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Polaris 9919820 User's Manual

1.
2. 10 39 d mE BATTERY SPEEDO DIAGNOSTIC ACCESSORES lt 2005 SPORTSMAN EFI Stator Poo re DIAONOSTIC HOLDER LOCATED INSIDE POD SWITCHED POWER l 05 5 RECTIFIER RIGHT END LOW O FRONT CRANKSHAFT sero WORK n 1 n PAGE 1 OF 2
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4. 10 34 Accessory Wire Connections 10 35 Winch Wiring Diagram 10 36 Starter System Troubleshooting 10 37 Starter Motor Service 10 37 10 43 POLARIS 10 1 ELECTRICAL CRANKSHAFT POSITION SENSOR GAP Measure trigger coil gap with a feeler gauge The gap should be 059 inch 1 0 mm Crankshaft Position Sensor 9 Crankshaft Position Sensor Gap 059 010 inch 1 0 26mm 10 2 GEAR POSITION INDICATOR SWITCH TEST NOTE Also see INSTRUMENT CLUSTER TROUBLESHOOTING for gear switch re sistance TRANSMISSION SWITCH High Low Neutral Reverse Park Switch High Range Low Range Neutral Reverse Park Green White Brown Red Purple White Blue Orange Red Red E ED F E D CB A p D PARK POLARIS INSTRUMENT CLUSTER OVERVIEW jp 70 Trip PESL ARIS Introduction Refer to Illustration 1 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 right front wheel speed sensor and one from the vehicle main harness
5. 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 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 seat On machines with separate low beam lights the drop should be 8 20 3 cm in 25 from the center of the low beam lamp 5 Adjust beam to desired position POLARIS ELECTRICAL LOWER HEADLAMP REMOVAL INSTALLATION 1 Turn the back of the headllamp harness in counter clockwise direction to loosen 2 Pull the harness assembly out from the headlight assembly 3 Remove the lamp and replace with a new headlamp NOTE Do not touch the new lamp with bare fingers Hold the plastic part 1 of the lamp Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp 4 Install the harness assembly into the headlight assembly Turn the headlight harness clockwise to secure the headlamp into place 10 31 ELECTRICAL Lower Headlamp Housing Removal if required 5 Remove the screw that secures the lower headlamp 6 Pull the headlamp out of the locking tab LOW BEAM HEADLIGHT ADJUSTMENT 1 Thelow beam can be adjusted slightly upward or downward Loosen Screw Ld E T
6. 3 10 AE Engine Fastener Torque Patterns 3 11 et m Engine Service Data 3 12 3 14 Cooling System Specifications 3 15 Cooling System Test 3 15 Engine Removal Installation 3 16 3 17 Engine Installation Notes 3 17 3 18 Cylinder Honing 3 19 Oil F OW osse eir 3 20 Rocker Arm Pushrod Inspection 3 21 Cylinder Head Disassembly Inspection 3 21 3 23 Valve Inspection 3 24 Combustion Chamber 3 25 Valve Seat 0 3 25 3 27 Cylinder Head Assembly 3 27 Valve Sealing Test 3 28 Valve Train Exploded View 3 28 Engine Head Reassembly 3 29 3 30 Cylinder Removal 3 31 Valve Lifter Removal Inspection 3 31 Piston Removal gt us cassis ER sata D t ed 3 31 3 32 Cylinder Inspection 3 32 3 33 Piston Rod Ring Service 3 33 3 35 Starter Bendix Removal Inspection 3 36 Flywheel Stator Removal Inspection 3 37 Flywheel Stator Installation 3 37 3 38 Engine Crankcase Disassembly Inspection 3 38 3 46 Camshaft Inspection 3 47 Engi
7. BODY STEERING SUSPENSION the groove in the rack then press in the bottom of the cover until the notches snap into place SHE c Unuor Might Fonder M 7 Remove the front headlights C or simply disconnect the electric connector D before removing the front plasti Winch Installation Area 6 Remove the front cover piece by lifting up on sides of the two locking tabs as shown Pull the tabs out of the notches and lift up on the cover piece 8 Remove the remaining bolts and screws that secure the front bumper section to the frame To install the front cover place top lip of the cover into POLARIS 5 6 BODY STEERING SUSPENSION FRONT STORAGE INSTALLATION Front Storage REAR RACK REMOVAL INSTALLATION _ T 25 Screw Front Cab 14 ft lbs 19 Nm 10 in Ibs 1 13 Nm 10 in lbs 1 13 Nm D 24 in lbs 2 7 Nm 1 Place the front storage rack onto the frame 2 Install the four bolts A into the inside of the compartment hand tight T 27 Screw A 36 in lbs 4 Nm 3 Install the four screws and washers B T 25 B 18 in lbs 2 Nm under the fender area 2 each side 1 Remove the six A T27 screws and two bolts B that secure the rear rack to the rear cab and frame 2 Liftthe rear rack from the ATV Remove the two rack spacers C 4 Install the four screws C T 25 into the front
8. 4 14 Replacement 4 15 TPS Initialization 4 15 4 16 Engine Temperature Sensor 4 16 Test Refer to Diagnostic Software 4 16 Replacement 4 16 Diagnostics using Blink Codes 4 17 Troubleshooting 4 18 POLARIS 4 1 FUEL SYSTEM FUEL INJECTION SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION PU 47063 Polaris EFI Diagnostic Software Fuel Pressure Test Kit PU 47082 Throttle Position Sensor Tester Fuel Pressure Sender PU 43506 IMPORTANT The EFI fuel system remains under high pressure even when the engine is not running Before attempting to service any part of the fuel system the pressure must be relieved The pressure adapter has an integrated relief valve Connect to the test valve and release the pressure PU 43506 J Fuel Pressure Tester q PU 43506 Polaris EFI Diagnostic Software PU 47063 This dealer only software installs on laptop computers equipped with a CD drive and serial port connection and is designed to replace multiple shop tools often used to test EFI components It also includes step by step diagnostic procedures to aid technician repair and troubleshooting 4 2 Throttle Position Sensor Tester PU 47082 This tester allows the use of a digital multi meter to test TPS function as well perform initialization procedures Gasoline is extremely fla
9. Ar 2 Loosenthe phillips screw located at the rear of the headlamp 3 Tilt the headlamp upward or downward 4 Tighten the screw 10 32 HEADLAMP SWITCH TEST 1 Remove the headlight pod cover 2 Set meter to DC Volts and probe the headlamp plug wires Brown and Yellow at back of connector for 12 Volts 3 Turn ignition and headlight on If there is no power continue with checks to the harness and fuses Brown Yellow Upper Headlamp Plug Wires Brown Green 4 WORKLIGHT SWITCH Remove the headlight pod cover to locate the switch wires The switch snaps out by pushing in on the tabs on both sides of the switch Squeeze Tabs Push Thru to Remove fs Ww If the rear work lights will not come on check the following POLARIS ELECTRICAL Check for continuity between the switch 2 Toremove the brake light electrical connector contacts Place meter leads between two press in on the tab on the connector to unlock the contacts with switch in ON position connector and pull the connector from the bulb Probe the worklight plug wires at back of assembly vehicle there should be at least 12V at the plug Check for 12 volt power at the blue wire Worklight Plug Wires 3 To remove either of the bulbs turn the holder BRAKE LIGHT WORK
10. e ELECTRICAL SPEEDOMETER REMOVAL SPEEDOMETER INSTALLATION 1 Remove the three screws that secure the 1 Spray a soap and water mixture onto the outer headlight pod cover and disconnect the wire surface area of the instrument cluster This will connectors from the instrument cluster help the instrument cluster slide into the pod assembly more easily 2 Besurethe rubber grommet inside the pod is fully 2 Pushthe instrument cluster out from the backside installed and that the indexing key is in the of the pod while securely holding the pod 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 motion to properly seat the instrument cluster into the pod assembly Apply pressure on the bezel while pressing down on the instrument cluster Instrument Cluster Rubber Mount Push Instrument Cluster Outward NOTE Do not remove the rubber grommet in the pod Only remove the rubber grommet if necessary The bezel is a snap on assembly and is a serviceable part NOTE Do not allow alcohol or petroleum products to come in contact with the instrument cluster lens POLARIS 10 8 ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 1 NO ALL WHEEL DRIVE START HERE ENGINE OFF KEY SWITCH ON TRANSMISSION IN LOW AWD SWITCH ON INSTRUMENT CLUSTER IN DIAGN
11. p The Way Out 2005 SPORTSMAN 700 EFI 2005 SPORTSMAN 800 EFI SERVICE MANUAL PN 9919820 The Way Out 2005 SPORTSMAN 700 800 EFI 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 700 800 EFI 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 manuals can be downloaded from www polarisindustries com or purchased from www purepolaris com or contact your nearest Polaris dealer 2005 Sportsman 700 800 EFI ATV Service Manual PN 9919820 Copyright 2004 Polaris Sales Inc All information cont
12. 2 25 2 27 Exhaust System Maintenance 2 27 2 28 Brake System Service 2 28 2 29 Suspension Service 2 29 2 30 2 30 Wheel Tire Removal Installation Inspection 2 31 2 32 Warn Winch Operation 2 33 2 34 Cleaning and 2 35 2 36 800 EFI Exhaust Canister Maintenance 2 36 2 1 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 Frequent immersion mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip co
13. Body Assembly Exploded View Headlight Pod Exploded View Handlebar Block Installation Procedure Steering Assembly Exploded View A Arm Replacement Rear Suspension Assembly Strut Assembly Exploded View Front Strut Cartridge Replacement Front Strut Ball Joint Replacement Steering Post Assembly Decal Replacement POLARIS 5 BODY STEERING SUSPENSION TORQUE SPECIFICATIONS SPECIAL TOOLS Compression Tool 22004231 Gas Shock Recharging Kt 2871199 Seal Sleeve Installation Tool Kit 2870872 Shock Spanner Wrench 2871351 Fox Shock IFP Depth Tool COMPONENT Front A Arm Attaching Bolt Front A Arm Ball Joint Stud 25 35 Nut d Handlebar Adjuster Block 11 13 15 18 Master Cylinder Clamp 45 55 5 2 6 3 Bolts Rear Shock Bolt Upper PLASTIC INSERT REMOVAL Rear Wheel Hub Nut INSTALLATION Some Polaris ATVs use a two piece plastic insert in place of a metal screw The plastic inserts are easy to remove and install Upper Stabilizer Support 17 Nuts Upper Control Arm Mount 1 Use a a pair of diagonal side cutters to lift the plastic insert A until you feel some slight pressure or lift the insert approximately 1 4 6 35 mm Apply just enough pressure on the side cutters to lift up on the insert DO N
14. 5 Check for leaks OSEE 6 Reinstall fill plug and torque to 10 14 ft lbs 14 19 Nm View From Back prem PS Transmission Fill Plug Fill to the Bottom of Fill Plug Hole Threads Q Proper Oil Level PELARIS 213 THROTTLE CABLE ELECTRONIC THROTTLE CONTROL ETC SWITCH ADJUSTMENT 1 Slide boot off throttle cable adjuster and jam nut 2 Place shift selector in neutral and set parking brake 3 Loosen lock nut on in line cable adjuster Ill 1 Adjuster Lock Boot Sleeve nut H 4 Turn adjuster until 1 16 to 1 8 freeplay is achieved at thumb lever Ill 2 After making adjustments quickly actuate the thumb lever several times and reverify freeplay Direction of travel 1 16 1 8 Freeplay 5 Tighten lock nut securely and slide boot completely in place to ensure a water tight seal 6 Turn handlebars from left to right through the entire turning range If idle speed increases check for proper cable routing If cable is routed properly and in good condition repeat adjustment procedure 2 14 MAINTENANCE THROTTLE INSPECTION Check for smooth throttle opening and closing in all handlebar positions Throttle lever operation should be smooth and lever m
15. 5 in Ibs 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 15 Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasion Replace hose if wear or abrasion is found MASTER CYLINDER REMOVAL 1 Clean master cylinder and reservoir assembly Make sure you have a clean work area to disassemble brake components POLARIS BRAKES 2 Placeashop 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 3 Remove master cylinder from handlebars 4 Hold brake upright and continue to remove master cylinder Cover brake line to avoid spillage MASTER CYLINDER INSTALLATION Notice When replacing the brake master cylinder assembly or master cylinder parts use the correct parts There are different brake master cylinders for the different Polaris ATV models Refer to your parts manual or guide for the correct parts This master cylinder is not serviceable and is replaced as a unit 1 Install master cylinder on handlebars Torque mounting bolts to 25 in lbs 8 Nm Torque the inside bolt first as indicated in the illustration to the righ
16. a we v Emissions amp Year Designation Basic Chassis Model Option Designation Engine Designation ENGINE DESIGNATION NUMBERS EHO68OLE Twin cylinder Liquid Cooled 4 Stroke Electric Start EHO76OLE Twin cylinder Liquid Cooled 4 Stroke Electric Start VIN IDENTIFICATION World Mfg ID Vehicle Description Vehicle Identifier Body Style Emissions Model e This could be either Engine Year Individual Serial No a number or a letter Powertrain Check Digit Plant No ENGINE SERIAL NUMBER LOCATION Be sure to refer to the engine model number and serial number whenever corresponding about an engine This information can be found on the sticker applied to the top side of the crankcase A An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION The machine model number and serial number are important for vehicle identification The machine serial number is stamped on the lower left side of the frame tube B TRANSMISSION I D NUMBER The transmission 1 0 number is located on LOCATION the right side of machine 12 is MODEL 2005 SPORTSMAN 700 EFI MODEL NUMBER A05MH68AU ENGINE MODEL EHO680LE22 Dimension Capacity S MODEL 2005 SPORTSMAN 800 EFI MODEL NUMBE
17. 1 With the engine and temperature sensor at room temperature 68 F 20 C disconnect the harness connector 2 Withthe meter in the ohms mode place the meter leads onto the sensor contacts One lead on Yellow wire and one lead on the Violet wire 3 Use the table Temperature Resistance table to determine if the sensor needs to be replaced Temperature 68 F 20 C 2 5 kQ 6 0 186 kQ 2 NOTE If the coolant temperature sensor or circuit malfunctions the radiator fan will default to ON 212 F 100 C NOTE The fan may not function or operation may be delayed if coolant level is low or if air is trapped in the cooling system Be sure cooling system is full and purged of air Refer to Maintenance Chapter 2 for cooling system information FAN CONTROL CIRCUIT OPERATION TESTING Power is supplied to the fan via the Orange Black wire when the relay is ON The ground path for the fan motor is through the Brown harness wire Refer to page 10 20 for more information on Fan Relay functions CAUTION Keep hands away from fan blades during operation Serious personal injury could result NOTE The fan may not function or operation may be delayed if coolant level is low or if air is trapped in the cooling system Be sure cooling system is full and purged of air Refer to Maintenance Chapter 2 for cooling system information FAN CONTROL CIRCUIT BYPASS TEST 1 Disconnect harness from coolant temperatu
18. Apply engine oil to valve guides and seats Coat valve stem with molybdenum disulfide grease or OW 40 Synthetic oil Install valve carefully with a rotating motion to avoid damaging valve seal Valve seals should be installed after the valves are in the head to avoid valve seal damage Install new valve seals on valve guides ENGINE Dip valve spring and retainer in clean engine oil and install Place retainer on spring and install Valve Spring Compressor PU 45257 Install split keepers with the gap even on both sides NOTE A small parts magnet can aid in installation of the keepers Repeat procedure for remaining valves When all valves are installed tap lightly with soft faced hammer on the end of the valves to seat the split keepers NOTE To prevent damage to the valve seals do not compress the valve spring more than necessary to install the keepers 3 27 VALVE SEALING TEST 1 Clean and dry the combustion chamber area A Refer to Page 3 25 for cleaning tips 2 Pour a small amount of clean solvent onto 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 PUSH RODS Rs PA SPRING SEATS HYDRAULIC LIFTERS VALVES 328 ENGINE HEAD REASSEMBLY 4 Lubricate push r
19. FRONT DRIVE SHAFT CV JOINT BOOT REPLACEMENT 1 Remove wheel brake caliper and wheel hub Refer to Front Drive Axle Removal Page 7 2 for procedure 2 Remove cotter pin and castle nut from A arm ball joint 3 Disconnect A arm from ball joint using a tie rod fork 4 Slide strut off end of drive shaft and tie it up out of the way of the shaft 5 Remove clamps from rubber boot using the proper boot clamp pliers 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 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 4 Pull shaft to remove from CV joint 7 Remove small clamp and boot from driveshaft NOTE Ifthe 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 3 5 oz of grease 8 Before installing the new boot remove all grease from the boot area and shaft NOTE Itis very important to use the correct type and quantity of grease Use only the grease contained in the boot kit DO NOT use a substitute grease and DO NOT overfill or underfill the CV joint CV Joint Grease 3 5 oz Refer to parts manual for boot kit CV Boot Clamp Pliers Earl
20. Replace with correct belt Adjust alignment offset Inspect adjust or replace Clear obstruction Inspect system Clean repair or replace as necessary Seal PVT system ducts Remove weight Inform operator Instruct operator on guidelines for operation in proper driving range for different terrain as outlined in Owner s Safety and Maintenance Manual Find leak and repair as necessary Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual POLARIS CLUTCH CLO 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 Instruct firm effective use of throttle for efficient engage ment PVT noise Belt worn or separated thin spots loose Replace belt belt 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 POLRRIS 6 29 CLUTCH NOT
21. WARNe WINCH OPERATION If Equipped This information is for Sportsman models equipped with a 2500 Ib 2 5chi Warn Winch in the front Pre Wired Warn Winch Kits 2 5 ci PN 2875309 3 0 ci PN 2875308 Winch Handlebar Controls The winch is located in the front bumper area POLARIS The mini rocker IN OUT control controls the direction of the cable for the winch IN pulls the cable into the winch and OUT feeds the cable out of the winch Winch Control The winch control located on the side of the winch gives the operator easy access to switch between ENGAGED and FREESPOOL When the winch is ENGAGED the winch only allows the cable to be pulled IN or released OUT via the mini rocker switch on the handlebar When the winch is FREESPOOL the winch allows the cable to be pulled out freely NOTE The switch on the handlebar does not have to be in the OUT position FREESPOOL 2 33 Winch Wire Locations The winch wires can be located under the front cab area Locate the wires remove the cap and hook up to winch the Blue and Yellow 6 Ga wires to the winch Refer to the installation instructions for more details Winch Connecting Wires Located Nes ES Under Right Front Cab Area Under Right Side Front Fender 2 34 MAINTENANCE The Red wire 6 Ga with the yellow crimp cover is lo
22. XY Armature Plate Tabs Fit Into Rollcage Slots O NOTE This photo is for reference only the armature plate is actually installed in the output cover 16 Using a hex wrench turn the back lash screw out 3 4 turns Re apply red loctite onto the bottom screw threads 12 Install output cover with new O ring and torque bolts to 14 ft Ibs 19 Nm NOTE sure the square O ring is placed flat on the cover surface if the O ring is twisted fluid leakage may occur 17 Turnthe screw in until it is lightly seated then turn the screw out 1 4 turn 18 Setthe gearcase upright Rotate the pinion shaft at least 4 times This ensures the ring gear completes one full rotation POLARIS 7 15 FINAL DRIVE e 19 If a tight spot is felt during rotation loosen the backlash screw another 1 8 turn Perform the previous step again Repeat this procedure until the pinion shaft rotates smoothly 4 times 1 revolution of ring gear FRONT GEARCASE DIAGNOSIS Symptom AWD Will Not Engage 1 Check the gearcase coil resistance To test the gearcase coil resistance use the coil harness Grey amp Brown White The gearcase coils should measure between 22 8 ohms and 25 2 ohms 2 Check the minimum battery voltage at the wire Grey amp Brown White that feeds the hub coil wire There should be a minimum of 11 80 12 0 Volts present for proper operation 3 Inspect the armature plate for a consistent wear
23. 0 2596 11 5 V or Needs At least 20 less Charge hours POLARIS LOW MAINTENANCE BATTERY INSPECTION REMOVAL The battery is located under the seat 1 Remove the seat and Disconnect holder strap 2 Disconnect battery negative black cable first followed by the positive red cable A CAUTION Whenever removing or reinstalling the battery disconnect the negative black cable first and reinstall the negative cable last 3 Remove the battery LOW MAINTENANCE BATTERY INSTALLATION 1 Clean battery cables and terminals with a stiff wire brush Corrosion can be removed using a solution of one cup water and one tablespoon baking soda Rinse well with clean water and dry thoroughly 2 Route the cables correctly 3 Reinstall battery attaching positive red cable first and then the negative black cable Coat terminals and bolt threads with Nyogel Grease PN 2871329 4 Reinstall the holder strap POLARIS ELECTRICAL LOW MAINTENANCE BATTERY TESTING Whenever a service complaint is related to either the starting or charging systems the battery should be checked first Following are three tests which can easily be made on a battery to determine its condition Test Specific Gravity Test and Load Test LOW MAINTENANCE BATTERY OCV OPEN CIRCUIT VOLTAGE TEST Battery voltage should be checked with a digital multitester Readings of 12 8 volts or less require further
24. 10 14 ft Ibs 14 19 Nm POLARIS TRANSMISSION 24 Place a small amount of grease PN 2871551 into the pocket before installing the sector gear Install the shift gear 16T on the shift drum shaft Install the sector gear in the bushing pocket onthe left side Aligning the timing marks on the gears ed 28 Install the park lockout assembly Torque park lockout to 12 14 ft lbs 16 19 Nm Gee Disc 4 29 Apply Crankcase Sealant PN 2871557 onto the cover and case mating surfaces Install the cover NOTE Note the location of the skip tooth on the and hand tighten all of the bolts splines Apply a light coating of grease on the gear teeth 25 Install the lockout disc Use the white marks that were previously applied for reference 26 Install the shift shaft and the detent star Note the keyed spline on the end of the shaft Install Cover and Bolts 30 Tighten the bolt shown below first This helps to align the cover and shafts to ensure smoother and precise shifting Torque the bolt to 6 12 ft Ibs 12 16 Nm 27 Install the detent pawl and spring Install a new o ring onto the shift shaft after the detent pawl is assembled to the shaft Place a small amount of grease on the small O ring on the shift shaft and on the detent star Grease the o ring on the end of the shift drum 77 J ae ft lbs Tighten This Bolt First 12 16 Nm POLARIS 8 15 TRANSMISSION
25. Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life e The complete driveshaft and joint should be handled by getting hold of the interconnecting shaft to avoid disassembly or potential damage to the driveshaft joints e Over angling of joints beyond their capacity could result in boot or joint damage e Make sure surface ground areas and splines of shaft are protected during handling to avoid damage e Do not allow boots to come into contact with sharp edges or hot engine and exhaust components e driveshaft is not to be used asa lever arm to position other suspension components e Never use a hammer or sharp tools to remove or to install boot clamps e sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned Refer to text for grease capacity of CV joints and CV joint boots POLARIS FINAL DRIVE REAR DRIVE SHAFT 6 Install rear wheel and torque wheel nuts to INSTALLATION specification 80 ft Ibs 1 09 Nm Flat Washer 1 Slide shaft assembly into bearing carrier hub 2 Apply anti seize compound to splines of shaft ene AE 3 Install a new lock ring and install the shaft Refer to Page 7 2 4 Lift bearing carrier into place and install bolt to upper control arm Torque bolt to 35 ft Ibs 48 Nm 7 Grease all
26. Front Housing Capacity 5 0 fl oz 148 ml FRONT HOUSING INSTALLATION 1 To install gearcase reverse removal procedure Use new spring pin in front prop shaft Front Housing Mount Bolt Toque 30 ft lbs 41 Nm 2 Torque mounting bolts to 30 ft Ibs 41 Nm POLARIS 717 FINAL DRIVE FRONT GEARCASE CENTRALIZED HILLIARD EXPLODED VIEW Dmi uy Deww Asm Mid Gearcase O Ring Cover Output Seal O Ring Kit Bolt Insert Cover Input Coil Bearing Roller Ball Kit Shim Set Incl Shims Shaft Pinion 11T Bearing Roller Ball Bushing Hub Race Output Male Gearcase LH N gt Pin Dowel Seal Oil Dowel Plug Cil Fill Clutch Housing Ring Gear N A Spring N A Kit Roll Plug Cil Drain Retaining Ring Washer Bushing Bearing Needle Roller Thrust Hub Race Output Female Roll Cage Aluminum Bushing Plate Armature Vent Back Lash Plate N A LL op BB Ss pp N A POLARIS FINAL DRIVE R EAR H U B R E M OVAL 8 Removehub nut domed washer and flat washer 1 Placethe ATV in Park and lock the parking brake Remove rear hub cap 9 Remove hub Remove cotter pin Loosen the hub retaining nut Loosen the wheel nuts Safely support the rear of the ATV ark CAUTION
27. Secure the machine Serious injury could occur if machine tips or falls 6 Remove wheel nuts and wheel 7 Remove the rear brake caliper and safely suspend the caliper from the frame with a piece of wire PELARIS 719 FINAL DRIVE 11 Remove both lower control arm bolts m Rear Hub Nut Torque Remove bearing carrier 80 ft Ibs 109 Nm REAR HUB INSTALLATION Rudd sq Refer to Page 7 2 1 Insert bearing carrier on drive shaft 2 Align bottom of carrier housing and lower control arm Grease and slide lower control arm 5 Pull drive shaft outward and install hub onto bushings into place securing corner housing driveshaft splines 6 Install cone washers with domed side facing outward 7 Install retainer nut wheel and wheel nuts 8 Remove jackstand and torque axle nut and wheel nuts 9 Install a new cotter pin Tighten nut slightly to align holes if required Lower Control Arm Bolt Torque 40 ft Ibs 54 Nm Upper Control Arm Bolt Torque 35 ft Ibs 48 Nm 10 Install hub cap 3 Install and torque both lower control arm bolts 4 Lift bearing carrier until top aligns with upper control arm Install and torque upper control arm bolt and torque to specification POLARIS 7 20 FINAL DRIVE REAR HUB DISASSEMBLY REAR HUB ASSEMBLY 1 Remove outer snap ring 1 Support bottom of bearing carrier housing 2 From the back
28. 18 ft Ibs 24 Nm fa new bolts have pre applied locking agent Remove bolts and disc Clean mating surface of disc and hub Install disc on hub Install new bolts and tighten to specified torque ak Front Brake Disc Mounting Bolt Torque 18 ft Ibs 24 Nm 9 13 BRAKES CAUTION Always use new brake disc mounting bolts The bolts have a pre applied locking agent 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 Using a line wrench loosen and remove brake line to caliper Place a container under caliper to catch fluid draining from brake line 2 Remove the brake caliper mounting bolts 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 Push upper pad retainer pin inward and slip brake pads past edge Remove mounting bracket pin assembly and dust boot L Remove Mounting Bracket Remove piston dust seal and piston seal POLARIS BRAKES 5 Clean the caliper body piston and retaining 2 Inspect piston for nicks scratches wear or bracket with brake cleaner or alcohol damage Measure diameter and replace if NOTE Besureto clean seal grooves in caliper body damaged or worn beyond service limit 3 Inspe
29. B using piston to push ring squarely into place as shown See next page POLARIS ENGINE Piston Ring Installed Gap Refer To Engine Service Data Pg 3 12 3 14 NOTE Ring should be installed with the mark facing upward 2 Measure installed gap with a feeler gauge C at both the top and bottom of the cylinder REMINDER A difference in end gap indicates cylinder taper The cylinder should be measured for excessive taper and out of round 3 Ifthe bottom installed gap measurement exceeds the service limit replace the rings If ring gap is smaller than the specified limit file ring ends until gap is within specified range NOTE Always check piston ring installed gap after re boring a cylinder or when installing new rings A re bored cylinder should always be scrubbed thoroughly with hot soapy water rinsed and dried completely Wipe cylinder bore with oil immediately to remove residue and prevent rust 3 35 STARTER DRIVE BENDIX REMOVAL INSPECTION 1 2 Remove stator housing bolts and remove housing Remove the flywheel nut and washer 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 Remove starter bendix assembly A Note the thrust washers located on both sides of the bendix Inspect the thrust washer for wear or damage and replace if necessary After
30. 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 POLARS 9 11 BRAKES FRONT PAD ASSEMBLY 1 Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease and install rubber dust boots Front Caliper Mounting Bolts Torque 18 ft Ibs 24Nm 4 Slowly pump the brake lever until pressure has been built up Maintain at least 1 2 12 7 mm of Polaris Premium All Season Grease brake fluid in the reservoir to prevent air from entering the brake system PN 2871423 5 Install the adjuster screw and turn clockwise until stationary pad contacts disc then back off 1 2 2 Compress mounting bracket and make sure dust turn counterclockwise boots are fully seated Install pads with friction material facing each other WARNING f the brake pads are contaminated with grease oil or liquid soaked do not use the pads use only new clean pads 6 Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap Master Cylinder Fluid 3 Install caliper on hub strut and torque mounting Up to MAX line inside reservoir bolts 9 12 POLARIS 7 Ins
31. Ne A Rear Shock Lower Control Arm 4 Orientate Rear Front 1 Bushings Bushing Orientation gt M 2 POLARIS 5 17 BODY STEERING SUSPENSION STRUT ASSEMBLY Nut 15 ft Ibs 21 Nm Strut Bumper Washer Spacer Rubber 1 y SR Upper Pivot Ball Washer Spacer 7 18 ft 165 Nut amp 25 Nm Bolt Lower Pivot Ball 9 Spring Retainer 5 Spring dd Mme idm US Hubstrut Bearing 2 r iper Retaining Ring NOTE Grease fitting location Check lubrication guide for recommended service intervals 5 18 POLARIS STRUT CARTRIDGE REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5 18 1 Hold strut rod and remove top nut 2 Remove upper strut pivot assembly Strut Rod Wrench PN 2871572 Strut Spring Compressor Tools PN 2871573 and PN 2871574 3 Compress spring using strut spring compressor tools and remove the spacer nut 4 Remove coil spring and collapse strut cartridge 5 Remove two pinch bolts from strut casting 6 Remove strut cartridge 7 Install cartridge until bottomed in strut casting 8 Install pinch bolts with wire clamp s Torque pinch bolts to 15 ft 165 21 Nm 9 Reassemble spring and top pivot assembly Be sure all parts are installed properly and seated fully 10 Torque
32. SENSOR E A d cc WIRES ARE REPRESENTED BY FUEL PUMP 8 SWITCH SOLID OR DASHED LINES 10 IN FUEL TANK 2 al fe Ll E e 9 t iia SINPLIFY TRACING IN PUNP org ii n 288 E EE ace _ _ 2 eae 2 ges TRANS SWITCH SENDER T 75 gt 5 RESISTOR MODULE COLOR CODE EMPTY 4 VOLTAGE LOCATED ON RIGHT FRONT BRAKE 85 uo ESISTANGE EST BLK BLACK FULL 9 REGULATOR c sao s i ENGINE o nn 7 T yee ROUND FH fto 9 E 4 dit CHASSIS 6 SPLICE 5 R ho ot ii iz LL 18 Y J 4o oi E zs eS ed Ez F lt diu gz ss 25 WHITE SPLICE 4 SPLICE 46 27 s2TT 2 i TWO COLOR WIRES ARE SHOWN WITH eee5 1250 ge 225521 NORMAL OPERATION 15 OPEN UNDER THROTTLE MAIN TRACE COLORS EXAMPLE 5E 5222 82 1S REOU R Y RED WITH YELLOW TRACER 238 l Eae essct H NC SWITCH NORMALLY CLOSED z 8 se 1111 2 T 8 SWITCH NO SWITCH NORMALLY Tus 3 NT a ind L D anu H AWD QN OFF 38 T Artes x ON OFF BIE LOCATED ON RIGHT HANDLEBAR mcg wi LP ossa ro r act Ee 22 RIGRY 5 130 88 l JOFF cir Bru HAMDL EGARS me 1 BRN D 18 ORN FRONT WHEEL GRY TO 24 OHKS 89 999699 5 44 17 GRNIW S DRIVE COIL GR
33. 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 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 Tach Trip Ode 10 6 veo Km Kilometers NOTE As long as you are in the diagnostic mode the wrench icon will remain lit NOTE To leave the diagnostic mode turn the key switch off and on NOTE Any movement of the tires will trigger the speedometer out of the diagnostic mode and into standard display mode EFI DIAGNOSTIC MODE NOTE The EFI diagnostic mode is intended to quickly view fault codes stored in the EFI module Polaris dealers are equipped with the proper diagnostic tools to further diagnose the blink code To download blink codes failure codes from you EFI module 1 Be sure the ATV key switch is off and with the shifter is in Park 2 Turn the key switch ON and OFF 3times within 5 seconds and leave the key switch in the ON position on the third turn w _ POLARIS 3 The word Wait will appear the EFI module is now searching for blink codes If any blink codes are stored they will display on the instrument cluster one at a time NOTE The check engine icon will flash during this mode This picture is an example of how
34. TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR TEST The temperature and barometric air pressure sensor T BAP is a non serviceable item If it is faulty it must be replaced This sensor requires a 5 Vdc input to operate therefore the T BAP sensor should only be tested using the Polaris Diagnostic Software dealer only Refer to the EFI Diagnostic Software Manual for TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR REPLACEMENT 1 Disconnect sensor from engine harness 2 Using a 10mm wrench remove the retaining bolt and replace the sensor using a light coating of oil on the o ring to aid installation 3 Torque the retaining bolt to 29 in Ibs 3 3 Nm POLARIS kl THROTTLE POSITION SENSOR TPS The throttle position sensor TPS is used to indicate throttle plate angle to the ECU Mounted on the throttle body and operated directly off the end of the throttle shaft the TPS works like a rheostat varying the voltage signal to the ECU in direct correlation to the angle of the throttle plate This signal is processed by the ECU and compared to the internal pre programmed maps to determine the required fuel and ignition settings for the amount of engine load NOTE The correct position of the TPS is established and set at the factory Do not loosen the TPS or alter the mounting position If the TPS is repositioned replaced or loosened it must be recalibrated THROTTLE POSITION SENSOR TEST The throttle position s
35. and a 3 4 full oil filter before initial start up Follow Steps 45 46 in this section to properly prime the engine and to help aid proper engine break in NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts 3 47 6 1 Installoil pick up A if removed Torque bolt to 60 4 Apply Moly Lube Grease to cam journals and 6 in lbs 6 8 0 68 Nm balance shaft bearing surfaces of the MAG case halve Install cam and balance shafts 2 Install oil baffle weldment Torque bolts to 60 6 in lbs 6 8 0 68 Nm Oil Baffle Weldment amp Oil Pick Up 5 Install crankshaft assembly and apply engine oil Bolt Torque to crank pins and rods D Apply Moly Lube Grease to the main journals and bearings 60 6 in Ibs 6 8 0 68 Nm 3 Install the balance shaft Inspect balance shaft clearance C in both gearcase halves Rotate balance shaft to ensure that there is clearance between it and oil baffle weldment NOTE Always install new balance shaft bearings 6 Apply Crankcase Sealant PN 2871557 to the top gearcase halve NOTE Do not apply sealant to cam relief hole E 3 48 _ PG anis 5 7 Assemble the crankcase halves Apply LocTite 10 Lubricate connecting rods with OW 40 engine oil 242 PN 2871949 to the threads and pipe sealant to the bolt flang
36. pattern There should one or two distinct wear bands one band inside the other If only one 7 16 band of wear is present or if there is wear between the two bands inspect the coil area as indicated in Step 4 A band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation See Illustration 1 Armature Plate Possible Wear Ring on Armature Plate OK Condition Bad Condition Wear from Coil On Armature Plate Check to make sure the coil is seated in the U shaped insert that is pressed into the gearcase cover The top ofthe coil should be seated below the U shaped insert U shaped insert controls the pole gap Ifthe top ofthe coil is above the surface of the U shaped insert it raises the armature plate thereby increasing pole gap If the pole gap increases the coil will not be strong enough to engage the AWD system If this is the cause order a new Plate Cover Assembly PN POLARIS FINAL DRIVE 3233952 30 ft lbs 41 Nm Gearcase Cover U shaped insert Side Cutaway View of Centralized Hilliard Cover 5 Inspect the rollers for nics and scratches The rollers must slide up and down and in and out freely within the roll cage sliding surfaces 3 Add the proper lubricant to the front gearcase Check drain plug for proper torque Refer to Chapter 2 for fluid fill and change information Premium Front Hub Fluid PN 2871654
37. vehicle 1 Turnoffthe engine and remove the key to prevent loss during transporting 2 Always place the transmission in park and lock the parking brake 3 Turn the fuel valve off 4 Besurethe fuel cap oil cap and seat are installed correctly 5 Alwaystiethe frame ofthe ATV tothetransporting unit securely using suitable straps or rope 2 36 MAINTENANCE LETEA ANN SS 800 EFI Exhaust Canister Maintenance The exhaust canisters on Polaris 800 5 are ceramic coated To maintain a beautiful finish and prevent corrosion periodic maintenence is required DO NOT use caustic chemicals to clean as they may damage the finish 1 Wash any accumulated mud or debris from the canisters with a soft brush and soapy water 2 Use a cleaner such as HPC HiPerWash to clean away any remaining grime salts or oils 3 If the canisters are stained from oils or other fluids use fine steel wool with HPC Liquid Buff Cleaner and Polish to remove the stain 4 Afterremovingthe stains polish using Liquid Buff and a soft cloth Repeat this procedure as often as desired to maintain the canister s finish POLARIS LO ENGINE CHAPTER 3 POLARIS ENGINE Engine Exploded Views 3 2 3 7 Exhaust System View Notes 3 8 Special Tools 3 r4 se is 3 9 Piston Identification 3 9 P Torque Specifications
38. 10 12 POLARIS ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST7 FUEL GAUGE DISPLAY NOT WORKING START HERE CHECK INSTRUMENT SPEEDOMETER CLUSTER FUNC TION OK PERFORM TEST 2 Black Ignition Kill 16 Pin Connector Red 12V Ignition Switch 9 Blue White Engine Overheat Switch Red White 12V ETC and AWD Switch 10 N C Grey Orange Mode Override button 11 Black White Engine Check Light 12 Purple White Fuel Sender it equipped Brown Red Trans Switch Ground Green Diagnostic Factory Use Only White Gear Shift Signal Blue Diagnostic Factory Use Only UN 2 Yellow Red RPM Input ES RE CO Ee Brown Ground TURN KEY SWITCH OFF GAIN ACCESS TO FUEL SENDER WIRING CHECK FOR CONTINUITY ON REPAIR GAIN ACCESS TO BACK OF GAUGE WIRES FIXED BUT PROBLEM REMAINS CHECK CONNECTION CHECK FOR CONTINUITY AND RE FROM BRN TO GROUND TEST ARE WIRES OK AT GAUGE PIN 12 DOES FUEL INDICATOR WORK TEST SENDER FOR PROPER OPERATION REPLACE REFER TO TEST PROCEDURES IS IT OK CLEAN CONNECTOR TERMINALS CHECK RELATED WIRING TEST 8 SHIFT INDICATOR NOT WORKING TRANSMISSION SWITCH Operation The Instrument cluster sends a signal through the White wire to the resistor module This signal completes it s path on the Brown Red wire through the transmission switch Depending on the transmission switch position the Instrument cluster
39. 31 Torque the remaining bolts to 6 12 ft lbs 12 16 Nm Cover Bolt Torque 6 12 ft Ibs 12 16 Nm 32 Install a new bellcrank onto the shift shaft Note the keyed spline on the bellcrank and shaft Install the washer and nut Torque the bellcrank nut to 12 18 ft Ibs 16 24 Nm Bellcrank Nut Torque 12 18 ft Ibs 16 24 Nm 33 Install the shift switch Install the retaining clip Hook up the switch harness and reconnect the lockout plunger spring NOTE Rotate the bellcrank to line the flat side of the Switch up to the flat side of the shaft 34 Install transmission and add Polaris AGL Gearcase Lubricant PN 2873602 in the recommended amount Refer to Maintenance Chapter 2 for more information 8 16 POLARIS BRAKES CHAPTER BRAKES Special Tools Specifications Torques Brake System Components Rear Caliper Exploded View Front Caliper Exploded View Rear Auxiliary Master Cylinder Exploded View Brake System Service Notes Brake Noise Troubleshooting Hydraulic Brake System Overview Hydraulic Caliper Bleeding Brake Bleeding Fluid Change Master Cylinder Removal Master Cylinder Installation Front Pad Front Pad Assembly Brake Burnishing Front Disc Inspection Front Disc Removal Replac
40. 40 Check dipstick and add to Change after 1st month 6 months or 100 Synthetic proper level hours thereafter Change more often 25 50 hours in extremely dirty condi tions or short trip cold weather operation 2 Transmis Polaris AGL Gear Add lube to bottom of fill hole Change annually 2 sion case Lubricant 3 Front Gear Premium Demand Drain completely Add lube to spe Change annually 2 Case Drive Hub Fluid cified quantity Rear Gear ATV Angle Drive Drain completely Add lube to spe Change annually 2 Case Fluid cified quantity 5 Brake Fluid Polaris Dot 3 Brake Fill master cylinder reservoir to in As required Change fluid every 2 years Fluid dicated level inside reservoir 2 9 9 POLARIS MAINTENANCE LUBRICATION CONT AH 6 Front Prop Shaft U Joint s 7 Front Hub strut Front Hubstrut All Models Front Prop Shaft Polaris U Joint Locate grease fitting and Semi annually 1 Grease 3 grease with grease gun 7 Front Hub strut Polaris All Season Locate fitting and grease Semi annually Grease 3 More often under severe use such as operated in water or under severe loads 7 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 2 Annually or 100 hours of operation refer to Maintena
41. 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 A The speedometer needle indicates speed from an electronic wheel speed sensor located on the right front brake caliper bracket and the needle also flashes during a warning condition speedometer needle indicates speed in MPH and KPH NOTE A flashing needle could indicate a hot engine low battery warning or the No 10 Pin could be grounded B The speedometer features numbers in Mile Per Hour MPH and Kilometers Per Hour KPH The Rider Information Center performs a number of functions See Illustration 2 POLARIS ELECTRICAL 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 if reset before each trip or total miles to 999 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 Inthe Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Me
42. ECU computer chip and the ECU adjusts the fuel delivery and ignition timing to match the values During operation the ECU has the ability to re adjust temporarily providing compensation for changes in overall engine condition and operating environment so it will be able to maintain the ideal air fuel ratio During certain operating periods such as cold starts warm up acceleration etc a richer air fuel ratio is automatically calculated by the ECU INITIAL STARTING PRIMING PROCEDURE NOTE The Injection system must be purged of all air prior to the initial start up and or any time the system has been disassembled If the EFI system is completely empty of fuel or has been disassembled and repaired 1 Cycle the key switch from OFF to ON 6 times waiting for approximately 3 seconds at each cycle to allow the fuel pump to cycle and shut down 2 Once step 1 is completed turn the key switch to START until the engine starts or 5 seconds seconds has passed 3 If the engine failed to start repeat step 1 for 2 more cycles and attempt to start the engine Ifthe engine fails to start a problem may still exist and should be diagnosed NOTE Accurate testing of EFI components is recommended utilizing the Polaris Diagnostic Software dealer only 4 7 FUEL SYSTEM FUEL INJECTION ELECTRONIC CONTROL UNIT ECU The ECU is the brain or central processing computer of the entire EFI fuel ignition manag
43. INJECTORS NOTE 800 EFI fuel connections are quick connect couplings vs 700 EFI connections The fuel injectors mount into the intake manifold and the fuel rail attaches to them at the top end Replaceable O Rings on both ends of the injector prevent external fuel leakage and also insulate it from heat and vibration When the key switch is on the fuel rail is pressurized and voltage is present at the injector At the proper instant the ECU completes the ground circuit energizing the injector The valve needle in the injector is opened electromagnetically and the pressure in the fuel rail forces fuel down through the inside The director plate atthe tip of the injector see inset contains a series of calibrated openings which directs the fuel into the intake port in a cone shaped spray pattern The injector is opened and closed once for each crankshaft revolution however only one half the total amount of fuel needed for one firing is injected during each opening The amount of fuel injected is controlled by the ECU and determined by the length of time the valve needle is held open also referred to asthe injection duration or pulse width It may vary in length from 1 5 8 milliseconds depending on the speed and load requirements of the engine POLARIS 8 FUEL INJECTOR SERVICE Injector problems typically fall into three general categories electrical dirty clogged or leakage An electrical problem usually caus
44. Ignition Kil 12 Purple White Fuel Sender t equipped Green Diagnostic Factory Use Only Whe P Ground Blue Diagnostic Factory Use Only White Blue High Gear Signal Yellow Red RPM Input Brown White AWD Coil Brown Ground CHECK FUEL amp SHIFT TO LOW OR HIGH IGNITION SYSTEMS GEARS IS REVERSE INDICA TOR ICON ON OR GEAR ON Y DOES GEAR INDICATOR GO BLANK TURN KEY SWITCH OFF REMOVE 16 PIN PLUG FROM BACK OF PROBLEM REPLACE INSTRUMENT CLUSTER REMAINS SPEEDOMETER RESTART ATV AND 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 Static Timing Light Harness PN 2871745 Hall Sensor Probe Harness PN 2460761 or equivalent jumper wires To test wheel speed sensor 1 Disconnect 3 Pin connector from speedometer 2 Connect wires from test light to sensor 3 Pin connector as shown at right using the Hall Sensor 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 Static Timing Light Harness test light PN 2871745 5 If light flashes sensor is Be sure connections are good and 9 volt battery is in good condition WHEEL SPEED SENSOR
45. LIGHT assembly counter clockwise to remove and pull out Turn the holder assembly clockwise to REPLACEMENT install Refer to the parts manual for the correct The brake light A and the work light B are both bulb part number located in the rear tail lamp housing 1 the worklight electrical connector B pull down on the connector lock and pull the connector from the bulb assembly POLARIS 10 33 ELECTRICAL BRAKE LIGHT SWITCH FUEL SENDER TEST 1 Remove the front cover 1 Drain the fuel tank and remove it from the atv 2 Setthe fuel tank on a flat surface 3 Hook up an ohm meter to the fuel sender harness Violet White wire B and Brown wire C 4 With the sender float in the empty position the meter should read 5 ohms 5 Slowly tilt invert the tank so that gravity moves the sender float to the full position the meter should S7 now read 90 ohms Brake Lamp Switch FUEL SENDER Empty 69 5 Half 47Q 5 Full 909 5 Brake Switch Location Under 6 Ifthe readings are not between 5 ohms and 90 front cover below headlight pod ohms or if the reading is erratic or LCD display sticks check the following before replacing the 2 Disconnect wire harness from switch fuel pump assembly 3 Connect an ohmmeter across switch contacts Loose float Reading should be infinite o 4 Apply br
46. Max Cylinder Out of Round Limit 002 05mm Max Standard Bore Size Both Cylinders Sportsman 700 800 3 1496 80 mm PISTON TO CYLINDER CLEARANCE Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin Subtract this measurement from the maximum cylinder measurement obtained in Step 5 lt __ Piston Piston Pin Piston to Cylinder Clearance Refer To Engine Service Data Pg 3 12 3 14 Piston O D Refer To Engine Service Data Pg 3 12 3 14 3 33 PISTON ROD INSPECTION 1 Measure piston pin bore Piston Pin Bore Refer To Engine Service Data Pg 3 12 3 14 2 Measure piston pin O D Replace piston and or piston pin if out of tolerance Piston Pin Measurement Locations Piston Pin O D Refer To Engine Service Data Pg 3 12 3 14 3 34 3 LO Measure connecting rod small end ID 9 Connecting Rod Small End I D Refer To Engine Service Data Pg 3 12 3 14 POLARIS LO 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 Feeler Gauge Piston Ring to Ring Groove Clearance Refer To Engine Service Data Pg 3 12 3 14 PISTON RING INSTALLED GAP 1 Place each piston ring A inside cylinder
47. Nut 5132501 D 1 EBS Main Adapter 5132029 E 1 EBS Bushing 5132028 Removal Tool 1 Instructions 9915111 Also required Bushing Replacement Kit PN 2871226 Piston Pin Puller PN 2870386 OPTIONAL KIT PN 2871025 Includes the above listed tools and is for all clutches Special Tool NOTE Sportsman 800 EFI Drive Clutch requires Bushing Removal PA 47336 Order from Polaris tool supplier SPX 1 800 328 6657 REMOVAL AND INSTALLATION INSTRUCTIONS Special Tool NOTE Bushings are installed at the factory using Loctite 609 In order to remove bushings it will be necessary to apply heat evenly to the area around each bushing Clean all residual Loctite from bushing bore prior to installing new bushing EBS Drive Clutch Moveable Sheave Bushing Removal 1 Remove clutch as outlined previously in this chapter 2 Install handle end of Piston Pin Puller PN 2870386 securely into bench vise and lightly grease puller threads 3 Remove nut from puller rod and set aside 4 Install puller adapter Item 10 from kit PN 2871226 POLARIS 5 10 11 CLUTCH Install main adapter Item D onto puller Puller Tool A B Side A toward gt Piston Pin Puller With towers pointing toward the vise slide sheave onto puller rod Install removal tool Item A B into center of sheave with side toward sheave 800 EFI Clutch Use Bushing Tool PA 47336 Install nut C onto end of puller rod and ha
48. Removal Front 9 10 Brake Pad Removal Rear 9 17 Brake System Inspection 2 28 Brake System Main Components 9 3 Brake System Operation 9 6 Brake Auxiliary Hydraulic 2 29 Brake Auxiliary Testing 2 29 Breather Filter Maintenance 2 21 Breather Hose Inspection 2 22 Brush Replacement Starter Motor 10 39 C Cam Gear Assembly 3 41 Cam Gear Disassembly 3 40 Cam Gear Removal 3 40 Camber amp Caster 2 25 Camshaft Inspection 3 47 Charging System Break Even Test 10 19 Charging System Testing 10 21 Cleaning the ATV 2 35 Clutch Alignment 6 18 Clutch Offset 6 18 Cold Weather Heater Plug 1 6 Combustion Chamber 3 25 Compression Test 2 15 Controls Inspection 2 30 Coolant Level Inspection 2 19 Coolant Strength 2 18 Coolant Temperature Sensor 10 14 Cooling System Hoses 2 19 Cooling System Overview 2 18 Cooling System Test 2 19 Crank Position Sensor 4 13 Current Draw 10 18 CV Joint Handling Tips 7 22 CV Shaft Boot Inspection 2 30 Oylinder Head Assembly 3 27 Oylinder Head Disassembly 3 22 3 23 Oylinder Head Inspection 3 22 Oylinder Head Reconditioning 3 25 Cylinder Head Removal 3 21 3 28 Oylinder Head Warpage 3 22 Oylinder Honing 3 19 Oylinder Inspection 3 32 Oylinder Removal Inspection 3 31 D Decal Replacement 5 20 Decimal Equivalents 1 13 Diagnostic Codes 4 18 Diagnostic Mode 10 4 Diagnostic Mode Service Interval 10 5 Drive Belt Installation 6 17 Drive Belt Re
49. START HERE 5 Green Diagnostic Factory Use Only Brown Red Trans Switch Ground 6 Blue Diagnostic Factory Use Only 14 NECEM nal 7 Yellow Red RPM Input Brova Mhie AWD 8 Brown Ground S THE SPEEDO CHECK READ OUT SPEEDOMETER NOTE Mode Override button provides a grounding sink PERFORM TEST 2 prit OK ing input to the instrument cluster REPLACE TEST TRANSMISSION SE EDO SWITCH SHIFT MODULE AND WIRING INSPECT WIRING AND CDI SHIFT INTO REVERSEN SWITCH CLUSTER IS REVERSE INDICA DIAGNOSTIC MODE READING TOR ON GEAR SWITCH DIAGNOSTIC CORRECT RESTART ATV 10 7 JUMPER TO PIN 4 Y REPLACE TURN KEY SWITCH OFF BLACK TO PIN 8 SPEEDO REMOVE 16 PIN PLUG BROWN DOES FROM BACK OF ENGINE STOP SPEEDOMETER HEAD 10 10 POLARIS ELECTRICAL SPEEDOMETER TROUBLESHOOTING 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 FUNCTIONING CHECK ACTIVATE DIAGNOSTI SPEEDO 2 MODE TOGGLE TO celu OMETER SETTING amp REV ENGINE TEST NO 2 HOLD UNTIL DISPLAY STABILIZES DOES IT APPEAR ACCURATE RESTART ATV ENGINE IDLING Y REPLACE TURN KEY SWITCH OFF ANE SPEEDOMETER RAISE ATV WHEELS OFF GROUND AND OE ON SUPPORT IN A SAFE MANNER CONNECTOR FROM BACK OF 2 MONITOR VOLTAGE AT HUB COIL INSTRUMEN
50. STATOR 0 STATOR LOCATED ON RIGHT SIDE OF CRANK TEST 1 Resistance Value of Each Stator Leg 1 Measure the resistance value of each of the three stator legs Y1 to Y2 Y1 to Y3 and Y2 to Y3 Each should measure 0 19 15 Reading In Test Connect Meter Wires To Ohms Charge Coil Y1 to Y2 0 19 Q 15 Charge Coil Y1 to Y3 0 19 Q 15 Charge Coil Y2 to 0 19 Q 15 96 Charge Coil Y1 Y2 or to Ground Open Infinity NOTE If there are any significant variations in ohm s readings between the three legs itis an indication that one of the three stator legs maybe weak or failed TEST 2 Resistance Value of Stator Leg to Ground 1 Measuretheresistance value of each ofthe stator legs to ground Y1to Ground Y2to Ground Y3to Ground NOTE Any measurement other than Infinity open will indicate a failed or shorted stator leg 10 19 ELECTRICAL t3 TEST 3 Measure AC Voltage Output of Each RELAYS Stator Leg at Charging RPM H 1 Set the selector dial to measure AC Voltage These relays located next to the ECU assist with 2 Start the engine and let it idle component operation such as the fan fuel pump etc 3 While holding the ATV at a specified RPM Thefanrelay controlled by the ECU operates the fan separately measure the voltage across each leg The power relay controlled by the ECU turns on of the stator by connecting the meter leads to the powe
51. View Rear 7 30 Gearcase Installation Front 7 17 Gearcase Installation Rear 7 29 Gearcase Lubrication Front 2 11 Gearcase Lubrication Rear 2 12 Gearcase Removal Front 7 9 Glossary of Terms 1 14 H Headlamp Service 10 30 10 31 10 32 Headlamp Switch Testing 10 32 Headlight Adjustment 10 31 10 32 High Engine Coolant Temperature 10 3 High Low Battery Voltage 10 3 Honing to Oversize 3 19 Hub Installation Rear 7 20 Hub Removal Rear 7 19 Ignition System Components 10 17 Instrument Cluster Overview 10 3 K Keys Replacement 1 6 L Load Test 10 24 10 28 Lubrication Charts 2 9 2 10 Lubrication Transmission 2 13 8 4 Mag Cover Seal Replacement 3 53 MAINTENANCE AND LUBRICATION 2 3 2 4 25 Maintenance ATV Component Location 2 6 Master Cylinder Installation 9 9 Master Cylinder Removal 9 9 Model amp Serial Number Location 1 2 Model Identification 1 2 O Odometer Tachometer Trip Meter 10 3 Oil Water Pump Disassembly 3 44 Oil Check Engine 2 23 Oil Filter Change 2 24 Oil Flow 3 20 Oil Pressure Test 3 19 Oil Rotor Clearance 3 44 P Paint Codes 1 6 Periodic Maintenance Chart 2 3 2 4 2 5 Piston Identification 3 9 Piston Removal 3 31 Piston Ring Installed Gap 3 35 3 37 Piston to Cylinder Clearance 3 33 Piston Rod Inspection 3 34 Plastic Insert Removal 5 2 Progammable Service Interval Diagnostic Mode 10 3 Publication Numbers 1 6
52. a failure code appears 4 The word End will display after all of the codes have been displayed POLARIS ELECTRICAL Blink Code Identification Table Code Code tion No RPM Signal 54 Engine Temp Lamp Open Load Loss of Syn Engine Temp chronization Lamp Short Circuit to Ground Engine Temp Lamp Short Circuit to Bat tery Diag Lamp Open Load 45 54 Pressure Sen sor Circuit Low Input 46 Barometric 5 Pressure Sen sor Circuit High Input 22 TPS Open or 55 Short Circuit to Ground 2 TPS Short Cir cuit to Battery Diag Lamp Short Circuit to Ground Diag Lamp Short Circuit 23 RAM Error De 56 Pump Relay fective ECU Open Load 42 Engine Temp 56 Pump Relay Sensor Circuit Short Circuit Short to Ground to Ground 42 Engine Temp Sensor Circuit Open or Short to Battery 51 Injector 1 Open 58 Cooling Fan Load Open Load 1 Injector 1 Short 58 Cooling Fan Circuit to Short Circuit Ground to Ground 1 Injector 1 Short 58 Circuit to Bat tery Injector 2 Open Load Pump Relay Short Circuit to Battery Cooling Fan Short Circuit to Battery Intake Air Temp Sensor Open or Short Circuit to 1 Sensor Volt age Intake Air Temp Sensor Short Circuit to Ground END of Check 10 7 Injector 2 Short Circuit to Ground 52 Injector 2 Short 61 Circuit to Bat tery
53. and release throttle lever If the ETC system is functioning properly the engine will lose spark and stop Electronic Throttle Control ETC Switch Composite Throttle Housing ETC switch contacts are closed in a fault condition throttle cable slack Switch contacts are open during normal operation NORMAL OPERATION I OPEN MENS CIRCIUT IF CLOSED ADJUSTMENT 15 REQUIRED SWITCH 0 OFF W D AWD SWITCH ON OFF LOCATED ON RIGHT HANDLEBAR CDI UNIT PN 10 15 ELECTRICAL FLYWHEEL IDENTIFICATION Timing Marks 0 Production Date Kokusan EFI Flywheel Part Number 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 Cast Comment Application Kokusan Flywheel EFI DC CDI IGNITION The Sportsman EFI system has incorporated into it s design a DC CDI ignition system Some of the advantages of DC ignition are Stronger more consistent spark at low rpm for better performance Easier starts Simpler component design for ease trouble shooting and maintenance NOTE DC CDI systems and compo SD Operation Overview The DC CDI system relies on battery power for ignition Instead of generating DC voltage via magnetic induction a 12 volt DC curr
54. and system load the break even point may vary slightly The battery should be fully charged before performing this test WARNING Never start the engine with an ammeter connected in series Damage to the meter or meter fuse will result Do not run test for extended period of time Do not run test with high amperage accessories 1 Connect a tachometer to the engine 2 Using an inductive amperage metering device set to DC amps connect to the negative battery cable 3 With engine off and the key kill switch and lights in the ON position the ammeter should read negative amps battery discharge Reverse meter lead if a positive reading is indicated 4 Shifttransmission into Park and start the engine With the engine running at idle observe meter readings 5 Increase engine RPM while observing ammeter and tachometer 6 Note RPM at which the battery starts to charge ammeter indication is positive 7 With lights and other electrical loads off the break even point should occur at approximately 1500 RPM or lower 8 With the engine running turn the lights on and engage parking brake lock to keep brake light on 9 Repeattest observing ammeter and tachometer With lights on charging should occur at or below 2000 RPM POLARIS ELECTRICAL ALTERNATOR OUTPUT TEST Three tests can be performed using a multimeter to determine the condition of the stator alternator TO VOLTAGE REGULATOR
55. appropriate section POLARIS se GENERAL INFORMATION CONVERSION TABLE 2402 LL hg 8 7 rue 0 US quarts US q kg m m km 9 02 iters iters I Kilograms force per square cm Kilopascals kPa 3 14 x R x H height Oylinder Volume C to F 9 40 5 40 F F to 5 F 40 9 40 112 GENERAL INFORMATION SAE TAP DRILL SIZES 0394 1 2 13 27 64 1 2 20 29 64 2mm 0787 9 16 12 31 64 9 16 18 33 64 3 mm 1181 5 8 11 17 32 5 8 18 37 64 4mm 1575 3 4 10 21 32 3 4 16 11 16 3 16 5 mm 1969 7 8 9 49 64 7 8 14 13 16 6mm 2362 1 8 7 8 1 12 59 64 7 mm 2756 1 1 8 7 63 64 1 1 8 12 1 3 64 5 6 8mm 3150 1 1 4 7 1 7 64 7 11 4 12 1 11 64 9mm 3543 1 1 2 6 1 11 32 j 1 1 2 12 1 27 64 10 mm 3937 1 3 4 5 19 16 4331 13 4 12 1 43 64 dep ar 2 4 1 2 1 25 32 2 12 1 59 64 12 4724 2 1 4 4 1 2 2 1 32 13 5118 2 1 2 4 2 1 4 M 2 3 4 4 2 1 2 9 16 15mm 5906 16 mm 6299 Decimal Nearest 17 mm 6693 Equiva Fraction lent 18 7087 19 7480 20 7874 21 8268 22 8661 23 9055 24 mm 9449 25 9843 PELARIS 1 13 GENERAL INFORMATION GLOSSARY OF TERMS ABDC After
56. at 25 hours one 1000 month Oil filter change 100 H 620 Replace with oil change 1000 Oil tank vent hose 100 H 12M 620 Inspect routing condition 1000 Valve clearance 100 H 12M 620 Inspect 1000 Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California Have an authorized Polaris dealer perform these services 2 4 POLARIS MAINTENANCE Y MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km Fuel system 100 H 12M 620 Check for leaks at tank cap lines fuel pump 1000 filter pump injectors replace lines every two years Fuel filter 100 H 12M 620 Replace yearly 1000 Radiator 100 H 12M 620 Inspect clean external if applicable 1000 surfaces Cooling hoses 100 H 12M 620 Inspect for leaks if applicable 1000 Engine mounts 100 H 12M 620 Inspect 1000 Exhaust muffler 100 H 12M 620 Inspect pipe 1000 H Spark plug 100 H Inspect replace as needed 1000 Ignition Timing 100 H 12M 620 Inspect 1000 Wiring 100 H 12M 620 Inspect for wear routing 1000 security apply dielectric grease to connectors subjected to water mud etc Clutches drive 100 H 12M 620 Inspect clean replace worn parts and driven 1000 Front wheel 100 H 12M 1000 Inspect replace as needed bearings 1600 Brake fluid 200 H 24 M 1240 Change every two years 2000 Spar
57. battery cables To avoid the possibility of explosion connect positive red cable first and negative black cable last 5 After connecting the battery cables install the cover on the battery and attach the hold down strap 6 Install clear battery vent tube from vehicle to battery vent WARNING Vent tube must be free from obstructions and kinks securely installed If not battery gases could accumulate and cause an explosion Vent 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 7 Route cables so they are tucked away in front and behind battery LOW MAINTENANCE BATTERY NOTE All Low Maintenance batteries are fully charged and tested at the factory before installation Expected shelf life varies on storage conditions As a general rule before placing the battery into service check the battery condition and charge accordingly Battery Check 1 Check the date label on the side of the battery to calculate when to check voltage The battery should be checked every 3 months 10 25 ELECTRICAL 2 Checkthe voltage with a voltmeter or multimeter A fully charged battery should be 12 8 V or higher 3 Ifthe voltage is below 12 8 V the battery will need to be recharged STEP 2 Check voltage with voltmeter or multimeter Fully charged is 1
58. 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 electrolyte levels hard crystal sulfation will form on the plates reducing the efficiency and service life of the battery NOTE Use a voltmeter or multimeter to test batter voltage OPEN CIRCUIT VOLTAGE State of Maintenance Low charge Free Maintenence 10096 13 0V 12 70V 12 80V 12 50V 12 50V 12 20V 12 20V 12 0V less than 12 0V less than 11 9V At 80 F NOTE Subtract 01 from the specific gravity reading at 40 75 Charged 50 Charged 25 Charged 0 Charged 10 27 ELECTRICAL LOW MAINTENANCE BATTERY LOAD TEST CAUTION To prevent shock or component damage remove spark plug high tension leads and connect securely to engine ground before proceeding NOTE This test can only be performed on machines with electric starters This test cannot be performed with an engine or starting system that is not working properly A battery may indicate a full charge condition in the OCV test and the specific gravity test but still may not have the storage capacity necessary to properly function in the electrical system Forthis 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 mann
59. brake systems are light weight low maintenance and perform well in the conditions ATVs routinely encounter However there are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life Perform brake burnishing procedure after installing new pads to maximize service life e Optional pads are available to suit conditions in your area Select a pad to fit riding style and environment e Do not over fill the master cylinder fluid reservoir Make sure the brake lever and pedal returns freely and completely e Adjust stop pin on front caliper after pad service e Check and adjust master cylinder reservoir fluid level after pad service Make sure atmospheric vent on reservoir is unobstructed POLARIS 2 Reservoir e Test for brake drag after any brake system service and investigate cause if brake drag is evident e Make sure caliper moves freely on guide pins where applicable e Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely CAUTION _ Use only DOT 3 brake fluid as assembly aid for all procedures described in this chapter to prevent brake system contamination DO NOT USE LUBRICANTS OF ANY KIND FOR ASSEMBLY AS THEIR USE CAN CAUSE RUBBER COMPONENTS TO SWELL BRAKE NOISE TROUBLESHOOTING Dirt or dust buildup on the brake pad
60. fender area of the storage box 2 each side 5 Install the two screws D into the rear area of the cab if removed 6 Install the two plastic inserts E into the front cab if removed 7 Torque all bolts and screws according to the illustration 8 Install the front radiator cap cover E and shock tower covers F POLARIS 57 BODY STEERING SUSPENSION Rear Rack Installation 3 Place spacers on frame 4 Install rear rack onto rear frame and cab 5 Install the two bolts B and six A T 27 screws Torque the bolts A to 18 2 Nm and six T 27 screws to 36 in lbs 4 Nm Refer to the illustration for torque values FRONT CAB FENDER REMOVAL INSTALLATION 1 Follow the FRONT RACK BUMPER REMOVAL section to begin removal of the front cab rack and bumper 2 Remove the plastic inserts A that secure the front cab to the upper strut support 3 Remove the two screws B that secure the front cab to the frame in the fuel tank mount area 5 8 4 Remove the side panels D refer to the SIDE PANEL REMOVAL section 5 Remove the plastic inserts E that secure the front of the foot wells to the front cab 6 Remove the fuel cap and place a clean lint free shop towel into the tank neck to keep any debris from falling into the tank 7 The front cab should now slide back over the fuel tank and fuel tank neck NOTE When removing the front cab use
61. if cracked or damaged Align the alignment mark on the cover with the mark on the engine seal Seal this edge to cover on engine side Place a new seal on transmission input shaft 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 on engine side Surfaces must be clean to ensure adhesion of silicone sealant Reinstall cover and tighten rear cover bolts just enough to hold it in place Fitlip of inner cover seal A to engine Install seal retainer plate and tighten screws securely Torque rear inner cover bolts B to specification Seal outer edge to cover with RTV silicone sealant Inner Cover Bolt Torque Rear 12 ft Ibs 16 6 Nm Driven Clutch Retaining Bolt Torque 17 ft Ibs 23 5 Nm Drive Clutch Retaining Bolt Torque 40 ft Ibs 55 Nm 7 CX Install clutch offset spacer s on transmission input shaft 8 9 10 11 12 13 14 Clean splines inside driven clutch the transmission input shaft Apply a light film of grease to the splines on the shaft Install the driven clutch washer lock washer and retaining bolt Torque to specification Clean end of taper on crankshaft and the taper bore inside drive clutch Install drive clutch and torque retaining bolt to specification Reinstall drive belt noting direction of rotation Ifa new belt is installed install so number
62. into taper on wheel Torque to proper specification Steel Wheel Aluminum Wheel TIRE PRESSURE CAUTION Maintain proper tire pressure Refer to the warning tire pressure decal applied to the vehicle Tire Pressure Inspection PSI Cold 2 31 TIRE INSPECTION Improper tire inflation may affect ATV maneuverability When replacing a tire always use original equipment size and type The use of non standard size or type tires may affect ATV handling Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Tread Depth 1 8 3 mm A WARNING Operating an ATV with worn tires will increase the possibility of the vehicle skidding and pos sible loss of control Worn tires can cause an accident Always replace tires when the tread depth measures 1 8 3 cm or less 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 2 32 MAINTENANCE FRONT REAR STORAGE COMPARTMENTS The front and rear storage compartments are easily accessible To open the front compartment turn the latch handle to the horizontal position on both sides To close the storage compartment turn the latch handles to the vertical position Rear Storage Latched POLARIS
63. its amp hour rating Examples 1 10 of 9 amp battery 9 amp 1 10 of 14 amp battery 1 4 amp 1 10 of 18 amp battery 1 8 amp recommended charging rates 6 Check specific gravity of each cell with a hydrometer to assure each has a reading of 1 270 or higher BATTERY TERMINALS TERMINAL BOLTS Use Polaris corrosion resistant Nyogel grease PN 2871329 on battery bolts See Battery Installation on Page 10 23 CONVENTIONAL BATTERY INSPECTION REMOVAL The battery is located under the seat Inspect the battery fluid level When the battery fluid nears the lower level remove the battery and fill with distilled water only to the upper level line To remove the battery POLARIS ELECTRICAL Maintain between upper and lower level marks 1 Disconnect holder strap and remove covers 2 Disconnect battery negative black cable first followed by the positive red cable A CAUTION Whenever removing or reinstalling the battery disconnect the negative black cable first and reinstall the negative cable last 3 Remove the battery 4 Remove the filler caps and add distilled water only as needed to bring each cell to the proper level Do not overfill the battery A Refill using only distilled water Tap water contains minerals which are harmful to a battery A Do not allow cleaning solution or tap water inside the battery Battery life may be reduced 5 Reinstall the battery caps CO
64. its compression rate This may result in complete COMPRESSED SPRING LENGTH INCHES stacking of the coils and subsequent clutch component failure Measuring Spring Length 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 125 NUMBER 7041063 Pupe 1687 497 POLARIS 6 9 CLUTCH ama SHIFT WEIGHTS Shown below are optional shift weights which may be used in the PVT system These shift weights have many different 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 the effects they have on belt to sheave clearance clutch balance engagement and shifting characteristics PN 5630418 PN 5630279 PN 5630095 PN 5630509 50 gr 43 gr 53 gr 55 gr 10 MA PN 5630709 PN 5630513 PN 5630710 PN 5630711 44 gr 50 5 gr 46 gr 479 5631214 5631215 5631216 54 gr 56 gr 58 gr 6 10 1 2 POLARIS CX SHIFT WEIGHT INSPECTION 1 Inspect as shown using a cl
65. leakage exceeds 15 ENGINE MOUNTS Inspect rubber engine mounts A for cracks or damage 1 3 Check engine fasteners and ensure they are tight 2 16 MAINTENANCE BATTERY MAINTENANCE WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Anti dote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician im mediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Venti late when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN NOTE New Batteries Batteries must be fully charged before use or battery life will be reduced by 10 30 of full potential Charge battery for 3 5 hours at a current equivalent of 1 10 of the battery s rated amp hour capacity Do not use the alternator to charge a new battery Refer to battery video PN 9917987 The battery is located under the seat Inspect the battery fluid level When the electrolyte nears the lower level remove the battery and add distilled water only to the upper level line IIl 1 Maintain between upper and lower level marks POLARIS MAINTENANCE To remove the battery 1
66. over housing making sure boot is seated in groove Position clamp over boot end and make sure clamp tabs are located in slots Note Before tightening boot clamp on inboard joint make sure any air pressure which may have built up in joint boot has been released The air should be released after the plunging joint has been centered properly Tighten boot clamp using boot clamp pliers Open snap ring and pull CV joint away from shaft POLARIS FINAL DRIVE Boot Replacement 1 Remove CV joint from end of shaft 2 Remove boot from shaft NOTE When replacing a damaged boot check the grease for contamination by rubbing it between two fingers gritty feeling indicates contamination If the grease is not contaminated the boot can be replaced without cleaning the CV joint Use the recommended amount of grease for boot replacement only see below Proceed to Boot Installation CV JOINT CLEANING REPLACEMENT 3 Thoroughly clean and dry the CV joint and inspect ball tracks and cages for wear cracks or other damage NOTE Shiny areas in ball tracks and on the cage spheres are normal Do not replace CV joints because parts have polished surfaces Replace CV joint only if components are cracked broken worn or otherwise unserviceable 4 Addthe recommended amount of grease for CV joint cleaning to the joint as shown below Be sure grease penetrates all parts of the joint 7 25 FINAL DRIVE BOOT INS
67. running Never use a quick start battery charger to start the engine Do not charge battery with key switch on Always disconnect negative battery cable lead before charging battery Always unplug ECU from the wire harness before performing welding on the ATV 4 3 FUEL SYSTEM FUEL INJECTION EFI SYSTEM EXPLODED VIEW o 400 Electronic Control Unit Intake Air Temperature and Barometric Air Pressure Sensor T BAP Crankshaft Position Sensor CPS Fuel Injectors Fuel Filter s Fuel Pump Regulator Gauge Sender Assembly located in tank as an assembly Fuel Rail 800 EFI utilizes quick connect couplings Engine Coolant Temperature Sensor 9 Throttle Position Sensor TPS 10 Throttle Body 11 Wire Harness Integrated into main harness assembly 800 EFI Fuel Rail 800 EFI Fuel Filter w quick connect line w quick connect lines POLARIS 38 FUEL SYSTEM FUEL INJECTION EFI SYSTEM COMPONENT LOCATIONS ONONA Electronic Control Unit ECU Intake Air Temperature and Barometric Air Pressure Sensor T BAP Crankshaft Position Sensor CPS Fuel Injectors 2 Fuel Filters 1 located in tank 1 under front cab cover not pictured Fuel Pump Regulator Gauge Sender Assembly located In tank as an assembly Fuel Rail Engine Coolant Temperature Sensor 9 10 11 Throttle Position Sensor TPS Thro
68. speeds for extended periods during the first three hours of use Excessive heat can build up and cause damage to close fitted engine parts 1 Fill fuel tank with unleaded or leaded fuel which has a minimum pump octane number of 87 M 2 2 Check oil reservoir level indicated on dipstick Add oil if necessary lt 0 802 3 Driveslowly atfirst to gradually bring engine up to operating temperature 4 Vary throttle positions not operate at sustained idle or sustained high speed 5 Perform regular checks on fluid levels controls and all important areas on the vehicle 6 Pull only light loads during initial break in 7 Change break in oil and filter at 20 hours or 200 miles 3 18 POLARIS LO CYLINDER HONE SELECTION AND HONING PROCEDURE CAUTION A hone which will straighten as well as remove material from the cylinder is very important Using a common spring loaded glaze breaker for honing is not advised for nicasil cylinders Polaris recommends using a rigid hone or arbor honing machine Cylinders may be wet or dry honed depending upon the hone manufacturer s recommendations Wet honing removes more material faster and leaves a more distinct pattern in the bore HONING TO DEGLAZE A finished cylinder should have a cross hatch pattern to ensure piston ring seating and to aid in the retention of the fuel oil mixture during initial break in Hone cylinder acco
69. strike the housing as magnet damage is possible If magnets are damaged starter must be replaced STARTER REASSEMBLY INSTALLATION 6 Besure wire insulation is in place around positive 1 Install brush plate to field magnet housing aligning brush wire and pushed completely into slot on index tab phenolic plate 7 Using a non petroleum grease lubricate brush end bushing and install shims Dielectric Grease PN 2871329 8 Align brush plate and install cover and screws 9 Lightly grease pinion shaft and install pinion spring stopper and snap ring 2 Install O ring two small phenolic spacers large phenolic washer flat washer lock washer and terminal nut 3 While holding brush springs away from brushes push brushes back and hold in place 4 Slide armature into field magnet housing Release brushes 5 Lightly grease the drive roller bearing and reinstall drive end frame on armature Inspect seal for wear or damage Replace drive end cap if necessary 10 Install the starter onto the engine case Hand tighten each of the starter bolts Torque the bottom bolt first to 9 ft lbs 12 NM Then torque the top bolt to the same specification 10 40 1 0 POLARIS NOTE It is important to tighten the bottom starter bolt first as the bottom hole acts as a pilot hole to properly align the starter drive bendix with the flywheel This helps to prevent binding and starter damage 9 ft Ibs S
70. system to 10 psi The Pressure system must retain 10 psi for five minutes or longer If pressure loss is evident within five Recommended Coolant minutes check the radiator hoses clamps and water pump seals for leakage Use only high quality antifreeze coolant mixed with distilled water a 50 50 or 60 40 ratio depending on Radiator Cap Pressure Test freeze protection required in your area CAUTION 1 Remove radiator cap and test cap using a Using tap water in the cooling system will lead to a commercially available cap tester buildup of deposits which may restrict coolant flow and 2 The radiator cap relief pressure is 13 bs Replace reduce heat dissipation resulting in possible engine cap if it does not meet this specification damage Polaris Premium 60 40 Antifreeze Coolant is recommended for use in all cooling systems and comes pre mixed ready to use Upper Engine Hose Surge Tank Filler Neck Assy Shroud Thermostat ey Lower Engine Hose Cylinder VN Head Radiator Exploded View Coolant Flow Diagram To Water Pump Top Radiator Front View Bottom Lj Radiator Left Side View POLRRIS 3 15 ENGINE REMOVE amp INSTALL L WARNING Always wear safety glasses and proper shop clothing when performing the procedures in this manual Failing to do so may lead to possible injury or death 1 2 3 4 10 Clean wo
71. the bendix is removed tap on the starter assembly with a soft faced mallet to loosen the starter from the crankcase 3 36 LO Inspect gear teeth on starter drive B Replace starter drive if gear teeth are cracked worn or broken Inspect the bendix bushing C in the mag cover for wear Replace as needed POLARIS LO FLYWHEEL STATOR REMOVAL INSPECTION 1 Remove stator housing bolts and remove housing Remove Stator Cover 2 Remove flywheel nut and washer 3 Install Flywheel Puller PN 2871043 and remove flywheel CAUTION Do notthread the puller bolts into the flywheel more than 1 4 or stator coils may be damaged 4 Use caution when removing the wire holddown B trigger coil C and the stator assembly D Do not tap or bump the gear stator housing cover or the stator This could cause the seal around the gear stator housing cover and the crankcase to break causing a leak POLARIS ENGINE 5 Remove the bendix E if necessary FLYWHEEL STATOR INSTALLATION NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts 1 Carefully install the stator and trigger coil to the gear stator housing cover Do not tap on the stator or the gear stator housing cover This may cause a leak in between the gear stator housing cover and the crankcase 2 Properly place the stato
72. 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 POLARIS when the lever is released and the master cylinder piston is outward 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 Duetothe 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 expan
73. the valve will be very narrow and is a normal condition Look for an even and continuous contact point all the way around the valve face B B Proper Seat Contact On Valve Face Bottom 60 Seat 45 Top 30 Seat Width Valve Seat Width Intake Std 028 7 mm Limit 055 1 4 mm Exhaust Std 039 1 0 mm Limit 071 1 8 POLARIS LO VALVE SEAT RECONDITIONING CONT D 8 Clean all filings from the area with hot soapy water rinse and dry with compressed air WARNING Wear eye protection face shield when working with compressed air during cylinder head disassembly and reassembly 10 Lubricate the valve guides with clean engine oil and apply oil or water based lapping compound to the face of the valve NOTE Lapping is not required with an interference angle valve job Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem 11 12 Rotate the valve rapidly back and forth until the cut sounds smooth Liftthe valve slightly off ofthe seat rotate 1 4 turn and repeat the lapping process Dothis four to five times until the valve is fully seated and repeat process for the other valve s Thoroughly clean cylinder head and valves CYLINDER HEAD REASSEMBLY NOTE Assemble the valves one at atime to maintain proper order 1 2 3 POLARIS
74. to determine when to activate the fan during operation If for any reason the engine temperature sensor circuit is interrupted the fan will default to ON ENGINE TEMPERATURE SENSOR TEST Refer to Chapter 10 for testing Polaris dealers can also test the sensor by using the Polaris Digital Wrench Software dealer only Refer to the Digital Wrench Software Manual for more information POLARIS FUEL SYSTEM FUEL INJECTION ENGINE TEMPERATURE SENSOR REPLACEMENT 1 Disconnect sensor from engine harness 2 Using a wrench remove and replace the sensor applying a light coating of thread sealant to aid installation 3 Torque the sensor to 18 5 ft Ibs 25 Nm 4 17 FUEL SYSTEM FUEL INJECTION DIAGNOSTICS USING BLINK CODES en To enable the blink codes turn the ignition from off to on times leaving it on the 3rd time ON within 5 seconds Any blink codes stored in the ECU will display one at a time in numerical order The word END will display after all codes have been transmitted NOTE To clear codes manually disconnect the NOTE See Chapter 10 for more details positive battery lead for 20 seconds DIAGNOSTIC BLINK CODES CHART RAM Error Defective ECU Temp Sensor Open or Short Circuit to Sensor Voltage ECU Yes SAE Code P0335 P0122 P0123 P0601 P0113 P0112 P0117 P0118 P0107 P0108 P1260 P0261 P0262 P1263 P0264 P0265 P0655 P
75. 0 component GEAR TIMING AT TDC MS UM POLARIS 3 3 o ENGINE EXPLODED VIEW Crease J Apply Polaris OW 40 oil to seal Loctite Pipe Sealant PN 2871956 bf SS Bolts HEY Tighten Top Bolt First 9 m a Gasket Water Pump Cover Bolt 84 8 ft Ibs 207904 NO Grease or Oil Tighten Sequence 9 50 0 9 Nm d V g UT Water Pump 96 12 in Ibs 10 85 1 35 Nm ee d Washer Carus Nut Pos Cable 65 7 ft Ibs Neg Cable A Stator Cover 88 9 50 Nm Gasket 1 Fill Tube 50 5in lbs o 5 64 0 56 Nm Dipstick 22 2 165 amp 4 i O ring 30 3 Nm v Bolts C 96 12 in Ibs A 10 85 1 35 Nm Hex Plug 216 24 in Ibs 24 4 2 71 Nm Filter Nipple 35 4 ft Ibs 47 5 5 4 Nm E Stator Cover Bolt Tighten Sequence 4 CO POLARIS LO ENGINE EXPLODED VIEW END END Head Bolts d gt Each Bolt Lubricate threads and be Threads tween washers and underside of bolt heads with engine oil Torque in sequence provided a Apply Moly Lube grease to valve tips Gasket free of oil Verify tabs are visible Apply thin film of OW 40 to 25 55 mm of cylinder bore G Apply OW 40 to piston pin or pin bore 6 Apply OW 40 t
76. 0 total if joint is cleaned REAR GEARCASE DISASSEMBLY 1 Drain and properly dispose of used oil 2 Remove the gearcase housing cover bolts and the gearcase housing cover POLARIS FINAL DRIVE 3 Removethe shim thrust button and thrust button 5 Inspect the ring gear for abnormal wear broken shim from the gearcase or chipped teeth Spin the bearing to check the ball bearings for smoothness Replace the bearing if needed 6 Removethe input shaft cover and the pinion shaft from the gearcase housing See next page Thrust Button Y 7 nspect the ring gear for abnormal wear broken or chipped teeth Spin the bearing to check the ball bearings for smoothness Replace the bearing if needed 4 Remove rear bevel gear from the gearcase housing cover POLARIS 727 FINAL DRIVE REAR GEARCASE 3 Install the pinion shaft into the gearcase housing Install the pinion shaft cover and torque the cover REASSEMBLY bolts to 25 ft Ibs 34 Nm 1 Inspect the pinion shaft bushing for wear Pinion Shaft Cover Bolt Torque 2 Replace all O rings seals and worn 25 ft Ibs 34 Nm components 4 Install the original shim s thrust button and thrust button shims into the gearcase cover 7 28 FINAL DRIVE 5 Apply Crankcase Sealant PN 2871557 to REAR GEARCASE surface of
77. 069 mm 6 Remove valve guide seals IMPORTANT It is recommended to replace seals whenever the cylinder head is disassembled Hardened cracked or worn valve seals will cause excessive oil consumption and carbon buildup 7 Mark the valves with a white pen Remove the valves from the cylinder head This will ensure that the valves are properly placed during engine reassembly 5 Measure free length of spring with a Vernier caliper Compare to specifications Replace spring if measurement is out of specification Valve Spring Free Length POLARIS 2 23 VALVE INSPECTION 1 2 3 4 Remove all carbon from valves with a soft wire wheel or brush 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 indicator Check end of valve stem for flaring pitting wear or damage A Inspect split keeper groove for wear or flaring of the keeper seat area B NOTE The valves can be re faced or end ground if necessary They must be replaced if extensively worn burnt bent or damaged Measure diameter of valve stem with a micrometer in three places then rotate 90 degrees and measure again six measurements total Compare to specifications 3 24 Valve Stem Diameter Intake 0 2356 0 00039 5 985 0 01 mm Exha
78. 10 9 10 10 10 11 10 12 1018 Speedometer Removal 10 8 Spider Disassembly 6 22 Spider Removal 6 12 Starter Assembly 10 40 10 42 Starter Disassembly 10 37 Starter Drive 10 41 Starter Drive Removal Inspection 3 36 Starter Motor Armature Testing 10 39 Starter Motor Brush Inspection Replacement 10 38 Starter Motor Cleaning 10 39 Starter Solenoid Bench Test 10 41 Starter System Test 10 43 Stator Removal Inspection 3 37 3 38 Steering Maintenance 2 25 Steering Post Assembly 5 20 ATV Cleaning amp Storage 2 35 Storage Tips 2 35 2 36 Suspension Preload Adjustment 2 29 Suspension Front Inspection 2 30 Suspension Rear Inspection 2 30 T Tap Drill Chart 1 13 Temperature amp Barometric Sensor T Bap 4 14 Throttle Cable Adjustment 2 14 Throttle Operation 2 14 Throttle Position Sensor 4 15 Tie Rod Inspection 2 25 Tire Inspection 2 32 Tire Pressure 2 31 Tire Tread Depth 2 32 Toe Alignment 2 26 2 27 Torque Patterns Engine 3 11 Transmission Disassembly 8 6 Transmission D Location 1 2 Transmission Information 8 4 Transmission Installation 8 5 Transmission Reassembly 8 11 Transmission Removal 8 4 Transmission Exploded View 8 2 8 3 Transporting the ATV 2 36 3 8 Trigger Coil Gap 10 2 Troubleshooting Brakes 9 23 Troubleshooting Cooling System 3 60 Troubleshooting Engine 3 59 3 60 Troubleshooting Fuel System 4 19 Troubleshooting Ignition System 10 18 T
79. 12 40V 12 10V 11 90V less than 11 80V 12 70V 12 50V 12 20V 12 0V less than 11 9V At 80 F NOTE Subtract 01 from the specific gravity reading at 40 F LOAD TEST CAUTION To prevent shock or component damage remove spark plug high tension leads and connect securely to engine ground before proceeding NOTE This test can only be performed on machines with electric starters This test cannot be performed with an engine or starting system that is not working properly A battery may indicate a full charge condition in the OCV test and the specific gravity test but still may not have the storage capacity necessary to properly function in the electrical system For this reason a battery capacity POLARIS 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 done in the OCV test The reading should be 12 6 volts or greater Engage the starter and observe the battery voltage while cranking the engine Continue the test for 15 seconds During cranking the observed voltage should not drop below 9 5 volts If the beginning voltage is 12 6 volts or higher and the cranking voltage drops below 9 5 volts during the test replace the battery OFF SEASON STORAGE To prevent battery damage during extended periods of non use the following basic battery maintenance items must be performed Remove the battery from th
80. 1657 P1658 P1651 P1652 P1653 P1231 P1232 P1233 P1480 P1481 P1482 njector 1 Short Circuit to Ground njector 1 Short Circuit to battery njector 2 Open Load njector 2 Short Circuit to Ground Injector 2 Short Circuit to Battery Engine Temperature Lamp Open Load Air Temp Sensor Short Circuit to Ground 21 22 22 23 41 41 42 42 45 46 51 5 wy 2 52 52 54 54 54 55 55 55 56 56 56 58 58 58 eae ee 418 TROUBLESHOOTING FUEL STARVATION LEAN MIXTURE Symptoms start or no start bog backfire popping through intake exhaust hesitation detonation low power spark plug erosion engine runs hot surging high idle idle speed erratic No fuel in tank Restricted tank vent or routed improperly Fuel lines or fuel injectors restricted Fuel filter plugged Fuel pump inoperative Air leak in system Intake air leak throttle shaft intake ducts airbox or air cleaner cover Incorrect throttle stop screw adjustment RICH MIXTURE Symptoms Fouls spark plugs black sooty exhaust smoke rough idle poor fuel economy engine runs rough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel quality old fuel Fouled spa
81. 2 Recommended Air Pressure 5 psi Front F R 5 psi Rear Brake Front Dual Hydraulic Disc Dual Hydraulic Disc Brake Rear CLUTCH CHART EBS Models have no helix spring adjustment Shift Drive Driven Driven Altitude Weight Spring Spring Helix 0 1800 20 60 Blu Green EEN Meters 0 6000 5631689 7041157 3794233 Feet 1800 3700 20 58 Blu Green 6000 12000 6631216 2234233 3254254 1 5 se GENERAL INFORMATION PUBLICATION NUMBERS Model Model No Owner s Parts Parts Manual Manual PN Micro Fiche PN PN Sportsman 700 EFI AOSMH68AU 9919426 9919427 9919428 Sportsman 800 EFI A05MH76AU 9917720 9917721 9917722 When ordering service parts be sure to use the correct parts manual NOTE Some Polaris factory publications can be found at www polarisindustries com or purchased from www purepolaris com PAINT CODES PAINTED PART COLOR DITZLER POLARIS DESCRIPTION NUMBER NUMBER FRAME COLOR All P067 Medium Gloss Black 9440 8520147 Order direct at www polarisdealers com dealers only Mix as directed 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 Should both keys become lost ignition switch replacement is required Part Number 4010278 4010278 Key Series Nu
82. 2 8 or higher Examine date label to calculate when to check voltage If voltage is below 12 8 volts a refresh charge may be required New Batteries Batteries must be fully charged before use or battery life can be reduced by 10 30 6 of full potential Charge battery for 3 5 hours using a variable rate charger Do not use thealternator 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 case and shorten the life of the battery Refer to the Battery Activation and Maintenance Video PN 9917987 for proper instruction on servicing Low Maintenance batteries NOTE New Batteries Batteries must be fully charged before use or battery life will be reduced by 10 30 6 of full potential Charge battery for 3 5 hours at a current equivalent of 1 10 of the battery s rated amp hour capacity Do not use the alternator to charge a new battery Refer to Battery Activation and Maintenance video PN 9917987 NEVER attempt to add electrolyte or water to a Low Maintenance battery Doing so wi
83. 210 2200634 PU 45257 2871043 2870290 45497 2 45497 1 Cam Gear Spring Installation Kit 3 Tapered Pins PU A5498 45828 44995 PU 45483 PU A5658 45401 PU 45778 2870975 PU 43506 PU 47082 2870871 2870623 2871572 2871573 2871574 2870506 9314177 2871358 2870341 2870913 2870910 2871226 270386 2872292 PU 47086 and 8700220 2671025 2872608 8700226 PV 43568 270630 2870836 Special Tools be ordered through SPX Corporation www polaris spx com 23 25 2400 amp 2 8 POLARIS MAINTENANCE Y gt LUBRICATION Dipstick Fill Tube Fill Check Drain Plu 2 Transmission g 3 Front Gear Case Fill Plug 4 Rear Gear Case Fill Plug Master Cylinder P 93 Reservoir 5 Brake Fluid Left hand Master Cylinder More often under severe use such as operated in water or under severe loads 7 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 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 NJ Grease conforming to NLGI No 2 such as Polaris Premium All Season Grease Conoco Superlube M or Mobilegrease Special ESAE 2 22 1 Engine Oil Polaris OW
84. 8 QNNOYS 3WvVu3 Nn0U9 1 321145 29V 004 1 9110 3 91 NMOU8 121145 51 1480M H1 NAO 310008 10151538 21145 SNY 31 1HM N338U5 t 321145 HY NMO 121145 54 02 13101 121145 HY NAO t 121145 05835 4 8 02 13101 t 321145 NNOYS 3NV33 NMO 9 121145 1102 NOILINO 02 lt 9 138 2 321145 9110 3 Hu N3349 yt 121145 3ILSONOV 02 6 034 2 321145 9110 3 H1 N3349 S 321145 02 Q1HS 01083105 LYVIS HOLIMS NOILINOI 34 311 St 121145 JILSONOV 02 Q18 H1 MOSN3S 1 911 34VU8 JONVYO 1 321145 HOLIMS NOILINSI 02 y2v18 2 321145 399 2 121145 805835 03345 02 NMOU8 AHO 0V3H 83440 NV83T10NYH MOTI3A 9 321145 2 321145 2 18 434 JINGOW 50151539 21185 SNVHL 3101 2 321145 OVW 80123781 1313 32v18 034 JINON 80151538 21105 SNVUL 034 39NVY0 6 121145 121145 02 NMOU 1102 31138003345 02 3LIHA NMOUN y 12114 32018 3501 02 434 310008 80151538 313800114 02 2 121148 Old 401903781 1313 32v18 034 211 5 SNVUL 32130003345 02 q39 NMOUH 02 311HM 30 18 dNnd 1313 313800114 02 31 IHM 13101A 1102 NOILIN5I 123 02 NMONG MOT13A 32114 32130003345 02 NAO 1102 NOILINOI 02 311HM N33U9 uolvNuil V 313800114 02 Q33 N0113A 53120003345 02 31 IHM X2V 18 2IISONOVIO 043345 313003345 02 ang AV139 53404 02 JL IHM AVUS 21150 9 10 043345 313003345 02 3399 93130003345 02 3018 3L1HM 121145 213003345 02 1 321145 02 y2v18 uv8iTONVH H1 313800114 02 39NYUO AVUO MOSN3
85. 90 Nm Torque in Proper Sequence Pg 3 3 19 Align the bolt holes and install oil pump assembly into crankcase Rotate the rotors in the housing during installation as this checks for binding if new rotors are used NOTE Forassembly of the gears the cam gear and the crankshaft gear are stamped with This Side Out This indicates the side of the gear that faces outward or away from the case 21 Apply Loctite 242 PN 2871949 to the crankshaft 22 Before installing the crankshaft gear 1 heat the crankshaft gear to 250 F 121 C on a hot plate POLFRRIS 3 51 CAUTION The crankshaft gear is extremely hot Severe burns or injury can occur if the gear is not handled with extreme care and caution Follow the procedure below to help ensure safety 23 Use extreme caution when removing the crankshaft gear from the hot plate Use a pair of pliers and leather gloves when handling the crankshaft gear 24 Install the crankshaft gear I onto the crankshaft NOTE For assembly of the gears the cam gear and the crankshaft gear are stamped with This Side Out This indicates the side of the gear that faces outward or away from the case 25 Install counter balance shaft gear J with new key aligning timing marks with crankshaft gear 3 52 LO 1 In
86. 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 attention To ensure maximum service life and performance from a new battery perform the following steps NOTE Do not service the battery unless it will be put into regular service within 30 days After initial service add only distilled water to the battery Never add electrolyte after a battery has been in service NOTE New Battery Battery must be fully charged before use or battery life will be significantly reduced 10 30 of the battery s full potential To activate a new battery 1 Remove vent plug from vent fitting Remove cell caps 2 Fillbattery with electrolyte to upper level marks on case 3 Set battery aside to allow for acid absorption and stabilization for 30 minutes 4 Add electrolyte to bring level back to upper level mark on case NOTE This is the last time that electrolyte should be added Ifthe level becomes low after this point add only distilled water POLARIS 5 Charge battery at 1 10 of
87. Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts 37 Install shaft seal with ceramic surface facing inward 38 Install water pump impeller P Secure the impeller with the washer and a new nylok nut Q Torque the nut to specification 3 56 Water Pump Impeller Nut Torque 108 12 in Ibs 6 8 0 68 Nm 39 Install water pump cover R with new O ring seal Torque bolts to specification in proper sequence See Pg 3 4 Install Dry Do not use lubricants or Sealants on O ring Seal Ss Sd 2 96 12 in Ibs 10 85 1 35 Nm Water Pump Housing Bolt Torque 96 12 in Ibs 10 85 1 35 Nm Torque Bolts in Proper Sequence Pg 3 4 POLARIS LO 40 Sparingly apply Starter Drive Grease PN 2871423 to the starter drive Install the starter bendix NOTE There are thrust washers on both sides of starter drive 41 Install stator assembly S and bolts Torque bolts to 96 12 165 10 85 0 35 Nm 42 Install the the wire hold down bracket T Install two new wire hold down bolts New bolts contain patch lock Torque bolts to 96 12 in Ibs 10 85 0 35 Nm and follow the proper bolt torque sequence on Pg 3 3 Coat the stator wire grommet U with Nyogel Grease 2871329 NOTE Be sure the stator wires are routed properly under the wire hold down bracket Repl
88. D and water pump impeller E Remove part of the water pump seal behind the impeller 3 Remove flywheel nut and washer POLARIS wW ENGINE 4 Install Flywheel Puller PN 2871043 and remove flywheel F CAUTION Do not thread the puller bolts into the flywheel more than 1 4 or stator coils may be damaged 5 Remove the starter bendix G wire holddown plate and the woodruff key I from the crankshaft The stator does not have to be removed at this point 8 Use a white pen to accent the timing marks on the following gears camshaft gear K crankshaft gear M or counterbalance gear N This will ensure proper gear alignment and timing during reassembly of the gears 6 Remove the gear stator housing bolts and remove the gear stator housing cover J and gasket from the crankcase Be sure to catch the excess oil from the crankcase POLARIS 3 39 6 NOTE If replacing one of the gears it is 11 The cam gear assembly contains three loaded recommended that all of the gears be replaced A springs To open the cam gear assembly gear kit is available in the parts book e Place the cam gear on a flat surface Cam Gear Removal with the timing mark side facing up e While holding both gears together lightly work a small flathead screwdriver between the two gears e Remove the top gear The springs should stay in place CAUTION 9 Use the Cam Gear Tooth Alignment Too
89. Differenttypes of batteries require different service procedures Proper servicing and upkeep of your battery is very important for maintaining long battery life Your ATV may have a Conventional Battery or a Sealed Low Maintenance Battery To identify which type of battery your ATV has refer to the illustration below and follow the correct service and charging procedures that follow in the manual CONVENTIONAL BATTERY Removable Top View Electrolyte Level Indicator UEFA FYFI lo LOWER EVEL POLARIS 5022 Side View WADE IN U S A SEALED LOW MAINTENANCE BATTERY No Caps Non removable sealed top DO NOT OPEN CHARGING m METHOD 0 2 x 52 Top View No Electrolyte Level Indicator POLARIS YTX 4A C GR Be Pb Pb NONSP LLABLE 1509000 NADE IN U S A Side View 10 22 BATTERY ACTIVATION CONVENTIONAL AWARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from con tact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention
90. Disconnect holder strap and remove cover 2 Disconnect battery negative black cable first followed by the positive red cable A CAUTION To reduce the chance of sparks Whenever removing the battery disconnect the negative black cable first When reinstalling the battery install the negative cable last 3 Disconnect the vent hose 4 Remove the battery 5 Conventional Batteries Only Remove the filler caps and add distilled water only as needed to bring each cell to the proper level Do not overfill the battery Fully recharge after filling AN Use only distilled water Tap water contains minerals which are harmful to a battery AN Do not allow cleaning solution or tap water to enter the battery as it will shorten the life of the battery 6 Reinstall the battery caps 7 Clean battery cables and terminals with a stiff wire brush Corrosion can be removed using a solution of one cup water and one tablespoon baking soda Rinse well with clean water and dry thoroughly 8 Reinstall battery attaching positive red cable first and then the negative black cable 9 Reattach vent hose making sure it is properly routed and not kinked or pinched 10 Coat terminals and bolt threads with Dielectric Grease PN 2871329 11 Reinstall battery cover and holder strap SPARK PLUG 1 Clean plug area so no dirt and debris fall into engine when plug is removed Remove spark plug high tension
91. Drive new joint into strut housing until fully seated 9 Apply Loctite 242 PN 2871949 to threads of retaining plate screws or install new screws with pre applied locking agent Torque screws to 8 ft Ibs 11 Nm 10 Install A arm on ball joint and torque castle nut to 25 ft Ibs 35 Nm 11 Reinstall cotter pin with open ends toward rear of machine DECAL REPLACEMENT Plastic polyethylene material must be flame treated prior to installing a decal to ensure good adhesion The flame treating procedure can often be used to 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 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 5 20 To flame treat the decal area 1 2 S 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 flame treating Do not hold the torch too close to the surface Keep the torch moving to prevent damage Apply the decal TEERING POST ASSEMBLY 2 ft Ibs 16 Nm Hand tighten steering post slotted nut A Align the cotter pin hole on the steering post slot
92. EERING SUSPENSION FRONT COVER REMOVAL FOOT WELL REMOVAL INSTALLATION INSTALLATION 1 Open the front storage compartment 1 Remove the four plastic inserts A that secure 2 Pull up and outward on the front cover to remove the wheel well to the front and rear cabs See the cover PLASTIC INSERT REMOVAL INSTALLATION for help 2 Remove the four screws B from the bottom of the foot well Remove the footwell 3 Toinstallthe front cover insert the tabs of the front cover into the inserts of the cab Make sure the tabs are aligned with the slots Then press the rear tabs into the slots 3 Reverse the removal procedures to install the foot well Be sure to properly align the the cab ends into the foot wells upon reassembly 4 POLRRIS BODY STEERING SUSPENSION FRONT STORAGE REMOVAL 2 Remove the strut tower caps B Squeeze the caps inward and lift up to remove Front Storage 3 Remove the four bolts that secure the storage rack to the frame Front Cab T 25 Screws 1 Remove the front radiator cap cover A by lifting upward on the cover 4 Remove the two T25 screws that secure the storage box to the front fender well areas each side 5 Remove the two T25 screws that secure the outside of the storage box to the front fenders each side POLARIS
93. EFI Harness NOTE See Chapter 4 for more information the EFI system POLARIS 37 6 EXHAUST SYSTEM NOTE Silencer Removal Silencer removal requires replacement of the silencer grommets item 24 as they become damaged during removal 800 EFI Exhaust Canister Maintenance The exhaust canisters on Polaris 800 EFls are ceramic coated To maintain a beautiful finish and prevent corrosion periodic maintenence is required DO NOT use caustic chemicals to clean as they may damage the finish 1 Wash any accumulated mud or debris from the canisters with a soft brush and soapy water 2 Use a cleaner such as HPC HiPerWash to clean away any remaining grime salts or oils 3 If the canisters are stained from oils or other fluids use fine steel wool with HPC Liquid Buff Cleaner and Polish to remove the stain 4 After removing the stains polish using Liquid Buff and a soft cloth Repeat this procedure as often as de sired to maintain the canister s finish Ref Qty Description Description Nut Nylok Washer Bushing Washer Rubber Bushing Bracket Silencer Frame Dampener Vibration Bolt Exhaust Silencer RH Washer Clean Out Bolt Seal Exhaust Socket Spring Exhaust Pipe Dual Black Screw Washer Shield Heat Dual Screw Gasket Shield Heat Exhaust Top Seal Exhau
94. EL SYSTEM FUEL INJECTION 8 Remove the air box cover and remove the two gas tank mounting bolts at the rear of the gas tank Remove 2 Bolts Front of we 9 Carefully pull the fuel tank out of the frame Keep the fuel tank horizontal during removal this will keep the fuel in the tank from spilling out the top inlet Fuel Pump Tank Installation 1 Reinstall the pump tank assembly 2 Reconnect the sender wiring harness and route the harness properly Install the fuel line and tighten the fuel line clamp 3 Reinstall the two fuel tank mounting bolts at back of tank 4 Reinstall the PVT intake duct gas tank vent line front cab assembly and side panels NOTE Properly route the gas tank vent line use tape to secure the vent line in place See Pic 1 5 Reconnect the negative battery cable Test the sender for proper operation FUEL PRESSURE REGULATOR The fuel pressure regulator maintains the required operating system pressure of 39 psi 3psi A rubber fiber diaphragm divides the regulator into two separate sections the fuel chamber and the pressure regulating chamber The pressure regulating spring presses against the valve holder part of the diaphragm pressing the valve against the valve seat The combination of atmospheric pressure regulating spring tension equals the desired operating pressure Any time the fuel pressure against the bottom of the diaphragm exceeds the desired top pressur
95. ES 630 lt FINAL DRIVE CHAPTER 7 FINAL DRIVE Final Drive Torque Specifications 7 1 AWD Front Axle Remove Install 7 2 7 3 AWD Front CV Joint Boot Replace 7 4 7 5 AWD Front Drive Axle Exploded View 7 15 Front Hub Disass Assemble 7 5 AWD Front Prop Shaft Removal 7 6 U Joint Disassemble Assemble 7 6 7 7 Drive Axle Propshaft Exploded View 7 8 AWD Front Gearcase Operation 7 9 AWD Front Gearcase Service 7 9 7 17 Rear Hub Remove install 7 19 7 20 Rear Hub Disassembly Assembly 7 21 7 22 Rear Drive Shaft Removal 7 22 Driveshaft CV Joint Tips 7 22 Rear Driveshaft Installation 7 23 Rear Driveshaft Service 7 24 7 26 Rear Gearcase Service 7 26 7 30 POLARS 71 1 FINAL DRIVE WHEEL AND HUB TORQUE TABLE COMPONENT FT LBS IN LBS F R Steel Wheel Nuts 41 F R Aluminum Wheel Nuts 122 Front Hub Nut 95 Rear Hub Nut EN 109 CAUTION Locking nuts and bolts with preapplied locking agent should be replaced if removed The self locking properties of the nut or bolt are reduced or destroyed during removal SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2872608 Roller Pin Removal Tool 8700226 CV Boot Clamp Pliers 1 3 4 Straight Wrench 2870772 FRONT DRIVE AXLE REMOVAL Set the ATV in park Remove hub dust cap Remove cotter pi
96. Even RPM Con tinued problems would call for battery inspection Meter Setting DC Amps Perform Break Even Amperage Test Does charging occur as specified 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 20 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 x wire must be connected to harness Battery Check regulator rectifier connections voltage must be present on red wire terminal 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 POLRRIS 10 21 ELECTRICAL BATTERY IDENTIFICATION NOTICE It is important to identify what type of battery you have installed in your ATV
97. LECTRONIC THROTTLE CONTROL ETC SWITCH The Electronic Throttle Control ETC system is designed to stop the engine of an ATV in the event of a mechanical problem with the throttle mechanism The ETC switch is mounted independently of the throttle actuator lever inside the throttle block assembly This is a normally closed switch and is held in the open position contacts are separated as shown below by throttle cable tension The contacts are open during normal operation regardless of throttle lever position In the event of a mechanical problem in the throttle mechanism cable tension is lost the switch contacts close connecting the black wire to ground which prevents ignition spark This is the same as turning the key or engine stop switch OFF NOTE Test the ETC switch at the harness connector ETC will not activate unless there is throttle plate movement off of zero detected by the ECU Adjust throttle cable freeplay ETC switch and make sure throttle mechanism is functioning properly before testing the switch Refer to Maintenance Chapter 2 for cable adjustment procedure POLARIS ELECTRICAL ETC OPERATION TEST Remove throttle block cover by carefully releasing all tabs around edge of cover Place transmission in neutral and apply parking brake Start engine and open throttle lever slightly until engine RPM is just above idle speed Hold throttle cable with fingers at point A as shown below
98. N 2871951 to screw threads and torque screws to 6 12 ft Ibs 8 16 Pinion Retainer Plate Bolt Torque 6 12 ft Ibs 8 16 Nm 9 Install the a new needle bearing the 24T reverse sprocket washer and a new snap ring Install the shift dogs and wave spring Install the washer a new needle bearing and the high gear Install the press fit gear and ball bearing POLARIS NOTE Install a new snap ring at this time When installing the new snap ring open the the snap ring just far enough to go over the shaft to avoid stressing the snap ring If the snap ring is over stressed it could come off the shaft and cause internal damage to the transmission 10 Slide the reverse shaft assembly through the silent chain 11 Install a new needle bearing the low gear the thrustwasher and the snap ring Use of a new snap ring is recommended 12 Install the engagement dogs wave springs and bearing 13 Install the ball bearing onto the end of the input shaft 14 As the engagement dogs are installed onto the shaft place the wave springs into the spring groove Keep the spring in place while the fork is being installed on the shaft and while placing the shafts into the case POLARIS TRANSMISSION NOTE Use caution when installing the fork as the spring can easily fall out NOTE Installing the shift rail will aid in keeping the shift forks shift dogs and the springs in place 15 Carefully instal
99. NVENTIONAL BATTERY INSTALLATION 1 Clean battery cables and terminals with a stiff wire brush Corrosion can be removed using a solution of one cup water and one tablespoon baking soda Rinse well with clean water and dry thoroughly 2 Route the cables correctly 3 Reinstall battery attaching positive red cable first and then the negative black cable Coat terminals and bolt threads with Nyogel Grease PN 2871329 4 Install clear battery vent tube from vehicle to battery vent WARNING Vent tube must be free from obstructions and kinks and securely installed If not battery gases could accumulate and cause an explosion The vent tube should be routed away from frame and body to prevent contact with 10 23 ELECTRICAL electrolyte Avoid skin contact with electrolyte as severe burns could result If electrolyte contacts the vehicle frame corrosion will occur 5 Reinstall the holder strap CONVENTIONAL BATTERY TESTING Whenever a service complaint is related to either the starting or charging systems the battery should be checked first Following are three tests which can easily be made on a battery to determine its condition Test Specific Gravity Test and Load Test CONVENTIONAL BATTERY OCV OPEN CIRCUIT VOLTAGE TEST Battery voltage should be checked with a digital multitester Readings of 12 6 volts or less require further battery testing and charging See charts and Load Test on bel
100. O 33 8674 mm Camshaft journal OD uri 654 0 00039 42 0 010 mm 1 634 0 00039 41 50 0 010 mm E 0 00039 41 0 010 mm Camshaft journal 42 07 x 0 010 mm bore ID 0 00089 41 58 0 010 mm 1 617 0 00039 41 07 0 010 mm 0 00276 0 00079 0 07 0 02 mm End Play 0 0167 0 0098 0 425 0 25 mm Counter End Play 0 005 0 127 mm Balance Oylinder Surface warpage limit 0 00394 0 1 mm Head Standard height 3 478 88 35 mm Valve Seat Contacting width 0 0472 0 00787 0 0039 1 20 0 20 0 10 mm 0 0591 0 00787 0 0039 1 50 0 20 0 10 mm Seat Angle 45 5 gt 0 25 Inner 0 2367 0 00029 6 012 0 007 mm Guide 0 807 0 0039 20 50 0 01 mm Valve Margin 0 79 20 06mm Thickness Max 0 98 24 89mm Min 0 59 14 98mm 0 80 3 488 mm Max 1 0 25 4mm Min 0 60 15 24mm 0 2356 0 00039 5 985 0 01 mm 4 51 0 01476 114 5550 0 375 mm 4 5453 01496 115 45 0 38 mm 1 735 46 069 mm Intake 1 4638 37 18 mm Exhaust 1 4736 37 43 mm denotes cylinder head with bronze valve guide 12 700 800 EFI ENGINE SERVICE DATA Cylinder Piston Connecting Rod EFI Engine No EFI Engine No EH6800LE EH7800LE Cylinder Surface warpage limit 0 004 0 10 mm Same mating with cylinder head Cyl
101. OLID OR DASHED LINES TO SIMPLIFY TRACING IN DIAGRAM COLOR CODE BLK BLACK BRN BROWN GRN GREEN PUR PURPLE 172 ENGINE GROUND BLU BLUE GRY GRAY NO CHASSIS GROUND OR ORANGE Y YELLOW R RE W WHITE TWO COLOR WIRES ARE SHOWN WITH AIN TRACE COLORS EXAMPLE R Y RED WITH YELLOW TRACER C SWITCH NORMALLY CLOSED SWITCH NORMALLY OPEN BLU mR BLK 3 WINCH MOTOR E SMALL WIRE RESISTANCE T BRN G 440 50 BRN BLK 45050 1 Q Oar LARGE WIRE RESISTANCE BLK Y 0Q 0 POWER BLK BLU Q O T BLK R OPE 0 50 0 50 BLK Y Q GRN POWER BLU Q L 1 BLK OPE 52 lt gt R Y BLK POWER BLU BRN 0 Q BLK OPE CONTACTOR SWITCH QUT gu IN GRN POLARIS 36 10 STARTER SYSTEM TROUBLESHOOTING Starter Motor Does Not Turn Battery discharged gravity Loose or faulty battery cables or corroded connections see Voltage Drop Tests Related wiring loose disconnected or corroded Poor ground connections at battery cable starter motor or starter solenoid see Voltage Drop Tests Faulty key switch Faulty kill switch Faulty starter solenoid or starter motor Engine pro
102. OSTIC MODE SET TO AWD DIAGNOSTIC SCREEN PROBLEM MECHANICAL Note If AWD icon comes on instru ment cluster is O K Proceed to me chanical tests in Service Manual Check the AWD icon on instrument clus ter to verify it s operation The AWD switch is directly powered by switched 12 volts red white The gear switch only interfaces with the instrument clus 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 DOES CLUSTER SHOW 16 Pin Connector INSTRUMENT m OK PROCEED TO TEST 2 Red 12V Ignition Switch Red White 12V ETC and AWD Switch Grey Orange Mode Override button Black Ignition Kill Green Diagnostic Factory Use Only Blue Diagnostic Factory Use Only Yellow Red RPM Input Brown Ground Blue White Engine Overheat Switch N C Black White Engine Check Light Purple White Fuel Sender if equipped Brown Red Trans Switch Ground White Gear Shift Signal White Blue High Gear Signal Brown White AWD Coil ON HUB COIL CONNECTOR LEAVE IT CONNECTED MEASURE FOR 12V FROM BROWN WHITE TO GROUND NOT AN INSTRUMENT Y CLUSTER PROBLEM CHECK AWD SWITCH AND WIRING Note Reversing polarity when connecting the battery or other DC power source will fail the AWD control and the instrument cluster If the key switch and the AWD switch a
103. OT apply too much pressure on the side cutters or damage to the insert will occur ing Bolt Lower Wheel Bearing Carri 3 er Bolt Top Strut Casting Pinch Bolt 5 0 Strut Rod Retaining Nut 5 5 Tie Rod End Jam Nut 12 14 17 19 Tie Rod End Castle Nut 40 45 54 61 Tie Rod End Attaching Bolt 25 30 35 41 8 7 8 1 1 1 NOTE Refer to exploded views throughout this chapter for identification and location of components 5 2 POLARIS 2 Next use the diagonal side cutters under outside insert B to completely remove the assembly NOTE The inside insert A will still be installed in the outside insert B 3 Toinstall the inserts press outside insert B into the hole Press inside insert A until it snaps into place NOTE The outside insert B should be flush surface after installation The inside insert A should be flush with the top of the outside insert B POLARIS BODY STEERING SUSPENSION SIDE PANEL REMOVAL Side panel removal is quick and easy use the following instructions for removal and installation 1 Remove seat by releasing the latch and lifting up on the seat 2 Grasp the rear ofthe side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it from the ATV 3 Reinstall the side panel by reversing the removal procedure 5 3 BODY ST
104. OdS 5000 POLARIS 10 40 A Arm Replacement 5 16 Air Filter Service 2 20 Alternator Output Test 10 19 ATV Specifications 1 3 1 4 1 5 Auxiliary Brake Removal 9 22 Back Lash Pad Adjustment 7 15 Battery Charging 10 25 10 26 10 28 Battery Check Before Install 10 25 Battery Installation 10 23 10 27 Battery Maintenance 2 16 10 25 Battery Service 10 22 10 23 10 24 10 25 10 27 10 28 Battery Storage 2 36 Battery Terminal Bolts 10 23 Battery Testing 10 24 10 27 Battery Off Season Storage 10 25 10 28 Bleeding Procedure 4 Stroke Cooling System 3 61 Body Assembly Exploded View 5 11 Body Rack Exploded View 5 12 Brake Bleeding Fluid Change 9 7 9 8 9 13 9 17 Brake Caliper Disassembly Front 9 14 Brake Caliper Exploded View Front 9 4 Brake Caliper Exploded View Rear 9 4 9 23 Brake Caliper Inspection Front 9 15 Brake Caliper Installation Front 9 16 Brake Caliper Removal Front 9 14 Brake Caliper Removal Inspection Rear 9 19 Brake Disc Inspection Front 9 13 Brake Disc Inspection Rear 9 21 Brake Disc Removal Replacement Front 9 13 Brake Fluid Level 2 28 Brake Hose Fitting Inspection 2 29 Brake Light Switch Testing 10 34 Brake Light Work Light Replacement 10 33 Brake Master Cylinder Exploded View Rear 9 5 9 22 Brake Noise 9 5 Brake Pad Assembly Front 9 12 Brake Pad Inspection 2 28 Brake Pad Installation Rear 9 18 Brake Pad
105. PART NUMBER 2871358 2870913 2201379 PU 47086 8700220 2871025 Drive Clutch Spider EBS 200 ft Ibs 271 Nm Clutch Drive Clutch Spider Lock Nut 15 ft lbs 20 3 Nm Plastic 301r bs ONT 6 4 CX PVT OPERATION OVERVIEW WARNING All PVT maintenance or repairs should be performed only by a certified Polaris Master Service Dealer MSD technician who has received the proper training and understands the procedures outlined in this manual Because of the critical nature and precision balance incorporated into the PVT components it is absolutely essential that no disassembly or repair be made without factory authorized special tools and service procedures The Polaris Variable Transmission PVT consists of three major assemblies 1 The Drive Clutch 2 The Driven Clutch and 3 The Drive Belt The internal components of the drive clutch and driven clutch 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 and the vehicle s intended usage Therefore modifications or variations of components at random are never recommended Proper clutch setup and careful inspection of existing components must be the primary objective when troubleshooting and tuning DRIVE CLUTCH OPERATION Drive clutches primarily sense engine RPM The two major compon
106. PECIFICATIONS The following torque specifications are to be used as a general guideline There are exceptions in the steering suspension and engine areas Always consult the exploded views in each manual section for torque values of fasteners before using standard torque Q Q Bolt Size Threads In Grade 2 Grade 5 Grade 8 Torque in Ibs Nm 10 DA cc BIB AY oie eo le te 43 5 0 60 6 9 10 ret obe 49 5 6 i ee ct 68 7 8 Torque ft Ibs Nm 14 MER SEIL RUN ERN Pe 12 16 14 zi GB TOUA c ote iii 14 19 546 17 60 25 35 5 16 DAN AED 12 16 3 cum LES 215 29 40 38 COMME EP 20 27 30 40 45 62 38 29 G2 DR DE 35 48 50 69 7 16 142 5 n ios etos 3O 40 50 69 70 97 7 16 205 reife 35 48 55 76 80 110 12 18 15 555a 50 69 75 104 110 152 12 55 76 90 124 120 166 Metric 6x 1 0 72 78 In Ibs 8x 1 25 14 18 ft Ibs 10x1 25 26 30 ft Ibs To convert ft lbs to Nm multiply foot pounds by 1 382 To convert Nm to ft Ibs multiply Nm by 7376 SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the
107. 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 TIE ROD END STEERING INSPECTION check for play in the tie rod end grasp the steering tie rod pull in all directions feeling for movement Repeat inspection for inner tie rod end on steering post Replace worn Steering components Steering should move freely through entire range of travel without binding 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 and hub by pushing inward and pulling outward If abnormal movement is detected inspect the hub and wheel assembly to determine the cause possible loose wheel nuts or loose front hub components Check for Loose Wheel or Hub Refer to the Body Steering Chapter 5 or Final Drive Chapter 7 for service procedures CAMBER AND CASTER The camber and caster are non adjustable POLARIS 2 25 WHEEL ALIGNMENT METHOD 1 STRAIGHTEDGE OR STRING Be sure to keep handlebars centered See notes below NOTE String should just touch side sur face of rear tire on each side of m
108. Puller EBS Drive Clutch Cover Bushing Removal 2 Install adapter reducer Item 9 3 From outside of clutch cover insert removal tool Item 3 into cover bushing 4 With inside of cover toward vise slide cover onto puller 5 Install nut onto puller rod and hand tighten Turn puller barrel to increase tension as needed 6 Turn clutch cover counterclockwise on puller rod until bushing is removed and cover comes free 7 Remove nut from puller rod and set aside 8 Remove bushing and bushing removal tool from puller Discard bushing EBS Drive Clutch Cover Bushing Installation 1 Apply Loctite 609 evenly to bushing bore in cover 2 Working from inside of cover insert new bushing and bushing installation tool into center of clutch cover 3 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 4 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 5 Turn clutch cover counterclockwise on puller rod until bushing is seated 6 Remove nut from puller rod Take installation tool and clutch cover off rod POLARIS CLUTCH CLS EBS DRIVEN CLUTCH 1 Remove driven clutch from the transmission input Aeneas shaft Do not attempt disassembly of the driven DISASSEMBLY INSPECTION clutch from the outside snap ring driven EBS Driven Clutch Operation clutch must be disassembled from the helix side T
109. Push Rod Inspection 3 21 PVT Assembly 6 8 PVT Disassembly 6 7 PVT Drying 2 22 6 5 PVT Maintenance 6 5 PVT Operation 6 4 PVT Overheating 6 6 PVT System Sealing Ducting Components 6 2 PVT Troubleshooting 6 28 R Radiator Coolant Level Inspection 2 19 Radiator Front Cover Removal 2 20 5 10 Radiator Maintenance 2 19 Rear Cab Removal Installation 5 9 Rear Caliper Assembly 9 20 Rear Drive Shaft Installation 7 23 Rear Drive Shaft Removal 7 22 Rear Drive Shaft Service 7 24 Hub Assembly Rear 7 21 Hub Disassembly Rear 7 21 Rear Rack Removal Installation 5 7 Rear Storage Compartment Removal 5 9 Rear Suspension Exploded View 5 17 Rocker Arm Inspection 3 21 S Sediment Tube Maintenance 2 21 Shift Linkage Adjustment 2 15 Shift Weights 6 10 Side Panel Removal 5 3 Solid State Relay 10 20 Spark Plug Maintenance 2 17 Special Tools 1 7 1 8 2 8 4 2 5 2 7 2 9 2 Special Tools Engine 3 9 Special Tools PVT 6 4 Specifications Brake 9 2 Specifications Cooling System 3 15 Specifications Drive Clutch Spring 6 9 Specifications Torque Brakes 9 2 Specifications Torque Engine 3 10 Specifications Torque Final Drive 7 2 Specifications Torque PVT 6 4 Specifications Torque Standard 1 11 Specifications Torque Steering 5 2 Specifications Torque Suspension 5 2 Specifications Torque Transmission 8 4 Speedometer Installation 10 8 Speedometer Troubleshooting
110. R A05MH86AU ENGINE MODEL EHO76OLE011 Dimension Capacity Wheel Base 50 75 in 128 9 cm Dry Weight 770 Ibs 326 6 kg Gross Vehicle Weight 1220 Ibs 553 kg Front Rack Capacity 100 Ibs 45 4 kg Towing Capacity 1500 Ibs 454 kg Hitch Tongue Capacity 150 Ibs 68 kg Body 5 se Rear Rack Capacity 200 Ibs 90 7 kg POLARIS 1 3 GENERAL INFORMATION MODEL 2005 SPORTSMAN 700 EFI MODEL NUMBER A05MH68AU ENGINE MODEL EHO68OLE Polaris Twin Cylinder EHO680LE022 2 Platform Engine Model Number Engine Displacement Number of Cylinders 80 x 68 mm Bore amp Stroke mm Compression Ratio Compression Pressure Engine Idle Speed 1150 100 RPM Engine Max Operating Rpm 6500 Rpm gt 200 Rpm Cooling System Capacity Overheat Warning Oil Requirements Capacity Exhaust System Fuel System Fuel System Electronic Fuel Injection EFI Fuel Pump in tank assembly 25L per hour at 39 PSI Fuel Filter s 30 Micron in Tank not replaceable 10 Micron In Line replaceable Bosch MSE 1 1 ECU 4 13 gal US 15 6 Itr 87 Octane minimum 89 Oxygenated 227 Alternator Output Ignition System RC7YC 035 in 0 9 mm Lead Acid 30 Amp Hr Fan 20 amp Harness 20 amp Fuel pump ECU 15 amp Instrument Cluster Voltage Regulator 6 amp Liquid 3 2 qt 3 ltr Fuel Injector s EFI Controller Fuel Capacity Requirement Ignition Timing Spark plug Gap B
111. S dVB l 02 321145 313800114 02 311H4 03 121145 11 23 02 5 49 4138 32018 3513 32130003345 0 1 105835 dNW3 0 3101 321145 HI 02 NAO 2 321145 02 NMOUE ANNOYS 3NVUJ 01083105 18 15 NAO 4 02 JONVYO 321145 HOLIMS Y 213 02 311HA 03 211SON5V 02 311HM N3399 43404 MS 5318055122 39v 404 1 9110 3 9 11 39NYUO 9VN 80123781 1303 02 12V18 3111HM 2 321145 311HA 03 Old 4012378 1313 02 3LIHM 2 321145 080089 9 NMO Av138 02 32v 18 401134 2 321145 MOSN3S 1 911 34VU8 9 311H4 03 MOSN3S 03345 02 39NYUO AVUD 1 321145 HOLIMS NOILINOI 3L1HA 03 105835 43145 02 39NV30 3LIHM 1 321145 Jv83 T0NVH HI 9 311HA 03 Sd 02 N3349 uvg3TONVH HT HOLIMS NOILIN2I 12v18 03 MOSN3S dVG L 02 31 IHM JNId uvg3TONVH HT HOLIMS NOILINOI 12v 18 03 805835 dW3 02 01131 83 04 MS 5318055322 32018 3513 9 311HM 39NVUO MOSN3S dVB L 02 FONVYO HOLIMS NOILINOI 392018 350 9 NOTI3A t 121145 02 3101 Av13U u3MOd 32018 3513 9 39NVuO 21150 9 1 02 lt 5 088 07131 0 HY MOSN3S 1 911 JONVYO 2 321145 02 20 2 321145 32018 3513 9 311HA 03U v 121145 3 02 033 YOLISNNOD 01 YOLIENNOD WOH3 390V9 80109 YOLISNNOD OL YOLISNNOS 40109 J3H JVL NOLLVNINHSL 318V1 NOLLVNIWH3L WVYSVIG NI 9NIOVUL 19 OL S3NIT Q3HSVQ 01105 A8 463183538438 39 5311 30 2 39Vd 7 19048 60 ALY NVINSLY
112. SOR 5 z LOCATED ABOVE TERIS on TES SPEED SENSOR 282 LA zu T LEET FRONT WHEEL SIDE OF CYLINDER HEAD LOCATED ON LOWER 5 PTS 2 i25 S REAR RECOIL COVER tc N zzz ieee au 7 T J dh T 8 I o T tt 3 J 3 lt 9 R 6 GAUGE o RR ox gt 5 papa T BAP SENSOR TPS FUEL FUEL a LOCATED UNDER SEAT Q INJECTOR MAG INJECTOR PTO STARTER 905 BEHIND THROTTLE BODY H Ex mE SB BATTERY ra WOTOR op 9 29 XD 5 qD qD 1 R 6 GAUGE D y RTER SOLE 5601 0 lt MS Ld Hine OF LEFT im WHEEL 22 1 Ke ee a onis LOCATI FRAME zz zz AT 20 2 5 LH TAILLIGHT LH WORKLIGHT RH TAILLIGHT WORKLIGHT 5 b DE GROUND 55 55 AT 100920186 00225 gt Go POLARIS ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN 700 800 EFI
113. T CONNECTOR BETWEEN BROWN WHITE CLUSTER AND GROUND CHECK CHARGING SYSTEM STATOR REGULATOR AND WIRING TURN AWD OFF START THE ENGIN REV AND HOLD THE RPM S ABOVE 3100 TURN AWD ON NO PROBLEM DOES FRONT DRIVE ENGAGE 16 Pin Connector Red 12V Ignition Switch 9 Blue White Engine Overheat Switch Red White 12V ETC and AWD Switch 10 N C Grey Orange Mode Override button 11 Black White Engine Check Light Black Ignition Kill 12 Purple White Fuel Sender it equipped Green Diagnostic Factory Use Only Brown Red Trans Switch Ground Blue Diagnostic Factory Use Only White Gear Shift Signal White Blue High Gear Signal Yellow Red RPM Input Aa eni d WD Coil 9 Brown Ground INSPECT HUB COIL WIRING FOR SHORT CIRCUITS TO GROUND DISCONNECT REPLACE CONNECTOR amp MEASURE BETWEEN HUB COIL SEEEBOMETER BROWN WHT amp GROUND IS THE AWD ICON ON N MECHANICAL PROBLEM REPAIR HUB COIL WIRING CO POLARIS 10 11 ELECTRICAL SPEEDOMETER TROUBLESHOOTING 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 Red 12V Ignition Switch 9 Blue White Engine Overheat Switch NSTRUMENT SPEEDOMETER Red White 12V ETC and AWD Switch 10 N C gt Grey Orange Mode Override button Black White Engine Check Light NOR ae PERFORM TEST 2 4 Black
114. TALLATION 5 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 6 Add grease through large end of boot 7 Install a new boot onto the axle shaft and fill the CV joint and boot with the correct type and amount of grease 8 While pulling out on the CV shaft fully extend the CV joint and slide a straight O ring pick or a small slotted screw driver between the small end of the boot and the shaft This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life Before you remove your instrument be sure the small end of the boot is in its correct location on the axle CARE MUST BE TAKEN TO AVOID DAMAGE TO THE NEWLY INSTALLED BOOT 9 Install the small clamp on the boot 10 Be sure to use only the Constant Velocity Joint grease supplied with boot service kit IF CV JOINT WAS CLEANED add the recommended amount of grease to the joint in aadition to the grease pack supplied with boot kit NOTE Joint Grease Capacity 7 26 Joint Capacity 50 Grams Joint Capacity 50 Grams Ho OUTBOARD 80g Total Boot Capacity 30 Grams INBOARD 100g Total Boot Capacity 50 Grams CV Joint Grease 30g PN 1350046 50g PN 1350047 Outboard joint 30g if boot is replaced only Another 50g 80 total if joint is cleaned Inboard joint 50g if boot is replaced only Another 50g 10
115. TARTER SOLENOID BENCH TEST To measure the resistance of the pull in coil connect one meter lead to the solenoid lead wire and the other to ground The resistance should be 2 8 3 6 ohms Refer to Electric Starter System Testing in this section to further test the solenoid POLARIS ELECTRICAL STARTER DRIVE Pinion Gear Anti Kick out Shoe Garter Spring Replacement If the garter spring is damaged the overrun clutch may fail to return properly Use either of the following methods to remove and install a new garter spring Spring AC Over Stopper Q AL Thrust Bushing Retaining Ring Thrust Washer Polaris Premium Starter Drive Grease PN 2871460 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 ofthe shaft Slide the new spring over the overrun clutch and into the spring groove Make sure that the spring is positioned between the shoe alignment pins and the back flange of the anti kick out shoes 2 Remove the retaining ring thrust washer spring retainers and clutch return spring Screw the overrun clutch off the end of the pinion shaft Remove the old spring and install a new one Lightly grease the pinion shaft and reinstall the clutch spring retainers end washer and lock ring inthe reverse order Make sure the end washer is posi
116. Y TO GROUND NO CONNECTION il 7 rmm 41 R 02 R W 03 MUS coL 05 ORN 01 PNK LOCATED UNDER Ri i BRN FRONT COVER TO BLK FUSED 15 WBLK L 89 6A SPEEDO ECU B 53 BRN 126 B 19 QR 15A EFI POWER 130 BRN 51 33 R BLK 3b BRN 125 B 81 0 20 CHASSIS POWER 35 BRN 9 oy UR 118 ibn ACC POWER e Y FUSE BLOCK eo 18 BRN JD 102 R W 02 R W JD 124 GRN 14 BLI Sk L20A 20A LEFT HANDLEBAR 4 HE jl 52 113 120 GRN 43 vi o I 0 UNDER co SWITCH ASSEMBLY 1S RRN 6 F Aes 12 s 4 V iit Lu a eR SPLICE 1 SPLICE 2 gt eo a 92 RN I USED OFF ofr 0 N 54 BRN EU uma e EN 129 5 Fon Pg RELAY COIL 2 5 pit T Q 41 lt iL aL sre vm e dris yn 20 AMP FAN OMEN p ssh o BREAI gt B S EI 10 ento CIRCUIT KER al VERRI DE ono 28 GRY W OVERRIDE S 1 65 R 82 R 81 ORN F 63 R LOCATED IN FRONT 64 RIBLI T tc OF FUEL TANK 1 lt 12 101 ORN POWER RELAY 3 IE 86 ORN A e 34 RN BRAKE LAMP SWITCH CLOSED WITH ID caste HAND BRAKE APPLIED LO seg Eg e ae I i iz 222 2 35 e SEE as PF N 28 vas ill D eae EY OOO OOO 1 11 i 5 1 IGNITION SEN
117. ace 2 bolts with new bolts Stator Assembly Bolt Torque 96 12 in Ibs 10 85 0 35 Nm POLARIS ENGINE 43 Install the flywheel washer nut and key Torque flywheel nut to 65 7 ft Ibs 88 9 50 Nm 65 7 ft Ibs 88 9 50 Nm Flywheel Nut Torque 65 7 ft Ibs 88 9 50 Nm 44 Install stator housing with new O rings Torque the bolts to 96 12 in lbs 10 85 0 35 Nm and follow proper bolt torque sequence Pg 3 4 96 12 in Ibs 10 85 0 35 Nm Stator Housing Bolt Torque 96 12 in Ibs 10 85 0 35 Nm Torque in Proper Sequence Pg 3 4 3 57 45 46 After the engine is completely assembled and ready for installation the engine must be properly primed with Polaris OW 40 Synthetic Oil PN 2871281 Fill the oil filter three quarters full with Polaris OW 40 Synthetic Oil PN 2871281 Let the oil soak into the filter for 8 10 minutes Install the filter onto the engine Fill 3 4 full with OW 40 oil Remove primer plug from the engine Install the Oil System Priming Adapter PU 45778 into the oil plug hole Push 3 5 oz approx of Polaris OW 40 into the adapter until resistance is felt Remove the adapter Apply pipe dope or Teflon tape to the plug threads Install the plug and torque to 216 24 165 24 4 2 71 Nm Oil System Priming Adapter PU 45778 3 58 LO WARNING After any reassembly or rebuild the engine mu
118. ace Engagement Dog 6 Pin Switch Wave Spring O ring Washer Detent Star Needle Cage Bearing Lockout Disc 30T 6 Face Gear 16T Sector Gear 47T Mid Output Helical Gear Lock Nut Shift Shaft Rail Dowel Pin Shift Fork Ball Bearing Dowel Pin Thrust Washer Silent Chain 31T Spiral Gear Input Shaft Assy Output Shaft LH Main Cover Shim Dual Lip Seal Thrust Button Transmission Mount Bracket Shim Hex Screw Output Cover 33T 6 Face Gear Screw Washer EPRE T os os op po Ss es Ss Ss Sf Ss a ee Plain Bearing Label Park Lock Bolts POLARIS 1 1 1 1 1 1 1 1 4 1 4 1 1 1 1 2 4 2 1 2 1 1 1 2 2 1 1 1 1 1 2 1 1 1 1 1 1 Park Plate 8 3 TRANSMISSION TRANSMISSION INFORMATION TORQUE SPECIFICATIONS COMPONENT Trans Mounting Bolts Snorkel Lock Screw 11 16 LUBRICATION Refer to maintenance section for transmission lubricant type and capacity 30 12 Trans Drain Plug Fill Plug 10 14 14 19 5 12 GEAR SELECTOR REMOVAL 1 Disconnect linkage rod from gear selector handle 2 Remove two bolts attaching gear selector mount to machine frame 3 Lift gear selector out of mounting bracket and away from frame TRANSMISSION REMOVAL 1 Remove seat rear rack rear cab air box and exhaust system and r
119. achine Q ae 0 0 0 Q Bad 2 Va Og Sa Ge 22020 Cs v a 0 9 90090 090 9400 2 On Q 59 0 5 2 Rear rim Measure from string to rim at front and rear of rim measure ment should be 1 16 to 1 8 2 to 3 cm more than front rim measure NOTE The steering post arm frog can be used as an indicator of whether the handle bars are straight The frog should always point straight back from the steering post 2 26 MAINTENANCE WHEEL ALIGNMENT METHOD 2 CHALK 1 Place machine on a smooth level surface Set handlebars in a straight ahead position and secure handlebars in this position NOTE The steering arm frog can be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post Place a chalk mark on the center line of the front tires approximately 10 25 4 cm fromthe 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 Measure the distance between the marks and record the measurement Call this measurement Rotatethe tires 180 by moving vehicle forward or backward Position chalk marks facing rearward even with the hub axle centerline Again measure the distance b
120. ained 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 N Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A DANGER Failure to follow DANGER instructions will result in severe injury or death to the operator bystander or person inspecting or servicing the ATV 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 Loctite Registered Trademark of the Loctite Corporat
121. ake 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 slight pressure Float contact with tank Bent float rod If none of the conditions exists the sender assembly is faulty Fuel pump assembly replacement is required 10 34 5 POLARIS ACCESSORY WIRE CONNECTIONS Winch Installation The 2005 Sportsman models have the main winch cables routed and installed from the factory This enables quick installation Refer to Chapter 2 for more information on winch installation and operation Accessory Power Wires The accessory power leads for all accessories are located under the front cover The wires are 12 Volt wires and are Orange White in color To locate the wires remove the front cover The wires will be located in the main wire loom on the right side If you have trouble locating the Orange White wires remove the left side panel and search under the front fender area NOTE Refer to the accessory instructions for accessory hook up and installation POLARIS ELECTRICAL Accessory Wires Exec OR 60 OR ACC 1 LOCATED BELOW HEAD LAMPS ACC 2 10 35 l lt O Lu l LLI BASIC WINCH WIRING 2005 ATV MODELS 2005 ATV WINCH WIRING DIAGRAM WIRES ARE REPRESENTED BY S
122. ake line and tighten securely with a line wrench Torque the banjo brake lines to the proper torque specification 3 Install the adjuster screw and turn until stationary pad contacts disc then back off 1 2 turn 4 Follow brake bleeding procedure outlined on Pages 9 7 9 8 5 Install wheels and torque wheel nuts to specification Front Wheel Nut Torque See Page 7 2 POLARIS 9 16 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 not allow pads or disc to become hot or warpage may result Repeat this procedure 10 times REAR BRAKE PAD REMOVAL 1 Support the machine Remove the rear tire 2 Remove one of the slide pin clips from the slide bolt POLARIS BRAKES 4 Remove caliper mounting bolts and lift caliper off of disc NOTE When removing caliper be careful not to damage brake line Support caliper so as not to kink or bend brake line 5 Push caliper pistons into caliper bore slowly with pads installed 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 6 Remove the caliper slide p
123. anent marker mark the cover spider and moveable and stationary sheaves for reference as the previous X s may not have been in alignment before disassembly 6 11 CLUTCH DRIVE CLUTCH DISASSEMBLY CONT D 2 Remove cover bolts evenly in a cross pattern and remove cover plate 3 Inspect cover bushing A The outer cover bushing is manufactured with a Teflon coating Wear is determined by the amount of Teflon remaining on the bushing Cover Bushing inspection Cover Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replace ment in this chapter 4 nspect area on shaft where bushing rides for wear galling nicks or scratches Replace clutch assembly if worn or damaged 5 Remove and inspect spring See Page 6 9 6 12 CX SPIDER REMOVAL 1 Remove the limiter nut using the Clutch Spider Nut Socket PN 2870338 Install clutch in holding fixture loosen the spider counterclockwise using Clutch Spider Install Tool PN 2870341 Clutch Holding Fixture PN 2871358 Spider Removal Tool PN 2870341 Special Tool 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 To maintain proper clutch balance and belt to sheave clearance be sure to reinstall original quantity and thickness wa
124. ar Alignment Tool PU 45497 2 R use a twisting motion when pushing down on the tool 21 To remove the balance shaft gear the flat side of the camshaft P must face the balance shaft gear To rotate the camshaft use the Cam Spanner Wrench PU 45498 to rotate the camshaft so the flat side of the camshaft faces the balance shaft gear NOTE This Cam Spanner Wrench PU 45498 is only needed to rotate the camshaft when the entire valve train is assembled If the rocker arms are removed the cam shaft can be turned by hand 22 Remove the bolt and nut from the balance shaft gear Try to remove the balance shaft gear If the gear does not come off manually use the Flywheel Puller PN 2871043 to remove the POLARIS wW ENGINE balance shaft gear 2871043 23 Inspect the crankshaft gear Q for broken or worn teeth If the crankshaft gear does not need to be replaced it does not need to be removed If Water Oil Pump Removal Disassembly the crankshaft gear is damaged remove the 26 Rotate the water oil pump gear S so that all four crankshaft gear with the Flywheel Puller PN bolts are visible though the gear Remove the four 2871043 bolts with a hex wrench Pull out the pump 24 Install the two puller bolts R Tighten the puller bolts up so that the bolts are at equal length 27 Inspect the oil pump rotors for wear Mark the rotors with a white pen to ensure upon reassembly that the correct sides ofthe ro
125. ark plug cap or poor connection to high tension lead Related wiring loose disconnected shorted or corroded Engine Stop switch or ignition switch faulty ETC switch misadjusted or faulty Wire harness or connections wet corroded Poor ignition coil ground e g coil mount loose or corroded Incorrect wiring inspect color coding in connectors etc Faulty ignition coil winding measure resistance of primary and secondary Sheared flywheel key Flywheel loose or damaged Faulty ECU CURRENT DRAW KEY OFF CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running Damage will occur to electrical components Connect an ammeter in series with the negative battery cable Check for current draw with the key off If the draw is excessive loads should be disconnected from the system one by one until the draw is eliminated Check component wiring as well as the component for partial shorts to ground to eliminate the draw Refer to Illustration 1 on the next page 10 18 POLRRIS CHARGING SYSTEM BREAK EVEN TEST CAUTION Do not allow the battery cables to become disconnected with the engine running Follow the steps below as outlined to reduce the chance of damage to electrical components The break even point of the charging system is the point at which the alternator overcomes all system loads lights etc and begins to charge the battery Depending on battery condition
126. ashers positioned properly in recess X or the marks that were made earlier 6 Install limiter nut on top of spider using the Clutch under weight Spider Nut Socket PN 2870338 Torque to 15 ft lbs Reinstall shift weights using new lock nuts on the bolts 7 Reinstall clutch spring 1 Rotation POLARIS 6 15 CLUTCH 8 Reinstall cover aligning bosses on the tower and cover Torque cover bolts evenly to specification Spider Torque 200 ft Ibs 271 Nm Cover Screw Torque 90 in Ibs 10 4 Nm DRIVE BELT REMOVAL INSPECTION 1 2 6 16 Remove outer PVT cover as described in PVT Disassembly Mark drive belt direction of rotation so that it can be installed in the same direction NOTE Normally positioned so part numbers are easily read To remove drive belt apply brake pull upward and rearward on belt to open driven clutch sheaves pull out and down on belt to slip over the driven clutch outer sheave Special Tool NOTE When reinstalling the belt with the drive clutch and driven clutch already removed follow these steps Install the driven clutch nstall the belt onto the driven clutch Loop the drive clutch through the belt Install the drive clutch onto the crankshaft 4 Measure belt width and replace if worn Generally belts should be replaced if clutches can no longer be adjusted to provide proper belt deflection Thetop edges have be
127. ates during installation Thoroughly clean parts tools and hands before installation 28 Before installing the gear stator housing replace the seals in the cover Install a new water pump seal N into the gear stator housing O Use the Water Pump Mechanical Seal Installer PA 44995 to properly install the seal to the correct depth in the cover 3 53 44995 To remove the water pump seal the gear stator housing must be removed The water pump seal cannot be removed or installed with the gear stator housing attached to the engine Shaft damage will occur NOTE Install the waterpump seal with the seal lip facing out towards the crankcase Use of a hydraulic press is recommended for this procedure 29 Install a new crankshaft seal P into the gear stator housing cover O Use the Universal Driver Handle PU 45543 and the Main Seal Installer PU 45483 to seat the crankshaft seal into place PU 45543 PU 45483 NOTE Install the crankshaft seal P with the seal lip facing out towards the crankcase 3 54 Seal lip goes towards the crankcase 30 Oncethe crankshaft seal is installed into the gear stator housing cover set the direction of the paper lip by sliding the Main Crankshaft Seal Saver PA 45658 into the crankshaft seal from the rubber lipped side to the paper lip side Back to Front Remove the tool Important Set the direction of the paper seal l
128. ator are working properly Turn the key Switch off and depress the valve button on the tester to relieve the system pressure fthe pressure is too high or too low replace the fuel pump assembly 3 Ifthe pump did not activate step 2 disconnect the plug from the fuel pump Connect a DC voltmeter across terminals and C in the plug turn on the key switch and observe if a minimum of 7 volts is present If voltage is between 7 and 14 turn key switch off and connect an ohmmeter between the terminals A and C on the pump to check for continuity f there was no continuity between the pump terminals replace the fuel pump tank assembly fthevoltage was below 7 Vdc test the battery ignition switch wiring harness Load shed Relay and ECU 4 If voltage at the plug was good and there was continuity across the pump terminals reconnect the plug to the pump making sure you have good clean connections Turn on the key switch and listen for the pump to activate Ifthe pump starts repeat steps 1 and 2 to verify correct pressure f the pump still does not operate check for correct ECU operation by plugging in a known good ECU f the pump still does not operate replace the pump tank assembly FUEL PUMP TANK ASSEMBLY REPLACEMENT NOTE 800 EFI fuel connections are quick connect couplings vs 700 EFI connections WARNING Always wear safety goggles when working with high pressure or flammable f
129. attery Model Amp Hr Circuit Breakers Starting Instrument Cluster 1 4 city Gear Ratio Low Rev High Front Drive Rear Drive Front Suspension Shock Two x 2 Coil over Shock Front Non Adjustable Rear Ratchet Style Std Turning Radius 76 in 193 cm unloaded Toe Out 0 1 16 in 0 159 mm Wheels Brakes Wheel Size Pattern Front Steel 25x8 12 4 156 205 80R 12 Wheel Size Pattern Rear Steel 25x11 12 4 156 270 60R 12 Front Travel Rear Suspension Shock Rear Travel Ground Clearance Shock Preload Adjustment Front Rear Front Tire Size 25x8 12 Rear Tire Size 25x11 12 Recommended Air Pressure 5 psi Front F R 5 psi Rear Brake Front Dual Hydraulic Disc Dual Hydraulic Disc Brake Rear CLUTCH CHART EBS Models have no helix spring adjustment Shift Drive Driven Driven Altitude Weight Spring Spring Helix 0 1800 20 56 Blu Green White 60 56 40 Meters 0 6000 6631215 7041157 3234199 8234208 Feen 1800 3700 20 54 Blu Green White 60 56 40 6000 12000 5631214 7041157 8234199 3234208 POLARIS GENERAL INFORMATION MODEL 2005 SPORTSMAN 800 EFI MODEL NUMBER A05MH76AU AW ENGINE MODEL EHO76OLE Platform Polaris Twin Cylinder EHO760LE011 2 Engine Model Number Engine Displacement Number of Cylinders 80 x 68 mm Bore amp Stroke mm Compressi
130. be disassembled from the helix end to reduce spring pressure Review all information below before proceeding DRIVEN DISASSEMBLY ASSEMBLY 4 Placethe driven assembly into the Clutch Holding Tool PU 47086 Install the compression POLARIS 6 21 CLUTCH cylinder of the holding tool on top of the spider assembly and retaining ring Install the clutch holding tool handle and slowly compress the spider onto the shaft Push helix inward Remove snap ring A 7 Remove the E clip F washer G and the clutch rollers H Inspect the rollers for wear replace if worn 5 Remove the spider assembly spring B and spacer washer C NOTE The spring is a compression spring only and has no torsional wind 8 Remove the clutch assembly from the holding tool Remove the large outer retaining ring I and the inner retaing ring J SPIDER DISASSEMBLY 6 Remove the inside spider plate D and spider dampener E Inspect the spider dampener E for wear and replaced if needed 6 22 5 CLUTCH CLUTCH ROLLER REMOVAL 9 Press out the spring pins K in the inner sheave 10 Pull out the clutch roller pins L and rollers M 12 Inspect the bearing for wear Spin the bearing if the bearing does not spin smoothly replace as needed To remove the bearing simply press the bearing from the shaft 13 Inspect BOTH sheaves for signs of wear grooving or cracki
131. blem seized or binding Can engine be rotated easily with recoil starter Starter Motor Turns Over Slowly Low specific Battery discharged low specific gravity Excessive circuit resistance poor connections see Voltage Drop Test below Engine problem seized or binding Can engine be rotated easily Faulty or worn brushes in starter motor Starter Motor Turns Engine Does Not Rotate Faulty starter drive Faulty starter drive gears or starter motor gear Faulty flywheel gear or loose flywheel VOLTAGE DROP TEST 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 1 47 to perform voltage POLARIS ELECTRICAL drop tests on the starter system Voltage should not exceed 1 DC volts per connection STARTER MOTOR REMOVAL DISASSEMBLY NOTE Use electrical contact cleaner to clean starter motor parts Some solvents may leave a residue or damage internal parts and insulation 1 Remove the starter from the engine 2 Remove the two bolts washers and sealing O Rings Inspect O Ri
132. 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 Crankshaft Run Out Run out or 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 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 Ib 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 Ib 12 in Ibs 1 ft kg cm a Kilograms per square centimeter kg m Kilogram
133. can scratch the body finish Polaris offers a detailing kit for your ATV see Page 2 7 CAUTION Certain products including insect repellants and chemicals will damage plastic surfaces Use caution when using these products near plastic surfaces Storage Tips See Page 2 7 for the part numbers of Polaris products CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime Don t use harsh detergents or high pressure washers Some detergents deteriorate rubber parts Use dish soap type cleaners only High pressure washers may force water past seals POLARIS Stabilize the Fuel Fill the fuel tank Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon clean will also reduce the possibility of bacterial growth in the fuel system Allow 15 20 minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor Turn the fuel valve off and drain the carburetor bowl Oil and Filter Warm the engine and change the oil and filter Follow the procedure in this chapter for proper oil change Air Filter Air Box Inspect and clean or replace the pre cleaner and ai
134. case and install cover bolts Install the gearcase cover onto the gearcase housing INSTALLATION Torque the cover bolts to 25 ft Ibs in a criss cross pattern 1 Toinstall the rear gearcase reverse the removal procedures 2 Torque the installation bolts and nuts to the torques specified 3 Refill the rear gearcase with 5 oz 150 ml of Polaris Premium Gearcase Lubricant PN 2871653 Torque the fill plug to 14 18 ft Ibs 19 24 Nm Gearcase Cover Bolt Torque 25 ft Ibs 34 Nm 6 Install the drain plug and fill plug Replace the drain plug washers to ensure proper sealing after filling Fill Plug N umet 5 14 18 ft lbs 19 24 Nm Drain Plug POLARIS 7 29 FINAL DRIVE REAR GEARCASE EXPLODED VIEW 14 18 FT LBS 19 24 NM 16 Ref Qty Description ey ey FT LB 6 19 24 NM Ret Oy 11 2 2 5 Ball Bearing Ball Bearing Triple Lip Seal Triple Lip Seal 10T Straight Bevel Pinion Retaining Ring Bushing Plug Thrust Button Bolts S 0 N D 9 S N 7 30 POLRRIS TRANSMISSION CHAPTER TRANSMISSION Transmission Exploded View 8 2 8 5 Torque Specifications Lubrication 8 5 Gear Shift Selector Removal 8 5 Transmission 8 6 8 7 Transmission Installation 8 7 8 8 Transmission Di
135. cated under the left rear fender next to the starter solenoid The red wire connects to the battery The Orange White wires are located under the front cover under headlight pod The Orange White wires supply the control power to the winch POLARIS MAINTENANCE CLEANING amp STORAGE OF ATV Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components With a few precautions your ATV can be cleaned much like an automobile Washing the ATV The best and safest way to clean your ATV is with garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning and safety labels are damaged contact your a Polaris dealer for free replacement Polaris does not recommend the use of a high pressure type car wash system for washing the ATV If a high pressure system is used exercise extreme care to avoid water damage to the wheel bearings transmission seals body panels brakes and warning labels NOTE Grease all zerk fittings immediately after washing and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system Waxing the ATV Your ATV can be waxed with any non abrasive automotive paste wax Avoid the use of harsh cleaners since they
136. caution so the plastic cab does not scratch or get caught on other components 8 Reverse the removal steps for installation Torque two front cab to frame screws to 24 in Ibs 2 7 Nm POLARIS REMOVAL INSTALLATION 1 Follow the REAR RACK REMOVAL procedure to remove the rear rack 2 Remove the three screws A T 25 that secure the rear cab to the storage container 3 Remove the ten plastic inserts that secure the rear cab to the frame and plastic T 25 6 in lbs ha 4 T os plastic dart inserts POLARIS BODY STEERING SUSPENSION 4 Disconnect the rear lights by pulling the locks on each side and removing the connectors Lift the rear cab from the frame Remove Connectors 5 Reverse the removal steps for installation REAR STORAGE REMOVAL INSTALLATION 1 Follow the REAR RACK REMOVAL and REAR CAB REMOVAL procedure to remove the rear storage compartment After the rear cab is removed the storage compartment comes out 2 Remove the two plastic inserts that hold the rear storage compartment in place 3 For installation reverse the removal steps 4 Torque the 3 T 25 screws that hold the rear storage to the rear cab to 6 in lbs 0 70 Nm 5 9 BODY STEERING SUSPENSION RADIATOR SCREEN REMOVAL 1 Pull out slightly on the top of the ra
137. ct the brake disc and pads as outlined for FRO NT CALIPER brake pad replacement this section See Pages INSPECTION E 1 Inspect caliper body for nicks scratches or wear FRONT CALIPER REASSEMBLY Measure bore size and compare to specifications 1 Install new O rings A in the caliper body B Be Replace if damage is evident or if worn beyond 4 f D eG sure groove is clean and free of residue or brakes service limit may drag upon assembly Front Caliper Piston Bore I D Std 1 188 30 2 mm Service Limit 1 193 30 30 mm Coat piston with clean Polaris DOT 3 Brake Fluid PN 2870990 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 PELARIS 015 BRAKES FRONT CALIPER INSTALLATION 1 Install caliper on hub strut and torque mounting bolts 15 ft lbs Q1Nm Polaris Premium All Season Grease PN 2871423 4 Compress the mounting bracket and make sure Torque Specifications the dust seals are fully seated Install the pads as shown on Page 9 10 Clean the disc and pads Front Caliper Mounting Bolt with brake parts cleaner or denatured alcohol to 18 ft Ibs 24 Nm remove any dirt oil or grease Front Banjo Bolt Brake Line 15 ft Ibs 21 Nm 2 Install br
138. diator screen 2 With the top free pull out on the bottom of the Screen to remove the screen 3 Toinstall the screen simply press the tabs on the screen back into the mounting grommets Be sure the screen is securely in place 5 10 O POLARIS BODY STEERING SUSPENSION BODY ASSEMBLY EXPLODED VIEW Pull UP on rear of seat and back Rear Cab Assembly to disengage tabs at front of seat 1 Latch x Release Rear Cab Storage Wheelwell Front Cab Assembly Front Cover Side Cover Front Brush Guard POLARIS 5 BODY STEERING SUSPENSION BODY RACK EXPLODED VIEW Rack Rails Rear Rack Support Rack Mounting 2 7 Hardware Rack Rails Support e Radiator Shield A Radiator Screen un Front Bumper 12 1 BODY STEERING SUSPENSION HEADLIGHT POD EXPLODED VIEW Worklight Switch 7 2 Me Instrument Cluster E Disassembly Remove two side Phillips screws Remove one rear Phillips screw B Lift top half of pod Disconnect instrument cluster wire connectors Disconnect work light switch connector Disconnect 12V power plug G Disconnect headlight harness Remove ignition switch C and choke cable D Remove headlight F with adjuster Wheel Speed Sensor Remove two screws sec
139. ding fluid may build pressure in the brake system leading to brake failure When servicing Polaris ATV brake systems use only Polaris DOT 3 Brake Fluid PN 2870990 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 which can lead to brake fade and the possible loss of control HYDRAULIC CALIPER BLEEDING The front calipers a single piston conventional design The rear caliper piston is a T shaped which allows both hand and foot brake to use the same caliper piston but remain separated by seals The hand brake system applies hydraulic pressure to both front calipers and only the outer diameter of the rear caliper pistons The auxiliary foot brake applies pressure to the inner portion of the rear caliper pistons Because the hand and foot brake hydraulic systems are separate there are also two bleed screws one for the outer fluid chamber hand brake and one for the inner fluid chamber foot brake The basic procedure for bleeding the brake system is the same as outlined on page 9 7 9 8 however each system must be bled separately Hydraulic Auxiliary Brake inspection and adjustment is outlined in Chapter 2 beginning on Page 2 28 POLARIS BRAKES NOTE Uppermost inner bleed sc
140. djustment for a longer center distance to obtain proper belt deflection Belts which measure shorter than nominal length may require driven shimming or a shorter center distance Remember proper belt deflection is the desired goal not a specific center distance A P a i 8 Replace belt if worn past the service limit Belts 3 The belt then should be able to be pushed down with thin spots burn marks etc should be into and between the sheaves replaced to eliminate noise vibration or erratic 4 PVT operation See Troubleshooting Chart at the end of this chapter for possible causes Install clutch cover temporarily Verify engine is in PARK Start engine and raise engine RPM enough to engage the clutch rotating the belt and seating it in the clutches Remove clutch cover and verify belt is seated properly before final cover installation POLARIS 6 17 CLUTCH CLUTCH ALIGNMENT 1 Remove belt and install the Clutch Offset Alignment Tool PN 2872292 as shown Offset Alignment Tool PN 2872292 EBS 1 8 0 1 16 3 2mm 0 1 6 mm 2 With tool touching rear of driven clutch inner sheave the distance at point A should be 1 8 Special Tool NOTE If the distance is greater than 1 8 or less than 1 16 clutch alignment must be adjusted as follows 3 Remove drive and driven clutch PVT Disassembly Pages 6 7 6 8 4 Remove PVT inner cover 5 Loosen all engine mounts Move fro
141. dles But Will Not Rev Up Spark plug fouled weak spark Broken throttle cable Obstruction in air intake Air box removed reinstall all intake components Incorrect or restricted carburetor jetting ETC switch limiting speed Reverse speed limiter limiting speed Incorrect ignition timing Restricted exhaust system Cam worn excessively Engine Has Low Power Spark plug fouled Cylinder piston ring or valve wear or damage check compression PVT not operating properly Restricted exhaust muffler Cam worn excessively 3 59 TROUBLESHOOTING CONT Piston Failure Scoring e Lack of lubrication e Dirt entering engine through cracks in air filter or ducts e Engine oil dirty or contaminated Excessive Smoke and Carbon Buildup e e Excessive piston to cylinder clearance e Wet sumping e Worn rings piston or cylinder e Worn valve guides or seals e Restricted breather e Air filter dirty or contaminated Low Compression e Cylinder head gasket leak e No valve clearance cam wear e Cylinder or piston worn e Piston rings worn leaking broken or sticking e Bent valve or stuck valve e Valve spring broken or weak e Valve not seating properly bent or carbon accumulated on sealing surface e Rocker arm sticking Backfiring 5 e ETC or speed limiter system malfunction e Fouled spark plug or incorrect plug or plug gap e Exhaust system air leaks e Ignition s
142. e the valve opens relieving the excess pressure returning the excess fuel back to the tank 4 11 FUEL SYSTEM FUEL INJECTION FUEL PRESSURE REGULATOR TEST Refer to the Fuel Pump Test procedure FUEL PRESSURE REGULATOR REPLACEMENT The regulator is a sealed non serviceable assembly If it is faulty the pump assembly must be replaced Refer to the Fuel Pump Tank Assembly Replacement procedure FUEL FILTERS NOTE 800 EFI fuel connections are quick connect couplings vs 700 EFI connections EFI Engines use a non serviceable high volume high pressure 30 micron internal fuel pump filter and a replaceable 10 micron in line fuel filter FUEL FILTER SERVICE In line filter replacement is recommended every 2 years of operation or more frequently under extremely dusty dirty conditions Use only the specified filter and install it according to the directional arrows DO NOT use an aftermarket filter as operating performance and safety can be affected FUEL FILTER REPLACEMENT To replace the filter 1 Relieve system pressure through the test valve in the fuel rail before servicing 2 Loosen clamps and slide hose off the filter ends 3 Install new filter with arrow pointing to the fuel line connected to the injector rail NOTE When replacing the fuel filter wet the interior of the new filter with gasoline before installation to ensure high pump pressure doesr t tear the filtering material 4 12 FUEL
143. e 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 14 POLRRIS CHAPTER 2 MAINTENANCE POLARIS Periodic Maintenance Chart 2 2 2 5 Component Locations 2 6 Lubricant and Maintenance Product Numbers 2 7 Special Tools 2 8 Lubrication 2 9 2 10 Front amp Rear Gearcase Lubrication 2 11 2 12 Transmission Lubrication 2 13 Throttle Cable Adjustment 2 14 Transmission Linkage Inspection 2 15 Fuel System 2 15 Compression Test 2 15 2 16 Battery 2 16 2 17 RR a er 2 17 Coolant System Maintenance 2 18 2 20 Radiator Screen Removal 2 20 Air Fiter Service 2 20 2 21 Air Box Sediment Tube Service 2 21 Breather Filter 2 21 2 22 PVT Drying amp PVT Drain Plug 2 22 Oil Change Filter 2 23 2 24 Steering and Toe Alignment
144. e machine and wash the case and battery tray with a mild solution of baking soda and water Rinse with lots of fresh water after cleaning NOTE Do not get any of the baking soda into the battery or the acid will be neutralized Using a wire brush or knife remove any corrosion from the cables and terminals sure that the electrolyte is at the proper level Add distilled water if necessary Charge at arate no greater than 1 10 of the battery s amp hr capacity until the electrolyte s specific gravity reaches 1 270 or greater Store the battery either in the machine with the cables disconnected or store in a cool place NOTE Recharge to full capacity every 30 to 60 days during a non use period Ifthe battery is stored during the winter months electrolyte will freeze at higher temperatures as the battery discharges The chart below indicates freezing points by specific gravity of Electrolyte Point POLARIS ELECTRICAL CHARGING PROCEDURE 1 Remove the battery from the ATV to prevent damage from leaking or spilled acid during charging 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
145. e Illustration above 12 Install air box cover and secure with clips POLARIS AIR BOX SEDIMENT TUBE Periodically check the air box drain tube located 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 _ Sediment Tube 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 2 21 BREATHER HOSE 1 Be sure breather line is routed properly and secured in place CAUTION Makesure lines are not kinked or pinched 2 22 MAINTENANCE PVT DRYING amp PVT DRAIN PLUG NOTE If operating the in or through water be sure to check the PVT cover and other components for water ingestion The ATV should be checked immediately 1 To release any water that maybe trapped in the PVT cover simply remove the PVT drain plug and O ring located on the bottom of the PVT cover and let the water drain out The PVT drain plug is shown below PVT Drain Plug amp O ring To further expel water from the cover and to dry out the PVT system shift the transmission to neutral and rev engine slightly to expel the moisture and air dry the belt and clutches Allow engine RPM to settle to idle speed shift transmission to lowest available range and test for belt slippage Operate ATV in low
146. e amount necessary to remove it 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 scratch the ring lands 4 Repeat procedure for second ring 5 Remove the oil control 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 which fits into a notch B in the upper oil ring land of the piston To Remove Remove the top rail first followed by the bottom rail b Remove the expander Compression Rings 3 32 CYLINDER INSPECTION 1 Remove all gasket material from the cylinder sealing surfaces 2 Inspect the top of the cylinder B for warpage using a straight edge A and feeler gauge C Refer to Ill 1 and Ill 2 1 Cylinder Warpage 004 0 1 mm Max POLARIS LO 3 Inspect cylinder for wear scratches or damage 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 side on three different levels 1 2 down from top in the middle and 1 2 up from bottom 1 2 Down From Top of Cylinder 1 2 Up From Bottom POLARIS ENGINE 5 Record measurements If cylinder is tapered or out of round beyond 002 the cylinder must be replaced Cylinder Taper Limit 002 05mm
147. e 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 6 11 Gp POLARIS CX PVT DISASSEMBLY NOTE Some fasteners and procedures will vary Refer to the appropriate parts manual for proper fasteners and fastener placement 1 2 3 gt 7 Remove driven clutch retaining bolt and driven clutch Use puller if necessary POLARIS Remove seat Remove or loosen rear cab fasteners as necessary to gain access to PVT outer cover Remove PVT air outlet duct hose Remove outer cover screws Refer to Page 6 2 Mark the drive belt direction of rotation and remove drive belt See Page 6 16 for drive belt removal Remove drive clutch retaining bolt and remove drive clutch using puller Drive Clutch Puller PN 2870506 Clutch Holding Wrench PN 9314177 CLUTCH Driven Clutch Puller PN 2870913 Remove driven clutch offset spacers from the transmission input shaft NOTE Remember to keep spacers in order for proper clutch offset on reassembly Inner cover Retainer Seal Foam Seal 10 Remove inner cover retaining bolts at rear of cover 11 Remove cover along with foam seal on back of cover or shaft 6 7 CLUTCH PVT ASSEMBLY INSPECTION Inspect PVT inner cover to engine seal Replace
148. e to return fully Parking brake left on Residue build up under caliper seals Operator riding brakes Brakes Lock Alignment of caliper to disc 9 23 BRAKES NOTES 24 8 PGLRIRIS ELECTRICAL CHAPTER EL EC T Frei CAs Crankshaft Position Sensor Gap 10 2 Gear Position Switch Test 10 2 Instrument Cluster Overview 10 3 10 7 Speedometer Removal Installation 10 8 Speedometer Operation Troubleshooting 10 9 10 13 Coolant Sensor Tests 10 14 Fan Motor Tests 10 14 Fan Control Switch Tests 10 14 Electronic Throttle Circuit System Operation 10 15 Flywheel Identification 10 16 Ignition System Operation 10 16 Ignition Components 10 17 Ignition System Troubleshooting 10 18 10 19 Charging System Testing 10 19 Fan ECU 10 20 Charging System Testing Flow Chart 10 21 Battery 10 22 Conventional Battery Activation Service 10 22 10 23 Low Maint Battery Activation Service 10 24 10 28 Head Light Lamp Switch Service 10 28 10 32 Work Brake Light Lamp Switch Service 10 32 10 34 Fuel Sender
149. ear 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 A from air box cover and remove cover Inspect the gasket It should adhere tightly to the cover and seal all the way around 4 Loosen remove air filter assembly clamp Pre filter Main Element 5 Slip the pre filter element off of main element Clean the pre filter with high flash point solvent followed by hot soapy water 6 Rinse and dry thoroughly 7 nspect element for tears or damage 8 Apply foam filter oil or clean engine oil and squeeze until excess oil is removed POLARIS MAINTENANCE 9 Inspect main filter and replace if necessary If the filter has been soaked with fuel or oil it must be replaced Installation 10 Reinstall pre filter element over main filter Be sure the element covers entire surface of main filter without folds creases or gaps 11 Reinstall filter on main filter mount Place filter clamp over the assembly and tighten NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling Proper Filter Placement Main Filter Air Box NOTE The air filter should rest on the filter support Proper placement of the air filter is important to prevent rattles and air leaks Se
150. eated 9 20 Carefully assemble caliper body making sure O rings are properly positioned in groove Tighten the caliper anvil bolts and then torque the anvil bolts evenly to 16 18 ft lbs 22 24 Nm 16 18 ft lbs 22 24 Nm Caliper Anvil Bolt Torque 16 18 ft Ibs 22 25 Nm Install brake pads in caliper body with friction material facing each other Install the slide pins and the slide pin retaining ring Torque the slide pins to 30 35 ft lbs 41 48 Nm NOTE The slide pins can be torqued when installed on caliper mount also POLARIS BRAKES 5 Install brake line and tighten securely with a line wrench Torque the brake lines to the proper torque specification 6 Follow bleeding procedure outlined on Pages 9 6 9 7 of this section and refer to system overview and illustrations on Pages 9 2 9 3 7 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 when lever is released If the brake drags re check assembly and installation aliper Slide Pin REAR BRAKE DISC INSPECTION capan sed Ue pe 1 Visually inspect disc for scoring scratches or 30 35 ft Ibs 41 Nm 48 Nm gouges Replace the disc if any deep scratches are evident 2 Use a 0 1 micrometer and measure disc thickness at 8 different points around perimeter of disc Replace disc if worn beyond service limit 4 Install caliper and torque mounti
151. eded Clean the inside surfaces of both gearcase halves Input Cover Bolts Torque 14 ft Ibs 19 Nm POLARIS 7 13 FINAL DRIVE 5 Install the output hub A into the gearcase housing The output hub should spin freely 9 Install the ring gear onto the output hub on the output cover 6 Install the other output hub B and thrust bearing C into the output cover Apply a small amount of grease onto the thrust bearing Cz e ud gt 10 Install the rollers and roll cage into the ring gear 7 Install the armature plate D and spacer washer Insert the rollers as the roll cage is installed E into the output cover NOTE sure backlash plate in in place rr 11 Install the output cover assembly onto the main Backlash Plate 8 Install the retaining ring F into the output cover gearcase Be sure the retaining ring is properly seated into NOTE Be sure armature plate tabs are placed into the cover the slots on roll cage See Reference Photo 7 14 POLRRIS FINAL DRIVE Cover Bolts Torque 14 ft Ibs 19 Nm 13 Install new seals into the gearcase housing and gearcase housing cover Back Lash Pad Thrust Pad Adjustment 14 Laythe gearcase onthe side with the output cover facing up 15 The backlash screw is loctited into place Use a heat gun to lightly heat up the loctite on the screw 1
152. eded the ECU suppresses the injection signals cutting off the fuel flow This process repeats it self in rapid succession limiting operation to the preset maximum Sportsman 700 800 EFI Rpm Limit Hard limit Injector Suppression occurs High 6500 Low 6500 Neutral 6500 Reverse 6500 Park 6500 Soft limit Timing Suppression occurs High None Low 6300 Neutral 6300 Reverse 6300 Park 6300 ECU SERVICE Never attempt to disassemble the ECU It is sealed to prevent damage to internal components Warranty is void if the case is opened or tampered with in any way All operating and control functions within the ECU are pre set No internal servicing or readjustment may be performed If a problem is encountered and you determine the ECU to be faulty contact the Polaris Service Department for specific handling instructions Do not replace the ECU without factory authorization The relationship between the ECU and the throttle position sensor TPS is very critical to proper system operation If the TPS is faulty or the mounting position of the TPS is altered the TPS must be re initialized For the purpose of troubleshooting a known good ECU from another Polaris ATV EFI may be used without system or engine component damage ECU REPLACEMENT 1 Removethe 2 retaining screws holding the ECU 2 With the Ignition turned off disconnect the wire harness from the ECU 3 Toinstall reverse the procedures reap
153. ement Front Caliper Removal Front Caliper Disassembly Front Caliper Inspection Front Caliper Reassembly Front Caliper Installation Rear Pad Removal Rear Pad Installation Rear Caliper Removal Inspection Rear Caliper Reassembly Rear Disc Inspection Rear Auxiliary Brake Remove Install Troubleshooting 323 ei Ao xt eu are aR POLARIS 9 9 9 10 9 10 9 11 9 12 9 13 9 13 9 13 9 13 9 14 9 14 9 14 9 15 9 15 9 15 9 16 9 17 9 17 9 18 9 18 9 19 9 20 9 20 9 21 9 21 9 1 BRAKES SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2870975 Mity Vac Pressure Test Tool SPECIFICATIONS Front Brake Caliper Brake Pad Thickness 298 7 6mm 180 4 6mm Brake Disc Thickness 150 165 3 81 4 19mm 140 3 556mm Brake Disc Thickness Variance Between 002 051mm Measurements 010 254mm Brake Disc Runout Rear Axle Brake Caliper Brake Pad Thickness 318 7 6mm 180 4 6mm Brake Disc Thickness 150 165 3 81 4 19mm 140 3 Brake Disc Thickness Variance Between 002 051mm Measurements Brake Disc Runout 010 254mm Master Cylinder I D Front Master Cylinder I D Aux Rear TORQUE SPECIFICATIONS Torque Torque ft Ibs except where noted Nm Front Rear Caliper Mounting Bolts Handlebar Master Cylinder Clamp 25 in Ibs Bolts Hand Master Cy
154. ement system During operation sensors continuously gather data which is relayed through the wiring harness to input circuits within the ECU Signals to the ECU include ignition on off crankshaft position and speed RPM throttle position engine coolant temperature air temperature intake manifold air pressure and battery voltage The ECU compares the input signals to the programmed maps in its memory and determines the appropriate fuel spark requirements for the immediate operating conditions The ECU then sends output signals to set the injector duration and ignition timing During operation the ECU continually performs a diagnostic check of itself each of the sensors and system performance If a fault is detected the ECU turns on the Malfunction Indicator Light MIL Check Engine Light on the speedometer and stores the fault code in its fault memory Depending on the significance or severity of the fault normal operation may continue or Fail Safe operation slowed speed richer running may be initiated A technician can access the stored fault code using a blink code diagnosis flashed out through the Instrument cluster The ECU requires a minimum of 7 0 volts to operate The memory in the ECU is operational the moment the battery cables are connected 4 8 prevent engine over speed and possible failure rev limiting feature is programmed into the ECU If the maximum RPM limit 6500 is exce
155. en trimmed on some drive belts It will be necessary to project the side profiles and measure from corner to corner Place a straight edge on each side of the drive belt POLARIS Gm CLUTCH Place another straight edge on top of belt Measure the distance where the side straight edges intersect the top as shown in the illustration Projected Belt Width E 5 Distance Clutch Center Distance 10 1 05 254 2 5 1 3mm Belt Nominal Length 40 875 3 16 103 8 cm 48 DRIVE BELT INSTALLATION Belt Width New 1 174 1 188 2 98 3 02 cm Special Tool NOTE Be sure 10 position belt so part number is easily read Verfiy new belt is seated Wear Limit 1 125 2 86 cm properly in the clutches before operating the ATV 1 Loop belt over drive and over top of driven sheave 5 Inspect belt for loose cords missing cogs cracks 2 While pushing down on top of belt turn the back abrasions thin spots or excessive wear or moveable driven sheave clockwise Replace if necessary 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 continuously in one spot 7 Measure belt length with a tape measure around the outer circumference of the belt Belts which measure longer than nominal length may require driven shimming or engine a
156. ensor TPS is a non serviceable item If it is faulty it must be replaced It can be tested using the following method Set up the TPS voltage check tool PN PU 47082 according to the instructions Make sure that the 9 volt battery has a minimum of 6 volts Figure 2 Tool PN PU 47082 No Jumps in read out 70 Black Probe Vde Red Probe ack Pink Figure 2 Red 009 aN BI With the test leads connected and the meter set move the throttle open and closed slowly while reading the display The voltage should increase smoothly with no jumps or decreases when the throttle is applied f the sensor does not function correctly replace it POLARIS FUEL SYSTEM FUEL INJECTION THROTTLE POSITION SENSOR REPLACEMENT The correct position of the TPS is established and set at the factory If the TPS is repositioned replaced or loosened it must be recalibrated 1 Remove the front fender assembly and fuel tank 2 Disconnect sensor from the harness 3 Loosen and rotate the throttle body to gain access to the retaining screw 4 Remove the retaining screw and replace the sensor 5 Refer to TPS Initialization for setting the TPS voltage THROTTLE POSITION SENSOR INITIALIZATION The correct position of the TPS is established and set at the factory Use this procedure only if the TPS was repositioned replaced or loosened This set procedure can be accomplished with t
157. ent is supplied directly to the ECU from the battery 12 volt DC current charges an internal capacitor to build up the initial ignition charge An A C signal from the Crank Shaft Position Sensor is processed by the ECU which determines ignition timing by calculating from a point pre determined in the crankshaft rotation This signal releases the electrical charge which saturates the coil for ignition DC CDI systems have the ability to ignite with as little as 6 volts of power nents are not interchangeable with any other system Timing curve shown is not indicative of EFI ignition operation 0 27 BIDC20 c gt E 5 E es 300 1000 FIXED TIMING 10 16 Oo 000 5005 ENGINE RPM POLARIS ELECTRICAL COMPONENTS OF EFI 500 WATT ALTERNATOR IGNITION SYSTEM L Ignition Coils e N Battery to Solenoid Cable b Solenoid Switch 8 starter switch P L g e 27 Amp Hr Battery x Coil Wires Solenoid to Starter Cable Control Module M p EU VA n Pre Wire Winch Cables 72 o O 8 E Spark Plugs Q ce Fuses Voltage Regulator Stator Assembly Flywheel Crank Position Sensor 2 POLARIS 10 17 ELECTRICAL IGNITION SYSTEM TROUBLESHOOTING Current Draw Inspection No Spark Weak or Intermittent Spark Spark plug gap incorrect Fouled spark plug Faulty sp
158. entralized hilliard is set at the factory No adjustment is required unless the front cover needs to be replaced or the back lash pad screw is removed See the FRONT GEARCASE ASSEMBLY procedure later in this chapter for details on backlash setting 15 Remove the other output hub K from the main gearcase Inspect the inner bearing L for wear If there is excessive wear replace bearing as needed POLARIS FINAL DRIVE 18 Remove and replace the O rings and seals from the assembly 16 Remove the input cover M bearing N and the pinion gear O Inspect the pinion gear O for FRO NT GEARCASE chipped broken or missing teeth Replace the input cover O ring REASSEMBLY INSPECTION 1 Replace O rings seals worn components 2 Press the pinion shaft seal into the pinion cover until the seal is flush with the sealing surface 3 Inspect bearings on output and pinion shafts To replace press new bearing on to shaft 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 4 Install pinion shaft bearing and input cover with new o ring and torque bolts to 14 ft Ibs 19 Nm 17 Inspect the output shaft bushing Replace as ne
159. ents which control its shifting function are the shift weights and the coil spring Whenever engine RPM is increased centrifugal force is created causing the shift weights to push against rollers on the moveable sheave which is held open by coil spring preload When this force becomes higher than the preload in the spring the outer sheave moves inward and contacts the drive belt This motion pinches the 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 POLARIS CX DRIVEN CLUTCH OPERATION CONT D As engine RPM and horsepower increase the load from the drive belt increases resulting in the belt rotating up toward the outer diameter of the drive clutch sheaves and downward into the sheaves of the driven clutch This action which increases the driven clutch speed is called upshifting Should the throttle setting remain the same and the vehicle i
160. er Cooling System Polaris Premium Antifreeze 2871534 Quart 2871323 Gallon 3 61 3 62 38 FUEL SYSTEM FUEL INJECTION CHAPTER A FUEL INJECTION Special TOOlS b ota a ed 4 2 Service 4 3 EFI System Exploded View 4 4 4 5 Fuel Tank Exploded View 4 6 Electronic Fuel Injection System 4 7 Operation Overview 4 7 Initial Start Priming Procedure 4 7 Electronic Control Unit 4 8 SENICE dies a tr ee caine a Deut 4 8 Replacement 4 8 Fuel Pump Tank Assembly 4 9 TeSt isa sus cou osi E As 4 9 4 10 Replacement 4 10 4 11 Fuel Pressure Regulator 4 11 TOS sates utet ore EA a 4 11 Replacement 4 11 F el Fitters io ce Pbi coste 4 11 ir ves ic hh 4 11 Replacement 4 12 Fuel Injectors 4 12 Phe 4 13 Replacement 4 13 Crankshaft Position Sensor 4 13 Test ce 4 13 Replacement 4 13 Temperature Barometric Air Pressure Sensor 4 14 Test Refer to Diagnostic Software 4 14 Replacement 4 14 Throttle Position 4 14 tnd tle
161. er as was done in the OCV test The reading should be 12 6 volts or greater Engage the starter and observe the battery voltage while cranking the engine Continue the test for 15 seconds During cranking the observed voltage should not drop below 9 5 volts If the beginning voltage is 12 6 volts or higher and the cranking voltage drops below 9 5 volts during the test replace the battery LOW MAINTENANCE BATTERY OFF SEASON STORAGE To prevent battery damage during extended periods of non use the following basic battery maintenance items must be performed Remove the battery from the machine and wash the case and battery tray with a mild solution of baking soda and water Rinse with lots of fresh water after cleaning Using a wire brush or knife remove any corrosion from the cables and terminals sure that the electrolyte is at the proper level Charge at arate no greater than 1 10 of the battery s amp hr capacity until the electrolyte s specific gravity reaches 1 270 or greater Store the battery either in the machine with the cables disconnected or store in a cool place 10 28 NOTE Stored batteries lose their charge at the rate of 196 per day Recharge to full capacity every 30 to 60 days during non use period If the battery is stored during the winter months electrolyte will freeze at higher temperatures as the battery discharges The chart below indicates freezing points by specific gra
162. es Torque bolts to 22 2 ft Ibs 30 3 Nm following torque pattern on Page 3 11 Crankcase Bolt Torque 22 2 ft Ibs 30 3 Nm Torque in Proper Sequence Pg 311 8 Lubricate cam lobes and valve lifters with Moly Lube Grease Moly lube Cam Lobes 11 Install new cylinder gasket on crankcase Align gasket on the dowel pins for proper gasket alignment Moly lube Lifters 9 Lubricate lifters with engine oil and install in the original order as removed in disassembly Apply Lubriplate or Moly Lube to the ends of the lifters NOTE Always replace the camshaft and lifters as a set NOTE Gasket must be installed dry Do not use sealers or lubricants to hold in place during installation 12 Orientate the piston rings on the piston before installation into the cylinders Set the gaps of the rings every 120 see illustration Piston Ring Orientation 1 TOP RING v L OIL RING 2 49 6 13 Install piston assemblies into cylinder aligning the NOTE While installing in piston pins cover all piston pin holes to ensure proper alignment of the engine passages The clip could fall into the engine pistons to the connecting rods upon assembly during installation Partially install the piston pins into the pistons NOTE help align the pistons slide a rod that is close to the same diame
163. es one or both of the injectors to stop functioning Several methods may be used to check if the injectors are operating With the engine running at idle feel for operational vibration indicating that they are opening and closing When temperatures prohibit touching listen for a buzzing or clicking sound with a screwdriver or mechanic s stethoscope Disconnect the electrical connector from an injector and listen for a change in idle performance only running on one cylinder or a change in injector noise or vibration NOTE Do not apply voltage directly to the fuel injector s Excessive voltage will burn out the injector s Do not ground the injector s with the ignition Injector s will open turn on if relay is energized If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem Check as follows Injector leakage is very unlikely but in rare instances it can be internal past the tip of the valve needle or external weeping around the injector body The loss of system pressure from the leakage can cause hot restart problems and longer start up times Injector problems due to dirt or clogging are unlikely due to the design of the injectors the high fuel pressure the use of filters and the detergent additives in the gasoline Symptoms that could be caused by dirty clogged injectors include rough idle hesitation stumble during acceleration or tr
164. ess Type PN 8700226 Boot replacement with complete CV joint cleaning requires the entire 3 5 oz of grease 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 10 Add grease through large end of boot 11 Install a new boot onto the axle shaft and fill the CV joint and boot with the correct type and amount of grease 12 While pulling out on the CV shaft fully extend the CV joint and slide a straight O ring pick or a small slotted screw driver between the small end of the boot and the shaft This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life Before you remove your instrument be sure the small end of the boot is in its correct location on the axle CARE MUST POLARIS TAKEN TO AVOID DAMAGE THE NEWLY INSTALLED BOOT FRONT HUB DISASSEMBLY 1 Remove outer snap ring 2 Fromthe back side tap on the outer bearing race with a drift punch in the reliefs as shown POLARIS FINAL DRIVE NOTE Drive bearing out evenly by tapping on outer race only Once bearing is at bottom of casting support casting on outer edges so bearing can be removed 3 Inspect the bearing 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 co
165. est available range for a short period of time until PVT system is dry POLARIS MAINTENANCE ENGINE OIL LEVEL The 700 engine is a wet sump engine meaning the oil is contained in the bottom of the crankcase To check the oil level 1 Set machine on a level surface 2 Be sure the machine has sat for awhile before removing the dipstick Do not run the machine and then check the dipstick 3 Unlock the lever lock Ill 2 Remove dipstick and wipe dry with a clean cloth Lever Lock Dipstick sAFEQ ADD8 POLARIS 4 Reinstall dipstick and push it into place Do not lock the dipstick NOTE Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of stick consistent When reinstalling the dipstick make certain to seat the lever lock 5 Remove dipstick and check to see that the oil level is in the normal range Add oil as indicated by the level on the dipstick Do not overfill See NOTE below NOTE Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Proper level indication is determined on the upper surface of the dipstick as it is being removed regardless of the level marks being on top or on bottom See the next illustration Dipstick Always read top side of dipstick to properly check oil level in crankcase NOTE A rising oil level between checks in cool weathe
166. etween the marks and record Call this measurement B Subtract measurement B from measurement A The difference between measurements A and B is the vehicle toe alignment The recommended vehicle toe tolerance is 1 8 to 1 4 3 to 6 cm toeout This meansthe measurement at the front ofthe tire A is 1 8 to 1 4 3 to 6 cm wider than the measurement at the rear B Chalk Line Measurement Measurement B POLARIS MAINTENANCE 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 CAUTION During tie rod adjustment it is very important that the following precautions be taken when tightening tie rod end jam nuts If the rod end is positioned incorrectly it will not pivot and may break Hold Rod End Correctly Incorrectly Tightened Tightened Jam Nut Jam Nut 1 2 To adjust toe alignment Hold tie rod end to keep it from rotating Loosen jam nuts at both end of the tie rod 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 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 immed
167. event the formation of surface rust ENGINE LUBRICATION Oil Type Polaris Premium OW 40 Synthetic PN 2871281 Capacity Approximately 2 U S Quarts 1 91 Filter PN 2540086 Filter Wrench PV 43527 or equivalent Oil Pressure Specification 35 39 PSI 5500 RPM Polaris OW 40 Synthetic Engine at operating temperature NOTE See Chapter 1 for oil change kit part numbers OIL PRESSURE TEST 1 Remove blind plug sender from left side of crankcase 2 Insert a 1 8 NPT oil pressure gauge adaptor into the crankcase and attach the gauge 3 Start engine and allow it to reach operating temperature monitoring gauge indicator NOTE Use only Polaris Premium 0W 40 Synthetic Engine Lubricant Oil Pressure at 5500 RPM Engine Hot Standard 39 PSI Minimum 35 PSI 3 19 6 OIL FLOW This chart describes the flow of oil through the 600 700 800 engine Beginning in the crankcase sump the oil is drawn through an oil galley to the feed side of the oil pump The oil is then pumped through the oil filter If the oil filter is obstructed a bypass valve contained in the filter allows oil to bypass the filter element At this point the oil is supplied to the main oil galley through a crankcase passage Oil is then diverted three ways from the main oil galley with the first path entering the camshaft bores onto the rear balance shaft journal and then draining back into the crankcase sump The second oil path fr
168. ever remove the radiator pressure cap when the engine is warm or hot Escaping steam and fluid can cause severe burns The engine must be allowed to cool before removing the pressure cap NOTE This procedure is only required if the cooling system has been drained for maintenance and or repair However if the recovery bottle has run dry or if overheating is evident the level in the radiator should be inspected via the radiator cap first and coolant added if necessary NOTE Use of a non standard pressure cap will not allow the recovery system to function properly 2 19 To access the radiator pressure cap Remove the four screws securing front rack Turn handle bars full left or right to provide more clearance Remove front cover by placing your fingers under the front of the cover and pulling upward Remove Cover RADIATOR SCREEN REMOVAL 1 Pull out slightly on the top of the radiator screen 2 With the top free pull out on the bottom of the Screen to remove the screen 3 Toinstall the screen simply press the tabs on the screen back into the mounting grommets Be sure the screen is securely in place MAINTENANCE 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 r
169. fittings thoroughly with Premium lt a U Joint Lubricant 2871551 5 Install hub flat washer domed washer domed side out and nut Torque center hub nut to 80 ft Ibs 109 Nm Install new cotter pin and hub cap Rear Hub Nut Torque 80 ft Ibs 109 Nm PLFRRIS 1 23 FINAL DRIVE REAR DRIVE SHAFT SERVICE 1 Removeclamps from rubber boot s using the CV Boot Clamp Pliers PN 8700226 A Tap CV Housing Off Shaft 4 4 Placeanewsnap ring the groove ofthe CV joint inner hub with tabs facing the shaft as shown clarity Wipe grease away from recess in CV joint inner hub to locate snap ring Snap ring located in recessed area Snapring 3 Open the snap ring using a snap ring pliers or small needle nose pliers Tap CV housing off shaft with a softfaced hammer while holding snap ring open 724 1 5 5 Refit CV joint on interconnecting shaft by tapping with a plastic hammer on the joint housing Take care not to damage threads on the outboard CV joint The joint is fully assembled when the snap ring is located in the groove on the interconnecting shaft Tap joint onto shaft gt 7 Bu 6 Install and tighten large boot clamp with boot clamp pliers 7 Remove excess grease from the OV joint s external surfaces and position joint boot
170. g 10 15 Exhaust Canister Maintenance 2 36 Exhaust System Maintenance 2 27 F Fan Control Circuit Testing 10 14 Fan Control Switch Bypass Test 10 14 Fan Motor Current Draw Test 10 14 Flywheel Identification 10 16 Foot Well Removal Install 5 4 Frame Nuts Bolts Fasteners 2 32 Front Rear Storage Compartment 2 32 Front Axle Installation 7 3 Front Axle Removal 7 2 Front Cab Removal Installation 5 8 Front Cover Removal Install 5 4 Front Drive Axle Exploded View 7 8 Front Gearcase Assembly Inspection 7 13 Front Gearcase Diagnosis Centralized Hilliard 7 16 Front Gearcase Disassembly 7 10 Front Gearcase Exploded View Centralized Hil liard 7 18 Front Gearcase Operation 7 9 Front Hub Assembly 7 5 Front Hub Disassembly 7 5 Front Prop Shaft Removal 7 6 Front Storage Installation 5 7 Front Storage Removal 5 5 Front Strut Assembly 5 18 Front Strut Ball Joint Replacement 5 19 Front Strut Weldment Replacement 5 19 Fuel Filter 4 12 Fuel Filter Maintenance 2 15 Fuel Injector 4 12 Fuel Pressure Regulator 4 11 Fuel Pump Service 4 9 4 18 Fuel Sender Test 10 34 10 35 Fuel Stabilizer 2 35 Fuel Tank Assembly Exploded View 4 6 G Gear Circuit Readings Instrument Cluster 10 5 Gear Position Switch Test 10 2 Gear Shift Selector Removal 8 4 Gearcase Assembly Rear 7 28 Gearcase Coil Resistance Front 7 11 Gearcase Disassembly Rear 7 26 Gearcase Exploded
171. ge sender function refer to Chapter 10 in this service manual POLARIS FUEL SYSTEM FUEL INJECTION FUEL PUMP TEST The fuel pump tank assembly is non serviceable and must be replaced if determined to be faulty If a fuel delivery problem is suspected make certain the filters are not plugged that the pump is being activated through the ECU all electrical connections are properly secured the fuses are good and a minimum of 7 0 volts is being supplied If during starting the battery voltage drops below 7 0 volts a reduction of fuel pressure may occur resulting in a lean starting condition If required testing of the fuel pump and circuitry may be conducted CAUTION Check the fuel test valve for any possible fuel seepage after performing tests procedures Fuel is extremely flammable and may cause severe burns injury or death Do not use any device that produces a flame or electrical devices that may spark around fuel or fuel vapors 700 EFI Shown 1 Remove the fuel test valve cap Connect the pressure hose of the Polaris pressure tester PN PU 43506 to the test valve on the fuel rail Route the clear hose into a portable gasoline container or the equipment fuel tank FUEL SYSTEM FUEL INJECTION 2 Turn on the key switch to activate the pump and check the system pressure on the gauge If system pressure of 39 psi 3 is observed the ignition switch ECU fuel pump and pressure regul
172. ges the central coil which creates a magnetic field This magnetic field attracts an armature plate keyed to a roller cage that contains 14 rollers and roller cam The difference in rpm by input shaft and front axles the forces the rollers up the external cam The rollers engage themselves to the output hubs that link both front axles resulting POLARIS FINAL DRIVE in True All Wheel Drive CAUTION If the rear wheels are spinning release the throttle before turning the AWD switch on If AWD is engaged while the wheels are spinning severe drive shaft and clutch damage could result Roller Cage and Roller s Rotate Inward and Grip the Output Hub for AWD Engagement Output Hub Roller Cage amp Bearings Disengagement As the front and rear wheels gain traction rotating very close to the same speed the front wheels overdrive the output hubs and the rollers are forced outward disengaging the AWD The vehicle is now back to rear wheel drive until the next loss of traction FRONT GEARCASE REMOVAL 1 Stop engine place machine in Park and set parking brake 2 Loosen right front wheel nuts slightly 3 Elevate support machine footrest frame area 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 bearings and seals under 4 Remove right wheel nuts and wheel 5 Remove t
173. ghly clean the lifters in cleaning solvent and wipe them with a clean lint free cloth 3 Markthe lifters with a white pen if using the lifters forreassembly This will ensure thatthe lifters are properly placed during engine reassembly POLARIS ENGINE 4 Check the lifters for wear or scores 5 Check the bottom end of lifter to make sure that it has a slight convex 6 Ifthe bottom surface has worn flat it may be used with the original camshaft only Inspect Hydraulic Lifter NOTE Lifters that are scored worn or if the bottom is not smooth should be replaced with new lifters and cam as an assembly If replacing the lifters the camshaft should also be replaced PISTON REMOVAL 1 Remove A Mark the piston with a white pento ensure proper orientation if reused during assembly Mark the piston NOTE If the pistons are to be reused reassemble the pistons in the same cylinder and direction from which they were removed NOTE New pistons are non directional and can be placed in either cylinder 3 31 2 Remove piston circlip and push piston out of piston If necessary heat the crown of the piston slightly with a propane torch CAUTION Do not apply heat to the piston rings The ring may lose radial tension 3 Remove top compression ring Using a piston ring pliers Carefully expand ring and lift it offthe piston CAUTION Do not expandthe ring more than th
174. hassis ground cable Remove all engine mount nuts and or engine mount plates Remove the frame brace F from the front left side of the frame POLARIS frame Use engine lift or other means if the engine is too heavy to be lifted manually Use caution when lifting the engine out of 22 For engine installation reverse procedures ENGINE INSTALLATION NOTES After the engine is installed in the frame review this checklist and perform all steps that apply General Items 1 Install previously removed components using new gaskets seals and fasteners where applicable 2 Perform regular checks on fluid levels controls and all important areas on the vehicle as outlined in the daily pre ride inspection checklist refer to Chapter 2 or the Owner s Manual PVT System 1 Adjust center distance of drive and driven clutch Chapter 6 POLARIS 2 Adjust clutch offset deflection Chapter 6 3 Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing Chapter 6 Transmission alignment belt 1 Inspecttransmission operation and adjust linkage if necessary Refer to Chapter 2 and Chapter 8 Exhaust 1 Replace exhaust gaskets Seal connections with high temp silicone sealant 2 Checkto be sure all springs are in good condition Bleed Cooling System NOTE This cooling system contains vent lines to help purge trapped ai
175. he throttle body attached to the engine This procedure is meant to allow the TPS flow and idle offset voltage to be correctly set without the use of a flow bench No steps can be eliminated Step 1 Establishing zero offset voltage This step is crucial as it sets the TPS position using a fixed physical stop This will insure that the correct offset voltage is reached once the correct throttle body flow is set Throttle Plate must be closed Remove cover and disconnect throttle cable from throttle cam 4 15 FUEL SYSTEM FUEL INJECTION With engine off back out air flow Step 2 screw until it no longer is in contact with throttle plate cam The throttle plate should seal off throttle bore completely Establishing correct flow Now that the zero offset voltage has been set you can now set the throttle body to the correct air flow value With voltmeter still attached to tool PN PU 47082 turn the air flow adjustment screw until the voltmeter reads 710 01 volts The throttle body is now adjusted to the correct flow value Figure 3 Back air flow screw out until no contact is made Turn air flow screw in Open and close throttle plate a couple of times to ensure full throttle closing Do not snap closed as this could cause unnecessary throttle late to throttle body interference and or damage Set up the TPS voltage check tool PN PU 47082 according to the Tool PN PU 47082 SE read instruct
176. he front brake caliper and suspend the safely suspend the brake caliper from the frame 7 9 FINAL DRIVE with a piece of wire 9 Pull both driveshafts from the front gearcase Replace the circlip on the driveshaft end for reassembly 10 Remove the roller pin from the front prop shaft Use the Roller Pin Removal Tool PN 2872608 11 Remove bolts securing bottom of housing to frame Bolts are accessible through the skid plate Remove vent line Remove the front gearcase from right side of frame CAUTION Do not hang the caliper by the brake line Use wire to hang the caliper to prevent possible damage to the brake line 6 Remove the front hub from the drive shaft 7 Remove cotter pin lower ball joint nut and A arm from ball joint Remove 4 Bols FRONT GEARCASE DISASSEMBLY INSPECTION 1 Drain and properly dispose of used oil Remove any metal particles from the drain plug magnet 2 Remove bolts and output shaft cover 8 Pull the hub and strut assembly out and pull the drive shaft out of the hub Front Gearcase Coil Resistance 22 8 25 2 Ohms 710 FINAL DRIVE Gearcase Coil Resistance NOTE Totestthe gearcase coils resistance use the coil harness The gearcase coils should measure between 22 8 ohms and 25 2 ohms 3 Remove output shaft assembly 8 Inspectroll cage B sliding surface This surface must be clean and free of nicks burrs or scra
177. heckthe contact area of the seat on the valve face apply athin coating of Prussian Blue paste to the valve seat If using an interference angle 46 apply black permanent marker to the entire If the contact area of the cutter is in the same place the valve guide is distorted from improper installation If the contact area of the initial cut is greater than 7596 continue to cut the 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 valve face A 6 Insert valve into guide and tap valve lightly into gt place a few times 7 Remove valve and check where the Prussian Blue indicates seat contact on the valve face The valve seat should contact the middle of the valve face or slightly above and must be the proper width 3 26 If the indicated seat contact is at the top edge of the valve face and contacts the margin area B it is too high on the valve face Use the 30 cutter to lower the valve seat If too low use the 60 cutter to raise the seat When contact area is centered on the valve face measure seat width If the seat is too wide or uneven use both top and bottom cutters to narrow the seat LO e Ifthe seat is too narrow widen using the 45 cutter and re check contact point on the valve face and seat width after each cut NOTE When using an interference angle the seat contact point on
178. his EBS driven clutch provides the same engine braking abilities as the earlier EBS driven clutch One way Clutch Do not disassemble from this side Downhill 2 Itis important to mark the position of the shaft Belt Rotation cam cover and sheave before disassembly or use the lt on the components for reference This will aid in reassembly and helps to maintain clutch balance after reassembly Mark Components Before Disassembly When the ATV is moving downhill the drive train turns the driven clutch belt and one way clutch in the direction of engine rotation When the one way clutch see exploded view of drive clutch exceeds the drive clutch rotational speed the one way clutch locks to the drive clutch shaft and engine braking occurs Essentially the driven clutch has become the 3 Remove the four torx screws that secure the cam driving clutch The spider assembly with the two assembly helix using a T25 torx rollers that is fixed to the transmission shaft rotates in the pockets of the sheave allowing the stationary sheave to rotate with the moveable sheave as the rollers move to the other side of the ramp providing instant EBS braking Engine braking EBS continues until the drive clutch speed exceeds the one way clutch speed or until the throttle is applied and the engine reaches clutch engagement speed lifting the belt off of the one way clutch CAUTION The driven clutch must
179. housing assembly Press off gear 32 Remove the snap ring from the assembly Place the housing in a support and press out the bearing shaft assembly POLARIS WATER OIL PUMP REASSEMBLY 34 Press new bearing onto the shaft Press out shaft and bearing assembly Bearing S Bearing j Ring lui 35 Press the bearing shaft assembly using the bearing s outer race Do not use the shaft to press the assembly into the housing bearing Bearing damage may result Install retaining ring Press Bearing Shaft assembly using outer race only Bes pr gt lt 2 36 Press gear onto shaft while supporting the housing PELARIS 3 45 CRANKCASE DISASSEMBLY CONT D 37 Remove thrust plate U 38 Remove PTO end engine mount Remove crankcase bolts Tap on the reinforced areas on the cases using soft hammer Carefully separate the two crankcase halves Separate the crankcase halves 41 Remove and inspect crankshaft main journal bearings for abnormal wear It is recommended to replace the bearings anytime the engine is disassembled NOTE Only remove the oil baffle if the baffle is damaged When removing the oil baffle bolts use a heat gun to heat the bolts and loosen the Loctite This will prevent any possible damage to the bolts or t
180. iately apparent if done incorrectly See illustration 2 After alignment is complete torque jam nuts to 12 14 ft lbs 16 19 Nm POLARIS EXHAUST PIPE The exhaust pipe must be periodically purged of accumulated carbon as follows 1 Remove the clean out plugs located on the bottom of the muffler as shown in illustration 1 M 2 11 1 Clean Out Plug 2 Place the transmission in neutral and start the engine Purge accumulated carbon from the system by momentarily revving the engine several times If some carbon is expelled cover the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times If particles are still suspected to be in the muffler back the machine onto an incline so the rear of the machine is one foot higher than the front Set the hand brake and block the wheels Make sure the machine is in neutral and repeat Steps 2 and 3 SEE WARNING If particles are still suspected to be in the muffler drive the machine onto the incline so the front of the machine is one foot higher than the rear Set the hand brake and block the wheels Make sure the machine is in neutral and repeat Steps 2 and 3 SEE WARNING 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
181. iggering of fault codes related to fuel delivery Injector clogging is usually caused by a buildup of deposits on the deflector plate restricting the flow of fuel and resulting in a poor spray pattern Some contributing factors to injector clogging include dirty air filters higher than normal operating temperatures short operating intervals and dirty incorrect or poor quality fuel Cleaning of clogged injectors is not recommended they should be replaced Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem POLARIS FUEL SYSTEM FUEL INJECTION FUEL INJECTOR REPLACEMENT 1 Engine must be cool Depressurize fuel system through test valve in fuel rail 2 Remove the front fender assembly and fuel tank 3 Thoroughly clean the area around and including the throttle body manifold and the injectors 4 Disconnect the fuel injector harness s at the ECU 5 Remove the fuel rail mounting screw and carefully loosen pull the rail away from the injectors 6 Reverse the procedures to install the new injector s and reassemble Use new O rings any time an injector is removed new replacement injectors include new O rings Lubricate O rings lightly with oil to aid installation Torque the fuel rail mounting screw to 16 20 ft 165 22 6 27 Nm CRANKSHAFT POSITION SENSOR CPS The engine speed sensor is essential to engine operation constantly monitoring the rotational
182. ight footwell if required for access 8 4 Transmission Mountin quet 2 Disconnect transmission vent line 3 Drain transmission lubricant 4 Disconnect shift linkage rod end from transmission bellcrank Transmission Switch POLARIS 6 Remove auxiliary brake mounting bracket from frame and secure out of way for transmission removal 7 Remove PVT outer cover both drive and driven clutch and inner PVT cover refer to Clutch Chapter 6 8 Use the Roll Pin Removal Tool PN 2872608 to remove the roll pins from the front prop shaft and h 9 Loosen or remove the bolts that secure the rear gearcase Move the rear gearcase back just enough to slide the rear propshaft from the transmission shaft Remove or Loosen Rear Gearcase Bolts POLARIS TRANSMISSION 10 Remove the park lock spring S S RAN E Park Lock Spring T 11 Remove left side transmission bracket rear bracket and lower right bracket bolt 12 Remove front transmission to engine mount bolts See illustration 13 Remove transmission from right side of frame TRANSMISSION INSTALLATION 1 Install transmission from right side of vehicle Align rear output shaft to rear propshaft yoke and roll pin hole Slide rear output shaft into propshaft yoke Position transmission in frame Install front propshaft and roll pin Loosely install left side and rear mounting brackets Loosely ins
183. iled Test starter solenoid coil by connecting an ohmmeter between the solenoid wire and the solenoid mounting plate Resistance should be 3 49 Check Yes solenoid ground path by measuring resistance between mounting plate and Voltage Drop Testing battery negative terminal See Page 10 37 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 No 1 V D C press starter button Reading should be less than Yes Connect the black tester lead to the solenoid end of the solenoid to starter cable Connect the red teste lead to the starter end of the same cable Depress the starter button The reading should be less than 1 V D C Clean the solenoid to starter cable ends or replace the cable 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 43 POLARIS ELECTRICAL NOTES 10 44 POLARIS
184. ime 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 flashing When the wrench stops blinking your 10 5 ELECTRICAL service hours are set Next Page 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 service interval mode 2 Press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center The service interval is now off 3 To enable turn on the service interval mode repeat the steps above in Setting Service Interval After Countdown 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
185. in and remove the brake pads from the caliper y Remove Brake Pads 7 Clean the caliper with brake cleaner or alcohol 8 Measure the thickness of the pad material Replace pads if worn beyond the service limit 9 17 BRAKES gt Measure Thickness Rear Brake Pad Thickness New 318 8 0 mm Service Limit 180 4 6 mm REAR BRAKE PAD INSTALLATION 1 Install new brake pads in caliper body WARNING f the brake pads are contaminated with grease oil or liquid soaked do not use the pads use only new clean pads Install Pads 2 Install and tighten the slide pin with a hex wrench 3 Install caliper and torque the mounting bolts 9 18 24 Nm Torque Specifications Rear Brake Caliper 18 ft Ibs 24 Nm Caliper Slide Pin Torque 30 35 ft Ibs 41 Nm 48 Nm 4 Installthe slide bolt snap ring Torquethe slide pin to 30 35 ft Ibs 41 Nm 48 Nm 30 35 ft lbs 41 48 Nm m g I 5 Slowly pump the brake lever until pressure has been built up Maintain at least 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the master cylinder 6 Itisrecommended 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 Repeat procedure 10 times POLARIS BRAKES REAR CALIPER 5 Remove the anvil bol
186. inder bore 3 1495 80 mm 0 000317 0 008 mm Out of round limit 0 00030 0 0075 mm Piston clearance 040 015 Same 041 016 mm Outer Diameter 0 84245 0 00025 Same 21 39 8 0 00635 mm Block Bore Std 0 8438 0 00062 Same 21 4822 0 0157 mm Piston 3 1477 000121 3 14803 00028 79 954 003 79 960 007 mm Standard inner diameter of piston 0 78789 00009 0 70902 00012 bore 20 0125 0 003 mm 18 009 0 003 mm Piston Pin Outer diameter 0 7874 0 7872 0 70866 0 70846 20 19 995 mm 18 17 995 mm Standard clearance piston pin to pin 0 00059 0 0002 0 00047 0 00024 bore 0 015 0 005 mm 0 012 0 006 mm Degree of fit Piston pin must be a push Same hand fit at 68 F 20 POLARIS 313 6 700 800 EFI ENGINE SERVICE DATA Cylinder Piston Connecting Rod EFI Engine No EFI Engine No EH6800LE EH7800LE i Piston ring installed Top ring Std 0 0059 0 0138 0 0059 0 0138 gap 0 15 0 35 mm 0 15 0 35 mm Second Std 0 0098 0 0197 0 0098 0 0197 ring 0 25 0 50 mm 0 25 0 50 mm 1596 Leakdown 1596 Leakdown Oilring Std 0 0196 00984 0 0196 00984 0 50 0 25 mm 0 50 0 25 mm gt 15 Leakdown gt 15 Leakdown Standard clearance ring Std 0 0024 0 0008 0 0024 0 0008 piston ring to ring 0 060 0 020
187. interprets the resistance reading and displays the corre sponding shift position in the LCD panel Testing Use the diagram provided to test the continuity loop at each of the shift points with a multi meter NOTE The Instrument cluster contains this diagnostic feature 16 Pin Connector Red 12V Ignition Switch Red White 12V ETC and AWD Switch Grey Orange Mode Override button Black Ignition Kill Green Diagnostic Factory Use Only Blue Diagnostic Factory Use Only Yellow Red RPM Input Brown Ground Blue White Engine Overheat Switch 10 N C 11 Black White Engine Check Light 12 Purple White Fuel Sender if equipped 13 Brown Red Trans Switch Ground 14 White Gear Shift Signal 15 White Blue High Gear Signal 16 Brown White AWD Coil POLARIS REPLACE TANK ASSEMBLY 0 0 B 40 010 geet D Ej e 9O REV F 6 9O PARK 04 BLU W 45 R II R W 29 BLK W 6 GRY OR TRANS SWITCH 49 PUR W 03 BLK 18 BRN R 38 GRN L 4 W 39 BLU 26 W BLU 15 Y R 4 BRN W4 4460 8 08 BRN gt 56 BLU R 55 WIBLU 18 BRN R 54 GRN W L 53 PUR 52 OR R 14 W ELECTRICAL COOLANT TEMPERATURE SENSOR The coolant temperature sensor can be tested using an ohmeter or voltmeter
188. ion STA BIL Registered Trademark of Gold Eagle Nyogel Trademark of Wm F Nye Co Fluke Registered Trademark of John Fluke Mfg Co Mity Vac Registered Trademark of Neward Enterprises Inc Ammco Registered Trademark of Ammco Tools Inc Torx Registered Trademark of Textron Hilliard Trademark of the Hilliard Corporation Warn Trademark of the Warn Industries HiPerWash Liquid Buff are trademarks of HPC inc POLARIS Do Ee 3 Bms H GENERAL INFORMATION CHAPTER 7 GENERAL Model Identification 1 2 Serial Number Location 1 2 2005 Sportsman EFI Dimensions 1 3 Specifications Sportsman EFI 1 4 1 5 Publication Numbers 1 6 CodeS v aw hs toe coe od ce es 1 6 Replacement Keys 1 6 Standard Torque Specifications 1 6 Special Tools e Efe its 1 7 1 10 Torque Table 1 11 Conversion Table 1 12 Tap Drill Charts 1 13 Decimal Equivalent Chart 1 13 Glossary of Terms 1 14 POLARIS 1 se GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service Machine Model Number Identification A 05 68 AU
189. ions Verify that the 9 volt 25d battery has a minimum of 6 volts Figure 2 Black Probe Red Probe S Tool PN PU 47082 Should read 528v N 528 Reconnect the TPS harness lead us Reinstall throttle cable on throttle cam and install cover Adjust cable freeplay Usingavoltmeter attached to tool PN PU 47082 check the voltage output of the TPS It should read 528 01 volts If it does not read 528 01 volts loosen the screw holding the TPS to the throttle body Rotate TPS until voltmeter reads 528 01 volts Retighten TPS mounting screw and verify the voltage did not change POLARIS 4 16 Gj ENGINE TEMPERATURE SENSOR Mounted on the cylinder the engine temperature sensor measures coolant temperature The engine temperature sensor is a Negative Temperature Coefficient NTC type sensor as the temperature increases the resistance decreases Engine Temperature Sensor Refer to Chapter 10 for testing Standard resistance readings according to temperature Temperature F C 68 F 20 C 2 5 KQ 6 212 F 100 C 0 186 2 Coolant passes through the cylinder and by the sensor probe creating a resistance reading which is relayed to the ECU This signal is processed by the ECU and compared to its programming for determining the fuel and ignition requirements during operation The ECU also uses this signal
190. ip lt 31 Carefully install the tapered end of the Crankshaft Seal Protection Tool PA 45658 through the paper side of the crankshaft seal Back to Front Leave the seal protector installed in the crankshaft seal Check the crankshaft seal lips to verify they have not been rolled or damaged POLARIS 34 Apply Crankcase Sealant PN 2871557 to the outside edges of the crankcase halves See arrows where the crankcases mate See photos below This helps to prevent coolant leakage 32 Before installing the gear stator housing cover install the Water Pump Seal Saver PA 45401 onto the water pump shaft 106 35 Install the gear stator housing gasket onto he 33 Install the new gasket to the gear stator housing crankcase cover and crankcase With the tools installed carefully place the gear stator housing cover over G EX A ear Stator the protection tools NOTE New gasket is not hae gi Housing Gasket shown in the picture 2 36 Secure the gear stator housing cover O to the crankcase with the cover bolts Torque bolts to 96 12 in lbs 10 85 0 35 Nm in proper tightening sequence see Pg 3 3 Remove seal protectors from the shaft ends once secure POLARIS 3 55 45401 E 45658 Gear Stator Housing Bolt Torque 96 12 in Ibs 10 85 gt 0 35 Nm Torque in Proper Sequence Pg 3 3 NOTE
191. is enabled 7 Gear Indicator Specifies what position the shift lever and transmission are in This area is blank if a fault occurs 8 Mode Indicator Indicates which modes are being utilized 9 Fuel Gauge The segments of the fuel gauge indicate the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All related icons will flash FUEL will display in the LCD and the speedometer needle will blink If riding be sure to refuel immediately wt Blink When Low Fuel DIAGNOSTIC MODE 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 To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Setthe 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 NOTE The initial screen display refers to the software version installed on your ATV This information is only displayed briefly 10 4 Screen 1 The first screen indicates batte
192. isually checked for straightness while they are installed in the engine by rotating them with the valve closed Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness POLARIS ENGINE 5 f the push rod A is visibly bent it should be replaced CYLINDER HEAD REMOVAL 1 Loosen the six cylinder head bolts evenly 1 8 turn each in a criss cross pattern until loose 2 Remove bolts A and tap cylinder head B lightly with a soft face hammer until loose CAUTION Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging the head or cylinder 3 Remove cylinder head B and head gasket C from the cylinder D 3 21 CYLINDER HEAD INSPECTION 1 Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon CAUTION Use care not to damage sealing surface CYLINDER HEAD WARPAGE 1 Layastraight edge A across the surface of the cylinder head B at several different points and measure warpage by inserting a feeler gauge between the straight edge and the cylinder head surface If warpage exceeds the service limit replace the cylinder head Measure at different points on the surface Bottom Side Vie Cylinder Head Warpage Limit 004 1016 mm Max CYLINDER HEAD DISASSEMBLY NOTE The following procedure is only for servicing the top end of the valve trai
193. k arrestor 300 H 36 M 1860 Clean out 3000 E Idle speed Adjust as needed Toe adjustment Inspect periodically adjust when parts are re placed El Auxiliary brake EE Inspect daily adjust as needed Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California Have an authorized Polaris dealer perform these services POLARIS 2 5 SPORTSMAN COMPONENT LOCATIONS Instrument Cluster AWD Switch Brake Fluid Work wee Light Control amp Run Switch Q Reverse Override Throttle Front Storage EFI Diagnostic lgnition Key Compartment Plug Cover ee amp Rack Rear Storage Compartment Front Gearcase Behind Radiator SERRE PVT Cover Drain Gas Cap Gear Shifter Right Aj Front Drive Shafts Front Prop Shaft Auxiliary Brake 2 6 Gg POLARIS MAINTENANCE POLARIS LUBRICANTS FLUIDS FOR SPORTSMAN MODELS Pure Polaris Lubricants and Maintenance Kits can be purchased at your local Polaris dealer Premium Fuel Stabilizer Significantly reduces gum and varnish formation Formulated for 2 cycle and 4 cycle Polaris engines 2870652 EL UEL STABILIZER 2872280 2 5 gallon 2971281 Quart Premium Antifree
194. ke line is the pipe fit style torque the fitting to 12 15 ft Ibs 16 20 Nm REAR AUXILIARY MASTER CYLINDER ASSEMBLY Brake Reservoir PE qo Rear Master Cylinder N e 92 L P Rear Foot Brake Line Mount Plate Bolts 8 ft lbs X 11 Nm Wash Ds as 9 e V Bushing Cotter Pin Ne 9 22 sssi OO PGLRHIS BRAKES REAR BRAKE CALIPER EXPLODED VIEW 3 APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT 3 Piston Front Caliper Snap Ring TROUBLESHOOTING Brakes Squeal Dirty contaminated friction pads Improper alignment Worn disc Worn disc splines Poor Brake Performance Air in system Water in system brake fluid contaminated Caliper disc misaligned Caliper dirty or damaged Brake line damaged or lining ruptured Worn disc and or friction pads Incorrectly adjusted lever Incorrectly adjusted stationary pad Worn or damaged master cylinder or components Improper clearance between lever and switch Lever Vibration Disc damaged Disc worn runout or thickness variance exceeds service limit Caliper Overheats Brakes Drag Compensating port plugged POLARIS Washers Rear Caliper nvil Bolts N Torque 16 18 ft Ibs 22 24 25 30 in Ibs O rings 2 80 3 40 Nm Seals 3 Slide Pins Torque 30 35 ft Ibs 41 48 Nm Pad clearance set incorrectly Auxiliary brake pedal incorrectly adjusted Brake lever or pedal binding or unabl
195. kness of brake pad friction material BRAKE PAD INSPECTION Pads should be changed when the friction material is worn to 3 64 1 cm or about the thickness of a dime Minimum Thickness POLARIS MAINTENANCE HOSE FITTING INSPECTION 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 function 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 Foot Brake Pedal Full Full Height Engagement 5557 Board Surface AUXILIARY BRAKE ADJUSTMENT HYDRAULIC Use the following procedure to inspect the hydraulic auxiliary foot brake system and adjust or bleed if necessary POLARIS First check foot brake effectiveness by applying 50 Ib approx downward force onthe pedal The top of the pedal should be at least 1 inch 25 4mm above the surface of the footrest 1 8 to 1 4 Free Play 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 inch 3 2 6 35 mm If free play is excessive inspect pedal linkage and master cylinder for wea
196. l Polaris Sales Inc Service Publications Dept Send Comment Card 2100 Hwy 55 Medina MN 55340 X USA The Way Out 9919820 BEA LE ELM Printedein USA
197. l PU 45497 2 O to align the cam split gear assembly With the split gear aligned remove the bolt and cam gear assembly WEAR SAFETY GLASSES AT ALL TIMES USE CAUTION WHEN WORKING WITH THE TOP GEAR THE SPRINGS COULD CAUSE INJURY OR BECOME LOST SHOULD THEY POP OUT 12 Remove all three springs using one of the tapered pins from the Tapered Pins PU 45497 1 NOTE Install the Cam Gear Tooth Alignment Tool PU 45497 2 into the assembly hole counter clockwise from the timing mark as shown Cam Gear Alignment Tool PU 45497 1 PU 45497 2 13 With a white marking pen accent the timing mark Cam Gear Disassembly on the gear that contains the springs 10 Inspect the cam gear teeth and check to make sure there is spring tension offsetting the teeth between the two gears If there is no tension i Accent the Timing Marks check the springs inside of the cam gear assembly 3 Loaded Springs 14 Inspect the gear teeth and the three tabs on the gears for wear 3 40 _ Inspect Teeth amp Tabs Replace Three Springs Cam Gear Reassembly 15 Install the new springs into the grooves of the cam gear Insert Springs 16 Insert the pointed dowels from the Tapered Pins 45497 1 into the cam gear POLARIS ENGINE PU 45497 1 To assemble e Hold the spring with one finger e Start the pointed end of the tapered pin i
198. l the shaft assembly and gear cluster as a unit into their respective bearing case recesses Tap with a soft face hammer to seat shaft assemblies 8 13 TRANSMISSION 16 Position the shift forks up and so the the pins point toward the 9 o clock position before installing the shift drum assembly 17 Replace and grease the O rings on the shift drum before installation NOTE positioned in the slot on selector arms Make sure shift shaft pins are properly 8 14 19 Lift the shift rail slightly and rotate the rail fork assembly so it meshes with the tracks on the shiftdrum Be sure the wave springs are properly in place and that the shift rail is seated into the pocket on the backside of the case 20 Install the helical gear and bearing onto the pinion shaft 21 Clean the mating surfaces of the case and cover Apply Crankcase Sealant PN 2871557 to the mating surfaces Be sure the locating pins knock pipes are in place Reinstall cover LH mounting bracket and torque bolts in a criss cross pattern in 3 steps to 27 34 ft Ibs 36 50 46 Nm Front Cover Bolt Torque 27 34 ft Ibs 36 50 46 Nm 22 Grease the seal lips of the input shaft seal Apply electricians tape or somehow cover the splines of the shaft to protect the seal lips during installation Install new input shaft seal 23 Install drain plug with a new sealing washer Torque drain plug to 14 18 ft Ibs 19 24 Nm Drain Plug Torque
199. lace every two years Be sure vent lines are routed properly and secured with cable ties CAUTION Make sure lines are not kinked or pinched FUEL FILTER The fuel filter should be replaced in accordance with the Periodic Maintenance Chart 1 Relieve the pressure on the fuel rail See Ch 4 2 Remove line clamps at both ends of the filter 3 Remove fuel lines from filter 4 Install new filter with arrow pointed in direction of fuel flow 5 Install clamps on fuel line 6 Start engine and inspect for leaks COMPRESSION TEST NOTE This engine does NOT have decompression components Compression readings will vary in proportion to cranking speed during the test Average compression measured is about 150 200 psi during a compression test A smooth idle generally indicates good compression Low engine compression is rarely a factor in running condition problems above idle speed Abnormally high compression can be caused by carbon deposits in the combustion chamber or worn damaged exhaust lobes Inspect camshaft and combustion chamber if compression is abnormally high 2 15 cylinder leakdown test is the best indication of engine condition Follow manufacturer s instructions to perform a cylinder leakage test Never use high pressure leakage testers as crankshaft seals may dislodge and leak Cylinder Compression Standard 150 200 PSI Cylinder Leakdown Service Limit 15 6 Inspect for cause if
200. lacement Kits Inner Clamp 3 5 oz Grease GREASE PACK 3 5 oz Outer Clamp Front Prop Shaft Components Propshaft Assembly O Ring Prop Shaft Cross and Bearing Kit d Yoke Front Gearcase Yoke Propshaft to Transmission Rear Prop Shaft Components Yoke Propshaft to Transmission Yoke Rear Gear case 7 8 POLIS FRONT GEARCASE OPERATION CENTRALIZED HILLIARD Engaging Front Gearcase The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains while the front gearcase is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where the front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest Normal Operation With the AWD switch off the vehicle drives only the rear wheels 2 wheel drive When the AWD switch is activated it engages the Hilliard locking both front axles into All Wheel Drive Roller Cage Output 4x4 Engagement When the AWD switch is activated a 12 VDC current char
201. ld 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 m CAUTION Due to the nature of these adjustments it is recommended this service be performed by an authorized Polaris dealer p 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
202. lead 2 Remove spark plug 3 Inspect electrodes for wear and carbon buildup Look for a sharp outer edge with no rounding or POLARIS Inspect electrode for wear and buildup erosion of the electrodes 4 Clean with electrical contact cleaner or a glass bead spark plug cleaner only CAUTION A wire brush or coated abrasive should not be used 5 Measure gap with a wire gauge Refer to specifications for proper spark plug type and gap Adjust gap if necessary by bending the side electrode carefully Illustration below 6 If necessary replace spark plug with proper type CAUTION Severe engine damage may occur if the incorrect spark plug is used 7 Apply a small amount of anti seize compound to the spark plug threads Install spark plug and torque to specification Recommended Spark Plug Refer to Specifications Chapter 1 Spark Plug Torque 18 Ft Lbs 24 Nm Spark Plug Gap m 036 0 9 mm IGNITION TIMING Refer to Chapter 10 for ignition timing procedures 2 17 ENGINE TO FRAME GROUND Inspect engine to frame ground cable connection Be sure it is clean and tight Typica Ground Cable LIQUID COOLING SYSTEM 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 hea
203. liary Brake Line F is Hand Brake Line L Outer Bleed Screw Auxiliary Brake Inner Bleed Screw Hand Brake 2 4 BRAKE BLEEDING CONT D NOTE Fluid may be forced from supply port B when brake lever is pumped Place diaphragm C in reservoir to prevent spills Do not install cover See Illustration above 7 Slowly pump brake lever D until pressure builds and holds 8 While maintaining lever pressure open bleeder screw Close bleeder screw and release brake lever NOTE Donotrelease lever before bleeder screw is tight or air may be drawn into caliper Bleeder Screw Torque 25 30 in Ibs 2 80 3 40 Nm 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 the bleeder screw to 25 30 in lbs 2 80 3 40 Nm 11 Repeat procedure Steps 5 9 for the remaining caliper s 12 Add Polaris Dot 3 Brake Fluid PN 2870990 to MAX level inside reservoir Master Cylinder Fluid Level MAX level inside reservoir Sight glass must look dark if sight glass is clear fluid level is too low POLARIS 13 Install diaphragm cover and screws Tighten screws to specification 5 in lbs 0 56 Nm Reservoir Cover Torque
204. linder Reservoir 5 lbs Cover Bolt Front Brake Disc Balls NOTE Refer to the tightening procedures in this chapter when torquing the bolts Some special procedures are used when torquing certain bolts and fasteners 9 2 COMO PGLRRIS BRAKES BRAKE SYSTEM MAIN COMPONENTS 1 All Banjo Style Fittings All Flare Style Fittings 15 ftlbs 21Nm 16 21 A fuge All Bleed Screws 3 507 25 30 in lbs 2 80 3 40 Nm 2 Screws 5 in lbs 0 56 Nm N ri Apply Pipe Sealant to Threads 9 3 POLARIS BRAKES REAR BRAKE CALIPER EXPLODED VIEW nvil Bolts 3 APPLY POLARIS DOT 3 BRAKE d 3 FLUID TO COMPONENT Torque Washers 16 18 ft Ibs 22 25 Rear k P d m 3 Piston Torque 25 30 in Ibs 2 80 3 40 Nm Seals 3 Slide Pins Torque 30 35 ft Ibs 41 48 Nm 3 APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT APPLY POLARIS ALL PURPOSE GREASE GREASE Square 3 Piston g Brake Pads Bleeder Screw 35 60 IN LBS 4 6 5 NM Caliper Assembly Caliper Mount 4 Gp POLARIS BRAKES REAR AUXILIARY MASTER CYLINDER Brake Reservoir se Rear Brake Line e Clamp Bolt E c Sea p A SS x Rear Brake aster Cylinder Screw Spring Washer Bushing y Washer 7 Bushing BRAKE SYSTEM SERVICE NOTES Polaris disc
205. ll damage the case and shorten the life of the battery Refer to the Battery Maintenance Video PN 9917987 for proper instruction on servicing Low Maintenance batteries 10 26 To service a Low Maintenance battery 1 Remove battery from the vehicle 2 Test battery with a voltage meter or load tester to determine battery condition This will determine the length of time required to charge the battery to full capacity Refer to capacity table 3 Charge battery using a variable rate charger LOW MAINTENANCE 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 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 Battery Charging Reference Table Voltage Charge Time See note below 100 12 8 13V None check volt age at 3 mos after manufac ture date 3 6 hours 75 100 12 5 12 8 V May need slight charge 50 75 12 0 12 5 V Needs 5 11 hours Charge 25 50 11 5 12 0 Needs At least 13 Charge hours verify state of charge
206. luids Failure to do so could result in serious injury or complications NOTE The fuel pump cannot be replaced as an individual part the entire fuel pump and fuel tank is replaced as an assembly Refer to your parts book for the proper part number 1 Disconnect the negative battery cable 2 Remove the side panels and front cab assembly Refer to COVER PANEL REMOVAL in Chapter 5 for details 4 10 E 3 Remove the gas tank cover vent hose Be sure to properly route the vent hose upon reassembly 4 Remove the clamps on the PVT intake duct and remove the PVT duct 5 With all the body panels removed from the front of the ATV and the gas tank exposed disconnect the pump wiring harness WARNING Wear safety goggles while performing this procedure failure to do so could result in serious injuries POLARIS 8 6 Relieve the fuel pressure at the fuel test valve 7 Loosen the fuel tank hose and pull the fuel line fromthetank NOTE Asmall amount of fuel may come out of the fuel line or tank Plug the fuel line andtank inlet or use a shop towel during removal CAUTION Check the fuel test valve for any possible fuel seepage after performing tests or procedures Fuel is extremely flammable and may cause severe burns injury or death Do not use any device that produces a flame or electrical devices that may spark around fuel or fuel vapors 700 EFI Shown POLARIS FU
207. ly to maintain clutch balance Q 800 EFI 700 EFI Transmission Cover Inner Clutch Cover Boot Duct Clutch Cover Seal Q Inner Cover Seal Seal Retainer Bracket Clutch Cover 62 5 CLUTCH ENGINE BRAKING SYSTEM EBS EXPLODED VIEW Drive Clutch Assembly 700 EFI Shown p di d b _ aas PTFE p 7 Way Washer nii Clutch Drive 7 a Brass Washer Screws ShiftWeights 2 N Coil Torque to 271 Nm 5 Spacer Sleeve Drive Belt Roller Bushing Assembly Spider Lock Nut Clutch Rollers Bolts Lock Washers Compression CY EN Spring C Clutch N X Shaft QNO S d Spacer Washer Retaining Rings Sheaves Bearing POLARIS 6 3 CLUTCH SPECIAL SERVICE TOOLS AND SUPPLIES TOOL DESCRIPTION Clutch Puller 2870506 Clutch Holding 9314177 Wrench Clutch Holding Fixture Spider Nut Socket 2870338 Drive Clutch 2870341 Spider Removal and Install Tool Driven Clutch Puller Roller Pin Tool 2870910 Clutch Bushing 2871226 Replacement Tool Kit Piston Pin Puller 2870386 EBS Clutch 2872292 Alignment Tool EBS Bushing Replacement Kit Driven Clutch Compression Tool Std Clutch Compression Tool Clutch Bushing Replacement Tool Kit 800 EFI Drive PA 47336 Clutch Bushing Replacement Tool PVT SYSTEM FASTENER TORQUES 40 ft Ibs 54 Nm
208. mber 4110148 4010278 4010278 WE BE XN zc 700 ENGINE COLD WEATHER FROST PLUG HEATER Frost Plug Heater for Sportsman 700 800 PN 2873069 16 POLRRIS GENERAL INFORMATION SPECIAL TOOLS Special Tools maybe required while servicing your machine Some of the tools listed are mandatory and other tools maybe substituted with a similar tool if available Polaris recommends the use of Polaris special tools when servicing any Polaris product Standard Tools and Engine Tools PU 45432 Caliper or A Basic Caliper Basic Micrometer 2871043 Flywheel Puller m 2870773 C Clip Install Tool b 2 2870386 Piston Pin Puller ve 2871445 Piston Pin Puller Adapter POLARIS emm 2870390 Piston Support Block PA 44995 Water Pump Mechanical Seal Install Tool PU 45543 Universal Driver Handle 5 PA 45483 Main Seal Installer lt PA 45658 Main Crank Seal Saver P PA 45401 Water Pump Seal Saver PU 45778 Oil Pump Priming Tool 1 7 E SPECIAL TOOLS Standard Tools and Engine Tools 2870588 Hone Oil 12 oz o T N ces 2200634 Valve Seat Reconditioning Kit 2870459 Dial Indicator A 1 mM eleg B PV 35667 A Oylinder Leak down Tester GENERAL INFORMATION Clutch PVT Tools 2870506 D
209. mended Engine Oil Polaris Premium 4 Season Synthetic OW 40 PN 2871281 Ambient Temperature Range 40 F to 120 F Crankcase Drain Plug Torque 192 24 in Ibs 21 7 2 7 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 Place gear selector in neutral and set parking brake Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly POLARIS MAINTENANCE STEERING The steering components should be checked periodically for loose fasteners worn tie rod ends and damage Also check to make sure all cotter pins are in place If cotter pins are removed they must not be re used Always use new cotter pins Replace any worn or damaged steering components Steering should move freely through entire range of travel without binding Check routing of all cables hoses and wiring to be sure the steering mechanism is not restricted or limited NOTE Whenever steering components are replaced check front end alignment Use only genuine Polaris parts 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
210. ment cluster harness A and work light switch B 7 Install the new headlamp and harness assembly into the headlight assembly Turn the headlight harness clockwise to secure the headlamp into place POLARIS 10 29 ELECTRICAL HEADLIGHT HOUSING REPLACEMENT 1 Remove three Phillips screws on the headlight pod 2 Disconnect instrument cluster harness A and work light switch B 4 Remove O Ring D from headlight pivot pins Both Sides 10 30 5 Pullthe headlight housing up to release from the locking tabs Both Sides b M EL ps N 6 Lift the adjusting knob up to remove from the locking tabs 7 Carefully pull the assembly up and out of pod 8 Reverse the steps to install the new housing and reassemble the pod NOTE The distance from the headlamp parting line to the end of the adjustment knob stop is 5 1 8 13 cm See illustration 9 Adjust the headlight aim by turning the adjusting knob POLRRIS HIGH BEAM HEADLIGHT ADJUSTMENT The headlight beam can be adjusted to any position desired by turning the adjusting knob located on the bottom right side of the headlight pod Raise Headlight Turn knob counter counterclockwise Lower Headlight Turn knob clockwise Headlight Knob 1 Place the vehicle on a level surface with the headlight approximately 25 7 6 m from a wall
211. meters Kilogram meter A force of one kilogram at the end of a lever one meter in length applied in a rotational direction Itr Liter Left 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 qt Quart quarts RPM Revolutions per minute Regulator Voltage regulator Regulates battery charging system output at approx 14 5 DCV as engine RPM increases Resistance In the mechanical sense friction or load In the electrical sense ohms Both result in energy conversion to heat Right Side Always referred to based on normal operating position of the driver 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 Plat
212. mm 0 060 0 020 mm groove Second Std 0 0028 0 0008 0 0028 0 0008 ring 0 070 0 020 mm 0 070 0 020 mm Connect Connecting rod small end ID 789 78841 7096 0 0003 ing Rod 20 030 20 015 mm 18 023 008 mm Connecting rod small end ra 0 00098 0 00039 Same dial clearance mmi 025 0 010 mm Connecting rod big end side clearance 0 OST 0 00591 0 30 m 15 Connecting rod big end radial clearance x lose OE 0 00006 0 0038 0 0015 mm Crankshaft Crankshaft runout limit 0 00236 0 060 mm KEY Std Standard OS Oversize ID Inner Diameter OD Outer Diameter Mag Magneto Side PTO Power Take Off Side 3 14 PGLRRIS COOLING SYSTEM COOLING SYSTEM SPECIFICATIONS Condition Approx Reading Temperature Min Max Hot Light 178 190 215 F On 102 C 296Q 3160 180 F 82 C Never remove radiator cap when engine is warm or hot The cooling system is under pressure and serious burns may result Allow the engine and cooling system to cool before servicing 2360 2510 195 F 91 1 Remove front cover System 2 25 Quarts 2 Remove recovery bottle hose from coolant filler Capacity 2 131 Radiator 3 Connect a Mity Vac PN 2870975 to the filler Cap Relief neck nipple and pressurize
213. mmable and explosive under certain conditions components are under high pressure Verify system pressure has been relieved before disassembly NIS drain the fuel system when the engine is hot Severe burns may result Aio not overfill the tank The tank is at full capacity when the fuel reaches the bottom of the filler neck Leave room for expansion of fuel Ae start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time An not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Ar you get gasoline in your eyes or if you should swallow gasoline seek medical attention immediately A If you spill gasoline on your skin or clothing immediately wash with soap and water and change clothing NA stop the engine and refuel outdoors or in a well ventilated area POLARIS 38 FUEL SYSTEM FUEL INJECTION Service Notes POLARIS For more convenient and accurate testing of EFI components it is recommended dealers utilize the Polaris Diagnostic Software dealer only or testing may be done manually using the procedures provided 80 of all EFI problems are caused by wiring harness connections For the purpose of troubleshooting difficult running issues a known good ECU from another Polaris ATV EFI may be used without damaging system or e
214. moval Inspection 6 16 Drive Clutch Assembly 6 15 Drive Clutch Disassembly 6 11 6 12 6 13 Drive Clutch Exploded View 6 2 Drive Clutch Inspection 6 11 Drive Clutch Operation 6 4 Drive Shaft Boot Inspection 7 3 Drive Shaft Boot Replacement 7 4 Driven Clutch Assembly 6 24 Driven Clutch Operation 6 4 6 5 Dual Hydraulic Caliper Bleeding 9 7 E EBS Drive Clutch Bushing Service 6 19 EBS Drive Clutch Inspection 6 13 EBS Driven Clutch Disassembly 6 21 EBS Driven Clutch Disassembly Late 2004 6 27 EBS Exploded View 6 3 EBS Moveable Sheave Bushing Inspection 6 14 EBS One Way Drive Clutch Inspection 6 13 EFI Component Locations 4 5 EFI Diagnostic Mode 10 6 EFI System Exploded View 4 4 EFI System Overview 4 7 Electronic Control Unit 4 8 Engine Accessible Components 3 9 Engine Bottom End Disassembly 3 31 3 32 3 34 Engine Bottom End Disassembly Inspection 3 47 Engine Break in Period 3 18 Engine Designation Numbers 1 2 Engine Exploded View 3 2 3 3 3 4 3 5 3 6 3 7 Engine Fogging 2 35 Engine Head Assembly 3 29 3 30 Engine Lower Disassembly Inspection 3 38 Engine Lower Reassembly 3 47 Engine Lubrication 3 19 Engine Removal 3 16 Engine Serial Number Location 1 2 Engine Service Data 3 12 3 13 3 14 Engine Temperature Sensor 4 17 Engine to Frame Ground 2 18 Engine Top End Disassembly 3 21 3 24 3 28 ETC Operation Test 10 15 ETC Switch Adjustment 2 14 ETC Switch Testin
215. n Loosen the hub retaining nut Loosen but do not remove the wheel nuts Safely lift and support the front of the ATV af WON gt CAUTION Serious injury could occur if machine tips or falls 6 Remove wheel 7 Remove the two brake caliper attaching bolts CAUTION Do not hang the caliper by the brake line Use wire to hang the caliper to prevent possible damage to the brake line 7 2 8 Remove hub 9 Remove cotter pin and nut from lower A arm ball joint Remove lower A arm from ball joint 10 Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly POLARIS FINAL DRIVE 11 With short sharp jerks remove drive shaft from Front Hub Retaining Nut Torque front gearcase 70 ft Ibs 95 Nm DRIVE SHAFT CV BOOT INSPECTION Check the front and rear driveshaft cv boots for any tears or leaking grease If the driveshaft boot loses all of the grease cv joint failure will occur FRONT DRIVE AXLE INSTALLATION 1 Install new spring ring on drive shaft Apply an anti seize compound to splines Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft with rubber faced hammer 2 Install drive shaft in strut 3 Install lower ball joint torque nut to 25 ft Ibs 34 5 Nm and install new cotter pin 4 Install hub and tighten hub nut to 70 ft Ibs 95 Nm POLARIS 7 3 FINAL DRIVE
216. n plug 15 Nm To check the lubricant level The front and rear gearcase lubricant level cannot be checked with a dipstick The gearcase must be Fill with 5 oz lubricant drained and re filled with the proper amount of 4 or bottom of fill plug lubricant or be filled to the bottom of the fill plug hole threads threads Refer to procedures Plug Threads 5 Install torque fill plug and check for leaks POLARIS 211 REAR GEARCASE LUBRICATION The gearcase lubricant level should be checked and changed accordance with the maintenance schedule Be sure vehicle is level and in Park before proceeding Check vent hose to be sure it is routed properly and unobstructed The correct rear gearcase lubricant to use is Polaris ATV Angle Drive Fluid REAR GEARCASE SPECIFICATIONS Specified Lubricant ATV Angle Drive Fluid PN 2871653 Capacity 5 Oz 150 ml Drain Plug Fill Plug Torque 14 ft Ibs 19 4 Nm To Check Lubricant Level Place the ATV a level surface and in Park The rear gearcase fluid level should be level with the bottom of the fill plug threads Refer to the bottom illustration 2 Fill to bottom of fill plug threads 2 To Change Lubricant 1 Remove gearcase drain plug located on the bottom of the gearcase and drain oil The drain plug is accessible through the skid plate Catch 2 12 MAINTENANCE and discard used
217. n when replacing valve springs or replacing valve seals Valve Train Servicing In some cases the valve train can be serviced while the cylinder head is still on the engine Keep all parts in order with respect to their location in the cylinder head 3 22 Wear eye protection or a face shield during cylinder head disassembly and reassembly 1 Having already removed the valve cover rocker arms and pushrods align the cylinder to be worked on at top dead center Install the Valve Pressure Hose PU 45652 into the spark plug hole Hook the hose to an air compressor and supply 5010100 psi to the hose This will seat the valves during valve spring removal Do not remove air from the hose at anytime until reassembly is completed 2 Usingthe Valve Spring Compressor PU 45257 compress the valve spring and remove the valve keepers NOTE A small parts magnet A can aid in the removal of the retainers B PU 45257 Valve Spring Compressor PU 45257 Valve Pressure Hose PU 45652 NOTE To prevent damage to the valve seals do not compress the valve spring more than is needed to remove the valve keepers 3 Remove spring retainer and spring 4 The valve seals are now serviceable POLARIS wW ENGINE CYLINDER HEAD DISASSEMBLY CONT NOTE Carefully remove the cylinder components Place the hydraulic lifters C pushrods D and rocker arms E in a safe clean area Valve Spring Length Std 1 735 44
218. nce Schedule for additional information More often under severe conditions operating in water or hauling heavy loads 3 Grease conforming to NLGI No 2 such as Polaris Premium All Season Grease Conoco Superlube M or Mobilegrease Special 2 10 POLARIS MAINTENANCE FRONT GEARCASE LUBRICATION The gearcase lubricant level should be checked and To change gearcase lubricant changed accordance with the maintenance schedule Besure vehicle is level before proceeding and in PARK Check vent hose to be sure it is routed properly and unobstructed The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid FRONT GEARCASE SPECIFICATIONS Y S 11 ft Ibs 15 Nm Specified Lubricant Premium Demand Drive Hub Fluid 2871654 1 Remove gearcase drain plug A 11 mm located on the bottom of the gearcase and drain oil The oS drain plug is accessible through the skid plate Catch and discard used oil properly 2 Clean and reinstall drain plug using a new 15 Nm Fill Plug Torque 8 10 ft lbs 11 14 Nm Drain Plug Torque 11 ft Ibs 15 Nm FRONT GEARCASE Make sure vent is unobstructed Fill plug 8 10 ft Ibs 11 14 Nm y 3 Remove fill plug 8 mm hex Check the O ring 4 Fill with the recommended fluid amount 5 oz or tothe bottom ofthe fill plug hole threads See ILL e 11 ft lbs Drai
219. nd tighten Turn puller barrel to increase tension on sheave if needed Using a hand held propane torch apply heat around outside of bushing until tiny smoke tailings appear Turn sheave counterclockwise on puller rod until it comes free Lift sheave off puller Remove nut from puller rod and set aside Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard 6 19 CLUTCH EBS Drive Moveable Bushing Installation 1 8 9 Place main adapter Item 8 on puller Puller Tool A B Side toward sheave Bushing Main Adapter 8 Sm i EBS Drive Clutch Moveable Sheave Bushing Installation Apply Loctite 609 evenly to bushing bore inside moveable sheave Set bushing in place on sheave Insert installation puller tool Item A B with A side down into center of bushing 800 EFI Clutch Use Bushing Tool PA 47336 With towers pointing upward slide sheave bushing and tool onto puller rod Install nut on puller rod and hand tighten Turn barrel to apply additional tension if needed Turn sheave counterclockwise making sure bushing is drawn straight into bore Continue until bushing is seated Remove nut from puller rod and set aside Remove sheave from puller 10 Remove installation tool 6 20 oO EBS Drive Clutch Cover Bushing Removal 1 Install main adapter Item 8 on puller Adapter Reducer 9 Main 8 Piston Pin
220. nditioned Ifthe valve seat is cracked the cylinder head must be replaced Follow the manufacturers instructions provided with the valve seat cutters in the Cylinder Head Reconditioning Kit PN 2200634 Abrasive stone POLARIS ENGINE seat reconditioning equipment can also be used Keep all valves in order with their respective seat 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 seat is too narrow heat transfer from valve to seat is reduced The valve may overheat and warp resulting in burnt valves Too Uneven Good Too Wide Narrow 1 Install pilot into valve guide 2 Apply cutting oil to valve seat and cutter 3 Place 46 cutter on the pilot and make a light cut 4 Inspect the cut area of the seat e If the contact area is less than 75 of the circumference of the seat rotate the pilot 180 and make another light cut e If the cutter now contacts the uncut portion of the seat check the pilot Look for burrs nicks or runout Ifthe pilot is bent it must be replaced 3 25 VALVE SEAT RECONDITIONING CONT D 5 Toc
221. ne Crankcase Assembly 3 47 3 58 Troubleshooting 3 59 3 60 4 Stroke Coolant System Bleeding Procedure 3 61 3 1 ENGINE EXPLODED VIEW CRANKCASE Flange Seal mm Oil Pickup 60 6 in Ibs 6 8 68Nm Crankcase Crankcase Bolts 22 2 ft Ibs 30 3 Nm SEE PAGE 3 11 FOR CRANKCASE BOLT TIGHTENING SEQUENCE 3 2 Thrust Plate h d 0 NY SD Re N Balance 115 12 in Ibs Shaft 9 1821 35 Nm Woodruff Key 60 6 in Ibs 6 8 68 Nm NOTE If needed heat the oil baffle bolts with a heat gun to remove Noi Plug 192 24 in lbs 21 7 2 7 Nm Washer 4 Apply Loctite 242 to the bolt threads Apply White Lithium Grease pu Apply Moly Lube Grease POLARIS ENGINE EXPLODED VIEW Split Gear Washer Bolt 22 2 ft Ibs 30 3 Nm Oil rotor Oil Pump No Grease on this portion of gasket Mag Gasket Cover Counterbalance Gear Impeller eT Oil Pum Wash 22 2 ft Ibs Bolt Boe f pm asher 80 3 Nm 84 8 in Ibs 7 9 5 90 Nm See Note Wire Hold Down Gear Stator Housing Bolt 6 12 in Ibs 10 85 35 Nm 108 12 Ibs 6 8 68 Nm Oil Pump Bolt Tighten Sequence NOTE Apply Corrosion Resistant Grease to Stator Grommet Area Mag Cover Bolt Tighten Sequence Apply Polaris OW 4
222. ng Clean surfaces with a 3M pad if needed 11 Press the shaft and bearing out of the outer Inspect Sheave Surface sheave using a press 14 Inspect the cam assembly helix bushing for wear If the bushing is worn or the shaft does not fit snug into the bushing replace the cam assembly cover Inspect Bushing POLARIS 6 0023 CLUTCH 20 4 Line up the X ont the moveable sheave with the EBS DRIVEN CLUTCH X on the stationary sheave or use the marks REASSEM BLY previously used Put the sheaves together Press the bearing onto the output shaft using a press 1 Align X s 2 9 75 2 P BS A 5 Sides Install the small and large retaining rings into the 3 outer sheave above the bearing Install the roller A onto the roller pin B Both POLARIS 6 24 6 Install the roller into the sheave assembly Both sides The flat side of the roller pin faces downward when the shaft side is laying flat on the bench Flat Side of Roller Downward 7 Install the spring pins C to secure the roller pins 8 Install the spacer washer Install Spacer Washer POLARIS CLUTCH Install the spring over the shaft 10 Install the clutch rollers D onto each side of the outside spider Install the washers E and E clips F to secure the rollers Spin the roller the rollers should spin freely 11 In
223. ng Refer to bushing replacement in this chapter 614 5 CLUTCH DRIVE CLUTCH REASSEMBLY CONT D 2 Install moveable sheave onto fixed sheave 3 Install spider spacers Use same quantity and thickness as were removed 4 Compress spider buttons for each tower and install spider making sure that X or the marks that were made earlier on spider aligns with X or the marks that were made earlier on the 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 3 for torque specification CAUTION DRIVE CLUTCH REASSEMBLY Be sure the spider spacer washers are fully seated in the recessed area of the spider Any misalignment will Special Tool NOTE It is important that the same alter clutch balance Inverting the clutch while initially number and thickness of washers are reinstalled tightening the spider will help position the washers beneath the spider during assembly The Teflon 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 made earlier are aligned during each phase of assembly a X or the marks that were made earlier on cover b X on spider making sure spacer washers are installed underneath spider Spacer w
224. ng bolts to 18 ft lbs 25 Nm Rear Brake INEN Disc at 30 35 ft lbs 41 48 Nm Measure Thickness Brake Disc Thickness 150 165 3 81 4 19 Service Limit 140 3 556 mm Brake Disc Thickness Variance Service Limit 002 051 mm difference between measurements e Mount dial indicator and measure disc runout Replace the disc if runout exceeds specifications Brake Disc Runout Service Limit 010 254 mm Caliper Mounting Bolt Torque 18 ft Ibs 24 Nm PESLERIS 0 21 BRAKES REAR AUXILIARY BRAKE Rear Brake Master Cylinder Removal REMOVAL INSTALL ions 1 Ifnecessary remove the rear brake line from the Brake Pedal Removal Install master cylinder Use a suitable container to catch the brake fluid Dispose of brake fluid properly 1 To remove the brake pedal 2 Remove the two bolts that secure the rear master e Remove the spring attached to the cylinder to the brake mount plate Replace parts transmission park lock mechanism as needed e Remove the cotter key 3 install the rear brake master cylinder mount e Remove the washers bushings and the master cylinder to the mount plate and torque tension spring bolts to 8 ft lbs 11 Nm 2 Reverse the steps for installation use a new 4 Reinstall the brake line and torque the banjo bolt cotter key during installation to 15 ft lbs 21 Nm If the rear bra
225. ngine components Always depressurize the fuel system through the fuel rail test valve before disconnecting or servicing any EFI system components Never attempt to service any fuel system component while engine is running or ignition switch is on Cleanliness is essential and must be maintained at times when servicing or working on the EFI system Dirt even small quantities can cause significant problems Do not use compressed air if the system is open Cover any parts removed and wrap any open joints with plastic if they will remain open for any length of time New parts should be removed from their protective packaging just prior to installation Clean any connector before opening to prevent dirt from entering the system Although every precaution has been taken to prevent water intrusion failure avoid direct water or spray contact with system components Do not disconnect or reconnect the wiring harness connector to the control unit or any individual components with the ignition on This can send a damaging voltage spike through the ECU Do not allow the battery cables to touch opposing terminals When connecting battery cables attach the positive cable to positive battery terminal first followed by negative cable to negative battery terminal Never start the engine when the cables are loose or poorly connected to the battery terminals Never disconnect battery while engine is
226. ngs and replace if damaged NOTE Note the alignment marks on both ends of the starter motor casing These marks must align during reassembly 3 Remove the front bracket assembly and the rear bracket assembly Remove the shims from the armature shaft and inspect the O rings located on the armature housing 10 37 ELECTRICAL The shims will be replaced during reassembly BRUSH INSPECTION REPLACEMENT 1 Measure resistance between starter input terminal and insulated brushes The reading should be 3 ohms or less Remember to subtract meter lead resistance 2 Measureresistance between insulated brush and starter housing Reading should be infinite OL Inspect insulation on brush wires for damage and repair or replace as necessary 10 38 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate Slide brush end frame off end of starter NOTE The electrical input post must stay with the field coil housing Measure resistance between ground brush and brush plate Resistance should be 3 ohms or less Inspection 1 Measure length of each carbon brush Replace brush assembly when worn to 5 16 8 mm or less The brushes must slide freely in their holders POLARIS Brush Length Limit 5 16 8mm Brush Replacement 1 Remove terminal nut with lock washer flat washer large phenolic washer the small phenolic
227. ns have no directional identification marks New pistons are non directional Engine Model No Piston Diameter Standard Piston Identification POLARIS 3 9 6 TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS 700 800 700 800 in Lbs Nm ft Ibs Nm 6 mm 115 12 13 1 35 7 49 0 1 8 mm 216 24 24 5 2 7 BENE SENE 5 mm 20 5 2 5 0 55 216 24 24 5 2 70 ex 6 mm 96 12 10 85 0 35 Camshaft Gear Camshaft Thrust Plate Carburetor Adaptor Bolts Counterbalance Gear 8mm Crankcase Bolts Crankcase Breather 8mm Flywheel Magneto Cover Oil Baffle Weldment Oil Drain Bolt Crankcase Fill Tube Bolt Oil Filter Pipe Fitting 12 mm 192 24 21 7 2 7 5mm 50 5 5 64 0 56 20 mm 35 4 47 5 5 4 Oil Pressure Relief Plug 10 mm 22 2 30 3 22 2 30 3 6 mm 84 8 9 5 0 9 14 mm 216 24 24 5 2 7 5 l Pump Housing Screw 6 mm 8 mm Rocker Cover Starter Motor 6 mm 84 8 9 5 0 9 96 12 10 85 1 35 O es 6 mm 96 12 10 85 1 35 rut 6 mm 84 8 9 5 0 9 mmc 21 34 16 5 mm 96 12 10 85 1 35 6 mm 96 12 10 85 1 35 Po Stator Assembly 6mm Temperature Switch Thermostat Housing Timing Plug Trigger Coil Stator Wire Holddown Water Pump Housing Cover Water Pump Impeller Nut 8mm 108 12 12 1 35 EIL MENU Ee _ cum
228. nside of the spark plug cap and install the cap onto the plug 6 Turn the engine over several times to ensure coverage of piston rings cylinder walls and crankshaft bearings 7 Treat the fuel system with Polaris Carbon Clean 8 If Polaris fuel system additive is not used fuel tank fuel lines and carburetor should be completely drained of gasoline To eliminate any fuel remaining in the carburetor run the engine until it stops Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant Follow lubrication guidelines in the maintenance section of the service or owner s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease Storage Tips Battery Storage Remove the battery from the vehicle and ensure that its fully charged before placing it in storage See Chapter 10 for instructions Engine Anti Freeze Test engine coolant strength and change if necessary Coolant should be replaced every two years See Page 2 18 for the proper test procedure Storage Area Covers Set the tire pressure and safely support the ATV with the tires 1 2 off the ground Be sure the storage area is well ventilated and cover the machine with a genuine Polaris ATV cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Transporting the ATV Follow these procedures when transporting the
229. nspect gear teeth for wear cracks chips or broken teeth Note the location of the hubs on the gear 33 Remove seals from transmission case IMPORTANT New seals should be installed after the transmission is completely assembled 34 Inspect bearings for smooth operation Check for excessive play between inner and outer race TRANSMISSION REASSEMBLY 1 Reinstall the chain onto the front output shaft and rear output shaft 2 Install front and rear output shafts into the case 30 Clean all components in a parts washer and inspect for wear POLARIS 8 11 TRANSMISSION 3 Before installing the cover make sure the sealing surfaces are clean and dry and shafts are fully seated in the transmission case Apply Crankcase Sealant PN 2871557 to the mating surfaces Crankcase Sealant PN 2871557 4 Reinstall the thrust button shim thrust button and other shims into the cover Reinstall cover and torque bolts in a criss cross pattern in 3 steps to 27 34 ft Ibs 36 50 46 Nm NOTE Make sure that the case locating pins knock pipes are in place Front Cover Bolt Torque 27 34 ft Ibs 36 50 46 Nm 5 Install new front and rear output shaft seals Apply grease to the seal lips Cover the splines of the shaft to protect the seal lips during installation 6 Install pinion shaft with bearing 7 Install retainer plate with flat side toward bearing 8 12 8 Apply Loctite 262 Red P
230. nt of engine tothe right or left slightly until alignment is correct 6 Tighten engine mounts and verify alignment is correct 7 Measure belt deflection and measure offset both above and below shaft centerlines Adjust if necessary Center line Measure offset above and below centerline 6 18 CX Special Tool NOTE On some models minor adjustments can be 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 decrease the distance at point A Shim Kit PN 2200126 CLUTCH OFFSET Important Inspect clutch alignment and center distance before adjusting offset Offset is correct when rear of tool contacts rear of inner sheave with driven clutch pushed completely inward on shaft and bolt torqued Adjust offset by adding or removing spacer washers between back of driven clutch and spacer Spacer Washer PN 7556401 1 Install offset alignment tool as shown Remember to measure above and below the shaft centerlines Offset Alignment Tool should contact rear edge of driven clutch sheave Driven Clutch Offset washers from behind the driven clutch POLARIS CX EBS DRIVE CLUTCH BUSHING SERVICE SPECIAL TOOL REQUIREMENTS EBS CLUTCH BUSHING REMOVAL AND INSTALLATION Tool Kit PN 2201379 contents of this kit include ltem Qty Part Description Part No A B 1 EBS Puller Tool 5132027 1 EBS Puller
231. nto the cam gear hole and slowly push the dowel through the hole until the end of the dowel is almost flush with the spring Perform this procedure with all three tapered pins Do not push the pins too far through or the springs will pop out NOTE Do not remove the tapered pins at this time 17 Note in the photograph that the Tapered Pins PU 45497 1 are below flush with end of the springs This helps to align the three gear tabs during the next step PU 45497 1 3 41 Cam Gear Spring Installation Tool Kit PU 45497 Tapered Pins PU 45497 1 Cam Gear Tooth Align Tool PU 45497 2 18 Line up the two gears using the timing marks and the three gear tabs that were referenced earlier Push the gears back together using both hands and hold securely 19 Once the gears are pressed together firmly hold the gears together with one hand Carefully remove the Tapered Pins PU 45497 1 by pulling them out one at a time with the other hand 20 After the tapered pins are removed be sure the cam gear assembly is held together tightly Place the cam gear assembly on a flat surface Use the Cam Gear Tooth Alignment Tool PU 45497 2 3 42 LO R to align the teeth of the cam gears as shown in the picture NOTE Install the Cam Gear Alignment Tool PU 45497 2 into one assembly hole counter clockwise from the timing mark PU 45497 2 NOTE For ease of installing the Cam Ge
232. o air dry the belt and clutches Allow engine RPM to settle to idle speed shift transmission to lowest available range and test for belt slippage Repeat as needed Operate ATV in lowest available range for a short period of time until PVT system is dry PVT Drain Plug amp O ring CLUTCH ama 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 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 DI High Range High ground speeds speeds above 7 MPH Diagnosis of Clutch Drive Belt amp 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 Starting out going up a steep incline When starting out on an incline use low range or dismount the bp de MEE 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 The use of Low at approximately 3 7 MPH Range is highly
233. o lifters Do not install expansion plug more than 1 5 mm inward 1 5mm Side View E apply Polaris OW 40 oil p Apply Moly Lube Grease POLARIS ENGINE Initial 15 2 ft Ibs 20 3 2 7 Nm to seat gasket and back off 5 turns Re torque to 35 4 ft Ibs 47 5 5 5 Nm Finalize sequence by tight ening an additional 90 1 4 turn O Q Head Bolt Tighten Sequence Rocker Arms 22 2 ft Ibs 30 3 Nm 3 5 3 ENGINE EXPLODED VIEW OUTER COMPONENTS a S 84 8 in lbs 3 CD 9 5 0 9 Nm Breather x we 20 5 105 Breather Bolts 27 2 5 0 55 216 24 in lbs 24 5 2 7 Nm Apply Dielectric Grease Tips of Spark Plugs Carburetor Boot 21 24 lbs 24 5 2 7 Nm Bolts amp 2 20 5 105 Boot Clamp 2 5 0 55 Crank Position Apply Corrosion Resistant Grease Sensor 84 8 in Ibs 9 5 0 9 Nm 200 20 in lbs Thermistor 1 41 0 14 Nm 4 i E xa f N RN A ad 2 Gasket Exhaust Manifold pL 4 A 7 2 25 sring O CY On _ Housing OR Bolts 84 8 in Ibs 9 5 0 9 Nm Thermostat 216 24 in Ibs 24 5 2 7 NM 3 6 1 O POLARIS wW ENGINE ENGINE EXPLODED VIEW Fuel Injector Fuel Rail on 77 AN y
234. o the crankcase casting 39 Remove and clean oil pick up V and oil baffle weldment W 3 46 I CAMSHAFT INSPECTION 1 Thoroughly clean the cam shaft 2 Visually inspect each cam lobe for wear chafing or damage Lobe height 3 Measure height of each cam lobe using a micrometer Compare to specifications Cam Lobe Height Intake amp Exhaust Std 1 3334 33 8674 mm 4 Measure camshaft journal outside diameters O D Journal O D s POLARIS ENGINE Camshaft Journal O D Mag 1 654 gt 00039 42 010 mm B Ctr 1 634 00039 41 50 010 mm PTO 1 614 00039 41 010 mm 5 Measure ID of camshaft journal bores Camshaft Journal Bore I D Mag 1 656 0 00039 42 07 0 010 mm Ctr 1 637 0 00039 41 58 0 010 mm PTO 1 617 0 00039 41 07 0 010 mm 6 Calculate oil clearance by subtracting journal O D s from journal bore D s Compare to specifications Camshaft Oil Clearance Std 0 0027 070mm Limit 0039 10 mm NOTE Replace camshaft if damaged or if any part is worn past the service limit NOTE Replace engine block if camshaft journal bores are damaged or worn excessively ENGINE CRANKCASE REASSEMBLY WARNING After any reassembly or rebuild the engine must be primed using the Oil Priming Adapter PU 45778
235. ods D and install into lifters Before reassembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts 1 Install the head gasket A on the cylinder B 2 Install cylinder head on cylinder 3 Lubricate threads and top of washers underside of bolt head with engine oil Install head bolts C Torque to 35 4 ft Ibs 47 5 gt 5 5 Nm sequence provided Pg 3 11 Allow the gasket to set for 1 minute at this torque then turn bolts 90 1 4 turn in sequence Refer to Page 3 11 for tightening sequence 6 Verify pushrods are engaged in lifters 7 Install rockers Be sure that tab of fulcrum is seated in head stand off Torque bolts to 22 2 ft Ibs 30 3 Nm Cylinder Head Bolt Torque 35 4 ft Ibs 47 5 5 5 Nm Then turn additional 90 1 4 turn Torque Bolts In Sequence Pg 3 11 Allow to set for 1 min Rocker Arm Bolt Torque 22 2 ft Ibs 30 3 Nm POLRRIS 53 090 ENGINE HEAD REASSEMBLY CONT D 8 Install breather reed G into rocker cover H Lightly apply black RTV sealant to the outer edges of the breather reed The reed has a tab and will assemble one way only Torque the breather bolts to 20 5 in Ibs 2 5 0 55 Nm NOTE When applying RTV do not get any RTV inside the reed assembly 9 Place a new seal I into the bottom of the cover Be
236. oil properly Clean and reinstall drain plug using a new sealing washer B Remove fill plug C Fill with the recommended fluid amount or fill to the bottom of the fill plug hole threads Install fill plug and check for leaks REAR GEARCASE Make sure vent is unobstructed C Fill Plug BS A Drain plug ILL 1 POLARIS TRANSMISSION LUBRICATION The transmission lubricant level should be checked and changed in accordance with the maintenance schedule Be sure the vehicle is level before proceeding Check vent hose to be sure it is not kinked or TRANSMISSION SPECIFICATIONS Specified Lubricant Polaris AGL Gearcase Lubricant PN 2873603 gal PN 2873602 120z obstructed Follow instructions to check change transmission Capacity 15 oz 450 ml lubricant Drain Plug Fill Plug Torque To check the level 10 14 ft Ibs 14 19 Nm 1 Remove fill plug from the back of the transmission and visually inspect the oil level Level is correct when it reaches the bottom of the fill hole as shown at below To change lubricant 1 Remove transmission drain plug to drain the oil Catch and discard used oil properly 2 Clean and reinstall the drain plug Torque to specification 3 Remove fill plug 4 Add 15 oz of Polaris AGL Gearcase Lubricant or fill to top of the fill plug hole threads
237. om the main oil galley feeds the lifter bores and then drains back to the crankcase sump The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump The oil pressure switch is fed off the main oil galley Crankshaft Crankcase Main Bearing Sump nee Crankshaft Bearings Main Bearing Counterbalance Bore Camshaft Bore Counterbalance Bore PTO SIDE Oil Pressure Relief MAGNETO SIDE Main Oil Gallery Crankcase Sump 3 20 _ POLARIS LO ROCKER ARM INSPECTION 1 Markortagrocker arms in order of disassembly to keep them in order for reassembly 2 Inspectthe wear padatthe valve end ofthe rocker arm for indications of scuffing or abnormal wear If the pad is grooved replace the rocker arm NOTE grinding Do not attempt to true this surface by 3 Check the rocker arm pad and fulcrum seat for excessive wear cracks nicks or burrs PUSH ROD INSPECTION 1 Clean push rods A in a suitable solvent Blow dry push rods with compressed air 2 Usecompressed air to confirm the oil passage is clear in the center of the push rod Always wear safety glasses when working with compressed air to prevent personal injury 3 Check the ends of the push rods A for nicks grooves roughness or excessive wear 4 The push rods A can be v
238. on Ratio Compression Pressure Engine Idle Speed 1150 100 RPM Engine Max Operating Rpm 6500 Rpm 200 Rpm Cooling System Capacity Overheat Warning Oil Requirements Capacity Exhaust System Fuel System Fuel System Electronic Fuel Injection EFI Fuel Pump in tank assembly 25L per hour at 39 PSI Fuel Filter s 30 Micron in Tank not replaceable 10 Micron In Line replaceable Bosch MSE 1 1 ECU 4 13 gal US 15 6 Itr 87 Octane minimum 89 Oxygenated 227 Alternator Output Ignition System RC7YC 035 in 0 9 mm Lead Acid 30 Amp Hr Fan 20 amp Harness 20 amp Fuel pump ECU 15 amp Instrument Cluster Voltage Regulator 6 amp Liquid 3 2 qt 3 ltr Fuel Injector s EFI Controller Fuel Capacity Requirement Ignition Timing Spark plug Gap Battery Model Amp Hr Circuit Breakers Starting Instrument Cluster POLARIS city Gear Ratio Low Rev High Front Drive Rear Drive Front Suspension Shock Two x 2 Coil over Shock Front Non Adjustable Rear Ratchet Style Std Turning Radius 76 in 193 cm unloaded Toe Out 0 1 16 in 0 159 mm Wheels Brakes Wheel Size Pattern Front Cast Alum 26x8 12 4 156 205 80R 12 Wheel Size Pattern Rear Cast Alum 26x11 12 4 156 270 60R 12 Front Travel Rear Suspension Shock Rear Travel Ground Clearance Shock Preload Adjustment Front Rear Front Tire Size 26x8 12 Rear Tire Size 26x11 1
239. oolant 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 cap area 2 Stop the engine and let cool for a few minutes or until 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 filing to the top of the neck to replace air that has been purged from the system Fill the reservoir only after you have completely filled the cool ing system at the radiator filler neck 4 Repeat Steps 1 and 2 four or five times or until no more coolant is pulled into the system 5 n 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 POLARIS Pump hose by hand to help purge system Squeeze Hose Here to Help Purge Air From Temperature Sensor Remote Fill
240. oughout entire range without contacting switch body POLARIS MAINTENANCE WHEELS Inspect all wheels for runout or damage Check wheel nuts and ensure they are tight Do not over tighten the wheel nuts WHEEL HUB TORQUE Steel Front Wheel Nuts 30 Ft Lbs 41 Nm Steel Rear Wheel Nuts 30 Ft Lbs 41 Aluminum 90 Ft Lbs 122 Nm Front Wheel Nuts Aluminum 90 Ft Lbs 122 Nm Rear Wheel Nuts Front Hub Retaining Nut 70 ft Ibs 90 Nm Rear Hub Retaining Nut 80 Ft Lbs 108 Nm WHEEL REMOVAL FRONT OR REAR Front amp Rear Wheels 1 Stop the engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest frame POLARIS 4 Remove the wheel nuts and remove the wheel WHEEL INSTALLATION 1 With the transmission in gear and the parking brake locked place the wheel in the correct position on the wheel hub Be surethe valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 2 Attach the wheel nuts and finger tighten them 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts to the proper torque listed in the table CAUTION Improperly installed wheels could affect vehicle handling and tire wear On vehicles with tapered rear wheel nuts make sure tapered end of nut goes
241. ow 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 stored or used in a partially charged condition or with low electrolyte levels hard crystal sulfation will form on the plates reducing the efficiency and service life of the battery CONVENTIONAL BATTERY SPECIFIC GRAVITY TEST A tool such as a Battery Hydrometer PN 2870836 can be used to measure electrolyte strength or specific gravity As the battery goes through the charge discharge cycle the electrolyte goes from a heavy more acidic state at full charge to a light more water state when discharged The hydrometer can measure state of charge and differences between cells in a multi cell battery Readings of 1 270 or greater should be observed in a fully charged battery Differences of more than 025 between the lowest and highest cell readings indicate a need to replace the battery 10 24 Battery Hydrometer PN 2870836 1 1 1 15 Detail 5 1 2 1 OPEN CIRCUIT VOLTAGE State of Conventional Low charge Lead acid Maintenance 100 Charged 7596 Charged 5096 Charged 2596 Charged 0 Charged SPECIFIC GRAVITY State of Conventional Low charge lead acid Maintenence 10096 1 265 1 275 Charged 1 210 1 225 7596 Charged 1 160 1 175 5096 Charged 1 120 1 135 2596 Charged less than 1 100 less than 1 115 0 Charged 12 60V
242. plugs A WARNING Do not perform clean out immediately after the engine has been run as the ex haust system becomes very hot Serious burns could result from contact with ex haust components To reduce fire hazard make sure that there are no combustible materials in the area when purging the spark arrestor Wear eye protection Do not stand behind or in front of the ve hicle while purging the carbon from the spark arrestor Never run the engine in an enclosed area Exhaust contains poisonous car bon monoxide gas Do not go under the machine while it is inclined Set the hand brake and block the wheels to prevent roll back Failure to heed these warnings could result in serious personal injury or death BRAKE SYSTEM INSPECTION The following checks are recommended to keep the brake system in good operating condition Service life of brake system components depends on operating conditions Inspect brakes in accordance with the maintenance schedule and before each ride Keep fluid level inthe master cylinder reservoir to the indicated level inside reservoir Use Polaris DOT Brake Fluid PN 2870990 Parking Brake 2 28 MAINTENANCE Rear Master Cylinder Reservoir Located Under Seat a Check brake system for fluid leaks Check brake for excessive travel or spongy feel Check friction pads for wear damage or looseness Check surface condition of the disc Inspect thic
243. ply a small amount of dielectric grease to the connector if desired Tighten screws to 10 in Ibs 1 1 Nm POLARIS FUEL PUMP ASSEMBLY NOTE 800 EFI fuel connections are quick connect couplings vs 700 EFI connections An electric fuel pump assembly is usedto transfer fuel to the EFI system from inside the fuel tank This assembly includes the fuel pump regulator and fuel gauge sender The pump is rated for a minimum output of 25 liters per hour at 39 psi and has a non serviceable internal 30 micron filter In addition the pump has a replaceable 10 micron filter attached to the pump outlet which is located under the strut mount Fuel pump is not replaceable Picture is for reference only 700 EFI Shown Regulator Fuel Pump Internal 30 Micron Strainer Bottom Fuel Gauge Sender When the key switch is turned to ON the ECU activates the fuel pump which pressurizes the system for start up The ECU switches off the pump preventing the continued delivery of fuel in these instances f the key switch is not promptly turned to the start position if the engine fails to start or if the engine is stopped with the key Switch on as in the case of an accident In these situations the check engine light will go on but will turn off after 4 cranking revolutions if system function is OK Once the engine is running the fuel pump remains on NOTE FUEL GAUGE SENDER TEST To test fuel gau
244. pping If problems are noted in either direction continue with disassembly DRIVE CLUTCH INSPECTION Special Tool NOTE Remove cover spring and spider following instructions for drive clutch removal then proceed as follows 1 Remove moveable sheave spacer sleeve and the thrust washer Visually inspect the washer for damage Measure the thickness and compare to specification Replace if worn or damaged 6 13 CLUTCH Shaft Diameter Standard 1 3745 1 375 Service Limit 1 3730 Thrust Washer Thickness Standard 030 76mm Service Limit 025 64mm 4 Remove 2 1 2 PTFE washer from shaft Visually inspect the washer for damage Measure the thickness and compare to specification Replace if worn or damaged 2 Lift one way clutch off shaft Replace as an assembly if worn damaged or if problems were noted PTFE Washer Thickness Standard 030 76mm Service Limit 025 64mm MOVEABLE SHEAVE BUSHING INSPECTION 1 Inspect the Teflon coating on the moveable sheave bushing Inspect BOTH sheaves for signs of wear grooving or cracking Clean surfaces with pad if needed MEN Moveable Sheave Bushing Inspection 3 Inspect surface of shaft for pitting grooves or damage Measure the outside diameter and Replace the cover bushing if more compare to specifications Replace the drive brass than Teflon is visible on the clutch assembly if shaft is worn or damaged bushi
245. prings 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 inthe 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 fresh air through a vented cover All connecting POLARIS CLUTCH air ducts as well as the inner and outer covers must be properly sealed to ensure clean air is being used for cooling the PVT system This also will prevent water and other contaminants from entering the PVT area A sealed PVT is especially critical on units subjected to frequent water forging PVT DRYING Special Tool NOTE If operating the ATV through water be sure to check the PVT cover and other ATV components for water ingestion The ATV should be checked immediately Refer to Owner s Manual for Safe Riding Tips PVT Drain Plug To drain any water that may be trapped inside the PVT cover simply remove the PVT drain plug and O ring located on the bottom of the PVT cover and let the water drain out The PVT drain plug is shown below To further expel water in the PVT cover and to dry out the PVT system shift the transmission to neutral and rev engine slightly to expel the moisture This will als
246. r filter Clean the air box and drain the sediment tube Breather Filter Inspect and clean or replace the breather filter Fluid Levels Inspect the following fluid levels and change if necessary front gearcase transmission brake fluid change every two years or as required if fluid looks dark or contaminated Drain the Recoil Housing Remove the recoil housing drain plug and drain any moisture Storage Tips Polaris offers storage kits for you ATV see Page 2 7 for the part numbers of Polaris products Fog the Engine Use Polaris Fogging Oil following the instructions as directed If you choose not to use Polaris Fogging Oil perform the following procedure 1 Treat the fuel system with Polaris Carbon Clean Turn fuel petcock to OFF 2 To eliminate any fuel remaining the carburetor run the engine until it stops If Polaris fuel system additive is not used fuel tank fuel lines and carburetor should be completely drained of gasoline 3 Toaccess the plug hole use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil 4 Remove the spark plug s Rotate the piston to BDC and pour approximately two ounces of Polaris oil into the cylinder NOTE Dothis carefully If you miss the plug hole oil will drain from the spark plug cavity into the hole at the front of the cylinder head and appear to be an oil leak 2 35 5 Apply dielectric grease to the i
247. r driving can indicate contaminants such as gas or moisture collecting in the crankcase If the oil level is over the full mark change the oil immediately 2 23 OIL AND FILTER CHANGE 1 Place vehicle on a level surface 2 Runengine twoto three minutes until warm Stop engine 3 Clean area around drain plug at bottom of oil engine 4 Placeadrain pan beneath crankcase and remove drain plug Crankcase Drain Engine Oil Drain Plug Bottom View CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as serious burns may result Oil Filter PN 2540006 5 Allow oil to drain completely 6 Replace the sealing washer on drain plug NOTE The sealing surfaces on drain plug and oil tank should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and torque to 192 24 in Ibs 21 7 2 7 Nm 2 24 MAINTENANCE Place shop towels beneath oil filter Filter Wrench PV 43527 turn counterclockwise to remove Using a clean dry cloth clean filter sealing surface on crankcase Using Oil filter Lubricate O ring on new filter with a film of fresh engine oil Check to make sure the O ring is in good condition Install new filter and turn by hand until filter gasket contacts the sealing surface then turn an additional 1 2 turn Remove dipstick and fill sump with 2 quarts 1 91 of Polaris Premium 4 Synthetic Oil PN 2871281 Recom
248. r during filling Refer to Page 3 15 for hose routing Bleeding generally should not be necessary 1 Remove radiator cap and slowly add coolant to the bottom of filler neck 2 Fill coolant reservoir tank to full mark 3 Install radiator cap and gently squeeze coolant hoses to force any trapped air out of system 4 Again remove radiator cap and slowly add coolant to the bottom of fill neck if needed 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 temperature After engine is cool check level in reservoir tank and add coolant if necessary NOTE Should the reservoir tank become empty it will be necessary to refill at the radiator and repeat the bleeding procedure 3 17 The break in period for a Polaris engine is defined as the first ten hours of operation or the time it takes to use two full tanks of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully CAUTION Use only Polaris Premium 0 40W All Season synthetic oil or equivalent Never substitute or mix oil brands Serious engine damage and voiding of warranty can result Do not operate at full throttle or high
249. r for components such as the fuel pump wires leading from the alternator Y1 to Y2 Y1 to injectors etc Y2 to 4 Refer to the table below for approximate Voltage AC readings according to RPM Test each leg at the specified RPM in the table Example The Y BLK alternator current output reading should be RELAY COIL approximately 18 Vac at 1300 RPM between R zB each leg a NOTE If one or more of the stator leg output ORN BLK voltage varies significantly from the specified value H the stator may need to be replaced ATV RPM AC Voltage Vac Reading Reading GRY W ee ORN ad R N 89 dz R BLK ch 8000 9 ae25 POWER RELAY FAN RELAY COLOR FUNCTION RED Fused 20 amp unswitched FAN power supply YELLOW BLK Fan ON Command Ground is supplied by the ECU closing the relay to turn on the fan RED WHITE Battery power supply switched on by the key and LH control switches enables power to relay ORANGE BLK Fan power output ON when the ECU sends a signal on the Y BLK wire closing the relay Supplies 20 amp power for fan operation POWER RELAY COLOR FUNCTION RED WHITE KEY ON Battery power supply
250. r or damage and replace any parts as needed Bleeding If free play is correct and brake pedal travel is still excessive air may be trapped somewhere in the system Bleed the hydraulic auxiliary brake system in a conventional manner following the procedure outlined in Brake Chapter 9 SUSPENSION SPRING PRELOAD ADJUSTMENT Operator weight and vehicle loading affect suspensionspringpreloadrequirements Adjustas necessary Shock Spanner Wrench PN 2870872 2 29 FRONT SUSPENSION Compress and release front suspension Damping should be smooth throughout the range of travel Check all front suspension components for wear or damage Inspect front strut cartridges for leakage REAR SUSPENSION Rear Spring Adjustment Cam Compress and release rear suspension Damping should be smooth throughout the range of travel Check all rear suspension components for wear or damage Inspect shock for leakage CV SHAFT BOOT INSPECTION Inspect the cv shaft boots in the front and rear of the ATV for damage tears wear or leaking grease Ifthe rubber 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 2 30 MAINTENANCE CONTROLS Check controls for proper operation positioning and adjustment 7 gt H Brake control and switch must be positioned to allow brake lever to travel thr
251. r wires under the wire holddown and install the bolts Inspect the bolts if new bolts are needed replace them with new bolts The new bolts contain patch lock so Loctite is not needed on the new bolts Torque bolts to 96 12 in Ibs 10 85 0 35 Nm 3 Install the starter bendix if removed 4 Install woodruff key Install the flywheel Install the flywheel washer and nut Torque the flywheel nut to 65 7 ft lbs 88 9 50 Nm 3 37 Flywheel Nut Torque 65 7 ft Ibs 88 9 50 Nm 5 Inspect the mating surface around the gear stator housing cover and the crankcase for oil seepage If there is seepage between the mating surfaces then the gear stator housing cover must be resealed Clean the gearcase surfaces and reseal with a new gasket Refer to the Lower Engine Disassembly section and the Lower Engine Assembly section for details Inspect the areas pointed out in the illustration for possible oil seepage OQ ZNN 2 c SS Ip FLYWHEEL STATOR INSTALLATION 6 Install stator housing with new O rings Torque the bolts to 96 12 in Ibs 1 85 1 35 Nm Follow bolt torque sequence on Pg 3 4 96 12 in lbs 3 38 Stator Housing Bolt Torque 96 12 in Ibs 1 85 1 35 Nm Torque Bolts In Sequence 3 4 ENGINE CRANKCASE DISASSEMBLY INSPECTION 1 Remove the stator cover A and water pump cover B 2 Remove the nylok nut C washer
252. raised edge on the detent gear for reassembly 7 Remove the shift shaft and detent lever 10 Set the upper gear cluster on a flat surface and inspect the components POLRRIS 8 7 TRANSMISSION 11 Remove the shift forks from the assembly Note the correct position of each fork Engagement 14 Remove the bearing from the input shaft with a puller 12 Remove the bearing from the reverse shaft using a puller 15 Remove the snap ring and washer from the reverse shaft 13 Remove the park lock engagement dog Remove the wave spring and reverse engagement dog 8 8 POLARIS TRANSMISSION 16 Remove low gear 33T and the needle bearing 21 Remove the gear split bearing and washer from the reverse shaft 18 Remove the rest of the bearings from the shafts 19 Use a press to remove the gear from the shaft 23 Remove the snap ring washer gear and split 20 Make note of the direction of the gear and hub bearing location POLARIS 8 9 TRANSMISSION 26 Remove the front housing cover screws 25 Remove the pinion shaft retainer plate and the pinion shaft 8 10 POLARIS 27 Remove the front housing cover shim thrust button and thrust button shim 29 Remove the silent chain from the assembly for shaft inspection Note Location of Hubs TRANSMISSION 31 Inspect engagement dogs of gears and replace if edges are rounded 32 I
253. ransmission oil 25H Monthly 155 250 Inspect level change yearly p Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California Have an authorized Polaris dealer perform these services La S peel Wheelsfasteners Frame fasteners Pe POLARI S 23 MAINTENANCE gt MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km Engine breather 25 H Monthly 155 250 Inspect replace if necessary filter if equipped Engine oil change 25 H 1M 155 250 Perform a break in oil change at one month break in General 50 H 3M 310 500 Lubricate all fittings pivots cables etc lubrication Shift Linkage 50H 6M 919 600 Inspect lubricate adjust Steering 50H 6M 310600 Lubricate Front suspension 50H 6M 310 600 Lubricate Rear suspension 50H 6M 310 600 Lubricate Throttle Cable 50 H 310 500 Inspect adjust lubricate replace if necessary ETC Switch E Air intake ducts LEN 310 500 Inspect ducts for proper sealing air leaks flange Drive bet 50H 6M 310 500 Inspect adjust replace as needed Cooling system 50 H 310 500 Inspect coolant strength if applicable seasonally pressure test system yearly Engine oil change 100 H 620 Perform a break in oil change
254. rding to hone manufacturer s instructions or these guidelines e Honing should be done with a diamond hone Cylinder could be damaged if the hone is not hard enough to scratch the nicasil lining e Use a motor speed of approximately 300 500 RPM run the hone in and out ofthe cylinder rapidly until cutting tension decreases Remember to keep the hone drive shaft centered or cylinder centered on arbor and to bring the stones approximately 1 2 1 3 cm above and below the bore at the end of each stroke e Release the hone at regular intervals and inspect the bore to determine if it has been sufficiently deglazed and to check for correct cross hatch NOTE Do not allow cylinder to heat up during honing e After honing has been completed inspect cylinder for thinning or peeling If cylinder wear or damage is excessive it will be necessary to replace the cylinder The cylinders are lined with a nicasil coating and are not repairable Hone only enough to deglaze the outer layer of the cylinder bore POLARIS ENGINE EXAMPLE OF CROSS HATCH PATTERN IMPORTANT Clean the Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material Wash the cylinder in a solvent then in hot soapy water Use electrical contact cleaner if necessary to clean these areas Rinse thoroughly dry with compressed air and oil the bore immediately with Polaris 4 Cycle Lubricant to pr
255. re sensor on engine 10 14 2 With the ATV in Park and with the parking brake on turn the ignition key and engine stop switch The fan should start running 3 Ifthefan does notrun or runs slowly check the fan motor wiring ground motor condition and mechanical relay for proper operation refer to Fan Motor Current Draw this section Repair or replace as necessary If the fan runs with the sensor harness disconnected but will not turn on when the engine is hot check the coolant temperature sensor and connector terminals 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 Fan Motor Ape 3 L Brn Connect ammeter between Or BIk pins Fan Harness 1 Disconnect the harness from the coolant sensor 2 Connect a DC ammeter in between the fan switch harness wires as shown 3 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 f the fan motor draws more than 15 Amps replace the motor Fan Motor Current Draw Should Be Less Than 15 Amps NOTE This fan motor current draw specification only applies to Sportsman EFI models POLARIS E
256. re turned on LEAVE AWD SWITCH ON URN KEY SWITCH OFF DISCONNECT 16 PIN CONNECTOR FROM CLUSTER TURN KEY SWITCH ON CHECK FOR 12V ROM BRN WHITE TO GROUND REPLACE INSTRUMENT CLUSTER WIRING PROBLEM LEAVE KEY SWITCH OFF REMOVE THROTTLE CONTROL COVER DISCONNECT THROTTLE CONTROL HARNESS CHECK FOR CONTINUITY ACROSS AWD SWITCH PROCEED TO N MECHANICAL AWD COMPONENTS IF AWD PROBLEM TURN KEY SWITCH OFF PERSISTS RECONNECT CLUSTER LEAVE HEADLIGHT POD DISASSEMBLED SHIFT TO LOW OR HIGH LEAVE AWD ON POLARIS 40 9 ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 2 NO SPEEDOMETER AND OR ODOMETER DISPLAY Y CHECK FOR START HERE MINIMUM 6VDC ONPIN B TO KEY amp STOP 3 Pin Connector SWITCHES ON REPLACE MEASURE SPEEDO BACK OF 5 gears SPEEDO WITH elg CONNECTORS C Ground PLUGGED IN vl REPLACE CHECK CHECK SPEEDO WHEEL SENSOR SPEED BACK OF SPEEDO SENSOR CHECK FOR 10 12 SEE NA VDC ON PIN A TO PIN TEST 6 C ON THE 3 PIN NECTOR 16PIN MEA N SURE 12VDC REPAIR ON PINS 1 WIRING SPEEDO REPLACE SPEEDO ODOMETER CHANGE TEST 3 NO REVERSE SPEED LIMIT 16 Pin Connector 1 Red 12V Ignition Switch 9 Blue White Engine Overheat Switch VEHICLE EXCEEDS 7 9 MPH IN REVERSE 2 Red White 12 ETC and AWD Switch 10 3 Grey Orange Mode Override button Black White Engine Check Light 4 Black Ignition Kill 12 Purple White Fuel Sender if equipped
257. recommended for cooler PVT operating tem peratures 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 speed Plowing snow dirt etc utility use Use Low Range only Stuck in mud or snow Shift the transmission to Low Range 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 carefully use fast stopped position aggressive throttle application to engage clutch Warning Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow 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 and test for belt slippage Repeat several times as required During this procedure the throttle should not be held at th
258. rew and brake line A is for hand brake system Lower outer bleed screw and brake line B is for auxiliary foot brake system i WW Outer Bleed Screw Auxiliary Brake Inner Bleed Screw Hand Brake BRAKE BLEEDING FLUID CHANGE NOTE When bleeding the brakes or replacing the fluid always start with the caliper farthest from the master cylinder CAUTION Always wear safety glasses during these procedures Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces NOTE Do not remove brake lever when reservoir fluid level is low This procedure should be used to change fluid or bleed brakes during regular maintenance 1 Clean reservoir cover thoroughly 2 Remove screws cover and diaphragm C from reservoir 3 Inspect vent slots A in cover and remove any debris or blockage 9 7 BRAKES 4 If changing fluid remove old fluid from reservoir with a Mity Vac pump or similar tool Mity PN 2870975 5 Add brake fluid to the indicated MAX level inside reservoir Polaris DOT 3 Brake Fluid PN 2870990 6 Begin bleeding procedure with the caliper that is farthest from the master cylinder Install a box end wrench on caliper bleeder screw Attach a clean clear hose to fitting and place the other end in a clean container Be sure the hose fits tightly on fitting E is Auxi
259. rive Clutch Puller 2870913 Driven Clutch Puller v 2872292 EBS Clutch Align Tool xt 9914177 A Drive Clutch Holding Tool 2870341 Drive Clutch Spider Removal Tool POLARIS GENERAL INFORMATION Clutch PVT Tools Sco 2871025 Clutch Bushing Replace Tool Kit 2870910 Roll Pin Tool Ve ovo 2871226 Clutch Bushing Replacement Kit 2201379 EBS Bushing Replacement Kit 2871358 Clutch Holding Fixture POLARIS 2870871 ATV Ball Joint Tool Kit gt 2871071 Shock Body Holding Tool 2871573 amp 2871574 Strut Spring Compressor 8700225 amp 8700226 CV Boot Clamp Pliers 1 9 Suspension Tools x 2870872 Shock Spanner Wrench 2872608 Roll Pin Removal Tool 2871351 Shock IFP Depth Tool Fuel amp Brake Systems 2870975 Mity Vac Electrical Tools GENERAL INFORMATION Electrical Tools 2870630 Light 2871745 Static Timing Light Harness lt x CX 2460761 Hall poe Probe Harness PV 39991 Peak Reading Adapter DD 2 H amasra I 5 PV 37453 Christie Se Sulfating Multi PV 63070 Christie Multi Battery Charger P pee e Ims 2870836 Battery Hydrometer NGINE ITI 1 A J 8712500 PV 39951 A Tachometer Tachometer POLARIS GENERAL INFORMATION STANDARD TORQUE S
260. rk area Thoroughly clean the ATV engine and chassis Disconnect battery negative cable Remove the following parts as required Seat e Left and Right Side Covers Refer to Chapter 5 Fuel Tank Cover Front Cab Refer to Chapter 5 e Fuel Tank Refer to Chapter 4 Remove springs from exhaust pipe and remove pipe Drain coolant and engine oil Remove air pre cleaner and duct Remove airbox Disconnect the throttle body sensor C and the T map sensor D Remove throttle body A Insert a shop towel into the engine intake to prevent dirt from entering the intake port Relieve the fuel pressure in the fuel rail refer to Chapter 4 FUEL INJECTION for proper procedure Carefully remove the fuel rail B and injectors 11 3 16 Disconnect spark plug high tension leads 12 16 17 18 19 20 LO Remove the crank position sensor E located on the mag cover Disconnect the coolant hoses Properly dispose of any antifreeze from the engine or hoses Refer to PVT System Chapter 6 to remove outer clutch cover drive belt drive clutch driven clutch and inner cover F When removing starter cables note and mark ground cable and positive cable mounting angle and locations Remove cables Remove transmission linkage rod from gear selector and secure out of the way Disconnect coolant temperature sensor wire located on the cylinder Remove engine to c
261. rk plug TPS setting incorrect Injector failure POLARIS FUEL SYSTEM FUEL INJECTION POOR IDLE Idle Too High If greater than 1300 RPM when engine is warm Throttle stop screw set incorrect Throttle cable sticking improperly adjusted routed incorrectly Idle Too Low If less than 900 RPM when engine is warm Plugged air filter Leaking injector rich condition Belt dragging Throttle stop screw set incorrect Erratic Idle Throttle cable incorrectly adjusted Air leaks dirty injector TPS damaged or adjusted incorrectly Tight valves Ignition timing incorrect Belt dragging Dirty air cleaner Engine worn Spark plug fouled Throttle stop screw set incorrectly out of sync with ECU 4 19 FUEL SYSTEM FUEL INJECTION NOTES 4 20 POLARIS BODY STEERING SUSPENSION CHAPTER 5 BODY AND STEERING Torque Specifications and Special Tools 5 2 Cover Panel Removal Side Panel Removal Front Cover Removal Footwell Removal Install Front Storage Removal Install Rear Rack Removal Install Front Cab Removal Install Rear Cab Removal Install Rear Storage Removal Install Radiator Screen Removal
262. roubleshooting Spark Plug 3 59 Troubleshooting Starter System 10 37 U U Joint Assembly 7 7 U Joint Disassembly 7 6 Unit of Measure Conversion Table 1 12 V Valve Inspection 3 24 Valve Lifter Removal Inspection 3 31 Valve Seal Testing 3 28 Valve Seat Inspection 3 25 Valve Seat Reconditioning 3 25 3 26 3 27 Vent Line Maintenance 2 15 VIN Identification 1 2 Voltage Drop Test 10 37 Voltage Test Open Circuit 10 24 10 27 Washing the 2 35 Water Oil Pump Removal 3 43 Waxing the ATV 2 35 Wheel Inspection 2 31 Wheel Installation 2 31 Wheel Removal Front or Rear 2 31 Wheel Hub Torque 2 31 Winch Operation 2 33 Winch Wiring 10 36 Worklight Switch 10 32 Polaris Service Publications NUR 4 Publication Title Part Number Page s Product and Year Error Suggestion Comments Please communicate to Polaris any suggestions concerning our publica tions Simply fill out the form and mail it to the address listed below the form Address City State Zip Country Email E Polaris Sales Inc Service Publications Dept 2100 Hwy 55 Medina MN 55340 USA Polaris Service Publications Publication Title Part Number Page s Product and Year Error Suggestion Comments Name Address City State Zip Country Emai
263. rrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 4 Inspect bearing housing for scratches wear or damage Replace housing if damaged FRONT HUB ASSEMBLY 1 Support bottom of hubstrut housing 2 Start bearing in housing 3 Press bearing into place until outer race bottoms on housing CAUTION When using an arbor press be sure to press only on the outer race as bearing damage may occur 4 Install snap ring into groove 7 5 FINAL DRIVE FRONT PROP SHAFT NOTE If yoke or bearing is removed cross bearing en Re ELS must be replaced Note orientation of grease fitting REMOVAL and mark inner and outer yoke for correct re positioning during installation 1 Using Roll Pin Removal Tool PN 2872608 Nub A remove the roll pin from prop shaft at rear of housing Slide prop shaft back and away from front housing Pull sharply forward to remove from transmission shaft 2 Supportinner yoke as shown and drive outer yoke down bearing cap out with a soft face hammer Roll Pin Remover Tool PN 2872608 NOTE If removing front housing use roll pin removal tool to remove the pins from both front drive axles U JOINT DISASSEMBLY 3 Support U joint in vise as shown and drive inner yoke down to remove remaining bearing caps CAUTION Always wear eye protection 1 Remo
264. ry voltage Refer to Ill 2 Screen 3 AWD diagnostic screen This screen indicates whether or not current is flowing through the AWD coil on models with switchable AWD POLARIS 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 23 Ohms in Park v 75 Ohms in Reverse PSLARIS 297 Ohms in Low POLARIS ELECTRICAL PSLARiIS v 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 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 O 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 Set at 50 hrs from Factory 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 t
265. s Multi Purpose Lubricant aerosol 3 07 of All Season Grease Carbon Clean Fuel Treatment Patented additive displaces moisture Revival Detailing Kit Oil Filter amp 2 Qts of OW 40 oil Instruction Sheet Includes Restore Swirl and Scuff Eliminator Reflect Professional Final Finish Wax Renew Vinyl and Rubber Protectant foam applicator and buffing cloth e Products also available separately Excellent fuel stabilizer for storage Formulated for 2 cycle and 4 cycle Polaris engines 1 ounce treats 1 gallon of fuel 2871326 12 07 12 Maintenance Kit his kit indudes everything you need to change your drive train fluids and keep your fuel system clean Quart of AGL Oil 12 oz of Carbon Clean 8 az of Angle Drive Fluid 8 oz of Demand Drive Hub Fluid 8 oz of All Season Grease 2859062 POLRRIS LJ ATV MAINTENANCE KIT 2872195 Revival Detailing Kit 2872192 Restore swirl and Scuff Eliminator 12 oz 2872193 Reflect Professional Final Wax System 12 oz 2872194 Renew Vinyl and Rubber Protectant 12 oz Grease Gun Kit steel construction Custom hose and fittings Includes 3 oz all season grease cartridge Complete with standard zerk fitting needle zerk fitting and flush nipple fitting adapters 2871312 4 per case gt SPECIAL TOOLS PART NUMBER 43527 23 2870872 2 5 8712100 8712500
266. s and disc is the most common cause of brake noise squeal caused by vibration If cleaning does not reduce the occurrence of brake noise Permatex Disc Brake Quiet PN 2872113 can be applied to the back of the pads Follow directions on the package This will keep pads in contact with caliper piston s to reduce the chance of squeaks caused by dirt or dust 9 5 BRAKES Brake Noise Troubleshooting Possible Cause Dirt dust or im Spray disc and pads bedded material with CRC Brake Kleen on pads or disc or equivalent non flam mable aerosol brake cleaner Remove 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 Check position of controls amp switches Insufficient lever or pedal clearance Set to proper level Clean compensating port Master cylinder res Inspect ervoir overfilled Repair as necessary Clean piston s seal Master cylinder compensating port restricted Educate operator Master cylinder pis ton not returning com pletely Caliper piston s not returning Operator error riding the brake park brake applied Loose wheel hub or Check wheel and hub bearings for abnormal movement Brake disc warped or Replace disc excessively worn Brake disc Inspect and repair as misaligned or loose necessary If noise does not change when brake is applied check other So
267. s can be easily read Only replace PVT outer cover rubber gasket if it is damaged Place the gasket with the narrow side out C Toward outer cover ux PVT Cover Gasket 15 16 Reinstall PVT outer cover and secure with Screws Reinstall rear cab assembly panel and seat POLARIS CLUTCH DRIVE CLUTCH SPRING SPECIFICATIONS The drive clutch spring has two NEUTRAL FULL UPSHIFT primary functions 1 Controls clutch engagement 2800 RPM The springs which have a 5 higher rate when the clutch is in E neutral will increase clutch 240 ul engagement RPM 2 Controls the rate at which the 220 drive belt moves upward in the 200 drive clutch sheaves This is referred to as drive clutch upshift 180 The drive clutch spring is one of the Green most critical components of the PVT ape WI Me system It is also one of the easiest to ja fa service Due to the severe stress the coil spring is subject to during 120 7041021 operation it should always be TOAST inspected for tolerance limits during 100 any clutch diagnosis or repair Black 7041022 There are other components which control upshift but the spring is one of 60 the primary components in insuring optimum performance lt is very 39 important that the spring is of correct 20 design and is in good condition CAUTION Never shim a drive clutch D E 2 25 2 00 1 75 1 50 125 1 19 spring to increase
268. s subjected to a heavier load the drive belt rotates back up toward the outer diameter of the driven clutch and downward into the sheaves of the drive clutch This action which decreases the driven clutch speed is called backshifting In situations where loads vary such as uphill and downhill and throttle settings are constant the drive and driven clutches are continually shifting to maintain optimum engine RPM At full throttle a perfectly 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 Under normal operation the PVT system will provide years of trouble free operation Periodic inspection and maintenance is required to keep the system operating at peak performance The following list of items should be inspected and maintained to ensure maximum performance and service life of PVT components Refer to the troubleshooting checklist at the end of this chapter for more information 1 Drive to Driven Clutch Offset Belt Width See Page 6 16 6 18 2 Drive and Driven Clutch Rollers and Bushings Drive Clutch Shift Weights and Pins Drive Clutch Spider Rollers and Roller Pins Drive and Driven Clutch S
269. san e GEN Jom 0 JI Sm d A E 2312 LIII MN NN 45 0050 005 E LC NEM EIN 9 ewm MEER E X pWGerPumpEeNengCewer o vem emm See exploded views for notes or torque sequences 3 10 O POLARIS wW ENGINE ENGINE FASTENER TORQUE PATTERNS Tighten cylinder head cylinder base and crankcase fasteners in the following sequence outlined below CRANKCASE BOLT TIGHTEN SEQUENCE 9 3 22 2 ft Ibs 30 3 Nm CYLINDER HEAD BOLT TIGHTEN SEQUENCE Lubricate threads and between washer and underside of bolt with engine oil Torque in sequence to spec provided allow the gasket to set for 1 minute then tighten in sequence 90 1 4 turn 35 4 ft Ibs 47 5 5 5 Nm 5 GE 9 90 1 4 turn PoLARs 293 1 6 700 800 EFI ENGINE SERVICE DATA OylinderHead Valve Head OylinderHead Valve EFI Engine No EH6800LE EH7800LE Camshaft Cam lobe height EN 33 8674 mm Ex LESSE GT ooo
270. sassembly 8 8 8 13 Transmission Reassembly 8 13 8 18 841 TRANSMISSION TRANSMISSION EXPLODED VIEW Qm TORQUE SPECIFICATIONS item Torque EH 12 18 fl lbs 16 24 Nm FOR REASSEMBLY 3 7 9 165 9 5 12 Nm Apply White Lithium 28 22 5 us 26 es EH Based Grease 33 27 34 ft lbs 37 46 Nm 4 ft lbs 37 46 Nm Apply Polaris 39 6 12 ft Ibs 8 16 Nm Sealant 14 18 ft lbs 19 24 Nm 6 12 ft lbs 8 16 Nm EUM 10 14 ft Ibs 14 19 Nm 8 2 POLARIS Apply Loctite 262 to the bolt threads TRANSMISSION TRANSMISSION EXPLODED VIEW CONT Ret Oy Description Re GWv 35 1 22T Sprocket Nut 19T Sprocket Shift Drum Bellcrank Silent Chain Sector Cover Screws Front Main Output Shaft Sector Cover 10T Spiral Pinion Shaft Sector Cover Gasket Ball Bearing O ring Spacer Detent Pawl Retaining Ring gt N gt Compression Spring Bearing Center Drive Cover Shift Shaft Torx Screws 31T Sector Gear 60T Mid Output Helical Gear Hollow Hex Plug Ball Bearing Triple Lip Seal Reverse Shaft Gearcase Needle Cage Bearing Vent Tube 24T 6 Face Sprocket O ring Washer Shift Drum External Retaining Ring External Retaining Ring 6 F
271. sen Helix 16 Use a T25 torx to install the four torx screws and torque to 42 52 in 165 4 75 5 88 Nm in a star pattern 6 26 POLARIS CX 1 2 3 4 5 6 7 8 9 EBS DRIVEN CLUTCH EXPLODED VIEW Torx Screw Cam Assembly Retaining Ring E clip Washer Roller Outer Spider Spring Shaft 10 Thrust Washer 11 Moveable Sheave 12 Roller Pin 13 Spring Pin 14 Stationary Sheave 15 Bearing 16 Retaining Ring 17 Retaining Ring 18 Inner Spider Plate 19 Spider Dampener 20 Clutch Roller POLARIS CLUTCH 6 27 CLUTCH TROUBLESHOOTING Situation Probable Cause Engine RPM below specified operating range although engine is properly tuned Erratic engine operating RPM during accelera tion or load vari ations Engine RPM above specified operating range Harsh drive clutch engage ment Drive belt turns over PVT cover overheating melting Water ingestion 6 28 Wrong or broken drive clutch spring Drive clutch shift weight too heavy Driven clutch spring broken or installed wrong Drive clutch binding Belt worn unevenly thin burnt spots Driven clutch malfunction Sheave face grooved Incorrect drive clutch spring too high spring rate Drive clutch shift weights incorrect for ap plication too light Drive clutch binding Driven clutch binding Converter sheaves greasy belt
272. sensor connector from wiring harness the connector with one heavy black lead Viewing the connector with dual aligning on top test resistance between the terminals A reading of 560 1096 should again be obtained NOTE f the resistance is incorrect remove the Screw securing the sensor to the mounting bracket and replace the sensor If the resistance in step 2 was incorrect but the resistance of the sensor alone was correct test the main harness circuit between the sensor connector terminals and the corresponding pin terminals in the main connector Correct any observed problem reconnect the sensor and perform step 2 again CRANKSHAFT POSITION SENSOR REPLACEMENT 1 Disconnect sensor harness connector 2 Using a 6mm hex wrench remove the retaining bolt and replace the sensor using a light coating of oil on the o ring to aid installation 3 Torque the retaining bolt to 25 in Ibs 2 8 Nm 4 14 E BAP TEMPERATURE and AIR PRESSURE SENSOR Mounted on the throttle body intake the temperature and barometric air pressure sensor T BAP performs two functions in one unit Air passing through the intake is measured by the T BAP and relayed to the ECU These signals comprised of separate air temperature barometric air pressure readings are processed by the ECU and compared to it s programming for determining the fuel and ignition requirements during operation
273. shers POLARIS CX Moveable Sheave Bushing Inspection 2 Inspect the Teflon coating on the moveable sheave bushing Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replacement in this chapter Roller Pin and Thrust Washer Inspection 3 Inspect all rollers bushings and roller pins by pulling a flat metal rod across the roller Turnroller with your finger If you notice resistance galling or flat spots replace rollers pins and thrust washers in sets of three Also inspect to see if roller and bushing are separating Bushing must fit tightly in roller Use the Roller Pin Tool PN 2870910 to replace rollers and pins Take care not to damage roller bushing or bearing surface of the new pin during installation 4 Rubber backed buttons can and should be usedin all ATV clutches the hollow roller pin is changed toa solid roller pin NOTE The rubber side of the POLARIS CLUTCH button is positioned toward the solid roller pin Itis recommended to switch all buttons to the rubber version during service if needed ONE WAY CLUTCH INSPECTION DRIVE CLUTCH 1 Rotate one way clutch clockwise as viewed from the cover plate side The clutch should rotate on the shaft with only slight amount of drag Verify there is no binding or rough spots When rotated counterclockwise the clutch should lock to the shaft without sli
274. side tap on the outer bearing race 2 Start bearing in housing with a drift punch in the reliefs as shown 3 Press bearing into place until outer race bottoms NOTE Drive bearing out evenly by tapping on outer on housing race only Once bearing is at bottom of casting support casting on outer edges so bearing can be removed 3 Inspect bearing 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 sideways between inner and outer race 4 Inspect bearing housing for scratches wear or damage Replace housing if damaged PELARIS 7 21 FINAL DRIVE CAUTION Use an arbor press only on the outer race as bearing damage may occur 4 Install snap ring into groove REAR DRIVE SHAFT REMOVAL 1 Remove rear hub and bearing carrier Pages 7 19 2 Tip hub outward and remove shaft from hub 3 Pull sharply outward to remove shaft from transmission Install a new lock ring upon assembly 7 22 DRIVESHAFT AND CV JOINT HANDLING TIPS Care should be exercised during driveshaft removal or when servicing CV joints Driveshaft components are precision parts
275. slippage Drive belt worn too narrow Excessive belt sheave clearance with new belt Wrong belt for application Clutch alignment out of spec Engine mount broken or loose Plugged air intake or outlet Belt slippage due to water oil grease etc rubbing on cover Clutches or weight being applied to cover while in operation Use of High vs low range Cover seals or ducts leaking Operator error CX Replace with recommended spring Install correct shift weight kit to match engine application Replace spring refer to proper installation location a Disassemble drive clutch inspect shift weights for wear and free operation b Clean and polish stationary shaft hub reassemble clutch without spring to determine problem area Replace belt a Replace ramp buttons b Inspect movable sheave for excessive bushing clearance replace Replace the clutch Install correct recommended spring Install correct recommended shift weights Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Disassemble clean and inspect driven clutch noting worn sheave bushing and ramp buttons and helix spring location Clean sheaves with denatured alcohol or brake cleaner install new belt Replace belt Perform belt sheave clearance adjustment with shim wash ers beneath spider
276. spacers and sealing O ring Inspect O ring and replace if damaged 2 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate Cleaning CAUTION Some cleaning solvents may damage the insulation the starter Care should be exercised when selecting an appropriate solvent If the commutator needs cleaning use only electrical contact cleaner ARMATURE TESTING 1 Remove armature from starter casing Note order of shims on drive end for reassembly POLARIS 2 Inspect surface of commutator 4 Measure the ELECTRICAL Replace if excessively worn or damaged 3 Using a digital multitester measure the resistance between each of the commutator segments The reading should be 3 ohms or less resistance between each commutator segment and the armature shaft The reading should be infinite no continuity 5 Check commutator bars for discoloration Bars discolored in pairs indicate shorted coils requiring replacement of the starter motor 10 39 ELECTRICAL 6 Place armature in a growler Turn growler on and position a hacksaw blade or feeler gauge E x lengthwise 1 8 3 cm above armature coil Roller Bearing laminates Rotate armature 360 If hacksaw A blade is drawn to armature on any pole the armature is shorted and must be replaced CAUTION Use care when handling starter housing Do not drop or
277. speed RPM of the crankshaft Crankshaft Position Sensor A ferromagnetic 60 tooth ring gear with two consecutive teeth missing is mounted on the flywheel The inductive speed sensor is mounted 1 0 0 26 mm 0 059 0 010 in away from the ring gear During rotation an AC pulse is created within the sensor for each passing tooth The ECU calculates engine speed from thetime interval between the consecutive pulses The two tooth gap creates an interrupt input signal corresponding to specific crankshaft position for PTO cylinder This signal serves as a reference for the control of ignition timing by the Synchronization of the CPS and crankshaft position takes place during the first two revolutions each time the engine is started This sensor must be properly connected at all times If the sensor fails or becomes disconnected for any reason the engine will quit running 4 13 FUEL SYSTEM FUEL INJECTION CRANKSHAFT POSITION SENSOR TEST The crankshaft position sensor is a sealed non serviceable assembly If fault code diagnosis indicates a problem within this area test and correct as follows 1 Disconnect main harness connector from ECU 2 Connectan ohmmeter between the pin terminals A resistance value of 560 10 at room temperature 20 C 68 F should be obtained If resistance is correct check the mounting air gap toothed ring gear damage runout etc and flywheel key 3 Disconnect speed
278. st Clamp Exhaust Exhaust Silencer LH Grommet Silencer Mount Bracket Silencer Mount Spring POLARIS SPECIAL TOOLS PART NUMBER PV 43527 Oil Filter Wrench 2200634 Valve Seat Reconditioning Kit PU 45257 Valve Spring Compressor Valve Pressure Hose 2871043 Flywheel Puller 2870390 Piston Support Block PU 45497 2 Cam Gear Tooth Alignment Tool PU 45497 1 Cam Gear Spring Installation Kit Tapered Pins PU 45498 Cam Spanner Wrench PU 45838 Gear Holder PA 44995 Water Pump Mechanical Seal Installer Universal Driver Handle PU 45483 Main Seal Installer PU 45658 Main Crankshaft Seal Saver PA 45401 Water Pump Seal Saver 2870975 Mity Vac Pressure Test Tool ACCESSIBLE COMPONENTS The following components can be serviced or The following components require engine removed with the engine installed in the frame removal for service e Flywheel e Counterbalance Shaft or Bearing s e Alternator Stator e Connecting Rod e Starter Motor Starter Drive e Crankshaft e Cylinder Head e Crankshaft Main Bearings e Cylinder e Crankcase e Piston RIngs Camshaft e Rocker Arms e pump Water Pump and Pump Drive Gear Gear Train Components PISTON IDENTIFICATION Four stroke engine rings have a rectangular profile See text on Page 3 29 for ring installation Use the information below to identify pistons and rings NOTE The pisto
279. st be primed using the Oil Priming Adapter PU 45778 and a 3 4 full oil filter before initial start up Follow the steps in this section to properly prime the engine and aid proper engine break in Failure to perform this procedure may cause internal engine damage on initial start up POLARIS LO TROUBLESHOOTING Spark Plug Fouling Spark plug cap loose or faulty e Incorrect spark plug heat range or gap e PVT system calibrated incorrectly components worn or mis adjusted e Fuel quality poor old or octane too high e Low compression e Restricted exhaust Weak ignition loose coil ground faulty coil stator or ETC switch ETC switch mis adjusted e Restricted air filter main or pre cleaner or breather system e Improperly assembled air intake system e Restricted engine breather system Oil contaminated with fuel Engine Turns Over But Fails to Start e No fuel e Dirt in fuel line or filter e Fuel will not pass through fuel valve e Fuel pump inoperative restricted e Tank vent plugged or pinched e Engine flooded e compression high cylinder leakage e spark Spark plug fouled ignition component failure Engine Does Not Turn Over e Dead battery e Starter motor does not turn e Engine seized rusted or mechanical failure Engine Runs But Will Not Idle e Restricted carburetor pilot system e compression e Crankcase breather restricted POLARIS ENGINE Engine i
280. stall the spider dampener G inside the outer spider and install the inside spider plate H 12 Install the clutch assembly into the Clutch Holding Tool PU 47086 Install the spider assembly onto the shaft with the retaining ring on top of the spider NOTE Use the marks previously made to align the skip tooth spider or use the X on top of the spider and aling it with the skip tooth on the shaft CLUTCH 13 Install the compression cylinder of the holding tool on top of the spider assembly and retaining ring Install the clutch holding tool handle and slowly compress the spider onto the shaft Align the marks on the spider with the skip tooth on the shaft 14 Slowly compress the spider into place If the spider appears to bind while compressing stop and make sure the skip tooth on the shaft and the spider are aligned Once the spider passes the retaining ring notch on the shaft install the retaining ring CX 15 Install the cam assembly helix over the shaft Line up the X on the cam on spider and X on the stationary sheave or use the marks previously made before disassembly NOTE If the cam assembly helix is difficult to install be sure the sheaves are aligned To align the sheaves place the clutch assembly on a flat surface with the cam assembly helix side down Press down on the moveable sheave belt face with both hands and the helix will release Press Down to Loo
281. stall washer and bolt Use the Gear Holder PU 45838 Torque to 22 2 ft Ibs 30 3 Nm PU 45838 Balance Shaft Gear Bolt Torque 22 2 ft lbs 30 3 Nm 26 Use the Cam Gear Alignment Tool PU 45497 2 to align the teeth of the cam gear M Install the cam gear M with the Cam Gear Alignment Tool still in place onto the camshaft The timing marks on the camshaft gear should align with the keyway on the balance shaft gear NOTE Ifthe timing mark on the camshaft gear does not align properly remove the camshaft gear and tool Use the Cam Spanner Wrench PU 45498 to rotate the cam to the proper position NOTE Cam Spanner Wrench PU 45498 is only needed to rotate the camshaft when the entire valve train is assembled POLARIS 27 Reinstall the camshaft gear so the timing marks are properly aligned Install the washer and bolt Torque to 22 2 ft Ibs 30 Nm NOTE Be sure all of the timing marks are properly aligned Timing Marks Water Pump Gear POLARIS Counterbalance Gear and Camshaft Gear Bolt Torque 22 2 ft Ibs 30 3 Nm GEAR STATOR HOUSING SEAL REPLACEMENT IMPORTANT Due to seal design construction these seals MUST be installed dry no lubricant during assembly Use of lubricants oil soapy water etc will not allow the seal to wear in and seal properly Do not touch seal surface or allow seal surface to come in contact with contamin
282. strut rod nut to specification Do not over torque the nut Strut Rod Nut Torque 15 ft Ibs 21 Nm BALL JOINT REPLACEMENT NOTE Refer to the illustration on the previous page for this procedure 1 Loosen front wheel nuts slightly 2 Elevate and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure POLARIS BODY STEERING SUSPENSION Remove wheel nuts and wheels Remove cotter pin A from ball joint castle nut B Remove castle nut B and separate A arm C from ball joint stud Remove screws D and ball joint retaining plate plate E Use the Ball Joint Replacement Tool PN 2870871 remove ball joint F from strut housing Refer to photos at right e Install puller guide with extension cap e Apply grease to extension threads of puller bolt to ease removal e Thread bolt J with nut I onto ball joint stud as shown e Apply heat to ease removal e Hold bolt J and turn nut lI clockwise unti ball joint is removed from strut housing 5 19 BODY STEERING SUSPENSION 8 To install new ball joint e Remove extension and attach puller guide using short bolts provided in the kit e Insert new ball joint into driver L e Slide ball joint driver assembly into guide e Apply heat to ease installation e
283. sure the seal is seated into the cover properly 20 5 in lbs 2 5 55 Nm REMINDER Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts 10 Install rocker cover Torque bolts to 84 8 in Ibs 9 5 0 9 Nm See Page 3 6 for proper torque sequence Rocker Cover Bolt Torque 84 8 in Ibs 9 5 0 9 Nm Torque In Proper Sequence Pg 3 6 3 30 LO 11 Install thermostat J new O ring thermostat housing Torque thermostat housing bolts to 84 8 165 9 5 0 9 Nm 84 8 in lbs 9 5 0 9 Nm 25 x 3 ft Ibs 34 4 Nm Thermostat Housing Bolt Torque 84 8 in Ibs 9 5 0 9 Nm 12 Install temperature sender and torque to 200 20 in Ibs 1 4 14 Nm Temperature Sender Torque 200 20 in Ibs 1 4 14 Nm POLARIS LO CYLINDER REMOVAL 1 Follow engine disassembly procedures to remove rocker cover and cylinder head 2 Tap cylinder A lightly with a rubber mallet in the reinforced areas only until loose 3 Rockoylinder forward and backward while lifting it from the crankcase supporting pistons and connecting rods Support pistons with Piston Support Block PN 2870390 VALVE LIFTER REMOVAL INSPECTION 1 Remove the valve lifter s by reaching into the crankcase and pushing the lifter up through the lifter bore by hand 2 Thorou
284. switched on by the key and LH control switches enables power to relay Tied to Fan Relay terminal GRAY WHITE Relay ON command The ECU supplies a ground which closes the relay supplying power to run the fuel pump injectors etc ORANGE Fused 15 amp unswitched battery power IN supply for EFI component operation RED BLK EFI power output ON when ECU sends a signal on the GRY W wire closing the relay Supplies 15 amp power for ECU controlled operation of EFI components 10 20 POLRRIS 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 vice Reinstall the fully charged battery earlier test It should be 12 4 volts or more Is it or a fully charged shop battery Yes Meter Setting DC Volts With the transmission in Park start the en gine and increase RPM to between 3000 and 4000 Read battery voltage with the multi Check Key off Current Draw tester Readings should increase to between 13 0 14 6 1 Check for owner modification discuss operating habits The battery Yos will continually discharge if operated below the Break
285. t Torque this bolt first Torque both bolts to 25 in lbs 3 Nm NOTE To speed up the brake bleeding procedure the master cylinder can be purged of air before brake line is attached Fill with DOT3 Brake Fluid PN 2870990 and pump lever slowly two to three times with finger over the outlet end to purge master cylinder of air 9 9 BRAKES 2 Placenew sealing washers on each side of banjo FRONT PAD REMOVAL line and torque banjo bolt to specification 1 Elevate and support front of machine Torque to 15 ft Ibs SANON 21 Nm 0 0 Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine Banjo Bolt tips or falls 2 Remove the front wheel Loosen pad adjuster Sealing Washers screw 2 3 turns Brake Line Hand Master Cylinder Clamp Bolt Torque 25 in Ibs 3 Nm Brake Line Banjo Bolt Torque 15 ft Ibs 21 Nm 3 Fill reservoir with DOT3 Brake Fluid PN 2870990 Polaris DOT 3 Brake Fluid PN 2870990 4 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed 4 Follow bleeding procedure on Pages 9 7 9 8 Check all connections for leaks and repair if necessary 9 10 PGLanis BRAKES Measure Thickness Front Brake Pad Thickness New 298 7 6 mm Service Limit 180 4 6 mm
286. tall lower right bracket bolt Loosely install front mounting bolts Tighten mounting fasteners in order A F as shown DA KW NOTE Align clutches as outlined in Clutch Chapter 6 Transmission Mounting Bolts Torque 25 ft Ibs 34 5 Nm 8 5 TRANSMISSION Tighten Bolts In Sequence A through E TRANSMISSION DISASSEMBLY 1 Place the bellcrank in neutral position Shift Shaft Cover AN NONAG Detent Pawl Bellcrank 2 Remove the nut and washer that secure the bell crank Remove the bellcrank 3 Remove the e clip and then remove the transmission switch 8 6 4 Remove the five bolts that secure the cover Remove the detent spring 5 Mark the detent gear with a white pen Remove the detent gear from the case POLARIS TRANSMISSION NOTE It may be helpful to place a mark just above 8 Note the timing marks on the shift gears Remove the keyed spline Note the raised edge on the detent the shift gears from the case gear for reassembly 6 Mark the shift lockout disc this will indicate which side of the disc faces outward during assembly Remove the shift lockout disc NOTE You may have to tap the shift drum from the backside of the case to aid in removal 9 Remove the upper gear cluster and shift forks You may need to move the assembly back and forth to aid in removal NOTE It may be helpful to place a mark just above the keyed spline Note the
287. tall wheels and torque wheel nuts Front Wheel Nut Torque See Page 7 2 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 not allow pads or disc to become hot or warpage may result Repeat this procedure 10 times FRONT DISC INSPECTION 1 Visually inspect the brake disc for nicks scratches or damage 2 Measure the disc thickness at eight different points around the pad contact surface using a 0 1 micrometer Replace disc if worn beyond service limit Brake Disc Thickness New 150 165 3 810 4 19 mm Service Limit 140 3 556 mm Brake Disc Thickness Variance Service Limit 002 051 difference between measurements POLARIS BRAKES 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 runout exceeds specifications Brake Disc Runout Service Limit 010 254 mm FRONT BRAKE DISC REMOVAL REPLACEMENT NOTE Toreducethe possibility of warpage try removing the brake disc mounting bolts before 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
288. tches Remove and inspect the H springs NOTE Becareful not to misplace the thrust bearing located between the two output shafts 4 Clean all parts and inspect spacers for wear Inspect ring gear for chipped broken or missing teeth 5 Remove the roll cage assembly rollers and H springs 9 Use a flat head screwdriver to remove the retaining clip from the output cover 6 Thoroughly clean all parts Inspect the rollers A for nicks and scratches The rollers must slide up and down freely within the roller cage surfaces B 7 nspect the ring gear C for consistent wear patterns The surfaces should be free of nicks and scratches POLARIS 7 11 FINAL DRIVE 10 Remove the spacer washer D armature plate E and rubber O ring from the output cover 11 Inspect the armature plate E for a consistent wear pattern Uneven wear of the armature plate E indicates a warped plate which may cause intermittent operation NOTE See FRONT GEARCASE DIAGNOSIS later in this chapter for more details 12 Remove the output hub G from the cover Remove the thrust bearing F from the output hub G Inspect the thrust bearing F and the dowel H 7 12 13 Inspect the magnetic coil I inthe output housing NOTE See FRONT GEARCASE DIAGNOSIS later in this chapter for more details on the coil 14 Inspect the back lash pad J for excessive wear NOTE Thebacklash for the c
289. ted excesscoolantisforcedoutofthe radiator past the pressure cap and into the recovery bottle Asenginecoolanttemperature 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 purgingitselfoftrappedair Observe coolant levels often during the break in period Overheating of engine could occur if air is not fully purged from system PolarisPremium60 A0anti freezeis premixed and ready to use Do not dilute with water 2 18 MAINTENANCE COOLANT STRENGTH TYPE Test the strength of the coolant using an antifreeze hydrometer Antifreeze Hydrometer A 50 50 or 60 40 mixture of antifreeze and distilled water will provide the optimum cooling corrosion protection and antifreeze protection Do not use tap water Tap water contains minerals and impurities which build up in the system Do not add straight antifreeze or straight water to the system Straight water or antifreeze may cause the system to freeze corrode or overheat Polaris 60 40 Anti Freeze Coolant PN 2871323 POLARIS COOLING SYSTEM HOSES Inspect all hoses for cracks deterioration abrasion or leaks Replace if necessary S Coolant Bottle Upper Radiator Hose Lower Radiator Hose 1 Check tightness of all hose clamps 2 Do not over tighten hose clamps at radia
290. ted nut A Install the cotter pin B Bend both ends of the cotter pin around the slotted nut A in opposite directions Check the steering the handle bars must move freely and easily from full left to full right without binding POLARIS CLUTCH CHAPTER CL aS T Crm INC CX Drive Clutch Exploded View 6 2 PVT Sealing and Ducting Components 6 2 EBS System Exploded View 6 3 Special Tools Supplies amp Torques 6 4 PVT Operation Overview 6 4 PVT Maintenance Inspection Drying 6 5 PVT Overheating Diagnosis 6 6 PVT Disassembly 6 7 PVT Assembly Inspection 6 8 Drive Clutch Spring Specifications 6 9 Shift Weights Inspection 6 10 6 11 700 Drive Clutch Disassembly Inspection 6 11 6 15 700 Drive Clutch Reassembly 6 15 6 16 Drive Belt Removal Inspection 6 16 Drive Belt Installation 6 17 Clutch Alignment Offset 6 18 Drive Clutch Bushing Service 6 19 6 20 Driven Clutch Service 6 21 6 26 Driven Clutch Exploded View 6 27 Troubleshooting 6 28 6 29 POLARIS 8 1 CLUTCH 700 800 DRIVE CLUTCH EXPLODED VIEW EBS Drive Clutch with permanent marker before disassemb
291. ter as the wrist pin holes to properly align them in the cylinder 16 Install camshaft thrust plate G with new bolts Torque bolts to 115 12 in Ibs 13 1 35 Nm 14 Position cylinder and piston assemblies onto the NOTE New bolts have patch lock on the threads and connecting rods and push the piston pins through do not require Loctite the piston and connecting rods PS ON 17 Assemble rotors as marked when disassembled 15 Install the piston pin keepers F The pin keeper Use a cleaner to remove the marks previously ends should be installed at the 12 O clock made on the rotors position Place Pin Keeper F in 12 O clock position 3 50 POLRRIS NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any Line Up Marks debris This will ensure proper sealing when installing bolts and new Loctite 20 Install oil pump housing bolts H The new bolts contain patch lock so Loctite is not needed on the new bolts Torque bolts to 84 8 in Ibs 9 50 0 90 Nm and follow the torque sequence on Pg 3 3 NOTE Occasionally spin the oil pump when installing bolts to check for binding of the rotors 18 Apply moly lube lubriplate or oil to the rotors on the oil pump shaft NOTE The application of oil or lubriplate aids in priming the oil pump during initial engine start up Lubricate Rotors Oil Pump Bolt Torque 84 8 in Ibs 9 50 0
292. ter logs the total hours the engine has been in operation 2 Programmable Service Interval Diagnostic Mode Service Interval purpose of the programmable service interval is to provide the consumer and the dealer with a convenient way to schedule routine maintenance When the ATV leaves 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 Toresetthe Service Interval follow the directions on the on Page 10 5 Setting New Service Interval 3 Check Engine Warning Indicator The word HOT will display alpha numerically when the engine is overheating Do not continue to operate the ATV if this warning appears Refer to Chapter 3 Cooling System Troubleshooting for help with diagnosis of overheating 4 High Low Battery Voltage This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged A low battery warning may also occur under normal operation if the machine is at idle and high electrical load lights cooling fan accessories is applied Driving at a higher RPM or connecting a battery charger will usually clear the warning 10 3 ELECTRICAL 5 Engine Hour Display Indicator Displays number of hours of engine operation 6 AWD Indicator Illuminates when the electrical portion of the AWD system
293. the procedures marked with liil could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 2 2 POLARIS MAINTENANCE MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km Steerng PreRide Make adjustments as needed See Pre Ride gt Fenrsuspenson Pride _ __ on Page 1 7 gt Resrsusenson We p Ped gt Prego PeRd Pre Ride Air filter pre filter pem Inspect clean often Air box sediment SS M Drain deposits when visible 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 main element Recoil housing Weekly Drain water as needed check often if operating if applicable in wet conditions EJ Brake pad wear Monthly 60 100 Inspect periodically Battery 20H Monthly 125 200 Check terminals clean test Front gearcase oil 25H 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 25H Monthly 155 250 Inspect level change yearly if equipped T
294. the way until A arm can be removed Examine A arm shaft Replace if worn Discard hardware Insert A arm shaft into new A arm N m Install CV joint shields Vehicle Frame Apply Loctite 242 to Bolt 30 ft Ibs the bolt threads 41 Nm Bushing Ball Joint Nut Stud C A Arm Tube e E 8 ft Ibs A Arm Shaft 11 Nm 25 ft lbs amp Cotter Pin 8 Install new A arm assembly onto vehicle frame Torque new bolts to 30 ft Ibs 41 4 Nm 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 A arm Attaching Bolt Torque 9 Attach A arm to hub strut assembly Tighten ball joint nut to 25 ft lbs 35 Nm If cotter pin holes are not 30 ft Ibs 41 Nm aligned tighten nut slightly to align Install a new cotter pin with open ends toward rear of machine Bend both Ball Joint Stud Nut Torque ends in opposite directions around nut Upon A arm installation completion test vehicle at low speeds before putting into regular service 25 ft Ibs 35 Nm 5 16 POLARIS BODY STEERING SUSPENSION REAR SUSPENSION ASSEMBLY 17 ft Ibs 17 ft Ibs 24 Nm 24 Nm HE 35 ft Ibs 48 Nm 30 ft Ibs 1 Nm CCS HHS 35 ft Ibs 48 Nm aes OKC
295. tioned properly so that it will hold the lock ring in its groove 10 41 ELECTRICAL STARTER ASSEMBLY Ref Description Ref Description Rubber Ring Gear Assembly Brush Spring Though Bolt Thrust Washer Gear Assembly O Ring Brush Complete O Ring Flange Bolt Thrust Washer Thrust Washer Flange Bushing JONDAN gt 10 4 2 CO POLARIS 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 7 lead on the battery positive Remove battery and properly service Install fully charged shop battery to continue Reading should be 12 4 V D C or greater test Check voltage on both sides of circuit Disconnect coil engagement wire Tom 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 on and the starter button depressed Re place component if fa
296. tor or radiator fitting may distort causing a restriction or leak Radiator hose clamp torque is 36 in Ibs 4 Nm RADIATOR 1 Check radiator external air flow passages for restrictions or damage 2 Carefully straighten any bent radiator fins 3 Remove any obstructions with compressed air or low pressure water COOLING SYSTEM PRESSURE TEST Refer to Chapter 3 for pressure test procedures COOLANT LEVEL INSPECTION Never remove the radiator pressure cap when the engine is warm or hot Escaping steam and fluid can cause severe burns The engine must be allowed to cool before removing the pressure cap POLARIS The recovery bottle located on the left side of the machine must be maintained between the minimum and maximum levels indicated Ill 1 With the engine at operating temperature the coolant level should be between the upper and lower marks on the coolant reservoir If it is not 1 Remove reservoir cap Verify the inner splash cap vent hole is clear and open 2 Fill reservoir to upper mark with Polaris Premium 60 40 Anti Freeze Coolant PN 2871323 or a mixture of antifreeze and distilled water as required for freeze protection in your area 3 Reinstall cap NOTE If overheating is evident allow system to cool completely and check coolant level in the radiator Inspect for signs of trapped air in system Recovery Bottle Accessible Under RADIATOR COOLANT LEVEL INSPECTION N
297. tored and continually corrected during operation to maintain peak performance The central component of the system is the Bosch Engine Control Unit ECU which manages system operation determining the best combination of fuel mixture and ignition timing for the current operating conditions An in tank electric fuel pump is used to move fuel from the tank through the fuel line and in line fuel filter The in tank fuel pressure regulator maintains a system operating pressure of 39 psi and returns any excess fuel to the tank At the engine fuel is fed through the fuel rail and into the injectors which inject into the intake ports The ECU controls the amount of fuel by varying the length of time that the injectors are This can range from 1 5 8 0 milliseconds POLARIS FUEL SYSTEM FUEL INJECTION depending on fuel requirements The controlled injection of the fuel occurs each crankshaft revolution or twice for each 4 stroke cycle One half the total amount of fuel needed for one firing of a cylinder is injected during each injection When the intake valve opens the fuel air mixture is drawn into the combustion chamber ignited and burned The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for air temperature barometric air pressure engine temperature speed RPM and throttle position load These primary signals are compared to the programming in the
298. tors are installed and mesh with the same edges as previously installed Mark Rotors M 25 Install the Flywheel Puller PN 2871043 and remove the crankshaft gear if needed NOTE If replacing the old rotors new replacement rotors will fit into the old oil water pump housing POLARIS 2 43 Oil Rotor Clearance 28 Use a feeler gauge to measure the clearance between the two rotors Measure the gap between the two rotor tips as shown below The clearance should not exceed 0 006 0 15 mm Qe 0 006 0 15 mm Max Tip Clearance 29 Remove the oil pressure relief The oil pressure relief consists of a bolt washer spring and valve dowel Inspectthe the valve dowel for signs of possible obstructions Use compressed air to blow out any debris 30 Reinstall the valve dowel chamfered end first Install the spring washer and bolt Torque the bolt to 22 2 ft lbs 30 3 Nm 3 44 22 2 ft lbs 30 3 Nm Chamfered end first NOTE Be sure to place the tapered end of the valve dowel in first If the valve is installed incorrectly oil pressure and oil priming problems will occur DISASSEMBLY OF WATER OIL PUMP SHAFT WARNING Wear appropriate safety gear during this procedure Protective gloves clothing and eyewear are required 31 Carefully press the gear off the assembly while supporting the
299. ts and separate caliper REMOVAL INSPECTION Clean caliper area before removal Using a flare nut wrench remove hand brake inner and auxiliary brake outer lines Place a container to catch brake fluid draining from brake lines K Anvil Bolts 1 2 halves and remove pistons with piston pliers Piston amp O rings 6 Remove seals and O rings Clean the O ring grooves 7 Clean disc caliper body and pistons with brake cleaner or alcohol 8 Remove the slide bolt bushings Inspect the bushings and O rings and replace if necessary Remove the two caliper mounting bolts and the caliper Remove the slide bolt snap rings A the slide pins B the bracket pad C and the brake pads D 9 Measure the inside diameter of the rear caliper The caliper body is a 2 step piston The rear step is measured as well as the outside step PELARIS 0 19 BRAKES 23 88 mm 1 5 in 38 1 mm 10 Inspect caliper piston bore for scratches severe corrosion or galling and replace if necessary Inspect 11 Inspect surface of caliper piston for nicks scratches or damage and replace if necessary REAR CALIPER ASSEMBLY 1 Install new O rings in the slide bolt bushing holes Be sure O ring and seal grooves are thoroughly cleaned of all residue or piston may bind in bore Apply brake fluid to piston seals and install carefully with a twisting motion to ease assembly until fully s
300. ts to 11 13 ft lbs 15 18 Nm NOTE There will be a slight gap on the backside of the blocks after the procedure is performed Install and Torque Front Bolts First 11 13 ft lbs 15 18 Nm Clean the knurling when repositioning handlebars 514 5 BODY STEERING SUSPENSION STEERING A ARM EXPLODED VIEW NOTE To avoid damage to tie rods and other steering components be sure to install tie rod end bolts in the 25 30 ft Ibs proper direction The steering post arm bolt B points up 35 41 Nm the rod end bolts point down sure inner rod ends are placed between the steering post arms Steering Post Steering Post Arm Frog 40 45 ft Ibs 54 61 Nm 30 ft Ibs 41 Nm Zum 25 ft Ibs 8 ft Ibs 11 Nm 35 Nm Always use new bolts Always use new cotter pins upon upon reassembly reassembly Install with open end Apply Loctite 242 to toward rear of machine the bolt threads POLARIS 8 15 BODY STEERING SUSPENSION A ARM REPLACEMENT Elevate and safely support vehicle with weight removed from front wheel s Remove cotter pin from ball joint stud at wheel end of A arm and loosen nut until it is flush with end of stud Using a soft face hammer tap nutto loosen A arm from bolt Remove nut and A arm from hub strut assembly Loosen two bolts on A arm tube by alternating each about 1 3 of
301. ttle Body Wire Harness Assembly Right Side of ATV Side Panel Removed Front of ATV Front Rack amp Panel Removed POLARIS Aa ear FUEL SYSTEM FUEL INJECTION FUEL TANK ASSEMBLY Q Cap Cay 6 Vent Fuel Pump Tank Assembly NE Rear Tank Mount Protective Foil Front of em 2003 Polaris Sales Inc FUEL FLOW Excess Fuel Fuel Tank Fuel Tank Vent Fuel Pump Pressure Regulato Fuel Filter Unit 30 Micron X External Fuel Filter 10 Micron Fuel Supply Rail Injectors Located in Fuel Tank 46 ELECTRONIC FUEL INJECTION SYSTEM OVERVIEW General The Electronic Fuel Injection EFI system is complete engine fuel and ignition management design This system includes the following principal components Fuel Pump Fuel Rail Fuel Line s Fuel Filter s Fuel Injectors Pressure Regulator Throttle Body Intake Manifold Engine Control Unit ECU Ignition Coils Coolant Temperature Sensor Throttle Position Sensor TPS Crankshaft Position Sensor CPS Intake Air Temperature Barometric Air Pressure Sensor T BAP Wire Harness Assembly Check Engine Light MIL EFI OPERATION OVERVIEW The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions The ignition and injection functions are electronically controlled moni
302. urces Inspect and repair as necessary Wrong pad for Change to a softer or conditions harder pad Noise is from other Source chain axle hub disc or wheel 9 6 HYDRAULIC BRAKE SYSTEM OPERATION OVERVIEW Typical Hydraulic Brake System Compensating port compensates for temperature changes by allow ing fluid back to C master cylinder Must be clear to allow proper dia phragm move The Polaris disc 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 piston B within the master cylinder As the master cylinder piston moves inward it closes a small opening compensating port C within the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the piston D located in the brake caliper moves outward and applies pressure to the brake pad This pad contacts the brake disc and moves the caliper in its floating bracket pulling the stationary side pad into the brake disc The resulting friction reduces brake disc and vehicle speed As the lever pressure is increased the braking affect is also increased The friction applied to the brake pads will cause the pads to wear As these pads wear the piston within
303. uring bottom half of pod E NOTE To install handlebars follow A the handlebar block torque procedure Assembly on the next page Install bottom of pod onto handlebar and secure to brackets e Install key switch choke cable and headlight NOTE Refer to Chapter 10 for more 4 information on headlight pod compo Connect 12V power outlet where applicable nents Connect headlight Connect instrument cluster connectors to instrument cluster Install top of pod onto bottom half making sure interlocking tabs mate properly Install two side Phillips screws Install one rear Phillips screw To adjust headlight refer to procedure outlined in Chapter 2 To apply decals refer to Page 5 20 POLARIS 5 153 BODY STEERING SUSPENSION HANDLEBAR BLOCK INSTALLATION PROCEDURE 1 The pin A on the bottom side of the top handlebar block faces down and to the front of the ATV 2 The bottom handle bar block has a side with 3 holes the side with 3 holes faces up and to the front of the ATV 3 Align the pin A in the top block with the middle hole B in the bottom block for proper installation The pin A and middle hole B should face the front of the ATV 4 Install the pin side bolts first and evenly tighten the bolts down Evenly torque the 2 front bolts to 11 13 ft lbs 15 18 Nm 5 Install the rear bolts and tighten evenly Evenly torque the 2 rear bol
304. ust 0 2351 0 00039 5 972 0 01 mm Measure valve stem in several places Rotate the valve 90 degrees and mea sure for wear Measure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer Measure in two directions Valve Guide Valve Guide I D 0 23672 0 000295 6 0617 0 0075 mm Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance NOTE The valve guides cannot be replaced Be sure to measure each guide and valve combination individually POLARIS LO COMBUSTION CHAMBER 1 Clean all accumulated carbon deposits from combustion chamber and valve seat area with carbon cleaner and a soft plastic scraper IMPORTANT Do not usea wire brush metal scraper or abrasive cleaners to clean the bottom of the cylinder head Extensive damage to the cylinder head may result Wear safety glasses during cleaning VALVE SEAT RECONDITIONING Cylinder Head Reconditioning NOTE Polaris recommends that the work be done by a local machine shop that specializes in this area NOTE The cylinder head valve guides cannot be replaced Wear eye protection or a face shield during cylinder head disassembly and reassembly 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 reco
305. ust return freely without binding 1 Place the gear selector in neutral 2 Set parking brake 3 Start the engine and let it idle 4 Turn handlebars from full right to full left If idle speed increases at any point in the turning range inspect throttle cable routing and condition Adjust cable tension as needed until lock to lock turning can be accomplished with no rise in engine rpm 5 Replace the throttle cable if worn kinked or damaged To remove the ETC cover 1 Use a medium flat blade screwdriver and insert blade into the pocket of the cover starting on the 1 position 2 Twistscrewdriver slightly while lifting on the cover to release snap Repeat procedure at the other five locations as shown NOTE Do not attempt to remove cover until all latch points are released ETC Cover Removal Sequence POLARIS SHIFT LINKAGE INSPECTION NOTE Shift rod is preset at time of manufacture 1 Inspect shift linkage tie rod ends clevis pins and pivot bushings and replace if worn or damaged Lubricate the tie rod ends with a light aerosol lubricant or grease 2 Note orientation of tie rod end studs with the ends that are up down vertical Remove both rod end bolts from transmission bell crank Shifter Shift Linkage Rod POLARIS VENT LINES Check fuel tank oil tank carburetor battery and transmission vent lines for signs of wear deterioration damage or leakage Rep
306. utch holding tool to compress the moveable sheave The contact surface of the weight should be smooth and free of dents or gall marks Remove shift weight bolts and weights Broken Worn Good Inspect the weight pivot bore and pivot bolts for wear or galling If weights or bolts are worn or broken replace in sets of three with new bolts NOTE Adamaged shift weight is usually caused by a damaged or stuck roller in the spider assembly See roller inspection Page 6 13 The clutch assembly is a precisely balanced unit Never replace parts with used parts from another clutch assembly All PVT maintenance or repairs should be performed only by a certified Polaris Master Service Dealer MSD technician who has received the proper training and understands the procedures outlined in this manual Because of the critical nature and precision balance incorporated into the PVT system it is absolutely essential that no attempt at disassembly or repair be made without factory authorized special tools and service procedures POLARIS 2 Inspect sheave surfaces CLUTCH 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 Removal Page 6 12 See Spider Button to Tower Clearance 000 001 Replace the entire clutch as an assembly if worn damaged or cracked DRIVE CLUTCH DISASSEMBLY 1 Using a perm
307. ve internal or external snap ring from all bearing caps 76 POLRRIS 4 Force U joint cross to one side and lift out of inner yoke U JOINT ASSEMBLY 1 Install new bearing caps in yoke by hand Carefully install U joint cross with grease fitting properly positioned inward toward center of shaft Take care not to dislodge needle bearings upon installation of cross joint Tighten vise to force bearing caps in A ks m VE wi 4 E 2 Using a suitable arbor fully seat bearing cap in one side Continually check for free movement of bearing cross as bearing caps are assembled 3 Install snap ring to contain bearing cap just installed Repeat procedure for other side POLARIS FINAL DRIVE Install outer yoke aligning marks made before disassembly Repeat Steps 1 3 to install bearing caps on outer yoke Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown 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 7 7 FINAL DRIVE AWD FRONT DRIVE AXLE EXPLODED VIEW NOTE Refer to your parts manual for the proper replacement parts Front Drive Axle Components Inner CV Joint Circlip Inner Boot Outer Boot Circlip Outer CV Joint Clamp Front Drive Boot Rep
308. vity of Electrolyte Point LOW MAINTENANCE BATTERY CHARGING PROCEDURE 1 Remove the battery from the ATV to prevent damage from leaking or spilled acid during charging 2 Charge the battery with a variable rate charging output 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 Nyogel Grease 2871329 4 Routecables so they aretucked away in front and behind battery 5 Connect battery cables To avoid the possibility of sparks and explosion connect positive red cable first and negative black cable last 6 After connecting the battery cables install the cover on the battery and attach the hold down strap POLRRIS ELECTRICAL HIGH BEAM HEADLIGHT 4 Turn the headlight lamp socket counter clockwise and remove BULB REPLACEMENT CAUTION not service while headlight is hot Serious burns may result Protect lamp during install Remove 3 screws otal a 5 Carefully remove headlamp bulb from housing 6 Remove the headlamp and replace with a new headlamp NOTE Do not touch the lamp with bare fingers Hold the plastic part 1 of the lamp Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp 1 Remove three Phillips screws on the headlight pod 2 Lift pod cover up 3 Disconnect instru
309. ystem faulty Spark plug cap cracked broken Ignition coil faulty Ignition or kill switch circuit faulty Ignition timing incorrect Sheared flywheel key 5 e Poor connections in ignition system Valve sticking 3 60 LO Air leaks in intake Lean condition COOLING SYSTEM TROUBLESHOOTING Overheating Low coolant level Air in cooling system Wrong type mix of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins causing restriction to air flow passages blocked in radiator lines pump or water jacket accident damage Lean mixture restricted jets vents fuel pump or fuel valve Fuel pump output weak Electrical malfunction Water pump failure Loose impeller Thermistor failure Cooling fan inoperative or turning too slowly perform current draw test Ignition timing misadjusted Low oil level Spark plug incorrect heat range Faulty hot light circuit Thermostat stuck closed or not opening completely Temperature Too Low Thermostat stuck open Leak at Water Pump Weep Hole Faulty water pump mechanical seal coolant leak Faulty pump shaft oil seal oil leak POLARIS LO ENGINE BLEEDING PROCEDURE FOR 4 STROKE COOLING SYSTEMS Use this procedure when a unit overheats and no appar ent leaks in the cooling system are found Note If the coolant level is LOW in the radiator or if there are leaks in the system the coolant system will not draw c
310. ze Formulated specifically for Polaris high performance cooling systems Protects against corrosion gel formation and hard water deposits 16 oz 2871534 Quart 12 per case 2871323 Gallon 2 per case Premium 4 Synthetic 4 Cycle Oil OW 40 Extremely shear stable for extended lubricant life at high RPM Durable additives keep engine components clean and running efficiently Excellent hiqh temperature operation protection Protects during cold temperature start up 12 per case 2871844 Gallon 4 per case 2871567 16 Gallon 2871818 55 Gallon 2859066 TWIN CYLINDER ATV MAINTENANCE KIT Demand Drive Hub Fluid Ensures positive engagement release and corrosion protection of Polaris Demand Drive Hubs 2871654 8 oz Bottle 12 per case 2872277 2 5 Gallon 2 per case ATV ANGLE DRIVE FLUID Extreme pressure ant wear high viscosity film lubrication for maximum protection of Polaris gear drive 2871653 8 oz Bottle 12 2872276 2 5 Gallon 2 per case Sportsman 600 700 Maintenance Kit Oil Filter amp 2 Qts of OW 40 oil Drive Belt PVT Cover Seal Spark Plug Instruction Sheet 2202166 Sportsman 600 700 Oil Change Kit Engine Storage Kit This kit indudes everything you need for proper off season storage of your 12 oz of Polaris Rust Preventative Fogging Oil aerosol 12 oz of Polaris Fuel Stabilizer 12 oz of Polari

Polaris 9919820 User's Manual

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