramp buttons.

b. Inspect movable sheave for excessive bushing clearance/
replace.
-Sheave face grooved. -Replace the clutch.

Engine RPM -Incorrect drive clutch spring (too high -Install correct recommended spring.
above specified spring rate).
operating
range. -Drive clutch shift weights incorrect for ap- -Install correct recommended shift weights.
plication (too light).
-Drive clutch binding. -Disassemble and clean clutch, inspecting shift weights and
rollers. Reassemble without the spring and move sheaves
through entire range to further determine probable cause.
-Driven clutch binding. -Disassemble, clean, and inspect driven clutch, noting worn
sheave bushing and ramp buttons and helix spring location.
-Converter sheaves greasy; belt slippage. -Clean sheaves with denatured alcohol or brake cleaner,
install new belt.
Harsh drive -Drive belt worn too narrow. -Replace belt.
clutch engage-
ment. -Excessive belt/sheave clearance with new -Perform belt/sheave clearance adjustment with shim wash-
belt. ers beneath spider.
Drive belt turns -Wrong belt for application. -Replace with correct belt.
over
-Clutch alignment out of spec. -Adjust alignment offset.
-Engine mount broken or loose. -Inspect/adjust or replace.

PVT cover -Plugged air intake or outlet -Clear obstruction.
overheating
(melting) -Belt slippage due to water, oil, grease, -Inspect system. Clean , repair or replace as necessary.
etc., rubbing on cover Seal PVT system ducts.
-Clutches or weight being applied to cover -Remove weight. Inform operator.

while in operation
-High vs. low range -Instruct operator on guidelines for operation in proper driving
range for different terrain as outlined in Owner’s Safety and
Maintenance Manual.
Water ingestion -Cover seals or ducts leaking -Find leak and repair as necessary.
-Operator error -Instruct operator on guidelines for operation in wet terrain as

outlined in Owner’s Safety and Maintenance Manual.
6.25
CLUTCH
TROUBLESHOOTING
Situation Probable Cause Remedy

Belt slippage -Belt worn out -Replace belt.
-Water ingestion -Inspect and seal PVT system.
-Belt contaminated with oil or grease -Inspect and clean.

Belt burnt, thin -Abuse (continued throttle application when -Caution operator to operate machine within guidelines.
spots vehicle is stationary, excess load)
-Dragging brake -Vehicle operated with park brake on. Inspect brake system.
-Slow, easy clutch engagement -Fast, effective use of throttle for efficient engagement.
PVT noise -Belt worn or separated, thin spots, loose -Replace belt.
belt
-Broken or worn clutch components, cover -Inspect and repair as necessary.
hitting clutches
Engagement -Thin spots on belt, worn belt -Replace belt. Refer to belt burnt troubleshooting and instruct
erratic or stabby operator.
-Drive clutch bushings stick -Inspect and repair clutches.
6.26
GENERAL INFORMATION
Final Drive Torque Specifications . . . . . 7.1

AWD Operation Overview . . . . . . . . . . . 7.2--7.3
AWD Front Hub Removal . . . . . . . . . . . 7.3
AWD Hub/Bearing Installation . . . . . . . . 7.3
AWD Front Hub Bearing Adjustment . . 7.4
AWD Front Hub Exploded View . . . . . . 7.5
AWD Hub Seal Replacement . . . . . . . . 7.6
AWD Magnetic Coil Service . . . . . . . . . 7.6--7.7
AWD Hilliard Clutch Disass./Inspect. . . 7.7--7.8
AWD Armature Plate Inspection . . . . . . 7.8
AWD Front Drive Axle Removal . . . . . . 7.8-7.9
AWD Front Drive Axle Installation . . . . 7.9--7.10
AWD Front CV Joint Boot Replace. . . . 7.10-7.11
AWD Front Drive Axle Exploded View . 7.12
AWD Strut Casting Seal Replacement 7.13
AWD Strut Seal Sleeve Replacement . 7.13--7.14
AWD Front Prop Shaft Removal . . . . . . 7.14
U-Joint Disassembly . . . . . . . . . . . . . . . . 7.15
U-Joint Assembly . . . . . . . . . . . . . . . . . . 7.15-7.16
AWD Front Housing Removal . . . . . . . . 7.16
AWD Front Housing Disassembly . . . . 7.16-7.17
AWD Front Housing Assembly . . . . . . . 7.17-7.18
AWD Front Housing Installation . . . . . . 7.18
AWD Front Housing Exploded View . . 7.19
Middle Axle Removal . . . . . . . . . . . . . . . 7.20-7.21
Middle Axle Disassembly . . . . . . . . . . . . 7.22
Middle Axle Assembly . . . . . . . . . . . . . . 7.22-7.23
Middle Axle Installation . . . . . . . . . . . . . 7.23-7.24
Middle Axle Exploded View . . . . . . . . . . 7.25
Middle Housing Removal . . . . . . . . . . . . 7.26
Middle Housing Service . . . . . . . . . . . . . 7.26
Rear Axle Removal . . . . . . . . . . . . . . . . . 7.27
Rear Axle Installation . . . . . . . . . . . . . . . 7.27
Rear Axle Service . . . . . . . . . . . . . . . . . . 7.28-7.29
7.1
GENERAL INFORMATION
WHEEL AND HUB TORQUE drive vehicle until the rear wheels lose traction. If the
rear wheels lose traction the front wheel rotational
TABLE speed will decrease, causing the front drive axle
speed to exceed front wheel speed. Restricting the
Item Specification rotation of the drive clutch roller cage (2) (see Electric
Front Wheel Nuts 20 Ft. Lbs. (27 Nm)
Hub Operation) will cause the rollers (3) to climb the
ramps of the cam (5), and become squeezed between
Middle & Rear Wheel Nuts 50 Ft. Lbs. (68 Nm) the ramps and the ring in the hub. See Ill. 1.
Front Hub Nut Refer to text for procedure
(Pg 7.4)
When the hub clutch assembly, wheel hub, and drive
axle are engaged, the front wheels will drive and stay
Rear Hub Retaining Nut 80 Ft. Lbs. (109 Nm) engaged until rear wheel traction is regained. When
traction is regained, the front wheels will overdrive the
¡ Refer to exploded views and text for torque values hub clutch, pushing the clutch rollers (3) toward the
of other fasteners lower part of the cam (5), disengaging the clutch. The
CAUTION: Locking nuts, and bolts with preapplied rollers are held in place by the spring (4). See Ill. 2.
locking agent should be replaced if removed. The The tension of this spring is critical to AWD hub
self-locking properties of the nut or bolt are reduced operation. Always use the correct spring (refer to
or destroyed during removal. appropriate parts manual) and use installatiolHilliard
Clutch Garter Spring Installation Tool (PN 2870888).
SPECIAL TOOLS WARNING

PART NUMBER TOOL It is important that the front and rear axle drive ratio
DESCRIPTION and tire size are not changed. Changing this ratio will
2871199 Seal Sleeve cause erratic engagement, which could result in a loss
Installation Tool Kit of vehicle control and serious injury or death.
2870888 Hilliard Clutch
Garter Spring
Installation Tool ELECTRIC HUB
2872608 Roller Pin
Removal Tool ENGAGEMENT
8700226 CV Boot Clamp
Pliers 1. Armature Plate
2. Roller Cage
2870772 1 3/4” Straight
3. Roller
Wrench
4. Garter Spring
5. Cam
Spacer
Tabs must engage the slots
AWD OPERATION OVERVIEW 3 5
Ramps A
Hub
Cage (2) 1 2 4
Ill. 2
Axle When AWD is selected in a forward gear, current

flows through a coil of wire located in the strut housing,
creating a magnetic field. An armature plate (1)
Roller (3) coupled to the roller cage (2) is attracted to the
magnetic field, and resists rotation, creating drag on
Cam (5) the drive roller cage assembly. This causes the roller
Ill. 1 to climb the ramps of the cam, engaging the hub.
NOTE: In reverse gear the override button must be
With the Polaris All Wheel Drive System activated pushed to deliver power to the wheel coil. Electric hub
(AWD selected), the machine operates as a 2 wheel engagement offers an advantage over mechanical
7.2
GENERAL INFORMATION
systems. When the AWD button is switched off, the possible damage to the brake
machine will have the steering ease of a 2 wheel drive line.
unit; and with the switch turned on, All wheel drive will
be engaged whenever the rear wheels lose traction.
FRONT HUB REMOVAL (AWD)

If an AWD problem is encountered, thoroughly inspect
the electrical portion of the system as well as the front
hub mechanism. Refer to the electrical chapter.
4. Place a catch pan beneath the front hub and

remove the hub cap.
5. Remove cotter pin and nut.
6. Remove front hub and bearings.
HUB/WHEEL BEARING
INSTALLATION
1. Carefully lift and support the front end of the
machine as shown with the jack stands under the
front end of the foot rests. CAUTION: Make sure
the machine is solidly supported before
proceeding. Serious injury could occur if the
machine tips or falls.
2. Remove the front wheels and thoroughly clean
the area around the hub, strut casting, brake
caliper and brake disc.
1. Thoroughly inspect the hub internally. If the hub

bearing sleeve is damaged or shows signs of
movement, the hub assembly must be replaced.
When the sleeve is pressed into the hub it should
be flush with the outside surface of the hub.
2. Grease hub seal to allow it to slide over roller
clutch components.
3. Install wheel hub inner bearing. NOTE: All
bearings must slide freely onto the spindle. If
bearings do not slide freely, wheel bearing torque
will be affected.
4. Install wheel hub, outer bearing, washer, and
3. Remove the two brake caliper attaching bolts. attaching nut. NOTE: It is very important that the
CAUTION: Do not hang the caliper by the brake hub is not moved outward once installed, or the
hose. Use wire to hang the caliper to prevent seal on the hub will disengage the armature plate.
7.3
GENERAL INFORMATION
AWD FRONT HUB BEARING 5. Install cotter pin. Bend each leg of cotter pin
around castle nut in different directions.
ADJUSTMENT NOTE: If cotter pin hole does not align, tighten slightly
to align and install pin. Do not exceed 144 in. lbs. (16
Nm).
WARNING
6. Reinstall hub cap.
The following bearing adjustments are very important.
Incorrect adjustment will increase bearing wear, 7. Remove fill check plug and rotate hole to either
reduce braking action, and may affect front drive hub 4:00 or 8:00 position.
engagement, which could result in serious personal 8. Fill with Polaris Premium Demand Drive Hub
injury or death. Fluid or Type F Automatic Transmission Fluid
until fluid trickles out. NOTE: Do not force the oil
into the hub under pressure. This can cause seal
damage and leaks.
Premium Demand Drive Hub Fluid
(PN 2871654) (8 oz.)

(PN 2872277) (2.5 gal.)
1. Torque spindle nut to 160-170 inch lbs. (13

Nm--14Nm) while rotating hub continuously.
2. Back off nut 1/2 turn.
3. Rotate axle several revolutions by raising rear of
machine and rotating rear wheels with the
machine in gear.
4. Re-torque hub nut to 108-144 inch lbs. (12 --16
Nm).
Front Spindle Nut Torque:

108-144 in. lbs.
9. Reinstall plug.
Brake Caliper Retaining Bolt Torque: 10. Reinstall brake caliper assembly. Torque
18 ft. lbs. (25 Nm) retaining bolts to 18 ft. lbs. (25 Nm).
11. Reinstall front wheels. Torque retaining nuts to 20
ft. lbs. (27 Nm).
12. Carefully lower vehicle.
13. Field test vehicle for proper operation of brake
system and AWD operation.
7.4
GENERAL INFORMATION
AWD FRONT HUB EXPLODED

VIEW
Garter Spring
Brake Disc
Seal Armature Plate

Detail Bearing (1.000″ I.D.)
A
DETAIL A
Bearing Race Front Hub Clutch Spacer
Front Hub Clutch
Bearing (1.000″ I.D.)
Cotter Pin
Castle Nut¡ (Use new
cotter pin)
O-Ring
Bearing Race
Washer
Wheel Nut
¡Refer to text on page 7.5 for more information.
7.5
GENERAL INFORMATION
AWD HUB SEAL

REPLACEMENT
1. Remove and disassemble front hub. Refer to
Page 7.3.
4. With spring side of new seal facing toward hub

casting, press it in until flush with brake disc
mating surface. CAUTION: Do not use a
hammer as damage to the seal will result.
5. Thoroughly clean the brake disc with brake
cleaner. It is very important that the brake disc be
free of any oil or solvents.
2. Remove brake disc attaching bolts and brake 6. Reinstall the brake disc using genuine Polaris
disc. OEM bolts that have a pre-applied locking agent.
NOTE: If the attaching bolts are difficult to Do not substitute bolts or use old ones.
remove, it may be helpful to heat the outer 7. Install attaching bolts and torque to 18 ft. lbs.
surfaces of the hub in the area of the disc (25 Nm).
mounting bolts, to soften the locking agent.
MAGNETIC COIL SERVICE
1. Remove the front drive axle as described later in
this chapter.
2. Remove the seal sleeve from the strut casting
using a drift punch and hammer, tapping evenly
on each side until the sleeve slides off.
3. Remove the existing coil and clean the coil wire
channel, coil mount area, and the seal sleeve
mounting area of all silicone and foreign matter.
4. Disconnect the coil wires at the connector or
terminal board.
3. Apply heat to the hub seal area. When the hub

becomes too hot to touch, pry out the old seal as
shown. Do not damage the surface of the seal
cavity. Clean the hub in the seal mating area.
7.6
GENERAL INFORMATION
MAGNETIC COIL block to contain the coil wires. Make

sure the foam block is bonded well to
INSTALLATION protect the coil wires.
NOTE: Coil wires must be contained in the brake line
Brake Line clip on the back side of the upper strut casting and the
Clip Location wires must be snug against the casting.
Strut Ribs
5. Route the wires smoothly and away from any
moving parts and secure in place with tie straps.
Coil Wire 6. Assemble front axle and connect hub wires.
Channel
Seal HILLIARD CLUTCH
Sleeve
Mounting DISASSEMBLY/INSPECTION
Area
Coil Mounting
Surface 1. Remove front hub. See Page 7.3.
(Inner Magnet 2. Remove Hilliard clutch assembly.
Pole)
(Fixed) 3. Disassemble the roller clutch and thoroughly
clean all parts. CAUTION: Do not remove the
Electromagnet Coil garter spring. If the spring is removed, it will
Seal Sleeve (Outer Magnet Pole) become over stressed and will require
(Adjustable) Must use Seal Sleeve replacement.
Installation Tool Kit (PN 2871199)
4. Inspect roll cage sliding surface (A). This surface
must be clean and free of nicks, burrs or
scratches. Inspect roller cage (2) carefully for
1. Apply 1/4I (.6 cm) bead of silicone in the coil wire cracks.
channel.
5. Inspect rollers (3). The rollers must slide up and
2. Install the coil to the coil mount surface and press down freely within the roller cage sliding surfaces
the coil wires into the silicone in the coil wire A.
channel.
6. Without removing the garter spring, inspect the
3. Apply 1/4I (.6 cm) bead of Loctitet Ultra Blue coils for consistency. If coils are distorted or
silicone around the seal sleeve mounting area. uneven, cut the old spring with a side cutter to
NOTE: This includes applying silicone over the remove it, and replace it.
coil lead wires again. Always allow 12 hours’ cure
1. Armature Plate NOTE: Armature plate is
time for silicone.
positioned with tabs in round holes of cage.
4. Press on the seal sleeve until even with the inner 2. Roller Cage
pole. See Page 7.14 for additional information. 3. Roller
Once the seal sleeve is properly positioned, a 4. Garter Spring
1/16I (.16 cm) bead of silicone should remain 5. Cam Inspect for cracks
around the inner edge. Clean off all excess Spacer
Engage tabs in the slots
silicone. The seal sleeve area must be free of
silicone or the hub seal may leak. 3 5
NOTE:
S Always install a new seal sleeve
when replacing the coil. Use Seal A
Sleeve Installation Tool Kit (PN
2871199). 1 2 4
S It may be necessary to apply more
silicone (or an equivalent fast drying 7. If garter spring replacement is necessary, it is
glue) to the wire channel area to very important that the correct installation
properly secure and protect the coil procedure and special tool be used. Hold rollers
wires. in place on roller cage with a light film of grease.
S Apply 401 Loctitet to the inside of Gently and evenly roll the spring down the Hilliard
the strut ribs and press the foam Clutch Garter Spring Installation Tool (PN
7.7
GENERAL INFORMATION
2870888) and into the groove of the rollers and

cage. WARNING: If this procedure is not
AWD ARMATURE PLATE
followed the spring will be over stressed and lose INSPECTION
its tension. Springs with incorrect tension may
allow rollers to move outward at high vehicle
speeds. If the rollers move outward, the front Seal Sleeve
hub(s) will engage and cause vehicle instability,
which could result in serious injury or death.
Must use Hilliard Clutch Garter

Spring Installation Tool
(PN 2870888)
Armature Plate Tabs
1. As the armature plate is engaged, it should

contact the outer magnet pole (seal sleeve) and
the inner magnet pole. Also, the armature plate
must be flat when placed on a flat surface. Bent
armature plates should be replaced.
WARNING: Be sure to use correct garter spring. NOTE: It is not unusual to see a double wear ring
These springs are very similar in appearance to those on the armature plate; however, the wear rings
used on earlier models. If the old, lighter springs were should be even.
installed on a machine requiring the heavier spring, 2. Install the roller clutch (Hilliard Clutch) assembly
the front wheels may engage at high speed, possibly and be sure the armature plate (A) is positioned
resulting in serious injury or death. Check springs properly. Also, when installing the hub assembly,
before installation. Always verify the correct be sure the armature plate tabs remain engaged
replacement spring part number by referring to with the roller clutch cage.
the appropriate parts manual. CAUTION: After the hub is installed, the slightest
8. Current electro-mechanical spring, (PN movement outward with the hub may cause the
3250032); wire diameter .018″ (.46 mm); spring armature plate tabs to disengage from the roller clutch
free length end to end inside hooks 6.968″ (177 cage. If the unit is driven with the armature plate out
mm). of position, it will cause roller clutch damage.
AWD FRONT DRIVE AXLE

REMOVAL
Measure wire diameter
Measure free length to inside of

loops as shown
7.8
GENERAL INFORMATION
1. Loosen front wheel nuts slightly.

2. Elevate and support machine under
footrest/frame area with front wheels elevated.
CAUTION: Serious injury may result if machine tips
or falls. Be sure machine is secure before beginning
this service procedure. Wear eye protection when
removing and installing drive axles or component
parts.
3. Remove wheel nuts and wheels.
9. Remove cotter pin and nut from lower A-arm ball

joint. Remove lower A-arm from ball joint.
4. Remove hub cap.

5. Remove the two brake caliper attaching bolts.
CAUTION: Do not hang the caliper by the brake
hose. Use wire to hang the caliper to prevent
possible damage to the brake line.
6. Place a catch pan beneath the front hub and
remove the hub cap.
10. Using Roll Pin Remover (PN 2872608), remove
the roll pin at front housing.
Roller Pin Removal Tool (PN 2872608)
11. Remove the spindle and axle assembly from the

strut casting bearing by pulling the strut outward
as shown. Drive out the old seal, taking care not
to damage the tapered roller bearing. Install the
new seal until it bottoms against the shoulder in
the strut casting.

7. Remove cotter pin and nut.
8. Remove hub, bearings, hilliard assembly, and
INSTALLATION
armature plat 1. Install spring washer and drive shaft. Align hole in
U-joint yoke with hole in eccentric shaft, and
install new roll pin.
2. Install new seal in strut casting. Refer to Page
7.13.
7.9
GENERAL INFORMATION
3. Install drive shaft in strut. cleaned. Refer to text for grease

4. Install lower ball joint, torque nut to 25 ft. lbs. (34.5 capacity of CV joints and CV joint boots.
Nm) and install new cotter pin.
5. Follow procedure to install hilliard clutch
components and hub as outlined on Page 7.9.
FRONT DRIVE SHAFT CV
6. Tighten hub nut following procedure on Page 7.4. JOINT BOOT REPLACEMENT
DRIVESHAFT AND CV JOINT

HANDLING TIPS
Care should be exercised during driveshaft removal
or when servicing CV joints. Driveshaft components
are precision parts.
Cleanliness and following these instructions is very
important to ensure proper shaft function and a
normal service life.
S The complete driveshaft and joint should

be handled by getting hold of the 1. Remove wheel, brake caliper and wheel hub.
interconnecting shaft to avoid Refer to Front Hug Removal Page 7.3 for
disassembly or potential damage to the procedure.
driveshaft joints. 2. Remove cotter pin and castle nut from A-arm ball
joint.
S Over-angling of joints beyond their
capacity could result in boot or joint 3. Disconnect A-arm from ball joint using a tie rod
damage. fork.
S Make sure surface-ground areas and

splines of shaft are protected during
handling to avoid damage.
S Do not allow boots to come into contact

with sharp edges or hot engine and
exhaust components.
S The driveshaft is not to be used as a lever

arm to position other suspension
components.
S Never use a hammer or sharp tools to

remove or to install boot clamps.
4. Slide strut off end of drive shaft and tie it up out of
S Be sure joints are thoroughly clean and
the way of the shaft.
that the proper amount and type of
grease is used to refill when joint boots NOTE: Be careful not to damage the wheel coil wires
are replaced and when joints are when positioning the strut. Front Drive Shaft CV Joint
Boot Replacement Cont.
7.10
GENERAL INFORMATION
5. Remove clamps from rubber boot using the

proper boot clamp pliers. (PN1350046
CV Joint Grease - 30g PN 1350046)
Retaining ring CV Boot

CV Boot Clamp
Clamp Pliers:
Pliers:
Earless
Earless Type
Type (PN 8700226)
8700226
Boot Replacement requires 30g

Boot replacement with complete CV
joint cleaning requires an additional
30g. (Total 60g)
Pull shaft to remove from

CV joint
FRONT SHAFT
6. Remove the large end of the boot from the CV
joint, slide the boot back and separate the wheel
spindle and CV joint assembly from the axle shaft Joint Capacity
30 Grams
by pulling the shaft sharply outward, away from
the CV joint. It may be necessary to tap the CV
joint assembly outward with a soft faced hammer.
7. Remove small clamp and boot from driveshaft.
If the ATV has been operated with a damaged boot,
the CV joint grease may be contaminated. Inspect the
grease carefully for contamination, and clean the joint
thoroughly if necessary. Front drive axle CV boot
replacement requires 30g of grease. If CV joint is
cleaned, an additional 30g of grease is required.
Refer to information below.
Boot Capacity
8. Before installing the new boot, remove all grease 30 Grams
from the boot area and shaft.
NOTE: It is very important to use the correct type and
quantity of grease by using the grease contained in
the boot kit. DO NOT use a substitute grease and DO
NOT overfill or underfill the CV joint.
9. Slide the new clamp and boot (small end first)
over the splined shaft, then slide (tap) the CV joint
into the splines of the axle. Install small boot
clamp.
10. Add grease through large end of boot.
11. Position large end of boot on CV joint, purge
excess air by partially compressing axle into CV
bell, lift one edge of boot to let out excess air
Secure with
clamp.
Front outboard joint capacity: 30g if boot

is replaced only. Another 30g (60g total) if
joint is cleaned.
7.11
GENERAL INFORMATION

EXPLODED VIEW
Front Drive Axle Components
Boot Drive Axle
CV Joint Assy Clamps Circlip Yoke

U--Joint Assy
Front Prop Shaft Components
Propshaft Assembly O-Ring

Prop Shaft
Cross and Bearing Kit
Yoke, Propshaft to Transmission

Spring Pin
Yoke, Front Gearcase
7.12
GENERAL INFORMATION
AWD STRUT CASTING BEARING REPLACEMENT

FRONT DRIVE AXLE SEAL NOTE FOR FRONT DRIVE
REPLACEMENT AXLE AND FRONT HUB
NOTE: The front axle bearings have a larger I.D.
(1.0625″) than the hub bearings (1.000″). Be sure to
install the bearings with the larger I.D. in the strut
housing, and the bearings with the smaller I.D. in the
hub.
SEAL SLEEVE
REPLACEMENT
Front Drive Axle Seal Sleeve
1. Disassemble front hub. Refer to Page 7.3.

2. Remove the cotter pin and castle nut from the A-
arm ball joint. Separate A-arm from ball joint.
3. Remove the spindle and axle assembly from the
strut casting bearing by pulling the strut outward A Seal Sleeve
as shown. Drive out the old seal, taking care not
to damage the tapered roller bearing. Install the
new seal until it bottoms against the shoulder in
the strut casting.
1. If front axle sleeves become damaged and leak
fluid they are replaceable. Using a hammer and
Pull drift punch, remove the seal sleeve by driving it off
strut off evenly being careful not to nick or damage the
drive sleeve mounting area (A).
shaft 2. Coat the sleeve mounting area (A) with silicone
and using extreme care, press the new seal
sleeve onto area (A) until it bottoms. Allow 12
hours for silicone to cure.
4. Apply grease to the seal inner lip, reinstall the

spindle and axle assembly.
5. Reinstall the A-arm to the ball joint. Torque to 25
ft. lbs. (35 Nm).
NOTE: If the cotter pin hole does not align at the
above torque, tighten slightly until the cotter pin hole
aligns and install the pin with open ends toward rear
of machine.
7.13
GENERAL INFORMATION
Hub Seal Sleeve Replacement

3. New front drive axle CV joint assemblies and
drive axle assemblies have the seal sleeve
installed from the factory.
Not Unusual To See
Seal
Two Wear Rings
Sleeve
(Outer
Magnet
Inner Magnet Pole Pole)
(Fixed)
Coil
Max. .001″ Inner Pole Shoe

Seal Sleeve (.025mm)
(Outer Magnet Measure at 3
Pole) (Adjustable) places 120_
apart AWD FRONT PROP SHAFT
REMOVAL
Pole Gap:
.000”-- .001” (.00-- .025 mm)
Seal Sleeve Installation Tool Kit:

(PN 2871199)
4. The hub seal sleeve must be driven onto the strut

casting until flush with the inner magnet pole. Use
the flat side (no step) of the Seal Sleeve
Installation Tool Kit (PN 2871199).
5. To check the gap between the inner and outer
poles place a straight edge on the outer pole so
that it just intersects with the inner pole. The gap
between the straight edge and inner pole should
be 0 to .001I (0-.025mm). This measurement 1. Using Roller Pin Removal Tool (PN 2872608),
should be checked in three different positions remove the roll pin from the prop shaft at rear of
around the pole assemblies. The three housing. Slide prop shaft back and away from
measurements must be within .0005I (.013 mm) front housing. Pull sharply forward to remove
of each other. If the gap is excessive, the hub may from transmission shaft.
notengage. NOTE: If removing front housing, use roll pin
remover to remove the roll pins from both front drive
Seal Sleeve Tool
axles.
Use flat side to install seal sleeve
Roller Pin Remover Tool (PN 2872608)
Step
7.14
GENERAL INFORMATION
U-JOINT DISASSEMBLY
4. Force U-joint cross to one side and lift out of inner

CAUTION: Always wear eye protection. yoke.
1. Remove internal or external snap ring from all
bearing caps. U-JOINT ASSEMBLY
NOTE: If yoke or bearing is removed, cross bearing
must be replaced.
1. Install new bearing caps in yoke by hand.

Carefully install U-joint cross, taking care not to
dislodge needle bearings upon installation of
2. Support inner yoke as shown and drive outer yoke
down (bearing cap out) with a soft face hammer. cross joint. Tighten vise to force bearing caps in.
2. Using a suitable arbor, fully seat bearing cap in

one side. Continually check for free movement of
3. Support U-joint in vise as shown and drive inner
yoke down to remove remaining bearing caps. bearing cross as bearing caps are assembled.
7.15
GENERAL INFORMATION
3. Install snap ring to contain bearing cap just 3. Elevate and support machine under
installed. Repeat procedure for other side. footrest/frame area.
CAUTION: Serious injury may result if machine tips
this service procedure. Wear eye protection when
removing and installing bearings and seals.
4. Remove right wheel nuts and wheel.
4. Install outer yoke, aligning marks made before

disassembly.
5. Repeat Steps 1-3 to install bearing caps on outer
yoke.
5. Remove cotter pin, lower ball joint nut and A-arm

from ball joint.
6. Punch spring pins out from both axle splines and
front prop shaft.
7. Remove bolts securing bottom of housing to
frame. Remove vent line. Remove housing from
right side of frame.
FRONT HOUSING
DISASSEMBLY
6. Seat all bearing caps against snap rings by 1. Drain and properly dispose of used oil.
supporting cross shaft and tapping on each
corner as shown.
7. When installation is complete, yokes must pivot
freely in all directions without binding. If the joint is
stiff or binding, tap the yoke lightly to center the
joint until it pivots freely in all directions.
AWD FRONT HOUSING

REMOVAL
1. Stop engine, place machine in gear and set
parking brake.
2. Loosen right front wheel nuts slightly.
7.16
GENERAL INFORMATION
2. Remove bolts and output shaft cover. 5. Remove pinion cover and O-ring.
AWD FRONT HOUSING

DISASSEMBLY, CONT.
6. Unscrew fill plug and remove pinion shaft

assembly. Inspect pinion gear for chipped broken
or missing teeth.
NOTE: Pinion shaft assembly will not clear the fill
3. Remove output shaft assembly, large shim, and plug unless it is backed out.
thrust button with its small shim.
4. Clean all parts and inspect spacers for wear.
Inspect ring gear for chipped, broken, or missing AWD FRONT HOUSING
teeth. ASSEMBLY
1. Replace all O-rings, seals, and worn
components.
Bushings
2. Press pinion shaft seal into pinion cover until flush

with sealing surface.
3. Inspect pinion and output shaft bushings.
7.17
GENERAL INFORMATION
NOTE: Due to extremely close tolerances and

minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by hand,
inspect for rough spots, discoloration, or corrosion.
The bearings should turn smoothly and quietly, with
no detectable up and down movement and minimal
movement side to side.
5. Clean pinion shaft and lock nut with PrimerNt
and apply red LocTitet to threads. Tighten lock
nut to specification.
4. Inspect bearings on output and pinion shafts. To

replace, press new bearing on to shaft.
6. Install pinion shaft and pinion cover plate with new

o-ring and torque bolts to 14 ft. lbs. (19 Nm).
Pinion Shaft Lock Nut

Torque
65 ft. lbs. (89.7 Nm)
Cover Bolts Torque
14 ft. lbs. (19 Nm)
Equal Shims
7.18
GENERAL INFORMATION
7. Install output shaft assembly.

NOTE: The same shim thickness placed behind ring
gear bearing must also be put behind the cover
button.
8. Install output shaft cover with new o-ring and
torque bolts to 14 ft. lbs. (19 Nm).
Cover Bolts Torque
14 ft. lbs. (19 Nm)
FRONT HOUSING
INSTALLATION
Fill Plug
1. To install housing, reverse removal procedure.

Use new roll pins in drive shafts.
2. Add Polaris Premium Front Housing Lubricant or
GL5 80-90 gear lube to front housing. Check drain
plug for proper torque.
ATV Angle Drive Fluid

(PN 2871653) (12 oz.)
Front Housing Capacity

4.0 fl. oz. (118 ml)
7.19
GENERAL INFORMATION
AWD FRONT HOUSING

EXPLODED VIEW
Vent
Bushing
Seal
Pinion Shaft Output Shaft

Pinion Cover
Bearing
Retaining Ring
Shim O-Ring
Output Cover
Bearing
O-Ring Thrust Button
Seal
Shim
Seal
7.20
GENERAL INFORMATION
CONCENTRIC SWINGARM
MIDDLE AXLE REMOVAL
B
5. Remove retaining ring (A), nut retainer (B) and foam

seal (C) from right side of axle.
1. Securely support rear of machine with middle

wheels off the floor. Remove middle wheels and
hubs.
2. Remove the rear chain gaurd.
6. Loosen the jam nut with a 1 3/4” Straight Wrench

(PN 2870772).
3. Remove rear and middle drive chains.

E
4. Remove swing arm brackets from rear swing arm

weldment. Lower rear swing arm to the ground.
7.21
GENERAL INFORMATION
7. Remove the jam nut (D) and locking middle axle 10. Remove rear brake caliper. Support with wire or
hub (E). tie strap. Do not hang caliper by brake line.
8. Remove swing arm housing (F), bearing spacer

(G), and O-rings (H). Discard O-rings. Inspect
bearing and seals, replace if worn or damaged. 11. Slide axle assembly out left side of housing.
K CONCENTRIC SWINGARM
MIDDLE AXLE DISASSEMBLY
1. Remove rear axle. (See Page 7.28)
J
C
9. Remove the 30 tooth spocket (J) and the 38 tooth

sprocket (K). A
B
2. Remove retaining ring (A), nut retainer (B), and

foam seal (C).
7.22
GENERAL INFORMATION
3. Remove jam nut (D) and locking mid axle hub (E). 2. Install disc hub assembly on axle. Be sure hub
Remove swing arm housing and O-rings (F). covers stop ring. Install disc in soft jawed vise.
Discard O-rings. Inspect bearing and seals, Apply Never Seize to threads, install left axle nut
replace if worn or damaged. and tighten to 120 ft. lbs (166 Nm). Keep tightening
nut until flat aligns with flat on brake hub.
Disc Hub
Stop Ring
Groove in spline Spacer
Threads
Splines O-ring
4. Remove brake disc assembly, and stop ring.

Inspect axle for straightness and damage.
Replace if necessary. Axle Nut (Disc Side) Torque:
120 ft. lbs. (166 Nm)

CONCENTRIC SWINGARM
MIDDLE AXLE ASSEMBLY 3. Lubricate spacer and new O-ring. Install on axle.
Foam Seal
Disc Hub
Nut Retainer
Stop Ring (Taper toward hub)
Groove in spline
Retaining Ring
1. Install stop ring in groove on left side of axle.

4. Lubricate and install swing arm assembly with
NOTE: Left side of axle is identified by the small
grease zerk facing away from brake disc.
groove in the middle of the spline.
Lubricate and install new O-ring and locking hub.
Foam Seal
Nut Retainer
(Taper toward hub)
Retaining Ring
Stop ring
7.23
GENERAL INFORMATION
5. Install foam seal and nut retainer with taper inside of middle chain sprocket hub and slide
toward locking hub. Install retaining ring. sprocket hub assembly onto the axle as the axle is
being installed. Seat the hub against O-ring and
bearing. Lubricate and install bearing spacer and
O-ring.
O-ring
Spacer
6. Lubricate and install axle spacer and O-ring.
CONCENTRIC SWINGARM 3. Seat the 38 tooth sprocket hub and hub against
O-ring and bearing. Lubricate and install bearing
MIDDLE AXLE INSTALLATION between the spacer and O-ring.
F
4. Lubricate and install new O--rings (E), the bearing

1. Install axle from left to right. spacer (G), and the swing arm housing (F) with
grease zerk facing away from chain sprockets.
H
E
2. Lubricate and install a new O-ring on right side of

axle. Slide the new O-ring against RH axle 5. Lubricate and install new O--ring (E) and locking
bearing seal. Apply grease to sealing area on middle axle hub (H).
7.24
GENERAL INFORMATION
6. Apply Never Seize to threads of and install nut (I). 9. Torque brake caliper mounting bolts to 18 ft. lbs.
Tighten nut with wrench to approximately 8-10 ft. (25 Nm).
lbs. (11-14 Nm). Align flat of nut with flat on hub.
Axle must rotate smoothly without binding. If axle
binds the nut is too tight. If axle movement (up and
down or side to side) is detected, axle is too loose.
Grease Zerk Faces Upward
Brake Caliper Mounting Torque:

18 ft. lbs. (25 Nm)
Caliper Mounting Bracket Torque:

10-12 ft. lbs. (14-17 Nm)
7. Install foam seal and slide nut retainer with taper
inward onto locking hub. Install retaining ring. 10. Install rear swing arm. NOTE: The grease zerk
on the swing arm housing faces upward. Torque
bolts to 40 ft lbs. (55 Nm).
Nut Retainer
Foam Seal
Retaining Ring
Axle Nut (Sprocket Side) Torque:

Rear Swing Arm Mounting Torque:
8-10 ft. lbs. (11-14 Nm) 40 ft. lbs. (55 Nm)
11. Install rear drive chain. Adjust drive chain if

8. Install brake caliper and middle drive chain.
necessary (refer to Maintenance Chapter 2 for
Adjust drive chain-3/8” -- 1/2” (6.77 -- 12.70 mm)
procedure).
deflection at the tightest point in the chain, refer to
Maintenance Chapter 2 for procedure). If housing 12. Apply Never Seize to axle splines and install
was removed, torque eccentric pinch bolts to 30 wheel hubs. Torque center hub nut to 80 ft. lbs.
ft. lbs. (41 Nm) and torque brake caliper and install a new cotter pin. Torque wheel nuts to
mounting bracket 10-12 ft. lbs. (14-17 Nm). Verify 50 ft. lbs. (68 Nm).
proper chain adjustment after torquing eccentric 13. Lubricate eccentric housing and swing arm
by rolling ATV forward and checking chain tension housings grease fittings with Polaris Premium All
in several places on chain. Season Grease until grease is purged on each
side of eccentric and swing arm housing.
7.25
GENERAL INFORMATION
CONCENTRIC SWINGARM MIDDLE AXLE ASSY, EXPLODED VIEW
13
3 8
2 4 6
1
5 7 9 15
10 14 16
17 18 19
11 12
20 21 22
23 24 26
25
28
27
43
29
30 31 32
1. Retaining Ring 33 34 35
2. Retainer Nut 36 37 38 39
40 41
42
3. Foam Seal
4. Jam Nut 19. Lip Seal
5. Locking Middle Axle Hub 20. Bearing Cone
6. O--ring 21. Bearing Cup
7. Seal 22. Rear Axle Housing
8. Swing Arm Housing 23. Bearing Cup
34. Bearing
9. Bearing 24. Bearing Cone
35. Swing Arm Housing
10. Rear Axle Seal 25. Lip Seal
36. Seal
11. O--ring 26. O--ring
37. O--ring
12. Bearing Spacer 27. Middle Axle
38. Locking Middle Axle Hug
13. Nylok Nut 28. Connector Link
39. Jam Nut
14. Brake Disc Hub 29. 38T Sprocket
40. Foam Seal
15. Locking Brake Disc Hub 30. 30T Sprocket
41. Retainer Nut
16. O--ring 31. Bearing Spacer
42. Retaining Ring
17. Axle Spacer 32. O--ring
43. 80 P Chain
18. O--ring 33. Rear Axle Seal
7.26
GENERAL INFORMATION
CONCENTRIC SWINGARM MIDDLE HOUSING

MIDDLE HOUSING REMOVAL DISASSEMBLY/BEARING
1. Remove middle axle. (See Page 7.20) SERVICE
Upper Bearing
Caliper Mount
Caliper Seal
Seal
Lower
Caliper Mount
Mount Bolts Bearing Race
2. Remove the upper and lowerbrake caliper
mounting brackets. 1. Remove seals from housing.
2. Remove bearings.
3. Drive bearing race out from opposite sides.
4. Inspect housing for cracks or wear. Replace if
damaged.
MIDDLE HOUSING
ASSEMBLY/BEARING
SERVICE
1. Drive in new bearing race with brass drift.
2. Lubricate and install new tapered bearings.
3. Lubricate and install new seals.
3. Remove brake caliper pivot bushing from stud.

NOTE: Flange inward as shown.
4. Loosen pinch bolts and remove middle axle

housing.
7.27
GENERAL INFORMATION
CONCENTRIC SWINGARM 4. Remove axle nut and washer.

5. Place a block of wood on end of axle or use a soft
MIDDLE HOUSING face hammer, and drive axle out from right to left.
INSTALLATION 6. Tap locating collar on left side of axle toward the
right enough to expose the circlip retainer.
Remove retainer and locating collar.
7. Inspect locating collar on left side of axle and
replace if worn or damaged. A worn collar will
allow dirt to enter axle bearing area.
1 3/4″ Straight Wrench
(PN 2870772)
REAR AXLE INSTALLATION

1. Slide locating collar on left end of axle with recess
facing outward.
1. Place brake caliper pivot bushing on stud with
flange inward as shown. 2. Install a new circlip.
3. Tap locating collar back towards left end of axle
until it captivates circlip.
4. Apply a light coat of grease to axle and install a
new O-Ring.
5. Insert axle from left to right.
6. Install O-Ring, sprocket hub, and washer.
7. Clean axle nut threads with a wire brush. Apply
Loctitet 242 (PN 2871949)to threads and install
axle nut. Torque to 150 ft. lbs. (203 Nm). Rotate
axle and check for smooth operation.
8. Install lock nut and torque to 150 ft. lbs. (203 Nm).
Fill the middle housing 9. Lightly grease splines of axle and install wheel
with grease. hubs, flat washers, and cone washers with
concave side facing flat washer.
10. Torque hub nuts to 80 ft. lbs. (110 Nm) and install
2. Install middle axle. (See Page 7.27) new cotter pin, bending one leg of cotter pin
3. Fill housing with grease until grease purges from inward and one outward against end of axle.
both seals. 11. Install hub cap.
12. Place wheels on hubs and install wheel nuts with
tapered side facing in. Torque evenly to
REAR AXLE REMOVAL specifications.
REFER TO EXPLODED VIEW ON PAGE
7.28 Rear Axle Retaining Nut:
1. Elevate and safely support machine under 150 ft. lbs. (203 Nm)
footrest/frame area.
Rear Hub Retaining Nut:
CAUTION: Serious injury may result if machine tips 80 ft. lbs. (110 Nm)
this service procedure. Wear eye protection when Rear Wheel Nuts:
removing and installing bearings and seals. 50 ft. lbs. (69 Nm)
2. Remove wheels and hubs.
3. Hold inner axle nut and remove outer axle nut.
7.28
GENERAL INFORMATION
REAR DRIVE AXLE SERVICE

Apply Loctitet 242 to
the bolt threads.
242
150 ft. lbs. (207 Nm)
242
Hub
50 ft. lbs.
(69 Nm)
A
I
D
C
E
F
G
80 ft. lbs.
F E (110 Nm)
B K
D C
H J
80 ft. lbs.
(110 Nm)
Flat Washer
A. Retainer Ring
B. Bearing Spacer
C. O--ring
Cone washer D. Seal
tapered to
outside Lubricate hub splines E. Cone Bearing
with light film of grease. F. Cup Bearing
G. Rear Housing
H. 30T Sprocket
I. Jam Nut
Out Replace all cotter
pins if removed. J. Chain
Cone K. Rear Hub Sprocket
Washer L. Rear Axle
REAR AXLE BEND

The rear axle shaft is hardened to approximately 3″ to blocks, a hydraulic press, and a dial indicator.
4″ (7.6 to 10 cm) from the outer ends. This allows the CAUTION: Do not use heat on any part of the axle.
shaft to bend in case of impact or accident. Small Heat will destroy the temper and cause the shaft to
amounts of axle runout can be straightened using V become brittle.
7.29
GENERAL INFORMATION
NOTES
7.30
TRANSMISSION
Special Tools and Torque Specifications . . . . . 8.2

Gear Shift Selector Removal . . . . . . . . . . . . . . . 8.2
Gear Shift Selector Disassembly . . . . . . . . . . . 8.2--8.3
Gear Shift Selector Assembly . . . . . . . . . . . . . . 8.3--8.4
Gear Shift Selector Installation . . . . . . . . . . . . . 8.4
Boot Replacement . . . . . . . . . . . . . . . . . . . . . . . 8.4
Transmission Removal/Installation . . . . . . . . . 8.5
Transmission Disassembly . . . . . . . . . . . . . . . . 8.5-8.7
Transmission Assembly . . . . . . . . . . . . . . . . . . . 8.7-8.8
Transmission Exploded View . . . . . . . . . . . . . . 8.9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.1
TRANSMISSION
SPECIAL TOOLS
PART NUMBER TOOL
DESCRIPTION
2871710 10” Center
Distance Tool
Torque Specifications
Transmission Case Bolts . . . . . 12 ft. lbs. (16.6 Nm)
Bell Crank Nut . . . . . . . . . . . . . . 12 ft. lbs. (16.6 Nm)
Transmission Drain Plug . . . . . 14 ft. lbs. (19.3 Nm)
Speedometer Angle Drive . . . . 11 ft. lbs. (15 Nm)
Transmission Mounting Bolts . . 25 ft. lbs. (34.5 Nm)
Drive Sprocket Bolt . . . . . . . . . . 17 ft. lbs. (23.5 Nm) 1. Clamp gear selector body lightly in a soft jawed
Output Shaft Bearing vice. Using a cross pattern, loosen each of the
Mounting Nuts . . . . . . . . . . . . . . 12 ft. lbs. (16.6 Nm) four screws holding the gear shift selector cover
to the gear shift selector body. Loosen each
Swing Arm Pivot Bolts . . . . 150 ft. lbs. (207.5 Nm) screw only a few turns, then proceed to another
screw.
LUBRICATION NOTE: These parts are under pressure from the
internal springs.
NOTE: Refer to maintenance section for
transmission lubricant type and capacity.
GEAR SHIFT SELECTOR

REMOVAL
NOTE: To change fluid, remove selector box
assembly, disassemble, clean, and assemble.
1. Remove parts that interfere with access to shift
selector (seat, right side panel, and exhaust heat
shield, etc.).
2. Disconnect the two linkage rods from gear shift
selector slides.
3. Remove five bolts attaching gear shift selector to
the mounting bracket. 2. Carefully pull the gear shift selector cover and rod
4. Lift gear selector out of mounting bracket and from the gear shift selector body.
away from frame. 3. Set the cover/rod assembly aside.
4. Remove the three springs from gear shift
GEAR SHIFT SELECTOR selector.
DISASSEMBLY 5. Slowly tilt gear shift selector body sideways to
drain oil.
CAUTION: NOTE: Do not tip gear shift selector body upside

down or detent bullets and stop pin may fall out.
Wear eye protection during this procedure. Read Check for signs of moisture in the selector body.
each step completely before proceeding. Essential Inspect shift boot closely if moisture is present in
parts may be lost or damaged if you do not heed this selector box.
caution! 6. Tap gear shift selector body, top down, against a
hard, smooth, flat surface to jar the dowel pin and
8.2
TRANSMISSION
two detent bullets loose. Pull the detent bullets

and the dowel pin out of the gear shift selector
GEAR SHIFT SELECTOR
body. ASSEMBLY
7. Remove the two slides, one at a time.
NOTE: The LH (low) slide has two short notches and
the RH (high/rev) slide has one short and one long
notch. The slides must be replaced in the proper
channels.
Cap
Screw
Knob
Clamp
Boot Handle 1. Insert slides into gear shift selector body, taking
care not to cut or tear O-rings in the process.
NOTE: The LH slide has two short notches and the
Cover (Apply
Centering Spring RH side has one short and one long notch. The slides
Loctitet 515)
must be replaced in the proper channels for the shifter
to function properly.
Plastic Detent Spring
Sphere
Detent
Groove Bullet
Pin
Dowel High/Reverse
Pin (1 Short,
1 Long Notch)
Detent
Spring
Detent Low
Bullet 2 Short
Notches Selector Slides
8. Inspect O-rings for damage. Replace if any

damage is found. 2. Replace detent bullets, dowel pin, and springs by
9. Flush housing with parts washer fluid or reversing Steps 5-7 of Gear Shift Selector
penetrating oil to remove all moisture. Disassembly.
10. Dry all gear shift selector parts and remove any 3. Clamp gear shift selector body lightly in a soft
corrosion with a wire brush. jawed vise.
4. Fill selector body with Polaris 0W-40 All Season
Synthetic motor oil. The oil level should be at one
half the height of the slides (approx. 1 oz.).
Gear Shift Selector Capacity: 1 oz.

Polaris 0W-40 All Season Synthetic Oil
(PN 2871281) - Quart
(PN 2871844) - Gallon
8.3
TRANSMISSION
5. Slide boot off selector rod and replace with a new

one.
CAUTION: Too much oil could cause the selector to
hydrolock. Be sure the selector box is level when 6. Apply RTV silicone to selector rod to seal top of
adding oil. boot.
7. Place band clamp in position and tighten using CV
5. Wipe gear selector dry, clean surfaces of cover
boot clamp pliers.
and selector box with Loctitet Primer T and place
a bead of Loctitet 518 Gasket Eliminator (PN 8. Replace shift knob, securing it to selector rod with
2870587) or Crankcase Sealant (PN 2871557) screw removed in Step 2.
completely around the edge of the gear shift 9. Push shift knob cover back into place. Allow
selector body. approximately 12 hours for RTV silicone to cure.
Cap
Screw
Knob
Clamp
Seal with
RTV silicone
Boot
6. Carefully reattach cover/rod assembly to gear

shift selector body. Make sure slides are in
neutral, or butterfly may be damaged.
7. Torque cover screws to 12 ft. lbs. (17 Nm).
GEAR SHIFT SELECTOR

INSTALLATION
1. Place gear shift selector back into the mounting
bracket and replace five bolts.
2. Reconnect linkage rods to gear shift selector
slides. Adjust as required. See linkage
adjustment procedures.
3. Replace remaining parts.
BOOT REPLACEMENT
NOTE: If moisture is found in the gear shift selector
the boot should be replaced.
1. Using a slotted screwdriver, remove cap from
gear shift knob.
2. Remove torx screw securing knob to selector rod.
3. Pull selector knob off selector rod.
4. Remove band clamp on rubber boot.
8.4
TRANSMISSION
TRANSMISSION REMOVAL TRANSMISSION

DISASSEMBLY
1. Place both bellcranks in neutral position.
2. Remove sprocket retaining clip and sprocket.
CAUTION: Remove switch(es) BEFORE
removing case cover.
3. Remove the transmission cover bolts.
Remove Gear Indicator Switches
1. Remove seat, cab and air box.

2. Remove right side shield and auxiliary brake
master cylinder and reservoir.
3. Remove PVT outer cover, both drive and driven
clutch, and inner PVT cover (refer to Clutch
Chapter 6).
4. Remove rear PVT bracket. Tap with soft
face hammer
5. Remove pin from front prop shaft at front housing. Ill. 1
Position U-joint to allow pin to clear skid plate. 4. With a soft face hammer tap on the cover bosses
6. Remove carburetor. and carefully remove the cover. See Ill. 1.
7. Disconnect harness from gear position switch.
8. Remove drive chain and sprocket.
9. Remove mounting bolts and brackets as shown.
10. Remove through-bolt from bottom of
transmission.
Puller
11. Loosen left side swingarm bolt until clear of
transmission case.
12. Remove recoil.
13. Remove transmission from right side of frame.
TRANSMISSION
INSTALLATION Bearing
1. Reverse removal steps to install transmission.
Ill. 2
NOTE: Install the 10” Center Distance Tool (PN
2871710) on engine and transmission input shaft 5. Using the battery cable clamp puller, remove the
before tightening transmission mounting bolts. Align bearing from the sliding gear shaft. See Ill. 2.
clutches as outlined in Clutch Chapter 6.
8.5
TRANSMISSION
6. Remove outer thrust washer.
Low Gear
(2) Remove
needle bearing
(1) Work gear back

and forth until bearing
is exposed 10. Remove snap ring from front drive input shaft.
Ill. 3 11. Remove output shaft and gear assembly along
with sprocket and chain, by tapping on shaft with a
7. To remove the needle bearing from the low gear, soft faced hammer, from the back side of the gear
tip transmission to point end of shaft downward. case.
Work gear back and forth as shown until bearing 12. Remove roller chain. Note position of sprockets
is exposed and slide bearing out. See Ill. 3. and gear. Stretch chain tight on a flat surface and
measure the length of 8 pitches in a minimum of
three places on chain. Replace chain if
measurement is longer than 5.05I.
Chain Stretch Limit
8 pitch length = 5.05I Maximum
8. Remove the low gear and inner thrust washer.

9. Use a 1/2″ wrench to rotate the low range
bellcrank and remove low range shift fork with dog
gear.
NOTE: High/Reverse bell crank must be in neutral to
remove low gear shift fork shaft.
8.6
TRANSMISSION
13. Use a 1/2″ wrench to rotate high/reverse bell

crank and remove shift fork along with shafts.
2. Torque bolts in 3 steps using a criss-cross pattern

14. Remove front drive input shaft bearing retainer to 18 ft. lbs. (25 Nm).
plate.
15. Remove pinion shaft assembly.
3. Install pinion shaft assembly.

4. Install retainer plate with flat side toward bearing.
16. Remove front output shaft cover and ring gear 5. Apply Loctitet 242 (PN 2871950) to bolts and
assembly. torque to 18 ft. lbs. (25 Nm).
17. Clean all components in a parts washer and
inspect for wear.
18. Inspect engagement dogs of gears and replace if
edges are rounded.
19. Inspect gear teeth for wear, cracks, chips or
broken teeth.
20. Remove seals from transmission case.
NOTE: New seals should be installed after the
transmission is completely assembled.
21. Inspect bearings for smooth operation. Check for
excessive play between inner and outer race.
TRANSMISSION ASSEMBLY
1. Install front output shaft cover and ring gear
6. Carefully install high/reverse shaft assembly and
assembly.
gear cluster as a unit into their respective bearing
8.7
TRANSMISSION
case areas. Tap with a soft face hammer to seat 11. Install low gear with slots facing dog gear.
shaft assemblies.
NOTE: Make sure high/reverse shift shaft pin is
properly positioned within legs of shift fork shaft return
spring.
NOTE: After installation, the High / Reverse shift arm

must be placed in the neutral position to complete
reassembly.
12. Lubricate and install needle bearing in low gear.

13. Install washer (small inside diameter) on shaft.
14. Install ball bearing.
15. Prior to reinstalling the cover make sure the
mating cover surfaces are clean and dry. Apply
Loctitet 518 (PN 2870587) or Crankcase
Sealant (PN 2871557) to mating surfaces.
16. Reinstall cover and torque bolts in a criss-cross
7. Install output shaft and gear assembly along with pattern in 3 steps to 18 ft. lbs. (25 Nm).
sprocket and chain.
17. Install drain plug with a new sealing washer.
8. Install snap ring. Torque drain plug to 14 ft. lbs. (19 Nm).
18. Install transmission and add Polaris AGL
Gearcase Lubricant in the recommended
Small I.D. washer amount. Refer to Maintenance Chapter 2.
Large I.D. washer Low

High/Rev
Low gear
Large I.D.
Needle bearing
Dog gear
9. Place shift fork and dog gear assembly (dogs face

outward) on shaft. Place dog gear on shaft and
shift fork shaft into case, aligning splines of gear
with shaft while engaging shift shaft pin in legs of
19. Install gear indicator switches. Apply Loctitet
shift fork shaft return spring. Push the assembly
242 (PN 2871950) to threads of switch screws
into case until seated.
and torque to 13-16 in. lbs. (1.5-1.9 Nm).
10. Install thrust washer (with larger inside diameter)
on shaft (against splines of shaft).
8.8
TRANSMISSION
TRANSMISSION EXPLODED
VIEW 31
30
23
32
22
29 41 42
28 54
21
40 52
27 39
20
19 26 38 49
53
37 47
51
18 25
17 36
46
35 48 50
24
34 49
15
14 46
33
16 47
46
45
44
43
13
12
9
11 10 8 7 5
6 4 3 2 1
1. Seal 12. Oil Fill Plug 23. Seal 34. 13 T Pinion Shaft 45. Washer
2. Screws 13. H/L/R Bellcrank 24. Bearing 35. Bearing 46. Retaining Ring
3. Snorkel Cover
14. H/R Bellcrank 25. Roller Chain 36. Retaining Ring 47. Low Engagement Dog
4. O--ring 15. Interlock Assembly 26. 16/26T Sprocket 37. Bearing Cover 48. 24T Sprocket
5. Shim 16. Oil Deflector 27. Output Shaft 38. Screws 49. Needle Bearing
6. Bearing 17. 2 Position Switch 28. 98T Gear 39. 14/22T Sprocket 50. 31T Reverse Shaft
7. 25T--Gear 18. 3 Position Switch 29. Bearing 40. Retaining Ring 51. 37T Gear
8. Snorkel Shaft 19. Bearing 30. LH Gearcase 41. Low Shift Fork 52. Washer
9. Bushing 20. Silent Chain 31. Screws 42. H/R Shift Fork 53. Retaining Ring
10. RH Gearcase 21. H/L/R 14T Shaft 32. H/R Shift Fork 43. Bearing 54. Bearing
11. Seal 22. Bearing 33. Bushing 44. Retaining Ring
8.9
TRANSMISSION
TROUBLESHOOTING
CHECKLIST
Check the following items when shifting difficulty is encountered.
G Idle speed adjustment
G Transmission oil type/quality
G Transmission torque stop adjustment
G Engine torque stop adjustment
G Drive belt deflection
G Loose fasteners on rod ends
G Loose fasteners on shifter
G Worn rod ends, clevis pins, or pivot arm bushings
G Linkage rod adjustment and rod end positioning
G *Worn, broken or damaged internal transmission components
*NOTE: To determine if shifting difficulty or problem is caused by an internal transmission problem, isolate the
transmission by disconnecting linkage rods from transmission bellcranks. Manually select each gear range at
the transmission bellcrank, and test ride vehicle. If it functions properly, the problem is outside the transmission.
If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding),
damage. Inspect all bearings for wear.
8.10
GENERAL INFORMATION
Specifications/Torques . . . . . . . . . . . . . . 9.2
Special Tools . . . . . . . . . . . . . . . . . . . . . . 9.3
Brake System Service Notes . . . . . . . . 9.3
Brake Noise Troubleshooting . . . . . . . . 9.3
Hydraulic Brake System Operation . . . 9.4
Dual Hydraulic Caliper Bleeding . . . . . . 9.5
Brake System Main Components . . . . . 9.6
Front Caliper Exploded View . . . . . . . . . 9.6
Fluid Replacement/Bleeding Procedure 9.7-9.8
Master Cylinder Disassembly . . . . . . . . 9.8--9.9
Master Cylinder Installation . . . . . . . . . . 9.9
Front Pad Removal . . . . . . . . . . . . . . . . . 9.10--9.11
Front Pad Assembly/Adjust . . . . . . . . . . 9.11--9.12
Brake Pad Burnishing Procedure . . . . . 9.12
Front Disc Inspection . . . . . . . . . . . . . . . 9.12
Front Disc Removal/Replacement . . . . 9.12--9.13
Front Caliper Removal . . . . . . . . . . . . . . 9.13
Front Caliper Disassembly . . . . . . . . . . 9.13--9.14
Front Caliper Inspection . . . . . . . . . . . . . 9.14--9.15
Front Caliper Assembly . . . . . . . . . . . . . 9.15
Front Caliper Installation . . . . . . . . . . . . 9.16
Rear Pad Removal . . . . . . . . . . . . . . . . . 9.16
Rear Pad Installation . . . . . . . . . . . . . . . 9.17
Rear Caliper Removal/Inspection . . . . . 9.17--9.18
Rear Caliper Assembly . . . . . . . . . . . . . 9.18
Rear Disc Inspection . . . . . . . . . . . . . . . 9.19
Troubleshooting . . . . . . . . . . . . . . . . . . . . 9.19
9.1
GENERAL INFORMATION
SPECIFICATIONS
Item Standard Service Limit
Brake Pad Thickness .298 ± .0073″ / 7.56 ± .185 mm .180″ / 4.6 mm
Brake Disc Thickness .150-.165″ / 3.810-4.191 mm .140″ / 3.556 mm
Brake Disc Thickness Variance Between - .002″ / .051 mm
Measurements
Brake Disc Runout - .010″ / .254 mm
RH Master Cylinder I.D. .625″ / 15.8 mm Replace if spec not met
LH Master Cylinder I.D. .750″ / 18.4 mm Replace if spec not met
Rear Brake Caliper
Item Standard Service Limit

Brake Pad Thickness .38″ / 9.65mm .170″ / 4.32mm
Brake Disc Thickness .178-.198″ / 4.52-5.03mm .168″ / 4.27mm
Brake Disc Thickness Variance Between - .002″ / .051mm
Measurements
Brake Disc Runout - .010″ / .254mm
Item Torque Torque
(ft. lbs. except where noted*) (Nm)
Front Caliper Mounting Bolts 18.0 25
Rear Caliper Mounting Bolts 15.0 21
Master Cylinder Mounting Bolts *25 in. lbs. 3.0
Master Cylinder Reservoir *5 in. lbs. 0.56
Cover Bolt
Brake Line Banjo Bolt 15.0 21
Front Brake Disc 18.0 25
Rear Brake Disc 24.0 33
Front Wheel Mounting Nuts 20.0 28
Bleeder Screw 2.5 3.4
NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures
are used when torquing certian bolts and fasteners.
9.2
GENERAL INFORMATION
SPECIAL TOOLS S Test for brake drag after any brake system
service and investigate cause if brake
PART NUMBER TOOL drag is evident.
DESCRIPTION S Make sure caliper moves freely on guide
2870975 Mity Vact pins.
Pressure Test Tool
S Inspect caliper piston seals for foreign
material that could prevent caliper pistons
from returning freely.
BRAKE SYSTEM SERVICE S Perform a brake burnishing procedure
NOTES after installing new pads to maximize
service life.
Disc brake systems are light weight, low
maintenance, and perform well in the conditions ATVs CAUTION:
routinely encounter. There are a few things to Use only DOT 3 brake fluid as an
assembly aid for all procedures described in this chapter to
remember when replacing disc brake pads or
prevent brake system contamination. DO NOT USE
performing brake system service to ensure proper LUBRICANTS OF ANY KIND FOR ASSEMBLY.
system function and maximum pad service life.
S Optional pads are available to suit
conditions in your area. Select a pad to fit BRAKE NOISE
riding style and environment.
S Do not over-fill the master cylinder fluid TROUBLESHOOTING
reservoirs.
Dirt or dust buildup on the brake pads and disc is the
S Make sure the brake levers return freely most common cause of brake noise (squeal caused by
and completely. vibration). If cleaning does not reduce the occurrence
S Adjust stop pin on front caliper after pad of brake noise, Permatext Disc Brake Quiet (PN
service. 2872113) can be applied to the back of the pads. Follow
S Check and adjust master cylinder directions on the package. This will keep pads in
reservoir fluid levels after pad service. contact with caliper piston(s) to reduce the chance of
squeaks caused by dirt or dust. See table below.
S Make sure atmospheric vent on reservoirs
are unobstructed.
Brake Noise Troubleshooting
Possible Cause Remedy
Dirt, dust, or imbedded material on pads or disc Spray disc and pads with CRC Brakeleent or an
equivalent non-flammable aerosol brake cleaner. Re-
move pads and/or disc hub to clean imbedded material
from disc or pads.
Pad(s) dragging on disc (noise or premature pad wear)
Improper adjustment Adjust pad stop (front calipers)
Insufficient lever or pedal clearance Check position of controls & switches.
Master cylinder reservoir overfilled Set to proper level
Master cylinder compensating port restricted Clean compensating port
Master cylinder piston not returning completely Inspect. Repair as necessary
Caliper piston(s) not returning Clean piston(s) seal
Operator error (riding the brake / park brake Educate operator
applied)
Loose wheel hub or bearings Check wheel and hub for abnormal movement.
Brake disc warped or excessively worn Replace disc
Brake disc misaligned or loose Inspect and repair as necessary
Noise is from other source (chain, axle, hub, disc or If noise does not change when brake is applied check
wheel) other sources. Inspect and repair as necessary
Wrong pad for conditions Change to a softer or harder pad
9.3
GENERAL INFORMATION
HYDRAULIC BRAKE SYSTEM

OPERATION
Typical Hydraulic Brake System Compensating port compensates
E for temperature changes by allowing
fluid back to master cylinder
Must be clear to allow
proper diaphragm C
movement
F
A B
Moveable
Brake Pad G
D
The Polaris brake system consists of the following components or assemblies: brake lever; master cylinder;
hydraulic hose; brake calipers (slave cylinder); brake pads; and brake discs, which are secured to the drive line.
When the hand activated brake lever (A) is applied it contacts a 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 moveable 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.
Brake fluid level is critical to proper system operation. Too little fluid will allow air to enter the system and cause
the brakes to feel spongy. Too much fluid could cause brakes to drag due to fluid expansion.
Located within the master cylinder is the compensating port (C) which is opened and closed by the master cylinder
piston assembly. The port is open when the lever is released and the master cylinder piston is outward. As the
temperature within the hydraulic system changes, this port compensates for fluid expansion (heated fluid) or
contraction (cooled fluid). During system service, be sure this port is open. Due to the high temperatures created
within the system during heavy braking, it is very important that the master cylinder reservoir have adequate space
to allow for fluid expansion. Never overfill the reservoir! Fill to 1/4″ - 5/16″ (.64 - .80 cm) from top of the cylinder.
This system also incorporates a diaphragm (E) as part of the cover gasket; and a vent port (F) located between
the gasket and the cover. The combination diaphragm and vent allow for the air above the fluid to equalize
pressure as the fluid expands or contracts. Make sure the vent is open and allowed to function. If the reservoir
is over filled or the diaphragm vent is plugged the expanding fluid may build pressure in the brake system leading
to brake failure.
When servicing Polaris ATV brake systems use only Polaris DOT 3 High Temperature Brake Fluid (PN 2870990).
Polaris brake fluid is sold in 5.5 oz. bottles. WARNING: Once a bottle is opened, use what is necessary and
discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid. Brake fluid is
hygroscopic, meaning it rapidly absorbs moisture. This causes the boiling temperature of the brake fluid to drop,
9.4
GENERAL INFORMATION
which can lead to early brake fade and the possibility of serious injury.
DUAL HYDRAULIC CALIPER

BLEEDING
DH CALIPER CUTAWAY VIEW Left Hand Brake
Bleed Screw
Left Hand
Brake Line
Piston
Right Hand
Brake Bleed
Screw
Right Hand
Brake Line
Dust Seal
Square Ring Piston Seals
Ill. 1
This caliper is a stepped piston design, with two - 9.8; however, each system must be bled separately.
independent hydraulic systems contained in the same Outer Bleed Screw
caliper body (see Ill.1). The caliper piston is
T-shaped, which allows both left and right hand brake
Left Hand Brake A
to use the same caliper piston, but remain separated
by seals. The left hand brake system applies
hydraulic pressure to both front calipers and only the
outer diameter of the rear caliper piston. The right
hand brake applies pressure to the inner portion of the
rear caliper piston. Because the left and right hand
brake hydraulic systems are separate, there are also
two bleed screws -- one for the outer fluid chamber
(left hand brake), and one for the inner fluid chamber
(right hand brake). The basic procedure for bleeding
the brake system is the same as outlined on Page 9.7 B Inner Bleed Screw
Right Hand Brake
-- Upper most (outer) bleed screw and brake line (A) is

for the left hand brake system.
-- Lower (inner) bleed screw and brake line (B) is for the
right hand brake system.
9.5
GENERAL INFORMATION
BRAKE SYSTEM MAIN COMPONENTS
RIGHT BRAKE
CALIPER
MASTER CYLINDER
LEFT BRAKE
BRAKE LINE CALIPER
CROSS FITTING
SWITCH
MASTER CYLINDER
REAR BRAKE CALIPER
FRONT BRAKE CALIPER EXPLODED VIEW

Adjuster Screw
Square
3 O--Rings
Bleeder Screw
35--60 IN. LBS. 3 Piston
(4--6.5 NM)
Caliper Body
Pads
Pin Boot
Caliper Mount
APPLY POLARIS DOT 3 BRAKE APPLY POLARIS ALL PURPOSE

3 FLUID DURING ASSEMBLY GREASE DURING ASSEMBLY
9.6
GENERAL INFORMATION
FLUID
REPLACEMENT/BLEEDING
PROCEDURE MAX
NOTE: When bleeding the brakes or replacing the

fluid always start with the caliper farthest from the
master cylinder.
CAUTION:
Always wear safety glasses.
CAUTION:
Brake fluid will damage finished surfaces. Do not

allow brake fluid to come in contact with finished 5. Add brake fluid to the upper level mark on
surfaces. reservoir.
BRAKE BLEEDING - FLUID Polaris DOT 3 Brake Fluid
CHANGE (PN 2870990)
NOTE: This procedure should be used to change

fluid or bleed brakes during regular maintenance.
DH Caliper
Forward
Left Hand
C Brake Line
Left hand brake
bleeder screw
B
A Right Hand
Brake Line
D Right hand brake bleeder screw
6. Begin bleeding procedure with the caliper that is

farthest from the master cylinder. Install a box
1. Clean reservoir cover thoroughly. end wrench on caliper bleeder screw. Attach a
clean, clear hose to fitting and place the other end
2. Remove screws, cover, and diaphragm (C) from in a clean container. Be sure the hose fits tightly
reservoir. on fitting.
3. Inspect vent slots (A) in cover and remove any NOTE: Fluid may be forced from compensation port
debris or blockage. (B) when brake lever is pumped. Place diaphragm (C)
in reservoir to prevent spills. Do not install cover.
4. If changing fluid, remove old fluid from reservoir
with a Mity Vact (PN 2870975) or similar tool. 7. Slowly pump brake lever (D) until pressure builds
NOTE: Do not remove brake lever when reservoir and holds.
fluid level is low.
8. While maintaining lever pressure, open bleeder
screw. Close bleeder screw and release brake
lever. NOTE: Do not release lever before bleeder
screw is tight or air may be drawn into caliper.
9.7
GENERAL INFORMATION
9. Repeat procedure until clean fluid appears in

bleeder hose and all air has been purged. Add
fluid as necessary to maintain level in reservoir.
CAUTION:
Maintain at least 1/2″ (1.27 cm) of brake fluid in the

reservoir to prevent air from entering the master
cylinder.
10. Tighten bleeder screw securely and remove

bleeder hose. Torque bleeder screw to 36--60 in.
lbs. (4--6.5 Nm).
11. Repeat procedure Steps 5-9 for the remaining
caliper(s).
13. Install diaphragm, cover, and screws. Torque the

screws to 5 in.lbs. (0.56 Nm).
Reservoir Cover Torque -
5 in. lbs. (0.56 Nm)
14. 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.
12. Add brake fluid to the proper level. 15. Check brake system for fluid leaks and inspect all
hoses and lines for wear or abrasion. Replace
Master Cylinder Fluid Level: hose if wear or abrasion is found.
MAX level inside reservoir
Sight glass must look dark, if sight

glass is clear, fluid level is too low
9.8
GENERAL INFORMATION
MASTER CYLINDER 3. Remove master cylinder from handlebars.
DISASSEMBLY Brake Lines

Banjo Bolt
Master Cylinder Assembly

1. Clean master cylinder and reservoir assembly. Sight Glass
Make sure you have a clean work area to Cover
disassemble brake components.
Diaphragm
2. Place a shop towel under brake line connection at
master cylinder. Loosen banjo bolt; remove bolt
and sealing washers.
CAUTION:
Brake fluid will damage finished surfaces. Do not

allow brake fluid to come in contact with finished
surfaces.
Master Cylinder
Piston Assy
MASTER CYLINDER
INSTALLATION
Notice: When replacing the brake master cylinder
assembly or master cylinder parts, use the correct
parts. There are differnt brake master cylinders for
the different Polaris ATV models. Refer to your parts
manual or guide for the correct parts.
9.9
GENERAL INFORMATION
FRONT PAD REMOVAL

5 in.lbs. (0.56 Nm)
1. Elevate and support front of machine.
Torque this bolt first
Torque both bolts to

25 in.lbs. (3 Nm)
1. Install master cylinder on handlebars. Torque

mounting bolts to 25 in. lbs. (3 Nm). Torque the
inside bolt first as indicated in the illustration to the
right.
NOTE: To speed up the brake bleeding procedure
the master cylinder can be purged of air before brake
CAUTION:
line is attached. Fill with DOT3 Brake Fluid (PN
2870990) and pump lever slowly two to three times
Use care when supporting vehicle so that it does
with finger over the outlet end to purge master cylinder
not tip or fall. Severe injury may occur if machine
of air.
tips or falls.
2. Remove the front wheel. Loosen pad adjuster
Torque to 15 ft.lbs. screw 2-3 turns.
(21 Nm)
3. Remove caliper from mounting bracket.
Banjo Bolt
Sealing Washers
Brake Line
2. Place new sealing washers on each side of banjo

line and torque banjo bolt to specification.
4. Push caliper piston into caliper bore slowly using

a C-clamp or locking pliers with pads installed.
9.10
GENERAL INFORMATION
NOTE: Brake fluid will be forced through

compensating port into master cylinder fluid reservoir
when piston is pushed back into caliper. Remove
excess fluid from reservoir as required.
5. Push mounting bracket inward and slip outer
brake pad past edge. Remove inner pad.
Measure
Thickness
Front Brake Pad Thickness

New.298″/7.6 mm
Service Limit .180″ / 4.0 mm
FRONT PAD ASSEMBLY

6. Measure the thickness of the pad material. 1. Lubricate mounting bracket pins with a light film of
Replace pads if worn beyond the service limit. Polaris Premium All Season Grease, and install
rubber dust boots.
9.11
GENERAL INFORMATION
18 ft. lbs.
(25 Nm)
Front Caliper Mounting Bolts

Polaris Premium All Season Grease
Torque: 18 ft. lbs. (25Nm)
(PN 2871423)
4. Slowly pump the brake lever until pressure has
2. Compress mounting bracket and make sure dust been built up. Maintain at least 1/2″ (12.7 mm) of
boots are fully seated. Install pads with friction brake fluid in the reservoir to prevent air from
material facing each other. Be sure pads and disc entering the brake system.
are free of dirt or grease. 5. Install the adjuster screw and turn clockwise until
stationary pad contacts disc, then back off 1/2
turn (counterclockwise).
3. Install caliper on hub strut, and torque mounting

bolts. 6. Verify fluid level in reservoir is up to MAX line
inside reservoir and install reservoir cap.
Master Cylinder Fluid

Up to MAX line inside reservoir
9.12
GENERAL INFORMATION
7. Install wheels and torque wheel nuts. 3. Mount dial indicator as shown to measure disc
runout. Slowly rotate the disc and read total
runout on the dial indicator. Replace the disc if
Front Wheel Nut Torque runout exceeds specifications.
20 ft. lbs. (27 Nm)
BRAKE BURNISHING
PROCEDURE
It is required that a burnishing procedure be
performed after installation of new brake pads to
extend service life and reduce noise.
Start machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Allow pads
and disc to cool sufficiently during the procedure. Do Brake Disc Runout
not allow pads or disc to become hot or warpage may
result. Repeat this procedure 10 times. Service Limit .010″ (.254 mm)
FRONT DISC INSPECTION

FRONT BRAKE DISC
1. Visually inspect the brake disc for nicks,
scratches, or damage. REMOVAL / REPLACEMENT
2. Measure the disc thickness at eight different
points around the pad contact surface using a NOTE: To reduce the possibility of warpage, try
0-1″ micrometer. Replace disc if worn beyond removing the brake disc mounting bolts before
service limit. applying heat to the bolts.
1. Apply heat to the hub in the area of the brake disc
mounting bolts to soften the bolt locking agent.
18 ft. lbs. (25 Nm)

new bolts have
pre-applied
locking agent.
2. Remove bolts and disc.

Brake Disc Thickness 3. Clean mating surface of disc and hub.
4. Install disc on hub.
New .150--.165″ (3.81--4.19 mm)
5. Install new bolts and tighten to specified torque.
Service Limit .140″ / 3.56 mm
Brake Disc Thickness Variance Front Brake Disc Mounting Bolt Torque
Service Limit: .002″ (.051 mm) 18 ft. lbs. (25 Nm)
difference between measurements.
9.13
GENERAL INFORMATION
CAUTION: Always use new brake disc mounting 2. Push upper pad retainer pin inward and slip brake
bolts. The bolts have a pre-applied locking agent pads past edge.
which is destroyed upon removal.
FRONT CALIPER REMOVAL
CAUTION:
Use care when supporting vehicle so that it does

not tip or fall. Severe injury may occur if machine
tips or falls.
1. Remove brake pads. See Page 9.10--9.11.
2. Using a line wrench, loosen and remove brake
line to caliper. Place a container under caliper to
catch fluid draining from brake line.
3. Remove brake caliper and drain fluid into

container. Do not reuse brake fluid.
FRONT CALIPER
DISASSEMBLY
1. Remove brake pad adjuster screw.
9.14
GENERAL INFORMATION
3. Remove mounting bracket, pin assembly and

dust boot.
FRONT CALIPER
INSPECTION
Remove 1. Inspect caliper body for nicks, scratches or wear.
Mounting Bracket Measure bore size and compare to specifications.
Replace if damage is evident or if worn beyond
service limit.
Front Caliper Piston Bore I.D.
Std. 1.25″ (31.75mm)

Replace if bore is worn or damaged
4. Remove piston, dust seal and piston seal.
2. Inspect piston for nicks, scratches, wear or

damage. Measure diameter and replace if
damaged or worn .
5. Clean the caliper body, piston, and retaining

bracket with brake cleaner or alcohol.
NOTE: Be sure to clean seal grooves in caliper body.
Clean Components
3. Inspect the brake disc and pads as outlined for

brake pad replacement this section. See Pages
9.10--9.11.
9.15
GENERAL INFORMATION
FRONT CALIPER ASSEMBLY 4. Compress the mounting bracket and make sure
the dust seals are fully seated. Install the pads as
1. Install new O-rings (A) in the caliper body (B). Be shown on Page 9.11--9.12. Clean the disc and
sure groove is clean and free of residue or brakes pads with brake parts cleaner or denatured
may drag upon assembly. alcohol to remove any dirt, oil or grease.
C
B
2. Coat piston with clean Polaris DOT 3 Brake Fluid

(C). Install piston (D) with a twisting motion while
pushing inward. Piston should slide in and out of
bore smoothly, with light resistance.
3. Lubricate the mounting bracket pins with Polaris
Premium All Season Grease, and install the
rubber dust seal boots.
Polaris Premium All Season Grease
(PN 2871423)
9.16
GENERAL INFORMATION
FRONT CALIPER
INSTALLATION Front Wheel Nut Torque
1. Install caliper on hub strut, and torque mounting 20 ft. lbs. (27 Nm).
bolts.
REAR BRAKE PAD REMOVAL
18 ft. lbs.
(25 Nm)
Front Caliper Mounting Bolt Torque
18 ft. lbs. (25 Nm)
2. Install brake line and tighten securely with a line

wrench. 1. Remove caliper mounting bolts and lift caliper off
of disc.
3. Install the adjuster screw and turn until stationary
pad contacts disc, then back off 1/2 turn. NOTE: When removing caliper, be careful not to
damage brake line. Support caliper so as not to kink
or bend brake line.
NOTE: Brake pads will be free when caliper is
removed from disc.
2. Clean the caliper with brake cleaner or alcohol.

3. Inspect O-Rings in caliper mounting ears.
4. Follow brake bleeding procedure outlined on

Pages 9.7-9.8.
5. Install wheels and torque wheel nuts to Measure
specification. Thickness
4. Measure the thickness of the pad material.

Replace pads if worn beyond the service limit.
9.17
GENERAL INFORMATION
5. It is recommended that a burnishing procedure be

performed after installation of new brake pads to
Rear Brake Pad Thickness extend service life and reduce noise. Start
New .38″ (9.65 mm) machine and slowly increase speed to 30 mph.
Service Limit .170″ (4.32 mm) Gradually apply brakes to stop machine. Repeat
procedure 10 times.
REAR BRAKE PAD REAR CALIPER

INSTALLATION REMOVAL/INSPECTION
1. Clean caliper area before removal.
Align pad ears

and caliper Remove inner
and outer
brake lines
1. Install caliper on brake disc. Start front shoulder
bolt.
2. Using a flare nut wrench, remove left hand brake
2. Insert brake pads on front shoulder bolt. While (outer) and right hand brake (inner) lines. Place a
holding caliper and pads, align rear mounting pad container to catch brake fluid draining from brake
lugs with rear shoulder bolt. Install rear shoulder lines.
bolt.
3. Remove the caliper and pads.
3. Torque mounting bolts to specified torque.
Rear Caliper Piston
Dust Seal Groove
DH Brake Caliper Mounting Bolts Torque:

15 ft. lbs. (21 Nm)
4. Slowly pump the brake levers 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 master cylinder.
Auxiliary Brake Master Cylinder

Fluid Level Square Rings
Between MIN and MAX lines 4. Remove piston with air pressure to brake line
inlet.
9.18
GENERAL INFORMATION
5. Remove square-rings and dust seal. Clean 2. Seat dust seal in caliper body.
square-ring grooves.
3. Install new O-rings in caliper mounting ears.
6. Clean disc, caliper body, and piston with brake
cleaner or alcohol. 4. Install caliper and brake pads with friction material
facing each other on brake disc.
Rear Caliper
5. Apply LocTitet242 (PN 2871949) and torque
mounting bolts to 15 ft. lbs. (21 Nm).
Caliper Mounting Bolt Torque:

15 ft. lbs. (21 Nm)
Left Brake Line
Inspect Bores
7. Inspect caliper piston bores for wear, scratches,

severe corrosion, or galling. Replace if
necessary.
Rear Caliper Piston Bore I.D.
Std. 1.68″ (42.67mm) Right Brake Line

Replace if bore is worn or damaged
6. Install brake lines and securely tighten.
8. Inspect surface of caliper piston for nicks, 7. Follow bleeding procedure outlined on Pages
scratches, or damage and replace if necessary. 9.7--9.8 of this section and refer to system
overview and illustration on Page 9.5.
REAR CALIPER ASSEMBLY 8. Field test unit for proper braking action before
putting into service. Inspect for fluid leaks and
firm brakes. Make sure the brake is not dragging
Dust Seal when lever is released. If the brake drags,
re-check assembly and installation.
O-Rings
1. Install new square-rings on piston. Be sure

square-ring grooves are thoroughly cleaned of all
residue, or piston may bind in bore. Apply brake
fluid to piston and install carefully with a twisting
motion to ease assembly. Install dust seal on
piston before fully seating piston.
9.19
GENERAL INFORMATION
REAR BRAKE DISC TROUBLESHOOTING

INSPECTION Brakes Squeal
S Dirty/contaminated friction pads
1. Visually inspect disc for scoring, scratches, or
S Improper alignment
gouges. Replace the disc if any deep scratches
are evident. S Worn disc
S Worn disc splines
S Poor Brake Performance
Rear Brake S Air in system
Disc S Water in system (brake fluid
contaminated)
S Caliper/disc misaligned
S Caliper dirty or damaged
S Brake line damaged or lining
ruptured
Measure
Thickness S Worn disc and/or friction pads
S Incorrectly adjusted lever
S Incorrectly adjusted stationary pad
S Worn or damaged master cylinder or
2. Use a 0-1″ micrometer and measure disc
components
thickness at 8 different points around perimeter of
disc. Replace disc if worn beyond service limit. S Improper clearance between lever
and switch
Lever Vibration
Brake Disc Thickness S Disc damaged
New .178-.198″ (4.52-5.03 mm) S Disc worn (runout or thickness
Service Limit .168″ (4.27 mm) variance exceeds service limit)
S Caliper Overheats (Brakes Drag)
Brake Disc Thickness Variance S Compensating port plugged
Service Limit .002″ (.051 mm) S Pad clearance set incorrectly
difference between measurements S Auxiliary brake pedal incorrectly
adjusted
S Brake lever or pedal binding or
3. Mount dial indicator and measure disc runout. unable to return fully
Replace the disc if runout exceeds specifications. S Parking brake left on
S Residue build up under caliper seals
S Operator riding brakes
Brake Disc Runout
Brakes Lock
Service Limit .010″ (.254 mm) S Alignment of caliper to disc.
9.20
ELECTRICAL
Special Tools and Electrical Notes . . . . 10.2

Timing Check Procedure / Curve . . . . . 10.2
ECM Operation . . . . . . . . . . . . . . . . . . . . 10.3-10.4
Trans. Gear Position Switch Test . . . . . 10.4
2004 Model -- Instrument Cluster . . . . 10.5-10.13
2005 Model -- Instrument Cluster . . . . . 10.14--10.22
Instrument Cluster Remove/Install . . . . 10.23
Coolant Sensor Tests . . . . . . . . . . . . . . 10.24
Fan Motor Current Draw Test . . . . . . . . 10.24-10.25
ETC System Operation . . . . . . . . . . . . . 10.25
Flywheel Identification . . . . . . . . . . . . . . 10.26
DC/CDI Operation . . . . . . . . . . . . . . . . . . 10.26
250 Watt Alternator, Exploded View . . . 10.27
Ignition System Testing Flow Chart . . . 10.28
Charging System Testing Flow Chart . 10.29
Ignition System Troubleshooting . . . . . 10.30
Cranking Output Test . . . . . . . . . . . . . . . 10.30
Charging System Testing . . . . . . . . . . . . 10.31
Battery Service . . . . . . . . . . . . . . . . . . . . 10.32-10.39
Head Light/Brake Light Lamp Service . 10.40--10.42
Starter Troubleshooting / Voltage Test 10.42-10.43
Starter Motor Service . . . . . . . . . . . . . . . 10.43-10.45
Starter Drive . . . . . . . . . . . . . . . . . . . . . . . 10.46
Starter System Testing Flow Chart . . . . 10.47
10.1
ELECTRICAL
SPECIAL TOOLS TIMING CHECK PROCEDURE

PART NUMBER TOOL 1. The ignition timing check hole is in the starter
DESCRIPTION recoil/magneto housing. Remove the check plug.
PV--43568 Fluket77 Digital NOTE: The ignition timing marks are stamped on the
Multimeter outside of the flywheel. Ignition timing must be
2870630 Timing Light inspected with the engine at room temperature (68°F
2870836 Battery / 20° C).
Hydrometer
2. With the transmission in neutral, start the engine
2460761 Hall Sensor Probe
and set engine speed to 3500 ± 200 RPM.
Harness
2871745 Static Timing Light
3. Direct the timing light at the ignition timing check
Harness hole and check the ignition timing. NOTE: Do not
allow the engine to warm up. The timing will retard
approximately 2° when the engine is warm.
If the ignition timing is not within the specified range,
a faulty component is the most likely cause, as
ELECTRICAL SERVICE
Flywheel
NOTES Rotation 32
Keep the following notes in mind when diagnosing an

electrical problem.
GRefer to wiring diagram for stator and Timing
Pointer
electrical component resistance
specifications. 30
GWhen measuring resistance of a component 28
that has a resistance value under10
Ohms, remember to subtract meter lead EH50PL
resistance from the reading. Connect the the stator is non--adjustable on DC/CDI ignitions.
leads together and record the resistance.
The resistance of the component is equal
to tested value minus the lead resistance. TYPICAL IGNITION TIMING
GBecome familiar with the operation of your
meter. Be sure leads are in the proper
CURVE
jack for the test being performed (i.e. 10A * Actual advance point may vary by several hundred
jack for current readings). Refer to the RPM either above or below 3500. Use the point of
Owner’s manual included with your maximum advance when checking ignition timing.
meter for more information.
GVoltage, amperage, and resistance values
included in this manual are obtained
with a Fluket 77 Digital Multimeter
(PV--43568). This meter is used for
when diagnosing electrical problems.
Readings obtained with other meters
may differ.
GPay attention to the prefix on the multimeter
reading (K, M, etc.) and the position of
the decimal point.
GFor resistance readings, isolate the
component to be tested. Disconnect it
from the wiring harness or power supply.
10.2
ELECTRICAL
ECM OPERATION Engine Temperature Controller:

The engine temperature controller has several
features. Its primary function is to control the fan
ECM or Logic Box motor. The fan motor is turned on and off at preset
temperatures as determined by the engine
temperature thermistor. If the engine temperature
continues to rise it will turn on an engine hot indicator.
The module also contains provisions for detecting an
open thermistor. An open thermistor will cause the
engine hot indicator to light and cause the fan motor
to come on.
The engine temperature controller is enabled by the
RUN signal (Pin G). The controller can only come on
if the RUN signal is active. The engine hot output
provides a grounded output for a lamp. When the
engine hot output is on it blinks on and off. The FAN
output (Pin J) is protected against short circuit and
overload by electronic means internal to the module.
The FAN output has a linear current limit. If the
53 OR/WHT
maximum temperature of the switching device is
26 OR/BLK exceeded the fan output will turn off until the device
55 BRN has cooled.
47 R/WHT
21 RED Solid State Circuit Breaker Outputs:
The module provides two solid state circuit breaker
outputs. The first output (BAT_PROT) is active at all
times. This output is routed to the key switch and the
left hand control assembly to provide power for lamps,
pod, and front hub coils. The second output
20 RED 56 ORANGE (ACC_PWR) is enabled by the RUN signal. This
45 RED 62 ORANGE second output is used for accessories.
04 BLU/WHT The BAT_PROT output is protected from overloads
22 BROWN
and short circuits. If a overload or short circuit occurs
that output turns off. The output can be reset by
The ECM (logic box) integrates three electronic removing load from it by turning the key switch or
features found on the Polaris ATV. These features are LHCA switch off.
alternator rectifier/regulator, engine temperature The ACC_PWR switch has a linear current limit. If the
controller, and solid state circuit breaker outputs. maximum output current is exceeded the output
voltage will be reduced. If the maximum temperature
Regulator: of the solid--state device is exceeded it will shut off.
The regulator takes the output of the 3--phase It will automatically turn back on when it has cooled.
alternator and applies it to the battery. SCR’s are used
to connect and disconnect the alternator from the
Alternator BAT+
batter to achieve regulation of the battery voltage. Input
3 Phase
The regulator circuit produces current on the Regulator IPS BAT_PROT
BATTERY pin (Pins E & F). If a high voltage transient
is detected on the BATTERY pin this causes the Ground
regulator to assume an open battery condition. The IPS ACC_PWR
high voltage transient will cause the regulator to turn
off for a short period of time. If there truly is an open Run
battery then the regulator will remain off, as the Hot Lamp
minimum battery requirement will not be met. The Engine
Thermistor Temp IPS Fan
regulator will not turn on unless there exists a battery Controller
voltage in excess of the minimum battery voltage
requirement.
10.3
ELECTRICAL
Wire Pin Description

Color
Orange A BAT_PROT -- Protected battery
and output used to power the headlight
B and instrument cluster.
Brown C GND -- Battery Negative
and
H
Blue/ D HOT_LAMP -- Engine hot signal.
White Provides a ground path for a lamp.
Red E BAT+ -- Positive side of battery.
and Both pins should be used to carry
F current.
Pink F Provides +12V When engine is
running or cranking.
Red / G RUN -- At +12V when ignition
White switch is on and RUN/OFF switch
is RUN.
Orange J Signal that enables operation of
/ Black the fan.
Orange K ACC_PWR -- This signal provides
/White power to the accessories.
GEAR POSITION INDICATOR

SWITCH TEST
Switch Continuity Table
Rear Trans. Switch Front Trans. Switch

High/Neutral/Rev. Switch Low/Neutral Switch
D C B A DC B A
High Range F F F F
Reverse F F F F
Neutral F F F F
Low Range F F F F
10.4
ELECTRICAL
INSTRUMENT INSTRUMENT CLUSTER/

CLUSTER/SPEEDOMETER SPEEDOMETER INFO -- 2004
IDENTIFICATION PER MODEL MODELS
NOTE: The 2004 Sportsman 6x6 and 2005
Sportsman 6x6 have different instrument INSTRUMENT CLUSTER
clusters. Follow the correct instrument cluster
information in the service manual when reading
TROUBLESHOOTING -- 2004
the manual. Introduction
The Polaris ATV Instrument Cluster is powered by
battery voltage (12 VDC) and requires inputs from the
engine RPM, transmission gear, and wheel speed
sensor for proper operation. Two harnesses plug into
the cluster head; one from the wheel sensor, and one
from the vehicle main harness. A non-serviceable
internal memory battery maintains odometer and
hour meter data when the machine is not running.
The illumination lamp inside the gauge is
non-serviceable and is designed to last for the life of
the unit. In addition to the ground speed in Kilometers
Per Hour (KPH), odometer, and trip odometer, the
electronic speedometer provides the following
functions: (See Illustration) 1. Hour meter
2. Programmable Service Interval
3. Gear Indicator
4. High Engine Coolant Temperature
2004 Sportsman 6x6 5. High/Low Battery Voltage
Instrument Cluster
Vehicle Speed and Odometer
An electronic wheel speed sensor located on the right
front brake caliper bracket senses vehicle speed. The
speedometer head does not differentiate between
forward and reverse wheel rotation. Static Timing
Light Harness (PN 2871745), with the Hall Sensor
Probe Harness (PN 2460761), can be used to quickly
test the sensor.
Hour Meter (Engine Run Time)

Logs the total hours the engine has been in operation.
Programmable Service Interval

The purpose of the programmable service interval is
to provide the consumer and their dealer with a
convenient way to schedule routine maintenance.
When the ATV leaves the factory, this feature is
turned “OFF”. You must enable this feature if you
2005 Sportsman 6x6 intend to use it to track maintenance requirements.
Instrument Cluster
High Engine Coolant Temperature
Indicates the engine is overheating. Refer to Chapter
3 “Cooling System Troubleshooting” for help with
diagnosis of overheating.
High/Low Battery Voltage

Indicates that the battery is nearing full discharge, or
that a failed battery or voltage regulator is causing an
10.5
ELECTRICAL
excessively high voltage on the DC bus. 2. Begin entering the next service hour total by
releasing and pressing the mode/reverse override
Diagnostic Mode button. Each time the mode/reverse override button
Refer to Page 10.13 on how to operate the diagnostic is pressed and released the service interval time is
mode. increased by an hour. NOTE: Continuing to hold
down the mode button will add to the hour total faster.
1 3. When the desired hour total has been reached,

2
stop pressing the mode/reverse override button and
wait for the wrench icon to quit flashing. Once the
wrench icon quits flashing the service hours are set.
If you scroll past the intended number, hold the button
down until the count turns over to “0”. At this point you
can re--attempt to set the number.
4. The P.S.I. then counts down from this total per
hours of engine operation.
5. When the number reaches “0”, the wrench icon will
flash for five seconds during vehicle start up to remind
3 4 5 the driver that the next scheduled service is due. To
turn the P.S.I. off, toggle to the service interval mode
and press the mode/reverse override button for
approximately seven seconds until the word “OFF”
2 3 appears in the Rider Information Center.
Diagnostic Mode
Warning Indications Displayed on Rider
Information Center
Warning Indication Warning Explanation

“E” Most of the time this error
message indicates that you
are between gears. It can
also indicate that the trans-
mission switch is broken.
1 “StAtr” “Stator” -- is displayed when

the gauge senses ground
speed but no engine rpm for
at least 10 seconds. May in-
1. Rider Information Center
dicate a failing stator or wir-
ing problem.
2. Speedometer Needle -- In addition to depicting
vehicle speed, this needle will flash to indicate a fault “hdLbr” “Handlebar” -- is displayed
condition. when the mode/override but-
ton is stuck in for more than
3. Speedometer graph depicting both miles per hour ten seconds in any mode ex-
and kilometers per hour. cept Programmable Service
Interval or Diagnostic
Programmable Service Interval modes.
To enable the programmable service interval function,
scroll to the Programmable Service Interval (P.S.I.) NOTE: The gauge will shut itself off if the voltage on
mode, which is initially indicated by the “wrench” icon the DC bus is too excessive. This is usually the result
and the word “OFF”. of an open battery condition. The gauge is designed
1. Press and hold the mode/reverse override button to survive such an event.
until the wrench icon begins flashing. When the NOTE: If the gauge will not indicate what gear it is in
wrench icon begins to flash, release the button. and will not allow AWD operation, AWD can still be
enabled by holding in the mode/override button.
10.6
ELECTRICAL
To enter the diagnostics mode: NOTE: Any movement of the tires will trigger the
1. Turn the key switch off and wait 10 seconds. speedometer out of the diagnostic mode.
2. Set the park brake and shift the transmission to
neutral.
3. Hold the mode/reverse override button as you
turn the key switch on.
The initial screen displayed looks similar to Ill. 1 and
is referring to the software version currently installed
in your instrument cluster. This information is only
briefly displayed.
Ill. 1
Use the mode/reverse override button to toggle

through the diagnostic screens.
The first screen indicates battery voltage. Refer to Ill.
2.
Ill. 2
Screen three (Ill. 4) is the tachometer for setting idle

speed. This mode is not operational while in motion.
Ill. 4
NOTE: As long as you are in the diagnostic mode, the

wrench icon will remain lit.
To leave the diagnostic mode, either shift the machine
out of neutral or turn the key switch off and on.
10.7
ELECTRICAL
SPEEDOMETER TROUBLESHOOTING -- 2004 MODELS

TEST 1 -- NO ALL WHEEL DRIVE
Note: If AWD light comes on, instru-
START HERE ment cluster is O.K. Proceed to me-
chanical tests (in Service Manual).
Shade the AWD light with your hand to
SPEED CHECK
READOUT
N SPEEDOMETER verify it’s operation. The AWD switch is
OK? directly powered by switched 12 volts
(PERFORM (red/white). The gear switch only inter-
TEST 2)
faces with the instrument cluster. To en-
able AWD, the cluster must be display-
Y ing low or high gear, or reverse gear with
the override button pushed in.
-- KEY SWITCH ON
-- TRANSMISSION IN
NEUTRAL 16 Pin Connector
-- AWD SWITCH ON 1. Red-- 12V Constant
2. Red/White-- 12V Switched
Y 3. Grey/Orange-- Mode/Override button
4. Black-- Ignition Kill
5. N/C
6. N/C
7. Yellow/Red-- RPM Input
8. Brown-- Ground
ON HUB COIL
CONNECTOR NOT AN INSTRUMENT 9. Blue White-- Engine Overheat Switch
10. Purple/Yellow-- Oil Pressure Switch
(LEAVE IT CONNECTED) N CLUSTER PROBLEM; 11. Orange/Red-- Park Gear
MEASURE FOR 12V FROM CHECK AWD SWITCH 12. Purple-- Reverse Gear
BROWN/WHITE TO THE 13. Green/White-- Neutral
AND HUB COIL 14. White/Blue-- Low Gear
COIL BODY 15. Blue/Red-- High Gear
(GROUND) 16. Brown/White-- AWD Control
Note: Reversing polarity when connecting

the battery or other DC power source
Y backwards will fail the AWD control and
the instrument cluster If the key switch
and the AWD switch are turned on.
LEAVE AWD
SWITCH ON
TURN KEY SWITCH OFF N REPLACE
WIRING INSTRUMENT
DISCONNECT 16 PIN
PROBLEM CLUSTER
CONNECTOR FROM CLUSTER
TURN KEY SWITCH ON Y
CHECK FOR 12V
FROM BRN/WHITE
TO GROUND
LEAVE KEY
SWITCH OFF
REMOVE THROTTLE BAD AWD BULB.
CONTROL COVER PROCEED TO
Y DISCONNECT THROTTLE N MECHANICAL AWD
TURN KEY SWITCH OFF CONTROL HARNESS COMPONENTS
RECONNECT CLUSTER CHECK FOR CONTINUITY IF AWD PROBLEM
LEAVE HEADLIGHT POD ACROSS AWD PERSISTS.
DISASSEMBLED INDICATOR BULB
SHIFT TO LOW OR HIGH
LEAVE AWD ON
10.8
ELECTRICAL

TEST 2 -- NO SPEEDOMETER AND/OR ODOMETER DISPLAY S
Y CHECK FOR
START HERE MINIMUM 6VDC N
ON PIN B TO REPLACE
KEY & STOP PIN C SPEEDO
3 Pin Connector
SWITCHES ON REPLACE
SPEEDO A: D.C. Power MEASURE
B: Signal Y BACK OF
C: Ground S SPEEDO WITH
Y CONNECTORS
Y S
PLUGGED IN
REPLACE N CHECK CHECK
SPEEDO WHEEL SENSOR
AT BACK OF SPEEDO:
POINTER SPEED POWER
CHECK FOR 10--12
MOVE? SENSOR SUPPLY
VDCON PIN A TO PIN C
(TEST 6) PIN A
ON THE 3 PIN CON-
Y NECTOR?
16PIN MEA-
SURE 12VDC N
ON PINS 1
REPAIR
WIRING
N
&8 AND 2 & 8 REPLACE
N SPEEDO REPLACE
SPEEDO
N
N Y
ODOMETER TEST ODOMETER Y POINTER
Y SPEEDO
DISPLAY DRIVE CHANGE? OK
MOVE?
VEHICLE
TEST 3 -- NO REVERSE SPEED LIMIT 16 Pin Connector

1. Red-- 12V Constant 9. Blue White-- Engine Overheat Switch
2. Red/White-- 12V Switched 10. Purple/Yellow-- Oil Pressure Switch
(VEHICLE EXCEEDS 7--9 MPH IN REVERSE) 3. Grey/Orange-- Mode/Override button 11. Orange/Red-- Park Gear
4. Black-- Ignition Kill 12. Purple-- Reverse Gear
START HERE 5. N/C 13. Green/White-- Neutral
6. N/C 14. White/Blue-- Low Gear
7. Yellow/Red-- RPM Input 15. Blue/Red-- High Gear
N 8. Brown-- Ground 16. Brown/White-- AWD Control
CHECK
IS THE SPEEDO
READ OUT
SPEEDOMETER NOTE: Mode/Override button provides a grounding
(PERFORM TEST 2)
OK? (sinking) input to the instrument cluster.
INSPECT WIRING
Y AND CDI
N
TEST TRANSMISSION
SHIFT INTO REVERSE: N (SHIFT) SWITCH AND
H Measure Harness Side
IS REVERSE INDICA- WIRING
TOR ON? RESTART ATV
H
TURN KEY SWITCH OFF JUMPER TO PIN 4 Y REPLACE
(BLACK) TO PIN 8
Y REMOVE 16 PIN PLUG (BROWN). DOES
SPEEDO
FROM BACK OF ENGINE STOP?
SPEEDOMETER HEAD
10.9
ELECTRICAL

TEST 4 -- NO AWD HUB SAFETY LIMIT
NOTE: IF THE AWD LIGHT DOES NOT COME ON OR IF
12 VDC IS NOT REGISTERING AND AWD IS ENGAGING
ABOVE 3100 RPM,IT MAY BE A MECHANICAL PROBLEM. START HERE
IS
TURN ATV SPEEDO
Y FUNCTIONING N CHECK
ON IN DIAGNOSTIC SPEEDO
CORRECTLY?
MODE. TOGGLE TO TACH--
OMETER SETTING & REV ENGINE. (TEST NO. 2)
HOLD UNTIL DISPLAY STABILIZES.
DOES IT APPEAR
ACCURATE?
RESTART ATV
N
ENGINE IDLING
MEASURE AC VOLTAGE
Y REPLACE
TURN KEY SWITCH OFF SPEEDOMETER
BETWEEN PIN 7 AND
1. RAISE ATV WHEELS OFF GROUND AND REMOVE 16 PIN PIN 8.
SUPPORT IN A SAFE MANNER. CONNECTOR FROM OVER 3 VAC?
BACK OF
2. MONITOR VOLTAGE AT HUB COIL INSTRUMENT
CONNECTOR, BETWEEN BROWN/WHITE CLUSTER.
AND GROUND
NOTE: IF THE AWD
LIGHT IS FLICKERING N
RATHER THAN ON
CONTINUOUSLY,
THERE IS AN OPEN IN CHECK CHARGING SYSTEM
THE HUB COIL. (STATOR, REGULATOR,
AND WIRING)
TURN
AWD OFF.
START THE ENGINE
REV AND HOLD THE N 16 Pin Connector
RPM’S ABOVE 3100. NO PROBLEM 1. Red-- 12V Constant
TURN AWD ON. 9. Blue White-- Engine Overheat Switch
2. Red/White-- 12V Switched 10. Purple/Yellow-- OIl Pressure Switch
DOES FRONT
3. Grey/Orange-- Mode/Override button 11. Orange/Red-- Park Gear
DRIVE
ENGAGE? 4. Black-- Ignition Kill 12. Purple-- Reverse Gear
5. N/C 13. Green/White-- Neutral
8. Brown-- Ground 16. Brown/White-- AWD Control
Y
INSPECT
HUB COIL WIRING
IS THE
Y FOR SHORT CIRCUITS N
TO GROUND. (DISCONNECT REPLACE
AWD LIGHT ON? CONNECTOR & MEASURE SPEEDOMETER
BETWEEN HUB COIL
BROWN/WHT
& GROUND.)
N Y
MECHANICAL PROBLEM REPAIR HUB COIL WIRING
10.10
ELECTRICAL

TEST 5 REVERSE SPEED LIMITER ACTIVATED IN FORWARD GEAR
(Engine loses spark when vehicle speed is above 7-9 mph.)
START HERE
16 Pin Connector
CHECK 1. Red-- 12V Constant 9. Blue White-- Engine Overheat Switch
INSTRUMENT SPEEDOMETER 2. Red/White-- 12V Switched 10. Purple/Yellow-- Oil Pressure Switch
CLUSTER FUNC-
(PERFORM TEST 2) 3. Grey/Orange-- Mode/Override button 11. Orange/Red-- Park Gear
TION OK?
4. Black-- Ignition Kill 12. Purple-- Reverse Gear
5. N/C 13. Green/White-- Neutral
Y 8. Brown-- Ground 16. Brown/White-- AWD Control
CHECK FUEL &

SHIFT TO LOW OR HIGH IGNITION SYSTEMS
GEARS. IS REVERSE INDICA-
TOR LIGHT ON OR GEAR ON? N Y
DOES THE LETTER “E”
TURN KEY SWITCH OFF
APPEAR?
REMOVE 16 PIN
PLUG FROM BACK OF
INSTRUMENT CLUSTER
PROBLEM N REPLACE
REMAINS? SPEEDOMETER
RESTART ATV AND
Y TEST DRIVE
TEST TRANSMISSION SWITCH

CHECK RELATED WIRING NOTE: OVERRIDE SWITCH PLAYS NO ROLE IN
REVERSE GEAR OUTPUT ON THE ATV.
TEST 6 WHEEL SPEED SENSOR

Tools Required: To Sensor Red
Brn
GStatic Timing Light Harness (PN 2871745)
GHall Sensor Probe Harness (PN 2460761) or equiva- 680Ω
Wht
lent jumper wires.
To test wheel speed sensor: -- + To Sensor
LED
1.Disconnect 3 Pin connector from speedometer. 9V White
2. Connect wires from test light to sensor 3 Pin To Sensor
connector as shown at right, using the Hall Sensor Blk Black
Probe Harness (PN 2460761) or jumper leads.
3. Elevate front right side of vehicle until tire is off the
ground.
4. Slowly turn right front wheel while observing the
test light.
5. If light flashes, sensor is O.K. Be sure connections Static Timing Light Harness
are good and 9 volt battery is in good condition. (PN 2871745)
WHEEL SPEED
SENSOR LOCATION
10.11
ELECTRICAL

TEST 7 SHIFT INDICATOR NOT WORKING (TRANSMISSION SWITCH)
Operation:
The Instrument cluster sends signals from the #12, #13, #14
and #15 output wires on the connector to the transmission
switches. These signals complete their path on the Brown
wire at the front transmission switch. Depending on switch
position, the Instrument cluster displays the corresponding
shift indicator in the LCD panel.
Testing:
Use the diagram provided to test the continuity loop at each
of the shift points with a multi--meter. Replace Instrument
cluster if no connection problems are found.
16 Pin Connector
1. Red-- 12V Ignition Switch
2. Red/White-- 12V ETC and AWD Switch
3. Grey/Orange-- Mode/Override button
4. Black-- Ignition Kill
5. Green-- N/C
6. Blue-- N/C
8. Brown-- Instrument Ground
9. Blue White-- Engine Overheat Switch
10. N/C
11. N/C
12. Purple-- F Trans Switch -- Reverse
13. Green/White--R Trans Switch -- Neutral
14. White/Blue-- R Trans Switch -- Low
15. Blue/Red-- F Trans Switch -- High
16. Brown/White-- AWD Coil
Accessory Plug
10.12
ELECTRICAL
SPEEDOMETER
TROUBLESHOOTING CONT’D
-- 2004 MODELS
TEST 8 -- -- RESET SPEEDOMETER
If the key switch or engine stop switch is turned off with
the vehicle in motion, the speedometer indicator
needle may stick, indicating the speed at which the
vehicle was traveling when the speedometer lost
power. For example: If the ATV was traveling 30 mph
when the engine stop switch is turned off, speedo may
indicate 30 mph until reset:
1. Operate vehicle at a speed greater than indicated
on speedometer (past point where needle is stuck).
Needle should return to normal operation.
2. In the above example, the ATV speed would have
to exceed 30 mph to reset.
10.13
ELECTRICAL
INSTRUMENT CLUSTER/ is non-serviceable and is designed to last for the life

of the unit. (A) The speedometer needle indicates
SPEEDOMETER -- 2005 speed from an electronic wheel speed sensor located
on the right front brake caliper bracket and the needle
MODELS also flashes during a warning condition. The
speedometer needle indicates speed in MPH and
INSTRUMENT CLUSTER KPH. NOTE: The flashing needle could indicate a
hot engine, low battery warning, or the No. 10 Pin
OVERVIEW -- 2005 could be grounded. (B) The speedometer features
numbers in Mile Per Hour (MPH) and Kilometers Per
(A) Speedo Needle (also flashes Hour (KPH). (C) The Rider Information Center
during warning condition) performs a number of functions (See Illustration 2):
(B) Speedometer
in MPH/KPH Refer to Illustration 2:
1. Odometer/Tachometer/Trip meter/Hour Meter
* Odometer records the miles traveled by the ATV.
*Tachometer displays engine RPM. This feature will
also display with the vehicle in motion NOTE: Small
RPM fluctuations from day to day are normal because
of changes in humidity, temperature, and elevation.
*Trip meter records the miles traveled by the ATV on
each trip it it’s reset before each trip. To reset the trip
meter, select the trip meter mode. Press and hold the
mode button (override button) until the total changes
to 0. NOTE: In the Rider Information Center, the trip
meter display contains a decimal point, but the
odometer displays without a decimal point.
(C) Rider Information Center Ill.1 *Hour Meter logs the total hours the engine has been
in operation.
2.Programmable Service Interval/Diagnostic

5 2 4 1 Mode
*Service Interval -- The purpose of the
3 programmable service interval is to provide the
consumer and their dealer with a convenient way to
schedule routine maintenance. When the ATV leaves
6 the factory, this feature is set at “50 hours”. When the
first 50 hours of engine operation are finished the
wrench icon will flash for 10 seconds each time the
ATV is started as a reminder that ATV maintenance
is due. NOTE: To reset the Service Interval, follow the
8 directions on the Page 10.16, “Setting New Service
7 Ill.2 Interval”.
*Diagnostic Mode is for informational purposes only.
Introduction Consumers should return the ATV to their Polaris
Refer to Illustration 1: dealer. See “Diagnostic Mode Operation” on the
The Polaris ATV Instrument Cluster is powered by next page for more information.
battery voltage (12 VDC) and requires inputs from the 3. Check Engine Warning Indicator
engine RPM, transmission gear, and wheel speed The word HOT will display alpha numerically when the
sensor for proper operation. Two harnesses plug into engine is overheating. Do not continue to operate the
the cluster head; one from the right front wheel speed ATV if this warning appears. Refer to Chapter 3
sensor, and one from the vehicle main harness. A “Cooling System Troubleshooting” for help with
non-serviceable internal memory battery maintains diagnosis of overheating.
odometer and hour meter data when the machine is
not running. The illumination lamp inside the gauge
10.14
ELECTRICAL
The initial screen display refers to the software

version installed on your ATV. This information is only
displayed briefly.
Screen 1: The first screen indicates battery voltage.
Refer to Ill. 2.
4. High/Low Battery Voltage

This warning usually indicates that the ATV is being
operated at an RPM too low to keep the battery Ill. 2
charged. A low battery warning may also occur under
normal operation if the machine is at idle and high Screen 2: Tachometer (Ill. 3) indicates engine rpm
electrical load (lights, cooling fan, accessories) is for setting idle speed.
applied. Driving at a higher RPM or connecting a
battery charger will usually clear the warning.
5. Engine Hour Display Indicator
Displays number of hours of engine operation.
6. AWD Indicator
Illuminates when the electrical portion of the AWD
system is enabled.
7. Gear Indicator
Specifies what position the shift lever and
Ill.3
transmission are in. This area is blank if a fault occurs.
8. Mode Indicator
Indicates which modes are being utilized. Screen 3: AWD diagnostic screen. This screen
indicates whether or not current is flowing through the
AWD coil on models with switchable AWD.
DIAGNOSTIC MODE -- 2005
MODELS
NOTE: This gauge features auto shut--off protection
if the voltage on the DC bus is excessive. This is
usually the result of an open battery condition, and the
gauge is designed to survive such an event.
NOTE: If the gauge will not indicate what gear it is in
and will not allow AWD operation, AWD can still be
enabled by holding in the mode/override button. AWD Off
To enter the diagnostics mode:

1. Turn the key switch off and wait 10 seconds.
2. Set the park brake and shift the transmission to
neutral.
3. Hold the mode/reverse override button as you
turn the key switch on.
4. Release the switch as soon as the display is
activated.
Use the mode/reverse override button to toggle
through the diagnostic screens. AWD On
10.15
ELECTRICAL
Screen 4: Gear circuit diagnostic. This screen

displays the resistance value (in ohms) being read at
the gear switch input of the gauge. NOTE: 10--20%
variance from these readings is within normal
parameters.
628 Ohms in High
Screen 5: Programmable service interval. The

purpose of the programmable service interval is to
provide the consumer and dealer with a convenient
23 Ohms in Park reminder for routine maintenance. When the ATV
leaves the factory, this feature is set at 50 hours.
Once the service interval mode is set with the hours

when service is due, the hours of actual engine
operation are subtracted from the set hours until 0 is
reached. When the counter reaches 0, the wrench
icon will flash quickly for 10 seconds each time the
vehicle is started as a reminder that the periodic
maintenance is due.
158 Ohms in Neutral
Set at 50 hrs. from Factory
75 Ohms in Reverse SETTING A NEW SERVICE INTERVAL:
Setting Service Interval After Countdown (zero):

1. While in the service interval mode, press and hold
the mode/override button until the wrench icon
flashes. When it begins to flash, release the button.
2. The setting will increase by one hour each time the
button is pressed. Pressing and holding the button will
allow the numbers to escalate much faster.
3. When the desired time increment is displayed,
release the button and wait for the wrench to stop
297 Ohms in Low flashing. When the wrench stops blinking, your
service hours are set.
NOTE: If you scroll past the intended number, hold
the button down until the count turns over to 0. You
can then reset the number.
Turn Service Interval OFF:

1. If the service interval is enabled (functioning) on
your ATV and you wish to turn it off, toggle to the
10.16
ELECTRICAL
service interval mode. NOTE: To leave the diagnostic mode, turn the key
2. Press and hold the mode button for approximately switch off and on.
7 seconds until the word OFF appears in the Rider
Information Center. The service interval is now off. NOTE: Any movement of the tires will trigger the
3. To enable (turn on) the service interval mode, speedometer out of the diagnostic mode and into
repeat the steps above in “Setting Service Interval standard display mode.
After Countdown”.
NOTES:
Change Service Interval Time:
If you would like to change the service interval time,
(for example change the interval from 50 hrs. to 55
hrs.). Follow the steps below:
1. While in the service interval mode, press and hold
the mode button for approximately 7 seconds until the
word OFF appears in the Rider Information Center.
2. Wait 5 seconds and then press the mode button in
until the wrench icon flashes. Press the mode button
again to set the desired service increment. Release
the button and wait for the wrench icon to stop
flashing. The new service interval is now set.
Screen 6: Miles/Kilometers toggle, The display in

the trip meter and odometer can be changed to
display either kilometers or miles. The current display
mode will be shown as “KM” or “MP”. To change, hold
in the mode button until the letters flash, then press
and release the button once. When the display stops
flashing, the mode has been set.
MP = Miles
Km = Kilometers
NOTE: As long as you are in the diagnostic mode, the

wrench icon will remain lit.
10.17
ELECTRICAL

TEST 1 -- NO ALL WHEEL DRIVE
Note: If AWD icon comes on, instru-
START HERE -- ENGINE OFF ment cluster is O.K. Proceed to me-
--KEY SWITCH ON chanical tests (in Service Manual).
--TRANSMISSION IN LOW Check the AWD icon on instrument clus-
--AWD SWITCH ON MECHANICAL ter to verify it’s operation. The AWD
--INSTRUMENT CLUSTER IN
PROBLEM switch is directly powered by switched
DIAGNOSTIC MODE SET TO 12 volts (red/white). The gear switch
AWD DIAGNOSTIC SCREEN only interfaces with the instrument clus-
Y ter. To enable AWD, the cluster must be
displaying low or high gear, or reverse
gear with the override button pushed in.
TURN ON AWD
SWITCH N
DOES CLUSTER
SHOW 16 Pin Connector
“ON”? CHECK
INSTRUMENT 1. Orange/White-- 12V Ignition Switch
Y CLUSTER N CLUSTER 2. Red/White-- 12V ETC and AWD Switch
READOUT PROCEED 3. Grey/Orange-- Mode/Override button
OK? TO TEST 2 4. Black-- Ignition Kill
5. Green-- Diagnostic (Factory Use Only)
6. Blue-- Diagnostic (Factory Use Only)
ON HUB COIL 8. Brown-- Ground
CONNECTOR NOT AN INSTRUMENT 9. Blue White-- Engine Overheat Switch
(LEAVE IT CONNECTED) 10. N/C
Y CLUSTER PROBLEM; 11. N/C
MEASURE FOR 12V FROM CHECK AWD SWITCH 12. Purple/White-- Fuel Sender (if equipped)
BROWN/WHITE TO 13. Brown/Red-- Trans Switch Ground
AND WIRING 14. White-- Gear Shift Signal
GROUND 15. N/C
Note: Reversing polarity when connecting

the battery or other DC power source will
N fail the AWD control and the instrument
cluster If the key switch and the AWD
switch are turned on.
LEAVE AWD
SWITCH ON
TURN KEY SWITCH OFF
REPLACE
DISCONNECT 16 PIN N WIRING INSTRUMENT
CONNECTOR FROM CLUSTER
PROBLEM CLUSTER
TURN KEY SWITCH ON Y
CHECK FOR 12V
FROM BRN/WHITE
TO GROUND
LEAVE KEY
SWITCH OFF
REMOVE THROTTLE PROCEED TO
CONTROL COVER MECHANICAL AWD
Y N COMPONENTS
DISCONNECT THROTTLE
TURN KEY SWITCH OFF CONTROL HARNESS IF AWD PROBLEM
RECONNECT CLUSTER PERSISTS.
CHECK FOR CONTINUITY
LEAVE HEADLIGHT POD ACROSS AWD
DISASSEMBLED SWITCH
SHIFT TO LOW OR HIGH
LEAVE AWD ON
10.18
ELECTRICAL

TEST 2 -- NO SPEEDOMETER AND/OR ODOMETER DISPLAY S
Y CHECK FOR N REPLACE
START HERE MINIMUM 6VDC
SPEEDO
ON PIN B TO
KEY & STOP 3 Pin Connector PIN C
SWITCHES ON REPLACE MEASURE
SPEEDO A: D.C. Power BACK OF
B: Signal Y S SPEEDO WITH
CONNECTORS
C: Ground PLUGGED IN
Y
CHECK S
REPLACE N WHEEL
CHECK
SPEEDO SENSOR
SPEED AT BACK OF SPEEDO:
POINTER POWER
SENSOR CHECK FOR 10--12
MOVE? SUPPLY
(SEE VDC ON PIN A TO PIN
PIN A
TEST 6) C ON THE 3 PIN CON-
Y NECTOR?
16PIN MEA-
SURE 12VDC N
ON PINS 1
REPAIR
WIRING
N
&8 AND 2 & 8 REPLACE
N SPEEDO REPLACE
SPEEDO
N N
Y
ODOMETER TEST ODOMETER Y POINTER
Y SPEEDO
DISPLAY DRIVE CHANGE? OK
MOVE?
VEHICLE
TEST 3 -- NO REVERSE SPEED LIMIT

16 Pin Connector
1. Orange/white-- 12V Ignition Switch 9. Blue White-- Engine Overheat Switch
(VEHICLE EXCEEDS 7--9 MPH IN REVERSE) 2. Red/White-- 12V ETC and AWD Switch 10. N/C
3. Grey/Orange-- Mode/Override button 11. N/C
4. Black-- Ignition Kill 12. Purple/White-- Fuel Sender (if equipped)
START HERE 5. Green-- Diagnostic (Factory Use Only) 13. Brown/Red-- Trans Switch Ground
6. Blue-- Diagnostic (Factory Use Only) 14. White-- Gear Shift Signal
15. N/C
7. Yellow/Red-- RPM Input 16. Brown/White-- AWD Coil
8. Brown-- Ground
IS THE SPEEDO
N CHECK
READ OUT SPEEDOMETER NOTE: Mode/Override button provides a grounding (sink-
(PERFORM TEST 2)
OK? ing) input to the instrument cluster.
REPLACE TEST TRANSMISSION
SPEEDO SWITCH, SHIFT MODULE
Y AND WIRING
Y INSPECT WIRING
N AND CDI
IS
SHIFT INTO REVERSE: N SWITCH CLUSTER TO RESISTANCE N H
IS REVERSE INDICA- DIAGNOSTIC MODE READING
TOR ON? GEAR SWITCH DIAGNOSTIC CORRECT? RESTART ATV Measure Harness
(PG 10.11)
H Side
TURN KEY SWITCH OFF JUMPER TO PIN 4 Y REPLACE

(BLACK) TO PIN 8 SPEEDO
REMOVE 16 PIN PLUG (BROWN). DOES
Y FROM BACK OF ENGINE STOP?
SPEEDOMETER HEAD
10.19
ELECTRICAL

TEST 4 -- NO AWD HUB SAFETY LIMIT
NOTE: IF THE AWD ICON DOES NOT COME ON OR IF 12
VDC IS NOT REGISTERING AND AWD IS ENGAGING
ABOVE 3100 RPM,IT MAY BE A MECHANICAL PROBLEM. START HERE
IS
SPEEDO
ATV IN NEUTRAL Y FUNCTIONING N CHECK
ACTIVATE DIAGNOSTIC SPEEDO
CORRECTLY?
MODE. TOGGLE TO TACH--
Y OMETER SETTING & REV ENGINE. (TEST NO. 2)
HOLD UNTIL DISPLAY STABILIZES.
DOES IT APPEAR
ACCURATE?
RESTART ATV
N
ENGINE IDLING
MEASURE AC VOLTAGE
Y REPLACE
TURN KEY SWITCH OFF SPEEDOMETER
BETWEEN PIN 7 AND
1. RAISE ATV WHEELS OFF GROUND AND REMOVE 16 PIN PIN 8.
SUPPORT IN A SAFE MANNER. CONNECTOR FROM OVER 3 VAC?
BACK OF
2. MONITOR VOLTAGE AT HUB COIL INSTRUMENT
CONNECTOR, BETWEEN BROWN/WHITE CLUSTER.
AND GROUND
CHECK CHARGING SYSTEM

(STATOR, REGULATOR,
AND WIRING)
TURN
AWD OFF. 16 Pin Connector
START THE ENGINE
REV AND HOLD THE N 1. Orange/White-- 12V Ignition Switch 9. Blue White-- Engine Overheat Switch
RPM’S ABOVE 3100. NO PROBLEM 2. Red/White-- 12V ETC and AWD Switch 10. N/C
TURN AWD ON. 3. Grey/Orange-- Mode/Override button 11. N/C
DOES FRONT 4. Black-- Ignition Kill 12. Purple/White-- Fuel Sender (if equipped)
DRIVE 5. Green-- Diagnostic (Factory Use Only) 13. Brown/Red-- Trans Switch Ground
ENGAGE? 6. Blue-- Diagnostic (Factory Use Only) 14. White-- Gear Shift Signal
15. N/C
8. Brown-- Ground
INSPECT
HUB COIL WIRING
IS THE
Y FOR SHORT CIRCUITS N
TO GROUND. (DISCONNECT REPLACE
AWD ICON ON? CONNECTOR & MEASURE SPEEDOMETER
BETWEEN HUB COIL
BROWN/WHT
& GROUND.)
N Y
MECHANICAL PROBLEM REPAIR HUB COIL WIRING
10.20
ELECTRICAL

TEST 5 REVERSE SPEED LIMITER ACTIVATED IN FORWARD GEAR
(Engine loses spark when vehicle speed is above 7-9 mph.)
START HERE
16 Pin Connector
1. Orange/White-- 12V Ignition Switch 9. Blue White-- Engine Overheat Switch
CHECK 2. Red/White-- 12V ETC and AWD Switch 10. N/C
INSTRUMENT SPEEDOMETER
3. Grey/Orange-- Mode/Override button 11. N/C
CLUSTER FUNC-
(PERFORM TEST 2) 4. Black-- Ignition Kill 12. Purple/White-- Fuel Sender (if equipped)
TION OK?
5. Green-- Diagnostic (Factory Use Only) 13. Brown/Red-- Trans Switch Ground
6. Blue-- Diagnostic (Factory Use Only) 14. White-- Gear Shift Signal
15. N/C
8. Brown-- Ground
Y
CHECK FUEL &

SHIFT TO LOW OR HIGH IGNITION SYSTEMS
GEARS. IS REVERSE INDICA-
N
TOR ICON ON OR GEAR ON? Y
DOES GEAR INDICATOR
GO BLANK? TURN KEY SWITCH OFF
REMOVE 16 PIN
PLUG FROM BACK OF
INSTRUMENT CLUSTER
PROBLEM N REPLACE
REMAINS? SPEEDOMETER
RESTART ATV AND
Y TEST DRIVE
CHECK TRANSMISSION
SWITCH, RESISTOR MODULE NOTE: OVERRIDE SWITCH PLAYS NO ROLE IN
AND RELATED WIRING REVERSE GEAR OUTPUT
TEST 6 WHEEL SPEED SENSOR

Tools Required: To Sensor Red
Brn
GStatic Timing Light Harness (PN 2871745)
GHall Sensor Probe Harness (PN 2460761) or equiva- 680Ω
Wht
lent jumper wires.
To test wheel speed sensor: -- + To Sensor
LED
1. Disconnect 3 Pin connector from speedometer. White
12V
2. Connect wires from test light to sensor 3 Pin To Sensor
connector as shown at right, using the Hall Sensor Blk Black
Probe Harness (PN 2460761) or jumper leads.
3. Elevate front right side of vehicle until tire is off the
ground.
4. Slowly turn right front wheel while observing the
test light.
5. If light flashes, sensor is O.K. Be sure connections Static Timing Light Harness
are good and 9 volt battery is in good condition. (PN 2871745)
WHEEL SPEED
SENSOR LOCATION
10.21
ELECTRICAL

TEST 7 SHIFT INDICATOR NOT WORKING (TRANSMISSION SWITCH)
Operation: 16 Pin Connector
The Instrument cluster sends signals from the #12, #13, #14
and #15 output wires on the connector to the transmission 1. Orange/White-- 12V Ignition Switch
switches. These signals complete their path on the Brown 2. Red/White-- 12V ETC and AWD Switch
wire at the front transmission switch. Depending on switch
3. Grey/Orange-- Mode/Override button
position, the Instrument cluster displays the corresponding
shift indicator in the LCD panel. 4. Black-- Ignition Kill
5. Green-- N/C
Testing: 6. Blue-- N/C
Use the diagram provided to test the continuity loop at each 7. Yellow/Red-- RPM Input
of the shift points with a multi--meter. Replace Instrument 8. Brown-- Instrument Ground
cluster if no connection problems are found. 9. Blue White-- Engine Overheat Switch
10. N/C
11. N/C
12. Purple-- F Trans Switch -- Reverse
13. Green/White--R Trans Switch -- Neutral
14. White/Blue-- R Trans Switch -- Low
15. Blue/Red-- F Trans Switch -- High
51 WHT/BLU
14 GRN/WHT
35WHT
32 BRN/R
28 PUR
50 BLU/R
35WHT
10.22
ELECTRICAL
INSTRUMENT CLUSTER INSTRUMENT CLUSTER

REMOVAL INSTALLATION
1. Remove the three screws that secure the NOTE: Do not allow alcohol or petroleum products to
headlight pod cover and disconnect the wire come in contact with the instrument cluster lens.
connectors from the instrument cluster.
1. Spray a soap and water mixture onto the outer
surface area of the instrument cluster. This will
help the instrument cluster slide into the pod
assembly more
easily.
2. Push the instrument cluster out from the backside

of the pod, while securely holding the pod.
2. Be sure the rubber grommet inside the pod is fully
installed and that the indexing key is in the
headlight pod keyway.
Align Index Points
3. Hold the pod assembly securely and insert the

instrument cluster into the pod assembly. Twist
the instrument cluster gently in a clockwise
Bezel motion to properly seat the instrument cluster into
Instrument Cluster the pod assembly. Apply pressure on the bezel
Rubber Mount while pressing down on the instrument cluster.
Pod
Push Instrument
Cluster Outward
NOTE: Do not remove the rubber grommet in the pod.

Only remove the rubber grommet if necessary.
10.23
ELECTRICAL
TEMPERATURE SENSOR THERMISTER READING DURING OPERATION
(THERMISTOR) TEST Condition Approx. Reading

(Min--Max)
Temperature
Hot Light 178Ω -- 190Ω 215° F

On (102° C)
Fan Off 296Ω -- 316Ω 180° F (82° C)
Fan On 236Ω -- 251Ω 195° F (91° C)
FAN MOTOR CURRENT DRAW

A current draw test will provide a good indication of fan
motor condition. A worn or damaged fan motor will
draw more current, which causes a reduction in blade
speed and reduced cooling.
If the thermistor circuit is open the engine Hot light and

fan will both come on. With engine cold, disconnect Fan Motor
lead and measure resistance of sensor between the
two Yellow/Black connector terminals. There should
be no continuity or very high resistance (see chart). Org/Blk Org/Blk
See “Engine Temperature Controller” on Page 10.5
for information on thermistor operation.
SITUATION OHMS DIAGNOSIS / Brn

READING ACTION
Hot light ON & Above 50k Open Thermistor /
Fan ON Replace Thermis-
tor
Hot light ON Below 178 Engine Overheat
or Bad Thermistor
1. Disconnect the harness from the fan motor.

2. Connect a DC ammeter in between the fan switch
harness wires as shown.
3. Be sure fan blade is free to rotate.
4. Turn ignition key and engine stop switch to “ON”
position. Read the current draw on ammeter with
fan running.
5. If the fan motor draws more than 7.5 Amps,
replace the motor.
Fan Motor Current Draw:
Should Be Less Than 7.5 Amps
CAUTION: Keep hands away from fan blades

during this procedure. Serious personal injury
could result.
10.24
ELECTRICAL
FAN CONTROL SWITCH ETC OPERATION TEST

OPERATION TEST Remove throttle block cover by carefully releasing all
tabs around edge of cover.
The fan is controlled through the ECM and thermistor.
Refer to “Engine Temperature Controller” for fan Place transmission in neutral and apply parking
operation information. Also refer to “COOLANT brake.
TEMPERATURE SENSOR (THERMISTOR) TEST” Start engine and open throttle lever slightly until
for Fan ON and Fan OFF readings on the previous engine RPM is just above idle speed.
page.
Hold throttle cable with fingers at point “A” as
shown below and release throttle lever. If the ETC
ELECTRONIC THROTTLE system is functioning properly, the engine will lose
spark and stop.
CONTROL (ETC) SWITCH
The Electronic Throttle Control (ETC) system is Electronic Throttle Control (ETC) Switch
designed to stop the engine of an ATV in the event of (Composite Throttle Housing)
a mechanical problem with the throttle mechanism.
ETC switch contacts
The ETC switch is mounted independently of the
are closed in a fault
throttle actuator lever inside the throttle block
condition (throttle cable
assembly. This is a normally closed switch, and is slack).
held in the open position (contacts are separated (as Switch contacts are
shown below) by throttle cable tension. The contacts open during normal op-
are “open” during normal operation regardless of eration
throttle lever position. In the event of a mechanical
problem in the throttle mechanism (cable tension is
lost), the switch contacts close, connecting the CDI
black wire to ground, which prevents ignition spark.
This is the same as turning the key or engine stop
switch “OFF”.
Test the ETC switch at the harness connector. NOTE:
Adjust throttle cable freeplay (ETC switch) and make
sure throttle mechanism is functioning properly before
testing the switch. Refer to Maintenance Chapter 2 A
for cable adjustment procedure.
Blk
Brn Brn
CDI UNIT
10.25
ELECTRICAL
FLYWHEEL IDENTIFICATION
Flywheel Identification Stamp Location

The flywheel can be identified by the stamp mark in location A. Refer to “I.D.” location in chart below. Do not
use the cast mark to determine flywheel application.
Engine Application Type Cast Stamp Comment I.D. Stamp

Sportsman 500 -- EH500PLE N/A N/A N/A 250W N/A
DC / CDI IGNITION
The Sportsman has incorporated into it’s design a DC/ At the CDI, 12 volt DC current charges an internal
CDI ignition system. capacitor to build up the initial ignition charge. A small
A/C signal from the Trigger (Pulse) coil closes a
Some of the advantages of DC ignition are:
thyristor (located in the CDI) at a point
GStronger, more consistent spark at low pre--determined in the crankshaft rotation by magnets
rpm for better performance on the flywheel’s outer diameter. This signal releases
GEasier starts the electrical charge which saturates the coil for
GSimpler component design for ease of ignition. DC/CDI systems have the ability to ignite
trouble shooting and maintenance with as little as 6 volts of power.
Operation Overview:
The DC/CDI system relies on battery power for ignition. NOTICE: Do not remove the wiring
Instead of generating DC voltage via magnetic harness from the CDI box while the key
induction, a 12 volt DC current is supplied directly to the switch is on or while the engine is
CDI unit from the battery. running. Damage to the CDI box may
occur!
NOTE: Maximum Timing
DC/CDI systems and compo-

nents are not interchangeable
with any other system.
10.26
ELECTRICAL
COMPONENTS OF EH500PLE / 250 WATT ALTERNATOR
NOTE: CDI boxes may look the same but have

different internal circuitry. Be sure to always use
the correct CDI box part number.
Refer To Wiring Diagrams For

Specified Stator Coil Resistance
Resistor
Cap
Ignition
Coil
Meter
10.5k Ω
Stator
Plate
CDI Box
Pulse Coil (Trigger)

Air Gap: .016-.030″
(.4 - .75 mm)
Battery Charging
Coils
Flywheel and
Ring Gear Casting.
Refer to page 10.26
for identification.
10.27
ELECTRICAL
IGNITION SYSTEM TESTING FLOW CHART

Whenever troubleshooting an electrical problem, 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.
Condition: No Spark or intermittent spark

Replace Spark Plug
Disconnect the black wire at the CDI module -Test the ignition switch, engine stop
to isolate the ignition from the kill system. switch, and speed limiter circuit for
Verify the CDI has a good ground (Brown) Yes shorts to ground.
for operation. -Check connectors for moisture,
Does it have spark? wire color matching or corrosion.
No
Verify that 12 VDC power is getting to the CDI

Inspect connectors, wiring and
module. Refer to the wiring schematic for meter
grounds to the component in
connections and specifications. Compare results
No question. Replace the compo-
to the specifications on the exploded views. Are
nent if a wiring problem cannot
all within specifications?
be found.
Yes
Check coil ground connection between engine and coil Clean coil mounting area.
mount using an ohmmeter. The coil mount should No
Repair ground wire connections.
have good continuity to ground on the engine (0-.2 Ω).
Yes
Disconnect and check the secondary coil. Resis-

tance values should be:
Primary Side - Primary Wire Tab to Ground
(on coil mount or engine): .3 to .5 Ohms
Secondary Side High Tension Wire to High Ten-
sion Wire-- Cap installed - 10.500Ω No Replace the ignition coil.
Cap removed - 6300Ω
Are these values within specs?
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 Page 10.30 or replace the CDI module.
10.28
ELECTRICAL
CHARGING SYSTEM TESTING FLOW CHART

Whenever charging system problems are suspected, proceed with the following system check after verifying that
all wires are in good condition, connected and not kinked or pinched.
Using a multitester set on D.C. volts, mea-

sure the battery open circuit voltage (See Remove the battery and properly ser-
earlier test). It should be 12.4 volts or vice. Reinstall the fully charged battery
more. Is it? No
or a fully charged shop battery.
Yes
Meter Setting: DC Volts

With the transmission in neutral, start the
engine and increase RPM to between 3000
and 4000. Read battery voltage with the Check Key off Current Draw
multitester. Readings should increase to be- Yes
tween 13.0 and 14.6 V D.C. Are they?
No
Meter Setting: DC Amps Check for owner modification, and

Perform system “Break Even Amperage” discuss operating habits. The battery
test outlined on 10.31. will continually discharge if operated
Yes
below the “Break Even” RPM. Con-
Does charging occur as specified? tinued problems would call for battery
inspection.
No
Ohm stator wires. If bad, replace stator. If

good, continue with alternator output test.
Meter Setting: AC Amps Inspect the wiring harness be-
Disconnect the wires from the regulator/rec- tween the panel and the stator for
tifier. Using a multitester, perform an Alter- damage. If no damage is found,
nator Output (AC amp) test. See test pro- No remove the recoil and flywheel.
cedure on Page 10.31 for procedure. Inspect the flywheel magnets, sta-
Is output above 7 amps? tor coils and stator wire harness
for damage. Repair or replace
any damaged components.
Yes
Meter Setting: DC Volts

Reconnect the alternator wires. Note: Red
wire must be connected to harness. Battery Check regulator/rectifier connections
voltage must be present on red wire terminal No and ground, battery connections, cir-
on harness side of voltage regulator connector. cuit breaker and connecting wires.
Repair or replace faulty wiring or
Is it? components.
Yes
If all of the previous tests indicate a

good condition, but the charging voltage
does not rise above battery voltage at the
connector or wire harness, replace the volt-
age regulator.
10.29
ELECTRICAL
IGNITION SYSTEM CDI CRANKING OUTPUT

TROUBLESHOOTING TEST WITH PEAK READING
No Spark, Weak or Intermittent Spark VOLTMETER
GSpark plug gap incorrect The following peak voltage tests will measure the
GFouled spark plug amount of output directly from each component. A
GFaulty spark plug cap or poor peak reading voltmeter must be used to perform the
connection to high tension lead tests. A variety of peak reading adaptors are
commercially available for use with the Fluke t 77
GRelated wiring loose, disconnected, Digital Multitester (PV--43568) and other digital VOMs
shorted, or corroded which will allow peak voltage tests to be performed
GEngine Stop switch or ignition switch accurately. Follow the directions provided with the
faulty adaptor. All measurements are indicated in DC Volts.
GETC switch misadjusted or faulty Readings obtained without a peak reading adaptor will
GWire harness or connections wet, be significantly different.
corroded Disconnect the stator connectors from the CDI
GPoor ignition coil ground (e.g. coil module. Test output from exciter coil, pulse (trigger)
mount loose or corroded) coil, and compare to the chart. The following
GFaulty stator (measure resistance of measurements are obtained when cranking the
all ignition related windings) engine with the electric starter, spark plug installed.
The starter system must be in good condition and the
GIncorrect wiring (inspect color coding battery fully charged.
in connectors etc)
GFaulty ignition coil winding (measure 250 Watt 4 Stroke
resistance of primary and
secondary)
Coil Connect Meter Reading
GWorn magneto (RH) end Crankshaft Wires To: (With Peak Read-
bearings ing Volt meter)
GSheared flywheel key
GFlywheel loose or damaged Exciter 1 White/Blue and 3 DCV
GTrigger coil air gap too wide (where Ground
applicable) - should be .016-.040″ Detection White/Red and 185 Ohms
(.4-1.0 mm) White
GExcessive crankshaft runout on
magneto (RH) end - should not
exceed .0024″
CURRENT DRAW - KEY OFF
GFaulty CDI module
CAUTION: Do not connect or disconnect the battery
cable or ammeter with the engine running. Damage
CDI OUTPUT TEST USING will occur to electrical components.
PEAK READING ADAPTOR Connect an ammeter in series with the negative
battery cable. Check for current draw with the key off.
Re-connect all CDI wires to stator wires. Disconnect If the draw is excessive, loads should be
CDI module wire from ignition coil primary terminal. disconnected from the system one by one until the
Connect one meter lead to engine ground and the draw is eliminated. Check component wiring as well
other to the ignition coil primary wire leading from the as the component for partial shorts to ground to
CDI module. Crank engine and check output of CDI eliminate the draw.
wire to coil (130 DCV). Reconnect coil wire to CDI.
Refer to Illustration 1 on the next page.
Output w/ Peak output tester

130 DCV
Average Output w/ Digital Voltmeter
20 DCV
10.30
ELECTRICAL
5. Increase engine RPM while observing ammeter

and tachometer.
Current Draw Inspection
6. Note RPM at which the battery starts to charge
Key Off (ammeter indication is positive).
7. With lights and other electrical load off, the “break
even” point should occur at approximately 1500
RPM or lower.
+ -- 8. Turn the lights on and engage parking brake lock
YB30L--B to keep brake light on.
9. Repeat test, observing ammeter and tachometer.
With lights on, charging should occur at or below
2000 RPM.
Ill. 1
ALTERNATOR OUTPUT TEST
Current Draw - Key Off: (AC AMP)
Maximum of .01 DCA (10 mA)
This test measures AC amperage from the alternator.
CAUTION: This test simulates a “full load” on the
CHARGING SYSTEM “BREAK alternator at idle. Do not increase idle RPM or perform
this test longer than required to obtain a reading. The
EVEN” TEST alternator stator windings may overheat. 3--5
seconds is acceptable.
CAUTION: Do not allow the battery cable or
ammeter to become disconnected with the
engine running. Follow the steps below as To Calculate Available Alternator Output
outlined to reduce the chance of damage to
electrical components. P 200W
I = = 16.7 Amps
WARNING: Never start the engine with the ammeter E 12V
connected in series. Damage to the meter or meter
250W
fuse will result. Do not run test for extended period of I = Current in Amps = 20.8 Amps
time. Do not run test with high amperage accessories. P = Power in Watts
12V
The “break even” point of the charging system is the E = Electromotive Force (Volts)
point at which the alternator overcomes all system
loads (lights, etc.) and begins to charge the battery. 1. Maximum alternator output will be indicated on
Depending on battery condition and system load, the the meter. DO NOT increase engine RPM above
break even point may vary slightly. The battery should idle.
be fully charged before performing this test. 2. Place the red lead on the tester in the 10A jack.
1. Connect a tachometer according to 3. Turn the selector dial to the AC amps position.
manufacturer’s instructions. 4. Connect the meter leads to the Yellow and
2. With the negative cable still connected to the Yellow/Red wires leading from the alternator.
battery, connect one meter lead (set to DC amps) 5. Start the engine and let it idle. Reading should be
to the battery post and the other to the negative a minimum of 7A/AC at idle.
battery cable
3. With engine off and the key and kill switch in the
ON position, the ammeter should read negative Alternator Current Output:
amps (battery discharge). Reverse meter leads if Minimum of 7 AC Amps at Idle
a positive reading is indicated.
4. Shift transmission into neutral and start the
engine. With the engine running at idle,
disconnect the negative cable from the battery
post without disturbing the meter leads. Observe
meter readings
10.31
ELECTRICAL
BATTERY IDENTIFICATION INITIAL BATTERY ACTIVATION

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 your battery is very WARNING
important for maintaining long battery life.
Your ATV may have a Conventional Battery or a Battery electrolyte is poisonous. It contains
Sealed Low Maintenance Battery. To identify which sulfuric acid. Serious burns can result from con-
type of battery your ATV has, refer to the illustration tact with skin, eyes or clothing. Antidote:
below and follow the correct service and charging External: Flush with water.
procedures that follow in the manual.
Internal: Drink large quantities of water or milk.
CONVENTIONAL BATTERY Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.
Removable Eyes: Flush with water for 15 minutes and get
Caps prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc. away. Ventilate
when charging or using in an enclosed space.
Top View Always shield eyes when working near batter-
ies. KEEP OUT OF REACH OF CHILDREN.
Electrolyte Level
Indicator WARNING: The gases given off by a battery are
explosive. Any spark or open flame near a battery can
cause an explosion which will spray battery acid on
anyone close to it. Should battery acid spill, wash the
affected area with large quantities of cool water and
seek immediate medical attention.
NOTE: All 2004 Sportsman 6x6 ATV batteries are

Side View
Low Maintenance in design and construction. All
Low Maintenance batteries are fully charged and
SEALED LOW tested at the factory before installation. Expected
shelf life is 6--8 months depending on storage
MAINTENANCE BATTERY
conditions. As a general rule before placing the
No Caps battery into service, check the battery condition
(Non--removable and charge accordingly.
sealed top)
NOTE: Expected shelf life of a Low Maintenance
battery is 6--8 months depending on storage
conditions. As a general rule before placing the
Top View battery into service, check the battery condition
and charge accordingly. Low Maintenance
batteries should be charged anytime the voltage
drops below 12.5 VDC.
No Electrolyte
Level Indicator
Side View
10.32
ELECTRICAL
SEALED LOW MAINTENANCE case and shorten the life of the battery. Refer to the
Battery Activation and Maintenance Video (PN
BATTERY 9917987) for proper instruction on servicing Low
Maintenance batteries.
NOTE: All Low Maintenance batteries are fully NEVER attempt to add electrolyte or water to a Low
charged and tested at the factory before Maintenance battery. Doing so will damage the
installation. Expected shelf life varies on storage case and shorten the life of the battery. Refer to the
conditions. As a general rule before placing the Battery Maintenance Video (PN 9917987) for proper
battery into service, check the battery condition instruction on servicing Low Maintenance
and charge accordingly. batteries.
To service a Low Maintenance battery:
1. Remove battery from the vehicle
Battery Check:
2. Test battery with a voltage meter or load tester to
1. Check the date label on the side of the battery to determine battery condition. This will determine
calculate when to check voltage. The battery the length of time required to charge the battery to
should be checked every 3 months. full capacity. Refer to capacity table.
2. Check the voltage with a voltmeter or multimeter. 3. Charge battery using a variable rate charger.
A fully charged battery should be 12.8 V or
higher.
3. If the voltage is below 12.8 V, the battery will need SEALED LOW MAINTENANCE
to be recharged.
BATTERY CHARGING
If battery voltage is 12.8 V or less, the battery may
need recharging. When using an automatic charger,
refer to the charger manufacturer’s instructions for
recharging. When using a constant current charger,
use the following guidelines for recharging.
NOTE: Always verify battery condition before and 1-2
hours after the end of charging.
WARNING: An overheated battery could explode,
causing severe injury or death. Always watch
charging times carefully. Stop charging if the battery
becomes very warm to the touch. Allow it to cool
before resuming charging.
New Batteries: Batteries must be fully charged

before use or battery life can be reduced by
10-30% of full potential. Charge battery for 3--5
hours using a variable rate charger. Do not use
the alternator to charge a new battery. A high rate
battery charger can cause battery damage.
Low Maintenance batteries are permanently
sealed at the time of manufacture. The use of
lead--calcium and AGM technology instead of
lead--antimony allows the battery acid to be fully
absorbed. For this reason, a Low Maintenance
battery case is dark and the cell caps are not
removable, since there is no need to check
electrolyte level.
NEVER attempt to add electrolyte or water to a Low
Maintenance battery. Doing so will damage the
10.33
ELECTRICAL
Battery Charging Reference Table Whenever removing or reinstalling the battery,

disconnect the negative (black) cable first and
State of Voltage Action Charge reinstall the negative cable last!
Charge Time (*See
note below) 3. Remove the battery.
100% 12.8--13 V None, None Re-
check volt- quired
age at 3
SEALED LOW MAINTENANCE
mos. after BATTERY INSTALLATION
manufac-
ture date 1. Clean battery cables and terminals with a stiff wire
75--100% 12.5--12.8 V May need 3--6 hours brush. Corrosion can be removed using a
slight solution of one cup water and one tablespoon
charge baking soda. Rinse well with clean water and dry
thoroughly.
50--75% 12.0--12.5 V Needs 5--11 hours
Charge 2. Route the cables correctly.
25--50% 11.5--12.0 V Needs At least 13 3. Reinstall battery, attaching positive (+) (red) cable
Charge hours, first and then the negative (-) (black) cable. Coat
verify state terminals and bolt threads with Nyogelt Grease
of charge (PN 2871329).
4. Reinstall the holder strap.
0--25% 11.5 V or Needs At least 20
less Charge hours
SEALED LOW MAINTENANCE BATTERY TESTING
BATTERY INSPECTION/ Whenever a service complaint is related to either the
starting or charging systems, the battery should be
REMOVAL checked first.
The battery is located under the left rear fender. Following are three tests which can easily be made on
a battery to determine its condition: OCV Test,
Specific Gravity Test and Load Test.
Battery Location
BATTERY -- OCV - OPEN
CIRCUIT VOLTAGE TEST
Battery voltage should be checked with a digital
multitester. Readings of 12.8 volts or less require
further battery testing and charging. See charts and
Load Test.
NOTE: Lead-acid batteries should be kept at or near

a full charge as possible. If the battery is stored or
used in a partially charged condition, or with low
1. Disconnect holder strap and remove cover. electrolyte levels, hard crystal sulfation will form on
the plates, reducing the efficiency and service life of
2. Disconnect battery negative (-) (black) cable first, the battery.
followed by the positive (+) (red) cable.
NOTE: Use a voltmeter or multimeter to test batter
CAUTION voltage.
10.34
ELECTRICAL
OPEN CIRCUIT VOLTAGE GCharge at a rate no greater than 1/10 of

the battery’s amp/hr capacity until
State of Maintenance YuMicront the voltage reaches 13.0VDC or
charge Free Type greater.
100% 13.0V 12.70V GStore the battery either in the machine
75% Charged 12.80V 12.50V with the cables disconnected, or
50% Charged 12.50V 12.20V store in a cool place.
25% Charged 12.20V 12.0V
0% Charged less than 12.0V less than 11.9V NOTE: Stored batteries lose their charge at the rate
* At 80_F
of up to 1% per day. Recharge to full capacity every
NOTE: Subtract .01 from the specific gravity reading at 40_ F. 30 to 60 days during a non-use period. If the battery
is stored during the winter months, electrolyte will
freeze at higher temperatures as the battery
SEALED LOW MAINTENANCE discharges. The chart below indicates freezing points
by specific gravity.
BATTERY LOAD TEST
Electrolyte Freezing Points
CAUTION: To prevent shock or component
damage, remove spark plug high tension leads Specific Gravity Freezing
of Electrolyte Point
and connect securely to engine ground before
proceeding. 1.265 -75° F
NOTE: This test can only be performed on machines 1.225 -35° F
with electric starters. This test cannot be performed 1.200 -17° F
with an engine or starting system that is not working
properly. 1.150 +5° F
A battery may indicate a full charge condition in the OCV 1.100 +18° F
test and the specific gravity test, but still may not have 1.050 +27° F
the storage capacity necessary to properly function in
the electrical system. 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 manner as was BATTERY CHARGING
done in the OCV test. The reading should be 12.6 volts
or greater. Engage the starter and observe the battery PROCEDURE
voltage while cranking the engine. Continue the test for
15 seconds. During cranking the observed voltage 1. Remove the battery from the ATV to prevent
should not drop below 9.5 volts. If the beginning voltage damage from leaking or spilled acid during
is 12.6 volts or higher and the cranking voltage drops charging.
below 9.5 volts during the test, replace the battery. 2. Charge the battery with a variable rate charging
output. Charge as needed to raise the voltage to
12.8VDC or greater.
SEALED LOW MAINTENANCE 3. Install battery in vehicle with positive terminal
BATTERY OFF--SEASON toward the front. Coat threads of battery bolt with
a corrosion resistant Nyogelt Grease (PN
STORAGE 2871329).
4. Route cables so they are tucked away in front and
To prevent battery damage during extended periods
behind battery.
of non-use, the following basic battery maintenance
items must be performed: 5. Connect battery cables.
GRemove the battery from the machine WARNING
and wash the case and battery tray
with a mild solution of baking soda To avoid the possibility of sparks and explosion,
and water. Rinse with lots of fresh connect positive (red) cable first and negative (black)
water after cleaning. cable last.
GUsing a wire brush or knife, remove any 6. After connecting the battery cables, install the
corrosion from the cables and cover on the battery and attach the hold down
terminals. strap.
10.35
ELECTRICAL
CONVENTIONAL BATTERY 5. Charge battery at 1/10 of its amp/hour rating.

Examples: 1/10 of 9 amp battery = .9 amp; 1/10
ACTIVATION/ SERVICE of 14 amp battery = 1.4 amp; 1/10 of 18 amp
battery = 1.8 amp (recommended charging
To ensure maximum service life and performance rates).
from a battery, perform the following steps. 6. Check specific gravity of each cell with a
NOTE: This section contains information for both hydrometer to assure each has a reading of 1.270
Conventional Lead--Acid batteries and Sealed Low or higher.
Maintenance batteries. Before service, identify the
battery type in the vehicle. Use the section that
applies to the battery. BATTERY
TERMINALS/TERMINAL BOLTS
WARNING Use Polaris corrosion resistant Nyogelt grease (PN
2871329) on battery bolts. See Battery Installation.
Battery electrolyte is poisonous. It contains

sulfuric acid. Serious burns can result from con- CONVENTIONAL BATTERY
tact with skin, eyes or clothing. Antidote:
External: Flush with water.
INSPECTION/REMOVAL
Internal: Drink large quantities of water or milk. The battery is located under the seat and right rear
Follow with milk of magnesia, beaten egg, or fender.
vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get Battery Location
prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc. away. Ventilate
when charging or using in an enclosed space.
Always shield eyes when working near batter-
ies. KEEP OUT OF REACH OF CHILDREN.
WARNING: The gases given off by a battery are

explosive. Any spark or open flame near a battery can
cause an explosion which will spray battery acid on
anyone close to it. Should there be contact with
battery acid, wash the affected area with large
quantities of cool water and seek immediate medical Inspect the battery fluid level. When the battery fluid
attention. nears the lower level, remove the battery and fill with
NOTE: New Battery: Battery must be fully charged distilled water only to the upper level line. To remove
before use or battery life will be significantly reduced the battery:
10-30% of the battery’s full potential.
To activate a new battery:
1. Remove vent plug from vent fitting. Remove cell
caps.
2. Fill battery with electrolyte to upper level marks on Maintain
case. between upper
3. Set battery aside to allow for acid absorption and and lower level
stabilization for 30 minutes. marks
4. Add electrolyte to bring level back to upper level
mark on case. NOTE: This is the last time that
electrolyte should be added. If the level becomes
low after this point, add only distilled water.
10.36
ELECTRICAL
1. Disconnect holder strap and remove covers. Following are three tests which can easily be made on
2. Disconnect battery negative (-) (black) cable first, a battery to determine its condition: OCV Test,
followed by the positive (+) (red) cable. Specific Gravity Test and Load Test.
CAUTION
CONVENTIONAL BATTERY
Whenever removing or reinstalling the battery,
disconnect the negative (black) cable first and OCV - OPEN CIRCUIT
reinstall the negative cable last!
VOLTAGE TEST
3. Remove the battery.
4. Remove the filler caps and add distilled water Battery voltage should be checked with a digital
only as needed to bring each cell to the proper multitester. Readings of 12.6 volts or less require
level. Do not overfill the battery. further battery testing and charging. See charts and
Load Test on below.
Refill using only distilled water. Tap water
contains minerals which are harmful to a battery. NOTE: Lead-acid batteries should be kept at or near
a full charge as possible. Electrolyte level should be
kept between the low and full marks. If the battery is
Do not allow cleaning solution or tap water inside stored or used in a partially charged condition, or with
the battery. Battery life may be reduced. low electrolyte levels, hard crystal sulfation will form
5. Reinstall the battery caps. on the plates, reducing the efficiency and service life
of the battery.
INSTALLATION
SPECIFIC GRAVITY TEST
1. Clean battery cables and terminals with a stiff wire
brush. Corrosion can be removed using a solution A tool such as a Battery Hydrometer (PN 2870836)
of one cup water and one tablespoon baking soda. can be used to measure electrolyte strength or
Rinse well with clean water and dry thoroughly. specific gravity. As the battery goes through the
2. Route the cables correctly. charge/discharge cycle, the electrolyte goes from a
heavy (more acidic) state at full charge to a light (more
3. Reinstall battery, attaching positive (+) (red) cable
water) state when discharged. The hydrometer can
first and then the negative (-) (black) cable. Coat
measure state of charge and differences between
terminals and bolt threads with Nyogelt Grease
cells in a multi-cell battery. Readings of 1.270 or
(PN 2871329).
greater should be observed in a fully charged battery.
4. Install clear battery vent tube from vehicle to battery Differences of more than .025 between the lowest and
vent. WARNING: Vent tube must be free from highest cell readings indicate a need to replace the
obstructions and kinks and securely installed. If not, battery.
battery gases could accumulate and cause an
explosion. The vent tube should be routed away
from frame and body to prevent contact with
electrolyte. Avoid skin contact with electrolyte, as
severe burns could result. If electrolyte contacts the
vehicle frame, corrosion will occur. Battery Hydrometer (PN 2870836)
5. Reinstall the holder strap.
1.10
1.15
CONVENTIONAL BATTERY Detail A
1.20
TESTING 1.25
1.30
Whenever a service complaint is related to either the
starting or charging systems, the battery should be
checked first.
10.37
ELECTRICAL
OPEN CIRCUIT VOLTAGE CONVENTIONAL BATTERY

State of
charge
Conventional
Lead-acid
YuMicront
Type
OFF SEASON STORAGE
100% 12.60V 12.70V To prevent battery damage during extended periods
Charged 12.40V 12.50V of non-use, the following basic battery maintenance
75% Charged 12.10V 12.20V items must be performed:
50% Charged 11.90V 12.0V GRemove the battery from the machine
25% Charged less than less than 11.9V and wash the case and battery tray
0% Charged 11.80V with a mild solution of baking soda
and water. Rinse with lots of fresh
SPECIFIC GRAVITY water after cleaning. NOTE: Do not
State of Conventional YuMicront get any of the baking soda into the
charge* lead-acid Type battery or the acid will be neutralized.
100% 1.265 1.275 GUsing a wire brush or knife, remove any
Charged 1.210 1.225 corrosion from the cables and
75% Charged 1.160 1.175 terminals.
50% Charged 1.120 1.135 GMake sure that the electrolyte is at the
25% Charged less than 1.100 less than 1.115 proper level. Add distilled water if
0% Charged necessary.
* At 80_F GCharge at a rate no greater than 1/10 of
NOTE: Subtract .01 from the specific gravity reading at 40_ F. the battery’s amp/hr capacity until
the electrolyte’s specific gravity
CONVENTIONAL BATTERY reaches 1.270 or greater.
LOAD TEST GStore the battery either in the machine
with the cables disconnected, or
CAUTION: To prevent shock or component store in a cool place.
damage, remove spark plug high tension leads
and connect securely to engine ground before NOTE: Stored batteries lose their charge at the rate
proceeding. of 1% per day. Recharge to full capacity every 30 to
60 days during a non-use period. If the battery is
NOTE: This test can only be performed on machines stored during the winter months, electrolyte will freeze
with electric starters. This test cannot be performed
at higher temperatures as the battery discharges.
with an engine or starting system that is not working
properly. The chart below indicates freezing points by specific
gravity.
A battery may indicate a full charge condition in the OCV
test and the specific gravity test, but still may not have Electrolyte Freezing Points
the storage capacity necessary to properly function in
the electrical system. For this reason, a battery capacity Specific Gravity Freezing
or load test should be conducted whenever poor battery of Electrolyte Point
performance is encountered. To perform this test, hook 1.265 -75° F
a multitester to the battery in the same manner as was 1.225 -35° F
done in the OCV test. The reading should be 12.6 volts
or greater. Engage the starter and observe the battery 1.200 -17° F
voltage while cranking the engine. Continue the test for 1.150 +5° F
15 seconds. During cranking the observed voltage
1.100 +18° F
should not drop below 9.5 volts. If the beginning voltage
is 12.6 volts or higher and the cranking voltage drops 1.050 +27° F
below 9.5 volts during the test, replace the battery.
10.38
ELECTRICAL
CONVENTIONAL BATTERY HEADLIGHT LAMP

CHARGING PROCEDURE REPLACEMENT
1. Remove the battery from the ATV to prevent CAUTION: Do not service while headlight is hot.
damage from leaking or spilled acid during Serious burns may result. Protect lamp during install.
charging. Remove 3 screws
2. Charge the battery with a charging output no
larger than 1/10 of the battery’s amp/hr rating.
Charge as needed to raise the specific gravity to
1.270 or greater.
3. Install battery in vehicle with positive terminal
toward the front. Coat threads of battery bolt with
a corrosion resistant dielectric grease.
Dielectric Grease
(PN 2871329)
4. Connect battery cables.

WARNING
To avoid the possibility of explosion, connect positive Position Snap pins

(red) cable first and negative (black) cable last. knob in into tabs
5. After connecting the battery cables, install the slot and
cover on the battery and attach the hold down secure
strap. in lock-
ing tabs
6. Install clear battery vent tube from vehicle to
battery vent. WARNING: Vent tube must be free
from obstructions and kinks and securely Route
installed. If not, battery gases could accumulate Adjustment plug over
and cause an explosion. Vent should be routed Knob Stop handlebar
away from frame and body to prevent contact with
electrolyte. Avoid skin contact with electrolyte, as
severe burns could result. If electrolyte contacts
the vehicle frame, corrosion will occur.
7. Route cables so they are tucked away in front and 1. Remove three Phillips screws on the headlight pod.
behind battery. 2. Lift pod cover up.
3. Unplug headlamp from wiring harness.
4. Turn bulb connector housing counter clockwise and
remove.
5. Carefully remove headlamp bulb from housing.
6. Reverse procedure to install new headlamp bulb.
10.39
ELECTRICAL
LOWER HEADLAMP 1. From the rear of the taillight remove two screws
holding lens cover in place and remove lens
REMOVAL/INSTALLATION cover.
2. Remove lamp and replace it with recommended
Lower Headlamps lamp. Apply Nyogelt Grease (PN 2871329).
3. Test the taillight/brakelight to see it is working.
4. Reinstall the lens cover removed in step 1.
Turn Harness Assembly
BRAKE LIGHT SWITCH

Loosen 1. Remove the front cover.
Tighten
Headlamp
Adjustments
1. Turn the back of the headlight harness in a

counter--clockwise direction to loosen.
2. Pull the harness assembly out from the headlight Brake Lamp Switch
assembly.
3. Remove the headlamp and replace with a new
headlamp. 2. Disconnect wire harness from switch.
4. Install the new headlamp and harness assembly 3. Connect an ohmmeter across switch contacts.
into the headlight assembly. Turn the headlight Reading should be infinite (∞).
harness clockwise to secure the headlamp into
place. Brake Switch Locations: Un-
der front cover close to CDI
Lower Headlamp Adjustment box.
5. Loosen the nuts that secure the lower headlamps.
Adjust the headlamps as needed.
6. Tighten the nuts on the headlamps after
adjustment is made.
TAILLIGHT/BRAKELIGHT
LAMP REPLACEMENT
If the taillight/brakelight does not work the lamp may
need to be replaced. 4. Apply brake at handlebar lever and check for
continuity between switch contacts. Replace
switch if there is no continuity or greater than .5
ohms resistance when the brake is applied with
Lens Cover slight pressure.
Bulb
10.40
ELECTRICAL
HIGH BEAM HEADLIGHT Position Snap pins

knob in into tabs
ADJUSTMENT slot and
secure Slip O-Ring
in lock- over pin
25’ (7.6 m) ing tabs
Lamp Center Height Route

Adjustment plug over
Knob Stop handlebar
2″ (5.1 cm)
5. Carefully remove headlamp bulb from housing.

6. Reverse procedure to install new headlamp bulb.
7. Pull headlight housing up to release from locking
tabs.
The headlight beam can be adjusted to any position
desired by turning the adjusting knob located on the
Distance from head-
bottom right side of the headlight pod.
lamp parting line to end
1. Place the vehicle on a level surface with the of adjustment knob
headlight approximately 25’ (7.6 m) from a wall. stop is 5 1/8″ (13 cm).
2. Measure the distance from the floor to the center
of the headlight and make a mark on the wall at
the same height.
3. Start the engine and turn the headlight switch to
high beam.
4. Observe headlight aim. The most intense part of 5 1/8″
(13 cm)
the headlight beam should be aimed 2″ (5.1 cm)
below the mark placed on the wall in Step 2
NOTE: Rider weight must be included on the 8. Lift adjusting knob up to remove from locking
seat. On machines with separate low beam tabs.
lights, the drop should be 8″ (20.3 cm) in 25’ from 9. Carefully pull assembly up and out of pod.
the center of the low beam lamp.
10. Reverse steps to install new housing and
5. Adjust beam to desired position . reassemble pod.
11. Adjust headlight aim by turning adjusting knob.
HIGH BEAM HEADLIGHT
LAMP REPLACEMENT
CAUTION: Do not service while headlight is hot.
Serious burns may result.
1. Remove three Phillips screws from headlight pod.
2. Lift pod cover up.
3. Unplug headlamp from wiring harness.
4. Turn headlamp housing counter clockwise and
remove.
10.41
ELECTRICAL
HEADLAMP SWITCH STARTER SYSTEM

TROUBLESHOOTING
Starter Motor Does Not Turn
GBattery discharged - low specific gravity
GLoose or faulty battery cables or corroded
connections (see Voltage Drop Tests)
GRelated wiring loose, disconnected, or
corroded
GPoor ground connections at battery cable,
starter motor or starter solenoid (see
Voltage Drop Tests)
GFaulty starter button
GFaulty ignition switch (Do other systems
function?)
GFaulty starter solenoid or starter motor.
Remove the headlight pod cover. Probe the high
GEngine problem - seized or binding (Can
beam headlamp plug wires (Brown and Yellow) at
engine be rotated easily with recoil
back of connector. Probe the low beam headlamp
starter?)
plug wires (Brown and Green). Turn headlight on.
Test for battery voltage across the connections. Starter Motor Turns Over Slowly
GBattery discharged - low specific gravity
GExcessive circuit resistance - poor
connections (see Voltage Drop Test
below)
GEngine problem - seized or binding (Can
Brown Yellow Green engine be rotated easily with recoil
(High) (Low) starter?)
Headlamp Plug Wires GFaulty or worn brushes in starter motor
GAutomatic compression release inoperative
Starter Motor Turns - Engine Does Not Rotate
GFaulty starter drive
GFaulty starter drive gears or starter motor
gear
GFaulty flywheel gear or loose flywheel
10.42
ELECTRICAL
VOLTAGE DROP TEST 2. Remove the two bolts, washers, and sealing
O-Rings. Inspect O-Rings and replace if damaged.
The Voltage Drop Test is used to test for bad
connections. When performing the test, you are
testing the amount of voltage drop through the
connection. A poor or corroded connection will
appear as a high voltage reading. Voltage shown on
the meter when testing connections should not
exceed .1 VDC per connection or component.
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 on next page to perform
voltage drop tests on the starter system.
Voltage should not exceed:

.1 DC volts per connection
3. Remove brush terminal end of housing while

holding other two sections together.
STARTER MOTOR
DISASSEMBLY
NOTE: Use only electrical contact cleaner to clean
starter motor parts. Some solvents may leave a
residue or damage internal parts and insulation.
1. Note the alignment marks on both ends of the
starter motor casing. These marks must align
during reassembly.
4. Remove shims from armature shaft. NOTE: All

shims must be replaced during reassembly.
10.43
ELECTRICAL
BRUSH 4. Inspect surface of commutator for wear or

discoloration. See Steps 3-6 of armature testing
INSPECTION/REPLACEMENT on Page 10.44.
5. Install a new carbon brush assembly in the brush
housing. NOTE: Be sure that the terminal bolt
insulating washer is properly seated in the
Brush Set
housing, and the tab on the brush plate engages
the notch in the brush plate housing.
6. Place a wrap of electrical tape on the threads of
the terminal bolt to prevent O-Ring damage
during reinstallation.
7. Install the O-Ring over the bolt. Make sure the
O-ring is fully seated.
1. Using a digital multitester, measure the

resistance between the cable terminal and the
insulated brush. The reading should be .3 ohms
or less. Measure the resistance between the
cable terminal and brush housing. Make sure the
brush is not touching the case. The reading
should be infinite.
2. Remove nut, flat washer, large phenolic washer,
two small phenolic washers, and O-Ring from
brush terminal. Inspect the O-Ring and replace if
damaged.
8. Remove the electrical tape and reinstall the two
Brush Length small phenolic washers, the large phenolic
washer, flat washer, and nut.
ARMATURE TESTING
1. Remove armature from starter casing. Note
5/16″ (.8 cm) order of shims on drive end for reassembly.
2. Inspect surface of commutator. Replace if
excessively worn or damaged.
Brush Length Service Limit:

5/16″ (.8 cm)
3. Remove brush plate and brushes. Measure

length of brushes and replace if worn past the
service limit. Replace springs if they are
discolored or have inadequate tension.
10.44
ELECTRICAL
3. Using a digital multitester, measure the 2. Place shims on drive end of armature shaft with
resistance between each of the commutator phenolic washer outermost on shaft. Engage
segments. The reading should be .3 ohms or tabs of stationary washer in drive end housing,
less. holding it in place with a light film of grease.
3. Install case sealing O-Ring. Make sure O-Ring is
in good condition and not twisted on the case.
Lubricate needle bearing and oil seal with a light
film of grease, and install housing, aligning marks.
4. Install O-Ring on other end of field magnet casing.
Make sure it is in good condition and not twisted
on the case.
5. Align casing marks and install housing, pushing
back brushes while installing shaft in bushing.
6. Reinstall starter motor housing bolts.
Make sure O-Rings are in good condition and
seated in groove.
7. Inspect permanent magnets in starter housing.
Make sure they are not cracked or separated from
housing.
4. Measure the resistance between each
commutator segment and the armature shaft. CAUTION: Use care when handling starter housing.
The reading should be infinite (no continuity). Do not drop or strike the housing as magnet damage
is possible. If magnets are damaged, starter must be
5. Check commutator bars for discoloration. Bars replaced.
discolored in pairs indicate shorted coils,
requiring replacement of the starter motor.
6. Place armature in a growler. Turn growler on and NOTES
position a hacksaw blade or feeler gauge
lengthwise 1/8″ (.3 cm) above armature coil
laminates. Rotate armature 360°. If hacksaw
blade is drawn to armature on any pole, the
armature is shorted and must be replaced.
STARTER ASSEMBLY
1. Place armature in field magnet casing.
10.45
ELECTRICAL
STARTER DRIVE 2. Remove the lock ring, end washer, spring

retainers and clutch return spring. Screw the
Pinion Gear - Anti Kick-out Shoe, Garter overrun clutch off the end of the pinion shaft.
Spring Replacement Remove the old spring and install a new one.
Lightly grease the pinion shaft and reinstall the
If the garter spring is damaged, the overrun clutch clutch, spring, retainers, end washer and lock ring
may fail to return properly. The replacement spring is in the reverse order. Make sure the end washer is
(PN 7042039). Use either of the following methods to positioned properly so that it will hold the lock ring
remove and install a new garter spring. in its groove.
Starter Motor Exploded View

Polaris Premium Starter Drive Grease
Rear Brkt Assy
Carbon
Washer Set Brush (PN 2871460)
Set
Armature NOTES
Rubber Rings
Washer
O-ring
Set Bolt Assy
Weight Spring
Return 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.
10.46
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
lead on the battery positive. Remove battery and properly service.
Install fully charged shop battery to continue
No test.
Reading should be 12.4 V D. C. or greater.
Yes
Check voltage on both sides of circuit

Disconnect coil engagement wire from the starter breaker, ignition switch/engine stop switch
solenoid. Connect tester black wire to battery and starter button. The voltage on both
ground. Connect red tester lead to harness wire at sides should be the same. NOTE: The igni-
solenoid. Turn on ignition switch and depress the tion switch and engine stop switch must be
starter button. Tester should read battery voltage.
No
on and the starter button depressed. Re-
place component if failed .
Test starter solenoid coil by connecting an ohmmeter between the solenoid

wire and the solenoid mounting plate. Resistance should be 3.4Ω. Check
Yes solenoid ground path by measuring resistance between mounting plate and
Voltage Drop Testing battery negative terminal (-).
See Page 10.24 for instructions.
Reconnect the solenoid. Connect the tester black

lead to the battery positive and the red lead to the Clean the battery-to-solenoid cable ends or
solenoid end of the battery-to-solenoid wire. De- No replace the cable.
press starter button. Reading should be less than
.1 V D.C.
Yes
Connect the black tester lead to solenoid end of

battery-to-solenoid cable. Connect red tester lead
to solenoid end of solenoid-to-starter cable. De- No Replace the starter solenoid.
press starter button. Reading should be less than
.1 V D.C.
Yes
Connect the black tester lead to the solenoid end of

the solenoid-to-starter cable. Connect the red tester Clean the solenoid-to-starter cable ends or
lead to the starter end of the same cable. Depress No replace the cable.
the starter button. The reading should be less than
.1 V D.C.
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.
10.47
ELECTRICAL
NOTES
10.48
ELECTRICAL
WIRING DIAGRAM 2004 SPORTSMAN 6X6

ELECTRICAL
WIRING DIAGRAM 2004 SPORTSMAN 6X6

NOTES:
ELECTRICAL
WIRING DIAGRAM 2005 SPORTSMAN 6X6 (BUILT BEFORE JULY 12, 2004)
ELECTRICAL
WIRING DIAGRAM 2005 SPORTSMAN 6X6 (BUILT BEFORE JULY 12, 2004)
NOTES:
ELECTRICAL
WIRING DIAGRAM 2005 SPORTSMAN 6X6 (BUILT AFTER JULY 12, 2004)
ELECTRICAL
WIRING DIAGRAM 2005 SPORTSMAN 6X6 (BUILT AFTER JULY 12, 2004)
NOTES:
Index Brake Hose/Fitting Inspection, 2.33
Brake Light Switch Testing, 10.40
Specifications, 1.5
Brake Noise, 9.3
Specifications, 1.4 Brake Pad Application, 9.3
Brake Pad Assembly, Front, 9.11
A Brake Pad Inspection, 2.33
Brake Pad Installation, Rear, 9.18
A-Arm Replacement, 1.8
Brake Pad Removal, Front, 9.10
Air Filter Service, 2.22
Brake Pad Removal, Rear, 9.17
Alternator Output Test, 10.31
Brake System Inspection, 2.32
AWD Armature Plate Inspection, 7.8
Brake System Main Components, 9.6
AWD Magnetic Coil Installation, 7.7
Brake System Operation, 9.4
AWD Magnetic Coil Removal, 7.6
Brake System Service Notes, 9.3
AWD Operation, 7.2
Brake, Auxiliary, Hydraulic, 2.33
Brake, Auxiliary, Testing, 2.33
B Brakelight Lamp Replacement, 10.40
Breather Filter Maintenance, 2.24
Battery Charging, 10.33, 10.35, 10.39
Breather Hose Inspection, 2.24
Battery Check Before Install, 10.33
Battery Installation, 10.34, 10.37
Battery Maintenance, 2.19, 10.33 C
Battery Service, 10.32, 10.34, 10.35, 10.36, Cam Chain Drive Sprocket Installation, 3.43
10.37, 10.38
Cam Chain Tensioner Inspection, 3.15
Battery Terminal Bolts, 10.36
Cam Chain Tensioner Installation, 3.49
Battery Testing, 10.34, 10.37
Cam Chain Tensioner Removal, 3.14
Battery, Off Season Storage, 10.35, 10.38
Cam Chain/Camshaft Installation, 3.46
Body Assembly Exploded View, 1.4
Cam Chain/Tensioner Blade, 3.32
Brake Bleeding, 9.7 Camber & Caster, 2.29
Brake Bleeding/Fluid Change, 9.13 Camshaft Inspection, 3.18
Brake Caliper Assembly, Rear, 9.19 Camshaft Removal, 3.16
Brake Caliper Disassembly, Front, 9.14 Camshaft Timing, 3.46, 3.48
Brake Caliper Inspection, Front, 9.15 Carburetor Assembly, 4.9
Brake Caliper Installation, Front, 9.17 Carburetor Disassembly, 4.7
Brake Caliper Removal, Front, 9.14 Carburetor Exploded View, BST34, 4.2
Brake Caliper Removal, Rear, 9.18 Carburetor Float Bowl Draining, 2.18
Brake Disc Inspection, Front, 9.13 Carburetor Float Height Adjustment, 4.10
Brake Disc Inspection, Rear, 9.20 Carburetor Float System, 4.7
Brake Disc Removal/Replacement, Front, 9.13 Carburetor Fuel Level Testing, 4.11
Brake Fluid Change, 9.7 Carburetor Inspection, 4.8, 4.9
Brake Fluid Level, 2.32 Carburetor Main System, 4.7
Carburetor Needle and Seat Testing, 4.10 Counter Balancer Installation, 3.41
Carburetor Operation, 4.5 Counter Balancer Shaft End Play, 3.40
Carburetor Pilot System, 2.16, 4.6 Counter Balancer Shaft Removal/Inspection, 3.35
Carburetor Starter System, 4.6 Cover/Panel Removal, 1.2
Carburetor System Function, 4.5 Crankcase Assembly, 3.41
CDI Output Test, 10.30 Crankcase Bearing Inspection, 3.37
Chain Adjustment -- Middle Axle, 2.34 Crankcase Bearing Installation, 3.38
Chain Adjustment -- 6x6 Rear Axle, 2.34 Crankcase Disassembly, 3.31
Charging System Break Even Test, 10.31 Crankcase Inspection, 3.37
Charging System Testing, 10.29 Crankcase Installation, 3.41
Choke Adjustment, 2.15 Crankcase Separation, 3.33
Clutch Alignment, 6.15 Cranking Output Test, 10.30
Clutch Offset, 6.16 Crankshaft End Play Adjustment, 3.38
Cold Weather Kits, 2.6 Crankshaft Removal/Inspection, 3.36
Combustion Chamber, 3.23 Crankshaft Straightening, 3.10
Compression Release Removal/Inspection, 3.17, Current Draw, 10.30
3.18 CV Joint Handling Tips, 7.10
Compression Test, 2.19 CV Shaft Boot, Inspection, 2.35
Concentric Swing Arm Installation, 1.10 Cylinder Cleaning, 3.9
Concentric Swing Arm Removal, 1.9 Cylinder Head Assembly, 3.26
Concentric Swingarm Middle Axle Assembly, 7.23 Cylinder Head Disassembly, 3.21
Concentric Swingarm Middle Axle Assembly, Ex- Cylinder Head Inspection, 3.21
ploded View, 7.26
Cylinder Head Installation, 3.46
Concentric Swingarm Middle Axle Disassembly,
7.22 Cylinder Head Reconditioning, 3.23
Concentric Swingarm Middle Axle Installation, Cylinder Head Removal, 3.19, 3.20
7.24 Cylinder Head Warpage, 3.21
Concentric Swingarm Middle Axle Removal, 7.21 Cylinder Honing, 3.9
Concentric Swingarm Middle Housing Removal, Cylinder Inspection, 3.29
7.27
Cylinder Installation, 3.45
Controls Inspection, 2.36
Cylinder Removal/Inspection, 3.27
Conversion Table, 1.15
Coolant Level Inspection , 2.22
Coolant Strength, 2.21 D
Coolant Temperature Sensor, Late 2004, 10.24 Decal Replacement, 1.15
Cooling System Hoses, 2.21 Decimal Equivalents, 1.14
Cooling System Overview , 2.21 Diagnostic Mode, 2004 Model, 10.6
Cooling System Pressure Test, 3.7 Diagnostic Mode, 2005 Model, 10.15
Cooling System Test, 2.21 Diagnostic Mode, Service Interval, 2005 Model,
10.16
Cooling System, 4--Stroke Bleeding Procedure,
3.6 Draining Recoil Housing, 2.24
Drive Belt Removal/Inspection, 6.14 ETC Operation Test, 10.25
Drive Belt Tension, 6.13 ETC Switch Adjustment, 2.17
Drive Chain Inspection/Adjustment, 2.34 ETC Switch Testing, 10.25
Drive Clutch Assembly, 6.12 Exhaust System, Maintenance, 2.32
Drive Clutch Bushing Service, 6.16, 6.18, 6.19 Exhaust Valve Adjustment, 2.28, 3.27
Drive Clutch Disassembly, 6.11, 6.12
Drive Clutch Exploded View, 6.7 F
Drive Clutch Inspection, 6.10
Fan Control Switch Testing, 10.25
Drive Clutch Operation, 6.2 Fan Motor Current Draw Test, 10.24
Drive Shaft Boot Replacement, 7.10 ECM (Logic Box) Operation, 10.3
Driven Clutch Assembly, 6.21 Flywheel Identification, 10.26
Driven Clutch Bushing Service, 6.22, 6.23 Flywheel Installation, 3.49
Driven Clutch Disassembly, 6.19 Flywheel Removal/Inspection, 3.32
Driven Clutch Operation, 6.2, 6.3 Frame, Nuts, Bolts, Fasteners, 2.29
Dual Hydraulic Caliper Bleeding, 9.5 Front Axle Installation, 7.9
Dump Box Exploded View, 1.3 Front Axle Removal, 7.8
Front Axle Seal Sleeve Replacement, 7.13
Front Drive Axle Exploded View, 7.12
E Front Hub Bearing Adjustment, AWD, 7.4
Electrical Service Notes, 10.2 Front Hub Disassembly, 7.3
Electrical Special tools, 10.2 Front Hub Exploded View, AWD, 7.5
Engine Accessible Components, 3.8 Front Hub Fluid Change, 2.31
Engine Assembly, 3.37, 3.38, 3.40, 3.41, 3.42, Front Hub Fluid Level Inspection, 2.31
3.43, 3.44, 3.45, 3.46, 3.48, 3.49, 3.50 Front Hub Seal Replacement, AWD, 7.6
Engine Bottom End Disassembly, 3.27, 3.28, Front Hub/Wheel Bearing Installation, 7.3
3.29, 3.30, 3.31, 3.32, 3.33, 3.34, 3.35, 3.36,
3.37 Front Prop Shaft Removal, 7.14
Engine Break in Period, 3.9 Front Strut Assembly, 1.13
Engine Designation Numbers, 1.2 Front Strut Ball Joint Replacement, 1.14
Engine Exploded View, 3.13 Front Strut Weldment Replacement, 1.14
Engine Fastener Torque Patterns, 3.5 Fuel Filter Maintenance, 2.18

Fuel Pump Exploded View, 4.12
Engine Installation Notes, 3.8
Fuel Pump Service, 4.11
Engine Lubrication, 3.10
Fuel Tank Assembly, Exploded View, 4.3
Engine Mounts, 2.19
Engine Removal, 3.8
Engine Serial Number Location, 1.2 G
Engine Service Data, 3.3, 3.4 Gear Circuit Readings, Instrument Cluster, 2005
Engine to Frame Ground, 2.20 Model, 10.16
Gear Position Switch Test, 10.4
Engine Top End Disassembly, 3.14, 3.15, 3.16,
3.17, 3.18, 3.19, 3.20, 3.21, 3.22 Gear Shift Boot Replacement, 8.4
Gear Shift Selector Assembly, 8.3
J
Gear Shift Selector Disassembly, 8.2
Jetting Guidelines, 4.4
Gear Shift Selector Installation, 8.4
Gear Shift Selector Removal, 8.2
Gearcase Assembly, Front, 7.17 K
Gearcase Disassembly, Front, 7.16, 7.17 Keys, Replacement, 1.6
Gearcase Exploded View, Front, 7.20
Gearcase Installation, Front, 7.19
L
Gearcase Lubrication, Front, 2.13
Load Test, 10.35, 10.38
Gearcase Removal, Front, 7.16
Lubricant Symbol I.D. Chart, 2.7
Glossary of Terms, 1.16
Lubricants, 2.7
Lubricants, Recommended, 2.6
H Lubrication Chart, 2.11
Headlamp Service, 10.40, 10.41 Lubrication Charts, 2.9, 2.10
Headlamp Switch Testing, 10.42 Lubrication, Transmission, 2.12, 8.2
Headlight Adjustment, 10.41

High Engine Coolant Temperature, 2004 Model, M
10.5
MAINTENANCE AND LUBRICATION, 2.3, 2.4,
High Engine Coolant Temperature, 2005 Model, 2.5
10.14
Master Cylinder Disassembly, 9.9
High/Low Battery Voltage, 2004 Model, 10.5
Master Cylinder Installation, 9.9
High/Low Battery Voltage, 2005 Model, 10.15
Middle Housing Bearing Service, 7.27
Hilliard Clutch Disassembly/Inspection, 7.7
Middle Housing Disassembly, 7.27
Honing to Oversize, 3.9
Middle Housing Installation, 7.28
Hour Meter, 2004 Model, 10.5
Model & Serial Number Location, 1.2
Model Identification, 1.2
I
Idle Speed Adjustment, 2.15 O
Ignition System Components, 10.27 Odometer, Tachometer,Trip Meter, 2005 Model,
Ignition System Testing, 10.28 10.14
Ignition Timing Curve, 10.2 Oil Check , Engine, 2.25
Instrument Cluster Installation, 10.23 Oil Filter Change, 2.25
Instrument Cluster Overview, 2005 Model, 10.14 Oil Flow, 3.11, 3.12
Instrument Cluster Removal, 10.23 Oil Pipes, 3.51
Instrument Cluster/Speedometer ID, 10.5 Oil Pressure Test, 3.11
Instrument Cluster Troubleshooting, 2004 Models, Oil Pump Assembly, 3.35

10.5 Oil Pump Installation, 3.41
Intake Valve Adjustment, 2.28 Oil Pump Priming, 3.11
Oil Pump Priming--Magnum 500, 2.27 Rear Axle Bend, 7.29
Oil Pump Removal/Inspection, 3.34 Rear Axle Installation, 7.28
Oil Pump Shaft End Play, 3.40 Rear Axle Removal, 7.28
One Way Valve, 3.33 Rear Drive Axle, Exploded View, 7.29
One Way Valve Installation, 3.43 Rear Strut Stabilizer, 1.11
Optional Springs, 1.6 Rear Swing Arm Weldment, 1.12
Recoil Assembly, 3.52
Recoil Disassembly/Inspection, 3.51
P Recoil Draining, 2.24
Paint Codes, 1.6 Rocker Arm/Shaft Inspection, 3.15, 3.16
Periodic Maintenance Chart, 2.3, 2.4, 2.5 Rocker Shaft/Arm Assembly Installation, 3.50
Pilot Screw Adjustment, 2.16 Troubleshooting, Transmission, 8.10
Piston Identification, 3.5
Piston Installation, 3.44 S
Piston Removal, 3.28
Sediment Tube, Maintenance, 2.24
Piston Ring Installation, 3.44
Shift Linkage Adjustment, 2.14
Piston Ring Installed Gap, 3.31
Shift Weights, 6.9
Piston to Cylinder Clearance, 3.30
Side Panel Removal, 1.6
Piston/Rod Inspection, 3.30
Spark Plug Maintenance, 2.20
Pre-Ride Inspection, 2.6 Special Tools, 1.7, 1.8, 3.5, 4.4, 6.2, 7.2, 8.2, 9.3
Programmable Service Interval, 2004 Model, Specifications, 1.3
10.5, 10.6
Specifications, Brake, 9.2
Programmable Service Interval, Diagnostic Mode,
Intl. Models, 10.14 Specifications, Cooling System, 3.7
Publication Numbers, 1.6 Specifications, Drive Clutch Spring, 6.8
Pump Shaft Oil Seal Installation, 3.41 Specifications, Torque, Brakes, 9.2
PVT Assembly, 6.6 Specifications, Torque, Engine, 3.2
PVT Disassembly, 6.5 Specifications, Torque, Final Drive, 7.2
PVT Drying, 6.3 Specifications, Torque, PVT, 6.2

Specifications, Torque, Standard, 1.13
PVT Maintenance, 6.3
Specifications, Torque, Suspension, 1.2
PVT Operation, 6.2
Specifications, Torque, Transmission, 8.2
PVT Overheating, 6.4
Speedometer Troubleshooting, 2004 Models,
PVT System Sealing/Ducting Components, 6.7 10.8, 10.9, 10.10, 10.11, 10.12, 10.13
PVT Troubleshooting, 6.25, 6.26 Speedometer Troubleshooting, 2005 Model,
10.18, 10.19, 10.20, 10.21, 10.22
Speedometer/Odometer, 2004 Model, 10.5
R Spider Removal, 6.11
Radiator Cap Pressure Test, 3.7 Starter Assembly, 10.45
Radiator Coolant Level Inspection, 2.22 Starter Disassembly, 10.43
Radiator, Maintenance, 2.21 Starter Drive, 10.46
Starter Drive Installation, 3.50 Transmission Removal, 8.5
Starter Drive Removal/Inspection, 3.31 Troubleshooting, Brakes, 9.20
Starter Motor Armature Testing, 10.44 Troubleshooting, Cooling System, 3.54
Starter Motor Brush Inspection/Replacement, Troubleshooting, Engine, 3.53
10.44
Troubleshooting, Fuel System/Carb, 4.13
Starter System Test, 10.47
Troubleshooting, Ignition System, 10.30
Stator Installation, 3.49
Troubleshooting, Spark Plug, 3.53
Stator Removal/Inspection, 3.32
Troubleshooting, Starter System, 10.42
Steering Assembly, Exploded View, 1.7
Steering Maintenance, 2.28
Steering Post Assembly, 1.15
U
Strut Casting Seal Replacement, 7.13 U--Joint Assembly, 7.15
Suspension Preload Adjustment, 2.35 U--Joint Disassembly, 7.15
Suspension Special Tools, 1.2
Suspension, Front, Inspection, 2.35
V
Suspension, Rear, Inspection, 2.35
Valve Clearance, 2.27
Valve Guide Removal/Installation, 3.23
T Valve Inspection, 3.22
Taillight Lamp Replacement, 10.40 Valve Seal Testing, 3.26
Tap Drill Chart, 1.14 Valve Seat Inspection, 3.23
Tensioner Blade Installation, 3.44 Valve Seat Reconditioning, 3.23
Thermostat Installation, 3.50 Vent Line Maintenance, 2.18
Throttle Cable Adjustment, 2.17 VIN Identification, 1.2
Throttle Operation, 2.15 Voltage Drop Test, 10.43
Tie Rod Inspection, 2.29 Voltage Test Open Circuit, 10.34, 10.37
Timing Check Procedure, 10.2
Tire Inspection, 2.37
W
Tire Pressure, 2.37
Warning Indications for Rider Information Center,
Tire Tread Depth, 2.37
2004 Model, 10.6
Toe Alignment, 2.30
Water Pump Mechanical Seal Installation, 3.42
Torque Patterns, Engine, 3.5
Water Pump Mechanical Seal Removal, 3.37
Transmission Assembly, 8.7
Water Pump Mechanical Seal Removal, Engine
Transmission Disassembly, 8.5 Installed, 3.42
Transmission Exploded View, 8.9 Water Pump Shaft Oil Seal, 3.37
Transmission I.D. Location, 1.2 Wheel Inspection, 2.36
Transmission Installation, 8.5 Wheel Installation, 2.36
Transmission Linkage Adjustment, 2.13 Wheel Removal Front or Rear, 2.36
31504
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SPORTSMAN

2004--2005 Sportsman 6x6 ATV Service Manual (PN 9919504)

Polaris acknowledges the following products mentioned in this manual:

FLEXLOC, Registered Trademark of SPS Technologies

BODY AND STEERING

Model Identification . . . . . . . . . . . . . . . . . . . . . . . 1.2

Machine Model Number Identification

ENGINE DESIGNATION NUMBERS

Body Style Emissions Model * This could be either

ENGINE SERIAL NUMBER LOCATION

MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION

TRANSMISSION I.D. NUMBER

MODEL: . . . . . . . . . . Sportsman 500 6x6

2004 SPORTSMAN 6X6

MODEL: . . . . . . . . . . 2004 SPORTSMAN 500 6x6

Exhaust System Single Pipe Front Travel 6.7 in. / 17.02 cm

Ignition Timing 30° ± 2° BTDC @ 5000 RPM above 1800

MODEL: . . . . . . . . . . 2005 SPORTSMAN 500 6x6

Exhaust System Single Pipe Front Travel 6.7 in. / 17.02 cm

Ignition Timing 30° ± 2° BTDC @ 5000 RPM above 1800

NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com

ACCESSORY ENGINE HEATER

Standard Tools and Engine Tools

2870569 -- Crankshaft True Kit

2870386 -- Piston Pin Puller

2871445 -- Piston Pin Puller Adapter

2871043 -- Flywheel Puller 2870968 -- Counter Balance Puller

2870773 -- C--Clip Install Tool

2870967 -- Slotted Nut Socket

2870390 -- Piston Support Block

Standard Tools and Engine Tools

2870303 -- Hone Kit 2871283 -- Crank/Water Pump Seal

2870305 -- Stone Replacement Kit

2870588 -- Hone Oil (12 oz.) 2870913 -- Driven Clutch Puller

2200634 -- Valve Seat

2870459 -- Dial Indicator

9914177--A -- Drive Clutch Holding Tool

2872105 -- Water Pump Seal Puller 8700220 -- Clutch Compression Tool

Clutch (PVT) Tools Suspension Tools

2870341 -- Drive Clutch Spider

2870871 -- ATV Ball Joint Tool Kit

2870910 -- Roll Pin Tool

2871025 -- Clutch Bushing Replace 2871071 -- Shock Body Holding Tool

2871226 -- Clutch Bushing

2871572 -- Strut Rod Wrench

2870338 -- Spider Nut Socket

8700225 & 8700226 -- CV Boot

Suspension Tools Fuel & Brake Systems

2870872 -- Shock Spanner Wrench

2872608 -- Roll Pin Removal Tool 2870975 -- Mity Vac

2871351 -- Shock IFP Depth Tool

PV--43568 --Fluke 77 Multimeter

2870772 -- 1.75” Wrench

PV--39617 -- Current Clamp

2871702 -- Shaft Drive Transmission

2870630 -- Timing Light

2871745 --Static Timing Light Harness

2460761 -- Hall Sensor Probe Harness

PV--39991 -- Peak Reading Adapter

SPORTSMAN