Cvr_9919820 10/14/04 10:19 AM Page 1 2005 SPORTSMAN 700/800 EFI SERVICE MANUAL PN 9919820 PART # 9919820 Printed in USA 2005 SPORTSMAN 700 EFI 2005 SPORTSMAN 800 EFI SERVICE MANUAL PN 9919820
005 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.
UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions, important information is brought to your attention by the following symbols: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! DANGER Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person inspecting or servicing the ATV.
GENERAL MAINTENANCE ENGINE ELECTRONIC FUEL INJECTION BODY AND STEERING CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL
GENERAL INFORMATION Specs Model Identification . . . . . . . . . . . . . . . . . . . . . . . Serial Number Location . . . . . . . . . . . . . . . . . . . 2005 Sportsman EFI Dimensions . . . . . . . . . . . Specifications - Sportsman EFI . . . . . . . . . . . . Publication Numbers . . . . . . . . . . . . . . . . . . . . . Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Keys . . . . . . . . . . . . . . . . . . . . . . . Standard Torque Specifications . . . . . . . . . . . .
GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 05 MH 68 AU Year Designation Emissions & Model Option Basic Chassis Designation Engine Designation ENGINE DESIGNATION NUMBERS EH068OLE . . . . . . . . . . . . . . . . . Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start EH076OLE . . . . . . . . . . . . . . . . .
GENERAL INFORMATION MODEL: . . . . . . . . . . 2005 SPORTSMAN MODEL NUMBER: . A05MH68AU ENGINE MODEL: . . EH068OLE22 Category Dimension / Capacity Length 83 in./205.74 cm Width 48 in./116.8 cm Height 48 in./119.4 cm Seat Height 34 in./86.4 cm Wheel Base 50.75 in./128.9 cm Dry Weight 770 lbs./326.6 kg Gross Vehicle Weight 1220 lbs. / 553 kg Front Rack Capacity 100 lbs./45.4 kg Rear Rack Capacity 200 lbs./90.7 kg Towing Capacity 1500 lbs./454 kg Hitch Tongue Capacity Body Style 150 lbs.
GENERAL INFORMATION MODEL: . . . . . . . . . . 2005 SPORTSMAN MODEL NUMBER: . A05MH68AU ENGINE MODEL: . . EH068OLE Engine 700 EFI Drivetrain Platform Polaris Twin Cylinder Transmission Type Drumshift -- H/L/N/Rev/Park Engine Model Number EH0680LE022 Transmission Capacity 15 oz. / 450m Engine Displacement 683cc Rear Gearcase Capacity 5 oz. / 150ml Number of Cylinders 2 Front Gearcase Capacity 5 oz. / 150ml Bore & Stroke (mm) 80 x 68 mm Compression Ratio 9.78:1 Rev 5.
GENERAL INFORMATION MODEL: . . . . . . . . . . 2005 SPORTSMAN MODEL NUMBER: . A05MH76AU/AW ENGINE MODEL: . . EH076OLE Engine 800 EFI Drivetrain Platform Polaris Twin Cylinder Transmission Type Drumshift -- H/L/N/Rev/Park Engine Model Number EH0760LE011 Transmission Capacity 15 oz. / 450m Engine Displacement 760cc Rear Gearcase Capacity 5 oz. / 150ml Number of Cylinders 2 Front Gearcase Capacity 5 oz. / 150ml Bore & Stroke (mm) 80 x 68 mm Compression Ratio 10:1 Rev 5.
GENERAL INFORMATION PUBLICATION NUMBERS Year Model Model No. Owner’s Manual PN Parts Manual PN Parts Micro Fiche PN 2005 Sportsman 700 EFI A05MH68AU 9919426 9919427 9919428 2005 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.
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.
GENERAL INFORMATION SPECIAL TOOLS Standard Tools and Engine Tools Clutch (PVT) Tools 2870506 -- Drive Clutch Puller 2870303 -- Hone Kit 2870913 -- Driven Clutch Puller 2870305 -- Stone Replacement Kit 2872292 -- EBS Clutch Align Tool 2870588 -- Hone Oil (12 oz.) 9914177--A -- Drive Clutch Holding Tool 2200634 -- Valve Seat Reconditioning Kit 2870459 -- Dial Indicator PV--35667--A -- Cylinder Leak down Tester 1.
GENERAL INFORMATION Clutch (PVT) Tools Suspension Tools 2871025 -- Clutch Bushing Replace Tool Kit 2870871 -- ATV Ball Joint Tool Kit 2870910 -- Roll Pin Tool 2871071 -- Shock Body Holding Tool 2871226 -- Clutch Bushing Replacement Kit 2201379 -- EBS Bushing Replacement Kit 2870623 -- Shock Spring Compressor 2871572 -- Strut Rod Wrench 2871573 & 2871574 -- Strut Spring Compressor 2870338 -- Spider Nut Socket 8700225 & 8700226 -- CV Boot Clamp Pliers 2871358 -- Clutch Holding Fixture 1.
GENERAL INFORMATION Suspension Tools Electrical Tools 2870872 -- Shock Spanner Wrench 2870630 -- Timing Light 2872608 -- Roll Pin Removal Tool 2871745 --Static Timing Light Harness 2871351 -- Shock IFP Depth Tool Fuel & Brake Systems 2460761 -- Hall Sensor Probe Harness PV--39991 -- Peak Reading Adapter 2870975 -- Mity Vac PV--37453 -- Christie Se--Sulfating Multi--Battery Charger Electrical Tools PV--63070 -- Christie Multi--Battery Charger PV--43568 --Fluke 77 Multimeter 2870836 -- Battery Hydro
GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS 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. Bolt Size Threads/In #10 #10 - 24 . . . . . . . . . . . . . . 32 . . . . . . . . . . . . . . 1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 - 20 . . . . . . . . . . . . . . 28 . . . . . . . . .
GENERAL INFORMATION CONVERSION TABLE Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m Nm x .7376 = ft.lbs. kg-m x 7.233 = ft. lbs. kg-m x 86.796 = in. lbs. kg-m x 10 = Nm in. x 25.4 =mm mm x .03937 = in. in. x 2.54 = cm mile (mi.) x 1.6 = km km x .6214 = mile (mi.) Ounces (oz) x 28.35 = Grams (g) Fluid Ounces (fl. oz.) x 29.
GENERAL INFORMATION SAE TAP DRILL SIZES DECIMAL EQUIVALENTS Thread Size/Drill Size Thread Size/Drill Size #0-80 #1-64 #1-72 #2-56 #2-64 #3-48 #3-56 #4-40 #4-48 #5-40 #5-44 #6-32 #6-40 #8-32 #8-36 #10-24 #10-32 #12-24 #12-28 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 7/8-9 7/8-14 1-8 1-12 1 1/8-7 1 1/8-12 1 1/4-7 1 1/4-12 1 1/2-6 1 1/2-12 1 3/4-5 1 3/4-12 2-4 1/2 2-12 2 1/4-4 1/2 2 1/2-4 2 3/4-4 3-4 3/64 53 53 51 50 5/64 45 43
GENERAL INFORMATION GLOSSARY OF TERMS ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8″ or 1 cm).
MAINTENANCE Periodic Maintenance Chart . . . . . . . . . . . . . . . Component Locations . . . . . . . . . . . . . . . . . . . . Lubricant and Maintenance Product Numbers Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Charts . . . . . . . . . . . . . . . . . . . . . . . . Front & Rear Gearcase Lubrication . . . . . . . . . Transmission Lubrication . . . . . . . . . . . . . . . . . . Throttle Cable Adjustment . . . . . . . . . . . . . . . . .
MAINTENANCE PERIODIC MAINTENANCE CHART Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Service and adjustments are critical.
MAINTENANCE MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) -- -- Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride -- " Steering Front suspension Rear suspension Tires Brake fluid level Brake lever travel Brake systems Wheels/fasteners Frame fasteners Engine oil level " Air filter, pre-filter -- Daily -- Inspect; clean often Air box sediment tube Coolant (if
MAINTENANCE MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Engine breather filter (if equipped) Engine oil change (break-in) General lubrication Shift Linkage Steering Front suspension Rear suspension Throttle Cable/ ETC Switch Air intake ducts/ flange Drive belt Cooling system (if applicable) 25 H Monthly 25 H 1M 155 (250) Perform a break-in oil change at one month 50 H 3M 310 (500) Lubricate all fittings, pivots
MAINTENANCE MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Maintenance Interval Hours Calendar J Fuel system 100 H 12 M J Fuel filter 100 H 12 M 100 H 12 M 100 H 12 M " Radiator (if applicable) Cooling hoses (if applicable) Engine mounts 100 H 12 M 100 H 12 M J Exhaust muffler/ pipe Spark plug 100 H 12 M J Ignition Timing 100 H 12 M " Wiring 100 H 12 M Clutches (drive and driven) Front wheel bearings Brake fluid 100 H 12 M 100 H 12 M 200 H 24 M Spark arr
MAINTENANCE SPORTSMAN COMPONENT LOCATIONS Instrument Cluster (Speedometer) Brake Fluid Reservoir Work light AWD Switch Brake Lever Light Control & Run Switch Reverse Override Front Storage Compartment & Rack EFI Diagnostic Plug Cover Throttle Ignition/Key Rear Storage Compartment Front Gearcase (Behind Radiator) Oil Dipstick PVT Cover Drain Gas Cap Transmission Gear Shifter Muffler Right Side View Front Prop Shaft (Between Transmission and Front Gearcase) Auxiliary Brake 2.
MAINTENANCE POLARIS LUBRICANTS/FLUIDS FOR SPORTSMAN MODELS Pure Polaris Lubricants and Maintenance Kits can be purchased at your local Polaris dealer. ATV ANGLE DRIVE FLUID 2859066 -- Sportsman 600/700 Maintenance Kit ------ Oil Filter & 2 Qts. of 0W--40 oil Drive Belt PVT Cover Seal Spark Plug Instruction Sheet 2202166 -- Sportsman 600/700 Oil Change Kit -- Oil Filter & 2 Qts. of 0W--40 oil -- Instruction Sheet 2.
MAINTENANCE SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN PV--43527 Oil Filter Wrench 2,3 2870872 Shock Spanner Wrench 2, 5 8712100 or 8712500 Tachometer 2,10 2200634 Valve Seat Reconditioning Kit 3 PU--45257 Valve Spring Compressor 3 PU--45652 Valve Pressure Hose 3 2871043 Flywheel Puller 3 2870390 Piston Support Block 3 PU--45497--2 Cam Gear Tooth Alignment Tool 3 PU--45497--1 Cam Gear Spring Installation Kit (3 Tapered Pins) 3 PU--45498 Cam Spanner Wre
MAINTENANCE LUBRICATION Dipstick/Fill Tube Fill / Check 0W/40 AGL 1. Engine Oil 2. Transmission Drain Plug DHF ADF Fill Plug Fill / Check Drain Plug Drain Plug 4. Rear Gear Case Fill Plug 3. Front Gear Case Fill Plug Master Cylinder Reservoir 5. Brake Fluid (Left hand Master Cylinder) * More often under severe use, such as operated in water or under severe loads.
MAINTENANCE LUBRICATION, CONT. 6. Front Prop Shaft U-Joint 7. Front Hub strut Front Hubstrut (All Models) Ill. # Item 6. Front Prop Shaft 7. Front Hub strut Lube Rec. Method Frequency* Polaris U-Joint Grease¢ Locate grease fitting and grease with grease gun. Semi-annually ¡ Polaris All Season Grease¢ Locate fitting and grease Semi-annually ¡ * More often under severe use, such as operated in water or under severe loads.
MAINTENANCE FRONT GEARCASE LUBRICATION The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule. G Be sure vehicle is level before proceeding and in PARK. G Check vent hose to be sure it is routed properly and unobstructed. G The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid. To change gearcase lubricant: B A FRONT GEARCASE SPECIFICATIONS Specified Lubricant: Premium Demand Drive Hub Fluid (PN 2871654) Capacity: . . . . . . . .
MAINTENANCE REAR GEARCASE LUBRICATION The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule. G Be sure vehicle is level and in Park before proceeding. G Check vent hose to be sure it is routed properly and unobstructed. G 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: and discard used oil properly. B A 2.
MAINTENANCE TRANSMISSION LUBRICATION The transmission lubricant level should be checked and changed in accordance with the maintenance schedule. G Be sure the vehicle is level before proceeding. G Check vent hose to be sure it is not kinked or obstructed. G Follow instructions to check / change transmission lubricant. To check the level: 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.
MAINTENANCE 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). Boot Adjuster Sleeve Locknut Boot Ill. 1 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.
MAINTENANCE SHIFT LINKAGE INSPECTION VENT LINES NOTE: Shift rod is preset at time of manufacture. Check fuel tank, oil tank, carburetor, battery and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years. Shift Linkage Rod 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.
MAINTENANCE A 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 % (Inspect for cause if leakage exceeds 15%) BATTERY MAINTENANCE WARNING Battery electrolyte is poisonous. It contains sulfuric acid.
MAINTENANCE To remove the battery: 1. Disconnect holder strap and remove cover. 2. Disconnect battery negative (-) (black) cable first, followed by the positive (+) (red) cable. erosion of the electrodes. Inspect electrode for wear and buildup 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.
MAINTENANCE ENGINE-TO-FRAME GROUND COOLANT STRENGTH / TYPE Inspect engine-to-frame ground cable connection. Be sure it is clean and tight. Test the strength of the coolant using an antifreeze hydrometer. Antifreeze Hydrometer G Typical 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.
MAINTENANCE COOLING SYSTEM HOSES Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary. Coolant Bottle Upper Radiator Hose 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.
MAINTENANCE 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 Cap 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.
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. AIR BOX SEDIMENT TUBE Periodically check the air box drain tube located toward the rear of the machine.
MAINTENANCE BREATHER HOSE 1. Be sure breather line is routed properly and secured in place. CAUTION: Make sure lines are not kinked or pinched. PVT DRYING & PVT DRAIN PLUG NOTE: If operating the ATV 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.
MAINTENANCE ENGINE OIL LEVEL 4. Reinstall dipstick and push it into place. Do not lock the dipstick. The 700 engine is a wet--sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level: 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.
MAINTENANCE OIL AND FILTER CHANGE 1. Place vehicle on a level surface. 2. Run engine two to three minutes until warm. Stop engine. 3. Clean area around drain plug at bottom of oil engine. 4. Place a drain pan beneath crankcase and remove drain plug. Crankcase Drain 8. Place shop towels beneath oil filter. Using Oil Filter Wrench (PV--43527), turn filter counterclockwise to remove. 9. Using a clean dry cloth, clean filter sealing surface on crankcase. 10.
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. G G 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.
MAINTENANCE WHEEL ALIGNMENT METHOD 1: STRAIGHTEDGE OR STRING Be sure to keep handlebars centered. See notes below. NOTE: String should just touch side surface of rear tire on each side of machine. Measure from string to rim at front and rear of rim. Rear rim measurement should be 1/16″ to 1/8″ (.2 to .3 cm) more than front rim measurement. WHEEL ALIGNMENT METHOD 2: CHALK 1. Place machine on a smooth level surface. 2. Set handlebars in a straight ahead position and secure handlebars in this position.
MAINTENANCE TOE ALIGNMENT ADJUSTMENT EXHAUST PIPE 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. Ill.2 1.
MAINTENANCE 6. Repeat Steps 2 through 5 until no more particles are expelled when the engine is revved. 7. Stop the engine and allow the arrestor to cool. 8. Reinstall the clean out plugs. Rear Master Cylinder Reservoir WARNING Max Min. G Do not perform clean out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with exhaust components.
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 First, check foot brake effectiveness by applying 50 lb. (approx.) downward force on the 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 The auxiliary brake should be checked for proper function.
MAINTENANCE 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. G G G REAR SUSPENSION Inspect Boots Rear Spring Adjustment Cam G Compress and release rear suspension. Damping should be smooth throughout the range of travel. G Check all rear suspension components for wear or damage. G Inspect shock for leakage.
MAINTENANCE WHEELS 4. Remove the wheel nuts and remove the wheel. Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts. WHEEL INSTALLATION WHEEL, HUB, TORQUE Item Specification Steel -- Front Wheel Nuts 30 Ft. Lbs. (41 Nm) Steel -- Rear Wheel Nuts 30 Ft. Lbs. (41Nm) Aluminum 90 Ft. Lbs. (122 Nm) 1. With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub.
MAINTENANCE TIRE INSPECTION G G G 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. 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.
MAINTENANCE WARN® WINCH OPERATION (If Equipped) This information is for Sportsman models equipped with a 2500 lb. (2.5chi) Warn® Winch in the front. 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. Mini--Rocker Switch IN OUT Pre--Wired Warnt Winch Kits 2.5 ci -- PN 2875309 3.0 ci -- PN 2875308 Winch Handlebar Controls The winch is located in the front bumper area.
MAINTENANCE 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. The Red wire (6 Ga.) with the yellow crimp cover is located under the left rear fender next to the starter solenoid. The red wire connects to the battery.
MAINTENANCE CLEANING & STORAGE OF ATV Stabilize the Fuel 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. 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.
MAINTENANCE 5. Apply dielectric grease to the inside 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.
ENGINE Engine Exploded Views . . . . . . . . . . . . . . . . . . . . . . Exhaust System View / Notes . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Identification . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . Engine Fastener Torque Patterns . . . . . . . . . . . . . Engine Service Data . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE ENGINE EXPLODED VIEW CRANKCASE ML Camshaft Thrust Plate Journal Bearings ML 115 ± 12 in. lbs. (13 ± 1.35 Nm) Balance Shaft Flange Seal 60 ± 6 in. lbs. (6.8 ± .68 Nm) Woodruff Key WL Crankshaft ML Oil Pickup Journal Bearings Baffle 60 ± 6 in. lbs. (6.8 ± .68 Nm) NOTE: If needed, heat the oil baffle bolts with a heat gun to remove. O--ring Oil Plug 192 ± 24 in. lbs. (21.7 ± 2.7 Nm) Washer Crankcase Bolts 22 ± 2 ft. lbs. (30 ± 3 Nm) SEE PAGE 3.
ENGINE ENGINE EXPLODED VIEW MAG SIDE Split Gear Washer 22 ± 2 ft. lbs. (30 ± 3 Nm) OIL Bolt Oil rotor Oil Pump No Grease on this portion of gasket! Mag Gasket Cover Counterbalance Gear Impeller Washer 22 ± 2 ft. lbs. Bolt (30 ± 3 Nm) Oil Pump Bolts 84 ± 8 in. lbs. (9.5 ± .90 Nm) 1 4 3 2 Oil Pump Bolt Tighten Sequence Washer Nut Gear/Stator Cover *See Note Wire Hold Down Gear/Stator Housing Bolt 96 ± 12 in. lbs. (10.85 ± .35 Nm) 108 ± 12 in. lbs. (6.8 ± .
ENGINE ENGINE EXPLODED VIEW Apply Polaris Starter Grease. Apply Polaris 0W--40 oil to seal. MAG SIDE OIL SG 5 2 4 7 6 Loctitet Pipe Sealant 1 (PN 2871956) 3 Bolts Gasket (Tighten Top Bolt First) (NO Grease or Oil!) 84 ± 8 ft. lbs. (9.50 ± 0.9 Nm) Starter 1 SG Nut Water Pump Cover 96 ± 12 in. lbs. (10.85 ± 1.35 Nm) Bendix Washer 2 Washer SG 108 ± 12 ft. lbs. (12 ± 1.35 Nm) Water Pump Cover Bolt Tighten Sequence Washer SG Flywheel Pos. Cable Washer Crankshaft Nut 65 ± 7 ft. lbs.
ENGINE ENGINE EXPLODED VIEW Head Bolts OIL TOP END (Each Bolt Threads) 1 Lubricate threads and be- tween washers and underside of bolt heads with engine oil Torque in sequence provided. 2 3 Apply Moly Lube grease to valve tips. Gasket free of oil. Verify tabs are visible. 6 Apply 0W--40 to lifters. 1 5 6 2 4 Rocker Arms 22 ± 2 ft. lbs. (30 ± 3 Nm) ML 3 Gasket Bushing Do not install expansion plug more than 1.5 mm inward. 1.5 mm 3 Head Bolt Tighten Sequence 25--55 mm of cylinder bore.
ENGINE ENGINE EXPLODED VIEW OUTER COMPONENTS Screws 84 ± 8 in. lbs. (9.5 ± 0.9 Nm) 1 3 6 Rocker Cover 5 Breather 4 2 7 O--ring Seal 20 ± 5 in. lbs. Breather Bolts (2.5 ± 0.55 Nm) Spark Plugs 216 ± 24 in. lbs. (24.5 ± 2.7 Nm) (*Apply Dielectric Grease Tips of Spark Plugs) Carburetor Boot 216 ± 24 in. lbs. (24.5 ± 2.7 Nm) Bolts 20 ± 5 in. lbs. Boot Clamp (2.5 ± 0.55 Nm) Throttle Body *Apply Corrosion Resistant Grease Crank Position Sensor 84 ± 8 in. lbs. (9.5 ± 0.9 Nm) 200 ± 20 in. lbs.
ENGINE ENGINE EXPLODED VIEW ELECTRICAL COMPONENTS Fuel Injector Fuel Rail 216 ± 24 in. lbs. (24.5 ± 2.7 Nm) EFI Harness NOTE: See Chapter 4 for more information the EFI system. 3.
ENGINE EXHAUST SYSTEM NOTE: Silencer Removal Silencer removal requires replacement of the silencer grommets, item #24, as they become damaged during removal. 1. 2. 26. 3. 4. 5. 6. 800 EFI Exhaust Canister Maintenance The exhaust canisters on Polaris 800 EFIs 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. 2. 3. 4.
ENGINE SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION PV--43527 Oil Filter Wrench 2200634 Valve Seat Reconditioning Kit PU--45257 Valve Spring Compressor PU--45652 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 PU--45543 Universal Driver Handle PU--45483 Main
ENGINE TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Size 700/800 in. Lbs. (Nm) 700/800 ft.lbs. (Nm) Camshaft Gear 8 mm -- 22 ± 2 (30 ± 3) Camshaft Thrust Plate 6 mm 115 ± 12 (13 ± 1.35) -- Carburetor Adaptor Bolts 8 mm 216 ± 24 (24.5-± 2.7) -- Counterbalance Gear 8 mm -- 22 ± 2 (30 ± 3) Crankcase Bolts 8 mm -- *22 ± 2 (30 ± 3) Crankcase Breather 5 mm 20 ± 5 (2.5 ± 0.55) -- Cylinder Head Bolts 11 mm -- *35 ± 4 (47.5 ± 5.5) Exhaust Manifold 8 mm 216 ± 24 (24.5 ± 2.
ENGINE ENGINE FASTENER TORQUE PATTERNS Tighten cylinder head/cylinder base, and crankcase fasteners in the following sequence outlined below. CRANKCASE BOLT TIGHTEN SEQUENCE 22 ± 2 ft. lbs. (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. lbs. (47.5 ± 5.5 Nm) + 90° (1/4 turn) 3 1 5 6 2 4 3.
ENGINE 700/800 EFI ENGINE SERVICE DATA **Cylinder Head / Valve Camshaft Cam lobe height g In Std Ex Camshaft journal j OD Camshaft journal j b bore ID Camshaft Oil clearance l Counter Balance Cylinder y H d Head Std 1.3334” (33.8674 mm) Mag Center PTO Mag Center PTO Std 1.654” ± 0.00039” (42 ± 0.010 mm) 1.634” ± 0.00039” (41.50 ± 0.010 mm) 1.614” ± 0.00039” (41 ± 0.010 mm) 1.656” ± 0.00039” (42.07 ± 0.010 mm) 1.637” ± 0.00039” (41.58 ± 0.010 mm) 1.617” ± 0.00039” (41.07 ± 0.010 mm) 0.00276” ± 0.
ENGINE 700/800 EFI ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod Cylinder Lifter Piston Piston Pin Surface warpage limit (mating with cylinder head) Cylinder bore Taper limit Out of round limit Piston clearance EFI Engine No. EH680OLE 0.004” (0.10 mm) Std Std Boring limit Outer Diameter Std Block Bore Std Std Standard inner diameter of piston pin bore Outer diameter Standard clearance-piston pin to pin bore Degree of fit 3.1495” (80 mm) 0.00031” (0.008 mm) 0.00030” (0.0075 mm) .
ENGINE 700/800 EFI ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod Piston Ring g Piston ring installed gap g p EFI Engine No. EH680OLE 0.0059-- 0.0138” (0.15 ± 0.35 mm) EFI Engine No. EH780OLE 0.0059 -- 0.0138” (0.15 ± 0.35 mm) Limit Std > 15% Leakdown > 15% Leakdown 0.0098 -- 0.0197” (0.25 ± 0.50 mm) 0.0098 -- 0.0197” (0.25 ± 0.50 mm) > 15% Leakdown > 15% Leakdown Oil ring Limit Std 0.0196” ± .00984” (0.50 ± 0.25 mm) 0.0196” ± .00984” (0.50 ± 0.
ENGINE COOLING SYSTEM SPECIFICATIONS COOLING SYSTEM WARNING Condition Approx. Reading (Min--Max) Temperature Hot Light On 178Ω -- 190Ω 215° F (102° C) Fan Off 296Ω -- 316Ω 180° F (82° C) Fan On 236Ω -- 251Ω 195° F (91° C) System Capacity 2.25 Quarts (2.13L) Radiator Cap Relief Pressure 13 PSI Recommended Coolant Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area.
ENGINE ENGINE REMOVE & INSTALL 12. Remove the crank position sensor (E) located on the mag cover. WARNING E 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. 5. 6. 7. 8. 9. 10. Clean work area. Thoroughly clean the ATV engine and chassis. Disconnect battery negative (-) cable.
ENGINE 2. Adjust clutch offset, alignment, and belt deflection. (Chapter 6) 3. Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing. (Chapter 6) Transmission 1. Inspect transmission operation and adjust linkage if necessary. Refer to Chapter 2 and Chapter 8. Exhaust F 21. Remove the engine from the left side of the frame. NOTE: Use caution when lifting the engine out of frame. Use an engine lift or other means if the engine is too heavy to be lifted manually.
ENGINE Engine Break In Period The break in period for a Polaris ATV 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.
ENGINE 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.
ENGINE 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.
ENGINE ROCKER ARM INSPECTION 5. If the push rod (A) is visibly bent, it should be replaced. 1. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. 2. Inspect the wear pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. If the pad is grooved, replace the rocker arm. NOTE: Do not attempt to true this surface by grinding. 3. Check the rocker arm pad and fulcrum seat for excessive wear, cracks, nicks or burrs.
ENGINE CYLINDER HEAD INSPECTION 1. Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon. WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly. CAUTION: Use care not to damage sealing surface. CYLINDER HEAD WARPAGE 1. Lay a straight 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.
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: 1.735I (44.069 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. D C 7. Mark the valves with a white pen.
ENGINE VALVE INSPECTION Valve Stem Diameter: 1. Remove all carbon from valves with a soft wire wheel or brush. 2. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” blocks and a dial indicator. Intake: 0.2356” ± 0.00039” (5.985 ± 0.01 mm) Exhaust: 0.2351” ± 0.00039” (5.972 ± 0.01 mm) Measure valve stem in several places. Rotate the valve 90 degrees and measure for wear. 3.
ENGINE COMBUSTION CHAMBER seat reconditioning equipment can also be used. Keep all valves in order with their respective seat. 1. Clean all accumulated carbon deposits from combustion chamber and valve seat area with carbon cleaner and a soft plastic scraper. 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.
ENGINE VALVE SEAT RECONDITIONING CONT’D If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation. S If the contact area of the initial cut is greater than 75%, 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. 5. To check the contact area of the seat on the valve face, apply a thin coating of Prussian Bluet paste to the valve seat.
ENGINE 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 or a face shield when working with compressed air during cylinder head disassembly and reassembly. 9. 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. 10.
ENGINE VALVE SEALING TEST A 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. VALVE TRAIN EXPLODED VIEW ROCKER ARMS SPRING RETAINERS SPRINGS 22 ± 2 ft. lbs.
ENGINE ENGINE HEAD REASSEMBLY 4. Lubricate push rods (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). D A 5. Lubricate rockers (E) with engine oil. B E 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.
ENGINE 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. lbs. (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 sure the seal is seated into the cover properly. 11.
ENGINE 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. Rock cylinder forward and backward while lifting it from the crankcase, supporting pistons and connecting rods. Support pistons with Piston Support Block (PN 2870390). 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.
ENGINE 2. Remove piston circlip and push piston pin 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 off the piston. CAUTION: Do not expand the ring more than the amount necessary to remove it from the piston, or the ring may break. CYLINDER INSPECTION 1.
ENGINE 3. Inspect cylinder for wear, scratches, or damage. 5. Record measurements. If cylinder is tapered or out of round beyond .002, the cylinder must be replaced. Cylinder Taper Limit: .002I (.05mm)Max. Cylinder Out of Round Limit: .002I (.05mm)Max. Standard Bore Size (Both Cylinders): Sportsman 700 / 800 : 3.1496I (80 mm) 4. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge.
ENGINE PISTON/ROD INSPECTION 3. Measure connecting rod small end ID. 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 Connecting Rod Small End I.D. Refer To Engine Service Data Pg. 3.12 -- 3.
ENGINE 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. Piston Ring Installed Gap Refer To Engine Service Data Pg. 3.12 -- 3.14 NOTE: Ring should be installed with the mark facing upward. Piston Ring Feeler Gauge Piston Ring-to-Ring Groove Clearance 2. Measure installed gap with a feeler gauge (C) at both the top and bottom of the cylinder.
ENGINE STARTER DRIVE/BENDIX REMOVAL/INSPECTION 1. Remove stator housing bolts and remove housing. 2. 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. 3. Remove starter bendix assembly (A). Note the thrust washers located on both sides of the bendix. B 4. Inspect the thrust washer for wear or damage and replace if necessary. 5.
ENGINE FLYWHEEL/STATOR REMOVAL/INSPECTION 1. Remove stator housing bolts and remove housing. E C B D 5. Remove the bendix (E) if necessary. Remove Stator Cover 2. Remove flywheel nut and washer. 3. Install Flywheel Puller (PN 2871043) and remove flywheel (A). CAUTION: Do not thread the puller bolts into the flywheel more than 1/4″ or stator coils may be damaged. 2871043 FLYWHEEL/STATOR INSTALLATION NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris.
ENGINE Flywheel Nut Torque: 65 ± 7 ft. lbs. (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. lnspect the areas pointed out in the illustration for possible oil seepage.
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. J 2871043 7. Note the positions of the gears in the photo. F 5. Remove the starter bendix (G), wire holddown plate (H), and the woodruff key (I) from the crankshaft. The stator does not have to be removed at this point. Camshaft Gear I Counterbalance Gear Crank Gear G H 8.
ENGINE NOTE: If replacing one of the gears, it is recommended that all of the gears be replaced. A gear kit is available in the parts book. Cam Gear Removal 9. Use the Cam Gear Tooth Alignment Tool (PU--45497--2) (O) to align the cam split gear assembly. With the split gear aligned, remove the bolt and cam gear assembly. PU--45497--2 O 11. The cam gear assembly contains three loaded springs. To open the cam gear assembly: S Place the cam gear on a flat surface with the timing mark side facing up.
ENGINE Inspect Teeth & Tabs PU--45497--1 Replace Three Springs Cam Gear Reassembly 15. Install the new springs into the grooves of the cam gear. Insert Springs To assemble: Hold the spring with one finger. Start the pointed end of the tapered pin into the cam gear hole and slowly push the dowel through the hole until the end of the dowel is almost flush with the spring. S Perform this procedure with all three tapered pins. S Do not push the pins too far through or the springs will pop out.
ENGINE Cam Gear Spring Installation Tool Kit: (PU--45497) (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. 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.
ENGINE balance shaft gear. 2871043 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 the crankshaft gear is damaged, remove the crankshaft gear with the Flywheel Puller (PN 2871043). Water/Oil Pump Removal/Disassembly 26. Rotate the water/oil pump gear (S), so that all four bolts are visible though the gear. Remove the four bolts with a hex wrench. Pull out the pump. S Q 24.
ENGINE 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). 22 ± 2 ft.lbs. (30 ± 3 Nm) Chamfered end first 0.006” (0.15 mm) 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. Max Tip Clearance DISASSEMBLY OF WATER/OIL PUMP SHAFT WARNING 29.
ENGINE WATER/OIL PUMP REASSEMBLY 34. Press new bearing onto the shaft. Press out shaft and bearing assembly Bearing Bearing Retaining Ring 33. Place the shaft in a press to remove the bearing. Bearing 35. Press the bearing/shaft assembly using the bearing’s outer race. Do not use the shaft to press the assembly into the housing, as bearing damage may result. Install retaining ring. Press Bearing/Shaft assembly using outer race only 36. Press gear onto shaft while supporting the housing. 3.
ENGINE CRANKCASE DISASSEMBLY CONT’D 37. Remove thrust plate (U). U W V 40. Remove balance shaft and crankshaft. 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.
ENGINE CAMSHAFT INSPECTION 1. Thoroughly clean the cam shaft. 2. Visually inspect each cam lobe for wear, chafing or damage. Camshaft Journal O.D. : A. (Mag): 1.654” ± .00039” (42 ± .010 mm) B. (Ctr.): 1.634” ± .00039” (41.50 ± .010 mm) C. (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) Lobe height 3.
ENGINE 1. Install oil pick up (A), if removed. Torque bolt to 60 ± 6 in. lbs. (6.8 ± 0.68 Nm). 4. Apply Moly Lube Grease to cam journals and balance shaft bearing surfaces of the MAG case halve. Install cam and balance shafts. B A 2. Install oil baffle weldment (B). Torque bolts to 60 ± 6 in. lbs. (6.8 ± 0.68 Nm). Oil Baffle Weldment & Oil Pick UpBolt Torque: 60 ± 6 in. lbs. (6.8-0.68 Nm) 5. Install crankshaft assembly and apply engine oil to crank pins and rods (D).
ENGINE 7. Assemble the crankcase halves. Apply LocTitet 242 (PN 2871949)to the threads and pipe sealant to the bolt flanges. Torque bolts to 22 ± 2 ft. lbs. (30 ± 3 Nm) following torque pattern on Page 3.11. 10. Lubricate connecting rods with 0W--40 engine oil. Crankcase Bolt Torque: 22 ± 2 ft. lbs. (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.
ENGINE 13. Install piston assemblies into cylinder aligning the piston pin holes, to ensure proper alignment of the pistons to the connecting rods upon assembly. Partially install the piston pins into the pistons. Cylinder Installation NOTE: While installing in piston pins, cover all engine passages. The clip could fall into the engine during installation. F NOTE: To help align the pistons, slide a rod that is close to the same diameter as the wrist pin holes to properly align them in the cylinder. 16.
ENGINE Line Up Marks 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 and new Loctitet. 20. Install oil pump housing bolts (H). The new bolts contain patch lock, so Loctitet is not needed on the new bolts. Torque bolts to 84 ± 8 in.lbs. (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.
ENGINE (J). (I). Install washer and bolt. Use the Gear Holder (PU--45838). Torque to 22 ± 2 ft. lbs.(30 ± 3 Nm). I J J I PU--45838 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.
ENGINE Timing Marks PU--45498 Timing Marks 27. Reinstall the camshaft gear; so the timing marks are properly aligned. Install the washer and bolt. Torque to 22 ± 2 ft. lbs.(30 ± 3 Nm). NOTE: Be sure all of the timing marks are properly aligned. Timing Marks M K Counterbalance Gear and Camshaft Gear Bolt Torque: 22 ± 2 ft. lbs.
ENGINE PA--44995 O P N Seal lip goes towards the crankcase. NOTE: 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 (N) with the seal lip facing out (towards the crankcase). Use of a hydraulic press is recommended for this procedure. 30.
ENGINE 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. (PA--45658) 32. Before installing the gear/stator housing cover, install the Water Pump Seal Saver (PA--45401) onto the water pump shaft. PA--45401 33. Install the new gasket to the gear/stator housing cover and crankcase.
ENGINE P (PA--45401) (PA--45658) O Q Gear/Stator Housing Bolt Torque: 96 ± 12 in. lbs. (10.85 ± 0.35 Nm) Water Pump Impeller Nut Torque: *Torque in Proper Sequence (Pg. 3.3) 108 ± 12 in. lbs. (6.8 ± 0.68 Nm) 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. 39. Install water pump cover (R) with new O-ring seal. Torque bolts to specification in proper sequence (See Pg. 3.4). 37.
ENGINE 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. 43. Install the flywheel, washer, nut, and key. Torque flywheel nut to 65 ± 7 ft. lbs. (88 ± 9.50 Nm). 65 ± 7 ft. lbs. (88 ± 9.50 Nm) Flywheel Nut Torque: 41. Install stator assembly (S) and bolts. Torque bolts to 96 ± 12 in.lbs. (10.85 ± 0.35 Nm). 42. Install the the wire hold down bracket (T). Install two new wire hold down bolts.
ENGINE 45. After the engine is completely assembled and ready for installation, the engine must be properly primed with Polaris 0W--40 Synthetic Oil (PN 2871281). Fill the oil filter three--quarters full with Polaris 0W--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 0W--40 oil 46. Remove primer plug from the engine. Install the Oil System Priming Adapter (PU--45778) into the oil plug hole. Push 3--5 oz. (approx.
ENGINE TROUBLESHOOTING Spark Plug Fouling S Spark plug cap loose or faulty Engine Idles But Will Not Rev Up S Incorrect spark plug heat range or gap S PVT system calibrated incorrectly/ components worn or mis-adjusted S S S S S Fuel quality poor (old) or octane too high S S Low compression S Restricted exhaust S Weak ignition (loose coil ground, faulty coil, stator, or ETC switch) S ETC switch mis-adjusted S Restricted air filter (main or pre-cleaner) or breather system S Improperly as
ENGINE TROUBLESHOOTING, CONT Piston Failure - Scoring S S S Lack of lubrication Dirt entering engine through cracks in air filter or ducts Engine oil dirty or contaminated Excessive Smoke and Carbon Buildup S Excessive piston-to-cylinder clearance S Wet sumping S Worn rings, piston, or cylinder S Worn valve guides or seals S Restricted breather S Air filter dirty or contaminated Low Compression S Cylinder head gasket leak S No valve clearance ( cam wear ) S Cylinder or piston worn S Pi
ENGINE BLEEDING PROCEDURE FOR 4--STROKE COOLING SYSTEMS Use this procedure when a unit overheats and no apparent leaks in the cooling system are found. Pump hose by hand to help purge system Note: If the coolant level is LOW in the radiator, or if there are leaks in the system, the coolant system will not draw coolant from the reservoir tank. 1. Park Machine on a flat surface. Remove radiator cap and top off coolant. Leave the cap off of the radiator.
ENGINE NOTES 3.
FUEL SYSTEM / FUEL INJECTION Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . EFI System Exploded View . . . . . . . . . . . . . . . . Fuel Tank Exploded View . . . . . . . . . . . . . . . . . . Electronic Fuel Injection System . . . . . . . . . . . Operation Overview . . . . . . . . . . . . . Initial Start/Priming Procedure . . . . . . Electronic Control Unit . . . . . . . . . . . . . . . . . . . Service . . . . . .
FUEL SYSTEM / FUEL INJECTION SPECIAL TOOLS Throttle Position Sensor Tester -- PU--47082 PART NUMBER TOOL DESCRIPTION PU--47063 Polaris EFI Diagnostic Software PU--43506 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.
FUEL SYSTEM / FUEL INJECTION Service Notes: G G G G G G G G G 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 engine components.
FUEL SYSTEM / FUEL INJECTION EFI SYSTEM EXPLODED VIEW 1. Electronic Control Unit (ECU) 2. Intake Air Temperature and Barometric Air Pressure Sensor (T--BAP) 3. Crankshaft Position Sensor (CPS) 4. Fuel Injectors 5. Fuel Filter(s) 6. Fuel Pump / Regulator / Gauge Sender Assembly (located in tank as an assembly) 7. Fuel Rail ( 800 EFI utilizes quick connect couplings) 8. Engine Coolant Temperature Sensor 9. Throttle Position Sensor (TPS) 10. Throttle Body 11.
FUEL SYSTEM / FUEL INJECTION EFI SYSTEM COMPONENT LOCATIONS 1. Electronic Control Unit (ECU) 2. Intake Air Temperature and Barometric Air Pressure Sensor (T--BAP) 3. Crankshaft Position Sensor (CPS) 4. Fuel Injectors 5. 2 Fuel Filters (1 located in tank, 1 under front cab cover not pictured) 6. Fuel Pump / Regulator / Gauge Sender Assembly (located In tank as an assembly) 7. Fuel Rail 8. Engine Coolant Temperature Sensor 9. Throttle Position Sensor (TPS) 10. Throttle Body 11.
FUEL SYSTEM / FUEL INJECTION FUEL TANK ASSEMBLY Cap Tank Vent Fuel Pump/Tank Assembly Rear Tank Mount Protective Foil Front of ATV Frame E 2003 Polaris Sales Inc. FUEL FLOW Fuel Tank Excess Fuel Fuel Pump / Pressure Regulator Unit L External Fuel Filter -- 10 Micron L Located in Fuel Tank 4.
FUEL SYSTEM / FUEL INJECTION ELECTRONIC FUEL INJECTION SYSTEM OVERVIEW General The Electronic Fuel Injection (EFI) system is a complete engine fuel and ignition management design.
FUEL SYSTEM / FUEL INJECTION ELECTRONIC CONTROL UNIT (ECU) The ECU is the brain or central processing computer of the entire EFI fuel/ignition management 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.
FUEL SYSTEM / FUEL INJECTION FUEL PUMP ASSEMBLY NOTE: 800 EFI fuel connections are quick--connect couplings vs 700 EFI connections. An electric fuel pump assembly is used to 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.
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 regulator are working properly. Turn the key switch off and depress the valve button on the tester to relieve the system pressure. G If the pressure is too high or too low, replace the fuel pump assembly. 3. If the pump did not activate (step 2), disconnect the plug from the fuel pump.
FUEL SYSTEM / FUEL INJECTION 6. Relieve the fuel pressure at the fuel test valve. 8. Remove the air box cover and remove the two gas tank mounting bolts at the rear of the gas tank. Remove 2 Bolts Test Valve 7. Loosen the fuel tank hose and pull the fuel line from the tank. NOTE: A small amount of fuel may come out of the fuel line or tank. Plug the fuel line and tank inlet or use a shop towel during removal.
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 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.
FUEL SYSTEM / FUEL INJECTION FUEL INJECTOR SERVICE FUEL INJECTOR REPLACEMENT Injector problems typically fall into three general categories-- electrical, dirty/clogged, or leakage. An electrical problem usually causes one or both of the injectors to stop functioning. Several methods may be used to check if the injectors are operating. 1. Engine must be cool. Depressurize fuel system through test valve in fuel rail. 2. Remove the front fender assembly and fuel tank. 3.
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. Connect an ohmmeter between the pin terminals. A resistance value of 560 Ω ± 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.
FUEL SYSTEM / FUEL INJECTION 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.
FUEL SYSTEM / FUEL INJECTION G With engine off, back out air flow screw until it no longer is in contact with throttle plate cam. The throttle plate should seal off throttle bore completely. Step 2 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. G Back air flow screw out until no contact is made With voltmeter still attached to tool PN PU--47082, turn the air flow adjustment screw until the voltmeter reads .
FUEL SYSTEM / FUEL INJECTION 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 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.
FUEL SYSTEM / FUEL INJECTION DIAGNOSTICS USING “BLINK CODES” To enable the blink codes, turn the ignition from ’off’ to ’on’ 3 times, leaving it ’on’ the 3rd time, within 5 seconds. ON OFF 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 positive battery lead for 20 seconds. NOTE: See Chapter 10 for more details.
FUEL SYSTEM / FUEL INJECTION TROUBLESHOOTING POOR IDLE FUEL STARVATION/LEAN MIXTURE Idle Too High (If greater than 1300 RPM when engine is warm) G Throttle stop screw set incorrect G Throttle cable sticking, improperly adjusted, routed incorrectly Idle Too Low (If less than 900 RPM when engine is warm) Symptoms: Hard 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.
FUEL SYSTEM / FUEL INJECTION NOTES 4.
BODY / STEERING / SUSPENSION Torque Specifications and Special Tools . . . . . . . . Cover/Panel Removal . . . . . . . . . . . . . . . . . . . . . . . Side Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . Footwell Removal/Install . . . . . . . . . . . . . . . . . . . . . Front Storage Removal/Install . . . . . . . . . . . . . . . . Rear Rack Removal/Install . . . . . . . . . . . . . . . . . . . Front Cab Removal/Install . .
BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS COMPONENT FT. LBS. NM (IN.LBS.
BODY / STEERING / SUSPENSION 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 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. Step 1. B 3. To install the inserts, press outside insert (B) into the hole.
BODY / STEERING / SUSPENSION FRONT COVER REMOVAL / INSTALLATION FOOT WELL REMOVAL / INSTALLATION 1. Open the front storage compartment. 2. Pull up and outward on the front cover to remove the cover. 1. Remove the four plastic inserts (A) that secure the wheel well to the front and rear cabs. (See “PLASTIC INSERT REMOVAL / INSTALLATION” for help). 3. To install the front cover, insert the tabs of the front cover into the inserts of the cab. Make sure the tabs are aligned with the slots.
BODY / STEERING / SUSPENSION FRONT STORAGE REMOVAL 2. Remove the strut tower caps (B). Squeeze the caps inward and lift up to remove. Front Storage B Inserts 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. Remove Bolts A 4. Remove the two (T25) screws that secure the storage box to the front fender well areas (each side). Remove Bolts 5.
BODY / STEERING / SUSPENSION T--25 Screws the groove in the rack, then press in the bottom of the cover until the notches snap into place. 1. Place Lip in Groove Groove Lip 2. Press Tabs In View -- Under Right Fender Winch Installation Area 7. Remove the front headlights (C) or simply disconnect the electric connector (D) before removing the front plastic bumper. 6. Remove the front cover piece by lifting up on sides of the two locking tabs as shown.
BODY / STEERING / SUSPENSION FRONT STORAGE INSTALLATION F Front Storage A B C E REAR RACK REMOVAL/ INSTALLATION E Inserts C A B A A D -- T--25 Screw Front Cab A B C B A. 14 ft.lbs. (19 Nm) C. 10 in.lbs. (1.13 Nm) B. 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. 3. Install the four screws and washers (B) (T--25) under the fender area (2 each side). 4.
BODY / STEERING / SUSPENSION Rear Rack Installation 3. Place spacers on frame. B B 24 in.lbs. (2.7 Nm) A 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 in.lbs. (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.
BODY / STEERING / SUSPENSION REAR CAB / FENDER REMOVAL / INSTALLATION 4. Disconnect the rear lights by pulling the locks on each side and removing the connectors. Lift the rear cab from the frame. 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. Remove Connectors Lock A 5. Reverse the removal steps for installation. REAR STORAGE REMOVAL/INSTALLATION 3.
BODY / STEERING / SUSPENSION 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. To install the screen, simply press the tabs on the screen back into the mounting grommets. Be sure the screen is securely in place. 5.
BODY / STEERING / SUSPENSION BODY ASSEMBLY EXPLODED VIEW Pull UP on rear of seat and back to disengage tabs at front of seat Rear Cab Assembly Seat Latch Release Rear Cab Seat Latch Wheelwell Storage Frame Wheelwell Front Cab Assembly Front Cover Side Cover Frame Front Brush Guard Front Cab Support Side Cover Splash Shields 5.
BODY / STEERING / SUSPENSION BODY RACK EXPLODED VIEW Rack Rails Rear Rack Support Rear Rack Rack Mounting Hardware Rack Rails Box Latches Front Brush Guard Front Box Assy. Cover Support Strut Covers Radiator Shield Radiator Screen Grill 5.
BODY / STEERING / SUSPENSION HEADLIGHT POD EXPLODED VIEW B Controls Worklight Switch A F Instrument Cluster A Brake ETC Clean knurling when repositioning handlebars G Disassembly S S S S S S S S S S Remove two side Phillips screws (A). 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).
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.
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 proper direction. The steering post arm bolt (B) points up; the rod end bolts (A) point down. Be sure inner rod ends are placed between the steering post arms. 25-30 ft. lbs. (35-41 Nm) Steering Post Steering Post Arm (Frog) 12-14 ft. lbs. (17-19 Nm) A B 40-45 ft. lbs. (54-61 Nm) 30 ft. lbs. (41 Nm) 1 2 30 ft. lbs.
BODY / STEERING / SUSPENSION A-ARM REPLACEMENT 1. Elevate and safely support vehicle with weight removed from front wheel(s). 2. Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud. 3. Using a soft face hammer, tap nut to loosen A-arm from bolt. Remove nut and A-arm from hub strut assembly. 4. Loosen two bolts on A-arm tube by alternating each about 1/3 of the way until A-arm can be removed. 5. Examine A-arm shaft. Replace if worn.
BODY / STEERING / SUSPENSION REAR SUSPENSION ASSEMBLY 17 ft. lbs. (24 Nm) 17 ft. lbs. (24 Nm) Stabilizer Support 1 35 ft. lbs. (48 Nm) 35 ft. lbs. (48 Nm) 30 ft. lbs. (41 Nm) 35 ft. lbs. (48 Nm) Upper Control Arm Bushings 1 Rear Shock 30 ft. lbs. (41 Nm) Lower Control Arm 1 Orientate Bushings Correctly Rear Front Bushing Orientation 5.
BODY / STEERING / SUSPENSION STRUT ASSEMBLY Nut 15 ft. lbs. (21 Nm) Washer Strut Bumper Spacer Rubber Upper Pivot Ball Strut Washer Clamp 18 ft. lbs. (25 Nm) Spacer Nut Lower Pivot Ball 15 ft. lbs. (21 Nm) Bolt Spring Retainer Lubrication Fitting Spring Hubstrut Bearing Brake Caliper Retaining Ring NOTE: Grease fitting location. Check lubrication guide for recommended service intervals. 5.
BODY / STEERING / SUSPENSION FRONT STRUT CARTRIDGE REPLACEMENT 3. Remove wheel nuts and wheels. REFER TO ILLUSTRATION ON PAGE 5.18 1. Hold strut rod and remove top nut. 2. Remove upper strut pivot assembly. F E B 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.
BODY / STEERING / SUSPENSION To flame treat the decal area: B A K C E D 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. 2. Apply the decal. STEERING POST ASSEMBLY L 8.
CLUTCH Drive Clutch Exploded View . . . . . . . . . . . . . . . PVT Sealing and Ducting Components . . . . . . EBS System Exploded View . . . . . . . . . . . . . . . Special Tools, Supplies & Torques . . . . . . . . . . PVT Operation Overview . . . . . . . . . . . . . . . . . . PVT Maintenance/Inspection/Drying . . . . . . . . PVT Overheating/Diagnosis . . . . . . . . . . . . . . . PVT Disassembly . . . . . . . . . . . . . . . . . . . . . . . . PVT Assembly/Inspection . . . . . . . . . . . . . . . . .
CLUTCH 700 / 800 DRIVE CLUTCH EXPLODED VIEW EBS Drive Clutch Mark with permanent marker before disassembly to maintain clutch balance 800 EFI 800 EFI One way clutch 700 EFI 700 EFI One way clutch E 2004 Polaris Sales Inc. PVT SEALING AND DUCTING COMPONENTS Clutch Inlet Duct Transmission Cover Seal Inner Clutch Cover Boot Duct Clutch Cover Seal Inner Cover Seal Seal Retainer Bracket Clutch Cover 6.
CLUTCH ENGINE BRAKING SYSTEM (EBS) EXPLODED VIEW Drive Clutch Assembly (700 EFI Shown) 2.25″ PTFE Washer One Way Clutch Drive Screws Brass Washer Shift Weights Coil Spring Torque to 200 Ft. Lbs. (271 Nm) Cam Assy. Spacer Sleeve Cover Bushing Retaining Ring Drive Belt Roller/Bushing Assembly Spider Lock Nut Spider Assy. Clutch Rollers Bolts, Lock Washers Compression Spring Clutch Shaft Spacer Washer Retaining Rings Sheaves Bearing 6.
CLUTCH SPECIAL SERVICE TOOLS AND SUPPLIES TOOL DESCRIPTION PART NUMBER Clutch Puller 2870506 Clutch Holding Wrench 9314177 Clutch Holding Fixture 2871358 Spider Nut Socket 2870338 Drive Clutch Spider Removal and Install Tool 2870341 Driven Clutch Puller 2870913 Roller Pin Tool 2870910 Clutch Bushing Replacement Tool Kit 2871226 Piston Pin Puller 2870386 EBS Clutch Alignment Tool 2872292 EBS Bushing Replacement Kit Driven Clutch Compression Tool Std.
CLUTCH 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.
CLUTCH PVT OVERHEATING/DIAGNOSIS During routine maintenance or whenever PVT system overheating is evident, it’s important to check the inlet and outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system operating temperatures. The ATV should be operated in LOW RANGE when pulling or plowing heavy loads, or if extended low speed operation is anticipated.
CLUTCH PVT DISASSEMBLY NOTE: Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement. 1. Remove seat. 2. Remove or loosen rear cab fasteners as necessary to gain access to PVT outer cover. 3. Remove PVT air outlet duct hose. 4. Remove outer cover screws. Refer to Page 6.2. 5. Mark the drive belt direction of rotation and remove drive belt. See Page 6.16 for drive belt removal. 6.
CLUTCH PVT ASSEMBLY/INSPECTION 7. Install clutch offset spacer(s) on transmission input shaft. 1. Inspect PVT inner cover-to-engine seal. Replace 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 Offset Spacer 2. Place a new seal on transmission input shaft. 3. Apply RTV silicone sealant to outside edge of inner cover-to-engine seal, to ensure a water tight fit between the seal and the cover on engine side.
CLUTCH DRIVE CLUTCH SPRING SPECIFICATIONS 1. Controls clutch engagement RPM. The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM. 2. Controls the rate at which the drive belt moves upward in the drive clutch sheaves. This is referred to as drive clutch upshift. The drive clutch spring is one of the most critical components of the PVT system. It is also one of the easiest to service.
CLUTCH 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.
CLUTCH SHIFT WEIGHT INSPECTION 1. Inspect as shown, using a clutch 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. BUTTON TO TOWER CLEARANCE INSPECTION 1. Inspect for any clearance between spider button to tower. If clearance exists, replace all buttons and inspect surface of towers. See Spider Removal Page 6.12. Button to Tower Clearance: .000 - .001I 2. Inspect sheave surfaces.
CLUTCH DRIVE CLUTCH DISASSEMBLY CONT’D SPIDER REMOVAL 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 Teflont coating. Wear is determined by the amount of Teflon™ remaining on the bushing. 1. Remove the limiter nut using the Clutch Spider Nut Socket (PN 2870338). Install clutch in holding fixture and loosen the spider (counterclockwise) using Clutch Spider Install Tool (PN 2870341).
CLUTCH Moveable Sheave Bushing Inspection 2. Inspect the Teflont coating on the moveable sheave bushing. Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflont 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. Turn roller with your finger.
CLUTCH Thrust Washer Thickness Standard: .030″ (.76mm) Service Limit: .025″ (.64mm) 2. Lift one-way clutch off shaft. Replace as an assembly if worn, damaged, or if problems were noted. Shaft Diameter Standard: 1.3745″ - 1.375″ Service Limit: 1.3730″ 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. PTFE Washer Thickness Standard: .030″ (.76mm) Service Limit: .025″ (.
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.
CLUTCH 8. Reinstall cover, aligning bosses on the tower and cover. Torque cover bolts evenly to specification Spider Torque: 200 ft. lbs. (271 Nm) Cover Screw Torque: 90 in. lbs. (10.4 Nm) DRIVE BELT REMOVAL/INSPECTION 1. Remove outer PVT cover as described in PVT Disassembly. 2. 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. 3.
CLUTCH G G 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 Center Distance Clutch Center Distance 10″ +.1 / -.05 (254 +2.5 / -1.3mm) Belt Nominal Length - 40.875″± 3/16 (103.8 cm ± .48 cm) Belt Width: New 1.174 - 1.188″ (2.98-3.02 cm) Wear Limit 1.125″ (2.86 cm) 5. Inspect belt for loose cords, missing cogs, cracks, abrasions, thin spots, or excessive wear. Replace if necessary. 6.
CLUTCH CLUTCH ALIGNMENT 1. Remove belt and install the Clutch Offset Alignment Tool (PN 2872292) as shown. Offset Alignment Tool (PN 2872292) - EBS 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) B CLUTCH OFFSET A 1/8I +0 / -- 1/16 3.2mm +0 / -- 1.
CLUTCH EBS DRIVE CLUTCH BUSHING SERVICE 5. Install main adapter (Item D) onto puller.
CLUTCH EBS Drive Moveable Bushing Installation EBS Drive Clutch Cover Bushing Removal 1. Place main adapter (Item 8) on puller. 1. Install main adapter (Item 8) on puller. Puller Tool (A/B) Side “A” toward sheave Nut (C) Removal Tool (3) Bushing Main Adapter (8) Piston Pin Puller EBS Drive Clutch Moveable Sheave Bushing Installation 2. Apply Loctitet 609 evenly to bushing bore inside moveable sheave. 3. Set bushing in place on sheave. 4.
CLUTCH EBS DRIVEN CLUTCH DISASSEMBLY/INSPECTION EBS Driven Clutch Operation 1. Remove driven clutch from the transmission input shaft. Do not attempt disassembly of the driven clutch from the outside snap ring. The driven clutch must be disassembled from the helix side. This EBS driven clutch provides the same engine braking abilities as the earlier EBS driven clutch. One--way Clutch Drive Clutch Driven Downhill Belt Rotation Do not disassemble from this side 2.
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). D E 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 B H G 8.
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). Press Shaft/Bearing Out K Inspect Bearing 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 cracking. Clean surfaces with a 3Mt pad if needed K M L 11.
CLUTCH EBS DRIVEN CLUTCH REASSEMBLY 4. Line up the “X” ont the moveable sheave with the “X” on the stationary sheave or use the marks previously used. Put the sheaves together. 1. Press the bearing onto the output shaft using a press. Align X’s 2. Install the shaft/bearing into the outer sheave. 3. Install the small and large retaining rings into the outer sheave above the bearing. 5. Install the roller (A) onto the roller pin (B). (Both Sides) A B 6.
CLUTCH 6. Install the roller pin 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. 9. Install the spring over the shaft. Install Spring Flat Side of Roller Downward 7. Install the spring pins (C) to secure the roller pins. Install until flush with sheave surface. 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.
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. 15. Install the cam assembly (helix) over the shaft. Line up the “X” on the cam, “X” on spider, and “X” on the stationary sheave or use the marks previously made before disassembly.
CLUTCH EBS DRIVEN CLUTCH EXPLODED VIEW 1. Torx Screw 2. Cam Assembly 3. Retaining Ring 4. E--clip 5. Washer 6. Roller 7. Outer Spider 8. Spring 9. 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 1 2 3 5 4 20 7 8 19 18 9 6 10 13 11 14 12 15 16 17 6.
CLUTCH TROUBLESHOOTING Situation Engine RPM below specified operating range although engine is properly tuned. Probable Cause Remedy -Wrong or broken drive clutch spring. -Replace with recommended spring. -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine application. -Driven clutch spring broken or installed wrong . -Replace spring; refer to proper installation location. Erratic engine -Drive clutch binding.
CLUTCH Belt slippage Belt burnt, thin spots PVT noise Engagement erratic or stabby -Belt worn out -Replace belt. -Water ingestion -Inspect and seal PVT system. -Belt contaminated with oil or grease -Inspect and clean. -Abuse (continued throttle application when -Caution operator to operate machine within guidelines. vehicle is stationary, excess load) -Dragging brake -Vehicle operated with park brake on. Inspect brake system.
CLUTCH NOTES 6.
FINAL DRIVE Final Drive Torque Specifications . . . . . AWD Front Axle Remove/Install . . . . . . AWD Front CV Joint Boot Replace. . . . AWD Front Drive Axle Exploded View . Front Hub Disass./Assemble . . . . . . . . . AWD Front Prop Shaft Removal . . . . . . U-Joint Disassemble/Assemble . . . . . . Drive Axle / Propshaft Exploded View . AWD Front Gearcase Operation . . . . . 7.1 7.2-7.3 7.4-7.5 7.15 7.5 7.6 7.6--7.7 7.8 7.9 AWD Front Gearcase Service . . . . . . . . Rear Hub Remove/Install . . . . . . .
FINAL DRIVE WHEEL AND HUB TORQUE TABLE COMPONENT FT. LBS. NM (IN.LBS.) F/R Steel Wheel Nuts 30 41 F/R Aluminum Wheel Nuts 90 122 Front Hub Nut 70 95 Rear Hub Nut 80 109 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. 8. Remove hub.
FINAL DRIVE New Cotter Key 11. With short, sharp jerks, remove drive shaft from front gearcase. Front Hub Retaining Nut Torque 70 ft. lbs. (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.
FINAL DRIVE FRONT DRIVE SHAFT CV JOINT BOOT REPLACEMENT Retaining ring 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. Pull shaft to remove from CV joint 7. Remove small clamp and boot from driveshaft. NOTE: If the ATV has been operated with a damaged boot, the CV joint grease may be contaminated. Inspect the grease carefully for contamination, and clean the joint thoroughly if necessary.
FINAL DRIVE BE TAKEN TO AVOID DAMAGE TO THE NEWLY INSTALLED BOOT. 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. 13. Install the small clamp on the boot. Front Shaft 3.5 oz. 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 corrosion.
FINAL DRIVE FRONT PROP SHAFT REMOVAL 1. Using Roll Pin Removal Tool (PN 2872608), 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. NOTE: If yoke or bearing is removed, cross bearing must be replaced. Note orientation of grease fitting and mark inner and outer yoke for correct re-positioning during installation. 2.
FINAL DRIVE 4. Force U-joint cross to one side and lift out of inner yoke. U-JOINT ASSEMBLY 4. Install outer yoke, aligning marks made before disassembly. 5. Repeat Steps 1-3 to install bearing caps on outer yoke. 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. 2.
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 Inner Boot Circlip Outer Boot Circlip Circlip Outer CV Joint Clamp Front Drive Boot Replacement Kits Inner Clamp 3.5 oz. Grease Boot 3.5 oz.
FINAL DRIVE 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. in True All Wheel Drive. CAUTION: If the rear wheels are spinning, release the throttle before turning the AWD switch on.
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. Front Gearcase Removal CAUTION: Do not hang the caliper by the brake line.
FINAL DRIVE Gearcase Coil Resistance NOTE: To test the gearcase coils resistance, use the coil harness. The gearcase coils should measure between 22.8 ohms and 25.2 ohms. B 3. Remove output shaft assembly. C A 8. Inspect roll cage (B) sliding surface. This surface must be clean and free of nicks, burrs or scratches. Remove and inspect the H--springs. B NOTE: Be careful not to misplace the thrust bearing located between the two output shafts. 4. Clean all parts and inspect spacers for wear.
FINAL DRIVE 10. Remove the spacer washer (D), armature plate (E), and rubber O--ring from the output cover. H G O--ring D E 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. E F 13. Inspect the magnetic coil (I) in the output housing.
FINAL DRIVE 18. Remove and replace the O--rings and seals from the assembly. K L 16. Remove the input cover (M), bearing (N), and the pinion gear (O). Inspect the pinion gear (O) for chipped, broken, or missing teeth. Replace the input cover O--ring. N M O FRONT GEARCASE REASSEMBLY/INSPECTION 1. Replace all O--rings, seals, and 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.
FINAL DRIVE 5. Install the output hub (A) into the gearcase housing. The output hub should spin freely. F A 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. B 9. Install the ring gear onto the output hub on the output cover. G C 7. Install the armature plate (D) and spacer washer (E) into the output cover. NOTE: Be sure backlash plate in in place. 10. Install the rollers and roll cage into the ring gear.
FINAL DRIVE Cover Bolts Torque 14 ft. lbs. (19 Nm) 13. Install new seals into the gearcase housing and gearcase housing cover. Back Lash Pad (Thrust Pad) Adjustment 14. Lay the gearcase on the 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).
FINAL DRIVE 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 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).
FINAL DRIVE 3233952). 30 ft.lbs. (41 Nm) Gearcase Cover Coil 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. New Roller Pin Rollers 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) FRONT HOUSING INSTALLATION 1.
FINAL DRIVE FRONT GEARCASE -- CENTRALIZED HILLIARD EXPLODED VIEW 18 22 31 30 19 21 20 2 9 24 37 25 5 28 13 26 10 7 1 22 23 11 3 4 12 36 6 34 8 6 17 35 14 15 16 27 33 32 Ref. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 7.18 Qty. 1 1 1 1 1 1 2 1 1 1 1 1 14 2 1 1 1 1 1 1 Description Asm., Mid Gearcase Cover, Output O-- Ring Insert Coil Kit, Shim Set (Incl.
FINAL DRIVE REAR HUB REMOVAL 8. Remove hub nut, domed washer and flat washer. 1. Place the ATV in Park and lock the parking brake. Remove rear hub cap. 9. Remove hub. 2. 3. 4. 5. Remove cotter pin. Loosen the hub retaining nut. Loosen the wheel nuts. Safely support the rear of the ATV. CAUTION: 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.
FINAL DRIVE 11. Remove both lower control arm bolts. 12. Remove bearing carrier. REAR HUB INSTALLATION 1. Insert bearing carrier on drive shaft. 2. Align bottom of carrier housing and lower control arm. Grease and slide lower control arm bushings into place, securing corner housing. Install upper and lower bolts Rear Hub Nut Torque: 80 ft. lbs. (109 Nm) Rear Wheel Nut Torque: Refer to Page 7.2 5. Pull drive shaft outward and install hub onto driveshaft splines. 6.
FINAL DRIVE REAR HUB DISASSEMBLY REAR HUB ASSEMBLY 1. Remove outer snap ring. 1. Support bottom of bearing carrier housing. 2. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown. 2. Start bearing in housing. 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. Press bearing into place until outer race bottoms on housing. 3. Inspect bearing.
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. (See Pages 7.19). 2. Tip hub outward and remove shaft from hub. DRIVESHAFT AND CV JOINT HANDLING TIPS Care should be exercised during driveshaft removal or when servicing CV joints. Driveshaft components are precision parts.
FINAL DRIVE REAR DRIVE SHAFT INSTALLATION 6. Install rear wheel and torque wheel nuts to specification. 80 ft. lbs. (109 Nm) 1. Slide shaft assembly into bearing carrier hub. Flat Washer Out Cone Washer Cone washer dome to outside 2. Apply anti-seize compound to splines of shaft. 3. Install a new lock ring and install the shaft. 4. Lift bearing carrier into place and install bolt to upper control arm. Torque bolt to 35 ft. lbs. (48 Nm). Rear Wheel Nut Torque: Refer to Page 7.2 7.
FINAL DRIVE REAR DRIVE SHAFT SERVICE Spread ends of snap ring to remove joint from shaft 1. Remove clamps from rubber boot(s) using the CV Boot Clamp Pliers (PN 8700226) (A). A Tap CV Housing Off Shaft 4. Place a new snap ring in the groove of the CV joint inner hub, with tabs facing the shaft as shown. 2. NOTE: Photo below is shown without shaft for clarity. Wipe grease away from recess in CV joint inner hub to locate snap ring. Snap ring located in recessed area Snap ring 3.
FINAL DRIVE 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 (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.
FINAL DRIVE (BOOT INSTALLATION) 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.
FINAL DRIVE 3. Remove the shim, thrust button, and thrust button shim from the gearcase. Thrust Button 5. Inspect 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. 6. Remove the input shaft cover and the pinion shaft from the gearcase housing. See next page. Shims 7. Inspect the ring gear for abnormal wear, broken, or chipped teeth. Spin the bearing to check the ball bearings for smoothness.
FINAL DRIVE REAR GEARCASE REASSEMBLY 3. Install the pinion shaft into the gearcase housing. Install the pinion shaft cover and torque the cover bolts to 25 ft. lbs. (34 Nm). 1. Inspect the pinion shaft bushing for wear. 2. Replace all components. O--rings, seals, and worn Pinion Shaft Cover Bolt Torque: 25 ft. lbs. (34 Nm) 4. Install the original shim(s), thrust button, and thrust button shims into the gearcase cover. 7.
FINAL DRIVE 5. Apply Crankcase Sealant (PN 2871557) to surface of case and install cover bolts. Install the gearcase cover onto the gearcase housing. Torque the cover bolts to 25 ft. lbs. in a criss cross pattern. REAR GEARCASE INSTALLATION 1. To install 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.
FINAL DRIVE REAR GEARCASE EXPLODED VIEW 17 9 2 13 8 3 6 14--18 FT.LBS. 7 10 1 11 (19--24 NM) 16 5 4 14--18 FT.LBS. 13 Ref. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 7.30 Qty. 1 1 1 1 1 1 1 1 1 1 1 Description Asm., Rear Gearcase RH Gearcase LH Cover 31T Straight Bevel Gear 10T Straight Bevel Pinion Bushing Thrust Button Shim Dowel Pin Vent Shim 16 (19--24 NM) Ref. 11. 12. 13. 14. 15. 16. 17. Qty.
TRANSMISSION Transmission, Exploded View . . . . . . . . . . . . . . Torque Specifications/Lubrication . . . . . . . . . . . Gear Shift Selector Removal . . . . . . . . . . . . . . . Transmission Removal . . . . . . . . . . . . . . . . . . . . Transmission Installation . . . . . . . . . . . . . . . . . . Transmission Disassembly . . . . . . . . . . . . . . . . Transmission Reassembly . . . . . . . . . . . . . . . . . 8.2--8.5 8.5 8.5 8.6--8.7 8.7--8.8 8.8-8.13 8.13-8.18 8.
TRANSMISSION TRANSMISSION EXPLODED VIEW 72 262 71 70 TORQUE SPECIFICATIONS Torque 12-- 18 fl.lbs. (16-- 24 Nm) 7-- 9 ft.lbs. (9.5-- 12 Nm) 15--19 ft.lbs. (20--26 Nm) 27--34 ft.lbs. (37--46 Nm) 6--12 ft.lbs. (8--16 Nm) 14--18 ft.lbs. (19--24 Nm) 6--12 ft.lbs. (8--16 Nm) 11 10--14 ft. lbs. (14--19 Nm) 8.2 FOR REASSEMBLY Apply White Lithium Based Grease. Apply Polaris Crankcase Sealant 262 Item 1 3 23 33 39 70 71 Apply Loctitet 262 to the bolt threads.
TRANSMISSION TRANSMISSION EXPLODED VIEW, CONT. Ref. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. Qty.
TRANSMISSION TRANSMISSION INFORMATION Transmission Mounting TORQUE SPECIFICATIONS COMPONENT FT. LBS. NM Front (IN.LBS.) Transmission Case Bolts 27--34 37--46 Oil Deflector Screws (16--30) 2--3.3 Shift Cover Bolt 6--12 8--16 Bell Crank Nut 12--18 16--24 Trans. Drain Plug / Fill Plug 10--14 14--19 Trans. Mounting Bolts 25 34.5 Snorkel Lock Screw 8--12 11--16 2. Disconnect transmission vent line. 3. Drain transmission lubricant. 4.
TRANSMISSION 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 the rear prop shaft. Remove the front propshaft. Remove Roll Pin 9. Loosen or remove the bolts that secure the rear gearcase.
TRANSMISSION A D C Transmission Switch B 4. Remove the five bolts that secure the cover. Remove the detent spring. E Tighten Bolts In Sequence A through E TRANSMISSION DISASSEMBLY 1. Place the bellcrank in neutral position. Spring Shift Shaft Cover NO TAG Bellcrank 5. Mark the detent gear with a white pen. Remove the detent gear from the case. Detent Pawl Case 2. Remove the nut, and washer that secure the bell crank. Remove the bellcrank. 3.
TRANSMISSION NOTE: It may be helpful to place a mark just above the keyed spline. Note the raised edge on the detent gear for reassembly. 8. Note the timing marks on the shift gears. Remove the shift gears from the case. 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.
TRANSMISSION 11. Remove the shift forks from the assembly. Note the correct position of each fork. Engagement Dogs 12. Remove the bearing from the reverse shaft using a puller. 13. Remove the park lock engagement dog. Remove the wave spring and reverse engagement dog. 8.8 14. Remove the bearing from the input shaft with a puller. 15. Remove the snap ring and washer from the reverse shaft.
TRANSMISSION 16. Remove low gear (33T) and the needle bearing. 17. Remove the reverse gear shaft. 18. Remove the rest of the bearings from the shafts. 19. Use a press to remove the gear from the shaft. 20. Make note of the direction of the gear and hub location. 21. Remove the gear, split bearing, and washer from the reverse shaft. 22. Slide off the shift dogs and wave springs. 23. Remove the snap ring, washer, gear, and split bearing. 8.
TRANSMISSION 26. Remove the front housing cover screws. 24. Remove bearing and the helical gear. 25. Remove the pinion shaft retainer plate and the pinion shaft. 8.
TRANSMISSION 27. Remove the front housing cover, shim, thrust button, and thrust button shim. 31. Inspect engagement dogs of gears and replace if edges are rounded. 32. Inspect 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 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. lbs. (36.50--46 Nm). NOTE: Make sure that the case locating pins (knock pipes) are in place.
TRANSMISSION 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. NOTE: Use caution when installing the fork, as the spring can easily fall out.
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. 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.
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 on the left side. Aligning the timing marks on the gears. 28. Install the park lockout assembly. Torque park lockout to 12 -- 14 ft. lbs. (16--19 Nm). Sector Gear Lockout Disc NOTE: Note the location of the skip tooth on the splines. Apply a light coating of grease on the gear teeth. 29.
TRANSMISSION 31. Torque the remaining bolts to 6--12 ft.lbs. (12--16 Nm). Cover Bolt Torque: 6-- 12 ft. lbs. (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. lbs. (16--24 Nm). Bellcrank Nut Torque: 12--18 ft. lbs. (16--24 Nm) 33. Install the shift switch. Install the retaining clip. Hook up the switch harness and reconnect the lockout plunger spring.
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 . . . . . . . . . . . . .
BRAKES SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2870975 Mity Vact Pressure Test Tool SPECIFICATIONS Front Brake Caliper Item Standard Service Limit 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 Measurements - .002″ / .051mm Brake Disc Runout - .010″ / .254mm Rear Axle Brake Caliper Item Standard Service Limit Brake Pad Thickness .318″ / 7.6mm .180″ / 4.6mm Brake Disc Thickness .
BRAKES BRAKE SYSTEM MAIN COMPONENTS 2 Screws 5 in.lbs. (0.56 Nm) 1 3 2 1 3 1 2 1 2 1 2 3 All Flare Style Fittings 12--15 ft.lbs. (16--21Nm) Apply Pipe Sealant to Threads 3 All Bleed Screws: 25--30 in.lbs.(2.80--3.40 Nm) All Banjo Style Fittings 15 ft.lbs. (21Nm) 2 9.
BRAKES REAR BRAKE CALIPER EXPLODED VIEW 3 Anvil Bolts APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT Torque 16--18 ft.lbs. (22--25 Nm) Washers Rear Housing Bleed Screws 3 Piston Torque 25--30 in. lbs. (2.80--3.40) Nm O--rings Bracket Seals 3 Pads Slide Pins Bushings Seal Torque 30--35 ft.lbs.
BRAKES REAR AUXILIARY MASTER CYLINDER Brake Reservoir Frame Clamp Rear Brake Line Reservoir Hose Bolt Seal Rear Brake Master Cylinder Brake Mount Screw Spring Washer Screw Bushing Washer Bushing BRAKE SYSTEM SERVICE NOTES Polaris disc brake systems are light weight, low maintenance and perform well in the conditions ATVs routinely encounter.
BRAKES Brake Noise Troubleshooting Possible Cause Dirt, dust, or imbedded material on pads or disc Pad(s) dragging on disc (noise or premature pad wear) Improper adjustment Insufficient lever or pedal clearance Master cylinder reservoir overfilled Master cylinder compensating port restricted Master cylinder piston not returning completely Remedy Spray disc and pads with CRC Brake Kleent or equivalent non-flammable aerosol brake cleaner.
BRAKES when the lever is released and the master cylinder piston is outward. As the temperature within the hydraulic system changes, this port compensates for fluid expansion (heated fluid) or contraction (cooled fluid). During system service, be sure this port is open. Due to the high temperatures created within the system during heavy braking, it is very important that the master cylinder reservoir have adequate space to allow for fluid expansion. Never overfill the reservoir! Fill to 1/4″ - 5/16″ (.
BRAKES 4. If changing fluid, remove old fluid from reservoir with a Mity Vact pump or similar tool. Mity Vact (PN 2870975) 5. Add brake fluid to the indicated MAX level inside reservoir. 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.
BRAKES 13. Install diaphragm, cover and screws. Tighten screws to specification 5 in. lbs. (0.56 Nm). 2. Place a shop towel under brake line connection at master cylinder. Loosen banjo bolt; remove bolt and sealing washers. CAUTION: Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 3. Remove master cylinder from handlebars. 4. Hold brake upright and continue to remove master cylinder. Cover brake line to avoid spillage.
BRAKES 2. Place new sealing washers on each side of banjo line and torque banjo bolt to specification. FRONT PAD REMOVAL 1. Elevate and support front of machine. Torque to 15 ft.lbs. (21 Nm) CAUTION: Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. Banjo Bolt 2. Remove the front wheel. Loosen pad adjuster screw 2-3 turns. Sealing Washers Brake Line Hand Master Cylinder Clamp Bolt Torque 25 in. lbs.
BRAKES Measure Thickness 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. Front Brake Pad Thickness New .298″/7.6 mm Service Limit .180″ / 4.6 mm 5. Push mounting bracket inward and slip outer brake pad past edge. Remove inner pad. 6. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. 9.
BRAKES FRONT PAD ASSEMBLY 1. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots. 18 ft. lbs. (25 Nm) Front Caliper Mounting Bolts Torque: 18 ft. lbs. (24Nm) Polaris Premium All Season Grease (PN 2871423) 2. Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other.
BRAKES 7. Install wheels and torque wheel nuts. Front Wheel Nut Torque: 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. 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.
BRAKES CAUTION: Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 2. Push upper pad retainer pin inward and slip brake pads past edge. 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. 3.
BRAKES 5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTE: Be sure to clean seal grooves in caliper body. 2. Inspect piston for nicks, scratches, wear or damage. Measure diameter and replace if damaged or worn beyond service limit. Clean Components FRONT CALIPER INSPECTION 1. Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage is evident or if worn beyond service limit. Front Caliper Piston Bore I.
BRAKES FRONT CALIPER INSTALLATION 1. Install caliper on hub strut, and torque mounting bolts. 15 ft. lbs. (21 Nm) Polaris Premium All Season Grease 18 ft. lbs. (24 Nm) (PN 2871423) 4. Compress the mounting bracket and make sure the dust seals are fully seated. Install the pads as shown on Page 9.10. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease. Torque Specifications Front Caliper Mounting Bolt: 18 ft. lbs.
BRAKES 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. 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. 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.
BRAKES 18 ft.lbs. (24 Nm) 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: If the brake pads are contaminated with grease, oil, or liquid soaked do not use the pads, use only new clean pads. Torque Specifications: Rear Brake Caliper: 18 ft. lbs. (24 Nm) Caliper Slide Pin Torque: 30--35 ft. lbs. (41 Nm--48 Nm) 4. Install the slide bolt snap ring. Torque the slide pin to 30--35 ft.
BRAKES REAR CALIPER REMOVAL/INSPECTION 5. Remove the anvil bolts and separate caliper halves and remove pistons with piston pliers. Caliper 1. Clean caliper area before removal. 2. 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. Anvil Bolts Seal Piston & 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.
BRAKES Seals .94 in. 23.88 mm 1.5 in. 38.1 mm O-Rings 10. Inspect caliper piston bore for scratches, severe corrosion, or galling and replace if necessary. Inspect 2. 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) 11. Inspect surface of caliper piston for nicks, scratches, or damage and replace if necessary. REAR CALIPER ASSEMBLY 1.
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.
BRAKES REAR (AUXILIARY) BRAKE REMOVAL / INSTALL Brake Pedal Removal / Install 1. To remove the brake pedal: S Remove the spring attached to the transmission park lock mechanism S Remove the cotter key S Remove the washers, bushings, and tension spring 2. Reverse the steps for installation, use a new cotter key during installation. Rear Brake Master Cylinder Removal / Install 1. If necessary, remove the rear brake line from the master cylinder. Use a suitable container to catch the brake fluid.
BRAKES REAR BRAKE CALIPER EXPLODED VIEW 3 Anvil Bolts APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT Torque 16--18 ft.lbs. (22--24 Nm) Washers Rear Caliper Bleed Screws 3 Piston Bracket O--rings Seals Pads Torque 25--30 in. lbs. (2.80--3.40) Nm 3 Slide Pins Bushings Seal Torque 30--35 ft.lbs.
BRAKES NOTES 9.
ELECTRICAL Crankshaft Position Sensor Gap . . . . . . . . . . . . . . Gear Position Switch Test . . . . . . . . . . . . . . . . . . . . Instrument Cluster Overview . . . . . . . . . . . . . . . . . Speedometer Removal/Installation . . . . . . . . . . . . Speedometer Operation Troubleshooting . . . . . . Coolant Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . Fan Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Control Switch Tests . . . . . . . . . . . . . . . . . . . .
ELECTRICAL CRANKSHAFT POSITION SENSOR GAP Measure trigger coil gap with a feeler gauge. The gap should be .059 inch (1.0 mm). GEAR POSITION INDICATOR SWITCH TEST NOTE: Also see “INSTRUMENT CLUSTER TROUBLESHOOTING” for gear switch resistance. TRANSMISSION SWITCH High/Low/Neutral/Reverse/Park Switch A Crankshaft Position Sensor Crankshaft Position Sensor Gap: .059” ± .010 inch (1.0 ± .
ELECTRICAL INSTRUMENT CLUSTER OVERVIEW 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.
ELECTRICAL 5. Engine Hour Display Indicator Displays number of hours of engine operation. Screen 1: The first screen indicates battery voltage. Refer to Ill. 2. 6. AWD Indicator Illuminates when the electrical portion of the AWD system 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.
ELECTRICAL Screen 4: Gear circuit diagnostic. This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. NOTE: 10--20% variance from these readings is within normal parameters. 628 Ohms in High 23 Ohms in Park 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.
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.
ELECTRICAL 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 a failure code appears. 4. The word “End” will display after all of the codes have been displayed.
ELECTRICAL SPEEDOMETER REMOVAL SPEEDOMETER INSTALLATION 1. Remove the three screws that secure the headlight pod cover and disconnect the wire connectors from the instrument cluster. 1. Spray a soap and water mixture onto the outer surface area of the instrument cluster. This will help the instrument cluster slide into the pod assembly more easily. 2. Push the instrument cluster out from the backside of the pod, while securely holding the pod. 2.
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 DIAGNOSTIC MODE SET TO AWD DIAGNOSTIC SCREEN TURN ON AWD SWITCH DOES CLUSTER SHOW “ON”? Y MECHANICAL PROBLEM Y Note: If AWD icon comes on, instrument cluster is O.K. Proceed to mechanical tests (in Service Manual). Check the AWD icon on instrument cluster to verify it’s operation.
ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 2 -- NO SPEEDOMETER AND/OR ODOMETER DISPLAY START HERE KEY & STOP SWITCHES ON A: D.C.
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. Y START HERE IS SPEEDO FUNCTIONING CORRECTLY? Y ATV IN NEUTRAL ACTIVATE DIAGNOSTIC MODE. TOGGLE TO TACH-OMETER SETTING & REV ENGINE. N CHECK SPEEDO (TEST NO. 2) HOLD UNTIL DISPLAY STABILIZES. DOES IT APPEAR ACCURATE? RESTART ATV N ENGINE IDLING MEASURE AC VOLTAGE BETWEEN PIN 7 AND PIN 8.
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 INSTRUMENT CLUSTER FUNCTION OK? 16 Pin Connector CHECK SPEEDOMETER (PERFORM TEST 2) Y SHIFT TO LOW OR HIGH GEARS. IS REVERSE INDICATOR ICON ON OR GEAR ON? DOES GEAR INDICATOR GO BLANK? Y 1. 2. 3. 4. 5. 6. 7. 8.
ELECTRICAL SPEEDOMETER TROUBLESHOOTING TEST 7 FUEL GAUGE DISPLAY NOT WORKING 16 Pin Connector START HERE INSTRUMENT CLUSTER FUNCTION OK? N CHECK SPEEDOMETER (PERFORM TEST 2) Y GAIN ACCESS TO BACK OF GAUGE CHECK CONNECTION AT GAUGE (PIN #12) 1. 2. 3. 4. 5. 6. 7. 8.
ELECTRICAL COOLANT TEMPERATURE SENSOR The coolant temperature sensor can be tested using an ohmeter or voltmeter. 1. With the engine and temperature sensor at room temperature (68° F = 20° C), disconnect the harness connector. 2. With the 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.
ELECTRICAL ELECTRONIC 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.
ELECTRICAL FLYWHEEL IDENTIFICATION Timing Marks Kokusan EFI Flywheel Production Date A 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 Application Cast Stamp Comment Kokusan Flywheel 4010912 NA 500 W EFI -- DC / CDI IGNITION The Sportsman EFI system has incorporated into it’s design a DC/ CDI ignition system.
ELECTRICAL COMPONENTS OF EFI 500 WATT ALTERNATOR/IGNITION SYSTEM Ignition Coils Battery to Solenoid Cable Solenoid Switch (starter switch) 30 Amp Hr. Battery Coil Wires Solenoid to Starter Cable Control Module Relays Negative Battery Cable Fuses Spark Plugs Pre--Wire Winch Cables (Steering Post Area) Voltage Regulator Stator Assembly Flywheel Crank Position Sensor 10.
ELECTRICAL IGNITION SYSTEM TROUBLESHOOTING Current Draw Inspection Key Off No Spark, Weak or Intermittent Spark G G G G G G G G G G G G G Spark plug gap incorrect Fouled spark plug Faulty spark 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.
ELECTRICAL 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. ALTERNATOR OUTPUT TEST Three tests can be performed using a multimeter to determine the condition of the stator (alternator). Y1 Y3 Y2 The “break even” point of the charging system is the point at which the alternator overcomes all system loads (lights, etc.
ELECTRICAL TEST 3: Measure AC Voltage Output of Each Stator Leg at Charging RPM RELAYS 1. Set the selector dial to measure AC Voltage. 2. Start the engine and let it idle. 3. While holding the ATV at a specified RPM, separately measure the voltage across each ’leg’ of the stator by connecting the meter leads to the wires leading from the alternator (Y1 to Y2, Y1 to Y3, Y2 to Y3). 4. Refer to the table below for approximate Voltage AC readings according to RPM.
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, measure the battery open circuit voltage (See earlier test). It should be 12.4 volts or more. Is it? No Remove the battery and properly service. Reinstall the fully charged battery or a fully charged shop battery.
ELECTRICAL BATTERY IDENTIFICATION NOTICE: It is important to identify what type of battery you have installed in your ATV. Different types of batteries require different service procedures. Proper servicing and upkeep of your battery is very important for maintaining long battery life. Your ATV may have a Conventional Battery or a Sealed Low Maintenance Battery.
ELECTRICAL 5. Charge battery at 1/10 of 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. Maintain between upper and lower level marks BATTERY TERMINALS/TERMINAL BOLTS Use Polaris corrosion resistant Nyogelt grease (PN 2871329) on battery bolts. See Battery Installation on Page 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. Battery Hydrometer (PN 2870836) CONVENTIONAL BATTERY TESTING Whenever a service complaint is related to either the starting or charging systems, the battery should be checked first. 1.10 Battery voltage should be checked with a digital multitester. Readings of 12.
ELECTRICAL 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.
ELECTRICAL 2. Check the voltage with a voltmeter or multimeter. A fully charged battery should be 12.8 V or higher. 3. If the voltage is below 12.8 V, the battery will need to be recharged. 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.
ELECTRICAL LOW MAINTENANCE BATTERY INSPECTION/ REMOVAL The battery is located under the seat. 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: OCV Test, Specific Gravity Test and Load Test. LOW MAINTENANCE BATTERY -- OCV - OPEN CIRCUIT VOLTAGE TEST Battery voltage should be checked with a digital multitester.
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.
ELECTRICAL HIGH BEAM HEADLIGHT BULB REPLACEMENT 4. Turn the headlight lamp socket counter--clockwise and remove. CAUTION: Do not service while headlight is hot. Serious burns may result. Protect lamp during install. Turn Harness Assembly Remove 3 screws Loosen Tighten 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.
ELECTRICAL HEADLIGHT HOUSING REPLACEMENT 5. Pull the headlight housing up to release from the locking tabs. 1. Remove three Phillips screws on the headlight pod. 2. Disconnect instrument cluster harness (A) and work light switch (B). A B Both Sides 3. Unplug headlamp harness (C). C 4. Remove O-Ring (D) from headlight pivot pins. (Both Sides) 6. Lift the adjusting knob up to remove from the locking tabs. 7. Carefully pull the assembly up and out of pod. 8.
ELECTRICAL HIGH BEAM HEADLIGHT ADJUSTMENT LOWER HEADLAMP REMOVAL/INSTALLATION 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 Turn Harness Assembly Loosen Headlight Adjustment Knob Tighten 1. Turn the back of the headllamp harness in a counter--clockwise direction to loosen. 2.
ELECTRICAL Lower Headlamp Housing Removal (if required) 5. Remove the screw that secures the lower headlamp. Remove Screw 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 6. Pull the headlamp out of the locking tab.
ELECTRICAL G G G Check for continuity between the switch contacts -- Place meter leads between two contacts with switch in ON position. Probe the worklight plug wires at back of vehicle, there should be at least 12V at the plug. Check for 12 volt power at the blue wire. Worklight Plug Wires BRAKE LIGHT / WORK LIGHT REPLACEMENT The brake light (A) and the work light (B) are both located in the rear tail lamp housing. B A 2.
ELECTRICAL BRAKE LIGHT SWITCH FUEL SENDER TEST 1. Remove the front cover. 1. Drain the fuel tank and remove it from the atv. 2. Set the 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 now read 90 ohms.
ELECTRICAL ACCESSORY WIRE CONNECTIONS Orange / White Wires 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.
ELECTRICAL BASIC WINCH WIRING -- 2005 ATV MODELS 2005 ATV WINCH WIRING DIAGRAM 10.
ELECTRICAL STARTER SYSTEM TROUBLESHOOTING Starter Motor Does Not Turn G G G G G G G G Battery discharged. Low specific 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.
ELECTRICAL O--rings Shims NOTE: 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. 3. Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate. Slide brush end frame off end of starter. NOTE: The electrical input post must stay with the field coil housing. 4.
ELECTRICAL Brush Length Limit 5/16″ (8mm) Brush Replacement 1. Remove terminal nut with lock washer, flat washer, large phenolic washer, the small phenolic spacers, and sealing O-ring. Inspect O-ring and replace if damaged. 2. Inspect surface of commutator. 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. 4.
ELECTRICAL 6. Place armature in a growler. Turn growler on and position a hacksaw blade or feeler gauge lengthwise 1/8″ (.3 cm) above armature coil laminates. Rotate armature 360°. If hacksaw blade is drawn to armature on any pole, the armature is shorted and must be replaced. Roller Bearing Seal CAUTION: Use care when handling starter housing. Do not drop or strike the housing as magnet damage is possible. If magnets are damaged, starter must be replaced. STARTER REASSEMBLY/INSTALLATION 1.
ELECTRICAL 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.lbs. (12 Nm) 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.
ELECTRICAL STARTER ASSEMBLY 11 16 6 2 7* 1* 8 3 1* 15 9 5* 10 12 17 4 Ref. 1. 2. 3. 4. 5. 6. 7. 8. 9. Description Rubber Ring* Brush Spring Thrust Washer Gear Assembly O-Ring* Brush Complete O-Ring* Thrust Washer Shaft Complete *Do not reuse. Replace with new parts. 10.42 13 18 14 15 Description Ref. 10. 11. 12. 13. 14. 15. 16. 17. 18.
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 tester’s black lead on the battery negative and the red lead on the battery positive. Reading should be 12.4 V D. C. or greater. No Remove battery and properly service.
ELECTRICAL NOTES 10.
ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN 700/800 EFI Stator 10.
ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN 700/800 EFI 10.
A Brake Master Cylinder Exploded View, Rear, 9.5, 9.22 A-Arm Replacement, 5.16 Brake Noise, 9.5 Air Filter Service, 2.20 Brake Pad Assembly, Front, 9.12 Alternator Output Test, 10.19 Brake Pad Inspection, 2.28 ATV Specifications, 1.3, 1.4, 1.5 Brake Pad Installation, Rear, 9.18 Auxiliary Brake Removal, 9.22 Brake Pad Removal, Front, 9.10 Brake Pad Removal, Rear, 9.17 B Brake System Inspection, 2.28 Brake System Main Components, 9.3 Back Lash Pad Adjustment, 7.15 Brake System Operation, 9.
Current Draw, 10.18 EBS Moveable Sheave Bushing Inspection, 6.14 CV Joint Handling Tips, 7.22 EBS One Way Drive Clutch Inspection, 6.13 CV Shaft Boot, Inspection, 2.30 EFI Component Locations, 4.5 Cylinder Head Assembly, 3.27 EFI Diagnostic Mode, 10.6 Cylinder Head Disassembly, 3.22, 3.23 EFI System Exploded View, 4.4 Cylinder Head Inspection, 3.22 EFI System Overview, 4.7 Cylinder Head Reconditioning, 3.25 Electronic Control Unit, 4.8 Cylinder Head Removal, 3.21, 3.
Front Axle Removal, 7.2 Gearcase Lubrication, Front, 2.11 Front Cab Removal / Installation, 5.8 Gearcase Lubrication, Rear, 2.12 Front Cover Removal / Install, 5.4 Gearcase Removal, Front, 7.9 Front Drive Axle Exploded View, 7.8 Glossary of Terms, 1.14 Front Gearcase Assembly/Inspection, 7.13 Front Gearcase Diagnosis -- Centralized Hilliard, 7.16 H Front Gearcase Disassembly, 7.10 Headlamp Service, 10.30, 10.31, 10.32 Front Gearcase Exploded View -- Centralized Hilliard, 7.
O Odometer, Tachometer,Trip Meter, 10.3 Oil / Water Pump Disassembly, 3.44 Oil Check , Engine, 2.23 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 Oil Filter Change, 2.24 Rear Rack Removal / Installation, 5.7 Oil Flow, 3.20 Rear Storage Compartment Removal, 5.9 Oil Pressure Test, 3.19 Rear Suspension Exploded View, 5.17 Oil Rotor Clearance, 3.44 Rocker Arm Inspection, 3.
Starter Drive, 10.41 Trigger Coil Gap, 10.2 Starter Drive Removal/Inspection, 3.36 Troubleshooting, Brakes, 9.23 Starter Motor Armature Testing, 10.39 Troubleshooting, Cooling System, 3.60 Starter Motor Brush Inspection/Replacement, 10.38 Troubleshooting, Engine, 3.59, 3.60 Starter Motor Cleaning, 10.39 Troubleshooting, Ignition System, 10.18 Starter Solenoid Bench Test, 10.41 Troubleshooting, Spark Plug, 3.59 Starter System Test, 10.43 Troubleshooting, Starter System, 10.
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Cvr_9919820 10/14/04 10:19 AM Page 1 2005 SPORTSMAN 700/800 EFI SERVICE MANUAL PN 9919820 PART # 9919820 Printed in USA 2005 SPORTSMAN 700 EFI 2005 SPORTSMAN 800 EFI SERVICE MANUAL PN 9919820