Polaris 600 Dragon SP, Service Manual

Page 1: ...2004 SPORTSMAN 600 700 SERVICE MANUAL PN 9918803 ...

Page 2: ...erations component identification and unit repair along with service specifications for 2004 Polaris Sportsman 600 700 ATVs Comments or suggestions about this manual may be directed to Service Publications Dept Polaris Sales Inc 2100 Hwy 55 Medina Minnesota 55340 2004 Sportsman 600 700 ATV Service Manual PN 9918803 ECopyright 2003 Polaris Sales Inc All information contained within this publication...

Page 3: ...N A CAUTION indicates special precautions that must be taken to avoid personal injury or ATV or property damage NOTE A NOTE provides key information to clarify instructions Trademarks Polaris acknowledges the following products mentioned in this manual FLEXLOC Registered Trademark of SPS Technologies Loctite Registered Trademark of the Loctite Corporation STA BIL Registered Trademark of Gold Eagle...

Page 4: ...GENERAL MAINTENANCE ENGINE CARBURETION CLUTCHING FINAL DRIVE BODY AND STEERING TRANSMISSION BRAKES ELECTRICAL ...

Page 5: ...ations Early 2004 Sportsman 600 1 6 Specifications Late 2004 Sportsman 600 1 7 Specifications Early 2004 Sportsman 700 1 8 Specifications Late 2004 Sportsman 700 1 9 Publication Numbers 1 10 Paint Codes 1 10 Replacement Keys 1 10 Standard Torque Specifications 1 11 Conversion Table 1 12 Tap Drill Charts 1 13 Decimal Equivalent Chart 1 13 Glossary of Terms 1 14 Specs ...

Page 6: ...gine Emissions Model Year Plant No Individual Serial No Body Style Check Digit World Mfg ID This could be either a number or a letter ENGINE SERIAL NUMBER LOCATION Be sure to refer to the engine model number and serial number whenever corresponding about an engine This information can be found on the sticker applied to the top side of the crankcase A An additional number is stamped on the side of ...

Page 7: ... or LATE 2004 use the correct procedure according to the model you are working on If the procedure title does not specify a EARLY 2004 or LATE 2004 then the procedure pertains to both models To identify which model Sportsman you have refer to the identification illustration below Late 2004 Early 2004 INSTRUMENT CLUSTER Fuel Level Indicator 2004 SPORTSMAN MODEL IDENTIFICATION EARLY LATE MODELS Earl...

Page 8: ...ck Capacity 200 lbs 90 8 kg Towing Capacity 1500 lbs 681 kg Hitch Tongue Capacity 150 lbs 68 kg Body Style Gen VI MODEL 2004 EARLY LATE SPORTSMAN 700 MODEL NUMBER A04CH68 ENGINE MODEL EH068OLE Category Dimension Capacity Length 81 in 205 7 cm Width 46 in 116 8 cm Height 47 in 119 4 cm Wheel Base 50 75 in 128 9 cm Dry Weight 740 lbs 335 6 kg Gross Vehicle Weight 1240 lbs 562 45 kg Front Rack Capaci...

Page 9: ...lbs 681 kg Hitch Tongue Capacity 150 lbs 68 kg Body Style Gen VI Warn Winch Standard Hand Thumb Warmer Standard MODEL LATE 2004 SPORTSMAN 700 HUNTER EDITION MODEL NUMBER A04CH68 ENGINE MODEL EH068OLE Category Dimension Capacity Length 81 in 205 7 cm Width 46 in 116 8 cm Height 47 in 119 4 cm Wheel Base 50 75 in 128 9 cm Dry Weight 740 lbs 335 6 kg Gross Vehicle Weight 1240 lbs 562 45 kg Front Rack...

Page 10: ... Circuit Breakers Fan 10 amp Harness 20 amp Starting Electric Instrument Cluster LCD Drivetrain Transmission Type Drumshift H L N Rev Park Transmission Capacity 13 5 oz 400ml Rear Gearcase Capacity 5 oz 150ml Front Gearcase Capacity 5 oz 150ml Gear Ratio Low Rev High Front Drive Rear Drive 7 5 1 5 11 1 3 09 1 3 82 1 3 10 1 Clutch Type PVT w EBS Belt 3211091 Steering Suspension Front Suspension Sho...

Page 11: ...0 Amp Hr Circuit Breakers Fan 10 amp Harness 20 amp Starting Electric Instrument Cluster LCD Drivetrain Transmission Type Drumshift H L N Rev Park Transmission Capacity 15 2 oz 450ml Rear Gearcase Capacity 5 oz 150ml Front Gearcase Capacity 5 oz 150ml Gear Ratio Low Rev High Front Drive Rear Drive 7 5 1 5 11 1 3 09 1 3 82 1 3 10 1 Clutch Type PVT w EBS Belt 3211091 Steering Suspension Front Suspen...

Page 12: ...p Hr Circuit Breakers Fan 10 amp Harness 20 amp Starting Electric Instrument Cluster LCD Drivetrain Transmission Type Drumshift H L N Rev Park Transmission Capacity 13 5 oz 400ml Rear Gearcase Capacity 10 oz 300ml Front Gearcase Capacity 5 oz 150ml Gear Ratio Low Rev High Front Drive Rear Drive 7 5 1 5 11 1 2 89 1 3 82 1 3 10 1 Clutch Type PVT w EBS Belt 3211091 Steering Suspension Front Suspensio...

Page 13: ...it Breakers Fan 10 amp Harness 20 amp Starting Electric Instrument Cluster LCD Drivetrain Transmission Type Drumshift H L N Rev Park Transmission Capacity 15 2 oz 450m Rear Gearcase Capacity 10 oz 300ml Front Gearcase Capacity 5 oz 150ml Gear Ratio Low Rev High Front Drive Rear Drive 7 5 1 5 11 1 2 89 1 3 82 1 3 10 1 Clutch Type PVT w EBS Belt 3211091 Steering Suspension Front Suspension Shock A a...

Page 14: ...RT COLOR DESCRIPTION DITZLER NUMBER POLARIS NUMBER Springs Black 9440 P 067 FRAME COLOR All P067 Medium Gloss Black 9440 8520147 Order direct from Midwest Industrial Coatings 952 942 1840 Mix as directed 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 pr...

Page 15: ...4 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 6 x 1 0 72 78 In lbs 8 x 1 25 14 18 ft lbs 10 x 1 25 26 30 ft lbs To c...

Page 16: ...ubic centimeters cc x 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters l Liters l x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Liters l Liters l x 0 88 Imperial quarts Imp qt Imperial quarts Imp qt x 1 201 US quarts US qt US quarts US qt x 0 833 Imperial quarts Imp qt US quarts US qt x 0 946 Liters l Liters l x 1 057 US quarts US qt US gallons US gal x 3 785 Liters l Li...

Page 17: ...6 11 32 R 3 8 13 32 13 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 1...

Page 18: ...t the end of a lever one meter in length applied in a rotational direction l or ltr Liter Left Side Always referred to based on normal operating position of the driver m Meter meters Mag Magneto Magnetic Induction As a conductor coil is moved through a magnetic field a voltage will be generated in the windings Mechanical energy is converted to electrical energy in the stator mi Mile miles mm Milli...

Page 19: ...uel System 2 15 2 16 Compression Test 2 16 2 17 Battery Maintenance 2 17 2 18 Ignition 2 18 Coolant System Maintenance 2 19 2 20 Radiator Screen Removal 2 20 Air Filter Service 2 21 Air Box Sediment Tube Service 2 21 2 22 Breather Filter 2 22 PVT Drying PVT Drain Plug 2 22 Oil Change Filter 2 23 2 24 Steering and Toe Alignment 2 24 2 27 Exhaust System Maintenance 2 27 2 28 Brake System Service 2 2...

Page 20: ...evel Change 10 hrs 100 160 Check level pre ride Break In service at 1 hour E Oil Filter 10 hrs 100 160 Replace with oil change E Air Filter Pre Filter Daily Daily Inspect clean more often in dirty or wet conditions E Air Filter Main Element Weekly Weekly Inspect Replace if necessary Air Box Sediment Tube Daily Drain deposits whenever visible Engine Breather Filter 20 hrs Monthly 200 320 Inspect an...

Page 21: ...thly 250 400 Inspect Monthly Change Annually Rear Gearcase Lubricant Level 25 hrs Monthly 250 400 Inspect Monthly Change Annually Transmission Lubricant Level 25 hrs Monthly 250 400 Inspect Monthly Change Annually Drive Belt 50 hrs 6 months 500 800 Inspect Adjust Replace if Necessary H Drive and Driven Clutches 100 hrs 12 months 1000 1600 Inspect Clean Replace Worn Parts H Steering Pre ride Pre ri...

Page 22: ... check for free operation G Headlight 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 and axle nuts check to be sure axle nuts are secured by cotter pins G Air cleaner element check for dirt or water clean or replace G Steering check for free operation noting any unusual looseness in any ar...

Page 23: ...1312 Grease Gun Kit 2871329 Dielectric Grease Nyogelt Coolant 2871323 60 40 Coolant Gallon 6 Count 2871534 60 40 Coolant Quart 12 Count Part No Description Additives Sealants Thread Locking Agents Misc 2870585 Loctitet Primer N Aerosol 25 g 2871956 Loctitet Thread Sealant 565 50 ml 6 Count 2871949 Loctitet Threadlock 242 50 ml 10 Count 2871950 Loctitet Threadlock 242 6 ml 12 Count 2871951 Loctitet...

Page 24: ...uretor Float Adjustment Tool 4 2870871 Ball Joint Replacement Tool 5 2870623 Shock Absorber Spring Compression Tool 5 2871572 Strut Rod Wrench 5 2871573 LH Strut Spring Compressor 5 2871574 RH Strut Spring Compressor 5 7052069 Charging Needle 5 2200421 Gas Shock Recharging Kit 5 2871352 Shock Rod Holding Tool 5 2871351 Foxt Shock IFP Depth Tool 5 2870506 Clutch Puller 6 9314177 Clutch Holding Wren...

Page 25: ... Change after 1st month 6 months or 100 hours thereafter Change more often 25 50 hours in extremely dirty condi tions or short trip cold weather operation 2 Transmis sion Polaris AGL Gear case Lubricant Add lube to bottom of fill hole Change annually 3 Front Gear Case Premium Demand Drive Hub Fluid Drain completely Add lube to spe cified quantity Change annually 4 Rear Gear Case ATV Angle Drive Fl...

Page 26: ...ate fittings and grease Semi annually 9 Front Hub strut Polaris All Season Grease Locate fittings and grease Semi annually More often under severe use such as operated in water or under severe loads Semi annually or 50 hours of operation refer to Maintenance Schedule for additional information More often under severe conditions operating in water or hauling heavy loads Annually or 100 hours of ope...

Page 27: ...by visual reference The gearcase must be drained and re filled with the proper amount of lubricant Refer to procedures below To change gearcase lubricant Early 2004 Front Gearcase 1 Remove gearcase drain plug 11 mm located on the bottom of the gearcase and drain oil The drain plug is accessible through the skid plate Catch and discard used oil properly 2 Clean and reinstall drain plug using a new ...

Page 28: ...bricant Refer to procedure below To change gearcase lubricant 1 Remove gearcase drain plug located on the bottom of the gearcase and drain oil The drain plug is accessible through the skid plate Catch and discard used oil properly 2 Clean and reinstall drain plug using a new sealing washer 3 Remove fill plug 4 Fill with the recommended fluid amount or fill to the bottom of the fill plug hole threa...

Page 29: ...om of the fill hole as shown at right To change lubricant 1 Remove propshaft shield from the right side of the vehicle 2 Remove transmission drain plug to drain the oil Catch and discard used oil properly 3 Clean and reinstall the drain plug with a new sealing washer Torque to specification 4 Remove fill plug 5 Add Polaris AGL Gearcase Lubricant to proper level as described above 6 Check for leaks...

Page 30: ... the fill hole as shown at below To change lubricant 1 Remove transmission drain plug to drain the oil Catch and discard used oil properly 2 Clean and reinstall the drain plug Torque to specification 3 Remove fill plug 4 Add 13 5 oz of Polaris AGL Gearcase Lubricant or fill to top of the fill plug hole threads 5 Check for leaks 6 Reinstall fill plug and torque to 14 ft lbs 19 4 Nm TRANSMISSION SPE...

Page 31: ...ottle cable routing and condition Adjust cable tension as needed until lock to lock turning can be accomplished with no rise in engine rpm 5 Replace the throttle cable if worn kinked or damaged To remove the ETC cover 1 Use a medium flat blade screwdriver and insert blade into the pocket of the cover starting on the 1 position 2 Twist screwdriver slightly while lifting on the cover to release snap...

Page 32: ...plies 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 PEA CRAB regulations for air quality standards and is sealed with a brass plug to prevent tampering Removal of the tamper proof plug is not permitte...

Page 33: ...tremely flammable and explosive under certain conditions G Always stop the engine and refuel outdoors or in a well ventilated area G Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored G Do not overfill the tank Do not fill the tank neck G If you get gasoline in your eyes or if you swallow gasoline seek medical attention immediat...

Page 34: ...n the bottom left side of the float bowl 1 Turn fuel valve to the off position 2 Place a clean container beneath the bowl drain spigot or bowl drain hose 3 Turn drain screw out two turns and allow fuel in the float bowl and fuel line to drain completely 4 Inspect the drained fuel for water or sediment 5 Tighten drain screw 6 Turn fuel valve to ON 7 Start machine and check for leaks NOTE All tubes ...

Page 35: ...ies of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician im mediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Venti late when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN NOTE New Batteries B...

Page 36: ...t is properly routed and not kinked or pinched 10 Coat terminals and bolt threads with Dielectric Grease PN 2871329 11 Reinstall battery cover and holder strap SPARK PLUG 1 Remove spark plug high tension lead Clean plug area so no dirt and debris can fall into engine when plug is removed 2 Remove spark plug 3 Inspect electrodes for wear and carbon buildup Look for a sharp outer edge with no roundi...

Page 37: ... the strength of the coolant using an antifreeze hydrometer Antifreeze Hydrometer G A 50 50 or 60 40 mixture of antifreeze and distilled water will provide the optimum cooling corrosion protection and antifreeze protection G Do not use tap water Tap water contains minerals and impurities which build up in the system Do not add straight antifreeze or straight water to the system Straight water or a...

Page 38: ...OOLANT LEVEL INSPECTION WARNING Never remove the radiator pressure cap when the engine is warm or hot Escaping steam and fluid can cause severe burns The engine must be allowed to cool before removing the pressure cap NOTE This procedure is only required if the cooling system has been drained for maintenance and or repair However if the recovery bottle has run dry or if overheating is evident the ...

Page 39: ...s or damage 8 Apply foam filter oil or clean engine oil and squeeze until excess oil is removed 9 Inspect main filter and replace if necessary If the filter has been soaked with fuel or oil it must be replaced Installation 10 Reinstall pre filter element over main filter Be sure the element covers entire surface of main filter without folds creases or gaps 11 Reinstall filter on main filter mount ...

Page 40: ...engine without the pre filter BREATHER HOSE 1 Be sure breather line is routed properly and secured in place CAUTION Make sure lines are not kinked or pinched PVT DRYING PVT DRAIN PLUG NOTE If operating the ATV in or through water be sure to check the PVT cover and other components for water ingestion The ATV should be checked immediately 1 To release any water that maybe trapped in the PVT cover s...

Page 41: ...l See NOTE below NOTE Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Proper level indication is determined on the upper surface of the dipstick as it is being removed regardless of the level marks being on top or on bottom See the next illustration Always read top side of dipstick to properly check oil level in crankcase Dipstic...

Page 42: ...ge 40_ F to 120_ F Crankcase Drain Plug Torque 20 22 ft lbs 27 30 Nm Oil Filter Torque Turn by hand until filter gasket contacts sealing surface then turn an additional 1 2 turn Oil Filter Wrench PV 43527 13 Place gear selector in neutral and set parking brake 14 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 15 Re check the oil level on the dipstick ...

Page 43: ...ement G Repeat inspection for inner tie rod end on steering post G Replace any worn steering components Steering should move freely through entire range of travel without binding G Elevate front end of machine so front wheels are off the ground Check for any looseness in front hub wheel assembly by grasping the tire firmly at top and bottom first and then at front and rear Try to move the wheel an...

Page 44: ...d always point straight back from the steering post 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible NOTE It is important that the height of both marks be equally positioned in order to get an accurate measurement 4 Measure the distance between the marks and record the measurement Call this measur...

Page 45: ...n run as the ex haust system becomes very hot Serious burns could result from contact with ex haust components G To reduce fire hazard make sure that there are no combustible materials in the area when purging the spark arrestor G Wear eye protection G Do not stand behind or in front of the ve hicle while purging the carbon from the spark arrestor G Never run the engine in an enclosed area Exhaust...

Page 46: ...voir G Use Polaris DOT 3 Brake Fluid PN 2870990 Parking Brake Lock Sight Glass Min Max Rear Master Cylinder Reservoir G Check brake system for fluid leaks G Check brake for excessive travel or spongy feel G Check friction pads for wear damage or looseness G Check surface condition of the disc G Inspect thickness of brake pad friction material BRAKE PAD INSPECTION Pads should be changed when the fr...

Page 47: ...age and replace any parts as needed Bleeding If free play is correct and brake pedal travel is still excessive air may be trapped somewhere in the system Bleed the hydraulic auxiliary brake system in a conventional manner following the procedure outlined in Brake Chapter 9 SUSPENSION SPRING PRELOAD ADJUSTMENT Operator weight and vehicle loading affect suspensionspringpreloadrequirements Adjustas n...

Page 48: ...rest frame 4 Remove the wheel nuts and remove the wheel WHEEL INSTALLATION 1 With the transmission in gear and the parking brake locked place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 2 Attach the wheel nuts and finger tighten them 3 Lower the vehicle to the ground 4 Securely tighten...

Page 49: ...hat all cotter pins are in place Refer to specific fastener torques listed in each chapter WARN WINCH OPERATION SPORTSMAN HUNTER EDITION The Sportsman Hunter package is equipped with a 2500 lb 2 5chi Warn Winch in the front Winch Handlebar Controls The winch is located in the front bumper area The mini rocker IN OUT control controls the direction of the cable for the winch IN pulls the cable into ...

Page 50: ... NOTE The hand and thumb warmers may not heat up if the machine is running at low idle speed with the headlights on Warmer performance will be better at higher engine speeds If operating at low engine speeds warmer performance will be better with the headlights off The thumb warmer switch is located on the right side of the headlight pod Simply flip the switch to HI OFF or LO for operation Thumb W...

Page 51: ...3 22 Combustion Chamber 3 22 Valve Seat Reconditioning 3 23 3 25 Cylinder Head Assembly 3 25 Valve Sealing Test 3 26 Valve Train Exploded View 3 26 Engine Head Reassembly 3 27 3 29 Cylinder Removal 3 29 Valve Lifter Removal Inspection 3 29 Piston Removal 3 29 3 30 Cylinder Inspection 3 30 3 31 Piston Rod Ring Service 3 31 3 33 Starter Bendix Removal Inspection 3 34 Flywheel Stator Removal Inspecti...

Page 52: ...ug Washer Journal Bearings Baffle NOTE If needed heat the oil baffle bolts with a heat gun to remove 60 6 in lbs 6 8 68 Nm 60 6 in lbs 6 8 68 Nm Oil Pickup O ring Crankshaft Ball Bearing Bushing Flange Seal Journal Bearings Balance Shaft ML WL ML Apply White Lithium Grease Camshaftt Thrust Plate 115 12 in lbs 13 1 35 Nm ML WL 192 24 in lbs 21 7 2 7 Nm Woodruff Key ...

Page 53: ...0 3 Nm Bolt Oil Gerotor OIL OIL Oil Pump Oil Pump Bolts 84 8 in lbs 9 5 90 Nm 1 2 3 4 Oil Pump Bolt Tighten Sequence Mag Gasket Cover No Grease on this portion of gasket Gear Stator Cover Wire Hold Down 96 12 in lbs 10 85 35 Nm Gear Stator Housing Bolt Impeller Nut Washer 108 12 in lbs 6 8 68 Nm 1 2 3 4 Mag Cover Bolt Tighten Sequence GEAR TIMING AT TDC TIMING MARKS MAG SIDE WL ...

Page 54: ... Bendix Washer SG Apply Polaris Starter Grease Washer Starter Neg Cable Pos Cable Nut Washer 108 12 ft lbs 12 1 35 Nm 84 8 ft lbs 9 50 0 9 Nm Bolts Tighten Top Bolt First 1 2 Oil Filter 50 5 in lbs 5 65 0 56 Nm Apply Polaris 0W 40 oil to seal OIL Oil Filter Nipple 35 4 ft lbs 47 5 5 4 Nm Hex Plug 216 24 in lbs 24 4 2 71 Nm Loctitet Pipe Sealant PN 2871956 Dipstick Oil Fill Tube 50 5 in lbs 5 64 0 ...

Page 55: ...pply Moly Lube grease to valve tips 2 Gasket 3 Gasket free of oil Verify tabs are visible 3 Pushrods Bushing Expansion Plug Cylinder Apply Polaris 0W 40 oil OIL 4 4 Apply thin film of 0W 40 to 25 55 mm of cylinder bore Piston Assembly Circlip UP for Install 5 5 Apply 0W 40 to piston pin or pin bore 3 Gasket Hydraulic Lifter 6 Apply 0W 40 to lifters Side View Do not expansion plug install more than...

Page 56: ...Spark Plugs 216 24 in lbs 24 5 2 7 Nm O ring Seal Carburetor Boot 216 24 in lbs 24 5 2 7 Nm Bolts Boot Clamp 20 5 in lbs 2 5 0 55 Nm BST34 Carburetor Vent Line Exhaust Manifold Gasket Bolts 216 24 in lbs 24 5 2 7 Nm Coolant Temp Switch 25 3 ft lbs 34 4 Nm O ring Thermostat Housing Bolts 84 8 in lbs 9 5 0 9 Nm OUTER COMPONENTS Check Valve ...

Page 57: ...BLE COMPONENTS The following components can be serviced or removed with the engine installed in the frame G Flywheel G Alternator Stator G Starter Motor Starter Drive G Cylinder Head G Cylinder G Piston RIngs G Camshaft G Rocker Arms G Oil pump Water Pump and Oil Pump Drive Gear G Gear Train Components The following components require engine removal for service G Counterbalance Shaft or Bearing s ...

Page 58: ...rankcase 12 mm 192 24 21 7 2 7 Oil Fill Tube Bolt 5 mm 50 5 5 64 0 56 Oil Filter Pipe Fitting 20 mm 35 4 47 5 5 4 Oil Pick Up 5 mm 60 6 6 8 0 68 Oil Pressure Relief Plug 10 mm 22 2 30 3 Oil Pump Housing Screw 6 mm 84 8 9 50 0 90 Rocker Arm 8 mm 22 2 30 3 Rocker Cover 6 mm 84 8 9 5 0 9 Spark Plug 14 mm 216 24 24 5 2 7 Starter Motor 6 mm 84 8 9 5 0 9 Stator Assembly 6 mm 96 12 10 85 1 35 Stator Hous...

Page 59: ...tlined below CRANKCASE BOLT TIGHTEN SEQUENCE 3 1 5 6 2 4 Lubricate threads and between washer and underside of bolt with engine oil Torque in sequence to spec provided allow the gasket to set for 1 minute then tighten in sequence 90 1 4 turn CYLINDER HEAD BOLT TIGHTEN SEQUENCE 35 4 ft lbs 47 5 5 5 Nm 90 1 4 turn 22 2 ft lbs 30 3 Nm ...

Page 60: ...d Surface warpage limit 0 00394 0 1 mm y Head Standard height 3 478 88 35 mm Valve Seat Contacting width In Std 0 0472 0 00787 0 0039 1 20 0 20 0 10 mm Ex Std 0 0591 0 00787 0 0039 1 50 0 20 0 10 mm Seat Angle Std 44 75 0 25 Valve G id Inner diameter 0 2374 0 00059 6 030 0 015 mm Guide Protrusion above head 0 5610 0 00394 14 25 0 10 mm Valve Margin thick In Std 0 1394 0 0065 3 541 0 165 mm g ness ...

Page 61: ...on Piston ring installed Top ring Piston Ring Piston ring installed gap Top ring Limit 0 01181 0 00393 0 30 0 10 mm g g Second Second ring Limit 0 01476 0 00492 0 375 0 125 mm Oil ring Oil ring Limit 0 00984 00393 0 25 0 10 mm Standard clearance Top ring Standard clearance i t i t i Top ring Limit 0 0019 0 00069 0 0475 0 0175 mm piston ring to ring groove Second groove Second ring Limit 0 0017 0 0...

Page 62: ... H d Surface warpage limit 0 00394 0 1 mm y Head Standard height 3 478 88 35 mm Valve Seat Contacting width In Std 0 0472 0 00787 0 0039 1 20 0 20 0 10 mm Ex Std 0 0591 0 00787 0 0039 1 50 0 20 0 10 mm Seat Angle Std 44 75 0 25 Valve G id Inner diameter 0 2374 0 00059 6 030 0 015 mm Guide Protrusion above head 0 5610 0 00394 14 25 0 10 mm Valve Margin thick In Std 0 1394 0 0065 3 541 0 165 mm g ne...

Page 63: ... Piston Piston ring installed Top ring Piston Ring Piston ring installed gap Top ring Limit 0 01083 0 00295 0 275 0 075 mm g g Second Second ring Limit 0 0177 0 00394 0 45 0 10 mm Oil ring Oil ring Limit 0 0177 00984 0 45 0 25 mm Standard clearance Top ring Standard clearance i t i t i Top ring Limit 0 0019 0 00069 0 0475 0 0175 mm piston ring to ring groove Second groove Second ring Limit 0 0017 ...

Page 64: ...systems and comes pre mixed ready to use Radiator Thermostat Cylinder Head Water Pump Cylinder FLOW COOLING SYSTEM WARNING Never remove radiator cap when engine is warm or hot The cooling system is under pressure and serious burns may result Allow the engine and cooling system to cool before servicing 1 Remove front cover 2 Remove recovery bottle hose from coolant filler neck 3 Connect a Mity Vact...

Page 65: ...ect the coolant hoses Properly dispose of any antifreeze from the engine or hoses 13 Refer to PVT System Chapter 6 to remove outer clutch cover drive belt drive clutch driven clutch and inner cover D 14 When removing starter cables note and mark ground cable and positive cable mounting angle and locations Remove cables 15 Remove transmission linkage rod from gear selector and secure out of the way...

Page 66: ...bserve coolant level in the radiator Allow air to purge and top off as necessary Reinstall radiator cap and bring engine to operating temperature After engine is cool check level in reservoir tank and add coolant if necessary NOTE Should the reservoir tank become empty it will be necessary to refill at the radiator and repeat the bleeding procedure Engine Break In Period The break in period for a ...

Page 67: ...ntly deglazed and to check for correct cross hatch NOTE Do not allow cylinder to heat up during honing G After honing has been completed inspect cylinder for thinning or peeling If cylinder wear or damage is excessive it will be necessary to replace the cylinder The cylinders are lined with a nicasil coating and are not repairable Hone only enough to deglaze the outer layer of the cylinder bore EX...

Page 68: ...he first path entering the camshaft bores onto the rear balance shaft journal and then draining back into the crankcase sump The second oil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump The o...

Page 69: ...workingwith compressed air to prevent personal injury 3 Check the ends of the push rods A for nicks grooves roughness or excessive wear 4 The push rods A can be visually checked for straightness while they are installed in the engine by rotating them with the valve closed Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness 5 If the push rod...

Page 70: ...ad is still on the engine Keep all parts in order with respect to their location in the cylinder head WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly 1 Having already removed the valve cover rocker arms and pushrods align the cylinder to be worked on at top dead center Install the Valve Pressure Hose PU 45652 into the spark plug hole Hook the hose to an...

Page 71: ...t of specification Valve Spring Free Length Valve Spring Length Std 1 827I 46 40 mm Installed Height 1 47 37 34 mm 6 Remove valve guide seals IMPORTANT It is recommended to replace seals whenever the cylinder head is disassembled Hardened cracked or worn valve seals will cause excessive oil consumption and carbon buildup 7 Mark the valves with a white pen Remove the valves from the cylinder head T...

Page 72: ...f valve stem with a micrometer in three places then rotate 90 degrees and measure again six measurements total Compare to specifications Valve Stem Diameter Intake 0 2356 0 00039 5 985 0 01 mm Exhaust 0 2346 0 00039 5 96 0 01 mm Measure valve stem in several places Rotate the valve 90 degrees and mea sure for wear 6 Measure valve guide inside diameter at the top middle and end of the guide using a...

Page 73: ...h the valve seat cutters in the Cylinder Head Reconditioning Kit PN 2200634 Abrasive stone seat reconditioning equipment can also be used Keep all valves in order with their respective seat NOTE Valve seat width and point of contact on the valve face is very important for proper sealing The valve must contact the valve seat over the entire circumference of the seat and the seat must be the proper ...

Page 74: ...should contact the middle of the valve face or slightly above and must be the proper width G If the indicated seat contact is at the top edge of the valve face and contacts the margin area B it is too high on the valve face Use the 30 cutter to lower the valve seat G If too low use the 60 cutter to raise the seat When contact area is centered on the valve face measure seat width G If the seat is t...

Page 75: ...the other valve s 12 Thoroughly clean cylinder head and valves CYLINDER HEAD REASSEMBLY NOTE Assemble the valves one at a time to maintain proper order 1 Apply engine oil to valve guides and seats 2 Coat valve stem with molybdenum disulfide grease or 0W 40 Synthetic oil 3 Install valve carefully with a rotating motion to avoid damaging valve seal 4 Valve seals should be installed after the valves ...

Page 76: ...an solvent onto the intake port and check for leakage around each intake valve The valve seats should hold fluid with no seepage 3 Repeat for exhaust valves by pouring fluid into exhaust port A VALVE TRAIN EXPLODED VIEW HEAD VALVES SPRINGS RETAINER LOCKS SPRING RETAINERS GUIDE SEALS ROCKER ARMS PUSH RODS HYDRAULIC LIFTERS 22 2 ft lbs 30 3 Nm ...

Page 77: ...5 5 Nm in sequence provided Pg 3 9 Allow the gasket to set for 1 minute at this torque then turn bolts 90 1 4 turn in sequence Refer to Page 3 9 for tightening sequence C Cylinder Head Bolt Torque Allow to set for 1 min 47 5 5 5 Nm Then turn additional 90 1 4 turn Torque Bolts In Sequence Pg 3 9 35 4 ft lbs 4 Lubricate push rods D and install into lifters D 5 Lubricate rockers E with engine oil E ...

Page 78: ...olt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts 10 Install rocker cover Torque bolts to 84 8 in lbs 9 5 0 9 Nm See Page 3 6 for proper torque sequence Rocker Cover Bolt Torque 84 8 in lbs 9 5 0 9 Nm Torque In Proper Sequence Pg 3 6 11 Install thermostat J new O ring and thermostat housing Torque thermostat housing bolts to 84 8 in lbs 9...

Page 79: ...ng engine reassembly Mark the Hydraulic Lifter 4 Check the lifters for wear or scores 5 Check the bottom end of lifter to make sure that it has a slight convex 6 If the bottom surface has worn flat it may be used with the original camshaft only Inspect Hydraulic Lifter NOTE Lifters that are scored worn or if the bottom is not smooth should be replaced with new lifters and cam as an assembly If rep...

Page 80: ...ond ring 5 Remove the oil control ring The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section The top rail has a locating tab on the end which fits into a notch B in the upper oil ring land of the piston To Remove a Remove the top rail first followed by the bottom rail b Remove the expander Oil Ring Compression Rings B CYLINDER INSPECTI...

Page 81: ...op of Cylinder 1 2 Up From Bottom X X Y Y X Y 5 Record measurements If cylinder is tapered or out of round beyond 002 the cylinder must be replaced Cylinder Taper Limit 002I 05mm Max Cylinder Out of Round Limit 002I 05mm Max Standard Bore Size Both Cylinders Sportsman 700 3 1496I 80 mm Sportsman 600 3 0018 76 50 mm PISTON TO CYLINDER CLEARANCE Measure piston outside diameter at a point 5 mm up fro...

Page 82: ...7 0 005 mm 700 0 00059 0 0002 0 015 0 005 mm 2 Measure piston pin O D Replace piston and or piston pin if out of tolerance Piston Pin Measurement Locations Piston Pin O D 0 7874 7872 20 19 995 mm 3 Measure connecting rod small end ID Connecting Rod Small End I D 789 78841 20 030 20 015 mm 4 Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness ...

Page 83: ... 0 0177 00984 0 45 0 25 mm 600 700 NOTE Ring should be installed with the mark on the ring facing upward 2 Measure installed gap with a feeler gauge C at both the top and bottom of the cylinder REMINDER 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...

Page 84: ...be damaged 3 Remove starter bendix assembly A Note the thrust washers located on both sides of the bendix B 4 Inspect the thrust washer for wear or damage and replace if necessary 5 After the bendix is removed tap on the starter assembly with a soft faced mallet to loosen the starter from the crankcase B 6 Inspect gear teeth on starter drive B Replace starter drive if gear teeth are cracked worn o...

Page 85: ...STATOR INSTALLATION NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts 1 Carefully install the stator and trigger coil to the gear stator housing cover Do not tap on the stator or the gear stator housing cover This may cause a leak in between the gear stator housing cover and the crankcase 2 Proper...

Page 86: ... in the illustration for possible oil seepage FLYWHEEL STATOR INSTALLATION 6 Install stator housing with new O rings Torque the bolts to 96 12 in lbs 1 85 1 35 Nm Follow bolt torque sequence on Pg 3 4 96 12 in lbs Stator Housing Bolt Torque 96 12 in lbs 1 85 1 35 Nm Torque Bolts In Sequence Pg 3 4 ENGINE CRANKCASE DISASSEMBLY INSPECTION 1 Remove the stator cover A and water pump cover B B A 2 Remo...

Page 87: ...ousing bolts and remove the gear stator housing cover J and gasket from the crankcase Be sure to catch the excess oil from the crankcase J 7 Note the positions of the gears in the photo Crank Gear Counterbalance Gear Camshaft Gear 8 Use a white pen to accent the timing marks on the following gears camshaft gear K crankshaft gear M or counterbalance gear N This will ensure proper gear alignment and...

Page 88: ...re is no tension check the springs inside of the cam gear assembly 3 Loaded Spring 11 The cam gear assembly contains three loaded springs To open the cam gear assembly G Place the cam gear on a flat surface with the timing mark side facing up G While holding both gears together lightly work a small flathead screwdriver between the two gears G Remove the top gear The springs should stay in place CA...

Page 89: ...e pointed end of the tapered pin into the cam gear hole and slowly push the dowel through the hole until the end of the dowel is almost flush with the spring G Perform this procedure with all three tapered pins G Do not push the pins too far through or the springs will pop out NOTE Do not remove the tapered pins at this time 17 Note in the photograph that the Tapered Pins PU 45497 1 are below flus...

Page 90: ...he cam gears as shown in the picture NOTE Install the Cam Gear Alignment Tool PU 45497 2 into one assembly hole counter clockwise from the timing mark PU 45497 2 NOTE For ease of installing the Cam Gear Alignment Tool PU 45497 2 R use a twisting motion when pushing down on the tool 21 To remove the balance shaft gear the flat side of the camshaft P must face the balance shaft gear To rotate the ca...

Page 91: ...Install the Flywheel Puller PN 2871043 and remove the crankshaft gear if needed 2871043 Water Oil Pump Removal Disassembly 26 Rotate the water oil pump gear S so that all four bolts are visible though the gear Remove thefour bolts with a hex wrench Pull out the pump S 27 Inspect the oil pump rotors for wear Mark the rotors with a white pen to ensure upon reassembly that the correct sides of the ro...

Page 92: ... the tapered end of the valve dowel in first If the valve is installed incorrectly oil pressure and oil priming problems will occur DISASSEMBLY OF WATER OIL PUMP SHAFT WARNING Wear appropriate safety gear during this procedure Protective gloves clothing and eyewear are required 30 Carefully press the gear off the assembly while supporting the housing assembly Press off gear 31 Remove the snap ring...

Page 93: ...orting the housing CRANKCASE DISASSEMBLY CONT D 36 Remove thrust plate U U 37 Remove PTO end engine mount Remove crankcase bolts Tap on the reinforced areas on the cases using soft hammer Carefully separate the two crankcase halves Separate the crankcase halves NOTE Only remove the oil baffle if the baffle is damaged When removing the oil baffle bolts use a heat gun to heat the bolts and loosen th...

Page 94: ...nytime the engine is disassembled CAMSHAFT INSPECTION 1 Thoroughly clean the cam shaft 2 Visually inspect each cam lobe for wear chafing or damage Lobe height 3 Measure height of each cam lobe using a micrometer Compare to specifications Cam Lobe Height Intake Exhaust Std 0 2170 0 00236 5 5118 0 060 mm 4 Measure camshaft journal outside diameters O D Journal O D s A B C ...

Page 95: ...G After any reassembly or rebuild the engine must be primed using the Oil Priming Adapter PU 45778 and a 3 4 full oil filter before initial start up Follow Steps 45 46 in this section to properly prime the engine and to help aid proper engine break in NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bo...

Page 96: ...ief hole E 7 Assemble the crankcase halves Apply LocTitet 242 PN 2871949 to the threads and pipe sealant to the bolt flanges Torque bolts to 22 2 ft lbs 30 3 Nm following torque pattern on Page 3 9 Crankcase Bolt Torque 22 2 ft lbs 30 3 Nm Torque in Proper Sequence Pg 3 9 8 Lubricate cam lobes and valve lifters with Moly Lube Grease Moly lube Cam Lobes Moly lube Lifters 9 Lubricate lifters with en...

Page 97: ...ation 13 Install piston assemblies into cylinder aligning the piston pin holes to ensure proper alignment of the pistons to the connecting rods upon assembly Partially install the piston pins into the pistons Cylinder Installation NOTE To help align the pistons slide a rod that is close to the same diameter as the wrist pin holes to properly align them in the cylinder 14 Position cylinder and pist...

Page 98: ...moly lube lubriplate or oil to the rotors on the oil pump shaft NOTE The application of oil or lubriplate aids in priming the oil pump during initial engine start up Lubricate Rotors 19 Align the bolt holes and install oil pump assembly into crankcase Rotate the rotors in the housing during installation as this checks for binding if new rotors are used NOTE For assembly of the gears the cam gear a...

Page 99: ...shaft gear to 250 F 121 C on a hot plate J I J CAUTION The crankshaft gear is extremely hot Severe burns or injury can occur if the gear is not handled with extreme care and caution Follow the procedure below to help ensure safety 23 Use extreme caution when removing the crankshaft gear from the hot plate Use a pair of pliers and leather gloves when handling the crankshaft gear 24 Install the cran...

Page 100: ...move the camshaft gear and tool Use the Cam Spanner Wrench PU 45498 to rotate the cam to the proper position NOTE Cam Spanner Wrench PU 45498 is only needed to rotate the camshaft when the entire valve train is assembled PU 45498 27 Reinstall the camshaft gear so the timing marks are properly aligned Install the washer and bolt Torque to 22 2 ft lbs 30 3 Nm NOTE Be sure all of the timing marks are...

Page 101: ...seal cannot be removed or installed with the gear stator housing attached to the engine Shaft damage will occur NOTE Install the waterpump seal N with the seal lip facing out towards the crankcase Use of a hydraulic press is recommended for this procedure 29 Install a new crankshaft seal P into the gear stator housing cover O Use the Universal Driver Handle PU 45543 and the Main Seal Installer PU ...

Page 102: ...ed or damaged PA 45658 32 Before installing the gear stator housing cover install the Water Pump Seal Saver PA 45401 onto the water pump shaft PA 45401 33 Install the new gasket to the gear stator housing cover and crankcase With the tools installed carefully place the gear stator housing cover over the protection tools NOTE New gasket is not shown in the picture 34 Apply Crankcase Sealant PN 2871...

Page 103: ...e PA 45401 PA 45658 O Gear Stator Housing Bolt Torque 96 12 in lbs 10 85 0 35 Nm Torque in Proper Sequence Pg 3 3 NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts 37 Install shaft seal with ceramic surface facing inward 38 Install water pump impeller P Secure the impeller with the washer and a ne...

Page 104: ... 96 12 in lbs 10 85 0 35 Nm 42 Install the the wire hold down bracket T Install two new wire hold down bolts New bolts contain patch lock Torque bolts to 96 12 in lbs 10 85 0 35 Nm and follow the proper bolt torque sequence on Pg 3 3 Coat the stator wire grommet U with Nyogelt Grease PN 2871329 NOTE Be sure the stator wires are routed properly under the wire hold down bracket T Replace 2 bolts wit...

Page 105: ... primer plug from the engine Install the Oil System Priming Adapter PU 45778 into the oil plug hole Push 3 5 oz approx of Polaris 0W 40 into the adapter until resistance is felt Remove the adapter Apply pipe dope or Teflon tape to the plug threads Install the plug and torque to 216 24 in lbs 24 4 2 71 Nm PU 45778 Oil System Priming Adapter PU 45778 WARNING After any reassembly or rebuild the engin...

Page 106: ...el will not pass through fuel valve G Fuel pump inoperative restricted G Tank vent plugged or pinched G Carb starter circuit plugged G Engine flooded G Low compression high cylinder leakage G No spark Spark plug fouled ignition component failure Engine Does Not Turn Over G Dead battery G Starter motor does not turn G Engine seized rusted or mechanical failure Engine Runs But Will Not Idle G Restri...

Page 107: ...cap cracked broken Ignition coil faulty Ignition or kill switch circuit faulty Ignition timing incorrect Sheared flywheel key G Poor connections in ignition system G Valve sticking G Air leaks in intake G Lean condition COOLING SYSTEM TROUBLESHOOTING Overheating G Low coolant level G Air in cooling system G Wrong type mix of coolant G Faulty pressure cap or system leaks G Restricted system mud or ...

Page 108: ... will aid in purging the system of air Pump the hose using your hand several times as shown in the diagram Elevating the rear of the ATV with a floor jack rear tires 4 6 off the ground also aids the purging of air from the system 3 Always add coolant to the radiator first filling to the top of the neck to replace air that has been purged from the system Fill the reservoir only after you have compl...

Page 109: ...rt Numbers 4 4 CV Carburetor System Function 4 Cycle 4 5 CV Carburetor Vent System 4 Cycle 4 5 CV Carburetor Operation 4 5 4 8 Disassembly Notes CV Carburetor 4 8 4 10 Cleaning CV Carburetor 4 9 Inspection CV Carburetor 4 9 Assembly CV Carburetor 4 10 4 11 Float Adjustment CV Carburetor 4 11 Needle Seat Leakage Test 4 11 Fuel Level 4 12 Fuel Pump Service 4 12 Fuel Sender Service 4 13 Troubleshooti...

Page 110: ... Jet 7 Screw 8 Spring Washer 9 Jet Block 10 Washer 11 Main Jet 12 Cap 13 Seal 14 Packing 15 E ring 16 Cap 17 Float Pin 18 Plate 19 O ring 20 Screw 21 Float Body Assy 22 Screw 23 Float Assy 24 Screw 25 Needle Valve 26 O ring 27 Pilot Jet 28 O ring 29 Washer 30 Spring 31 Adjuster 32 Adjuster Screw 33 Ring 34 Spring 35 Throttle Valve 36 Spring 37 Ring 38 Screw 39 Throttle Shaft 40 Cable Guide 41 Scre...

Page 111: ...Gasket NOTE Late build 2004 Models equipped with a fuel sender have NO reserve feature Early 2004 Models are NOT equipped with a sender and have the reserve feature on fuel valve See Note Above Fuel Tank Fuel Valve Engine Filter Fuel Pump Carburetor Fuel Tank Vent Carburetor Vent Fitting Screens L L Located Above Oil Tank FUEL FLOW ...

Page 112: ... 0 6000 ft 0 1800 meters and ambient temperatures between 40 and 80 F 5 to 26 C Carburetors must be re calibrated if operated outside this temperature and or altitude range The jetting installed in production is not intended for all altitudes and or temperatures In addition air screw pilot screw adjustments and PVT adjustments may be required to suit operating conditions CARBURETOR JETTING CAUTION...

Page 113: ...mid range and high throttle settings 1 4 to full throttle VENT SYSTEMS CV CARBURETOR The carburetor float bowl vent lines supply atmospheric pressure to the float bowl The lines must be free of kinks restrictions and be properly routed This allows fuel to flow in the proper amount and prevents contaminants from entering the carburetor MIKUNI CV CARB OPERATION The constant velocity carburetor incor...

Page 114: ...Mikuni BST carburetor PILOT IDLE AND SLOW SYSTEM This system supplies fuel during engine operation with throttle valve closed 1 or slightly opened The fuel from float chamber 2 is metered by pilot jet 3 where it mixes with air coming in through pilot air jet 4 The mixture then goes up through pilot passage to pilot screw 5 A part of the mixture is discharged into the main bore out of bypass ports ...

Page 115: ...er the needle valve admits and shuts off fuel alternately to maintain a practically constant fuel level inside the float chamber Inlet Pipe 1 4 2 3 MAIN SYSTEM As throttle valve 1 is opened engine speed rises and this increases negative pressure in the venturi Consequently the vacuum slide 2 moves upward The fuel in float chamber 3 is metered by main jet 4 and the metered fuel enters needle jet 5 ...

Page 116: ...lled Brass Plug Removed CARBURETOR DISASSEMBLY MIKUNI CV Use the following disassembly assembly and inspection techniques to service a CV carburetor 1 Remove carburetor diaphragm chamber cover with a ratchet style screwdriver DO NOT use an impact driver to remove the screws or carburetor may be permanently damaged 2 Remove float bowl and carefully remove the pressed float pin Support Here NOTE Be ...

Page 117: ...h fuel residue and varnish soak for short periods only in carburetor cleaner and rinse in hot water 3 Replace the jets if they have a buildup of fuel residue or bacterial growth that cannot be removed Even a small amount of residue will reduce the flow characteristics of the jet 4 Verify all passages and jets are unobstructed by spraying electrical contact cleaner through the passages CAUTION Do n...

Page 118: ...t swollen The diaphragm should fit properly in the carburetor body Replace diaphragm assembly if diaphragm is damaged E D C A B 3 Replace parts in proper order The spring seat washer B is stepped and must be placed on TOP of E Clip C Spacer washer D must be installed below the E Clip Refer to parts manual for more information 4 Be sure the tab E on outer edge of diaphragm is positioned properly in...

Page 119: ... the inlet needle valve pin without compressing the spring Float Height Std 13 14 mm 51 55 in 2 Measure the height from the float bowl mating surface to the top of step in float as shown Both sides of float should be parallel to each other The measurement should be made 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...

Page 120: ...l off 2 Disconnect impulse line from pump 3 Connect Mity Vact PN 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 Filter Fuel Pump Impulse line FUEL PUMP DISASSEMBLY 1 Rem...

Page 121: ...screws that secure the fuel sender to the tank 7 Slowly lift the sender out of the tank Lift the sender out at an angle so the float will more easily come out of the fuel tank Fuel Sender Installation 1 Reinstall the fuel send and a new gasket 2 Install the 5 screws and torque the screws to 18 24 in lbs 2 3 Nm in a criss cross pattern Reconnect the sender wiring harness and route the harness prope...

Page 122: ...G Choke plunger sticking 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 pisto...

Page 123: ... 5 Body Rack Assembly Exploded View 5 6 Winch Assembly Component Exploded View 5 7 Headlight Pod Exploded View 5 8 Steering A Arm Exploded View 5 9 Rear Suspension Exploded View 5 10 A Arm Replacement 5 11 Steering Post Assembly 5 12 Front Strut Assembly Exploded View 5 13 Front Strut Cartridge Replacement 5 14 Front Strut Ball Joint Replacement 5 14 5 15 Decal Replacement 5 15 ...

Page 124: ...ng Bolt 25 30 ft lbs 35 41 Nm COVER PANEL REMOVAL To Remove Seat 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 To Remove Side panels See Page 5 3 Remove Seat Disengage tabs at front and rear and pull away To Remove Headlight pod See Page 5 8 To Remove Front Cover Remove Front rack Disengage cover and lift out To Remov...

Page 125: ...ge 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 two tabs Then pull up on side panel to disengage front upper and lower tab Push down to disengage top rear two tabs Step 2 3 To reinstall side panel align panel tabs with slots on front cab Push panel upward and forward until tabs lock Be...

Page 126: ...emove Bolt REAR RACK REMOVAL 1 Remove the four bolts that secure the rear rack to the rear rack support FRONT GRILL REMOVAL 1 Pull out slightly on the top of the radiator screen 2 With the top free pull out on the bottom of the screen 3 To install the screen place the top of the screen up into the bumper area Press in the bottom of the screen into the rubber grommets first and then press in the to...

Page 127: ... Assembly Front Cab Assembly Seat Latch Release Storage Rear Mud Guard Rear Cab Side Cover Front Cover Front Cab Wheelwell Front Mud Guard Pull UP on rear of seat and back to disengage tabs at front of seat Splash Guard Frame Frame Wheelwell Seat Latch Front Housing ...

Page 128: ...TEERING SUSPENSION 5 6 BODY RACK EXPLODED VIEW Rear Rack Extender Rear Rack Rear Rack Support Front Rack Extender Front Rack Front Rack Support Front Bumper Side Shield Brush Guard Radiator Screen Grill Panel ...

Page 129: ...RTSMAN HUNTER PACKAGE NOTE The Warn Winch Assembly is only standard on the Hunter Package Sportsman ATV Winch Switch Assembly Winch Contactor Main Harness Mount Plate Rack Support Front Bumper Winch Fairlead Mount Plate Fairlead Roller Hook Headlight Front Harness ...

Page 130: ...curing bottom half of pod E Assembly G Install bottom of pod onto handlebar and secure to brackets G Install key switch choke cable and headlight G Connect 12V power outlet where applicable G Connect headlight G Connect speedometer connectors to speedometer G Install top of pod onto bottom half making sure interlocking tabs mate properly G Install two side Phillips screws G Install one rear Philli...

Page 131: ... 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 threads 242 242 BODY STEERING SUSPENS...

Page 132: ...5 ft lbs 48 Nm Upper Control Arm Lower Control Arm 35 ft lbs 48 Nm Stabilizer Support Wheel Bearing Carrier A Arm Bushing Skid Plate Strap Rear Shock Lower Control Bushing Stabilizer Bar Arm Orientate Bushings Correctly Rear Front Bushing Orientation Forward 1 1 Orientate Bushings Correctly Left Right Bushing Orientation 2 2 ...

Page 133: ... 4 Nm WARNING The locking features on the existing bolts were destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation A arm Attaching Bolt Torque 30 ft lbs 41 Nm Ball Joint Stud Nut Torque 25 ft lbs 35 Nm 9 Attach A arm to hub strut assembly Tighten ball joint nut to 25 ft lbs 35 Nm If cotter pin holes are not aligned tighten nu...

Page 134: ...MBLY 12 ft lbs 16 Nm 1 Torque to 75 ft lbs 101 Nm 2 Align cotter pin hole 3 Install cotter pin Bend both ends of cot ter pin around nut in op posite directions 4 Check steering must move freely and easily from full left to full right without binding ...

Page 135: ...ck lubrication guide for recommended service intervals 15 ft lbs 21 Nm Nut 15 ft lbs 21 Nm 18 ft lbs 25 Nm Washer Upper Pivot Ball Lower Pivot Ball Spacer Rubber Spring Retainer Spring Bolt Spacer Nut Washer Clamp Strut Strut Bumper Hubstrut Bearing Retaining Ring Lubrication Fitting Brake Caliper ...

Page 136: ...INT REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5 13 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 5 Remove castle nut B and separate A arm C fro...

Page 137: ...ne or other flammable materials Be sure the area to be flame treated is clean and free of gasoline or flammable residue The side panels front and rear fender cabs are plastic polyethylene material 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...

Page 138: ...BODY STEERING SUSPENSION 5 16 NOTES ...

Page 139: ... 6 10 6 11 Drive Clutch Disassembly Inspection 6 11 6 13 Drive Clutch Reassembly 6 13 6 14 Drive Belt Removal Inspection 6 14 6 15 Drive Belt Installation 6 16 Clutch Alignment Offset 6 16 6 17 Drive One way Clutch Inspection 6 17 6 18 Early 2004 Driven Clutch Inspection 6 18 6 20 Early 2004 Drive Clutch Bushing Service 6 20 6 21 Early 2004 Driven Clutch Bushing Service 6 22 6 23 Late 2004 Driven ...

Page 140: ...Clutch Mark with permanent marker before disassembly One way clutch PVT SEALING AND DUCTING COMPONENTS Clutch Cover Clutch Inlet Duct Clamps Clutch Cover Seal Seal Retainer Bracket Inner Cover Seal Transmission Cover Seal Inner Clutch Cover Boot Duct ...

Page 141: ...Roller Bushing Assembly Retaining Ring Bushing Bushing Ramp Bushing Torque to 200 Ft Lbs 271 Nm Roller One Way Clutch Driven Spider Lock Nut NOTE Refer to the correct section of Chapter 6 when servicing the driven clutch Two different style EBS driven clutches were used The Drive clutch did not change Refer to the EARLY 2004 or LATE 2004 DRIVEN CLUTCH section for service To determine if you have a...

Page 142: ...ive Clutch 2 The Driven Clutch and 3 The Drive Belt The internal components of the drive 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 compone...

Page 143: ...fset Belt Width See Page 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 Th...

Page 144: ...s Warm engine at least 5 min then with 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 we...

Page 145: ...lt removal 6 Remove drive clutch retaining bolt and remove drive clutch using puller Drive Clutch Puller PN 2870506 Clutch Holding Wrench PN 9314177 7 Remove driven clutch retaining bolt and driven clutch Use puller if necessary Driven Clutch Puller PN 2870913 8 Remove driven clutch offset spacers from the transmission input shaft NOTE Remember to keep spacers in order for proper clutch offset on ...

Page 146: ... B C Inner Cover Bolt Torque Rear 12 ft lbs 16 6 Nm Driven Clutch Retaining Bolt Torque 17 ft lbs 23 5 Nm Drive Clutch Retaining Bolt Torque 40 ft lbs 55 Nm 7 Install clutch offset spacer s on transmission input shaft Offset Spacer 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 ...

Page 147: ... its compression rate This may result in complete stacking of the coils and subsequent clutch component failure Measuring Spring Length With the spring resting on a flat surface measure its free length from the outer coil surfaces as shown Refer to the spring specification chart for specific free length measurements and tolerances Also check to see that spring coils are parallel to one another Dis...

Page 148: ...t weights should not be changed or altered without first having a thorough understanding the effects they have on belt to sheave clearance clutch balance engagement and shifting characteristics 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 5630709 44 gr PN 5630710 46 gr PN 5630711 47gr RH BH 10 10 10 WH PN 5631214 20 54 54 gr 20 56 PN 5631215 56...

Page 149: ...by a certified Polaris Master Service Dealer MSD technician who has received the proper training and understands the procedures outlined in this manual Because of the critical nature and precision balance incorporated into the PVT system it is absolutely essential that no attempt at disassembly or repair be made without factory authorized special tools and service procedures BUTTON TO TOWER CLEARA...

Page 150: ...wear galling nicks or scratches Replace clutch assembly if worn or damaged 5 Remove and inspect spring See Page 6 9 Inspect shaft SPIDER REMOVAL 1 Remove the limiter nut using the Clutch Spider Nut Socket PN 2870338 Install clutch in holding fixture and loosen the spider counterclockwise using Clutch Spider Install Tool PN 2870341 Clutch Holding Fixture PN 2871358 Spider Removal Tool PN 2870341 NO...

Page 151: ...ing or bearing surface of the new pin during installation 4 Rubber backed buttons can and should be usedin all ATV clutches if the hollow roller pin is changed to a solid roller pin NOTE The rubber side of the button is positioned toward the solid roller pin It is recommended to switch all buttons to the rubber version during service if needed DRIVE CLUTCH REASSEMBLY NOTE It is important that the ...

Page 152: ... the clutch while initially tightening the spider will help position the washers Spacer washers 6 Install limiter nut on top of spider using the Clutch Spider Nut Socket PN 2870338 Torque to 15 ft lbs Reinstall shift weights using new lock nuts on the bolts 7 Reinstall clutch spring Engine Rotation Nut on trailing side 8 Reinstall cover aligning bosses on the tower and cover Torque cover bolts eve...

Page 153: ...74 1 188 2 98 3 02 cm Wear Limit 1 125 2 86 cm 5 Inspect belt for loose cords missing cogs cracks abrasions thin spots or excessive wear Replace if necessary 6 Inspect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt Hour glassing occurs when the drive train does not move and the drive clutch engages the belt continuously in one spot 7 Measure belt le...

Page 154: ... tool touching rear of driven clutch inner sheave the distance at point A should be 1 8 NOTE If the distance is greater than 1 8 or less than 1 16 clutch alignment must be adjusted as follows 3 Remove drive and driven clutch See PVT Disassembly Pages 6 7 6 8 4 Remove PVT inner cover 5 Loosen all engine mounts Move front of engine to the right or left slightly until alignment is correct 6 Tighten e...

Page 155: ...NE WAY CLUTCH INSPECTION DRIVE CLUTCH 1 Rotate one way clutch clockwise as viewed from the cover plate side The clutch should rotate on the shaft with only slight amount of drag Verify there is no binding or rough spots When rotated counterclockwise the clutch should lock to the shaft without slipping If problems are noted in either direction continue with disassembly DRIVE CLUTCH INSPECTION NOTE ...

Page 156: ...signs of wear grooving or cracking Clean surfaces with a 3Mt pad if needed Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflont is visible on the bushing Refer to bushing replacement in this chapter EARLY 2004 EBS DRIVEN CLUTCH DISASSEMBLY INSPECTION CAUTION The driven clutch must be disassembled from the helix end to lessen the chance of damage to seals in the o...

Page 157: ...effort needed to push thehelix inward 5 Remove spring seat washer and inspect for wear or damage Replace if worn 6 Inspect surface of rollers for flat spots and wear Rollers must rotate freely on pins without excessive clearance Check the roller pin and roller bore for wear and replace if necessary Rollers ROLLER PIN DISASSEMBLY New roller retaining bolts have a dry locking agent applied to the th...

Page 158: ...ar Inspect BOTH sheaves for signs of wear grooving or cracking Clean surfaces with a 3Mt pad if needed Moveable Sheave Bushing Inspection Replace the bushing if more brass than Teflont is visible on the surface of the bushing 8 Check for movement of the shaft in the one way clutch If the shaft can be moved laterally or if the one way clutch does not function properly as described in Step 1 and 2 o...

Page 159: ...uller Nut C 6 With towers pointing toward the vise slidesheave onto puller rod 7 Install removal tool Item A B into center of sheave with A side toward sheave 8 Install nut C onto end of puller rod and hand tighten Turn puller barrel to increase tension on sheave if needed Using a hand held propane torch apply heat around outside of bushing until tiny smoke tailings appear 9 Turn sheave counterclo...

Page 160: ...h cover 3 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 4 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 5 Turn clutch cover counterclockwise on puller rod until bushing is seated 6 Remove nut from puller rod Take installation tool and clutch cover off rod EARLY 2004 EBS DRIVEN BUSHING SERVICE EBS Driven Bushin...

Page 161: ...s will be hot In order to avoid serious burns wear insulated gloves during the removal process 4 Flip sheave over onto puller 5 Install bushing tool Item 2 6 Install left hand nut C and spacer onto puller rod and tighten by hand Turn puller barrel for further tension if needed 7 Turn clutch sheave counterclockwise until bushing is removed and sheave comes free 8 Remove nut C left hand thread from ...

Page 162: ...o the transmission shaft rotates in the pocket of the sheave allowing the stationary sheave to rotate with the moveable sheave as the rollers move to the other side of the ramp providing instant EBS braking Engine braking EBS continues until the drive clutch speed exceeds the one way clutch speed or until the throttle is applied and the engine reaches clutch engagement speed lifting the belt off o...

Page 163: ...nly and has no torsional wind A B NOTE Rotating the moveable sheave so that the rollers are not in contact with either helix ramp surfaces will lessen the effort needed to push the helix inward 4 Remove helix C spring D and spring seat washer E and inspect for wear or damage Replace if worn NOTE Note the keyed spline on the shaft and helix for reassembly The keyed shaft ensure proper alignment of ...

Page 164: ... the hex wrench to ensure a tight fit Always use new bolts if they are removed for inspection Apply Loctitet 680 retaining compound sparingly to the tapered head portion of the roller retaining screws Do not allow locking agent to contact the inside of the rollers Do not lubricate the roller or roller pin Roller Dry Locking Agent Applied To New Screws Apply Loctitet 680 To Tapered Portion Of Screw...

Page 165: ...be limited to prevent the plate from raising out of the sheave pocket One Way Clutch Disassembly 8 It is important to mark the position of the shaft stop plate and sheave before disassembly This will aid in reassembly Mark Components Before Disassembly Stop Plate 9 Remove the snap ring F F 10 Remove the stop plate G and spacer washer H G H 11 Remove the shaft I from the sheave assembly Inspect was...

Page 166: ...r for replacement of driven bushings 2 Be sure to use the alignment marks for reassembly LATE 2004 EBS DRIVEN CLUTCH EXPLODED VIEW 1 Snap Ring 2 Spacer 3 Stationary Ramp Helix 4 Spring 5 Spacer Washer 6 Moveable Bearing 7 Sheave 8 Bearing 9 Screw 10 Taper Roller 11 Shaft 12 Washer 13 Plate 14 Washer 15 Spring Lock Washer 16 Bolt 1 1 2 3 4 5 6 6 7 7 8 9 10 11 12 13 14 15 16 14 ...

Page 167: ...uller Nut C 6 With towers pointing toward the vise slidesheave onto puller rod 7 Install removal tool Item A B into center of sheave with A side toward sheave 8 Install nut C onto end of puller rod and hand tighten Turn puller barrel to increase tension on sheave if needed Using a hand held propane torch apply heat around outside of bushing until tiny smoke tailings appear 9 Turn sheave counterclo...

Page 168: ...h cover 3 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 4 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 5 Turn clutch cover counterclockwise on puller rod until bushing is seated 6 Remove nut from puller rod Take installation tool and clutch cover off rod LATE 2004 EBS DRIVEN BUSHING SERVICE EBS Driven Bushing...

Page 169: ...ts will be hot In order to avoid serious burns wear insulated gloves during the removal process 4 Flip sheave over onto puller 5 Install bushing tool Item 2 6 Install left hand nut C and spacer onto puller rod and tighten by hand Turn puller barrel for further tension if needed 7 Turn clutch sheave counterclockwise until bushing is removed and sheave comes free 8 Remove nut C left hand thread from...

Page 170: ...sing a hand held propane torch apply heat around outside of bushing until tiny smoke tailings appear CAUTION Clutch components will be hot In order to avoid serious burns wear insulated gloves during the removal process 4 Install bushing tool Item 2 5 Install the left hand nut C and spacer onto puller rod and tighten by hand Turn puller barrel for further tension if needed 6 Turn clutch sheave cou...

Page 171: ...le and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Disassemble clean and inspect driven clutch noting worn sheave bushing and ramp buttons and helix spring location Clean sheaves with denatured alcohol or brake cleaner install new belt Harsh drive clutch engage ment Drive belt worn too nar...

Page 172: ...ngagement Caution operator to operate machine within guidelines Vehicle operated with park brake on Inspect brake system Instruct firm effective use of throttle for efficient engage ment PVT noise Belt worn or separated thin spots loose belt Broken or worn clutch components cover hitting clutches Replace belt Inspect and repair as necessary Engagement erratic or stabby Thin spots on belt worn belt...

Page 173: ...e Removal Install 7 8 7 9 Early 2004 Front Gearcase Information 7 10 7 15 Early 2004 Front Gearcase Exploded View 7 16 Late 2004 Front Gearcase Information 7 17 7 24 Late 2004 Front Gearcase Exploded View 7 25 Rear Hub Removal 7 26 7 27 Rear Hub Installation 7 27 Rear Hub Disassembly 7 28 Rear Hub Assembly 7 28 Rear Driveshaft Removal 7 29 Driveshaft and CV Joint Tips 7 30 Rear Driveshaft Installa...

Page 174: ... U Joint and Yoke Front Drive Axle Components Front Prop Shaft Components O Ring Yoke Propshaft to Transmission Prop Shaft Cross and Bearing Kit Spring Pin Yoke Front Gearcase Propshaft Assembly FINAL DRIVE 7 2 AWD FRONT DRIVE AXLE EXPLODED VIEW ...

Page 175: ...ck for movement 3 If movement is detected inspect hub hub nut torque and bearing condition and correct as necessary FRONT DRIVE AXLE REMOVAL 1 Shift the the ATV into park Remove hub dust cap 2 Remove cotter pin 3 Loosen the hub retaining nut 4 Loosen but do not remove the wheel nuts 5 Safely lift and support the front of the ATV CAUTION Serious injury could occur if machine tips or falls 6 Remove ...

Page 176: ...g these instructions is very important to ensure proper shaft function and a normal service life G The complete driveshaft and joint should be handled by getting hold of the interconnecting shaft to avoid disassembly or potential damage to the driveshaft joints G Over angling of joints beyond their capacity could result in boot or joint damage G Make sure surface ground areas and splines of shaft ...

Page 177: ...ged boot the CV joint grease may be contaminated Inspect the grease carefully for contamination and clean the joint thoroughly if necessary Front drive axle CV boot replacement requires 30g of grease If CV joint is cleaned an additional 30g of grease is required Refer to information following 8 Before installing the new boot remove all grease from the boot area and shaft NOTE It is very important ...

Page 178: ...ected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 4 Inspect bearing housing for scratches wear or damage Replace housing if damaged FRONT HUB ASSEMBLY 1 Support bottom of hubstrut housing 2 Start...

Page 179: ...and outer yoke for correct re positioning during installation 2 Support inner yoke as shown and drive outer yoke down bearing cap out with a soft face hammer 3 Support U joint in vise as shown and drive inner yoke down to remove remaining bearing caps 4 Force U joint cross to one side and lift out of inner yoke U JOINT REASSEMBLY 1 Install new bearing caps in yoke by hand Carefully install U joint...

Page 180: ...n is complete Yokes must pivot freely in all directions without binding If the joint is stiff or binding tap the yoke lightly to center the joint until it pivots freely in all directions FRONT GEARCASE REMOVAL 1 Stop engine place machine in Park and set parking brake 2 Loosen right front wheel nuts slightly 3 Elevate and support machine under footrest frame area CAUTION Serious injury may result i...

Page 181: ... from the front gearcase Replace the circlip on the driveshaft end for reassembly 10 Remove bolts securing bottom of housing to frame Remove vent line Remove the front gearcase from right side of frame Frame Front Gearcase FRONT GEARCASE INSTALLATION 1 To install gearcase reverse removal procedure Use new spring pin in front prop shaft New spring Pin 2 Add the proper lubricant to the front gearcas...

Page 182: ...hubs that link both front axles resulting in True All Wheel Drive CAUTION If the rear wheels are spinning release the throttle before turning the AWD switch on If AWD is engaged while the wheels are spinning severe drive shaft and clutch damage could result Roller Cage Bearings Output Hub Armature Plate Disengagement As the front and rear wheels gain traction rotating very close to the same speed ...

Page 183: ...chipped broken or missing teeth 5 Remove the roll cage assembly rollers and H springs 6 Thoroughly clean all parts Inspect the rollers A for nicks and scratches The rollers must slide up and down freely within the roller cage surfaces B A B C 7 Inspect the ring gear C for consistent wear patterns The surfaces should be free of nicks and scratches 8 Inspect roll cage B sliding surface This surface ...

Page 184: ...earing G from the output hub D Inspect the thrust bearing G and the dowel H D G H 12 Remove the other output hub from the main gearcase 13 Remove the O ring and seal from the output cover 14 Remove the input cover bearing and the pinion gear Inspect the pinion gear for chipped broken or missing teeth Inspect the output shaft bushing Replace as needed Clean the inside surfaces of both gearcase halv...

Page 185: ...ted visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement side to side 4 Install pinion shaft bearing and input cover with new o ring and torque bolts to 14 ft lbs 19 Nm Cover Bolts Torque 14 ft lbs 19 Nm 5 Install the output hub into the gear...

Page 186: ...over with new o ring and torque bolts to 14 ft lbs 19 Nm Cover Bolts Torque 14 ft lbs 19 Nm 12 Install new seals into the gearcase housing and gearcase housing cover EARLY 2004 FRONT GEARCASE DIAGNOSIS Symptom AWD Will Not Engage 1 Check the gearcase coil resistance To test the gearcase coil resistance use the coil harness Grey Brown White The gearcase coils should measure between 22 8 ohms and 25...

Page 187: ...mature Plate ILL 1 4 Check to make sure the coil is seated in the U shaped insert that is pressed into the gearcase cover The top of the coil should be seated below the U shaped insert The U shaped insert controls the pole gap If the top of the coil is above the surface of the U shaped insert it raises the armature plate thereby increasing pole gap If the pole gap increases the coil will not be st...

Page 188: ...Hub Race Output Male 27 1 Gearcase LH 8 1 Pin Dowel 28 2 Seal Oil 9 1 Bearing Roller Ball 29 1 Plug Oil Fill 10 1 Clutch Housing Ring Gear 30 4 Washer Spring Lock 11 1 Spring 31 4 Screw 12 14 Kit Roll 32 1 Plug Oil Drain 13 2 Ring Retaining 33 1 Washer 14 1 Bushing 34 1 Bearing Needle Roller Thrust 15 1 Hub Race Output Female 35 1 Roll Cage Aluminum 16 1 Bushing 36 1 Plate Armature 17 AR Line Fuel...

Page 189: ...engage themselves to the output hubs that link both front axles resulting in True All Wheel Drive CAUTION If the rear wheels are spinning release the throttle before turning the AWD switch on If AWD is engaged while the wheels are spinning severe drive shaft and clutch damage could result Roller Cage Bearings Output Hub Roller Cage and Roller s Rotate Inward and Grip the Output Hub for AWD Engagem...

Page 190: ...t ring gear for chipped broken or missing teeth 5 Remove the roll cage assembly rollers and H springs 6 Thoroughly clean all parts Inspect the rollers A for nicks and scratches The rollers must slide up and down freely within the roller cage surfaces B 7 Inspect the ring gear C for consistent wear patterns The surfaces should be free of nicks and scratches A B C 8 Inspect roll cage B sliding surfa...

Page 191: ...e output hub G from the cover Remove the thrust bearing F from the output hub G Inspect the thrust bearing F and the dowel H G F H 13 Inspect the magnetic coil I in the output housing NOTE See FRONT GEARCASE DIAGNOSIS later in this chapter for more details on the coil 14 Inspect the back lash pad J for excessive wear NOTE The backlash for the centralized hilliard is set at the factory No readjustm...

Page 192: ...n gear O Inspect the pinion gear O for chipped broken or missing teeth Replace the input cover O ring M N O 17 Inspect the output shaft bushing Replace as needed Clean the inside surfaces of both gearcase halves 18 Remove and replace the O rings and seals from the assembly ...

Page 193: ... visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement side to side 4 Install pinion shaft bearing and input cover with new o ring and torque bolts to 14 ft lbs 19 Nm Input Cover Bolts Torque 14 ft lbs 19 Nm 5 Install the output hub A into the...

Page 194: ... output cover G 10 Install the rollers and roll cage into the ring gear Insert the rollers as the roll cage is installed 11 Install the output cover assembly onto the main gearcase NOTE Be sure armature plate tabs are placed into the slots on roll cage See Reference Photo Photo for reference only Armature Plate Tabs Fit Into Rollcage Slots NOTE This photo is for reference only the armature plate i...

Page 195: ...coils should measure between 22 8 ohms and 25 2 ohms 2 Check the minimum battery voltage at the wire Grey Brown White that feeds the hub coilwire There should be a minimum of 11 80 12 0 Volts present for proper operation 3 Inspect the armature plate for a consistent wear pattern There should one or two distinct wear bands one band inside the other If only one band of wear is present or if there is...

Page 196: ...he pole gap If the top of the coil is above the surface of the U shaped insert it raises the armature plate thereby increasing pole gap If the pole gap increases the coil will not be strong enough to engage the AWD system If this is the cause order a new Plate Cover Assembly PN 3233952 U shaped insert Coil Gearcase Cover Side Cutaway View of Centralized Hilliard Cover 5 Inspect the rollers for nic...

Page 197: ...Ball 26 1 Bushing 7 1 Hub Race Output Male 27 1 Gearcase LH 8 1 Pin Dowel 28 2 Seal Oil 9 1 Dowel 29 1 Plug Oil Fill 10 1 Clutch Housing Ring Gear 30 4 N A 11 1 Spring 31 4 N A 12 14 Kit Roll 32 1 Plug Oil Drain 13 2 Retaining Ring 33 1 Washer 14 1 Bushing 34 1 Bearing Needle Roller Thrust 15 1 Hub Race Output Female 35 1 Roll Cage Aluminum 16 1 Bushing 36 1 Plate Armature 17 1 Vent 37 1 Backlash ...

Page 198: ...en the wheel nuts 5 Safely support the rear of the ATV CAUTION Secure the machine Serious injury could occur if machine tips or falls 6 Remove wheel nuts and wheel 7 Remove the rear brake caliper and safely suspend the caliper from the frame with a piece of wire 8 Remove hub nut domed washer and flat washer 9 Remove hub 10 Remove upper control arm bolt as shown ...

Page 199: ...35 ft lbs 48 Nm 3 Install and torque both lower control arm bolts 4 Lift bearing carrier until top aligns with upper control arm Install and torque upper control arm bolt and torque to specification Rear Hub Nut Torque 80 ft lbs 109 Nm Rear Wheel Nut Torque 30 ft lbs 41 Nm 5 Pull drive shaft outward and install hub onto driveshaft splines 6 Install cone washers with domed side facing outward 7 Ins...

Page 200: ...ly close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 4 Inspect bearing housing for scratches wear or damage Replace housing if damaged R...

Page 201: ...all snap ring into groove REAR DRIVE SHAFT REMOVAL 1 Remove rear hub and bearing carrier See Pages 7 26 2 Tip hub outward and remove shaft from hub 3 Pull sharply outward to remove shaft from transmission Install a new lock ring upon assembly Pull outward sharply to re move from transmission Lock ring ...

Page 202: ...pension components G Never use a hammer or sharp tools to remove or to install boot clamps G Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned Refer to text for grease capacity of CV joints and CV joint boots REAR DRIVE SHAFT INSTALLATION 1 Slide shaft assembly into bearing carrier hub 2 App...

Page 203: ...ecess in CV joint inner hub to locate snap ring Snap ring located in recessed area Snap ring 3 Open the snap ring using a snap ring pliers or small needle nose pliers Tap CV housing off shaft with a soft faced hammer while holding snap ring open Tap CV Housing Off Shaft Spread ends of snap ring to remove joint from shaft 4 Place a new snap ring in the groove of the CV joint inner hub with tabs fac...

Page 204: ...nation If the grease is not contaminated the boot can be replaced without cleaning the CV joint Use the recommended amount of grease for boot replacement only see below Proceed to Boot Installation CV Joint Cleaning Replacement NOTE Shiny areas in ball tracks and on the cage spheres are normal Do not replace CV joints because parts have polished surfaces Replace CV joint only if components are cra...

Page 205: ... shaft G Tighten the rear gearcase as shown in illustration 1 A B D B C C C Ill 1 30 ft lbs 41 Nm 4 bolts 30 ft lbs 41 Nm 2 bolts 30 ft lbs 41 Nm 5 bolts 30 ft lbs 41 Nm 5 bolts Remove Propshaft REAR GEARCASE REMOVAL CAUTION Serious injury may result if the machine tips or falls Be sure the machine is secure before beginning this service procedure 1 Place the ATV in park and set the parking brake ...

Page 206: ...orque the fill plug to 14 ft lbs 19 Nm Fill Plug REAR GEARCASE DISASSEMBLY 1 Drain and properly dispose of used oil 2 Remove the gearcase housing cover bolts and the gearcase housing cover 3 Remove the shim thrust button and thrust button shim from the gearcase Thrust Button Shims 4 Remove rear bevel gear from the gearcase housing cover 5 Inspect the ring gear for abnormal wear broken or chipped t...

Page 207: ...ken or chipped teeth Spin the bearing to check the ball bearings for smoothness Replace the bearing if needed REAR GEARCASE REASSEMBLY 1 Inspect the pinion shaft bushing for wear 2 Replace all O rings seals and worn components 3 Install the pinion shaft into the gearcase housing Install the pinion shaft cover and torque the cover bolts to 25 ft lbs 34 Nm ...

Page 208: ...arcase cover 5 Apply Crankcase Sealant PN 2871557 to surface of case and install cover bolts Install the gearcase cover onto the gearcase housing Torque the cover bolts to 25 ft lbs in a criss cross pattern Gearcase Cover Bolt Torque 25 ft lbs 34 Nm 6 Install the drain plugs Replace the drain plug washers to ensure proper sealing after filling ...

Page 209: ...1 1 Cover Output LH 12 1 Ball Bearing 2 8 Screw 13 1 O ring 3 1 Tube Vent 14 1 Cover Input 4 2 Washer 15 1 Seal 5 2 Plug 16 1 Rear Gearcase Housing 6 2 Bearing Roller Ball 17 2 Ball Bearing 7 AR Shim 18 1 31T Gear 8 1 Thrust Button 19 AR Shim 9 2 Knock Pipe 10 1 Bushing 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 2 5 4 6 16 17 18 17 19 ...

Page 210: ...FINAL DRIVE 7 38 NOTES ...

Page 211: ...sion Exploded View 8 2 8 5 Torque Specifications Lubrication 8 5 Gear Shift Selector Removal 8 5 Transmission Removal 8 6 8 7 Transmission Installation 8 7 8 8 Transmission Disassembly 8 8 8 13 Transmission Reassembly 8 13 8 18 ...

Page 212: ...1 42 1716 43 44 45 46 47 48 49 50 51 8 52 53 16 54 55 56 57 58 17 59 60 61 62 63 64 65 66 67 68 69 Apply White Lithium Based Grease Apply Loctitet 262 to the bolt threads Apply Polaris Crankcase Sealant 262 FOR REASSEMBLY 262 TORQUE SPECIFICATIONS Item 1 3 10 52 38 58 Torque 12 18 ft lbs 16 24 Nm 6 12 ft lbs 8 16 Nm 14 18 ft lbs 19 24 Nm 27 34 ft lbs 37 46 Nm 6 12 ft lbs 8 16 Nm 14 18 ft lbs 19 24...

Page 213: ...13 4 Bearing 48 AR Shim 14 1 Silent Chain 49 AR Shim 15 1 Input Shaft 50 1 Front Output Cover 16 4 Bearing 51 17 Screw 17 4 Knock Pipe 52 1 Plug 18 1 LH Cover 53 1 Washer 19 1 Seal 54 1 Front Output Shaft 20 1 Shift Drum 55 1 Silent Chain 21 2 Shift Fork 56 1 22 22T Sprocket 22 2 Dowel Pin 57 1 Bushing 23 1 Shift Shaft Rail 58 1 Park Lockout 24 1 Park Plate 59 1 Main Gearcase 25 1 Engagement Dog 6...

Page 214: ...ctitet 262 to the bolt threads Apply Polaris Crankcase Sealant 262 FOR REASSEMBLY TORQUE SPECIFICATIONS Item 1 3 23 33 39 70 71 Torque 12 18 fl lbs 16 24 Nm 7 9 ft lbs 9 5 12 Nm 15 19 ft lbs 20 26 Nm 27 34 ft lbs 37 46 Nm 6 12 ft lbs 8 16 Nm 14 18 ft lbs 19 24 Nm 6 12 ft lbs 8 16 Nm 70 71 72 262 ...

Page 215: ...le Cage Bearing 14 1 Vent Tube 49 1 24T 6 Face Sprocket 15 1 O ring 50 1 Washer 16 1 Shift Drum 51 2 External Retaining Ring 17 1 External Retaining Ring 52 4 6 Face Engagement Dog 18 1 6 Pin Switch 53 2 Wave Spring 19 1 O ring 54 1 Washer 20 1 Detent Star 55 2 Needle Cage Bearing 21 1 Lockout Disc 56 1 30T 6 Face Gear 22 1 16T Sector Gear 57 1 47T Mid Output Helical Gear 23 2 Lock Nut 58 1 Shift ...

Page 216: ...tion for transmission lubricant type and capacity GEAR SELECTOR REMOVAL 1 Disconnect linkage rod from gear selector handle 2 Remove two bolts attaching gear selector mount to machine frame 3 Lift gear selector out of mounting bracket and away from frame TRANSMISSION REMOVAL 1 Remove seat rear rack rear cab air box and exhaust system and right footwell if required for access Front Transmission Moun...

Page 217: ...de transmission bracket rear bracket and lower right bracket bolt 12 Remove front transmission to engine mount bolts See illustration 13 Remove transmission from right side of frame TRANSMISSION INSTALLATION 1 Install transmission from right side of vehicle 2 Align rear output shaft to rear propshaft yoke and roll pin hole 3 Slide rear output shaft into propshaft yoke 4 Position transmission in fr...

Page 218: ...lcrank 3 Remove the e clip and then remove the transmission switch Transmission Switch 4 Remove the five bolts that secure the cover Remove the detent spring Spring 5 Mark the detent gear with a white pen Remove the detent gear from the case NOTE It may be helpful to place a mark just above the keyed spline for reference 6 Mark the shift lockout disc this will indicate which side of the disc faces...

Page 219: ...rking pen for reference 9 Remove the bolts on the LH transmission case Tap the cover off with a soft face hammer if necessary 10 Lift shift rail 0 5 1 12 70 25 40 mm Then rotate the shift rail forks and shift drum so the the forks pins disengage fro the drum 11 Remove the shift drum NOTE You may have to tap the shift drum from the backside of the case to aid in removal 12 Remove the upper gear clu...

Page 220: ...move the shift forks from the assembly Note the correct position of each fork 15 Remove the bearing from the reverse shaft using a puller 16 Remove the park lock engagement dog Remove the wave spring and reverse engagement dog Engagement Dogs 17 Remove the bearing from the input shaft with a puller ...

Page 221: ... gear 33T and the needle bearing 20 Remove the reverse gear shaft 21 Remove the rest of the bearings from the shafts 22 Use a press to remove the gear from the shaft 23 Make note of the direction of the gear and hub location 24 Remove the gear split bearing and washer from the reverse shaft ...

Page 222: ...f the shift dogs and wave springs 26 Remove the snap ring washer gear and split bearing 27 Remove bearing and the helical gear 28 Remove the pinion shaft retainer plate and the pinion shaft 29 Remove the front housing cover screws ...

Page 223: ... gears and replace if edges are rounded 35 Inspect gear teeth for wear cracks chips or broken teeth Note the location of the hubs on the gear 36 Remove seals from transmission case IMPORTANT New seals should be installed after the transmission is completely assembled 37 Inspect bearings for smooth operation Check for excessive play between inner and outer race TRANSMISSION REASSEMBLY 1 Reinstall t...

Page 224: ... place Front Cover Bolt Torque 27 34 ft lbs 36 50 46 Nm 5 Install new front and rear output shaft seals Apply grease to the seal lips Cover the splines of the shaft to protect the seal lips during installation 6 Install pinion shaft with bearing 7 Install retainer plate with flat side toward bearing 8 Apply Loctitet 262 Red PN 2871951 to screw threads and torque screws to 6 12 ft lbs 8 16 Nm Pinio...

Page 225: ... 12 Install the engagement dogs wave springs and bearing 13 Install the ball bearing onto the end of the input shaft 14 As the engagement dogs are installed onto the shaft place the wave springs into the spring groove Keep the spring in place while the fork is being installed on the shaft and while placing the shafts into the case NOTE Use caution when installing the fork as the spring can easily ...

Page 226: ...he pocket on the backside of the case 20 Install the helical gear and bearing onto the pinion shaft 21 Clean the mating surfaces of the case and cover Apply Crankcase Sealant PN 2871557 to the mating surfaces Be sure the locating pins knock pipes are in place Reinstall cover LH mounting bracket and torque bolts in a criss cross pattern in 3 steps to 27 34 ft lbs 36 50 46 Nm Front Cover Bolt Torque...

Page 227: ... on the end of the shaft Keyed Spline Detent Star 27 Install the detent pawl and spring Install a new o ring onto the shift shaft after the detent pawl is assembled to the shaft Place a small amount of grease on the small O ring on the shift shaft and on the detent star Grease the o ring on the end of the shift drum 28 Install the park lockout assembly Torque park lockout to 12 14 ft lbs 16 19 Nm ...

Page 228: ...llcrank nut to 12 18 ft lbs 16 24 Nm Bellcrank Nut Torque 12 18 ft lbs 16 24 Nm 33 Install the shift switch Install the retaining clip Hook up the switch harness and reconnect the lockout plunger spring NOTE Rotate the bellcrank to line the flat side of the switch up to the flat side of the shaft 34 Install transmission and add Polaris AGL Gearcase Lubricant PN 2873602 in the recommended amount Re...

Page 229: ...nt Pad Installation 9 9 9 10 Brake Burnishing 9 10 Front Disc Inspection 9 10 Front Disc Removal Replacement 9 10 9 11 Front Caliper Removal 9 11 Front Caliper Disassembly 9 11 9 12 Front Caliper Inspection 9 12 Front Caliper Reassembly 9 13 Front Caliper Installation 9 13 9 14 Front Caliper Exploded View 9 15 Rear Pad Removal 9 16 Rear Pad Installation 9 17 Rear Caliper Removal Inspection 9 18 Re...

Page 230: ...ance 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 if equipped 15 0 21 Brake Line Pipe Fittings if...

Page 231: ...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 unobstructed G Test for brake drag after any brake system serv...

Page 232: ...ster cylinder Move able Brake Pad G Typical Hydraulic Brake System The Polaris disc brake system consists of the following components or assemblies brake lever master cylinder hydraulic hose brake calipers slave cylinder brake pads and brake discs which are secured to the drive line When the hand activated brake lever A is applied it contacts piston B within the master cylinder As the master cylin...

Page 233: ... single piston design The caliper pistons are T shaped which allows both hand and foot brake to use the same caliper piston but remain separated by seals The hand brake system applies hydraulic pressure to both front calipers and only the outer diameter of the rear caliper pistons The auxiliary foot brake applies pressure to the inner portion of the rear caliper pistons Because the hand and foot b...

Page 234: ...ion 1 on the previous page 7 Slowly pump brake lever D until pressure builds and holds 8 While maintaining lever pressure open bleeder screw Close bleeder screw and release brake lever NOTE Do not release lever before bleeder screw is tight or air may be drawn into caliper Bleeder Screw Torque 25 30 in lbs 2 80 3 40 Nm 9 Repeat procedure until clean fluid appears in bleeder hose and all air has be...

Page 235: ...ome in contact with finished surfaces 3 Remove master cylinder from handlebars 4 Hold brake upright and continue to remove master cylinder Cover brake line to avoid spillage MASTER CYLINDER INSTALLATION Notice When replacing the brake master cylinder assembly or master cylinder parts use the correct parts There are different brake master cylinders for the different Polaris ATV models Refer to your...

Page 236: ...necessary FRONT PAD REMOVAL 1 Elevate and support front of machine CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 2 Remove the front wheel Loosen pad adjuster screw 2 3 turns 3 Remove caliper mounting bolts 4 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid ...

Page 237: ...ss mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other Be sure pads and disc are free of dirt or grease 3 Install caliper on hub strut and torque mounting bolts 18 ft lbs 25 Nm Front Caliper Mounting Bolts Torque 18 ft lbs 25Nm 4 Slowly pump the brake lever until pressure has been built up Maintain at least 1 2 12 7 mm of brake fluid in ...

Page 238: ...he brake disc for nicks scratches or damage 2 Measure the disc thickness at eight different points around the pad contact surface using a 0 1 micrometer Replace disc if worn beyond service limit Brake Disc Thickness Service Limit 140 3 556 mm New 150 164 3 810 4 166 mm Brake Disc Thickness Variance Service Limit 002 051 mm difference between measurements 3 Mount dial indicator as shown to measure ...

Page 239: ...AUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 1 Remove brake pads See Page 9 9 9 10 2 Using a line wrench loosen and remove brake line to caliper Place a container under caliper to catch fluid draining from brake line 3 Remove brake caliper and drain fluid into container Do not reuse brake fluid FRONT CALIPER DISASSEMBLY 1 ...

Page 240: ... caliper body for nicks scratches or wear Measure bore size and compare tospecifications Replace if damage is evident or if worn beyond service limit Front Caliper Piston Bore I D Std 1 191 1 192 30 25 30 28 mm Service 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 ou...

Page 241: ...mium All Season Grease PN 2871423 4 Compress the mounting bracket and make sure the dust seals are fully seated Install the pads as shown on Page 9 10 Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease FRONT CALIPER INSTALLATION 1 Install caliper on hub strut and torque mounting bolts 18 ft lbs 25 Nm Front Caliper Mounting Bolt Torque 18 ft lbs 2...

Page 242: ...r screw and turn until stationary pad contacts disc then back off 1 2 turn 4 Follow brake bleeding procedure outlined on Pages 9 5 9 6 5 Install wheels and torque wheel nuts to specification Front Wheel Nut Torque 20 ft lbs 27 Nm NOTES ...

Page 243: ...PONENT 3 3 3 35 60 IN LBS 4 6 5 NM BRAKE BURNISHING PROCEDURE It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Allow pads and disc to cool suffi ciently during the procedure Do not allow pads or disc to become hot or warpage ma...

Page 244: ...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 clip from the slide bolt Clip 5 Remove a slide bolt with a hex wrench 6 Remove the brake pads from the caliper Remove Brake Pads 7 Clean the caliper with brake cleaner or alcohol 8 Measure the thickness of the pad ma...

Page 245: ...que the mounting bolts Torque Mounting Bolts Rear Brake Caliper Torque 18 ft lbs 25 Nm 5 Slowly pump the brake lever until pressure has been built up Maintain at least 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the master cylinder 6 It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise S...

Page 246: ... 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 and O rings and replace if necessary Bushing O ring 9 Inspect...

Page 247: ... 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 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 pin retaining ring Torque the slide pins to 30 35 ft lbs 41 48 Nm Caliper Slide Pin Torque...

Page 248: ...luid leaks and firm brakes Make sure the brake is not dragging when lever 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 s...

Page 249: ...e 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 If the rear brake line is the pipe fit style torq...

Page 250: ...inated G Caliper disc misaligned G Caliper dirty or damaged G Brake line damaged or lining ruptured G Worn disc and or friction pads G Incorrectly adjusted lever G Incorrectly adjusted stationary pad G Worn or damaged master cylinder or components G Improper clearance between lever and switch Lever Vibration G Disc damaged G Disc worn runout or thickness variance exceeds service limit Caliper Over...

Page 251: ...8 Ignition System Testing Flow Chart 10 19 Ignition System Troubleshooting 10 20 CDI Output Tests 10 20 Charging System Testing 10 20 10 22 Battery Identification 10 23 Conventional Battery Activation Service 10 23 10 26 Low Maint Battery Activation Service 10 26 10 29 Head Light Brake Light Lamp Service 10 29 10 32 Fuel Sender Service 10 33 Hand Thumb Warmer Switches 10 33 10 34 Winch Wiring Basi...

Page 252: ... plug Check Plug NOTE The ignition timing marks are stamped on the outside of the flywheel Ignition timing must be inspected with the engine at room temperature 68 F 20 C 2 With the transmission in neutral start the engine and open throttle until engine is at 5000 200 RPM 3 Direct the timing light at the ignition timing check hole and check the ignition timing NOTE Do not allow the engine to warm ...

Page 253: ...IMING DEGREES B T D C MAXIMUM ADVANCE POINT 0 1000 2500 3000 3500 4000 4500 5000 5500 6000 Typical Ignition Timing Curve Actual advance point may vary by several hundred RPM above or below 5000 Use the point of maximum advance when checking ignition timing TRIGGER COIL GAP Measure trigger coil gap with a feeler gauge The gap should be 022 028 inch 56 71 mm Measure Trigger Coil Gap Trigger Coil Gap...

Page 254: ...e Red White Blue Brown Red Green White Purple Orange Red NOTE Also see INSTRUMENT CLUSTER TROUBLESHOOTING for gear switch re sistance INSTRUMENT CLUSTER OVERVIEW C Rider Information Center A Speedo Needle also flashes during warning condition Ill 1 EARLY 2004 LATE 2004 A Speedo Needle also flashes during warning condition B Speedometer in MPH KPH C Rider Information Center B Speedometer in MPH KPH...

Page 255: ...in humidity temperature and elevation Trip meter records the miles traveled by the ATV if reset before each trip or total miles to 999 To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider InformationCenter the trip meter display contains a decimal point but the odometer displays without a decimal point Hour...

Page 256: ... and the gauge is designed to survive such an event NOTE If the gauge will not indicate what gear it is in and will not allow AWD operation AWD can still be enabled by holding in the mode override button To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Set the park brake and shift the transmission to neutral 3 Hold the mode reverse override button as you turn the key s...

Page 257: ...ours of actual engine operation are subtracted from the set hours until 0 is reached When the counter reaches 0 the wrench icon will flash quickly for 10 seconds each time the vehicle is started as a reminder that the periodic maintenance is due Set at 50 hrs from Factory SETTING A NEW SERVICE INTERVAL Setting Service Interval After Countdown zero 1 While in the service interval mode press and hol...

Page 258: ...s in the Rider Information Center 2 Wait 5 seconds and then press the mode button in until the wrench icon flashes Press the mode button again to set the desired service increment Release the button and wait for the wrench icon to stop flashing The new service interval is now set Screen 6 Miles Kilometers toggle The display in the trip meter and odometer can be changed to display either kilometers...

Page 259: ... the instrument cluster This will help the instrument cluster slide into the pod assembly more easily 2 Be sure the rubber grommet inside the pod is fully installed and that the indexing key is in the headlight pod keyway Align Index Points 3 Hold the pod assembly securely and insert the instrument cluster into the pod assembly Twist the instrument cluster gently in a clockwise motion to properly ...

Page 260: ...AVE HEADLIGHT POD DISASSEMBLED SHIFT TO LOW OR HIGH LEAVE AWD ON Y REMOVE THROTTLE CONTROL COVER CHECK FOR CONTINUITY ACROSS AWD SWITCH Y REPLACE INSTRUMENT CLUSTER PROCEED TO IF AWD PROBLEM PERSISTS MECHANICAL AWD COMPONENTS N WIRING PROBLEM N TURN KEY SWITCH OFF TURN KEY SWITCH ON TURN KEY SWITCH OFF LEAVE KEY SWITCH OFF DISCONNECT THROTTLE CONTROL HARNESS Note Reversing polarity when connecting...

Page 261: ...INTO REVERSE IS REVERSE INDICA TOR ON Y VEHICLE EXCEEDS 7 9 MPH IN REVERSE TEST TRANSMISSION SWITCH SHIFT MODULE AND WIRING N REPLACE SPEEDO JUMPER TO PIN 4 BLACK TO PIN 8 BROWN DOES ENGINE STOP INSPECT WIRING AND CDI N Y H Measure Harness Side H NOTE Mode Override button provides a grounding sink ing input to the instrument cluster TURN KEY SWITCH OFF RESTART ATV START HERE 16 Pin Connector 1 Red...

Page 262: ...INSPECT HUB COIL WIRING FOR SHORT CIRCUITS TO GROUND DISCONNECT CONNECTOR MEASURE BETWEEN HUB COIL BROWN WHT GROUND REPAIR HUB COIL WIRING REPLACE SPEEDOMETER NO PROBLEM N N Y Y Y NOTE IF THE AWD ICON DOES NOT COME ON OR IF 12 VDC IS NOT REGISTERING AND AWD IS ENGAGING ABOVE 3100 RPM IT MAY BE A MECHANICAL PROBLEM TEST 4 NO AWD HUB SAFETY LIMIT N START HERE TURN KEY SWITCH OFF RESTART ATV Y 16 Pin...

Page 263: ...ds 3 Elevate front right side of vehicle until tire is off the ground 4 Slowly turn right front wheel while observing the test light 5 If light flashes sensor is O K Be sure connections are good and 9 volt battery is in good condition 12V Static Timing Light Harness LED Brn To Sensor Red To Sensor White To Sensor Black 680Ω Wht Blk START HERE PN 2871745 Y N CLUSTER NOTE OVERRIDE SWITCH PLAYS NO RO...

Page 264: ... OPERATION REFER TO TEST ON PAGE 10 33 IS IT OK Y WIRES FIXED BUT PROBLEM REMAINS REPLACE SENDER N TEST 8 SHIFT INDICATOR NOT WORKING TRANSMISSION SWITCH Operation The Instrument cluster sends a signal through the White wire to the resistor module This signal completes it s path on the Brown Red wire through the transmission switch Depending on the transmission switch position the Instrument clust...

Page 265: ...n the cooling system Be sure cooling system is full and purged of air Refer to Maintenance Chapter 2 for cooling system information FAN CONTROL SWITCH BYPASS TEST 1 Disconnect harness from fan switch on radiator 2 Place a jumper wire between the Red Blk and Org Blk wires in the connector 3 With the ATV in Park and with the parking brake on turn the ignition key and engine stop switch ON The fan sh...

Page 266: ... cable tension The contacts are open during normal operation regardless of throttle lever position In the event of a mechanical problem in the throttle mechanism cable tension is lost the switch contacts close connecting the CDI black wire to ground which prevents ignition spark This is the same as turning the key or engine stop switch OFF Test the ETC switch at the harness connector NOTE Adjust t...

Page 267: ... DC ignition are G Stronger more consistent spark at low rpm for better performance G Easier starts G Simpler component design for ease trouble shooting and maintenance 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 curr...

Page 268: ...fore to 2 20 03 If Built After 2 20 03 Ignition Controller Ignition Controller Ignition Coil NOTE CDI boxes may look the same but have different internal cir cuitry Be sure to always use the correct CDI box part number LR302 If Built Before 2 20 03 If Built After 2 20 03 Magnetic Switch Stator Assembly Voltage Regulator Flywheel ...

Page 269: ...between engine and coil mount using an ohmmeter The coil mount should have good continuity to ground on the engine 0 2 Ω 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 Tension Wire to High Ten sion Wire Cap installed 11 300Ω Cap removed 6300Ω Are these values wit...

Page 270: ... w Digital Voltmeter 20 DCV CDI CRANKING OUTPUT TEST WITH PEAK READING VOLTMETER The following peak voltage tests will measure the amount of output directly from each component A peak reading voltmeter must be used to perform the tests A variety of peak reading adaptors are commercially available for use with the Fluke t 77 Digital Multimeter PV 43568 and other digital VOMs which will allow peak v...

Page 271: ...on the ammeter should read negative amps battery discharge Reverse meter leads if a positive reading is indicated 4 Shift transmission into neutral and start the engine With the engine running at idle disconnect the negative cable from the battery post without disturbing the meter leads Observe meter readings 5 Increase engine RPM while observing ammeter and tachometer 6 Note RPM at which the batt...

Page 272: ... terminal on harness side of voltage regulator 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 wire harness replace the volt age regulator No Y...

Page 273: ...away Ventilate when charging or using in an enclosed space Always shield eyes when working near batter ies KEEP OUT OF REACH OF CHILDREN WARNING The gases given off by a battery are explosive Any spark or open flame near a battery can cause an explosion which will spray battery acid on anyone close to it Should there be contact with battery acid wash the affected area with large quantities of cool...

Page 274: ...erfill the battery Refill using only distilled water Tap water contains minerals which are harmful to a battery Do not 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 tables...

Page 275: ...cront Type 100 Charged 75 Charged 50 Charged 25 Charged 0 Charged 12 60V 12 40V 12 10V 11 90V less than 11 80V 12 70V 12 50V 12 20V 12 0V less than 11 9V SPECIFIC GRAVITY State of charge Conventional lead acid YuMicront Type 100 Charged 75 Charged 50 Charged 25 Charged 0 Charged 1 265 1 210 1 160 1 120 less than 1 100 1 275 1 225 1 175 1 135 less than 1 115 At 80_F NOTE Subtract 01 from the specif...

Page 276: ...ific 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 explosion connect positive red cable first and negative black cable last 5 After connecting the battery cables install the cover on th...

Page 277: ...aintenance battery Doing so will damage the case and shorten the life of the battery Refer to the Battery Maintenance Video PN 9917987 for proper instruction on servicing Low Maintenance batteries To service a Low Maintenance battery 1 Remove battery from the vehicle 2 Test battery with a voltage meter or load tester to determine battery condition This will determine the length of time required to...

Page 278: ...y should be checked first Following are three tests which can easily be made on a battery to determine its condition OCV Test Specific Gravity Test and Load Test LOW MAINTENANCE BATTERY OCV OPEN CIRCUIT VOLTAGE TEST Battery voltage should be checked with a digital multitester Readings of 12 8 volts or less require further battery testing and charging See charts and Load Test NOTE Lead acid batteri...

Page 279: ...oper level G Charge at a rate no greater than 1 10 of the battery s amp hr capacity until the electrolyte s specific gravity reaches 1 270 or greater G Store the battery either in the machine with the cables disconnected or store in a cool place NOTE Stored batteries lose their charge at the rate of 1 per day Recharge to full capacity every 30 to 60 days during a non use period If the battery is s...

Page 280: ...20 3 cm in 25 from the center of the low beam lamp 5 Adjust beam to desired position HIGH BEAM HEADLIGHT BULB REPLACEMENT CAUTION Do not service while headlight is hot Serious burns may result Protect lamp during install Remove 3 screws 1 Remove three Phillips screws on the headlight pod 2 Lift pod cover up 3 Disconnect instrument cluster harness 4 Remove rubber shield from headlamp housing 5 Push...

Page 281: ...e adjusting knob LOWER HEADLAMP REMOVAL INSTALLATION Turn Harness Assembly Lower Headlamps Loosen Tighten Headlamp Adjustments 1 Turn the back of the headlight harness in a counter clockwise direction to loosen 2 Pull the harness assembly out from the headlight assembly 3 Remove the headlamp and replace with a new headlamp 4 Install the new headlamp and harness assembly into the headlight assembly...

Page 282: ... cover Probe the headlamp plug wires Brown and Yellow at back of connector Turn headlight on Headlamp Plug Wires Brown Yellow BRAKE LIGHT SWITCH 1 Remove the front cover Brake Lamp Switch Brake Switch Locations Un der front cover close to CDI box 2 Disconnect wire harness from switch 3 Connect an ohmmeter across switch contacts Reading should be infinite 4 Apply brake at handlebar lever and check ...

Page 283: ...eplace the fuel sender HAND THUMB WARMER SWITCHES SPORTSMAN HUNTER EDITION Button Removal Installation 1 Disconnect the negative battery cable 2 Remove the top of the headlight pod 3 screws Hand Switch Thumb Switch 3 Disconnect the harness from the backside of the switch 4 On the inside of the pod squeeze the button tabs to together and push the button out of the top of the headlight pod 5 To inst...

Page 284: ...wn Route the wire between the switch mounting bracket and the master cylinder clamp next to the front spacer 3 Reposition the spacers between the mini rocker switch mounting bracket and the master cylinder clamp and reinstall the bolts to secure the switch Torque the rear bolt first then torque the front bolt Torque to 25 in lbs 3 N m 4 Secure the cables to the handlebars as needed with the new pa...

Page 285: ...SMAN HUNTER EDITION Red 20 ga Green Black Black 6 ga Cable Boot Blue Cable 6 ga Yellow Cable 6 ga 12V Contact Red Cable 6 ga Rocker Switch IN OUT Fairlead Roller Mounting Hardware Strap Clevis Battery Winch Contactor Located under left rear fender ...

Page 286: ... TEST The Voltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection will appear as a high voltage reading Voltage shown on the meter when testing connections should not exceed 1 VDC per connection or component To perform the test place the meter on DC volts and place the meter leads...

Page 287: ...e infinite OL Inspect insulation on brush wires for damage and repair or replace as necessary 3 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate Slide brush end frame off end of starter NOTE The electrical input post must stay with the field coil housing 4 Measure resistance between ground brush and brush plate Resistance should be 3 ohms or less Ins...

Page 288: ...ropriate solvent If the commutator needs cleaning use only electrical contact cleaner ARMATURE TESTING 1 Remove armature from starter casing Note order of shims on drive end for reassembly 2 Inspect surface of commutator Replace if excessively worn or damaged 3 Using a digital multitester measure the resistance between each of the commutator segments The reading should be 3 ohms or less 4 Measure ...

Page 289: ...hile holding brush springs away from brushes push brushes back and hold in place 4 Slide armature into field magnet housing Release brushes 5 Lightly grease the drive roller bearing and reinstall drive end frame on armature Inspect seal for wear or damage Replace drive end cap if necessary Roller Bearing Seal 6 Be sure wire insulation is in place around positive brush wire and pushed completely in...

Page 290: ...w garter spring Gear Assembly Thrust Washer Bushing Spring Thrust Washer Retaining Ring Stopper Cover Polaris Premium Starter Drive Grease PN 2871460 1 Screw the overrun clutch out to the engaged position on the pinion shaft assembly Use a small piece of wire with the end bent in a hook and pick the old spring out of its channel Slide it off the end of the shaft Slide the new spring over the overr...

Page 291: ...scription Ref 1 Rubber Ring 10 Gear Assembly 2 Brush Spring 11 Though Bolt 3 Thrust Washer 12 Cover 4 Gear Assembly 13 Stopper 5 O Ring 14 Snap Ring 6 Brush Complete 15 Washer 7 O Ring 16 Flange Bolt 8 Thrust Washer 17 Thrust Washer 9 Shaft Complete 18 Flange Bushing Do not reuse Replace with new parts ...

Page 292: ...solenoid Connect the tester black lead to the battery positive 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...

Page 293: ...ELECTRICAL 10 43 WIRING DIAGRAM HAND AND THUMB WARMERS WINCH HUNTER EDITION ...

Page 294: ...ELECTRICAL 10 44 NOTES ...

Page 295: ...ELECTRICAL WIRING DIAGRAM EARLY 2004 SPORTSMAN 600 700 BUILT BEFORE FEB 20 2003 Built Before February 20 2003 ...

Page 296: ...ELECTRICAL WIRING DIAGRAM EARLY 2004 SPORTSMAN 600 700 BUILT BEFORE FEB 20 2003 Built Before February 20 2003 NOTES NOTES ...

Page 297: ...ELECTRICAL WIRING DIAGRAM LATE 2004 SPORTSMAN 600 700 BUILT AFTER FEB 20 2003 Built After February 20 2003 ...

Page 298: ...ELECTRICAL WIRING DIAGRAM LATE 2004 SPORTSMAN 600 700 BUILT AFTER FEB 20 2003 Built After February 20 2003 NOTES ...

Page 299: ...ELECTRICAL WIRING DIAGRAM LATE 2004 SPORTSMAN 600 700 MODELS WITH FUEL GAUGE Models Equipped with Fuel Gauge ...

Page 300: ...ELECTRICAL WIRING DIAGRAM LATE 2004 SPORTSMAN 600 700 MODELS WITH FUEL GAUGE NOTES ...

Page 301: ...ELECTRICAL WIRING DIAGRAM 2004 SPORTSMAN 600 700 HUNTER EDT HAND WARM WINCH ...

Page 302: ... Identification 9 3 Brake Master Cylinder Exploded View Rear 9 21 Brake Noise 9 3 Brake Pad Assembly Front 9 9 Brake Pad Inspection 2 28 Brake Pad Installation Rear 9 17 Brake Pad Removal Front 9 8 Brake Pad Removal Rear 9 16 Brake System Inspection 2 28 Brake System Operation 9 4 Brake Auxiliary Hydraulic 2 29 Brake Auxiliary Testing 2 28 Brakelight Lamp Replacement 10 31 Breather Filter Maintena...

Page 303: ...S Drive Clutch Bushing Service Early 2004 6 21 EBS Drive Clutch Bushing Service Late 2004 6 29 EBS Drive Clutch Inspection 6 17 EBS Driven Clutch Bushing Service Early 2004 6 22 EBS Driven Clutch Bushing Service Late 2004 6 30 EBS Driven Clutch Disassembly Early 2004 6 18 EBS Driven Clutch Disassembly Late 2004 6 24 6 28 EBS Exploded View 6 3 EBS Moveable Sheave Bushing Inspection 6 18 EBS One Way...

Page 304: ...embly 5 13 Front Strut Ball Joint Replacement 5 14 Fuel Filter Maintenance 2 16 Fuel Pump Service 4 12 Fuel Sender Removal Late 2004 4 13 Fuel Sender Test 10 33 Fuel System 2 15 Fuel Tank Assembly Exploded View 4 3 G Gear Circuit Readings Instrument Cluster 10 7 Gear Position Switch Test 10 4 Gear Shift Selector Removal 8 6 Gearcase Assembly Rear 7 35 Gearcase Coil Resistance Front 7 11 7 18 Gearc...

Page 305: ...ush Rod Inspection 3 19 PVT Assembly 6 8 PVT Disassembly 6 7 PVT Drying 2 22 6 5 PVT Maintenance 6 5 PVT Operation 6 4 PVT Overheating 6 6 PVT System Sealing Ducting Components 6 2 PVT Troubleshooting 6 33 6 34 R Radiator Coolant Level Inspection 2 20 Radiator Front Cover Removal 2 20 Radiator Maintenance 2 19 Rear Caliper Assembly 9 19 Rear Drive Shaft Installation 7 30 Rear Drive Shaft Removal 7...

Page 306: ...Tire Pressure 2 30 Tire Tread Depth 2 31 Toe Alignment 2 26 2 27 Torque Patterns Engine 3 9 Transmission Disassembly 8 8 Transmission I D Location 1 2 Transmission Information 8 6 Transmission Installation 8 7 Transmission Reassembly 8 13 Transmission Removal 8 6 Transmission Exploded View Early 2004 8 2 8 3 Transmission Exploded View Late 2004 8 4 8 5 Trigger Coil Gap 10 3 Troubleshooting Brakes ...

Page 307: ...Winch Switch Installation 10 34 Winch Wiring 10 35 Wiring Diagram Hand Thumb Warmer Winch 10 43 ...

Page 308: ...PN 9918803 Printed in USA ...