Release the ratchet pawl A and push the tensioner plunger B all the way into the tensioner body. Install the tensioner body with a new gasket and tighten the bolts.
Tensioner Bolt Torque: 6 ft. Torque bolts evenly to specification. Stator Plate Bolt Torque: 5. Seal stator wire grommet with 3 Bond or equivalent sealer. Flywheel 1. Install flywheel, washer, and nut. Torque flywheel to specification. Page Thermostat Installation - projex inbox. Assemble rocker arms, rocker shaft, and shaft supports. Install and tighten rocker arm shaft locating bolt.
Apply starter drive grease to the cam lobes and cam follower surfaces. A face shield and eye protection is required during this proce- dure. Replace any parts found to be worn or damaged.
Remove bolts and recoil housing. Hold reel firmly in housing. Place rope in notch on outer edge of reel. Release tension on hub and allow reel to unwind Page Recoil Assembly - projex inbox. To install a new spring: 1.
Place spring in housing with the end positioned so the spring spirals inward in a counterclockwise direction. See photo at right. Main Jet Selection. Page Jetting Guidelines - projex inbox. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense.
Page Fuel Flow Diagram - projex inbox. Page Mikuni Jet Part Numbers - projex inbox. Page Mikuni Cv Carb Operation - projex inbox. The venturi cross-sectional area in the carburetor bore is increased or decreased automatically by the vacuum slide, which moves according to the amount of negative pressure less than atmo- spheric present in the venturi.
The fuel from float cham- ber 2 is metered by pilot jet 3 where it mixes with air coming in through pilot air jet 4. Page Float System - projex inbox. As the fuel fills the float cham- ber, the float 1 rises and forces the inlet needle against the seat, shutting off the orifice in the seat.
Carburetor Assembly 2. Screw 3. Throttle Valve 4. Cover, Diaphragm 5. Jet Block Assembly 6. Spring 7. Diaphragm Assembly 8. Ring 9. Ring Needle Jet Cover, Diaphragm 2. Spring 3. Spring Seat 4. Spacer 6. Jet Needle 7. Throttle Valve 9. Cable Guide Spring Adjuster Cable 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. Page Carburetor Cleaning - projex inbox. Do not misplace the pilot mixture screw, spring, flat washer, or O-Ring. If anti-tamper plug is installed in pilot screw cavity, refer to Maintenance chapter 2 for removal procedure. O-Ring Washer Spring Page Carburetor Inspection - projex inbox.
Inspect jet needle and needle jet for wear. Look for discoloration, shiny spots, or and area that looks different than the rest of the needle. The middle to upper portion of the needle where it contacts the needle jet is the most likely wear point. Page Carburetor Assembly - projex inbox. 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. Page Float Height Adjustment - projex inbox. Place the carburetor on a level surface as shown at right to remove weight from float arm.
In this position, the float tongue will rest lightly on the inlet needle valve pin without compressing the spring. Install the float bowl. Apply 5 PSI pressure to inlet fitting. The needle and seat should hold pressure indefinitely. The pump is located under the headlight cover at the front of the machine. Refer to illustration on following page for fuel pump compo- nent identification. Page Fuel Pump Exploded View - projex inbox. Fuel Pump Assembly 2.
Diaphragm, Gasket Set 3. Screw and Washer Assembly 4. Screw and Washer Assembly 5. Screw and Washer Assembly 6. Pressure Regulator 7. Fuel Inlet 8. Fuel Outlet 4. Page Troubleshooting - projex inbox. No fuel in tank Restricted tank vent, or routed improperly Fuel lines or fuel valve restricted Fuel filter plugged Body Assembly, Exploded View Page Body Assembly Exploded View - projex inbox. Pull release lever at the rear of the seat Lift and pull seat rearward, disengaging seat from tabs at the rear of the fuel tank Side panels See page 5.
Page Headlight Pod Exploded View - projex inbox. Page Side Panel Removal - projex inbox. Remove seat. Grasp rear of side panel near rear Step 1. Page Steering Assembly, Exploded View - projex inbox. The steering post arm bolt B points up; the rod end bolts A point down. Page A-Arm Replacement - projex inbox.
Elevate and safely support vehicle with weight removed from front wheel s. Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud. Page Rear Suspension Assembly - projex inbox. Page Strut Assembly - projex inbox. Upper Pivot Ball 25 Nm 15 ft. Page Front Strut Cartridge Replacement - projex inbox. Hold strut rod and remove top nut. Compress spring using strut spring compressor tools. Page Ball Joint Replacement - projex inbox.
Loosen front wheel nuts slightly. Page Steering Post Assembly - projex inbox. Hand tighten. Align cotter pin hole. Install cotter pin. Bend both ends of cotter pin around nut in opposite directions. Page Pvt System - projex inbox.
PVT System Operation The internal components of the drive clutch and driven clutch control clutch engagement for initial vehicle movement , clutch upshifting and backshifting. Periodic inspection and main- tenance is required to keep the system operating at peak performance.
The following list of items should be in- spected and maintained to ensure maximum performance and service life of PVT components. Page Pvt Overheating 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch malfunction. For inspection of clutch components, please contact your Polaris dealer. Poor engine performance. Fouled plugs, foreign material in gas tank, fuel lines, or carburetor.
Page Pvt Disassembly - projex inbox. Refer to the appropriate parts manual for proper fasteners and fastener placement. See page 6. Remove or loosen rear cab fasteners as necessary to gain access to PVT outer cover.
Remove driven clutch retaining bolt and driven clutch. Use puller if necessary. Driven Clutch Puller PN 8. Remove driven clutch offset spacers from the transmission input shaft. Keep Spacers In Order 9. Page Pvt Assembly - projex inbox. Inspect PVT inner cover-to engine seal. Replace if cracked or damaged. Seal this edge to cover on engine side 2. Place a new foam seal on transmission input shaft.
Apply RTV silicone sealant to outside edge of inner cover-to-engine seal, to ensure a water tight fit between the seal and the cover on engine side. This is accomplished through weights and a spring inside the unit which react to the centrifugal force applied to the clutch from the engine RPM. Page Drive Clutch Spring Specifications - projex inbox. To control clutch engagement Gold RPM.
The springs which have a higher rate when the clutch is in Silver neutral Page Shift Weights - projex inbox. These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern.
Page Shift Weight Inspection All PVT system maintenance repairs must be per- formed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this manual. Page Drive Clutch Inspection - projex inbox. Page Drive Clutch Disassembly - projex inbox. Using a permanent marker, mark the cover, spider, Mark and moveable and stationary sheaves for reference. Remove cover bolts evenly in a cross pattern, and remove cover plate.
Page Spider Removal - projex inbox. Install clutch in holding fixture and loosen the spider counterclockwise using spider removal tool. Inspect all rollers, bushings and roller pins by pulling a flat metal rod across the roller. Turn roller with your finger. If you notice resistance, galling, or flat spots, replace rollers, pins and thrust washers in sets of three.
Page Drive Clutch Assembly - projex inbox. The Teflon bushings are self-lubricating. Do not apply oil or grease to the bushings. Page Drive Belt Tension - projex inbox. Torque cover bolts evenly to specification. Spider Torque: ft. Mark drive belt direction of rotation so that it can be installed in the same direction. NOTE: Normally positioned so part numbers are easily read.
Page Drive Belt Installation - projex inbox. Measure belt length with a tape measure around the outer circumference of the belt. Belts which measure longer than nominal length may require driven shimming or engine adjustment for a longer center distance to obtain proper belt deflection.
Page Drive Clutch Bushing Service - projex inbox. Part Description Part No. Turn sheave puller barrel together counterclockwise on puller rod until bushing is removed. Remove nut from puller rod and set aside. Pull bushing removal tool and adapter from puller rod.
Remove bushing from tool and discard. Install main adapter Item 8 on puller. From outside of clutch cover, insert removal tool Item 3 into cover bushing. With inside of cover toward vise, slide cover onto puller. Apply Loctite retaining compound to the back side of new bushing. Working from inside of cover, insert bushing and bushing installation tool into center of clutch cover. One must always be installed.
Apply and hold downward pressure on the helix, or place driven clutch in compressor tool PN Check alignment of tabs on spring. Replace the spring if tabs are misaligned or the spring coils are distorted.
Tabs Aligned 6. Inspect ramp buttons in the moveable sheave and replace if worn. Re- fer to bushing replacement in this chapter. Page Driven Clutch Assembly - projex inbox.
Install moveable sheave with spacer washers. Important: At least one spacer washer must be installed. Teflon bushings are self-lubricating. Install spring, inserting spring tab into proper hole in moveable sheave.
In order to remove the bushing it will be necessary to apply heat. A press can be used to remove and install some of the bushings. Working from the top, install bushing removal tool Item 5 into center of clutch sheave with smaller diameter toward bushing to be removed. Bushing Removal Tool 5 6. Working from the top, insert adapter number ten onto puller. See illustration at right.
Start new bushing evenly in moveable sheave. Install nut onto puller rod and hand tighten against installation tool.
Turn clutch sheave counterclockwise until bushing is seated. Because of the critical nature and precise balance of components within the PVT system, it is absolutely essential that no attempt at disassembly or repair be made without factory authorized special tools and service procedures. Page Ebs Exploded View - projex inbox.
Rotate one-way clutch clockwise as viewed from the cover plate side. The clutch should rotate on the shaft with only slight amount of drag. There should not be any binding or rough spots. Page Moveable Sheave Bushing Inspection - projex inbox. Remove moveable sheave. Lift one-way clutch off shaft. Replace as an assembly if worn, damaged, or if problems were noted on page 6. Inspect surface of shaft for pitting, grooves, or damage. Review all information below before proceeding. Push helix inward.
Remove snap ring, washer, helix, and spring. The spring is a compression spring only and has no torsional wind. NOTE: Rotating the moveable sheave so that the roll- ers are not in contact with either helix ramp surfaces will lessen the effort needed to push helix inward. Inspect moveable sheave bushing for wear. Check for movement of the driven clutch shaft in the one-way clutch. Place main adapter Item 8 on puller. Apply Loctitet evenly to bushing bore inside sheave moveable sheave.
Install puller adapter Item 10 onto puller. See Ill. Install bushing removal tool Item E into center of clutch sheave. Install main puller adapter Item 8 onto puller. Install adapter reducer Item 9. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear. Belt burnt, thin -Abuse continued throttle application when -Caution operator to operate machine within guidelines.
Page Final Drive - projex inbox. AWD Operation Overview Front Hub Disassembly. Front Hub Nut Refer to text for procedure Pg 7. Page Awd Operation Overview - projex inbox. If the rear wheels lose traction the front wheel rotational speed will decrease, causing the front drive axle speed to exceed front wheel speed. Refer to the electrical chapter. Carefully lift and support the front end of the machine as shown with the jack stands under the front end of the foot rests.
Thoroughly inspect the hub internally. If the hub bearing sleeve is damaged or shows signs of movement, the hub assembly must be replaced. When the sleeve is pressed into the hub it should be flush with the outside surface of the hub.
Remove fill check plug and rotate hole to either or position. NOTE: Do not force the oil into the hub under pressure. Page Awd Hub Seal Replacement It is very important that the brake disc be free of any oil or solvents. Reinstall the brake disc using genuine Polaris OEM bolts that have a pre-applied locking agent. Do not substitute bolts or use old ones. Remove the front drive axle as described later in this chapter. Remove the seal sleeve from the strut casting using a drift punch and hammer, tapping evenly on each side until the sleeve slides off.
Remove front hub. See page 7. Remove Hilliard clutch assembly. Disassemble the roller clutch and thoroughly clean all parts. If the spring is removed, it will become over stressed and will require replacement. Page Awd Armature Plate Inspection - projex inbox. As the armature plate is engaged, it should contact the outer magnet pole seal sleeve and the inner magnet pole.
Also, the armature plate must be flat when placed on a flat surface. Bent armature plates should be replaced. Be sure machine is secure before beginning this service procedure. Remove cotter pin and nut from lower A-arm ball joint. Remove lower A-arm from ball joint. Driveshaft components are precision parts. Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life. Remove clamps from rubber boot using the proper boot clamp pliers.
Retaining ring 6. Remove the large end of the boot from the CV joint, slide the boot back and separate the wheel spindle and CV joint assembly from the axle shaft by pulling the shaft sharply outward, away from the CV joint. Disassemble front hub. Refer to page 7. Remove the cotter pin and castle nut from the A- arm ball joint. Separate A-arm from ball joint. If front axle sleeves become damaged and leak fluid they are replaceable. Using a hammer and drift punch, remove the seal sleeve by driving it off evenly being careful not to nick or damage the sleeve mounting area A.
Slide prop shaft back and away from front housing. Pull sharply forward to remove from transmission shaft. Page U-Joint Disassembly - projex inbox. Remove internal or external snap ring from all bearing caps.
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 dur- ing installation. Page U-Joint Assembly - projex inbox. Force U-joint cross to one side and lift out of inner yoke. Install new bearing caps in yoke by hand. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft.
Install outer yoke, aligning marks made before disassembly. Repeat steps to install bearing caps on outer yoke. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown. Page Awd Front Housing Removal - projex inbox. Stop engine, place machine in gear and set parking brake. Loosen right front wheel nuts slightly. Remove output shaft assembly, large shim, and thrust button with its small shim.
Clean all parts and inspect spacers for wear. Inspect ring gear for chipped, broken, or missing teeth. Page Awd Front Housing Assembly - projex inbox. Replace all O-rings, seals, and worn components. Press pinion shaft seal into pinion cover until flush with sealing surface. Inspect pinion and output shaft bushings. Bushings 4. Inspect bearings on output and pinion shafts. To replace, press new bearing on to shaft. To install housing, reverse removal procedure. Use new roll pins in drive shafts.
Check drain plug for proper torque. Fill Plug Lock the parking brake. Remove rear hub cap. Remove cotter pin. Loosen the hub retaining nut. Loosen the wheel nuts. Safely support the rear of the ATV.
Remove hub. Remove upper control arm bolt as shown. Remove both lower control arm bolts. Remove bearing carrier. Page Rear Hub Installation - projex inbox.
Start bearing carrier on drive shaft. Align bottom of carrier housing and lower control arm. Grease and slide lower control arm bushings into place, securing corner housing. Install and torque both lower control arm bolts. Lower Control Arm Bolt Torque: 30 ft.
Page Rear Hub Disassembly - projex inbox. Remove outer snap ring. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown. NOTE: Drive bearing out evenly by tapping on outer race only. Page Rear Hub Assembly - projex inbox. Support bottom of bearing carrier housing. Start bearing in housing. Press bearing into place until outer race bottoms on housing. Page Rear Drive Shaft Removal - projex inbox.
Remove rear hub and bearing carrier. See pages 7. Tip hub outward and remove shaft from hub. Pull sharply outward to remove shaft from transmission. Page Rear Drive Shaft Installation - projex inbox. Slide shaft assembly into bearing carrier hub. Apply anti-seize compound to splines of shaft. Install a new lock ring and install the shaft. Lift bearing carrier into place and install bolt to upper control arm. Page Rear Drive Shaft Service - projex inbox. Remove clamps from rubber boot s using the proper boot clamp pliers.
Place a new snap ring in the groove of the CV joint inner hub, with tabs facing the shaft as shown. Tabs face shaft 5.
Previous Page. Next Page. Polaris industries all-terrain vehicles owner's manual 96 pages. Polaris snowmobile universal owner's manual pages. Offroad Vehicle Polaris sportsman efi Service Manual pages. This is an adult vehicle only. If you cannot locate this card, or if it has been removed, please call for assistance. Page 4 All information in this manual is based on the latest product data and specifications available at the time of printing. Polaris Industries Inc. No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc.
Have your accessories and clothing delivered right to your door! In the event your vehicle is stolen, these numbers are essential to the recovery and identification of your vehicle.
Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. To prevent serious injury, do not operate vehicle with guard removed. Do not modify engine or clutch.
Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury. A Polaris ATV is not a toy and can be hazardous to operate.
This vehicle handles differently than other vehicles, such as motorcycles and cars. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.
S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. S Always follow proper procedures for climbing hills. Test the brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads.
S Always check for obstacles or people behind the ATV before operat- ing in reverse. Reaction time may be slower and operator balance and perception could be affected. Avoid exhibition driving. Failure to properly maintain the ATV. Always check the terrain carefully before ascending any hill.
NOTE: A special technique is required when braking while traveling downhill. If all forward speed is lost: Keep your weight uphill. Avoid operating over large obstacles such as rocks and fallen trees when possible.
Page 35 Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including but not limited to brakes, throttle and steering systems.
Do not activate the override switch while the throttle is open. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise.
The fluid level can be seen through an indicator window 2 on the top of the master cylinder. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. Place the transmission in first gear or in PARK if equipped. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward.
The rear wheels may skid and slide sideways, causing loss of control and serious injury or death. Refer to the engine starting procedure on page 53 for correct choke and throttle settings during starting. Fuel Valve The fuel valve 1 is located on the left side panel.
It has three positions: OFF: For vehicle storage and when transporting. Shift patterns vary, depending on your model. When the switch is off, the ATV is in 2 wheel drive at all times. The instrument cluster measures distance in miles as well as hours of operation. All segments will light up for 2. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electrical system.
Please return your ATV to your dealer for all major repairs. As long as the gauge is in the diagnostic mode, the wrench icon will remain lit. When your vehicle leaves the factory, this feature is set at 50 hours. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped, and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
No single action on your part is as important as following the procedures for a proper break-in. Use the following checklist to verify that your vehicle is in proper working condition before each use. Never run an engine in an enclosed area.
Place the transmission in neutral or PARK if equipped and lock the parking brake. These repair manuals are identical to the repair manuals you'd obtain in a book store. They cover ever aspect of maintenance, troubleshooting and repair. It's the only manual you should be using if you plan to perform service or repairs to your Sportsman four-wheeler.
Does the manual contain this diagram? Yes, there is a download manual for the Sportsman News Ticker. General Information Model number information Serial number locations Machine dimensions Vehicle specifications Paint codes Standard torque specifications Tap drill charts Decimal equivalent chart Conversion table.
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