GENERAL INFORMATION

CHAPTER 1 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL:2006 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2006 HAWKEYE 4X4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL:2006 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MODEL:2006 HAWKEYE 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

1.1
GENERAL INFORMATION

VEHICLE IDENTIFICATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.

Machine Model Number Identification

A 0 6 LB
} 27 AA
}

}
Year Designation } Emissions &
Model Option
Basic Chassis
Designation Engine Designation

Engine Designation Number

ES30PFE ............................................................Single, Air Cooled, SOHC 4 Stroke, Electric Start

Vehicle Identification Number (VIN)

World
Mfg. ID Vehicle Descriptor Vehicle Identifier
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A P B 2 0 A * 5 P 0 0 0 0 0 0
}

}
Engine Model
Year Individual Serial Number
Body Style
Emissions Plant No
Powertrain * This could be either
Check Digit a number or a letter

Vehicle and Engine Serial Number Locations

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

The machine serial number (1- lower frame rail) and

2
engine number (2- right side engine) are important for
vehicle identification.

1.2
 GENERAL INFORMATION

SPECIFICATIONS
MODEL: 2006 HAWKEYE 2x4
MODEL NUMBER: . . . . . . . . . A06LB27AA
ENGINE MODEL: . . . . . . . . . . ES30PFE
Category Dimension
Length 74 in./188 cm
Width 42 in./107 cm
Height 45.5 in./116 cm
Wheel Base 46 in./117 cm
Ground Clearance 8 in./20.3 cm
Dry Weight 525 lbs./238 kg
Gross Vehicle Weight 930 lbs./422 kg
Front Rack Capacity 70 lbs./31.75 kg
Rear Rack Capacity 100 lbs./45 kg
Towing Capacity 750 lbs./340 kg
Hitch Tongue Weight 75 lbs./34 kg
Body Style Recreational/Utility

MODEL: . . . . . . . . . . . . 2006 HAWKEYE 4x4

MODEL NUMBER: . . . . . . . . . A06LD27AA
ENGINE MODEL: . . . . . . . . . . ES30PFE
Category Dimension
Length 74 in./188 cm
Width 42 in./107 cm
Height 45.5 in./116 cm
Wheel Base 46 in./117 cm
Ground Clearance 8 in./20.3 cm
Dry Weight 550 lbs./250 kg
Gross Vehicle Weight 930 lbs./422 kg
Front Rack Capacity 70 lbs./31.75 kg
Rear Rack Capacity 100 lbs./45 kg
Towing Capacity 750 lbs./340 kg
Hitch Tongue Weight 75 lbs./34 kg
Body Style Recreational/Utility

1.3
 GENERAL INFORMATION

MODEL: 2006 HAWKEYE 2x4 Drivetrain

Transmission Type H-N-R
MODEL NUMBER: A06LB27AA
ENGINE MODEL: ES30PFE Transmission Capacity 15.2 oz. (450 ml)
Gear Ratio : Foward 15.18:1
Engine Reverse 14.05:1
Platform Fuji 4 stroke, Single Cylinder Clutch Type CVT w/EBS
Engine Model Number ES300PFE010 Belt 3211108
Engine Displacement 299cc
Steering / Suspension
Number of Cylinders 1
Front Suspension / Shock Mac Pherson Strut
Bore & Stroke (mm) 78.5 x 68 mm
Front Travel 7 in. / 17.8 cm
Compression Ratio 9.2:1 Full Stroke
Rear Suspension Independent
Compression Pressure Compression Relase 60-90 psi Style / Shock Coil-over Adjustable
Engine Idle Speed 1300 RPM Rear Travel 8 in. / 20.3 cm
Cooling System/Capacity Air/Oil Cooled Ground Clearance 8 in. / 20.3 cm
Overheat Warning None Shock Preload Adjustment Front - Cam
Lubrication Wet Sump Front / Rear Rear - Cam
Oil Requirements Polaris 0W-50 / 2 qts (1.9L) Turning Radius 62.5 in. (159 cm) unloaded
Exhaust System Single Pipe - USFS Approved Toe Out 0-1/16 in. (0-.159 mm)
Carburetion Wheels / Brakes
Carburetor model Mikuni BST 34mm Tire/Rim Size - Front 22 x 7-12
Main Jet 147.5
Tire/Rim Size - Rear 22 x 10-12
Pilot Jet 42.5
Air Press. F/R Tires 3-5 psi
Jet Needle 4HB42-5
Brake - Front Single Control Hydraulic Disc
Needle Jet 0-4m
Brake - Rear Single Control Hydraulic Disc
Pilot/Air Screw 2.5 Turns Out (Initial setting)
Brake Fluid Polaris DOT 3 or 4 Brake Fluid
Float Height 13mm from carburetor body
Fuel Delivery Fuel Pump JETTING CHART
AMBIENT TEMPERATURE
Fuel Capacity / 4.5 gal. (17 L) Altitude Below 40o F Above +40o F
Requirement 87 Octane (minimum) Below 5o C Above +5o C
89 Oxygenated Meters 0-1800 152.5 147.5
Electrical (Feet) (0-6000)
1800-3700 147.5 142.5
Alternator Output 250 watt / 18.6 Amp @ 6000
(6000-12000)
Voltage Regulator 3-phase
Lights : High Beam -- CLUTCH CHART
Low Beam 37.5 watts
Altitude Shift Weight
Brake 12V / 26.9 watts
0-1800 14 g (Yellow)
Tail 12V / 8.26 watts
Meters (0-6000) 5412989
Ignition System DC CDI (Feet) 1800-3700 12 g (Red)
Ignition Timing BTDC 30+/-2deg. @ 5000 RPM (6000 - 12000) 5412987
Spark plug / Gap NGK CR8E
.031 in. / .8 mm
Battery / Model / Amp Hr Conventional 14 Amp/hr
Circuit Breakers Fusible Link / 15 amp Main / 15 Amp Accsy

Starting Electric / Recoil Back-up

Indicator Panel LCD / Indicator lights

1.4
 GENERAL INFORMATION

MODEL: 2006 HAWKEYE 4x4 Drivetrain

Transmission Type H-N-R
MODEL NUMBER: A06LD27AA
ENGINE MODEL: ES30PFE Transmission Capacity 15.2 oz. (450 ml)
Gear Ratio : Front Output Fwd 5.17:1 / Rev 4.79:1
Engine Rear Output Fwd 15.18:1 / Rev 14.05:1
Platform Fuji 4 stroke, Single Cylinder Clutch Type CVT w/EBS
Engine Model Number ES300PFE010 Belt 3211108
Engine Displacement 299cc
Steering / Suspension
Number of Cylinders 1
Front Suspension / Shock Mac Pherson Strut
Bore & Stroke (mm) 78.5 x 68 mm
Front Travel 7 in. / 17.8 cm
Compression Ratio 9.2:1 Full Stroke
Rear Suspension Independent
Compression Pressure Compression Relase 60-90 psi Style / Shock Coil-over Adjustable
Engine Idle Speed 1300 RPM Rear Travel 8 in. / 20.3 cm
Cooling System/Capacity Air/Oil Cooled Ground Clearance 8 in. / 20.3 cm
Overheat Warning None Shock Preload Adjustment Front - Cam
Lubrication Wet Sump Front / Rear Rear - Cam
Oil Requirements Polaris 0W-50 / 2 qts (1.9L) Turning Radius 62.5 in. (159 cm) unloaded
Exhaust System Single Pipe - USFS Approved Toe Out 0-1/16 in. (0-.159 mm)
Carburetion Wheels / Brakes
Carburetor model Mikuni BST 34mm Tire/Rim Size - Front 22 x 7-12
Main Jet 147.5
Tire/Rim Size - Rear 22 x 10-12
Pilot Jet 42.5
Air Press. F/R Tires 3-5 psi
Jet Needle 4HB42-5
Brake - Front Single Control Hydraulic Disc
Needle Jet 0-4m
Brake - Rear Single Control Hydraulic Disc
Pilot/Air Screw 2.5 Turns Out (Initial setting)
Brake Fluid Polaris DOT 3 or 4 Brake Fluid
Float Height 13mm from carburetor body
Fuel Delivery Fuel Pump JETTING CHART
AMBIENT TEMPERATURE
Fuel Capacity / 4.5 gal. (17 L) Altitude Below 40o F Above +40o F
Requirement 87 Octane (minimum) Below 5o C Above +5o C
89 Oxygenated Meters 0-1800 152.5 147.5
Electrical (Feet) (0-6000)
1800-3700 147.5 142.5
Alternator Output 250 watt / 18.6 Amp @ 6000
(6000-12000)
Voltage Regulator 3-phase
Lights : High Beam -- CLUTCH CHART
Low Beam 37.5 watts
Brake 12V / 26.9 watts Altitude Shift Weight

Tail 12V / 8.26 watts 0-1800 14 g (Yellow)

Meters (0-6000) 5412989
Ignition System DC CDI (Feet) 1800-3700 12 g (Red)
Ignition Timing BTDC 30+/-2deg. @ 5000 RPM (6000 - 12000) 5412987
Spark plug / Gap NGK CR8E
.031 in. / .8 mm
Battery / Model / Amp Hr Conventional 14 Amp/hr
Circuit Breakers Fusible Link / 15 amp Main / 15 Amp Accsy

Starting Electric / Recoil Back-up

Indicator Panel LCD / Indicator lights

1.5
GENERAL INFORMATION

GENERAL INFORMATION
PUBLICATION NUMBERS
Year Model Model No. Owner’s Manual Parts Manual Parts Micro
PN PN Fiche PN

2006 Hawkeye 2x4 A06LB27AA 9920202 9920207 9920208

2006 Hawkeye 4x4 A06LD27AB,AC 9920202 9920207 9920208

NOTE: When ordering service parts be sure to use the correct parts manual.
NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com or purchased from
www.purepolaris.com.
REPLACEMENT KEYS
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key
and refer to the chart to the right for the proper part number. Should both keys become lost, replacement of the ignition switch
assembly is necessary.
Series # Part Number
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278

1.6
 GENERAL INFORMATION

SPECIAL TOOLS Standard Tools and Engine Tools

Special Tools may be required while servicing your machine.

Some of the tools listed are mandatory and other tools may be
substituted with a similar tool, if available. Polaris
recommends the use of Polaris special tools when servicing
any Polaris product.

Standard Tools and Engine Tools 2870569 - Crankshaft True Kit

2871293 - B - Crankshaft
Slotted Nut Socket
PV - 35667 - A - Cylinder Leakdown Tester

PA - 47344 - Balance Shaft

Slotted Nut Socket PU - 45432 - Caliper or A Basic Caliper

Suspension Tools

2870975 - Mity VacTM

2870871 - ATV Ball Joint Tool Kit

2870773 - C - Clip Install Tool

2870390 - Piston Support Block

2870623 - Shock Spring Compressor

PA-47478 - Drive Clutch Holder

1.7
GENERAL INFORMATION

Standard Tools and Engine Tools Electrical Tools

PV-43568 - FlukeTM 77 Multimeter

2870303- Hone Kit

PV-39617 - Current Clamp

2870305 - Stone Replacement Kit

2870836 - Battery Hydrometer

8712500 - PV-39951-A
2870588 - Hone Oil (12 OZ.) Tachometer Tachometer

2200634 - Valve Seat Reconditioning Kit

2870459 - Dial Indicator

1.8
 GENERAL INFORMATION

STANDARD TORQUE SPECIFICATIONS

The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS Refer to
exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

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

Metric / Torque

6 x 1.0. . . . . . . . . . . 72-78 In.lbs.. . . . . . . . . 8 x 1.25 14-18 ft.lbs . . . . 10 x 1.25 26-30 ft.lbs.

1.9
GENERAL INFORMATION

SAE TAP DRILL SIZES DECIMAL EQUIVALENTS

Thread Size/ Drill Size Thread Size / Drill Size 1/64 ................ .0156
#0-80 3/64 1/2-13 27/64 1/32 . . . . . . . . . . . . . .0312 . . .1 mm= .0394"
3/64 ................ .0469
#1-64 53 1/2-20 29/64 1/16 . . . . . . . . . . . . . .0625
#1-72 53 9/16-12 31/64 5/64 ................ .0781 . . .2 mm = .0787"
#2-56 51 9/16-18 33/64 3/32 . . . . . . . . . . . . . .0938
7/64 ................ .1094 . . .3 mm =.1181"
#2-64 50 5/8-11 17/32 1/8 . . . . . . . . .1250
#3-48 5/64 5/8-18 37/64 9/64 ................ .1406
#3-56 45 3/4-10 21/32 5/32 . . . . . . . . . . . . . .1563 . . .4 mm = .1575"
11/64 ................ .1719
#4-40 43 3/4-16 11/16 3/16 . . . . . . . . . . . . . .1875 . . .5mm= .1969"
#4-48 42 7/8-9 49/64 13/64 ................ .2031
7/32 . . . . . . . . . . . . . .2188
#5-40 38 7/8-14 13/16 15/64 ................ .2344 . . .6 mm = .2362"
#5-44 37 1-8 7/8 1/4 . . . . . . . . .25
#6-32 36 1-12 59/64 17/64 ................ .2656 . . .7 mm = .2756"
9/32 . . . . . . . . . . . . . .2813
#6-40 33 1 1/8-7 63/64 19/64 ................ .2969
#8-32 29 1 1/8-12 1 3/64 5/16 . . . . . . . . . . . . . .3125 . . .8mm= .3150"
#8-36 29 1 1/4-7 1 7/64 21/64 ................ .3281
11/32 . . . . . . . . . . . . .3438 . . .9 mm = .3543"
#10-24 24 1 1/4-12 1 11/64 23/64 ................ .3594
#10-32 21 1 1/2-6 1 11/32 3/8 . . . . . . . . .375
#12-24 17 1 1/2-12 1 27/64 25/64 ................ .3906 . . .10 mm = .3937"
13/32 . . . . . . . . . . . . .4063
#12-28 4.6mm 1 3/4-5 1 9/16 27/64 ................ .4219 . . .11 mm =.4331"
1/4-20 7 1 3/4-12 1 43/64 7/16 . . . . . . . . . . . . . .4375
1/4-28 3 2-4 1/2 1 25/32
29/64 ................ .4531
15/32 . . . . . . . . . . . . .4688 . . .12 mm = .4724"
5/16-18 F 2-12 1 59/64 31/64 ................ .4844
5/16-24 I 2 1/4-4 1/2 2 1/32 1/2 . . . . . . . . .5. . . . . . . . . . . .13mm = .5118"
33/64 ................ .5156
3/8-16 O 2 1/2-4 2 1/4 17/32 . . . . . . . . . . . . .5313
3/8-24 Q 2 3/4-4 2 1/2 35/64 ................ .5469 . . .14 mm = .5512"
7/16-14 U 3-4 2 3/4 9/16 . . . . . . . . . . . . . .5625
37/64 ................ .5781 . . .15 mm = .5906"
7/16-20 25/64 19/32 . . . . . . . . . . . . .5938
39/64 ................ .6094
METRIC TAP DRILL SIZES 5/8 . . . . . . . . .625. . . . . . . . . .16mm=. 6299"
41/64 ................ .6406
Tap Size Drill Size Decimal Nearest
21/32 . . . . . . . . . . . . .6563 . . .17 mm =.6693"
Equivalent Fraction 43/64 ................ .6719
3x.50 #39 0.0995 3/32 11/16 . . . . . . . . . . . . .6875
3x.60 3/32 0.0937 3/32 45/64 ................ .7031 . . .18 mm = .7087"
23/32 . . . . . . . . . . . . .7188
4x.70 #30 0.1285 1/8 47/64 ................ .7344 . . .19 mm = .7480"
4x.75 1/8 0.125 1/8 3/4 . . . . . . . . .75
49/64 ................ .7656
5x.80 #19 0.166 11/64
25/32 . . . . . . . . . . . . .7813 . . .20 mm = .7874"
5x.90 #20 0.161 5/32 51/64 ................ .7969
6x1.00 #9 0.196 13/64 13/16 . . . . . . . . . . . . .8125 . . .21 mm =.8268"
53/64 ................ .8281
7x1.00 16/64 0.234 15/64 27/32 . . . . . . . . . . . . .8438
8x1.00 J 0.277 9/32 55/64 ................ .8594 . . .22 mm = .8661"
8x1.25 17/64 0.265 17/64 7/8 . . . . . . . . .875
57/64 ................ .8906 . . .23 mm = .9055"
9x1.00 5/16 0.3125 5/16 29/32 . . . . . . . . . . . . .9063
9x1.25 5/16 0.3125 5/16 59/64 ................ .9219
10x1.25 11/32 0.3437 11/32 15/16 . . . . . . . . . . . . .9375 . . .24 mm = .9449"
61/64 ................ .9531
10x1.50 R 0.339 11/32 31/32 . . . . . . . . . . . . .9688 . . .25 mm = .9843"
11x1.50 3/8 0.375 3/8 63/64 ................ .9844
12x1.50 13/32 0.406 13/32 1 . . . . . . . . . 1.0
12x1.75 13/32 0.406 13/32

1.10
 GENERAL INFORMATION

CONVERSION TABLE
Unit of Measure Multiplied by Converts to
ft. lbs. x 12 = in. lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.356 = Nm
in. lbs. x .0115 = kg-m
Nm x .7376 = ft. lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 = in. lbs.
kg-m x 10 = Nm
in. x 25.4 =mm
mm x .03937 = in.
in. x 2.54 = cm
mile (mi.) x 1.6 = km
km x .6214 = mile (mi.)
Ounces (oz.) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x 0.035 = Ounces (oz.)
lb. x .454 = kg
kg x 2.2046 = lb.
Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in)
Imperial pints (Imp pt.) x 0.568 = Liters (l)
Liters (l) x 1.76 = Imperial pints (Imp pt.)
Imperial quarts (Imp qt.) x 1.137 = Liters (l)
Liters (l) x 0.88 = Imperial quarts (Imp qt.)
Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.)
US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.)
US quarts (US qt.) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt.)
US gallons (US gal) x 3.785 =Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x 0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)
π(3.14)xR2x H (height) = Cylinder Volume

°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F

°F to °C: 5 (°F + 40) ÷ 9 - 40 = °C

1.11
GENERAL INFORMATION

GLOSSARY OF TERMS
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches.
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and
grip the drive belt.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V
blocks or resting in crankcase. Measure at various points especially at PTO.
CVT: Centrifugal Variable Transmission (Drive Clutch System)
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder
bore.
Electrical Open: Open circuit. An electrical circuit which isn't complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire
touching the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm2: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in2: Pounds per square inch.
Left or Right Side: Always referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical
energy is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040".
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.

1.12
 MAINTENANCE

CHAPTER 2
MAINTENANCE
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2
LUBRICANTS / FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
POLARIS LUBES/FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS. . . . . . . . . . . . . 2.7
POLARIS LUBRICANT SYMBOL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
VEHICLE INSPECTION / MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
HAWKEYE HANDLEBAR COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FRONT GEARCASE LUBRICATION (4X4 ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
LUBRICATION / GREASE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
THROTTLE OPERATION - ALL MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
CHOKE (ENRICHER) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
PILOT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
PILOT SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
ELECTRONIC THROTTLE CONTROL (ETC SWITCH)/THROTTLE CABLE ADJUSTMENT2.14
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
ENGINE FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
MAIN AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
AIR FILTER/PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
AIR BOX SEDIMENT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
CVT DRAIN PLUG & DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
TIE ROD END/STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
TOE ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
TOE ALIGNMENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
EXHAUST CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
BRAKE SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
HOSE/FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
BRAKE FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
SUSPENSION SPRING FRONT / REAR PRELOAD ADJUSTMENT. . . . . . . . . . . . . . 2.24
FRONT SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
REAR SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL, HUB, AND SPINDLE
TORQUE TABLE2.25
WHEEL REMOVAL/INSTALL- FRONT OR REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

2.1
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. If you’re not familiar with safe service and adjustment procedures, have
a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of
approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the
oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to
rise, discontinue use and determine the cause or see your dealer.

Maintenance Chart Key

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

WARNING

Improperly performing the procedures marked with

a could result in component failure and lead to
serious injury or death. Have an authorized Polaris
dealer perform these services.

2.2
 MAINTENANCE

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart
Item Maintenance Interval Remarks
(whichever comes first)
Hours Calendar Miles
(KM)
Steering - Pre-Ride - Check for free operation.
 Front-suspension - Pre-Ride - Make adjustments as needed. See Pre-
 Rear-suspension - Pre-Ride - Ride Checklist on Page 2.8.
Tires - Pre-Ride -
Engine Stop Switch - Check Operation
Make adjustments as needed. See Pre-
 Brake fluid level - Pre-Ride -
Ride Checklist on Page 2.8
 Brake lever travel - Pre-Ride - Make adjustments as needed. See Pre-
Brake systems - Pre-Ride - Ride Checklist on Page 2.8
Throttle - Pre-Ride - Check Operation
Wheels /fasteners - Pre-Ride - Make adjustments as needed. See Pre-
Frame Fasteners - Pre-Ride - Ride Checklist on Page 2.8
 Engine oil level - Pre-Ride -
Make adjustments as needed. See Pre-
E Ride Checklist on Page 2.8
 Air filter, pre-filter - Daily - Inspect;clean often
E
 Air box sediment tube - Daily - Drain deposits when visible
E
Coolant Check level daily, change coolant every 2
- Daily -
(if applicable) years
Check operation; apply dielectric grease if
Headlamp/tail lamp - Daily -
replacing
 Air filter, - Weekly - Inspect; replace as needed
E main element
Recoil housing Drain water as needed, check often if
- Weekly -
(if equipped) operating in wet conditions

Brake pad wear 10 H Monthly 100 (160) Inspect periodically

Battery 20 H Monthly 200 (320) Check terminals; clean; test
 Engine oil change 20 H 1M 100 (160)
Perform a break-in oil change at one
E (break-in) month
Front gearcase oil (if
 equipped) 25 H Monthly 250 (400) Inspect level; change yearly

 Middle gearcase oil (if

25 H Monthly 250 (400) Inspect level; change yearly
equipped)
Rear gearcase oil
 (if equipped) 25 H Monthly 250 (400) Inspect level; change yearly

 Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly

Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
 Have an authorized Polaris dealer perform these services.

2.3
MAINTENANCE

Item Maintenance Interval Remarks

(whichever comes first)
Hours Calendar Miles
(KM)
 Engine breather 25 H Monthly 250 (400) Inspect; replace if necessary
E filter (if equipped)
Engine breather
100 H 6M 1000 (1600) Inspect
hose
General Lubricate all grease fittings, pivots,
 lubrication
50 H 3M 500 (800)
cables, etc.
Shift Linkage 50 H 6M 500 (800) Inspect, lubricate, adjust

Steering 50 H 6M 500 (800) Inspect daily, Lubricate

Inspect, Lubricate, Tighten
 Front suspension 50 H 6M 500 (800)
Fasteners
Inspect, Lubricate, Tighten
 Rear suspension 50 H 6M 500 (800)
Fasteners
Carburetor float Drain bowl periodically and prior to
50 H 6M 500 (800)
bowl storage
 Throttle Cable/ Inspect; adjust; lubricate; replace if
50 H 6M 500 (800)
E ETC Switch necessary
 Inspect; adjust; lubricate; replace if
Choke cable 50 H 6M 500 (800)
E necessary
Carburetor air Inspect ducts for proper sealing/air
E 50 H 6M 500 (800)
intake ducts/flange leaks
Drive belt 100 H 12 M 1000 (1600) Inspect; adjust; replace as needed
Cooling system Inspect coolant strength seasonally;
50 H 6M 500 (800)
(if applicable) pressure test system yearly
Engine oil change 500 Perform a break-in oil change at 20
*Severe Duty 25 H 6M (800) hours/one month, change more
 frequently during cold weather
E
**Normal Duty 50 H 12 M 1000
(1600)
Engine oil change 500 Replace at oil change
*Severe Duty 25 H 6M (800)

**Normal Duty 50 H 12 M 1000

(1600)
 Oil filter change 100 H 6M 1000 (1600) Replace with oil change
E
 Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust
E
 Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
 Have an authorized Polaris dealer perform these services

2.4
 MAINTENANCE

Item Maintenance Interval Remarks

(whichever comes first)
Hours Calendar Miles
(Km)
 1000 Check for leaks at tank cap, lines, fuel valve, filter,
Fuel system 100 H 12M
E (1600) pump, carburetor, replace lines every two years
 1000
Fuel Filter 100 H 12M Replace yearly
E (1600)
Radiator 1000
 (if applicable) 100 H 12M
(1600)
Inspect; clean external surfaces
Cooling hoses 1000
 (if applicable) 100 H 12M
(1600)
Inspect for leaks
1000
 Engine mounts 100 H 12M
(1600)
Inspect
Exhaust muffler / 1000
100 H 12M Inspect
pipe (1600)
 1000
Spark plug 100 H 12M Inspect; replace as needed
E (1600)
 1000
Ignition Timing 100 H 12M Inspect
E (1600)
1000 Inspect for wear, routing, security; apply dielectric
 Wiring 100 H 12M
(1600) grease to connectors subjected to water, mud, etc.
Clutches (drive 1000
 100 H 12M Inspect;clean; replace worn parts
and driven) (1600)
Front wheel 1000
 100 H 12M Inspect; replace as needed
bearings (1600)
2000
 Brake fluid 200 H 24M Change every two years
(3200)
3000
Spark arrestor 300 H 36M Clean out
(4800)
E Idle Speed - Adjust as needed
 Toe adjustment - Inspect periodically; adjust when parts are replaced
 Auxiliary brake Pre- Ride Inspect daily; adjust as needed

Headlight aim - Adjust as needed
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
 Have an authorized Polaris dealer perform these services.

2.5
MAINTENANCE

LUBRICANTS / FLUIDS
POLARIS LUBES/FLUIDS

0W/40
2874865 - Quarts
2874867 - 55 Gallon Drum

ATV Angle Drive Fluid

2.6
 MAINTENANCE

POLARIS LUBRICANTS,MAINTENANCE Part No. Description

AND SERVICE PRODUCTS
Additives / Sealants / Thread Locking Agents /
Misc.

Part No. Description 2870585 Loctite™ Primer N, Aerosol, 25 g

Engine Lubricant Loctite™ Thread Sealant 565

2871956
(50 ml.) (6 Count)
2870791 Fogging Oil (12 oz. Aerosol)
Loctite™ Threadlock 242
2871949
2874865 0W-50 Quarts (50 ml.) (10 Count)

2874867 0W-50 55 Gallon Drum Loctite™ Threadlock 242

2871950
(6 ml.) (12 Count)
Gearcase / Transmission Lubricants
Loctite™ Threadlock 262
Premium Synthetic AGL Gearcase Lube 2871951
2873602 (50 ml.) (10 Count)
(12 oz. bottle) (12 Count)
Loctite™ Threadlock 262
Premium Synthetic AGL Gearcase Lube 2871952
2873603 (6 ml.) (12 Count)
(1 Gal.) (4 Count)
Loctite™ Threadlock 271
Premium ATV Angle Drive Fluid 2871953
2871653 (6 ml.) (12 Count)
(8 oz.) (12 Count)
Loctite™ Threadlock 271
Premium ATV Angle Drive Fluid 2871954
2872276 (36 ml.) (6 Count)
(2.5 Gal) (2 Count)
Loctite™ 680-Retaining Compound
2870465 Oil Pump for 1 Gallon Jug 2870584
(10 ml.)
Grease / Specialized Lubricants Loctite™ 518 Gasket Eliminator / Flange
2870587
Premium All Season Grease Sealant (50 ml.) (10 Count)
2871322
(3 oz. cartridge) (24 Count) Premium Carbon Clean
2871326
Premium All Season Grease (12 oz.) (12 Count)
2871423
(14 oz. cartridge) (10 Count) 2870652 Fuel Stabilizer (16 oz.) (12 Count)
2871460 Starter Drive Grease (12 Count) Black RTV Silicone Sealer
2871957
2871312 Grease Gun Kit (3 oz. tube) (12 Count)

2871329 Dielectric Grease (Nyogel™) Black RTV Silicone Sealer

2871958
(11 oz. cartridge) (12 Count)

NOTE: Each item can be purchased separately at your 2870990 DOT3 Brake Fluid (12 Count)
local Polaris dealer.
2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)

2872893 Engine Degreaser (12oz.) (12 Count)

NOTE: The number count indicated by each part number

in the table above indicates the number of units that are
shipped with each order.

2.7
MAINTENANCE

POLARIS LUBRICANT SYMBOL IDENTIFICATION

NOTE: The symbols are used to properly identify the correct lube or grease to use in the maintenance section.

Polaris DOT 3 Polaris Synthetic Polaris Synthetic Polaris All Season Grease Polaris ATV
Brake Fluid Gearcase Lube OW-50 Oil Angle Drive Fluid

VEHICLE INSPECTION / MAINTENANCE

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

2.8
 MAINTENANCE

HAWKEYE HANDLEBAR COMPONENT LOCATIONS

Indicator Lights 4x4 switch
(if applicable)
Front Brake Speedo

Light Control Throttle

& Run Switch

Choke
Ignition/Start Key
Reverse
Override

MAINTENANCE QUICK REFERENCE

III. # Item Lube Rec. Method Frequency*

Change after 1st month (25

hours), 50 hours thereafter;
Engine Oil Polaris 0W-50 Change more often (25 hours)
1 Add oil to proper level.
Synthetic in severe duty conditions, or
short trip cold weather
operation.

Polaris AGL
2 Transmission See procedure. Change annually2
Lubricant

Fill master cylinder reservoir

Polaris DOT 3 Brake As required. Change fluid
3 Brake Fluid to indicated level inside
Fluid every 2 years.
reservoir.

Drain and refill with pre-

Rear Polaris ATV Angle Drive
4 measured amount of As required*
Gearcase Fluid
lubricant.

Locate grease fitting on

A-Arm Polaris All Season
5 swing arm and grease with Semi-annually 1
Bushings Grease 3
grease gun.

* More often under severe use, such as operated in water or under severe loads.
1 Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
2 Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
3 Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special.

2.9
MAINTENANCE

NOTE: Refer to Page 2.6-2.8 for the Polaris Lubricant Identification table.

1. Engine Oil 2. Transmission Oil

Reservoir Level

3. Brake Fluid
5. Bottom Rear Lower Control Arm 4. Rear Gearcase Oil
Lower Rear Bearing Carrier Pivot
Prop Shaft

2.10
 MAINTENANCE

TRANSMISSION LUBRICATION FRONT GEARCASE LUBRICATION (4X4

The transmission lubricant level should be checked and ONLY)
changed in accordance with the maintenance schedule. The front gearcase lubricant level should be checked and
changed in accordance with the maintenance schedule.
• Be sure vehicle is level before proceeding.
• Check vent hose to be sure it is routed properly and • Be sure vehicle is level before proceeding.
unobstructed. • Check vent hose to be sure it is routed properly and
unobstructed.
TRANSMISSION SPECIFICATIONS
FRONT GEARCASE SPECIFICATIONS
Specified Lubricant:
Polaris AGSL Gearcase Lubricant: Specified Lubricant:
(PN 2873603) (Gallon) (PN 2873602) (12 oz.) Polaris Premium Demand Drive Hub Fluid:
(PN 2872277) (2.5 gallon) (PN 2871654) (8 oz.)
Capacity:
Even with fill plug Capacity:
Even with fill plug
Drain Plug and Fill Plug Torque:
15 ft. lbs. (20 Nm) Drain Plug Torque:
8-10 ft. lbs. (11-13 Nm)
To change / check transmission fluid:
Fill / Check Plug Torque:
1. Place a drain pan beneath oil pan and remove drain plug 8-10 ft. lbs. (11-13 Nm)
from the crankcase. Allow oil to drain completely.
2. Reinstall the drain plug. Tighten to specification.
3. Add the proper amount of lubricant to bring level into
operating range as shown. Do not over fill.
A

C
Drain Plug

Gearcase oil Oil Level Check

flush with the bottom 1. Position the vehicle on a level surface.
of thread area.
2. Remove the check/fill plug (A) and view the oil level. The
oil level should be at the bottom of the check plug (B)
4. Verify fluid level is correct and no leaks are present. threads.
3. Reinstall the check/fill plug (A). Torque to specification.
4. Reinstall the check plug (A) and a new sealing washer.
Torque to specification.

2.11
MAINTENANCE

5. Check for leaks.

Oil Change Verify free play of 1/16-3/16” (1.6-4.76 mm) and smooth
operation of choke cable.Adjustments to the freeplay can be
1. Remove the drain plug (C). Drain the oil into an appropriate
made by loosening the choke cable adjustment in or out to gain
container. Discard used oil properly
the desired freeplay.
2. Clean and reinstall the drain plug with a new sealing
If smooth choke operation is not obtainable, inspect choke
washer. Torque to specification.
cable for kinks or sharp bends in routing.
3. Remove the check plug (A).
CARBURETOR DRAINING
4. Remove the fill plug (B) and add a pre-measured amount of
Polaris Angle Drive Fluid. The fluid should not be above The carburetor float bowl should be drained periodically to
the bottom of the check plug (A) threads. remove moisture or sediment from the bowl, or before extended
periods of storage.
5. Reinstall the fill plug (B) and check plug (A). Torque to
specification. NOTE: The bowl drain screw is located on the bottom left
side of the float bowl.
6. Check for leaks.
1. Turn fuel valve to the OFF position.
LUBRICATION / GREASE POINTS 2. Place a clean container beneath the bowl drain spigot or
bowl drain hose.
There are grease zerks rear lower control arm inner pivots,
lower rear bearing carrier pivots, and the prop shaft. Apply 3. Turn drain screw out two turns and allow fuel in the float
grease until it is visible on the ends of the pivot points. bowl and fuel line to drain completely.
4. Inspect the drained fuel for water or sediment.
5. Tighten drain screw.
THROTTLE OPERATION - ALL MODELS
6. Turn fuel valve to “ON”.
Check for smooth throttle opening and closing in all handlebar
positions. Throttle lever operation should be smooth and lever 7. Start machine and check for leaks.
must return freely without binding. NOTE: All tubes attached to the carburetor must be
1. Place the gear selector in neutral. check for pinching or blockage, as this will effect engine
performance
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle speed
increases at any point in the turning range, inspect throttle
cable routing and condition. If cable is routed properly and
in good condition, repeat adjustment procedure.
5. Replace the throttle cable if worn, kinked, or damaged.

CHOKE (ENRICHER) ADJUSTMENT Drain tube

attached
here

III. 1 Drain Screw

CHOKE

2.12

PILOT SCREW
The pilot system supplies fuel during engine operation with the
throttle valve closed or slightly opened. The fuel/air mixture is
metered by pilot screw and discharged into the main bore
through the pilot outlet.
CAUTION
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 tamper-
ing. Removal of the tamper proof plug is not permit-
ted. For service purposes, cleaning of the pilot
circuit can be done only by a certified repair shop to
ensure air quality standards are not exceeded.
Pilot Screw Location
Brass Plug Installed
Brass Plug Removed
MAINTENANCE
PILOT SCREW ADJUSTMENT
FRONT
(Engine)
Pilot Screw
1. Start engine and warm it up to operating temperature (about
10 minutes).
2. Turn pilot screw in (clockwise) until lightly seated. Turn
screw out the specified number of turns. NOTE: Do not
tighten the pilot screw forcefully against the seat or the
screw and/or seat will be permanently damaged.
Pilot screws are calibrated at the factory. Each
carburetor has a slightly different pilot screw
setting. The specifications may require
additional tuning to achieve the desired results.
3. Connect an accurate tachometer that will read in increments
of + or - 50 RPM such as the PET 2100DX (PN
8712100DX) or the PET 2500 (PN 8712500).
4. Set idle speed to 1200 RPM. Always check throttle cable
freeplay after adjusting idle speed and adjust if necessary.
5. Slowly turn mixture screw clockwise using the pilot screw
wrench until engine begins to miss.
2.13
MAINTENANCE

6. Slowly turn mixture screw counterclockwise until idle • Do not overfill the tank. Do not fill the tank neck.
speed increases to maximum RPM. Continue turning
• If you get gasoline in your eyes or if you swallow
counterclockwise until idle RPM begins to drop.
gasoline, seek medical attention immediately.
7. Center the pilot screw between the points in Step 5 and 6.
• If you spill gasoline on your skin or clothing,
8. Re adjust idle speed if not within specification. immediately wash it off with soap and water and
change clothing.
ELECTRONIC THROTTLE CONTROL (ETC • Never start the engine or let it run in an enclosed
SWITCH)/THROTTLE CABLE ADJUSTMENT area. Engine exhaust fumes are poisonous and can
1. Slide the boots off inline cable adjuster sleeve. Loosen result loss of consciousness or death in a short
adjuster locknut. time.

2. With handlebars centered and wheels pointing forward, turn • Never drain the float bowl when the engine is hot.
adjuster sleeve until 1/16” - 1/8” freeplay is achieved at the Severe burns may result.
thumb lever. After making any adjustment, “flip” the lever
slightly to confirm adjustment. FUEL LINES
1. Check fuel lines for signs of wear, deterioration, damage, or
leakage. Replace if necessary.
2. Be sure fuel lines are routed properly and secured with
cable ties.
Boot
Locknut
Boot CAUTION
Adjuster
Sleeve Make sure lines are not kinked or pinched

3. Replace all fuel lines every two years.

Direction
of travel VENT LINES
1/16” to 1/8”
Freeplay 1. Check fuel tank, crankcase, carburetor, battery and
transmission vent lines for signs of wear, deterioration,
3. Tighten locknut and slide boots over cable adjuster until damage or leakage. Replace every two years.
they touch at the middle point of the adjuster.
2. Verify vent lines are routed properly and secured with cable
4. With engine running, turn the handlebars from full left to ties.
full right with transmission in neutral. Engine RPM should
not change and the engine should not die. If either of these CAUTION
occur, return to the first step.
NOTE: If the throttle cable is adjusted too tight, the ETC Make sure lines are not kinked or pinched
will limit operation at low throttle positions.

FUEL SYSTEM FUEL FILTER

The fuel filter should be replaced in accordance with the
WARNING Periodic Maintenance Chart. The fuel filter is located between
the fuel tank and carburetor.
Gasoline is extremely flammable and explosive
under certain conditions. 1. Clamp fuel lines
• Always stop the engine and refuel outdoors or in a 2. Remove line clamps at both ends of the filter.
well ventilated area.
3. Remove fuel lines from filter.
• Do not smoke or allow open flames or sparks in or
4. Install new filter and clamps onto fuel lines with arrow
near the area where refueling is performed or
pointed in direction of fuel flow.
where gasoline is stored.

2.14

Fuel Filter
To Carburetor
5. Install clamps on fuel line.
6. Start engine and inspect for leaks.
7. Remove clamps
COMPRESSION TEST
NOTE: This 4-Stroke engine is equipped with an
automatic decompressor. Compression readings will vary
in proportion to cranking speed during the test. Average
compression (measured) is about 90 psi during a
compression test.
Smooth idle generally indicates good compression. Low engine
compression is rarely a factor in running condition problems
above idle speed. Abnormally high compression can be caused
by a decompressor malfunction, or worn or damaged exhaust
cam lobes. Inspect camshaft and automatic decompression
mechanism if compression is abnormally high.
A cylinder leakage test is the best indication of engine
condition on models with automatic decompression. Follow
tester manufacturer’s instructions to perform a cylinder leakage
test. (Never use high pressure leakage testers as crankshaft
seals may dislodge and leak).
Cylinder Compression
Standard: 90PSI
Cylinder Leakage
Service Limit: 10%
(Inspect for cause if leakage exceeds 10%)
ENGINE MOUNTS
Inspect rubber engine mounts for cracks or damage.
ENGINE FASTENER TORQUE
Check engine fasteners and ensure they are tight
MAINTENANCE
BATTERY MAINTENANCE
WARNING
Battery electrolyte is poisonous. It contains sulfuric
acid. Serious burns can result from contact with
skin, eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Fol-
low with milk of magnesia, beaten egg, or vegetable
oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get
prompt medical attention.
Batteries produce explosive gases. Keep sparks,
flame, cigarettes, etc. away. Ventilate when charg-
ing or using in an enclosed space. Always shield
eyes when working near batteries. KEEP OUT OF
REACH OF CHILDREN.
NOTE: All Hawkeye batteries are Low Maintenance
design and construction. All Low Maintenance
batteries are fully charged and tested at the factory
before installation. Expected shelf life is 6-8 months
depending on storage conditions. As a general rule
before placing the battery into service, check the
battery condition and charge accordingly.
Low Maintenance batteries are permanently sealed at the time
of manufacture. The use of lead-calcium and AGM technology
instead of lead-antimony allows the battery acid to be fully
absorbed. For this reason, a Low Maintenance battery case is
dark and the cell caps are not removable, since there is no need
to check electrolyte level.
NEVER attempt to add electrolyte or water to a Low
Maintenance battery. Doing so will damage the case and
shorten the life of the battery. Refer to the Battery Maintenance
Video (PN 9917987) for proper instruction on servicing Low
Maintenance batteries.
2.15
MAINTENANCE

The battery is located under front rack. SPARK PLUG

To remove the battery: 1. Remove the seat and left hand side panel.
1. Disconnect holder strap. 2. Remove spark plug high tension lead. Clean plug area so no
2. Disconnect battery negative (-) (black) cable first, followed dirt and debris can fall into engine when plug is removed.
by the positive (+) (red) cable. 3. Remove spark plug.

CAUTION 4.
To reduce the chance of sparks: Whenever re-
moving the battery, disconnect the negative
(black) cable first. When reinstalling the battery,
install the negative cable last.
Inspect electrodes for wear and carbon buildup. Look for a
sharp outer edge with no rounding or erosion of the
electrodes.
Inspect electrode for wear and buildup
Spark Plug Gap

3. Remove the battery.

4. Clean battery cables and terminals with a stiff wire brush.
Corrosion can be removed using a solution of one cup water
and one tablespoon baking soda. Rinse well with clean
water and dry thoroughly.
5. Clean with electrical contact cleaner or a glass bead spark
5. Reinstall battery, attaching positive (+) (red) cable first and
plug cleaner only. CAUTION: A wire brush or coated
then the negative (-) (black) cable.
abrasive should not be used.
6. Coat terminals and bolt threads with Dielectric Grease (PN
6. Measure gap with a wire gauge. Refer to specifications for
2871329).
proper spark plug type and gap. Adjust gap if necessary by
7. Reinstall battery cover and holder strap. bending the side electrode carefully.
7. If necessary, replace spark plug with proper type.
CAUTION: Severe engine damage may occur if the
incorrect spark plug is used.
8. Apply a small amount of anti-seize compound to the spark
plug threads.
9. Install spark plug and torque to 9-11 ft. lbs (12-14 Nm).

2.16
 MAINTENANCE

10. Replace side panel and seat. 2. Remove clips from air box cover (A) and remove cover.
Recommended Spark Plug:
A
NGK R7HSA

Spark Plug Torque: 9-11 Ft. Lbs.

(12 - 14 Nm)

IGNITION TIMING
Timing is CDI controlled and has no adjustment procedure.

Ignition Timing:

32o + 2o BTDC@3000RPM
3. Inspect the gasket. It should adhere tightly to the cover and
seal all the way around.
MAIN AIR FILTER CLEANING
4. Remove air filter assembly.
It is advisable to replace the filter when it is dirty. However, in
Cleaning:
an emergency it is permissible to clean the main filter if you
observe the following practices. 5. Slip the pre-filter element off of main element. Clean the
pre filter with hot soapy water.
• Never immerse the filter in water since dirt can be
transferred to the clean air side of the filter. 6. Rinse and dry thoroughly.

• If compressed air is used never exceed a pressure
of 40 PSI. Always use a dispersion type nozzle to
prevent filter damage and clean from the inside to
the outside.
• Replace the air filter every 50 hours, and possibly
more often in very dirty conditions.
AIR FILTER/PRE-FILTER SERVICE
It is recommended that the air filter and pre filter be replaced
annually. When riding in extremely dusty conditions,
replacement is required more often.
The pre filter should be cleaned before each ride using the
following procedure:
1. Remove the seat.
7. Inspect element for tears or damage.
8. Inspect main filter and replace if necessary. If the filter has
been soaked with fuel or oil it must be replaced.
Installation:
9. Reinstall pre-filter element over main filter. Be sure the
element covers entire surface of main filter without folds,
creases, or gaps.
10. Reinstall filter on main filter mount. Place filter clamp over
the assembly and tighten.
NOTE: Apply a small amount of general purpose grease
to the sealing edges of the filter before reinstalling.

2.17
MAINTENANCE

CVT DRAIN PLUG & DRYING

Proper Filter Placement NOTE: If operating the ATV through water, be sure to
Main Filter check the CVT and other components for water ingestion.
Filter The ATV should be checked immediately.
Support
1. To release any water that maybe trapped in the CVT cover,
simply remove the CVT drain plug and O-ring located on
Air Box the bottom of the CVT cover and let the water drain out.

III. 3 Rear

NOTE: The air filter should rest on the filter support.

Proper placement of the air filter is important to prevent
rattles and air leaks. See Illustration above.
11. Install air box cover and secure with clips.
AIR BOX SEDIMENT TUBE
Periodically check the air box drain tube located toward the
rear of the machine. Drain whenever deposits are visible in the
clear tube.
2. To further expel water from the cover and to dry out the
CVT system, shift the transmission to neutral and rev
engine slightly to expel the moisture and air-dry the belt and
clutches. Allow engine RPM to settle to idle speed, shift
transmission to lowest available range and test for belt
slippage. Operate ATV in lowest available range for a short
period of time until CVT system is dry.

ENGINE OIL LEVEL

To check the oil level:
1. Set machine on a level surface.
2. Place the transmission in neutral.
3. Lock the parking brake.
Sediment Tube

NOTE: The sediment tube will require more frequent

service if the vehicle is operated in wet conditions or at
high throttle openings for extended periods.
1. Remove drain plug from end of sediment tube.
2. Drain Tube.
3. Reinstall drain plug.
4. Start the engine. Allow it to idle for 30 seconds.
5. Turn the engine off.
6. The oil dipstick and fill hole are located behind the recoil on

2.18
 MAINTENANCE

the right side of the ATV. 6. Clean the area around the drain plug.

CAUTION
7. Remove the dipstick and wipe it clean.
8. Reinstall the dipstick completely Hot oil may result in serious burns. Do not allow hot oil
9. Remove the dipstick an check the oil level. to contact skin.
10. Add oil as needed to bring the level between the minimum 7. Place a drain pan under the vehicle.
and maximum marks. Do not over fill.
8. Remove the drain plug. Use a 6mm Allen wrench.
11. Reinstall the dipstick.
9. Drain the oil.

OIL AND FILTER CHANGE

1. Set machine on a level surface.
2. Place the transmission in neutral.
3. Lock the parking brake.
10. Reinstall the drain plug with a new sealing washer.
11. Torque to 14 ft-lb (19Nm).
NOTE: The sealing surfaces on the drain plug and
crankcase should be clean and free of burrs, nicks or
scratches.
12. Place towels under the oil filter.
13. Using an oil filter wrench, turn the filter counter clockwise
to remove it.

4. Start the engine. Allow it to idle for two to three minuets.

5. Turn the engine off.

2.19
MAINTENANCE

14. Clean the filter sealing area on the engine. VALVE CLEARANCE ADJUSTMENT
15. Lubricate the filter o-ring. Check to make sure the o-ring is
in good condition.

16. Install the new oil filter, After the filter contacts the engine
surface turn it 1/2 turn by hand.
INTAKE VALVE CLEARANCE
1. Verify cam lobes are pointed down.
2. Insert a .006” (.15 mm) feeler gauge between end of intake
valve stem and adjuster screw.
3. When clearance is correct, hold adjuster screw and tighten
locknut securely.
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until clearance is
17. Remove the dipstick.
correct with locknut secured.
18. Add 0W/50 oil.
INTAKE/ EXHAUST VALVE CLEARANCE

.006” (.15 mm)

EXHAUST VALVE CLEARANCE

1. Verify cam lobes are pointed down.
2. Insert an .006” (.15 mm) feeler gauge between end of
exhaust valve stem and adjuster screw.
3. Loosen locknut and turn adjuster screw until there is a slight
19. Reinstall the dipstick. drag on feeler gauge.

20. Start the engine and allow it to idle for two minuets. 4. When clearance is correct, hold adjuster screw and tighten
locknut securely.
21. Turn off the engine. Check for oil leaks.
5. Re-check the valve clearance.
22. Check the oil level. Add oil as needed to bring the level
between the min. and max marks. Do not overfill. 6. Repeat adjustment procedure if necessary until clearance is
correct with locknut secured.

23. Discard used oil and filter properly.
STEERING
The steering components should be checked periodically for
loose fasteners, worn tie rod ends, and damage. Also check to
make sure all cotter pins are in place. If cotter pins are
removed, they must not be re-used. Always use new cotter pins.

2.20
 MAINTENANCE

Replace any worn or damaged steering components. Steering first, and then at front and rear. Try to move the wheel and
should move freely through entire range of travel without hub by pushing inward and pulling outward.
binding. Check routing of all cables, hoses, and wiring to be
sure the steering mechanism is not restricted or limited. NOTE:
Whenever steering components are replaced, check front end
alignment. Use only genuine Polaris parts.

WARNING

Due to the critical nature of the procedures outlined in this

chapter, Polaris recommends steering component repair
and adjustment be performed by an authorized Polaris
Dealer. Only a qualified technician should replace worn or
damaged steering parts. Use only genuine Polaris
replacement parts.
Check for Loose Wheel or Hub
One of two methods can be used to measure toe
alignment: The string method and the chalk method. If
• If abnormal movement is detected, inspect the hub
adjustment is required, refer to following pages for
and wheel assembly to determine the cause.
procedure.
CAMBER AND CASTER
TIE ROD END/STEERING INSPECTION
The camber and caster are non-adjustable.
To check for play in the tie rod end, grasp the steering tie rod,
pull in all directions feeling for movement.
TOE ALIGNMENT
• Repeat inspection for inner tie rod end (on steering
1. Place machine on a smooth level surface.
post).
2. Set handlebars in a straight ahead position and secure
• Replace any worn steering components. Steering
handlebars in this position. NOTE: The steering arm can be
should move freely through entire range of travel
used as an indicator of whether the handlebars are straight.
without binding.
The arm should always point straight back from the steering
post.
3. Place a chalk mark on the center line of the front tires
approximately 10” (25.4 cm) from the floor or as close to
the hub/axle center line as possible. NOTE: It is important
that the height of both marks be equally positioned in order
to get an accurate measurement.
4. Measure the distance between the marks and record the
measurement. Call this measurement “A”.
5. Rotate the tires 180o by moving vehicle forward or
backward. Position chalk marks facing rearward, even with
the hub/axle centerline.
6. Again measure the distance between the marks and record.
Call this measurement “B”. Subtract measurement “B”
from measurement “A”. The difference between
measurements “A” and “B” is the vehicle toe alignment.
The recommended vehicle toe tolerance is 1/8” to 1/4” (.3
to.6 cm) toe out. This means the measurement at the front
• Elevate front end of machine so front wheels are off the of the tire (A) is 1/8” to 1/4” (.3 to.6 cm) wider than the
ground. Check for any looseness in front hub / wheel
assembly by grasping the tire firmly at top and bottom

2.21
MAINTENANCE

measurement at the rear (B). may not be immediately apparent if done

incorrectly. See illustration.
Hold
Rod End

Chalk Line
Measurement Correctly Incorrectly
“A” Tightened Tightened
Measurement “B”
Jam Nut Jam Nut

TOE ALIGNMENT ADJUSTMENT

If toe alignment is incorrect, measure the distance between
EXHAUST CLEANING
vehicle center and each wheel. This will tell you which tie rod
needs adjusting. NOTE: Be sure handlebars are straight ahead
before determining which tie rod(s) need adjustment.
CAUTION
During tie rod adjustment, it is very important that
the following precautions be taken when tightening
tie rod end jam nuts. If the rod end is positioned in-
correctly it will not pivot, and may break
To adjust toe alignment:
• Hold tie rod end to keep it from rotating.
• Loosen jam nuts at both end of the tie rod.
• Shorten or lengthen the tie rod until alignment is as
required to achieve the proper toe setting - (1/8” to
1/4”).
• Important: When tightening the tie rod end jam
nuts, the rod ends must be held parallel to prevent
rod end damage and premature wear. Damage
Failure to heed these warnings could result in serious
personal injury or death.
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.
• To reduce fire hazard, make sure that there
are no combustible materials in the area
when purging the spark arrestor.
• Wear eye protection.
• Do not stand behind or in front of the vehicle
while purging the carbon from the spark
arrestor.
• Never run the engine in an enclosed
area.Exhaust contains poisonous carbon
monoxide gas.
• Do not go under the machine while it is
inclined.Set the hand brake and block the
wheels to prevent roll back.

The exhaust pipe must be periodically purged of accumulated

carbon as follows:
1. Allow the muffler to cool if hot.
2. Remove the fastener (1) and remove the arrestor from the

2.22
 MAINTENANCE

end of the muffler. • Use Polaris DOT 3 or DOT 4 Brake Fluid

SIGHT GLASS

Arrestor

3. Use a non-synthetic brush to clean the arrestor screen. A • Check brake system for fluid leaks, excessive
synthetic brush may melt if components are warm. If travel or spongy feel.
necessary, blow debris from the screen with compressed
air. • Check brake pads for wear, damage or looseness.

4. Inspect the screen for wear and damage. Replace if • Check surface condition of the disc.
necessary. • Inspect thickness of brake pad friction material.
5. Remove and inspect the gasket. Replace if worn or
damaged. BRAKE PAD INSPECTION
6. Reinstall the gasket and arrestor. Front Brake Pads

7. Use a wire brush to clean the arrestor screen. (NOTE: A

synthetic brush may melt if components are warm.) If
necessary, blow debris from the screen with compressed
air.
8. Reinstall the clean out plug and arrestor.
9. Torque screws to 50 in. lbs. (5.6 Nm). Brake Pad
Measure
BRAKE SYSTEM INSPECTION Thickness
Service Limit - .059” (1.5 mm)
The following checks are recommended to keep the brake
system in good operating condition. Service life of brake
Brake pads should be changed when friction material is worn to
system components depends on operating conditions. Inspect
.59” (1.5 mm).
brakes in accordance with the maintenance schedule and before
each ride.
HOSE/FITTING INSPECTION
• Keep fluid level in the master cylinder reservoir to
the indicated level inside reservoir. Check brake system hoses and fittings for cracks, deterioration,
abrasion, and leaks.Tighten any loose fittings and replace any
• Check the fluid level “eye”. If it is clear, it is an
worn or damaged parts.
indication that fluid is needed or the brake pads may
be worn, which can reduce the fluid level.
BRAKE FREEPLAY
Hand Brake Lever
1. Check the brake lever, and foot brake for loose connections,
free play, and damage.
2. Measure the hand brake lever freeplay. Freeplay should be

2.23
MAINTENANCE

0.40-0.80 in. (10-20 mm). • If free play is excessive: Inspect brake pads, pedal,
linkage springs, and hoses for wear or damage and
3. If excessive free play exists, inspect brake pads, pedal,
replace any parts as needed.
linkage springs, and hoses for wear or damage and replace
any parts as needed.
SUSPENSION SPRING FRONT / REAR
PRELOAD ADJUSTMENT
.40” - .80”
(10-20 mm) Operator weight and vehicle loading affect suspension spring
preload requirements. Using Spanner Wrench (PN 2870872)
adjust as necessary to avoid bottoming of the shocks.

Hand Brake Lever Free Play

Rear Foot Brake

Rear Brake

4. Check foot brake effectiveness by applying approximately

50 lb. (23 kg) downward force on the pedal. The top of the
pedal should travel not more than 1 inch (25.4mm).

50 lbs 1” or greater

Floorboard

5. If more than one inch, two things must be examined:

• Free play of the brake pedal should be 1/8 - 1/4

inch (3.2 - 6.35 mm).

2.24
 MAINTENANCE

FRONT SUSPENSION INSPECTION WHEEL REMOVAL/INSTALL- FRONT OR

REAR
Compress and release front suspension. Damping should
Wheel Removal
be smooth throughout the range of travel.
Check all front suspension components for wear or damage. 1. Stop the engine, place the transmission in gear and lock the
parking brake.
Inspect front shocks for leakage.
2. Loosen the wheel nuts slightly.

REAR SUSPENSION INSPECTION 3. Elevate the side of the vehicle by placing a suitable stand
under the footrest frame.
Compress and release rear suspension. Damping should 4. Remove the wheel nuts and remove the wheel.
be smooth throughout the range of travel.
Wheel Installation
• Check all rear suspension components for wear or
1. With the transmission in gear and the parking brake locked,
damage.
place the wheel in the correct position on the wheel hub. Be
• Inspect shock for leakage. sure the valve stem is toward the outside and rotation
arrows on the tire point toward forward rotation.
NOTE:Apply an anti-seize compound on the front
Shock Spanner Wrench
wheel spindle before hub/wheel installation.
(PN 2870872) 2. Attach the wheel nuts and finger tighten them.
3. Lower the vehicle to the ground.
CONTROLS 4. Securely tighten the wheel nuts to the proper torque listed
in the table.
Check controls for proper operation, positioning and
adjustment. CAUTION
• Brake control and switch must be positioned to
allow brake lever to travel throughout entire range Improperly installed wheels could affect vehicle
without contacting switch body. handling and tire wear. On vehicles with tapered
rear wheel nuts, make sure tapered end of nut goes
WHEELS into taper on wheel.
Inspect all wheels for runout or damage. Check wheel nuts and
ensure they are tight. Do not over tighten the wheel nuts.

Wheel
WHEEL, HUB, AND SPINDLE
TORQUE TABLE Wheel Nuts (4)
27 ft. lbs. (37 Nm)
Item Specification

Front Wheel Nuts 27 Ft. Lbs. (37Nm)

Rear Wheel Nuts 27 Ft. Lbs. (37Nm)

Hub Retaining Nut 80 Ft. Lbs. (108 Nm) Cotter

Key

Hub Retaining Nut

80 ft. lbs. (108 Nm)

2.25
MAINTENANCE

WHEEL INSTALLATION Tire Tread Depth

1. With the transmission in gear and the parking brake locked, Always replace tires when tread depth is worn to 1/8” (3 mm)
place the wheel in the correct position on the wheel hub. Be or less.
sure the valve stem is toward the outside and rotation
arrows on the tire point toward forward rotation.
Tread
2. Attach the wheel nuts and finger tighten them. Depth 1/8” (3 mm)

3. Lower the vehicle to the ground.

4. Securely tighten the wheel nuts to the proper torque listed
in the table.

CAUTION

If wheels are improperly installed it could affect

vehicle handling and tire wear. Be sure to prop-
erly torque and install all wheel nuts.

TIRE PRESSURE FRAME, NUTS, BOLTS, FASTENERS

Periodically inspect the torque of all fasteners in accordance
Tire Pressure Inspection (PSI - Cold) with the maintenance schedule. Check that all cotter pins are in
Front Rear place. Refer to specific fastener torques listed in each chapter.

4 4

TIRE INSPECTION
WARNING

Operating an ATV with worn tires will increase the

possibility of the vehicle skidding and possible loss
of control.

Worn tires can cause an accident.

Always replace tires when the tread depth mea-

sures 1/8” (.3 cm) or less.

CAUTION

• Maintain proper tire pressure. Refer to the

warning tire pressure decal applied to the
vehicle.
• Improper tire inflation may affect ATV
maneuverability.
• When replacing a tire always use original
equipment size and type.
• The use of non-standard size or type tires
may affect ATV handling.

2.26
 ENGINE

CHAPTER 3
ENGINE
TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
ENGINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ENGINE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
OIL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3
PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
PISTON RING IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
TRANSMISSION INSTALLATION NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
OIL FLOW / PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
ENGINE BREATHER / OIL SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
CAM CHAIN TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
ROCKER ARM/SHAFT DISASSEMBLY AND INSPECTION. . . . . . . . . . . . . . . . . . . . . 3.17
CAMSHAFT REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
COMBUSTION CHAMBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
ENGINE BOTTOM END DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
CAM CHAIN GUIDE AND TESIONER BLADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
CYLINDER HONE SELECTION/ HONING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . 3.26
HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
FLYWHEEL REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
STARTER DRIVE CLUTCH REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
CAM CHAIN DRIVE SPROCKET REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . 3.29
OIL PUMP INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
STARTING CLUTCH AND ENGINE BRAKING CLUTCH REMOVAL /INSPECTION . . 3.30
STARTING CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION. . . . . . . . . . . . . . . . . . . . . . 3.33
CRANKCASE OIL PASSAGES & PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . 3.34

3.1
ENGINE

CAMSHAFT CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

BALANCE SHAFT BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
CRANKCASE OIL PICKUP STRAINER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
BEARING /SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
END PLAY INSPECTION/ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
CRANKSHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
COUNTER BALANCER SHAFT END PLAY ADJUST. . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
CAM CHAIN, OIL PUMP, & TENSIONER BLADE INSTALLATION . . . . . . . . . . . . . . . 3.38
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
CYLINDER HEAD AND CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
CAMSHAFT INSTALLATION & TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
ROCKER ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
STARTER DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
SPARK PLUG FOULING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
ENGINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

3.2
 ENGINE

TOOLS Oil Pressure Blind Plug 1/4 NPT 20-24 (27-33 Nm)

SPECIAL TOOLS Oil Pressure Relief

14 mm 15-17 (20-23 Nm)
Valve Plug
PART NUMBER TOOL DESCRIPTION Recoil Housing 6mm 7-8 (9-11 Nm)
Valve Seat
2200634
Reconditioning Kit Rocker Adjuster Screw 5mm 3.5-5 (5-7 Nm)
2870390 Piston Support Block
Rocker Cover 6mm 5-6.5 (7-9 Nm)
PA-47308 Flywheel Puller
PA-47457 Starting Clutch Holder Rocker Adjuster Screw
5mm 3.7-5.0 (5-7 Nm)
Crankshaft Slotted Nut Lock Nut
2871293-B
Socket Stator Plate to
6mm 7-8 (9-11 Nm)
Crankcase
TORQUE SPECIFICATIONS Stator to Stator Plate
Screws
5mm 5-6.5 (7-9 Nm)

ENGINE TORQUE SPECIFICATIONS Starter Motor 6mm 5-6.5 (7-9 Nm)

ENGINE TORQUE SPECIFICATIONS Starting Clutch Cover 8mm 14-15.5 (19-21Nm)
Thread ES300PFE010 103-118
Fastener Starting Clutch Nut 16mm
Size Ft. Lbs. (Nm) (140-160 Nm)
Camshaft Chain Spark Plug (New) 12mm 7.5-9 (10-12 Nm)
6mm 5-6.5 (7-9 Nm)
Tensioner Lever
Tighten 30-45
Camshaft Chain Spark Plug (Used) 12mm degrees after
6mm 6.5-8.0 (9-11 Nm)
Tensioner Body gasket contact
Camshaft Chain
8mm 6-7.5 (8-10 Nm)
Tensioner Cap
Camshaft Sprocket
6mm 6.5-8.0 (9-11 Nm)
Cover

Camshaft Sprocket Bolt 10mm 30-34 (40-46 Nm)

Carburetor
8mm 12-14 (16-20 Nm)
Adaptor
Refer to Torque
Cylinder Head Bolts 10mm
Procedure
Cylinder & Head 6mm
6mm 5-7 (7-9 Nm)
Bolts
Crankcase 6mm 6.5-8.0 (9-11 Nm)
Crankshaft Sprocket
25mm 34 (46 Nm)
Slotted Nut
Flywheel Nut 16mm 66-81 (90-110 Nm)
Oil Drain Bolt
14mm 13-16 (18-22 Nm)
(Crankcase)
Oil Filter Pipe Fitting
20mm 9.5-12 (13-16 Nm)
(Crankcase)

3.3
ENGINE

TORQUE PATTERNS
Tightening method for cylinder head nuts:

1) Apply engine oil to washer and threads of 10mm bolts.

2) Tighten 10mm bolts in pattern below to 18.5 ft. lbs. (25

Nm)

3) Loosen 180 degrees

4) Tighten to 11 ft. lbs. (15 Nm)

5) Tighten 90 degrees

6) Tighten 60 degrees

7) Tighten 6mm head and base bolts to 8 ft. lbs. (11 Nm)

Cylinder Head / Cylinder Base

3 2
5
6 mm
6
1 4

3.4
 ENGINE

GENERAL ENGINE SERVICE

ENGINE EXPLODED VIEW
Crankcase Cylinder/
Cylinder Head
6 ft. lbs.

8 ft. lbs.

15 ft. lbs.

15 ft. lbs. SEE

PROCEDURE

12-14 ft. lbs.

5.5 ft. lbs.

16 ft. lbs.

5.5 ft. lbs.

Crankshaft
and Piston Valve Train
3.5 ft. lbs.
7 ft. lbs.

6 ft. lbs.

6 ft. lbs.

30-34 ft. lbs.

34 ft. lbs.

3.5
ENGINE

ENGINE SERVICE DATA

Cylinder Head / Valvetrain ES300PFE010

Camshaft Lobe Height In Std 1.2938-1.2977" (32.863 - 32.963mm)
Limit 1.2820" (32.563 mm)
Ex Std 1.2938-1.2977" (32.863 - 32.963mm)
Limit 1.2820" (32.563 mm)
Journal O.D. PTO 1.0998-1.1004" (27.935-27.950mm)
Journal O.D. MAG 1.5328-1.5334" (38.935-38.950mm)
Journal Bore I.D. PTO 1.1025-1.1033" (28.005-28.025mm)
Journal Bore I.D. MAG 1.5356-1.5364" (39.005-39.025mm)
Std .0021-.0035" (.055 - .090mm)
Camshaft Journal Oil Clearance
Limit .0039" (.10mm)
Camshaft Chain Install new as a part of any crankshaft removal

Cylinder Head Surface Warpage Limit .0020” (.05 mm)

Rocker Arm/Shaft Rocker arm ID .8669-.8677" (22.02-22.04 mm)
Rocker shaft OD .8656-.8661" (21.987-22.00 mm)
Oil Clearance (Limit) .0039" (.10 mm)
Valve Clearance In Std .006" (.15 mm)
Ex Std .006" (.15 mm)
Valve Seat Angle Contacting Width In Std .039" (1.0 mm)
Limit .055" (1.4 mm)
Ex Std .059" (1.5 mm)
Limit .070" (1.8 mm)
Valve Stem Diameter In .2342-.2348" (5.950-5.965 mm)
Ex .2340-.2346" (5.945-5.960 mm)
Limit .1921" (4.9 mm)
In 3.976" (101.0mm)
Stem Length
Ex 3.984" (101.2mm)
In Limit .031" (.8mm)
Margin
Ex Limit .031" (.8mm)
Valve Guide Inner Diameter In .2362-.2367" (6.0-6.012 mm)
Ex .2362-.2367" (6.0-6.012 mm)
Stem to Guide Oil Clearance Limit .006" (.15 mm)
Valve Spring Free Length 1.640" (41.66 mm)
1.377" (35.0 mm)
Squareness 0.075” (1.9 mm)

KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off

3.6
 ENGINE

ENGINE SERVICE DATA

Cylinder / Piston / Connecting Rod ES300PFE010
Cylinder Surface warpage limit (mating with cylinder .002” (0.05 mm)
head)
Cylinder bore Std 3.0590-3.0598" (77.70-77.72 mm)
Taper or Out-of-Round Limit Limit .002” (0.05 mm)
Piston to cylinder clearance Std .0015-.0032" (0.038-0.082 mm)
Limit .0043" (0.11 mm)
1st O.S. + .0098” (.25 mm)
Boring Limit
2nd O.S. + .0197” (.50 mm)
Piston Outer diameter Std 3.0566-3.0575" (77.638-77.662 mm)
1st O.S. .0098" (.25 mm) Oversize
2nd O.S. .0197" (.50 mm) Oversize
Pin Bore - Inner Diameter .7089-.7094" (18.007-18.020 mm)
Piston Pin Pin outer diameter clearance in piston .00015- .00047” (.004- .012 mm)
Degree of fit Push (by hand) fit @ 68o F (20o C) (Standard
clearance 0-.0005" (0-.012mm)
Piston Ring Piston Ring Installed Gap Top ring Std .008-.0012" (.2-.3 mm)
Limit .032" (.8 mm)
Second Std .018-.019" (.35-.50 mm)
ring
Limit .039" (1.0mm)
Oil ring Std .0079-.0275" (.2-.7 mm)
Limit .059" (1.5 mm)
Top ring Std .0006-.0029" (.015.-.074 mm)
Limit .006" (.15 mm)
Piston Ring to Ring Groove Second Std .0009-.0025" (.025-.065 mm)
Clearance ring
Limit .006" (0.15 mm)
Oil ring Std .002-.0057" (.055-.145 mm)
Limit N/A
Connecting Rod Connecting rod small end ID .7089-.7094" (18.007-18.020 mm)
Connecting rod small end radial Std 0 - .0007" (0 - 0.019 mm)
clearance (to piston pin) Limit .0011" (.03 mm)
Connecting rod big end axial (side) Std
.0035-.0196" (.09-.50 mm)
clearance
Limit
.023" (.60 mm)

Connecting rod big end radial Std

0.0004-.0014" (.011-0.038 mm)
clearance
Limit
.0019" (.05 mm)

3.7
ENGINE

Crankshaft / Counter Balancer / Oil Pump ES300PFE010

Crankshaft Crankshaft End Runout Limit 0.0024" (0.06 mm)
Std 0.006-.012" (.15 - .30 mm)
Crankshaft End Play
Limit N/A
Std 0.004-.029" (0.1 - .74 mm)
Counter Balancer Counter Balancer Shaft End Play
Limit N/A
Oil Pump Oil Pump Shaft End Play N/A

Std 0.0027-.0051" (.070 - .130 mm)

Oil Pump End Clearance
Limit N/A

Std 0.0047" (.12 mm)

Pump Rotor Tip Clearance
Limit N/A

Std 0.006 - 008" (.15 - .21 mm)

Pump Feed Rotor to Pump Body
Clearance
Limit N/A

Oil Pressure (Polaris 0W-50 @ Std Above 9 PSI

Normal Operating Temperature @ Idle
Speed) Limit Below 9 PSI

KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off.

3.8
 ENGINE

OIL FLOW DIAGRAM

Rocker Arm
Rocker Shaft
Valve Springs

ES300PFE010
Chain Room

Cylinder Head Camshaft

(RH Cam Journal) Sprocket & Chain

Connecting Rod Small End

Piston Skirt / Rings

Nozzle Right Rear

Cylinder Bolt

Counter Balance Gear Crankshaft

Main Bearing
Connecting Rod Big End

MAG SIDE
Starting Clutch
One Way Clutch Crankcase
Stator Plate
Oil Passage

Oil Cooler / Filter Crankcase

Main Bearing Oil Passage

PTO SIDE Oil Pressure Inspection

& Accy Oil Cooler
Crankcase Fitting Location
Starting Clutch Oil Passage

Oil Pump

Crankcase Oil Pickup Engine Sump

OIL FLOW DIAGRAM KEY Oil Passage Screen

Direct

Indirect

3.9
ENGINE

PISTON IDENTIFICATION • Cylinder Head

The piston is identified by the marking ES30A. • Valves

• Carburetor
Note the directional and identification marks when
viewing the pistons from the top. The letters “IN” must • Piston/RIngs
always be toward the intake side of the engine.
The following components require engine removal for
service:
Piston rings must be installed correctly to ensure engine
performance. The numbers or letters on all rings (except • Starting Clutch (transmission removal required)
oil control rings) must be positioned upward. See text for
• One-Way Clutch (engine braking)
oil control ring upper rail installation. Use the information
below to identify pistons and rings. • Crankshaft
• Crankshaft Main Bearings
Standard
Engine Model Oversize • Counter Balance Shaft or Bearings
Piston
No. Available (mm)
Identification • Crankcase
Valve Pocket to • Transmission
.25mm
ES300PFE010 Rear
.50mm NOTE: Crankshaft components are not serviceable.
(Intake Side)
Replace crankshaft as an assembly.
PISTON RING IDENTIFICATION
ENGINE SERVICE
The piston ring profile is shown below. Install top and
second ring with marking UP. Refer to text for oil control
ENGINE REMOVAL
ring installation.
NOTE: The engine removal procedure described
below removes the engine and transmission as an
Installation
Piston Ring Profile assembly, and the engine is then removed from the
Note
transmission case. The transmission can be removed
Inner Bevel; separately from the engine (see Transmission
TOP RING Mark Faces UP
Barrel Face Removal procedure in this chapter).
1. Clean work area.
Undercut;
SECOND RING Mark Faces UP
Taper Face 2. Thoroughly clean the ATV engine and chassis.
3. Disconnect battery cables at battery.
ACCESSIBLE COMPONENTS
4. Drain engine oil.
The following components can be serviced or
removed with the engine installed in the frame: 5. Disconnect spark plug high tension lead.

• Flywheel 6. Remove the following parts:

• Alternator/Stator • Seat

• Starter Motor/Starter Drive • Left and Right Side Covers

• Oil pump • Rear cab

• Rocker Arms / Rocker Shaft 7. Remove CVT cover and both clutches (refer to CVT
• Camshaft

• Cam Chain and Sprockets

• Cylinder

3.10
 ENGINE

Chapter 8) 13. CVT air intake and exhaust ducts

8. Front prop shaft (4x4 models) (Drive pin out at front
gearcase, pull shaft back, then forward. Refer to Drive
Chapter)
14. Remove carburetor. Insert a clean shop towel into the
carburetor flange to prevent dirt from entering the
intake port.
15. Remove exhaust head pipe.
16. Starter motor positive (+) and negative (-) cables at
starter motor.

9. Remove transmission linkage rod (A) and vent hose

(B)
10. Disconnect gear indicator switch harness (at
transmission)

11. Disconnect speed sensor from transmission (left rear

side).
12. Rear fuel tank bracket

3.11
ENGINE

17. Recoil housing, flywheel and stator (or if front cab is 23. Top rear shock bolts.
removed, remove front cab and disconnect wires.) 24. Top bolts from sway bar bracket.
See “Flywheel Removal / Inspection” on page 3.28. for 25. Lower the jack and pull engine / transmission
flywheel removal procedure. assembly out the rear.
NOTE: If front cab is already removed, the stator
wires can be disconnected. Disregard the steps to
remove recoil cover, flywheel, and stator from the
engine.

18. Front engine mount

19. Support lower sub-frame with a stable platform jack.
20. Rear lower engine mount
21. Sub frame bolts (2 each side)

Rear mount 2 both sides

22. Rear wheel (left side) and brake caliper. Re-install

rear wheel after caliper removal.

3.12
 ENGINE

26. Support engine and remove (9) transmission-to- Engine Break In Period
engine bolts.
4 Cycle Engine Break-In Period is defined as the first 10
hours of engine operation or 2 full tanks of fuel.
• Use only Polaris Premium 4 All Season Synthetic
Oil, or API certified “SH” oil.
• Use fuel with a minimum octane of 87 (R+M)/2
method.
• Change break-in oil and filter at 20 hours or 100
miles, whichever comes first.

IMPORTANT: DO NOT LIFT ENGINE BY THE

STARTING CLUTCH SHAFT!

ENGINE INSTALLATION NOTES

After the engine is installed in the frame, review this checklist

and perform all steps that apply:

General Items
• Install previously removed components using new
gaskets, seals, and fasteners where applicable.
• Perform checks on fluid levels, controls, and all
important areas on the vehicle as outlined in the daily
pre-ride inspection checklist (refer to Chapter 2).

CVT System

• Clean clutch sheaves thoroughly and inspect inlet

and outlet ducts for proper routing and sealing.
• Inspect drive and driven clutch as described in
chapter 8.

Transmission

• Inspect transmission operation.

Exhaust

• Replace exhaust gaskets. Seal connections if

necessary with high temp sealant.
• After running the engine, verify all bolted exhaust
connections are tight and in good condition.
Engine Mount Torque

• Inspect all engine mount fasteners and verify they

are tightened properly

3.13
ENGINE

TRANSMISSION REMOVAL 8. Remove transmission linkage rod (A) and vent hose
(B)
NOTE: The transmission can be removed separately 9. Disconnect gear indicator switch harness (at
from the engine. Follow this procedure if engine transmission)
removal is not required.
1. Clean work area.
2. Thoroughly clean the ATV engine and chassis.
3. Disconnect battery cables at battery.
A
4. Drain transmission oil.
5. Remove the following parts:
• Seat
• Left and Right Side Covers B
• Rear cab

6. Remove CVT cover and both clutches (refer to CVT

Chapter 8) 10. Disconnect speed sensor at transmission (left rear
side).
11. Rear fuel tank bracket.
12. CVT air inlet duct.

7. Front prop shaft (4x4 models) (Drive pin out at front

gearcase, pull shaft back, then forward. Refer to Drive
Chapter)

13. Support frame under engine with a stable platform

jack.
14. Rear wheels and brake caliper.

3.14
 ENGINE

15. Remove rear plate (lower control arm bolts) and upper 22. Loosen, but do not remove the 4 bolts from the rear
control arm bolts. transmission hanger bracket.
16. Remove rear shocks. 23. Remove (9) transmission-to-engine bolts.
24. Remove the top 2 rear bracket bolts.
25. Carefully lower the transmission jack until rear bracket
is clear of frame.
26. Slide transmission to the left until alignment pins in
cover are release from engine case.
27. Remove transmission out to the left side.
28. Remove sway bar bracket from transmission.
29. Refer to transmission disassembly in CVT/
Transmission Chapter 8.

TRANSMISSION INSTALLATION NOTES

1. Install new gasket on engine
2. Install transmission to engine until alignment pins are
17. Remove rear suspension (both sides) with drive
engaged, and screw in 4 bolts to hold in place but do
shafts.
not completely tighten at this time.
18. Rear lower engine mount
3. Loosely install upper frame mount bolts and all
19. Sub frame bolts (2 each side) subframe bolts.
4. Install all remaining transmission-to-engine crankcase
bolts and tighten all in 2 steps to specified torque
following a cross pattern.
5. Tighten subframe to main frame bolts (4) and rear
engine mount bolts.
6. Tighten rear upper bracket bolts.
7. Tighten rear upper bracket bolts.

Rear mount 2 both sides

20. Remove sub frame.

21. Support transmission with another jack.

3.15
ENGINE

ENGINE LUBRICATION CAM CHAIN TENSIONER REMOVAL

Oil Type: . . . . . . . .Polaris Premium 0W-50 Synthetic To position crankshaft at Top Dead Center (TDC) on
compression stroke:
Capacity (DRY):
1.64-1.95 U.S. Quarts (1.55-1.85 l) 4. Remove the valve cover.
Capacity (OIL/FILTER/COOLING BLOCK CHANGE): 5. Rotate engine in normal direction and watch the intake
1.4-1.7 U.S. Quarts (1.3-1.6 l) valve open and begin to close.
6. Continue to rotate engine slowly while watching
Drain Plug:. . . . . .14-18 ft. lbs. (19-24.4 Nm) camshaft sprocket marks and the mark in the timing
Oil Pressure Specification: inspection hole.
(Using Polaris 0W-50 Synthetic @ Operating Single TDC Mark Aligned
Temperature @ Idle) Any pressure reading above 9 PSI.

OIL FLOW / PRESSURE TEST TDC Mark

WARNING
Rotation
Oil temperature can cause serious injury and dam-
age. Wear the proper safety gear when performing
these procedures.

NOTE: Due to the engine assembly having a majority of

roller bearings, oil pressure readings hot or cold will be
very low. Low oil pressure is not an indication of a oil
delivery problem.
1. Remove plug from the crankcase. See Page 3.6
2. Insert a 1/4 Pipe Thread oil pressure gauge adaptor
into the crankcase and attach an oil pressure gauge.
3. Start engine and allow it to reach operating
temperature while monitoring gauge indicator. Any
pressure above 9 PSI is an indication of good oil flow.
7. Align single (T) mark on flywheel with in the inspection
hole, and the cam sprocket pin (facing upward)
aligned with the camshaft to crankshaft center line.
NOTE: The sprocket marks align with gasket surface,
the cam lobes should be pointing down and the valves
should have clearance at this point.

ENGINE BREATHER / OIL SEPARATOR

Dot
The breather / oil separator is located behind the gas tank
on the left side. The breather provides ventilation for the
valve cover and crankcase through the air box.
A FITTING
BREATHER Marks Aligned

8. Remove the cam chain tensioner end cap.

CAUTION: The plunger is under spring tension.
Maintain inward pressure while removing.
9. Remove 2 cam chain tensioner bolts.

3.16

10. Tap lightly on tensioner body with a soft face hammer
to loosen and remove tensioner if required.
CAM CHAIN TENSIONER INSPECTION
1. Pull cam chain tensioner plunger (A) out to the end of
its travel and inspect ratchet teeth on plunger and
pawl. Inspect spring (B) for wear or damage.
A
2. Hold the ratchet open and slide the plunger in and out
of the tensioner body. The plunger should move
smoothly throughout the travel range.
3. Replace entire tensioner assembly if any part is worn
or damaged.
ENGINE
ROCKER ARM/SHAFT DISASSEMBLY AND
INSPECTION
NOTE: Orientation of the components is important for
reassembly. Mark all components before disassembly.
1. Remove the valve cover. Be sure engine is positioned
at TDC on the compression stroke (there should be
clearance on both rocker arm adjusters).
2. Mark the rocker arms to keep them in order for
assembly.
3. Slide the rocker shaft out and be prepared to catch the
wave washer (A) positioned on the PTO end of the
shaft between the casting and the intake rocker arm.
4. Inspect each rocker arm cam follower surface. If there
is any damage or uneven wear, replace the rocker
arm. NOTE: Always replace camshaft if lobe of either
rocker arm is worn or damaged.
Inspect surface of followers
3.17
ENGINE

5. Inspect the rocker arm shaft and the shaft bore in the 4. If not removing the cylinder for other service, secure
cylinder head for wear or signs of scoring. the cam chain with a wire to prevent it from falling into
6. Measure I.D. of each rocker arm (A) for out-of-round the crankcase.
and visually inspect the I.D. surface. Replace arm if
excessive wear is evident.
7. Inspect rocker adjuster screws (B) for wear, pitting, or
damage to threads of the adjuster or locknut. Replace
all worn or damaged parts. NOTE: The end of the
adjuster is hardened and cannot be ground or re-
faced.

5. Inspect cam sprocket teeth for wear or damage.

8. Measure O.D. of rocker shafts for out-of -round.

Inspect them for wear or damage. Replace if 6. Inspect the automatic compression release
excessive wear is evident. NOTE: Orientation of the mechanism. Replace the cam if parts are worn.
rocker shafts is important for reassembly.

Compression Release-one-way operation

CAMSHAFT REMOVAL AND INSPECTION
NOTE: Cam chain tensioner must be removed before
performing this procedure.
1. Remove the camshaft end cover.
2. Remove the sprocket bolt.
3. Slip the chain over the sprocket and remove sprocket.

3.18
 ENGINE

CAMSHAFT INSPECTION 2. Loosen each of the four cylinder head bolts evenly
1. Thoroughly clean the camshaft. 1/4 turn each time in a cross pattern until loose.
2. Visually inspect each cam lobe and bearing journal for
wear, scoring, or damage. Verify oil delivery passages
are clean.
3. Check the automatic decompressor spring legs and
replace if broken. Spring preload is very light (about
45 degrees).
4. Measure the height of the cam lobes with a
micrometer and compare to specification. Replace
cam if worn below minimum height (service limit).

3. Remove bolts (A) and tap the cam support tower with
a plastic hammer until loose. Remove.
4. After removing the camshaft and securing the cam
chain, tap cylinder head lightly with a plastic hammer
until loose. CAUTION: Tap only in reinforced areas or
on thick parts of cylinder head casting.
5. Remove cylinder head, gasket, front chain guide and
dowel pins.

Cam Lobe Height

Intake & Exhaust

Std: 1.2938”-1.2977 (32.863-32.963 mm)
Limit: 1.2820” (32.563 mm)

CYLINDER HEAD REMOVAL

NOTE: Cam chain and tensioner must be removed. If no
crankshaft service is being performed, secure cam chain
with wire to avoid dropping chain into the crankcase.
1. Remove the (two) 6mm screws on the cylinder head
and the two on the cylinder base.
CYLINDER HEAD INSPECTION
1. Thoroughly clean cylinder head surface to remove all
traces of gasket material and carbon.
CAUTION

Use care not to damage sealing surface. If there is

damage found on the cylinder head combustion
chamber, it is recommended the component be re-
placed.

3.19
ENGINE

CYLINDER HEAD WARP INSPECTION
1. Lay a straight edge across the surface of the head at
several different points and measure warpage by
inserting a feeler gauge between the straight edge
and the cylinder head surface. If warpage exceeds the
service limit, replace the cylinder head.
3. Push valve out, keeping it in order for reassembly in
the same guide.
4. Measure free length of the inner and outer springs
with a Vernier caliper, Ill.1. Check spring for
squareness as shown in Ill.2. Replace spring if
measurements are out of specification.

A
Valve Spring
Free Length

III.1

Cylinder Head Warp Limit:

.002” (.05 mm) Coil fatigue/

Squareness
COMBUSTION CHAMBER INSPECTION

Clean all accumulated carbon deposits from combustion

chamber and valve seat area with a soft wire brush.
Inspect the combustion chamber for cracks and/or
damage from foreign debris.
III.2
CYLINDER HEAD DISASSEMBLY 5. Remove valve seals. NOTE: Replace seals whenever
the cylinder head is disassembled. Hardened,
WARNING cracked or worn valve seals will cause excessive oil
consumption and carbon buildup.
Wear eye protection or a face shield during cylinder
head disassembly and reassembly. Cylinder head
service should be performed by a technician knowl-
edgeable in cylinder head reconditioning in a prop-
erly equipped shop.
NOTE: Keep all parts in order with respect to their
location in the cylinder head.
1. Using a valve spring compressor, compress the valve
springs and remove the split keeper. NOTE: To
prevent loss of tension, do not compress the valve
spring more than necessary.
2. Remove spring retainer and spring.
NOTE: The valve springs should be positioned with the
tightly wound coils (A) against the cylinder head.

3.20
 ENGINE

VALVE INSPECTION
1. Remove all carbon from valve with a soft wire wheel.
2. Check valve face for runout, pitting, and burnt spots.
To check for bent valve stems, mount valve in a drill or
use “V” blocks and use a dial indicator.
6. Measure valve guide inside diameter at the top middle
and end of the guide using a small hole gauge and a
micrometer. Measure in two directions, front to back
and side to side.

3. Check end of valve stem for flaring, pitting, wear or 7. Subtract valve stem measurement to obtain stem to
damage (A). guide clearance. NOTE: Be sure to measure each
guide and valve combination individually.
A 8. Replace valve and/or guide if clearance is excessive.
NOTE: If valve guides are replaced, valve seats must be
reconditioned. Refer to Valve Seat Reconditioning for
procedure.
VALVE SEAT RECONDITIONING
Valve Seat Inspection
B
Inspect valve seat in cylinder head for pitting, burnt spots,
roughness, and uneven surface. If any of the above
4. Inspect split keeper groove for wear or flaring of the conditions exist, the valve seat must be reconditioned. If
keeper seat area (B). NOTE: The valves cannot be re- the valve seat is cracked the cylinder head must be
faced or end ground. Valves must be replaced if worn, replaced.
bent, or damaged.
5. Measure diameter of valve stem with a micrometer in
three places and in two different directions (six
measurements total). Replace if excessive wear is
evident.
Measure valve stem in Too Uneven Good Too
several places Wide Narrow

3.21
ENGINE

Cylinder Head Reconditioning 3. Place 46o cutter on the pilot and make a light cut.

NOTE: Servicing the valve guides and valve seats

requires special tools and a thorough knowledge of
reconditioning techniques. Follow the instructions
provided in the Valve Seat Reconditioning Kit (PN
2200634).

CAUTION

Wear eye protection when performing cylinder

head service. Valve guide replacement will require
heating of the cylinder head. Wear gloves to pre-
4. Inspect the cut area of the seat.
vent burns.
• If the contact area is less than 75% of the
Follow the manufacturers instructions provided with the circumference of the seat, rotate the pilot 180o and
valve seat cutters in the Valve Seat Reconditioning Kit make another light cut.
(PN 2200634). Abrasive stone seat reconditioning
equipment can also be used. Keep valves in order with • If the cutter now contacts the uncut portion of the
their respective seat. seat, check the pilot. Look for burrs, nicks, or runout.
If the pilot is bent it must be replaced.
NOTE: Valve seat width and point of contact on the valve • If the contact area of the cutter is in the same place,
face is very important for proper sealing. The valve must the valve guide is distorted from improper installation
contact the valve seat over the entire circumference of and must be replaced. Be sure the cylinder head is at
the seat, and the seat must be the proper width all the the proper temperature and replace the guide.
way around. If the seat is uneven, compression leakage
will result. If the seat is too wide, seat pressure is • If the contact area of the initial cut is greater than
reduced, causing carbon accumulation and possible 75%, continue to cut the seat until all pits are
compression loss. If the seat is too narrow, heat transfer removed and a new seat surface is evident. NOTE:
from valve to seat is reduced and the valve may overheat Remove only the amount of material necessary to
and warp, resulting in burnt valves. repair the seat surface.
1. Install pilot into valve guide.
5. To check the contact area of the seat on the valve
face, apply a thin coating of Prussian Blue™ paste to
the valve seat. If using an interference angle
(46o)apply black marker to the entire valve face (A).

(A)

2. Apply cutting oil to valve seat and cutter.

6. Insert valve into guide and tap valve lightly into place
a few times.

3.22

7. Remove valve and check where the Prussian Blue™
or black marker 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 (A).
(B)
(A)
Proper Seat Contact On Valve Face
• 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.
When contact area is centered on the valve face,
measure seat width.
• If the seat is too wide or uneven, use both top and
bottom cutters to narrow the seat.
• If the seat is too narrow, widen using the 45o cutter
and re-check contact point on the valve face and seat
width after each cut.
Bottom 60o or 75o Seat - 45o or 46o
Top - 30o
ENGINE
NOTE: When using an interference angle, the seat
contact point on the valve will be very narrow, and is a
normal condition. Look for an even and continuous
contact point on the black marker, all the way around the
valve face.
Seat
Width
8. Clean all filings from the area with hot soapy water,
rinse, and dry with compressed air.
9. Lubricate the valve guides with clean engine oil, and
apply oil or water based lapping compound to the face
of the valve. Lapping is not required with an
interference angle.
10. Insert the valve into its respective guide and lap using
a lapping tool or a section of fuel line connected to the
valve stem.
11. Rotate the valve rapidly back and forth until the cut
sounds smooth. Lift the valve slightly off of the seat,
rotate 1/4 turn, and repeat the lapping process. Do this
four to five times until the valve is fully seated, and
repeat process for the other valve.
12. Clean cylinder head, valves, and camshaft oil supply
passages thoroughly.
13. Spray electrical contact cleaner into oil passages and
dry using compressed air.
3.23
ENGINE

CYLINDER HEAD ASSEMBLY 6. Place retainer on springs and install valve spring
compressor. Compress spring only enough to allow
CAUTION split keeper installation and prevent loss of spring
tension. Install split keepers with the gap even on both
sides.
Wear eye protection during assembly.
7. Repeat procedure for remaining valve.
NOTE: Assemble the valves one at a time to maintain 8. When all valves are installed, tap lightly with soft faced
proper order. hammer on the end of the valves to seat the Split
1. Install new valve seals on valve guides. keepers.

VALVE SEALING TEST

1. Clean and dry the combustion chamber area.
2. Pour a small amount of cleaning solvent into each port
and check for leakage around each valve. The valve
seats should hold fluid with no seepage.

2. Apply engine oil to valve guides and seats.

3. Coat valve stem with molybdenum disulfide grease.
4. Install valve carefully with a rotating motion to avoid
damaging valve seal.
5. Dip valve spring and retainer in clean engine oil and
install spring with closely spaced coils toward the
cylinder head.

Closely spaced
coils toward
cylinder head

3.24

ENGINE BOTTOM END DISASSEMBLY
Cylinder Removal
Follow engine disassembly procedures to remove valve
cover, camshaft and rocker arms, and cylinder head.
1. Lift to remove cam chain guide at front of cylinder.
2. Remove the two 6 mm cylinder base bolts.
3. Tap cylinder lightly with a plastic hammer in reinforced
areas only until loose.
4. Rock cylinder forward and backward and lift it from the
crankcase, supporting piston and connecting rod.
Support piston with Piston Support Block (PN
2870390).
CAM CHAIN GUIDE AND TESIONER BLADE
1. The guide can be removed after cylinder head is
removed by pulling it upward out of the channel in the
crankcase.
2. Remove blade and inspect. Replace if worn., cracked,
or damaged.
3. Tensioner blade removal requires recoil, flywheel, and
stator plate removal. Refer to lower end service
procedures to access the bolt securing the tensioner
blade to the crankcase.
ENGINE
PISTON REMOVAL
1. Remove one circlip. Note valve pocket on intake side
of piston for installation.
2. Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston
slightly with a propane torch. CAUTION: Do not apply
heat to the piston rings. The ring may lose radial
tension.
3. Remove the compression rings, starting with the top
ring.
*Using a piston ring pliers: Carefully expand ring and lift
it off the piston. CAUTION: Do not expand the ring more
than the amount necessary to remove it from the piston,
or the ring may break.
*By hand: Placing both thumbs at end gap, carefully
spread the ring open and lift ring over piston at the
opposite side. Use care to not scratch the ring lands.
4. Repeat procedure for second ring.
5. The oil control ring is a three piece design consisting
of a top and bottom steel rail and a center expander
section. Remove the top rail first followed by the
bottom rail and expander.
3.25
ENGINE

CYLINDER INSPECTION CYLINDER HONE SELECTION/ HONING

1. Remove all gasket material from the cylinder sealing PROCEDURE
surfaces.
CAUTION
2. Inspect the top of the cylinder for warpage using a
straight edge and feeler gauge.
A hone which will straighten as well as remove ma-
terial from the cylinder is very important. Using a
common spring loaded glaze breaker for honing is
not advised. Polaris recommends using a rigid
hone or arbor honing machine.

Cylinders may be wet or dry honed depending upon the

hone manufacturer’s recommendations. Wet honing
removes more material faster and leaves a more distinct
pattern in the bore.

Cylinder Warp: HONING TO DEGLAZE

.002” (.05 mm) MAX
3. Inspect cylinder for wear, scratches, or damage.
4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure in
two different directions, front to back and side to side,
on three different levels (1/2” down from top, in the
middle, and 1/2” up from bottom).
1/2” Down From Top of Cylinder
X Y
Y deglazed, and to check for correct cross-hatch.
X
Y
X clean the cylinder to remove all honing residue.
1/2” Up From Bottom
5. Record measurements. If cylinder is tapered or out of
round beyond specification, the cylinder must be
honed, bored or replaced.
Cylinder Taper
Limit: .002” (.05 mm) Max.
Cylinder Out of Round
Limit: .002” (.05 mm) Max.
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”
(1.3 cm) above and below the bore at the end of
each stroke.
• Release the hone at regular intervals and inspect
the bore to determine if it has been sufficiently
NOTE: Do not allow cylinder to heat up during
honing.
• After honing has been completed, THOROUGHLY
IMPORTANT: Clean the Cylinder After Honing
Wash the cylinder in a solvent, then in hot, soapy water.
Use electrical contact cleaner if necessary to clean areas
that cannot be scrubbed. Rinse thoroughly, dry with
compressed air, and oil the bore immediately with Polaris
4 Cycle Lubricant to prevent the formation of surface rust.

3.26
 ENGINE

If cylinder wear or damage is excessive, it will be 3. Measure piston pin bore. Replace piston if out-of-
necessary to replace the cylinder. Hone only enough to round
deglaze the outer layer of the cylinder bore.

Piston Pin Bore

4. Measure piston pin O.D. Replace piston pin if out-of-

round.

EXAMPLE OF CROSS HATCH PATTERN

PISTON INSPECTION
1. Measure piston outside diameter at a point 7 mm up
from the bottom of the piston at a right angle to the
direction of the piston pin.
Piston Pin Measurement Locations
5. Measure connecting rod small end ID. Replace
crankshaft if out-of-round.
7mm

Piston
Piston Pin

2. Subtract this measurement from the maximum

cylinder measurement obtained earlier.

Piston to Cylinder Clearance

Std: .0015- .0032” (0.038- 0.082 mm)

Limit: .0043” (.11 mm)

3.27
ENGINE

6. Measure piston ring to groove clearance by placing
the ring in the ring land and measuring with a
thickness gauge. Replace piston and rings if ring-to-
groove clearance exceeds service limits.
Piston
Ring
Feeler Gauge
cylinder should be measured for excessive taper and out
of round.
3. If the installed gap measurement exceeds the limit,
replace the rings. If using new rings and the
measurement is too small, file the ring ends to achieve
the proper gap.
NOTE: Always check piston ring installed gap after re-
boring a cylinder or when installing new rings. A re-bored
cylinder should always be scrubbed thoroughly with hot
soapy water, rinsed, and dried completely. Wipe cylinder
bore with an oil rag immediately to remove residue and
prevent rust.
FLYWHEEL REMOVAL / INSPECTION
CAUTION

The crankshaft end contains an oil passage plunge

PISTON RING INSTALLED GAP
1. Place each piston ring inside cylinder using piston to
push ring squarely into place as shown.
Piston ring installed end gap
joint (A) as shown below. The plunger must be able
to move in and out freely. Avoid damage to the
crankshaft end or plunge joint and spring, which
can cause loss of oil pressure, resulting in severe
engine damage.

1. Remove the recoil housing, recoil hub, and flywheel

nut.
Feeler Gauge

Cylinder 25-50 mm

Piston Ring

Piston Ring Installed Gap

Top Ring 2. Install Flywheel Puller (PN PA-47308) and remove

Std: .008- .012” (.2- .3 mm) flywheel. CAUTION: Do not hammer or strike the tool
Limit: .032” (0.8 mm) while attached to the crankshaft end.
Second Ring
Std: .014- .020” (0.35- 0.50 mm)
Limit: .039” (1.0 mm)
Oil Ring
Std: .008- .028” (0.2- 0.7 mm)
Limit: .059” (1.5 mm)

2. Measure the gap with a feeler gauge at both the top

and bottom of the cylinder.
NOTE: Measure at two points in the cylinder A
difference in end gap indicates cylinder taper. The

3.28
 ENGINE

STARTER DRIVE CLUTCH REMOVAL/ CAM CHAIN DRIVE SPROCKET REMOVAL /

INSPECTION
INSPECTION
1. Remove recoil housing bolts and remove housing.
1. Remove recoil housing, flywheel, flywheel key, and
2. Remove the starter drive clutch and washer by pulling
stator.
the shaft and tilting the gear slightly.

3. Measure the OD of the starter drive shaft on both ends
for out-of-round.
4. Measure the ID of the bushings in the recoil housing
and in the crankcase (A) in two directions 90o apart to
determine if out-of-round. Replace worn bushings.
2. Using the Slotted Nut Socket, remove the crankshaft
slotted nut by turning it clockwise. NOTE: Slotted nut
is left hand thread.

REMOVE

Slotted Nut Socket

5. Inspect gear teeth on starter drive. Replace starter
drive if gear teeth are cracked, worn, or broken. (PN 2871293-A)

3. Remove cam chain drive sprocket and Woodruff key

from crankshaft.
4. Inspect sprocket teeth for wear or damage.

Visually inspect for

tooth wear or damage

5. Inspect Woodruff key for wear.

3.29
ENGINE

OIL PUMP INSPECTION / REMOVAL STARTING CLUTCH AND ENGINE BRAKING

NOTE: Mark the oil pump geroters to keep parts mated
CLUTCH REMOVAL /INSPECTION
for assembly.
1. Remove recoil housing, flywheel, flywheel key, and NOTE: The transmission must be removed from the
stator. engine to access the starting clutch and one-way
2. Use a feeler gauge to check oil pump rotor tip engine braking clutch.
clearance at “A”, and pump body clearance at “B”. 1. Inspect the starting clutch drum bearing in the
Compare to specifications. Replace the oil pump housing. The shaft must turn smoothly (by hand)
assembly if any parts are damaged, scored, or without binding in the clockwise direction, and should
measure beyond the service limit. not turn by hand in the counter clockwise direction.
Minimal movement in the shaft is NORMAL with
engine removed due to the lack of clutch cover
bearing support on the free end of the shaft
(approximately 0-.060” (0-1.5mm). Press the shaft out
of the housing and replace the bearing if worn or
A rough.
B DO NOT LIFT ENGINE WITH
CLUTCH SHAFT

A
B
3. Mark the oil pump geroters and shaft and carefully lift
the geroters from the housing.

2. Remove all screws from the starting clutch housing.

3. Remove the one-way clutch from the starting clutch
drum with a twisting motion. Note direction of
installation with flange toward drum for assembly.

Inspect Drum For

Wear or Damage

Flange toward drum

4. Inspect the one-way clutch closely for cracks or

damage on the sprag shoes and the cage.

3.30
 ENGINE

5. Open the staked portion of the nut (A) with a center 8. Inspect the shoes and springs of the starting clutch.
punch. Inspect the one-way clutch hub surface on the Measure the thickness of the friction material on the
starting clutch (B). The hub must be smooth without shoes as shown, from the bottom of the friction
any nicks or burrs. Replace the starting clutch material to the top at the thinnest point.
assembly if the one-way clutch hub is uneven or
damaged
Standard Thickness: .100” (2.54mm)
LIMIT: .039” (1.00mm)
Inspect entire surface of
one-way clutch hub.
B

6. Install the starting clutch holder (PA-47457) onto the

starting clutch and engage the tabs (C).
STARTING CLUTCH ASSEMBLY
C
1. Clean the mating surfaces of the crankcase and clutch
starting clutch housing to remove all gasket material.
2. Install the starting clutch on the shaft.
3. Start a NEW stake nut on the shaft.
4. Install the starting clutch holder on the clutch.
5. Torque the nut to specification.

Starting Clutch Stake Nut:

103-118 ft. lbs. (140-160 Nm)
7. Remove the nut (counterclockwise). This is a standard
thread. 6. Use a center punch or a pin punch to thoroughly stake
the nut at the depression in the shaft.

3.31
ENGINE
7. If drum bearing was replaced in the starting clutch
housing, press the drum/shaft into the housing until
fully seated.
8. Clean the inside of the starting clutch drum and
lubricate the drum and one-way clutch with engine oil.
9. Install one-way clutch in starting clutch drum with the
flanged side toward the hub, using a rotating motion.
Flange side toward hub
10. Install a new housing gasket.
11. Install the drum / housing assembly onto the case,
install the housing bolts and torque in two steps using
a cross pattern to specification.
Starting Clutch Drum
Housing:
14-15.5 ft. lbs. (19-21 Nm)
12. CHECK the clutch shaft to be sure it rotates smoothly
in the clockwise direction and will not rotate in the
counterclockwise direction. If binding is evident, or if
the shaft rotates in both directions (without turning the
engine over) disassemble and inspect the one-way
clutch and hub.
3.32
CRANKCASE DISASSEMBLY
NOTE: Engine must be removed from the frame to
perform any crankcase or crankshaft removal.
NOTE: The starter, starter drive, flywheel, stator, oil
pump and transmission can be serviced with the engine
in the frame.
CRANKCASE SEPARATION
NOTE: Stator housing, flywheel and gears have are
previously removed for this procedure. Use care during
the removal process to avoid damage to the cam chain.
NOTE: Valvetrain and cylinder removal must be
performed prior to this procedure.
1. Remove all bolts and the pressure relief valve (A) from
the magneto side crankcase.
A
2. Tap carefully on reinforced areas of the cases to
separate the halves. Watch the gap along the
crankcase mating surface and separate the
crankcase evenly.
3. Lift the right case half off of the left, leaving the
crankshaft and balance shaft in the left case.
 ENGINE

CRANKSHAFT REMOVAL visual inspection.

1. Lift the crankshaft and balance shaft from the left
case.
2. Note the number and thickness of any shims installed
on either shaft.
NOTE: Crankshaft and balance shaft end play must
be measured and adjusted with shims if any new
components are installed (bearings, crankcase,
crankshaft, or balance shaft. See procedure this
chapter.
3. The connecting rod utilizes a roller bearing. Clearance
can be measured with a dial indicator to check radial
clearance. Visually inspect the connecting rod, crank
pin, and thrust washers for scoring, damage,
excessive wear, or signs of overheating. Check for
roughness or noise when rotating the connecting rod
on the crank pin. Replace crankshaft if it fails visual
inspection, or if any up and down movement is
detectable in the connecting rod.

Connecting Rod Big End

Radial Clearance:
.0004-.0014” (.011-.038 mm)
LIMIT: .0019” (.05mm)
CRANKSHAFT / CAM CHAIN /
SPROCKET INSPECTION 4. Check connecting rod side clearance with a feeler
1. Inspect the crankshaft main bearings for wear or gauge.
damage. 5. Refer to piston inspection in this chapter to inspect the
connecting rod small end.

Connecting Rod Side

Clearance:
.0035-.0196” (.09-.50mm)
Limit: .023” (.60mm)

6. Clean crankshaft oil passages by running a stream of

clean solvent through the crankshaft. Be sure all
passages are clear and free of nicks or scratches.
NOTE: Due to extremely close tolerances and minimal
movement, the ball bearings must be inspected visually,
and by feel. Look for signs of discoloration, scoring or
galling. Turn the outer race of each bearing. The bearings
should turn smoothly and quietly. The inner race of PTO
bearing each bearing should fit tightly on the crankshaft.
The outer race should be firm with minimal side to side
movement and no detectable up and down movement.
The MAG end bearing usually stays in the case. Check
the inner race of the MAG bearing in the same manner.
2. Replace the main bearings if the components fail

3.33
ENGINE
CRANKCASE OIL PASSAGES & PRESSURE
RELIEF VALVE
1. Remove the pressure relief valve assembly from the
case.
2. Clean all crankcase oil passages with a stream of
clean solvent.
CAMSHAFT CHAIN
1. Replace the cam chain as part of any crankshaft
repair.
2. The cam chain can be removed by removing the
engine top end, the recoil assembly, flywheel and
flywheel key, stator plate, and slotted nut.
3. Lift the sprocket slightly until chain clears the
crankcase to remove.
ote: Install new chain as a part of crankshaft repa
BALANCE SHAFT BEARING INSPECTION
NOTE: Replace all seals whenever the crankcase is
disassembled.
1. Inspect the balance shaft bearings in the crankcase.
NOTE: Due to extremely close tolerances and minimal
movement, the bearing must be inspected visually and by
feel. Look for signs of discoloration, scoring or galling.
3.34
Turn the inner race of bearing. The bearing should turn
smoothly and quietly. The outer race should fit tightly in
the crankcase. The inner race should be firm with minimal
side to side movement and no detectable up and down
movement.
2. To remove balance shaft bearings, use a blind hole
bearing puller.
NOTE: Bearings are stressed during the removal
procedure and should not be re-used.
CRANKCASE OIL PICKUP STRAINER
INSPECTION
A
1. Pull the strainer screen (A) from the case carefully and
clean or replace it if heavily clogged, or if damaged.
BEARING /SEAL INSTALLATION
NOTE: To ease crankcase bearing installation, warm the
crankcase until hot to the touch. Placing the bearing in a
freezer prior to installation will assist the assembly
process.
1. Install the bearing so the numbers are visible.
2. Drive or press the new bearing into the crankcase,
using the proper driver.
CAUTION
Press only on outer race of bearing to prevent bear-
ing damage.
3. Install new seals with the lip facing in.
CAUTION
Press only on outer diameter to prevent damage.
 ENGINE

END PLAY INSPECTION/ADJUSTMENT 3. Subtract the thickness of the straightedge from the
measurement obtained in Step 2 and record.
Before reassembling the crankcase, the following steps
should be performed to determine the amount of
crankshaft, counter balancer shaft, and pump shaft end
play. Excessive end play may cause engine noise at idle
and slow speeds. Too little play will side load the
bearings which may lead to premature bearing failure.

CRANKSHAFT END PLAY ADJUSTMENT

NOTE: The method described here is shown with
the PTO main bearing on the crankshaft, which is the
most common situation. If the bearing is in the case,
the procedure is the same, but the photo examples
will differ.
1. Make sure all bearings are firmly seated in the
crankcase. PTO Case Depth_________________________

4. Measure the distance from the Magneto crankcase

mating surface to the main bearing using the same
method and record.

2. Lay a straightedge on the left (PTO) crankcase and

measure the distance from the straightedge to the
bottom of the main bearing bore (if bearing is still on
the crankshaft) or to the bearing race (if the bearing
is installed in the case) using a dial caliper.
5. Subtract the thickness of the straightedge from the
measurement obtained in Step 4 and record.

Mag Case Depth_______________

3.35
ENGINE
6. Add the readings recorded in Step 3 and Step 5 and
record below.
Total Case Width_________________
7. Measure the width of the crankshaft at the bearing
seats (or to the outside of bearing if bearing is on the
crankshaft as shown) with a micrometer or dial
caliper and record.
Crankshaft Width____________
8. Subtract the Crankshaft Width measured in Step 7
from the Total Case Width recorded in Step 6, and
record below.
Total End Play_____________
9. Subtract the thickness of the existing shim from the
result of Step 8 to determine if a different shim is
required. The result must be within the specified
range listed below.
Crankshaft End Play:
.006-.012” (.15-.30 mm)
3.36
COUNTER BALANCER SHAFT END PLAY
ADJUST.
NOTE: The counterbalance shaft end play
measurement procedure is the same as that outlined
for the crankshaft. The exception is that
measurements are taken to the balance shaft
bearings in the case, rather than the crankshaft main
bearings, and the width of the balance shaft is
measured, not the crankshaft.
1. Make sure the counterbalance shaft bearings are
firmly seated in each crankcase.
Measure to balance shaft
bearing race
2. 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.
MAG Case Depth_________________________
3. Measure the distance from the PTO crankcase
mating surface to the bearing using the same method
outlined for the MAG side.
PTO Case Depth_________________________
4. Measure the width of the counter balancer shaft at
the bearing seats with a dial caliper or micrometer,
and record reading.
5. Add the readings obtained in Step 2 and Step 3.
6. Subtract the counter balancer shaft width measured
in Step 4 from the result obtained in Step 5.
 ENGINE

7. Subtract the thickness of the existing shim from the 3. Be sure balance dots on gear teeth are aligned.
result of Step 6 to determine if a different shim is
needed. The result must be within the specified range
listed at below.
8. Add or subtract shims or change shim thickness as
required and install them upon assembly.

Counter Balance Shaft End Play:

.004”-.029” (.1-.74 mm)

CRANKCASE REASSEMBLY

Crankshaft Installation
4. Apply a thin coat of crankcase sealant to the outer
Lubricate all bearings with clean engine oil before mating surface of the left crankcase. Sealant is not
assembly. Be sure crankcase mating surfaces are clean required on the inner mating surfaces (A).
and free from oil or grease. A
1. Place the required shims on the crankshaft and
balance shaft.

2. Support the PTO side crankcase on blocks. Install the

crankshaft and balance shaft in the case, aligning the Crankcase Sealant
balance dots on the gears.
PN 2871557

5. Install the mag side case and tap with a soft faced
hammer to seat.
6. Install case screws and torque in a cross pattern to
specification.

Crankcase Bolt Torque:

6.5-8.0 ft. lbs. (9-11 Nm)

3.37
ENGINE

CAM CHAIN, OIL PUMP, & TENSIONER it with Loctite 242 (blue) before installation.
BLADE INSTALLATION
This screw must be sealed
1. Install the cam chain over the drive sprocket.
2. Lubricate and install the oil pump geroters, aligning
the marks made during disassembly. Clean the marks
off the geroters.

7. Torque the screws to specification.

Geroters Stator Plate Screw Torque:

6.5-8.0 ft. lbs. (9-11 Nm)
3. Install the tensioner blade and tighten the mounting
bolt to specified torque. 8. Install the flywheel key and flywheel.

Flywheel Nut:
67-81 ft. lbs. (90-110 Nm)

Recoil Drive Hub:

12-14 ft. lbs. (17-19 Nm)

Tensioner Blade Mounting Bolt Torque:

5-6.5 ft. lbs. (7-9 Nm)

4. Install a new O-ring on the stator plate.

5. Lubricate the stator plate seal and bushing with
engine oil and install the stator plate.
6. IMPORTANT! Be sure the sealed screw is placed in
the hole that aligns with the cam chain cavity or an oil
leak may result. If you are installing the old screw seal

3.38
 ENGINE

PISTON RING INSTALLATION piston pin bore, piston pin, and piston skirt. Lubricate
the connecting rod (both ends) and crankshaft main
NOTE: Apply clean engine oil to all ring surfaces and ring bearing area.
lands. Always check piston ring installed gap before rings
3. IMPORTANT- Install the piston on the connecting
are installed on piston. If the piston has been in service,
rod with the valve pocket facing the intake side of
clean any accumulated carbon from the ring grooves and
engine. The piston pin should be a push fit into the
oil control ring holes.
piston.
1. Place the oil control ring expander in oil ring groove Pocket
with the end gap facing forward. The expander has no
up or down marking and can be installed either way.
The ends should butt squarely together and must
not overlap.
2. Install the oil ring top rail with the end gap at least 30o
from the end of the expander.
3. Install the bottom rail with the gap at least 30o from the
end of the expander on the side opposite the top rail
gap.
4. Install the second ring with the mark facing up. The
second ring has an undercut with a tapered face. 4. Install the other circlip with the gap facing up or down.
Position the end gap toward the rear (intake) side of Push the piston pin in both directions to make sure the
the piston. clips are properly seated in the groove.
5. Install the top ring with the marking facing up. The top 5. Lubricate the piston and rings with engine oil and
ring has an inner bevel with a barrel face. install a ring compressor on the piston assembly.
Top Ring: Verify that the ring gaps are 120o - 180o apart from
Bevel on Inner Edge Install with each other before installation.
mark UP

Second Ring
Mark Faces UP

6. Verify proper installation of rings by checking to be

sure the top and second rings rotate freely in the
groove when compressed by hand.
PISTON INSTALLATION

CAUTION

Do not re-use circlips. Circlips become deformed

during the removal process. Do not compress the
new clip more than necessary to prevent loss of ra-
dial tension. Severe engine damage may result if
circlips are re-used or deformed during installation.
1. Install a new circlip on one side of the piston with the
end gap facing up or down.
2. Apply clean engine oil to the piston rings, ring lands,

3.39
ENGINE

CYLINDER INSTALLATION 8. Install the cam chain guide and dowel pins into the
NOTE: Clean the gasket surfaces on the crankcase and cylinder. Verify the bottom end of the guide is seated
properly in the crankcase.
cylinder. Remove all traces of old gasket material or
sealant. The surfaces must be oil-free!
1. Apply a small amount of crankcase sealant at the case
parting lines (A). Do not allow sealant to dry.
Assemble the top end immediately.

CYLINDER HEAD AND CAMSHAFT

2. Install the dowel pin(s).
3. Install a new base gasket onto the mating surface and
position the Piston Support Block (PN 2870390)
beneath the piston skirt to support the piston during
cylinder installation.
4. Apply clean engine oil liberally to the bore and tapered
area of the cylinder. Place the cylinder on to the studs.
NOTE: Route cam chain through the cylinder chain room
and secure it, holding it up to avoid damage to the chain,
drive sprocket teeth or tensioner blade.
5. Loop the cam chain through the cylinder chain room
and secure with mechanic’s wire.
INSTALLATION
NOTE: Clean the gasket surfaces on the cylinder head
and cylinder. Remove all traces of old gasket material.
The surfaces must be oil-free!
1. Install the dowel pin(s) and a new cylinder head
gasket.
2. Pull the cam chain through the cylinder head chain
room and secure with mechanic’s wire.
3. Place the cylinder head on the cylinder.
4. Install the two 6 mm bolts on cylinder base and on the
head, but do not tighten.

6. Install cylinder carefully with a front to back rocking

motion until rings are fully captive in the sleeve, then
remove the compressor and support block.
7. Seat the cylinder firmly onto the base gasket.

3.40
 ENGINE

5. Lubricate the washers and the threads of the cylinder timing mark on the flywheel is aligned with the mark
head bolts and install the bolts with washers. in the timing inspection window of the recoil housing.
Be sure to use the correct mark when installing the
cam. Do not use any advance timing marks.

2. Apply engine oil or starter drive grease (molybdenum

disulfide paste) to the camshaft main journals and
cam lobes. Lubricate automatic compression release
6. Torque the cylinder head following the procedure and mechanism with clean engine oil.
pattern below.
Starter Drive Grease:
Cylinder Head / Cylinder Base
(PN 2871460)
3 2
5 3. Orient the camshaft with the lobes facing downward,
6 mm
and install the cam into the cylinder head.
6
1 4

Forward

• Tighten M10 bolts to 18.5 ft. lbs. (25 Nm)

• Loosen 180 degrees
• Tighten to 11 ft. lbs. (15 Nm)
• Tighten 90 degrees
• Tighten 60 degrees
• Tighten 6mm head & base bolts to 8 ft.lbs.(11 Nm) 4. Disconnect the wire or tie strap securing the cam
chain (if used).
CAMSHAFT INSTALLATION & TIMING 5. Be sure the pin on the camshaft is pointing DOWN.

CAUTION

Serious engine damage will result if the camshaft is

not properly timed to the crankshaft.
IMPORTANT CAMSHAFT TIMING NOTE: In order to
time the camshaft to the crankshaft, the piston must be
precisely located at Top Dead Center (TDC). If flywheel
key and flywheel are not installed, install them at this
time. The recoil housing must also be temporarily
installed to use the timing inspection hole.
1. Rotate the crankshaft until the “T” (Top Dead Center)

3.41
ENGINE

6. Loop the cam chain over the sprocket and shift the assembly with a new gasket and tighten the bolts to
chain on the sprocket until it can be installed onto the specification.
camshaft.

A
B

B
A

Tensioner Bolt Torque:

7. VERIFY the following:
• “T” Mark on flywheel is aligned with the
projection in the timing hole of the recoil
housing.
• The mark (A) on the camshaft sprocket is
aligned with the projection (B) in the camshaft
cover window as shown above.
8. Verify all marks are aligned. Install the cam sprocket
bolt and torque to specification.
Camshaft Sprocket Bolt
35.5-50 ft. lbs. (48-70 Nm)
CAM CHAIN TENSIONER INSTALLATION
1. Hold the tensioner ratchet pawl (A) open and push
the plunger (B) in to the fully retracted position.
5-6.5 ft. lbs. (7-9 Nm)
3. Install the pin, spring, and tensioner cap with a new
sealing washer. Torque cap to specification.
Tensioner Cap Torque:
6-7.5 ft. lbs. (8-10 Nm)
4. Slowly rotate engine two to three revolutions in the
direction of rotation and re-check cam timing.
ROCKER ARM INSTALLATION
1. Lubricate the rocker arms and shaft with engine oil.
Apply a light film of starter grease (moly grease) to
the cam follower pad on the rocker arms.
Starter Drive Grease:

A (PN 2871460)

2. With the plunger retracted, install the tensioner

3.42
 ENGINE

2. Slide the shaft through the tower just enough to install STARTER DRIVE ASSEMBLY
the wave washer (A). 1. Be sure the washer is positioned on the back of the
NOTE: The flats of the wave washer are positioned drive gear.
against the intake rocker arm.

Starter Drive Grease:

3. Install the rocker arms in the same position as
marked during disassembly. (PN 2871460)

2. Apply Starter Drive Grease (PN 2871460) to the drive

bushings in the cases and all moving surfaces of the
starter drive gears and install.
3. Install recoil housing and torque bolts to specification.

TROUBLESHOOTING
SPARK PLUG FOULING
TROUBLESHOOTING
• Restricted air filter (main or pre-cleaner), or air
inlet ducts.
• Choke cable adjustment or plunger/cable sticking
4. Turn the engine through several revolutions to be • Foreign material on choke plunger seat or plunger
sure parts rotate freely and smoothly.
• Incorrect spark plug heat range or gap
5. Adjust valve clearance as outlined in the
maintenance section. • Jet needle and/or needle jet worn or improperly
adjusted
• Excessive carburetor vibration (check all engine
and carburetor mounts)
• Oil contaminated with fuel
• ETC switch mis-adjusted
• Low compression
• Spark plug cap loose or faulty
• Loose jets in carburetor or calibration incorrect for
altitude/temperature

3.43
ENGINE

• Incorrect float level setting Engine Idles But Will Not Rev Up
• Carburetor inlet needle and seat worn
• Spark plug fouled/weak spark
• CVT system calibrated incorrectly or components
• Broken throttle cable
worn or mis-adjusted
• Obstruction in air intake
• Fuel quality poor (old)
• Air box removed (reinstall all intake components)
• Restricted exhaust
• Incorrect or restricted carburetor jetting
• Restricted crankcase breather system
• ETC switch limiting speed
• Weak ignition (loose coil ground, faulty coil, stator,
engine to chassis ground, or ETC switch) • Reverse speed limiter limiting speed
• Improperly assembled air intake system • Carburetor vacuum slide sticking/diaphragm
damaged
ENGINE Troubleshooting • Incorrect ignition timing

Engine Turns Over But Fails to Start • Restricted exhaust system

• Camshaft lobes worn
• No fuel
• Dirt in fuel line or filter • Flywheel key sheared

• Fuel will not pass through fuel valve Engine Has Low Power
• Fuel pump inoperative/restricted
• Spark plug fouled
• Fuel tank vent plugged
• Cylinder, piston, ring, or valve wear or damage
• Carburetor starter circuit restricted (check compression)
• Engine flooded • CVT not operating properly
• Low compression (high cylinder leakage) • Restricted exhaust muffler
• No spark (Spark plug fouled) • Dirty carburetor

Engine Does Not Turn Over • Cam lobe worn

• Dead battery Piston Failure - Scoring

• Starter motor does not turn • Lack of lubrication

• Engine seized, rusted, or mechanical failure • Dirt entering engine through cracks in air filter or
ducts
Engine Runs But Will Not Idle
• Engine oil dirty or contaminated
• Idle speed set too low
Excessive Smoke and Carbon Buildup
• Faulty ETC system
• Restricted carburetor pilot system • Oil level too high

• Carburetor misadjusted • Excessive piston-to-cylinder clearance

• Choke not adjusted properly or sticking plunger • Worn rings, piston, or cylinder

• Low compression • Worn valves, guides or seals

• Crankcase breather restricted • Restricted crankcase vent

• Air filter restriction • Air filter dirty or contaminated

3.44
 ENGINE

Low Compression

• Decompressor stuck
• Cylinder head gasket leak
• No valve clearance or incorrectly adjusted
• Cylinder or piston worn
• Piston rings worn, leaking, broken, or sticking
• Bent valve or stuck valve
• Valve spring broken or weak
• Valve not seating properly (bent or carbon
accumulated on valve area)
• Rocker arm sticking

Backfiring

• ETC or speed limiter system malfunction

• Fouled spark plug or incorrect plug or plug gap
• Carburetion faulty - lean condition
• Intake / Exhaust system air leaks
• Ignition system faulty:
•Spark plug cap cracked/broken
•Ignition coil faulty
•Ignition or kill switch circuit faulty
•Ignition timing incorrect
•Sheared flywheel key
• Poor connections in ignition system
• System wiring wet
• Cam lobe worn or Valve sticking

• Lean condition

3.45
ENGINE

NOTES

3.46
 FUEL SYSTEM / CARBURETION

CHAPTER 4
FUEL SYSTEM / CARBURETION
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
CARBURETITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
BST 34 CARBURETOR EXPLODED VIEW 1 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
BST 34 CARBURETOR EXPLODED VIEW 2 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
CARBURETOR VENTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
CARBURETOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
CARBURETOR JETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
MIKUNI JET PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
CV CARBURETOR SYSTEM FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
CARBURETOR VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
MIKUNI CV CARB OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
STARTER SYSTEM (CHOKE OR ENRICHMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
PILOT (IDLE AND SLOW) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
MAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
FLOAT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
PILOT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
4
AIR/FUEL MIXTURE RATIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
NEEDLE JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
THROTTLE OPENING VS. FUEL FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
CARBURETOR DISASSEMBLY – MIKUNI CV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
CARBURETOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
CARBURETOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FLOAT HEIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
NEEDLE AND SEAT LEAKAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
FUEL LEVEL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
FUEL TANK/FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
FUEL TANK / FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19

4.1
FUEL SYSTEM / CARBURETION

SPECIAL TOOLS NOTE: It is strongly recommended that Polaris Carbon

Clean be added regularly as directed to the fuel systems
of all Polaris ATVs. Carbon Clean stabilizes the fuel,
preventing clogging of the small passages and orifices
common to ATV carburetors, and ensures constant
TOOL
PART NUMBER performance, reliability and easier starting.
DESCRIPTION

2870975 Mity VacTM Pressure Test

Tool

Carburetor Float
2872314
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. The tank is at full ca-

pacity when the fuel reaches the bottom of
the filler neck. Leave room for expansion of
fuel.

Never start the engine or let it run in an en-

closed area. Gasoline powered engine ex-
haust fumes are poisonous and can cause
loss of consciousness and death in a short
time.

Never drain the float bowl when the engine is

hot. Severe burns may result.

Do not smoke or allow open flames or sparks

in or near the area where refueling is per-
formed or where gasoline is stored.

If you get gasoline in your eyes or if you

should swallow gasoline, seek medical atten-
tion immediately.

If you spill gasoline on your skin or clothing,

immediately wash with soap and water and
change clothing.

4.2
 FUEL SYSTEM / CARBURETION

CARBURETITION
BST 34 Carburetor Exploded View 1 of 2

A
G

C
N
M
P L
D
J

E
F

Table 4-1: Carburetor Components

Reference Description Reference Description

A Jet Needle J 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

4.3
FUEL SYSTEM / CARBURETION

BST 34 Carburetor Exploded View 2 of 2

A D

B F

C
E

J
K

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

4.4
 FUEL SYSTEM / CARBURETION

Carburetor Venting System

D
B
E
C

Table 4-3: Carburetor Venting System

Reference Description

A Check Valve

B Hose (Float Bowl Drain)

C Hose (Vents)

D Tee Fitting

E Filter

4.5
FUEL SYSTEM / CARBURETION

CARBURETOR SPECIFICATIONS CV CARBURETOR SYSTEM FUNCTION

2006 Hawkeye 2x4 / 4x4 Carburetor Component Function

(Domestic and International) Main Main Main
System
Components Function Affect
Ambient Below 40F Above 40F
Float Inlet Pipe, Maintains All systems
Temperature (Below 5C) (Above 5C)
System Needle and specified fuel All throttle
(Level Seat, Float, level in float ranges
0-6000 152.5 147.5 Control) Float Pin chamber
Altitude
(0-1800) (carburetor float
Feet
bowl)
(Meters) 6000-12000
147.5 142.5 Venting Passages in Supplies All systems
(1800-3700)
Carburetor, Vent atmospheric All throttle
lines pressure to float ranges
CARBURETOR JETTING to frame chamber
IMPORTANT: The following guidelines must be followed
when establishing a main jet setting: Starter Choke Lever, Supplies All throttle
(Choke/ Cable, Plunger, additional fuel ranges
1. Select the lowest anticipated temperature and altitude
Enrichment) Return Spring, air mixture Greatest
at which the machine will be operated.
Carb Passages necessary for effect at low
2. Select the correct main jet according to the engines
(Starter Jet, cold starting throttle
fuel/performance requirements.
Starter Bleed settings and
CAUTION Pipe) idle

A main jet that is too small will cause a lean operat-

ing condition resulting in serious engine damage. Pilot (Idle Pilot Jet/ Primarily Mainly idle
Select the correct main jet carefully for elevation System) Passage-ways, supplies fuel at to 1/4
and temperature according to the charts in the Pilot–Mixture idle and low throttle
Specifications section or in the Owner’s Safety and Screw with throttle Minimal
Maintenance Manual for each particular model. Spring Washer positions effect after
and Sealing O– 1/2 throttle
MIKUNI JET PART NUMBERS Ring, By-pass
Ports (Behind
Main Jets - BST 34 Pilot Jets - BST 34 Throttle Plate),
Pilot Air Jet,
Jet Number Part Number Jet Number Part Number
Pilot Outlet,
130 3130561 25 n/a
Throttle Plate
132.5 3130562 27.5 n/a
135 3130563 30 n/a Main Main Jet, Main Supplies fuel at 1/4 to full
137.5 3130564 32.5 n/a System Air Jet, Main Air mid–range and throttle
140 3130527 35 n/a Passage, high throttle
142.5 3130566 37.5 n/a Needle Jet, Jet settings.
145 3130567 40 3130624 Needle, Vacuum
147.5 3130568 42.5 3130526 Slide, Throttle
152.5 3130570 45 3131397 Plate
155 3130571 47.7 3131226
157.5 3130572 50 3131132
160 3131141 55 n/a
162.5 3131142 57.5 n/a
165 3131143 60 n/a
167.5 3131144 65 n/a
170 3131145 70 n/a

4.6
 FUEL SYSTEM / CARBURETION

CARBURETOR VENTING When the throttle plate is opened and engine speed
begins to increase, the pressure in the venturi (and
The carburetor float bowl vent lines supply atmospheric therefore in the chamber above the diaphragm) becomes
pressure to the float bowl. The lines must be free of kinks, significantly lower than atmospheric. Atmospheric
restrictions and be properly routed. This allows fuel to pressure in the chamber below the diaphragm forces the
flow in the proper amount and prevents contaminants diaphragm upward, raising the slide against spring
from entering the carburetor. pressure. When the pressure above and below the
MIKUNI CV CARB OPERATION diaphragm are nearly equal, the slide moves downward
under spring pressure. Raising or lowering the slide
The constant velocity carburetor incorporates a mechani- increases or decreases the cross sectional area in the
cally operated throttle plate and a vacuum controlled slide venturi, and therefore the air velocity in the venturi is kept
valve (vacuum slide). The venturi cross–sectional area in relatively constant. This provides improved fuel
the carburetor bore is increased or decreased automati- atomization and optimum fuel/air ratio.
cally by the vacuum slide, which moves according to the
amount of negative pressure (less than atmospheric)
present in the venturi.
A diaphragm attached to the top of the vacuum slide is
sealed to the slide and to the carburetor body forming two
chambers. The chamber above the diaphragm is
connected to the venturi area by a drilled orifice in the
center of the vacuum slide. The chamber below the
diaphragm is vented to atmospheric pressure by a
passage on the air box side of the carburetor. A spring,
installed in the center of the vacuum slide, dampens the
slide movement and assists the return of the slide.

Low Pressure
Diaphragm
From Venturi

Atmospheric
Pressure

Atmospheric
Air inlet

Vacuum Note: Diagrams are for explanation of theory only, and are not true
Slide representations of Mikini BST carburetor.
Throttle Plate

Venturi

= Air Flow = Low pressure

4.7
FUEL SYSTEM / CARBURETION

STARTER SYSTEM (CHOKE OR PILOT (IDLE AND SLOW) SYSTEM

ENRICHMENT) This system supplies fuel during engine operation with
When the choke cable (1) is activated, the starter plunger throttle valve closed (1) or slightly opened. The fuel from
(5) is lifted off the seat. float chamber (2) is metered by pilot jet (3) where it mixes
with air coming in through pilot air jet (4). The mixture
8 then goes up through pilot passage to pilot screw (5). A
5 1
part of the mixture is discharged into the main bore out of
bypass ports (6). The remainder is then metered by pilot
screw and discharged into the main bore through pilot
outlet (7).
7 6

4
4
2
3 1

Fuel is drawn into the starter circuit from the float

chamber (2) through the starter jet (3). Starter jet meters
this fuel, which then flows into starter pipe (4) and mixes
with the air (7) coming from the float chamber. The 6
mixture, rich in fuel content, reaches starter plunger and
mixes again with the air coming through a passage (8)
extending from underneath the diaphragm. The rich fuel/
air mixture for starting is discharged through starter outlet
(6) in the main bore. 7

5
2
3

4.8
 FUEL SYSTEM / CARBURETION

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. The emulsified fuel then passes through the
clearance between needle jet (5) and jet needle (7), and
is discharged into the venturi (A). Mixture proportioning is
accomplished in needle jet (5); the clearance through
which the emulsified fuel must flow is determined
ultimately by throttle position and vacuum slide height.
Fuel enters the float chamber (3) by means of the inlet
pipe and passage, through a screen on the back of the
inlet needle seat (4), and around the inlet needle (2). As
the fuel fills the float chamber, the float (1) rises and
forces the inlet needle against the seat, shutting off the
orifice in the seat. When fuel level is up in float chamber,
floats are up and needle valve remains pushed up against
valve seat. Under this condition, no fuel enters the float
chamber. As the fuel level falls, floats go down and
needle valve unseats itself to allow fuel into the chamber.
In this manner, the needle valve releases and shuts off
fuel alternately to maintain a constant fuel level inside the
float chamber.

Inlet
A Pipe
6

3 3
5 1

4
4 2

4.9
FUEL SYSTEM / CARBURETION

PILOT SCREW AIR/FUEL MIXTURE RATIO

The pilot system supplies fuel during engine operation E-Clip Position vs. Fuel Flow
with the throttle valve closed or slightly opened. The fuel/
air mixture is metered by pilot screw and discharged into 2
3
the main bore through the pilot outlet.
4

CAUTION 4

The pilot screw is calibrated at the factory to meet

EPA / CARB regulations for air quality standards 3
and is sealed with a brass plug to prevent tamper-
ing. Removal of the tamper proof plug is not permit-
ted. For service purposes, cleaning of the pilot 2
circuit can be done only by a certified repair shop to
ensure air quality standards are not exceeded.

15 50 75 100%
Throttle Valve Opening
Pilot Screw Location
A carburetor with a slide type throttle valve is also called a
variable venturi type carburetor. In this type of carburetor,
the needle jet and jet needle serve to control proper air/
fuel mixture ratio at the medium throttle valve opening
(between 1/4 and 3/4 opening).
Brass Plug Installed
Having the proper needle jet and jet needle has a major
impact on engine performance at partial load. The jet
needle tapers off at one end and the clearance between
the jet needle and the needle jet increases as the throttle
valve opening gets wider. The air/fuel mixture ratio is
controlled by the height of the “E” clip inserted into one of
the five slots provided in the head of the jet needle. The
previous chart shows the variation of fuel flow based on
the height of the “E” clip.

Brass Plug Removed

4.10
 FUEL SYSTEM / CARBURETION

JET NEEDLE NEEDLE JET

The jet needle has five adjustment grooves cut into the The needle jet works in conjunction with the jet needle to
upper portion, and is tapered from approximately the regulate fuel flow rate. An air bleed opening in the side of
middle of the needle to the lower end. The top is fixed to the needle jet brings in air measured by the air jet. This
the center of the throttle valve by the needle clip, and the air initiates the mixing and atomizing process inside the
tapered end extends into the needle jet. Fuel flows needle jet.
through the space between the needle jet and jet needle.
This space does not vary until the throttle reaches the 1/4
Needle Jet
open point. At that time the tapered portion of the needle
begins to move out of the jet, affecting fuel flow as the
opening enlarges. If the needle clip is changed from the
standard position to a lower groove, the needle taper
starts coming out of the jet sooner, resulting in a richer
mixture. Moving the clip higher produces a leaner
mixture. If the taper is worn due to vibration, fuel flow may
be significantly affected. Main Jet
Jet Needle

Leaner
THROTTLE OPENING VS. FUEL FLOW
Position#
In a full throttle condition the cross sectioned area
Richer between the jet needle and the needle jet is larger than
the cross sectioned area of the main jet. The main jet
therefore has greater control over fuel flow.
Small Medium Large
Clearance Clearance Clearance

Closed One-half Full

Throttle Throttle Throttle

4.11
FUEL SYSTEM / CARBURETION

CARBURETOR DISASSEMBLY – MIKUNI CV 3. Remove inlet needle seat retaining screw along with
plate, and carefully remove needle seat. NOTE: Do
Use the following disassembly, assembly, and inspection not use a pliers to remove the seat or permanent
techniques to service a CV carburetor. damage may occur.
1. Remove carburetor diaphragm chamber cover with a
ratchet style screwdriver. DO NOT use an impact
driver to remove the screws or carburetor may be
permanently damaged.

Remove Screw

4. Remove the pilot mixture screw, spring, flat washer,

and O–Ring. If an anti–tamper plug is installed over
the pilot screw cavity, it must be removed for access.
2. Remove float bowl. Remove the float pin screw. The
float and float pin can be removed.

O-Ring
Washer
Spring

Pilot Screw

NOTE: The starter jet is removable. Upon disassembly,

place the parts in a container for safe keeping.

4.12

CARBURETOR CLEANING
WARNING
Protect eyes from contact with cleaner. Take appro-
priate safety measures during these procedures.
Safety glasses and chemical resistant gloves are
required. Should you get cleaner in your eyes or if
you swallow cleaner, seek medical attention imme-
diately.
Carburetor cleaners can be extremely caustic. Ex-
tended periods of soaking can loosen the adhesive
sealer on the passage drill-way plugs. Do not soak
rubber or plastic components (such as the vacuum
slide diaphragm, needle seat screen, or O-Rings in
caustic cleaning solutions. Irreparable damage may
occur. Do not use agitator-type carburetor cleaning
equipment. Rubber parts must be cleaned with mild
detergent and hot water only.
1. Thoroughly clean the carburetor body, jets, and all
passages with carburetor cleaner or electrical contact
cleaner.
2. If the carburetor is extremely dirty or contaminated
with fuel residue and varnish, soak for short periods
only in carburetor cleaner, and rinse in hot water.
3. Replace the jets if they have a buildup of fuel residue
or bacterial growth that cannot be removed. Even a
small amount of residue will reduce the flow
characteristics of the jet.
4. Verify all passages and jets are unobstructed by
spraying electrical contact cleaner through the
passages. CAUTION: Do not use wire or welding tip
cleaners as the orifice size may be altered.
5. Use low pressure air to dry carburetor body and all
components.
FUEL SYSTEM / CARBURETION
CARBURETOR INSPECTION
1. Inspect jet needle and needle jet for wear. Look for
discoloration, shiny spots, or an area that looks
different than the rest of the needle. The middle to
upper portion of the needle contacts the needle jet and
is the most likely wear point. If jet needle shows signs
of wear replace both the needle and needle jet to
prevent a rich condition. TIP: A worn needle jet is
difficult to spot. To check, slide a slightly larger new jet
needle into the needle jet and hold it to a light source.
Light will be visible between the needle and needle jet
if it is worn.
Needle Jet
Jet Needle
Inspect this
area
2. Inspect the inlet needle tapered surface for any sign of
wear or damage. Be sure the spring loaded pin is free
moving and returns freely when pushed. The inlet
needle and seat should be pressure tested after
assembly.
Good Condition Worn, Deposits
Seat
Wear areas
Needle
4.13
FUEL SYSTEM / CARBURETION
CARBURETOR ASSEMBLY
Inspect the diaphragm (A) for holes, deterioration, or
damage. Make sure the diaphragm is pliable but not
swollen. The diaphragm should fit properly in the
carburetor body. Replace diaphragm assembly if
diaphragm is damaged.
1. Replace parts in proper order. The spring seat (B) is
stepped and must be placed on TOP of “E” Clip (C).
Spacer washer (D) must be installed below the E–Clip.
Refer to parts manual for more information.
2. Be sure the tab (E) on outer edge of diaphragm is
positioned properly in the carburetor body.
FRONT
(Engine)
Pilot Screw
3. Install the pilot mixture screw, spring, washer, and O–
ring as an assembly. Lubricate the O–Ring with oil or
light grease before installation. CAUTION: Do not
4.14
damage the O–ring during installation. Turn the screw
in until it lightly contacts the seat. Back out the
specified number of turns. NOTE: The final pilot (idle)
mixture must be adjusted with the engine running.
Refer to Page 2.10.
Pilot Screw Base Setting
(Set at Factory)
Factory Specification: 2.5 Turns Out
FLOAT HEIGHT ADJUSTMENT
1. Illustration 1: Place the throttle side of the carburetor
on a level surface to remove weight from float arm. In
this position, the float tongue will rest slightly outward.
2. Illustration 2: With the carburetor still resting on the
level surface, use one hand to slightly tilt the
carburetor back. The float will then fall into the correct
position, with the float tongue resting lightly on the
inlet needle valve pin without compressing the spring.
The bottom of the float should be parallel with the float
bowl mating surface. Illustration 3: NOTE: If the float
is past parallel with the mating surface, the carburetor
has been tilted back too far and the float tongue is
likely compressing the needle valve pin.
Float parallel with float
bowl mating surface

3. Measure the height from the float bowl mating surface
to the top of step of the float as shown in Illustration 2.
Both sides of float should be parallel to each other.
The measurement should be made at the mid–point
on top of the float using Float Adjustment Tool (PN
2872314) or a vernier caliper. When measuring the
height, be sure the inlet needle valve spring is not
compressed.
Float Bowl Height: 13-14 mm
4. If adjustment is necessary, bend the tongue slightly.
Be sure float measurement is even on left and right
side.
NEEDLE AND SEAT LEAKAGE TEST
1. Install the float bowl. Invert the carburetor and install a
Mity–Vac™ (PN 2870975) to the fuel inlet fitting. Apply
5 PSI pressure to inlet fitting. The needle and seat
should hold pressure indefinitely. If not, inspect needle
and seat and seat O–ring.
Mity VacTM (PN 2870975)
FUEL SYSTEM / CARBURETION
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. Be sure line fits
tightly on fitting. Position hose along side of carburetor
as shown.
1.5 mm
.060 in. Bowl Mating
Surface
2. Open bowl drain screw by turning counterclockwise
approximately two turns. Start and run engine for 3 to
5 seconds to allow fuel level to stabilize in the line. If
level is out of specification, remove carburetor and
inspect inlet needle and seat, float height, passages,
etc.
NOTE: If a line was removed to perform this procedure, it
must be replaced.
4.15
FUEL SYSTEM / CARBURETION

TROUBLESHOOTING POOR IDLE

FUEL STARVATION/LEAN MIXTURE Idle Too High

• Idle adjusted improperly/idle mixture screw
Symptoms: Hard start or no start, bog, backfire, popping damaged
through intake / exhaust, hesitation, detonation, low
power, spark plug erosion, engine runs hot, surging, high • Sticky vacuum slide
idle, idle speed erratic. • Throttle cable sticking, improperly adjusted, routed
incorrectly
• No fuel in tank
• Choke cable sticking, improperly adjusted, routed
• Restricted tank vent, or routed improperly incorrectly
• Fuel lines or fuel valve restricted • Plugged or restricted idle jet
• Fuel filter plugged Idle Too Low
• Carburetor vent line(s) restricted • Choke cable bending or incorrectly adjusted
• Plugged or restricted inlet needle and seat screen • Idle speed set incorrectly
or inlet passage
• Idle mixture screw misadjusted or damaged
• Clogged jets or passages
• Belt dragging
• Float stuck, holding inlet needle closed or inlet
needle stuck • Ignition timing incorrect

• Float level too low • Worn jet needle/needle jet

• Intake air leak ( throttle shaft, intake ducts, airbox or • Plugged or restricted idle jet
air cleaner cover) Erratic Idle
• Jet needle position incorrect • Choke cable bending or incorrectly adjusted
• Incorrect pilot screw adjustment • Throttle cable incorrectly adjusted

RICH MIXTURE • Air leaks, dirty carburetor passages (pilot circuit)

• Pilot mixture screw damaged or adjusted
Symptoms: Fouls spark plugs, black, sooty exhaust incorrectly
smoke, rough idle, poor fuel economy, engine runs rough/
misses, poor performance, bog, engine loads up, • Tight valves
backfire. • Ignition timing incorrect

• Air intake restricted (inspect intake duct) • Belt dragging

• Air filter dirty/plugged • Dirty air cleaner

• Electric choke inoperative • Engine worn

• Incorrect pilot air/fuel screw adjustment • Spark plug fouled

• Faulty inlet needle and seat • Idle speed set incorrectly (speed limiter)

• Faulty inlet needle seat O-Ring • Worn jet needle/needle jet

• Float level too high • Plugged or restricted idle jet

• Poor fuel quality (old fuel)

• Loose jets
• Worn jet needle/needle jet or other carburetor parts
• Dirty carburetor (air bleed passages or jets)

4.16
 FUEL SYSTEM / CARBURETION

AIR INTAKE SYSTEM

Air Intake System

G H

Table 4-4: Air Intake System

Reference Description Reference Description
A Pre-Filter J Crankcase Breather Hose
B Air Filter
C Intake Box Snorkel
D Intake Box Cover
E Cover Seal
F Crankcase Breather Foam
G Intake Box Drains
H Carburetor Snorkel

4.17
FUEL SYSTEM / CARBURETION

FUEL TANK/FUEL DELIVERY SYSTEM

Fuel Tank / Fuel Delivery System

B D

N
J

G
K

Table 4-5: Fuel Tank / Fuel Delivery System

Reference Description Reference Description
A Fuel Cap J Hose (Fuel Tank-To-Supply petcock)
B Fuel Cap O Ring K Fuel Pump
C Fuel Level Gauge L Hose (Fuel Pump-To-Carburetor)
D Fuel Tank Vent M Hose (Fuel Pump-To-Carburetor Vacuum Impulse)
Fuel Filter (Arrow points in direction of fuel flow to
E Fuel Tank Hold-Down Bracket / Pad N
carburetor.)
F Fuel Tank
G Fuel Supply Petcock
H Hose (Supply Petcock-To-Fuel Pump)

4.18
 FUEL SYSTEM / CARBURETION

EXHAUST SYSTEM
Exhaust System

Table 4-6: Exhaust System

Reference Description

A Tip / Spark Arrestor

B Muffler

C Pipe Clamp

D Gasket

E Head Pipe

F Flange Gasket

4.19
FUEL SYSTEM / CARBURETION

NOTES

4.20
 BODY AND STEERING

CHAPTER 5
BODY AND STEERING
PLASTIC INSERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
SEAT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
FRONT CAB/FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
FRONT CAB/FENDER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
FRONT CAB/FENDER INSTALATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
REAR CAB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
FOOTWELL REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
BODY RACK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
REAR RACK REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
POD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
POD/KEY SWITCH/CHOKE/SPEEDO CONNECTION REMOVAL/INSTALLATION. . . 5.10
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
HANDLEBAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
HANDLEBAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
STEERING POST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
STEERING POST BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
STEERING POST INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
5
STEERING / A-ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
A-ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
A-ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
A-ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
FRONT STRUT CARTRIDGE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
FRONT STRUT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
FRONT STRUT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
BALL JOINT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
UPPER AND LOWER REAR CONTROL ARM REMOVAL/INSTALLATION . . . . . . . . . 5.19

5.1
BODY AND STEERING

PLASTIC INSERT 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
Removal / Installation surface after installation.
Some Polaris ATVs use a two piece plastic insert in place of a
metal screw. The plastic inserts are simple to remove and
install.

1. Use a a pair of diagonal side cutters to lift the plastic insert

(A) until you feel some slight pressure or lift the insert
approximately 1/4" (6.35 mm). Apply just enough
pressure on the side cutters to lift up on the insert. DO
NOT apply too much pressure on the side cutters, or
damage to the insert will occur.

The inside insert (A) should be flush with the top of the
A outside insert (B).

A
B

2. Next, use the diagonal side cutters under outside insert (B)
to completely remove the assembly. NOTE: The inside
insert (A) will still be installed in the outside insert (B).

SEAT
B SEAT REMOVAL/INSTALLATION

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

NOTE: The inside insert (A) will still be installed in
the outside insert (B).

5.2
 BODY AND STEERING

seat. FRONT CAB/FENDER

2. Grasp the rear of the side panel near the rear cab. With a
firm motion, pull the panel outward to disengage the side
panel. Pull the panel downward and rearward to remove it
from the ATV.
3. Reinstall the side panel by reversing the removal
procedure.

5.3
BODY AND STEERING

FRONT CAB/FENDER REMOVAL

For this procedure please refer to the diagram on page 5.3.

1. Remove the seat.

2. Remove the fuel tank cover (4).
3. Remove the side panels (1,3).
4. Remove the plastic rivets on the mud guards (below) and remove them from the front cab assembly.

5. Remove the battery connections (negative first).

6. Remove the battery from the battery compartment.
7. Route the battery cables through the front compartment.
8. Remove the front cab fasteners (8).
9. Remove the plastic rivets from the footwells.
10. Carefully lift off the front cab.

FRONT CAB/FENDER INSTALATION

For this procedure please refer to the diagram on page 5.3.

1. Carefully place front of the cab onto the frame.

2. Route the battery connections through the cab and into the battery box.
3. Insert the mud guards and plastic rivets.
4. Replace the fuel tank cover (4).
5. Replace the plastic rivets into the footwells.
6. Install the front cab fasteners.
7. Install the battery.

5.4
 BODY AND STEERING

BODY ASSEMBLY 1. Follow the procedure to remove the rear rack. See “REAR
RACK REMOVAL/INSTALLATION” on page 5.6.
2. Remove the screws (1,19) that secure the rear cab to the
Exploded View frame.
3. Remove the plastic inserts (9) that secure the rear cab to the
frame footwells (11,14).
4. Disconnect the rear lights.
5. Lift the rear cab (4) from the frame.
6. Reverse the removal steps for installation.

FOOTWELL REMOVAL/INSTALLATION
1. Remove the plastic inserts (A) that secure the wheel well
to the front and rear cabs. See “PLASTIC INSERT” on
page 5.2.
2. Remove the screws (B) from the bottom of the foot well.
Remove the footwell.
3. Reverse the removal procedures to install the foot well.
NOTE: Be sure to properly align the cab ends into
the footwells upon reassembly.
B

REAR CAB REMOVAL/INSTALLATION

5.5
BODY AND STEERING

BODY RACK EXPLODED VIEW

REAR RACK REMOVAL/INSTALLATION

1. Remove the fasteners 2,3,7,9,10 and 11.
2. Remove the rear rack.
3. Replace in reverse order.

5.6
 BODY AND STEERING

POD EXPLODED VIEW

5.7
BODY AND STEERING

POD/KEY SWITCH/CHOKE/SPEEDO CONNECTION REMOVAL/INSTALLATION

1. Remove the plastic dart clips(1) from the pod (2).
2. Press the center and pull the speedo connection away from the speedo (3).
3. Remove the key switch connection by turning the ignition nut (9) counter clock wise.
4. Remove the choke connection by turing the choke nut (14) counterclockwise.
5. Remove the choke cable (13) from the pod.
6. Replace in reverse order of removal.

STEERING
HANDLEBAR REMOVAL
1. Remove the handlebar pod. See “POD/KEY SWITCH/CHOKE/SPEEDO CONNECTION REMOVAL/INSTALLATION”
on page 5.8.
2. Remove the handlebar block fasteners and (A) the mounting bracket (B).

3. Remove the handlebar assembly from the steering post.

5.8
 BODY AND STEERING

HANDLEBAR INSTALLATION
1. Replace the handlebar assembly into the steering post to the desired angle.
2. Place the handlebar block onto the steering post. Make sure that the peg (C) is inserted to the steering post dimple (D).

3. Insert the bolts through the top of the handlebar block.

4. Place the mounting bracket (B) onto the bottom of the steering post and install the nuts on the bolts.
5. Evenly torque the two front nuts to 12 ft-lb (16Nm).
6. Torque the rear nuts evenly to 12 ft-lb (16Nm).
NOTE: There will be a slight gap on the backside of the blocks after the procedure is performed.
7. Replace the handlebar pod.

5.9
BODY AND STEERING

STEERING POST REMOVAL 9. Remove the steering tie rod ends (D) from the steering
bracket (E). Note the orentation of the fasteners and
1. Remove the front cab. See “FRONT CAB/FENDER” on
bracket on the steering assembly.
page 5.3.
2. Remove the handle bar pod. See “POD/KEY SWITCH/
CHOKE/SPEEDO CONNECTION REMOVAL/ E
INSTALLATION” on page 5.8.
3. Remove the handle bar. See “HANDLEBAR
D
REMOVAL” on page 5.8.
4. Remove the fuel tank bracket (A).

10. Remove the steering post bracket (F) at the front gear case
(4x4 shown)/plate (2x4).

5. Turn the fuel valve to the “OFF” position

6. Remove the fuel line (B) from the fuel pump (C).

C
11. Remove the top steering bracket (G).

G
B

7. Remove the vent line from the frame that comes from the
top of the fuel tank. Note the vent line routing.
8. Remove the fuel tank from the frame.

12. Remove the steering post.

5.10
 BODY AND STEERING

STEERING POST BEARING REPLACEMENT 5. Place the steering post upper bracket to the frame, torque
1. Remove the steering post. the upper nuts to 22 ft-lb (30Nm).
2. Press out the steering post cotter pin (A).
3. Remove the steering post nut (B), bushing (C). G
4. Inspect the bushings
5. Remove and replace the bearing (D).
6. Install the bearing as shown in the image.
7. Torque the steering post nut (B) to 50 ft-lb (68Nm).
8. Install a new cotter pin (A).
NOTE: Make sure that the cotter pin is not
obstructing steering movement.

6. Place the tie rod retainer (H) on to a tie rod bolt (I).
D 7. Insert the tie rod bolts from the bottom of the tie rod, and
line up the retainer to the bottom of the tie rods.
C
8. Torque the tie rod fasteners to 40 ft-lb (54Nm).
B

A
2x4 4x4

STEERING POST INSTALLATION

1. Insert the steering post assembly into the chassis.
2. Place the lower bracket (F) into the front gear case on the
4x4 units, and into the bracket on the 2x4 units.
3. Apply blue Loctite to the threads of the bracket bolts.
4. Torque the bolts to 19-22 ft-lb (26-30Nm).

F I H

9. Replace the fuel tank into the frame.

5.11
BODY AND STEERING

10. Make sure that the routing of the vent line is correct. STEERING / A-ARM
Exploded View

11. Place the fuel tank bracket in place. Note to get the routing
of the throttle cable and carburetor venting correct.
12. Tighten the fuel tank bracket fasteners.
13. Hook up the fuel line to the fuel pump and move the clamp
to the correct area.

NOTE: To avoid damage to tie rods and other

steering components, be sure to install tie rod end
bolts in the proper direction. The steering post arm
bolt (B) points up; the rod end bolts (A) point down.
Be sure inner rod ends are placed between the

5.12
 BODY AND STEERING

steering post arms. Replace all cotter pins if FRONT STRUT CARTRIDGE
removed (4,11).
REPLACEMENT
A-ARM
A-ARM REMOVAL

Refer to drawing on page page 5.12

1. Apply parking brake and loosen the lug nuts.

2. Elevate the front of the machine and secure it with jack
stands.
3. Remove the rim from the hub and release the parking
brake.
4. Remove the pinch bolt (10) and nut (9) that hold the A-
Arm ball joint (13) to the carrier bearing assembly.
5. Remove the flange bolt (19) and flange nut (3) from the
frame.
6. Remove A-Arm.

WARNING

The locking features on the existing bolts were destroyed

during removal. DO NOT reuse old bolts. Serious injury
or death could result if fasteners come loose during op-
eration.

A-ARM ASSEMBLY

Refer to drawing on page page 5.12

1. Assemble A-Arm with all bushings (17), pivot tube (18),

ball joint (12,13), and brush guard (15) (if applicable).
2. Place the A-Arm to the frame and insert the flange bolt
(19) with the head toward the front of the machine and the
flange nut (3) toward the rear.
3. Torque the flange bolt (19) to 40 ft-lbs (54Nm).
4. Insert the ball joint (13) far enough into the carrier bearing
assembly so that the pinch bolt (10) can be inserted.
5. Insert the pinch bolt (10) so that the flange head is at the
front of the machine and the flange nut (9) is at the rear.
6. Torque the pinch bolt to 20 ft-lbs (27Nm).

WARNING

Upon A-arm installation completion, test vehicle at low

speeds before putting into regular service.

5.13
BODY AND STEERING

FRONT STRUT REMOVAL

Refer to drawing on page page 5.13

1. Remove the wheel on the side of the strut that is to be replaced.

2. Remove the front cab.
3. With an open end wrench hold the shock tower nut (16) and with a socket turn the shock rod.
4. Remove the screw that holds on the brake line to the strut.
5. Remove the carrier bearing assembly fasteners (4,7).
6. Remove the strut from the vehicle.

FRONT STRUT INSTALLATION

Refer to drawing on page page 5.13

1. Place strut assembly into the frame and insert the strut flange nut (16).
2. Insert the strut into the carrier bearing assembly and insert the fasteners (4,7).
3. Torque the top strut flange nut (16) to 40 ft-lb (54 Nm).
4. Torque the carrier bearing fasteners (7) to 37 ft-lb (50Nm).
5. Replace the torx fastener that holds the brake line in place.
6. Replace front cab.

BEARING REPLACEMENT

Refer to drawing on page page 5.13

1. Remove the front bearing carrier (1).

2. Remove the snap ring (3) from the bearing carrier.
3. Press out the bearing (2).
4. Press in new bearing.
5. Replace the snap ring
6. Install bearing carrier.
7. Torque the bearing carrier to strut mounting fasteners to 37 ft-lb (50Nm).

5.14
 BODY AND STEERING

BALL JOINT REAR SUSPENSION

REPLACEMENT

1. Remove the A-Arm. See “A-ARM REMOVAL” on

page 5.13.
2. Remove the snap ring (1) from the ball joint.
3. Press out the old ball joint (2).
4. Press in new ball joint into A-Arm.
5. Replace the snap ring (1) onto the new ball joint.
6. Assemble the A-Arm, See “A-ARM ASSEMBLY” on
page 5.13.

5.15
BODY AND STEERING

UPPER AND LOWER REAR CONTROL ARM REMOVAL/INSTALLATION

Described in this section is for one side of the machine. Duplicate this process for the other side.

1. Raise and secure the rear of the machine.

2. Remove the rear wheel.
3. Remove the rear shock.
4. Remove the Upper Control Arm (UCA) (15) fasteners (1,4,12) from the transmission and bearing carrier. Note the long (12,14)
and short (1,3) fasteners and pivot shaft locations.
5. Remove the x short grey bushings (2) and pivot shafts (3,14).
6. Remove the Lower Control Arm (LCA) (11) fasteners (4,5,12) from the frame and bearing carrier. Note the long (5,8) and
short (12,14) fasteners and pivot shaft locations.
7. Remove the long grey bushings (9) and pivot shaft (8) from the frame.
8. Remove the short bushings (13) and pivot shaft (14) from the bearing carrier.
9. Remove the LCA (11) from the unit.
10. Replace in reverse order with the following torque values.

• LCA to Bearing Carrier 40 ft-lb (54Nm)

• LCA to Frame 40 ft-lb (54Nm)
• UCA to Bearing Carrier 40 ft-lb (54Nm)
• UCA to Transmission 40 ft-lb (54Nm)
• Shock Mounts (top and bottom) 40 ft-lb (54Nm)
• Wheel Lug Nuts 27 ft-lb (37Nm)

5.16
BODY AND STEERING

5.17
BODY AND STEERING

5.18
BODY AND STEERING

5.19
BODY AND STEERING

NOTES

5.20
 BRAKES

CHAPTER 6
Brakes
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
BRAKES / TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
BRAKE NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
BRAKE SYSTEM MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
REAR MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BRAKE BLEEDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
HAND BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
FRONT CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16 6
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
THICKNESS / RUNOUT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
WEAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
FOOT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
FOOT PEDAL REMOVAL / INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
FOOT BRAKE MASTER CYLINDER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . 6.18
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18

6.1
BRAKES

SPECIFICATIONS
Brakes / Torque

Table 6-1: FRONT BRAKE

Item Standard Service Limit

Brake Pad Thickness .275” / 7 mm .155” / 3.9 mm

Brake Disc Thickness .157” / 4.0 ± 2 mm .140” / 3.55 mm

Brake Disc Thickness Variance

-- .002” / .051 mm
Between Measurement

Brake Disc Runout -- .010” / .254 mm

Caliper Piston Diameter (Front) 1.250” / 31.75 mm --

Table 6-2: REAR BRAKE

Item Standard Service Limit

Brake Pad Thickness .275” / 7 mm .155” / 3.9 mm

Brake Disc Thickness .157” / 4.0 ± 2 mm .140” / 3.55 mm

Brake Disc Thickness Variance

-- .002” / .051 mm
Between Measurements

Brake Disc Runout -- .010” / .254 mm

Caliper Piston Diameter (Rear) 1.250” / 31.75 mm --

Table 6-3: TORQUE SPECIFICATIONS

Torque ft.lbs.
Item Torque (Nm)
(in.lbs.)
Front / Rear Caliper Mounting Bolts 22 30

Handlebar Master Cylinder Clamp Bolts (70 in.lbs.) 7.9

Hand Master Cylinder Reservoir Cover (7 in.lbs.) .79

Brake Line Banjo Bolt 15 20

Brake Disc Bolts 18 24

Brake Line Flare Fittings 12-15 16-21

Bleeder Screw (36-46 in.lbs.) 4-5

NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures
are used when torquing certain bolts and fasteners. Do not re-use fasteners that have pre-applied locking
agents.

6.2
 BRAKES

TROUBLESHOOTING Table 6-4: BRAKE NOISE

TROUBLESHOOTING
Brake Noise
Possible Cause Remedy
Dirt or dust buildup on the brake pads and disc is the most
common cause of brake noise (squeal caused by vibration). If If noise does not change
cleaning does not reduce the occurrence of brake noise, a Noise is from other source when brake is applied
product such as Permatex™ Disc Brake Quiet or an equivalent (chain, axle, hub, disc or check other sources.
can be applied to the back of the pads. Follow directions on the wheel) Inspect and repair as
package. This will keep pads in contact with caliper piston(s) necessary
to reduce the chance of squeaks caused by dirt or dust. Wrong pad for Change to a softer or
conditions harder pad (if available)
Table 6-4: BRAKE NOISE
TROUBLESHOOTING

Possible Cause Remedy

Dirt, dust, or imbedded
material on pads or disc
Spray disc and pads with a
non-flammable aerosol
brake cleaner. Remove
pads and/or disc hub to
clean imbedded material
from disc or pads.

Pad(s) dragging on disc

Adjust pad stop
(noise or premature pad
(front calipers)
wear)

Insufficient lever or pedal

Set to proper level
clearance

Master cylinder reservoir Check brake fluid level,

overfilled adjust as needed

O-rings worn Rebuild Caliper

Master cylinder
compensating port
restricted, Master cylinder
Clean piston(s) seal
piston not returning
completely, Caliper
piston(s) not returning

Operator error (riding the

brake / park brake Educate operator
applied)

Loose wheel hub or Tighten wheel nuts or

bearings replace bearing if worn

Brake disc warped or

Replace disc
excessively worn

Brake disc misaligned or Inspect and repair as

loose necessary

6.3
BRAKES

BRAKE SYSTEM MAIN COMPONENTS

System Exploded View

2 screws - 7 in. lbs. (.79Nm )

All Flare Style Fittings: 12-15 ft.lbs. (16-21 Nm)

All Bleed Screws: 36-46 in.lbs. (4-5 Nm)

Apply a Light
Amount of Pipe
Sealant to Threads

All Banjo Style Fittings: 15 ft.lbs. (20 Nm)

6.4
 BRAKES

BRAKE CALIPER
Exploded View
A.Bleeder Screw C A
B. Caliper Body
C. Internal Caliper Slide Pin O-rings (small) B
D. Square Seals
E. Piston
F. Caliper Mount
G. Brake Pads D
H. Internal Caliper Slide Pin O-rings (large)
I. Caliper mount O-ring

E
H

HYDRAULIC BRAKE SYSTEM

6.5
BODY AND STEERING

Operation Overview The friction applied to the brake pads will cause the pads to
wear. As these pads wear, the piston within the caliper moves
Must be clear to Compensating port further outward and becomes self adjusting. Fluid from the
allow proper E compensates for reservoir fills the additional area created when the caliper
diaphragm temperature changes by piston moves outward.
movement allowing fluid back to
master cylinder Brake fluid level is critical to proper system operation. Too
little fluid will allow air to enter the system and cause the
F C brakes to feel spongy. Too much fluid could cause brakes to
drag due to fluid expansion.

Located within the master cylinder is the compensating port

A B
D temperatures created within the system during heavy braking,
Move Brake Pad
The Polaris disc brake system consists of the following
components or assemblies: hand brake lever; foot brake lever,
hand and foot brake master cylinders; hydraulic hoses; brake
calipers (slave cylinders); brake pads; and brake discs, which
are secured to the drivetrain.
When the hand activated brake lever (A) is applied it contacts
piston (B) within the master cylinder. As the master cylinder
piston moves inward it closes a small opening (compensating
port C) within the cylinder and starts to build pressure within
the brake system. As the pressure within the system is
increased, the piston (D) located in the brake caliper moves
outward and applies pressure to the brake pad. This pad
contacts the brake disc and moves the caliper in its floating
bracket, pulling the stationary side pad into the brake disc.
The resulting friction reduces brake disc and vehicle speed.
As the lever pressure is increased, the braking affect is also
increased.
(C) which is opened and closed by the master cylinder piston
assembly. The port is open when the lever is released and the
master cylinder piston is outward. As the temperature within
the hydraulic system changes, this port compensates for fluid
expansion (heated fluid) or contraction (cooled fluid). During
system service, be sure this port is open. Due to the high
it is very important that the master cylinder reservoir have
adequate space to allow for fluid expansion. Never overfill
the reservoir! Fill to 1/4, - 5/16, (.64 - .80 cm) from top of
the cylinder.
This system also incorporates a diaphragm (E) as part of the
cover gasket; and a vent port (F) located between the gasket
and the cover. The combination diaphragm and vent allow for
the air above the fluid to equalize pressure as the fluid
expands or contracts. Make sure the vent is open and allowed
to function. If the reservoir is over filled or the diaphragm
vent is plugged the expanding fluid may build pressure in the
brake system leading to brake fail
When servicing Polaris ATV brake systems, use only DOT 3
or DOT 4 Brake Fluid.
WARNING
Once a bottle is opened, use what is necessary and dis-
card the rest in accordance with local laws. Do not store
or use a partial bottle of brake fluid. Brake fluid is hy-
groscopic, meaning it rapidly absorbs moisture. This
causes the boiling temperature of the brake fluid to drop,
which can lead to brake fade and the possible loss of con-
trol.

6.6
 BRAKES

REAR MASTER CYLINDER • Inspect caliper piston seals for foreign material that
could prevent caliper pistons from returning freely.
Operation Overview
CAUTION
Brake Fluid Reservoir

Use only DOT 3 or 4 brake fluid as an assembly aid for

all procedures described in this chapter to prevent brake
system contamination. DO NOT USE LUBRICANTS
OF ANY KIND FOR ASSEMBLY, AS THEIR USE
CAN CAUSE RUBBER COMPONENTS TO SWELL.
Rear Brake MC
Frame BRAKE BLEEDING
Rear Brake Line
Fluid Change
NOTE: When bleeding the brakes or replacing the
Spring fluid, always start with the caliper farthest from the
master cylinder.

Brake Mount CAUTION

Always wear safety glasses during these procedures.

Brake Lever Brake fluid will damage finished surfaces. Do not allow
brake fluid to come in contact with finished surfaces.

NOTE: Do not move brake lever when reservoir fluid

When the foot activated brake lever is applied it contacts level is low.
piston of the master cylinder. As the pressure within the
system is increased, the piston located in the brake calipers This procedure should be used to change fluid or bleed brakes
move outward and apply equal pressure to the brake pads. during regular maintenance.
• Perform a brake burnishing procedure after installing 1. Clean reservoir cover thoroughly.
new pads to maximize service life. 2. Remove screws, cover and diaphragm (C) from reservoir.
• Optional pads are available to suit conditions in your 3. Inspect vent slots (A) in cover and remove any debris or
area. Select a pad to fit riding style and environment. blockage.
• Do not over-fill the master cylinder fluid reservoir.
• Make sure the brake lever and pedal returns freely and
completely.
• Adjust stop pin on front caliper after pad service.
• Check and adjust master cylinder reservoir fluid level
after pad service.
• Make sure atmospheric vent on reservoir is
unobstructed.
• Test for brake drag after any brake system service and
investigate cause if brake drag is evident.
• Make sure caliper moves freely on guide pins (where
applicable).

6.7
BODY AND STEERING
4. If changing fluid, remove old fluid from reservoir and
lines at the bleeders with a Mity Vac™ pump or similar
tool, topping off the reservoir with fresh DOT 3 or DOT 4
fluid as it drains to the MIN reservoir level. DO NOT
allow the reservoir to drain completely. Continue this
process at each bleeder until the fluid runs clear.
Sight Glass
C brake lever is pumped. Place diaphragm (C) in
D See Illustration above.
B 2. Slowly pump brake lever (D) until pressure builds and
A
MAX Level - Brake
6.8
Brake Bleeding
1. Begin bleeding procedure with the caliper that is farthest
from the master cylinder. Install a box end wrench on
caliper bleeder screw. Attach a clean, clear hose to fitting
and place the other end in a container. Be sure the hose fits
tightly on fitting.
NOTE: Fluid may be forced from supply port (B) if
reservoir to prevent spills. Do not install cover tight.
holds.
3. While maintaining lever pressure, open bleeder screw.
Allow lever to relax slowly toward the hand grip while
tightening the bleeder screw. Watch for signs of air
bubbles in the fluid as the screw is tightened. When no air
is present, the bleeding procedure should be complete.
4. Allow lever to return back to it’s normal position once the
brake bleeder is securely tightened.
NOTE: Do not release lever before bleeder screw is
tight or air may be drawn into caliper.
5. Repeat procedure until clean fluid appears in bleeder hose
and all air has been purged. Add fluid as necessary to
maintain level in reservoir.
CAUTION
Maintain at least 1/2, (1.27 cm) of brake fluid
in the reservoir to prevent air from
entering the master cylinder.
6. Tighten bleeder screw securely and remove bleeder hose.
Torque the bleeder screw to specification.
7. Repeat procedure for the remaining caliper(s).
8. Add DOT 3 or DOT 4 brake fluid to the MAX level inside
reservoir.
 BRAKES

9. Install diaphragm, cover and screws. Align any marks (if HAND BRAKE MASTER
present) into the proper holes in the master cylinder.
Wiggle and press down on the cap to be sure it fits evenly CYLINDER
and snug. Torque the screw to 7 in.lbs. (0.79 Nm).
Removal
1. Clean master cylinder and reservoir assembly. Make sure
you have a clean work area to disassemble brake
components.

2. Remove the banjo bolt that connects the brake line to the
master cylinder. Discard the copper washers.

CAUTION
Cap Must Be Even
Brake fluid will damage finished surfaces.
7 in.lbs. (0.79 Nm)
Do not allow brake fluid to come in
contact with finished surfaces.

3. Remove master cylinder clamps from handlebars.

4. Hold brake upright and continue to remove master
cylinder. Cover brake line to avoid spilling of fluid.

Torque Outer
Screw First

10. Field test machine at low speed before putting into service.
Check for proper braking action and lever reserve. With
lever firmly applied, lever reserve should be no less than 1/
2”, (1.3 cm) from handlebar.
11. Check brake system for fluid leaks and inspect all hoses
and lines for wear or abrasion. Replace hose if wear or
abrasion is found.

6.9
BODY AND STEERING

Installation 2. Place NEW sealing washers on each side of banjo line and
torque banjo bolt to specification.
NOTE: When replacing the brake master cylinder
assembly or master cylinder parts, use the correct Torque to specification (15 ft.lbs.)
parts. There are different brake master cylinders for Sealing Washer
the different Polaris ATV models. Refer to your
parts manual or guide for the correct parts. Some
master cylinders are not serviceable and are
replaced as an assembly. Banjo Bolt
1. Install master cylinder on handlebars. Torque mounting
bolts to 70 in. lbs. (7.9 Nm). Torque the inside bolt first
as indicated in the illustration to the right.
7 in.lbs. (.79 Nm)
Brake Line
Torque Bolt First

3. Fill reservoir with DOT3 or DOT 4 brake fluid.

70 in.lbs. (7.9 Nm)

NOTE: To speed up the brake bleeding procedure,

the master cylinder can be purged of air before
brake line is attached. Fill with DOT 3 or DOT 4
Brake Fluid and pump lever slowly two to three
times with finger over the outlet end to purge master
cylinder of air. 4. Follow bleeding procedures. Check all connections for
leaks and repair if necessary.

6.10
 BRAKES

BRAKE PADS 4. Push mounting bracket inward and slip outer brake pad
past edge. Remove inner pad.
Removal
1. Loosen the wheel nuts. Elevate and support front of
machine and remove the tire(s).

CAUTION

Use care when supporting vehicle so that it does not tip

or fall. Severe injury may occur if machine tips or falls.

2. Remove caliper from mounting bracket.

5. Measure the thickness of the pad material. Replace pads if

worn beyond the service limit.

3. Push caliper piston into caliper bore slowly using a C-

clamp or locking pliers with pads installed.

Measure Pad
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper. Front Brake Pad Thickness
Remove excess fluid from reservoir as required.
New : .275”/ 7 mm
Service Limit: .155” / 3.9 mm

6.11
BODY AND STEERING

Installation 3. Install caliper on hub strut, and torque mounting bolts.

1. Lubricate mounting bracket pins and external slide pin O-

ring with a light film of Polaris Premium All Season
Grease (PN 2871423).

22 ft.lbs.
(30 Nm)

4. Slowly pump the brake lever until pressure has been built
up. Maintain at least 1/2, (12.7 mm) of brake fluid in the
reservoir to prevent air from entering the brake system.
2. Compress mounting bracket. Install pads with friction 5. Verify fluid level in reservoir is up to MAX line inside
material facing each other. reservoir and install reservoir cap.
6. Install wheels and torque wheel nuts to specification.
NOTE: Front Wheel Nut Torque: Refer to Torque
Table at beginning of chapter.

FRONT CALIPER
Removal

CAUTION

Use care when supporting vehicle

so that it does not tip or fall.
Severe injury may occur if machine tips or falls.

1. Using a line wrench, loosen and remove brake line to

WARNING caliper. Place a container under caliper to catch fluid

If the brake pads are contaminated with grease, oil, or

liquid soaked do not use the pads, use only new clean
pads.

6.12
 BRAKES

draining from brake line. 3. Remove mounting bracket pin assembly .

2. Push pad retainer pin inward and slip brake pads past the
pin edges. A pliers may be used to compress the pad
retainer for removal if the pads are too thick. Use caution
not to bend or damage the retainer or the brake pad ears.
4. Remove piston using a twisting, pulling motion. Remove
the piston square seals using a wooden or plastic pick. Use
caution not to scratch or damage the piston or the bore of
the caliper.
NOTE: Do not use a metal pick or awl to remove the
square seals.

The use of compressed air may be

required to remove the piston.

CAUTION

Always wear eye protection

when using compressed air.

6.13
BODY AND STEERING

5. Remove the four (4) O-rings from the caliper body. Note Inspection
the orientation of the O-rings for reassembly. Clean the
caliper body, piston, and retaining bracket with brake 1. Inspect caliper body for nicks, scratches or wear. Measure
cleaner or alcohol. bore size and check for out of round. Replace if damage is
evident or if worn.
NOTE: Be sure to clean grooves in caliper body. Do
not use a petroleum based spray to clean the
caliper.

NOTE: O-ring grooves are size-specific

2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn beyond
service limit.

Clean Components

3. Inspect the brake disc and pads as outlined for brake pad
replacement this section. See “BRAKE PAD
INSPECTION” in this chapter.

6.14
 BRAKES

Reassembly 4. Compress the mounting bracket into the caliper and make
sure the O-rings are fully seated. Install the brake pads.
1. Install new piston square seals (A) in the caliper body (B). Clean the disc and pads with brake parts cleaner or
Be sure groove is clean and free of residue or brakes may denatured alcohol to remove any dirt, oil or grease.
drag upon assembly.

C
B

Installation
2. Coat piston with clean Polaris DOT 3 or DOT 4 Brake
Fluid (C). Install piston (D) with a twisting motion while 1. Install caliper on hub strut, and torque mounting bolts.
pushing inward. Piston should slide in and out of bore
15 ft.lbs. (20 Nm)
smoothly, with light resistance.
3. Install new slide pin O-rings in the caliper body for the
Lubricate the mounting bracket pins with Polaris Premium
All Season Grease (PN 2871423), and install..
NOTE: Do not use Polaris Premium All Season
Grease (PN 2871423) on the square seals. The
petroleum based lubricant will cause the square
seals to swell up.

22 ft.lbs.
(30 Nm)

2. Install brake line and tighten securely with a line wrench.

Torque the banjo brake lines to the proper torque
specification.
3. Perform brake bleeding procedure as outlined earlier in
this chapter.
4. Install wheels and torque wheel nuts to specification (See
NOTE: O-ring grooves are size-specific Chapter 2).

6.15
BODY AND STEERING

BRAKE BURNISHING 3. Mount dial indicator as shown to measure disc runout.

Slowly rotate the disc and read total runout on the dial
PROCEDURE indicator. Replace the disc if runout exceeds
specifications.
Overview

It is required that a burnishing procedure be performed after

installation of new brake pads to extend service life and
reduce noise.

Start machine and slowly increase speed to 30 m.p.h..

Gradually apply brakes to stop machine. Allow pads and disc
to cool sufficiently after each stop during the procedure. Do
not allow pads or disc to become hot or warping may result.
Repeat this procedure 10 times.

BRAKE DISC
Thickness / Runout Inspection
1. Visually inspect the brake disc for nicks, scratches, or
damage. Brake Disc Runout Service
2. Measure the disc thickness at eight different points around
Limit: .010” / .254 mm
the pad contact surface using a 0-1, micrometer. Replace
disc if worn beyond service limit.

Wear Inspection
1. visually inspect disc for scoring, scratches, or gouges.
replace the disc if any deep scratches are evident.
2. use a 0-1” micrometer and measure disc thickness at 8
different points around perimeter of disc. replace disc if
worn beyond service limit.
BRAKE DISC

Brake Disc Thickness:

New: .157”(4.0 ± .2mm)
Service Limit: .140” / 3.556 mm

Disc Thickness

6.16
 BRAKES

5. Install NEW bolts and tighten to 18 ft.lbs. (24 Nm).

Brake Disc Thickness
New: .157”(4.0 ± .2mm)
Service Limit: .140”
(3.556 mm)

Brake Disc Thickness

Variance
Service Limit: .002”
(.051 mm)
difference between
measurements
Torque New Bolts: 18 ft.lbs. (24 Nm)
Brake Disc Runout
CAUTION
Service Limit: .010”
(.254 mm)
Always use NEW brake disc mounting bolts.
The bolts have a pre-applied locking agent
Removal / Replacement which is destroyed upon removal.

NOTE: To reduce the possibility of warping, try

removing the brake disc mounting bolts before FOOT BRAKE
applying heat to the bolts.
1. Apply heat to the hub in the area of the brake disc Foot Pedal Removal / Install
mounting bolts to soften the bolt locking agent.
1. Remove the cotter key (A).
2. Remove the washers, bushings, and tension spring and
remove the brake lever (F).
3. Reverse the steps for installation, using a new cotter key
during installation.

2. Remove bolts and disc.

3. Clean mating surface of disc and hub.
4. Install new disc on hub.

6.17
BODY AND STEERING

Foot Brake Master Cylinder Removal / • Worn disc and/or friction pads
Installation • Incorrectly adjusted lever
1. If necessary, remove the rear brake lines (B) from the • Incorrectly adjusted stationary pad
master cylinder (C). Use a suitable container to catch the
brake fluid. Dispose of brake fluid properly. • Worn or damaged master cylinder or components
2. Remove the two bolts that secure the rear master cylinder • Improper clearance between lever and switch
to the brake mount plate. Replace parts as needed.
3. To install the rear brake master cylinder, mount the master LEVER VIBRATION
cylinder to the mount plate and torque bolts to 8 ft.lbs. (11
Nm). • Disc damaged
4. Reinstall the brake line and torque the banjo bolt (with
• Disc warp (runout or thickness variance exceeds
new copper washers installed) to 22 ft.lbs. (30 Nm).
service limit)
Torque the flared fitting (if removed) to 12-15 ft.lbs. (16-
21) Nm.
CALIPER OVERHEATS (BRAKES DRAG)
5. Bleed the master cylinder following the procedure
outlined in the brake bleeding section of this manual. • Compensating port plugged
• Foot brake pedal incorrectly adjusted
B
• Brake lever or pedal binding or unable to return fully
• Parking brake left on
C • Residue build up under caliper seals
D • Operator riding brakes

BRAKES LOCK

• Alignment of caliper to disc

F
A • Compensating port plugged
• Parking brake left on

TROUBLESHOOTING
BRAKE SQUEAL

• Dirty/contaminated friction pads

• Improper alignment
• Worn disc
• Worn caliper

POOR BRAKE PERFORMANCE

• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured

6.18
 FINAL DRIVE

CHAPTER 7
FINAL DRIVE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
COMPONENT TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
FRONT DRIVE CV SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
CV BOOT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
FRONT HUB BEARING (2X4/4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
FRONT PROP SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
AWD FRONT DRIVE AXLE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
FRONT DRIVE SHAFTS AND PROPSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
FRONT GEARCASE - CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
FRONT GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
CENTRALIZED HILLIARD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
ALL WHEEL DRIVE GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
AWD DIAGNOSTICS: AWD WILL NOT ENGAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
REAR HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
REAR HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
REAR CV SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
DRIVE SHAFT AND CV JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
REAR CV SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
CV JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
CV JOINT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
REMOVAL AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25

7.1
FINAL DRIVE

SPECIFICATIONS 5. Safely lift and support the front of the ATV.

CAUTION
Component Torques
IMPORTANT: Verify which type of tire your ATV is
Serious injury could occur if machine tips or falls.
equipped with (aluminum or steel wheel) when
torquing wheel nuts. 6. Remove wheels.
7. Remove cotter pin and nut from lower A-arm ball joint.
Table 7-1: Torque Table Remove lower A-arm from ball joint using a suitable tool.

ft.lbs.
Component Nm
(in.lbs.)
F/R Steel Wheel Nuts 27 41

F/R Aluminum Wheel

90 122
Nuts

Front Hub Nut 80 109

Rear Hub Nut 80 109

Lower Front A-arm 38 51

CAUTION 8. Pull strut assembly out while pivoting front drive shaft
downward until it clears strut assembly. (Hub removed for
Locking nuts, and bolts with pre-applied locking agent clarity - removal optional)
should be replaced if removed.
The self-locking properties of the nut or bolt
are reduced or destroyed during removal

Table 7-2: Special Tools

Part Number Tool Description

2872608 Roller Pin Removal Tool

8700226 CV Boot Clamp Pliers

-- A- Arm Removal Tool

FRONT DRIVE CV SHAFT

Removal
1. Remove hub dust caps.
2. Remove cotter pins.
3. Loosen the hub retaining nuts.
4. Loosen - but do not remove - the wheel nuts.

7.2
 FINAL DRIVE

9. Pull sharply or use a pry bar to remove CV shaft from the CV BOOT SERVICE
gearcase.
Inspection

Check the front and rear driveshaft CV boots for signs of

cracking, tearing, punctures or leaking grease. If the
driveshaft boot loses all of the grease, CV joint failure will
occur.

Installation
1. Apply an anti-seize compound to all splines. Align splines
of drive shaft with front gearcase and install by lightly
tapping on drive shaft with rubber faced hammer.
2. Install drive shaft into strut housing.
3. Install lower A-arm ball joint. Install cross bolt and torque
nut to 38 ft. lbs. (51 Nm) and install new cotter pin.
4. Install hub, washer and nut. Tighten hub nut to
specification and install new cotter pin.
Disassembly
1. Refer to the “CV SHAFT REMOVAL” section in this
chapter for procedures.
2. Remove clamps from rubber boot using the proper boot
clamp pliers.
3. Remove the large end of the boot from the CV joint, slide
the boot back and separate the wheel spindle and CV joint
assembly from the axle shaft by pulling the shaft sharply
outward, away from the CV joint. It may be necessary to
tap the CV joint assembly outward with a soft faced
hammer.

Retaining Ring

Front Hub Retaining Nut

Torque:
80 ft. lbs. (109 Nm)
Pull Shaft to Remove
from CV Joint

7.3
FINAL DRIVE

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 4 oz. of grease.
CV Joint Grease -4 oz.
(Refer to parts manual for boot kit)
CV Boot Clamp Pliers:
Earless Type: (PN 8700226)
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 the instrument, verify the small
end of the boot is in its correct location on the axle. CARE
MUST BE TAKEN TO AVOID DAMAGE TO THE
NEWLY INSTALLED BOOT.

Boot replacement with

complete CV joint cleaning
requires the entire 4 oz. of
grease.

4. Before installing the new boot, remove all grease from the
boot area and shaft.
NOTE: It is very important to use the correct type
and quantity of grease. Use only the grease
contained in the boot kit. DO NOT use a substitute 9. Install the small clamp on the boot.
grease and DO NOT overfill or underfill the CV joint.
5. Slide the new clamp and boot (small end first) over the Front Shaft
splined shaft, then slide (tap) the CV joint into the splines
of the axle.
6. Add grease through large end of boot. 4
7. Install a new boot onto the axle shaft and fill the CV joint
and boot with the correct type and amount of grease.

7.4
 FINAL DRIVE

FRONT HUB BEARING (2x4/4x4) Installation

1. Support bottom of hubstrut housing in a press or suitable
Removal device.
2. Start bearing in housing.
1. Remove outer snap ring.
3. Press bearing into place until outer race bottoms on
housing.

CAUTION

When using an arbor press be sure to press only on the

outer race, as bearing damage may occur.

4. Install snap ring into groove.

FRONT PROP SHAFT

Removal
1. Using Roll Pin Removal Tool (PN 2872608), remove the
roll pin from prop shaft at rear of housing.
2. From the back side, tap on the outer bearing race with a
drift punch in the relief as shown.

2. Slide prop shaft back and away from front housing. Pull
sharply forward to remove from transmission shaft.

NOTE: Drive bearing out evenly by tapping on outer Installation

race only. Once bearing is at bottom of casting, 1. Apply anti-seize compound to all splines. Slide prop shaft
support casting on outer edges so bearing can be back onto the transmission housing, then connect to the
removed. front gearcase, verify pin holes are aligned.
3. Discard bearing once removed. 2. Using Roll Pin Tool (PN 2872608), install the prop shaft
NOTE: Due to extremely close tolerances and roll pin at rear of housing.
minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement sideways between inner and
outer race.
4. Inspect bearing housing for scratches, wear or damage.
Replace housing if damaged.

7.5
FINAL DRIVE

U-JOINT SERVICE 3. Support U-joint in vise as shown and drive inner yoke
down to remove remaining bearing ca
Disassembly

CAUTION

Always wear eye protection!

1. Remove internal or external snap ring from all bearing

caps.

4. Force U-joint cross to one side and lift out of inner yoke.

NOTE: If yoke or bearing is removed, cross bearing

must be replaced. Note orientation of grease fitting
and mark inner and outer yoke for correct re-
positioning during installation.
2. Support inner yoke as shown and drive outer yoke down
(bearing cap out) with a soft face hammer.

7.6
 FINAL DRIVE

Assembly Repeat procedure for other side.

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.

5. Install snap ring to contain bearing cap just installed.

Repeat procedure for other side.
6. Seat all bearing caps against snap rings by supporting cross
shaft and tapping on each corner as shown.

2. Using a suitable arbor, fully seat bearing cap in one side.

Continually check for free movement of bearing cross as
bearing caps. Using a suitable arbor, fully seat bearing cap
in one side. Continually check for free movement of
bearing cross as bearing caps are assembled. are
assembled.

7. When installation is complete, yokes must pivot freely in

all directions without binding. If the joint is stiff or
binding, tap the yoke lightly to center the joint until it
pivots freely in all directions.

3. Install snap ring to contain bearing cap just installed.

Repeat procedure for other side.
4. Install snap ring to contain bearing cap just installed.

7.7
FINAL DRIVE

AWD FRONT DRIVE AXLE EXPLODED VIEW

Front Drive Shafts and Propshafts
NOTE: Refer to your parts manual for the proper replacement parts.

Drive Axle Components

Outer CV Joint
Outer Boot Inner Boot Inner CV Joint
Shaft

Clamps
Drive Boot Replacement Kits
Clamp 4 oz. grease
Boot

4 oz
Outer Clamp

Propshaft Assy. Front Prop Shaft Components

Prop Shaft
Cross & Bearing Kit

Yoke, Front Gearcase Yoke, Prop to Transmission

7.8
 FINAL DRIVE

FRONT GEARCASE - to the output hubs that link both front axles, resulting in True
All Wheel Drive.
CENTRALIZED HILLIARD
Operation Overview Roller Cage & Bearings
Ring Gear
Engaging Front Gearcase: The AWD switch may be turned
on or off while the vehicle is moving. Initially, the vehicle's
electronic system will not enable the AWD until the engine
RPM is below 3100. Once enabled, the AWD remains while
the front gearcase is moving, it will not disengage until the
rear wheels regain traction.

Engage the AWD switch before getting into conditions where

the front wheel drive may be needed. If the rear wheels are
spinning , release the throttle before switching to AWD. Armature Plate

CAUTION
CAUTION
Switching to AWD while the rear wheels are spinning
If the rear wheels are spinning, release the throttle before
may cause severe drive shaft and gearcase damage. Al-
turning the AWD switch on. If AWD is engaged while
ways switch to AWD while the rear wheels have traction
the wheels are spinning, severe drive shaft and clutch
or are at rest.
damage could result.

With the AWD switch off the vehicle drives only the rear
Disengagement: As the front and rear wheels gain traction,
wheels (2 wheel drive). When the AWD switch is activated it
their rotational rpms are very close to the same speed. The
engages the hilliard, locking both front axles into All Wheel
front wheels ‘overdrive’ the output hubs and the rollers are
Drive.
forced outward, disengaging the AWD. The vehicle is now
back to rear wheel drive until the next loss of traction.

4x4 Engagement: When the AWD switch is activated, a 12

VDC current charges the central coil which creates a magnetic
field. This magnetic field attracts an armature plate keyed to a
roller cage that contains rollers and roller cam. The difference
in rotational rpm between the input shaft and front axles forces
the rollers up the external cam. The rollers engage themselves

7.9
FINAL DRIVE

FRONT GEARCASE
CENTRALIZED HILLIARD EXPLODED VIEW

7.10
 FINAL DRIVE

ALL WHEEL DRIVE GEARCASE center of the vehicle

Removal
1. Stop engine, place machine in gear and set parking brake.
2. Loosen right front wheel nuts slightly.
3. Elevate machine until the front wheels are off the ground
and support machine under footrest/frame area.

CAUTION

Serious injury may result if machine tips or falls. Be sure

machine is secure before beginning this service proce-
dure. Wear eye protection when removing and installing
bearings and seals.

4. Remove wheel nuts and wheels.

5. To remove the gearcase, the following items must be
removed or disconnected so that the steering post brackets
can be accessed and the post raised up:
* Battery and cables
* Seat
* Fuel Tank
* Front Fender Assy
* Side Panels
* Head Light Harnesses
* AWD Hub Coil Harness
* Gearcase vent line
6. Remove the front bumper. (4 Bolts)
7. Remove the front splash guards. (two screws and six slips
per side)
8. Remove the center tank cover. (replace gas cap to avoid
spills)
9. Remove the front cab by loosening the 4 screws that attach
the cab to the frame. Turn the handlebars full left. Rotate
and lift the front cab around the steering / components.
10. Remove the fuel tank. (Chapter 4)
11. Remove the steering post brackets from the gearcase
mounting flange and bulkhead. Lift the steering post
assembly from the front gearcase and move toward the

7.11
FINAL DRIVE

12. Remove cotter pin, lower ball joint nut and A-arm from 16. Remove bolts securing bottom of housing to frame. Bolts
ball joint. are accessible through the skid plate. Remove vent line.
Remove the front gearcase from either side of frame.

Front Gearcase Removal

Remove 4 Bolts
13. Pull the strut assembly out and pull the drive-shaft out of
the hub. (Hubs removed for clarity - removal not required)
DISASSEMBLY
1. Drain and properly dispose of used oil. Remove any metal
particles from the drain plug magnet.
2. Remove bolts and output shaft cover.

14. Pull both driveshafts from the front gearcase.

15. Remove the roller pin from the front prop shaft. Use the
Roller Pin Removal Tool (PN 2872608).

7.12
 FINAL DRIVE

3. Remove ring gear and roller assembly. 6. Remove the ring gear, roll cage assembly, rollers, and H-
springs from the gearcase.

4. Clean all parts and inspect for wear. Inspect ring gear
backlash pad (arrow) for wear or damage. 7. Thoroughly clean all parts. Inspect the rollers (A) for
nicks and scratches. The rollers must slide up and down
freely within the roller cage surfaces (B).
B
A

NOTE: Backlash for the front gearcase is set at the

factory. No adjustment can be made.
5. Remove the output hub assembly from the left-hand 8. Inspect the ring gear (C) for consistent wear patterns. The
gearcase half. Inspect surfaces for wear or signs of surfaces should be free of nicks and scratches.
damage. Replace component if found to worn or damaged.

7.13
FINAL DRIVE
9. Inspect roll cage (B) sliding surface. This surface must be
clean and free of nicks, burrs or scratches. Remove and
inspect the H-springs. Replace any H-springs that appear
damaged or have lost radial tension.
B H-Spring
10. Remove the output hub assembly from the right-hand
gearcase half. Inspect surfaces for wear or signs of
damage. Replace component if found to worn or damaged.
11. Inspect the output hub thrust bearing. Replace if wear or
damage is found.
7.14
12. Inspect the output hub bearings (arrows). Replace
bearings if wear or damage is found.
NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement side to side.
13. Inspect the armature plate (E) for a consistent wear
pattern. Uneven wear of the armature plate surface (E)
indicates a warped plate, which may cause intermittent
operation.
 FINAL DRIVE

14. Inspect the magnetic coil (I) in the output housing. Test the 16. Inspect the output shaft bushing (arrow). Replace as
resistance of the coil using an ohmmeter. Replace case half needed. Clean the inside surfaces of both gearcase halves.
if coil is found to be non-functional or if the coil surface is
damaged.

17. Remove and replace the O-rings and seals (arrows) from
the gearcase halve assemblies.

AWD Gearcase Coil

Resistance: 21.6 ohms and
23.9 ohms @ 68° F (20° C)

NOTE: To test the gearcase coil resistance, use the

AWD coil harness. The gearcase coil should
measure between 21.6 ohms and 23.9 ohms @ 68° F
(20° C).
15. Remove and inspect the input cover (M), bearing (N), and
the pinion gear (O). Inspect the pinion gear (O) for
chipped, broken, or missing teeth. Replace the input cover
O-ring and seal.

N REASSEMBLY
M 1. Replace all O-rings, seals, and worn components.
2. Press the pinion shaft seal into the pinion cover, until the
seal is flush with the sealing surface.
3. Install pinion shaft into the bearing cover, using a small
amount of grease on the seal bearing, and input cover with

7.15
FINAL DRIVE

new o-ring and torque bolts to 14 ft. lbs (19 Nm). 5. Install the rollers and roll cage into the ring gear. Insert the
rollers as the roll cage is installed, installing the lower row
first and then the upper row.

14 ft.lbs. (19 Nm)

4. Install the output hub (A) into the gearcase housing. Apply
a small amount of grease to the seal and seal surface as this 6. Install the ring gear over the output hub and into the output
will aid assembly. The output hub should spin freely. cover. Insert the backlash pad (G) and set assembly
upright..

G
A

7. Install the armature plate (D) onto the ring gear. Verify the
plate tabs are places into the slots on the roller cage.
NOTE: Verify backlash plate stays in place.

7.16

8. Install the other output hub (B) and thrust bearing (C) into
the output case half. Apply a small amount of grease onto
the seal surfaces to aid installation.
C B
9. Install the left-hand output cover onto the right-hand
assembly by holding it as shown. Verify the backlash plate
thrust bearing and armature plate stay in place during
assembly.
F There should one or two distinct wear bands (one band
10. Torque bolts to 14 ft. lbs. (19 Nm).
14 ft.lbs. (19 Nm)
FINAL DRIVE
AWD DIAGNOSTICS: AWD Will Not Engage
1. Check the gearcase coil resistance. To test the gearcase
coil resistance, use the coil harness. The gearcase coil
should measure between 21.6 ohms and 23.9 ohms @ 68°
F (20° C).
2. Check the minimum battery voltage at the wire that feeds
the hub coil wire. There should be a minimum of 11.80-
12.0 Volts present for proper operation.
3. Inspect the armature plate for a consistent wear pattern.
inside the other). If only one band of wear is present (or if
there is wear between the two bands, inspect the coil area
as indicated in Step 4. A band with an interrupted wear
mark may indicate a warped plate, which may cause
intermittent operation. See Illustration 1.
Wear Ring on
Armature Plate
Example of Bad
Condition (Wear from
(Coil on Armature
7.17
FINAL DRIVE

4. Check to make sure the coil is seated in the U-shaped 30 ft.lbs. (41 Nm).
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.

Side Cutaway View of Gearcase

Coil
30 ft.lbs. (41 Nm)

2. Coat splines with anti-seize compound. Install CV shaft

into the gearcase. Light tapping may be required to
properly seat the splines into the gearcase.

U-Shaped Insert

5. Inspect the rollers for nicks and scratches. The rollers

must slide up and down and in and out freely within the
roll cage sliding surfaces.

Rollers

INSTALLATION
1. Install gearcase into the frame. Torque mounting bolts to

7.18
 FINAL DRIVE

3. Pull strut assembly out while pivoting front drive shaft REAR HUB
downward until it enters strut assembly. (Hub and brake
removed for clarity - removal optional)
Removal
1. Place the ATV in Park and lock the parking brake.
Remove rear hub cap and loosen wheel nuts.

4. Install the lower A-arm. Torque nut and bolt to

specification.
B
5. Install the hub and retaining hardware. Torque the hub nut C
to specification.
6. Install cotter pin.
7. Install the wheel and wheel nuts. 2. Remove cotter pin (A).
8. Safely lift and lower the front of the ATV. 3. Loosen the hub retaining nut (B).
9. Torque the wheel nuts to specification. 4. Loosen the wheel nuts (C).
10. Add the proper lubricant to the front gearcase. Check 5. Safely support the rear of the ATV.
drain plug for proper torque. Refer to Chapter 2 for fluid 6. Remove wheel nuts and wheel.
fill and change information. 7. Remove the rear brake caliper and safely suspend the
caliper from the frame with a piece of wire. (Left side only)

7.19
FINAL DRIVE

8. Remove hub nut, domed washer and flat washer. 11. Remove both lower control arm bolts.

9. Remove hub.
12. Remove bearing carrier.

Disassembly
1. Remove outer snap ring.

10. Remove upper control arm bolt as shown.

7.20
 FINAL DRIVE

2. From the back side, tap on the outer bearing race with a 2. Start bearing in housing.
drift punch in the reliefs as shown.

3. Press bearing into place until outer race bottoms on

NOTE: Drive bearing out evenly by tapping on outer housing.
race only. Once bearing is at bottom of casting,
support casting on outer edges so bearing can be
removed.
3. Replace bearing.
NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement sideways between inner and
outer race.
4. Inspect bearing housing for scratches, wear or damage.
Replace housing if damaged.

Rear Hub Assembly

1. Support bottom of bearing carrier housing. CAUTION

Use an arbor press only on the outer race, as bearing

damage may occur.

4. Install snap ring into groove.

Installation
1. Insert CV shaft into rear hub bearing carrier .
2. Align bottom of carrier housing and lower control arm.
Grease and slide lower control arm bushings into place,
securing housing.

7.21
FINAL DRIVE

3. Install and torque lower control arm bolts. REAR CV SHAFT

Removal
1. Remove rear hub; see “REAR HUB REMOVAL”.
2. Tip hub outward and remove shaft from hub.

Lower Control Arm Bolt

Torque: 50 ft. lbs. (68 Nm)
Upper Control Arm Bolt
Torque: 35 ft. lbs. (48 Nm) 3. Pry and pull sharply outward to remove shaft from
transmission. Install a new lock ring upon assembly.
4. Lift bearing carrier until top aligns with upper control arm.
Install and torque upper control arm bolt and torque to Pull outward sharply to
specification. remove from transmission
5. Pull drive shaft outward and install hub onto driveshaft
splines.
6. Install cone washers with domed side facing outward.
7. Install retainer nut, wheel and wheel nuts.
8. Remove jackstand and torque axle nut and wheel nuts.
9. Install a new cotter pin. Tighten nut slightly to align holes
if required.

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.

10. Install hub cap.

7.22
 FINAL DRIVE

• The complete driveshaft / joint should be handled by 4. Lift bearing carrier into place and install bolt to upper
the interconnecting shaft to avoid disassembly or potential control arm. Torque bolt to 35 ft. lbs. (48 Nm).
damage to the driveshaft joints.
• Over-angling of joints beyond their capacity can result
in boot or joint damage.
• Make sure surface-ground areas and splines of shaft are
protected during handling to avoid damage.
• Do not allow boots to come into contact with sharp
edges or hot engine and exhaust components.
• Shafts should never be used as a lever arm to position
other suspension components.
• Never use a hammer or sharp tools to remove or to
install boot clamps.
• Be sure joints are thoroughly clean and that the proper
amount and type of grease is used to refill when joint
boots are replaced and when joints are cleaned. Refer to
text for grease capacity of CV joints and CV joint boots. 5. Install hub, flat washer, domed washer (domed side out)
and nut. Torque center hub nut to 80 ft. lbs. (109 Nm).
REAR CV SHAFT Install new cotter pin and hub cap.
6. Install rear wheel and torque wheel nuts to specification.
INSTALLATION
80 ft.lbs. (109 Nm)
1. Slide shaft assembly into bearing carrier hub.

Refer to specifications for

Wheel Nut Torque.
2. Apply anti-seize compound to splines of shaft.
3. Install a new lock ring and install the shaft. 7. Grease all applicable fittings thoroughly with Premium U-
Joint Lubricant (PN 2871551).

7.23
FINAL DRIVE

CV JOINT SERVICE hammer while holding snap ring open.

Spread ends of snap ring

CV Joint Replacement
to remove joint from
1. Remove clamps from rubber boot(s) using the CV Boot
Clamp Pliers (PN 8700226) (A).

Tap CV housing
off shaft
3. Place a new snap ring in the groove of the CV joint inner
hub, with tabs facing the shaft as shown.

NOTE: Photo below is shown without shaft for

clarity. Wipe grease away from recess in CV joint
inner hub to locate snap ring

Snap Ring Located in recessed area

Snap Ring

Tabs face shaft

2. Open the snap ring using a snap ring pliers or small needle
nose pliers. Tap CV housing off shaft with a soft faced

7.24

4. 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
5. Install and tighten large boot clamp with boot clamp pliers.
6. Remove excess grease from the CV joint's external
surfaces and position joint boot over housing, making sure
boot is seated in groove. Position clamp over boot end and
make sure clamp tabs are located in slots. Note: Before
tightening boot clamp on inboard joint, make sure any air
pressure which may have built up in joint boot has been
released. The air should be released after the plunging
joint has been centered properly. Tighten boot clamp
using boot clamp pliers.
Open snap ring and
pull CV joint away
FINAL DRIVE
Removal and Cleaning
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. A gritty feeling indicates contamination. If
the grease is not contaminated, the boot can be
replaced without cleaning the CV joint. Use the
recommended amount of grease for boot
replacement only (see below). Proceed to Boot
Installation.
3. Thoroughly clean and dry the CV joint and inspect ball
tracks and cages for wear, cracks or other damage.
NOTE: Shiny areas in ball tracks and on the cage
spheres are normal. Do not replace CV joints
because parts have polished surfaces. Replace CV
joint only if components are cracked, broken, worn
or otherwise unserviceable.
4. Add the recommended amount of grease for CV joint
cleaning to the joint as shown below. Be sure grease
penetrates all parts of the joint.
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.
6. Add grease through large end of boot. Be sure to use only
the Constant Velocity Joint grease supplied with boot
service kit. IF CV JOINT WAS CLEANED, add the
recommended amount of grease to the joint in addition to
the grease pack supplied with boot kit.
7. Install a new boot onto the axle shaft and fill the CV joint
and boot with the correct type and amount of grease.
7.25
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.
CARE MUST BE TAKEN TO AVOID DAMAGE TO
THE NEWLY INSTALLED BOOT.

9. Install the small clamp on the boot.

7.26
 CVT TRANSMISSION

CHAPTER 8
CVT / TRANSMISSION
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
CVT TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
GEAR SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SHIFT LINKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
GEAR SELECTOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
CVT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
CVT OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
STARTING CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
DRIVEN CLUTCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
ENGINE BRAKING CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
CVT MAINTENANCE/INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
CVT DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
CVT OVERHEATING/DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
CVT SYSTEM DISASSEMBLY / DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
CVT SYSTEM / DRIVEN CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
TRANSMISSION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14

8.1
CVT TRANSMISSION

TORQUE SPECIFICATIONS
CVT TORQUE SPECIFICATIONS

96 in. lbs. (10.8 Nm)

185 ft. lbs (250 Nm)

Use Clutch Holder PA-47478

14 ft. lbs. (19 Nm)

Clamps - 25 in. lbs.

8.2
 CVT TRANSMISSION

GEAR SELECTION SPECIAL TOOLS

SHIFT LINKAGE INSPECTION SPECIAL TOOLS
NOTE: Shift rod is preset at time of manufacture.
1. Inspect shift linkage rod bushing clips and replace if
worn or damaged. Lubrication of rod ends is not
required.

GEAR SELECTOR REMOVAL

1. Push linkage rod out of bushing clip to remove.
2. Remove bolts attaching gear selector mount to frame.
3. To remove gear selector handle, pry cap off and
remove screw.

Clutch Compression Tool 8700220

Arm, Clutch Spring Compressor

PA-47457-1
(Use with 8700220)

Clutch Adaptor PA-47457-2

Spring Retainer Alignment Tool PA-47457-3

Retainer Nut Socket, Driven Clutch PA-46076

Drive Clutch Holder PA-47478

Order tools from SPX Corp. 1-800-328-6657

8.3
CVT TRANSMISSION
CVT OPERATION
CVT OPERATION OVERVIEW
WARNING
All CVT maintenance or repairs should be performed
only by a certified Polaris Master Service Dealer (MSD)
technician who has received the proper training and un-
derstands the procedures outlined in this manual. Be-
cause of the critical nature and precision balance
incorporated into the CVT components, it is abso-
lutely essential that no disassembly or repair be
made without factory authorized special tools and
service procedures.
The power of the engine is transferred to the wheels
through the following components: Starting Clutch, Drive
Clutch, Drive Belt, Driven Clutch, Transmission, Drive
shaft(s), and Rear Gearcase (and Front Gearcase on 4x4
models).
During the development of a Polaris ATV, the CVT
system is matched first to the engine power curve; then
to average riding conditions and the vehicle’s intended
usage. Therefore, modifications or variations of
components at random are never recommended.
Proper clutch setup and careful inspection of existing
components must be the primary objective when
troubleshooting and tuning.
The Continuously Variable Transmission (CVT) consists
of four major assemblies: 1) Starting Clutch; 2) Drive
Clutch; 3) Drive Belt; and 4) Driven Clutch.
STARTING CLUTCH OPERATION
The starting clutch is located on the left (CVT) side of the
engine crankshaft. It is an RPM sensitive clutch that
connects the engine crankshaft to the CVT System.
When engine RPM is below the factory determined
engagement speed of the vehicle, return springs on the
staring clutch shoes hold the shoes inward away from the
starter clutch hub.
When engine RPM is increased, centrifugal force causes
the shoes to overcome the return spring force and swing
outward. When the shoes contact the surface of the
starter clutch hub, the hub rotates at engine speed. This
8.4
causes the CVT drive clutch mounted on the shaft of the
staring clutch hub to rotate at the same RPM.
Refer to the ENGINE section for more information.
DRIVE CLUTCH OPERATION
The CVT drive clutch, mounted on the starting clutch hub
shaft, is also RPM sensitive. The drive clutch basic
components are the inner (fixed) sheave, the outer
(moveable) sheave, the rollers (weights) and the cover
plate.
The drive clutch begins to rotate when engine RPM
reaches engagement speed and the starter clutch
engages.
At low RPM, the drive belt is located at the bottom
(smallest diameter) of the drive clutch sheaves resulting
in a low “gear” ratio. As engine RPM increases,
centrifugal force moves the drive clutch shift rollers
outward in their respective tracks toward the outside of
the drive clutch. This forces the moveable sheave farther
inward toward the fixed sheave. The inward movement
of the sheave forces the drive belt farther upward in the
sheaves toward progressively higher “gear” ratios (larger
diameter).
DRIVEN CLUTCH OPERATION
The driven clutch is connected to the drive clutch via the
drive belt and is mounted on the main gearcase input
shaft. The CVT driven clutch consists of a fixed sheave,
a moveable sheave with roller tracks, rollers, and a
compression style return spring.
The driven clutch is primarily torque sensitive, reacting to
the forces of engine power and vehicle load to control the
upshift and downshift of the CVT system.
Engine power is sensed by the driven clutch via the drive
belt. Vehicle loads are sensed by the driven clutch
through the main gearcase input shaft.
If forces on the drive belt (engine power) exceed the
forces on the transmission shaft (vehicle loads) the drive
clutch sheaves move inward and the belt upward, which
forces the sheaves of the driven clutch apart against
spring pressure. The drive belt moves downward into the
sheaves of the driven clutch to a smaller diameter (higher
“gear” ratio), increasing the speed of the driven clutch.
This process is called upshifting.
 CVT TRANSMISSION

If the torque resistance at the transmission input shaft is CVT DRYING

greater than the force through the drive belt, the driven
clutch spring forces the moveable sheave inward, and the
drive belt is forced toward the outer diameter of the
sheaves. This action, which decreases the driven clutch
speed, is called backshifting.
In situations where loads vary (such as uphill and
downhill) and throttle settings are constant, the drive and
driven clutches upshift or backshift accordingly to
maintain optimum engine RPM.
NOTE: If operating the ATV through water, be sure to
check the CVT cover and other ATV components for
water ingestion. The ATV should be checked immediately.
Refer to Owner’s Manual for Safe Riding Tips.
1. To drain any water that may be trapped inside the
CVT cover, remove the CVT drain plug located on the
bottom of the CVT cover and let the water drain out.
(The location of the CVT drain plug is shown on the
following page.)

At full throttle a perfectly matched CVT maintains engine NOTE: To further expel water in the CVT cover and to
RPM at the peak of the power curve during upshift and dry out the CVT system, shift the transmission to neutral
backshift. In this respect, the CVT system is similar to a and rev engine slightly to expel the moisture. This will
conventional power governor, but it functions by varying also air-dry the belt and clutches. Allow engine RPM to
the load rather than by varying throttle position. settle to idle speed, shift transmission to lowest available
range and test for belt slippage. Repeat as needed.
Operate ATV in lowest available range for a short period
ENGINE BRAKING CLUTCH
of time until CVT system is dry.
The engine braking clutch is a one-way clutch located
inside the starting clutch hub. This clutch “locks” the
starting clutch hub to the crankshaft whenever drive belt
(and drive clutch) speeds exceed the engine RPM, such
as when travelling down hill with the throttle released,
which provides engine braking.

Refer to the ENGINE section for more information.

CVT MAINTENANCE/INSPECTION
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 CVT
components. Refer to the troubleshooting checklist for
more information.
1. Drive and Driven Clutch Rollers (Weights),
Buttons and Bushings, and Driven Clutch Spring.
Inspect for wear.
2. Drive Belt. Inspect condition and width of belt.
3. Sheave Faces. Clean and inspect for wear.
4. CVT System Sealing. The CVT system is air cooled
by fins on the drive clutch stationary sheave. The fins
create a low pressure area in the CVT area, drawing
fresh air into the system through the intake air duct.
The opening for this intake duct is located at a high
point on the vehicle. All connecting air ducts and the
outer cover must be properly sealed to reduce the
chance of water ingestion into the CVT area. A sealed
CVT is especially critical on units subjected to
frequent water forging.

8.5
CVT TRANSMISSION

Air Intake Duct

Drain Plug Location

ct Air Intake Duct

Air Exhaust Duct

Clamps

CVT OVERHEATING/DIAGNOSIS
During routine maintenance or whenever CVT system overheating is evident, it’s important to check the inlet and
outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase CVT system
operating temperatures. The ATV should be operated in LOW RANGE (if equipped) when pulling or plowing heavy
loads, or if extended low speed operation is anticipated.

GENERAL RANGE OPERATION Low Range (if equipped): Heavy pulling, basic operational speeds
GUIDELINES: less than 7 MPH, riding through rough terrain (swamps, mountains,
etc.), low ground speeds.
High Range: High ground speeds, speeds above 7 MPH.
Diagnosis of Clutch Drive Belt & Cover Related Issues:
Possible Causes Solutions/What to do

8.6
 CVT TRANSMISSION

Loading the ATV into a pickup or tall Shift transmission to low range (if equipped) during loading of the ATV
trailer when in high range. to prevent belt burning.
Starting out going up a steep incline. When starting out on an incline, use low range (if equipped), or perform
the “K” turn to turn around. Warning: Excessive throttle may cause
loss of control and vehicle overturn.
Driving at low RPM or low ground speed Drive at higher speed or use Low Range. (if equipped) The use of Low
(at approximately 3-7 MPH). Range is highly recommended for cooler CVT operating temperatures
and longer component life.
Insufficient warm-up of ATVs exposed to Warm engine at least 5 min., then with transmission in neutral, advance
low ambient temperatures. throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will
become more flexible and prevent belt burning.
Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement. Continuous
operation at the point of engagement (initial vehicle movement)
increases CVT temperatures and component wear.
Towing/Pushing at low RPM/low ground Use Low Range only. (if equipped)
speed.
Plowing snow, dirt, etc./utility use. Use Low Range only. (if equipped)
Stuck in mud or snow. Shift the transmission to Low Range (if equipped), carefully use fast,
aggressive throttle application to engage clutch. Warning: Excessive
throttle may cause loss of control and vehicle overturn.
Climbing over large objects from a Shift the transmission to Low Range (if equipped), carefully use fast,
stopped position. aggressive, throttle application to engage clutch. Warning: Excessive
throttle may cause loss of control and vehicle overturn.
Belt slippage from water or snow Shift the transmission to neutral. Using the throttle, vary engine rpm
ingestion into the CVT system. from idle to 3/4 throttle. Engage transmission in the lowest possible
range (if equipped) and test for belt slippage Repeat several times as
required. During this procedure, the throttle should not be held at
the full position. Inspect CVT system for sealing or damage if
repeated water ingestion occurs.
Clutch malfunction. Inspection/repair of clutch components should be performed by a
certified Polaris MSD technician.

8.7
CVT TRANSMISSION

CVT SYSTEM DISASSEMBLY / DRIVE NOTE: If tool is not available, use two hands to hold
CLUTCH the cam plate and the primary sliding sheave
together when removing the primary sliding sheave
NOTE: Do not lubricate drive clutch components.
and the cam plate assembly. This prevents the rollers
1. Remove seat, left side cover, left foot well, rear rack from falling out of the assembly.
and rear cab. (Rear tire removal not required but
helpful.)
2. Remove all CVT cover screws and CVT cover.

3. Replace cover bearing if worn. Remove the snap ring

and draw bearing out with a blind hole puller or slide
hammer style puller.
NOTE: Do not re-use bearing if removed from cover.
4. Press or drive a new bearing into the cover. Press or
drive only on the outer race of bearing. Fit should be
snug with no tightness or sticking. Rotate the inner
race to be sure it rotates freely without binding after
installation.
5. Install the snap ring. Be sure it is fully seated in the
groove.

Cover Bearing 8. Separate driven clutch sheaves and force belt down
into the sheaves. Remove belt from driven, then from
drive clutch.

6. Inspect the CVT cover gasket and replace if

damaged.
7. Before removing drive belt, install the tool as shown to
prevent drive clutch moveable sheave from moving
inward.

8.8

9. Measure belt width and compare to specification.
Replace if any area is worn below the minimum width,
if belt is unevenly worn (hour glassed) or if damaged.
10. Remove the primary sliding sheave and cam plate
assembly as one assembly. Inspect the movable
sheave for scoring, grooving, or abnormal wear.
NOTE: If tool is not installed, be sure to hold cam
plate and primary sliding sheave together to prevent
rollers from falling out of the assembly.
11. Remove sleeve and fixed sheave. Inspect the cooling
fins for damage, the sleeve for wear or rough spots,
and the face of the fixed sheave for wear, grooving or
rough surface.
Fixed Sheave
Sleeve
CVT TRANSMISSION
12. Remove the rollers from the primary sliding sheave.
Check the rollers for wear, deep scoring, or flat spots.
Remove and inspect the slide bushings and cam
plate. Replace any components that found to be worn
excessively or appears abnormal.
Slide Bushings
Rollers
Bushing Cam Plate
13. Note direction of roller thrust surface (wide edge)
toward thrust face of sheave.
14. Inspect bushing for wear.
15. When installing cam plate, be sure to align offset hole
in cover with threaded hole in sheave.
Wide Surface Of Roller Against Thrust
Surface Of Roller Track
Wide Surface
Bushing
Threaded Hole
8.9
CVT TRANSMISSION
16. The clutch sheaves are balanced from the factory.
When installing clutch on the vehicle, be sure to align
the “X” marks on the sheaves to maintain proper
balance.
X mark
17. Install the fixed sheave and spacer sleeve.
18. Install the tool in the offset hole of the moveable
sheave assembly to hold it together for installation.
8.10
19. Install the moveable sheave, aligning the “X” mark
with the “X” mark on the fixed sheave, engage the
splines and install the nut. Do not apply any lubricants
to the components. Apply Loctite 242 (Blue) to
threads and torque the retaining nut to 185 ft. lbs. (250
Nm).
IMPORTANT: Be sure splines of cam plate are fully
engaged on shaft spline before tightening the nut!
CVT Drive Clutch Nut Torque
185 ft. lbs. (250 Nm)
Loctite 242 (Blue)
CVT SYSTEM / DRIVEN CLUTCH SERVICE
1. Remove retaining bolt.
2. Pull the clutch off the shaft using flywheel puller as
shown.
3. Remove the puller and place the driven clutch spring
side up in the clutch spring compressor 8700220.
4. Install arm PA-47457-1 on the spring compressor.
5. Install adaptor PA-47457-2 on the arm.
6. Remove nut (counterclockwise) using tool PA-46076
or a standard socket.
 CVT TRANSMISSION

7. Compress spring enough to remove the chain lock cover for wear.
and slowly release spring tension.

10. Remove roller pins using a needle-nose pliers and

CAUTION remove top and bottom O-rings.

Spring Pressure can cause components to eject

suddenly. Use care during removal.

NOTE: Use Loctite™ 242 upon reassembly.

8. Measure the free length of spring. Standard free
length is 7.52” (191.1mm). Replace spring if length is
less than standard or if spring coils are distorted.

NOTE “X” MARKS FOR ASSEMBLY

11. Clean all parts to remove old grease before inspecting

the components.
12. Carefully inspect the roller tracks in the hub of the
moveable sheave. Replace clutch assembly if tracks
are visibly worn.
13. Check the pin holes in the shaft of the fixed sheave.
Pins should be a firm fit in the holes.
Driven Compression Spring 14. Inspect sheaves for wear, damage, or rough spots.
Standard Length: Replace the clutch assembly if sheaves are worn or
7.52” (191.1 mm) damaged.
15. Apply a light film of moly grease to seal lips and to the
inside of the roller pin hub. Install the moveable
9. Carefully pry up the roller cover to remove it. Inspect
sheave over the shaft of the fixed sheave until the
sheaves contact each other.

8.11
CVT TRANSMISSION

16. Lift the moveable sheave enough to clean all excess 26. Install tool PA-47457-3
grease from the shaft and the sheave faces to prevent 27. Retainer Alignment Tool onto spring retainer.
belt contamination after assembly.

Turn to align flats

28. Compress the clutch spring slowly, turning the

17. With sheaves together, rotate the moveable sheave retainer with the tool as required to align the flats.
to ALIGN THE “X” MARK of moveable sheave with 29. When flats are aligned, fully compress the spring and
the “X” mark on fixed sheave. secure the compressor arm with the chain.
18. Lubricate the roller pins with grease and install all pins 30. Apply Loctite 242 to threads of the nut and the shaft,
until fully seated. The surface of the pins must be and install nut hand tight.
approximately flush with the surface of the roller pin 31. Release the tool and torque the nut to 45 ft lbs (61
hub. Nm) using the same tools for removal of the nut.
19. Install new O-rings on top and bottom of roller pin
hub. Driven Clutch Spring Retainer Nut Torque:
20. Pack all roller tracks with grease. 45 ft. lbs. (61 Nm)
21. Install the roller pin sleeve and push it down until fully LoctiteTM 242 (Blue)
seated against moveable sheave.
22. Clean the threads of the shaft, and threads of the
spring retaining nut to remove all oil or grease.
23. Place the driven clutch assembly in the compressor
tool.
24. Install spring.
25. Install spring retainer on spring, visually aligning the
flats of the retainer with the flats on the threaded shaft.

8.12
 CVT TRANSMISSION

TRANSMISSION

18 ft. lbs. (24.5 Nm)

8.13
CVT TRANSMISSION

TRANSMISSION SERVICE 5. Remove gear position switch and shift bell crank.

1. Drain transmission fluid.

2. Remove Transmission. Refer to the Engine Section
for transmission removal procedure.

TRANSMISSION DISASSEMBLY
1. Clean the exterior of the transmission.
2. Remove all case screws.
3. Remove the left case from the right. Be sure shafts
stay with right case.

6. Remove input shaft, counter shaft, and shift drum as

an assembly.

4. Remove output gear and shaft and pull oil deflector

from right case. Note orientation for installation later.
Oil Deflector

7. Clean all parts. Remove seals from gear case and

install new using an appropriate size seal driver.
8. Inspect all bearings, gear teeth, and splines for wear
or damage. Inspect gear dogs carefully and replace
if the edge of the dog is worn or rounded, chipped, or
broken.
9. Inspect the reverse chain for damage.
Output Gear
Gear Teeth
Bearings Reverse Chain

Splines
Engagement Dogs

8.14
 CVT TRANSMISSION

10. Gear dogs should be square at the corners. Replace 13. Reassemble the drum starting with shaft guide, detent
both mating gears if any are rounded. cam (wide flange faces toward the threaded end of
drum), the flat washer, and snap ring.

11. Inspect the shift drum tracks for wear or damage.

Inspect shift fork for bending, and the surface for wear,
burning, or scoring. 14. Place fork shaft through guide with pointed end as
shown.
Inspect Shift Fork

12. Inspect the shift fork shaft and all springs. Inspect
detent cam and pawl for wear.

8.15
CVT TRANSMISSION

15. Slide the spring collar, large diameter spring, shift 17. Assemble the shafts with chain and shift drum and
fork, small spring, and shaft support onto the shaft. install the assembly into the case.
The dot on the shaft support faces away from the fork.

Shaft Support
Spring Collar
Small Spring
Large Spring
Fork

18. Install the output gear and oil deflector. Lubricate all
components.
Oil Deflector
Output Gear
DOT

16. Install the detent ratchet with spring. Install the snap
ring.

8.16
 CVT TRANSMISSION

19. Apply 3-Bond 1215 sealant evenly to clean and oil-

free case sealing surfaces.

20. Install the left case and tap it into place until seated.
21. Install bolts and torque in two steps following a cross
pattern to 18 ft. lbs. (24.5 Nm).
22. Install the shift arm (bell crank).
23. Rotate the shafts to be sure they turn smoothly. Verify
shifting through all gears while rotating the shafts.
24. Verify drain plug is tight (18 ft. lbs. (24.5 Nm). Fill
transmission with specified type and quantity. (Refer
to Maintenance Section for procedure).

8.17
CVT TRANSMISSION

NOTES

8.18
 ELECTRICAL

CHAPTER 9
ELECTRICAL
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
FUSE SPLICE SAVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
FUSIBLE LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
GEAR POSITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
RPM LIMIT MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
INSTRUMENT GAUGE POWER / FWD / NEUTRAL SWITCHES / RPM SIGNAL . . . . . 9.4
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
AWD CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
ETC / REVERSE RPM CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
IGNITION COIL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
STATOR FUNCTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
CDI OUTPUT TEST USING PEAK READING ADAPTOR OR A VOLTMETER . . . . . . 9.12
CDI CRANKING OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 9.13
IGNITION SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
IGNITION SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
CHARGING SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
ALTERNATOR OUTPUT TEST (AC AMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
BATTERY IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
CONVENTIONAL BATTERY ACTIVATION/ SVC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
BATTERY TERMINALS/TERMINAL BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
CONVENTIONAL BATTERY INSPECTION/REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 9.20
CONVENTIONAL BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
CONVENTIONAL BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
CONVENTIONAL BATTERY OCV - OPEN CIRCUIT VOLTAGE TEST . . . . . . . . . . . . 9.20
CONVENTIONAL BATTERY SPECIFIC GRAVITY TEST . . . . . . . . . . . . . . . . . . . . . . . 9.21
CONVENTIONAL BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
CONVENTIONAL BATTERY OFF-SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . 9.22
CONVENTIONAL BATTERY CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 9.22
STARTER SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
STARTER MOTOR EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
VOLTAGE DROP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
BRUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
INSPECTION & REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
ARMATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
REASSEMBLY & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
9
STARTER SOLENOID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
BENCH TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
PINION GEAR - ANTI-KICK OUT SHOE, GARTER SPRING REPLACEMENT . . . . . . 9.29

9.1
ELECTRICAL

Electrical System FUSE SPLICE SAVER

The fuse splice saver is near the battery under the front storage
SPECIAL TOOLS compartment.

PART NUMBER TOOL DESCRIPTION

Fluke™77 Digital
PV-43568
Multimeter

2870836 Battery Hydrometer

2870630 Timing Light

ELECTRICAL SERVICE NOTES

Keep the following notes in mind when diagnosing an electrical
problem.
• Refer to wiring diagram for stator and electrical
component resistance specifications.
• When measuring resistance of a component that has a NOTE: Use only the recommended fuse capacity, as use
low resistance value (under 10 Ohms), remember to of a higher amperage fuse to correct blown-fuse
subtract meter lead resistance from the reading. Connect situations could lead to electrical component damage.
the leads together and record the resistance. The
resistance of the component is equal to tested value Fusible Link
minus the lead resistance. A fusible link is installed on the battery voltage circuit that
• Become familiar with the operation of your meter. Be supplies power to the main 15A fuse. The link is located at the
sure leads are in the proper jack for the test being starter motor solenoid + post.
performed (i.e. 10A jack for current readings). Refer to Fusible Link PN: 2202607
the Owner’s manual included with your meter for more
information. Always replace a blown fusible link with a new link. Never use
a piece of wire or metal in place of the link.
• Voltage, amperage, and resistance values included in this
manual are obtained with a Fluke™ 77 Digital
Multimeter (PV-43568). This meter is acceptable for use
when diagnosing electrical problems. Readings obtained
with other meters may differ.
• Pay attention to the prefix on the multimeter reading (K,
M, etc.) and the position of the decimal point.
• For resistance readings, isolate the component to be
tested. Disconnect it from the wiring harness or power
supply.

9.2

GEAR POSITION SWITCH
Switch Test
1. Locate the gear selector switch on the transmission.
Remove the wiring harness connector and insert the two
multimeter probes into the switch.
2. Move the gear selector handle to each of the three drive
positions (FWD, NEU, or REV).
3. Using an ohmmeter, test for continuity between the switch
contacts and connector leads. Replace the switch if no
continuity or high resistance is found.
ELECTRICAL
RPM LIMIT MODES
Engine RPM is limited when:
• Operator selects reverse gear. The maximum vehicle
speed when reverse gear is selected is 6.5 MPH
• If the wheel speed sensor malfunctions, the
speedometer will limit engine RPM to approximately
3500 RPM when the transmission is in reverse.
• Maximum engine RPM is reached.
The reverse engine RPM limit can be overridden when the
operator presses and holds the override button.
On AWD models, the speedometer also limits the maximum
engine RPM in which the operator can engage the AWD
system. The speedometer will not allow the AWD to engage
when the engine RPM is at or above 3100 RPMs.
9.3
ELECTRICAL

Instrument Gauge Power / FWD / Neutral Switches / RPM Signal

The instrument gauge determines engine RPM from the Y/RED AC signal from the voltage regulator.
The gauge is powered by switched R/BLK and switched R/WHT battery voltage. Both the key and the RUN switches have to be
closed to power-up the gauge.
The gear selector switch provides a ground path for the FWD (BLU/RED) or neutral (GRN/WHT) circuits.

9.4

Vehicle Speed Sensor
The vehicle speed sensor is mated to the transmission housing
and reads the speed of the transmission output gear.
The instrument gauge supplies the sensor with battery voltage
via the ORANGE circuit, a reference ground via the BRN/
RED circuit and receives a return signal via the GRN/RED
circuit.
To test the circuit:
1. Turn the ignition key to the ON position and move the
RUN/OFF switch to run.
2. Verify there is battery voltage present on the ORANGE
circuit. If voltage is not found, inspect the wiring harness,
or replace the instrument gauge.
ELECTRICAL
3. If voltage is found, test the BRN/RED ground circuit.
Verify there is continuity between the circuit and chassis
ground.
4. If all circuits function, remove the speed sensor from the
transmission. Verify the sensor is not damaged.
5. Back-probe the GRN/RED and BRN/RED wires with the
connector still connected to the sensor. Turn the
multimeter to measure vDC. Wave a screwdriver back in
forth across the face of the sensor while monitoring the
multimeter.
6. The multimeter display should flip between a voltage and
0vDC every time the screwdriver blade passes by the
sensor face. If this does not occur, replace the sensor.
9.5
ELECTRICAL

AWD Control System
The front differential coil is controlled by the speedometer the
AWD switch, and the RUN/OFF switch.
Battery voltage is supplied to the AWD coil when the operator
turns the key switch to RUN, moves the AWD switch to AWD
and moves the RUN/OFF switch to RUN.
The AWD coil ground circuit is supplied by the instrument
gauge. The speedometer will not allow the AWD to engage
when the engine RPM is 3100 RPM or higher.

9.6
 ELECTRICAL

ETC / Reverse RPM Control System

The instrumentation gauge will signal the CDI controller to limit engine RPM to approximately 3100 RPM (6.5 MPH) whenever
the transmission is in reverse gear. If the ETC switch connects to ground, the instrument gauge will shut the engine off.
The operator can override the RPM speed limit in reverse, but not the ETC RPM limit, by pressing and holding the reverse
override button located on the left handlebar.
The reverse override button also serves as the mode switch button for the instrumentation gauge. The mode button toggles
between the several function the gauge performs.
To rule out engine RPM limiting caused by the CDI or instrument gauge, disconnect the BLACK wire from the CDI controller.

9.7
ELECTRICAL

Charging System
The charging system consists of:.
• Stator
• Battery
• Regulator / Rectifier
The regulator / rectifier is responsible for converting AC voltage to DC voltage, and generating the tachometer pulse.

9.8
 ELECTRICAL

Ignition System
The ignition system consists of:.
• CDI Controller
• Battery
• Ignition Coil
• Stator - Pulse Coil
• ETC / Key / Run-Off Switches / Instrument Gauge

9.9
ELECTRICAL

Starting System
The starting system consists of:.
• Battery
• Key Switch / Run-Off Switch
• Solenoid
• Brake / Neutral Switches - Diodes
• Starter Motor

9.10
 ELECTRICAL

IGNITION COIL TESTING STATOR FUNCTION TEST

Three tests can be performed using a multimeter to determine
the condition of the stator.

Wire Description Resistance

Primary Coil (BLK/W to BLK) .21 Ohms

Secondary Coil (Black to High Tension lead

3.2KOhms
without cap.)

TEST 1: Resistance Value of Each Stator Leg

1. Measure the resistance value of each of the three stator legs:
W1 to W2, W1 to W3, and W2 to W3. Each should measure
0.314ohms.
2. Measure each of the white wires to ground, the reading
should be (O.L.).
NOTE: Significant variations in resistance readings
between each circuit is an indication that one of the three
circuits may be weak or failed.
TEST 2: Stator Output.
1. Place the red lead on the tester in the 10A jack.
2. Turn the selector dial to the AC-AMPs position.
3. Start the engine and let it idle (1200 RPM).
4. Separately test each leg of the stator by connecting the
meter leads to the wires leading from the alternator (W1 to
W2, W1 to W3, W2 to W3). Alternator Current Output
Reading should be no less than 8 AMPS.
NOTE: Use an inductive amp meter to test stator
amperage for engine speeds over 1200 RPM.

9.11
ELECTRICAL

CDI OUTPUT TEST USING PEAK CDI CRANKING OUTPUT TEST

READING ADAPTOR OR A
VOLTMETER
Re-connect all CDI wires to stator wires. Disconnect CDI
module wire from ignition coil primary terminal. Connect one
meter lead to engine ground and the other to the ignition coil
primary wire leading from the CDI module. Crank engine and
check output of CDI wire to coil. Reconnect CDI wire to the
coil.
The following peak voltage tests will measure the amount of
output from each component. A peak reading voltmeter can be
used to perform the tests. A variety of peak reading adaptors are
commercially available for use with the Fluke™ 77 Digital
Multimeter (PV-43568) and other digital VOMs which will
allow peak voltage tests to be performed accurately. Follow the
directions provided with the adaptor. All measurements are
indicated in Volts. Readings obtained without a peak reading
adaptor will be significantly different.
Disconnect the stator connectors from the CDI module. Test
output from the detection and pulse (trigger) coil, and compare
to the chart. The following measurements were obtained when
cranking the engine with the electric starter, spark plug
installed. The starting system must be in good condition and the
battery fully charged.

Voltage Connect Reading Reading

Test Meter Wires (With VOM) (With Peak
To: Reading
Adapter)
Pulse Coil W/R and B 0.15 Volts 5.3 - 5.4
minimum AC Volts
@ cranking minimum
RPM DC @
cranking
Connect Meter RPM
Test Reading
Wires To:

W/BLU to 200 - 250 Ohm Connect Reading Reading

CDI Output Test Meter Wires (With Peak
Ground Volts DC
To: Reading
Adapter)
Pulse Coil W/R and B 520 Ohms n/a
W/R to
O.L.
Ground

9.12
 ELECTRICAL

ELECTRONIC THROTTLE IGNITION SYSTEM TESTING

CONTROL (ETC) SWITCH
The Electronic Throttle Control (ETC) switch is designed to
close in the event where the throttle cable sticks or breaks.
During normal operation, the ETC switch contacts are open
(not touching). The contacts will close when slack is present in
the cable.
Electronic Throttle Control (ETC) Switch
Whenever troubleshooting an electrical problem you should
first check all terminal connections to be sure they are clean
and tight. Also be sure that colors match when wires are
connected. Use the following pages as a guide for
troubleshooting. The resistance values are also given on the
specification pages.

NOTE: The throttle cable must have the proper amount of

end-play adjustment. A cable that is too tight will cause ETC
interruption, resulting in false engine RPM limiting.

Electronic Throttle Control

Open / Closed ETC Switch is OPEN.
Throttle
Slack in Cable / ETC Switch is CLOSED
Throttle Stuck

9.13
ELECTRICAL

Condition: No spark or intermittent spark.

Verify 12 Volt DC power is present on the wire to CDI. Replace Spark Plug.

Disconnect the BLACK wire at the CDI
module to isolate the ignition from the
over-ride systems, but verify the CDI has a
good ground (BROWN) for operation.
Does it have spark?
-Test the ignition switch, engine stop
switch, and speed limiter circuit for
Yes shorts to ground.
- Check connectors for moisture,
wire color matching or corrosion.

No

Verify that a minimum of 10.5 VDC is getting to

the CDI module during cranking. Refer to the
wiring schematic for connections and specifica-
tions. Compare results to the specifications on
the exploded views. Are all within specifications?
Inspect battery condition, connec-
No tors, wiring and grounds to the
component in question. Replace
the component if a wiring problem
cannot be found.

Yes

Check coil ground connection between BROWN and coil

No Clean coil mounting area.
mount using an ohmmeter. The coil mount should
Repair ground wire connections.
have good continuity to ground (0-.2 Ω).

Yes

Disconnect and check the secondary coil. Resis-

tance values should be:
Primary Side - Primary Wire Tab to Ground
(on coil mount or engine): .21 Ohms No Replace the ignition coil.
Secondary Side High Tension Wire to engine
ground- Cap installed - 8,200Ω
Cap removed - 3,200Ω
Are these values within specs?

Yes
If all of the above tests are within specifications, and all grounds, connections, and wire color coding
have been inspected, perform voltage output tests on following page or replace the CDI module.

IGNITION SYSTEM TROUBLESHOOTING

No Spark, Weak or Intermittent Spark
• No12 volt power or ground to CDI
• Spark plug gap incorrect

9.14
 ELECTRICAL

• Fouled spark plug

• Faulty spark plug cap or poor connection to high tension lead
• Related wiring loose, disconnected, shorted, or corroded
• Engine Stop switch or ignition switch faulty
• ETC switch misadjusted or faulty
• Poor ignition coil ground (e.g. corroded)
• Faulty stator (measure resistance of all ignition related windings)
• Incorrect wiring (inspect color coding in connectors etc)
• Faulty ignition coil winding (measure resistance of primary and secondary)
• Worn magneto (RH) end Crankshaft bearings
• Sheared flywheel key
• Flywheel loose or damaged
• Excessive crankshaft runout on magneto (RH)
end - should not exceed .005”
• Faulty CDI module

9.15
ELECTRICAL

CHARGING SYSTEM TESTING

Whenever charging system problems are suspected, proceed with the following system checks:

Using a multitester set on D.C. volts, mea-
sure the battery open circuit voltage (see
procedure later in chapter). It should be
12.4 volts or more. Is it?
Yes
Remove the battery and properly ser-
No vice. Reinstall the fully charged battery
or a fully charged shop battery.

Meter Setting: DC Volts

With the transmission in neutral, start the
engine and increase RPM to between 3000
and 4000. Read battery voltage with the Yes Check Key off Current Draw.
multitester. Readings should be between Refer to Page 9.11.
13.0 and 14.6 V D.C.
Is it?
No
Check for owner modification, and
Meter Setting: DC Amps discuss operating habits. The battery
Perform system “Break Even Amperage” will continually discharge if operated
test outlined on Page 9.11. Yes below the “Break Even” RPM. Con-
tinued problems would call for battery
Does charging occur as specified? inspection.
No

Meter Setting: AC Amps

Disconnect the wires leading from the regu-
lator/rectifier. Using a multitester, perform
an Alternator Output (AC amp) test. See
test procedure on Page 9.11 for procedure.
Is output above 5 amps?
Yes
Inspect the wiring harness be-
tween the panel and the stator for
damage. If no damage is found,
No remove the recoil and flywheel.
Inspect the flywheel magnets, sta-
tor coils and stator wire harness
for damage. Repair or replace
any damaged components.

Meter Setting: DC Volts

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

If all of the previous tests indicate a

good condition, but the charging voltage does
not rise above battery voltage at the
connector or terminal board, replace the
voltage regulator.

9.16
 ELECTRICAL

CURRENT DRAW - KEY OFF • Clamp an inductive ammeter or connect an ammeter (set
to DC amps) in series between the negative battery cable
and terminal.
CAUTION
Current Drain Inspection
Do not connect or disconnect the battery cable or am- Key Off
meter with the engine running. Damage will occur to
light bulbs and speed limiter.
Connect an ammeter in series with the negative battery cable.
Check for current draw with the key off. If the draw is
excessive, 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. Less Than 9 mA
Do not use electric start.
Current Draw - Key Off:
Maximum of .02 DCA (20mA) • Connect a tachometer according to manufacturer’s
instructions.
CHARGING SYSTEM “BREAK • With engine off and the RUN/OFF switch in the RUN
position, the ammeter should read negative amps
EVEN” TEST (battery discharge). Reverse meter leads if a positive
reading is indicated
CAUTION
• Shift transmission into neutral and start the engine.

Do not connect or disconnect the battery cable or am- • Turn headlight on, and apply the brake light. Increase
meter with the engine running. engine RPM while observing ammeter and tachometer.
• Note RPM at which the battery starts to charge (ammeter
indication is positive).
CAUTION
• With lights and other electrical load off, this should
occur at approximately 1500 RPM or lower.
Never use the electric starter with an ammeter con-
nected in series, as damage to the meter or meter fuse • Turn the lights on and lock parking brake to keep brake
may result. Do not run test for extended period of time. light on.
Do not run test with high amperage accessories.
• Repeat test, observing ammeter and tachometer. With
The “break even” point of the charging system is the point at lights on, charging should occur at or below 2000 RPM.
which the alternator overcomes all system loads (lights, etc.)
and begins to charge the battery. Depending on battery
condition and system load, the break even point may vary
slightly. The battery should be fully charged before performing
this test.

9.17
ELECTRICAL

ALTERNATOR OUTPUT TEST ATV has, refer to the illustration below and follow the correct
service and charging procedures that follow in the manual.
(AC AMP) CONVENTIONAL BATTERY
This test measures AC amperage from the alternator.
Removable
CAUTION Caps

This test simulates a “full load” on the alternator. Do

not perform this test longer than required to obtain
a reading or the alternator stator windings may
overheat. Do not exceed idle rpm during this test. Top View

To Calculate Available Alternator Output Electrolyte Level

Indicator
I= P 150 W = 12.5 Amps
E 12 V

I = Current in Amps
P = Power in Watts
E = Electromotive Force (Volts)
Side View
Alternator Current Output:
Minimum of 8 AC Amps

• Maximum alternator output will be indicated on the

meter. It is not necessary to increase engine RPM above
idle.
• Place the red lead on the tester in the 10A jack.
• Turn the selector dial to the AC amps (A~) position.
• Connect the meter leads to the wires leading from the
alternator (see schematic for proper wiring colors).
• Start the engine and let it idle. Reading should be a
minimum of 8A at idle.

BATTERY IDENTIFICATION
NOTICE: It is important to identify what type of battery you
have installed in your ATV. Different types of batteries require
different service procedures. Proper servicing and upkeep of
your battery is very important for maintaining long battery life.
Your ATV may have a Conventional Battery or a Sealed Low
Maintenance Battery. To identify which type of battery your

9.18
 ELECTRICAL

CONVENTIONAL BATTERY NOTE: New Battery: Battery must be fully charged

ACTIVATION/ SVC
To ensure maximum service life and performance from a
battery, perform the following steps.
NOTE: This section contains information for both
Conventional Lead-Acid batteries and Sealed Low
Maintenance batteries. Before service, identify the battery
type in the vehicle. Use the section that applies to the
battery.
WARNING
Battery electrolyte is poisonous. It contains sulfuric
acid. Serious burns can result from contact with
skin, eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Fol-
low with milk of magnesia, beaten egg, or vegetable
oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get
prompt medical attention.
Batteries produce explosive gases. Keep sparks,
flame, cigarettes etc. away. Ventilate when charg-
ing or using in an enclosed space. Always shield
eyes when working near batteries. KEEP OUT OF
REACH OF CHILDREN.
before use or battery life will be significantly reduced 10-
30% of the battery’s full potential.
To activate a new battery:
1. Remove vent plug from vent fitting. Remove cell caps.
2. Fill battery with electrolyte to upper level marks on case.
3. Set battery aside to allow for acid absorption and
stabilization for 30 minutes.
4. Add electrolyte to bring level back to upper level mark on
case. NOTE: This is the last time that electrolyte should be
added. If the level becomes low after this point, add only
distilled water.
5. Charge battery at 1/10 of its amp/hour rating. Examples: 1/
10 of 9 amp battery = .9 amp; 1/10 of 14 amp battery = 1.4
amp; 1/10 of 18 amp battery = 1.8 amp (recommended
charging rates).
6. Check specific gravity of each cell with a hydrometer to
assure each has a reading of 1.270 or higher.
BATTERY TERMINALS/
TERMINAL BOLTS
Use Polaris corrosion resistant Nyogel™ grease (PN 2871329)
on battery bolts. See Battery Installation.

WARNING

The gases given off by a battery are explosive. Any

spark or open flame near a battery can cause an
explosion which will spray battery acid on anyone
close to it. Should there be contact with battery ac-
id, wash the affected area with large quantities of
cool water and seek immediate medical attention.

9.19
ELECTRICAL

CONVENTIONAL BATTERY CONVENTIONAL BATTERY

INSPECTION/REMOVAL INSTALLATION
The battery is located in the front rack storage compartment.
1. Clean battery cables and terminals with a stiff wire brush.
Inspect the battery fluid level. When the battery fluid nears the Corrosion can be removed using a solution of one cup water
lower level, remove the battery and fill with distilled water only and one tablespoon baking soda. Rinse well with clean
to the upper level line. To remove the battery: water and dry thoroughly.
2. Route the cables correctly.
3. Reinstall battery, attaching positive (+) (red) cable first and
then the negative (-) (black) cable. Coat terminals and bolt
Maintain threads with Nyogel™ Grease (PN 2871329).
between upper
and lower level 4. Install clear battery vent tube from vehicle to battery vent.
marks 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 electrolyte. Avoid skin contact with electrolyte, as
severe burns could result. If electrolyte contacts the vehicle
frame, corrosion will occur.
1. Disconnect holder strap and remove covers.
5. Reinstall the holder strap.
2. Disconnect battery negative (-) (black) cable first, followed
by the positive (+) (red) cable. CONVENTIONAL BATTERY
CAUTION
TESTING
Whenever a service complaint is related to either the starting or
Whenever removing or reinstalling the battery, dis- charging systems, the battery should be checked first.
connect the negative (black) cable first and reinstall Following are three tests which can easily be made on a battery
the negative cable last! to determine its condition: OCV Test, Specific Gravity Test and
Load Test.
3. Remove the battery.
4. Remove the filler caps and add distilled water only as CONVENTIONAL BATTERY OCV
needed to bring each cell to the proper level. Do not overfill - OPEN CIRCUIT VOLTAGE TEST
the battery.
Battery voltage should be checked with a digital multitester.
Refill using only distilled water. Tap water contains minerals Readings of 12.6 volts or less require further battery testing and
which are harmful to a battery. charging. See charts and Load Test on below.
Do not allow cleaning solution or tap water inside the battery. NOTE: Lead-acid batteries should be kept at or near a
Battery life may be reduced.Reinstall the battery caps. full charge as possible. Electrolyte level should be kept
5. Reinstall the battery caps. between the low and full marks. If the battery is stored or
used in a partially charged condition, or with low
electrolyte levels, hard crystal sulfation will form on the
plates, reducing the efficiency and service life of the
battery.

9.20
 ELECTRICAL

CONVENTIONAL BATTERY SPECIFIC GRAVITY

SPECIFIC GRAVITY TEST State of Conventional Low
A tool such as a Battery Hydrometer (PN 2870836) can be used charge* Lead-acid Maintenance
to measure electrolyte strength or specific gravity. As the Type
battery goes through the charge/discharge cycle, the electrolyte 100% Charged 1.265 1.275
goes from a heavy (more acidic) state at full charge to a light
(more water) state when discharged. The hydrometer can 75% Charged 1.210 1.225
measure state of charge and differences between cells in a
multi-cell battery. Readings of 1.270 or greater should be 50% Charged 1.160 1.175
observed in a fully charged battery. Differences of more than 25% Charged 1.120 1.135
.025 between the lowest and highest cell readings indicate a
need to replace the battery. 0% Charged less than 1.100 less than 1.115

* At 80oF
NOTE: Subtract .01 from the specific gravity reading at 40o F.

CONVENTIONAL BATTERY
Battery Hydrometer (PN 2870836)
LOAD TEST

1.10
CAUTION
1.15

Detail A 1.20
To prevent shock or component damage, remove
spark plug high tension leads and connect securely
1.25
to engine ground before proceeding.
1.30
NOTE: This test can only be performed on machines with
electric starters. This test cannot be performed with an
engine or starting system that is not working properly.
A battery may indicate a full charge condition in the OCV test
OPEN CIRCUIT VOLTAGE and the specific gravity test, but still may not have the storage
capacity necessary to properly function in the electrical system.
State of Conventional Low For this reason, a battery capacity or load test should be
charge Lead-acid Maintenance conducted whenever poor battery performance is encountered.
Type To perform this test, hook a multitester to the battery in the
100% Charged 12.60 V 12.70 V same manner as was done in the OCV test. The reading should
be 12.6 volts or greater. Engage the starter and observe the
75% Charged 12.40 V 12.50 V battery voltage while cranking the engine. Continue the test for
15 seconds. During cranking the observed voltage should not
50% Charged 12.10 V 12.20 V drop below 9.5 volts. If the beginning voltage is 12.6 volts or
25% Charged 11.90 V 12.0 V higher and the cranking voltage drops below 9.5 volts during
the test, replace the battery.
0% Charged less than less than
11.80 V 11.9 V

9.21
ELECTRICAL

CONVENTIONAL BATTERY OFF- CONVENTIONAL BATTERY

SEASON STORAGE
To prevent battery damage during extended periods of non-
use, the following basic battery maintenance items must be
performed:
• Remove the battery from the machine and wash the
case and battery tray with a mild solution of baking
soda and water. Rinse with lots of fresh water after
cleaning.NOTE: Do not get any of the baking soda into
the battery or the acid will be neutralized.
• Using a wire brush or knife, remove any corrosion from
the cables and terminals.
• Make sure that the electrolyte is at the proper level. Add
distilled water if necessary.
• Charge at a rate no greater than 1/10 of the battery’s
amp/hr capacity until the electrolyte’s specific gravity
reaches 1.270 or greater.
• Store the battery either in the machine with the cables
disconnected, or store in a cool place.
NOTE: Stored batteries lose their charge at the rate of
up to 1% per day. Recharge to full capacity every 30 to
60 days during a non-use period. If the battery is stored
during the winter months, electrolyte will freeze at higher
temperatures as the battery discharges. The chart below
indicates freezing points by specific gravity.
Electrolyte Freezing Points
Specific Gravity Freezing
of Electrolyte Point
1.265 -75o F
1.225 -35o F
1.200 -17o F
CHARGING PROCEDURE
1. Remove the battery from the ATV to prevent damage from
leaking or spilled acid during charging.
2. Charge the battery with a charging output no larger than 1/
10 of the battery’s amp/hr rating. Charge as needed to raise
the specific gravity to 1.270 or greater.
3. Install battery in vehicle. Coat threads of battery bolt with
a corrosion resistant dielectric grease.
Dielectric Grease
(PN 2871329)
4. Connect battery cables.
WARNING
To avoid the possibility of explosion, connect
positive (red) cable first and negative (black) ca-
ble last.
5. After connecting the battery cables, attach the hold down
strap.
6. Install clear battery vent tube from vehicle to battery vent.
WARNING: Vent tube must be free from obstructions
and kinks 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.
Do not run the engine with the battery disconnected. Electrical
components can become damaged.

1.150 +5o F

1.100 +18o F

1.050 +27o F

9.22
 ELECTRICAL

STARTER SYSTEM TESTING FLOW CHART

Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing
of starter system. A digital multitester must be used for this test.
With the tester on the VDC position, place the tes-
ter’s black lead on the battery negative and the red Remove battery and properly service.
lead on the battery positive. No Install fully charged shop battery to
continue test.
Reading should be 12.4 volts or greater.

Yes

Check voltage on both sides of the fuse,

Disconnect Blue/White engagement wire from
the starter solenoid. Connect tester black wire to
battery ground. Connect red tester lead to RED/
No
WHITE harness wire at solenoid.Turn on ignition
switch and depress the starter button.
Tester should read battery voltage.
ignition switch/engine stop switch and
starter button. The
voltage on both sides should be the same.
NOTE: The ignition switch and engine stop
switch must be on, the starter button
depressed. Replace the defective
component.

Yes
Voltage Drop Testing
See Page 9.22 for instructions.
Test starter solenoid coil by connecting an ohmmeter between the coil leads
Resistance should be 3.7Ω + 1. Check solenoid ground path between the
BLUE wire and battery NEG. with transmission in NEUTRAL and the hand
brake applied. Set the meter to check continuity of a diode.

Reconnect the solenoid. Connect the tester black

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

Yes

Connect the black tester lead to solenoid end of

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

Yes

Connect the black tester lead to solenoid end of

the solenoid-to-starter cable. Connect the red tester Clean the solenoid-to-starter cable ends or
No
lead to the starter end of the same cable. Depress replace the cable.
the starter button.
Reading should be less than .1 V D.C.

Yes

If all of these indicate a good condition, yet the starter still fails to turn, the
starter must be removed for static testing and inspection.

9.23
ELECTRICAL

STARTER MOTOR EXPLODED VIEW

BRUSH LENGTH SERVICE LIMIT:

5/16″ (8 MM)

9.24
 ELECTRICAL

STARTER SYSTEM To perform the test, place the meter on DC volts and place the
meter leads across the connection to be tested. Refer to the
chart on 1.47 to perform voltage drop tests on the starter
Troubleshooting system.
Starter Motor Does Not Run
• Battery discharged. Low specific gravity Voltage should not exceed
.1 DC volts per connection
• Loose or faulty battery cables or corroded connections
(see Voltage Drop Tests)
• Related wiring loose, disconnected, or corroded
STARTER MOTOR
• Poor ground connections at battery cable, starter motor
or starter solenoid (see Voltage Drop Tests) Removal / Disassembly
• Faulty key switch NOTE: Use electrical contact cleaner to clean starter
motor parts. Some solvents may leave a residue or
• Faulty kill switch
damage internal parts and insulation.
• Faulty starter solenoid or starter motor.
1. Remove the starter from the engine.
• Engine problem - seized or binding (Can engine be
2. Remove the two bolts, washers, and sealing O-Rings.
rotated easily with recoil starter?)
Inspect O-Rings and replace if damaged.
Starter Motor Turns Over Slowly
• Battery discharged - low specific gravity
• Excessive circuit resistance - poor connections (see
Voltage Drop Test below)
• Engine problem - seized or binding (Can engine be
rotated easily?)
• Faulty or worn brushes in starter motor
Starter Motor Turns - Engine Does Not Rotate
• Faulty starter drive
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel

NOTE: Note the alignment marks on both ends of the

VOLTAGE DROP starter motor casing. These marks must align during
reassembly.
Testing
The Voltage Drop Test is used to test for bad connections.
When performing the test, you are testing the amount of voltage
drop through the connection. A poor or corroded connection
will appear as a high voltage reading. Voltage shown on the
meter when testing connections should not exceed.1 VDC per
connection or component.

9.25
ELECTRICAL

3. Remove the front bracket assembly and the rear bracket as necessary.
assembly. Remove the shims from the armature shaft and
inspect the O-rings located on the armature housing.

O-Rings

Shims
3. Slide positive brush springs to the side, pull brushes out of
their guides and remove brush plate. Slide brush end frame
off end of starter.
NOTE: The shims will be replaced during
reassembly. NOTE: The electrical input post must stay with the
field coil housing.

BRUSHES 4. Measure resistance between ground brush and brush plate.

Resistance should be .3 ohms or less.
Inspection & Replacement
1. Measure resistance between starter input terminal and
insulated brushes. The reading should be .3 ohms or less.
Remember to subtract meter lead resistance.

Brush Inspection
1. Measure length of each carbon brush. Replace brush
assembly when worn to 5/16” (8 mm) or less. The brushes
must slide freely in their holders.
2. Measure resistance between insulated brush and starter
housing. Reading should be infinite. (OL). Inspect Brush Length
insulation on brush wires for damage and repair or replace

Limit 5/16” (8 mm)

9.26

Brush Replacement
1. Remove terminal nut with lock washer, flat washer, large
phenolic washer, the small phenolic spacers, and sealing O-
ring. Inspect O-ring and replace if damaged.
2. Slide positive brush springs to the side, pull brushes out of
their guides and remove brush plate.
CAUTION
Some cleaning solvents may damage the insulation in the
starter. Care should be exercised when selecting an ap-
propriate solvent. If the commutator needs cleaning use
only electrical contact cleaner.
ARMATURE
Testing
1. Remove armature from starter casing. Note order of shims
on drive end for reassembly.
2. Inspect surface of commutator. Replace if excessively worn
or damaged.
ELECTRICAL
3. Using a digital multitester, measure the resistance between
each of the commutator segments. The reading should be .3
ohms or less.
4. Measure the resistance between each commutator segment
and the armature shaft. The reading should be infinite (no
continuity).
5. Check commutator bars for discoloration. Bars discolored
in pairs indicate shorted coils, requiring replacement of the
starter motor.
6. Place armature in a growler. Turn growler on and position
a hacksaw blade or feeler gauge lengthwise 1/8” (.3 cm)
above armature coil laminates. Rotate armature 360°. If
hacksaw blade is drawn to armature on any pole, the
armature is shorted and must be replaced.
CAUTION
Use care when handling starter housing. Do not drop or
strike the housing as magnet damage is possible. If mag-
nets are damaged, starter must be replaced.
STARTER
Reassembly & Installation
1. Install brush plate to field magnet housing aligning index
9.27
ELECTRICAL

tab. 9. Lightly grease pinion shaft and install pinion, spring

stopper, and snap ring.

2. Install O-ring, two small phenolic spacers, large phenolic

washer, flat washer, lock washer, and terminal nut.
3. While holding brush springs away from brushes, push
brushes back and hold in place.
4. Slide armature into field magnet housing. Release brushes.
5. Lightly grease the drive roller bearing and reinstall drive
end frame on armature. Inspect seal for wear or damage.
Replace drive end cap if necessary.
10. Install the starter onto the engine case. Hand tighten each of
the starter bolts. Torque the bottom bolt first to 9 ft.lbs.
(12 Nm). Then torque the top bolt to the same specification.
NOTE: It is important to tighten the bottom starter
bolt first, as the bottom hole acts as a pilot hole to
properly align the starter drive (bendix) with the
flywheel. This helps to prevent binding and starter
damage.

Roller Bearing STARTER SOLENOID

Seal Bench Testing
To measure the resistance of the pull-in coil, connect meter
leads to the solenoid lead wires. The resistance should be 3.7
ohms. Refer to “Electric Starter System Testing” in this section
to further test the solenoid.

6. Be sure wire insulation is in place around positive brush

wire and pushed completely into slot on phenolic plate.
7. Using Dielectric Grease (PN 2871329), lubricate brush end
bushing and install shims.
8. Align brush plate and install cover and screws.

9.28
 ELECTRICAL

STARTER DRIVE
Pinion Gear - Anti-Kick Out Shoe, Garter
Spring Replacement
If the garter spring is damaged, the overrun clutch may fail to
return properly. Use either of the following methods to remove
and install a new garter spring:

H
G
A F
D

A. Gear Assembly E
B. Thrust Washer C
C. Busing
D. Retaining Ring
E. Thrust Washer
F. Stopper
G. Cover
H. Spring

1. Screw the overrun clutch out to the engaged position on the

pinion shaft assembly. Use a small piece of wire with the
end bent in a hook and pick the old spring out of its
channel. Slide it off the end of the shaft. Slide the new
spring over the overrun clutch and into the spring groove.
Make sure that the spring is positioned between the shoe
alignment pins and the back flange of the anti kick-out
shoes.
2. Remove the retaining ring, thrust washer, spring retainers
and clutch return spring. Screw the overrun clutch off the
end of the pinion shaft. Remove the old spring and install
a new one. Lightly grease the pinion shaft and reinstall the
clutch, spring, retainers, end washer and lock ring in the
reverse order. Make sure the end washer is positioned
properly so that it will hold the lock ring in its groove.

9.29
ELECTRICAL

NOTES

9.30
 WIRE DIAGRAM

2006 HAWKEYE 2X4/ 4X4

10.1