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

Lubrication / Grease Points

1. Engine Oil

3. Front Gearcase

2. Transmission Fluid

5. Brake Fluid

8. Front Propshaft

MAINTENANCE

4. Rear Gearcase

6. Front A-Arm

7. Rear A-Arm

1. Engine Oil Polaris 0W/40

2. Transmission

3A. 3B.

4. Rear Gearcase ATV Angle Drive Fluid

5. Brake Fluid Polaris Dot 3 Brake Fluid

6. Front A-Arm Polaris All Season Grease Locate fitting and grease.

7. Rear A-Arm Polaris All Season Grease Locate fitting and grease

5. Front Propshaft

* Perform more often under severe use, such as operation in water and under severe loads.

TEM LUBE METHOD

Check dipstick and add to

Front Gearcase

ADC Fluid

Polaris AGL Synthetic

Gearcase Lube

Demand Drive LT

Premium Hub Fluid

Polaris ADC Hydraulic

Polaris U-Joint Grease

Add lube to bottom fill hole.

Add specified quantity.

Drain completely . Add l ube to

specified quantity.

Fill master cylinder reservoir

Locate fitting and grease.



proper level.

Drain as directed.

to indicated level

FREQUENCY*

Change after 1st month, 6 months, or 100

hours thereafter; Change more often (25-50

hours) in extremely dirty conditions, or short

trip cold weather operation.

Change annually

Gearcase - Change annually

ADC - Change fluid every 2 years

Change annually

As required, change fluid every 2 years

Semi-annually Semi-annually Semi-annually



  

Semi-annually or 50 hours of operation 9refer to Maintenance Schedule for addition al information). More often under severe

conditions (operating in water or hauling heavy loads.

Annually or 100 hours of operation (refer to Maintenance Sched ule for additional information). More often under severe

conditions (operating in water or hauling heavy loads.

Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M, or Mobilgrease Special

2.11

MAINTENANCE

Front Gearcase Lubrication

The front gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is level before proceeding and in PARK

• Check vent hose to be sure it is routed properly and unobstructed

• The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid.

FRONT GEARCASE

Fill Plug 8-10 ft.lbs. (11-14 Nm)

Drain Plug

11 ft.lbs. (15 Nm)

To Change Gearcase Lubricant:

Drain Plug

1. Remove gearcase drain plug (A) 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 (A) using a new sealing washer (B). Torque to specification.

Specified Lubricant:

Demand Drive LT Premium Hub Fluid

CH Gearcase Capacity: 8.97 oz. (265 ml.)

ADC Gearcase Capacity: 9.3 oz. (275 ml.)

= T

Fill Plug Torque: 8-10 ft.lbs. (11-14 Nm)

Drain Plug Torque: 11 ft.lbs. (15 Nm)

To Check the Lubricant Level:

The front and rear gearcase lubricant level cannot be checked with a dipstick. The gearcase must be drained and re-filled with the proper amount of lubricant or be filled to the bottom of the fill plug hole threads. Refer to procedures.

Fill Plug

Left Side View

3. Remove fill plug. Inspect the O-ring.

4. Fill with th e recommended fluid amount or to the bottom of the fill plug hole threads. (See Illustration below).

Front Gearcase

Fill - Premium Demand Drive

Hub Fluid

2.12

5. Install / torque fill plug and check for leaks.

Transmission Lubrication

MAINTENANCE

The (transmission) lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is level and in Park before proceeding.

• Check vent hose to be sure it is routed properly and unobstructed.

• Follow instructions to check / change transmission lubricant.

SPORTSMAN

Transmission - Specified Lubricant:

Polaris AGL Gearcase Lubricant

(Gallon - PN 2873603) (12 oz. - PN 2873602)

Sportsman - Capacity: 15 oz. (450 ml)

Sportsman X2 - Capacity: 32 oz. (948 ml)

= T

Transmission

Sportsman - Drain / Fill Plug Torque:

14 ft.lbs. (19 Nm)

Sportsman X2 - Drain / Fill Plug Torque:

20-25 ft.lbs. (27-34 Nm)

To Check the Fluid Level:

1. Remove fill plug from the back of the transmission and visually inspect the oil level. Level is correct when it reaches the bottom of the fill hole as shown at below.

NOTE: The drain and fill plug use a 5/16” hex for removal and installation.

SPORTSMAN X2

Oil Fill Plug

Oil Fill LevelBottom Fill Plug

Hole Threads

To Change Lubricant:

1. Remove transmission drain plug t o drain the oil. Discard used oil properly.

2. Clean and reinstall the drain plug. Torque to specification.

3. Remove fill plug.

4. Add the correct amount of Polaris AGL Gearcase Lubricant.

5. Check for leaks.

6. Install fill plug. Torque to specification.

2.13

MAINTENANCE

ADC Differential Hydraulic Circuit Fluid Change

1. Make sure vehicle is parked on flat ground and allowed to sit at least 30 minutes prior to bleeding hydraulic circuit.

2. Thoroughly clean area around and on remote reservoir and bleeder valves.

3. Remove reservoir cap and diaphragm assembly.

4. Make sure hydraulic oil inside reservoir is free of debris. If any debris is found, use clean rag or suction device to remove from the reservoir.

NOTE: Debris in reservoir may block porting and produce inadequate bleeding of the system. Decreased performance may be encountered with inadequate bleed of the hydraulic circuit.

5. Begin the bleeding process by filli ng reservoir to ‘MAX’ line with clean Polaris ADC hydraulic fluid. (AW ISO 10 hydraulic fluid equivalent).

6. Locate bleeder valves found on either side of differential and remove the protective caps.

7. Turn bleeder valves counter-clockwise to loosen. Loosen bleeder screw slowly, allowing oil and any trapped air to flow out of fitting.

IMPORTANT: Do not allow hydraulic fluid in reservoir to drain below minimum fill line. Close bleeder valve before oil level falls below minimum fill line. Refilling empty reservoir will result in air pockets becoming trapped.

VEHICLE INSPECTION

Shift Link Rod Inspection

NOTE: Shift rod is preset at time of manufacturer.

1. Inspect shift link tie rod ends and replace if worn or damaged. Lubricate pivot points with a light aerosol lubricant or grease if desired.

Shift Mount

Shifter

Shift Link Rod

NOTE: If empty reservoir is encountered, filling of fluid is still possible. Verify air is not trapped before proceeding with step 7.

8. Continue steps 6 -8 on both sides in sequence until clean fluid is seen when bleeding occurs.

9. Re-torque both bleeder valves to specification and reinstall cover caps.

= T

Bleeder Valve Torque:

80 in. lbs. (9 Nm)

10. Fill reservoir with to a level midway between ‘MAX’ and ‘MIN’ fill lines. Verify no debris is found in reservoir oil.

11. Replace reservoir cap securely and wipe clean any residue.

2.14

MAINTENANCE

Throttle Inspection

Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding.

1. Place the gear selector in neutral.

2. Place shift selector in neutral and set parking brake.

3. Loosen lock nut on in-line cable adjuster (Ill. 1).

4. Turn handleb ars from full right to full left. If idle speed increases at any point in the turning range, inspect throttle 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 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.

3. Repeat procedure at the other five locations as show n.

NOTE: Do not attempt to remove cover until all latch points are released.

Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment

1. Slide boot off throttle cable adjuster and jam nut.

2. Place shift selector in neutral and set parking brake.

3. Loosen lock nut on in-line cable adjuster (Ill. 1).

Boot

Adjuster Sleeve

4. Turn adjuster until specified freeplay is achieved at thumb lever. (see illustration). After making adjustments, quickly actuate the thumb lever several times and reverify freeplay.

Lock Nut

Boot

ETC Cover Removal Sequence

Direction of Travel

1/16-1/8” Freeplay

= In. / mm.

Throttle Freeplay:

.0625 - .1250" (1.58 - 3.17mm)

5. Tighten lock nut securely and slide boot completely in place to ensure a water-resistant seal.

6. Turn handlebars from left to right through the entire turning range. If idle speed increases, check for proper cable routing. If cable is routed properly and in good condition, repeat adjustment procedure

2.15

MAINTENANCE

Fuel System

WARNING

* Gasoline is extremely flammable and explosive

under certain conditions. * EFI components are under high pressure. Verify system pressure has been relieved before disassembly. * Never drain the fuel system when the engine is hot. S e vere burn s may resul t * Do not overfill the tank. The tank is at full capacity when the fuel reaches the bottom of the filler neck. Leave room for expansion of fuel. * Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time. * Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. * If you get gasoline in your eyes or if you should swallow gasoline, seek medical attention immediately. * If you spill gasoline on your skin or clothing, immediately wash with soap and water and change clothing. * Always stop the engine and refuel outdoors or in a well ventilated area.Keep away from open flames and electrical components when removing fuel filter.

The fuel filter (1) should be replaced in accordance with the Periodic Maintenance Chart. To replace the filter:

EFI Example

(1)

4. Remove fuel lines from filter, use shop towels to catch any leaking fuel.

5. Install new filter in line with arrow pointed in direction of fuel flow.

6. Install line locks on fuel lines and verify locks are seated.

7. Start engine and inspect for leaks.

Vent Lines

Check fuel tank, oil tank, battery and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace Be sure vent lines are routed properly and secured with cable ties.

CAUTION

Verify vent lines are not kinked or damaged

Compression Test

NOTE: This engine does NOT have decompression components. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about 150-200 psi during a compression test.

A smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition problems above idle speed. Abnormally high compression can be caused by carbon deposits in the combustion chamber or worn, damaged exhaust cam lobes. Inspect camshaft and combustion chamber if compression is abnormally high.

A cylinder leakdown test is the best indication of engine condition. Follow manufacturer's instructions to perform a cylinder leakage test. (Never use high pressure leakage testers, as crankshaft seals may dislodge and leak).

Cylinder Compression

Standard: 150-200 PSI

Cylinder Leakdown

Service Limit 15%

1. Disconnect negative battery cable.

2. Relieve the pressure on the fuel rail. (See Ch. 4)

3. Remove line locks at both ends of the filter.

2.16

(Inspect for cause if test exceeds 15%)

MAINTENANCE

Engine Mounts

Inspect rubber engine mounts (A) for cracks or damage. Check engine fasteners and mounts, ensure they are tight.

Spark Plug

5. Measure gap with a wire gauge. Refer to specifications for proper spark plug type and gap. Adjust gap if necessary by bending the side electrode carefully.

Spark Plug Gap

.036 (0.9 mm)

6. If necessary, replace spark plug with proper type.

CAUTION

Severe engine damage may occur if the incorrect

spark plug is used.

7. Apply a small amount of anti-seize compound to the spark plug threads.

8. Install spark plug and to rque to specification.

1. Clean plug area so no dirt and debris can fall into engin e when plug is removed. Remove spark plug high tension lead.

2. Remove spark plug.

3. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes.

4. Clean with electrical contact cleaner or a glass bead spark plug cleaner only.

CAUTION

A wire brush or coated abrasive should not

be used for cleaning sparkplugs.

= T

Recommended Spark Plug

Refer to the Specifications page in

Chapter 1 for spark plug type.

Spark Plug Torque: 18 ft.lbs. (24 Nm)

Active Descent Control (ADC) Reservoir Level

The Active Descent Control reservoir (DELUXE Models Only) is located by the radiator fill cap. Check the level and verify it is between the ‘MAX’ and ‘MIN’ lines. Add only Polaris ADC fluid when required.

2.17

MAINTENANCE

Battery Maintenance

Complete battery servicing information for both conventional and sealed batteries can be found in Chapter 10 of this manual.

WARNING

Battery electrolyte is poisonous. It contains sulfuric

acid. Serious burns can result from contact with

Internal: Drink large quantities of water or milk.

Eyes: Flush with water for 15 minutes and get

Batteries produce explosive gases. Keep sparks,

charging or using in an enclosed space. Always

NOTE: Expected battery shelf life is 6-8 months depending on storage conditions. As a general rule before placing the battery into service, check the battery condition and charge accordingly.

NOTE: New Batteries: Batteries must be fully charged before use or battery life will be reduced by 10-30% of full potential. Charge battery for 3-5 h ours at a current equivalent of 1/10 of the battery's rated amp/hour capacity. Do not use the alternator to charge a new battery. (Refer to battery video PN

9917987).

(Conventional Battery Only)

When the electrolyte nears the lower level, remove the battery and add distilled water only to the upper level line .

skin, eyes or clothing. Antidote:

External: Flush with water.

Follow with milk of magnesia, beaten egg, or

vegetable oil. Call physician immediately.

prompt medical attention.

flame, cigarettes, etc. away. Ventilate when

shield eyes when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

Inspect the battery fluid level.

To Remove the Battery:

1. Disconnect holder strap and remove cover.

2. Disconnect battery negative (-) (black) cable first, followed by the positive (+) (red) cable.

CAUTION

To reduce the chance of sparks: Whenever

removing the battery, disconnect the negative

(black) cable first. When reinstalling the battery,

install the negative cable last.

3. Disconnect the vent hose.

4. Remove the battery.

5. (Conventional Battery Only) add distilled water only as needed to bring each cell to the proper level. Do not overfill the battery.

IMPORTANT: Use only distilled water. Tap water contains minerals which are harmful to a battery.

IMPORTANT: Do not allow cleaning solution or tap water to enter a battery, as it will shorte n the life of the battery.

6. Fully recharge the battery.

7. Reinstall battery caps (Conventional Battery Only)

8. Clean battery cables and terminals with a stiff wire brush. Corrosion can be removed using a solution of one cup water and one tablespoon baking soda. Rinse well with clean water and dry thoroughly.

9. Reinstall battery, attaching positive (+) (red) cable first and then the negative (-) (black) cable.

10. Reattach vent hose making sure it is properly routed and not kinked or pinched.

11. Coat terminals and bolt threads with Dielectric Grease (PN

2871329).

12. Reinstall battery cover and holder strap.

Remove the filler caps and

Cooling System

Maintain between

upper and lower

level marks

2.18

The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.

• Some coolant level drop on new machines is normal as

the system is purging itself of trapped air. Observe coolant levels often during the break-in period.

• Overheating of engine could occur if air is not fully

purged from system.

• Polaris Premium 60/40 anti-freeze is premixed and

ready to use. Do not dilute with water.

MAINTENANCE

Coolant Strength / Type

Test the strength of the coolant using an antifreeze hydrometer.

Antifreeze Hydrometer

• A 50/50 or 60/40 mixture of antifreeze and distilled water will provide the optimum cooling, corrosion protection, and antifreeze protection.

• Do not use tap water, straight antifreeze, or straight water in the system. Tap water contains minerals and impurities which build up in the system.

• Straight water or antifreeze may cause the system to freeze, corrode, or overheat.

Polaris 60/40 Anti-Freeze/ Coolant

(PN 2871323)

Radiator

1. Check radiator external air flow passages for restrictions or damage.

2. Carefully straighten any bent radiator fins.

3. Remove any obstructions with compressed air or low pressure water.

Cooling System Pressure Test

See Chapter 3 for pressure test procedures.

Reservoir 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.

Remove any obstructions with compressed air or low pressure water.

With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant reservoir. If it is not:

Cooling Hoses

Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary.

Upper Radiator Hose

Lower Radiator Hose

1. Check tightness of all hose clamps.

2. Do not over-tighten hose clamps at radiator or radiator fitting may distort, causing a restriction or leak.

Coolant Bottle

Fan

1. Remove reservoir cap. Verify the inner splash cap vent hole is clear and open.

2. Fill reservoir to upper mark with Po laris Premium 60/40 Anti Freeze / Coolant (PN 2871323) or a mixture of antifreeze and distilled water as required for freeze protection in your area.

3. Reinstall cap.

NOTE: If overheating is evident, allow system to cool completely and check coolant level in the radiator. Inspect for signs of trapped air in system.

Recover Bottley

2.19

MAINTENANCE

Radiator Coolant Level

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 level in the radiator should be inspected via the radiator cap first and coolant added if necessary.

NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly.

To Access the Radiator Pressure Cap:

Lift the front cargo cover . Remove access cover (A) by placing your fingers under the front of the cover and pulling upward. The radiator cap (B) is now accessible.

3. Remove clips (A ) from air box cover and remove cover. Inspect the gasket. It should adhere tightly to the cover and seal all the way around.

4. Loosen clamp and remove air filter assembly.

Cover

Seal

Air Filter Service

It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty conditions, replacement is required more often.

The pre filter should be cleaned before each ride using the following procedure:

1. Lift up on the rear of the seat.

2. Pull the seat back and free of the tabs.

NOTE: When reinstalling seat, make sure the slots in the seat engage the tabs in the fuel tank.

Pre-filter

Main Element

Cleaning:

5. Slip the pre-filter element off of main element. Clean the pre filter with hot soapy water.

6. Rinse and dry thoroughly.

7. Inspect element for tears or damage.

8. Inspect main filter and replace if necessary. If the filter has been soaked with fuel or oil it must be replaced.

Installation:

9. Reinstall pre-filter element over main filter. Be sure the element covers entire surface of main filter without folds, creases, or gaps.

10. Reinstall filter on main filter mount. Place filter clamp over the assembly and tighten.

2.20

MAINTENANCE

NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling.

Proper Filter Placement

Filter Support

Air Box

Main Filter

NOTE: The sediment tube will require more frequent service if the vehicle is opera ted in wet c ondit ion s or at high throttle openings for extended periods.

Engine Breather

Four-cycle ATV engines are equipped with a engine breather filter. The in-line filter is similar in appearance to a fuel filter. The breather lines are located on top of the cylinder head cover, below the gas tank. Be sure breather line is routed properly and secured in place. Make sure the lines are not kinked or pinched. In-line breather filters can be installed with the arrow pointing

in either direction.

Front of ATV

NOTE: The air filter should rest on the filter support. Proper placement of the air filter is important to prevent rattles and air leaks.

11. Install air box cover and secure with clips.

Air Box Sediment Tube

Periodically check the air box drain tube located toward the rear of the machine. Drain whenever deposits are visible in the clear tube.

1. Remove drain plug (A) from end of sediment tube (B).

2. Drain tube.

3. Reinstall drain plug.

To Cylinder Head Cover

Breather Hose

2.21

MAINTENANCE

PVT Inspection / Drying Procedure

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, simply remove the PVT drain plug and O-ring (A) located on the bottom of the PVT cover and let the water drain out. The PVT drain plug is shown below.

Engine Oil Level

The twin engine is a wet-sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level:

Dipstick

1. Set machine on a level surface.

2. Be sure the machine has sat for awhile before removing the dipstick. Do not run the engine and then check the oil level, as this will result in an incorrect reading.

2. To further expel wat er from the cover and to dry out the PVT system, shift the transmission to neutral and rev engine slightly to expel the moisture and air-dry the belt and clutches. Allow engine RPM to settle to idle speed, shift transmission to lowest available range and test for belt slippage. Operate ATV in lowest available range for a short period of time until PVT system is dry.

Engine Ground

Inspect engine-to-frame ground cable connection. Be sure the connection clean and tight.

3. Unlock the lever lock (A). Remove dipstick (B) and wipe dry with a clean cloth.

2.22

Typical Ground Cable

MAINTENANCE

4. Reinstall dipstick and push it into place. Do not lock the dipstick.

NOTE: Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of stick consistent. When reinstalling the dipstick, make certain to seat the lever lock.

5. Remove dipstick and check to see that the oil level is in the normal range. Add oil as indicated by the level on the dipstick. Do not overfill. (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 side of the dipstick as it is being removed, regardless of the level marks being on top or on bottom. (See illustration)

Dipstick

Always read top side of dipstick to properly check oil level in crankcase.

Oil/filter Change

1. Place vehicle on a level surface.

2. Run engine two to three minutes until warm. Stop engine.

3. Clean area around drain plug at bottom of engine.

4. Place a drain pan beneath crankcase and remove drain plug.

CAUTION

Do not allow hot oil to come into contact

with your skin, as serious burns may result.

5. Allow oil to drain completely.

6. Replace the sealing washer on drain plug.

NOTE: The sealing surfaces on drain plug and oil tank should be clean and free of burrs, nicks or scratches.

7. Reinstall drain plug and torque to specification.

= T

Drain Plug Torque:

15 ± 2 ft.lbs. (21.7 ± 2.7 Nm)

NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase . If th e oil level is over the full mark, change the oil immediately.

8. Place shop towels beneath oil filter. Using Oil Filter Wrench PV-43527, turn filter counterclockwise to remove.

Oil Filter

9. Using a clean dry cloth, clean filter sealing surface on crankcase.

10. Lubricate O-ring on new filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition.

11. Install new filter and turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn.

12. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris Premium 4 Synthetic Oil.

13. Place gear selector in park and set the parking brake.

2.23

MAINTENANCE

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 and add oil as necessary to bring the level to the upper mark on the dipstick.

16. Dispose of used filter and oil properly.

Recommended Engine Oil:

Polaris Premium 0W/40 Synthetic

(PN 2871281)

Oil Filter Wrench: (PV-43527)

Oil Filter Torque: Turn by hand until filter

gasket contacts sealing surface, then turn an

additional 1/2 turn

Steering Inspection

WARNING

Due to the critical nature of the procedures outlined

in this chapter, Polaris recommends steering

component repair and adjustment be performed by

an authorized Polaris MSD-certified technician

when replacing worn or damaged steering par ts.

Use only genuine Polaris replacement parts.

Tie Rod / Steering

• To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement.

• Repeat inspection for inner tie rod end on steering post.

• Replace any worn steering components. Steering should move freely through entire range of travel without binding.

• 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 and hub by pushing inward and pulling outward.

• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause ( possible loose wheel nuts or loose front hub components).

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

Replace any worn or damaged steering components. Steering should move freely through entire range of travel without binding. Check routing of all cables, hoses, and wiring t o be sure the steering mechanism is not restricted or limited.

NOTE: Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts.

One of two methods can be used to measure toe alignment. The string method and the chalk method. If adjustment is required, refer to following pages for procedure.

2.24

Check for loose wheel or hub.

• Refer to the Body/Steering Chapter 5 or Final Drive Chapter 7 for service procedures.

Camber/Caster

Camber and caster are non-adjustable.

MAINTENANCE

Wheel Alignment

1. Place machine on a smooth level surface.

2. Set handlebars in a straight ahead position and secure handlebars in this position.

3. Place a chalk mark on the center line of the front tires approximately 10, (25.4 cm) from the floor or as close to the hub/axle center line as possible.

NOTE: It is important that the height of both marks be equally positioned in order to get an accurate measurement.

4. Measure the distance between the marks and record the measurement. Call this measurement “A”.

5. Rotate the tires 180 backward. Position chalk marks facing rearward, even with the hub/axle centerline.

6. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8, to 1/4, (.3 to .6 cm) toe out. This means the measurement at the front of the tire (A) is 1/8, to 1/4, (.3 to .6 cm) wider than the measurement at the rear (B).

 by moving vehicle forward or

Toe Alignment

If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting.

NOTE: Be sure handlebars are straight ahead before determining which tie rod(s) need adjustment.

CAUTION

During tie rod adjustment, it is very important that

the following precautions be taken when tightening

tie rod end jam nuts. If the rod end is positioned

incorrectly it will not pivot, and may break.

To Adjust Toe Alignment:

• Hold tie rod end to keep it from rotating.

• Loosen jam nuts at both end of the tie rod.

• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified

• IMPORTANT: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly. See illustration above.

Chalk Line Measurement “A”

Wheel Toe-Out:

(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)

Measurement “B”

= In. / mm.

• After alignment is complete, torque jam nuts to specification.

Hold Rod End

Correctly Tightened Jam Nut

Incorrectly Tightened Jam Nut

= T

Tie Rod Jam Nut Torque:

12-14 ft. lbs. (16-19 Nm)

2.25

MAINTENANCE

Exhaust Pipe

The exhaust pipe must be periodically purged of accumulated carbon as follows:

1. Remove the clean out plugs locat ed on the bottom of the muffler as shown

Clean Out Plug

2. Place the transmission in neutral and start the engine. Purge accumulated carbon from the system by momentarily revving the engine several times.

3. If some carbon is expelled, cover the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times.

6. Repeat Steps 2 through 5 until no more particles are expelled when the engine is revved.

7. Stop the engine and allow the arrestor to cool.

8. Reinstall the clean out plugs.

WARNING

* Do not perform clean-out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with hot exhaust components. * To reduce fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor. * Wear eye protection. * Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor.Never run the engine in an enclosed area. * Exhaust contains poisonous carbon monoxide gas. * Do not go under the machine while it is inclined. Set the hand brake and block the wheels to prevent roll back. Failure to heed these warnings could result in serious personal injury or death.

4. If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Set the hand brake and block the wheels. Make sure the machine is in neutral and repeat Steps 2 and 3. See WARNING in this section.

5. If particles are still suspected to be in the muffler, drive the machine onto the incline so the front of the machine is one foot higher than the rear. Set the hand brake and block the wheels. Make sure the machine is in neutral and repeat Steps 2 and 3. SEE WARNING in this section.

1 ft. (30.5 cm)

Brake System Inspection

The following checks are recommended to keep the brake system in good operating condition. Service life of brake system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride.

• Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir (See Chapter 9)

• Use Polaris DOT-approved Brake Fluid.

• Check brake system for fluid leaks, look for dust build up on lines and connections that may indicate a fluid leak

• Check brake for excessive travel or spongy feel

• Check friction pads for wear, damage or looseness (see Chapter 9)

• Check surface condition of the disc (see Chapter 9)

2.26

MAINTENANCE

• Inspect thickness of brake pad friction material (see Chapter 9)

Sight Glass

Parking Lock Brake

Brake Hose Inspection

Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts.

Brake Pads

Pads should be changed when the friction material is worn beyond the service limit.

Brake Pad

Measure Thickness

= In. / mm.

Brake Pad Service Limit:

.180" (4.6 mm)

Auxiliary (Rear) Brake Test

The auxiliary brake (A) should be checked for proper function.

1. Support the rear wheels off the ground.

2.27

MAINTENANCE

2. While turning the rear wheels by hand, apply the auxiliary foot brake. This brake should not stop the wheels from turning until the lever is half way between its rest position and bottoming on the footrest.

Auxiliary Foot Brake

Pedal - Full Height

Full Engagement

Floor Board Surface

Auxiliary Brake Adjustment

Use the following procedure to inspect the hydraulic auxiliary (foot) brake system and adjust or bleed if necessary:

First, check foot brake effectiveness by applying 50 lb. (approx.) downward force on the pedal. The top of the pedal should be at least 1 inch, (25.4mm) above the surface of the footrest.

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 suspension spring preload requirements. Adjust as necessary . Use Shock Spanner

Wrench (PN 2870872) to adjust the rear springs.

Front Suspension

• Compress and release front suspension. Dampening should be smooth throughout the range of travel.

• Check all front suspension components for wear or damage.

• Inspect front strut cartridges for leakage.

Rear Suspension

• Compress and release rear suspension. Dampening should be smooth throughout the range of travel.

• Check all rear suspension components for wear or damage.

• Inspect shock for leakage.

1/8 to 1/4 inch Free Play

1 inch or greater

Floorboard

If less than one inch, two things must be examined: Free Play:

= In. / mm.

Foot Brake Freeplay:

1/8 - 1/4 inch (3.2 - 6.35 mm)

CV Shaft Boot Inspection

Inspect the CV shaft boots in the front and rear of the ATV for damage, tears, wear, or leaking grease. If the rubber boot exhibits any of these symptoms, replace the boot. Refer to Chapter 7 for CV boot replacement, or have your Polaris dealer replace the boot.

INSPECT BOOTS

If free play is excessive, inspect pedal, linkage, and master cylinder for wear or damage and replace any parts as needed.

2.28

MAINTENANCE

ATV Controls

Check controls for proper operation, positioning and adjustment.

Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body.

Wheel Inspection

Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts.

Item Specification

3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame.

4. Remove the wheel nuts and remove the wheel.

Wheel Installation

1. With the transmission in park 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 th e ground.

4. Securely tighten the wheel nu ts to th e proper torq ue listed in the table .

Steel Wheel

Aluminum Wheel

Steel - Front and Rear Wheel Nuts

Aluminum - Front and Rear Wheel Nuts

Front Hub Retaining Nut 70 ft.lbs. (90 Nm ) Rear Hub Retaining Nut 80 ft.lbs. (108 Nm)

27 ft.lbs. (37 Nm)

90 ft.lbs. (122 Nm)

Wheel Removal: Front Or Rear

4Wheel Nuts

Retaining Nut

CAUTION

Improperly installed wheels could affect vehic l e

handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end of nut goes into taper on wheel. Torque to proper specificatio n.

1. Stop the engine, place the transmission in gear and lock the parking brake.

2. Loosen the wheel nuts slightly.

2.29

MAINTENANCE

Tire Pressure

CAUTION

Maintain proper tire pressure. Refer to the warning

tire pressure decal applied to the vehicle.

Table 2-1:

TIRE PRESSURE INSPECTION (PSI - COLD)

Front Rear

Tire Inspection

• Improper tire inflation may affect ATV maneuverability.

• When replacing a tire always use original equipment size and type.

• The use of non-standard size or type tires may affect ATV handlin g.

Front / Rear Storage Compartments

The front and rear storage (Sportsman Only) compartments are easily accessible. T o open the fron t compartment turn t he latch handle to the horizontal position on both sides. To close the storage compartment turn the latch handles to the vertical position.

Front Storage - Unlatched

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8, (3 mm) or less.

Tread Depth - 1/8” (3 mm)

WARNING

Operating an ATV with worn tires will increase the

possibility of the vehicle skidding and possible loss

of control.

Worn tires can cause an accident.

Always replace tires when the tread depth

measures 1/8inch (.3 cm) or less.

Frame, Nuts, Bolts, Fasteners

Front Storage - Latched

Sportsman Rear Storage -

Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.

2.30

MAINTENANCE

Winch Operation (If Equipped)

This information is for Sportsman models equipped with a winch in the front.

The mini-rocker (IN/OUT) control controls the direction of the cable for the winch. IN pulls the cable into the winch and OUT feeds the cable out of the winch.

Winch Control

The winch control located on the side of the winch gives the operator easy access to switch between ENGAGED and FREESPOOL.

When the winch is ENGAGED, the winch only allows the cable to be pulled IN or released OUT via the mini-rocker switch on the handlebar.

Winch Handlebar Control

The winch is located in the front bumper area.

When the winch is FREESPOOL, the winch allows the cable to be pulled out freely.

NOTE: The switch on the handlebar does not have to b e in the OUT position.

FREESPOOL

ENGAGE

2.31

MAINTENANCE

Winch Wire Locat ions

The winch wires can be located under the front cab area. Locate the wires, remove the cap and hook up to winch the Blue and Yellow (6 Ga.) wires to the winch. Refer to the installation instructions for more details.

Winch Connector

Splash Guard for Contactor mount

Winch Connecting Harness

Locate the Red wire (6 Ga.) with the yellow crimp cover is located in the rear fender area. The red wire connects to the battery.

Winch Connecting Wire

The Orange/White wires are located under the front cover (under headlight pod). The Orange/White wires supply the control power to the winch.

2.32

Right Side Front Fender

MAINTENANCE

Cleaning And Storage Of ATV

Cleaning the ATV

Keeping your AT V clean will not on ly improve its appearan ce but it can also extend the life of various components. W ith a few precautions, your A TV can be cleaned much like a n automobile.

Washing the ATV

The best and safest way to clean your A TV is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Rinse with water frequently and dry with a chamois to prevent water spots.

NOTE: If warning and safety labels are damaged, contact your a Polaris dealer for free replacement.

Polaris does not recommend the use of a high pressure type car wash system for washing the ATV . If a high pressure system is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels.

NOTE: Grease all zerk fittings immediately after washing, and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system.

Waxing the ATV

ATVs can be waxed with any non-ab rasive automotive paste wax. A void the use of harsh cleaners since they can scratch the body finish. Spray-on furniture polish is an acceptable alternative. Do not use old cloths or pads which may contain dirt particles that can scratch the finish. Polaris offers a detailing kit for ATVs.

Clean the Exterior

Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime. Do n't use harsh detergents or high pressur e washers. Some detergen ts deteriorate rubber parts. Use dish soap type cleaners only. High pressure washers may force water past seals.

Stabilize the Fuel

Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer . Follow the instructions on the container for the recommended amount. (Carbon clean will also reduce the possibility of bacterial growth in the fuel system.) Allow 1520 minutes of operation for the stabilizer to disperse through the fuel in the tank and the fuel system.

Oil and Filter

Warm the engine and change the oil and filter. Follow the procedure in this chapter for proper oil change.

Air Filter / Air Box

Inspect and clean or replace the pre-cleaner and air filter. Clean the air box and drain the sediment tube.

Breather Filter

Inspect and clean or replace the breather filter.

Fluid Levels

Inspect the following fluid levels and change if necessary: front gearcase; transmission; brake fluid (change every two years or as required if fluid looks dark or contaminated).

Drain and Recoil Housing (If Applicable)

Remove the recoil housing drain plug and drain any moisture.

CAUTION

Certain products, including insect repellents and

chemicals, will damage plastic surfaces.

Use caution when using these

products near plastic surfaces.

Storage Tips

See the beginning of the chapter for Pure Polaris storage products.

CAUTION

Starting the engine during the storage period

will disturb the protective film created

by fogging. Damage could occur.

Never start the engine during the storage period

Fog the Engine

Use Polaris Fogging Oil, following the instructions as directed. If you choose not to use Polaris Fogging Oil, perform the

following procedure.

1. Treat the fuel system with Polaris Carbon Clean. If Polaris fuel system additive is not used, the fuel tank and fuel lines should be completely drained of gasoli n e .

2. To access the plug hole, use a section of clear 1/4" hose and a small plastic squeeze bottle filled with the pre-measured amount of oil.

3. Remove the spark plug(s). Rotate the pist on to BDC and pour approximately two ounces of Polaris oil into the cylinder.

NOTE: Do this carefully! If you miss the plug hole, oil will drain from the spark plug cavity into the hole at the front of the cylinder head and appear to be an oil leak.

4. Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug.

5. Turn the engine over several ti mes to ensure coverage of piston rings, cylinder walls and crankshaft bearings.

2.33

MAINTENANCE

6. After storage procedures are complete, do not start the engine until unit is ready to be removed from storage. Starting the engine will remove the protective coating from the engine components.

Lubrication

Inspect all cables and lubricate with Polaris Cable Lubricant. Follow lubrication guidelines in the maintenance section of the service or owner's manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease.

Battery Storage

Remove the battery from the vehicle and ensure that it's fully charged before placing it in storage. See Chapter 10 for instructions.

Engine Anti-Freeze

Test engine coolant strength and change if necessary. Coolant should be replaced every two years.

Storage Ar ea / Covers

Set the tire pressure and safely support the A TV with the tires 12" off the ground. Be sure the storage area is well ventilated, and cover the machine with a genuine Polaris ATV cover.

NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

Transporting the ATV

Follow these procedures when transporting the vehicle:

1. Turn off the engine and remove th e key to prevent loss during transporting.

2. Always place the transmission in park and lock the parking brake.

3. Be sure the fuel cap, oil cap and seat are installed correctly.

4. Always tie the frame of the A TV to the transporting unit securely using suitable straps or rope.

2.34

800 EFI Dual Exhaust Canister Maintenance (Sportsman Only)

The canisters on select dual exhaust Polaris Sportsman 800 EFIs

(X2 not applicable) are silver ceramic coated. To maintain a

beautiful finish and prevent corrosion, periodic maintenance is required.

CAUTION

DO NOT use caustic chemicals to clean, as they

may damage the finish.

1. Wash any accumulated mud or debris from the canisters with a soft brush and soapy water.

2. Use a cleaner, such as HPC HiPerWash to clean away any remaining grime, salts or oils.

3. If the canisters are stained from oils or other fluids, use fine steel wool with HPC Liquid Buff remove the stain.

4. After removing the stains, poli sh using Liquid Buff and a soft cloth.

 Cleaner and Polish to

MAINTENANCE

Repeat this procedure as often as desired to maintain the finish.

800 EFI Dual Exhaust System

(X2 not applicable)

2.35

MAINTENANCE

Maintenance Schedule

Service Date Hours / Miles Service Performed Serviced By:

2.36

ENGINE

CHAPTER 3

ENGINE

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

CRANKCASE EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2

ENGINE FASTENER TORQUE PATTERNS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10

700/800 EFI ENGINE SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13

GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14

PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14

COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14

COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15

FOUR STROKE - COOLANT AIR BLEEDING PROCEDURE. . . . . . . . . . . . . . . . . . . .3.15

ENGINE REMOVAL (TYPICAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17

CYLINDER HONE SELECTION AND HONING PROCEDURE. . . . . . . . . . . . . . . . . . .3.18

HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18

CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18

OIL FLOW CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19

ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19

OIL PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19

ENGINE DISASSEMBLY AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20

CYLINDER HEAD ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20

ROCKER ARMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21

PUSH RODS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21

CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22

CYLINDER HEAD WARP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22

VALVE SEAL/SPRING SERVICE

(ON ENGINE)3.22

CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23

VALVE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24

COMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25

VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25

CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27

VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28

CYLINDER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28

VALVE LIFTER REMOVAL/INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28

PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29

CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.30

PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31

PISTON/ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31

PISTON RING INSTALLED GAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.32

STARTER DRIVE/BENDIX REMOVAL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . .3.32

FLYWHEEL / STATOR REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33

ENGINE CRANKCASE DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .3.34

CAMSHAFT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41

ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42

FLYWHEEL / STATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.53

CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.54

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.56

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.56

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.57

800 EFI EXHAUST SYSTEM (DELUXE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58

DUAL EXHAUST LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.58

3.1

ENGINE

)

SPECIFICATIONS

Crankcase Exploded Views

A. J ourna lBear ings B. Camshaft C. Thrust Plate D. Balance Shaft E. Woodruff Key F. Flange Seal G. Crankshaft H. Oil Pickup I. Journal Bearings J. Baffle K. Oil Plug L. Washer M. O-ring N. Crankcase O. Crankcase Bolts

115  12 in.l (13  1.35 Nm

60  6 in.lbs. (6.8  .68 Nm)

60  6 in.l (6.8 .68 Nm

NOTE: If needed, heat the oil baffle bolts with a heat gun to remove.

192  24 in.lbs (21.7  2.7 Nm

3.2

22  2 ft.lbs. (30  3 Nm)

Apply Loctite242 to bolt threads.

Apply White Lithium Grease

Apply Moly Lube Grease.

Oil / Water Pump and Timing Cover Exploded View

22  2 ft.lbs. (30  3 Nm)

84  8 in.lbs. (9.5  .90 Nm)

A. Split Gear B. Washer C. Bolt D. Oil Rotor E. Oil Pump F . Mag Gasket Cover G . Impeller H. Washer I. Nut J. Counterbalance Gear K. Washer L. Bolt M. Oil Pump Bolts N. Gear/Stator cover O. Wire Hold down P . Stator Housing Bolts

ENGINE

Oil Pump Bolt Tighten Sequence

No Grease on this Portion of the Gasket!

Apply corrosion resistant grease to stator grommet area.

96  3 in.lbs.

(10.85  0.35 Nm)

Mag Cover Bolt Tighten Sequence

Apply Polaris OW-40 oil to component

108 12 in.lbs. (6.8  .68 Nm)

Apply White Lithium Grease

3.3

ENGINE

Starter / Flywheel / Water Pump Exploded View

Apply Polaris Starter Grease

Apply Polaris 0W-40 oil to seal

Loctite Pipe Sealant

(PN 2871956)

84  8 ft.lbs. (9.5 0.9 Nm)

Tighten Top Bolt First

108  12 ft.lbs. (12  1.35 Nm)

Water Pump Cover Bolt Tighten Sequence

No Grease or Oil

96  12 in.lbs. (10.85  1.35 Nm)

65  7 ft.lbs. (88  9.5 Nm)

A. Bolts B. Starter C. Washer D. Nut E. Positive Cable F. Negative Cable G. Gasket H. Clamp I. Bolts J. Gasket K. Wa ter P ump C over L. Bolts M. Cr ank Nu t/Wash er N. Flywheel O. Bendix

96  12 in.lbs. (10.85 1.35 Nm)

Stator Cover Bolt Tighten Sequence

3.4

Oil System / Level Assembly Exploded View

A. Clamp B. Oil Fill Tube C. Dipstick D. O-ring E. Hex Plug F. Oil Filter Nipple G. Oil Filter H. Dowel I. Galley Plug J. Nut/washer K. Spring

50  5 in.lbs. (5.64  0.56 Nm)

22  2 ft.lbs. (30  3 Nm)

ENGINE

18  2 ft.lbs. (24.4  2.71 Nm)

35  4 ft.lbs. (47.5  5.4 Nm)

50  5 in. lbs. (5.65 0.56 Nm)

3.5

ENGINE

Cylinder / Cylinder Head Exploded View

 Lubricate threads & between

washers and underside of bolt heads with engine oil. Torque in

sequence provided.

Apply Moly Lube grease to valve

tips.

Gasket free of oil. Verify tabs

are visible.

 Apply thin film of 0W-40

to 25-55 mm of cylinder bore.

 Apply 0W-40 to piston pin or

pin bore.

Apply 0W-40 to lifters.

Do Not install expansion plug more than 1.5 mm inward.

1.5 mm

(Apply each Bolt Threads)

22 ± 2 ft.lbs. (30 ± 3 Nm)

Initial: 35  4 ft. lbs (47.5  5.5 Nm) in sequence. Finalize sequence by tightening an

additional 90 (1/4 turn)

  

  

Head Bolt Tighten Sequence

Side View

A. Head Bolts B. Rocker Arms C. Head Assem bly D. Gasket E. Pushrods F . Bushing G. Expansion Plug H. Cylinder I. Piston Assembly J. Circlip K. Gasket L. Hydraulic Lifter

Apply Polaris 0W--40 Oil

Apply Moly Lube Grease

Circlip UP

for Install

3.6

Engine Sensors & Misc. Exploded View

ENGINE







A. Screws B. Rocker Cover C. Breather D. O-ring Seal E. Breather Bolts F. Spark Plugs G. Carburetor Boot H. Bolts I. Boot Clamp J. Throttle Body K. Crank Position Sensor L. Thermistor M. O-ring N. Thermostat Housing O. Bolts P. Gasket Q. Exhaust Manifold R. Bolts S. Thermostat







18  2 ft.lbs. (24.5  2.7 Nm)

20  5 in.lbs. (2.5  0.55 Nm)

Apply Corrosion Resistant Grease

84  4 in.lbs. (9.5  0.9 Nm)

20  5 in.lbs. (2.5  0.55 Nm)

18  2 ft.lbs. (24.5  2.7 Nm)

(Apply Dielectric Grease to threads of Spark Plug)

84  4 in.lbs. (9.5  0.9 Nm)

18  2 ft.lbs. (24.5  2.7 Nm)

25  3 ft.lbs. (34  0.14 Nm)

84  4 in.lbs. (9.5  0.9 Nm)

3.7

ENGINE

EFI Harness Exploded View

A. Fuel Injector B. Fuel Rail C. EFI Harness

18  2 ft.lbs. (24.5  2.7 Nm)

3.8

NOTE: See Chapter 4 for more information on the EFI system.

Engine Fastener Torque Patterns

Crankcase Bolt Tighten Sequence

ENGINE

22  2 ft.lbs. (30  3 Nm)

Lubricate threads and between washer and underside of bolt with engine oil. Torque in sequence to spec provided, allow the gasket t o set for 1 minute, then

tighten in sequence 90

35  4 ft.lbs. (47.5  5.5 Nm)

 (1/4 turn).

+ 90

 (1/4 turn)

3.9

ENGINE

Torque Specifications

Table 3-1: Engine Torque Specifications

FASTENER SIZE IN.LBS. (NM) FT.LBS. (NM)

Camshaft Gear 8 mm 22 ± 2 (30 ± 3) Camshaft Thrust Plate 6 mm 115 ± 12 (13 ± 1.35) 9.5 ± 1 (13 ± 1.35) Carburetor Adaptor Bolts 8 mm 216 ± 24 (24.5-± 2.7) 18 ± 2 (24.5 ± 2.7) Counterbalance Gear 8 mm 22 ± 2 (30 ± 3) Crankcase Bolts 8 mm * 22 ± 2 (30 ± 3) Crankcase Breather 5 mm 20 ± 5 (2.5 ± 0.55) Cylinder Head Bolts 11 mm * 35 ± 4 (47.5 ± 5.5) Exhaust Manifold 8 mm 216 ± 24 (24.5 ± 2.70) 18 ± 2 (24.5 ± 2.7) Flywheel 14 mm 65 ± 7 (88 ± 9.50) Injector Rail 8 mm 216 ± 24 (24.5 ± 2.70) 18 ± 2 (24.5 ± 2.7 ) Magneto Cover 6 mm * 96 ± 3 (10.85 ± 0.35) Oil Baffle Weldment 5 mm 60 ± 6 (6.8 ± 0.6 8) Oil Drain Bolt (Crankcase) 12 mm 192 ± 24 (21.7 ± 2.7) 16 ± (21.7) 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) 18 ± 2 (24.5 ± 2.7) Starter Motor 6 mm * 84 ± 8 (9.5 ± 0.9) Stator Assembly 6 mm 96 ± 3 (10.85 ± 0.35) Stator Housing 6 mm * 96 ± 3 (10.85 ± 0.35) Temperature Switch 3/8 NPT 25 ± 3 (34 ± 4) Thermostat Housing 6 mm 84 ± 8 (9.5 ± 0.9) Timing Plug 3/4-16 7-9 (10-12 Nm) Trigger Coil/Stator Wire Holddown 5 mm * 96 ± 3 (10.85 ± 0.35) Water Pump Housing Cover 6 mm * 96 ± 3 (10.85 ± 0.35) Water Pump Impeller Nut 8 mm 108 ± 3 (12 ± 0.35) -

NOTE: * See exploded views for notes or torque sequences.

3.10

700/800 EFI Engine Service Specifications

Table 3-1: Engine Specifications

MAIN COMPONENT: CYLINDER HEAD EH068OLE / EH076OLE

Cam Lobe Height - Intake / Exhaust 1.3334" (33.8674 mm) Camshaft Journal Outer Diameter - Mag 1.654"  0.00039" (42  0.010 mm) Camshaft Journal Outer Diameter - Center 1.634"  0.00039" (41.50  0.010 mm)

ENGINE

Camshaft Journal Outer Diameter - PTO 1.614"  0.00039" (41  0.010 mm)

Camshaft

Counter Balance C ounter Balance End Play 0.005" (0.127 mm)

Cylinder Head

Valve Seat

Valve Guide

Camshaft Journal Bore Inner Diameter - Mag 1.656"  0.00039" (42.07  0.010 mm) Camshaft Journal Bore Inner Diameter - Center 1.637"  0.00039" (41.58  0.010 mm) Camshaft Journal Bore Inner Diameter - PTO 1.617"  0.00039" (41.07  0.010 mm) Camshaft Oil Clearance 0.00276"  0.00079" (0.07  0.02 mm) Camshaft End Play 0.0167"  0.0098" (0.425  0.25 mm)

Cylinder Head - Surface warp limit 0.00394" (0.1 mm) Cylinder Head - Standard height 3.478" (88.35 mm)

Valve Seat - Contacting Width - Intake

Valve Seat - Contacting Width - Exhaust

Valve Seat Angle 45.5  0.255 Valve Guide Inner diameter 0.2367"  0.00029" (6.012  0.007 mm) Valve Guide Protrusion Above Head 0.807"  0.0039" (20.50  0.01 mm)

0.0472"  0.00787" - 0.0039" (1.20  0.20 - 0.10mm)

0.0591"  0.00787" - 0.0039" (1.50  0.20 - 0.10 mm)

Valve

Valve Spring

Valve Margin Thickness - Intake

Valve Margin Thickness - Exhaust

Valve Stem Diameter - Intake 0.2356"  0.00039" (5.985  0.01 mm) Valve Stem Diameter - Exhaust 0.2351"  0.00039" (5.972  0.01 mm) Valve Stem Oil Clearance - Intake 0.00228"  0.00098" (0.058  Valve Stem Oil Clearance - Exhaust 0.00275"  0.00098" (0.0870  0.025mm) Valve Stem Overall Length - Intake 4.51"  0.01476" (114.5550  0.375 mm) Valve Stem Overall Length - Exhaust 4.5453"  .01496" (115.45  0.38 mm) Valve Spring Overall Length - Free Length 1.735" (46.069 mm)

Valve Spring Overall Length - Installed Height

Standard: 0.79" (20.06 mm) Max- 0.98" (24.89 mm) Min- 0.59" (14.98 mm)

Standard: 0.80" (20.32 mm) Max- 1.0" (25.4 mm) Min- 0.60" (15.24 mm)

0.025 mm)

Intake - 1.4638" (37.18 mm) Exhaust - 1.4736" (37.43 mm)

3.11

ENGINE

Table 3-2: Engine Specifications

MAIN COMPONENTS: CYLINDER/PISTON/

ONNECTING ROD

Cylinder - Surface warp limit (mating with cylinder head)

Cylinder Bore - Standard 3.1495" (80 mm) 3.1495" (80 mm)

Cylinder

Lifter

Piston

Piston Pin

Cylinder Taper Limit 0.00031" (0.008 mm) 0.00031" (0.008 mm) Cylinder Out of Round Limit 0.00030" (0.0075 mm) 0.00030" (0.0075 mm )

Cylinder to Piston Clearance Lifter Outer Diameter

Standard Lifter Block Bore

Piston - Standard Piston Standard Inner

Diameter of Piston Pin Bore Piston Pin Outer Diameter Piston Pin - Standard

Clearance - Piston Pin to Pin

Piston Pin - Degree of Fit

EH068OLE EH076OLE

0.004" (0.10 mm) 0.004" (0.10 mm)

.0015"  .00059" (.040  .015mm)

0.84245"  0.00025" (21.39 8  0.00635 mm)

0.8438"  0.00062" (21.4322  0.0157 mm)

3.1477"  .000121" (79.954  .003mm)

0.78789"  .00009" (20.0125  0.003 mm)

0.7874" - 0.7872" (20 - 19.995 mm)

0.00059"  0.0002" (0.015  0.005 mm)

Piston pin must be a push fit (by hand) at 68 F (20 C)

.0015"  .00059" (.040  .015mm)

0.84245"  0.00025" (21.39 8  0.00635 mm)

0.8438"  0.00062" (21.4322  0.0157 mm)

3.14803" + .00028" (79.960 + .007 mm)

0.70902"  .00012" (18.009  0.003 mm)

0.70866" - 0.70846" (18 - 17.995 mm)

0.00047"  0.00024" (0.012  0.006 mm)

Piston pin must be a push fit (by hand) at 68 F (20 C)

3.12

ENGINE

Table 3-3: Engine Specifications

MAIN COMPONENTS: PISTON/ CONNECTING ROD EH068OLE EH076OLE

T op Ring - Standard Top Ring - Limit > 15% Leakdown > 15% Leakdown

Installed

Gap

Piston Ring

Ring to Groove

Clearance

Connecting

Rod

Crankshaft Crankshaft Runout Limit 0.00236" (0.060mm) Same

Second Ring - Standard Second Ring - Limit > 15% Leakdown > 15% Leakdown Oil Ring - Standard Oil Ring - Limit > 15% Leakdown > 15% Leakdown T op Ring - Standard Top Ring - Limit > 15% Leakdown > 15% Leakdown Second Ring - Standard Second Ring - Limit > 15% Leakdown > 15% Leakdown

Connecting Rod Small End I.D.

Connecting Rod Small End

Radial Clearance

Connecting Rod Big End

Side Clearance

Connecting Rod Big End

Radial Clearance

0.0059 0.138" (0.15 0.35mm)

0.0098  0.197" (0.25 0.50mm)

0.0196 0.00984" (0.50 0.25mm)

0.0024"  0.0008" (0.060  0.020 mm)

0.0028"  0.0008" (0.070  0.020 mm)

0.789" 0.78841" (20.030  20.015 mm)

0.0098" 0.00039" (0.025  0.010mm)

0.01181" 0.00591" (0.030  0.015mm)

0.0015" 0.00006" (0.0038  0.0015mm)

0.0059  0.138" (0.15 0.35mm)

0.0098  0.197" (0.25 0.50mm)

0.0196 0.00984" (0.50 0.25mm)

0.0024"  0.0008" (0.060  0.020 mm)

0.0028"  0.0008" (0.070  0.020 mm)

0.7096"  0.70846" (18 17.995 mm)

Same

Special Tools

PART NUMBER TOOL DESCRIPTION

PV-43527 OIL FILTER WRENCH

2200634 VALVE SEAT RECONDITIONING KIT PU-45257 VALVE SPRING COMPRESSOR PU-45652 VALVE PRESSURE HOSE

2871043 FLYWHEEL PULLER

2870390 PISTON SUPPORT BLOCK

PU-45497-1 CAM GEAR SPRING INSTALLATION KIT PU-45497-2 CAM GEAR TOOTH ALIGNMENT TOOL

PU-45498 CAM SPANNER WRENCH PU-45838 GEAR HOLDER PA-44995 WATER PUMP MECHANICAL SEAL INSTALLER PU-45543 UNIVERSAL DRIVER HANDLE PA-45483 MAIN SEAL INSTALLER PU-45658 CRANKSHAFT MAIN SEAL SAVER PA-45401 WATER PUMP SEAL SAVER

2870975 MITY VAC PU-45778 OIL SYSTEM PRIMING TOOL

 PRESSURE TEST TOOL

3.13

ENGINE

GENERAL ENGINE SERVICE

Accessible Components

Following Components can be serviced or removed with the engine installed:

• Flywheel

• Alternator (Stator)

• Starter Motor/Drive

• Cylinder Head

• Cylinder

• Piston/Rings

• Camshaft

• Rocker Arms

• Oil pump/Water Pump/Oil Pump Drive Gear

• Gear Train Components

Following Components Require Engine Removal for service:

• Counterbalance Shaft or Bearings

• Connecting Rod

•Crankshaft

Cooling System Specifications

Table 3-2:

APPROX.

CONDITION

Hot light ON 178 - 190

Fan Off 296 - 316

Fan On 236 - 251 System

Capacity

Radiator Cap

Pressure Relief

Recommended Coolant

Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area. CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/ Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.

EADING (MIN.-

AX)

Refer To Chapter 1 Specifications

215

180 195

13 PSI

EMPERATURE

F (108 C)

F (82 C) F (91 C)

• Crankshaft Main Bearings

• Crankcase

Piston Identification

Four stroke engine rings have a rectangular profile. See “PISTON RING INST ALLED GAP” for ring installation. Use the information below to identify pistons and rings.

Table 3-1:

ENGINE MODEL PISTON DIAMETER

EH068OLE EH076OLE

80 mm

Thermostat

Cylinder Head

Radiator

Water Pump

Cylinder

3.14

ENGINE

Cooling System Pressure Test

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 cool ant filler neck.

3. Connect a Mity Vac nipple and pressurize system to 10 psi. The system m ust retain 10 psi for five minutes or longer. If pressure loss is evident within five minutes, check the radiator, hoses, clamps and water pump seals for leakage.

 (PN 2870975) to the filler neck

Radiator Cap Pressure Test

1. Remove radiator cap and test cap using a commercially available cap tester.

2. The radiator cap relief pressure is 13 psi. Replace cap if it does not meet this specification.

Upper Engine Hose

Four Stroke - Coolant Air Bleeding Procedure

Pump Hose By Hand to Help Purge System

Squeeze Hose Here to Help Purge Air From System

Polaris Premium Antifreeze 2871534 - Quart 2871323 - Gallon

Use this procedure when a unit overheats and no apparent leaks in the cooling system are found.

NOTE: If the coolant level is LOW in the radi ator, or if there are leaks in the system, the coolant system will not draw coolant from the reservoir tank.

Fan Assembly

Hose

Lower Engine Hose Radiator

Surge Tank

1. Park machine on a flat surface. Remove radiator cap and top off coolant. Leave the cap off of the radiator. Start and idle machine for 5-10 minutes until steam is visible in the radiator cap area.

2. Stop the engine and let cool for a few m inutes or until an air bubble is seen at the filler neck, or there is a dropping of the coolant level indicating that coolant has been pulled into the system.

NOTE: Slowly squeezing the hose after the bend below the filler neck 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 completely filled the cooling system at the radiator filler neck.

4. Repeat Steps 1 and 2 four o r five times or until no more coolant is pulled into the system.

5. In some instances, Steps 1 and 2 may have to be performed with the radiator cap on to prevent coolant loss.

6. To test, install the radiator cap and idle machine until fan comes on. Make sure the fan comes on before the hot light.

3.15

ENGINE

Engine Removal (Typical)

WARNING

Always wear safety glasses and proper shop

clothing when performing the procedures in this

manual. Failing to do so may lead to possible inju ry

or death.

1. Clean work area.

2. Thoroughly clean ATV engine and chassis.

3. Disconnect battery (-) negative cable.

4. Remove the following parts as required:

• Seat

• Left and right side covers (refer to Chapter 5)

• Fuel tank covers

• Fuel tank (refer to Chapter 4)

• Springs from exhaust pipe and remove pipe.

5. Drain coolant and engine oil.

6. Remove air pre-cleaner and du ct.

7. Remove airbox.

8. Disconnect the throttle body sensor (C) and T-BAP sensor (D). Remove throttle body (A). Insert a shop towel into the engine intake to prevent dirt from entering the ports.

9. Relieve the fuel pressure in the fuel rail (refer to Chapter 4, FUEL INJECTION") for proper procedure. Carefully remove the fuel rail (B) and injectors.

10. Disconnect spark plug high tension leads.

11. R emove the crank position sensor (E) located on the mag cover.

12. Remove the air breather line .

13. Disconnect the coolant hoses. Properly dispose of any antifreeze from the engine or hoses.

3.16

ENGINE

14. Refer to PVT System Chapter 6 to remove outer clutch cover, drive belt, drive clutch, driven clutch, and inner cover (F).

15. When removing starter cables, note and mark ground cable and positive (+) cable mounting angle and locations. Remove cables.

16. Remove transmission linkage rod from gear selector and secure out of the way.

17. Disconnect coolant temperature sensor wire located on the cylinder.

18. Remove engine to chassis ground cable.

19. Remove all engine mount nuts and / or engine mount plates. Remove the frame brace (G) from the front left side of the frame.

20. Remove the engine from the left side of the frame.

NOTE: Use caution when lifting the engine out of frame. Use an engine lift or other means if the engine is too heavy to be lifted manually.

21. For engine installation, reverse procedures.

3.17

ENGINE

Engine Installation Notes

After the engine is installed in the frame, review this checklist and perform all steps that apply:

General Items

1. Install previously removed components using new gaskets, seals, and fasteners where applicable.

2. Perform regular checks on fluid levels, controls, and all important areas on the vehicle as outlined in the daily preride inspection checklist (refer to Chapter 2 or the Owner's Manual).

PVT System

1. Adjust center distance of drive and driven clutch. (Chapter

2. Adjust clutch offset, alignment, and belt deflection. (Chapter 6)

3. Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing. (Chapter 6)

Transmission

1. Inspect transmission operation and adjust linkage if necessary. Refer to Chapter 2 and Chapter 8.

Exhaust

1. Replace exhaust gaskets. Seal connections with high temp silicone sealant.

2. Check to be sure all springs are in good condi tion.

Bleed Cooling System

NOTE: This cooling system contains vent lines to help purge trapped air during filling. Bleeding generally should not be necessary.

1. Remove radiator cap and slowly add coolant to the bottom of filler neck.

2. Fill coolant reservoir tank to full mark.

3. Install radiator cap and gently squeeze coolant hoses to force any trapped air out of system.

4. Again, remove radiator cap and slow ly add coolant to the bottom of fill neck if needed.

5. Start engine and observe 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 Polaris ATV engine is defined as the first ten hours of operation, or the time it takes to use two full tanks of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

CAUTION

Use only Polaris Premium 0-40W All Season

synthetic oil or equivalent.

Never substitute or mix oil brands. Serious engine

d a m a g e a n d v o i d i n g o f w a r r a n t y c a n r e s u l t .

Do not operate at full throttle or high speed s fo r

extended periods during the first three hours of use.

Excessive heat can build up and cause damage to

close fitted engine parts.

1. Fill fuel tank with unleaded or leaded fuel which has a minimum pump octane number of 87= (R+ M)/2.

2. Check oil reservoir level i ndicated on dip stick. Add o il if necessary (Refer to Chapter 2, “Engine Oil Level” ).

3. Drive slowly at first to gradually bring engine up to operating temperature.

4. Vary throttle positions. Do not operate at sustained idle or sustained high speed.

5. Perform regular checks on fluid levels, controls and all important bolt torques. Pull only light loads duri ng initial break in.

6. Pull only light loads during initial break-in.

7. Change break in oil and filter at 20 hours or 200 miles.

Cylinder Hone Selection And Honing Procedure

CAUTION

A hone which will straighten as well as remove

material from the cylinder is very important. Using a

common spring loaded glaze breaker for honing is

not advised for nicasil cylinders.

Polaris recommends using a rigid hone or arbo r

honing machine. Cylinders may be wet or dry

honed depending upon the hone manufacturer's

recommendations.

Wet honing removes more material faster and

leaves a more distinct pattern in the bore.

Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations. Wet honing removes more material faster and leaves a more distinct pattern in the bore.

3.18

Honing To Deglaze

A finished cylinder should have a cross-hatch pattern to ensure piston ring seating and to aid in the retention of the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer's instructions, or these guidelines:

• Honing should be done with a diamond hone. Cylinder could be damaged if the hone is not hard enough to scratch the nicasil lining.

• Use a motor speed of approximately 300-500 RPM, run the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered (or cylinder centered on arbor) and to bring the stones approximately 1/2, (1.3 cm) above and below the bore at the end of each stroke.

• Release the hone at regular intervals and inspect the bore to determine if it has been sufficiently de-glazed, and to check for correct cross-hatch. NOTE: Do not

allow cylinder to heat up during honing.

• 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 de-glaze the outer layer of the cylinder bore.

ENGINE

Example of Cross Hatch Pattern

IMPORTANT: Clean the cylinder after honing

Cleaning the Cylinder After Honing

It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder in a solvent, then in hot, soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris Lubricant.

3.19

ENGINE

Oil Flow Chart

This chart describes the flow of oil through the 700/800 engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through th e oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. At this point, the oil is supplied to the main oil galley through a crankcase passage. Oil is then diverted three ways from the main oil galley, with the 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 oil pressure switch is fed off the main oil galley.

Engine Lubrication Specifications OIL PRESSURE TEST

1. Remove blind plug/sender from left side of crankcase.

Capacity - Approximately 2 U.S. Quarts (1.9 l)

Oil Type - Polaris Premium 0W-40 Synthetic

Filter Wrench - PV-43527 or equivalent

- Oil Pressure Specification -

35-39 PSI @ 5500 RPM, Polaris 0W-40 Synthetic ,

Engine at operating temperature.

2. Insert a 1/8 NPT oil pressure gauge adaptor into the crankcase and attach the gauge.

3. Start engine and allow it to reach operating temperature, monitoring gauge indicator.

NOTE: Use only Polaris Premium 0W-40 Synthetic Engine Lubricant.

Oil Pressure at 5500 RPM (Engine Hot):

Standard: 39 PSI

Minimum: 35 PSI

3.20

ENGINE DISASSEMBLY AND INSPECTION

Cylinder Head Assembly Exploded View

Rocker Arms

Retainer Locks (keepers)

ENGINE

Spring Retainers

Springs

Valve Seals

Cylinder Head

Valves

:Push Rods

Hydraulic Lifters

3.21

ENGINE

Rocker Arms

1. Mark or tag rocker arms in order of disassem bly to keep them in order for reassembly.

2. Inspect the wear pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. If the pad is grooved, replace the rocker arm.

NOTE: Do not attempt to true this surface by grinding.

3. Check the rocker arm pad and fulcrum seat for excessive wear, cracks, nicks or burrs.

Push Rods

5. If the push rod (A) is visibly bent, it should be replaced.

Cylinder Head Removal

1. Loosen the six cylinder head bolts evenly 1/8 turn each in a criss-cross pattern until loose.

2. Remove bolts (A) and tap cyli nder head (B) ligh tly with a soft face hammer until loose. CAUTION: Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging the head or cylinder.

3. Remove cylinder head (B) and head gasket (C) from the cylinder (D).

1. Clean push rods (A) in a su itable solvent. Blow dry push rods with compressed air.

2. Use compressed air to confirm the oil passage is clear in the center of the push rod.

WARNING

Always wear safety glasses when working with

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.

3.22

ENGINE

Cylinder Head Inspection

Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon.

CAUTION

Use care not to damage sealing surface.

Cylinder Head Warp

1. Lay a straight edge (A) across the surface of the cylinder head (B) at several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface. If warp exceeds the service limit, replace the cylinder head.

Valve Seal/Spring Service (On Engine)

NOTE: The following procedure is only for servicing the top end of the valve train when replacing valve springs or replacing valve seals.

In some cases the valve train can be serviced while the cylinder head 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 (TDC). Install the Valve Pressure Hose (PU-

45652) into the spark plug hole. Hook the hose to an air compressor and supply 50 to 100 psi to the hose. This will seat the valves during valve spring removal. Do not remove air from the hose at anytime until reassembly is completed.

2. Using the Valve Spring Compressor (PU-45257), compress the valve spring and remove the valve keepers. NOTE: A small parts magnet (A) can aid in the removal of the retainers (B).

Measure at different points on the surface.

Cylinder Head Warp Limit:

.004" (.1016 mm) max

= In. / mm.

PU-45257

NOTE: To prevent damage to the valve seals, do not compress the valve spring more than is needed to remove the valve keepers.

3. Remove spring retainer and spring.

4. The valve seals are now serviceable.

3.23

ENGINE

Cylinder Head Disassembly

1. Carefully remove the cylinder components. Place the hydraulic lifters (C), pushrods (D), and rocker arms (E ) in a safe, clean area.

3. 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.

4. Mark the valves with a white pen. Remove the valves from the cylinder head. This will ensure that the valves are properly placed during engine reassembly.

2. Measure free length of spring with a Vernier caliper. Compare to specifications. Replace spring if measurement is out of specification.

Valve Spring Free Length

Mark the Valves

3.24

= In. / mm.

Valve Spring Free Length:

Std: 1.735" (44.069 mm)

ENGINE

Valve Inspection

1. Remove all carbon from valv es with a soft wire wheel or brush.

2. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” blocks and a dial indicator.

3. Check end of valve stem for flaring, pitting, wear or damage (A).

measurements total). Compare to specifications.

Measure valve stem in several places. Rotate the valve 90 degrees and measure for wear.

= In. / mm.

Valve Stem Diameter:

Intake: 0.2356" + 0.00039"

(5.985 + 0.01 mm)

Exhaust: 0.2351" + 0.00039"

(5.972 + 0.01 mm)

6. Measure valve guide (C) inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer. Measure in two directions.

4. Inspect split keeper groove for wear or flaring of the keeper

seat area (B). NOTE: The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent, or damaged.

5. Measure diameter of valve stem with a micrometer in three places, then rotate 90 degrees and measure again (six

= In. / mm.

Valve Guide I.D.:

0.23672" + 0.000295" (6.0617 + 0.0075 mm)

7. Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance. NOTE: The valve guides cannot be replaced. Be sure to measure each guide and valve combination individually.

3.25

ENGINE

Combustion Chamber

1. Clean all accumulated carbon deposits from combustion chamber and valve seat area with carbon cleaner and a soft plastic scraper.

IMPORTANT: Do not use a wire brush, metal scraper, or abrasive cleaners to clean the bottom of the cylinder head. Extensive damage to the cylinder h ead may result. Wear safety glasses during cleaning.

Combustion Area

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 width all the way around. If the seat is uneven, compression leakage will result. If the seat is too wide, seat pressure is reduced, causing carbon accumulation and possible compression loss. If the seat is too narrow, heat transfer from valve to seat is reduced. The valve may overheat and warp, resulting in burnt valves.

Valve Seat Reconditioning

NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area.

NOTE: The cylinder head valve guides cannot be replaced.

WARNING

Wear eye protection or a face shield during cylinder

head disassembly and reassembly.

Valve Seat Inspection

Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be reconditioned. If the valve seat is

cracked the cylinder head must be replaced.

Follow the manufacturers instructions provided with 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.

1. Install pilot into valve guide.

2. Apply cutting oil to valve seat and cutter.

3. Place 46

 cutter on the pilot and make a light cut.

3.26

ENGINE

4. Inspect the cut area of the seat: * If the contact area is less than 75% of the circumference of the

seat, rotate the pilot 180 * If the cutter now contacts the uncut portion of the seat, check

the pilot. Look for burrs, nicks, or runout. If the pilot is bent it must be replaced.

* If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation

* If the contact area of the initial cut is greater than 75%, continue to cut the seat until all pits are removed and a new seat surface is evident. NOTE: Remove only the amount of material necessary to repair the seat surface.

5. To check the contact area of the seat on the valve face, apply a thin coating of Prussian Blue paste to the valve seat. If using an interference angle (46 marker to the entire valve face (A).

 and make another light cut.

) apply black permanent

NOTE: When using an interference angle, the seat contact point on the valve will be very narrow, and is a normal condition. Look for an even and continuous contact point all the way around the valve face. (B)

Proper Seat Contact On Valve Face

Bottom 60

Seat 45

Top 30

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

7. Remove valve and check where the Prussian Blue indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width.

* 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 * If too low, use the 60

area is centered on the valve face, measure seat width. * If the seat is too wide or uneven, use both top and bottom

cutters to narrow the seat. * If the seat is too narrow, widen using the 45

check contact point on the valve face and seat width after each cut.

 cutter to lower the valve seat.

 cutter to raise the seat. When contact

 cutter and re-



Seat Width

= In. / mm.

Valve Seat Width:

Intake Std: .028" (.7 mm)

Limit: .055" (1.4 mm)

Exhaust Std: .039I (1.0 mm)

Limit: .071" (1.8 mm)

8. Clean all filings from the area with hot soapy water, rinse, and dry with compressed air.

3.27

ENGINE

9. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve.

NOTE: Lapping is not required with an interference angle valve job.

10. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem.

11. Rotate the valve rapidly back and forth until the cut sounds smooth. Lift the valve slightly off of the seat, rotate 1/4 turn, and repeat the lapping process. Do this four to five times until the valve is fully seated, and repeat process for the other valve(s).

12. Thoroughly clean cylinder head and valves.

4. Valve seals should be inst alled after the valves are in the head to avoid valve seal damage. Install new valve seals on valve guides.

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 0W40 Synthetic oil.

3. Install valve carefully with a rotating motion to avoid damaging valve seal.

5. Dip valve spring and retainer in clean engine oil and install.

6. Place retainer on spring and install Valve Spring

Compressor (PU-45257). Install split keepers with the gap even on both sides.

NOTE: A small magnet can aid in installation of the keepers.

PU-45257

3.28

ENGINE

7. Repeat procedure for remaining valves. When all valves are installed, tap lightly with soft faced hammer on the end of the valves to seat the split keepers.

NOTE: To prevent damage to the valve seals, do not compress the valve spring more than necessary to install the keepers.

Valve Sealing Test

1. Clean and dry the combustion chamber area (A).

Valve Lifter Removal/Inspection

1. Remove the valve lifter's by reaching into the crankcase and pushing the lifter up through the lifter bore by hand.

2. Thoroughly clean the lifters in cleaning solvent and wipe them with a clean lint-free cloth.

3. Mark the lifters with a white pen if using the lifters for reassembly. This will ensure that the lifters are properly placed during engine reassembly.

Mark Hydraulic Lifter

2. Pour a small amount of clean solvent onto the inta ke 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.

Cylinder Removal

1. Follow engine disassemb ly procedures to remove rocker cover and cylinder head.

2. Tap cylinder (A) lightly with a rubber mallet in the reinforced areas only until loose.

3. Rock cylinder forward and backward while lifting it from the crankcase, supporting pistons and connecting rods. Support pistons with Piston Support Block (PN 2870390).

4. Check the lifters for wear or scores.

5. Check the bottom end of lifter to mak e 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 replacing the lifters, the camshaft should also be replaced.

3.29

ENGINE

Piston Removal

1. Remove circlip (A). Mark the piston with a white pen to ensure proper orientation (if reused) during assembly.

NOTE: If the pistons are to be reused, reassemble the pistons in the same cylinder and direction from which they were removed.

NOTE: New pistons are non-directional and can be placed in either cylinder.

*By hand: Placing both thumbs as shown, spread the ring open and push up on the opposite side. Do not scratch the ring lands.

4. Repeat procedure for second 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.

2. Remove piston circlip and push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch. CAUTION: Do not apply heat to the piston rings. The ring may lose radial tension.

3. Remove top compression ring:

*Using a piston ring pliers: Carefully expand ring and lift it off the piston. CAUTION: Do not expand the ring more than the amount necessary to remove it from the piston, or the ring may break.

To Remove: A) Remove the top rail first followed by the bottom rail. B) Remove the expander.

Compression Rings

Oil Ring

3.30

ENGINE

Cylinder Inspection

1. Remove all gasket material from the cylinder sealing surfaces.

2. Inspect the top of the cylinder (B) for warp using a straight edge (A) and feeler gauge (C). Refer to Ill. 1 and Ill. 2.

Measure at different points on surface.

3. Inspect cylinder for wear, scratches, or damage.

4. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure in two different directions, front to back and side to side, on three different levels (1/2, down from top, in the middle, and 1/ 2, up from bottom). Record measurements. If cylinder is tapered or out of round beyond .002", the cylinder must be replaced.

1/2” Down From Top of Cylinder

= In. / mm.

Cylinder Warp: .004" (0.1 mm) Max.

1/2” Up From Bottom

= In. / mm.

Cylinder Taper Limit:

.002" (9.05mm) Max.

Cylinder Out of Round:

Limit: .002" (.0 mm) Max.

700/800 Standard Bore Size

(Both Cylinders): 3.1496

" (80 mm)

3.31

ENGINE

Piston-To-Cylinder Clearance

Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin.

Subtract this measurement from the maximum cylinder measurement obtained in Step 5.

5 mm

Piston

Piston Pin

Piston to Cylinder Clearance:

See “700/800 EFI Engine Service

Specifications” on page 3.11

Piston O.D.:

See “700/800 EFI Engine Service

Specifications” on page 3.11

2. Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance.

Piston Pin Measurement Locations

Piston Pin O.D.:

See “700/800 EFI Engine Service

Specifications” on page 3.11

3. Measure connecting rod small end ID.

Piston/rod Inspection

1. Measure piston pin bore.

Piston Pin Bore:

See “700/800 EFI Engine Service

Specifications” on page 3.11

Connecting Rod Small End I.D.:

See “700/800 EFI Engine Service

Specifications” on page 3.11

3.32

ENGINE

4. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Replace piston and rings if ring-to-groove clearance exceeds service limits.

See “700/800 EFI Engine Service Specifications” on page 3.11

Piston

Ring

Feeler Gauge

Piston Ring Installed Gap

1. Place each piston ring (A) inside cylinder (B) using piston to push ring squarely into place as shown. (See next page)

thoroughly with hot soapy water, rinsed, and dried completely. Wipe cylinder bore with oil immediately to remove residue and prevent rust.

Starter Drive/Bendix Removal Inspection

1. Remove stator housing bolts and remove housing.

2. Remove the flywheel nut and washer. Install Flywheel Puller (PN 2871043) and remove flywheel.

NOTE: Do not thread the puller bolts into the flywheel more than 1/4, or stator coils may be damaged.

3. Remove starter bendix assembly (A). Note the thrust washers located on both sides of the bendix.

25-50 mm

Piston Ring Installed Gap

See “700/800 EFI Engine Service

Specifications” on page 3.11

NOTE: Ring should be installed with the mark 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 rings. If ring gap is smaller than the specified limit, file ring ends until gap is within specified range.

NOTE: Always check piston ring installed gap after re-boring a cylinder or when installing new rings. A re-bored cylinder should always be scrubbed

4. Inspect the thrust washer for wear or damage and replace if necessary.

5. After the bendix is remo ved, tap on the starter assembly with a soft faced mallet to loosen the starter from the crankcase.

3.33

ENGINE

6. Inspect gear teeth on starter drive (B). Replace starter drive if gear teeth are cracked, worn, or broken.

7. Inspect the bendix bushing (C) in the mag cover for wear. Replace as needed.

Flywheel / Stator Removal / Inspection

1. Remove stator housing bolts and remove housing.

3. Install Flywheel Puller (PN 2871043) and remove flywheel (A). CAUTION: Do not thread the puller bolts into the flywheel more than 1/4, or stator coils may be damaged.

2871043

4. Use caution when removing the wire holddown (B), trigger coil (C), and the stator assembly (D). Do not tap or bump the gear /stator housing cover or the stator. This could cause the seal around the gear/stator housing cover and the crankcase to break, causing a leak.

2. Remove flywheel nut and washer.

Remove Stator Cover

5. Remove the bendix (E) if necessary.

3.34

ENGINE

Engine Crankcase Disassembly / Inspection

1. Remove the stator cover (A) and water pump cover (B).

2. Remove the nylok nut (C), washer (D), and water pu mp impeller (E). Remove part of the water pump seal behind the impeller.

4. Install Flywheel Puller (PN 2871043) and remove flywheel (F). CAUTION: Do not thread the puller bolts into the flywheel more than 1/4, or stator coils may be damaged.

5. Remove the starter ben dix (G), wire holddown plate (H), and the woodruff key (I) from the crankshaft. The stator does not have to be removed at this point.

3. Remove flywheel nut and washer.

6. Remove the gear/stator housing bolts and remove the gear/ stator housing cover (J) and gasket from the crankcase. Be sure to catch the excess oil from the crankcase.

3.35

ENGINE

7. Note the positions of the gears in the photo.

Camshaft Gear

Crank 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 timing during reassembly of the gears.

Counterbalance Gear

Water Pump Gear

Timing Marks

10. Inspect the cam gear teeth and check to make sure there is spring tension offsetting the teeth between the two gears. If there is no tension, check the springs inside of the cam gear assembly.

3 Loaded Springs

11. T he cam gear assembly contains three loaded springs. To open the cam gear assembly:

* Place the cam gear on a flat surface with the timing mark side facing up.

* While holding both gears together, lightly work a small flathead screwdriver between the two gears.

NOTE: If replacing one of the gears, it is recommended that all of the gears be replaced. A gear kit is available in the parts book.

9. Use the Cam Gear Tooth Alignment Tool (PU-45497-2) (O) to align the cam split gear assembly. With the split gear aligned, remove the bolt and cam gear assembly.

NOTE: Install the Cam Gear Tooth Alignment Tool (PU-45497-2) into the assembly hole counter clockwise from the timing mark as shown.

* Remove the top gear. The springs should stay in place.

CAUTION

Wear safety glasses at all times. Use caution when working with the top gear. The springs could cause

injury or become lost should they pop out.

12. Remove all three springs using one of the tapered pins from

the Tapered Pins (PU-45497-1).

3.36

ENGINE

13. With a white marking pen, accent the timing mark on the gear that contains the springs.

Accent Timing Marks

14. Inspect the gear teeth and the three tabs on the gears for wear.

Inspect Teeth & Tabs

16. Insert the pointed dowels from the Tapered Pins (PU45497-1) into the cam gear.

PU-45497-1

To Assemble:

* Hold the spring with one finger. * Start the 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.

* Perform this procedure with all three tapered pins. * Do not push the pins too far through or the springs will pop

out.

NOTE: Do not remove the tapered pins at this time.

Replace 3 Springs

15. Install the new springs into the grooves of the cam gear.

Install Springs

17. Note in the photograph that the Tapered Pins (PU-45497-

1) are below flush with end of the springs. This helps to

align the three gear tabs during the next step.

PU-45497-1

Cam Gear Spring Installation Tool Kit:

(PU-45497)

Tapered Pins: (PU-45497-1)

Cam Gear Tooth Align Tool: (PU-45497-2)

3.37

ENGINE

18. Line up the two gears using the timing marks and the three gear tabs that were referenced earlier. Push the gears back together, using both hands and hold securely.

Align Timing Marks

19. Once the gears are pressed together, firmly hold the gears together with one hand. Carefully remove the Tapered Pins (PU-45497-1) by pulling them out one at a time with the other hand.

NOTE: Install the Cam Gear Alignment Tool (PU45497-2) 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 camshaft, use the Cam Spanner Wrench (PU-45498) to rotate the camshaft so the flat side of the camshaft faces the balance shaft gear.

20. After the tapered pins are removed, be sure the cam gear assembly is held together tightly. Place the cam gear assembly on a flat surface. Use the Cam Gear Tooth Alignment Tool (PU-45497-2) to align the teeth of the cam gears, as shown in the picture.

PU-45498

NOTE: This Cam Spanner Wrench (PU-45498) is only needed to rotate the camshaft when the entire valve train is assembled. If the rocker arms are removed, the cam-shaft can be turned by hand.

3.38

ENGINE

22. Remove the bolt and nut from the balance shaft gear. Try to remove the balance shaft gear. If the gear does not come off manually, use the Flywheel Puller (PN 2871043) to remove the balance shaft gear.

2871043

23. Inspect the crankshaft gear (Q) for broken or worn teeth. If the crankshaft gear does not need to be replaced, it does not need to be removed. If the crankshaft gear is damaged, remove the crankshaft gear with the Flywheel Puller (PN

2871043).

25. Install the Flywheel Puller (PN 2871043) and rem ove the

crankshaft gear, if needed.

2871043

26. Rotate the water/oil pump gear (S), so that all four bolts are visible though the gear. Remove the four bolts with a hex wrench. Pull out the pump.

24. Install the two puller bolts (R). Tighten the puller bolts up so that the bolts are at equal length.

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 rotors are installed and mesh with the same edges as previously installed.

NOTE: If replacing the old rotors, new replacement rotors will fit into the old oil/water pump housing.

3.39

ENGINE

28. Use a feeler gauge to measure the clearance between the two rotors. Measure the gap between the two rotor tips as shown below. The clearance should not exceed 0.006" (0.15 mm).

0.006” (0.15 mm) Max Tip Clearance

29. Remove the oil pressure relief. The oil pressure relief consists of a bolt, washer, spring, and valve (dowel). Inspect the valve (dowel) for signs of possible obstructions. Use compressed air to blow out any debris.

NOTE: Be sure to place the tapered end of the valve (dowel) in first. If the valve is installed incorrectly, oil pressure and oil priming problems will occur.

31. Carefully press the gear off the assembly while supporting the housing assembly.

Press Off Gear

CAUTION

Wear appropriate safety gear during this procedure.

Protective gloves, clothing and eyew ea r are

required.

30. Reinstall the valve (dowel chamfered end first). Install the spring, washer, and bolt. Torque to specification .

22 22  2 ft. lbs. (30  3 Nm).

Chamfer End First

32. Remove the snap ring from the assembly. Place the housing in a support and press out the bearing/shaft assembly.

Press Out shaft and bearing assembly.

Bearing

Retaining Ring

3.40

= T

22  2 ft. lbs. (30  3 Nm)

ENGINE

33. Place the shaft in a press to remove the bearing.

Bearing

34. Press shaft into the new bearing..

New Bearing

36. Press gear onto shaft while supporting the housing.

37. Remove thrust plate (U).

35. Press the bearing/shaft assembly using the bearing's outer race. Do not use the shaft to press the assembly into the housing, as bearing damage may result. Install retaining ring.

Press Bearing/Shaft Assembly using outer race only

38. 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 Crankcase Halves

3.41

ENGINE

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 the Loctite This will prevent any possible damage to the bolts or to the crankcase casting.

39. Remove and clean oil pick up (V) and oil baffle weldment (W).

.

40. Remove balance shaft and crankshaft.

41. R emove and inspect crankshaft main journal bearings for

abnormal wear. It is recommended to replace the bearings anytime the engine is disassembled.

NOTE: Plain bearing clearances may be checked using a commercially available plasti-gauge material.

Camshaft Inspection

1. Thoroughly clean the cam shaft.

2. Visually inspect each cam lobe for wear, chafing or damage.

3. Measure height of each cam lobe using a micrometer. Compare to specification.

3.42

Cam Lobe Height

= In. / mm.

Cam Lobe Height

(Intake & Exhaust):

Std: 1.3334" (33.8674 mm)

ENGINE

4. Measure camshaft journal outside diameters (O.D.).

= In. / mm.

Camshaft Journal O.D. :

A. (Mag): 1.654" ± .00039" (42 ± .010 mm)

B. (Ctr.): 1.634" ± .00039" (41.50 ± .010 mm)

C. (PTO): 1.614" ± .00039" (41 ± .010 mm)

5. Measure ID of camshaft journal bores.

ENGINE REASSEMBLY

CRANKCASE REASSEMBLY

CAUTION

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 of this section to prime the engine and

to help aid proper 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 bolts.

1. Install oil pick up (A), if removed. Torque to specification.

= In. / mm.

Camshaft Journal Bore I.D.:

(Mag): 1.656" ± 0.00039" (42.07± 0.010 mm)

(Ctr.) 1.637" ± 0.00039" (41.58 ± 0.010 mm)

(PTO) 1.617" ± 0.00039" (41.07 ± 0.010 mm)

6. Calculate oil clearance by subtracting j ournal O.D.'s from journal bore I.D.'s. Compare to specification.

= In. / mm.

Calculated Camshaft Oil Clearance:

Std: 0.0027" (.070mm) Limit: .0039" (.10 mm)

NOTE: Replace camshaft if damaged or if any part is worn past the service limit.

NOTE: Replace engine block if camshaft journal bores are damaged or worn excessively.

2. Install oil baffle weldment (B). Torque bolts to specification.

= T

Oil Baffle Weldment &

Oil Pick Up Bolt Torque:

60 ± 6 in. lbs. (6.8 ± 0.68 Nm)

3. Install the balance shaft. Inspect balance shaft clearance (C) in both gearcase halves. Rotate balance shaft to ensure that there is clearance between it and oil baffle weldment.

3.43

ENGINE

NOTE: Always install new balance shaft bearings.

4. Apply assembly lube to cam journals and balance shaft bearing surfaces of the MAG case halve. Install cam and balance shafts.

6. Apply Crankcase Sealant (PN 2871557) to the top gearcase

halve.

NOTE: Do not apply sealant to cam relief hole (E).

7. Assemble the crankcase halves. Apply LocTite™ 242 (PN

2871949) to the threads and pipe sealant to the bolt flanges.

Torque bolts to specification following torque pattern at beginning of this chapter.

5. Install crankshaft assembly and app ly engine oil to crank pins and rods (D). Apply assembly lube to the main journals and bearings.

= T

Crankcase Bolt Torque:

22 + 2 ft. lbs. (30 + 3 Nm)

Torque in sequence

8. Lubricate cam lobes and valve lifters with Moly Lube Grease.

Apply Moly Lube Cam Lobes

Lifters

3.44

Polaris 07, 700, 800 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual