Polaris 2009 Trail Blazer 330, Service Manual

Page 1: ...ation Numbers 1 3 Paint Codes 1 3 Specifications Trail Boss 330 1 4 1 5 Specifications Trail Blazer 330 1 6 1 7 Special Tools 1 8 Standard Torque Specifications 1 9 Tap Drill Charts 1 10 Decimal Equivalent Chart 1 10 Unit of Measure Conversion Table 1 11 Glossary of Terms 1 12 Specs P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 2: ...Digit World Mfg ID This could be either a number or a letter ENGINE SERIAL NUMBER LOCATION 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 UNIT ...

Page 3: ...polaris com PAINT CODES FRAME COLOR P067 Medium Gloss Black 9440 8520147 REPLACEMENT KEYS Replacement keys can be made from the original key To identify which series the key is take the first two digits on the original key and refer to the chart to the right for the proper part number Should both keys become lost ignition switch replacement is required Series Part Number 20 4010278 21 4010278 22 4...

Page 4: ...in 117 cm Height 46 in 117 cm Wheel Base 49 5 in 125 73 cm Ground Clearance 5 5 13 97 cm Dry Weight 505 lbs 230 kg Gross Vehicle Weight 845 lbs 383 kg Front Rack Capacity 75 lbs 34 kg Rear Rack Capacity 125 lbs 57 kg Towing Capacity 850 lbs 385 kg Hitch Tongue Weight 85 lbs 14 kg Body Style Gen IV P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 5: ...nce Free 14 Amp Hr Circuit Breakers Harness 20 amp Starting Electric Recoil Backup Indicator Panel Standard Drivetrain Transmission Type Inline H N R Transmission Capacity 11 3 oz 335 ml Gear Ratio High Rev Final 2 68 1 3 05 1 11 40 78P Chain Type 520 O Ring Clutch Type PVT Non EBS Belt 3211077 Steering Suspension Front Suspension Shock A arm MacPherson Strut Front Travel 8 2 in 20 83 cm Rear Susp...

Page 6: ...ht 46 in 117 cm Wheel Base 48 in 121 9 cm Ground Clearance 5 5 13 97 cm Dry Weight 488 lbs 221 kg Gross Vehicle Weight 830 lbs 377 kg Front Rack Capacity Accessory 30 lbs 13 6 kg Rear Rack Capacity Accessory 60 lbs 27 2 kg Towing Capacity 850 lbs 385 kg Hitch Tongue Weight Accessory 85 lbs 14 kg Body Style Gen III P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 7: ...mp Hr Circuit Breakers Harness 20 amp Starting Electric Recoil Backup Indicator Panel Standard Drivetrain Transmission Type Inline H N R Transmission Capacity 11 3 oz 335 ml Gear Ratio High Rev Final 2 68 1 3 05 1 11 40 78P Chain Type 520 O Ring Clutch Type PVT Non EBS Belt 3211077 Steering Suspension Front Suspension Shock A arm MacPherson Strut Front Travel 8 2 in 20 83 cm Rear Suspension Style ...

Page 8: ...2871573 LH Strut Spring Compressor 5 2871574 RH Strut Spring Compressor 5 2870506 Clutch Puller 6 9314177 Clutch Holding Wrench 6 2871358 Clutch Holding Fixture 6 2870341 Drive Clutch Spider Removal and Install Tool 6 2870654 Clutch Offset Alignment Tool 6 2870913 Driven Clutch Puller 6 2870910 Roller Pin Tool 6 2871226 Clutch Bushing Replacement Tool Kit 6 2870386 Piston Pin Puller 6 8700220 Clut...

Page 9: ...hreads 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 ...

Page 10: ... 32 0 0995 0 0937 0 1285 0 125 0 166 0 161 0 196 0 234 0 277 0 265 0 3125 0 3125 0 3437 0 339 0 375 0 406 0 406 3 32 3 32 1 8 1 8 11 64 5 32 13 64 15 64 9 32 17 64 5 16 5 16 11 32 11 32 3 8 13 32 13 32 DECIMAL EQUIVALENTS 1 64 0156 1 32 0312 1 mm 0394 3 64 0469 1 16 0625 5 64 0781 2 mm 0787 3 32 0938 7 64 1094 3 mm 1181 1 8 1250 9 64 1406 5 32 1563 4 mm 1575 11 64 1719 3 16 1875 5 mm 1969 13 64 20...

Page 11: ...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 gall...

Page 12: ... 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 cm 2 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 in 2 Pounds per square inch Left or Right Side Always referred to based on normal...

Page 13: ... 16 ETC Switch Adjustment 2 16 2 17 Fuel System 2 17 2 18 Compression Test 2 18 Battery Maintenance 2 19 Ignition Sparkplug 2 20 Air Filter Service 2 20 2 21 Air Box Sediment Tube Service 2 22 Recoil Housing PVT Drying 2 22 Oil Level Change Filter 2 23 2 24 Valve Clearance 2 24 2 25 Steering and Toe Alignment 2 25 2 27 Exhaust System Maintenance 2 28 Brake System Service 2 28 2 29 Drive Chain and ...

Page 14: ...se 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 H 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...

Page 15: ... Daily Check operation apply dielectric grease if re placing E Air filter main element Weekly Inspect replace as needed Recoil housing Weekly Drain water as needed check often if operating in wet conditions J Brake pad wear 10 H Monthly 60 100 Inspect periodically Battery 20 H Monthly 125 200 Check terminals clean test Front gearcase oil if equipped 25 H Monthly 155 250 Inspect level change yearly...

Page 16: ... 50 H 6 M 310 500 Inspect adjust lubricate replace if necessary J E Choke cable 50 H 6 M 310 500 Inspect adjust lubricate replace if necessary E Carburetor air intake ducts flange 50 H 6 M 310 500 Inspect ducts for proper sealing air leaks Drive belt 50 H 6 M 310 500 Inspect adjust replace as needed Cooling system if applicable 50 H 6 M 310 500 Inspect coolant strength seasonally pressure test sys...

Page 17: ... J E Ignition Timing 100 H 12 M 620 1000 Inspect Wiring 100 H 12 M 620 1000 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc J Clutches drive and driven 100 H 12 M 620 1000 Inspect clean replace worn parts J Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed J Brake fluid 200 H 24 M 1240 2000 Change every two years Spark arrestor 3...

Page 18: ...MAINTENANCE 2 6 POLARIS LUBES FLUIDS FOR TRAILBOSS 330 MODELS Pure Polaris Lubricants and Maintenance Kits can be purchased at your local Polaris dealer P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 19: ...t Coolant 2871323 60 40 Coolant Gallon 6 Count 2871534 60 40 Coolant Quart 12 Count NOTE Each item can be purchased separately at your local Polaris dealer Part No Description Additives Sealants Thread Locking Agents Misc 2874275 Loctitet Primer N Aerosol 2871956 Loctitet Thread Sealant 565 50 ml 6 Count 2871950 Loctitet Threadlock 242 6 ml 12 Count 2871951 Loctitet Threadlock 262 50 ml 10 Count 2...

Page 20: ...Taillight Brakelight check operation of all indicator lights and switches G Engine stop switch check for proper function G Wheels check for loose wheel nuts G Air cleaner element check for dirt or water clean or replace G Steering check for free operation noting any unusual looseness in any area G Loose parts visually inspect vehicle for any damaged or loose nuts bolts or fasteners G Engine coolan...

Page 21: ...d Reservoir Display Light Control Run Switch Reverse Override Throttle Muffler Headlights PVT Cover Front Rack Oil Dipstick Fuel Valve Right Side View Engine Recoil Auxiliary Brake Rear Axle Drive Sprocket Transmission Gear Shifter Engine Front Rack P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 22: ... dip stick Change annually 3 Brake Fluid Polaris DOT 3 Brake Fluid Fill master cylinder reservoir to in dicated level inside reservoir See Page 2 29 As required Change fluid every 2 years 4 Drive Chain Polaris Chain Lube or O Ring chain lube Apply to chain link plates and roll ers As required NOTE Refer to Page 2 6 for the Polaris Lubricant Identification table 2 Transmission 3 Brake Fluid 1 Engin...

Page 23: ...ease Apply fresh grease by hand and reassemble Semi annually 7 Swing Arm Bush ings Polaris All Season Grease Locate grease fitting on swing arm and grease with grease gun Semi annually 8 Rear Axle Housing Polaris All Season Grease Locate grease fitting on eccentric and grease with grease gun Semi annually More often under severe use such as operated in water or under severe loads Semi annually or ...

Page 24: ... into operating range as shown Full Operating Range TRANSMISSION FLUID CHANGE TORQUE STOP ADJUSTMENT 1 Remove skid plate if necessary 2 Place a drain pan beneath the transmission oil drain plug area 3 Loosen jam nut A 4 Turn adjuster bolt B in to allow the removal of drain plug 5 Remove the drain plug and wipe the magneticend clean to remove accumulated metallic filings 6 After the oil has drained...

Page 25: ...ission linkage may require adjustment G Visually check for contact of shift lever to shifter opening in the front fender Ensure shift linkage or shift lever is not contacting the frame or exhaust components G Tighten shift linkage rod end jam nuts properly after adjustment You should be able to rotate the linkage rod between 1 8 and 1 4 turn after both jam nuts are tight G The transmission shift l...

Page 26: ...nding 1 Place the gear selector in neutral 2 Set parking brake 3 Start the engine and let it idle 4 Turn handlebars from full right to full left If idle speed increases at any point in the turning range inspect throttle cable routing and condition If cable is routed properly and in good condition repeat adjustment procedure 5 Replace the throttle cable if worn kinked or damaged CHOKE ENRICHER ADJU...

Page 27: ...oved 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 Screw Adjustment Trailboss 330 2 Turns Out The pilot screw is set at the factory Each carburetor will ...

Page 28: ... sleeve until 1 16 1 8 freeplay is achieved at the thumb lever After making any adjustment flip the lever slightly to confirm adjustment 1 16 1 8 Freeplay Direction of travel Boot Adjuster Sleeve Lock nut Boot 3 Tighten locknut and slide boots over cable adjuster until they touch at the middle point of the adjuster 4 With engine running turn the handlebars from full left to full right with transmi...

Page 29: ...hen the engine is hot Severe burns may result FUEL LINES Fuel Lines Fuel Pump Ill 1 Pulse Line 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 CAUTION Make sure lines are not kinked or pinched 3 Replace all fuel lines every two years VENT LINES 1 Check fuel tank oil tank carburetor batter...

Page 30: ...hed as this will effect engine performance COMPRESSION TEST NOTE This Polaris 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 70 90 psi during a compression test Smooth idle generally indicates good compression Low engine compression is rarely a factor in running conditio...

Page 31: ...anufacture The use of lead calcium and AGM technology instead of lead antimony allows the battery acid to be fully absorbed For this reason a Maintenance Free 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 Maintenance Free battery Doing so will damage the case and shorten the life of the batt...

Page 32: ...e incorrect spark plug is used 7 Apply a small amount of anti seize compound to the spark plug threads 8 Install spark plug and torque to 9 11 ft lbs 12 14 Nm Recommended Spark Plug NGK BKR6E Spark Plug Torque 9 11 Ft Lbs 12 14 Nm IGNITION TIMING Refer to Electrical chapter for ignition timing procedure Ignition Timing 30 2 BTDC 5000RPM ENGINE TO FRAME GROUND Inspect engine to frame ground cable c...

Page 33: ...Slip the pre filter element C off of main element Clean the pre filter with hot soapy water 6 Rinse and dry thoroughly 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 fol...

Page 34: ...er handle B is disengaged from the rope guide when under water G After travelling in wet areas the recoil housing and starter should always be drained completely by removing the recoil G Do not open the crankcase drain unless the engine has ingested water Some engine oil will be lost if crankcase drain is opened G If recoil handle seal has been damaged the handle assembly should be replaced PVT DR...

Page 35: ...ndicate moisture collecting inthe oil reservoir If the oil level is over the full mark change the oil Recommended Engine Oil Polaris Premium 4 All Season Synthetic 2W 50 OIL AND FILTER CHANGE 1 Place vehicle on a level surface 2 Clean area around drain plug at bottom of oil pan 3 Run engine two to three minutes until warm Stop engine 4 Place a drain pan beneath oil pan and remove drain plug from u...

Page 36: ...acts sealing surface then turn an additional 1 2 turn Oil Filter Wrench PV 43527 VALVE CLEARANCE Inspect and adjust valve clearance while the engine is cold and the piston positioned at Top Dead Center TDC on compression stroke 1 Remove the seat 2 Remove body panels and fuel tank as necessary to gain access to valve cover 3 Remove the spark plug high tension lead and remove the spark plug CAUTION ...

Page 37: ...he plastic valve plugs replace if damaged Securely fasten valve plugs 7 Reinstall fuel tank and any body panels that were removed to gain access STEERING The steering components should be checked periodically for loose fasteners worn tie rod ends and damage Also check to make sure all cotter pins are in place If cotter pins are removed they must not be re used Always use new cotter pins Replace an...

Page 38: ...ng outward Check for Loose Wheel or Hub G If abnormal movement is detected inspect the hub and wheel assembly to determine the cause G Refer to the Body Steering or Final Drive chapter for more information CAMBER AND CASTER The camber and caster are non adjustable WHEEL ALIGNMENT METHOD STRAIGHTEDGE OR STRING Be sure to keep handlebars centered See notes below NOTE String should just touch side su...

Page 39: ... tolerance is 1 8 to 1 4 3 to 6 cm toe out This means the measurement at the front of the tire A is 1 8 to 1 4 3 to 6 cm wider than the measurement at the rear B Chalk Line Measurement A Measurement B TOE ALIGNMENT ADJUSTMENT If toe alignment is incorrect measure the distance between vehicle center and each wheel This will tell you which tie rod needs adjusting NOTE Be sure handlebars are straight...

Page 40: ...is expelled cover the exhaust outlet and lightly tap on the pipe around the clean out plugs while revving the engine several more times 4 If particles are still suspected to be in the muffler back the machine onto an incline so the rear of the machine is one foot higher than the front Set the hand brake and block the wheels Make sure the machine is in neutral and repeat Steps 2 and 3 SEE WARNING A...

Page 41: ...trest 50 lbs 1 or greater 1 8 to 1 4 Free Play Floorboard If less than one inch two things must be examined Free Play Free play of the brake pedal should be 1 8 1 4 inch 3 2 6 35 mm If free play is excessive inspect pedal linkage and master cylinder for wear or damage and replace any parts as needed Bleeding If free play is correct and brake pedal travel is still excessive air may be trapped somew...

Page 42: ...with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result Break In It is extremely important to maintain proper chain tension to ensure the best possible chain life There is a chain break in period of approximately 100 miles or two 2 tanks of fuel During this time chain tension should be watched very closely and loads to the chain should ...

Page 43: ...nch rotate the housing to adjust chain slack to the proper dimension and then proceed to Step 7 or follow Steps 5 and 6 for alternate method if 2 1 2 wrench is not available Tighten Loosen 5 Insert a pin punch through the sprocket hub and into the eccentric axle housing Alternate Adjustment Method Pin Punch Step 5 and 6 6 Roll the vehicle ahead or back to adjust chain slack to the proper dimension...

Page 44: ...on 11 Reinstall the chain guard where applicable Reposition chain guide to allow 1 8 3 cm clearance between sprocket and guide Chain Guide SUSPENSION SPRING PRELOAD ADJUSTMENT Operator weight and vehicle loading affect suspension spring preload requirements Adjust as necessary to avoid bottoming of the shocks FRONT SUSPENSION Compress and release front suspension Damping should be smooth throughou...

Page 45: ...ion in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel nuts and remove the wheel Front Wheel Nuts 4 27 ft lbs 37 Nm Front Spindle Nut 40 ft lbs 54 Nm Front Wheel Rear Wheel Rear Wheel Nuts 4 50 ft lbs 68 Nm Rear Hub Nut 80 ft lbs 108 Nm Taper end faces wheel for install WHEEL ...

Page 46: ...e tires when the tread depth measures 1 8 3 cm or less CAUTION G Maintain proper tire pressure Refer to the warning tire pressure decal applied to the vehicle G Improper tire inflation may affect ATV maneuverability G When replacing a tire always use original equipment size and type G The use of non standard size or type tires may affect ATV handling Tire Tread Depth Always replace tires when trea...

Page 47: ... 3 8 Lubrication Oil Flow 3 8 3 9 Engine Exploded View 3 10 Engine Top End Disassembly 3 11 3 18 Valve Valve Seat Service 3 18 3 22 Engine Bottom End Disassembly 3 22 3 32 Crankcase Bearing Assembly 3 32 Crankshaft End Play Inspection 3 32 3 33 Engine Assembly Inspection Adjustments 3 33 3 43 Recoil Disassembly Inspection Reassembly 3 44 3 45 Spark Plug Fouling Checklist 3 46 Troubleshooting 3 46 ...

Page 48: ... Oil clearance Std 0022 0035 055 090 mm Limit 0039 10 mm Cylinder Head Surface warpage limit 0020 05 mm y Standard height 2 908 73 8 mm Valve Seat Contacting width In Std 039 1 0 mm g Limit 055 1 4 mm Ex Std 059 1 5 mm Limit 071 1 8 mm Valve Guide Inner diameter 2362 2367 6 000 6 012 mm Protrusion above head 681 689 17 3 17 5 mm Valve Margin thickness In Std 039 1 0 mm g Limit 032 0 8 mm Ex Std 04...

Page 49: ...d gap Top ring Std 0079 0118 0 20 0 30 mm g g g p p g Limit 039 1 0 mm Second i Std 0138 0197 0 35 0 50 mm ring Limit 039 1 0 mm Oil ring Std 0079 0236 0 20 0 60 mm g Limit 059 1 5 mm Piston Ring Standard clearance i i i Top ring Std 0014 0030 0 035 0 075 mm g piston ring to ring groove p g Limit 0059 0 15 mm Second i Std 0010 0026 0 025 0 065 mm ring Limit 0059 0 15 mm Connecting Rod Connecting r...

Page 50: ...ne Assembly for torque pro cedure Drive Clutch Bolt 7 16 20 40 55 Nm Flywheel 16mm 58 72 78 98 Nm Oil Hose Fit tings 1 2 9 16 20 27 Nm Oil Delivery Pi pe 12mm 11 15 15 21 Nm Oil Drain Bolt Crankcase 14mm 14 17 19 23 Nm Oil Filter Pipe Fitting Con nector 20mm 36 43 49 59 Nm Oil Line Fitting 20 27 Nm Oil Pump Cov er 6mm 4 5 5 7 Nm Oil Relief Valve Plug 14mm 14 5 16 5 20 23 Nm Recoil Housing 6mm 5 6 ...

Page 51: ...rter Drive G Cylinder Head G Cylinder G Piston RIngs G Oil pump G Rocker Arms G Cam Chain and Sprockets The following components require engine removal for service G Camshaft G Connecting Rod G Crankshaft G Crankshaft Main Bearings G Crankcase ENGINE REMOVAL 1 Clean work area 2 Thoroughly clean the ATV engine and chassis 3 Disconnect battery negative cable 4 Remove the following parts as required ...

Page 52: ...ring loaded glaze breaker for honing is not advised for nicasil cylinders Polaris recommends using a rigid hone or arbor honing machine Cylinders may be wet or dry honed depending upon the hone manufacturer s recommendations Wet honing removes more material faster and leaves a more distinct pattern in the bore HONING TO DEGLAZE A finished cylinder should have a cross hatch pattern to ensure piston...

Page 53: ... beyond the bore at the end of each stroke G Release the hone at regular intervals and inspect the bore to determine if it has been cleared and to check piston fit NOTE Do not allow cylinder to heat up during honing The thinner areas of the liner around the ports will expand causing an uneven bore G After honing has been completed inspect all port opening areas for rough or sharp edges Apply a sli...

Page 54: ...ndard 71 99 PSI Minimum 20 PSI at idle ES32PF10 NOTE Use Polaris Premium 2W 50 Synthetic Engine Lubricant OIL COOLER ASSEMBLY Threaded Cooler Hose Top Bracket Lower Bracket Fan Motor Shroud Thermistor Oil Cooler U Clips Rubber Mounts Screws 330 Engine Oil Flow To and From Cooler 36 44 in lbs 4 5 Nm P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 55: ...aft Sprocket Chain Cam Lobe Cam Shaft Journal Indirect Lubrication Crankcase Oil Passage Crankshaft Small End Bearing Cylinder Sleeve Main Bearing Large End Bearing Crank Pin Oil Jet Fixed Crankcase Oil Passage Pressure Relief Connecting Rod Piston Through Front Right Cylinder Head Bolt Passage Oil Cooler Oil Hoses Out Crankcase Oil Passage In P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 56: ...ENGINE 3 10 ES32PFE ENGINE EXPLODED VIEW Crankcase Cylinder Cylinder Head Crankshaft and Piston Valve Train ES32PF P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 57: ...e NOTE The sprocket marks align with gasket surface and the cam lobes should be pointing down and valves should have clearance at this point Sprocket marks align with gasket surface 5 Remove cam chain tensioner plug sealing washer spring and pin CAUTION The plug is under spring tension Maintain inward pressure while removing 6 Remove the two 6x25 mm cam chain tensioner flange bolts 7 Tap lightly o...

Page 58: ...nspect surface of followers Wave washer PTO 3 Inspect each rocker arm cam follower surface If there is any damage or uneven wear replace the rocker arm NOTE Always inspect camshaft lobe if rocker arms are worn or damaged 4 Remove cylinder block plug using a 14 mm hex head wrench Cylinder block plug 5 Measure O D of rocker shaft Inspect it for wear or damage Compare to specifications Rocker Shaft O...

Page 59: ...ng or damage to threads of the adjuster or locknut Replace all worn or damaged parts NOTE The end of the adjuster screw is hardened and cannot be ground or re faced CAMSHAFT REMOVAL 1 Remove cam shaft end plug A A 2 Remove camshaft sprocket flange bolt and washer 3 Place a clean shop towel in the area below cam chain sprocket 4 Remove sprocket from camshaft and chain 5 Secure cam chain with a wire...

Page 60: ...ation throughout the entire range of rotation Lobe 2 Remove release lever shaft and return spring spacer 3 Inspect shaft for wear or galling 4 Inspect lobe on end of release lever shaft for wear and replace if necessary AUTOMATIC COMPRESSION RELEASE INSTALLATION 1 Slide spring onto shaft 2 Apply engine oil to release lever shaft CAMSHAFT INSPECTION 1 Visually inspect each cam lobe for wear chafing...

Page 61: ...35I 055 090 mm Limit 0039I 10 mm Replace camshaft if damaged or if any part is worn past the service limit Replace cylinder head if camshaft journal bore is damaged or worn excessively CYLINDER HEAD REMOVAL 1 Loosen each of the four cylinder head bolts evenly 1 8 turn each time in a cross pattern until loose A 2 Remove bolts A and tap cylinder head lightly with a plastic hammer until loose CAUTION...

Page 62: ... compressor compress the valve spring 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 A NOTE The valve springs should be positioned with the tightly wound coils against the cylinder head on progressively wound springs A 3 Push valve out keeping it in order for reassembly in the same guide 4 Measure...

Page 63: ...A A B 4 Inspect split keeper groove for wear or flaring of the keeper seat area B NOTE The valves cannot be re faced or end ground They must be replaced if worn bent or damaged 5 Measure diameter of valve stem with a micrometer in three places and in two different directions six measurements total Compare to specifications Measure valve stem in several places Valve Stem Diameter Intake 2343 2348I ...

Page 64: ...inder Head Reconditioning 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 prevent burns Valve G...

Page 65: ...ion chamber side Be careful not to damage guide bore or valve seat when removing guides 7 Place cylinder head on cylinder head table NOTE Be sure cylinder head is still at 212 F 100 C before installing new guides 8 Place a new guide in the valve guide installation tool and press guide in to proper depth Check height of each guide above the cylinder head A Refer to specifications NOTE The guide can...

Page 66: ...the valve face apply a thin coating of Prussian Bluetpaste to the valve seat If using an interference angle 46 apply black marker to the entire valve face A A 6 Insert valve into guide and tap valve lightly into place a few times 7 Remove valve and check where the Prussian Bluet or black marker indicates seat contact on the valve face The valve seat should contact the middle of the valve face or s...

Page 67: ...pping 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 passage A thoroughly A 13...

Page 68: ...y the combustion chamber area 2 Pour a small amount of clean solvent into the intake port and check for leakage around each intake valve The valve seats should hold fluid with no seepage 3 Repeat for exhaust valves by pouring fluid into exhaust port ENGINE BOTTOM END DISASSEMBLY Cylinder Removal Follow engine disassembly procedures to remove valve cover camshaft and rocker arms and cylinder head 1...

Page 69: ...the ring lands 4 Repeat procedure for second ring The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section 5 Remove the top rail first followed by the bottom rail 6 Remove the expander CYLINDER INSPECTION 1 Remove all gasket material from the cylinder sealing surfaces 2 Inspect the top of the cylinder for warpage using a straight edge and...

Page 70: ...bottom of the piston at a right angle to the direction of the piston pin 5 mm Piston Piston Pin 2 Subtract this measurement from the maximum cylinder measurement obtained in Step 5 Piston to Cylinder Clearance Std 0015 0032I 038 082 mm Limit 004I 11 mm Piston O D Std 3 0881 3 0891I 78 438 77 462 mm 3 Measure piston pin bore Piston Pin Bore 7095 7097I 18 007 18 013 mm 4 Measure piston pin O D Repla...

Page 71: ...ge at both the top and bottom of the cylinder NOTE A difference in end gap indicates cylinder taper The cylinder should be measured for excessive taper and out of round 3 If the bottom installed gap measurement exceeds the service limit replace the rings 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...

Page 72: ...rmine if bushing is out of round Calculate bushing clearance Replace bushing if clearance exceeds the service limit A Starter Drive Bushing Clearance Std 0015 004 038 102 mm Service Limit 008 203 mm 6 Inspect gear teeth on starter drive Replace starter drive if gear teeth are cracked worn or broken FLYWHEEL STATOR REMOVAL INSPECTION 1 Remove flywheel nut and washer A 2 Install Flywheel Puller PN 2...

Page 73: ...th of a 20 pitch section of chain Replace if worn past service limit Measure 20 Pitch Length Chain Service Limit 5 407 13 7 cm DRIVE SPROCKET REMOVAL INSPECTION 1 Using the Slotted Nut Socket PN 2871293 remove the crankshaft slotted nut A NOTE The slotted nut is a left hand thread A B Remove 2 Remove cam chain drive sprocket B and Woodruff key from crankshaft 3 Inspect sprocket teeth for wear or d...

Page 74: ...for wear 4 Check seat area for nicks or foreign material that may prevent proper sealing of valve OIL PUMP REMOVAL INSPECTION 1 Remove the five screws on the oil pump cover with an impact driver 2 Inspect rotors and mating surface of oil pump cover Check for nicks burrs or surface irregularities 3 Measure pump end clearance using a feeler gauge and straight edge Outer Feed Rotor to Crankcase Clear...

Page 75: ...ten screw securely 5 Install oil pump on crankcase and torque bolts to 6 ft lbs 8 Nm Oil Pump Attaching Bolt Torque 6 ft lbs 8 Nm CRANKCASE SEPARATION 1 Remove flange bolts 11 from magneto side crankcase evenly in a criss cross pattern 2 Separate crankcase by tapping with a soft faced hammer in reinforced areas 3 Watch the gap along the crankcase mating surface and separate the crankcase evenly 4 ...

Page 76: ...ng rod bearing cap NOTE It may be necessary to lightly tap on the side of the cap with a plastic mallet to loosen it CRANKSHAFT INSPECTION 1 Measure the width of the rod bearing journal 2 Measure the width of the connecting rod at the big end Connecting Rod Width Std 8233 8252I 20 88 20 93 mm 3 Visually inspect bearing journal for scoring damage or excessive wear Replace crankshaft if it fails vis...

Page 77: ...stigauge 6 Use the measuring scale on the Plastigauge wrapper to measure the thickness of the Plastigauge The rod must not turn during this procedure NOTE Use the widest part of the Plastigauge to determine the oil clearance Connecting Rod To Crankshaft Clearance Std 0007 0021 019 053 mm Limit 0026 065 mm 7 If oil clearance is not within specification install new rod bearings and recheck the oil c...

Page 78: ...the following steps should be performed to determine the amount of crankshaft 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 1 Make sure crankshaft bearing is firmly seated in the MAG side crankcase 2 Measure the distance from the MAG side crankcase mat...

Page 79: ...bring end play within range Crankshaft End Play 008 016 02 04 cm ENGINE ASSEMBLY CONNECTING ROD INSTALLATION 1 Clean all oil off connecting rod connecting rod cap and bearing inserts 2 Install bearing inserts onto connecting rod and cap NOTE First install bearing tab into groove then press the rest of the bearing into place 3 Apply assembly lube onto the connecting rod bearings and crank pin 4 Ins...

Page 80: ...the surfaces are tightly sealed 3 Install the crankcase flange bolts and tighten to specified torque in 3 steps according to the torque pattern See Page 3 4 Crankcase Bolt Torque 14 15 ft lbs 19 21 Nm Crankcase Sealant PN 2871557 OIL PUMP INSTALLATION 1 Inspect the oil pump sealing surface on the crankcase Apply a light film of engine oil to the surfaces Install outer and inner rotors over cranksh...

Page 81: ...op rail with the end gap at least 30 from the end of the expander 3 Install the bottom rail with the gap at least 30 from the end of the expander on the side opposite the top rail gap Ring Profile Top R1 Mark up R Mark up Second 4 Install the second ring with the R mark facing up Position the end gap toward the rear intake side of the piston 5 Install the top ring chrome faced with the R1 mark fac...

Page 82: ...pport Block PN 2870390 A beneath the piston skirt to support the piston during cylinder installation A 2 Apply clean engine oil liberally to the cylinder bore and tapered area of the sleeve Install the cylinder with a slight rocking motion until the rings are captive in the sleeve 3 Remove the ring compressor and support block 4 Push the cylinder downward until fully seated on the base gasket NOTE...

Page 83: ... chain drive sprocket to establish TDC see below Method 1 It is important to note that this method can only be used when the stator is removed and the cam chain drive sprocket is in view The plate links are not used to time the camshaft when the flywheel is installed When the stator assembly is installed use Method 2 This method establishes accurate Top Dead Center TDC by aligning the single mark ...

Page 84: ...e camshaft main journals and cam lobes Lubricate automatic compression release mechanism with clean engine oil To install the compression release mechanism refer to Page 3 18 2 Install the camshaft with the lobes facing downward and the sprocket alignment pin facing toward intake 3 Disconnect the wire from the cam chain and rotate the engine to align the single TDC timing mark Top Dead Center on t...

Page 85: ... Cam Chain Drive Sprocket Crankcase Projection NOTE Plated links will not align after engine is rotated Sprocket marks aligned with gasket surface at TDC on compression stroke cam lobes facing downward Crankshaft to Camshaft Centerline Method 1 Camshaft Timing with Stator Removed P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 86: ...TDC Mark Decompressor arm stop pin UP Cam lobes DOWN Cam Timing View through timing inspection hole Position crankshaft at TDC Sprocket marks aligned with gasket surface at TDC on compression stroke cam lobes facing downward de compressor arm stop pin UP Do not use dot on sprocket for cam timing Do Not Use Advance Marks For Cam Timing P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 87: ... starter drive and recoil can be assembled with the engine in the frame Stator 1 Apply a light film of grease to the crankshaft seal Apply molybdenum disulfide grease or assembly lubricant to the crankshaft bushing Timing Marks 2 Apply Crankcase Sealant PN 2871557 to the stator plate outer surface and install a new O Ring 3 Install the stator plate being careful not to damage the seal Align timing...

Page 88: ...ker shaft block plug 3 Apply engine assembly lube to the cam lobes and cam follower surfaces 4 Rotate the engine until the cam lobes are pointing downward 5 Apply clean engine oil liberally to the valve springs cam chain rocker arms and camshaft 6 Apply Crankcase Sealant PN 2871557 to the rocker cover mating surfaces Be sure the alignment pins are in place 7 Install the rocker cover assembly 8 Ins...

Page 89: ...s until there is a slight drag on feeler gauge s NOTE The 330 exhaust valve is adjusted the same as the intake valve The Valve Clutch Adjuster Tool PN PA 44689 can be used to adjust the 330 engines valves 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 correct with locknut secu...

Page 90: ...nt water and dirt from entering 3 Remove center bolt from recoil friction plate A A 4 Inspect plate for wear or damage Inspect plate friction spring for wear damage and proper tension The spring should fit tightly on friction plate 5 Remove ratchet pawl with spring and inspect Replace spring or ratchet pawl if worn broken or damaged NOTE Long arm of spring engages reel Short end rests against pawl...

Page 91: ...gh guide bushing in recoil housing and into reel Tie a secure knot in end of the rope 2 Wind rope counterclockwise onto the reel as viewed from ratchet side of reel 3 Lock rope into notch on outer edge of reel 4 Apply a small amount of grease or equivalent to the center post of the housing and the bushing 5 Install reel into housing making sure the spring drive tab on the reel engages the spring a...

Page 92: ...G Fuel will not pass through fuel valve G Fuel pump inoperative restricted G Tank vent plugged G Carb starter circuit G Engine flooded G Low compression high cylinder leakage G No spark Spark plug fouled Engine Does Not Turn Over G Dead battery G Starter motor does not turn G Engine seized rusted or mechanical failure G Recoil components damaged Engine Runs But Will Not Idle G Restricted carbureto...

Page 93: ... worn G Piston rings worn leaking broken or sticking G Bent valve or stuck valve G Valve spring broken or weak G Valve not seating properly bent or carbon accumulated on valve area G Rocker arm sticking Backfiring G ETC or speed limiter system malfunction G Fouled spark plug or incorrect plug or plug gap G Carburetion faulty lean condition G Intake Exhaust system air leaks G Ignition system faulty...

Page 94: ...ENGINE 3 48 NOTES P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 95: ... Part Numbers 4 6 CV Carburetor System Function 4 Cycle 4 6 CV Carburetor Vent System 4 Cycle 4 7 CV Carburetor Operation 4 7 4 9 Pilot Screw 4 9 Disassembly CV Carburetor 4 10 Cleaning CV Carburetor 4 11 Inspection CV Carburetor 4 11 Assembly CV Carburetor 4 12 Float Adjustment CV Carburetor 4 13 Needle Seat Leakage Test 4 13 Fuel Level 4 14 Fuel Pump Service 4 14 Troubleshooting 4 15 P a r t S h...

Page 96: ...8 Main Jet 29 Washer 30 Jet Needle 31 Float Assembly 32 Float Body Assembly 33 Float Pin 34 Needle Valve 35 O Ring 36 O Ring 37 Plug 38 Screw 39 Screw 40 Guide Holder 41 Spring 42 Plunger Assembly 43 Spring Washer 44 Screw 45 Air Jet 46 Cable Guide 47 Spring 48 Ring 49 Adjust Screw 50 Screw and Washer Assy 51 Plate 52 Screw Refer to Page 4 5 for Jet Part Numbers 1 2 3 4 5 Jet Needle E Clip Positio...

Page 97: ...ED VIEW 3 2 1 5 5 4 1 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 6 8 7 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 98: ...thly into center of steering post Forward 1 ON 2 Reserve Tank to fuel valve connection Gold fitting tall stand pipe to ON Gas Tank Mounting Hardware Fuel Valve 90 Degree Fuel Outlet Fitting 90 Degree Fuel Reserve Outlet Fitting Fuel Filter Fuel Line Marked 2 on fuel valve Marked 1 on fuel valve L Located Above Coolant Reservoir Above LH Front Tire P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 99: ...sult Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored If you get gasoline in your eyes or if you should swallow gasoline seek medical attention immediately If you spill gasoline on your skin or clothing immediately wash with soap and water and change clothing JETTING GUIDELINES Changes in altitude and temperature affect airden...

Page 100: ...150 3130569 152 5 3130570 155 3130571 157 5 3130572 160 3131141 162 5 3131142 165 3131143 167 5 3131144 170 3131145 Jet Number Part Number 40 0 3130624 42 5 3130526 50 0 3131132 Pilot Jets CV CARBURETOR SYSTEM FUNCTION Carburetor Component Function System Main Components Main Function Main Affect Float System Level Control Inlet Pipe Needle and Seat Float Float Pin Maintains specified fuel level i...

Page 101: ...e Low Pressure From Venturi CARBURETOR OPERATION CONT D When the throttle plate is opened and engine speed begins to increase the pressure in the venturi and therefore in the chamber above the diaphragm becomes significantly lower than atmospheric Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward raising the slide against spring pressure When the pressure above an...

Page 102: ...ter outlet 6 in the the main bore FLOAT SYSTEM 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 risesand 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 need...

Page 103: ...ied fuel must flow is determined ultimately by throttle position and vacuum slide height 1 A 5 4 3 6 7 2 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 re...

Page 104: ... pin removal Support the float pin tower while removing the float pin This helps to prevent the float pin towers from breaking off 3 Remove inlet needle seat retaining screw along with plate and carefully remove needle seat NOTE Do not use a pliers to remove the seat or permanent damage may occur 4 Remove the pilot mixture screw spring flat washer and O Ring NOTE If an anti tamper plug is installe...

Page 105: ...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 orwelding tip cleaners as the orifice size may be altered 5 Use low pressure air to dry carburetor body and all components CARBURETOR INSPECTION 1 Inspect jet needle ...

Page 106: ...parts manual for more information 4 Be sure the tab E on outer edge of diaphragm is positioned properly in the carburetor body Pilot Screw 5 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 damage the O ring during installation Turn the screw in until it lightly contacts the seat Back out the sp...

Page 107: ...ade at the mid point on the 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 3 If adjustment is necessary bend the tongue slightly Be sure float measurement is even on left and right side Bend to adjust float Float arms even NEEDLE AND SEAT LEAKAGE TEST 1 Install the float bowl Invert the ...

Page 108: ...N 2870975 to the impulse line fitting on the pump 4 Apply 5 inches Hg vacuum to the pump fitting The diaphragm should hold vacuum indefinitely If fuel is present in the impulse line or vacuum chamber of the pump the diaphragm is ruptured The pump diaphragms must be replaced Fuel Lines Fuel Pump Ill 1 Pulse Line FUEL PUMP DISASSEMBLY 1 Remove the screws from the pump diaphragm cover Note the locati...

Page 109: ...ng incorrectly adjusted choke G Choke cable binding or improperly routed G Incorrect pilot air fuel screw adjustment G Faulty inlet needle and seat G Faulty inlet needle seat O Ring G Float level too high G Poor fuel quality old fuel G Loose jets G Worn jet needle needle jet or other carburetor parts G Dirty carburetor air bleed passages or jets G Weak or damaged vacuum piston return spring G Foul...

Page 110: ...FUEL SYSTEM CARBURETION 4 16 NOTES P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 111: ...s and Special Tools 5 4 Cover Panel Removal 5 5 Side Panel Removal 5 5 A Arm Replacement 5 6 Concentric Swing Arm Removal 5 7 Concentric Swing Arm Assembly Installation 5 8 Front Strut Exploded View 5 9 Strut Assembly and Service 5 10 Front Strut Ball Joint Replacement 5 10 5 11 Steering Post Assembly 5 12 Decal Replacement 5 12 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 112: ... Assembly Front Cab Assembly Front Cover Fuel Tank Cover Seat Side Cover Front Cab Rock Guard Clutch Guard Frame Footwell Rear Cab Seat Latch Retainer Tool Box Seat Latch Footwell Frame Deflector Shield Front Rack Headlights Rear Rack P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 113: ...LY EXPLODED VIEW Rear Cab Assembly Front Cab Assembly Seat Clutch Guard Frame Footwell Rear Cab Seat Latch Retainer Tool Box Seat Latch Front Cab Front Cover Panel or Headlight Cover Mud Flap Rock Guard Foot Pad P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 114: ...2 1 30 ft lbs 41 Nm A 2 12 14 ft lbs 17 19 Nm 40 45 ft lbs 54 61 Nm Steering Post Steering Post Arm Frog 1 2 NOTE To avoid damage to tie rods and other steering components be sure to install tie rod end bolts in the proper direction The steering post arm bolt B points up the rod end bolts A point down Be sure inner rod ends are placed between the steering post arms Apply Loctitet 242 to the bolt t...

Page 115: ...L DESCRIPTION 2870871 Ball Joint Replacement Tool 2870872 Shock Spanner Wrench 2870623 Shock Absorber Spring Compression Tool 2871572 Strut Rod Wrench 2871573 LH Strut Spring Compressor 2871574 RH Strut Spring Compressor COVER PANEL REMOVAL To remove perform these steps Seat G Pull release lever at the rear of the seat G Lift and pull seat rearward disengaging seat from tabs at the rear of the fue...

Page 116: ...firm motion pull panel forward and outward to disengage the two rear tabs Pull forward and out to disengage two rear tabs Step 1 2 Place hand on top of side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear tabs Then pull up on side panel to disengage front tabs Push down to disengage top rear two tabs Step 2 3 To reinstall side panel ali...

Page 117: ...es on the existing bolts were destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation 5 Examine A arm shaft Replace if worn Discard hardware 6 Install new A arm assembly onto vehicle frame Torque new bolts to 30 ft lbs 41 Nm 7 Attach A arm to hub strut assembly Tighten ball joint nut to 25 ft lbs 35 Nm If cotter pin holes are no...

Page 118: ... of machine and support securely with wheels off the floor 2 Remove drive chain 3 Remove rear caliper CAUTION Do not allow the caliper to hang by the brake line Brake line damage may result 4 Remove rear wheels and or hubs and Pivot bolt retainers 8 5 Loosen both swingarm pivot bolts 5 and 8 and then remove both bolts while supporting swingarm 6 Remove lower shock bolt 7 Remove swingarm 8 Remove L...

Page 119: ...of the swingarm 1 Install bushing 6 in left side of swingarm and two piece bushings 3 in right side 2 Clean threads of nut 1 and pivot bushings 4 3 Install right pivot bushing 4 through the two piece bushing 3 4 Install washer 2 and nut 1 Hold pivot bushing 4 in vise and torque nut 1 to 120 ft lbs 163 Nm 5 Install left pivot bushing 7 6 Install swingarm assembly in frame 7 Install and tighten pivo...

Page 120: ... Nut 15 ft lbs 20 Nm 40 ft lbs 54 Nm Cotter Pin Lower A Arm Pivot Washer Spring Retainer Spring Pinch Bolt Jam Nut Spring Retainer Strut Bumper 45 ft lbs 61 Nm Strut 14 ft lbs 19 Nm Tie Rod Bolt Hub Nut 25 ft lbs 35 Nm P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 121: ...ft lbs 21 Nm BALL JOINT REPLACEMENT REFER TO ILLUSTRATION ON PAGES 5 9 1 Loosen front wheel nuts slightly 2 Elevate and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure 3 Remove wheel nuts and wheels 4 Remove cotter pin A from ball joint castle nut A B C D E F 5 Remove castl...

Page 122: ...ousing until fully seated 9 Apply Loctitet 242 PN 2871949 to threads of retaining plate screws or install new screws with pre applied locking agent Torque screws to 8 ft lbs 11 Nm 10 Install A arm on ball joint and torque castle nut to 25 ft lbs 35 Nm 11 Reinstall cotter pin with open ends toward rear of machine SAFETY REMINDER Remember to use safety glasses and other protective equipment when per...

Page 123: ...ial Therefore they must be flame treated prior to installing a decal to ensure good adhesion A bonus of the flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged To flame treat the decal area 1 Pass the flame of a propane torch back and forth quickly over the area where the decal is to be a...

Page 124: ...BODY STEERING SUSPENSION 5 14 NOTES P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 125: ...g Specifications 6 8 Shift Weights 6 9 Drive Clutch Inspection 6 10 Drive Clutch Disassembly Inspection 6 10 6 12 Drive Clutch Assembly 6 12 6 13 Drive Belt Tension 6 13 Drive Belt Removal Inspection 6 14 6 15 Drive Belt Installation 6 15 Clutch Alignment Offset 6 15 6 16 Drive Clutch Bushing Service 6 16 6 18 Driven Clutch Disassembly Inspection 6 19 6 20 Driven Clutch Assembly 6 20 Driven Clutch...

Page 126: ...ve clutch and driven clutch control engagement initial vehicle movement clutch upshift and backshift During the development of a Polaris ATV the PVT system is matched first to the engine power curve then to average riding conditions and the vehicle s intended usage Therefore modifications or variations of components at random are never recommended Proper clutch setup and careful inspection of exis...

Page 127: ...ge 6 16 6 18 2 Drive and Driven Clutch Buttons and Bushings Drive Clutch Shift Weights and Pins Drive Clutch Spider Rollers and Roller Pins Drive and Driven Clutch Springs See Pages 6 11 6 12 3 Sheave Faces Clean and inspect for wear 4 PVT System Sealing Refer to appropriate illustrations and photos The PVT system is air cooled by fins on the drive clutch stationary sheave The fins create a low pr...

Page 128: ...ith transmission in neutral advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow and easy clutch engagement Fast effective use of the throttle for efficient engagement Continuous operation at the point of engagement initial vehicle movement increases PVT temperatures and component wear Towing Pushing at low RPM low gr...

Page 129: ... A B 6 Install the Drive Clutch Holder PN 9314177 A 7 Remove drive clutch retaining bolt and remove drive clutch using the Drive Clutch Holder PN 9314177 B Drive Clutch Puller PN 2870506 Drive Clutch Holder PN 9314177 8 Remove driven clutch retaining bolt and driven clutch Use the Driven Clutch Puller PN 2870913 if necessary Driven Clutch Puller PN 2870913 Keep Spacers In Order 9 Remove driven clu...

Page 130: ...Driven Clutch Retaining Bolt Torque 17 ft lbs 23 5 Nm Drive Clutch Retaining Bolt Torque 40 ft lbs 55 Nm Offset Spacer Offset Spacer 7 Install clutch offset spacers on transmission input shaft 8 Clean splines inside driven clutch and on the transmission input shaft 9 Apply a light film of grease to the splines on the shaft 10 Install the driven clutch washer lock washer and retaining bolt Torque t...

Page 131: ...uter Cover Exhaust Duct Inner Cover Seal Retainer Cover Screws 9 Inner Cover Outer Cover Seal Drive Clutch Mark with permanent marker before disassembly Teflont coated brass bushing Teflont coated brass bushing Inlet Duct Drain Plug P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 132: ...ration it should always be inspected for tolerance limits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure its free length from the outer coil surfaces as shown Refer to the spring specification chart for specific free length measurements and tolerances Also check to see that spring coils are parallel to one another Distortion of the spring indicate...

Page 133: ...ot 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 PN 5630513 50 5 gr PN 5630509 55 gr 55 16 PN 5630279 43 gr PN 5630418 50 gr PN 5630095 53 gr 53 PN 5631358 40 gr PN 5630710 46 gr PN 5630711 47gr RH BH WH 10 10 10 S 40 20 40 20 38 PN 5631357 40 gr PN 5631356 38 gr...

Page 134: ...e of dents or gall marks Inspect the weight pivot bore and pivot bolts for wear or galling If weights or bolts are worn or broken replace in sets of three with new bolts NOTE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly See ROLLER PIN AND THRUST WASHER INSPECTION Page 6 12 Broken Worn Good BUTTON TO TOWER CLEARANCE INSPECTION 1 Inspect for any cleara...

Page 135: ... worn or damaged 5 Remove and inspect spring See Page 6 8 SPIDER REMOVAL Clutch Holding Fixture PN 2871358 Spider Removal Tool PN 2870341 1 Install clutch in holding fixture and loosen the spider counterclockwise using spider removal tool NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly Be sure to note the number and thickness of...

Page 136: ...H ASSEMBLY NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly The Teflont bushings are self lubricating Do not apply oil or grease to the bushings 1 Reassemble drive clutch in the following sequence Be sure the X or the marks that were made earlier are aligned during each phase of assembly a X or the marks that were made earlier on...

Page 137: ...lbs 10 4 Nm 8 Reinstall cover aligning bosses on the tower and cover Torque cover bolts evenly to specification DRIVE BELT TENSION 1 1 8 28 5 mm Straight Edge Belt Deflection Tension 1 1 8 2 9 cm 1 1 4 3 2 cm NOTE Pinch the sheaves lightly together with clamp to prevent the belt from being pushed into the driven sheave 1 Place a straight edge on top of the belt between drive and driven clutch 2 Pu...

Page 138: ...n severely Generally belt should be replaced if clutches can no longer be adjusted to provide proper belt deflection G The top edges have been trimmedon some drive belts It will be necessary to project the side profiles and measure from corner to corner G Place a straight edge on each side of the drive belt G Place another straight edge on top of belt G Measure the distance where the side straight...

Page 139: ... ALIGNMENT Offset Alignment Tool should contact rear edge of driven clutch sheave Driven Clutch Offset To adjust add or remove washers from behind the driven clutch 1 Remove belt and install the Clutch Offset Alignment Tool PN 2870654 as shown 2 With tool touching rear of driven clutch inner sheave the distance at point A should be 1 8 If the distance is greater than 1 8 or less than 1 16 clutch a...

Page 140: ...h Bushing Replacement Tool Kit PN 2871226 Stamp Qty Part Description Part 2 1 P 90 Drive Driven Clutch Bushing Install Tool 5020628 3 1 Drive Clutch Cover Bushing Removal Installation Tool all clutches 5020629 5 1 P 90 Driven Clutch Cover Bushing Re moval Tool 5020631 8 1 Main Puller Adapter 5020632 9 1 Adapter Reducer 5010279 10 1 Number Two Puller Adapter 5020633 DRIVE CLUTCH MOVEABLE SHEAVE BUS...

Page 141: ...ol and discard DRIVE CLUTCH MOVEABLE SHEAVE BUSHING INSTALLATION 1 Place the Main Puller Adapter 8 PN 5020632 onto the puller 2 Apply Loctitet 680 PN 2870584 to the back side of new bushing Push bushing into center of sheave on tower side by hand Bushing PN 3576504 Loctitet 680 PN 2870584 3 Insert the Clutch Bushing Installation Tool 2 PN 5020628 into center of sheave and with towers pointing away...

Page 142: ...ool from puller Discard bushing DRIVE CLUTCH COVER BUSHING INSTALLATION 1 Apply Loctitet 680 PN 2870584 to the back side of new bushing Working from inside of cover insert bushing and bushing installation tool into center of clutch cover Bushing PN 3576510 Loctitet 680 PN 2870584 2 With the Main Puller Adapter 8 PN 5020632 on the puller insert cover onto puller rod placing outside of cover toward ...

Page 143: ...move snap ring retainer Note hole location of spring in helix and sheave 3 Note the location of the spring and remove helix 4 Note the location of the spring in the moveable sheave and remove the spring 5 Check alignment of tabs on spring Replace the spring if tabs are misaligned or the spring coils are distorted 6 Inspect ramp buttons in the moveable sheaveand replace if worn NOTE The ramp button...

Page 144: ...oduction setting 1 Install moveable sheave with spacer washers Important At least one spacer washer must be installed Teflont bushings are self lubricating Do not apply oil or grease to the bushings 2 Install spring inserting spring tab into proper hole in moveable sheave 3 Insert spring tab into proper hole in helix See specifications Chapter 1 or Illustration 2 below The driven clutch helix move...

Page 145: ...on Pin Puller PN 2870386 1 Install Main Puller Adapter 8 PN 5020632 onto the Piston Pin Puller PN 2870386 2 Insert Adapter Reducer 9 PN 5010279 onto the puller sliding it inside the main adapter 3 Remove ramp buttons from moveable sheave 4 Using an electric or hand held propane torch apply heat directly on bushing until tiny smoke tailings appear CAUTION Clutch components will be hot In order to a...

Page 146: ...nd removal tool from adapters Discard bushing DRIVEN CLUTCH MOVEABLE SHEAVE BUSHING INSTALLATION Number Two Puller Adapter 10 Piston Pin Puller PN 2870386 1 Working from the top insert Number Two Puller Adapter 10 PN 5020633 onto the puller See illustration at above 2 Start new bushing evenly in moveable sheave Apply Loctitet 680 PN 2870584 to the back side of new bushing 3 Install sheave onto pul...

Page 147: ...clutch malfunction Sheave face grooved a Disassemble drive clutch inspect shift weights for wear and free operation b Clean and polish stationary shaft hub reassemble clutch without spring to determine problem area Replace belt a Replace ramp buttons b Inspect movable sheave for excessive bushing clearance replace Replace the clutch Engine RPM above specified operating range Incorrect drive clutch...

Page 148: ...anual Water ingestion Cover seals or ducts leaking Operator error Find leak and repair as necessary Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Belt slippage Belt worn out Water ingestion Belt contaminated with oil or grease Replace belt Inspect and seal PVT system Inspect and clean Belt burnt thin spots Abuse continued throttle...

Page 149: ...Front Hub Assembly 7 4 Front Hub Installation 7 4 7 5 Front Hub Exploded View 7 6 Rear Axle Removal 7 7 7 8 Rear Axle Installation 7 8 7 10 Rear Housing Removal 7 10 Rear Housing Disassembly 7 11 Rear Housing Installation 7 11 Rear Axle Exploded View 7 12 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 150: ...oved The self locking properties of the nut or bolt are reduced or destroyed during removal FRONT HUB DISASSEMBLY INSPECTION 1 Elevate front end and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure Wear eye protection when removing bearings and seals 2 Check bearings for sid...

Page 151: ...pacer to one side to expose inner bearing race Drive bearing out using a drift through opposite side of hub and discard Tap spacer to side 9 Remove spacer Drive other bearing out and discard 10 Clean hub and spacer thoroughly 11 Inspect spacer for wear or damage Measure length of spacer and replace if worn beyond service limit or if ends are rounded 0 774 0 008 19 66 0 203 mm 0 60 0 005 15 24 0 12...

Page 152: ...earing spacer D with grease and install into hub B Drive or press the other bearing E into hub until seated against spacer A B C 3 Install seal into hub backside numbers facing out until flush with end of seal bore Apply grease to the seal lip before mounting to spindle Seal FRONT HUB INSTALLATION 1 Inspect spindle seal and bearing surface for wear or damage Apply anti seize compound to the spindl...

Page 153: ...in different directions 6 Install hub cap 7 Rotate hub It should rotate smoothly without binding or rough spots or side play 8 Install brake caliper bolts flat washers and lock washers Tighten bolts to specified torque 18 ft lbs 25 Nm Caliper Mounting Bolt Torque 18 ft lbs 25 Nm 9 Install wheel and wheel nuts and tighten evenly in a crossing pattern to specified torque Flange Nuts Flat side agains...

Page 154: ...earing Spacer Spindle Nut 40 ft lbs 55 3 Nm Cotter Pin Washer Hub Cap 18 ft lbs 24 9 Nm Use new bolts with pre applied locking agent Wheel Nut 27 ft lbs 37 Nm Wheel Stud FINAL DRIVE 7 6 FRONT HUB EXPLODED VIEW P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 155: ... the chain Remove the Splice link Clip Opening Position 4 Loosen the concentric clamp bolts 5 Remove the two bolts that secure the brake caliper Support the rear caliper with wire or a tie strap Do not hang the caliper by brake line 6 Loosen the hex screw A to loosen the axle nut A 7 Turn the axle nut collar B counter clockwise with a 1 3 4 Wrench PN 2870772 until the retaining ring C is visible S...

Page 156: ...he O rings from left side of the axle 12 Slide the axle out the right side of the axle housing CONCENTRIC SWINGARM REAR AXLE ASSEMBLY INSTALLATION 1 Apply Never Seize onto the splines of the axle Lubricate and install the O ring A sprocket hub B and sprocket B Slide the axle into the right side of the axle housing A B C Never Seize 2 Mount sprocket to sprocket hub and install sprocket nuts Torque ...

Page 157: ... 1 3 4 Wrench PN 2870772 until the end of the axle nut G just covers the retaining ring H The retaining ring should still be visible under the axle nut from an angle Torque to 8 10 ft lbs 11 14 Nm H 7 Torque the axle nut pinch bolt to 50 in lbs 6 Nm 50 in lbs H 8 Reinstall the chain and master link To verify proper chain tension refer to Chapter 2 DRIVE CHAIN INSPECTION for this procedure 9 Torque...

Page 158: ...M 14 Install the rear wheels and torque wheel nuts to 50 ft lbs 68 Nm Rear Wheel Rear Wheel Nuts 4 50 ft lbs 68 Nm Rear Hub Nut 80 ft lbs 108 Nm Taper end faces wheel for install 15 Lubricate the axle housing through the grease fitting with Polaris All Season Grease PN 2871423 CONCENTRIC SWINGARM REAR HOUSING REMOVAL 1 Remove rear axle 2 Remove the caliper mounting bracket A from the side of the a...

Page 159: ...in new bearing race with brass drift making sure that race fully seats in the housing 2 Lubricate and install new tapered bearings 3 Lubricate and install new seals CONCENTRIC SWINGARM REAR HOUSING INSTALLATION 1 Re install the housing A into the swing arm mounts Re install the brake caliper mounting bracket B onto the housing Swing arm A B 2 Install rear axle See Page 7 22 3 Fill housing with gre...

Page 160: ... 1 Disc Brake 6 1 Hub Brake Disc 7 3 Screw 8 1 Ring Retaining 9 2 O Ring 10 2 Seal 11 2 Bearing Cone Tapered 12 2 Bearing Cup Tapered 13 1 Housing Axle Rear 14 1 Fitting Lubrication 15 1 Link Connector 520 16 1 Axle Rear 17 1 Chain 520 O Ring 18 6 Nut Nylok 19 1 Guard Sprocket 20 1 Spacer 21 1 Sprocket 36T 22 1 Asm Hub Sprocket Incl 24 23 3 Screw 24 3 Stud P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8...

Page 161: ...ools 8 2 Torque Specifications 8 2 Transmission Remove Install 8 2 Transmission Disassembly 8 2 8 5 Transmission Assembly 8 6 8 7 Troubleshooting 8 7 Transmission Exploded View 8 7 8 8 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 162: ...nd sprocket 8 Remove mounting bolts and brackets as shown 9 Remove through bolt from bottom of transmission 10 Remove transmission from right side of frame TRANSMISSION INSTALLATION 1 Reverse removal steps to install transmission NOTE Install the Center Distance Tool PN2871710 on engine and transmission input shaft before tightening transmission mounting bolts Align clutches as outlined in Clutch ...

Page 163: ...rive gear 8 Remove shift assembly and gear as an assembly NOTE Direction of shift fork 9 Inspect shift fork surface for wear or damage Replace if necessary 10 Remove shift fork guide pin 11 Mark orientation of bellcrank to the shift fork shaft 12 Remove bellcrank Use a small puller if necessary P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 164: ...ring Replace if necessary Lubricate O ring to ease in reassembly and to protect O ring during assembly 15 Remove input shaft bearing 16 Inspect gears for galling and wear on teeth and bearing surface Replace if necessary 17 Remove bearing from other end of input shaft Remove two snap rings and gear P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 165: ...4I Maximum TRANSMISSION ASSEMBLY 1 Assemble input shaft assembly NOTE Install bearings with numbers and letters facing out so they can be read after assembly Sprocket cogs face the dog gear NOTE Input gear cogs face inward on input shaft Input Shaft Bushing Sprocket Dog Gear Input Gear Thrust Washer Measure 8 pitches 2 Assemble output shaft with sprocket gear and bearing if they were disassembled ...

Page 166: ...rain plug with a new sealing washer Torque drain plug to 14 ft lbs 19 Nm 10 Insert shifting bullet with tip in position as shown Insert spring and plug Torque plug to 14 ft lbs 19 Nm 11 Install transmission and add Polaris AGL Gearcase Lubricant PN 2873602 in the recommended amount Refer to Maintenance Chapter 2 12 Install gear indicator switch Apply Loctitet 242 PN 2871949 to threads of switch sc...

Page 167: ...ains disassemble transmission and inspect all gear dogs for wear rounding damage Inspect all bearings for wear TRANSMISSION EXPLODED VIEW NOTE See next page for exploded view of transmission Ref Qty Description Ref Qty Description 1 Asm Gearcase 24 1 Washer 1 2 Bearing 25 1 Plug Detent Extension 2 1 Ring Retaining 26 1 Dipstick 3 1 Washer Thrust 27 2 Seal 4 1 Sprocket 19T 28 1 Tube Vent 5 1 Washer...

Page 168: ...5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 27 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 1 12 TRANSMISSION 8 8 TRANSMISSION EXPLODED VIEW P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 169: ...9 11 Front Disc Inspection 9 12 Front Disc Removal Replacement 9 12 Front Caliper Removal 9 13 Front Caliper Disassembly 9 13 Front Caliper Inspection 9 14 Front Caliper Reassembly 9 14 9 15 Front Caliper Installation 9 15 Front Caliper Exploded View 9 16 Rear Pad Removal 9 17 Rear Pad Installation 9 18 Rear Caliper Removal Inspection 9 19 9 20 Rear Caliper Reassembly 9 20 9 21 Rear Disc Inspectio...

Page 170: ...56mm Brake Disc Thickness Variance Between Measurements 002 051mm Brake Disc Runout 005 25mm Master Cylinder I D Front 750 Master Cylinder I D Aux Rear 500 TORQUE SPECIFICATIONS Item Torque ft lbs except where noted Torque Nm Caliper Mounting Bolts 18 0 24 Handlebar Master Cyl Clamp Bolts 25 in lbs 3 0 Handlebar Master Cyl Reservoir Cover Bolt 5 in lbs 0 56 Brake Line Banjo Bolts 15 0 21 Brake Dis...

Page 171: ...the system and cause the brakes to feel spongy Too much fluid could cause brakes to drag due to fluid expansion Located within the master cylinder is the compensating port C which is opened and closed by the master cylinder piston assembly The port is open when the lever is released and the master cylinder piston is outward As the temperature within the hydraulic system changes this port compensat...

Page 172: ...l pads are available to suit conditions in your area Select a pad to fit riding style and environment G Do not over fill the master cylinder fluid reservoir G Make sure the brake lever and pedal returns freely and completely G Adjust stop pin on front caliper after pad service G Check and adjust master cylinder reservoir fluid level after pad service G Make sure atmospheric vent on reservoir is un...

Page 173: ...ator Loose wheel hub or bearings Check wheel and hub for abnormal movement Brake disc warped or excessively worn Replace disc Brake disc misaligned or loose Inspect and repair as necessary Noise is from other source chain axle hub disc or wheel If noise does not change when brake is applied check other sources Inspect and repair as necessary Wrong pad for conditions Change to a softer or harder pa...

Page 174: ...lots A in cover and remove any debris or blockage B A D C Sight Glass Ill 1 4 If changing fluid remove old fluid from reservoir with a Mity Vact pump or similar tool Mity Vact PN 2870975 5 Add brake fluid to the indicated MAX level inside reservoir MAX Polaris DOT 3 Brake Fluid PN 2870990 Rear Brake Caliper Bleeding Procedure 6 Begin bleeding procedure with the caliper that is farthest from the ma...

Page 175: ... the bleeder screw to 25 30 in lbs 2 80 3 40 Nm Front Brake Caliper Bleeding Procedure 11 Locate the bleeder screw on one of the front calipers Bleeder Screw G Install a box end wrench on the bleeder screw G Attach a clean clear hose to bleeder screw and place the other end in a clean container 12 Repeat Steps 7 10 for the remaining caliper s 13 Add Polaris Dot 4 Brake Fluid to MAX level inside re...

Page 176: ...r or abrasion is found MASTER CYLINDER REMOVAL 1 Clean master cylinder and reservoir assembly Make sure you have a clean work area to disassemble brake components 2 Place a shop towel under brake line connection at master cylinder Loosen banjo bolt remove bolt and sealing washers CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 3 ...

Page 177: ... 5 in lbs 0 56 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 4 Brake Fluid and pump lever slowly two to three times with finger over the outlet end to purge master cylinder of air 2 Place new sealing washers on each side of banjo line and torque banjo bolt to specification Brake Line Banjo Bolt Sealing Washers ...

Page 178: ...ing a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 5 Push mounting bracket inward and slip outer brake pad past edge Remove inner pad 6 Measure the thickness of the pad material Replace pads if worn beyond the service...

Page 179: ... air from entering the brake system 5 Install the adjuster screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn counterclockwise 6 Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap Master Cylinder Fluid Up to MAX line inside reservoir 7 Install wheels and torque wheel nuts Front Wheel Nut Torque 20 ft lbs 27 Nm BRAKE BURNISHI...

Page 180: ... if runout exceeds specifications Brake Disc Runout Service Limit 010 254 mm FRONT BRAKE DISC REMOVAL REPLACEMENT NOTE To reduce the possibility of warpage try removing the brake disc mounting bolts before applying heat to the bolts 1 Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent 18 ft lbs 25 Nm new bolts have pre applied locking agent 2 Remove...

Page 181: ... caliper to catch fluid draining from brake line 3 Remove two brake caliper mounting bolts 4 Remove brake caliper and drain fluid into container Do not reuse brake fluid FRONT CALIPER DISASSEMBLY 1 Remove brake pad adjuster screw 2 Push upper pad retainer pin inward and slip brake pads past edge 3 Remove mounting bracket pin assembly and dust boot Remove Mounting Bracket 4 Remove piston dust seal ...

Page 182: ...ice Limit 1 193 30 30 mm 2 Inspect piston for nicks scratches wear or damage Measure diameter and replace if damaged or worn beyond service limit 3 Inspect the brake disc and pads as outlined for brake pad replacement this section FRONT CALIPER REASSEMBLY 1 Install new O rings A in the caliper body B Be sure groove is clean and free of residue or brakes may drag upon assembly A B C D 2 Coat piston...

Page 183: ...Install caliper on hub strut and torque mounting bolts 18 ft lbs 25 Nm 15 ft lbs 21 Nm Front Caliper Mounting Bolt Torque 18 ft lbs 25 Nm Brake Line Torque Banjo Style 15 ft lbs 21 Nm 2 Install brake line and tighten securely with a line wrench Torque the brake lines to the proper torque of 15 ft lbs 21 Nm 3 Install the adjuster screw and turn until stationary pad contacts disc then back off 1 2 t...

Page 184: ...ID TO COMPONENT 4 3 3 35 60 IN LBS 4 6 5 NM 3 9 8 10 6 4 5 1 Caliper Mount 2 Brake Pads 3 Piston 4 Brake Caliper Body 5 Boot Seal 6 Pin Bushing Seal 7 O rings 8 Banjo Bolt 9 Bleeder Screw 10 Sock Set NOTE IF PADS ARE DIRTY GREASY OILY OR FLUID SOAKED REPLACE WITH NEW PADS P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 185: ...piston into the caliper body NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 4 Remove the loose slide pin A The brake pad will now slide out A 5 Clean the caliper with brake cleaner or alcohol 6 Measure the thickness of the pad material Replace pads if worn beyond t...

Page 186: ...oir to prevent air from entering the master cylinder 7 It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Repeat procedure 10 times BRAKE BURNISHING PROCEDURE It is required that a burnishing procedure be performed after insta...

Page 187: ...de bolt snap rings A the slide pins B the bracket pad C and the brake pads D A Caliper B C D 5 Remove the anvil bolts and separate caliper halves and remove pistons with piston pliers Seal Piston O rings Caliper Anvil Bolts 6 Remove seals and O rings Clean the O ring grooves 7 Clean disc caliper body and pistons with brake cleaner or alcohol 8 Remove the slide bolt bushings Inspect the bushings an...

Page 188: ...l fully seated O Rings Seals 2 Carefully assemble caliper body making sure O rings are properly positioned in groove Tighten the caliper anvil bolts and then torque the anvil bolts evenly to 16 18 ft lbs 22 25 Nm 16 18 ft lbs 22 25 Nm Caliper Anvil Bolt Torque 16 18 ft lbs 22 Nm 25 Nm 3 Install brake pads in caliper body with friction material facing each other Install the slide pins and the slide...

Page 189: ...ver is released If the brake drags re check assembly and installation REAR BRAKE DISC INSPECTION 1 Visually inspect disc for scoring scratches or gouges Replace the disc if any deep scratches are evident 2 Use a 0 1 micrometer and measure disc thickness at 8 different points around perimeter of disc Replace disc if worn beyond service limit Measure Thickness Rear Brake Disc Brake Disc Thickness Se...

Page 190: ...m 25 30 in lbs 3 3 50 Nm 18 17 10 Item Torque Specification 3 3 3 1 Snap Ring 2 Outboard Anvil Body 3 Slide Pin Bushing 4 Brake Pad 5 Caliper Bracket 6 Dust Boot 7 Dust Boot 8 Pin Sleeve 9 Piston Ring 10 Slide Pin 11 Piston 12 Square Ring 13 Square Ring 14 Inboard Body 15 Slide Pin O ring 16 Flat Washer 17 Bleed Screw 18 Bolts P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 191: ...nder Use a suitable container to catch the brake fluid Dispose of brake fluid properly 2 Remove the two bolts that secure the rear master cylinder to the brake mount plate Replace parts as needed 3 To install the rear brake master cylinder mount the master cylinder to the mount plate and torque bolts to 8 ft lbs 11 Nm 4 Reinstall the brake line and torque the banjo bolt to 15 ft lbs 21 Nm AUXILIAR...

Page 192: ...ever S Incorrectly adjusted stationary pad S Worn or damaged master cylinder or components S Improper clearance between lever and switch Lever Vibration S Disc damaged S Disc worn runout or thickness variance exceeds service limit Caliper Overheats Brakes Drag S Compensating port plugged S Pad clearance set incorrectly S Auxiliary brake pedal incorrectly adjusted S Brake lever or pedal binding or ...

Page 193: ...rol Testing 10 11 Electronic Throttle Control System Operation 10 12 Flywheel Identification DC CDI Operation 10 13 ES32PF 210 Watt Alternator Exploded View 10 14 Ignition System Testing 10 15 Ignition System Troubleshooting 10 16 Cranking Output Tests 10 16 Charging System Testing 10 17 10 18 Battery Service 10 19 10 26 Headlight Tail Light Service 10 26 10 27 Starter System Testing 10 28 Starter...

Page 194: ...eters may differ GPay attention to the prefix on the multimeter reading K M etc and the position of the decimal point GFor resistance readings isolate the component to be tested Disconnect it from the wiring harness or power supply TIMING CHECK PROCEDURE 1 The ignition timing check hole is in the starter recoil magneto housing Remove the check plug NOTE The ignition timing marks are stamped on the...

Page 195: ... late model LR modules Whenever possible use part number to identify the module Modules may have same LR I D number with different part numbers terminals and internal function Speed Limiter Module LR ID Number Part number is printed on module LIMITER SPECIFICATIONS Refer to parts manual or microfiche for part num ber and application TYPE FUNCTION LIMIT RPM LR44 Reverse Limit 3500 NOTES P a r t S h...

Page 196: ...ELECTRICAL 10 4 REVERSE LIMIT SYSTEM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 197: ...TEST WIRING N TEST VOLTAGE REGULATOR AND CHARGING SYSTEM MEASURE DC VOLTS ON GRY OR WIRE TO GROUND AT LR MODULE MEASURE AC VOLTS ON Y R WIRE AT LR MODULE TO GROUND Y DISCONNECT BLACK WIRE FROM LR MOD ULE AND CONNECT TO GROUND ENGINE STOP N TEST WIRING TEST CDI BLACK WIRE Y REPLACE LIMITER MODULE 12 VOLTS DC ELECTRICAL 10 5 REVERSE SPEED LIMIT SYSTEM P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 198: ...e circuit breaker output Starter Lockout output and Engine temperature controller There are no service parts in the PDM If the PDM fails it must be replaced Following are overviews of the various PDM circuits and how they function Regulator The rectifier converts the the output of the 3 phase alternator COIL 1 2 3 and applies it to the battery and the PDM loads The regulator monitors the battery v...

Page 199: ... only If the FAN output is open circuit upon power up the engine temperature controller will activate the hot indicator If the engine temperature exceeds the engine hot thermistor limit or detects a fan overload condition the hot indicator will activate The controller also contains provisions for detecting an open or shorted thermistor A thermistor fault will cause the engine hot indicator and FAN...

Page 200: ...rmistor ground J1 F THERM Thermistor input J1 G TRANS Transmission signal voltage input for starter lockout J1 H LIGHTS Powers vehicle lighting J1 J COIL 3 Alternator coil input J1 K COIL 2 Alternator coil input J1 L COIL 1 Alternator coil input w resistance to ground J1 M BAT Battery Positive J1 N ACC_PWR IPS that provides power to the accessories J1 P GND Battery Ground J1 R BAT_PROT SSCB output...

Page 201: ... Current 8 Amp Nominal Continuous output current Limit 9 11 20 Amp Current level that will cause turn off after delay Time Delay 100 150 mSec Time above limit until SSCB trips Voltage 5 5 Vdc Min Battery voltage for BAT_PROT to remain on ACC_PWR OUTPUT Output Current 10 Amp Max continuous current Nominal Current 9 11 14 Amp Current above which the output will shut off after 15 25 seconds Overload ...

Page 202: ...ht socket is connected to the PDM If engine coolant reaches the specified temperature the thermistor sends a signal to the PDM which completes the ground path for the light An open thermistor will cause the engine hot indicator to light and cause the fan motor to come on HOT LIGHT CIRCUIT TEST 1 Disconnect the thermistor 2 Turn key and auxiliary switch to ON position The hot lamp and fan should co...

Page 203: ... engine THERMISTOR RESISTANCE VS TEMPERATURE Oil Temperature Resistance 20 Fan ON OFF Hot Light ON OFF 77 F 25 C 100KΩ Fan OFF OFF 240 F 116 C 3 5KΩ Fan OFF OFF 260 F 127 C 2 5KΩ Fan ON OFF 290 F 143 C 1 6KΩ Fan ON Hot Indi cator ON Battery Voltage Oil Cooler Fan Circuit HOT indication and fan ON with resistor leads disconnected from module and key on Power Control Module Indicator THERMISTOR BLK ...

Page 204: ...s turning the key or engine stop switch OFF Test the ETC switch at the harness connector NOTE Adjust throttle cable freeplay ETC switch and make sure throttle mechanism is functioning properly before testing the switch Refer to Maintenance Chapter 2 for cable adjustment procedure ETC OPERATION TEST 1 Remove throttle block cover by carefully releasing all tabs around edge of cover 2 Place transmiss...

Page 205: ...tenance Operation Overview The DC CDI system relies on battery power for ignition Instead of generating DC voltage via magnetic induction a 12 volt DC current is supplied directly to the CDI unit from the battery At the CDI 12 volt DC current charges an internal capacitor to build up the initial ignition charge A small A C signal from the Trigger Pulse coil closes a thyristor located in the CDI at...

Page 206: ...ter Ω Ignition Coil Primary Winding 3 Ω Ignition Kill Wire Black Coil Lead Secondary Coil Check coil mount to verify ground to engine 0 2 Ω Refer To Wiring Diagrams For Specified Stator Coil Resistance Magnetic Switch Meter 10 5KΩ Ω Note DC CDI components are not compatible with any other type of ignition 12 Volt DC Supply Wire Red 520Ω Ω Meter P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 207: ... Yes No Check coil ground connection between engine and coil mount using an ohmmeter The coil mount should have good continuity to ground on the engine 0 2 Ω Verify 12 Volt DC power is present on the red wire to CDI Replace Spark Plug Disconnect and check the secondary coil Resis tance values should be Primary Side Primary Wire Tab to Ground on coil mount or engine 3 to 5 Ohms Secondary Side High ...

Page 208: ...etc GFaulty ignition coil winding measure resistance of primary and secondary GWorn magneto RH end Crankshaft bearings GSheared flywheel key GFlywheel loose or damaged GExcessive crankshaft runout on magneto RH end should not exceed 005 GFaulty CDI module CDI OUTPUT TEST USING PEAK READING ADAPTOR Re connect all CDI wires to stator wires Disconnect CDI module wire from ignition coil primary termin...

Page 209: ...lator connector Is it Check regulator rectifier connections and ground battery connections cir cuit breaker and connecting wires Repair or replace faulty wiring or components 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 No Yes No Yes Perform system Break Even Ampe...

Page 210: ...nufacturer s instructions GWith engine off and the key and kill switch in the ON position the ammeter should read negative amps battery discharge Reverse meter leads if a positive reading is indicated GShift transmission into neutral Start engine with recoil only GIncrease engine RPM while observing ammeter and tachometer GNote RPM at which the battery starts to charge ammeter indication is positi...

Page 211: ...ion and charge accordingly Battery Check 1 Check the date label on the side of the battery to calculate when to check voltage The battery should be checked every 3 months 2 Check the voltage with a voltmeter or multimeter A fully charged battery should be 12 8 V or higher 3 If the voltage is below 12 8 V the battery will need to be recharged New Batteries Batteries must be fully charged before use...

Page 212: ...evere injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Battery Charging Reference Table State of Charge Voltage Action Charge Time 100 12 8 13 V None check volt age at 3 mos after manufac ture date None Re quired 75 100 12 5 12 8 V May need slight charge 3 6 hours 50 75 12 0 12 5 V Needs Char...

Page 213: ...onnect securely to engine ground before proceeding NOTE This test can only be performed on machines with electric starters This test cannot be performed with an engine or starting system that is not working properly A battery may indicate a full charge condition in the OCV test and the specific gravity test but still may not have the storage capacity necessary to properly function in the electrica...

Page 214: ...ehicle Use the section that applies to the battery WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from con tact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get pro...

Page 215: ...t allow cleaning solution or tap water inside the battery Battery life may be reduced 5 Reinstall the battery caps CONVENTIONAL BATTERY INSTALLATION 1 Clean battery cables and terminals with a stiff wire brush Corrosion can be removed using a solution of one cup water and one tablespoon baking soda Rinse well with clean water and dry thoroughly 2 Route the cables correctly 3 Reinstall battery atta...

Page 216: ...e of charge Conventional Lead acid 100 Charged 75 Charged 50 Charged 25 Charged 0 Charged 12 60V 12 40V 12 10V 11 90V less than 11 80V SPECIFIC GRAVITY State of charge Conventional lead acid 100 Charged 75 Charged 50 Charged 25 Charged 0 Charged 1 265 1 210 1 160 1 120 less than 1 100 At 80_F NOTE Subtract 01 from the specific gravity reading at 40_ F CONVENTIONAL BATTERY LOAD TEST CAUTION To prev...

Page 217: ...as needed to raise the specific gravity to 1 270 or greater 3 Install battery in vehicle with positive terminal toward the front Coat threads of battery bolt with a corrosion resistant dielectric grease Dielectric Grease PN 2871329 4 Connect battery cables WARNING To avoid the possibility of sparks and or explosion connect positive red cable first and negative black cable last 5 After connecting t...

Page 218: ...life of the lamp Hold the bulb by the base only Headlight Assembly Removal 1 Carefully unsnap the electrical harness from the back of the headlight assembly and remove the harness 2 Remove the screws and nuts from the sides of the headlight assembly 3 Remove the headlight assembly Headlamp Replacement 1 With the headlight assembly in place unsnap the electrical harness from the back the headlight ...

Page 219: ...ft handle bar switch assembly See illustration below Continuity R W Grn Off On F F NEUTRAL LIGHT CIRCUIT OPERATION Power is supplied to the transmission switch from the Red White wire when the key and engine stop switch are on When neutral is selected power flows through the switch to the Green White wire through the lamp and to ground via the Brown wire If the light is not on when neutral is sele...

Page 220: ... and the red lead to the solenoid end of the battery to solenoid wire De press starter button Reading should be less than 1 V D C Clean the battery to solenoid cable ends or replace the cable Connect the black tester lead to solenoid end of battery to solenoid cable Connect red tester lead to solenoid end of solenoid to starter cable De press starter button Reading should be less than 1 V D C Repl...

Page 221: ...voltage drop through the connection A poor or corroded connection will appear as a high voltage reading Voltage shown on the meter when testing connections should not exceed 1 VDC per connection or component To perform the test place the meter on DC volts and place the meter leads across the connection to be tested Refer to the chart on next page to perform voltage drop tests on the starter system...

Page 222: ...lignment marks on both ends of the starter motor casing These marks must align during reassembly 2 Remove the two bolts washers and sealing O Rings Inspect O Rings and replace if damaged 3 Remove brush terminal end of housing while holding other two sections together 4 Remove shims from armature shaft NOTE All shims must be replaced during reassembly P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 223: ... brushes and replace if worn past the service limit Replace springs if they are discolored or have inadequate tension 4 Inspect surface of commutator for wear or discoloration See Steps 3 6 of armature testing on Page 10 32 5 Install a new carbon brush assembly in the brush housing NOTE Be sure that the terminal bolt insulating washer is properly seated in the housing and the tab on the brush plat...

Page 224: ...EMBLY 1 Place armature in field magnet casing 2 Place shims on drive end of armature shaft with phenolic washer outermost on shaft Engage tabs of stationary washer in drive end housing holding it in place with a light film of grease 3 Install case sealing O Ring Make sure O Ring is in good condition and not twisted on the case Lubricate needle bearing and oil seal with a light film of grease and i...

Page 225: ... 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 lock ring end washer spring retainers and clutch return spring Screw the overrun clutch off the end of the pinion...

Page 226: ...ELECTRICAL 10 34 NOTES P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 227: ...ELECTRICAL WIRING DIAGRAM 2009 TRAIL BOSS P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 228: ...ELECTRICAL WIRING DIAGRAM 2009 TRAIL BOSS P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 229: ...ELECTRICAL WIRING DIAGRAM 2009 TRAIL BLAZER P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 230: ...ELECTRICAL WIRING DIAGRAM 2009 TRAIL BLAZER P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...