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2007 SPORTSMAN 450 / 500 EFI / 500 X2 EFI

SERVICE MANUAL

FOREWORD

This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly

equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from

the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop

procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with

service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper

tools as specified.

Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100

Hwy 55 Medina Minnesota 55340.

2007 Sportsman 450 / 500 EFI / 500 X2 EFI Service Manual PN 9920560

improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this

publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting

or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

Summary of content (406 pages)

PAGE 1
2007 SPORTSMAN 450 / 500 EFI / 500 X2 EFI SERVICE MANUAL FOREWORD This service 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.
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UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
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GENERAL 1 MAINTENENCE 2 ENGINE 3 FUEL SYSTEM 4 BODY / SUSPENSION 5 CLUTCH 6 TRANSMISSION 7 FINAL DRIVE 8 BRAKES 9 ELECTRICAL 10 INTERNATIONAL 11
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NOTES
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GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION 1 MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.
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GENERAL INFORMATION MODEL NUMBER INFORMATION Model Number The machine model number must be used with any correspondence regarding warranty or service. A 07 MN 50 AU Engine Designation Numbers EH50PLE - Single Cylinder, Liquid Cooled,4 Stroke, Electric Start Vehicle Identification Number (VIN) World Mfg.
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GENERAL INFORMATION Publications 1 Table 1-1: Publications Year Model Model No.
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GENERAL INFORMATION Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison For Model Year 2007, a Sportsman ‘Deluxe’ and ‘Standard’ model were offered.
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GENERAL INFORMATION Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison 1 For Model Year 2007, an X2 ‘Deluxe’ and ‘Standard’ model were offered. Use the following table as a guide: X2 ‘DELUXE’ MODEL Item Location X2 ‘STANDARD’ MODEL Winch 1 No Winch Rear Work Lights 2 No Work Lights Front Drive w/ Active Descent Control (ADC) 3 No Active Descent Control (ADC) Cast Aluminum Wheels 4 Steel Wheels 2 1 3 Standard Model Pictured 4 1.
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GENERAL INFORMATION 2007 SPORTSMAN 450 Model Number: A07MH46AA, AZ Engine Model: EH46PLE Table 1-4: Sportsman 450 General Specifications Category Length Width Height Wheel Base Ground Clearance Dry Weight Gross Vehicle Weight Front Rack Capacity Rear Rack Capacity Towing Capacity Body Style Hitch Tongue Capacity 1.6 Dimension / Capacity 83 in./211 cm 48 in./122 cm 48 in./122 cm 50.5 in./128.3 cm 11 in./27.94 cm 715 lbs./324 kg 1210 lbs./549 kg 90 lbs./40.8 kg 180 lbs./81.6 kg 1225 lbs./555.
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GENERAL INFORMATION Table 1-5: Sportsman 450 Table 1-6: Sportsman 450 Platform Fuji Single Cylinder Engine Model Number Engine Displacement EH46PLE010 455cc Number of Cylinders 1 Bore & Stroke (mm) 87.9 x 75 mm Compression Ratio Compression Pressure Engine Idle Speed Transmission Type 1100 ± 50 RPM 32 oz. / 948 ml Front Gearcase Capacity Gear Ratio : 9.8:1 50-90 psi W/Compression Release Drumshift - H/L/N/R/P Transmission Capacity 8.97 oz. / 265 ml 23.91:1 16.30:1 10.49:1 3.
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GENERAL INFORMATION 2007 SPORTSMAN 500 EFI Model Number: A07MH50AX, AY, AZ, AQ / A07MN50AL, AF / A07MH50FC (Standard Models) Engine Model: EH50PLE Table 1-9: Sportsman 500 EFI General Specifications Category Length Width Height Wheel Base Ground Clearance Dry Weight Gross Vehicle Weight Front Rack Capacity Rear Box Capacity Towing Capacity Body Style Hitch Tongue Capacity 1.8 Dimension / Capacity 83 in./211 cm 48 in./122 cm 48 in./122 cm 50.5 in./128.3 cm 11.25 in./28.6 cm 715 lbs./324 kg 1200 lbs.
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GENERAL INFORMATION Table 1-10: Sportsman 500 EFI Table 1-11: Sportsman 500 EFI Platform Fuji Single Cylinder Engine Model Number Engine Displacement EH50PLE210 499cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio Compression Pressure Engine Idle Speed 1100 ± 200 RPM 6000 Rpm ± 200 Rpm Liquid - 2.5 qt / 2.4 ltr Lubrication HOT on Instrument Cluster Pressurized Dry Sump Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.
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GENERAL INFORMATION 2007 SPORTSMAN X-2 500 EFI Model Number: A07TH50AU, AZ, AQ / A07TN50AF / A07TH50EA (Standard Models) Engine Model: (Deluxe Model) EH50PLE Table 1-13: Sportsman X-2 500 EFI General Specifications Category Length Width Height Wheel Base Ground Clearance Dry Weight Gross Vehicle Weight Front Rack Capacity Rear Box Capacity Towing Capacity Body Style Hitch Tongue Capacity Dimension / Capacity 93 in./236 cm 48 in./122 cm 48 in./122 cm 57 in./145 cm 11 in./28 cm 798 lbs./362 kg 1500 lbs.
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GENERAL INFORMATION Table 1-14: Sportsman X2 500 EFI Table 1-15: Sportsman X2 500 EFI Drivetrain ENGINE Platform Fuji Single Cylinder Engine Model Number Engine Displacement EH50PLE210 499cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio Compression Pressure Engine Idle Speed Transmission Type 32 oz. / 948 ml Front Gearcase Capacity- CH 8.97 / 265 ml Front Gearcase Capacity- ADC 9.3 / 275 ml Gear Ratio : 10.
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GENERAL INFORMATION MISC. NUMBERS/CHARTS 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. 1.
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GENERAL INFORMATION Decimal Equivalents SAE Tap Drill Sizes Thread Size/ Drill Size #0-80 3/64 #1-64 53 #1-72 53 #2-56 51 #2-64 50 #3-48 5/64 #3-56 45 #4-40 43 #4-48 42 #5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.
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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.
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GENERAL INFORMATION Glossary Of Terms ABDC: After bottom dead center. ACV: Alternating current voltage. ADC: Active Descent Control. 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).
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GENERAL INFORMATION NOTES 1.
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MAINTENANCE CHAPTER 2 MAINTENANCE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.
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MAINTENANCE AUXILIARY BRAKE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 AUXILIARY BRAKE ADJUSTMENT (HYDRAULIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 SUSPENSION SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 FRONT SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . .
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MAINTENANCE MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical.
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MAINTENANCE Periodic Maintenance Chart Item Steering Front-suspension Rear-suspension Maintenance Interval (whichever comes first) Hours Calendar Miles (KM) Pre-Ride Pre-Ride - Remarks - Pre-Ride - - Pre-Ride Pre-Ride - - Pre-Ride - - Pre-Ride Pre-Ride Pre-Ride - - Pre-Ride - - Pre-Ride Pre-Ride - Verify Seat is secured Verify Box is latched Air filter, pre-filter - Daily - Inspect; clean often Air box sediment tube - Daily - Drain deposits when visible Coolant -
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MAINTENANCE Periodic Maintenance Chart Item Hours Engine breather filter (if equipped) Engine oil change (break-in) General lubrication Shift Linkage E E E E E E E Remarks 25 H Monthly 155 (250) 25 H 1M 155 (250) 50 H 3M 310 (500) 50 H 6M 310 (500) Perform a break-in oil change at one month Lubricate all grease fittings, pivots, cables, etc.
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MAINTENANCE Periodic Maintenance Chart Item E E Fuel system Fuel Filter Radiator (if applicable) Cooling hoses (if applicable) Engine mounts Exhaust muffler / pipe E E Spark plug Ignition Timing Wiring Clutches (drive and driven) Front wheel bearings Brake fluid Spark arrestor Toe adjustment Auxiliary brake Headlight aim Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) 620 100 H 12M (1000) 620 100 H 12M (1000) 620 100 H 12M (1000) 620 100 H 12M (1
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MAINTENANCE LUBRICATION / FLUIDS SPORTSMAN Component Locations (Deluxe) 2 (Sportsman Only) 2.
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MAINTENANCE SPORTSMAN X2 Component locations Brake Fluid Reservoir Worklight Instrument Cluster AWD/Turf Switch (Speedometer) Brake Lever Diagnostic Port (under access panel) Light Control & Run Switch Throttle Reverse Override Ignition/Key Front Storage Compartment & Rack Front Demand Drive Unit Rear Dump Box / Passenger Area (Behind Radiator) Battery (Under Tank) Oil Dipstick PVT Cover Gear Shifter Gas Cap Muffler Transmission Rear Drive CV Shafts Right Side View Front Prop Shaft (Between
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MAINTENANCE Polaris Lubricants, Maintenance and Service Products Table 2-1: PART NUMBER DESCRIPTION Engine Lubricant 2870791 Fogging Oil (12 oz.
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MAINTENANCE Polaris Lubricant Symbol Identification Pre-ride / Daily Inspection NOTE: The symbols used are for quick reference in identifying which lubricant/grease to use on each component. Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
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MAINTENANCE Lubrication Components 1. Engine Oil 2. Transmission Fluid 4. Rear Gearcase 2 6. Front A-Arm 3. Front Gearcase 5. Brake Fluid 8. Front Propshaft 7. Rear A-Arm # ITEM 1. Engine Oil 2. Transmission 3A. Front Gearcase 3B. ADC Fluid LUBE METHOD FREQUENCY* Polaris 0W/40 Check dipstick and add to proper level. Change after 1st month, 6 months, or 100 hours thereafter; Change more often (25-50 hours) in extremely dirty conditions, or short trip cold weather operation.
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MAINTENANCE Front Gearcase Lubrication To Change Gearcase Lubricant: The front gearcase lubricant level should be checked and changed in accordance with the maintenance schedule. • Be sure vehicle is level before proceeding and in PARK • Check vent hose to be sure it is routed properly and unobstructed • The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid. FRONT GEARCASE Drain Plug 1. Fill Plug 8-10 ft.lbs. (11-14 Nm) 2.
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MAINTENANCE Transmission Lubrication To change lubricant: 1. 2. = Transmission - Specified Lubricant: Polaris AGL Gearcase Lubricant (Gallon - PN 2873603) (12 oz. - PN 2873602) Place a drain pan beneath the transmission oil drain plug area. Clean around the drain plug and remove the drain plug and wipe the magnetic end clean to remove all accumulated metallic filings. Transmission - Capacity: 32 oz. (948 ml) =T Transmission Drain / Fill Plug Torque: 20-25 ft.lbs.
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MAINTENANCE ADC Differential Hydraulic Circuit Fluid Change 1. Make sure vehicle is parked on flat ground and allowed to sit at least 30 minutes prior to bleeding hydraulic circuit. 2. Thoroughly clean area around and on remote reservoir and bleeder valves. 3. Remove reservoir cap and diaphragm assembly. 4. Make sure hydraulic oil inside reservoir is free of debris. If any debris is found, use clean rag or suction device to remove from the reservoir.
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MAINTENANCE Throttle Inspection Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding. 1. 2. 3. 4. 5. Place the gear selector in Park. Set parking brake. Start the engine and let it idle. Turn handlebars from full right to full left. If idle speed increases at any point in the turning range, inspect throttle cable routing and condition.
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MAINTENANCE Fuel System Fuel Lines EFI Example WARNING * Gasoline is extremely flammable and explosive under certain conditions. * EFI components are under high pressure. Verify system pressure has been relieved before disassembly. * Never drain the fuel system when the engine is hot. Severe burns may result * Do not overfill the tank. The tank is at full capacity when the fuel reaches the bottom of the filler neck. Leave room for expansion of fuel.
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MAINTENANCE Fuel Filter Compression Test The fuel filter should be replaced in accordance with the Periodic Maintenance Chart. NOTE: 450/500 4-Stroke engines are equipped with an automatic decompressor. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about 60-90 psi during a compression test. EFI Example Smooth idle generally indicates good compression.
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MAINTENANCE Spark Plug 1. 2. 3. 4. 5. Remove spark plug high tension lead. Clean plug area so no dirt and debris can fall into engine when plug is removed. Remove spark plug. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used. Measure gap with a wire gauge.
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MAINTENANCE New Batteries: Batteries must be fully charged before use or battery life can be reduced by 10-30% of full potential. Charge battery for 3-5 hours at a current equivalent of 1/10 of the battery’s rated amp/ hour capacity (i.e. 12amp hr x .10 = 1.2 amp charging). Do not use the alternator to charge a new battery. Cooling System Hoses 2 Liquid Cooling System Overview The engine coolant level is controlled or maintained by the recovery system.
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MAINTENANCE Cooling System Pressure Test NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. Refer to Chapter 3 for pressure test procedure. Coolant Level Inspection The recovery bottle, located on the left side of the machine, must be maintained between the minimum and maximum levels indicated on the recovery bottle. Remove Cover Recovery Bottle Radiator Cap To access the radiator pressure cap: 1. 2. Open the front cargo storage.
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MAINTENANCE 4. Loosen clamp and remove air filter assembly. Proper Filter Placement Main Filter Cover 2 Filter Support Pre-Filter Gasket Air Box Main Element Front Carb Boot Cleaning: 5. 6. 7. 8. 9. Slip the pre-filter element off of main element. Clean the pre filter with high flash point solvent, followed by hot soapy water. Rinse and dry thoroughly. Inspect element for tears or damage. Apply foam filter oil or clean engine oil and squeeze until excess oil is removed.
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MAINTENANCE Breather Filter Inspection Recoil Housing Four-cycle ATV engines are equipped with a breather filter. The in-line filter is similar in appearance to a fuel filter, and is visible on the left side (Location A). In-line breather filters can be installed in either direction. B Typical Breather Filter Location Recoil Drain • Drain the housing periodically to remove moisture.
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MAINTENANCE Engine Oil Level Oil and Filter Change Oil Filter Torque: Turn by hand until filter gasket contacts sealing surface, then turn an additional 1/2 turn 2 Oil Filter Wrench: (PV-43527) Oil Tank Screen Fitting Torque: 25 ft-lb (34Nm) A Recommended Engine Oil: Polaris Premium 4 All Season Synthetic, 0W-40 The oil tank is located on the left side of the vehicle. To check the oil level: 1. 2. 3. 4. 5. Set machine on a level surface. Clean the area around the dip stick.
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MAINTENANCE 5. Place a drain pan beneath oil tank and remove the drain plug (A). CAUTION: Oil may be hot. Do not allow hot oil to come into contact with skin as serious burns may result. 14. Install oil hose (E) on fitting (C) and re-install clamp (D). 15. Place shop towels beneath oil filter. Use Oil Filter Wrench (PV-43527), turn filter counterclockwise to remove. D B A E C Reference mark C 6. Allow oil to drain completely. 7. Replace sealing washer (B) on drain plug (A).
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MAINTENANCE 23. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick. 24. Dispose of used filter and oil properly. Valve Clearance Inspect and adjust valve clearance while the engine is cold and the piston positioned at Top Dead Center (TDC) on compression stroke. Oil Pump Priming Procedure 1. 2. NOTE: This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 3. 1.
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MAINTENANCE 7. Verify accurate TDC positioning by observing the “T” mark aligned with the pointer in the timing inspection hole. In this position there should be clearance on all valves. 1. Insert a .006" (.15mm) feeler gauge between end of exhaust valve stem and adjuster screw(s). 2. Loosen locknut(s) and turn adjuster screw(s) until there is a slight drag on feeler gauge(s). The Valve/Clutch Adjuster Tool (PA-44689) can be used to adjust the engines valves.
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MAINTENANCE Tie Rod End/Steering Inspection • To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement. Wheel Alignment 1. 2. • Repeat inspection for inner tie rod end on steering post. 3. 4. 5. 6. • Replace any worn steering components. Steering should move freely through entire range of travel without binding. • Elevate front end of machine so front wheels are off the ground.
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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. WARNING • 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.
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MAINTENANCE 3. If some carbon is expelled, cover the exhaust outlet and lightly tap on the pipe around the clean out plugs with a rubber mallet while revving the engine several more times. Brake System Inspection The following checks are recommended to keep the brake system in good operating condition. Service life of brake system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride.
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MAINTENANCE Brake Pad Inspection 2. Pads should be changed when the friction material is worn to .180” / 4.6 mm, or about the thickness of a dime. While turning the rear wheels by hand, apply the auxiliary foot brake. This brake should not stop the wheels from turning until the lever is half way between its rest position and bottoming on the footrest. Auxiliary Foot Brake Pedal Full Engagement Full Height Floor Board Surface .180” / 4.
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MAINTENANCE Suspension Spring Preload Adjustment Controls Center Spring Adjustment Ring 2 1 2 Check controls for proper operation, positioning and adjustment. Shock Spanner Wrench (PN 2871095) Operator weight and vehicle loading affect suspension spring preload requirements. Adjust as necessary, using the spanner wrench (2) to turn the adjustment cam (1). Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body.
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MAINTENANCE Wheel, Hub, And Spindle Torque Table Wheel Installation 1. Item Specification Steel - Front Wheel Nuts 27 Ft. Lbs. (37 Nm) Steel - Rear Wheel Nuts 27 Ft. Lbs. (37Nm) Aluminum Front Wheel Nuts 90 Ft. Lbs. (122 Nm) Aluminum Rear Wheel Nuts 90 Ft. Lbs. (122 Nm) Front Hub Retaining Nut 70 ft.lbs. (90 Nm) Rear Hub Retaining Nut 80 Ft. Lbs. (108 Nm) 2. 3. 4. With the transmission in Park and the parking brake locked, place the wheel in the correct position on the wheel hub.
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MAINTENANCE Tire Inspection • Improper tire maneuverability. Storage Compartments inflation may affect ATV • When replacing a tire always use original equipment size and type. The 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 just past the vertical position. Use the arrow located on top of the latch as a reference.
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MAINTENANCE Winch Operation (If Equipped) This information is for Sportsman models equipped with a 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. Winch Control The winch control located on the side of the winch gives the operator easy access to switch between ENGAGED and FREESPOOL.
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MAINTENANCE Yellow (6 Ga.) wires to the winch. Refer to the installation instructions for more details. The Orange/White wires are located under the front cover (under headlight pod). The Orange/White wires supply the control power to the winch. Winch Connector 2 Splash Guard for Contactor mount Winch Connecting Harness Right Side Front Fender Locate the Red wire (6 Ga.) with the yellow crimp cover is located in the rear fender area. The red wire connects to the battery. Winch Connecting Wire 2.
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MAINTENANCE ATV Cleaning & Storage Clean the Exterior Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime. Don’t use harsh detergents or high pressure washers. Some detergents deteriorate rubber parts. Use dish soap type cleaners only.
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MAINTENANCE 5. 6. Turn the engine over several times with the recoil only to ensure coverage of piston rings, cylinder walls and crankshaft bearings. If Polaris fuel system additive is not used, fuel tank, and fuel lines should be completely drained of gasoline. securely using suitable straps or rope. 2 Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant.
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MAINTENANCE Maintenance Schedule Service Date 2.
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ENGINE CHAPTER 3 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 ENGINE FASTENER TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.
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ENGINE OIL PUMP REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33 OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34 COUNTER BALANCER SHAFT REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . 3.34 CRANKSHAFT REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35 CRANKCASE BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . .
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ENGINE SPECIFICATIONS Special Tools Torque Specifications PART NUMBER 2200634 TORQUE SPECIFICATIONS EH50PLE Ft. Lbs. (Nm) 6.5-11 (9-15 Nm) 2870390 2871043 5-6.5 (7-9 Nm) 5-6.5 (7-9 Nm) 5131135 2870569 6mm 5-6.
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ENGINE Engine Service Data Cylinder Head / Valve Rocker Arm EH50PLE Rocker arm ID Rocker shaft OD .8669-.8678" (22.020-22.041 mm) .8656-.8661" (21.987-22.0 mm) Rocker shaft Oil Clearance Std Camshaft Cam lobe height In Ex .0039" (.10 mm) Std 1.2884-1.2924” (32.726-32.826 mm) Limit 1.2766" (32.426 mm) Std 1.2884-1.2924” (32.726-32.826 mm) Limit 1.2766" (32.426 mm) Mag 1.4935-1.4941” (37.935-37.950 mm) PTO 1.4935-1.4941” (37.935-37.950 mm) Camshaft journal bore ID Mag 1.4963-1.4970” (38.
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ENGINE Engine Service Data Cylinder / Piston / Connecting Rod Cylinder Surface warpage limit (mating with cylinder .0020” (0.05 mm) head) Cylinder bore Std 3.6221-3.6228” (92.00-92.02 mm) Taper limit .0020” (0.05 mm) Out of round limit .0020” (0.05 mm) Piston clearance Std .0006-.0018" (0.015-0.045 mm) Limit .0024” (0.060 mm) Boring Limit Piston EH50PLE Outer diameter 3 .020” (.5 mm) Std 3.6204-3.6215” (91.970-91.985mm) .0098" (.25 mm) OS 3.6304-3.6310” (92.21-92.23 mm) .0197" (.
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ENGINE GENERAL ENGINE SERVICE Cooling System Specifications Sensor 18.5 + ft. lbs. (25 Nm) Piston Identification The piston may have an identification mark or the piston may not have an identification mark for piston placement. If the piston has an identification mark, follow the directions for piston placement below. If the piston does not have an identification mark, the direction for placement of the piston does not matter.
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ENGINE Cooling System System Pressure Test 1. 2. 3. WARNING Never remove radiator cap when engine is warm or hot. The cooling system is under pressure and serious burns may result. Allow the engine and cooling system to cool before servicing. Radiator Cap Pressure Test 1. FLOW 2. Radiator Thermostat Water Pump Cylinder Head Cylinder Remove radiator cap cover located in storage box. Remove recovery bottle hose from coolant filler.
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ENGINE RECOMMENDED COOLANT Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area.. CAUTION Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/ Coolant is recommended for use in all cooling systems, and comes pre-mixed, ready to use.
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ENGINE Engine Installation Notes After the engine is installed in the frame, review this checklist and perform all steps that apply. Cylinder Hone Selection/ Honing Procedure CAUTION General Items 1. 2. Install previously removed components using new gaskets, seals, and fasteners where applicable. Perform regular checks on fluid levels, controls, and all important areas on the vehicle as outlined in the daily preride inspection checklist (refer to Chapter 2 or the Owner’s Safety and Maintenance Manual).
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ENGINE A finished cylinder should have a cross-hatch pattern to ensure piston ring seating and to aid in the retention of the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer’s instructions, or these guidelines: • Use a motor speed of approximately 300-500 RPM, run the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered (or cylinder centered on arbor) and to bring the stones approximately 1/2” (1.
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ENGINE If the crank rod pin location is 180o from the dial indicator (opposite that shown above), it will be necessary to spread the crankshaft at position A as shown in the illustration at right. When rebuilding and straightening a crankshaft, runout must be as close to zero as possible. NOTE: Maximum allowable runout is .0024”. 3. Engine LubricationEH 50PL Oil Type:Polaris Premium 4 Synthetic (PN 2871281); or API certified “SH” 0-40W oil Capacity:. . . . . . . . Approximately 2 U.S. Quarts (1.
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ENGINE EH50PL Oil Flow Diagram Vent Hose Internal passage to camshaft (front left head bolt) Oil Filter Oil feed to filter From filter to crankshaft One way valve Bottom fitting is oil exhaust or return Top fitting is oil to tank feed or intake from bottom of tank Oil Tank EH50PL Oil Flow Chart Top of Oil Tank Oil Tank Union Fitting (Lower) Oil Pump (Scavenging) Crankcase Oil Gallery Oil Hose Screen Fitting (Bottom of Tank) Union Fitting (Upper) Crankcase Oil Hose Crankcase Oil Gallery Oil Pump
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ENGINE EH50PL Engine Exploded Views Crankcase Cylinder/ Cylinder Head 3 Crankshaft and Piston Valvetrain 3.
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ENGINE ENGINE DISASSEMBLY NOTE: The cam lobe should be pointing down and valves should have clearance at this point. Cam Chain Tensioner/ROCKER ARM/ CAMSHAFT Removal 1. Remove ignition timing inspection plug from recoil housing. TDC “T” Mark Rotation Advance Marks 5. Remove cam chain tensioner plug, sealing washer, and spring. CAUTION To position crankshaft at Top Dead Center (TDC) on compression stroke: 2. 3.
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ENGINE 2. 3. Push ratchet pawl and hold it. The plunger should move smoothly in and out of the tensioner body. Release ratchet pawl and push inward on plunger. It should remain locked in position and not move inward. 2. Inspect each rocker arm cam follower surface. If there is any damage or uneven wear, replace the rocker arm. NOTE: Always inspect camshaft lobe if rocker arms are worn or damaged. 3 3. Tensioner Spring Free Length: 2.02” (5.13 cm) Limit 1.92 (4.88cm) 4. 5. Measure O.D. of rocker shaft.
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ENGINE 4. Measure I.D. of each rocker arm and compare to specifications. 3. Loosen three camshaft sprocket bolts. 4. Remove camshaft end cap and O-Ring. 5. Inspect camshaft end cap (thrust face) for wear. Replace if worn or damaged. Place a clean shop towel in the area below cam chain sprocket and remove sprocket retaining bolts. Rocker Shaft Oil Clearance: Std: .0008 - .0021 (.020-.054 mm) Limit: .0039” (.10 mm) 5. 6. 7. Measure I.D. of both rocker arm shaft supports and visually inspect surface.
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ENGINE 8. Secure cam chain with a wire to prevent it from falling into the crankcase. Sprocket Teeth Automatic Compression Release Removal/ Inspection NOTE: The automatic compression release mechanism can be inspected and serviced without removing the camshaft from the cylinder head. The actuator ball (C) in the camshaft is not replaceable. Replace the camshaft as an assembly if the actuator ball is worn or damaged. C 3 A Inspect for Areas of Tooth Wear or Damage 9.
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ENGINE Automatic Compression Release Installation Camshaft Inspection 1. 2. 1. Slide spring onto shaft. Apply engine oil to release lever shaft. The actuator ball must be held outward to allow installation of the release lever shaft. 2. Visually inspect each cam lobe for wear, chafing or damage. Thoroughly clean the cam shaft, making sure the oil feed holes are not obstructed. Stop Pin Spring in relaxed position Lubrication holes Lobe Height Cam Lobe Height (Intake & Exhaust) Std: 1.
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ENGINE 3. Measure height of each cam lobe using a micrometer. Compare to specifications. Journal O.D Cylinder Head Removal 1. 2. Remove the two 6mm flange bolts (A) from cylinder head. See next exploded view on next page. Loosen each of the four cylinder head bolts (B) evenly 1/8 turn each time in a criss-cross pattern until loose. B 3 Journal Camshaft Journal O.D.: Mag & PTO End: 1.4935-1.4941” (37.935- 37.950 mm) 4. 5. Measure camshaft journal outside diameter (O.D.
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ENGINE Cylinder Head Exploded View, EH50PL EH50PL A 3.
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ENGINE Cylinder Head Inspection Cylinder Head Disassembly WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly. NOTE: Keep all parts in order with respect to their location in the cylinder head. 3 A (A) 1. Thoroughly clean cylinder head (A) surface to remove all traces of gasket material and carbon. CAUTION Use care not to damage sealing surface. Cylinder Head Warp 1. Using a valve spring compressor (A), compress the valve springs and remove the split keeper.
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ENGINE 4. seat area (B). NOTE: The valves cannot be re-faced or end ground. Valves must be replaced if worn, bent, or damaged. Measure free length of spring with a Vernier caliper. Check spring for squareness. Compare to specifications. Replace spring if either measurement is out of specification Measure valve stem in several places Valve Stem Diameter: Intake: .2343-.2348” (5.950-5.965 mm) Exhaust: .2341-.2346” (5.945-5.960 mm) 5. 5.
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ENGINE Combustion Chamber 3. Heat cylinder head in an oven or use a hot plate to bring cylinder head temperature to 212o F (100o C). CAUTION Do not use a torch to heat cylinder head or warpage may result from uneven heating. Head temperature can be checked with a pyrometer or a welding temperature stick. Wear the appropriate safety equipment for working with heated metal. Follow the manufacturers instructions provided with the valve seat cutters in the Valve Seat Reconditioning Kit (PN 2200634).
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ENGINE 3. Place cylinder head on cylinder head table. NOTE: Be sure cylinder head is still at 212o F (100o C) before installing new guides. 8. Apply cutting oil to valve seat and cutter. Valve Guide Installed Height Valve Guide Height: .689-.709” (17.5-18.0 mm) 4. Place a new guide in the valve guide installation tool and press guide in to proper depth. Check height of each guide above the cylinder head (A). NOTE: The guide can also be driven in to the proper depth.
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ENGINE 13. Remove valve and check where the Prussian Blue™ indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width. • If the indicated seat contact is at the top edge of the valve face and contacts the margin area(B) it is too high on the valve face. Use the 30o cutter to lower the valve seat. • If too low use the 60o or 75o cutter to raise the seat.
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ENGINE Cylinder Head Assembly CAUTION Valve Sealing Test 1. 2. Wear eye protection during assembly. 3. NOTE: Assemble the valves one at a time to maintain proper order. Clean and dry the combustion chamber area. Pour a small amount of clean, high flash point solvent into the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage. Repeat for exhaust valves by pouring fluid into exhaust port. Valve Clearance Adjustment 1. 2. 3. 4. 5.
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ENGINE Cylinder/Piston Removal and Inspection 4. Remove the two 6 mm cylinder base bolts. NOTE: Follow engine disassembly procedures to remove valve cover, camshaft and rocker arms, and cylinder head. 3 5. 1. Remove cam chain guide at front of cylinder. 2. Loosen all four oil pipe banjo bolts and then remove the bolts and eight sealing washers. Remove the pipes. NOTE: The bolts are inside the water jacket. 6. 7. 8. 3.
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ENGINE Piston Removal *By hand: Placing both thumbs as shown, spread the ring open and push up on the opposite side. Do not scratch the ring lands. A 1. 1. 2. Remove circlip. Note piston directional arrow pointing toward the right (Mag) side of engine. Remove piston circlip and push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch. Remove top compression ring. 3. Repeat procedure for second ring.
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ENGINE 3. Inspect cylinder for wear, scratches, or damage. 2. 1/2” Down From Top of Cylinder X Subtract this measurement from the maximum cylinder measurement obtained in Step 5 above. Piston to Cylinder Clearance Y Std: .0006- .0018” (.015- .045 mm) Piston O.D.: X X Y Std: 3.6204- 3.6215” (91.970-91.985 mm) 3 Piston/Rod Inspection Y 1/2” Up From Bottom 4. 5. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge.
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ENGINE Piston Ring Installed Gap 1. Place each piston ring inside cylinder using piston to push ring squarely into place as shown at right. Feeler Gauge 25-50 mm Cylinder 2. 3. Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance. Measure connecting rod small end ID. Piston Piston Ring Piston Ring Installed Gap Ring Top Ring Std: .0079- .0138” (.20- .36 mm) Limit: .039” (1.0 mm) Second Ring Std: .0079- .0138” (.20- .36 mm) Limit: .039” (1.0 mm) Oil Ring Std: .0079- .0276” (.
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ENGINE Starter Drive Removal/Inspection 1. 5. Remove recoil housing bolts and remove housing. 6. Measure the ID of the bushing in the recoil housing (A) and in the crankcase and record. Measure in two directions 90o apart to determine if bushing is out of round. Calculate bushing clearance. Replace bushing if clearance exceeds the service limit. Inspect gear teeth on starter drive. Replace starter drive if gear teeth are cracked, worn, or broken. Flywheel/Stator Removal/Inspection 1. 2.
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ENGINE 7. Remove large sealing O-Ring from outer edge of stator plate. section of chain. Replace if worn past service limit. Chain Service Limit: 5.407” (13.7 cm) 4. Using the special socket, remove the crankshaft slotted nut. NOTE: The crankshaft slotted nut is a left-hand thread. 5. 6. 7. 8. Remove cam chain drive sprocket and woodruff key from crankshaft. Inspect sprocket teeth for wear or damage. Inspect woodruff key for wear. Replace any worn or damaged parts.
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ENGINE Crankcase Separation 3. Inspect drive gear teeth for cracks, damage or excessive wear. 3 1. 2. 3. Remove flange bolts (10) from magneto side crankcase evenly in a criss-cross pattern. Separate crankcase by tapping with a soft faced hammer in reinforced areas. Tap lightly on balancer gear with a brass drift through the hole in the crankcase if necessary, to ensure the balancer shaft stays in the PTO side crankcase. Watch the gap along the crankcase mating surface and separate the crankcase evenly.
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ENGINE 9. Measure pump end clearance using a feeler gauge and straight edge. Oil Pump Assembly 1. 2. 3. 4. 5. 6. 7. 8. Clean and dry all parts thoroughly. Apply clean engine oil to all parts. Do not use gasket sealer on the pump body mating surfaces or oil passages will become plugged. Install pump shaft and scavenge rotor drive pin. Install outer scavenge rotor, inner scavenge rotor, and scavenge casing. Install outer feed rotor and inner feed rotor drive pin.
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ENGINE 3. Turn the shaft until balancer counter weights clear the crankshaft and remove the balancer shaft from the crankcase. 8. Support the PTO side crankcase and crankshaft; press the crankshaft out. Be careful not to damage the crankcase mating surface or connecting rod. 3 4. 5. 6. Inspect the balancer drive gear and pump shaft drive gear. Replace the shaft if gear teeth are abnormally worn or damaged. Inspect the balancer shaft bearings.
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ENGINE Crankcase Bearing Inspection Pump Shaft Oil Seal/Water Pump Mechanical Seal Removal (Engine Disassembled) NOTE: The water pump mechanical seal can be removed without removing the engine. Refer to Water Pump Mechanical Seal Installation. Replace the pump shaft seal and water pump mechanical seal whenever the crankcase is disassembled. 1. 2. Remove the seal from the PTO side crankcase. Inspect the crankshaft main bearings, balancer shaft bearings, and pump shaft bearing.
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ENGINE Bearing Installation 4. NOTE: To ease bearing installation, warm the crankcase until hot to the touch. Place the bearings in a freezer. 1. 2. Measure the distance from the PTO crankcase mating surface to the main bearing using a dial caliper and a straight edge. Install the bearings so the numbers are visible. Drive or press new bearings into the crankcases, using the proper driver. CAUTION 3 Press only on outer race of bearing to prevent bearing damage • 70 mm (2.
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ENGINE 6. Measure the distance from the Magneto crankcase mating surface to the main bearing using the same method and record. 10. Subtract the Crankshaft Width measured in Step 7 from the Total Case Width recorded in Step 6, and record below. Total End Play_____________ 11. Subtract the thickness of the existing shim from the result of Step 8 to determine if a different shim is required. The result must be within the specified range listed. Crankshaft End Play: .008-.016” (.02-.
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ENGINE 14. Measure the distance from the Mag crankcase mating surface to the balance shaft bearing using a dial caliper and a straight edge. Subtract the thickness of the straightedge and record. 15. Measure the distance from the PTO crankcase mating surface to the bearing using the same method outlined in Step 1, 2, and-3. 16. Add the readings obtained in Step 3 and Step 4. 17. Subtract the counter balancer shaft width measured in Step 2 from the figure obtained in Step 5. 18.
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ENGINE ENGINE REASSEMBLY Pump Shaft Oil Seal Installation Crankshaft/Counter Balance/Oil Pump Installation Lubricate all bearings with clean engine oil before assembly. Use the Crankshaft/Water Pump Installation Kit (PN 2871283) to prevent damage to the crankshaft and main bearings during installation. 1. 2. 3. 1. 2. 3. Install the seal from the outside of the crankcase (water pump side) with the spring facing inward, toward the pump shaft bearing. Drive or press the seal into place using a 25 mm (.
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ENGINE Crankcase Assembly 1. 2. 3. 4. Apply Crankcase Sealant (PN 2871557) to the crankcase mating surfaces. Be sure the alignment pins are in place. Set the crankcase in position carefully to avoid damaging the pump shaft seal, and install the magneto end crankshaft installation tool (follow instructions provided with the Crankshaft/Water Pump Installation Kit (PN 2871283).
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ENGINE 2. Slide the main puller body over the outer portion of the mechanical seal as shown in Ill. 2 and turn T-Handle clockwise until it contacts water pump shaft. Continue rotating until outer portion of mechanical seal is separated from the metal seal body. 5. Tighten the hex socket screws on the puller legs sufficiently so the lip of the puller legs will grasp the mechanical seal. Ill. 5. T-Handle T-Handle Main Puller Body III. 5 Main Puller Body III. 2 3.
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ENGINE Cam Chain Drive Sprocket Installation 1. Install the Woodruff key, drive sprocket, and slotted nut. Tighten the nut to the specified torque. B NOTE: The top rail has a locating tab to prevent rotation. The tab must be positioned in the notch on the side of the piston as shown (A). A 3 Tighten 3. Slotted Nut Torque: 35-51 ft. lbs. (47-69 Nm) Tensioner Blade Installation 1. 4. 5. Install the tensioner blade and tighten the mounting bolt to specified torque. 6.
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ENGINE Piston Installation Cylinder Installation 1. 7. 2. Clean the gasket surfaces on the cylinder and crankcase. Remove all traces of old gasket material. Make sure the cylinder mounting bolt holes are clean and free of debris. 8. Tang Outward 3. Install a new circlip on one side of the piston with the end gap facing up or down, and tang outward. 9. Place the dowel pins in the crankcase and install a new cylinder base gasket.
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ENGINE 10. Apply clean engine oil liberally to the cylinder bore and tapered area of the sleeve. Install the cylinder with a slight rocking motion until the rings are captive in the sleeve. The following procedure must be used to torque the cylinder head properly: Torque all bolts evenly in a criss- cross pattern *Torque bolts to 22 ft. lbs. (30 Nm) *Torque bolts to 51 ft. lbs. (70 Nm) *Loosen bolts evenly 180o (1/2 turn) *Loosen bolts again another 180o (1/2 turn) *Torque bolts to 11 ft. lbs.
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ENGINE IMPORTANT CAMSHAFT TIMING NOTE: In order to time the camshaft to the crankshaft, the piston must be precisely located at Top Dead Center (TDC). 4. Loop the cam chain on the cam sprocket with the dots on the sprocket facing outward and the alignment pin notch facing directly upward. Camshaft Timing A 1. 2. 3. Apply Polaris Premium Starter Drive Grease (PN 2871460) to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil.
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ENGINE 6. Install the sprocket on the camshaft. Apply Loctite™ 242 (PN 2871949) to the cam sprocket bolts and torque to specification. Cam Sprocket Bolt Torque: 6 ft. lbs. (8 Nm) Single (TDC) Mark Aligned 3 7. Verify TDC mark in timing inspection hole and alignment pin is directly in line with crankshaft to camshaft centerline. Refer to illustration. 8. Apply Crankcase Sealant (PN 2871557) to the camshaft end cap and install using a new O-Ring. 9.
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ENGINE CAMSHAFT TIMING Crankshaft to Camshaft Centreline Dots Sprocket Alignment Pin Single TDC Mark Aligned TDC Mark Rotation Do Not Use Advance Marks 3.
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ENGINE Cam Chain Tensioner Installation 1. 3. Apply 3 Bond 1215 (PN 2871557) or an equivalent sealer to the stator plate outer surface and install a new O-Ring. Release the ratchet pawl (A) and push the tensioner plunger (B) all the way into the tensioner body. 3 A B 4. 2. Install the tensioner body with a new gasket and tighten the bolts. Tensioner Bolt Torque: 6 ft. lbs. (8 Nm) 3. 5. Install the stator plate being careful not to damage the seal.
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ENGINE install the cover and bolts. gear. Apply Starter Drive Grease to Bushing Rocker Cover Bolt Torque: 6 ft. lbs. (8 Nm) Thermostat Installation 2. 3. Apply starter drive grease to the drive bushing in the crankcase and all moving surfaces of the starter drive mechanism. Install the starter drive. Install recoil housing gasket and recoil housing. Starter Drive Grease: (PN 2871460) Rocker Shaft/Rocker Arm Assembly Installation 1. 2. 3. 4. 5. 6.
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ENGINE RECOIL 5. Recoil Disassembly/Inspection Inspect plate for wear or damage. Inspect plate friction spring for wear, damage, and proper tension. The spring should fit tightly on friction plate. CAUTION The recoil is under spring tension. A face shield and eye protection is required during this procedure. Replace any parts found to be worn or damaged. 3 A 6. Remove ratchet pawl with spring and inspect. Replace spring or ratchet pawl if worn, broken, or damaged.
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ENGINE Recoil Assembly post of the housing and the bushing. CAUTION Be sure to wear a face shield and eye protection when performing this procedure. 5. To install a new spring: 1. 2. Place spring in housing with the end positioned so the spring spirals inward in a counterclockwise direction. See photo at right. Hold spring in place and cut retaining wire. To reinstall an old spring: 1. 2.
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ENGINE TROUBLESHOOTING Spark Plug Fouling Engine Does Not Turn Over • Dead battery • Starter motor does not turn • Spark plug cap loose or faulty • Choke cable adjustment or plunger/cable sticking • Foreign material on choke plunger seat or plunger • Incorrect spark plug heat range or gap • Carburetor inlet needle and seat worn • Jet needle and/or needle jet worn or improperly adjusted • Excessive carburetor vibration (loose or missing needle jet locating pins) • Engine seized, rusted, or mechanical fail
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ENGINE • Cylinder, piston, ring, or valve wear or damage (check compression) • Ignition system faulty: Spark plug cap cracked/broken Ignition coil faulty Ignition or kill switch circuit faulty Ignition timing incorrect Sheared flywheel key • PVT not operating properly • Poor connections in ignition system • Restricted exhaust muffler • System wiring wet Engine Has Low Power • Spark plug fouled • Carburetor damaged vacuum slide sticking/diaphragm • Dirty carburetor Piston Failure - Scoring • Lack
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FUEL SYSTEM CHAPTER 4 FUEL SYSTEM ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 - 4.30 CARBURETOR (SPORTSMAN 450) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31 - 4.47 4 4.
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FUEL SYSTEM 4.
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FUEL INJECTION CHAPTER 4 FUEL INJECTION SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 PART NUMBERS / DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 EFI SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 GENERAL SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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FUEL INJECTION FUEL SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 FUEL STARVATION / LEAN MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 EFI DIAGNOSTICS USING ‘BLINK CODES’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24 BLINK CODES - OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24 TROUBLESHOOTING DIAGRAMS . . . . . . . . . . . . . . .
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FUEL INJECTION SPECIAL TOOLS Fuel Pressure Tester - PU-43506 Part Numbers / Descriptions IMPORTANT: The EFI fuel system remains under high pressure, even when the engine is not running. Before attempting to service any part of the fuel system, the pressure must be relieved. The pressure adapter has an integrated relief valve. Connect to the test valve and release the pressure.
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FUEL INJECTION Digital Wrench™ SmartLink Module Kit - PU-47471 Available to Polaris dealers through our tool supplier, SPX (1-800-328-6657) This module kit contains the necessary cables and hardware to communicate between the vehicle ECM and the Digital Wrench diagnostic software. Polaris dealers can also order separately: SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470. For use on all 15pin connector-based Polaris EFI systems.
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FUEL INJECTION EFI SERVICE NOTES General Service Information For more convenient and accurate testing of EFI components, it is recommended dealers utilize the Polaris Diagnostic Software (dealer only), or limited testing may be done manually using the procedures provided. • 80% of all EFI problems are caused by wiring harness connections. Follow a common sense approach when diagnosing a potential EFI issue: • 1. 2. 3. 4. 5. 6. Disconnect the harness at the suspected sensor connector.
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FUEL INJECTION EFI SYSTEM EXPLODED VIEW 1. Electronic Control Module (ECM) 2. Manifold Absolute Pressure Sensor (MAP) 3. Intake Air Temperature Sensor (IAT) 4. Idle Air Control (IAC) 5. Crankshaft Position Sensor (CPS - inside cover) 6. Fuel Injector 7. Fuel Rail 8. Fuel Filter(s) 9. Fuel Pump/Tank Assy. 10. Engine Coolant Temperature Sensor (ECT) 11. Throttle Position Sensor (TPS) LH side of Throttle body 12. Throttle Body 1 3 7 9 2 4 12 11 6 10 8 5 3 4.
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FUEL INJECTION EFI SYSTEM 7. Component Locations/Identification 1. Fuel Rail 2 7 Electronic Control Module (ECM) 6 9 & 10 8. Fuel Filters (1 located in tank, 1 under front cab) 2 2. Manifold Absolute Pressure Sensor (MAP) 4 9 & 10 9. Fuel Pump / Regulator / Gauge Sender Assembly (located In tank as an assembly) 2 3. Intake Air Temperature Sensor (IAT) 9 & 10 10. Throttle Position Sensor (TPS) 2 4. Idle Air Control (IAC) 11 10 9 & 10 11. Throttle Body 12. Wire Harness Assembly 13.
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FUEL INJECTION FUEL TANK ELECTRONIC FUEL INJECTION Exploded View General Information The Electronic Fuel Injection (EFI) system is a complete engine fuel and ignition management design.
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FUEL INJECTION Initial Priming / Starting Procedure FUEL LINES NOTE: The Injection system must be purged of all air prior to the initial start up, and/or any time the system has been disassembled. Quick Connect Removal/Installation CAUTION If the EFI system is completely empty of fuel or has been disassembled and repaired: 1. 2. 3.
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FUEL INJECTION ELECTRONIC CONTROL MODULE (ECM) Sportsman 500 EFI RPM Limit: Operation Overview “Hard” Limit - Ignition suppression occurs when RPM peaks rapidly: The ECM 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 ECM.
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FUEL INJECTION FUEL PUMP ASSEMBLY Operation / Testing NOTE: All EFI units utilize quick connect fuel lines. 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 nonserviceable internal 30-micron filter.
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FUEL INJECTION 3. If the pump did not activate (Step 2), disconnect the plug from the fuel pump. Connect a DC voltmeter across terminals “A” and “C” in the plug, turn on the key switch and observe if a minimum of 7 volts is present. If voltage is between 7 and 14, turn key switch off and connect an ohmmeter between the terminals “A” and “C”' on the pump to check for continuity. NOTE: If there was no continuity between the pump terminals, replace the fuel pump/tank assembly. 3.
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FUEL INJECTION 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 Line Fuel Tank Installation 1. 2. Reinstall the tank assembly. Reconnect the sender wiring harness and route the harness properly. Install the fuel line(s) and verify they are secure. 3. Reinstall the two fuel tank mounting bolts at back of tank. 4.
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FUEL INJECTION FUEL FILTERS FUEL INJECTOR General Information General Information NOTE: All EFI units utilize quick connect fuel lines. The fuel injector mounts into the intake manifold, and the fuel rail attaches at the top end. Replaceable O-Rings on both ends of the injector prevent external fuel leakage and also insulate it from heat and vibration. EFI Engines use a non-serviceable, high-volume, highpressure, 30-micron internal fuel pump filter and a replaceable 10-micron, in-line fuel filter.
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FUEL INJECTION Injector problems due to dirt or clogging are unlikely due to the design of the injectors, the high fuel pressure, the use of filters and the detergent additives in the gasoline. Symptoms that could be caused by dirty/clogged injectors include rough idle, hesitation/stumble during acceleration, or triggering of fault codes related to fuel delivery.
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FUEL INJECTION 3. Disconnect crankshaft sensor connector from wiring harness. Test resistance between the terminals. A reading of 185Ω ± 20% at room temperature (20°C, 68° F) should again be obtained. NOTE: If the resistance reading is incorrect, remove the screws securing the sensor to the mounting bracket and replace the sensor.
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FUEL INJECTION INTAKE AIR TEMPERATURE SENSOR (IAT) Operation Overview The intake air temperature sensor (IAT) is used to indicate charge air temperatures to the ECM. Mounted on the rear of the air box, the IAT sends a varying voltage signal to the ECM in direct correlation to the ambient air temperature. This signal is processed by the ECM and compared to the internal pre-programmed maps to determine the required fuel and ignition settings for the amount of engine load.
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FUEL INJECTION THROTTLE POSITION SENSOR (TPS) Using TPS Test Adapter Harness 2201519• Set up the TPS Test Harness 2201519 according to the instructions. Verify that the 9 volt battery is new. Figure 2 Operation Overview The throttle position sensor (TPS), mounted to the throttle body, is used to indicate throttle plate angle to the ECM. Tester 2201519 The correct position of the throttle body idle stop is established and set at the factory.
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FUEL INJECTION Tps Tester - Correct Reference Voltage A 5 volt reference voltage signal from the test harness is required for the TPS test to be accurate. Refer to the instructions provided with the TPS Test Adapter Harness (2201519) or follow these steps to check reference voltage. • Harness Test: Insert black voltmeter probe into the “Bk” test port. • Connect the red meter probe into the “R” port and verify the voltage is 4.99-5.01 vdc.
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FUEL INJECTION ENGINE TEMPERATURE SENSOR Engine Temperature Sensor Test General Information Polaris dealers can test the sensor by using the Polaris Digital Wrench™ Software (dealer only). Refer to the Digital Wrench™ Software Manual for more information. 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.
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FUEL INJECTION FUEL SYSTEM TROUBLESHOOTING POOR IDLE FUEL STARVATION / LEAN MIXTURE Symptom: Idle Too High (If greater than 1300 RPM when engine is warm) • Throttle stop screw tampering - replace throttle body The correct position of the throttle body idle stop is established and set at the factory. Do not loosen the throttle body idle stop or alter the stop position in any fashion. If the stop is repositioned, the entire throttle body assembly must be replaced.
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FUEL INJECTION EFI DIAGNOSTICS USING ‘BLINK CODES’ NOTE: To clear codes manually, disconnect the positive battery lead for 20 seconds. Blink Codes - Operation To enable the blink codes, turn the ignition from “OFF” to “ON” 3 times, leaving it 'on' the 3rd time, within 5 seconds. ON Any “blink codes” that are stored in the ECM will display, one at a time, in numerical order. The word ‘WAIT’ will appear on the LCD display and the Malfunction Indicator Light (MIL) or Check Engine light will begin to flash.
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FUEL INJECTION Table 4-1: DIAGNOSTIC “BLINK CODES” CHART BLINK CODE NAME MIL LIGHT ON? 12 21 22 22 31 31 41 41 42 42 44 45 46 47 47 51 51 55 55 55 56 56 58 58 61 BEGIN SEQUENCE Loss of Synchronization TPS Circuit: Sensor Low TPS Circuit: Sensor High System Voltage Low System Voltage High Air Temp Sensor (IAT): Low Voltage Air Temp Sensor (IAT): High Voltage Engine Temperature Sensor Circuit (ECT): Low Voltage Engine Temperature Sensor Circuit (ECT): High Voltage CPS Circuit Fault Barometric Pressure Sen
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FUEL INJECTION TROUBLESHOOTING DIAGRAMS EFI CIRCUIT - Power On EFI CIRCUIT - Crank Position Sensor 4.
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FUEL INJECTION EFI CIRCUIT - Fuel Pump 4 EFI CIRCUIT - Ignition Coil 4.
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FUEL INJECTION EFI CIRCUIT - Idle Air Control EFI CIRCUIT - Throttle Position Sensor 4.
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FUEL INJECTION EFI CIRCUIT - Manifold Absolute Pressure Sensor 4 EFI CIRCUIT - Engine Coolant Temperature 4.
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FUEL INJECTION EFI CIRCUIT - Air Temperature Sensor EFI CIRCUIT - Malfunction Indicator Light 4.
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CARBURETOR - SPORTSMAN 450 CHAPTER 4 CARBURETOR - SPORTSMAN 450 GENERAL INFORMATION AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32 CARBURETOR JETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32 MIKUNI JET PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CARBURETOR - SPORTSMAN 450 GENERAL INFORMATION AND SPECIFICATIONS Special Tools Carburetor Jetting IMPORTANT: The following guidelines must be followed when establishing a main jet setting: 1. PART NUMBER TOOL DESCRIPTION 2870975 Mity VacTM Pressure Test Tool 2872314 Carburetor Float Adjustment Tool WARNING Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not overfill the tank.
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CARBURETOR - SPORTSMAN 450 CARBURETION BST 34 Carburetor Exploded View 1 of 2 A G B 4 H C N M P D L J E F K Table 4-1: Carburetor Components REFERENCE DESCRIPTION REFERENCE J DESCRIPTION A Jet Needle Throttle Control Cover Plate B Diaphragm Assembly K Carburetor Body C Needle Jet L Enrichment Plunger D Jet Block Assembly M Enrichment Spring E Washer N Cable guide F Main jet P Pilot Air Jet G Cover H Spring 4.
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CARBURETOR - SPORTSMAN 450 BST 34 Carburetor Exploded View 2 of 2 M N A D B F C E G H J K L Table 4-2: Carburetor Components REFERENCE DESCRIPTION REFERENCE DESCRIPTION A Throttle Plate Shaft Retaining Components J Float Bowl O Ring B Pilot Jet K Float Bowl C Needle Valve Assembly L Float Bowl Drain Screw D Throttle Plate M Throttle Shaft E Idle RPM Speed Adjustment Screw N Throttle Shaft Return Spring F Spring G Needle Valve Retaining Plate H Floats 4.
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CARBURETOR - SPORTSMAN 450 CV Carburetor System Function Carburetor Venting Carburetor Component Function System Float System (Level Control) Venting Main Components Inlet Pipe, Needle and Seat, Float, Float Pin Main System Main Affect All systems Maintains specified fuel All throttle ranges level in float chamber (carburetor float bowl) All systems Supplies Passages in All throttle Carburetor, Vent atmospheric pressure to float ranges lines chamber to frame Starter Choke Lever, (Choke/ Cable, Plun
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CARBURETOR - SPORTSMAN 450 When the pressure above and below the diaphragm are nearly equal, the slide moves downward under spring pressure. Raising or lowering the slide increases or decreases the cross sectional area in the venturi, and therefore the air velocity in the venturi is kept relatively constant. This provides improved fuel atomization and optimum fuel/air ratio. Pilot (Idle and Slow) System This system supplies fuel during engine operation with throttle valve closed (1) or slightly opened.
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CARBURETOR - SPORTSMAN 450 Main System Float System As throttle valve (1) is opened, engine speed rises, and this increases negative pressure in the venturi. Consequently the vacuum slide (2) moves upward. The fuel in float chamber (3) is metered by main jet (4), and the metered fuel enters needle jet (5), in which it mixes with the air admitted through main air jet (6) to form an emulsion.
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CARBURETOR - SPORTSMAN 450 Pilot Screw Air/Fuel Mixture Ratio The pilot system supplies fuel during engine operation with the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet. E-Clip Position vs. Fuel Flow 2 3 4 CAUTION 4 The pilot screw is calibrated at the factory to meet EPA / CARB regulations for air quality standards and is sealed with a brass plug to prevent tampering.
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CARBURETOR - SPORTSMAN 450 Jet Needle Throttle Opening vs. Fuel Flow The jet needle has five adjustment grooves cut into the upper portion, and is tapered from approximately the middle of the needle to the lower end. The top is fixed to the center of the throttle valve by the needle clip, and the tapered end extends into the needle jet. Fuel flows through the space between the needle jet and jet needle. This space does not vary until the throttle reaches the 1/4 open point.
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CARBURETOR - SPORTSMAN 450 and float pin can be removed. 3. Remove inlet needle seat retaining screw along with plate, and carefully remove needle seat. NOTE: Do not use a pliers to remove the seat or permanent damage may occur. NOTE: The starter jet is removable. Upon disassembly, place the parts in a container for safe keeping. Carburetor Cleaning WARNING Protect eyes from contact with cleaner. Take appropriate safety measures during these procedures.
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CARBURETOR - SPORTSMAN 450 Carburetor Inspection 1. diaphragm should fit properly in the carburetor body. Replace diaphragm assembly if diaphragm is damaged. Inspect jet needle and needle jet for wear. Look for discoloration, shiny spots, or an area that looks different than the rest of the needle. The middle to upper portion of the needle contacts the needle jet and is the most likely wear point. If jet needle shows signs of wear replace both the needle and needle jet to prevent a rich condition.
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CARBURETOR - SPORTSMAN 450 float using Float Adjustment Tool (PN 2872314) or a vernier caliper. When measuring the height, be sure the inlet needle valve spring is not compressed. the engine running. Refer to Page 2.10. Pilot Screw Base Setting (Set at Factory) Float Bowl Height: 13-14 mm Factory Specification: 2.5 Turns Out 4. Float Height Adjustment 1. If adjustment is necessary, bend the tongue slightly. Be sure float measurement is even on left and right side.
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CARBURETOR - SPORTSMAN 450 Fuel Level Test A fuel level test can be performed on some models if the drain hose fitting is accessible. Be sure to re–attach the bowl drain hose after performing the test. A fuel level test allows you to observe the height of the fuel in the float bowl without removing the carburetor. The fuel level can be observed with the engine either running or shut off, however, engine must run briefly to allow fuel level to stabilize. 1. Attach a clear line to drain fitting.
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CARBURETOR - SPORTSMAN 450 FUEL TANK/FUEL DELIVERY SYSTEM Fuel System Exploded View 4.
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CARBURETOR - SPORTSMAN 450 FUEL PUMP Fuel Pump Testing This ATV is equipped with a pressure regulated fuel pump (13 PSI). The pump is located under the left front fender of the machine. To test the fuel pump: 1. 2. 3. Turn fuel off. Disconnect impulse line from pump. Connect Mity-Vac™(PN 2870975) to the impulse line fitting on the pump. 4 Impulse Line 4. Apply 5 inches (Hg) vacuum to the pump fitting. The diaphragm should hold vacuum indefinitely.
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CARBURETOR - SPORTSMAN 450 Fuel Pump Inspection and Reassembly FUEL GAUGE SENDING UNIT 1. Sending Unit Removal Inspect inlet and outlet check valves for cracks, warping or damage. 2. Inspect the diaphragms for cracks, holes or swelling. 3. To clean the valves or pump body, remove the set screw and washer. Remove the valve assembly and wash with soap and water. NOTE: Carburetor cleaner may used to clean the pump body when the check valves are removed. 1. 2. 3. Disconnect the negative battery cable.
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CARBURETOR - SPORTSMAN 450 6. Remove the 5 screws that secure the fuel sender to the tank. TROUBLESHOOTING FUEL STARVATION/LEAN MIXTURE 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. • No fuel in tank • Restricted tank vent, or routed improperly • Fuel lines or fuel valve restricted • Fuel filter plugged • Carburetor vent line(s) restricted 7.
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CARBURETOR - SPORTSMAN 450 POOR IDLE Idle Too High • Idle adjusted damaged improperly/idle mixture screw • Sticky vacuum slide • Throttle cable sticking, improperly adjusted, routed incorrectly • Choke cable sticking, improperly adjusted, routed incorrectly • Plugged or restricted idle jet Idle Too Low • Choke cable bending or incorrectly adjusted • Idle speed set incorrectly • Idle mixture screw misadjusted or damaged • Belt dragging • Ignition timing incorrect • Worn jet needle/needle jet • Plugged or
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BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 DECAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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BODY / STEERING / SUSPENSION GENERAL INFORMATION Special Tools Table 5-2: Torque Specifications Table 5-1: COMPONENT FT.LBS. (IN.LBS.
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BODY / STEERING / SUSPENSION Plastic Insert Removal / Installation Some Polaris ATVs use a two piece plastic insert in place of a metal screw. The plastic inserts are simple to remove and install. 1. 3. To install the inserts, press outside insert (B) into the hole. Press inside insert (A) until it snaps into place. NOTE: The outside insert (B) should be flush surface after installation.
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BODY / STEERING / SUSPENSION BODY 3. Reinstall the side panel by reversing the removal procedure. Step 3 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 Front Cover Removal / Installation 2. 1. 2. Open the front storage compartment Pull up and outward on the front cover to remove the cover. 3.
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BODY / STEERING / SUSPENSION Foot Well Removal / Installation X2 Foot Well Removal / Installation 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). 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). 2. Remove the four screws (B) from the bottom of the foot well. Remove the footwell. 2.
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BODY / STEERING / SUSPENSION Front Storage Removal 2. Remove the four bolts that secure the storage rack to the frame. Front Storage Remove Bolts 3. Remove the two (T25) screws that secure the storage box to the front fender well areas (each side). Remove Bolts T-25 Screws 1. Remove the front radiator cap cover (A) by lifting upward on the cover. A 4. Remove the two (T25) screws that secure the outside of the storage box to the front fenders (each side). T-25 Screws 5.
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BODY / STEERING / SUSPENSION Winch Installation Area 5. 6. Remove the front cover piece by lifting up on sides of the two locking tabs as shown. Pull the tabs out of the notches and lift up on the cover piece. Remove the front headlights (C) or simply disconnect the electric connector (D) before removing the front plastic bumper. C D Pull Out to Remove 7. Remove the remaining bolts and screws that secure the front bumper section to the frame.
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BODY / STEERING / SUSPENSION Front Storage Installation 8. Install the front radiator cap cover (E) . Front Storage A E F B C E inserts Sportsman Rear Rack Removal / Installation C B A B A A D T-25 Screw A. 14 ft.lbs. (19 Nm) B. 10 in.lbs. (1.13 Nm) 1. 2. 3. 4. 5. 6. 7. A B C. 10 in.lbs. (1.13 Nm) D. 24 in.lbs (2.7 Nm) Place the front storage rack onto the frame. Install the four bolts (A) into the inside of the compartment hand tight.
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BODY / STEERING / SUSPENSION 3. 3. Place spacers on frame. Remove the two screws (B) that secure the front cab to the frame in the fuel tank mount area. B B A 4. 5. Install rear rack onto rear frame and cab. 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. 4. 5. Remove the side panels (D), refer to the “SIDE PANEL REMOVAL” section.
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BODY / STEERING / SUSPENSION Sportsman Rear Cab / Fender Removal / Installation 1. 2. 4. Follow the “REAR RACK REMOVAL” procedure to remove the rear rack. Remove the three screws (A) (T-25) that secure the rear cab to the storage container. Disconnect the rear lights by pulling the locks on each side and removing the connectors. Lift the rear cab from the frame. Remove Connectors A Lock 5. Reverse the removal steps for installation. X2 Rear Quarter Panel Removal / Installation 3. 1. 2.
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BODY / STEERING / SUSPENSION Sportsman Rear Storage Removal / Installation 1. 2. 3. 4. Follow the “REAR RACK REMOVAL” and “REAR CAB REMOVAL” procedure to remove the rear storage compartment. After the rear cab is removed the storage compartment comes out. Remove the two plastic inserts that hold the rear storage compartment in place. For installation, reverse the removal steps. Torque the three T-25 screws that hold the rear storage to the rear cab to specification. Radiator Screen Removal 1. 2. 3.
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BODY / STEERING / SUSPENSION Sportsman Body Assembly Exploded View Rear Cab Assembly Pull UP on rear of seat and back to disengage tabs at front of seat. Seat Latch Rear Cab Wheelwell Storage Frame Front Cab Assembly Side Cover Frame Front Cover Front Brush Guard Support Front Cab 5.
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BODY / STEERING / SUSPENSION X2 Body Assembly Exploded View Rear Cab Assembly Footwell RH Rear Cab 5 Frame Footwell Support Front Cab Assembly Side Cover Frame Front Cover Front Brush Guard Support Front Cab Splash Shields 5.
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BODY / STEERING / SUSPENSION Body / Rack Exploded Views Rack Rails Sportsman Only Rear Rack Rear Rack Support Rack Rails Frame Box Assembly Cover Front Brush Guard Panel Radiator Shield Grill Radiator Screen Front Bumper 5.
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BODY / STEERING / SUSPENSION Headlight Pod Exploded View B Worklight Switch A Instrument Cluster F A ETC Brake Clean knurling when repositioning handlebars G 5 D C E Wheel Speed Sensor - Sportsman C Disassembly • Remove two side Phillips screws (A) (X2 Speed Sensor Located on Transmission) Assembly • Install bottom of pod onto handlebar and secure to brackets • Remove one rear Phillips screw (B) • Install key switch, choke cable, and headlight • Lift top half of pod • Connect 12Vdc power outlet
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BODY / STEERING / SUSPENSION STEERING Handlebar Block Installation Procedure A B Clean knurling when repositioning handlebars 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.
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BODY / STEERING / SUSPENSION Steering / A-arm Exploded View 1 30 ft.lbs. (41 Nm) Steering Post 25-30 ft.lbs. (35-41 Nm) 1 30 ft.lbs. (41 Nm) 3 Steering Post Arm 8 ft.lbs. (11 Nm) B A 25 ft.lbs. (35 Nm) 2 12-14 ft.lbs. (17-19 Nm) 40-45 ft.lbs. (54-61 Nm) 2 1 Always use new bolts upon reassembly. use new cotter pins upon 2 Always reassembly. Install with open end 3 Apply Loctite™ 242 to bolt threads. toward rear of machine.
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BODY / STEERING / SUSPENSION A-Arm Replacement Vehicle Frame Bolt - 30 ft.lbs. (41 Nm) Ball Joint Stud Bushing 30 ft.lbs. (41 Nm) Apply Loctite™ 242 to the bolt threads. 8 ft.lbs. (11 Nm) A-Arm Tube A-arm Shaft 25 ft.lbs. (35 Nm) Cotter Pin - (Install New) 1. 2. 3. 4. 5. 6. 7. 8. Elevate and safely support vehicle with weight removed from front wheel(s). Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud.
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BODY / STEERING / SUSPENSION Ball Joint Replacement NOTE: Refer to the illustration on the previous page for this procedure. 1. 2. Loosen front wheel nuts slightly. Elevate and safely support machine under footrest/frame area. 8. 9. Install puller guide (G) with extension cap (H). Apply grease to extension cap and threads of puller bolt to ease removal. 10. Thread bolt (J) with nut (I) onto ball joint stud as shown. 11. Apply heat to ease removal. 12.
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BODY / STEERING / SUSPENSION Steering Post Removal SUSPENSION 1. 2. 3. 4. 5. Front Strut Cartridge Replacement 6. 7. 8. Remove the front cab. Remove the handle bar pod. Remove the handle bar. Remove the fuel tank bracket assembly. Remove the steering tie rod ends from the steering bracket. Note the orientation of the fasteners and bracket on the steering assembly. Remove the steering post nut (A) at the mount plate. Remove the top steering bracket . Remove the steering post.
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BODY / STEERING / SUSPENSION Strut Assembly Nut - 15 ft.lbs. (21 Nm) Strut Bumper Spacer Rubber Washer Strut Upper Pivot Ball Spacer Nut Clamp Lower Pivot Ball Washer Spring Retainer 5 18 ft.lbs. (25 Nm) 15 ft.lbs. (21 Nm) Bolts Spring Brake Caliper Hubstrut Bearing Retaining Ring 5.
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BODY / STEERING / SUSPENSION Sportsman Rear Suspension Assembly 17 ft.lbs. (24 Nm) Stabilizer Bar 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 50 ft.lbs. (68 Nm) Rear Shock Lower Control Arm 30 ft.lbs. (41 Nm) 1 Orientate Correctly Bushings Rear Front Bushing Orientation 5.
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BODY / STEERING / SUSPENSION X2 Rear Suspension Exploded View Rear Compression Spring Preload Adjustment Cam Rear Shock Bushings 5 Control Arm Pivot Bracket Upper Control Arm Boot Shield A-Arm Shaft Lower Control Arm Wheel Bearing Carrier Grease Zerk 5.
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BODY / STEERING / SUSPENSION X2 Torsion Bar Exploded View Stabilizer Bar Linkage Bushing Stabilizer Bushing Bushing Torsion Mount Linkage Asm. 5.
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BODY / STEERING / SUSPENSION X2 CARGO BOX Exploded View 5 5.
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BODY / STEERING / SUSPENSION Removal / Installation 3. IMPORTANT: Before attempting to remove the cargo box, be sure that the cargo box is not set up for 2-UP riding. The passenger backrest should be face down in the cargo box and the driver seat backrest should be locked into position. 1. Disconnect the two wire harnesses connected to each of the taillights. Open the tailgate and remove the 2 torx head screws (A) securing the rear taillights on each side of the cargo box as illustrated below.
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BODY / STEERING / SUSPENSION 6. 7. Lift up firmly in the cargo box release lever on either side of the ATV. Remove the four bolts attaching the rear of the cargo box to the frame. There are two on each side. 9. Carefully remove the cargo box from the ATV. 10. Reverse the removal steps to reinstall the cargo box. Refer to the standard fastener torque values in Chapter 1 during assembly. 5 See “Standard Torque Specifications” on page 1.12. 8.
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BODY / STEERING / SUSPENSION X2 SEAT ASSEMBLY Exploded Views 5.
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BODY / STEERING / SUSPENSION X2 Seat Operation - Configuring Cargo Box For Passenger Riding 1. 4. Unlatch the driver seat backrest by turning the engagement knobs on each side in the directions shown below. Fold the driver seat backrest down into place to serve as the passenger seat bottom. Passenger Backrest A B Driver Seat Backrest / Passenger Seat Bottom 5. 2. While pulling the backrest towards the front of the ATV, lift up on the passenger backrest loop that is face down in the cargo box.
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BODY / STEERING / SUSPENSION Driver Seat Backrest Removal / Installation 1. 2. 3. 2. Lift up on the latch for the passenger seat bottom and lock it in the upright position as shown below. 3. Remove the two screws retaining the passenger backrest. 4. Remove the two pivot pins holding the backrest to the frame. 5. Lift up on the backrest latch and tilt the backrest in towards the cargo box and lift up to remove it. For installation, reverse the removal steps. Configure the seating for 2-UP riding.
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CLUTCH SYSTEM CHAPTER 6 CLUTCH SYSTEM SPECIAL TOOLS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 COMPONENT FASTENER TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 PVT EXPLODED VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.
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CLUTCH SYSTEM SPECIAL TOOLS AND SPECIFICATIONS Component Fastener Torques Special Tools COMPONENT FT.LBS. (IN.LBS.) NM Drive Clutch Retaining Bolt 40 54 TOOL DESCRIPTION PART NUMBER Clutch Puller 2870506 Driven Clutch Retaining Bolt 17 23 Clutch Holding Wrench 9314177 PVT Inner Cover Bolts 12 16 Clutch Holding Fixture 2871358 Drive Clutch Spider EBS Clutch 200 271 Spider Nut Socket 2870338 Drive Clutch Spider Removal & Install Tool 15 20.
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CLUTCH SYSTEM PVT EXPLODED VIEWS PVT Sealing And Ducting Components Clutch Inlet Duct Transmission Cover Seal Inner Clutch Cover Clamps Boot Duct Clutch Cover Seal Inner Seal Cover Seal Retainer Bracket Clutch Cover 6 Drive Clutch Exploded Views (Standard and Deluxe) EBS One Way Clutch “Deluxe” Models NON-EBS “Standard” Models 6.
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CLUTCH SYSTEM Driven Clutch Exploded Views (Standard and Deluxe) STANDARD - NON EBS DELUXE - EBS 1. Torx Screw 11. Moveable Sheave 2. Cam Assembly 12. Roller Pin 3. Retaining Ring 13. Spring Pin 4. E-clip 14. Stationary Sheave 5. Washer 15. Bearing 6. Roller 16. Retaining Ring 7. Outer Spider 17. Retaining Ring 8. Spring 18. Inner Spider Plate 9. Shaft 19. Spider Dampener 10. Thrust Washer 20. Clutch Roller 6.
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CLUTCH SYSTEM Engine Braking System (EBS) Exploded View One Way Clutch Drive Washer Drive Belt Washer Shift Weights Cam Assembly Roller/Bushing Assembly - Torque 200 ft.lbs. Retaining Ring Spacer Clutch Rollers Spider Assembly Spider Lock Nut Compression Spring Bushing Cover 6 Clutch Shaft Coil Spring Spacer Washer Bearing Sheaves Retaining Rings 6.
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CLUTCH SYSTEM PVT SYSTEM Driven Clutch Operation PVT Operation Overview Driven clutches primarily sense torque, opening and closing according to the forces applied to it from the drive belt and the transmission input shaft. If the torque resistance at the transmission input shaft is greater than the load from the drive belt, the drive belt is kept at the outer diameter of the driven clutch sheaves.
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CLUTCH SYSTEM EBS Clutch Operation PVT Maintenance / Inspection This EBS driven clutch provides the same engine braking abilities as the EBS drive clutch. Under normal operation the PVT system will provide years of trouble free operation. Periodic inspection and maintenance is required to keep the system operating at peak performance. The following list of items should be inspected and maintained to ensure maximum performance and service life of PVT components.
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CLUTCH SYSTEM Drive Clutch Spring Measuring Spring Length: With the spring resting on a flat surface, measure its free length from the outer coil surfaces as shown. Refer to the spring specification chart for specific free length measurements and tolerances. Also check to see that spring coils are parallel to one another. Distortion of the spring indicates stress fatigue, requiring replacement. Table 6-1: Primary Clutch Springs The drive clutch spring has two primary functions: 1. 2.
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CLUTCH SYSTEM Optional 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. - NLA - - NLA - 6 698 6.
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CLUTCH SYSTEM PVT Drying PVT Disassembly IMPORTANT: If operating the ATV through water, be sure to check the PVT cover and other ATV components for water ingestion. The ATV should be checked immediately. Refer to Owner's Manual for Safe Riding Tips. NOTE: Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement. PVT Drain Plug 1. 2. 3. 4. 5. 6. Remove seat.
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CLUTCH SYSTEM 8. Remove driven clutch offset spacers from the transmission input shaft. NOTE: Remember to keep spacers in order for proper clutch offset on reassembly. PVT Installation 1. Offset Spacer 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 9. Remove cover screws and retainer plate. Inner Cover 2. 3. Retainer Seal 4. 5. 6.
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CLUTCH SYSTEM 7. Install clutch offset spacer(s) on transmission input shaft. Drive Belt Removal / Inspection 1. Offset Spacer 2. 3. Remove outer PVT cover as described in PVT Disassembly. Mark drive belt direction of rotation so that it can be installed in the same direction. The belt is normally positioned so part numbers are easily read. To remove drive belt, apply brake, pull upward and rearward on belt while turning the back (moveable) driven sheave clockwise to open driven clutch sheaves.
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CLUTCH SYSTEM 6. Measure the distance where the side straight edges intersect the top, as shown in the illustration. Projected Belt Width DRIVE BELT INSTALLATION NOTE: Be sure to position belt so part number is easily read. Verify new belt is seated properly in the clutches before operating the ATV. 1. 2. Loop belt over drive and over top of driven sheave. While pushing down on top of belt, turn the back or moveable driven sheave clockwise. 3.
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CLUTCH SYSTEM Clutch Alignment 1. 7. Remove belt and install the Clutch Offset Alignment Tool (PN 2872292) as shown. B Measure belt deflection and measure offset both above and below shaft centerlines. Adjust if necessary. Center Line Offset Alignment Tool (PN 2872292) Measure Above and Below Centerline A 1/8” + 0 / -1/16 (3.2mm + 0 / - 1.6) 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”.
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CLUTCH SYSTEM EBS DRIVE CLUTCH SERVICE 5. Remove and inspect spring. See “Drive Clutch Spring Specifications” for spring inspection. Drive Clutch Disassembly 1. Inspect Shaft Using a permanent marker, mark the cover, spider, and moveable and stationary sheaves for reference, as the castin “X's” may not have been in alignment before disassembly. Spider Removal 1. 2. 3. Remove the limiter nut using the Clutch Spider Nut Socket (PN 2870338).
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CLUTCH SYSTEM NOTE: It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly. Be sure to note the number and thickness of these washers. 3. To maintain proper clutch balance and belt-to-sheave clearance, be sure to reinstall original quantity and thickness washers 2. Inspect all rollers, bushings and roller pins by pulling a flat metal rod across the roller. Turn roller with your finger.
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CLUTCH SYSTEM 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” procedure. 2. Inspect the weight pivot bore and pivot bolts for wear or galling. If weights or bolts are worn or broken, replace in sets of three with new bolts. NOTE: A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly.
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CLUTCH SYSTEM 2. 3. Lift one-way clutch (3) and thrustwasher (4) off shaft. Replace as an assembly if worn, damaged, or if problems were noted. Inspect surface of shaft for pitting, grooves, or damage. Measure the outside diameter and compare to specifications. Replace the drive clutch assembly if shaft is worn or damaged. Moveable Sheave Bushing Inspection Inspect the Teflon™ coating (arrow) on the moveable sheave bushing. Inspect BOTH sheaves for signs of wear, grooving or cracking.
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CLUTCH SYSTEM NOTE: Bushings are installed at the factory using Loctite™ 609. In order to remove bushings it will be necessary to apply heat evenly to the area around each bushing. Clean all residual Loctite™ from bushing bore prior to installing new bushing. Drive Clutch Bushing Installation 1. Place main adapter (Item 8) on puller. Puller Tool (A,B) Side “A” toward sheave Nut (C) CAUTION Clutch components will be hot! In order to avoid serious burns, wear insulated gloves during the removal process.
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CLUTCH SYSTEM Cover Bushing Removal One-Way Clutch Inspection (Drive Clutch) 1. 1. Install main adapter (Item 8) on puller. Removal Tool (3) Nut (C) Rotate one-way clutch clockwise (as viewed from the cover plate side). The clutch should rotate on the shaft with only slight amount of drag. Verify there is no binding or rough spots. When rotated counterclockwise, the clutch should lock to the shaft without slipping. If problems are noted in either direction, continue with disassembly.
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CLUTCH SYSTEM C) “X”, or the marks that were made earlier under weight 6. Install limiter nut on top of spider using the Clutch Spider Nut Socket (PN 2870338). Torque to specification. Reinstall shift weights using new lock nuts on the bolts. =T Spider Nut Torque: 15 ft. lbs. (20 Nm) 7. Reinstall clutch spring. Engine Rotation 2. 3. 4. 5. Install moveable sheave onto fixed sheave. Install spider spacers. Use same quantity and thickness as were removed.
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CLUTCH SYSTEM EBS DRIVEN CLUTCH SERVICE 4. Place the clutch into Clutch Compression Tool PN 8700220. Using Compression Extensions PN PS-45909, Press down on top of the spider assembly, compressing the spider onto the shaft. Remove snap ring (A) and slowly release the assembly. Press down on spider 5. Remove the spider assembly, spring (B), and spacer washer (C). NOTE: Spring is compression only and has no torsional wind Driven Clutch Disassembly 1. 2. 3.
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CLUTCH SYSTEM 6. Remove the inside spider plate (D) and spider dampener (E). Inspect the spider dampener (E) for wear and replaced if needed. 10. Pull out the clutch roller pins (L) and rollers (M). D E K M 7. L Remove the E-clip (F), washer (G), and the clutch rollers (H). Inspect the rollers for wear replace if worn. H G F K 11. Press the shaft and bearing out of the outer sheave using a press. 8. Remove the clutch assembly from the holding tool.
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CLUTCH SYSTEM 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 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.
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CLUTCH SYSTEM Driven Clutch Bushing Installation EBS DRIVEN CLUTCH REASSEMBLY 1. 2. 1. Press a new bearing onto the output shaft using a press. 2. Install the shaft/bearing into the outer sheave. 3. 4. 5. 6. 7. 8. 9. Install puller adapter (Item 10) onto puller. Install adapter (Item 9) onto puller. Apply Loctite™ 609 evenly to bushing bore inside moveable sheave. Install sheave face down on puller. Install new bushing on installation tool (Item 2) and install assembly into sheave.
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CLUTCH SYSTEM 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. 4. 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. Line up the “X” on the moveable sheave with the “X” on the stationary sheave or use the marks previously used. Put the sheaves together.
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CLUTCH SYSTEM 8. Install the spacer washer. 12. Install the spider assembly onto the shaft with the retaining ring on top of the spider. NOTE: Use the marks previously made to align the skip tooth spider, or use the “X” on top of the spider and align it with the skip tooth on the shaft. Install Spacer Washer Align Marks 9. 13. Place the clutch into Clutch Compression Tool PN 8700220.
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CLUTCH SYSTEM 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. NOTE: If the cam assembly (helix) is difficult to install, be sure the sheaves are aligned. To align the sheaves place the clutch assembly on a flat surface with the cam assembly (helix) side down. Press down on the moveable sheave belt face with both hands and the helix will release.
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CLUTCH SYSTEM Spider Removal 1. 2. Inspect the Teflon™ coating on the moveable sheave bushing. 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. Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflon™ is visible on the bushing. Refer to bushing replacement in this chapter.
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CLUTCH SYSTEM 4. Rubber backed buttons can and should be used in all ATV clutches if the hollow roller pin is changed to a solid roller pin. NOTE: The rubber side of the button is positioned toward the solid roller pin. It is recommended to switch all buttons to the rubber version during service (if needed). Shift Weight Inspection 1. If clutch is not disassembled, inspect as shown, using a clutch holding tool to compress the moveable sheave.
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CLUTCH SYSTEM Sheave / Bushing Inspection Inspect the Teflon™ coating on the sheave bushings and cover bushing. Inspect BOTH sheaves for signs of wear, grooving or cracking. Clean sheave surfaces with a 3M™ pad if needed. NOTE: Bushings are installed at the factory using Loctite™ 609. In order to remove bushings it will be necessary to apply heat evenly to the area around each bushing. Clean all residual Loctite™ from bushing bore prior to installing new bushing.
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CLUTCH SYSTEM Drive Clutch Bushing Installation Drive Clutch Reassembly 1. 2. NOTE: It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly. The Teflon bushings are self-lubricating. Do not apply oil or grease to the bushings. Place main adapter on puller. Apply Loctite™ 609 evenly to bushing bore inside moveable sheave. 3. Set bushing in place on sheave. 4. Insert installation puller tool into center of bushing. 5.
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CLUTCH SYSTEM 8. Reinstall cover, aligning bosses on the tower and cover. Torque cover bolts evenly to specification. Spacer Washers =T Spider Torque: 200 ft. lbs. (271 Nm) CAUTION Verify spider spacer washers are fully seated in the recessed area of the spider. Any misalignment will alter clutch balance. Inverting the clutch while initially tightening the spider will help position the washers. 5. =T =T Cover Screw Torque: 90 in. lbs. (10.4 Nm) Spider Limiter Nut Torque: 15 ft. lbs. (20 Nm) 6. 7.
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CLUTCH SYSTEM STANDARD DRIVEN CLUTCH 3. Separate the clutch sheaves by pulling upward while rotating the inner sheave. Disassembly 1. Using special tool PN 8700220, apply and hold downward pressure on the outer spring retainer and remove the snap ring (A). A Inspection 1. CAUTION 2. Inspect both the inner and outer sheave surfaces. Replace the entire clutch assembly if worn, damaged or cracked. Inspect the inner sheave helix (E) and spring retainer (F) for signs of wear.
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CLUTCH SYSTEM 4. Inspect the rollers in the stationary sheave for signs of wear. Assembly 1. Install inner spring retainer (if removed). 2. Install the inner sheave onto the outer sheave. NOTE: Verify ‘X’ marks on each side of the sheaves are aligned upon reassembly of sheaves. NOTE: Rollers and helix are non-serviceable items. Replacement of clutch assembly is required if damaged beyond usable condition. 5. Inspect the bushings inside the moveable sheave.
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CLUTCH SYSTEM PVT TROUBLESHOOTING General Range Operation Guidelines Overheating IMPORTANT: 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.
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CLUTCH SYSTEM Problem, Cause and Remedy Chart Table 6-2: Problem, Cause and Remedy SITUATION POSSIBLE CAUSE -Wrong or broken drive clutch spring. Engine RPM below specified operating range -Drive clutch shift weight too heavy. although engine is properly tuned. -Driven clutch spring broken or installed wrong . -Drive clutch binding. Erratic engine operating -Belt worn unevenly - thin/burnt spots RPM during acceleration or load variations. -Driven clutch malfunction.
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CLUTCH SYSTEM Table 6-2: Problem, Cause and Remedy SITUATION Belt burnt, thin spots PVT noise Engagement erratic or “jerks” 6.38 POSSIBLE CAUSE REMEDY -Abuse (continued throttle application when vehicle is stationary, excess load) -Caution operator to operate machine within guidelines. -Dragging brake -Vehicle operated with park brake on. Inspect brake system. -Slow, easy clutch engagement -Instruct firm, effective use of throttle for efficient engagement.
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FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 GEARCASE FLUID / CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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FINAL DRIVE SPECIFICATIONS Gearcase Fluid / Capacity Torque Table COMPONENT FT.LBS. (IN.LBS.) GEARCASE DESCRIPTION NM Centralized Hilliard (Standard Models) Demand Drive LT Premium Hub Fluid 8.97 oz. (265 ml) Centralized Hilliard w/ ADC (Deluxe Models) Demand Drive LT Premium Hub Fluid 9.3 oz.
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FINAL DRIVE 8. Remove hub. 9. Remove cotter pin and nut from lower A-arm ball joint. Remove lower A-arm from ball joint. 10. Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly. 11. Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly. 7 7.
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FINAL DRIVE Installation FRONT DRIVE SHAFT (CV) BOOT 1. Inspection 2. 3. Install new spring ring on drive shaft. Apply an anti-seize compound to splines. Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft with rubber faced hammer. Install drive shaft in strut. Install lower ball joint, torque nut to specification and install new cotter pin. Check the front and rear driveshaft CV boots for any tears or leaking grease.
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FINAL DRIVE 3. Disconnect A-arm from ball joint using a tie rod fork. 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. Front drive axle CV boot replacement requires 3.5 oz. of grease. CV Joint Grease -3.5 oz.
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FINAL DRIVE punch in the reliefs as shown. 13. Install the small clamp on the boot. Front Shaft FRONT HUB Disassembly 1. Remove outer snap ring. NOTE: Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed. 3. Inspect the bearing. NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel.
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FINAL DRIVE PROP SHAFT - FRONT OR REAR U-JOINT Removal and Installation Disassembly 1. 2. Using Roll Pin Removal Tool (PN 2872608), remove the roll pin from prop shaft at rear of housing (front only) or transmission output shaft (rear only). Slide prop shaft back and away from housing, then pull sharply forward to remove from transmission shaft. CAUTION Always wear eye protection when working with spring-tensioned components For installation, reverse the removal procedure. 1.
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FINAL DRIVE 3. 4. Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing ca Assembly 1. Install new bearing caps in yoke by hand. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft. Take care not to dislodge needle bearings upon installation of cross joint. Tighten vise to force bearing caps in. 2. Using a suitable arbor, fully seat bearing cap in one side.
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FINAL DRIVE 4. Install snap ring to contain bearing cap just installed. Repeat procedure for other side. 5. Install snap ring to contain bearing cap just installed. Repeat procedure for other side. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown. 6. 7 7. When installation is complete, yokes must pivot freely in all directions without binding.
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FINAL DRIVE DRIVE AXLE EXPLODED VIEWS Drive Shafts and Propshafts NOTE: Refer to your parts manual for the proper replacement parts. Drive Axle Components Inner CV Joint Circlip Circlip Inner Boot Outer Boot Outer CV Joint Circlip Clamps Drive Boot Replacement Kits Clamp 3.5 oz. grease Boot Outer Clamp Prop Shaft Components Propshaft Assy. Cross & Bearing Kit Yoke, Front Gearcase Yoke, Rear Gearcase 7.
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FINAL DRIVE FRONT GEARCASE - CENTRALIZED HILLIARD (STANDARD MODELS) Exploded View (Standard Models) 10 11 12 13 14 15 16 17 18 16 6 19 8 1 7 6 9 20 10 5 4 3 21 2 22 1 7 Ref. # 1 2 3 4 5 6 7 8 9 10 11 Description Bolt Oil Seal Input Cover Plate Asm. O-Ring Retaining Ring Bearing Pinion Gear Asm. Pinion Bushing Magnetic Drain Plug Oil Seal Plug Cap Qty Ref. # Description Qty 8 1 1 1 1 3 1 1 1 2 1 12 13 14 15 16 17 18 19 20 21 22 Vent Tube Plug Gearcase Sub Asm.
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FINAL DRIVE Operation Rollers Engaging front gearcase: The AWD switch may be turned on or off while the vehicle is moving. AWD will not enable until the engine rpm is below 3100 RPM. Once enabled, the AWD remains engaged while the front gearcase is moving and will not disengage until the rear wheels regain traction. Ring Gear Engage the AWD switch before getting into conditions where the front wheel drive may be needed. If the rear wheels are spinning , release the throttle before switching to AWD.
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FINAL DRIVE 5. Remove cotter pin, lower ball joint nut and A-arm from ball joint. 6. Pull the hub and strut assembly out and pull the drive-shaft out of the hub. 8. Remove bolts securing the bottom of housing to the skid plate frame. Bolts and fluid drain plug are accessible through the skid plate. 9. Remove vent line. 10. Remove the front gearcase from left side of frame, pulling both the remaining CV shaft and propshaft from the gearcase.
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FINAL DRIVE 2. Remove bolts retaining the outer cover plate assembly. 4. Remove the armature plate and RH output hub assembly from the outer cover plate. Inspect the bearing and contact surfaces of the output hub for signs of wear or damage. Replace component if found to be worn or damaged Output Hub Assembly 3. Armature Plate Remove the outer cover plate assembly. Thrust Bearing 5. NOTE: Thrust bearing located between the two output hubs is pressed into assembly. 7.
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FINAL DRIVE 6. 7. 8. Remove the LH output hub. Inspect the bearing and contact surfaces of the output hub for signs of wear or damage. Replace component if found to be worn or damaged. Thoroughly clean all parts. Inspect the bearing surfaces of the output hub. Inspect the rollers (A) for nicks, scratches and flat spots. Inspect the roll cage (B) for damage or cracks. The rollers must slide up and down freely within the roller cage surfaces. 9. Inspect roll cage (B) sliding surface.
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FINAL DRIVE 11. Inspect the magnetic coil (A) in the outer cover plate assembly. Inspect the backlash pad (B) for excessive wear. 13. Remove the snap ring retaining the input shaft assembly. A B NOTE: See “FRONT GEARCASE DIAGNOSIS” later in this chapter for more details on the coil. NOTE: The backlash for the centralized hilliard is set at the factory. No adjustment is required, unless the front cover needs to be replaced, or the back lash pad screw is removed.
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FINAL DRIVE Reassembly / Inspection 1. 5. Install the LH output hub (A) into the gearcase housing. The output hub should spin freely. Replace all O-rings, seals, and worn components. A A 6. 2. Press the pinion shaft seal into the pinion cover, until the seal is flush with the sealing surface. 3. Inspect bearings on output and pinion shafts. To replace, press new bearing on to shaft. C NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel.
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FINAL DRIVE 8. Install the ring gear and roll cage assembly into the gearcase housing. 9. Install the armature plate on top of the roll cage / ring gear assembly. Be sure that the armature plate tabs are fully engaged into the roll cage assembly. 11. Torque the cover plate bolts to specification. NOTE: Verify armature plate tabs are placed into the slots on roll cage. (See Photo Below) 14 ft.lbs. (19 Nm) =T Output Cover Bolt Torque 14 ft. lbs. (19 Nm) 12.
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FINAL DRIVE 2. Using a 3/32 hex wrench, turn the back-lash screw out 3-4 turns. Re-apply Loctite 262™ onto the bottom screw threads. 3. Turn the screw in until it is lightly seated, then turn the screw out 1/4 turn. Set the gearcase upright. Rotate the input shaft at least 4 times. This ensures the ring gear completes one full rotation. 4. NOTE: To test the gearcase coil resistance, use the coil harness. The gearcase coil should measure between 22.8 ohms and 25.2 ohms.
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FINAL DRIVE 4. Check to make sure the coil is seated in the U-shaped insert that is pressed into the gearcase cover. The top of the coil should be seated below the U-shaped insert. The U-shaped insert controls the pole gap. If the top of the coil is above the surface of the U-shaped insert it raises the armature plate, thereby increasing pole gap. If the pole gap increases the coil will not be strong enough to engage the AWD system. If this is the cause order a new Cover Plate Assembly.
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FINAL DRIVE FRONT GEARCASE - ACTIVE DESCENT CONTROL (DELUXE MODELS) ADC Gearcase Exploded View (Deluxe Models) 5 7 Ref. # Qty Ref.
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FINAL DRIVE Operation ADC Engagement: When the AWD switch is activated, a 12 Vdc current is present at the input shaft coil (1). Operation is controlled by the ECU grounding and ungrounding the coil. The coil’s magnetic field attracts a splined armature plate (2) on the pinion (input) shaft (4). The energized splined armature plate attracts the unsplined eccentric cam (3), which begins to turn with the input shaft. The eccentric cam drives a hydraulic piston/pump assembly (5).
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FINAL DRIVE ADC Coil Testing Disassembly / Inspection Refer to the following tests in Chapter 10: 1. Drain and properly dispose of used oil. Remove any metal particles from the drain plug magnet. 2. Remove the piston pump assembly from the gearcase. See “ALL WHEEL DRIVE (AWD) COIL” on page 10.24. See “ACTIVE DESCENT CONTROL (ADC) COIL” on page 10.24. ADC Differential Hydraulic Circuit Bleeding 1.
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FINAL DRIVE 4. Remove the outer cover plate assembly. Remove and inspect the cover o-ring (1). Inspect thrust bearing (2) for wear. Replace items as required. 6. Remove the armature plate. Inspect the armature plate for wear, distortion or other damage. Replace component as required. 7. Remove the spacer. Inspect for signs of wear or damage. Replace component as required. 2 1 NOTE: Thrust bearing (2) located between the two output assemblies is pressed into the clutch pack and is not removable. 5.
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FINAL DRIVE 8. 12. Inspect roll cage sliding surface (2). This surface must be clean and free of nicks, burrs or scratches. Remove and inspect the H-springs (4). Replace any components as required. Remove the ring gear (1) and spacer (2). 2 1 4 2 9. Remove and inspect the bearing surfaces of the output hub. 10. Thoroughly clean all parts. 11. Inspect the rollers (1) for nicks, scratches and flat spots. Inspect the roll cage (2) for damage or cracks.
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FINAL DRIVE 14. Inspect the magnetic coil (1) in the outer cover plate assembly. Inspect the backlash pad (2) for excessive wear. 1 2 16. Inspect the magnetic coil (1) and bushing in the input cover plate assembly. Replace the input cover seal. 1 NOTE: See “FRONT GEARCASE DIAGNOSIS” in this chapter. NOTE: Ring gear backlash (2) is set at the factory. No adjustment is required, unless the front cover is replaced or the back lash pad screw is removed.
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FINAL DRIVE 19. Remove the snap ring retaining the input shaft assembly. ADC Gearcase Piston Replacement Procedure CAUTION This repair procedure involves the use of compressed air. Safety glasses or a face shield are required. 1. Place ADC Piston Tool PA-48542 on top of the piston. Using moderate hand pressure, hold the tool on top of the piston while using compressed air at the gearcase passage (circled) to force piston up and out of the case. (See photo) AIR 20. Remove the input shaft assembly.
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FINAL DRIVE 4. Coat new piston and o-rings with a moderate amount of white lithium grease or assembly lube. Coat the edges of the piston cavities. Install the inner and outer piston o-rings. 6. Outer Place ADC Piston Tool PA-48542 on top of the piston and verify alignment of the sight hole (circled) and piston mark with the casting marks. Support the case and press the piston down evenly. The piston is fully seated and located in the pin bosses when the piston surface is just below the cavity edge.
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FINAL DRIVE Assembly 5. 1. Thoroughly clean the gearcase components before beginning reassembly. 2. Install a new seal in the main gearcase halve. 3. Install the input shaft assembly. Install the pinion gear/ bearing assembly (1). Install a new seal and o-ring the input shaft cover (2) prior to reassembly. Install the eccentric cam assembly (1). 1 2 1 6. 4. Install the splined armature plate (1). 1 Install the snap ring retaining the input shaft assembly. 7 7.
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FINAL DRIVE 8. Install a new seal (1) in the outer cover plate assembly. Install a new o-ring on the backlash pad (2) stem . 1 2 10. Install the clutch pack (1), spacer (2) and ring gear (3). NOTE: Align locating pins / holes for installation. 3 2 1 NOTE: Ring gear backlash (2) is set at the factory. No adjustment is required, unless the front cover is replaced or the back lash pad screw is removed. 9. NOTE: Align locating pins / holes for installation (arrow).
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FINAL DRIVE 12. Install new cover o-ring (1) on the cover plate assembly and a new passage o-ring (2) on the gear case. 14. Place cover assembly on Install bolts (arrows) retaining the outer cover plate assembly and torque to specification. 1 2 13. Install the remaining output clutch assembly. NOTE: Align locating pins / holes for installation. =T Input Cover Bolt Torque: 7-11 ft. lbs. (9.4-14.9 Nm) 15. Install a new passage o-ring (dotted circle) on the gearcase and install the piston pump assembly.
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FINAL DRIVE REAR HUB 8. Remove hub nut, domed washer and flat washer. 9. Remove hub. Removal 1. Place the ATV in Park and lock the parking brake. Remove rear hub cap. A B 2. 3. 4. 5. 6. 7. C Remove cotter pin (A). Loosen the hub retaining nut (B). Loosen the wheel nuts (C). Safely support the rear of the ATV. Remove wheel nuts and wheel. Remove the rear brake caliper and safely suspend the caliper from the frame with a piece of wire. 10. Remove upper control arm bolt as shown. 7.
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FINAL DRIVE 11. Remove both lower control arm bolts. 2. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown or press out using a hydraulic press. 12. Remove bearing carrier. Disassembly 1. Remove outer snap ring. NOTE: Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed. 3. Inspect bearing.
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FINAL DRIVE Assembly 1. Support bottom of bearing carrier housing. 2. Start bearing in housing. 3. Press bearing into place until outer race bottoms on housing. CAUTION Use an arbor press only on the outer race to avoid bearing damage. 4. Install snap ring into groove. 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.
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FINAL DRIVE =T REAR DRIVE (CV) SHAFT Removal Lower Control Arm Bolt Torque: 50 ft. lbs. (68 Nm) 4. 5. 6. 7. 8. Lift bearing carrier until top aligns with upper control arm. Install and torque upper control arm bolt and torque to specification. Pull drive shaft outward and install hub onto driveshaft splines. Install cone washers with domed side facing outward. Install retainer nut, wheel and wheel nuts. Remove jackstand and torque axle nut and wheel nuts to specification. 1.
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FINAL DRIVE Service 1. 3. Remove clamps from rubber boot(s) using the CV Boot Clamp Pliers (PN 8700226) (A). Open the snap ring using a snap ring pliers or small needle nose pliers. Tap CV housing off shaft with a soft faced hammer while holding snap ring open. Spread ends of snap ring to remove joint from shaft A Tap CV housing off shaft 4. 2. Photo below is shown without shaft for clarity.
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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 CV 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.
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FINAL DRIVE 8. While pulling out on the CV shaft, fully extend the CV joint and slide a straight O-ring pick or a small slotted screw driver between the small end of the boot and the shaft. This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life. Before you remove your instrument, be sure the small end of the boot is in its correct location on the axle. INSTALLATION 1. Slide shaft assembly into bearing carrier hub. 2. 3. 4.
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FINAL DRIVE 6. Install rear wheel and torque wheel nuts to specification. 80 ft.lbs. (109 Nm) Refer to Page 7.2 for Wheel Nut Torque. 7. Grease all fittings thoroughly with Premium U-Joint Lubricant (PN 2871551). Drive Shaft and CV Joint Handling Tips Care should be exercised during driveshaft removal or when servicing CV joints. Driveshaft components are precision parts. Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life.
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FINAL DRIVE NOTES 7.
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GENERAL INFORMATION CHAPTER 8 GENERAL INFORMATION TRANSMISSION - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 MOUNTING EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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GENERAL INFORMATION TRANSMISSION - GENERAL Mounting Exploded View x1 x1 x2 x4 x4 x1 x2 x3 8.
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GENERAL INFORMATION Torque Specifications COMPONENT Transmission Removal FT. LBS. (IN.LBS.) NM Transmission Case Bolts 25-30 36-43 Bell Crank Nut 12-18 17-26 Transmission Fill/Drain Plug 20-25 29-36 Trans. Mounting Bolts 40 57 Gear Sector Cover 8-12 11-17 Oil Deflector Screws (20-30) 2-3.6 Snorkel Torx Screw 8-12 11-17 Bearing Cover 8-12 11-17 Carrier Cover 23-27 33-39 Shift Fort Retainer Screws 8-12 11-17 Park Plate 8-12 11-17 1. 2. 3. 4. 5. Place vehicle in “park”.
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GENERAL INFORMATION 11. Remove all fasteners (X) attaching the torsion mount, and completely remove the mount (Z) from the ATV. 14. Remove the middle transmission support bracket (K) completely from the ATV. X K X X X Z 12. Remove both upper control arms (I). Refer to Chapter 7 for more details. H 15. Remove the rear transmission support brackets (L) completely from the ATV. L I 13. Remove all lower transmission mounting fasteners (J) from each side. 16.
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GENERAL INFORMATION Transmission Installation 1. 2. 3. Apply Polaris Premium All Season Grease (PN 2871423) to splines of front output shaft ,install new O–ring in prop shaft. With the help of an assistant, rotate transmission into place from the right side of the frame, aligning the forward transmission bracket into the rear engine mounting holes while ensuring that the output shaft and propshaft align and slide together.
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GENERAL INFORMATION 11. Once the PVT system is installed. Tighten all remaining transmission mounting bolts to 40 ft.lbs. (57Nm). See page 8.2 for transmission bolt placement. 12. Install transmission vent line. Be sure vent line is not kinked or pinched. 13. Install seat, both side panels, both rear cab quarter panels and both footwells. See Chapter 5. 14. Reconnect the differential, speed sensor and gear selection switch connectors to the transmission. 15. Reconnect the shift rod.
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GENERAL INFORMATION TRANSMISSION SERVICE Exploded View 262 = THREAD LOCKING AGENT FOR ALL ‘FT. LBS.’ FASTENERS 242 = THREAD LOCKING AGENT FOR ‘INCH LBS. ‘ FASTENERS 8 8.
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GENERAL INFORMATION 262 242 262 262 262 262 8.
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GENERAL INFORMATION Transmission Disassembly 1. 2. 3. 4. 6. Remove the compression spring (7). Place the transmission in the Neutral gear before disassembly. Drain and properly dispose of transmission oil. See Chapter 2. Remove the bellcrank nut (1) and remove the bellcrank (2). Remove the c-clip (3) that holds the gear selector switch (4) onto the shaft and remove the selector switch. 3 2 4 1 7 7. 5. Remove the sector cover bolts (5) and remove the sector cover (6).
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GENERAL INFORMATION 10. Remove all cover bolts. Using suitable pry tools, remove the cover using the designated pry points. Tap cover with soft face hammer to remove. The pry points are indicated by the white arrows in the photo below. 12. Remove the cam chain tensioner spring (14). Slide the cam chain tensioner shoe (15), pins (16), and cam chain tensioner cam (17) from the assembly. Pry points 17 16 16 14 CAUTION Do not pry on case half sealing surfaces.
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GENERAL INFORMATION 15. Remove the T27 screws that secure the output gear (21) with a T27 hex socket or driver. 21 Gear Cluster Disassembly 16. Remove the shift drum (22) from the gearcase by moving the drum up and to the right to clear the shift shaft. 22 Reverse Shaft Needle Bearing (2) 33T Gear (3) Washer 17. Remove the output gear (21) and gear cluster assembly from the gearcase by pulling both assemblies straight up. Place the gear cluster assembly on a clean surface for inspection.
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GENERAL INFORMATION 22. The reverse shaft should slide out of the silent chain (4) to separate the assembly. 26. To disassemble the shift fork rail remove the snap ring (10) from the end of the shift rail on either side. 10 4 10 CAUTION 23. Remove the rest of the bearings from the shafts. 24. Remove the engagement dog (5) from the reverse shaft. REVERSE SHAFT Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury.
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GENERAL INFORMATION 29. Use a 2 3/8” wrench to loosen and remove the front drive shaft snorkel tube (11). 30. If needed, remove the seal from the front of the snorkel tube. Remove the snap ring (12). 12 11 Front Drive Snorkel Assembly 31. Remove the second snap ring (13) and spacer (14) from the snorkel shaft. NOTE: Shim may or may not be present. Depending on input shaft tolerance. 13 14 A. O-ring B. Seal C. Retaining Ring D. Retaining Ring E. Spacer F. Ball Bearing G. Snorkel tube H.
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GENERAL INFORMATION 33. To remove the remaining bearing on the snorkel shaft (15), remove the retaining ring and press the bearing off. 3. Inspect the output gear assembly (1), replace bearings if needed. Inspect the 91T gear for nics, chips, or abnormal worn teeth. 15 Transmission Assembly 1. Install all new seals in the gearcases. Use the Rear Output Seal Driver (PN 2871698) and Rear Driveshaft Seal Guide (PN 2871699) to install the seals into the gearcases.
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GENERAL INFORMATION 6. Install the output gear assembly. Be sure to properly mesh the snorkel shaft bevel gear with the output bevel gear. Install the 4 torx screws (2) to secure the output gear assembly into place. Torque screws to 8-12 ft.lbs. (11-17 Nm). NOTICE! : It is important to set zero lash between the output gear and the snorkel shaft gear. If there is binding or excess lash, tighten or loosen the snorkel shaft until there is zero lash. • Check the output shaft gear backlash again by feel.
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GENERAL INFORMATION 2. Once the gear backlash is found, to install the snorkel lock screw, you may have to rotate the snorkel tube clockwise or counterclockwise slightly. This will allow the lock screw to thread itself into one of the slots of the snorkel tube (See illustration below) to secure the snorkel tube. 4. Assemble the input shaft assembly if previously disassembled. Input Shaft Assembly A. Ball Bearing B. Input Shaft C. Silent Chain Screw Fits in Slots of Snorkel Tube A B C A 5.
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GENERAL INFORMATION 6. Inspect the shift drum for any damage or wear. Inspect the splines of the shift drum. Replace the O-rings on the end of the shift drum and lubricate them before assembly. 7. Stretch the silent chain on a flat surface and measure the length of 8 pitches in a minimum of three places on the chain. Replace the chain if the measurement is longer than 3.0904” (7.8496 cm).
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GENERAL INFORMATION 11. Install the oil deflector shield into the gearcase. Apply Loctite™ 242 to the threads of the screws. Torque the screws to 16-30 in.lbs. (2-3.6 Nm). 14. Lift the leg of the spring up and over the rear pin. The tensioner cam will lift the shoe and tension chain. Tensioner Assembly - Top View Forward Spring Leg Tensioner 12.
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GENERAL INFORMATION 15. Apply a continuous bead of Crankcase Sealant (3-Bond) (PN 2871557) to the LH gearcase mating surface and install the cover. Install and tighten the 22 screws in a criss cross pattern to evenly secure the cover. Torque the screws to 2530 ft.lbs. (36-43 Nm). NOTE: Case-halve mating may be difficult due to tensioner 18. Install the O-ring (if not yet done) and lockout disc (H) onto the shift drum shaft.
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GENERAL INFORMATION 22. Install the bellcrank onto the shift shaft. Note the key splined on the bellcrank and shaft. Install the nut. Torque the nut to 12-18 ft.lbs. (16-26 Nm). 23. Install the transmission switch and secure the switch with the retaining ring. 8.
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BRAKES CHAPTER 9 BRAKES SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 COMPONENT SERVICE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 BRAKE SYSTEM EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.
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BRAKES SPECIFICATIONS Torque Table TORQUE SPECIFICATIONS (Sportsman and X2) ITEM TORQUE FT.LBS. (IN.LBS.) TORQUE NM Front / Rear Caliper Mounting Bolts Handlebar Master Cylinder Clamp Bolts Hand Master Cylinder Reservoir Cover Screws Brake Line Banjo Bolt Brake Line Flared Fittings Brake Disc Bolts Brake Switch Caliper Mounting Bolts Sportsman Caliper Slide Pins Rear Master Cylinder-to-Frame Bolts 18 (25 in.lbs.) (7 in.lbs.) 15.0 12-15 18.0 12-15 18.0 30-35 8 24 3.0 0.
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BRAKES BRAKE SYSTEM EXPLODED VIEWS X2 System Component Exploded View 1) Master Cylinder Cover Screws: 7 in.lbs. (0.79 Nm) 2) Banjo Style Fitting: 15 ft.lbs. (21 Nm) 3) Flare Style Fittings: 12-15 ft.lbs. (16-21 Nm) 4) Brake Switch: 12-15 ft.lbs. (16-21 Nm) *Apply Pipe Sealant to Threads 5) Dual Input Master Cylinder and Bleed Screw: 25-30 in. lbs. (2.8-3.4 Nm) 6) Front and Rear Caliper Bleed Screws: 36-60 in. lbs. (4.07-6.78 Nm) 2 1 2 2 5 3 4 2 6 3 9 3 2 2 *All Bleed Screws: 25-30 in.lbs. (2.80-3.
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9.4 2 Screws - 7 in.lbs. (0.79 m) All Flare Style Fittings: 12-15 ft.lbs. (16-21 Nm) Apply Pipe Sealant To Threads All Bleed Screws: 25-30 in.lbs. (2.80-3.40 Nm) All Banjo Style Fittings: 15 ft.lbs.
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BRAKES BRAKE CALIPER EXPLODED VIEWS Sportsman and X2 Front Caliper Assembly A Apply Polaris DOT approved Brake Fluid to Component 3 Apply Polaris All Purpose Grease B 3 E G H C A. Socket Set Screw B. Bleeder Screw C. Caliper Asm. D. Boot E. Square O-rings F. Piston G. Caliper Mount H. Brake PAds D F X2 Rear Caliper Assembly A 3 E B Apply Polaris DOT-approved Brake Fluid to Component A. Socket Set Screw B. Bleeder Screw C.Caliper Asm D. Boot E. Caliper Seals F. Piston G. Caliper Mount H.
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BRAKES Sportsman Rear Caliper Assembly 16-18 ft.lbs. (22-24 Nm) 3 Apply Polaris DOT approved Brake fluid to component. 30-35 ft.lbs. (41-48 Nm) H E A C D B 25-30 in lbs. (2.80-3.
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BRAKES This system also incorporates a diaphragm (E) as part of the cover gasket; and a vent port (F) located between the gasket and the cover. The combination diaphragm and vent allow for the air above the fluid to equalize pressure as the fluid expands or contracts. Make sure the vent is open and allowed to function.
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BRAKES 3. Inspect vent slots (A) in cover and remove any debris or blockage. C Sight Glass D A B 6. Slowly pump the brake lever until pressure builds and holds. 7. While maintaining lever pressure, open bleeder screw. Close bleeder screw and release brake lever. NOTE: Do not release lever before bleeder screw is tight or air may be drawn into caliper. 8. 4. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged.
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BRAKES 12. Install diaphragm, sight glass, cap and screws. Master Cylinder Cap Sight Glass 15. Field test machine at low speed before putting into service. Check for proper braking action and lever reserve. With lever firmly applied, lever reserve should be no less than 1/ 2”, (1.3 cm) from handlebar. 16. Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasion. Replace hose if wear or abrasion is found. FRONT MASTER CYLINDER Cap Screws Removal 1. Diaphragm 2.
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BRAKES 2. Place new sealing washers on each side of banjo fitting on the brake line and torque banjo bolt to specification. Torque to 15 ft.lbs. (21 Nm) Sealing Washer FRONT BRAKES Pad Removal 1. Elevate and support the of the ATV. CAUTION Banjo Bolt Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur. Brake Line 2. 3. Remove the wheel. Loosen pad adjuster screw 2-3 turns. 4. Remove caliper from mounting bracket. =T Banjo Bolt Torque: 15 ft.lbs. (21 Nm) 3.
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BRAKES 5. Push caliper piston into caliper bore slowly using a Cclamp or locking pliers with pads installed. Measure Pad = In. / mm. NOTE: Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 6. Push mounting bracket inward and slip outer brake pad past edge. Remove inner pad. Front Brake Pad Thickness Service Limit: .180” / 4.6 mm Assembly 1. 7.
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BRAKES 2. Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other. 5. Install the adjuster screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise). WARNING 6. Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap. 7. Install wheels and torque wheel nuts.
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BRAKES 2. Measure the disc thickness at eight different points around the pad contact surface. Replace disc if worn beyond service limit. Removal / Replacement NOTE: To reduce the possibility of warping, try removing the brake disc mounting bolts before applying heat to the bolts. 1. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent. 2. Remove bolts and disc. 3. Clean mating surface of disc and hub. 4. Install disc on hub. 5.
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BRAKES FRONT CALIPER 3. Remove mounting bracket, pin assembly and dust boot. 4. 5. Remove piston, dust seals and piston seals. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. Removal CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur. 1. Loosen and remove brake line to caliper. Place a container under caliper to catch fluid draining from brake line. NOTE: Be sure to clean seal grooves in caliper body.
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BRAKES Inspection Reassembly 1. 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. Install new caliper seals (A) in the caliper body (B). Be sure groove is clean and free of residue or brakes may drag upon assembly. C B D A 2. Coat piston with clean Polaris DOT-approved Brake Fluid (C). Install piston (D) with a twisting motion while pushing inward.
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BRAKES 4. Compress the mounting bracket and make sure the dust seals are fully seated. Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease. 6. Install brake line and torque the banjo bolt to specification. =T Brake Line Banjo Bolt Torque: 15 ft.lbs. (21 Nm) 7. Install the adjuster screw and turn until stationary pad contacts disc, then back off 1/2 turn. 8. Perform brake bleeding procedure as outlined earlier in this chapter.
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BRAKES REAR BRAKE PAD 5. Push caliper piston into the caliper bore slowly using a Cclamp or locking pliers with pads installed. X2 Pad Removal 1. Elevate and support the rear of the ATV. 2. Remove the rear wheel 3. Loosen pad adjuster screw 2-3 turns. 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. 4. 6.
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BRAKES 9. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. 3. Install caliper and torque the mounting bolts to specification. Measure Thickness = In. / mm. =T Rear Brake Pad Thickness Service Limit: .180” (4.6 mm) X2 Pad Installation 1. 2. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. Caliper Mount Bolt Torque: 18 ft.lbs. (24 Nm) 4.
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BRAKES Sportsman Rear Pad Removal 1. 2. Support the machine. Remove the rear tire. Remove the slide pin clips from the slide bolt. NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 5. 6. 3. Loosen the slide pins with a hex wrench. Push caliper pistons into caliper bore slowly with pads installed. Remove the caliper slide pins and remove the brake pads from the caliper. Remove Rear Pads 7. 8.
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BRAKES Sportsman Rear Pad Installation 1. 4. Install the slide bolt snap ring. Torque the slide pin to specification. Install new brake pads in caliper body. Install Pads 30-35 ft.lbs. (41-48 Nm) WARNING If the brake pads are contaminated with grease, oil, or liquid soaked do not use the pads, use only new clean pads. 2. 3. Install and tighten the slide pin with a hex wrench. Install caliper and torque the mounting bolts to specification. =T Caliper Slide Bolt Torque: 30-35 ft.lbs. (41-48Nm) 5. 6.
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BRAKES X2 REAR CALIPER 6. Remove piston, dust seals and piston seals. 7. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. Removal CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur. 1. Clean caliper area before removal. 2. Place a container below the caliper to catch brake fluid that will drain from the brake line. Remove brake line from caliper NOTE: Be sure to clean seal grooves in caliper body.
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BRAKES Inspection Reassembly 1. 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. Install new caliper seals (A) in the caliper body (B). Be sure groove is clean and free of residue or brakes may drag upon assembly. C B D A 2. Coat piston with clean Polaris DOT-approved Brake Fluid (C). Install piston (D) with a twisting motion while pushing inward.
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BRAKES 4. Compress the mounting bracket and make sure the dust seals are fully seated. Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease. 4. Remove the slide bolt snap rings (A), the slide pins (B), the bracket pad (C), and the brake pads (D). Caliper C D B A 5. SPORTSMAN REAR CALIPER Remove the anvil bolts and separate caliper halves and remove pistons with piston pliers. Removal and Inspection 1. 2.
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BRAKES 9. Measure the inside diameter of the rear caliper. The caliper body is a 2-step piston. The rear step is measured as well as the outside step. Assembly 1. Install new O-rings in the slide bolt bushing holes. Be sure O-ring and seal grooves are thoroughly cleaned of all residue, or piston may bind in bore. Apply brake fluid to piston seals and install carefully with a twisting motion to ease assembly until fully seated. Seals .94in. (23.88) mm) 1.5 in. (38.1 mm) = In. / mm.
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BRAKES NOTE: The slide pins should be torqued when installed on caliper mount. REAR BRAKE DISC Inspection 1. Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. 2. Use a micrometer and measure disc thickness at 8 different points around perimeter of disc. Replace disc if worn beyond service limit. =T Slide Pin Torque: 30-35 ft.lbs. (41-48 Nm) 4. Install caliper and torque mounting bolts to specification. 30-35 ft.lbs.
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BRAKES REAR MASTER CYLINDER X2 Exploded View I J C B A H E F D D G E 9.26 A. Master Cylinder Bolts B. Rear Brake Line C. Rear Master Cylinder D. Bushing(s) E. Washer(s) F. Cotter Pin G. Foot Pedal H. Spring I. Front Brake Line J.
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BRAKES Overview 2. Polaris disc brake systems are light weight, low maintenance and perform well in the conditions ATV’s routinely encounter. However, there are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life. If required, remove the rear brake line from the master cylinder. Use a suitable container to catch the brake fluid. Dispose of brake fluid properly.
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BRAKES Sportsman Rear Master Cylinder Removal / Installation 1. 2. 3. 4. 5. Remove the RH footwell to gain access to the rear master cylinder. Remove the rear brake lines from the master cylinder. Use a suitable container to catch the brake fluid. Dispose of brake fluid properly. Remove the two bolts that secure the rear master cylinder to the brake mount plate. Replace parts as needed.
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BRAKES Pedal Removal and Installation TROUBLESHOOTING Brakes Squeal • Dirty/contaminated friction pads • Improper alignment • Worn disc X2 Shown • Worn disc splines Poor Brake Performance • Air in system • Water in system (brake fluid contaminated) • Caliper/disc misaligned 1. 2. Remove the RH footwell to gain access to the rear master cylinder. Remove the cotter key. 3. Remove the washers, bushings, and tension spring. 4.
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BRAKES NOTES 9.
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ELECTRICAL CHAPTER 10 ELECTRICAL GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 IGNITION SYSTEM / BASIC ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . 10.3 ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 TROUBLESHOOTING . . . . . .
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ELECTRICAL LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36 HIGH BEAM HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36 HEADLIGHT HOUSING RELACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37 HIGH BEAM HEADLIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38 LOWER HEADLAMP REMOVAL / INSTALLATION. . . . . . . . . . . . .
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ELECTRICAL GENERAL INFORMATION Ignition System / Basic Electrical Components Special Tools Table 10-1: PART NUMBER TOOL DESCRIPTION PV-43568 Fluke™ 77 Digital Multimeter 2870630 Timing Light 2870836 Battery Hydrometer 2460761 Hall Sensor Probe Harness 2871745 Static Timing Light Harness 10 10.
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ELECTRICAL Electrical Service Notes Troubleshooting Keep the following notes in mind when diagnosing an electrical problem: No Spark, Weak or Intermittent Spark • Spark plug gap incorrect • Refer to wiring diagram for stator and electrical component resistance specifications. • Fouled spark plug • When measuring resistance of a component that has a resistance value under 10 Ohms, remember to subtract meter lead resistance from the reading. Connect the leads together and record the resistance.
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ELECTRICAL POWER DISTRIBUTION MODULES (PDM) Sportsman EFI Overview Power Distribution Module (PDM) PDM Located Inside Front Grill Cover SPORTSMAN 500 EFI X2 SPORTSMAN 500 EFI 10 The Power Distribution Module (PDM) integrates these electronic features found on Polaris 500 and 500 X2 EFI ATVs; rectifier/ regulator, main solid-state circuit breaker (SSCB) output, accessory power output, ignition relay output, fan relay controller, ECM relay output, ECM/cluster memory power, light output, starter lockout, ac
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ELECTRICAL Battery Protected Output The battery protected output (BAT_PROT) provides solidstate-circuit-breaker (SSCB) outputs and enables most of the functions on the PDM. The BAT_PROT output must be routed only to the vehicle key/run switch for proper power up sequence. BAT_PROT is enabled when the key/run switch connects the BAT_PROT output to loads (must include RUN input). This causes the micro-controller to power-up and energize BAT_PROT.
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ELECTRICAL CONNECTOR 1 - PIN # SIGNAL NAME DESCRIPTION - IPS = Intelligent Power Switch J1-A J1-B J1-C J1-D ACC_PWR Unused TRANS IDLE J1-E (X2 Only) TURF_MODE High side enable to control differential solenoid.
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ELECTRICAL CHARACTERISTIC PARAMETER UNIT NOTE Ambient temperatures at which module should remain within specified limits Ambient temperatures which should have no adverse effects on module operation Operating Temperature -40 to +55 °C Storage Temperature -50 to +85 °C CHARACTERISTIC MIN TYP MAX UNIT Battery Voltage Batt. Quiescent Current 10.5 14.4 1.5 16 2 Regulator Voltage 14.1 14.4 14.
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ELECTRICAL CHARACTERISTIC MIN TYP MAX UNIT NOTE ECM_MEM OUTPUT (constant power for ECM and Instrument Cluster) MEM Circuit Limit 0.2 1.2 Amp Current capability of the output REVERSE POLARITY PROTECTION Battery Reverse Current 1.8 2 mA Max reverse leakage current when connected in reverse Absolute maximum reverse voltage before device breakdown.
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ELECTRICAL Sportsman 450 Overview The Power Distribution Module (PDM) integrates these electronic features found on the Sportsman 450; rectifier/regulator, solidstate circuit breaker output, starter lockout output and engine temperature controller. There are no service parts in the PDM. If the PDM fails, it must be replaced.
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ELECTRICAL the micro-controller will remain 'ON' until RUN input goes low by disconnection of the BAT_PROT via the key switch or on/off switch. It will remain 'ON' for 5 seconds before turning off The BAT_PROT output is protected from overloads and short circuits. If this occurs, the output turns off. Once tripped, the SSCBs can be reset by removing the overload or cycling the key/ run switches. The SSCBs will trip again if the issue causing the overload is not removed.
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ELECTRICAL CHARACTERISTIC PARAMETER UNIT NOTE Ambient temperatures at which module should remain within specified limits Ambient temperatures which should have no adverse effects on module operation Operating Temperature -40 to +55 °C Storage Temperature -50 to +85 °C CHARACTERISTIC MIN TYP MAX UNIT Battery Voltage Batt. Quiescent Current 7 14.4 16 2 Regulator Voltage 14.1 14.4 14.8 Vdc 18 Adc Regulator Output Minimum Battery Voltage 2 Alternator Coil 1 Resistance 14.
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ELECTRICAL INSTRUMENT CLUSTER Introduction Overview Refer To Illustration 1: (A) Needle (also flashes during warning condition) The Polaris ATV Instrument Cluster is powered by battery voltage (12 VDC) and requires inputs from the engine RPM, transmission gear, and transmission speed sensor for proper operation. Two harnesses plug into the cluster head; one from the transmission speed sensor, and one from the vehicle main harness.
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ELECTRICAL 4. High/Low Battery Voltage • This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged. A low battery warning may also occur under normal operation if the machine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Driving at a higher RPM or connecting a battery charger will usually clear the warning. 5.
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ELECTRICAL Screen 2: Tachometer (Ill. 3) indicates engine rpm. NOTE: 10-20% Variance from these reading is within normal parameters. Ill.3 Screen 3: AWD diagnostic screen. This screen indicates whether or not current is flowing through the AWD coil on models with switchable AWD. AWD Off 23 Ohms in Park 158 Ohms in Neutral AWD On Screen 4: Gear Circuit Diagnostic 75 Ohms in Reverse This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. 10 10.
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ELECTRICAL Setting A New Service Interval 1. 297 Ohms in Low While in the service interval mode, press and hold the mode/override button until the wrench icon flashes. When it begins to flash, release the button. 2. The setting will increase by one hour each time the button is pressed. Pressing and holding the button will allow the numbers to escalate much faster. 3. When the desired time increment is displayed, release the button and wait for the wrench to stop flashing.
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ELECTRICAL Screen 6: Miles/Kilometers: 2. The display in the trip meter and odometer can be changed to display either kilometers or miles. The current display mode will be shown as “KM” or “MP”. To change, hold in the mode button until the letters flash, then press and release the button once. When the display stops flashing, the mode has been set. Turn the key switch ON and OFF 3 times within 5 seconds and leave the key switch in the ON position on the third turn. ON 3.
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ELECTRICAL Speedometer Removal Speedometer Installation 1. 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. Be sure the rubber grommet inside the pod is fully installed and that the indexing key is in the headlight pod keyway. 2. Remove the three screws that secure the headlight pod cover and disconnect the wire connectors from the instrument cluster.
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ELECTRICAL ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING TEST 1 - No All Wheel Drive 10 10.
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ELECTRICAL TEST 2 - No Speedometer Display TEST 3 - No Reverse Speed Limit 10.
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ELECTRICAL TEST 4 - No AWD Hub Safety Limit 10 10.
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ELECTRICAL TEST 5 - Reverse Speed Limiter Activated In Forward Gear TEST 6 - Wheel Speed Sensor 10.
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ELECTRICAL TEST 7 - Fuel Gauge Display Not Working TEST 8 - Shift Indicator Not Working 10 10.
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ELECTRICAL ACTIVE DESCENT CONTROL (ADC) COIL Operation Overview ALL WHEEL DRIVE (AWD) COIL Operation Overview • AWD switch must be ‘ON’. • AWD switch must be ‘ON’. 12Vdc power is present at the ADC hub coil. • PDM pin ‘M’ on SSCB #1 controls the power to the ADC hub coil for operation. • The instrument cluster senses grounding at pin #16. AWD icon should turn on at the instrument cluster.
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ELECTRICAL COOLING SYSTEM COMPONENTS Fan Motor Current Draw Test Fan Control Circuit Operation A current draw test will provide a good indication of fan motor condition. A worn or damaged fan motor will draw more current, which causes a reduction in blade speed and reduced cooling. Power is supplied to the fan via the Orange/Black wire when the relay is ON. The ground path for the fan motor is through the Brown harness wire. Refer to “RELAYS” later in this chapter for more information on fan functions.
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ELECTRICAL Coolant Temperature Sensor GEAR POSITION INDICATOR SWITCH The coolant temperature sensor can be tested using an ohmmeter or voltmeter. Test Diagram If the ECT circuit is open the engine Hot light and fan will both come on. With engine at an ambient temperature of 68°F (20°C), disconnect lead and measure the resistance of sensor between the two ECT terminals and compare to the specification listed. 1. 2. 3. NOTE: Also see “INSTRUMENT CLUSTER TROUBLESHOOTING” for gear switch resistance.
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ELECTRICAL ELECTRONIC THROTTLE CONTROL (ETC) SWITCH 4. Hold throttle cable with fingers at point “A” as shown below and release throttle lever. If the ETC system is functioning properly, the engine will lose spark and stop. Operation Overview 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.
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ELECTRICAL IGNITION SYSTEM Overview The Sportsman has incorporated into it's design a DC/ CDI ignition system. The DC/ ignition system relies on battery power for ignition. EFI - Instead of generating DC voltage via flywheel magnetic induction, a 12 volt DC current is supplied directly from the battery to the PDM. At the PDM, DC current is supplied to the ignition coil for the initial ignition charge.
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ELECTRICAL Components of EFI Alternator and DC / CDI Ignition System 10 10.
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ELECTRICAL EFI Ignition System Testing Flow Chart 10.
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ELECTRICAL Crankshaft Position Sensor Gap Ignition Output Test Using Gap Tester Measure trigger coil gap with a feeler gauge. The gap should be 0.4 - 1.2 mm (0.015 - .047 in.). Re-connect all wires. Disconnect spark plug wire from the spark plug. Connect gap tester lead to engine ground and the other to the ignition coil primary wire leading from the coil. Crank engine and check output. Spark should jump a 1/4" (6mm) gap. Reconnect coil wire.
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ELECTRICAL CHARGING SYSTEM 1. 2. Current Draw - Key Off 3. CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to electrical components. Connect an ammeter in series with the negative battery cable. Check for current draw with the key off. If the draw is excessive, loads should be disconnected from the system one by one until the draw is eliminated. Check component wiring as well as the component for partial shorts to ground to eliminate the draw.
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ELECTRICAL TEST 1: Resistance Value of Each Stator Leg 1. Measure the resistance value of each of the three stator legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3. Each should measure 0.19 Ω ± 15 %. Table 10-2: TEST CONNECT METER WIRES TO: READING IN OHMS Charge Coil Y1 to Y2 0.43 Ω ± 15% Charge Coil Y1 to Y3 0.43 Ω ± 15% Charge Coil Y2 to Y3 0.
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ELECTRICAL Charging System Testing Diagrams 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. SPORTSMAN 500 / 500 X2 EFI SPORTSMAN 450 10.
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ELECTRICAL 10 (PDM) 10.
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ELECTRICAL DIFFERENTIAL SOLENOID LIGHTING Testing High Beam Headlight Bulb Replacement Disconnect from the wire harness. Using a digital ohmmeter, test the solenoid at the connector leads and compare to the specification. Replacement of solenoid is required as it is not serviceable. Remove 3 Screws CAUTION Do not service while headlight is hot. Serious burns may result. Protect lamp during install. Differential Solenoid Resistance: 1.
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ELECTRICAL 4. Turn the headlight lamp socket counter-clockwise and remove. 3. Unplug head lamp harness (C). Turn Harness Assembly C Loosen Tighten 4. 5. Carefully remove head lamp bulb from housing. 6. Remove the head lamp and replace with a new head lamp. NOTE: Do not touch the lamp with bare fingers. Hold the plastic part (1) of the lamp. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. 7.
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ELECTRICAL 8. Reverse the steps to install the new housing and reassemble the pod. 1. Place the vehicle on a level surface with the headlight approximately 25' (7.6 m) from a wall. 25’ (7.6 m) Lamp Center Height 2” (5.1 cm) 5 1/8” (13 cm) NOTE: he distance from the head lamp parting line to the end of the adjustment knob stop is 5 1/8”, (13 cm). See illustration.
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ELECTRICAL 2. Pull the harness assembly out from the headlight assembly. Low Beam Headlight Adjustment 1. The low beam can be adjusted slightly upward or downward. Loosen Screw 3. Remove the lamp and replace with a new head lamp. NOTE: Do not touch the new lamp with bare fingers. Hold the plastic part (1) of the lamp. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. 2. 3. 4. Loosen the phillips screw located at the rear of the head lamp.
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ELECTRICAL Work Light Switch Brake Light / Work Light Replacement Remove the headlight pod cover to locate the switch wires. The switch (A) snaps out by pushing in on the tabs on both sides of the switch. The brake light (A) and the work light (B) are both located in the rear tail lamp housing. 1. A X2 - Open the tailgate and remove the 2 torx head screws (A) securing the rear taillights on each side of the cargo box as illustrated below. A Squeeze Tabs - Push Through Pod To Remove 2.
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ELECTRICAL 3. X2 and Sportsman - Carefully pull out the red locking tab on the connector. Brake Light Switch Test 1. Remove the front cover. Brake Lamp Switch 4. X2 and Sportsman - Once the red tab is pulled out, press in on the black tab and pull out to disconnect harness. Black Tab Red Tab Brake Switch Location 5. X2 and Sportsman - Disconnect the two wire harnesses connected to each of the taillights. Twist bulb housing to remove from lamp assembly and replace bulb. 2. 3. 4.
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ELECTRICAL SPEED SENSOR FUEL SENDER Testing Testing Using the special tools listed, test the speed sensor according to the tester instructions. Remove sensor and inspect the o-ring seal for damage or wear and replace as required. Replacement of sensor is required as it is not serviceable. 1. 2. 3. 4. 5. Drain the fuel tank and remove it from the ATV. Set the fuel tank on a flat surface. Hook up an ohm meter to the fuel sender harness wire (B) and wire (C).
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ELECTRICAL ACCESSORY POWER NOTE: Refer to the accessory instructions for accessory hook-up and installation. Wire Connections Winch Installation Orange/White Wires Located In This Area The 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.
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ELECTRICAL STARTER SYSTEM Troubleshooting Starter Motor Does Not Run • 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 Starter Lockout Troubleshooting- EFI Models The starter lockout is controlled by the PDM.
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ELECTRICAL Starter Lockout Diagram- EFI Starter Lockout Diagram- Sportsman 450 10 10.
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ELECTRICAL Starter Motor Removal / Disassembly O-rings located on the armature housing. NOTE: Use electrical contact cleaner to clean starter motor parts. Some solvents may leave a residue or damage internal parts and insulation. 1. 2. O-Rings Remove the starter from the engine. Remove the two bolts, washers, and sealing O-Rings. Inspect O-Rings and replace if damaged. Shims NOTE: The shims reassembly.
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ELECTRICAL 4. Inspect surface of commutator for wear or discoloration. See Steps 3-6 of ‘Armature Testing’. Armature Testing Brush Inspection 1. Remove armature from starter casing. NOTE: Note order of shims on drive end for reassembly. 1. 2. Measure length of each carbon brush. Replace brush assembly when worn to 5/16” (8 mm) or less. The brushes must slide freely in their holders. 3. Brush Length Inspect surface of commutator. Replace if excessively worn or damaged.
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ELECTRICAL Starter Reassembly 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. 1. 2. 3. 4. 5. 6. 7. 8. Inspect permanent magnets in starter housing. Make sure they are not cracked or separated from housing. Place armature in field magnet casing. Place shims on drive end of armature shaft with phenolic washer outermost on shaft.
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ELECTRICAL STARTER DRIVE Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement If the garter spring is damaged, the overrun clutch may fail to return properly. Use either of the following methods to remove and install a new garter spring: H G F A D B A. B. C. D. E. F. G. H. 1. 2. Gear Assembly Thrust Washer Bushing Retaining Ring Thrust Washer Stopper Cover Spring C E Screw the overrun clutch out to the engaged position on the pinion shaft assembly.
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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. This flow chart assumes that the starter lockout system is functional. 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.
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ELECTRICAL BASIC WINCH WIRING Pre-wired Models 10 10.
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ELECTRICAL TROUBLESHOOTING DIAGRAMS Power On - EFI To ECU Pin 12 Start Circuit - EFI 10.
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ELECTRICAL Ignition Coil - EFI Fuel Pump - EFI 10 10.
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ELECTRICAL Fan - EFI Charging System - EFI 10.
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ELECTRICAL All Wheel Drive - EFI Transmission Switch - EFI 10 10.
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ELECTRICAL Reverse Override - EFI Differential Solenoid - X2 10.
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ELECTRICAL BATTERY Battery Activation Battery Identification WARNING NOTE: 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. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water.
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ELECTRICAL 4. Add electrolyte to bring level back to upper level mark on case. NOTE: This is the last time that electrolyte should be added. If the level becomes low after this point, add only distilled water. 5. 6. Inspect the battery fluid level. When the battery fluid nears the lower level, remove the battery and fill with distilled water only to the upper level line. To remove the battery: Charge battery at 1/10 of its amp/hour rating. Examples: 1/10 of 9 amp battery = .
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ELECTRICAL 4. Install clear battery vent tube from vehicle to battery vent. WARNING Vent tube must be free from obstructions and kinks and securely installed. If not, battery gases could accumulate and cause an explosion. The vent tube should be routed away from frame and body to prevent contact with Route the cables correctly. 5. Low Maintenance Battery Off-Season Storage Battery voltage should be checked with a digital multitester. Readings of 12.
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ELECTRICAL cell battery. Readings of 1.270 or greater should be observed in a fully charged battery. Differences of more than .025 between the lowest and highest cell readings indicate a need to replace the battery. Battery Load Test CAUTION To prevent shock or component damage, remove spark plug high tension leads and connect securely to engine ground before proceeding. Battery Hydrometer (PN 2870836) NOTE: This test can only be performed on machines with electric starters.
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ELECTRICAL 6. Install clear battery vent tube from vehicle to battery vent. WARNING Vent tube must be free from obstructions and kinks and securely installed. If not, battery gases could accumulate and cause an explosion. Vent should be routed away from frame and body to prevent contact with electrolyte. Avoid skin contact with electrolyte, as severe burns could result. If electrolyte contacts the vehicle frame, corrosion will occur. 7. Route cables so they are tucked away in front and behind battery.
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ELECTRICAL Table 10-1: LOW MAINTENANCE BATTERY CHARGING REFERENCE TABLE STATE OF CHARGE VOLTAGE Low Maintenance Battery Load Test CAUTION CHARGE TIME ACTION 100% 12.8-13 V 75-100% 12.5-12.8 V 50-75% 12.0-12.5 V None, check voltage at 3 mos. after manufacture date May need slight charge Needs Charge 25-50% 11.5-12.0 V Needs Charge 0-25% 11.
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500 EFI INTERNATIONAL / QUADRICYCLE 500 EFI INTERNATIONAL / QUADRICYCLE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . 11.2 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 500 EFI INTERNATIONAL / QUADRICYCLE STEERING POST AND LOCK. . . . . . . . . 11.4 STEERING ASSEMBLY EXPLODED VIEW . . . . . . . .
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500 EFI INTERNATIONAL / QUADRICYCLE 500 EFI INTERNATIONAL / QUADRICYCLE BRAKE SYSTEM Overview The Sportsman International / Quadricycle brake system consists of a complete hydraulic brake system. All-wheel braking is integrated into the foot brake and hand brake systems and allows 4 wheel braking from either control separately, or at the same time.
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500 EFI INTERNATIONAL / QUADRICYCLE Foot Brake Supply Hand Brake Supply Exploded View 11 11.
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500 EFI INTERNATIONAL / QUADRICYCLE 500 EFI INTERNATIONAL / QUADRICYCLE STEERING POST AND LOCK Steering Assembly Exploded View The 500 EFI International / Quadricycle Sportsman is equipped with a steering locking mechanism to prevent theft or unauthorized use. Steering post removal may be required for lock service or repair. Lock System Item Number / Description: 11. Lock Collar 12. Lock Set 13. Bolt, Lock Set 14. Bolt(s), Lock Collar 15. Nut(s), Lock Collar 11 11.
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500 EFI INTERNATIONAL / QUADRICYCLE 500 EFI QUADRICYCLE EMISSIONS SYSTEM Overview 500 EFI Quadricycle model ATVs are equipped with an emissions system from the factory. The emission system is designed to meet the various international emissions standards. The emissions system consists of: • A. Air Valve Filter • B. Air Valve Assembly (one way operation) • C. Tubing • D. Air Injection Tube • E.
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500 EFI INTERNATIONAL / QUADRICYCLE 500 INTERNATIONAL & QUADRICYCLE ELECTRICAL Turn / Hazard Signal Diagram 11.
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A A-Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18 Active Descent Control (ADC) Coil . . . . . . . . . . . . . . 10.24 Active Descent Control Gearcase . . . . . . . . . . . . . . . . . . 7.22 ADC Gearcase Piston Service . . . . . . . . . . . . . . . . . . . . 7.27 ADC Gearcase, Disassembly / Inspection . . . . . . . . . . . 7.23 ADC reservoir level inspection . . . . . . . . . . . . . . . . . . . 2.18 Air Filter, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Crankshaft Position Sensor Gap . . . . . . . . . . . . . . . . . .10.31 Crankshaft Straightening . . . . . . . . . . . . . . . . . . . . . . . . .3.10 Crankshaft, Removal and Inspection . . . . . . . . . . . . . . . .3.35 Current Draw - Key Off Test . . . . . . . . . . . . . . . . . . . .10.32 CV Boot, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31 CV Boot, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .7.4 CV Carburetor System Function . . . . . . . . . . . . . . .
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H Handlebar Block Installation Procedure . . . . . . . . . . . . . 5.16 Headlamp Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 10.39 Headlight Housing Replacement . . . . . . . . . . . . . . . . . 10.37 Headlight Pod Exploded View . . . . . . . . . . . . . . . . . . . . 5.15 High Beam Bulb Replacement . . . . . . . . . . . . . . . . . . . 10.36 High Beam Headlight Adjustment . . . . . . . . . . . . . . . . 10.38 Hydraulic Brake System Operation Overview . . . . . . . . . 9.
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Special Tools, EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 Special Tools, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 Special Tools, Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .7.2 Special Tools, Speed Sensor . . . . . . . . . . . . . . . . . . . . .10.42 Specificaiton, Stator Plate Bolt Torque . . . . . . . . . . . . . .3.49 Specification, Brake Disc Service Limit . . . . . . . . . . . . .9.25 Specification, Brake Disc Thickness . . . . . . .
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Wheels, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 Wheels, Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 Wheels, Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 Wire Diagram, Winch Basic . . . . . . . . . . . . . . . . . . . . . 10.51 Wire Diagrams, Electrical . . . . . . . . . . . . . . . . . . . . . . 10.52 Work Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40 IX X X2, Seat Disassembly . . . . . .
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IX.
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WIRE DIAGRAM 2007 SPORTSMAN ACTIVE DESCENT CONTROL (ADC) WIRE DIAGRAM WD-1
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WIRE DIAGRAM INTENTIONAL BLANK PAGE WD-2
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WIRE DIAGRAM 2007 SPORTSMAN 450 WIRE DIAGRAM WD-3
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WIRE DIAGRAM WD-4
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WIRE DIAGRAM 2007 SPORTSMAN 500 EFI ‘STANDARD’ WIRE DIAGRAM WD-5
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WIRE DIAGRAM WD-6
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WIRE DIAGRAM 2007 SPORTSMAN 500 EFI ‘DELUXE’ WIRE DIAGRAM WD-7
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WIRE DIAGRAM WD-8
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WIRE DIAGRAM 2007 SPORTSMAN 500 EFI INTERNATIONAL WIRE DIAGRAM WD-9
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WIRE DIAGRAM WD-10
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WIRE DIAGRAM 2007 SPORTSMAN 500 EFI X2 WIRE DIAGRAM WD-11
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WIRE DIAGRAM WD-12
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WIRE DIAGRAM 2007 SPORTSMAN 500 EFI X2 QUADRICYCLE WIRE DIAGRAM WD-13
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WIRE DIAGRAM WD-14