Polaris 07, 700, 800 Service Manual

2007 SPORTSMAN 700/800/800 X2 EFI

SERVICE MANUAL

FOREWORD

This service manual is designed prim arily for use by ce rtified Polaris Mas ter Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly . T echnicians should read the text and be familiar with service procedures before starting the work. Certa in procedur es require the use o f special tools. Use o nly the proper to ols as specified.

Comments or suggestions about this manual may be d irected to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.

2007 Sportsman 700/800/ 800 X2 EFI Service Manual PN 9920378

© Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication . Due to constant improvements in the design and quality of production component s, some minor discrep ancies may result between t he actual vehicle and the inf ormation presented in t his publication. Depictions and/or procedures in this publ ication are intended f or reference use only. No liability can be accepted for omission s or inaccuracies. Any r eprinting

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

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS

Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle.

CAUTION

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE:

NOTE provides key information by clarifying instructions.

IMPORTANT:

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or

by contacting the nearest Polaris dealer.

GENERAL

MAINTENENCE

ENGINE

FUEL SYSTEM

BODY / SUSPENSION

CLUTCH

TRANSMISSION

FINAL DRIVE

BRAKES

ELECTRICAL

INTERNATIONAL

NOTES

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

ENGINE DESIGNATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

TRANSMISSION I.D. LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

ENGINE AND MACHINE SERIAL NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

SPORTSMAN ‘DELUXE’ AND ‘STANDARD’ MODEL COMPONENT COMPARISON . .1.3

2007 SPORTSMAN 700 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

MODEL NUMBER: A07MH68AX, A07MH68AY, A07MH68AZ, . . . . . . . . . . . . . . . . . . .1.4

2007 SPORTSMAN 800 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

MODEL NUMBER: A07MH76A, A07MN76A, A07MH76F. . . . . . . . . . . . . . . . . . . . . . . .1.6

2007 SPORTSMAN X2 800 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

MODEL NUMBER: A07TH76A, A07TN76A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8

MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11

SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14

1.1

GENERAL INFORMATION

MODEL INFORMATION

Model Number

The machine model number must be used with any correspondence regarding warranty or service.

A07 MH76 AU

Engine Designation Numbers

EH068OLE - T win Cylinder, Liquid Cooled,4 Stroke, Electric Start

EH076OLE - Twin Cylinder, Liquid Cooled,4 Stroke, Electric Start

VIN Identification

Engine and Machine Serial Numbers

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 the crankcase beneath the cylinder coolant elbow.

TRANSMISSION I.D. LOCATION

Sportsman X2

Sportsman

The machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the lower left side of the frame tube (B).

1.2

PUBLICATIONS

GENERAL INFORMATION

Table 1-1: Publications

Year Model Model No.

2007 Sportsman 700 EFI

2007 Sportsman 800 EFI

2007 Sportsman X2 800 EFI

2007

Sportsman 800 EFI

International

A07MH68A A07MN68A

A07MH76A A07MN76A

A07TH76A A07TN76A

A07MH76F 9920374 9920379

Owner's

Manual PN

9920374 9920375

9920374 9920379

9920632 9920903

Manual PN

PAINT CODES

Table 1-2: Paint Codes

PAINTED PART

Sportsman 700/800 EFI Frame Black 9440 P-067

COLOR

DESCRIPTION

DITZLER NUMBER

REPLACEMENT KEYS

Parts

POLARIS NUMBER

Replacement keys can be made from the original key. To identify which series t he key is, ta ke the first tw o digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, ignition switch replacement is required.

Table 1-3: Key Numbers

Series # Part Number

20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278

Key Boot

PN 5433534

1.3

GENERAL INFORMATION

Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison

For Model Year 2007, a Sportsman ‘Deluxe’ and ‘Standard’ model were offered. Use the following table as a guide:

SPORTSMAN ‘DELUXE’ MODEL Item Location SPORTSMAN ‘ST ANDARD’ MODEL

Winch 1 No Winch

PXT Tires 2 Titan Tires

PVT w/EBS 3 Non-EBS (800 X2 excluded)

Rear Work Lights 4 No Work Lights

Front Drive w/ Active Descent Control (ADC) 5 No Active Descent Control (ADC)

Speed Sensor Wiring for ADC 6 No Sensor Wiring Change

Rear Rack Extension 7 No Rack Extension

Cast Aluminum Wheels 8 Steel Wheels

Dual Exhaust (800 EFI only) 9 Single Exhaust (800 EFI and X2)

Wire Harness w/ Active Descent Control (ADC) 10 Standard Wire Harness

ECU w/ Active Descent Control (ADC) 10 Standard ECU

Deluxe Model Pictured

1.4

GENERAL INFORMATION

Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison

For Model Year 2007, an X2 ‘Deluxe’ and ‘Standard’ model were offered. Use the following table as a guide:

X2 ‘DELUXE’ MODEL Item Location X2 ‘STANDARD’ MODEL

Winch 1 No Winch

Rear Work Lights 2 No Work Lights

Front Drive w/ Active Descent Control (ADC) 3 No Active Descent Control (ADC)

Cast Aluminum Wheels 4 Steel Wheels

Standard Model Pictured

1.5

GENERAL INFORMATION

2007 SPORTSMAN 700 EFI

MODEL NUMBER: A07MH68AX, AY, AZ

(Standard Model Only)

ENGINE MODEL: EH068OLE

Table 1-4: Sportsman 700 EFI

General Specifications

Category Dimension / Capacity Length 83 in./205.74 cm Width 48 in./116.8 cm Height 48 in./119.4 cm

Seat Height

Wheel Base 50.75 in./128.9 cm Dry Weight 770 lbs./326.6 kg Gross Vehicle Weight 1220 lbs. / 553 kg Front Rack Capacity 100 lbs./45.4 kg Rear Rack Capacity 200 lbs./90.7 kg Towing Capacity 1500 lbs./680 kg Body Style Spirit Hitch Tongue Capacity 150 lbs./68 kg

34 in./86.4 cm

1.6

GENERAL INFORMATION

Table 1-5: 2007 700 EFI Specifications

ENGINE

Platform Polaris Twin Cylinder Engine Model Number EH068OLE025 Engine Displacement 683cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 68 mm Compression Ratio 9.78:1 Compression Pressure 150-170 psi Engine Idle Speed

Engine Max Operating Rpm Cooling System / Capacity L i qu id - 3.2 qt / 3 ltr

Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Wet Sump Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 ltr Exhaust System Single Pipe USFS Approved

Fuel System

Fuel System Electronic Fuel Injection (EFI) Fuel Pump (in tank assembly) 25L per hr. at 39 psi Fuel Filter(s) 30 micron in Tank -

Fuel Injector(s) Bosch EFI Controller Bosch MSE 1.1B Fuel Capacity / Requirement 4.13 gal US / 15.6 liters

87 Octane (minimum) or 89 Oxygenated

Electrical

Alternator Output 500 w @ 6000 RPM Lights : Pod 50 watts Grill Two x 27 watts Brake 8.26 watts Tail 26.9 watts Ignition System DC/CDI Ignition Ignition Timing

Spark plug / Gap RC7YC / .035 in. / 0.9 mm Battery / Amp Hr Lead Acid / 30 Amp Hr. Circuit Breakers Fan 20 amp / Harness 20 amp /

Starting Electric Instrument Cluster Analog Speedo w/ LCD

1150

 100 RPM

6500 Rpm

10 micron in-line (replaceable)

° BTDC @ 1200 RPM

ECU 15 amp / Inst. Cluster /

Voltage Regulator 6 amp

 200 Rpm

(unserviceable)

Table 1-6: 2007 700 EFI Specifications

Drivetrain

Transmission Type Drumshift - H/L/N/Rev/Park

Transmission Capacity 15 oz. / 445 ml Front Gearcase Capacity- CH 8.97 / 265 ml Rear Gearcase Capacity 5 oz. / 150 ml Gear Ratio : Low

Rev High Front Drive Rear Drive

Clutch Type PVT Non-EBS Belt 3211113

7.49:1

5.11:1

2.70:1

3.82:1

3.10:1

Steering / Suspension

Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 21 cm Rear Suspension / Shock Progressive Rate Independent -

Coil - over shock Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11.25 in. / 28.6 cm Shock Preload Adjustment

Front / Rear Turning Radius 76 in. / 193 cm unlocked Toe Out 0-1/16 in / .0 - .159 mm

Front -Non Adjustable.

Rear - Ratchet Style- Std.

Wheels / Brakes

Wheel Size / Pattern - Front Steel 24 x 8-12 / 4-156 Wheel Size / Pattern - Rear Steel 24 x 11-12 / 4-156 Front Tire Size 24 x 8-12 Rear Tire Size 24 x 11-12 Recommended Air Pressure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Dual Hydraulic Disc

Table 1-7: 2007 700 EFI Clutching

Altitude

Meters

0-1800

(0-6000)

1800-3700

(6000-12000)

(Feet)

A07MH68

(STANDARD)

A07MH68

(STANDARD)

Shift

Weight

20-58

5631216

20-56

5631215

Drive Clutch

Spring

Grn/Blu

7041157

Grn/Blu

7041157

Driven Clutch Type

(Non-Adjustable)

STD - 1322514

1.7

GENERAL INFORMATION

2007 SPORTSMAN 800 EFI

MODEL NUMBER: A07MH76AX, AY, AZ / A07MN76AQ, AF / A07MH76FA

(Standard) (Deluxe) (International)

ENGINE MODEL: EH076OLE

Table 1-8: Sportsman 800 EFI

General Specifications

Category Dimension / Capacity Length 83 in./205.74 cm Width 48 in./116.8 cm Height 48 in./119.4 cm

Seat Height

34 in./86.4 cm

1.8

Deluxe Model Shown

GENERAL INFORMATION

Table 1-9: 2007 800 EFI Specifications

ENGINE

Platform Polaris Twin Cylinder Engine Model Number EH076OLE013 Engine Displacement 760cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 76.5 mm Compression Ratio 10:1 Compression Pressure 150-200 psi Engine Idle Speed

Engine Max Operating Rpm Cooling System / Capacity Liquid - 3.2 qt/ 3 ltr.

Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Wet Sump Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 liters Exhaust System Dual Pipe / Silencer (Deluxe)

Fuel System

Fuel System Electronic Fuel Injection Fuel Pump 25L per hour at 39 PSI Fuel Filter(s) 30 micron in Tank -

Fuel Injector(s) Bosch EFI Controller Bosch MSE 1.1B Fuel Capacity / Requirement 4.13 gal US / 15.6 liters

87 Octane (minimum) or 89 Oxygenated

Electrical

Alternator Output 500 w @ 6000 RPM Lights : Pod 30 watts Grill Two x 27 watts Brake 8.26 watts Tail 26.9 watts

Worklights

(Deluxe Only) Ignition System DC/CDI Ignition Ignition Timing Spark plug / Gap RC7YC/ .035 in. / 0.9 mm Battery / Amp Hr Lead Acid / 30 Amp Hr Circuit Breakers Fan 20 amp / Harness 20 amp /

Starting Electric Instrument Cluster Analog Speedo w/ LCD

1150

 100 RPM

6500 Rpm

Single Pipe / Silencer (Standard)

10 micron in Line (replaceable)

°BTDC @ 1200 RPM

ECU 15 amp / Inst. Cluster /

Voltage Regulator 6 amp

 200 Rpm

(unserviceable)

2 x 13 watts

Table 1-10: 2007 800 EFI Specifications

Drivetrain

Transmission Type Drumshift - H/L/N/Rev/Park

Transmission Capacity 15 oz. / 450ml Front Gearcase Capacity- CH 8.97 / 265 ml Front Gearcase Capacity- ADC 9.3 / 275 ml Rear Gearcase Capacity 5 oz. / 150ml Gear Ratio : Low

Rev High Front Drive Rear Drive

Clutch Type PVT (Std) EBS (Deluxe) Belt 3211113

7.49:1

5.11:1

2.70:1

3.82:1

3.10:1

Steering / Suspension

Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 21 cm Rear Suspension / Shock Progressive Rate Independent -

Coil - over shock Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11.25 in. / 28.6 cm Shock Preload Adjustment

Front / Rear Turning Radius 76 in. / 193 cm Toe Out 0 - 1/16 in / .0 - .159 mm

Front -Non Adjustable.

Rear - Ratchet Style- Std.

Wheels / Brakes

Wheel Size / Pattern - Front 26 x 8 - 12 / 4-156 Wheel Size / Pattern - Rear 26 x 11 - 12 / 4-156 Front Tire Size 26 x 8 - 12 Rear Tire Size 26 x 11 - 12 Recommended Air Pressure Front - 5 psi & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Dual Hydraulic Disc

T able 1-1 1: A07MH76A/A07MN76A Clutching

0-1800

(0-6000)

1800-3700

(6000-12000)

Altitude

Meters

(Feet)

A07MH76

(STANDARD)

A07MN76

(DELUXE)

(INTERNATIONAL)

A07MH76

(STANDARD)

A07MN76

(DELUXE)

(INTERNATIONAL)

Shift

Weight

20-62

5631700

20-62

EBS

20-60

5631698

20-60

EBS

Drive Clutch

Spring

Blu/Red 7043199

Grn/Blu 7041157

EBS

Blu/Red 7043199

Grn/Blu 7041157

w/EBS

Driven Clutch Type

(Non-Adjustable)

STD - 1322514

EBS - 1322550

STD - 1322514

EBS - 1322550

1.9

GENERAL INFORMATION

2007 SPORTSMAN X2 800 EFI

MODEL NUMBER: A07TH76AU, A07TN76AF

(Standard) (Deluxe)

ENGINE MODEL: EH076OLE

Table 1-12: Sportsman X2 800 EFI

General Specifications

Category Dimension / Capacity Length 93 in./236.22 cm Width 48 in./116.8 cm Height 48 in./119.4 cm

Seat Height

Wheel Base 57 in./128.9 cm Dry Weight Standard 839 lbs./380.5 kg

Gross Vehicle Weight 1500 lbs./680.3 kg Front Rack/ Box Capacity 90 lbs./40.8 kg Rear Box Capacity 400 lbs./181.4 kg Towing Capacity 1500 lbs./680 kg Body Style Spirit Hitch Tongue Capacity 150 lbs./68 kg

34 in./86.4 cm

Deluxe 874 lbs./396 kg

1.10

Standard Model Shown

GENERAL INFORMATION

Table 1-13: 2007 800 X2 EFI Specifications

ENGINE

Engine Max Operating Rpm Cooling System / Capacity Liquid - 3.4 qt/ 3.2 ltr.

Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Wet Sump Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 liters Exhaust System Single Pipe / Silencer

Fuel System

Fuel System Electronic Fuel Injection Fuel Pump 25L per hour at 39 PSI Fuel Filter(s) 30 micron in Tank -

Fuel Injector(s) Bosch EFI Controller Bosch MSE 1.1B Fuel Capacity / Requirement 6.0 gal US / 22.7 liters

87 Octane (minimum) or 89 Oxygenated

Electrical

Alternator Output 500 w @ 6000 RPM Lights : Pod 50 watts Grill Two x 37 watts Tail 2 x 26.9 watts Brake 2 x 8.26 watts

Worklights

(Deluxe Only)

Indicator Panel 1 watt Ignition System DC/CDI Ignition Ignition Timing Variable - ECU controlled Spark plug / Gap RC7YC/ .035 in. / 0.9 mm Battery / Amp Hr Lead Acid / 30 Amp Hr Fuses Fan 20 amp / Harness 20 amp /

Starting Electric Instrument Cluster Analog Speedo w/ LCD

1150

 100 RPM

6500 Rpm

10 micron in Tank - (unserviceable)

10 micron in Line (replaceable)

ECU 15 amp / Inst. Cluster /

Voltage Regulator 6 amp

 200 Rpm

(unserviceable)

2 x 13 watts

Table 1-14: 2007 800 X2 EFI Specifications

Drivetrain

Transmission Type Drumshift - H/L/N/Rev/Park

Transmission Capacity 32 oz. / 946.3ml Front Gearcase Capacity- CH 8.97 / 265 ml Front Gearcase Capacity- ADC 9.3 / 275 ml Gear Ratio : Low

Rev High Front Drive

Clutch Type PVT w/ EBS (Standard and Deluxe) Belt 3211113

23.91:1

21.74:1

8.28:1

3.82:1

Steering / Suspension

Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 21 cm Rear Suspension / Shock Progressive Rate Independent -

Coil - over shock Rear Travel 8.75 in. / 22.22 cm Ground Clearance 11.25 in. / 28.6 cm Shock Preload Adjustment

Front / Rear Turning Radius 82 in. / 208.2 cm Toe Out 0 - 1/16 in / .0 - .159 mm

Front -Non Adjustable.

Rear - Ratchet Style- Std.

Wheels / Brakes

Wheel Size / Pattern - Front 25 x 8 - 12 / 4-156 Wheel Size / Pattern - Rear 25 x 11 - 12 / 4-156 Front Tire Size 25 x 8 - 12 Rear Tire Size 25 x 11 - 12 Recommended Air Pressure Front - 5 psi & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Dual Hydraulic Disc

Table 1-15: 2007 800 X2 EFI Clutching

Altitude

Meters

0-1800

(0-6000)

1800-3700

(6000-12000)

(Feet)

A07TH76A

(STANDARD)

A07TN76A

(DELUXE)

A07TH76A

(STANDARD)

A07TN76A

(DELUXE)

Shift

Weight

20-62

EBS

20-58

EBS

Drive Clutch

Spring

Grn/Blu

7041157

w/EBS

Grn/Blu

7041157

w/EBS

Driven Clutch Type

(Non-Adjustable)

EBS - 1322550

1.11

GENERAL INFORMATION

MISC. NUMBERS/CHARTS

Standard Torque Specifications

The following torque specifications are to be used as a general guideline. FOR SPECIFIC TO RQUE V ALUES OF F A STENERS Refer to exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

#10 - 24 . . . . . . . . . . . . . . . . . 27 (3.1) . . . . . . . . . 43 (5.0) . . . . . . . . 60 (6.9)

#10 - 32 . . . . . . . . . . . . . . . . . 31 (3.6) . . . . . . . . . 49 (5.6) . . . . . . . . 68 (7.8)

1/4 - 20 . . . . . . . . . . . . . . . . .5 (7). . . . . . . . . . . . 8 (11). . . . . . . . . . 12 (16)

1/4 - 28 . . . . . . . . . . . . . . . . .6 (8). . . . . . . . . . . . 10 (14). . . . . . . . . 14 (19)

5/16 - 18 . . . . . . . . . . . . . . . . . 11(15). . . . . . . . . . . 17 (23). . . . . . . . . 25 (35)

5/16 - 24 . . . . . . . . . . . . . . . . . 12(16) . . . . . . . . . . 19 (26). . . . . . . . . 29 (40)

3/8 - 16 . . . . . . . . . . . . . . . . . 20(27) . . . . . . . . . . 30 (40). . . . . . . . . 45 (62)

3/8 - 24 . . . . . . . . . . . . . . . . .23(32) . . . . . . . . . . 35 (48). . . . . . . . . 50 (69)

7/16 - 14 . . . . . . . . . . . . . . . . . 30(40) . . . . . . . . . . 50 (69). . . . . . . . . 70 (97)

7/16 - 20 . . . . . . . . . . . . . . . . . 35(48) . . . . . . . . . . 55 (76). . . . . . . . . 80 (110)

1/2 - 13 . . . . . . . . . . . . . . . . .50(69) . . . . . . . . . . 75 (104). . . . . . . . 110 (152)

1/2 - 20 . . . . . . . . . . . . . . . . .55(76) . . . . . . . . . . 90 (124). . . . . . . . 120 (166)

Metric / Torque

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

Torque in. lbs. (Nm)

Torque ft. lbs. (Nm)*

SPECIAL TOOLS

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory , while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, 1-800-328-6657.

1.12

GENERAL INFORMATION

SAE Tap Drill Sizes

Thread Size/ Drill Size Thread Size / Drill Size

#0-80 3/64 1/2-13 27/64 #1-64 53 1/2-20 29/64 #1-72 53 9/16-12 31/64 #2-56 51 9/16-18 33/64 #2-64 50 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 45 3/4-10 21/32 #4-40 43 3/4-16 11/16 #4-48 42 7/8-9 49/64 #5-40 38 7/8-14 13/16 #5-44 37 1-8 7/8 #6-32 36 1-12 59/64 #6-40 33 1 1/8-7 63/64 #8-32 29 1 1/8-12 1 3/64 #8-36 29 1 1/4-7 1 7/64 #10-24 24 1 1/4-12 1 11 /64 #10-32 21 1 1/2-6 1 11/32 #12-24 17 1 1/2-12 1 27 /64 #12-28 4.6mm 1 3/4-5 1 9/16 1/4-20 7 1 3/4-12 1 43/64 1/4-28 3 2-4 1/2 1 25/32 5/16-18 F 2-12 1 59/64 5/16-24 I 2 1/4-4 1/2 2 1/32 3/8-16 O 2 1/2-4 2 1/ 4 3/8-24 Q 2 3/4-4 2 1/ 2 7/16-14 U 3-4 2 3/4 7/16-20 25/64

Metric Tap Drill Sizes

Tap Size Drill Size

3x.50 #39 0.0995 3/32 3x.60 3/32 0.0937 3/32 4x.70 #30 0.1285 1/8 4x.75 1/8 0.125 1/8 5x.80 #19 0.166 11/64 5x.90 #20 0.161 5/32 6x1.00 #9 0.196 13/64 7x1.00 16/64 0.234 15/64 8x1.00 J 0.277 9/32 8x1.25 17/64 0.265 17/64 9x1.00 5/16 0.3125 5/16 9x1.25 5/16 0.3125 5/16 10x1.25 11/32 0.3437 11/32 10x1.50 R 0.339 11/32 11x1.50 3/8 0.375 3/8 12x1.50 13/32 0.406 13/32 12x1.75 13/32 0.406 13/32

Decimal Equivalent

Nearest Fraction

Decimal Equivalents

1/64 . . . . . . . . . . .. . . . . . . .0156

1/32 . . . . . . .. . . . . . . .0312 . . 1 mm= .0394"

3/64 . . . . . . . . . . .. . . . . . . .0469

1/16 . . . . . . .. . . . . . . .0625

5/64 . . . . . . . . . . .. . . . . . . .0781 . . 2 mm = .0787"

3/32 . . . . . . .. . . . . . . .0938

7/64 . . . . . . . . . . .. . . . . . . .1094 . . 3 mm =.1181"

1/8 . . . . . . . . .1250

9/64 . . . . . . . . . . .. . . . . . . .1406

5/32 . . . . . . .. . . . . . . .1563 . . 4 mm = .1575"

11/64 . . . . . . . . . . .. . . . . . . .1719

3/16 . . . . . . .. . . . . . . .1875 . . 5mm= .1969"

13/64 . . . . . . . . . . .. . . . . . . .2031

7/32 . . . . . . .. . . . . . . .2188

15/64 . . . . . . . . . . .. . . . . . . .2344 . . 6 mm = .2362"

1/4 . . . . . . . . .25

17/64 . . . . . . . . . . .. . . . . . . .2656 . . 7 mm = .2756"

9/32 . . . . . . .. . . . . . . .2813

19/64 . . . . . . . . . . .. . . . . . . .2969

5/16 . . . . . . .. . . . . . . .3125 . . 8mm= .3150"

21/64 . . . . . . . . . . .. . . . . . . .3281

11/32 . . . . . .. . . . . . . .3438 . . 9 mm = .3543"

23/64 . . . . . . . . . . .. . . . . . . .3594

3/8 . . . . . . . . .375

25/64 . . . . . . . . . . .. . . . . . . .3906 . . 10 mm = .3937"

13/32 . . . . . .. . . . . . . .4063

27/64 . . . . . . . . . . .. . . . . . . .4219 . . 11 mm =.4331"

7/16 . . . . . . .. . . . . . . .4375

29/64 . . . . . . . . . . .. . . . . . . .4531

15/32 . . . . . .. . . . . . . .4688 . . 12 mm = .4724"

31/64 . . . . . . . . . . .. . . . . . . .4844

1/2 . . . . . . . . .5 . . . . . . . . . . . 13mm = .5118"

33/64 . . . . . . . . . . .. . . . . . . .5156

17/32 . . . . . .. . . . . . . .5313

35/64 . . . . . . . . . . .. . . . . . . .5469 . . 14 mm = .5512"

9/16 . . . . . . .. . . . . . . .5625

37/64 . . . . . . . . . . .. . . . . . . .5781 . . 15 mm = .5906"

19/32 . . . . . .. . . . . . . .5938

39/64 . . . . . . . . . . .. . . . . . . .6094

5/8 . . . . . . . . .625 . . . . . . . . . 16mm=. 6299"

41/64 . . . . . . . . . . .. . . . . . . .6406

21/32 . . . . . .. . . . . . . .6563 . . 17 mm =.6693"

43/64 . . . . . . . . . . .. . . . . . . .6719

11/16 . . . . . .. . . . . . . .6875

45/64 . . . . . . . . . . .. . . . . . . .7031 . . 18 mm = .7087"

23/32 . . . . . .. . . . . . . .7188

47/64 . . . . . . . . . . .. . . . . . . .7344 . . 19 mm = .7480"

3/4 . . . . . . . . .75

49/64 . . . . . . . . . . .. . . . . . . .7656

25/32 . . . . . .. . . . . . . .7813 . . 20 mm = .7874"

51/64 . . . . . . . . . . .. . . . . . . .7969

13/16 . . . . . .. . . . . . . .8125 . . 21 mm =.8268"

53/64 . . . . . . . . . . .

27/32 . . . . . .. . . . . . . .8438

55/64 . . . . . . . . . . .. . . . . . . .8594 . . 22 mm = .8661"

7/8 . . . . . . . . .875

57/64 . . . . . . . . . . .. . . . . . . .8906 . . 23 mm = .9055"

29/32 . . . . . .. . . . . . . .9063

59/64 . . . . . . . . . . .. . . . . . . .9219

15/16 . . . . . .. . . . . . . .9375 . . 24 mm = .9449"

61/64 . . . . . . . . . . .. . . . . . . .9531

31/32 . . . . . .. . . . . . . .9688 . . 25 mm = .9843"

63/64 . . . . . . . . . . .. . . . . . . .9844

1. . . . . . . . . . 1.0

. . . . . . . .8281

1.13

GENERAL INFORMATION

Conversion Table

Unit of Measure Multiplied by Converts to

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

(3.14)xR

x H (height) = Cylinder Volume

°C to °F: 9 (°C + 40) 5 - 40 = °F °F to °C: 5 (°F + 40)

 9 - 40 = °C

1.14

Glossary Of Terms

GENERAL INFORMATION

ABDC: After bottom dead center. ACV: Alternating current voltage.

ADC: Active Descent Control. Engages front wheels for 4-wheel EBS. Alternator: Electrical generator producing voltage alternating current.

ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and

grip the drive belt. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.

CVT: Centrifugal Variable Transmission (Drive Clutch System) DCV: Direct current voltage.

Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator . Good for showing t aper and out-of-round in the cylinder bore. EBS: Engine Braking System. Uses engine compression to slow the ATV without the use of hydraulic brakes.

Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i .e. a bare wire touchi ng

the chassis).

End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.

: Kilograms per square centimeter.

kg/cm kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter.

: Pounds per square inch.

lbs/in Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil ) is moved through a magnetic field, a voltage wil l be generated in the winding s. Mechanical energy

is converted to electrical energy in the stator.

mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .0 40". Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approximately 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the pis ton onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mount ed under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts.

WOT: Wide open throttle.

1.15

GENERAL INFORMATION

NOTES

1.16

MAINTENANCE

CHAPTER 2

MAINTENANCE

MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4

LUBRICATION / FLUIDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

GENERAL COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . .2.8

POLARIS LUBRICANT SYMBOL IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9

PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9

LUBRICATION / GREASE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

FRONT GEARCASE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

TRANSMISSION LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

ADC DIFFERENTIAL HYDRAULIC CIRCUIT FLUID CHANGE. . . . . . . . . . . . . . . . . . .2.13

VEHICLE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

SHIFT LINK ROD AND THROTTLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

THROTTLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL ADJUSTMENT . . . . . . .2.14

FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

SPARK PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

ACTIVE DESCENT CONTROL (ADC) RESERVIOR LEVEL. . . . . . . . . . . . . . . . . . . . . 2.16

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

COOLANT STRENGTH / TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

COOLING HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

RADIATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

RESERVOIR LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

RADIATOR COOLANT LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

AIR BOX SEDIMENT TUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

ENGINE BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

PVT INSPECTION / DRYING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

ENGINE GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

ENGINE OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

OIL/FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

STEERING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

TIE ROD / STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

CAMBER/CASTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

WHEEL ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

TOE ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

BRAKE SYSTEM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

BRAKE HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

AUXILIARY (REAR) BRAKE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

AUXILIARY BRAKE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

SUSPENSION: SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

FRONT SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

ATV CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

2.1

MAINTENANCE

WHEEL REMOVAL: FRONT OR REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29

FRONT / REAR STORAGE COMPARTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29

WARN“WINCH OPERATION (IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

CLEANING AND STORAGE OF ATV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

2.2

MAINTENANCE

Overview

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer.

NOTE: Service and adjustments are critical. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:

 = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized

Polaris dealer.

 = SEVERE USE ITEM --If vehicle is subjected to severe use, decrease interval by 50% (Sever e Use is defined as frequent

vehicle immersion in mud, water or sand, racing or race-style high rpm use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is required under these conditions. Fluid changes, cable, chain and chassis lubrication are required more frequently. For engine oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A rising oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.)

E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING: Improperly performing the procedures marked with a  could result in component failure and lead to serious injury

or death. Have an authorized Polaris dealer perform these services.

2.3

MAINTENANCE

Periodic Maintenance Chart

Table 2-1: REQUIRED MAINTENANCE INTERVALS

ITEM MAINTENANCE INTERVAL REMARKS

Hours Calendar Miles (KM)  Steering -- Pre-Ride --

 Front Suspension -- Pre-Ride --  Rear Suspension -- Pre-Ride --

Tires -- Pre-Ride --

 ADC Fluid Level -- Pre-Ride --  Brake Fluid Level -- Pre-Ride --



, E Engine Oil Level -- Pre-Ride --

, E

Brake Lever Travel

Brake Systems -- Pre-Ride -Wheels/Fasteners -- Pre-Ride -Frame Fasteners -- Pre-Ride --

Air filter, pre-filter

Air Box Sediment Tube

Coolant (if applicable)

Head lamp/tail lamp

Air filter, main element

Recoil housing (if applicable)

-- Pre-Ride --

-- Daily -- Inspect; clean often

-- Daily -- Drain deposits when visible

-- Daily -- Check level daily, change coolant every 2 years

-- Daily -- Check operation; apply dielectric grease if replacing

-- Weekly -- Inspect; replace as needed

-- Weekly --

Make adjustments as needed.

Drain water as needed, check often if operating in wet conditions

, E Brake Pad Wear 10 H Month ly 60 (100) Inspect periodically

Battery 20 H Monthly 125 (200) Check terminals; clean; test

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

2.4

Table 2-1: REQUIRED MAINTENANCE INTERVALS

ITEM MAINTENANCE INTERVAL REMARKS

Hours Calendar Miles (KM)

MAINTENANCE



 Transmission Oil 25 H Monthly 155 (250) Inspect level; change yearly

, E



 Steering 50 H 6 M 310 (500) Lubricate

 Front Suspension 50 H 6 M 310 (500) Lubricate  Rear Suspension 50 H 6 M 310 (500) Lubricate

Front gearcase oil (if equipped)

Middle gearcase oil (if equipped)

Rear gearcase oil (if equipped)

Engine breather filter (if equipped)

Engine oil change (break-in)

General lubrication

Shift Linkage 50 H 6 M 310 (500) Inspect, lubricate, adjust

25 H Monthly 155 (250) Inspect level; change yearly

25 H Monthly 155 (250) Inspect; replace if necessary

25 H 1 M 1 55 (250) Perform a break-in oil change at one month

50 H 3 M 3 10 (500) Lubricate all fittings, pivots, cables, etc.

, E

E Air intake ducts 50 H 6 M 310 (500) Inspect ducts for proper sealing/air leaks

, E

, E Oil filter change 100 H 6 M 620 (1000) Replace with oil change

, E

, E Valve Clearance 100 H 12 M 620 (1000) Inspect ;  = Perform these procedures more often for vehicles subjected to severe use.

E = Emission Control System Service (California)

 = Have an authorized Polaris Dealer perform these services.

Throttle Cable/ ETC Switch

Drive belt 50 H 6 M 310 (500) Inspect; adjust; replace as needed Cooling system

(if applicable) Engine Oil

Change

Oil tank vent hose (iff applicable)

50 H 6 M 310 (500) Inspect; adjust; lubricate; replace if necessary

50 H 6 M 3 10 (500)

100 H 6 M 620 (1000) Perform a break-in oil change at 25 hours/one month

100 H 12 M 620 (1000) Inspect routing, condition

Inspect coolant strength seasonally; pressure test system yearly

2.5

MAINTENANCE

Table 2-1: REQUIRED MAINTENANCE INTERVALS

ITEM MAINTENANCE INTERVAL REMARKS

Hours Calendar Miles (KM)

, E Fuel system 1 00 H 12 M 620 (1000)

, E Fuel filter 100 H 12 M 620 (1000) Replace yearly



 Engine mounts 100 H 12 M 620 (1000) Inspect

, E Spark Plug 100 H 12 M 620 (1000) Inspect; replace as needed , E Ignition Timing 100 H 1 2 M 620 (1000) Inspect

 Wiring 100 H 12 M 620 (1000)



Radiator (if applicable)

Cooling hoses (if applicable)

Exhaust muffler/pipe

Clutches (drive & driven)

Front wheel bearings

100 H 12 M 620 (1000) Inspect; clean external surfaces

100 H 12 M 620 (1000) Inspect for leaks

100 H 12 M 620 (1000) Inspect

100 H 12 M 620 (1000) Inspect; clean; replace worn parts

100 H 12 M

1000 (1600)

Check for leaks at tank cap, lines, fuel pump, filter, pump, injectors; replace lines every two years

Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

Inspect; replace as needed

 Brake fluid 200 H 24 M

 ADC fluid 200 H 24 M

Spark arrestor 300 H 36 M

E Idle Speed ---- Adjust as needed

 Toe Adjustment ---- Inspect periodically; adjust when parts are replaced , 

 = Perform these procedures more often for vehicles subjected to severe use.

E = Emission Control System Service (California)

 = Have an authorized Polaris Dealer perform these services.

Auxiliary brake ---- Inspect daily, adjust as needed

Headlight aim ---- Adjust as needed

1240 (1000)

1860 (3000)

Change every two years

Clean out

2.6

LUBRICATION / FLUIDS

SPORTSMAN Component Locations

MAINTENANCE

(Deluxe)

(Sportsman Only)

2.7

MAINTENANCE

SPORTSMAN X2 Component Locations

Brake Fluid Reservoir

Brake Lever

Worklight

Instrument Cluster

(Speedometer)

AWD/Turf Switch

Diagnostic Port (under access panel)

Front St orage Compartment & Rack

Front Demand

Drive Unit

(Behind Radiator)

Light Control & Run Switch

Oil Dipstick

PVT Cover

Gear Shifter

Reverse Override

Gas Cap

Throttle

Ignition/Key

Rear Dump Box / Passenger Area

Battery (Under Tank)

2.8

Transmission

Rear Drive CV Shafts

Right Side View

Muffler

Auxiliary Brake

Front Prop Shaft

(Between Transmission and Front Gearcase)

Front Drive CV Shafts

MAINTENANCE

Polaris Lubricants, Maintenance and Service Products

Table 2-2:

PART

NUMBER

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol) 2871281

2871844

2871567

Gearcase / Transmission Lubricants 2876251 Demand Drive LT Premium Hub Fluid 3234438 Polaris ADC Hydraulic Fluid

2873602

2873603

2876160

2872276 2870465 Oil Pump for 1 Gallon Jug

2871322

2871423 2871460 Starter Drive Grease (12 count) 2871515

2871551 2871312 Grease Gun Kit

2871329

Engine Oil (Quart) Premium Synthetic

Engine Oil (Gallon) Premium Synthetic

Engine Oil (16 Gallon) Premium 4

Premium Synthetic AGL Gearcase Lube

Premium ATV Angle Drive Fluid

Grease / Specialized Lubricants

DESCRIPTION

0W-40 (4-cycle) (12 count)

0W-40 (4-cycle) (4 count)

Synthetic 0W-40 (4-cycle)

(12 oz. bottle) (12 count)

(1 Gal. bottle) (4 count)

(32 oz.) (12 count)

(2.5 Gal.) (2 count)

Premium All Season Grease

(3 oz. cartridge) (24 count)

Premium All Season Grease (14 oz. cartridge) (10 count)

Premium U-Joint Lube

(3 oz.) (24 Count)

Premium U-Joint Lube

(14 oz.) (10 count)

Dielectric Grease (Nyogel



Table 2-2:

PART

NUMBER

2871323 60/40 Coolant (Gallon) (6 count) 2871534 60/40 Coolant (Quart) (12 count )

Additives / Sealants / Thread Locking Agents / Misc.

2874275 2871956

2871950

2871951

2871953

2871557

2871326 2870652 Fuel Stabilizer (16 oz.) (12 count) 2871957

2871958 2870990 DOT 3 Brake Fluid (12 count)

2871557 Crankcase Sealant, 3 Bond 1215 (5 oz.)

DESCRIPTION

Coolant

Loctite

Primer N, Aerosol

Loctite

Thread Sealant 565

(50 ml.) (6 count)

Loctite

 Threadlock 242

(6 ml.) (12 count)

Loctite

 Threadlock 262

(50 ml.) (10 count)

Loctite

 Threadlock 271

(6 ml.) (12 count)

3-Bond 1215

Premium Carbon Clean

(12 oz.) (12 count)

Black RTV Silicone Sealer

(3 oz. tube ) (12 count)

Black RTV Silicone Sealer

(11 oz. cartridge) (12 count)

Sealant

(5 oz.)

2.9

MAINTENANCE

Polaris Lubricant Symbol Identification

NOTE: The symbols used are for quick reference in identifying which lubricant/grease to use on each component.

Polaris DOT Brake Fluid

Polaris ADC

Hydraulic Fluid

Polaris Synthetic

0W/40

Polaris Synthetic AGL

Gearcase Lube

Polaris 60/40

Coolant

Pre-Ride / Daily Inspection

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

• Tires - check tire conditio n an d air pressures

• Fuel and oil - fill both to their proper level; Do not overfill

• All brakes - check operation and adjustment (includes auxiliary brake)

• Throttle -check for free operation

• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches

• Engine stop switch - check for proper function

• Wheels - check for loose wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins

• Air cleaner element - check for dirt or water; clean or replace

• Steering - check for free operation, noting any unusual looseness in any area

• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners

Polaris ATV Angle

Drive Fluid

Polaris U-Joint Lube

Demand Drive LT

Premium Hub Fluid

Polaris All

Season Grease

• Engine coolant - check for proper level at the recovery bottle

• ADC Fluid Level - check for proper level

2.10

+ 295 hidden pages