Polaris 1999 Sportsman 400 Service Manual

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Page 1

CONTENTS

QUICK REFERENCE DATA . . . . . . . . • . . . • . • . . . . . . . . . . . . . . • . IX

CHAPTER ONE . GENERAL INFORMATION

Manualorganization

Notes, cautions and warnings Safety first Cleaning parts

Handling gasoline s Service hints

Torque sped fication s Fasteners Lubricants

Threadlocking compound

RTV gasket sealant

CHAPTER TWO . . . . .

TROUBLESHOOTING

Operatin g requirements

Troubleshooting instruments Starting the engine

Starting diffi culties

Engine is difficult to start

Engine starting system

Charging system

Ignition system

Electronic throttle contro l

ely

.. ..

Expendable supplies Serial numbers

Warning and information labels

Basic hand tools Precision measuring tools Special tools Fabricating tools Mechanic's tips

Beari ng replacement

Seals

Storage

Fuel system

Engine overheating Engine

Engine noises Cylinder leak down test

owe

r train

Steering

Frame noise

Brakes

. 1

Page 2

CHAPTER THREE .

....

.. ..

• .

•..

LUBRICATION, MAINTENANCE AND TUNE-UP

Pre-ride check list Tires and whee ls Battery Battery electrical cabl e connectors Periodic lubrication

Periodic maintenan ce Unscheduled inspection

and maint

Engine tune- up

enan

....

CHAPTER FOUR . ENGINE TOP END

Eng ine princip les

Engine cooling Engine lubrication Servicing the engine in the frame

Exhaust system Cylin

der

head cover

Rocker

ann

assembly

CHAPTER FIVE . . • . ENGINE LOWER END

Engine Flywheel and stator plate Recoi l starter Cra nkcase

Crankshaft inspec tion

Balancer shaft inspection

CHAPTER SIX • . . . .

FUEL SYSTEM

Carburetor operation Carburetor Carburetor cleaning and inspection Carburetor tests and adj ustments

Throttle cable replacemen t

.. .. ..

Camshaft

Cylinder head Valves and valve components Cylinder block Piston and piston rings Camshaft chain and sprockets Break-in proc

Shan end float measurement

and shim select ion Oil pumr Oil system one-way check valve

Break-in proc

all

ing enrichment (choke) cab le

Fuel tank

Fuel shutoff valve

Air filter air box

Fu~l

pllm p

edur

edu

......

. . . 137

175

CHAPTER

SEVEN.

COOLING SYSTEMS

Polaris va riable transmission (

air cooli ng system

Engine

cooling

system

Safety precauti ons

Hoses and hose clamps

Engine gaskets/seals

. . . . . . . . •

PVT)

Coo ling system inspection

Radiator Coo ling fan Coo lant pump Thermostat Temperature sensors

....

198

Page 3

CHAPTER EIGHT . CLUTCH/DRIVE BELT SYSTEM

Drive unit

Drive pulley

Special tools

Driven pulley Drive belt

.. .. ..

Drive pulley

Driven pulley

Clutch outer and innercover

(all models)

....

213

CHAPTER NINE . TRANSMISSION

Tra

nsmission

Tra

nsmission inspection

Shift shafts Front output shaft

CHAPTER TEN . . . . . . .

FRONT DRIVE SYSTEM

Front hub and Hillard clutch Front drive axle, boots and CV

(constant velocity) joints

CHAPTER ELEVEN . . ELECTRICAL SYSTEM

sic information

Negative battery terminal

Charging system

Alte

rna

torstator

Voltage regulator/rectificr

Capacitordischarge ignition

Ignition coil

Ignitionstatorcoils

Transmission gearcase oil seal

inspection andreplacement

Shift selector linkage

.....

Front drive shaft

Front

drive unit

.. ..

Electric starting syste m

tarter

drive gears

Starter solenoid Lighting system

Electrical components

itches

rin

g dia

gram

....

. . 249

290

. 303

CHAPTER TWELVE . FRONT SUSPENSION AND STEERING

Front wheel Front hub

Front strut cartridge and spring

Frontstrut/spindle

Control a

CHAPTER THIRTEEN . REAR SUSPENSION

Rear wheels

Tire changingand tirerepairs

Shock absorber

Rear hub and bearing carrier

Rearaxles

Upper control arm

. 337

Handlebar Tie rods Steering shaft

Tires and wheels

. 362

Lowercontrol Upper and lower control

arm inspection

Stabilizer linkage

Stabilizer support

arm

Page 4

CHAPTER FOURTEEN. BRAKES

Disc brakes

Front

brake

padreplacement

Front cal iper Ou tput

Output

Outpu

Outp

shaft brake pad replacement

(199

6-1997 models)

shall brake cal iper

(]

996-

1997 mode ls)

t shall brake pad repl acement

( I

998- on models)

ut shaft brake caliper

(I 998-on models)

.....

Fron

t mastercylinder

Rearmastercylinder

Brak e hose replacement

Rear brake pedal

Rembrake lever

(1996 -1997 Sweden mod els)

Foot brak e

(1998-on Sweden model s) Brake disc Bleeding the system

. . 382

CHAPTER FIFTEEN BODY

Seat

ront

rack

and grille

Side panels

Front fender

Front bum per (models so equipped )

SUPPLEMENT . 2001-2003 SERVICE INFORMATION

Startin

g theengine

Ignition system

Periodicmaintena Engine

Cylinder block

tUIl

nce

C-Up

Pistonand piston rings

Engine

ywhee

l and stator plate

arbur

etor (Sportsman 500 H.G. models)

Cleaning and inspection

Carburetortestsandadjustments

Drive belt

Driven pulley (2003 models bui lt

after 07/08102)

...

. 425

Radiator guard

Rear rack

Rearfender

Footv..'ells Rear bumper (models so eq uipped)

...

Tra

nsmission

....

. 437

Lighting system

Electrical components

Stee ring shall (2002-o n models)

Rear hub and bearing carrie r (2003 models)

Rear

brake

pad rep

lace

men

ode

(2003 m Rear calipers (2003 mod els)

ront

mastercylinder

Rear mastercylinder (2003 models) Rear brake disc (2003 models) Brake hose replacemen t (2003 models)

ls)

INDEX .

WIRING DIAGRAMS .

.470

Page 5

QUICK

MODEL: YEAR: _ VIN NUMBER:, _

ENGINE SERIAL NUMBER : _ CARBURETOR SERIAL NUMBER OR 1

TIRE

Model

Front

wheels

Rear "Tlre

pressure

for

original

equipment

REFERENCE

ATV

INFORMATION

.0.

MARK

: _

INFLATION

kPa

34.5 5

34.5 5 tires.Aftermarket

PRESSURE

tires

may

DATA

(COLD)'

require

different

PSI

Inflation

pressure

Item

Engine

011

Transmission

Front gear case

Front

hubs

Brake

fluid

Coolant

Grease

Item

Engine

all

Transmission

Front

gear case (all years)

Front

hubs

Coolant

RECOMMENDED

all

LUBRICANTS,

RECOMMENDED

FLUIDS

Lubricant Polaris

10W/40

Polaris Polaris API GL5 80·90 Polaris

ATF DOT 3 50:50

coolant and

Polaris

AND

CAPACITIES

fluid

Premium4Synthetic

motor

gearcase

gear

fluid

ethylene

season

all

gear

drive

grease,or

synthetic front

demand

Type

brake

mixture

compounded

engines

all

CAPACITIES

Quantity

1.89 L (2 U.S.

946.3 cc (32 U.S. oz.} 96 cc (3.25 U.S. oz.) 75 cc (2.5 U.S. oz.)

Appro

qts.)

x. 2.16 L (2.25 U.S.

type

case lube

lube

hub

fluid

glycol·based

for

aluminum

qts

10W/4Q

011

(part

No. 2871478)

(part

No. 2871653),or

(part No. 2871654),

radiators

equivalent

Page 6

MAIN

TENANCEAND

Item

Crankcase oil drain plug

N'm

TUN

E·UP TORQUE

SPECIFICATIONS

Cylinder head cover screws 8.2 72 Front gear case drain plug 9.4 83

Handlebar

tank

Oil

upper

drain

plug

hold

er bolts

13·17 115-150 19

011tank screen and fitting 20 Valve adjuster locknuts

Whee/lug

nuts

Front

6-7 53-62

Rear 21

in.

lb.

.·lb.

14 15

15 15

MAINTENANC

Item

Disc brake pad thickness wear limit

2003

Sportsman

500 & 500 H.O.

Rear brake

All other modelsand years

Front and rear brakes

Valve clearance(cold)

Intake

Spark

and exhaust

plug

400 cc

Heat r

ange

Gap

500 ee

Heat r

ange

1996-1997 1998-2001 2002

·on

Gap

1996·1998 1999-2000

·on

2001

Idle

speed 1996-1988, 2001-on 1997·2000

Carburetor pilot air screw (34 mm)

1996

·1998

1997 1999-2000

-on

moun

llight

-on

light

(400 ee)

ted

lights

2001

Carburetor pilot air screw (40 mm )

2001 2002-on

Item

Headlight

Grill

1996 1997

1998

Tai

Brake Indicator lights

1996 1997-on

E ANDTUNE

REPLACE

·UP

SPECIFICATIONS

Spec

ificat

ion

4.6 mm (0.180 In.)

3.81 mm (0.150 In.)

0.15 mm (0.006 In.)

NGK BKR5E

0.9 mm (0.036 in.)

NGK BKR5ES

BKR5 BKR6

E E

rpm

NGK NGK

0.6-0.7 mm (0.024-0.028 in.

0.7 mm (0.028 In.)

0.9 mm (0.036 in.)

1100-1300 rpm 1000-1400

1 1/2 turns out

2 turns out

2 5/8 turns out

23/4

turns out

2 1/2 turns out

2 turns out

MENTBULB

Specifica

12 volt, 6

12 volt, 37.5

12 volt, 35 watt (2) 12 volt, 27 watt 12 volt, 12 volt, 6.9 watt

12 volt, 1.25 watt

volt

tion

0/60

8.26 watt

,l.0

watt

Haloge

(2)

Page 7

CHAPTER ONE

GENERAL INFORMATION

This detailed. comprehensive

Polaris Sportsman 400, 500 and Xp lorer 500 4 x 4 from

I996-on.

Keep this book handy in the toolbox. Reading

and using it will help to better understand how the

vehi

cle

runs, lower repair costs and generally im-

prove personal satisfaction with the vehicle.

The following tables are included at the end

this chapter:

Tah

le 1 lists model year and number.

Tahle 2 lists general dimensions.

Table 3 lists vehicle weight (dry) .

manu

al covers the

Table 4 listsdecimal and metric equivalents.

Tab le 5 lists general torque specifications. Table 6 lists conversion tables .

Ta ble 7 lists technical abbrev iations.

Table 8 lists metric tap and drill sizes.

Tables 1-8 are at the end

MANUALORGANIZATlO

All dimensions and capacities are expresse d in

this chapter.

:'ll

Englishunits familiar to U.S. mechanics.as well as

in metric units.

This chapter provides general information and

discusses equipment and tools useful both for pre-

ventive maintenance and troubleshooting.

ChapterTwo provides methods and suggestions

for the quick and accu problems. Troubles

rate

diagnosis and repair

hoo

tingproceduresdiscuss typ-

Page 8

ica

l sy

mptomsand

roub

le.

terThree

Chap and routine maintenance necessary to cle

funning well. ommended nee

d to constant ly consult chapters on the various

assemb lies.

ubsequen

suc h as

the

engine,

logical

method

s to pinpoint the

explains all pe riodic lubrication

keep

Cha

pter

Three

also includes rec-

tUIl C

-Up

proce

t c

hapters

du res, el i

describe s pecific systems

clutch/drive

mina

belt sy stem, trans-

the

veh

ting the

mission, exhaust, coo ling, suspension and brakes.

Eac

h c

hapter

provides disass

sem bly procedures in a simple s tep-

Ifa

repairisimpract

ical for a home me

emb

ly, repair and as-

by-

step f

chan

orm

ic. it is

so indicated . It is usually faster ami less expensive

to take such repairs to a dealer or competent repair

shop. Spec ifications conc erning a parti cul ar system arcincluded

meofthe

pec

ial

inactual use or alone. Well-equi

ther ics may find they ca n subs titute similar tools alre

ady on ha nd or ca n fabricate thei r

NOTES,CAUTIONS

The have specific provides add itio nal information to

procedure couldcau

ipment

equ

CAUTION

mag

da could eve

r, personal inju ry is unlikely.

A WARNING emphasize s area s where pe

injury or

Mecha nical da mage may also

at the endofthe app ropriate chapter.

proc

edures in this

too

ls. In

most

case

s, the tool is illustrated ei-

AND

WARNI

termsNOT

easier or

se in

damage

e co

uld

cause

eve

E, CA UTION and

mean

ings in this ma nual. A NOTE

clearer

. Di

sre

gardi

con

venien ce, but

or personal

emp

hasize, areas where eq uipme nt

result. Di

permane

n death co uld resu lt from negligence.

sreg

nt mechanical

wou

injur

arding a CA UTION

occ

ur. W

manual

pped

mec han-

own

NGS

WAR

mak

e a step or

ng a NOTE

ld not cause

dama

ge; hO\\I-

ARNI

specify

NING

rsona

NGS

arefabe taken seriously. In some cases, serious in-

jut)' or death has resu lted from dis

warnings .

rETY

Professional

never

sustain a serious injury. If a few rules of co m-

mon

sense

canbeenjo

mechan

and

safety arc ob

yed serv icing the ATY. Ign oring these

ics can work for years

FIRST

served.

regarding

manysafe

similar

and

hours

CHAPTER

rules ca n injure so dam age the AT V.

I. Neverlise

solvent to clean parts,

dling Gasoline Safety

nfor

mat ion on part s cleaning, gaso line usc and

i safety.

The

lur

bustible li

flash

e at which the vapo

n ail:A

meo

ne working on the ve hicle. or

gaso

line o r any t

Sec Cleaning Parts and Han-

ype

of low flash po int

in this chapter for add itional

NOT

point is the lowest tempera-

rsfrom

quid

will ignite when in

lowjl

ash point solvent will

a com-

ignite at a lower temperature than a higlzj

lash

poi

nt solvent.

2. Never

flammable liquids in open co ntain line or cleaning so lvent.

smo ke or usc a torch in the vici nity of

ers

, such as

3. lf wclding or brazin g is req uired on the

arbur

remove the fue l rank, c shocks to awa y.

4. Use the pro per to fasteners.

5. Wh en loosening a tight or stuck nut, be guide d by what would h

6. W hen rep lacing with the sa me measurem one. Incorrect or mismatch ed fasteners can result in

mage

Beware

and p

pins. Refer to Faste ners in this chapt er for addi-

tion al inform ation.

7. K Wipe greasy

too ls arc difficult to ho ld

a safe dist

sized wre nches to

appenif

a fasten er, make sure to usc one

to the ve hi of

oor

ly mad e nuts. bolts,

eep

all

cle

fastene r kits that are filled with chea p

hand

and power tool s in go od condition.

and

oily too ls after using the m. Dirty

place or repair worn or

8. Kee p the

Wear volving u

sin

g che micals, c lea ning parts, wh en u pressed vo lved.

10.

Mak

for the

with a cap so thai it cannot be caught by a piece of mo ving eq uipme nt or tool.

work

area clean

safety gogglcs during all

drillin

g, grinding. the use of a co ld

air

ytim

e sure to wear the

b. Long h

air

etor, and fron t

ance

at leas t 50 feet ( 15 m)

avoiddamage

the wrench slips.

ent

s and strength as the old

and

possibl e personal injury.

was

hers

and

can

cause

dama

ged tools. and

uncl uttered.

operation

e the safety of

correct

should be tied up or covered

typ eofclothes

ONE

gas

vehicle

and

cotter

injury. Re-

s in-

chis

sing

com-

eyes

is in-

rear

el,

Page 9

ENE

RAL

INFO

RMATION

11. Keep an approved fire extinguisher nearby. Be

sure it is rated fur gasoline (Class B) and electrical

C) fires.

(Class

12. When drying bearings or other rotating paris

with compressedair,neverallow the air jet to rotate

the bearing or pari. The airjet is capab leofrotating them at speeds were designed . The bearing or rotating part is very likely to disintegrate and cause serious injury and damage. To prevent bearing damage when using com pressed air,hold the inner bearing race by hand.

tar in excess of those for which they

WARNING

Theimproper

velJ' dangerous. Using compressed

air to

workbench can causejlying particles

useofcompressed air is

tlUSI

off

clothes, the ATV or

to be blown into eyes or skill. Neve r direct or blow compress

skin or through any cluding cuts) as this can cause injury or death. Compressed air must

be used care

/id

ly; never allow chil-

dren to lise or play with a

pressedair equipment or hoses.

13. Never work on the upper partofthe vehicle

while someone is worki ng underneath

14. When putting the vehicle on a stand, mak e sure

the vehicle is secure before walking away from

15. Never carry sharp tools in clothing pockets.

16. There is always a right and wrong way to use

tools. Learn to use them the right way.

17. Do not start and run the ATV in an enclosed area, The colorless, odorless, poisonous gas. Carbon monoxide levels build quickly in a small closed area and can time. cle during a service procedure, always side, or in system.

ficu lt service jobs While there are a nnmber solvents available for home and shop lise, most arc poisonous and extremely flammable. To prevent chemical overexposure, vapor buildup, tire and sc-

exhaust gases contain carbon monoxide, a

cause unconsciousness and death in a short

When it is necessary to start and run the vehi-

a service area equip ped with a ventilating

CLEANING

Cleaning

parts is oneofthe more tedious and dif-

per

formed in the home garage.

air in/a

bod

y opening (in-

severe

ll)'

com-

it.

do so out-

PARTS

chemical cleaners and

it.

rious injury. observe all manufact urer'sdirect ions

and warn ings while notin g the following,

I. Read the entire product label before using the

chem ical. Observe the precautio ns and warnings on the label. Always know what type

ing used.

chem ical is be-

2. If the chemical product must be mixed, measure

the proper amount according to the directions.

3. Always provide sufficient ventilation when

working with solvents or other chemicals. If a chemical can be sme lled, there is some vapor in the air. The stronger the smell, concentration.

4. If a product is listed as combustible, flammable or an extremely flammable increases as the vapor collects and builds up in the shop.

5. lf a product is listed as a poison, the vapor is poi-

sonous as

well as the liquid.

the stronger the vapor

Iiquid, the danger

offi

o. To prevent skin exposure, wear protective

gloves when cleaning parts. Select cal-resistan t gloves suitable for the type of chernicals that will be used. Replace the gloves whcn they become thin, damaged, change

7. Wear safety gog gles when using chemicals and cleaning parts.

8. Do not lise more than one type of cleaning sol-

vent at

a lime.

a pan must be heated to remove a bearing,

9. If clean it thoroughly to remove all oil, grease and cleaner residue . Then wash with soapy water and

rinse with clear water,

10. Wear a respirator if the instruction label says to

do so.

II . Keep chemical produc ts out

dren and pets.

12. To prevent sparks, usc when cleaning paris.

13. When using a commercial paris washer, read

and follow the manufacturer's instructions lor se-

lecting the type of solvent to usc. Parts washers

must be equ ipped with a fusible link designed to melt and drop the cover in the event

14. Wash both hands and arms thoroughly after

cleaning parts,

HANDLING

Gasoline, a vola tile flammable liquid, is one

the most dangerou s items in the shop, However, be-

GASOLINE

a pair of chemi-

COIOf, or swell.

reach of chil-

a nylon bristle brush

fire.

SAFE

Page 10

cause gasoline is used so often, manypeople forget

that it is a dangerous prod uct. Gasoline should be

used only as fuel for internal-combustion engines. Never usc hand any othertype

ways be present in tbe fuel tank, fuel line and carbu-

retor.

around serve the following

I. Never usc gasoline to clean

Parts in this chapter for additional information

pans

2. Wh en workingon thefuel

gasoline to clean pa

s. When working on an ATV. motorcycle or

gasoline engine. gasoline will al-

Toavoidadisa

strou

gasoline oron thefuelsystem, carefully ob-

precauti

cleaning and safety.

s, tools or to wash

s accidentwhenw

ons:

part

s. See Cleaning

sys

tem, work

orkin

outside

or in a well-ventilated area.

3. Do not add fuel to the fuel t system while the ATV is in the vicinity of open

flames,

line vapors arc actually more dangerous than liquid

spark

sor

where

gasoline. Because these vapors are heavier

they collect in low areas and are easily ignited.

4. Allow the engine to

ank

or service the fuel

some

oneissmoking.Gaso-

coo

l completely

than

bef

air.

ore

working on any fuel system component.

5. When draining the carburetor, catch the gaso line

in a plastic container and then pour it into a safety-approved

6. Do not store gasoline in any typeofglass container. If the glass shoold break . a serious explosion

or firecould occu

7. Wipe up spilled gasoline immediately with dry

gas can.

rags. Store the rags in a metal container with a lid

ontil they can be properly disposedof. or put them

outside in a safe place todry.

8. Do

not pour water onto a gasoline tire. Water

spreads the lire andmakes it more difficult to put

oot. Use a C lass B. BC. or smother the

9. Always tum the engine

a wide-mouth

name

s and put the fire out.

funnel

onto the engine. exhaust pipe or overfillthe fuel

the fuel tank to prevent fuel from spilling out when insta lling the cap.

10. A lways refuel the ATV while it is parked out-

side andaway

II .

When

keep it upright with the fuel valve turned oiT.

12. Do not perform a spark test (as described in

tank

fro

m all open flames andsparks.

transporting the ATV in another vehicle.

AIlC

fire extinguisher to

off

before refu eling. Usc

to prevent spilling gasoline

muffl

er. Do not

. Leaveanairspaceat the topof

ChapterTwo)ifthere is any gasoline leaking from

fuel

tank

the

, fuel line or

carburetor

CIIAI'TER

ONT

REAR

SERVICE HINTS

Iost

the service p

straightforward and can be performed by any reasonably handy with tools. It is suggested. however. that the personal capabiliti es be carefully eon-

before

sidercd

majordisassembly

Take time and do thejob right. Do not forget that

a newly

attemp

rebuilt

engine mustbe broken in the same

rocedur

ting any o the engine.

es covered are

peratio

wayasanewone. RefertotheEngineBr

cdur

e listed in Chapter Four and Chapter Five .

Fron

t, as used in this manual, refersto the

of the vehicle; the closest to the front of the vehicle. The left and right

sides refertothe positionafthe p ridersitting 011 the seat

ple, the t

hrottle

front

any componentis theend

art

sas viewed bya

rac

ing

forward.

control is on the right side. The

rules aresimple.butconfusioncancausea

convenience duringservice. Sec Figure 1.

When

ever servicing an engine or suspe

component, securethe vehicle in a safe

3. Tag all similar internal

mark

all

matingpart

s for position. Record

part

s for location and

O~E

one

n involving

eak-In

pro-

fro

For exam-

major

in-

ion

mann

er.

number

Page 11

NERALINFORM A

nON

and thicknessofany shims as they are removed.

Small parts such as bolts can be identi fied by placing them in plastic sandw ich bags (F igu re 2). Seal and label

4. masking tape and a markin g pen. on memory alone.

5. Protect finished surfaces from physical damage or corrosion. Keep gaso line and other chemicals painted surfaces.

them with maskin g tape .

Tag disconnected wires and connectors with

ain, do not rely

off

6. Use penetrating oil on frozen or tight bolts, then

strike the bolt head a few times with a hammer and punch (use a screwdriver on screws). Avoid using heat where possible, as it can

war

p, melt or affect

the temperofparts. Heat also ruins finishes, espe-

cially paint and plastics.

7. When a part is a press fit or requires a special

tool to remove it, the necessary informat ion or type of

too l is called out in the text. Otherwise, if a part is

difficult to remove or install, lind out why before

proceeding. S. To prevent small objects and abrasive dust from

falling into the engine, cover all openings after exposing them.

9. Read each procedure completely while looking

at the actual parts before starting a job. Make sure

the procedural steps are fully understood, then fol-

low the procedure step by step.

10. Recommendations are occasionally made to refer service or maintenance to a Polaris dealership or a specialist in

will be done more quickly and economically

work

a particular field. In these cases, the

than by the home mechanic.

11. In procedural discard a defective part and replace rebui lt unit.

steps, the term replace means to

itwith a new or

Overhaul means to remove, disassem-

ble, inspect, measure, repair and/or replace parts as required.

12. Some operati ons require the uscofa hydraulic

press.Ifa press is not availab le, it is wiser to have

these operatio ns performed by a shop equip ped for such work, rather than to try to do the job yourself

with makeshift equipment that may damage the machine.

13. Repairs go much faster and easier if the vehi-

cle is clean before starting on the jo b. There are

many special cleaners on the mar ket, like Bel-Ray

Degrcascr, for wash ing the engine and related

parts. Follow the manufact

contai

ner

for the best results. C lean all oily or

urer'

s directions on the

greasy parts with cleani ng solvent as they are re-

moved.

WARNING

Never use gasoline to clean parts or tools.11presents all extreme fire haz-

i. Be sure 10 work in a

well-ventilated area when using cleaning solvent. Keep guisher rated f or gasoline

a fire extin-

fir

es near

by in any case.

CAUTI

If a car wash is used to clean tile A

1I0t

direct tire high-pressure water hose at steering hearings. carburetor hoses, suspension components, wheel bearings, or electrical components.

The water wtllflusb grease out of the

bearings or damage

14. Muc h of the labor charges for repairs made by

the seals.

dealerships are for the time involved during the re-

moval, disass

other parts in order to reach the defective part.

When poss ible, perform the preliminary operations

emb

ly, assembly, and reinstallation

and take the defective unit to the dealer for repair at considerable savings.

15. When special tools are required, make arrangcmcnts to get them before starting on the job. It is frustrating and time-consuming to get partly

into ajob and then be unable to com plete it. When

special too ls are requ ired, they will be described (including part number) at the beginning of a procedure.

16. Make diag rams wherever similar-appearing parts arc found. For instance, crankcase bolts arc ten not the same length. Do not rely on memory

rv,

Page 12

alone to rep lace part s in their proper location. There is also the possibility of being side tracked and not

able to return to wo rk for days or ing which time the carefully laid out parts may be-

eve

n wee ks, dur-

come disturbed.

17. When assembling parts,

and washers are reinstalled exactly as they cam e

make

sure all shims

out.

18. When

part, look for a shim or washer. Usc new gaskets if there is ones. A thin coating ofoil on n kets may help them scal morc effectively.

19. self-locking nut s. is lessened every time they are installed or r

It is recommendedthat they be replaced

eve

r a rotat ing part contacts a stationary

any

doubt

abou t the condition of the old

on-p

Som

e components are held in p l

The

locking ability

ressure type gas-

ace

with

these nuts

emo

ved.

eve

ry tim e

they are removed.

20. Use co ld heavy grease to hold small parts in place

ifth

cy tend to fall out during assembly. How-

ever, keep grease and oil away from electrical and brake components.

CHAPT ER ONE

TORQ

UE S

PEC

IFICAT IONS

The materials used in the manufacture of the Po-

laris may be subjected to un teners that hold the sub-assemblies are not installed and tightened correctly. Loose or m issing fasteners can ca use the cylinder head to leaks, and suspension failure from loose or missing fasteners.

prematur

e bearing and seal failure and

even

stresses if the fas-

warp

. crankcase

Therefore, usc an accurate torque wrenc h (de-

scribed in this chapter) tog specifica tions listed at the endofmost chapters.

Torque spec ifications throu

given in Newton-meters (Nsm). foot-pounds (f't.-lb.) and, w (in.-Ib.).

Existin g torque wre nches calibrated in meter ki-

lograms can be used.

place to the right; for example, 3.5 mkg =35 Nsm. The exact mathematical conversion is 3.5 mkg =

34.3 Nsm.

To mathemati cally convert foo t-pounds to New-

ton meters multiply the foot

1.3558 to achieve a Nsrn equivale nt. For ex ample

150 ft.-lb. x 1.3558 = 203 Nsrn.

Ref

er to Table 5 for general torque specifications

for various size screws, bolts and nuts not listed in

her

e applicable, in inch- pounds

ethe

r with the torqu e

gho

ut this manu al nrc

Move

the decimal point one

pound

s spec ification by

the respect ive chapter tables . To usc the table, first det

ermin

e the size of the bolt or nut. Use a vernier

caliper and threads of the nul (Figure 3) and across the threads

for a bolt (Fig

meas

ure the inside di

e 4).

men

sion of the

FASTENERS

The mat erials and designs

used on the Polaris are each designed fer a specific purpose. Fastener des ign de requ ired to wo rk with the fastener. Faste ner mat erial is carefully selected to d of physical failure.

Nuts, bo lts and sc

wide ran geofthread patt ern s. Tojoin a nut and bolt, the diameterofthe bolt

ofth

e various fasteners

tennines:the type oftool

ecr

ease the possibility

rews

are

manufactur

and

the diam eter of

ed in a

the hole in the nut mu st be the same. It is just as im-

por

tant that the thr

matched.

ead

s on both be pro perly

Page 13

GENERAL

Grade marking

INFO

RMATION

1.25-130 identifies a typical bolt. which would in-

dicate that the bolt has a nominal diameter o the distance between thread crests is 1.25 bolt length is

130 mm.

1I;·IRNING

Do not inst lower strength grade

all

screu-'s or bolts with a

classification

than installed originally by the manu-

factur

er. Doing so may calise engine

or equipment failure and possible in-

j ury.

111m

mm,

and

The best way to tell if two fast ener s' threads match is to turn the nut on the bolt (or the bolt into the threaded hole in a piece gers only. force is required,checkthe thread condition on each fastener. If the thread condi tion is good but the fastenersjam, the thread s are not compatible. A thread pitch gauge can be used to determine pitch. Polaris vehicles arc manufactured with ISO (International Organization for Standardization) metric as well as American fasteners. The threads are cut differently than those ers are metric threads while the frame components

Besure both pieces are clean. If excessive

American fastener s. All engi ne fasten-

equipment) with fin-

are secured with American thread s

Most threads are cut so that the fastener must be turned clockwise to tighten right-hand threads. Some fasteners have left-hand threads; they must be turned tightened. Left-hand threads are used in locat ions where normal rotation to loosen a right-hand threaded fastener.

ISO

MetricScr

(Bolls, Nuts and Screws)

ISO (International Organi zation for Standa rdization) metric threads

ew T hre

come

These arc called

counterclockwise to be

the equipment would tend

ads

in three standard thread

sizes: coarse, fine and constant pitch. The ISO

coarse pitch is used for almost all

applications. The fine pitch thread is used on certain precision tools and instrum ents. The constant pitch thread is

fasteners. The constant pitch thread, however, is

used on all metric thread spark plugs.

(L,

etween

used mainly on machine parts and not for

Metric screws and bolts are

Figure

5), nominal di

thread crests (

cla

ameter

The

common

ssified by length (D) and distance

fastener

numbers 8 x

The mea surement across two flats on the head

the bolt indi cates the proper wrench size to use. Flg-

nrc

4 Sh

O\\o'5 how to determine bolt diameter. When

buying a boll from a deale r or parts store, it is important to know how to specify bolt length. The correct way

length starting from undernea th the bolt head to the

end

manner to avoi d buying bolts that are length.

Machine

screws. The screw heads arc also designed to protrude above the metal (round ) or slightly recessed in the metal (flat) . See F

Nuts

sizes. Most are hexagonal (6-sided) and fit on bolts,

screws an d studs with the same diamete r and The co

lockwa that prevents the is requi red. Wing nuts are designed for fast removal by hand . Wing nuts are used for co nvenience in non-critica l locations.

10 measure bolt length is by measuring the

the bolt. Always measure bolt length in this

the wrong

Screws

Ther

e are man y diff

Nuts are manufactured in a variety of types and

mmo

n nut is generally used with a

sher

. Self-locking nuts have a nylon insert

nut from loosenin g; no lockwasher

erent

igure

types

machin e

pitch,

Toindicate the sizeofametric nut. manufac turers

specify the diameter of the opening and the thread pitch. Thi s is sim ilar to bolt spec ifications. but with out the length dimension. The measurement across two flats on the nut indicates the proper wrench size to

be used.

Page 14

CHAPTER

ONE

MACHINE

Hex Flat Oval

Self

-Locking

Severa l types of bolts, scr

rate

asystemthat developsinterference betweenthe

bolt, screw, and nut or lapped hole threads. Interfer-

ence is achieved in threads

ingthe topofanall-metalnut, using a nylon

disto

inthe ce

inse

Self-locking fasteners offer greater holding

strength and self-locking

not be reused.Others, likethenyloninsertnut,

an initial lock ing condition when Lite

stalled; the nylon forms close ly 10 the bolt thread

pattern, thus reducing any tendency for the nut to

loosen. Always disca rd

Fastene

,coatingt

nter

various

hread

s with

oratthe top

ews

and nuts incorpo-

ways: by dis

dry

adhesive ornylon,

ofanut.

better vibration resistance. The

fasteners used on the Po laris ATV can-

nut

and

replace selfClock ing

tort

ing

form

is first in-

fasteners afterremoval.

Was

hers

There arc two basic type s of washers: Ilat wash-

ers and lockwas hers. Flat washers are simple discs

with a hole to fit a screw or bolt. Lockwashers are

designed to prevent a fastener

fro

m working loose

due to vibration. expansion and contraction.

\Vasherscan be

I. As spacers.

2. To prevent galling or damage

used in the following functions:

the equipment

by the fastener.

3. Tohelpdistribute fastenerloadduring tightening.

4. As seals.

Note that flat washers arc often used between a

lockwasheranda fastenerto providea smooth bear-

ing surface. This

easily with a tool.

allows the fastener to be

turn

SCREWS

Fillister

NOTE

As much care should be given to the

selection and purchase that gi ven to bolts, nuts and othe

Round

washers as

r/as

teners. Bewareofwashers that are

made 0/ thin and weak materials.

These will

lime they are used in a high-to rque application.

Cotter Pins

def

orm and crush tile firs t

Incertain applications. a fastene r must be secured

so it cannot possibly loosen. The rear hub on an

is one of' these applications. Forthis purpose, a

cotterpinand

slotted orcastellatednul isoften used.

To use a cotter pin. first make sure the pin fits

snugly, but not too light. Th en align the slot in the

fastener with thc hole in the b

or axlc.

Insert the cotter pin thro ugh the nul and bolt or

axle and bend the ends overto secure the cotterpin tightly. enough to obtain the cifically instructed to

tcner 10 align thc slot and the hole. Because the

If the holes do notalign. tighten the nut just

prop

eralignment. Unless spe-

do so. never loosen the fas-

cotter pin is weakened after installation and re- moval, never reuse a cott er pin. Cotter pins are available in several styles. lengths

Measure the cott er pin length from the bottomofits

head to the lip

Circlips

They are used

type) or wit hin lubes (interna l type). In some app li-

thc shortest pron g.

can be internal or external in design.

to retain items on shafts (exte

and diameters.

cations. circlips of varying thicknesses are used to control the

endplay

assemblies. These are often

Page 15

GENE

RAL II\'FO

If:

RMATION

'~~=;1;'7

....

1..tf111h

~'\

Rounded edges

Sharp edges

Full support

areas

UBRICANTS

Periodic lubrication assures long Iifc for any type

equipme nt. The typeoflubricant used is

mportant

in an emergency the wrong typeoflubricant is

beller than none at all. The following paragraphs describe the types

ATVs. Be sure to follow the manufacturer's recommendations for l

Generally all liquid lubricants are called oil. They may be mineral-based (including petroleum bases), natural-based (vegetable and animal bases). synthetic-based or emu lsions (mixtures). Grease is oil to which a thickening base has been add ed so that the end prod uct is semi-solid. Grease is often classi-

fied by the type

commonly used ,

Engine

as the lubrication service itself, although

lubricants most often used for

ubr

icanttypes.

ofthiekcner

Oil

added; lithium soa p is

jus

t as

callcd selective circlips. Circlips should bc replaced

duringinstallation.asrem

orm

s them .

Two basic styles

and stamped circlips. Machined circlips (Figure 7)

canbeinsta

because

sharp edges. Stamped eirclips (Figure 8) are manu-

facture

When installing sta

as on

away from the part producing the thrust. When install-

ing circlips, observe the following:

I. Compress or expand circlips only enough to in-

stall them .

2. Afterthe circlipis installed, make sure itis completely seated within itsgroove.

increasesideplay.For

circlips whenever a

both

d withonesharpedgeand one roundededge.

tran

smission shafts. the sharp edge

Transmi

circlips are ava ilable: machined

lledin either

faces are ma

mpedcircli

ssioncirclips become WOntwithlise

tra

ru"

oval

weak

ens

and

dire

ction (shaftor housing)

chined.

thi

sreason.alwaysin

nsmission is reassembled.

thus creating two

ps in a

thru

st si

must

tuatio

stall

de-

face

anti

new

Engine oi l is classified by two standards: the

American Petroleum Institute (API)service classi-

fication (SA E) viscosity rating. Th is informat ion is on the oil contain

vice classification . The number or sequence of

number

viscosity the SAE viscosity index are not indications

quality.

meets specific lubrication standards. The first leiter

in the classification S indicates that the oil is for gasoline engines. dard the oil satisfies. Th e classificat ion started with

the leiter

mended by the

classification differentthanthatrecommended can cause engine damage.

Thin oils have a lowernumb

a higher

50-weight range for single-grade oils.

These oils

fied by a

the low-temperature viscosity.

and

the Society of Automo tive Engineers

label. Two leiters indicate the API ser-

s and leiter( IOW-40 for example}is the oi

ratin

g. The API service classification and

The service classification indicates that the oil

e second leiter indicates the stan -

A and is current ly at the letter1.

Always lise an oil with a classification recom-

manufacturer

Viscosity is an indication

number

Most manufacturers recommend mu

operating condition s. Multigrade oils are identi-

. Engine oils fall into the 5- to

perform

IVafter the first number, which indicates

efficiently across a wide

. Using an oil with a

the oil's thickness.

er while thick oils have

ltigra

l's

oil

de oil.

rang

Page 16

CHA

PTERON

Engine oils an:

111

0 St commonly mine

ral

(petroleum) based; howeversyntheticandsemi-synthetic types are used more

gine oil, followthe

for

tion

type, classi

fre

quently. When selecting en-

manufactur

fica

tion

er's recommenda-

and

viscosity.

Grease

The National Lubricating Grease

(NLGI) grades greases. Grea ses arc grad ed by num-

Institut

beraccording tothe consistency of the grease; these range from No. 000 to No. 6, with No. 6 being the

most solid. Typica l multipurpose grease is NLGI No

.2.For

facturers mayre

as molybdenum disulfide.

A threadlocking compound should be used to

specific applications, equipment manu-

qui

re grease with an additive

T HREAIlLOCKI

:'oI

G COM P

OU:'oI

such

help securemanyof the fasteners used 011the vehi-

cle. A threadlock co mpound will lock fasteners

against vibration loosening and seal against leaks.

The following thread locking c

ommended for many threadlo ck requirements de-

scribed in this m

\. Thrcelsond

quent

repai

2. Loctite No. 242 (blue): low-strength, frequent

anual.

TB134

2 (blue): low-strength, fre-

omp

ounds are rec-

repair.

Thr

eeBond T B1360 (green): medium-strength,

high temp erat ure.

Thr

eels ond No. 1333B (red) : medi um-strength,

bearing

5. Three

frequent repai

6. Loctite No. 27 1 (red): high- strength, infrequent

and

stud lock.

Bond

TB1303 (orange) : high-strength , in-

repair.

There are other quality thrcadlock brands

on the

market.

RTV

GASKETSEALA

Room temperature vulcanizing (RTV) sealant is

used on some preformed gaskets and to seal some

components. RTVis

asiliconegel supplied intubes

and is available at motorcycle andautomotive supplies storesandmajorhardware stores.

Moisture in the air

causes theRTV to cure. Al-

ways place the cap on the tube as soon as possible

whe n using RTV . RTV has a shelf life of approxi-

mately oneyearandwill not curep

shelf life has expired. Check the expiration date on

the RTV tube using the sealant. Keep scaled and discard

A(lIJlying RT V Sealant

Clcan all old gask et residu e from

faces. Remove all RTV gas ket material from blind

prior

topurchasing a new tube andon

parti

emafterthe expirationdate.

rop

erlywhenthe

ally used tubes tightly

all mating sur-

threadedholes; itcancauseahydraulic lock andaf-

fect bolt torque. leading to the bo ll not being ti

ened to the co

rrecttorqu

e specification. Finally, spray the mating surfaces with an aerosol parts cleanerand wipe with

Apply RTVsealantin

(0.08-0.12 in.) thick. Circle all mounting holes unless otherwi se spec ified. Do not allow any sealant to

enterthese holes. Assemble

ers to the specified t

a lint-free cloth.

a continuousbead 2-3 ITIm

and

tighten the

orqu

e within 10 m

application.

EXPEN IlABLESU PP

erta

in expendable supplies are required during

LIE

maintenanceandrepairwork. These include grease, oil. and gasket cement, wiping rags and cleaning solvent. Ask the dealership for the special locking compounds. silicone lubricants and otherp which make vehicle maintenance simplerand easier. Cleaning solvent or kerosene is available at some service s

Be sureto

andw

arn

used, Some cleaning supplies arc very caustic and

aredangerous ifn ot

tat

ions, paintorha

followthe manuf

rdwar

actur

er's instructions

ings listedonthe label of the p

used properly.

inut

es after

rodu

e stores.

roduct

sten-

being

ght

cts,

Page 17

GENERAL

INFORMATIOI'O

WARNI NG

Haring a hand is important when pe engine However. a rags them

til they can be washed or pro

sta

ofcl

ean shop rags Oil

l/a

and suspension

pileof

prese

nts a f ire hazard. Store

in asealed metal container

rvice work.

solvent-soaked

rming

/lI

per

discarded.

NO TE

70 prevent solvent and other chemicals fro m being absorbed into the skin.

leum-resistant parts.

through industrial supply houses 01'

well-equipped hardware stores.

Il'ear a

These can be purchased

pair

ofpetro-

gloves when cleaning

SERIAL N

Polaris makes freq

UMIlERS

uentcha

nges during a model

year- some minor, some relatively major. When

ordering parts from the dealership or other parts dis-

ribut

or, always order by VIN and engine serial

numbers. The serial number locations

arc

as fol-

lows:

I. Model and YIN number (Figure 9) is stamped

on the left lower frame rail near the rear portion

the

fro

nt A-armmou

nt.

On some models. a decal

with the YIN number is located on the front fender cover (Figure 10).

II)

2. Engine serial number (Figure

is stamped on

a pad onthe centertopof thecrankcase beneaththe

cylinder coolant elbow,

3. The

tra

of the

nsmissionse

tra

nsmission case below the shin bell crank

ria

lnumberislocatedon top

and on a label on the right side (Figure 12).

4. The carburetor serial number (Figure 13) is located on the left side of the carburetor body.

Enter these numbers on the ch

art

in the Quick

Reference Data table at the front of this book and

keep them for reference. Compare new parts to the

old ones before huying them. If they are not alike,

have the parts manager explain the difference.Table 1 lists the model numbers for the mode ls co v-

ered in this manual.

Page 18

CIIAPTER

O;;E

WAR;;ING

A number of warning

tachcd to the Polaris.

tion

that

operating.

refer to the inform ative labels fastened to the various

components on the vehicle. as this information

AND

INFORMATION

labels (F ig

The

se labels conta in informa-

LABE LS

ure

14) arc at-

is important to personal safety when

transportin

gandstoring the vehicle. Also

isveryuseful. Refertothe owner's manual fora de-

scription and locationofeach label. If a label is missing, order a replacement label from a Polaris dea lership.

BASIC

llANO

TOOLS

Manyof the procedures inthis manualcanbe car-

riedout with simple handtools and test equipment

familiarto thehome mechanic. Keepalltools clean

and in a toolbox. Keep them organi zed with the sockets and related drive s together, the open-end

combination w

tool,

wip

returnthe tool to itscorrect place.

Top quality tools are essential; they are also more

conomical

tool collection, stay away

fea

cials

and chain drug stores. These are usually poor grade

tools that arc

thick, heavy and clumsy to use. Their rough finish makes them difficult to clean and they usually do not

last very long.The wrenches do not fit the heads

bolts and nuts correctly and may damage the fas-

renche

off

dirt

inthe long run.

ture

d at some p

mad

s together, etc. After using a

andgrease with a cleanclothand

just startingto

from

the

art

s houses, discountstores

e of

infer

ior

material.

adverti

build

sed spe-

and arc

tener.

Quality tools arc madeofalloy steel and arc heat-treated for greater strength. They are lighter and better balanced than

inferior ones. Their surface

issmooth.making themapleasure to workwithand

easy to clean. The initialcost of good quality tools

may be more,

long run. Do not try to buy everything in all sizes in the beginning: buy a few at a time until all the nec-

essary tools arcon

butthey are more economical in the

hand

Screwd rivers

The screwdriver is a very basic tool, but if used

improp

erly itwill do moredamagethan good. The

slot on a screw has a definite dimension andshape.

A screwdriver must be selected to conformto t

hat

shape.Useasmallscrewdriverforsmallscrews and

a large one for large screws, orthescrew headwill

be damaged.

Two basic types

common (flatblade) screwdrivers and Phillips

screwdrivers are r

screwdrivers.

Screwdrivers arc available in sets that

clude an assortmentofcommon and Phillips blades. If purchased individually, buy at least the follow-

ing:

I. Commonscrewdriver- 5!16 x 6 in. blade.

2. Common screwdriver-3/8 x 12 in. blade .

3. Phillips screwdriver

4. Phillips screwdrive blade.

-s

ize 2 tip, 6 in. blade.

r-s

ize 3 tip, 6 and 10 in.

Use screwdrivers only fordriving screws. Never

usca screwdriver forp

ryin

g or chiseling metal. Do

not try to remove a Phillips or Allen head screw

withacommon screwdriver(unless thescrew hasa

combination head that will accept either type); if the head is damaged, the proper tool will be unable to remove it. Keep screwdrivers in the proper condition and they will last longer and p

ways keep the tip

ofa

commonscrewdriveringood

erf

orm better. Al-

condition.

Pliers

come in a wide

Pliers

Pliers are useful for cutting, bend ing and crimping.

Do not usc them to cut h

bolts or nuts. Each typeofpliers has a speciali zed

function.Slip-jointpliers are gene and are used mainly for holding

range

of types andsizes.

ardened

objects or to tum

l purpose pliers

thin

bending.

equired

often in-

gs and for

Page 19

GENERAL

INF

ORMATI

s K

...

~~~

Needlcnosc pliers are used to hold or bend small

objects. Water pum p pliers can be ad

various sizesofobjects; the jaws remain parallel to

griparound objects such as pipe or tubing. There arc many more types of pliers. The ones described here are most suitable for vehicle repairs.

Locking P

Locking pliers are used to hold objec ts very

tightly

essary since their sharp jaws

any objects that are held. Locking pliers are avail-

able in many types for more specific tasks.

Cir

Circlip pliers (Figure 15) are made for removing

and installing circlips. External pliers (spreading)

are used to remove circlips that fit on the outside

a shaft. Internal pliers (squeezing) are used to re-

move circlips which

lier

like a vise. But avoid using them unless nec-

will permanently scar

clip Pli

ers

fit inside a gear or housing.

sted to hold

WAR

NING

Because circlips call sometimes slip ami

fly

of]

when removing and install-

ing them. always

using them.

when

Box, O

pen-End

Open-end, box-end and combination wrenches

are available in sets or separately in a variety of

On open and box end wrenches, the number

sizes. stamped near the end refers to the distance between

two parallel flats on the hex head bolt or nut. On combination wren ches, the number the center.

Open-end wrenches (A,

and work best in areas with limited overhead ac-

cess.

Their wide, flat jaws make them unstable for

situations where the or close to the edge of a casting. These wrenches grip only two flats of a fastener; if eitherthe fastener

head or the wrench

slip ofT.

Box-end wrenches (B, Figu re 16) require clear overhead situations where the fastener head is close other pa rt. They grip on all six edges

for a very secure grip. They are available in either

6-point or 12-point. The 6-po int gives superior

holding flower and durability but requires a greater swinging radius. The 12-point worksbetter in situations where the swinging radius is limited.

open-end on one side and box-end on the other with

both ends being the same size. Professional me-

chanics favor these wrenches because of their ver-

satility.

djustable

wrench) can be adju sted to fit nearly any nut or bolt head that has clear access around its entire perimeter. Adjustable wrenches are best used as a backup wrench to keep a while the other end is being loosencd or tightened with a box-end or socket wre nch,

faces which make them more subject to slipping ofT the fastener and damaging the part and possibly

access to the fastener but can work well in

Combination wrenches (C. Figure J6) have

Wrenches

An adjustab le wrenc h (sometimes called crescent

jus

table wrenches have only two gripping sur-

wear safety glasses

and

Com

bination

Fig

bolt or nut is located in a bore

jaw

s are worn, the wrench may

large nut or bolt from turning

Wren

is stamped near

ure

16) are speedy

ches

a fastener

to an-

Page 20

CHA PTER

ONE

causing injury. The fact that one

only aggravates this shortcoming.

These wrenches are directiona l: the so lid jaw

must be the one transmitting the force. If the adjust-

able

jaw

is used(0transmit the force. it will loosen

and possibly slip otT.

Socket

safest and most convenient to use. Socket s. which

attach to a ratchet handle. are avai lable with 6-point

(A,

and 1/4, 3/8. 1/2 and 3/4 in. drives. The drive size indica tes the sizeofthe square hole which mates with the ratchet handle.

Allen

in a variety metric sizes. Allen bolts arc sometimes called socket bolts. Sometimes the bolts are

Wre

nches

This typeofwrench is undoubtedly the fastest,

Figur

e 17) or 12-point (B,

Wrenc

hes

Allen wrenches are available in sets or separately

sizes. These sets come in SAE and

jaw

is adjustable

Figu

re 17) openings

difficult to

reach and it is suggested that a variety orAllen

wrenches be purchased, such as the socke t driven. T-handle and extension type.

TorqueWrench

A torque \

how tightly a nut or bolt is installed. They come with either

18). The drive size indicates the sizeofthe square

drive that mates with the socket.

...

Tench is used with a socket to measure

1/4.318

or 1/2 in. square drive (F ig

ure

A B

(;;;\

Hamm

ers

The correct hammer is necessary for certain repairs. A hammer with a face (or head) plastic or a soft-faced type tilled with buckshot is sometimes necessary in engine disassembly. Never usc a metal-faced hammer on engine or suspension parts. as severe damage will result in most cases. The same amo untofforce can be produced with a soft-faced hammer. The shock

hammer, however, is required for using

pact driver or cold chisel.

rubber or

a metal-faced

a hand im-

mpact

Driver

This tool might have been designed with the ATV

mechanic in mind. This tool makes removaloffas-

teners easy and eliminates damage to bolts and

screw slots. Impact drivers (Figure 19) and inter-

changeable bits are available at most large hardware, vehicle or auto parts stores. Socke ts can

be used with a hand impact driver; however, make sure that the socket is designed for use with an impact driver or air tool. Do not use regular hand sock-

111

ets, as they

3y shatter during use.

also

pportJacks

The correct typeofsupport jack is necessary for

many routine service or major component replace-

ment procedures on the vehicle. The centerstand scissor jack

on this series

stable for usc with the frame configuration vehicle.

Also, the standard floor jack may

some applications, To protect all engine

is suitable for most service procedures

vehicles. It is adjustable and is very

this

be used for

and frame

Page 21

ENE

RAL IN

FOR

MATIO N

these specialized too ls.

descriptionoft he measuring tools required to per-

form the service procedures described in the vari-

ous chapters in this manual.

The

follow ing is a

surfaces, always place a pieceofwood between the

jack pad and the supported component.

PRE

CISION

Measurementis an im

suspension service. When per formi ng manyofthe

service procedures in this manual, a number measurements are required. These include basic checks such as enginecompression and spark plug

gap. As shop experience progresses into engine

disassemblyand service. many measurements

required todeterminethesize and condition

l\IEASURl:O;G

porta

ntpartofengine and

TOOL

arc

the

pistonandcylinderboreandcrankshaftrunoutand

other complex measurements. When making these

measurements, the degree of accuracy wi ll dictate

which tool is required. Precision measuring tools arc expensive.

gine orsuspension

while to have the checks and measurements

performed by a Polaris dealership. a competentin-

dependent vehicle repairshop or a machine shop.

However, as skills andenthusiasm increase fordo-

ing service work,

If this is the first experience at en-

service, it may be more worth-

it may be desirab le 10 buy some

Feeler Ga

Feeler gauges come in assorted sets and types

(Figure 20). The feeler gauge is made of either a piece o

thickness. Wire gauges are used to measure spark plug gap. ments. Feeler gauges are also designed forspecialized uses. For example. the end

small and angled to facilitate checking valve clear-

ances on models requiring

Vern

Digital E

These arc valuable tools for reading inside, out-

side and depth measurements. Although this type

tool is not as precise as a mic sonable, non-close tole

cally to within 0.025 mrn (0.001 in.). Common uses of

a vern ier caliper arc measuring the lengthofthe clutch springs, the thickness and thrust washers, brake pad or lining thickness or

the dcpth of a bearing borc. The

must be c1can and frcc

an accurate measurement. There are several types of

vernier calipers available.

caliper has a highly ac

handle (Fig must be calc ulated, follow ing the m

instructions. The dial indicator caliper is equipped

with a small dial and needle that indicates the mea-

surement reading; the digital electronic type has an

LCD display that shows thc measurement Oil thc

small display screen.Some verniercalipersmustbe

libra

ca accuracy. R

for this procedure.

uJ.:c

nat or round hardened steelofa specified

Flat gauges arc used for other measure-

a gauge can be

adjust

ment.

ier

Caliper, Dial C aliper

lectro

nic Caliper

ran

cur

e 21) in which the measurements

tedpriorto makingameasurementto ensure

er to the manufacturer's instructions

and

romet

er. it allows rea-

ce measurements, typi-

clutch plates. shims

jawsofthe caliper

burrs at all times to obtain

The

stan

dard

vernier

ate graduated scale on the

anuf

actur

er'

Outside l\l icrometcrs

An outside micrometeris a precision tool used to

accurately measure

sionsofthe inch or meter (Figure 22). While there

aremany types and styles of micrometers. this sec-

part

s using the decimal divi-

Page 22

crib

lion des The outside mi

es how to usc the outs ide mi

crom

eter is the most common type of

crom

eter.

micrometer used to service a vehicle, The outside micrometer is also used to measure the dimension

taken by a small hole describ ed later in this section.

her

types of m i

crometer and screw thread micrometer.

illustrates the various pari softhe

ter

with its part names and

gauge

or a telescopi ng gauge

crom

eters include the depth mi-

outside microme-

marki

ngs identified .

Figure

@ METRIC

----"

VERNIER

10 mm

\ :--

==l-

)

CALIPE

~Flxe

---"i

2 J 4 5 :

'!I""I""I"

I i lilt

CHAPTER

scale

s:=J=-

uli'

- IlI

!':·::.

'C:Jr

ONE

l\lic

romcter

Range

A micrometer's size indicates the minimum and

maximum sizeofa part that it can measure. The

usual s

izes

are: 0-1 in.(0-25 mm) , 1-2 in.(25-50

mm), 2-3 in. (50-75

hesemicrom

Some mic

ngeab

cha the installationofthe

cular

microm anvi ls. cove pensive, its

nien t to usc.

How To

henread from di fferent scales lo

wing

inch microm

standard metric micromet er and the metric vernier

crom

Sta

ndard

The one- tho usandth of the micromet er is its spindle screwwith 40 thread s

per inch . Eve ry tum

pindle

efore lea rning how 10 read a micrometer, study

rom

le anvils

job. Forexample, a 0-4 in. interchangeab le

eter is

Whilepur

r a range from 0-4 in, or 0-6 inches is less ex-

ove

Read

ing a micromet er,

sections describe how to r

eter

eter.

inch

sta ndard inch micro meter is uccuratc to

1/40ofan inch or 0.

the markings and part names in

mic

rom

eter thimble until its zero mark aligns with the zero mark on the sle ble

cou

nter

cloc

mark with

the sleeve line. The mic

mm)

and 3-4 (7

eters lise fixed anv ils.

eters use the same framewith inter-

different leng ths. Thi s all

cor

rect l

engt

equipped

chasing one or two

rall frame size makes it less conve -

Micromet

, the vernie r inch microm eter, the

micro

kwise

with four different length

and add ed together. Th e f

meter

an inch (0 .00 1 in.). T he heart

the thimble will move the

025

eve

line. Nowtumthe thim-

and align the next thimble

5-100

h anvil tora par-

mic

rom eters to

numb

ers are taken

ead

the standard

inch.

Figur

e 23. Tum the

rom

eter now

mm).

ows

• , .\ ( Movable

0.50mm

1. Reading on fixed scale:

2. Reading on movable scale:

reads 0.001 in. (one Thus, each thimb le mark is equal to 0.001 in. fifth t

himb

ing: 0, 5. 15 and 20.

Reset the mi sleeve line countercloc align the thimble ze ro mark with the first line in the sl

eeve

line. T he mi

(twenty-five thou sands) sl

eeve

line

tum

N counting the s leeve linc marks. Every fourth

on the sl

eeve

from one throu gh nine. M the last the end

sleeve num number I r sents 0.9 inch.

followi ng three mea them togeth er. give the mea (0.00 1 in.).

steps and r

mark

When reading a

ead

To r

Total reading:

one

le m

arkisnumb

crom

eter so that the thimbl e and

zero

mark

s align . Then

kwise

represent

one

com

crometer

s 0.025 inch.

the thimbl e co

line is marked with a

anufactur

on the sleeve with aO.Thi s indi cates

the microme ter's measuring range. Each

ber

represents 0.1 in. For exa mple, the

epresent

s 0.1 in. and the

sta ndard micrometer. tak e the

surement

The sumofthe three rea dings will

sur

ement in a thousandth of an inch

a micro meter. perf

efe

r to the exam ple in

10.00mm

+0.50 rom

10.50 mm

-thousandth) of an

ered to help with read-

tum

plete revolution and

now

reads 0.025 in.

an inch. Thus, cach

unterclock

numb

ers usuall y mark

numb

s des

crib

orm

the following

Figure

sc:

',e

inch

Every

the t

himb

wise while

mark

er ranging

er 9 repre-

ed and add

24.

Page 23

GE:'/ERAL INFOR:\lATlON

@r--------==:::...:...=:=.::...=-=--------,

0.1

DECIMAL

0.010

0.001

*Thls c

hart

represents

reading decima ls

version

chart

(for example: 0.001 in. Is

the

values of

from

one-tenthtoone

figures

STANDARD

PLACE

Indicates

Indicates 11100(one one-hundreth of

Indicates

of an

placedto the

one-thousandth

not

equalto0.001 mm).

INCH

Locknut

MICROMETER

Sleeve line

Thimble

VALUES'

1110

(one

or millimeter) an Inch or millimeter)

111,000

inchormillimeter)

right

of an

marks

tenth

(one one-th ousandth

of the decimal

Inch

or millimeter.It Is

of an inch

point.

Use it

when

notacon-

Largest

2. Number on sleeve marks visible

between the and the th

Thimble

sleeve line Q.QO§Jn,

the

number

sleeve

imble

mark

visible

line

numbered

edge

that

aligns

0.200 In.

sleeve

mark

with

Total reading: 0.231 in.

0.025 in.

Page 24

CHAPTER

ONE

VERNIER

Vernier sca le

tvernier.

--"t-

- -

_ _

- -

"t-

.r-

-r-

scale

imble

INCH MICROMETER

Vernier scale

-0

•

1. Largest number visible

on sleeve line 0.100 In.

2. Number of sleeve marks visible between the nu mbered sleeve mark and the

3. Thimble Is between

0.019 in. on the sleeve line 0.018 In.

4. Vernier line thimble line 0.0003In.

thimb

le edge 0.050 In.

O.D1S

and

coinciding

with

Total readi ng: 0.1683 In.

==E

-"""'--_

Sleeve

I. Read the sleeve line to find the largest numher

visible

-each

sleeve number mark equals 0.100

inch.

2. Count the numberofsleeve marks visible be-

tween the numbered sleeve mark and the thimble edge

-eac

h sleeve mark equals 0.025 inch.Ifthere

is no visible sleeve marks. continue to Step 3.

imble

3. Read the thimble mark that lines up with the sleeve line

-e

ach thimble mark equals 0.00 I inch.

NOTE

If a thimble mark does not line up er-

actly with the sleeve line butfa lls be-

tween two lilies. estimate the fra ction a/deci

mal amount between the lines.

Page 25

GENERAL INFORMATION

Anvil

4. Adding the microm eter readings in Steps I. 2

STANDARD

Locknut Sleeve line Thimble

METRIC

and3 gives the actual measurement,

MICROMETER

Sleeve marks

ten-t hou sandt hsofan inch to add to the initial read-

ing taken in Step I.

Vernier inch micrometer

A vernier micrometer can accurately measure in

ten-thousandthsofan inch (0.00 01 in.). While it has

the same

a ve rnier

makes it unique. The vernier scale

even each sleeve where each line is equal to 0.0001 inch.

Thus. the vernierscale divides a thousa

inch (0.001 in.) into ten-thous

(0.000 1 in.).

lowing steps and refer to the example in

I. Read the micrometer in the same way as on the

standardinchmi

2.Ifa th imble mark lines up

line. reading the vernierscale is not necessary. I

markin

gsasthe standardinch

scale

scribe d on the s

equally space d Iines marked 0-9 with a 0 on

end. Th ese lines run para llel on the topofthe

leeve

micrometer.

(Figure 25)

consistsof

ndth

andthsof

To read thevernier mic

crom

eter.

rome

ter,

This is the

exac

tly with the

perform

Fjuure

initialreadin

of 3

an inch

the fol-

26:

sleeve

thimble mark does not line exactly with the sleeve

line. read the ve

3. Read the m

ark

linesupwiththeone

ber

rnier

scale in Step 3.

vernier scale to find which ve

thimblemark

. The num-

that vernier mark is the number

rnier

Metric micrometer

le metric micrometeris verysimilarto thestan-

dard inch micrometer.

The

differences are the

uations on the thimble and sleeve as shown in

igure

27.

The standard metric micrometer is acc

one

one-

hund redth of an

millim

eter (0.0 I mm). On

the metric micrometer. the spindle screw is

with a threa d pitch of one-ha lf millimeter (0.5

Thus, every tum dle

0.5

111111

The sle

half millimeters.

sleeve line arc equal to 1.00 mru. Every fifth

the thimble will

eve

line is graduated in millimeters and

Themarks on the upper side

above the sleeve line is marked witha number.The

actual numbers dependon the size

ter. For example, on a 0-25 mm micrometer. the

sleev e marks are n

umbe

red 0, 5, 10

,15.20

On a 25-50 nun micrometer. the sleeve m

umbered

25, 30,

35,

40, 45 and 50 . This

sequence continues withlargermicrometers(50-75

and 75-IOO). Each mark on the lower sideofthe

sleeve line is equal to 0.5 mm.

grad

urate

ground

mm)

move

the spin-

mark

the microme-

and 25.

ark

s are

numbe

the

ring

Page 26

CIIAPTER

Ol'\E

Sleeve :

Sleeve

Thimbl

Thimble

The thimble scale is divided into fifty graduations where one graduatio n is equal to 0.0 I fifth

gradua

tion is numbered to help with read ing

111111

. Every

from 0-45. Th e thimble edge is used to indicate which sleeve marking s to read.

read the metric micrometer add the number of

To millimeters and half-millime ters on the sleeve line to the num

berofone-hundredth millimeters on the thimble. To do so, perform the followin g steps and refer to the

Take

marks

exa

mple in

Figur

e 28:

the first reading by co unting the number

visible on the upper sleeve line. Record the

reading.

2. Look below the sleeve line to see if a lower mark is visible directl y past the upper line mark. lf so, add

0.50 to the first reading.

3. Now read the thi

eeve

line. Record this reading.

a thimble mark does not align ex-

actly with the

mble

mark that aligns w ith the

NOTE

sle

eve line b

ill

fall

s he-

tween the twu lines, estimate the

decimal amount between the lines.

For an accurate reading. a metric

vernier microm eter must be used.

1. Reading on upper sleeve Hne

2. Reading on lower sleeve line

3. Thimble line coinciding with

sleeve line

Total reading:

5.0 mm

0.50 mm

0,18 mm

5.68 mm

,'\!etric vernier microm eter

A metric micrometer can accurately measure to two-thousandths o it

has the same markings as thc standard metri c mi-

millimeter (0.002

crometer. a vernier scale scribed on the sleeve (Fig-

ure

29) makes it unique. The vernier scale

five

equa

lly spaced lines 0, 2, 4, 6 and 8. These

lines run parallel on the top

the sleeve where

line is equal to 0.002 mm.

To read the metric vernier micrometer, pe the following steps and refer to the

ure

30:

I. Read the

way as with the standard m

metr

ic vernier microme ter the

etr

ic mi

exam

crom

the initial read ing.

2. If a thimble mark aligns exactly with the sle line. reading the vernier scale is not necessary.Ifa

docs

thimble line

not align exact ly with the sleeve

line, read the vernier sca le in Step 3.

3. Read the vernier scale to find which mark aligns

The

with one thimble mark.

mark is the num

ber

of thousand sofa millim eterto

numberofthe vern

add to the initial reading taken in Step I.

I\1icrometer Accuracy Check

mm)

. Whi le

con

sists

each

orm

ple in

Fig-

same

eter. Thi s is

eve

ier

Adding

the micrometer readi ngs in Step s I. 2

and 3 gives the actual measurement.

The micrometer must be checked frequently to

assu re accuracy as follows:

Page 27

GENE

RAL INFO R

MATION

VERNIER

Vernier scale

vernle~

scale

~=J

3 0

o 20

'ffl

t¢:'-

METRIC M

erni

er scale

ICRO

METER

1. Reading on upper sleeve line 4.0 rnm

2. Readin g on lower slee ve line 0.5 mm

3. Th

imb

le Is bet

ween

0.15 and 0.16

lines on the sleeve line 0.15 mm

4. Vernier line coinciding with

thimble line 0.008 mm

Total reading: 4.658 mm

Sleeve : Thimble

I. Make sure the anvil and spindle faces are clean

and dry.

2. To check a 0-1 in. (0-25 mm) micrometer, per-

form the following:

a. Tum the spindle until the spindle contacts the

anvil.

If the micrometer has a ratc het stop. use

it to ensure that the proper amount

is applied against the contact surfaces.

b. Read the micrometer. If the adj ustment is

rcct, the 0 mark on the thimble will be aligned

pressure

COf

exactly with the 0 mark on the sleeve line. the 0 marks do not align. the micrometer is out

adjustm ent.

c. To adjust the micrometer,

facture

r's

instructions provided with the mi-

crometer.

3. To check the accuracy

I inch (25 rnm) size, perform the following:

ofu

micrometer above the

follow the manu-

Page 28

Manufac turers usually supply a standard

gauge withtheirmicrometers. Astan

dard

isa

steel block, disc or rod that is ground to onex-

actsize tocheck theaccuracy

the rnicrome-

tcr, For example. a 1-2 inch micrometer is

equipped with a I ineh standard

25-50 mm micrometer is equipped with

standard

b. Place the

gauge.

standard gouge between the mi-

gouge. A

a 25

crometer's spindle andanvil andmeasurethe

outside diameterorlengthinthesame

manner

as measuring a vehicle component. Read the

micrometer.If the adjustmentisco

rrec

t,the 0

mark on the thimble will be aligned exactly

with the sleeve line.

align, the micrometer requires ca

c. To adjust the

factu

rer's instruction provided with the mi-

microm

the 0 marks do not

libra

eter. follow

theman

tion.

crometer.

Proper Care of a

Because the micrometer is a precision instru-

l\'1icr

omctcr

ment, it must be used correctly and with great care. When using and storing a micrometer, refer to the following:

1. Store a micrometer in its box or in a protected

place wheredust.oil. orotherdebriscannotcome in contact with them. Do not store micrometers in a drawer with

other tools nor hang them on a tool

board.

2. When storing a 0-1 in. (0-25 mill) micrometer,

the spindle and anvil must not

they do, this may cause

contact each other. If

st to form on the co

ntact

ends or the spindle will be damaged by temperature

changes.

3. Do not clean a micrometerwithcompressed

air.

Dirt forced under pressure into the tool can cause

premature

damage.

4. Occasionally lubricate the micrometer with

lightweight oil to preventrust andcorrosion.

5. Before using a micromete

check its accuracy,

Refer to Microm eter Accuracy Check previously

described in this section.

Cylinder Bore

Gauge

Thecylinderboregauge is a veryspecialized pre-

cision tool comprising of a dial indicator, handle

adapt

anda number ofdifferent length

ers(anvils) to

CIIA PT ER

adapt the gauge to different bore sizes. The bore gauge is used

10 make cylinderboremeasurements

such as bore size, taper and out-of-round. De-

pending used to

on the bore gauge, it can sometimes be

measure

ake caliper and master cylinder

bore sizes. In some cases. an outside micrometer

must be used to ca

librate

the gauge to a specific

bore diameter.

Select the correct length

forthe size

the boretobemeasured. Zero the bore

gauge according to manufac

sert the bore

around in the bore to make sure it is centered and

gouge into the cylinder,carefully move

that the gauge foot(8, Fig

adopter (A, Fig

turer'

s instructions, in-

ure

31) sits correctly on

the bore surface. This is necessaryinordertoobtain a correct reading. Refer to the manufacturer's instructions for reading the actual measurement ob-

tained.

SIIl:l1IIIole

Gauges

A set of small hole gouges, allows the measuring

a small hole,grooveor slot. The small hole gauge

is used for the smallest measurements and the tele-

scoping gaugesare used forslightly largermeasure-

ments. A

rocker

ameters.

small hole gauge is required to measure

ann bore and b

rake

mastercylinderboredi-

The telescoping gauge does not have a

scale for direct readings. An outside micrometer mustbe usedtogetherwith the telescoping gauge to

determine the bore dimension.

Carefully insert the small hole gauge into the bore

of the component to be measured. Tighten the

knurled end of the

gouge to carefully expanded the

gauge fingers to the limit within the bore.

overtighten

feature. If tightened toomuch.the gauge fingerscan

the gauge. as it has no built-in release

ONE

ure

31)

Do not

Page 29

GENERAL

INFORMATION

Voltmeter

micrometer must be used together with the tele-

scoping gauge to det

Select the correct size telescoping gauge for the bore to be measured . Compress the movable side the gauge post and carefully install the gauge into

the bore of the component to be measured, then release the movable post against the bore. Carefully move the gauge around in the bore to make sure centered. Tighten the knurled end hold the movable gauge post in this position. Care-

fully remove the gauge and measure the outside di-

mension of the gauge posts with a micrometer. See

erm

ine the bore dimen sion.

itis

the gauge to

Outside Micrometer in this chapter.

Mulrhueter

The multimetcr isa valuable tool for all electrical

system troub leshooting (F

application is used to indicate the voltage applied or available to various electr ical com ponents. The ohmm eter portion of the meter is used to check for continuity, or

resistance of a component.

lack of continuity, and to measure the

igure

32). The voltage

t z-vctt battery

damage the bore surface. Carefully remove the

gauge and mensure the outside dimensionofthe

gauge with a microm eter. Sec Out

in this chapter.

sid

e Micromet er

Telescoping Ga uges

A telescoping gauge is used to measure hole di-

ameters from approximately 8 mm (5/ 16 in.) to 150 mm (6 in.). For examp le, they could be used to mea-

sure brake caliper

Like the small hole gauge. the telescoping gauge does not have a scale fo rdirect readings. An outside

bor

e and cy linder bore dia meters.

Vol

tage

Voltage is the pressure in an electr icalcircuit. The

more pressure (vo ltage ) in the circuit, the more

work can be acco mplished. Alw ays measure volt-

age in a simple parallel connection. The con nection

a voltmeter directl y to the negative and positive

terminals connection (Figure 33) . Nothing must be disconnected to make

Direct current

flows in one direction only. All circuits powered by

a battery is an example of a parallel

a parallel connection.

(DC) voltage means that electricity

a battery arc DC circuits.

(

AC)

Alternating current

ity flows in one direction mom entari ly then switches to the opposite direction. which

AC voltage changes direction is

hertz. In motorcycle, or ATV. applications, charging system

verted to DC for storage in the

tance can he measured on an act ive circuit using a

voltme ter. Th is is called a voltage drop tesl. Ba-

sically,

the beginning of a circuit to the vo ltage ava ilable at

the end of the circuit while

output is AC voltage until the AC is con-

Since resistance causes voltage to drop. resis-

a voltage drop test compares the voltage at

means that the electric-

The frequency at

ref

erred to as

battery,

the circuit is being

oper

Page 30

CHAPTER

ONE

ated. If the circuit has no resistance. there will be no

voltage

drop and the meter wi IIread zero volts. The

more resistance the circuit has. the higher the volt-

age meter reading will be. Generally, a voltage drop

one or more volts is considered excessive. The

adva ntage to the voltage drop test over a resistance

test is that the circuit is tested during opera tion. It is important to remember that a zero read ing on a volt-

age drop test is desired while a reading

voltage indicates an open circuit.

mea

When

suring voltage, select the meter volt-

battery

age range one scale higher than the expected volt-

ageofthe circuit to prevent damage to the meter.

Resistance

NOTE

ln most cases, to obtain an accurat e resistance measurement, the component must be at approximately 20° C

(680F).

Resistance is the opposition to the flow of elec-

tricity in a circuit and is measured in ohms . Resis-

tance cau ses a reduction in current

reducti on or drop in available voltage . Resistance is measured with an tance, the ohmmeter sends tricity in the circuit and measures how push the electricity back

ohmm

eter. To measure resis-

a small amountofelec-

10 the oh mmeter.

TION

m\' and a

difficult it is

An ohmmeter must only be used on circuit or compon ent that is isolated

}I'0

11l

any other circuit or component

and has

will be dama

flO voltagepresent. The meter

ged

ifit

is connectedto 1I

circuit with voltage present.

An ohmmeter, although u

good indicator of a component's condition . This is

prima rily because resistance tests do not simulate

actualoperating conditio ns. For example, the pow er

source in most ohmmeters is only 6-9 vo lts. The voltage in the secondary windings

coil. however. can be

normal operat ion. Such high voltage can cause coil insulation leakage that cannot be ohmmeter.

Becau se resistance generally i perature. perform resistan ce tests with the component or circuit at room temperature. Resistanc e tests

sef

ul, is not always a

an ignit ion

several thou sand volts during

detected using an

ncr

eases with tem-

compo

on a hot

tance and may resu lt in unnecessary replacemen t of

a good

componen

nent will indicate increased resis-

Tocalibrate allanulog ohmm eter

Every time an analog ohmmeter is used or if the

scale is changed, the ohm meter must be cali

to zero the need le. Most dig ital ohm

ranging

-wh

en switched on they arc automatically

set to zero.

I. Make sure the meter battery

power, If the battery co nditio n is questionable. re-

place thc b

2. Make sure the test prob es arc clean and free of corrosion.

3. Touch the two lest probes together the meter needle location on the ohm scale. The need le must be aligned with the 0

4. If necessary, rotate the meter in either direction until the needl e is directly aligned with the 0 mark.

Continuity

Acontinuity test determines the integrity cuit or component. A broken wire or open circuit has no continuity, a complete circ uit has Continuity can be checked using an self-powered test lamp. Using an

low-resistance readin g, usually 0

continuity. An infinit y reading indicates no continu-

ity. Using a self-powered test lamp, continoity is indicatedifthe lest lamp glows. If the lamp docs not glow, no continuity is present.

The circuit or component must be isolated or dis-

connected from any other circuit

atter

Test

ohms adjust knob on the

mete

power

mark

ohmmeter

ohm, indi

to check continuity.

bra

rs are auto

is at full

and observe

on the scale.

a cir-

cont

inuity.

or a

ohmmeter

cates

ted

, a

Amperage

Ampere s (amps) arc the units used to measure current flow in a circuit or through a componen t. Current is the actual current that flows , the more work that can be accomplished . However, if excess ive current flows through a wire, the wire will overheat and pro bably melt. Melted wire s arc caused by excessive current,

not excessive volt

Amperes are measured using an ammeter attached in a simple series connection. Ampe rage

age

flow

electri city. The more

Page 31

GENERAL

INFORMATION

measurement require s that the

into the circuit in a series connection. A lways usc an

ammeter

that can read hig

amme

ter be spliced

her

that the ant icipat ed

current flow to prevent damage to the meter. Con-

nect the red leadofthe am meter to the electrical source and the black lead to the el

SPEC

IAL

Aseriesofspecial tools arc required to service the

drive and driven pulleys Transmission move

, disassemble, assemble and install these components onto the engine and transmi ssion. The special tools shown in Victor Specialty Tools (VST). directly from Victor Special ty Tools or throu gh a Polari s dea lership. The part num bers for eac h spccia! tool is listed along with each specific service

proeedure in Chapter Eight.

(PVT

). These tools are requ ired to re-

Fig

ure

FABRICATING

ectr

ical load .

TOOLS

the Polaris Variabl e

34 are avai lable from They

may be ordered

TOOLS

MECHANICS

Removing

I'a faste ner rusts and cannot be removed, several

methods may be used to loosen it. First, app ly penetrating oil such as Liquid Wrench or WD-40 (avail-

able at hardware or auto supply stores). Apply it

liberally

the fastener several

not hit it hard enough to ca use

penetrati ng

For frozen screws, apply penetratin g oil as de-

scribed, then insert

the top

ens the rust so mal way. this method, grip the head with locking pliers and twist the

Avoid appl ying heat unless spec ifically instruct ed to do so, as it may melt , warp or remove the temper from parts,

Removing

If the head break s off a screw or bolt, several methods are availab le for re por

tion. If a large portionofthe remainder projects

out, try gr ipping it with locking pliers.

jecting port ion is too small, file it to fit a

cut a slot in it to fit a screwdriver.

If the head breaks To do this, eenterpunch the exact center maining portion of thc screw or bolt. Drill a sma ll hole in the s

Back the screw out

(Figure

Frozen

and

Nuts

let it penetrate for 10-I5 minutes. Rap

times with a small hammer; do

oil

necessary.

a screwdriver in the slot and rap

the screwdrive r with a h

the screw can be removed in the nor-

If the screw head is too damaged to use

screw out.

IIrokenScrewsorBolts

off

crew

and tap the extractor into the hole.

with a wrench on the extractor

35).

and

Scr

ews

dama

ge. Reapply the

amm

er. This loos-

mov

ing the rema ining

wrench

lus

h, use a screw extrac tor.

the pro-

the re-

Some of'thc procedures in this manual requi re lIS- ing special tools. The res many cases,

cial 100 pieces or install a bearing or as complica ted as fabricating a tool from serap material. If the spec ial tool can be

designed and safely made but requ ires some type

mach ine work , contact a local community college

or high school that has a machine shop curriculum. Some shop teachers welco me outside

be used as pract ica l shop app lication for

students .

thinkofaccep

1s.

This can be as simple as using a few

threaded rod, washers and nuts to remove

our

ceful mechanic can, in

table substitutes lor spe-

wor

k that can adv

anced

Remedying

Occ

lessness or impact damage.

cleaned up

nuts) or die (for external thread s on bolts) through

the threads. To clea n or repair spark plug threads, a

spark plug tap can be used.

Ir an intern al

sary to install a Hclicoil or some other type of thread

insert. Follow the installin g their inse rt.

Strip

pedThreads

asionally, threads are stripped through care-

Often the threads can be

by running a tap (for interna l threads on

thr

ead is damaged, it may be neces-

manufacturer's instructions when

Page 32

CHAPTER ONE

REMOV

1. Center

ING

punch

BROK

broken stud

SCREWS

AND

2. Drill

BOLTS

hol

e in stud

3. Tap in screw extractor

If itis necessary to drill and tap a hole ,

ble 8 for metric tap and drill sizes.

BEAR ING REPLAC EMENT

Ball bearings arc used in some locations in the en-

gine and transmission assembly to reduce power

loss. heat and noise resulting from friction. Because

ball bearings arc precision

maintained by proper lubrication and mai ntenance.

If a bearing is damaged, it must be replaced imme-

diately. How ever, when installing a new bearing,

care should be taken to prevent damage to the new

made parts. they must be

ref

er 10

Ta-

4 ··1 1'

4. Remove broken stud

bearing. Bearing replacement is indicated in the individual chapter s where applicable; however, use

the following as a guidel ine.

Unless otherwise specified, ins/all bearings with mark or numberfacing outward.

Bearing Removal

While bearings are normall y removed only when

damaged, there may be times when it is necessary to

remove a bear ing that is in good condition. How-

NOTE

the manufacturer :\'

Page 33

GEI\ERALINFORl\IATIOI\

[

Bearing puller _

000

000 1

-~------.

=-=------

Spacer

W-

2. Whenusinga ham

ashan,do notstrikethe

Ill

ertoremove a

hammer

shaft.Instead, usc a brass oraluminum

the hammer and shaft (Figure 37) and make sure 10 support both bearing races with wooden blocks as

ShO\\'11.

press ram

Shaft

Bearing

Press bed

bearing

from

directlyagainstthe

rod

between

Shaft

Bearing

Blocks

ever, improper bearing removal will damage the

bearing and maybe the shaft or case half. Note the

following

I. When using a puller to remove a bearing from a

shaft, take care IhO!the shaft is nol damaged. Al-

ways place a piece of metal belween Ihe end

shaft and Ihe puller screw, In addition, place Ihe

puller

e 36.

whenremoving bearings.

arms

next to the innerbearing race. Sec Fig-

thc

3. The mosl ideal method

withah

ydra

ulicpress.However,

must be followed or damagemayoccurto the

ing, shaft or bearing housing. Note the following

when using a press:

a. Always support the inner and outer bearing

races with a suitable size wooden or alumi-

num ring supported, pressure applied against the ball

bearings and/or the inner race will damage thcm.

b. Always make surc the press ram (Figure 38)

(Figure

38). If only thc outer race is

alignswiththecenter

not centered, it may damage the bearing

and/or shaft.

c. The moment the

will drop to the floor,Secure or hold the shaft

to prevent it from falling.

shaft is free

bearing removal is

certain

procedure

the s

haft

the bearing, it

the

bear-

ram

Page 34

CHAPTER

ONE

Bearing

1. When installing a bearing in a housing, pressure

must be applied to the outer hearing race (Figure 39) .

When installing a bearing on a shaft. pressure must be

applied to the inner bearing race (Figure 40).

2. Wh en installing a bear ing as described in Step I,

Insta

llation

some type of driver will be requ ired. Never strike

the bearing directly with a h

will be

damag

ed, Whe n installing a bearing, a piece

pipe or a socket with a

bearing race is required.

rect way to use a socket and ham ing a bearing .

3. Step I describes how to insta ll a bearing in a case half or bea ring over a shaft and into a housing at the same time, a snug fit will be required for both outer and inne r bearing races. [11this situation, a spac er must be installed underneath the dr iver tool so that pressure is

42. If the outer rac e is not supported as shown in Fi

ing track and

ove

r a shaft. Howeve r, when insta lling a

appliedeven

gure

42 , the balls w ill push against the outer bear-

ly across bot h races.

damage

diameter

Figure

it.

ammer

or the bearing

that matches the

41 shows the cor-

mer

when

See

install-

Figure

•

Housing

Shaft

Shrink

I. Installing a bearing over a is smaller than the shaft. In this ing on the shaft using normal methods may cause bearing damage . Instead, the bearing sho uld be heated

Fit

shaft

: When a tight fit

required

a. Se

b. Clea n all residue from the bearing surface

c. FiB a suitable pot or

d. R

e. Turn the heat on and

, the bea ring inside diameter will be

case

, driving the

before

installation,

cure

the shaft so that it is ready for bearing

installation.

the shaft. R per.

era i oil. Place a th

than 120° C [248° F]) in the oil. Support the

ermo

bottom or side of the pot.

emo

cur

e it with a pieceofheavy wire bent to hold it in the pot. Han g the that it docs not touch the bottom or sides of the pot.

ter. When the oil temperature rises to approxi-

emove

meter so that it does not rest on the

ve the beari ng from its

Note

the fn lJowing:

burrs with a file or sandpa-

beake

r with clean min-

ermo

meter (rate d higher

wrapp

er and se-

bear

ing in the pot so

moni

tor the thermome-

bear

mately 120° C (248 ° F),

from the pot and quic kly install it. If

sary, place a socket on the i

and tap the bea ring into place. As the

chills, it will tighten on the shaft so be done quickly when install ing it. Make sure the bearing is installed all the way.

2. Installing a b generally installed in a housing with a slight inter-

feren ce fit. Driving the bearing into the housing using norma l methods may damage the hou sing or

cause bearing

be heated before the bearing is ins talled.

following:

ear

ing in a housing: Bea ring s are

damage

. Instead. the hous ing sho uld

CAUTION

remove

nner

Before heating the crankcases in this pr

edure to remove the bearings.

wash the cases thoroughly with deter-

gent

and

water: Rinse

and

rewash the

the

bear

work

bearing

nece

ing

bear

must

Not

e the

race

ing

Page 35

GENERAL INFOR

:VI

ATION

.,...-'

- ---=-

-------

immediately, the temperature is correct. Heat

only one hou

Do 1101 heat the housing

sing

at a time .

CAUTION

\1'i

th a torch

(propane or acetylenet-snever bring

lam

e into contact with the bearing

or housing. The direct heat will de-

stroy the case hardeningofthe bearing

and will

/ike~)l

WOI]) the housing.

b. Remove the housing from the oven or hot

plate and hold onto the housing with a kitchen pot holder, heavy gloves, or heavy shop

-it

cloth

is hot.

Shift

=-=

Shaft

cases as required to remove

ofo

and

other chemical deposits .

Bearing

~f--Drlver

pacer

::.J.f?±

Bearin g

;

,' ! Housing

all

traces

NOTE

Removal lind installation

ofbea

rings can be accomplished withIIsuitable size socket and extension.

e. Hold the housing with the bearing side down

and tap the bearing out. Repeat for all bearings in the housing,

d. Prior to heating the bearing housing, place the

newbearingin a

freeze

r,ifpossible,Chilling

a bearing will slightly reduce its outside diameter while the

heated bearing housing as-

sembly is slightly larger due to heat expansion. This will make bearing installation much easier.

NOTE

Always install bearings with the m

ufactu

rers

mark or number facing

outward.

afJ

c. Whi le the hou sing is still hot, install the Il C\V

bearing(s) into the housing. Install the bearings by hand, if possible.

lfn

ccessary, lightly tap the bearing(s) into the housing with a socket placed on the outer bearing race. Do not install new bearings

ner bear ing rac e. Install the bcaring(s) until it

by driving on the in-

scats completely.

SEALS

a. The housing must be healed to a tem pera ture

of about 2 12 hot plate. An easy way proper temperature is to water on

(l00

° C) in an oven or on a

10 check that it is at the

drop

tiny

drop

s of

the case;ifthey sizzle and evaporate

Seals (Figure 43) arc used to contain oil, water,

grease or co mbustion gasses in a housing or sha ft. Improper removalofa seal can damage the housing or shaft. I

mprop

er installationofthe seal can dam -

age the seal. Note the following:

Page 36

I. Prying is generally the easiest and most effective

method of removing a seal from a housing. lIow-

ever,

always place a rag underneath the

preventdamage to the

2. Pack waterproof grease in the seal lips

seal is ins

3. In mos t cases,oilsealsshould be installed su that

them

4. Install seals with a driver or socket placed on the outside

sure the seal is driven squarely into the housing.

Never install a seal by hitting against the top of the

seal with a

problems and general deteriorationofthe vehicle. This is especially important in areas with cold win-

ters.

fully.

talled

anufactur

er's

the seal as shown in

hamm

Several monthsofinactivity can cause serious

For

win

ter

housing.

numb

er.

STORAGE

storage.

ers or

prepare

mark

pry

tool to

bef

ore the

s face o

ut.

Figure

44. Make

the vehicle care-

f43\

Spring

tip

Dust

Main lip

CHAPTE

• Oil

R ONE

Stor

lities

age Area

. If a

garage

for

rentorlease inmost

ces

sive humidity. A

corro

torage

is not available,

sulated

dow

the

area

s. When

heat

ed a

tominimize

areas, If this

rect

sive fumes, Also avoid

cove

reare

rea

sun-

Selecting a

Most ATV riders store their vehicl es in their

home

garage

other

faci

selecting an area, consider the following points.

I. The storage area must be dry; there should be no

dampne

not

extreme temperature variations.

2. Avoid buildings with large win

ss or ex

nece

ssary,butitshouldbein

isnotpossible. musk the windowto keepdi

light

off

the vehicle.

3. Avoid buildings in industrial areas where facto-

ries arc liable to emit

buildings ncar large bodiesofsalt water.

4. S

ele

ct an area where there is minimum risk

fire, theft or vandalism. Check with the insurance agent to make sure that the insurance policy the vehicle in storage.

Prep

ari

ng Vehicle for S

Careful preparation will minimize deterioration

and make it easier to restore the vehicle to service.

Usc the following procedure.

I. Wash the vehicle thoroughly. Make certain all

the dirt and mud is thoroughly removed. Thor-

oughly clean all plastic and meta l components. Ap-

ply a plastic the plastic parts and apply a tire dressing to all tires.

Make sure to fo

when applying the plastic preservative.

2. Run the engine until it reaches operating temper-

ature.

gardlessofthe riding time since the last change. Fill

the engine and transmission with the recommended

type and quantity of fresh oil.

3. Drain all the gasoline from the fuel tank, fuel line and carburetor. Run the engine at idle speed un-

til all

4. Remove the spark plugand adda small quantity

preserva tive such as Armor-All to all

llow

the manufacturer' s instructions

Drain

the engine oi l and transmission oi l re-

the fuel is used up.

ofengineoil into the cylinder. Place a rag over the

cylinder head openings and slowly roll the engi ne

over a few times to distribute the oil, then reinstall

the spark plug.

5. Check the tire pressures. reduce the normal in-

flation pressure by 20%. and move the machine to

the storage area.

Page 37

GE;'IIE

RAL[;'II

FOR

l\IATl

6. Placethe vehiclesecurelyonastand.orwooden

blocks. so all four wheels are possible. place a piece of wood (plywood) under the

tires to keepmoisture away

After Storage

off

the groun d. If nOI

fro

mthetire

rubbe

1. Before returning the vehicle to service, thor-

oughly checkall fa

and

brake

compo

sten

ers. suspensioncomponents

nen

ts.

2. Check all controls and cables. Replace any cables thai are frayed or kinked.

3. Make sure both brakes. the clutch and the throttle operate smooth ly. Adjust the controls if necessary.

4. Ensure that all the wiring is correctly routed and

all con

nect

ions aretight and corrosion-free. Check

that the auxiliary shutoffswitch will stop the engine. Make sure the brake light is operationalwith both the hand lever

wiresarepositioned against the ex

5. Before

plug and out the excess storage oil. Place der head openings to keep the oil

and brake pedal. Make sure noneofthe

haust

pipe.

start

ing the engine.

tum

the engine over a few times to blow

remove

the spark

a rag over the cylin-

off

the engine. In-

stall a new spark plug and connect the spark plug

lead.

Table1MODEL

Year

1996

Sportsman 500 W969244

1997

Sport

sman

SOO

Sportsman 500 (Sweden) S9n SOAE Xplorer 500

1998

Sportsman Sportsman Sport

smanSOD

Sport

sman Sportsman Worker

SOD

Wor

ker

1999

Sportsman

Spor

tsman 500 (U.S.) A99CHSOAB Worker 500 (Sweden) A99CHSOEA Worker 500 (Sweden) A9BCHSOEB

Sportsman

2000

Sport

sman

Sport

sman

Worker 500 (Sweden) AOOCH50EA Worker 500 (Sweden) AOOCHSOEB

Sportsman

• Sportsman 500 Remington Special Edition (Cam ouflage color scheme).

(U.S.) W97CH SOA

SOD

(U.S.) W98CHSOAB

SOD

(U.S.) W98CHSOAC

(U.S.) W98CHSOAD 500 (U.S.) W98CH SOAE SOD

(U.S.) W98CH SOAF (Sweden) S98CHSOE

SOD

(Swed en)

SOD

(U.S.)

SOO

RSE'

SOO

(U.S.) AOOCH 500 (U.S.) AOOCH

500 RSE' AOOCH50AC

YEAR AND

Model

W97CD

S98CHSOEB

A99CH SOAA

A99CHSOAC

NUMBER

number

SOA

50A 50AB

Page 38

CHA PTER ONE

Year

1996 1997·1998

1999-on

ight

(In

1194 (47) 1194 (47) 2057 .4 (81) 1168.4 (46) 1194(47)

Vear

1996-1997

1998-0n

Table4DECIMAL

Decimal

Fract ions

In. mm

1/64 0.015625 1/32 0.03125 3/64 0.046875 1/16

0.0625 1.58750 9/16 0.5625 14.28750

Table2GENERAL

Length

.) mm

1955.8(n) 1168.4 (46)

2159 (85) 1168.4 (46)

Table3VEHICLE

Metric

0.39688

0.79375 17/32 0.53125 13.49375

1.19062 35/64 0.546875 13.89062

(In.)

294.4 649

316.1 697

AND

DIMENSIONS

Width

WEIGHT

METRIC

Fractions

33/64

(in.)

(DRY)

lb.

EQUIVALENTS

Wheel base

mm (i

n.)

1282.7 (50.50)

Decimal in. mm

0.515625

Metric

13.09687

5/64 0.078125 1.98437 37/64 0.578125 14.68437 3/32 0.09375 7/64 0.109375 2 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32

0.125 3.1750 5/8 0.625 15.87500

0.140625 3.57187 41/64 0.640625 16.27187

0.15625 3.96875

0.171875 4.36562 43/64

0.1875 4.76250 11/16

0.203125 5.15937 45/64

0.21875

0.234375 5.95312 47/64

0.250 6.35000 3/4

0.265625

0.28125

19/64 0.296875

5/16 0.3125

125

21/64

0.328 11/32 0.34375 23/64 3/8 25/64 13/32

0.359375 9.12812

0.375 9.52500 7/8

0.390625 9.92187 57/64 0.890625

0.40625 27/64 0.421875 7/16 29/64

15132 31/64 0.4

0.4375 11.11250 15/16 0.9375

0.453125 11.50937

0.46875 11.90625 31/32

8437

1/2 0.500

2.38125

.n812

19/32 39/64 0.609375 15.47812

21/32 0.65625 16.66875

5.55625 23/32 0.71875 18.25625

6.74687 49/64 0.765625 19.44687

7.14375

25/32

7.54062 51/64 0.796875 20.24062

7.93750 13/16 0.8125 20.63750

8.33437 53/64 0.828125

8.73125 27/32 0.84375 21.43125 55164 0.859375 22.8281 2

10.31875 29/32 0.90625 23.01875

10.71562 59/64 0.921875 23.41562

61/64 0.953125 24.20937

12.30312 63/64 0.984375 25.00312

12.70000 1

0.59375 15.08125

0.671875

0.6875

17.06 562

17.46250

0.703125 17.85937

0.734375

18.65312

0.750 19.05000

0.78125 19.84375

21.03437

0.875 22.22500

22.62187

23.812 50

0.96875 24.60625

1.00

25.4ססOO

Page 39

GENERAL

INFORMATION

Thread

diameter

5 mm 6m

10mm 12mm 14 mm

18 mm

Length

Inches

Miles

Feet Millimeter

Centimete r

Kilometer Meter

Fluid volume

U.S. quarts

U.S. gallons

U.S.ounces

Imperialgallons

Imperial quarts

Liters Liters Liters Liters Liters

Milliliters

Torque

Foot-pounds

Foot-pounds Inch-pounds

Newton-meters

Meters-kilograms

Volume

Cubic inches

Cubic centimeters

Temperature

Fahrenheit

Centigrade

Weight

Ounces

Pounds

Grams

Kilogra ms

Ta ble5 GE NERAL

Table6

CONVERSION

TORQUESPECIF

N·m

3.4-4.9

5.9-7.8 14-19 25-39 44-61 73-98 115-155 165-225

Multiply

by:

25.4

2.54

1.609

0.3048

0.03937

0.3937

0.6214

0.0006214

0.9463

3.785

29.573529

4.54609

1.1365

0.2641721

1.0566882

33.814023

0.22

0.8799

0.033814

1.0

0.001

ICATIONS

TABLES

ft.-lb.

30-43 52-69

10-14

18-29 32-45 54·72 85-114 122

·166

get

the

equivalent

Millimeter

Cent

imeter

Kilomet

Meter

Inches

Mile

Liters

Milliliters

Liters

U.S. gallons

U.S. quarts

U.S. ounce s

Imperial gallons

Imperial quarts

U.S. ounces Cubic centimeters

Liters

1.3558 Newton-meters

0.138255

0.11299

0.7375622

8.850 7

7.2330139

16.387064

0.0610237

(F _32°) x 0.556 (C x 1.8) + 32

28.3495

0.4535924

0.035274

2.2046224

(continued)

eter

s-kilograms

New

ton-meters

Foot-pounds Inch-pounds Foot-pounds

Cubic centimeters Cubic inches

Centigrade Fahrenheit

Grams Kilograms Ounces Pound s

of:

Page 40

34 CHAI'TER ONE

abl

Pressure

Pounds

Kilograms

per square Inch

per square

centimeter

Kllopascals

Pounds per square Inch

Speed

Miles per hour Kilometers per hour

e 6 CONVERSION

Multiply

0.070307

14.223343

0.1450

6.895

1.609344

0.6213712

TABLES

(co

nti

nued

by: To

)

get

the

equivalent

Kilograms per

square

Pounds per square Inch

centimeter

Pounds persquareInch

Kllopasca

Kilome ters per hour Miles per hour

of:

ABDC ATDC BBDC BDC BTDC

cc cld

COl

.ln.

EBS

It. It.-lb

gal.

H1A

hp In. in.-Ib.

1.0.

kg kgm km

kPa

L m MAG

ml mm

Nom

0 .0.

oz.

psi

PTO

PVT

pt.

qt.

rpm

VST

Table7TECHNICAL

ABBREVIATIONS

After bottom After top Before Bottom Before top

dead

bottom

dead

center

dead

center

Celsi us (Centigrade)

Cubiccentimeters Cubic Inch displacement

Capacitor

discharge

Ignition

CubicInches

Engine Braking Fahrenheit Feet

Foot-pounds Gallons High altitude

System

Horsepower

Inches Inch-pounds Inside

diameter

Kilograms

Kilogram meters Kilometer

Kllopascals Liter Meter Mag

neto

Mill

iliter

Milli

meter

Newton-meters Outside Ounces

Pounds per square

Power take off

Polaris Variable Transmission

diameter

Inch

Pint

Quart

Revolutions

Victory

per

Specially

minute

Tools

Page 41

GENERAL INFORMATION

Met

ric

size

3 x 0.50

3 x 0.60 4

x 0.70

x 0.75

x 0.80

x 0.90

x 1.00

8 x 1.00 8 x 1.25

x 1.00

x 1.25

.25

xl.50 11 x 1.50 12 x 1.50 12 x 1.75

Table8METRIC

Drill

equivalent

No. 39

3/32

No. 30

1/8

.19

No. 20

No.9

16/64

17/64 5/16 5/16 11/32

3/8 13/32

13/32

TAP

AND

Decima

'rac

tion

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3437

0.339

0.375

0.405

0.406

DRILL

SIZES

Near

3/32 3/32 1/8 1/8 11/64 5/32 13/64

15/6

9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32

est

fraction

Page 42

CHAPTER TWO

TROUBLESHOOTING

The

trouble

sho

oting procedures described in this

chapter pro vide typi cal symptoms and logica

lmeth

ods for isolating thecausers). There may be several

ways to solve a problem, but only a systematicap-

proach will be successful in avoiding wasted time

and possibly unnecessarily replacing parts.

Gatheras much informationas possible to aid in

diagnosis. Neverassume

look the obv ious. Ma kc sure there is fuel in the tank

and the spark plug is connected. Learn ing to recog-

nize symptoms will make

most cases, expensive and complicated test equip-

anyt

hing anddo not over-

troub

leshooting easier.In

mentis notneededto determine whetherrepairscan

be performed at h tic and do not start pro

experience and equipment on hand. Many service

departments ,..'i!l not lake work that involves the re-

ome

. On the other hand . be realis-

cedur

es that are beyond the

assembly do. expect the co st

dama

ged or abused equ ipment. [f they

to be high. If the ATV

quire theattentionofa professional, describesymptoms

andconditions a

ccurate

lyand fully.The more

informationa technician has available, the easier it

will be to diagnose the problem.

Prop

er l

ubri

cation, maintenance and periodic

tune-ups reduce the chance that problems will oc-

ur.

However even with the best of care, the motor-

cycle may require troubleshooting.

ERATING

An eng ine needs three basics to run properly: cor-

rectair/fuel mixture,compressionanda spark atthe

ght time. If one basic requirement is missing, the

engine will not

REQ

UIREMENTS

run

. Four-stroke engine operating

does

re-

Page 43

TRO

UBLESHOOTI

principles are described in Chapter Four under En-

gine Principles.

If the ATV has been sitting for any time and re-

fuses to start, check and clean the spark plug. If the plug is not fouled, look to the fuel delivery system. This includes the

fuel tank (Figure I), fuel shutoff

valve (F igure 2), fuel pump, fuel filter and fuel

lines. If the ATV sat for awhile with lite I in the car-

buretor. fuel deposits may have gummed up carbu-

retor jets and air passages. Gasoline tends to lose its

potency after sta nding for long periods, Condensa-

tion

may

contam

inate it with water. Drain the old

gas and try starting with a fresh tankful.

T ROU BLESHOOTIN

G INSTRU:\IEI'iTS

Chapter One lists the instruments needed and in-

struction for their lise.

AIn iN G TIlEENGI NE

Use the following outline as a guide for basic

starting procedures. Jn alt cases, make sure that there is an adequate supply

Sta

rting

a Cold Eugi ne

fuel in the lank.

I. Shill the transmission into NEUTRAL.

2A. On 1996-1998 models, perform the following:

a. Move the engine auxiliary shutoffswitch (A,

Figure 3) to the RUN position.

b. Tum the key, or ignition, switch to the

ON po-

sition.

e. Move the choke toggle lever (A, Figure 4) to

the ON position (Figure

4).

d. With the throttle completely closed, push the

start button (B, Figure 3).

NOTE

011

1999 and later models. the start

b U11011 is part (?f' the engine stop

switch. 17,l' engine Slop switch mm'es

.1;"0111

side-to-side and the start billion

portion start the

the switch moves UP to

engine.

2B. On 1999-on mode ls, perform the following:

Move

the

engine

auxiliary

shutoff

swi tch

(Figure 5) to the run position.

b. Tum the key, or ignition, switch to the

sition,

ON po-

Page 44

c. Move thc choke toggle lever (A, Figure 4) to

the ON position (Fig

d. With the throttle completely closed. push the

start button UP (Figure 5).

3. When the engine starts. work the Ihrottle lever slightly to kecp it running .

4. Idle the engine for approximately a minute or until the thrott le responds clean ly, thcn push the choke toggle Icver to the full OFF position.

Sta

ing a

Warm

01'

I. Shift thc transmission into NEUTRAL.

2. Move the engine auxiliary shutoff switch to the RUN position.

3. Turn the key, or ignition, switc h to the ON pos i-

ure

6).

Hot E ngine

tion.

4. Make sure the choke toggle leve r is in the OFF position.

5. Open the throttl e slightly and operate the start button.

CHA PTER

TWO

Star ting a Flooded Engine

If the engine will not start and there is a strong gasoline smell, the engine may be flooded. If so, open the throttle all the way and operate the starter.

Do notopen the choke. Hold ing the throttle open al-

lows

If the engi ne turns over but is difficult to start, or

will not start, check for obvious problems first. Use the following list and review the Operating Re-

quir

air to reach the engine.

TING

DIF

STAR

ements described earlier in this chapter.

FIC ULTIES

tf the engine still refuses to start, refer to the ap-

propriate troubleshooting procedures in this chap-

ter.

I. Makesure the choke toggle lever is in the correct position. Move the toggle lever to the ON position (Fig

e 6) for a co ld engine and to the full OFF po-

sition

(A, Figure 4) for a warm or hot engine.

ING

Do not usean ope

fuel in the lank. A serious explosion is

nfla

me to checkfor

certain to result.

2. Make sure there is fuel in the tank. Opcn the fuel filler cap (B,

the fuel sloshing around, Fill the tank i the fuel isold, drain the tank and fill it with fresh fuel.

3. If there is a possibil ity that the cylinder is flooded, or there is a strong smell of gaso line, open the throttle all the way and opera te the start button. If the cylinder is severely flooded (fouled or wet

spark plug), remove the spark plug and dry the base and electrode thoroughly with a soft cloth, or usc an aerosol parts cleaner. Reinstall the plug and attempt

to start the engine.

4. Make sure the auxi liary shutoff switch is not

Figure

4) and rock the ATV. Listen for fne

cessary. If

stuck or work ing improperly or that the wire is bro-

ken and shorting out. If necessary, test the auxiliary

shutoff switch as described under Switches in Chap-

ter Eleven.

5. Make sure the spark plug wire is on tight. Push the wire and boot (Figure 7) on and slightly rotate it to clean the electrical connection between the plug and the connector. Push or screw the plug cap into the high-tension lead.

6. Perform a spark test as described under Engine

Fails to Start (Spark Test) in this chapter. If there is a

Page 45

TROUBLESHOOTING

CAUTION

prevent

tent,

orm

h. Place your finger over the spark plug hole. c.Operate the start button. When the piston co-

damag

e to the ignition

ground ing thefill/owing steps.

the

sparkpl

ug when per-

.'1)'5 -

mesup on thecompressionstroke.pressurein

the cylinder should be felt coming from the spark plu g ho le. If so, the cy linde r probab ly bas sufficient compression to start the engine .

NOTE

There may still he a compression

problem even/hough it

vious test. The co

tested with a gauge

to the com

nism wi

d. Install thc spark plug and cap.

pres

thin/h

e camshaft.

pas

ses the

pre

mpress

ion cannot

all

this enginedue

sion release mecha-

strong spark, per form Step 7.Ifthere is no spark or

if the spark is very weak, test the ignit ion system as

scrib

ed in Chapter Eleven.

7. Check cylinder co

mpre

ssion as follows:

NOTE

Refer

10 Chap ter Thre

e/or

spark plug

removal information.

Engine

the ignition system is ope rating properly.

erform

Fails to St

the foll

art

(Spa rk Test)

owing

spark test to determine if

CAUTION

fore

removing the spark plugs in

Step I, clean all

f rom the

plu

the cylinder will cause

wem:

I. Refer to Chapter Three and disconnect the spark

plug wire and remov e thc spark plug.

dirtand

g base. Dirt that falls into

debris a

rapideng

way

ine

NOTE

A spark tester is a use/III tool

ing theignition systems spark output.

/or

test-

Figure 8 sho ws the Motion Pro Igni-

tion S ystem Tesler (part No. 08-(122). This too l is

inserted

ill

the spark p lug

cap and its base is grounded against the cylinder

adjust

spection

intensi ty

available

ead. The tool s

able.and

it allows the visual in-

the spark while testing the

the spark. This tool is

through most motorcycle

air

gap is

and ATV dealerships.

a. Remo ve and ground the spark plug shell

agai nst the cylinder head cover.

2. Insenthe spark plug (Figure

(0), into its cap and touch the spark plug

(Figure

9), or spark tester

Page 46

base against the cylinder head to ground it. Position the spark plug so the electrode is visible.

NOT

/fn

ot using a spark tester,

alw

ays lise a

newsparkplugjiJrthis lest procedure.

WAR

NING

Mount

the spark

fro

m the spark der so that the spa rk or t ignite the

der.

the engine is fl

perform this test. The

spark plug can ignite fuel

ejec

ted

through the sp

plu

g, or lester,away

plu

g hale in the cylin-

ester

gas

oline vapors in the C).'

ooded

firingof

ark

cannot

. do not

ttuu

plughol

/iIJ-

the

3. Tum the key.or ignitionswitch to the ON position.

WARNING

Do not hold

nnec

shock

may

the spark plug, wire or

tor. or a serious electrical

result.

4. Tum the engine over with the electric starter. A

crisp blue spark should be evident across the spark plug electrode or spark tester terminals. If there is

strong sunlight on the plug, shade the plug with a

hand to better see the spark.

5. I

fth

e spark is good, check for one or moreofthe

following possible malfunctions:

a. Obstructed fuel line or fuel filter or

malf unc-

tioning fuel pump.

b. Low compres sion or engine damage.

c. Flooded engine.

6. Ifthc spark is weak or ifthere is no spark, refer to

Engine is Difficult to Start in this chapter.

NO TE

the engine

backfi

res during star

ting

attempts, the ignition timing may be

incor

rect. Re

fer

10 I

gniti

on Tim

ing

pte

r Threefo r more inform ation.

Cha

ENGINEISDIFF

ICULTTOSTART

The following section groups the three main en-

gine operating systems with probab le causes.

CHAPTER

TWO

nectors. Check these carefully when troubleshoot-

mg.

I. Spa rk plug

-eh

eck for: a. Fouled spark plug. b. Incorrect spark plug gap. e. Incorrect spark plug heat range (Chapter

Three). d. Worn or damaged spark plug electrodes. e. Damaged spark plug.

r. Damaged spark plug cap or secondary wire.

NOTE

fer

Reading

Chap

ter

Three fo r

motion.

2. Ignition coil-eheck for:

a. Loose or damaged secondary or primary wire

leads. b. Cracked ignition coil body. c.

Loose or corroded ground wire.

3. S

...

vitc

hes

and wirin

a. Dirty or loose-fitting terminals.

b. Damaged wires or connectors.

c. Damaged start switch.

d. Damaged engine auxiliary shutoffswitch.

c. Damaged key, or ignition, switch.

4. Electrical compollents----eheck for:

a. Damaged CDI stator.

b. Damaged CD! unit.

Fuel System

Spark Plug, ill addi

tional inf or-

g------ch

eck for:

Electrical System

An often-overlooked sourceofelectrical mal-

functions is the wiring harness and electrical con-

A contaminated fuel system will cause engine

starting- and perfonnancc-rclated problems.

a small amount of dirt in the fuel valve, fuel

takes

It only

line or carburetor to cause problems.

Page 47

TROU BLESHOOTI

I. Ai

rfi

lter.

a. Clogged air filter. b. Clogged air filter housing. e. Leaking or damaged air filter hous-

ing-to-carburetor air boot.

2. Fuel shu

a. Clogged fuel hose. b. Clogged fuel valve filter.

3. Fuel tank:

a. No fuel. b. Clogged fuel filter. e. Contaminated fuel.

4. Carburetor:

a. Clogged or damaged choke system. b. Clogged main jet. c. Clogged slow jet. d. Loose slow jet or main jet. e. Clogged slow jet air passages. f. Incorrect float level.

g. Leaking or damaged float. h. Severely worn or damaged needle valve.

5. Fuel pump:

a. Fuel pump filter clogged. b. Fuel pump electrical connector faulty, cor-

Engine Co mpression

I. Cylinder and cylinder head:

a. Loose spark plug. b. Missing spark plug gasket. c. Leaking cylinder head gasket. d. Leaking cylinder block base gasket. e. Severely worn or seized piston, piston rings

f. Loose cylinder block and/or cylinder head

g. Cylinder head incorrectly installed and/or not

h. Warped cylinder head.

j. Blown cylinder block base gasket.

k. Loose cylinder fasteners.

2. Piston and piston rings:

a. Worn piston rings.

b. Damaged piston rings.

c. Piston seizure or piston damage.

3. Crankcase and crankshaft:

a. Seized connecting rod.

b. Damaged crankcase.

toff

valve:

roded or disconnected

andlor cylinder walls.

fasteners.

tightened to the correct torque specification.

Blown head gasket.

c. Damaged oil seals.

oor

Idle Speed

If the engine starts but otT-idle performance is

poor (eng ine hesitation, cutting out, etc .), check the

following:

I. Clogged or damaged air filter.

2. Carburetor:

a. Clogged slow jet. b. Loose slow jet. c. Damaged choke system. d. Incorrect throttle cable adjustment.

e. Incorrect carburetor adjustment.

f. Flooded carburetor (visually check carbure-

tor overflow hose for fuel).

g. Vacuum piston does

buretor bore.

3. Fuel:

a. Water and/or alcohol in fuel. b. Old fuel.

Performa

nce

n't

slide smoothly in car-

4. Engine:

a. Low engine comp ression.

5. Electrical system:

a. Damaged spark plug.

b. Damaged ignition coil.

c. Damaged CDI trigger coil. d. Damaged CD! unit.

Poor Med

Refer to

the following:

I. Carburetor:

a. Incorrect fuel level. b. Incorrect jet needle clip position

c. Clogged or loose main jet.

2. Clogged ai

3. Other considerations:

The starting system consistsofthe starter motor,

battery, start er relay and switch. This section

ium-

and High-Speed Pe

Engine is Difficult to Start, then check

able).

rfi

lter.

Ove

rhea ting .

b. Clutch/drive belt slippage. c. Brake drag. d. Engine oil viscosity too high or oil level too

high.

NE STA

RTING

rformanc

SYSTEM

(if

adjust-

de-

•

Page 48

scri

bes

pro

cedur

es for troubles A fully charged battery, bles

arerequired

If the starterdoes not operate, perform the follow-

ing tests b

for these tests.

efor

e go ing any farther.

ohmm

hoo

ting the system.

eter and

jumper

After

ca-

each test,

reconnec t any connector that was disconnected be-

fore proceeding.

I. Make sure the battery is fully charged and that

all cables and connec tions are correct, undamaged . clean and secure.

2. Make sure all electrical connections arc clean

and sec ure. In

Starter

the starter does no toperate, performthe follow-

ing.

When gine shu ON.

spe

ct the wiring harn ess for

Trou

bleshooting

operatin g the starter button, tumthe en-

toff

switch to RUN and the key switch to

damag

CAUTION

Do not operate an electric starter motor continuously onds. A110

J5 seconds between attempts to

least

for

\1'

the motor to

mor

e than 5

cool

for

sec

start the engine.

I. Check the

to the battery. the breaker, then go on to the next step.

2. Test the battery as described und er Battery in Chapter the prescribed range, cle an and recharge the battery as described place a damaged battery.

3. Disconnect the followingswitches (in the scribed und er Switches in Cha

20A

circuit br

[fn

ecessary, ope n the pouch and reset

Thre

e. If the batte ry vo ltage is not within

under

Battery in Chapter Three . Re-

seq

uence provided) and test them as de-

eaker(Figure

pter

Eleven . If the

one

II ) next

by one

switch operates correctly, reinstall the switch and

test the next one. If the sw itch does not operate cor rectly, replace it.

a. Key b. Start switch. c. Engine auxi liary shu

4. Disc from the starter solenoid. test l

red/w hite c key switch to the ON position and d button.

ohmmeter between the red

(or

ignition ) or start switch.

toff

switch.

onn

ect the red/w hite electrica l connector

Connec

ead

to ground and the red test lead to the

onn

ector

on the hamcss side. Tum the

There

should be ballery voltage.

t a voltmeterblack

epr

wir

e t

erm

inal and the 5

ess the start

Con

nect an

CHAPTER TW O

lenoid

moun

ting plate.

3.4

ohm

a. If the starter circuit solenoid te

perfonn Step 5.

b. If the starter circuit solenoid did not test cor-

rect ly, r

5. If the switches and solenoid tested succ

epla

ce the

The

specified resistance is

sole

noid and retest.

recheck the wiring for dirty or loose-fitting term inalsor damaged wires; clean and repair as required.

If a ll the connec tors and wires are in good condition. the starter move and under Starter in Chapter Eleven.

6. Make sure all connec tors disass

motor

is probably defccti ve. Re-

ove

rhaul the starter motor as described

this procedure are freeofcorrosion and arc recon-

nected prope rly.

C HA RG

A malfunction in the chargi ng system

causes the battery to remain undercharged .

Tro ubles hoot ing

Before testing the chargi ng

check the foll

owing

I. Chec k the battery

polarity is. or wa s, reversed , check for a

INGSYST

conn

system,

ections at the batte ry, If

regulat or/recti fief.

2. Check torloose or corroded battery cable co n-

nectors.

3. Inspect all wiring between the battery and CD!

stator for WOOlor cracked insulation or loose con-

nection s. nections as required.

4. Check battery condition . Clean and recharge as

required.

Rep

lace wi ring or clean and tighten con-

Sec

Battery in Chapter Three.

ste

d correctly,

emb

led

genera

damaged

ess

fully,

dur

ing

visually

lly

Page 49

T RO UB

LESHOOT

ING

5. Perform the Charging System Output resl listed under

Charging System in Chapter Eleven.

6. Test the regulator/rectifier as described under

gnkn

or/Rectifier in Chapter Eleven.

NITIONSYSTEM

All model s are equ ipped with a tran sistorized ignition system (Figure 12). Refer to the wiring diagrams at the end of this book for the specific model and year being worked on.

Because of the solid-state design. problems with

the transistorized system arc rare . If a probl em occurs,

it generally causes a we ak spark or no spark at

all. An ignition system with a weak spark or no

spark is relatively easy to troubl eshoot. It is difficult, however, to troubleshoot an igniti on sys tem that only malfunction s when the engine is hot or under load.

Ign

ition

System

Precaution

Certain measures must be taken to protect the ig-

nition syste

I. Never disconnect any uf the electrical connec-

tors whi le the engine is running.

2. Apply dielectric grea se to all electrica l connectors prior

out moisture.

3. Make sure all electrical connectors are free corrosion and are securely co upled.

4. to the frame.

Troubleshooting

Ref book for the speeific model being wor ked on when performing the following.

I. Check the wiring harness for visible signs

damage

2. Make sure all connectors are properly attached to eac h other and locked in place.

3. Check all electrical components for ground to the engine.

4. Check all cuits.

5. Mak e sure the fuel tank has an adequate supply of

to reconnecting them. This will help seal

Thc

COl unit must always be mounted securely

Prepar

ation

er to the wiring diagrams at the endofthis

wir

ing for short circuits or open cir-

fresh gasoline and is full.

a good

6. Make sure the spark plug cable is properly connected to the spark plug.

7. Remove the spark plug and examine it as described in Chapter Three.

Switch Test

Test the ignition swi tch and the

shu

toff

switch as described in Chapter Eleven.

Ign ition Coil Tes t

The ignition coi

cover.

I. Remove the front fende r cover (F igure 13) as

described in Chapter Fifteen.

2. Disconn connect or from the ignition coi l

3. Measure the ignition coil primary resistance using an ohmmeter set at between the prima ry wire terminal and the coil ground lug ( specifications.

4. To mea

sur

a. Rem ove the spark plug cap from the second-

ary cable.

b. Using an oh

sistance between the secondary cable and the

coil gro und lug (Figure 15). Refer to Table I

for test specifications.

e. Insta ll the cap onto the seco ndary cable.

" Connect the white/blue primary electrical con-

nector

igure 14) onto the igni tion coil.

6. If the ignition coil does not meet any spec ifications. the coil must be replaced. If the coi l exhibits visual damage, replace the co il as described in Chapter Eleven.

7. Install the front fender scribed in Chap ter Fifteen.

Exci

ter

(Stator) Coil and

Refer to

I. Locate the electrical cables gine flywh eel COl stator to the CD! unit. Care fully disconnec t the exciter coil and trigger coi l connectors from the

2. Meas ure the ohmme ter set at R x 100. Mea

I is located under the front fender

ect

the white/blue primary electrica l

R x I. Measure resistance

Figur

e 15). Refer 10 Ta ble I for test

e the secondaryresistance as foII0\\l5:

mmet

er setat Rx IK.measure re-

cover

Tri

Tab

le I for test speeilications.

l unit.

exciter

coil resistance using an

eng

igure 14).

(Figu re 13) as de-

gger

Coil Test

leading from the en -

sur

e resistance be-

ine auxiliary

these

...-

Page 50

CHAI

'TERTWO

IGNITION

SYSTEM

1. Flywheel

2. Stator colis

3. Trigger coil

4. Seal

5. Stator plate

6. Bushing

7. O-ring

B. COl

unll

9. Ignition high tension coil

10. Spark plug cap

11. Spark

plug

Page 51

TROUBLESHOOTI

Primary

tween the followingterminals on thea

of the co nnectors and check the resistance:

a. Between red and green terminals.

b. Between black/red and greenterminals.

lterna

torside

3. Measurethe CDItrigger coil resistanceusingan

ohmmeter set at R x 100. Measure resistance be-

tween the wh ite and white/red terminals on the COl magneto side.

4. If eitherthe excitercoil and/or trigger coil does notmeet any of these specifications, the CDl stator

semb

ly must be rep laced. The individual coils

cannot be replaced.

5.Ifthe co ils test acceptably. rec ci

ter

co il

and

trigger coil

unit.

EL E

CTRONICTHROTT

The electronic throttle control (ETC) disables the vehicle if'there is a mech anical problem in the throttle mechani sm. When the throttle is operating normally, throttle cable tension holds the ETC switch

inthe

open

position.

inthe

thro

ttle mec

the switc h contacts close. This grounds the COl unit and disables the igniti on system. The ETC is an important sa fety device. Do not opera te the ATV with

ETC

the

disabled.

hani

con

a mech

smandcable ten

onn

ect the ex-

necto

rs to the COl

LE C

Ol\T

icalfailureoccur

sion

ROL

is lost,

Secondary

Elect

ronic

Control Switch

1. Use a screwd

l.,,;\

--r

cover.

2. Shift the transmission into NEU the parking brake.

3. Block the rear wheels so the vehicle will not roll

inei

4. Start the engine and open the throttl e lever

slightly to increase engine RPM just above idle

pee

5. Use a finger and hold the throttle cable (A, Fig-

ure

igure

6A. On 1996-1998 models, the engine rpm should be limited to the specified ECT limit

the engine continues to run at a higher rpm. the

switch is faulty and must be replaced. Chapter Eleve n.

Throttle

Testing

river

to remove the t

therdirectio

16) stationary. then release the throttle lever (B,

16).

hrott

TRA

Land apply

1400 rpm . If

le con

Referto

trol

Page 52

68 . On 1999-on models, the eng ine should lose spark and stop. If the engine continues to run, the switch (C, placed, Refer to Cha pter Eleven.

7. Install the throttle control cover.

Do not automatically assum e that the carburet or is at fault when the engine does not run properly. While fuel sys tem problems are not unc

carburetor adjustment is se ldom the answer. In many cases, adjustment will only co mpound the prob

Begin fuel sys tem troubleshooti ng with the fuel

tank and wo rk through the system, reservi ng the carburetor as the final point. Mos t fuel sys tem prob-

lems result from an empty fuel tank, a plugged fuel

filter or fuel valve, fuel pump failure or old fuel,

Fuel

under

Figure

lem by making the engine run

syste

m troubleshooting is covered thoroughly

Engine Is Difficult To Start, Poor Idle Speed Performance Perfo rmance

gine

ove

quickl y cause engin e seizure and damage. The fol-

lowing sectiongroups five main systems with prob-

able causes that can cause eng ine overheating.

I. Ignition system:

a, Incorrect spark plug gap.

b. Incorrect spark plug heat range (Chapter

Three ).

c. Defective

2. Engine compression system:

a. Cy lin

b. Heavy carbo n buildup in combustion cham-

der

ber.

3. Engine cooling system:

a. Improper spark plug heat range.

Coo

ling system malfunction. c. Clogged radiator. d. Thermostat stuck closed.

e. Worn or damaged radiator cap.

f Fan sw itch malfunction,

g. Damaged cooling fan blades.

h. Clogged or blocked coolant passages in radia-

tor, hoses or engine.

i. Oil level low.

(6) is faulty and must be re-

FUE

L SYS

TEM

omm

on,

wor

se.

and Poor Medium- and High-Speed

in this chapter.

G[NEOVERHEAT[

rheating is a serious problem that can

COl un it/inc

head gasket leakage.

orr

ect ign ition timing.

CHA

PTER TWO

J. Oil not circu lating properly.

k. Valves leaking.

I. Dragging bra kes.

111

. Clutch/drive belt slippage.

. Heavy carbon bu ildup in combustion cham-

ber.

4. Fuel system:

a. Clogged air filter element. b. Carburetor fuel level too low.

c. Incorrect carburetor adjustment or j etting.

d. Loose carburetor hose cla mps. e. Leaking or damaged carburetor-to-a ir filter

housing air boot.

f. Incorrect

5. Engine load

a. Draggi ng brakc(s).

air/f

uel m ixture.

----<:

hcck for :

b. Damaged drive train components.

c. Slipping clutch/d rive belt. d. Engine oil level too high.

ENG[NE

Pre

ignition

Preignition is the premature burning cause d Glowing depos its equate cool ing or an ove rheated spark plug can all cause preignition.

loss but will eventually result in damage to the in-

ternal parts tion cha mber temperatu res.

Der

is the violent explosion

by hot spots in the comb ustion cham ber.

in the combustion chamber, inad-

This is first noticed as a power

the eng ine because o

nna

tion

Com monly called

sparkorfuetknock. detonation

fuel in the combustio n

fhig

her

fue

com

land is

hus-

Page 53

TROUBLES

HOO

TI NG

chambe r before the proper time o f combustion. Severe engin e damage can resu lt

if this condition per-

sists.Useoflaw-octanegasoline is a commoncause

detonation.

Even when using a high-octane gasoline, detona-

tion can still occur, Other causes are over-advanced

ignition timing, lean fuel mixture at or near full throttl e, inadequate engine cooling, or the excessive

accum ulation of carbon deposits in the combustion

chamber.

PowerLoss

Several factors can cause a lackofpower and

speed. Look for a clogged air filter or a fouled or

damaged spark plug. Galled piston or cylinder, in-

correct piston clearance or worn or sticky piston

rings may be responsible for any power loss. Look

for loose bolts, defeetive gas kets or leaking machined matin g surfaces on the cylinder head, cylinder block or crankcase.

Piston Seizure

This iscaused by incorrectbore clearance, piston

rings with an improper end gap, compression leak.

incorrect air/fuel mixture, heat range from any cause may result in piston seizure.

or incorrect ignition timing. Overheating

a spark plug of the wrong

Refer to Spark Plug Check also for excessive carbon buildup in the

combustion chamber or a defective ignition system

CD! unit.

eal Range in Chapter Three.

2. Slapping or rattling noises at low speed or during acceleration can be caused by excessive pis-

ton-to-cylinder wall clearance. Check also for a

bent connecting rod or worn piston pin and/or piston pin hole in the piston.

3. Knocking or rapping while decelerating usually

caused by excessive rod bearing

clearance.

4. Persistent knocking and vibration or other noise

usually ca used by worn ma in bearings. If the main

bearings are acceptable, consider the following:

a. Loose engine mounts.

Crac

ked frame. c. Leaking cylinder head gasket. d. Exhaust pipe leakage at cylinder head. e. Stuck piston ring(s).

f. Broken piston ring(s).

g. Partial engine seizure.

h. Excessive connecting rod bearing clearances.

I. Excessive connecting rod big end side clear-

ance.

j. Excessive crankshaft

k. Worn or dam aged primary drive gear.

5. Rapid on

leak around cylinder head gasket or spark plug.

-off

squeal indicates a

runout.

comp

ression

Pist on Slap

Piston slap is anaudible slapping or rattling noise

resulting from excess ive

ance. When allowe d to continue, piston slap will eventually cause the piston skirt to shatter.

To prevent piston slap, clean the air filter on a

regular schedule. When piston slap can be heard,

disassemble the engine top end and measure the cylinder bore and piston diameter and check for exces-

sive clearance. Replace parts that exceed wear

or show damage.

limits

ENGIN E N

piston-to-cylinder clear-

OISES

1. Knocking or pinging during acceleration can be

caused by using a

mended or a poorgrade of fuel. Incorrect carburetor

jetting and a too hot

lower octane fuel than recom-

spark plug can cause pinging.

CYLINDE R LEAKDOW N

A cylinder leakdown test can isolate an engine

malfunction caused by a leaking valve, d

cylinder head gasket,

ring(s), or defective piston. Perform a cylinder

leakdown test by applying compressed air into the cylinder, then measuring the percent cylinder leakage tester (Fi

pressor are required to perform this test.

Follow the manufacturer's directions along with

the following

der leak down test.

Start and run the engine until it reaches n

operating temperature, then turn ofTthe engine.

2. Remove the air filter assembly, Opcn and secure

the thrott le so that it is at its wide-open position.

3. Set the piston to TDC on its compression stroke.

Valve Clearance Check and

See

Chapter Three.

inf

worn, stuck or broken piston

gur

ormation when performing a cylin-

TEST

ective

leakage. A

e 17) and an air co m-

orm

Adj

ustment in

Page 54

CIIAI'TER

TWO

Cylinder

4. Rem ove the spark plug cap and the spark plug as described in Chapter Three.

pressure

LEAKDOWN

sots

The engine mny 'urn (weI' when air

pressure is applied to the c prevent this fro m happening, shift tire

low

range and set the parking brake.

ylinde

r. To

TESTER

Supply

pressure

To air

compressor

Low

Engine

(E ngine

1. Drive pulley spring is broken or wrong spring.

2. Drive pull ey we ight is

3. Drive belt is slipping.

OperatingSpeed

RunningProperly,but

100

heavy.

Lugs)

5. Install the le spark plug hole (Figure 18).

6. Apply pressure to the cylin manufa while n

ctur

otin

Air

cates a leakin g exhaust valve.

Air bod

c. Air leaking through the crankcase breather

tube indicates worn piston rings.

7. A cylinder with her

service.

furt

8. Install the spark plug and the air filter assembl y.

The following items provide a starting point from

whic h to troubleshoot power train malfunctions.

The possibl e causes for each malfunction are listed

akd

own tester into the cylinder

der

following the er's instru ctions, Listen for air leaking g the following:

leaking throu gh the exhaust pipe indi-

leaking through the

y indicates a leaking intake valve.

10%1cylinder Icakdown req uires

POWERTRA

car

buretor or throttle

in a logical sequence.

Engine

I. Incorrect drive pull ey sprin g.

2. Drive pull ey we ights arc too light.

3. Drive pulley is binding.

4. Driven pulley is binding.

Engine Speed During

I. Drive pulley is binding.

2. Driven

Operating

SpeedorLoadChanges

pulley is binding.

Speed

Erratic

Too Hig h

3. Pulley grooves arc worn.

Enga

Harsh

gement

I. The drive belt is worn (too narrow) .

2. Incorrect pulley-to-pulley clearance ( 1996- 1998 models).

Page 55

TROU

BLES

HOO

Tll'iG

4. Co ntaminated brake pads.

5. Sheared key on brake disc.

6. Air in

Leaking Transmission

brake lines.

I. Loose bolts.

2. Damaged gasket seal.

3. Damaged seals.

4, Cracked or broken case and/or c

over

Drive Belt Not

Smoothly in Primal")' She

Operating

ave

I. The drive pulley face is rough, grooved, pitted or

scored.

2. The drive belt is worn and/or defective.

Drive Bell Edg e Cord Failure or Uneven Drive

Bell Wea r

I. The drive and driven pulleys arc misaligned.

2. The engine mounts are loose.

Glazed Drive Bell

I. Excess ive slippage. May be caused by sticking

brakes.

2. Engine idle speed set too high.

Drive Belt Too T ight at Idl e

I. Engine idle speed set too high.

2. Incorrect distance between pulleys.

3. Incorrect drive belt length.

Drive C lutch

Specified Engagemen t RPM

Euga~es

efor

I. Worn spring.

2. Incorrect width.

Drive Clutch E

Specified Engagement

I. Incorrect spring.

2. \Vorn or damaged

rrati

c Shifti ug

ngag

es A

fter

sec

ondary sheavebuttons.

I. Worn rollers and bushings.

2. Scuffed or damaged weights.

3. Dirty drive pulley assembly.

4. Wom or damaged driven pulley ramps.

Engine Bogs

Donn

During Engagement

I. Incorrect driven pulley widthadjustment.

2. Drive belt worn too thin.

Incorrectdistance between driveanddrivenpulleys.

Dri

ve or Driven Pulley Sticks

Dr-ive

Bell Turns

Over

I. Incorrect drive belt,

2. Incorrect drive belt alignment,

3. Enginemount broken or

Brak

e Not

Holding

I . Incorrect brake adjustment.

Properl

loose

2. Worn brake pads.

3. Worn brake disks.

I. Damaged pulley assembly.

2. Movable pulley damaged.

3. Dirty pulley assembly.

Description of handling problemsarc

but the following items will provide a s

from which to troubleshoot handling and steering

problems. Some possib le causes for each malfunc-

tion arc listed in a logical sequence.

STEERI

:'II

subj

ective.

tart

ing point

Page 56

CHAPTER

TWO

DISC

IDisc brake fluid leakage :

IBrake overheating

IBrake chatter

BRAKE

I I

TROUBLESHOOTING

Check:

Looseor

Worn caliper piston seals

Scor

Loose banjo

Damaged washers

Leaking master cylinder diaphra gm

Leaking master cylinder secondary seal

Cracked

Brake

Loose or damaged master

Check:

Warped brake disc

Caliper pi

idin

Check:

Warped brake disc

Loose brake disc

Inco rrect ca

loo

Loose front axle nut and/or clamps

•

Worn wh eel bear

•

Damaged hub

Restricted brake hydraulic line

Cont

damage

ed c

aliper

pis

bolts

master

fluid

level

ston

and/or

g brakes

lip

er a

se caliper mounting

amin

ated

brake

d lin e f

ton an

cylinder

too

high

brakepads

lignment

ings

pads

itti

ngs

d/or

bore

housing

cylinder

bolts

cover

sticking

IBrake

IIns

uff

IBrake

locki

icient

sque

brakes

Check:

Inc

orrect

brake

lipe

pad

fluid

r pi

coll

fluid

brak

and/or

ston

ected

e adj

seals

aster

ust

brake

and/or

behind

cylinder

ment

adjustmen

master

and/or

brake

cylinder

disc

pad

Plugge

Check:

d passages in m Incorrect tront Caliper piston Warped bra ke disc

Air In brake lines W

orn

brake

low

brake Incorrect brake flu Id Worn brake di sc Worn ca Glazed brake pad s Leakin g primary cup seal In Contaminated brake pads

Cont

aminated brake pads Ousl or dirt Loose

parts

Page 57

TROU BLESHO

OTI

Generally Pooror Unpredictable Handli ng

I. Improper tire inflation pressure.

2. Improperly adjusted wheel alignment.

3. Worn or damaged steering components.

4. Worn or damaged suspension components.

5. Bent or broken frame.

Loose Steer ing

1. Loose steering shaft. bushings or steering shaft

fasteners.

2. Loose tie rod ends.

3. Worn spindle bushings.

Uneq ual Steering

I. Improperly adjusted tic rods.

2. Improperly adjusted steering stops.

3. Damaged steering components.

4. Uneven front tire pressure.

eer

ing \Vanders

1. Loose or ,..'om steering com ponents.

2. Improperly adjusted wheel alignment (toe ant).

3. Worn or damaged tires.

4. Damaged shock absorber(s).

5. Bent or broken frame.

FRA.\l E N

Noises traced to the frame or suspension arc usu-

OISE

ally caused by loose, worn or damaged parts. Various noises that arc related to the frame arc listed below:

I. Disc brake lIoise- A screeching sound dur ing

braking is the most common disc brake noise. Some other disc

brake associated noises can be caused by:

Glazed brake pad surface.

a. b. Excessively worn brake pads.

e. Warped brake dise(s).

d. Loose brake disc mounting bolts. e. Loose or missing caliper mounting bolts.

f. Damaged caliperts).

g. Cracked wheel flange or bosses, where the

brake disc mounts to the hub flange.

2. Front shock absorber noise:

a. Crac ked or broken shock spring(s). b. Damage shock absorber(s). c. Loose shock absorber mounting bolts and

nuts.

3. Rear shock absorber noise:

a. Loose shock absorber mounting bolts and

nuts. b. Cracked or broken shock spring. e. Damaged shock absorber(s).

4. Some other frame associated noises can be

caused by:

a. Cracked or brokeo frame. b. Cracked or broken rear upper and lower sus-

pension control arms.

c. Loose engine mounting bolts.

d. Damaged steering shaft bearings.

e. Loose mounting bracket.

BRAKES

The front performance and s frequently and repair any problem immediately. When replacing or refilling the disc brake fluid, use only DOT 3 brake fluid from container. See Chapter Fourteen for additional information un brake fluid selection and disc brake

service. The troubleshooting procedure s in F

19 will help to isolate the majority of disc brake

troubles.

When checking brake pad wear, check that the

brake pads in each cal iper contact the disc squarely.

If one

pect

and rear brake units arc critical to riding

ety. Inspect the brake system

a closed and sealed

igur

the brake pads is wearing unevenly. sus-

a warped or bent brake disc or damaged caliper,

Table1ison

the

following

ge.

Page 58

CHA

rTERTWO

Item

ternator

Exciter

Betwee

Between black/red and green

Exciter

Between red and green Between black/red and green

Trigger coil

Betwee

Yellow to yellow Yellow/red to

Charge

Yellow to yellow/red

Yellow

sta

coils (1996-1998)

n red andgreen

coils

n white and

harge

coil (1996-1998)

coil

tor

colis

(1999-on)

yellowlb

(1999-on)

ground

white/

rown

Ignition coil

Primary

Secondary

Starter

resistance

resist

solenoid

ance

resistance

Table1ELECTRICAL

red

SPECIFICATIONS

Specific

3.2 ohms

446

1.6 ohms

446 ohms

97 ohms

0.17 ohm

0.13 ohm

ohm

ation

Infinity

0.3 ohm

6.3K o

hms

3.4 ohms

Page 59

CHAPTER THREE

LUBRICATION, MAINTENANCE AND

TUNE·UP

Thischaptercovers lubrication,m

tune-up

ifications,

bles 1-6 at the end of this chapter.

proced

lubrica

ures. A ma

nts and

int

enance schedule, spec-

capacit

Tomaximizethe service life of the ATV

utm

ostinsafetyandperf

the

to p

erf

orm periodic inspections and maintenance.

Minor problems found during routine service can

be co rrected before they develop into major ones.

TIlerecommendedmaint

I) is to be cons idere d as a guide line. If the ATV is

operated under severe conditions (high humidity,

partia

l watersubmersion. muddiness, etc.) pcrfonn

the services more

Mostofthe service procedures in the schedule are

described in this chapter, however, those that re-

frequ

ormance

enan

ently.

aint

enancea

ies arelistedinTa-

and

gain

. it isnecessary

ce schedule (Table

quire

1110rc

an minor d

arecovered in the

isasse

appropria

mbly or

te chapters.

adj

ustment

I'R E-RI\) E CHEC KLIST

Perform

rid

e of the day. All of these checksarc described in

this chapter.

to the appropriate section.

At the end of

oughly and inspect it carefully. Then general lubrication and makeany adjustments nec-

essary.

I. Check the engine oil level in thc oil tank. Re-

move the oil fill ca p/dipstick clean. Reinsert the

the followin g checks prior to the first

If a component requires service.

each

riding day,clean thc ATV thor-

give

igu re I ). Wipe it

dip

stick and re

move

refer

it a

good

it. The oil

Page 60

level must be between the upper and lower lines on the dipstick (Fig

ype

of oil to bring the level up to the upper line. Re-

fer to T

2. Check the tran smission oil level as follows:

able

a. Remove the oil fill dipstick (Figure 3) and

wipe it clean. Reinsert the dipstick and remov

b. The oil level must be within the knurled sec-

tion of the dipstick (Fi g

c. If necessary, add the correct type of oil to

bring the level within the knur led section the dipstick. Refer to Table 3.

d. Install the oil fill cap/dipstick.

When performing any service work 10 the engine or cooling system, nel'er re-

e it.

e 2). If necessary. add the correct

e 4).

RNING

l1/O\'e theradiator cap(Figure 5), cool-

ant drain

coo/alithose when the engine and radiator are hot. Scalding fluid and steam are underpressure and wil! cause seri-

O/iS injuryif allowedtoescape.

scn..>ws

or disconnect any

I I

HAP

TER THREE

'I _

3. Check the coolant level with the eng ine cold. Check the cooling system for leaks and make sure

the coolant is up to the FULL mark on the coolant reservoir (F igure 6). Always add coolant to the res-

ervoir tank, not the radiator.

4. Turn the handlebar from side to side and check for steering play. Check that the co ntrol cables arc properly routed and do not int

dlebar

5. Check the throttle opera tion. Open the throttle all the way and release it. The throttle should close

quickly with no binding or roughness . Repeat this

step with the handlebar facing straig ht ahead and

both full lock positions.

6. Check that the front master cylinder brake lever and rear master cylinder peda l operate properly with no binding. Replace any broken lever or pedal. Check the lever and pedal housings for damage.

the handlebar controls.

WARNING

When checking the brake J the ball 0 11 the endofthe level: broken off, replace the lever immediately. The lever balls help the lever from

arm during

pnnc

afa

ll or crash.

erf

ere with the han-

ere

to prevent

nning

a hand or

l; check

it is

7. Inspect the front and rear suspension; make sure they have a good solid feel with no looseness.

8. Check all f

9. Make sure the the air box and carburetor or throttle body boots arc secured tightly.

10. Check tire pressure as listed in Table 2. II. Check the exhaust system for looseness or

damage.

12. Check the lightness of all fasteners, especially

engine, steering and suspension mounting hardware,

13. Make sure the fuel tank is full

our

wheels and tires for damage.

air filter element is clean and that

fresh gasoline.

Page 61

LUBRICAT

ION,

MAINTENAI'iCEAND

TUNE

-UP

life out

low-pressure gauge inthetoolbox.The

the tires. Carry a simple, accura te

approp

riate

tire pressures are listed inTable 2. Check tire pressure when the tires are cold.

WARNING

Always

inflate both tire

sets

(from and

rear) tires 10 correct air pressure. If

the vehicle is

pressures.

olle side, causing poor handling.

Do 11

will be permanently distorted

damaged. Over-inflated tires will cause

lire \l'

e(/1

The tire

ill Table 2 are

different tires have been installed,

rEm

with unequal air

the vehicle will nm to ward

AUT

ION

over

-inflate the tires, as they

handling and abn ormal

NOTE

pre

ssu

re specifications listed

for

the original tires. If

and

fo llo w the tire pressure recommenda-

tions spe

turcr.

cif

ied by the tire monufac-

14. Inspect the fuel lines and fittings for wetness.

15. Check the hrake fluid level in both brake mas-

ter cylinder reservoirs. If necessary. add DOT 3

brake fluid to bring the level up to the maximum

line. Refer to Table 3.

TIR

ESAND WHEEL S

Tire Pressure

Check and adjust the tire pressure to achieve

goodtractionandhandling. andtogetthe maximum

NOTE

After checking and adjusting tire air

essure, make sure to reinstall the air

valve cap. Thecap prevents small peb-

bles

fromcollecting in tire valve stem;

this could allow

inc

orr

ect tire pressure reading.

air

leakage or result in

Tire Inspection

The tires lake a lotofpunishment due to the vari-

ety of terrain they are sub

riodically forexcessive

cted to. Inspect them pe-

wear,

cuts, abrasions.etc. If

a nail or other object is found in the tire, mark its location with a light crayon prior to removing it. This will help locate the hole for repair. Refer to Chapter

Twelve fortire changing and repairinformation.

To gauge tirewear.inspect the shape

knobs.Togetanaccurate measurement measure a number of different knobs

the

tire we

around

tread

ar.

the

tire. If the drive knob vertical sides (F igure 7) are worn to less than 3 mm (1/8 in.), replace the tire as

described in ChapterTwelve.

WARN

ING

Donot

rid

orseverely

e the vehicle with damag

\1'o

rn tires. Replace dam-

Page 62

age

d or

severely

ately

Rim Inspectio n

Frequently inspect the condition

rims, especially the outer side.

wor

n tires immedi-

the wheel has hit a

the wheel

tree or large rock, rimdamage may be sufficientto

cause anairleakor knock

proper wheel ali

and re

sult

gnment

inanun

safe

itout

alignment.Im-

cancause severe vi

ridin

g condition.

bra

tion

Make sure the wheel lug auts are securely in place on all wheels, If they are loose, the wheel could damage the hub studs or fall

wheel lug nuts to the t

orqu

e specification listed in

off

Tighten

Table 5.

BATTERY

The battery is an important component in the

Yet

electrical system,

most electrical system trou-

bles can be traced to battery neglect. Therefore,

clean and inspect the battery and electrolyte level

once each week.

On all models covered in this manual, the nega-

tive side is grounded. When removing the battery,

disconnect the negative cable first, then the positive cable. This minimizes the chance

a tool shorting to ground when disconnecting the positive battery cable.

r------- -.

I I

CHAPTER

THRE

Safety

Precautions

When workingwith abattery.useex

treme

care to

avoid spilling or splashing the electrolyte. This so-

lution contains sulfuric acid, which will ruin clothing and cause serious chemical skin bums. If any

electrolyte is spilled or splashed on clothing or skin,

immediately neutralize it with a solution soda and water, then flush with an abundance of

water.

clean

WARNING

Electrolyte splashed into the eyes is extremely

protection while working with a bat-

tel)'. If' electrolyte gets into the eyes,

call a physician immedi the eyes open cool, clean water fo r approximately

15 minutes.

harmf

ul. Always wear eye

([11£1

flood

ate

ly. Force

them with

baking

While a battery is being charged, highly explo-

sive hydrogen gas forms in each cell. Some

gas escapes through filler cap openings and may fonn an explosive atmosphere in and around the

this

battery.This co ndition can persist for several hours.

Sparks, an open flame or a litcigarette can ignite the

gas, causing an explosion and possible serious per-

sonal injury.

Note the following precautions to prevent an ex-

plosion:

Page 63

LUBllI

CATlO1<, ;\IAINTENANCE AND T UNE-UP

1. Do not allow anyone to smoke or permit any

open flame near any battery being charged or re-

cently charged batt

2. Do not disconnec t live circuits at battery nals since a spark usually occurs when a live circ uit is broken .

ery

tCITIl

3. Be careful when connecting or disconnecting any battery charger. Make sure the main key switch

is in the offpositionbefore making or breaking con-

nectio ns. Poor connections are a common cause

electrical arcs that cause exp losions.

4. Keep children and pels away from charging

equipment and batteries.

W4RNING

When performing the.fiJI/owing proce-

dures, P1VI(:'ct the ercs, skin and cloth-

ing.Ifelectrolvtegets intothe eyes.flush

the eyest

gel prom

hor

oughlywitl: clean water and

medical attention.

Electro

marks on the

2. To adj ust the electrol yte level, remove the battery from the fram e

dure. Do not add water while the battery is still in

the will

3. tighten

4. If the electrolyte level is correct, reinstall the battery.

lyte Level C heck

Main tain the electrolyte level between the two

battery case (F

as described in the next proce-

igure

8).

frameas any spilled water along with electrolyte

now onto the rear fram e resultin g in corrosion.

Make sure all cell caps are in place and are tight;

if necessary.

Battery

Removal

/Installation

NOTE

The battery can be removed with the

rearfe

nder in place by removing the

rear wheel, bill

elY

limited. Remove whatever com-

ponent

IA. Remove the rear fender as described in Chapter

Fifteen.

IB, Remove the left-hand rear wheel as described in

Chapter

2. Usc a stiff whiskbroom or brush clean

off

prior to removin g any parts or connec tors.

3. Unhook and remove the battery ho ld dow n strap (A, Fig

4. R

cmove

5. Disconnect the from the battery. Leave the vent hose routed through the fram e.

conne

6. Dis ure

II)

7. Discon nect the positive battery cable (B, II)

from the battery.

8. Carefully lift the battery out tray and remove the

is most convenient.

Thirteen.

any

debris from the top of the battery c

ure

9). the battery cover

ct the negative battery cable (A, Fig-

from the ballcry.

'he working room is

(13,

Figu

battery vent hose

the battery frame

battery.

CAUTION

and thoro ughly

Be careful not to spill battery electro -

lyle on painted or polished surfaces.

The liquid

high~~

corrosive and will damage thefinish. Ij'it is spilled. wash it

off

immedia

tel

y with soapy water

and thoroughlyrinse with cleanwate

re 9).

(Figure

ove

10)

Figure

Page 64

9. Inspeet the cushion pads (F igure 12) in the battery frame tray for wear or deterioration. Replace if

necessary.

10. Posi tion the battery with the negati ve battery

terminal toward the rear

II.

Reinstall the battery into the battery frame tray.

12. Install and tighten the positive battery cable (B, Figure II ).

13. Install and tighten the nega tive battery cable ure

(A, Fig

II ).

CAUT

the ATY.

ION

Be sure the battery cables are con-

ected

to their proper terminals. The

red battery cable must be connected

10 the po sitive battery terminal and

the black battery cable must be connected to

the negative battery termi - nal. Connecting the battery backwards

will reverse the polarity

and damage the voltage regula-

tor/re ctifier and CD! unit.

CHAPTE

R T

HREE

14. Coa t the battery connections with d ielectric greaseorpetroleum jelly to retard corrosion,

15A. If remov ed, install the rear fender as described

Add ing

Fifteen.

Wal

in Chapter

15B. If removed, install the lett-hand rear whee l as

described in Chapter Th irteen.

Cleaning, Inspection

and

1. Inspect the battery pads in the battery frame tray

for contamination or damage. Clean with a baking

soda and water solution.

2. Check the entire battery ease for cracks or other If

damage. has a raised top, the battery has been sutTering from overcharging or overheating.

3. Check the battery terminal bolts, spacers and nuts for corrosion. deterioration parts thoroughly with a baking soda and water solution. Replace severely corroded or damaged parts.

4. Clean the top brush using the baking soda and water solution.

the battery case is warped, discolored or

damage. Clean

NOTE

Keep cleaning solutio n outofthe bat-

tel

cells,

the electrolyte level will

be seriously weakened.

the battery with a stitT bristle

Thoroughly rinse otTall bakin g soda residue with

freshwater.

5. Check the battery cable clamps for eorrosion and damage. If corrosion is minor. clean the battery cable clamps with a stitf wire brush. Replace seve rely worn or damaged cables.

NOTE

1101OWl/

6. nil'electrolyte expands due

iII

the battery cells in Step

heal

Page 65

LUBRICATION,MAINTENANCE

AND TUNE-UP

charge the battery after adding water

to the cells.

Take reading at eye level

Float must

be free

fro

m charging and will

level is above the upper Jere/line

ove

rflowif/Ire

6, Remove the fill caps (Figure 13) from the battery cells and check the electrolyte level in each

cell. Add distilled ,..-atcr,ifnecessary, to bring the

level within the upper and lower level lines on the

battery case (Figure 14). Install the caps and tighten securely.

Battery Testing

Checking the specific gravity

trolyte is the best way to check the state

the battery elec-

charge the battery. Specific gravity is the density of the electrolyte as compared to pure water. To check the specific gravity, use a hydrometer with numbered graduations from 1.100 to 1.300 rather than one witbjust color-coded bands. Touse tbe bydrometer, squeeze the rubber ball, insert the tip into the cell and release the ball (Figure 15).

NOTE

Addin

g wat er /0 the cells will lower

the

spec

ific gra vity (density)ofthe

lec

trolyte.Af ter adding H'ater ch

ry/o

the batte high enough to

r 15-20minutes at a rate

cause vigorous gas-

arg

sing.

Draw sufficient electrolyte to float the weighted

float inside the hydrometer. When using a tempera-

ture-compensated hydrometer, release the electro-

lyte and repeat tbis process several times to make

sure the thermometer has had time to adjust to tbe electrolyte temperature before taking tbe reading.

Hold thc hydrometer vertically and note the number in line with the surface of the electrolyte (Figure

15). This is the specific gravity for this cell.

Return the electrolyte to the cell from which it

came. The specific gravity of the electrolyte in each

battery cell is an excellent indication

condition. Refer to

Figure

16. A fully charged cell

tbat cell's

will read 1.260-1.280 whilea cell in good condition reads from 1.230-1.250 and anything below 1.140

is discharged. Charging is also necessary

gravity varies more than 0.050 from cell to

cific

the spe-

cell. After charging, if the specific gravity still var-

ies more than 0.050, the battery has failed.

CAUTION

Adding water to the cells will dilute

the electrolyte. The diluted electrolyte

can freeze and damage the batt

during sub-

freezing

temperatures.

ery

Theref ore, during cold weather,

NOTE

a t

emp

erature-compen

drom

ete

r is not used.

specific gravity reading

abo ve 800F (25 b

elow

800F (250C), subtract 0.004.

C).

add

0.004 to the

for

For

sated

eve

J)' 10°

evel}' 10

hy-

Page 66

1.28

1.26

1.24

1.220

1.200

1.18

1.160

1.140

1.120

1.100

CHAPTER THREE

0 0 0

BATIERY--S

50403020

taleofc

harg

e C

Olo)

100908070

Charging

Maintain a

good

state of charge in a battery used

for starting. When charging the battery, the electro-

lyte will begin to bubble. This is ca lled gass ing.

one

cell does

tive. Also,

not

bubbl e, it is probably defec-

the specific gravity of the ce ll is con-

siderably lower than the other cells (0.050 points or

def

more ) after the battery is charged, the cell is

ec-

tive.

If a battery not in usc loses its charge within a

week afterc quickly, the battery is defective. A good battery should only self-discharge approxima tely I% each day.

har

ging or if the specific gravity drops

WARNING

During charging.

high fv explosive

hydrogen gas is released f rom the

batt

ery

. Charge the bat tery 0116' in a

ell-vent

ilated

area, and a way

fro

openfl ames (including pilot lights 01/

some gas home appliances). Do not

allow

any

smo

king in the area.

check the charge

the battery by

Neve

arcing across the terminals; the re-

sulting spark can ign ite the hydrogen gas.

AUTfON

Always remo ve the battery

ehi

cle bef ore connecting the charg-

ing equipment.

1. Rem ove the battery from the vehicle as de-

scribed in this chap ter.

fro

m the

2. Connect the positi ve charger lead to the positive and

battery terminal

the negative charger lead to the

negative battery terminal.

3. Remove all fill/vent cap s (Figu re 13) from the

battery, set the cha rger Normally, charge rate

a battery should be charged at a slow

1110 its given capacity.

at 12 volts, and sw itch it on ,

CAUTION

Maintain the electrolyte level at the

upper

level duringthe charging cycle:

check

and refill with distilled 'water as

necessary.

4. The charging time depends on condition

5. pre-determined

the battery.

ter

the battery has been charged for the

time, turn the charger off, discon-

nect the leads and check the

the disc

specific gravity. It

should be within the limits spec ified in Battery

Testing. If it is, and remain s stable forone hour, the

battery is charged.

New B

atte

ry In stallation

A new battery mu st be

f ully charged (specific

grav ityof1.260-1.280) before installing it in the ve-

hicle. When electroly te is added to a new battery, its

charge or capacity at that time is approx imately

80%,.To bring the battery to a full charge , it must re-

ceive an initial or boost charge. Using a new battery

without an initial charge will cause permanent battery da

mage

. Th at is, the battery will never be ab le to hold more than an 80% charge. Charging a new battery after it has been used will not bring its charge to 100%. When purchasing a new battery,

har

ged

Page 67

LU BRICATlO:"l,

verify its charge status. If necessary. have the parts

I\IA

I:"lTENANCE AND T U:"lE-UP 61

supplier perform the initial or booster charge to

bring the batte ry up 10 100% charge .

2. Thoroughly clean each connector with a wire brush and then with a baking soda solution. Rinse thoroughly with clean water and wipe dry with a

clean cloth.

3. After cleaning. apply a thin layer

dielectric

grease to the batter)' terminals before reattaching

the cables.

4. Afte r connecting the electrical cables, apply a

light coating

minals

dielectric grease to the electrical ter-

the battery to retard corrosion.

PER

IODI

C L UBRI

CATl

O;\l

Perform the services listed in this section at the

maintenance intervals listed in

ble 3 for fluid types and capacities.

Table I . Refer to Ta-

the vehicle is

exposed to harder than normal usc with constant exposure to

water and high humidity. perform the ser-

vices more frequently.

The Polaris engine is a dry-sump design with an

oil tank (Fi engine. Th is tank must always be ommended type

gure

18) located on the leli side of the

filledwith thc rec-

engine oil listed in Table 3. The

oil within the tank is circulated throughout the en- gine and then is returned to this tank for cooling.

Reier to l.ubricunts in Chapter One.

NOTE

Rec

ycl

ethe old battery. When /he new

battery is purchased, return the old

one

for

recycling. The

the plastic case can be recycled.

vehicle deal erships will accept the battery ill trade when the new oll e is

purchased.

in the household trash . It is illegal 10

place any acid or lead (he

contents in landf

N(~I'e,.

BATTERY

place

ills

ELE

lead

all

old battery

avy

CTRICAL

pla tes

metal)

and

Most

old

CABL E CONNECTORS

To ensure good electrical contact between the battery and the electrical cables bles must be clean and free

\. If the electrical cable term inals are badly cor-

roded. disconnect them from the A

(Figu re 17). the ca-

corrosion.

TV's

electr ical

system.

Eng

ine Oil Leve l Check

Check the engine oil level nsing the oi l fill

cap/dipstick located on the top of the oil tank.

Start the engine and let it warm up approxi-

2-3 minutes.

mately

2. Park the ATV on level ground and set the park-

ing brake.

Shut off the engine and let the oil settle for 2-3

minutes.

4. Remove the oil lill cap/dipstick (Figure 19) and

wipe it clean . Reinsert the dipstick and re

The oil level must be between the upper and lower

lines on the dip stick (Figu re 20 ). If necessary. add

the correct type (Table 3)

10 thc upper line.

5. Install the oi l fill cap/dipstick and tighten seenrely.

oil to bring the level np

mov

e it.

Page 68

CHAPTER

THREE

Engine Oil

Regu lar oi l and filter changes will contribute

more to engi ne longevity than

nanc e

perfor

and

FilterChange

med.

any

other

mainte-

Themanufacturerrecommendsusing PolarisPre-

mium 4 syn thetic

IOW-40 eng ine oil. Usc the sa me brand of oil al

each oil change.

To change the engine oil and tilter the following

is required:

SAE

IOW-40 engine oil or

a. Drainpan.

b. Funnel.

c. Wrenc h and sockets.

Two

quar

ts (1.89 L)ofoil (see

New

oil filter.

f. Socket-type oil filter wrench.

NOTE

A socket-typ e oilfitter wrench must be used to the small working orea surrounding

remOl'ethe oilf ilter because

Table

3).

the oilfilter:

't'

NOTE

Never disposeofmotor oil in the trash. 0 11 the ground. or down the storm drain. Many service stations

occeps nsed motor oil and w

ers provide curbside used motor oil

collection. Do not combine other

ids with motor oil to be recycled. locate a recycler.contact the Ameri-

can Petroleum Institute (API) at

www.reeycleoil

.or

Warming the engine allows the oil to

heat up; thus u

contamination and any sludge

ries buildup

I. Start the engine and let it

matel y

2-3 minutes. Shut thc engine ofT.

2. Place the ATV on level ground ing brake.

3. Place a drain pan under the oi l t

flows

out with it.

WARN/NG

freely

war

The oil draining outofthe oil tank is

WI}'

hot; protect hands accordingly.

aste

haul

flu

and

car-

m up appro xi-

and set the park-

ank

drain plug.

4. Loose n the drain plug (Figure 21) mount ed on thc bottom

plug and gasket.

5. Loosen the oil fill cap/dipstick (Figure 19), as this will speed up the Ilow

6. Allow the oil

7. Inspect the co ndition of the tamination after arc found. this indicates some sort o damage is occ urring. Refer to Chapter Four and Chapter Five.

the oil t

com

ank

pletely dra in.

it has cooled down. I

. Then remove the drain

oil.

dra ined oil for co n-

fan

y particles

fintemaleng

ine

Page 69

LUBRICATION, MAINTENANCE AND TUNE-UP

8. Remove the scree n from the back side of the oil

tank as follow s:

a. Loosen and remove the banjo bolt (Figure

22) and scaling washers securing thc oil hose

anddisconnect the hose from the

b. Unscrew the fitting and screen

tank.

c. Thoroughlycleanthe screenwithsolventand

check fordamage.

d. Apply Loctite P

sealant, to the thread fitt ings.

STSO

S, or equiva lent thread

fittin

from

the oil

e. Install the screen and fitting onto the oil

and tighten to the torque specification listed

in Table s.

f. Install the hose,withasealingwasher on

side, and banjo bolt onto the fitting and tighten securely.

9. There is approximately I cup

will

rema

in in the crankcase after the oil tank is

rain

thi

drained. D

a. Move the drain pan under the right sideofthe

crankcase below the recoil start er assembly.

b. On the right side, remove the drain plug and

gasket low the oil to completely

c. Check

case and the damage. Clean off if necessaryto maintaina

leak-free seal.

d.Install a new gasketonthe

stall the drain plug. Tighten to the torque specification listed in

10. To rep lace the oil filter, perform the following: a. Move the drain pan under the oil filter, as re-

sidual oil will

ened and removed. Place a shop cloth under

the oil filter to catch residual oil as the oil fil-

ter is loosened.

b. Install a socket-type oil filter wrench onto the

oil tilter

terclockwise until oil begins to run out onto

the shop cloth. Wait until the oil stops then

loosen the filter until it iseasy to turn.

c. Due to limited space, remove the oi l filter

wrench from the end of the filter thencompletely unscrew andremove the filterholding

s oiIas follows:

(Figure 23) from the crankcase and al-

thatthe sealingsurface on thecrank-

drain

plug are freeofburrs

drain out when the filter is loos-

(Figure 24) and tum the filter CO

drain.

drain

Table s.

engine oil that

tank

each

plug andin-

itwiththe open facing up.

d. Hold the filter over the drainpan and pour out

any rema ining oil. Place the old filter in a heavy-duty plastic bag and close the bag. Discard the old filter properly.

e. Thoroughly clean the sealing surface

crankcase where the filter's rubberseal seats. This surface must be clean to achieve a good oil seal when the filteris installed and tightened.

Apply a light coatofclean engine oil to the rubber seal on the new tilter.

stallanew oil lilterontothe threadedfitting

on the c

nkcase.

and

l/Il-

the

Page 70

h. Tighten the filter by hand until the rubber gas-

ket contacts the crankcase surface, then

tighten it an additional 1/2 turn.

II. Install a new gasket on the oil tank drain plug.

12. lnstall the drain plug

Tig

hten to the torque specification in

13. Insert a funne l into the oil fill hole and fill the

oil tank and engine with the correct weight (T

3) and quantity

14. Remove the funnel, install the oil fill cap/dip-

stick and tighten secure ly.

15. Usually some oil will find its

frame and floorboards during this procedure. Wipe as much as possibleoff with a shop rag, then spray some aerosol parts cleaner to remove most of the oil residue.

16. Place the gea r selector in NE

sure the parking brake is still applied.

17. Start the engine and allow it to idle .

18. Check the oil filter and both drain plugs for eak

s. Tighten, if necessary.

19. Turn off the engine and allow the oil to settle.

Then check the engine oil level chapter, Adjust the oil level if necessary.

(Figure 21) and its gasket.

oil (Table 4).

UTR

as described in this

Tab

le 5.

abl

way onto the

AL and make

CHAPTE

R T HR

RNING

Contact with oil may cause cancel:

rVash both hands thoroughly with

soapand wa

fer handlingorcoming in contact with

teru

s soon as

pos

sible af-

motor oil.

Engine Oil

Usc this procedure to check the engine oil pressure after reassembling the engine or when troubleshooting the lubrication system.

Pre

ssu re Test

An oil pressure gauge and 1/8 NPT oil pressure

gauge and adapter or an equivalent, are required.

I. Place the ATV on level ground and set the park-

ing brake.

2. Remove the front fender as described in Chapter

Fifteen.

3. Check that the engine oil level is correct as described in this chapter. Add oil

if necessary.

4. Start the engine and allow it to reach normal operating temperature. Shut the engine ofT.

5. Place a drain pan under the blind plug on the cyl-

inder head as some oil will drain out.

NOTE

Figure 2S S

r clarity.

6. On the front len cornerofthe cylinder head, unscrew and remove the blind plug (Fig

the cy linder head.

7. Install the adapter into the blind plug hole. Make

hOlVS

the engine removed

ure

25) from

sure the fitting is tight to avoid an oil loss. Install the

gauge into the adapter.

CAU

TION

Keep the oil pressure gauge hose

away

/lVl1I

the exha ust pipe

this

fest.lfthe hose makes contact

with the exhaust pipe, it may melt a

dur

ing

spray hot oil onto the hut exhaust

pipe. resulting in a dangerous fire.

8. Place the gear selector in

NEUTRAL

and make

sure the park ing brake is still applied.

9. Start the engine and increase engine speed to

5000 rpm. The oil pressure should be approxi-

mately 138 kPa (20 psi). The minimum oil pressure is 83 kPa (12 psi).

Page 71

LUBRICATIOS,

MAISTESk'lCE

AND TUSE-UP

Transmission Oil Level Check

I. Park the ATV on level gro und and set the park-

ing brake.

2. Rem wipe

3. The oil level must be with in the knurled section of the dipstiek

4. [f necessary. add the correct type of oil (Table 3) to bring the level withindie knurled sectionofthedipstick.

5. lnstal l the o il fill cap/d ipstick,

ove

the oil fill dipstick (F igure 26) and

it clean. Reinsert the dipstick and remove it.

(Figure

rans

mission OilChange

27).

10.Ifthe oil pressure is lower tha n

the following:

a. Clogged oil filter an b. Oil leak from oil pas e. Damaged oil seal (s). d. Defective oil pum p. c. Co mbinationofthe above.

. If the oil pressure is higher than specified

the following:

a. Oil viscosity is too

fill with lighter weight oil.

b. Clogged oil passageway.

d/or

sagewa

heav

spec

ified c heck

screen.

y; drai n the oil

chec

and

re-

c. Combination of the above

12. Shut ofTthe eng ine and remov e the test equip-

ment.

13.

App

ly a light coat of gasket sealer to the blind plug, theo iostall the plug inder head and tighten securel y.

14. Check the oil level and adjustifnecessary.

15. Install the front feoder as described in Chapter

Fifteeo.

(Fig

ure

25) onto the cyl-

Polaris reco mmends the usc

gearcase lubricant, or equivalent, listed in Table 3.

change

lowing is required:

a. Drain pan . b. Funnel.

the transmission oil and filter, the fol-

c. Can opener or pour spout.

d. Wrench and sockets. e. 24 oz. bouleoflubricant.

NOTE

Never dispose

ofoil

in tile trash,

ground,or downthestorm drain.Alan)' service stations accept used oil and

waste haulerspITwidecurbsideusedoil

collection. To locale a recycle the American Petroleum

stitute (API)

at www.recycteoil.org.

NOTE

Warming.

oil to heat up. This causes it to flow

freely and ca

any sludge buildup out

the transmission allows the

n)'

contamination and

with it.

I. Ride the ATV for 10-15 minutes and shift through

both transmission ranges. Shut

2. Place the ATV on level ground ing brake.

3. Place a drain plug.

pan

under the transmission drain

off

the engine.

and

WARNING

oil draining out

The

sion is

\~eI

hot; p rotect hath

ofthe

transmis-

accordingly.

4. Loosen the drain

drain plug

and

gas ket.

plug

(F igure 28) .

a synthetic

on/h

contact

set the park -

hand

Remove

the

Page 72

CHAPTER THREE

5. Remove the oil fill/dipstick

(Figure

27), as this

will speed up the flow of oil.

6. Allow the oil to completely drain.

7. Inspect the cond ition tamination after arc

found, some typeofinternal transmission dam-

it has cooled down . If any particles

age has occ urred. Refer

the drained oil for con-

10 Chapter Nine.

8. Install a new gasket on the oil tank drain plug.

9. Install the drain plug (Figure 28) and its gasket. Securely tighten the drain plug.

10. Insert a funnel into the oil fill hole and fill the

transmission with the correct weight (Ta ble 3) and

quantity of oil (Table 4).

II. Remove the funnel, install the oil fill cap/dip-

stick and tighten securely.

12. Ride the ATV for 10-15 minutes and shill

through all transmission ranges. Shut o

gine.

the en-

13. Place the ATV on level ground and set the park-

ing brake.

14. Chec k f

leaks. Tighten if necessary.

15. Check the transmission oil level as descrihed in

this chapter. Adjust the oil level

if necessary.

WARNING

Contact with oil may cause cancer.

lIash both hands thoroughly with

soap and water as soon as possible after handling or coming

ill

contact with

transmission oil.

Front Geare

Oil

LeH I Check

I. Un

ase

(1996-1997 Models)

scr

ew the oil fill plug and check the transmis-

sion oil level. The oil level is correct if it reaches the

bottom

2. If necessary, add the correct type of oil

the level up

the oil fill hole.

to bring

10 the bottom of'the oil fill hole. Refer to

Table 3.

3. Install the oil fill plug and sealing washer and tighten securely.

Front Gea rease (1998 and Later Oil

eHI

Cheek

The oi

evcl cannot be checked on these models.

Mod

els)

The gearcasc must be drained and refilled with the

correct quantity

ail toensure correctoil level. Re-

fer to the following procedure,

Front

Gea

rca se Oil Change (AIIl\1odels)

NOTE

This procedure is shown all a 2000

model

and

relates 10 all models cov-

ered

ill

this manual. The 0

tion is the locationof'he oil fillplug

on /he gearcase.

(1' varia-

Page 73

LUBRI

CATION,MAI

NTE

NANCE AN DTUNE-UP 67

whatever component is most

move convenient.

3A. Remove the front fender as described in Chap-

ter Fifteen. 3B. Remove the right front wheel as described in

Chapter Twelve.

4. Place a drain pan under the front gearcase drain plug.

5. Loosen the drain plug. Then remove the drain plug and gasket.

6. Unscrew the oil fill plug (Figure 29) as this will

speed up the flow

oil

7. Allow the oil to com pletely drain. g. lnspcct

the conditionofthe drained oil for con-

tamination afterithascooleddown. Ifany particles

arc found. some type

internal f

ront

gcarcase

age has occurred. Refer to Chapter Ten.

9. Install a new gasket on the drain plug.

10. Install the drain plug and its gasket. Tighten the

drain plug to the torque specification listed in Table

II . Insert a funnel into the oil fill hole and fill the gearease with the correct weight (Table 3) and quantity

oil (Table 4).

12. Remove the funnel and install the oil fill plug

(Figure

29). Tighten the plug securely.

13. Check for leaks. Tighten if necessary.

dam

I. Ride the ATV for 10-15 minutes and shill

through both transmission ranges. Shut

gine.

off

the en-

2. Plaee the ATV on level ground and set the parking brake.

NOTE

Access 10 the front gem-case can be

achieved with thefrontf

end

illplace

by removing the rightfr ont wheel but

the working room is v

limited. Re-

Grease Service

Various suspens ion and drive train components

req

uireperiodic lubrication.

Wipe the grease fitting cle an prior to installing

the grease gun. Usc the recommended grease listed

in Ta ble 3 and inject the grease into the fitting with a grease gun . Wipe

off

any excess grease from the

fitting.

Apply grease

I. The front suspension anns (Figure 30 ).

'0the following fittings :

2. The front struts (Figure 31).

3. The lower end ofthe steering shall

4. The front drive ax le inner U-joints (Figure

33)

5. The front propeller shaft, front U-joint (F

(Figure

32).

igure

34) and the rear V-joint (Figure 35).

6. Upper (Fig

suspension arms.

7. Rear stabilizer bar assembly

e 36) and lower (Figure 37) rear

(Figure

38).

Page 74

FrontHub

Oil level check

I. Place the ATV on level groun d and set the park-

ing brake .

2. Remove the front whee l as desc ribed in Chapter Twelve.

3. Place a drain pan under the front hub.

4. Rotate the front hub until the fill/check plug igure

(F move the fill/check plug (Figure 40).

5. Slowly rotate the front hub until the fill/check

plug opening is located at either the 4

o'c lock position. If the oil starts to trickle out with

the hub in this position, the oil leve l is correct. If not, procee d to Step 3.

39) is at the 12 o'clock position , then re-

o'c

lock or 8

CHAPTER

THREE

CAUTION

Do not overfill the notf orce

the oil into the hub as the in-

ternal seals

6. Add the recommended lubricant listed in

3 to the front hub. Fill the hub oil starts to trickle out

[mnt

hub and do

willbe damaged.

(Fig

ure 41) until the

the filllcheck plug open-

Table

ing.

7. Rotate the front hub until the till/check plug is once again at the 12' clock position.

8. Install the fill/check plug tighten secure ly.

9. Install the front wheel as described in Chapter Twelve.

(Figure

40) and

Oil change

I. Place the ATV on level ground and set the park-

ing brake.

Page 75

UBRICATIO

N, :\IA IJliTEJliANCE

AND

TUJliE-U P 69

® ®

2. Remove the front wheel as described in Chapter Twelve.

3. Place a drain pan under the front hub.

4. Remove the three T-25 Torx bolts (Figu re 42) securing the hubcap . Carefully remove the hubcap (Figure

5. Allow the oil hub. Slowly rotate the hub back and drain out all fluid.

has entered thc front hubs, drain the oil, flush the

fronthub

the d

flush the hub until all moisture is removed.

7. Remove thc fill/check plug (Fig

R. Inspect the hubcap O-ring seals (Figure 44 ) for

nicks,cut sanddeter

9. Install the hubcap and lap il into place until it is completely seated. Install the three Torx bolts and

tighten securely.

10. Rotate the front hub until the fill/check plug

hub opening is located at the 4 o'c lock or 8 o

position.

43).

Ift

hevehiclehas been

with cleanoil and

rain

ed oil. If water is still

comp

letely drain from the front

riddeninwater or if water

dra

in again.Observe

pre

sent,continue to

ioration.

Rep

lace

asnecessary.

forth 10 help

e 40).

'clock

CAUTION

Do not overfill the front hub

no/force the oil ;"(0 the hub, as

ternal seals will he damaged.

II.

Fill the front hub (Figure 41 ) with the recommended lubricant starts to trickl e

12. lnstall the fill/check plug (Figu re 39) and

tighten securely.

13. Install the front whee l as described in Chapter

Twelve.

14. Ride the vehicle for 10-15 minutes and check

for

oil leakage,

able 3). Fill the hub until the oil

outofthe fill/check plug opening.

IIl1

lir

d do

e;,,-

Page 76

CHA

PTEI{T1IR

ControlCable

Clean and lubricate the throttle cable and choke

cable at the interva ls indicated in

tion, check the

and

damage or fraying that

fail or stick. not last forever under the best

The bcst method of control cable lubrication is

usin g a cable lubricator

an aerosol gen

not uscchain

1. Remove the scat as described in Chapter Fifteen.

2. Remove the fuel

Six. Thi s is necessary to access thc lower end cab les.

Luh

cables for

Cab

les are

eral

lub

eas a cable

rication

Tab kinksand cou

ld cause the cables to

exp

endable items and will

conditions.

(Figure

lubricant

tank

45) or, if necessary,

can be substituted. Do

lubr

ica

as described in Chapter

leI.In addi-

signsofwear

nt.

ofth

3. Disconnect the thrott le cable from the throttl e

housing .

4. Disconnect the chokecable fromthetoggle lever

on thc indictor pancl.

5. Attach a cab le lubricator to the end

following the manufacturer's in

Refer to Chapter Six .

stru

ctions.

the cable

6. Insert the lubricant can nozzle into the lubrica-

tor, press the button on the can and hold

the lubricant begins to flow out

the cab le. If the cab le lubc will not flow through thc

cable at one end, remove the lubricator, disconnect

the cables

the opp osite endofthc cable.

from

the

carburetor

NOTE

assembly, and try at

down

thc other end

until

Placea shop cloth at the end of the ca-

bles/0catch the oil as it runs

Ollt

7. Disconncct the lubricator.

8. Appl y a light

before reconnecting them. Reconnect the cables

andadjust as described in this

coa

ting

grease to the cable ends

chapter.

9. After lubricatin g the throttle cable, operate thc

throttl e

10. After lubricating the ch chok smoothly with no bind ing.

lever at the hand lebar. It should open and

smoo

thly with no binding.

oke

cable, operate thc

e togglc lever. It should open

PE R

IODIC

I\IA

INTENAJliCE

and

Maintenance intervals arelisted inTable I.

Drlve Belt ln spectlon

I. Remove the drive belt outercover as described

in Chapter Eight.

2. Check the drive belt

ing or unusual

wear as described in Chapter Eight.

(Fig

ure

46) for cracks, fray-

3. Replace a wo rn or damaged drive belt as de-

scribed in

4. Install the dr ive belt outer

Chapter Eight.

cove

r as described in

Chapter Eight.

Disc Brake System Inspection

Chcck the disc brakc system at the interval listed

Tahlc

On all models, a single

the left handl

brake ates the

Each front wheel is equipped with a disc brake.

The

rear

output shaft.

ebar

systems. The rearmastercylinder also oper-

rearbra

ke independent of the

disc

brakeismount

brake

master

operate s the front and rcar disc

ed on the transmission

cylinderon

front

brak

es.

Page 77

UBRICATIO

N, M

AINTENA

NCE

AND TUN

E-VI'

I. Place the ATV on level ground and set the park-

ing

brak

2. Clean any dirt f

prior to removing the cover.

control the small

fluid. punch a small hole into the seal

of a ne

to the edge

help eliminate f

ciatly while adding f

small reservoirs.

Use brakefluid clearlymarked DOT3

from II sea

may va

Always use the same brand n

01 intermix as many brands

compatible. Do not intermix sili-

cone-based

can cause brake component damage

leading to brake systemfa ilure.

rom

the area around the cove r

NOTE

ll'containe

por

oft

he pour spout. This will

lui

WARNING

led

ntainer:

ize and cause brak

(DOT

5) brak

flowofhyd

ofbra

kefl

uid next

d spiliage, espe-

luid

to the

Other Opes

efailu

ame

efluid

ruulic

vel}'

re.

; do

e not

, as it

Visually inspect each brake disc for cracks, deep

scoring, heat distorti on, checking and excessive

wear. Inspect the

ure 47. typical) and overheating. Install new brake

pads i

orn to the b

to the dimension listed in

Bleeding the system, servicing the brake system

compon

ered in Chapter Fourte en.

Disc

Check

ent

Brake

and

Maintain

atits

maximum level.lfnecessary, co

by adding fresh brake fluid.

painted or plated surfaces. as it witt

destroy the fi nish. ftlish o

immediately with soapy water and

thoroughly rinse it offwuh

bra

ke pads for uneven wear (Fig-

kepadservice limitgroove or

Table

s and

rep

lacing the

Fluid Level

Fill

brake

pad

s arccov-

thehydraulic brake fluidinthereservoir

rrect

the level

CAU

TION

I/O

! spill brake fluid Oil

fft

cle

pla

he area

water

stic.

3A. On the front master cylinder, perform the following:

a. Position the handlebar so the front master cyl-

inderis horizontal.

b. Remove the screws securing thereservoircap

and remove the reservoircover (Figure 48).

c. Refill the mastercylinderreservoir, ifnce cs-

sary, to maintain the correct fluid level as in-

dicatedon the side

d. Install the diaphragm and cover. Tighten the

coverscrews securely.

3B.Onthe

a. Remove the scat as described in Chapter Fif-

rear

mastercylinde

teen.

b. Unscrew and remove the reservoircap (Flg-

ure

49).

c. Refill the remote reservoir. if necessary. to

maintain the correct

011 the side

d. Install the reservoir cap and tighten securely.

Disc Brake Hoses

Check the brake hoses between the mastercylin-

derandeach

leakage, tighten the connectio ns and bleed the

bra

ke caliperassembly.

brakes as described

the reservoir.

perform the following:

fluid

level as indicated

the reservoir.

under

Bleeding the System in

there is any

Page 78

Chapter Fourteen. If tightening the connection does not stop the leak or if the brake hose(s) is obviously

damaged, cracked or chafed, replace the brake

hose(s) and bleed the system as described in Chap-

ter Fourt een.

CHA

PTE

R THREE

Aux iliary

(1996-1997

The auxiliary brake is intended for use as a backup ing the foot pedal on the right floorboard aetivates

the rear brake, located on the transmission output

shall.

Testing

I. Shift the transmission into NEUTRAL.

2. Support the vehicle with the rear wheels otTthe ground. Block the front wheels so the vehicle can-

not roll in eitherdirection.

3. Rotate the rear wheels by hand and depress the

auxiliary brake pedal.

4. The rear wheel should stop rotating when the brake pedal has traveled midway between the

at-rest position and bottoming out on the floor-

board.

5. If the rear wheel does not stop rotating within this pedal travel, adjust the auxiliary portion of the rear brake.

6. I

Adj ust

I. Shift the transmission into NEUTRAL.

2. Support the vehicle with the rear wheels off the ground. Block the front wheels so the vehicle can-

not roll in eitherdirection.

3. Remove the bolts and washers sec uring the drive

chain guard and remove the ehain guard.

4. At the rear brake caliper, loosen the loeknut (A,

Figure 50).

5. Rotate the rear wheels by hand.

6. Turn the adjust bolt (B, Fig

until the rearwheel rotationbecomes difficult. then

stop.

7. Continue to rotate the rear wheels nod tum the

adjust bolt (B, Figu re 50) countercloekwise and

have an assistant apply the rear brake. When the

Brake

Testing and Adjustm ent

Mode

ls)

ifth

e hydraulicsystem should fail. Depress-

djustment is not neeessary, lower the vehicle.

ing

e 50) clockwise

I I

brake pedal has traveled to the mid-way point stop turning the adjust bolt. Tighten the locknut.

8. Once again rotate the rear wheels by hand and apply the rear brake. The rear wheels should stop once the rear brake pedal has traveled to the mid-way point. Readjust if necessary,

9. Tighten the loeknut (B, F

10. Install the drive chain guard and ti

bolls sec urely.

11. Lowerthe vehicle andtest drive itto make sure

the auxiliary brake is operating makesuretherearbrakeis not dragging. Readjust

necessary.

Thrott leCable/Elect ronic Thrott le Co ntrol Adjustment

All models require some throttle cable play to

preventchanges in the idle speed when the handle-

bar is turned. The recommended amountofcable

free play is

1.6111111

igur

e 50) securely.

ghten

the

correc tly, Also,

(1/16 in.) when measured at the

Page 79

LUBRICATION, MAINTENANC E AND

TUNE-

2. Shift the transmission into NEUTRAL.

3. Block the front wheels so the vehicle cannot roll

in eitherdirection.

4. Start the engine and allow it to idle. Make sure

the handlebar m

slowest speed position.

5. Slide both rubber boots (A, Figure 51) 01Tthe in-line cab le adjuster.

6. Loosen the locknut (B,

7. Turn the

engine rpm starts to increase. then stop.

8. Turn the cable adjuster back in until the throttle lever(Figure 52) has 1.6 rnm ( 1/ 16 in.) fore the engine speed increases.

9. Securely tighten the locknut (B, Figure 51).

10. Shut

I I. Slide both rubber boots (A, Figure 51) back

onto the cable adjuster.

12. Turn the handlebar from side-to-side in the full turning range. If the idle speed increases, the throttic cable free play must be increased or the throttle cable is routed

13. Check for smooth throttle operation in all handlebar positions. The throttle lever should move

smoo thly an d return witho ut bind ing.

oun

ted speed

Figure 51).

cable adjuster (C, Fig

off

the engine.

incorrectly.

con

trol lever is at its

ure

51) out until

travelbe-

end of the throttle lever. In time, the cable will

stretch and the free play will become excessive.

NOTE

Fee

Check throttle cable handlebar lever II is important thai the

throttle cable has the correct

amount o

this procedure.

1, Set the

Speed Adjustment in this chapter.

ree play as described in

eng

ine idle speed as des

play at the

crib

ed under Idle

Thr

ott

le Ca ble Adjustment

(At Carbureto

The

equipped with a cable adjuster at the carburetor endofthe throttle cable.

I. Remove the fueltank as described in ChapterSix.

2. At the carburetor, slide the rubber boot up and

olTthe throttle cable adjuster.

3. Loose n the locknut and turn the adjuster (Fi

53) until the

1996-1998 Models)

NOTE

1999 and later models are 1101

cor

rect amountofcable free-play is ob-

gure

tained.

4. Sec ure ly tighten the locknut.

5. Slide the

cablc adjuster.

6. If necessary. perform a tine adj ustment at the

throttle housing as previo usly described.

7. Install the fuel tank asdescribed in ChapterSix.

rubb

er boot back down onto the throttle

Page 80

Air Fi

lterElement

emo

ve and repla ce the air filter at the interval

indicated in T

ately

The air filter remo ves dust and abrasive particles

beforethe air enters thecarb

Without the air filter, very fine particles could enter

into the engine and cause rapid wear of thepiston

rings. cylinderboresand bearings.Theyalso might clog small passages in the

ATV without the clement installed.

I. Place the ATV on level ground and set thc park-

ing brake.

2. R

emo

3. Thoroughly cle an any road debri s

surroundingtheair filterair box cover.

4. Unhook the spring clip securing the air filter air

boxcover andremovethecover(Figure

5. Loosen the clamp screw (A, Fi move the air filter

airbox.

6. Place a clean shop cloth into the opening in the

air filter air box to preventthe entry of debris.

7. Slide off' the foam pre-filter, or pre-fi lter sleeve (A, Fi

e 56) .

abl

eI.Replace the element imm edi-

it is damaged or sta

ve the scat as described in Chapter Fifteen.

element

gure

56) from the air lilter element (

ing to

deteriorate

ure

torand

carb

uretor.Neverrunthe

(13

, Figure

the

from the area

gur

e 55) and rc-

55)

S-I

from the

engine.

13,

Fig-

CIIA

PTE

R TIIREE

NOTE

If the air fi lter element is extremely

rty

ifthere

art!.

allY holes ill the el-

ement. wipe oul the interior

with a shop rag dampened ill

box

cleaning

that may have passed tbrougls a bro-

so/

rent. Remove allY debris

ken element.

8. Ge ntly tap the air filter eleme nt to loosen the trapped dirt and du st.

NOTE

Cleaning the a

recommended. Replace

element

9. Thorou ghly and carefully inspect the filter ele-

ment

(Figure 57). Ifit is tom or

replace the air filter element. Do not run the ATV

witha

damagedclement

the engine. If the clement is good, it can be used until

replacementis

10. Clean the foam pre-filter. or pre-filter sleeve,

withw

arm

water andmild soap.Wash several times

irf

itter element is not

if dirt)'or damaged.

as itmayallow di

requir

ed.

the air

broken

the air

lter

inany

to enter

are

Page 81

LUBRICATION,

MAINT

ENANCE AND TUNE-UP

if necessary to remove all dirtand rinse inclean wa-

ter.Thoroughlydry the pre-filterprior to installation.

11. Install the pre-filter onto the air filter clement.

12. Inspect the air box (Fi

Thoroughly clean out the air box.

13. Install the air filter clement assembly onto the

airbox

intak

e and tightenthe clampscrewsecurely.

Make sure the clamp is seated correctly and that the clamp screw is tight

14 . Inspect the air filter element cover gasket seal

(Figure 59) for damage or deterioration . Replace if

necessary.

15. Check the air intake holes (A,Figure 60) in the

rear lenside of the front fender for any debris that

gur

e 58) for any debris.

(A, Figure 55).

may obstruct intake airnow.

16.Install the air filter element cover and seal.

Make sure it is seated correctly and secure it with

thesix spring clips. Makesure the airintake tube is

positioned correctly within the rear

front fender (B, Figure 60).

17, Check the air box sediment drain as follows:

a. At the rear of the air box, place a rag under the

drain cap and remove it (Fig out water and other debris collected in the air box.

porti

on of the

e 61). Drain

b. Reinstall the drain cap and make sure the

clamp is inplace.

18. Install theseat as described inChapter Fifteen.

lant

Coo

tem. The cooling system is small; even a slight leak

can cause the engine to overheat. Therefore, check the coolant level and condition of the

hoses frequently.

evertroubleshooting the cooling system. equipmentisnotavailable,havethe tests performed

by a Polaris dealership,

tion.

I. Remove the front fendercover as described in

Chapter Fifteen.

Inspect

The ATV is equipped with a liquid cooling sys-

Never remove the radiator cap, open

the coo lant drain or disconnect any hose

fluid and steam

derpressure and causeserious injury.

Check the following items once ayea

ion

radiato

WARNING

while the engine is hot. Scalding

m(~y

be blown out

rad

iatorshoporservice sta-

1111

orwhen-

rand

the test

Page 82

2. Loosen the radiator cap (F igure 62) to its first detent and release the system pressure, then tum the

cap to its second detent and remove it from the radi-

ator.

3. Check the rubber washers on the rad iator cap (Figure 63) for tears or cracks. Check for a bent or

distorted cap. Raise the vacuum valve and rubber

seal

and

rinse the cap under warm tap water to flush

away any loose rust or dirt particles.

4. Inspect the radiator cap neck seat on the coolant

tank for dents, distortion or contamination. Wipe

the sealing surface with a clean clot h to remove any

rust or dirt.

CAUTION

Do 1101 exceed 89 kPo (13 psi) when

performing Steps

10 the cooling system will o

5. Have the radiator cap pressure-tested. The specified radi ator cap The

cap must be able to sustain this pressure for 5 minutes or longer. Replace the radiator cap if it does not hold

6. Leave the radiator cap cooling system to 69 kPa ( 10 psi). be able to hold this pressure. Replace or repair any components that fail this test.

7. deterioration. Replace any hose that is in question-

able condition. Make sure all hose

8. Check the radiator for leaks or other dama ge.

pressure.

Che

ck all coo ling system hoses for damage or

4 and 5, or damage

eew

relief

pressure is 89 kPa (13 psi).

off

and pressure-test the

The

clamp

system must

s arc tight.

Repair or replace the radiator as necessary.

9. Install the front fender Chapter Fi

Coola nt Cha nge

Drain and refill the cooling system at the interval

listed in Table

It is sometimes necessary to drain the coolant

ftecn.

cover

as described in

from the system to perform a service procedure on

some partofthe engine. If the coola nt is still in good

condition and it is not time to replace the coolant,

the coolant can be reused

it remains clean. Drain

the coolant into a clean drain pan and then pour the

coolant into a clean sealable container such as a

plastic milk or bleach bottle and screw on the cap.

Only use a high-quality ethylene glycol-based

coolant compounded for aluminum radiators and engines. Mix the coolant ,vith distilled water at a

CHAPTER

50:50 ratio. Coolant capacity is listed in

THREE

ble 4.

Never use tap or salt water, as this will damage en-

gine parts. Distilled (or purified) water can be pur-

chased at supermarkets.

WARNING

Antifreeze is an environmental toxin and

Cal1I10t

legally be disposed

flushing down a drain 01' pouring it

onto the ground. Place old antifreeze into a suitable container and dispose

it acco rding to

EPA

regulations. Do

not store coolant where it is accessi-

ble to children or animals.

WARNING

Do not remove the radiator

fill

cap

when the engine is hut. The coolant is

velJ~

hot ami is under pressure. Severe scalding could result mes in contact

((the coolantco-

with skin.

CAUTION

Coolant call stain concrete and will

damage or kill p

nts. Do not drain

the coolant onto a driveway or allow it fa drain

into a planted area. Be

Page 83

LUBRICATION, i\lA IN

TENAl'\CE

AND

TUNE-U

P 77

2. Remove the front fende r and right side footwell

asdescribed in

Chapter

Fifteen.

J. With the engine cold, remove the radiator cap

(F ig

ure

62).

4. Place a drain pan under the drain fitting on the

base of the

5. Open the drain valve on the base

(Figu re 64) and drain the coolant.

6. Move the d

bolt.

7. Remove the drain screw and sealing was

(Figure 65) and dra in the coo lant from the pump

and hoses.

8. Rock the ATV from side to side to drain any residual coo lant from the cooling system. Correctl y dispose of the coo lant.

radi

ator

NOTE

Figure 64 shows a 2000

the radiator

illustrate the step . The drain valve OIl

shroud

prioryears is located

the radiator.

rain

pan

under

mod

el with

removed to better

onthe

back

side

the radiator

the water pump drain

her

careful

1I0t

tospill coolant a

painted

plated or plastic surfaces. as it will

damage the finish and

Wash ony applicable area with

waterand rinse thoroughly with clean

waler.

/or

surface.

soap

Pcrfonn thefollowing procedurewhen theengine

iscold.

I. Place the ATV on level ground and set the park-

ing brake .

NOTE

If the coo lant is dirt);

drain

pan

under the radiator

flu sh out tile system with

Drain out

9. Tighten the radiator drai n valve and install the

water

pump drain screw and sealing washer.

Tighten thc drain screw securely.

10. Remove the coolant reservoir (A, Figu re 66)

mounting bolts. Partially pull the reservoir awa y

all

wat

pla

erfrom

ce a differ

dean

water.

thesystem.

ent

and

from the frame and disconnect the hoses from it.

Place a plug in the lower fitting to prevent the loss

coolant in the tank.

II.

Remove the coo lant reservoir cap and empty

outtheold coolant intoa suitable container.

12. If necessary. clean the inside

the reservoir

with a liquid detergent and thoroughly rinse with

clean water.

Remove all detergent residue fromthe

reservoir.

IJ. Attach both hoses to the coolant reservoir. Re-

install the reservoir and bolts and tighten securely.

CAUTION

Do not /lse a higher ratioofcoolant-to-water

the ambient te

concentration

than recommended

mpe

rature. A higher

coolant (60%

Jar

Page 84

greater) will actually decrease the

performanceofthe cooling system.

14. Place a funnel into the radiator filler neck and

refill theradia

15. Slowly add the 50%

water mi xture through the radiator

it slowly so it will expel as much air as possible

fromthe engine

the bottom ator cap at this time .

Be sure to fill the system eompletely. If the sys-

16.

tem is completely drai ned, loosen the clamp

torand

oft

engine.

coo

lant and 50% distilled

filler neck . Add

anti

radiator.Top off the coolantto

he tiller neck. Do not install the radi-

(B,

Figure 66) on the hose to the thennostat housing.

Pull the hose loose and fill the sys tem with

atthe radia

tor,

whileallowingairtoescape fromthe

coo

lant

loosened hose. When coo lant begins to flow from

the

thermostat and hose connection, reattach the

hose

and

tighten the clamp securely.

17. Squ eeze the coo lant hoses to syste

cooling

18. Remove the fill cap, then refill the coolant res-

ervoir to the FULL mark , install the cap and tighten secure ly.

m whil c filling with coolant.

pur

ge air from the

CHAPTE

R T

HREE

NOTE

Fill the cooling system slovvly so the

coolant can expel the air within the

radiator and engine.

19. Rock the ATV about 20° to the left and then to

the right several times . This will help bleed

some

the air trapped inthecooling system. If'ncc-

off

essary,addadditionalcoolantmixture to thesystem

until the coo lant leve l is to the botto m of the filler neck.

20. Install the radiator cap (Figure 62) . Tumthe ra-

diator ca p clockwise to the firs t stop. Then push

down and tum it clockwise until it stops.

CAUTION

If the radiator cap is not installed('or- rectly, coolant

healing will ocelli:

21. S

tart

the engineandrunitat idle until itreaches

operating temperature.

bubbles in the coo lant and that the

bilizesatthe

22. Test ride the ATVand readjust the coolant level

correct

inthe reservoir

loss and engine over-

Mak

e sure there are no air

coo

lant level sta-

level. Addcoolantifnccessary.

necessary.

Exhaust System

spect the exhaust system for cracks or dents

that

could alter pe

2. Remove the rear fenderas described in Chapter

Fifteen.

3. Check the tightnessofthe muffler

bolts

(Figure

6H).

4. Make sure the front springs (F ig

cure.

rformance.

67)

and

the atta ching springs

ure

69) are se-

mountin

(Figure

Page 85

LUBR

ICATION,

MAII\TEI\ANCE

A;IlD

TUI\E·

cracked or starting to

smallhose clamps are inplace

J damaged or deteriorated [uel line

presents (J vel)' danger

to both

Fuel Filte r Replace ment

An inlinc

pump and the carburetor, The fuel filter traps parti-

tir

fuel filter is located between the fuel

des thatmightotherwis e

uteparticles cancause the float valve andfuel inlet

needle to stick or

I. Remove the

Fineen.

2. Disconnect the negative battery cable as described in this chapte

3. Tum the fuel valve to the OFF position.

4. Place severalcloths underthe fuel filter. asgasoline still present in the fuel line will the fuel filter

5. Below thelen side of the ca

of the clamps securing the fuel filter (F igure 72) to

theoutlet hoses.

6. Disconnect that hose and plug it to stop the Ilow

of gasoline,

7. Disconnect the other fuel line from the fuel filter and plug

8. Remove the fuel filter.

9. Position the new fuel

ing in the directionoffuel flow. Install both fuel

hoses and tighten the clampssecurely.

10. Tu

check for fuel leakage.

II. Install the front

Fifteen.

fro

is removed.

it.

the shut-off valve to the ON positionand

deteriorate. M ake sure the

and

secure.

WARNING

ousf

ire haz

ard

e rider and tireATV

enter

the carbure

clo

g one of the jets.

ntfenderas described inChapter

rburetor, loosenone

filter

withthe

tender as deser ibed in Chapter

drain

arrow

tor.

outonce

Min-

point-

•

5. On models so equipped, remove the plug and

washer (F igure 70) at the base ofthe muffler. Drain

out any residue. Install a nov

plug securely.

Fuel Hos

tank to the fuel shutoff valve (A), the fuel pump (B)

and the carburetor. Replace any hoses that are

t:'

Inspection

Inspect the fuel hoses (Fig ure 7 1) from the fuel

....

washer and tighten the

Steering System and

Front Suspensio n lnspectl on

Checkthesteering systemandfront

intervals listed in

the spill or collision or suspected.

I. Park the vehicle on level ground and set the

parking

2. Visually inspect all components and

brak

front

suspension for obvio us problems. Pay

Tabl

e 1 following any hard

pro

blem with operation is

suspensionat

the steering

Page 86

clo

se att ention to the tie rods, steering sha n and

front struts. Some suggested indi catorsofdamage

arc:

a. Bent or

areas where pai nt is flaki ng b. c. Exce ssiv ely loose co mponents.

d. Stiff

bro

ken components. Especia lly check

Loose fastenersorlocknuts.

frozen components that normally

missing.

move freely.

3. Cheek the handlebar h tightness. See Table 5.

Mak

e sure the front wheel lug nuts are tight. Sec

Table

5. Ma ke sure the cap is in place on both front hubs.

6. Ma ke sure the front hub nut is tigh t and that the cotte r pin is in place. See Chapter Ten .

7. C

hee

k steering p

a. To check the steering shaft for radial play,

move the handlebar from side

attempting to tum the w heels). If play is ex-

cessive, the upp er benrings are probably wo rn and should be replaced.

laya

older

(Figure73) bolts f

s follow s:

to side (without

APTERTHR

NOTE

Figure 74 sho ws the tie rods removed

10 better show the cotter p i

b. To chec k the steering shaft for ax ial (vertical)

lin

play,

If cotter pin (Figu re 74) located

the steering shaft. If the nut and cotter pin are

in place and in good condition, check the

thrust bearings located at the lower end

up and push

excess ive play is noticed. check the nut and

and nut.

down

on the handlebar.

at the b

ottom

steering shaft.

8. T

urn

the

handlebar

quickly from side to side and

notice the following:

a. rf there is appr eciable looseness at the tie rod

ends, the ends may be worn.

b. Observe the joint between the lower

the stru t and the A-ann . Noticeable looseness

may indicate a

c. Obse rve the

A-anTIS. Noticeable looseness may indica te

worn ball-jo int.

join

ts at the inner endsofthe

worn bushings.

d. Check for missing cotter

pins and loose or

missing fasteners.

end

ont

Wbeel

Toe-O ut

outisadju

Toe-

sted by placin g the frontofthe

tires farther apart than the back. Thi s is acco m-

plished by changing the lengthofthe tie rod s.

Check and ad

the steering is imprecise or unpredicta ble. Inspect

the steering assembly

jus

t the toe-out periodi cally o r when

for damage and wear before

adjusting the toe-out. Inflate the tires to the pressure

listed in Table 2, then check the tires an d w heels for

the

dam

age.Ifa w

the "round and rotate it to check more carefully.

To check the toe adjustment. proceed as follows:

1. Position the vehicle on a flat, smooth surface

hee

lapp ears bent, raise that wheel

set the handlebar straight ahead.

2. Raise one front wheel. rotate the tire and lise

chalk to mark the ce nterline all around the tire. Lift

the other front wheel and mark the centerli ne of that

tire in the same way.

3. Use a tape meas ure to measu re the distance between the centerline at the front.

tires. The di

the tires should be 3. 18-6.35

stan

ce between the cent

then at the rear of

01111 ( 1/8- 1/4 in.) more at

the front than at the rem.

crline

off

and

s of the

Page 87

LUBRICATION,

MAINTENANCEAND

TUNE-UP 81

4. If the mea sured distance is inc follows:

orrect

, adjust as

a. Loosen the inner and outer tie rod end lock

nuts (A, Fig rods must be adj usted.

b. Rotate the tie rods (B , Figure

amount on both sides to establish the r mended toe-o ut. The distance between the ball end s of the two tie rod s sho uld be the same to center the steering.

e. Tighten the lock nuts (A,

when adju stment is correct. R sure toe-out is correct after ti

ure

75) on both tie rods. Both tie

75)

Figur

e 75) securely

ech

eck to mak e

ghten

ing the lock

the

same

ecom

nuts.Makesure the tierod has fullmovement

after tightening the lock nuts. The tie rod ends should be square with after the lock nuts are tight ened.

CAUTION

each

other (not cocked)

The fast eners that atta ch the lie rod ends must be installed in u certain direction to prevent steering

sys

tem in-

terference and binding. III addition. tile tie rod ends must be correctly po-

sitionedor interferencecanOCCIlI: Re-

fer

to Cha

pter

installation

Twelvefor

ofthe

inner tie rod to tire

cor

rect

plates a ll the base oI tire steering

shoji. The

threaded

tie 'rod end must

stud

Oil

the outer

ce do wn with the

nut 0 11 the bottom.

Frou

t lI uh

Wheel

Beari ngs

Inspect the front hub bearings for excessive wea r

damage

fer to FrontHub in the Periodic Lubrication section

this chapter for lubrication requirements.

at the intervals specified in

Table

I. Re-

Ref

to ChapterTwelve for r bearings and sea ls.

I. Support the vehicle with both front whee ls otT

the ground. Block the rear wheels so the vehi cannot roll in either direction.

Tum

both whee ls by hand. The wheels shou ld III

rotate smoothly without excessive noise or exces-

sive play.

3.lfnecessary, service the front hub bearin gs as de-

scribed in Chapt er Twe lve.

Rear

Suspeusion

emovi

ng and installing the

I. Place the ve hicle on level ground and set the

parking brake.

2. Push

the mo

3. Check the r age rods for

4. Inspect the rear drive axle ru

ness or tea rs.

5. If necessary, service the r nents as described in Chapter Thirteen,

tion can loosen many of the fasteners and all shou ld be checke d for tightness, espec ially:

1. Engine

2. Engine covers.

down

on the r

uts,

vement

Bolts,

of a ll rear sus pension components.

ubber

wea

r or

and

Other

Check the tightness

moun

ting ha rdware.

earofthe vehicle and observe

bushings on the stabilizer link-

deter

iorat ion.

bber

boots for hard-

ear

suspensi on

Fasteners

fasteners. Constant vibra-

3. Ilandlcbar mo unting.

4. Exhaust sys tem.

\Vire

Harn

ess, C

ontrol

Cab

les and Hose Lines

Inspect a ll wiring, cables and hoses for rooting. to the f

cab le tics. Tight en components, but not tight hoses.

quired, following the original routing. Attach a string to the old wire. cable or hose b drawing it to easier.Ifcarefu lly removed, the string ca ll then be used to pu ll the new co

path as the old

The

spark plug wire must be rooted directly

ront.

Secure hoses.

eplace

dama

cab

les and wires to the frame with

cab

le ties only

ged wires, hoses and cab les as re-

mak

e follow ing the original rou ting

mponent

one

enoug

h to collaps e the

through the same

cle

compo-

proper

h to hold the

efore

with-

Page 88

l\S

CHEDULE J) I

AND MAINT ENANCE

Recoil Starter

Pull out the starter rope and inspect it for fraying.

If its condition is questionable, replac e thc ropc as

described in Chapter Five, Check the action of the

starter.

It should be smooth, and when the rope is re-

leased. it should return

NSPECTIO

all the way. If the starter ac-

:,,/

tion is rough or if the ropedoes not return, service

the starter as described in Chapter Five.

Body Fasteners

Tighten any loose body fasteners. Replaec loose

rivets by first drilling out the old rivet

a new pop rivet. This tool, along with

rivets. is available at

parts stores. Follow the manufacturer's instructions for installing rivets.

Check welded joints for cracks and damage.

111

0st hardware and auto

and installing

an assortment

Have damaged weldedjoints repaired bya compe-

tent welding shop.

CHA

PTERTHREE

Fuel

Tank

and

Lines

Inspect the fuel the tank is damaged Chapter Six.

Oil

Tank

Inspect the oil tank for cracks, abrasions or leaks.

Replace the

Electr ical System

Check all of the switches for proper operation.

Refer10 Chapter Eleven.

Electrical Connectors

Inspect the higb-te nsion lead to the spark plug (Figure 76) for cracks and breaks in the insulation and replace the lead if it is not perfect. Breaks in the

insulation allow the spark to

impair engine perfonnancc .

Check primary ignition wiring and lightin g wir-

ing for damaged insulation. In some cases. minor

tank for cracks and abrasions. If

and leaking, replace it. See

tank if its condition is in doubt.

arc to ground and will

damage can be repaired by wrapping the damaged

area

with electrical insulating

damage is extensive, replace the damaged wires.

Abnormal Engine Noise

Start the engine and listen for abnormal noise s.

Often the first indication

change in sound. An unusual rattle mightindicate a

loose fastener that can be easily repaired, or itcould

be the first indication

ter becomin g familiar wit h the vehicle and with

practice, it will be possible to identify most new

sounds. Periodic inspections and quiek identifica-

tion o f abnormal engine noisescan prevent a com- plete enginefailure.

The f

oll

owing procedures cover each phaseofa rune-up. Unless engine is cool before starting any procedure. A spark plug wrench with a long reach is required to

severe engine damage.

El\G

I:"/ET UNE-UP

otherwise specified. make sure the

tape

. If insulation

developing trouble is a

Page 89

UBR

IC A

TIO

N, MAINT ENANC E AN D

remove the spark plug. Perf the following order:

I. Replace the air filter eleme nt. Clean the foam

pre-filter element

2. Check and adjust the valve clearances. 3, Check or replace the spark plugs,

4, Check and ad

AirFilter

If necessary, replace the air filter and clean the

pre- filter, as described in this chapter. before per-

orm

ing the following tunc- up procedures.

Valve Clea

The correct valve clearance is listed in Ta ble 6, The exhaust valves are located at the front of the engine and the intake valves arc located at the rear of the engine.

The photographs in the following procedures show the engine removed from the frame for clarity.

It is not necessary to remove the eng ine to adjust the

valves.

Elem

rance

ent

necessary.

st the carburetor idle speed,

Measurement

orm

the procedures in

TUNE-

NOTE

lve cleara

nce

measurement andad-

justment must be performed with the

engine cool, at room temperature (below

C195° F),

I, Place the ATV on a level surface and apply the parking brake, Block the wheels to kee p it from rolling in either direction.

2, Remo ve the seat and front fender as described in

Chapter Fifteen,

3, Remove the fuel tank as described in Chapter

Six,

4. Remove spark plug as described in this chapter. This

will make it easier to rotate the engine. Place a

piece of duct tape over the spark plug hole to prevent the entry of deb ris,

5. R

emo

ve the scr

over(Figure

cover and gasket.

6. Remove the plug from the timing inspection

(Figur

hole 7, Position the piston at top dead center (TDC) on the compression stroke

a, Using the recoil starter, slowly pull on the re-

coil handle and observe the opening and closing of both sets

b. Stop rotating the engine when both sets of in-

take and exhau st valves are closed.

c. Verify that the

shaft sprocket are parallel with the rocker cover gasket surf shaft lobes should be facing dow n away from the rocker a

d. Wiggle all four rocker arms, there should be

free play indicating that all four valves are closed. This indicates that the piston is at top dead center (TDC) on the compression stroke and all four valves are closed.

c. Check that the tlywheel timing mark is

aligned with the center line mark in the timing inspection hole starter cove r.

8. Insert metric feeler gauges of various thicknesses between the rocker a take valve stem

a. Wh en the

be a slight resistance on the feeler gauge when

b. Record the clearance and identify the valve

checked (right or left intake valve),

ews

securing the cylin

77) and remo ve the cylinder head

e 78),

as follows:

valves.

two raised pins on the cam-

ace

(Fi

gure

79), The cam-

(F igure 80 ) in the recoil

adjust screw and in-

CA,

Figure 81).

corr

ect gauge is selected, there will

it is inserted and withdr

awn

der

•

head

ann

Page 90

9. Check the clearance

valve.

A single common rocker arm (Figure

82)

controls both exhaust valves. nro

flat fe

eler

gauges are necessQI}' to

the remaining intake

NOTE

check the exhaust valve clearance.

This willprevent the rocker armfrom

tilting slightly during the next step.

10. Insert metric feeler gaugesofvarious thick-

nesses between each exhaustvalve stemand

ann

adju

stscrews.

a. When the correct gauge is selected, there will

be a slight resistance on the feeler gauge when it is inserted and withdrawn.

b. Record the clearance and identify the valve

checked (right or left exhaust valve).

II . If adjustment is required, refer to the

Clearance Adj ustment procedure.

12. If the valve clearance is correct on all four

valves, perform the following:

a. Clean the gasket surfaces of the cylinder head

and the cover. Inslall a new gasket to the cyl-

inder head cover (Figure 83).

b. Install the cylinder head cover and tighten the

tai

ningscrewsto thetorquelistedinTable5.

c. Install all

rema

iningcomponents removed.

rocker

tall'e

CHAPTER THREE

Valve

Clear

ance Adjustment

I. Use a 10 mm wrench (B, Figure 81) to loosen

the valve adjuster lockuut.

2. On the

gauges in place between each rocker

screw and valve stem end. This will prevent the

rocker arm from tiltiug slightly duriug the tighten-

ing

3. Use ascrewdriver

to obtain the correct clearance (Table 6).

4. Hold the adjuster with the screwdriver (A, ur

e 84) to prevent it from turning.

5. Install a to mm

onto the valve adjusterloc

exhaust valves, leave both flat feeler

arm

the locknuts.

and

turn

the

adju

sterinorout

off

set adapter (B, Figure 84)

knut.

NOTE

Use an offset adapter toprevent

adjuster

Fig-

overtightening the adj uster locknut.

Page 91

LUBRICATION, MAINTENAN CE AND TUNE-UP

Spa rk

Plug

Heal

Rau

Spark plugs arc availabl e in various heat ranges,

hotter or colder tha n the plugs or igina lly installed.

Select a plugoftile heat range desig ned for the loads and condit ions under which the ve hicle will he operated.

In general , use " hot plug for low speeds and low

tem peratures. U engine loads and high tem p should operate hot enough to posits, but not so hot that it is preign ition . A spark plug of the

wills

how

lator

within the cy linder after the plug has been in

service.

The reach or length

longer than normal plugcould interf

ton, causing p

l1igure 85.

Refer to Table 6 for rec

heat ranges.

" cold

plug

for high speeds, high

eratur

es. The plug

bum

off

unwant ed de-

dam

aged or causes

cor

rect heat range

a light tan color on the portion of'the insu-

a plug is "

erma

nent and severe damage; refer to

'SO

ere

omm

ended spark plug

importan t. A

with the pis-

Too short

6. Install a torque wrench (C,

offset adapt er at a 900angle and tighten the adjuster

lockn ut to the torque spec ification listed in

7. Recheck the clearance to make sure the adjuste rs did not move when the lo adjust the valve clearance if neces

8. Clean the gasket surfacesofthe cylinder head

and

cov

er, then install a new gas ket to the cy lin

ead

cover (Figu re 83) .

9. Install the cylinder head

Correct

ckn

Too long

Figure

ut was tightened. Re-

cover

84) onto the

Tab

sary

and tighten the re-

le 5.

der

taining screws to the torque listed in Tab le 5.

10. Install all rema ining components removed.

Cam

Chain

Adj ustment

The engine is equi pped wi th an automatic

chain tensioncr assembl y. No adjustment is possibl e

or required.

cam

SparkPlug

Remova

CAUTION

Whenever the spark plug is removed.

dirt around it can fall into the plug

('Ull

hole. This

cause serious engine

damage.

I. Re

move

the scat as describe d in C

2. Remove the fuel tank as described in Chapter Six.

3. Blowaway all loose dirt then wipe off' thecy lin-

der head. R

into the cylin

Gra

side-to-side to break the scal loose. Th en pull the cap off the spark plug and out of the cylinder head

(Fig ure 86). If the cap is stuck to the plug, twist it

slightly to bre ak it loose.

emo

ve nil loose debris that could fall

der

head spark plug tunnel.

sp the spark plug lead, twist from

NOTE

hap

ter Fifteen.

UseIIspecial spark plug socket

equipped with a rubber insert that

contacts

the sideofthe spark plug.

This type of socket is included in the

standard tool kit. It is nece

.'lsm:1'

for

both removal and instal/ation since

the s

park

plug

is recessed in the cylin-

der

head.

The spark plug cannot be

removed

installed with

lin

gers.

Page 92

5. Install the special 5/8 in. spark plug socket onto the spark plug. Ma ke sure insta ll an open end wrench (tool kit) or soc ket

dle to remove the spark plug.

6. Inspect the plug carefully. Look for a broken

it is

cor

rectly seated and

han-

center porcelain. excessively eroded electrodes and excessive carbon or oil fouling.

NOTE

Spark plug

sand-blast typedevice is 110 1 recom-

nded. While this type

thorough,

freeofa

when done.

cleaningmaterial to Jail into the cyl-

cle

aning with the Hse

the plug II1I1S! be com

ll abra

siv

e cleaningmaterial

not, if is

ssibl

cleaning is

pletely

efo r the

imler during operation and cause

damage.

Ga ppi ng

Carefully adjust the electrode gap of a new spark

d In stalling

IheSpark

Plug

plug to ensure a reliable, consistent spark. Use a

special spark plug gapping too l and a wire feeler

gauge.

Mak

e sure the sma ll termina l

tach ed to the end of the plug.

2. Insert a wire feeler gauge between the center and of

side electrode gap

is listed in be a slight drag felt there is no drag, or bend the side electrode with a gapping tool (F

89) 10set the proper gap listed in Tab le 6.

3. Apply the threads not

lise engi ne oil on the plug threads.

the plug

Table

6. Ifthe gap is correct, there will

as the wire is pulled throu gh. If

the gauge will not pass through.

a light coa tingofanti

the spa rk plug before installing it. Do

(Figure

(Figu

re 88) . 11,e correct

sciz

e com pound to

87) is at-

igure

CHAPTERTHREE

NOTE

Do not overtighten. This will only

squas h the g

ing abili ty.

6. Install the spark plug cap and lead and cap onto the spark plug. Rotate the cap slightly in both directions and make sure it as we ll as the sea ling surface of the cylinder head .

Read

ing

SparkPlugs

aske

t and des troy itsseal-

is attac hed to the spark plug

C·/uTiON

The cylinder h cross -threadingof'he

easily damage it.

4. Use the same tool set-up used during removal and screw the spark plug in by hand

Very little effort is required. If force is necessary.

the plug is cr

oss-

ead

is alu

minumand

spark

plu

g call

until it scats.

threaded-e-stop, unscrew it and try

again.

5. Tighten the plug until it scats 011the spark plug hole in the cylinder head. then tight en it an add itional 1/4 to 112 tom .

Read ing the spark plug can provide a significant

amoun t mance. A careful been in use will provide an indication of spark plug operation and engine condition (oil consumption, piston. ctc.). If the plug is new. medium load for a short perio d. Avoid prolonged

idling b spark plug as desc ribed in this chapter. Exa mine the plug and

retor

ofinf

orma

tion regarding engin e perfor-

exam

ination

(heat range), air/fuel mixture

efor

e shutting olT the engine. Remove the

compar

If the plug is being read to determin e

tting is

e it to those in

corr

ect. start with a new

a plug that has

operate the ATV under a

Figure

compo

sition

90.

if the carbu-

plugand

op-

Page 93

LUBRICATION ,

MAI

NTENANCE AND TUNE-UP

I. Too rich fuel mixture.

2. Spark plug heat ra

3. Clogged air fihcr,

nge

too co ld.

4. Improperly operating ignition component.

5. Ignition

com

pone

nt failure .

6. Low engine compression.

7. Prolonged idling.

Oil-fOlded

The tipofan oi l-foule d plug has a black insulator

tip,adampoily filmoverthe firingendandacarbon

layer over the entire nose. The electrodes

are not

worn. Common causes forthis conditionarc:

I. Incorrect air/fu el mixture.

2. Low idle speed or pro longed idling.

3. Ignition componentfailure.

4. Spark plug heat range too co ld.

5. Eng ine still bein g broken in.

lve guides worn.

7. Piston rings \V0

An oil-fouled spark plug may be cleaned in an

emerge ncy, but it is better to rep lace it.

tant

tocorrect thecause of foulingbefore the engine turn

is re

ed to service.

111

or broken.

It is impor-

erate the ATV at the load that corresponds to the

jetting information desired. For example,ifthe

main jet is in question, o

pera

te the ATVat full throt-

tle andshut the engineoff and coast to a stop.

Normal condition

If the plug has a light tan- or gray-colored deposit

and noabnormal gap wear or

air/fuel mixture

cated .The plug in use is of the p

and

eros

ion, goodengine,

ignition condition are indi-

rop

er heat ran ge and

may be serviced andreturned 10use.

Carbon-fouled

SoO, dry,

end ortheplug are evidence

soo

tydepositscoveringthe entirefiring

incomplctc combus-

tion. Even though the tiring endofthe plug is dry,

the plug's insulation decreases when in this condi-

tion. An electrical path is formed that bypasses the

electrodes resulting in a misfire condition. One or

moreofthe following can cause carbon fouling:

Gap bridging

Plugswiththisconditionexhibitgapsshortedout

by combustion deposits between the electrodes. If

nter

this condition is encou

rbon

oroil inthe combustionchamber.Be sureto

ca locate and correctthe cause of this condition.

Badly wo

electrodes and premature gap wear arc signs ofoverheating, along witha grayor blistered porcelain insulator common cause for this condition is using plug of the

wrong heat

plug has not been installed and the plug is overheated, considerthe

I. Leanair

Improp

uel mixture.

erly op

erati

3. Engine lubrication system malfun ction,

4. Cooling system malfunction.

5. Engine air leak.

6. Impropersparkpluginstallation(overtightening).

7. No spark plug gasket.

ed, check for excessive

surfac

e. The most

nge (too hot). If a hotter

followingcauses:

ng ignitioncom

white

a spark

ponent.

Page 94

CHAPTER

THREE

NORMAL

Iden

tif

ied by li

gray de

posits

firing

tip.

Can be cleaned.

ght

on the

tan or

SPARK

Identified by closing

PLUG

GAP

BRIDGED

deposit

gap between

CONDITION

electrodes. Caused by all or carbon

fouling.Ifdeposits

excessive, the plug can be

are

bui

not

ldup

OIL

Identif

ied by wet black

the

insulator electrodes. Caused by excessive com

bustion

rings

and clearance between valve guides and stemsOJworn or Can be cleaned. repa ired, use a

FOULED

shell

chamber

pistons,

hotterplug

deposits

bore

and

oil

entering

thro

excessi

loose

bear

If engi ne Is

ugh

ings not

worn

CARBON

Identified by black,

carbon

FOULED

depo

sits on insulator

dry

fluffy

tips, exposed shell surfaces and electrodes. Caused

weak

cleaner, too or

by too cold a plug,

Igniti on, dirty air

excessive

rich

Idli

fuel

mixture

ng. Can be

cleaned.

FUSED

dentif depo or Caused

blis

ied by

sit

s resemb

ters.

SPOT

melte

sudde

DEPOSIT

d or

spotty

ling

bubbles

acceleration.Can be cleaned.

LEAD

FOULED

Identified by dark gray,black,

yellow or tan deposits or a fused

glazed coating on Caused by

highly

the

insulator tip.

leaded

gasoline. Can be cleaned.

OVERHEATING

Identif ied by a white or

gray

insulator with small

gray brown

bluish-burnt

tro

elec

Caused by engine

overheating, wrong type of

loose

fuel, hot

a plug or

timing

. Replace the plug .

spotswith

appearance of

des.

spark

Incorrect

light

black

plugs,too

ignitio

Identified by severely eroded or worn electrodes

• Caused by Should

Identified and po Metallic ind

icate eng ine damage. Caused by Incorrect igni advance, va

lvesorengine

Replace the

WORN

normal

be replaced.

PREIGNITION

by melte d e

ssibly

blistered

depositsoninsula

wrong

tiontiming

too

hot

plug

wear.

lectrodes

Insulator

tor

type of fuel ,

a plug, b overheating. .

urned

Page 95

LUBRICATION,

MAINTENANCE

AND TUNE-VI'

NOTE

Because ignition componentsare temperature-sensitive, ing while the engine is cold. Timing may

change as much as 2° when the

engine

warms.

check ignition tim-

'Jlorll out

Corrosive gases formed by combustion and high voltage sparks have eroded the elect rode s. plug in this condition requires more voltage to fire un

der

hard acceleration. Replace with a

plug.

A spark

new

spark

Preignition

If the electrod es are melted, preignition is almost

certainly the cause. Check for intake leak age

over-advanced ignition timing. It is also possible

that a plug used. Find the cause turning the engi ne to service. For additional infor-

oft

he wrong heat range (too hot) is being

the preignition be fore re-

and

mation on preignition, refer to Preignition in

Cha

pter Two.

I. Place the ATV on a level surface and apply the

parking brake. Block the wheel s to keep it from roil-

ing in either direc tion.

2. Remove the plug from the timing hole in the re-

coil starter

3. Attach a strob plug lead following the tions.

4. Attac h manufacturer's instructions.

5. Shift the transm ission to NEU

6. Start the engine, allow it to idle for approxi-

mately

speed to the

ble 5

cove

r (Figure 78).

osco

pic timing light to the spark

manu

facturer' s instruc-

a por

ble tachometer according to its

TRAL.

RNING

Do not allow or

infro

gine is running. Keep hands,

cloth ing and drive chains.

10-15 seco nds, then increase the engin e

ignition timing speed rpm listed in Ta-

any

one to stand behind

nt of the vehicle when the en-

feet

and

awa.v from the engine, helt

7. Point the timing light at the recoil starter cov er

timing inspection hole flywheel timing mark.

igu re 78) and observe the

Chec

kin

Ignition Timing

All models are equi pped with a capacitor discharge ignition (C used. This ignition system is much less susceptible to failures caused

breaker-point ignition systems.

Change ignit ion timing by relocating the stator

plate located under the assembling, note that the holes for the stator plate attaching screws are elongated.

\Vhen assembling the stator plate, align the mark

on the stator plate with the mark

shown in Figure 9 1. It may be necessary to move

the stator plate slightly this chapter.

Ol)

and no breaker points are

by dirt, moisture and wear tha n

eng

inc llyw heei. When dis-

on the cra nkcase as

whe

n timi ng as described in

NOTE

The timing light wil

10 stop the timing

ignition.

Increase the engine speed briefly and observe

the timing mark that is aligned with the timing pointer

9. If timing is not the follow ing procedure.

move the tim ing light and ta the covers that were removed.

Adjusting

achieve optimum engin e perform anc e.

igur

e 92).

10. Whe n timing is correct, turn the engine off, re-

Ignition Tim ing

The

ignition must occur at a specifi c time to

lfl

ash, appearing

mark

sat the instant

cor

rect, adjust it as desc ribed in

chometer

. Insta ll all of

Page 96

90 CIIAI'TER TII REE

..;:::

=-- - - - -

I. Remove the recoil starter assem bly as described

in Chapter Five.

2. Remove the llywheel Five.

3. Loosen the stator plate mounting screws (Figure 93) and rotate the stator plate to adjust ignition timing. Turn the stator nition timing or

ing.

4. Tighten the stator plate retainin g screws.

5. Reinstall the flywheel, starter pulley and recoil starter assembly.

•

as described in Chapter

plate clockwise to retard ig-

counterclockwise to advance tim-

<l-

Timing

pointe

Carb u

reto

r Id le Mixt ure

The pilot air sc

rew

at idle speed. Turning the pilot air screw

wise

reduces the amo untofair and richens the

Adjustment

controls the

air

/fuel mixture

clock

mixture.

The pilot air screw is preset by the manufacturer.

The following proced ure is to be used only after the

carburetor has been disassembled and cleaned or

the pilot air screw is replaced.

I. The pilot air screw (Figure 94) is located on the

bottomofthe carburetor. nearest the eng ine.

2. Tum the pilot air screw in clockwise} until it

seats lightly.

1I()/

damage the sea l or the tip

NOTE

the pilot air sere\\' byfor

seat.

3. Back the pi lot air screw out the nu

turns

specified in

4. Start the orm

al operating t

n utes).

5. Con nec t an

pable

rending

engine

accurate

increments

Tnh

le 6.

and allow it to warm up to

emp

erature (about 10 min-

portabletachometer

cing

it into its

± 50 rpm.

mber

ca-

Page 97

LUBRICAT

ION,I\IA

INTENANCE

ANDTUNE·

6. Set the idle speed to 1200 rpm by turning the throttle adjust knob (Figure

95)

7. Slowly tum the pilot air screw cloc kwi se until the en gine speed begins to

decreaseby

50 rpm or

greater, stop and note the screw location .

8. Sl

owly

tum the pilot air sc rew counterclo until idle speed increases to max tinue to tum the pilot air screw

imum

coun

ckw

rpm. Co n-

terclockwise

until idle RPM begins to drop . Stop and note the

screw location.

9. Center the pilot air screw between the screw set-

tings achieved in Step 7 and Step 8.

10. Readjust idle speed

not within the idle speed

listed in Table 6.

Table1MAINTENANC

E AND LUBRICATION SCH

Idle

Speed

CAUTION

Donotusethepilotair

sell?\1'

theengine idlespeed.Thepilotairscrew

ise

mustbe set as described in this chapter orthe enginemayhe

damaged by «rces-

sivety leanair/iuel mixture.

I. Connect a tachometer according to its manufac-

turer's instructions.

2. Refer to

3. Tum the throttle sto p knob (Figure 95 ) in to increase or out to decrea se idle speed.

Tab

le 6 for the correct idle speed.

EDULE

Pre-rlde check Check tire condition and Inflation pressure

eck

whee l rim con

Check brake fluid level; add flu id if necessary Check brake lever operation and travel

eck

tightne ss of nuts,

Check I

uellevel

ally

check

s Check air fi l

Check air

Check coo lant levelI"reservoir

eck

Check drive chain te

oper

ter

fillerair

atio

dit

ion

bolt

s and fasteners

Jn fuel tank; top off if necessary

element

box sediment tube

n of hea

dlight

nsion

and brake l

and cond

itio

Weekly Check for moisture In recoil starter housing

Check

air

fil

ter

element

Every

mont

Every six m

h or after 10-25hoursofoperation

onth

s or after 50

hou

rs of operation General lubrication of chassis components

Check

battery

Check

transmissionoil Check fron t Check

Check brake pad wear

l ubricate steerin g s Change engine Check t Check ETC switch operation Check choke oper Drain carbu

Inspect all air intake d

Check Check Check Check and a Check and Check Check front

lubricate If

(con

tinu

ed)

drive

engine

hrott

le operation; lubricate cabl e If necessary

retor

coo

lant-to-wa

front

hub

dri

ve belt (EBS models)

djust

adjust

stee

ring ope rati on; lubricate if necessary

suspe

necessary

condi

tion

level

unit

oil level

breather

filter

haft

bushi ng

011

and fllter

atio

n; lubricate if necessary

float

bow

ucts

and fi

ter

ratio

lubrication

drive

belt

shift

nsi

(non-EBS models)

linkage

on mo

untingfitt

ttin

tochange

amp

ings;

Page 98

CHAPTER

THREE

Table1MAINTENANCE

AND

LUBRICATION

SCHEDULE(continued)

Every twelve months or after

100hours of operation Check all tank vent hose routing and condition

Every

afte r

twe

200

nty

hou

fourmon

ths or

rs of opera

tio

Check and

Check entire

hosedeterioration Replace Checkradiator Check engi ne

Inspect spark

Check Ignition tim

Change Change tra Check front

Insp Check auxiliary brake Check head Check Check exha R

emo

and drain

Allof the a

Change Check

adjust

valve clearance

fuel

system

fuel

filter

and

hoses

mounting

plug

; replace if necessary

ing;adj

lubr

icant

In front

nsmiss

ion fluid

hub

bearings for excessive wear

ect

clutchdrive pUlley for

light

fro

ve the

brake fluid

tightnessoffront

aim;

nt wheel

ust

systemmo

drain

plugonmuff

out

any

bovechecks

toe-outadjustme

residue

for leaks and

for

leakage

hardware

ust if

and

necessary

hubs

correct

for

ler

engagement

and

tightness

pedal

operation

adjustifnecessary

unts

plus the following

hub

nut

damage

adjustme

Mod

Front Wheels Rear

wheel

• Tire

pres

Engine oil

issi

Transm Front

gear

hubs

Front

Brake flu id Coolant

Grease

able2TIRE

INFLATION

kPa

34.5

s 34.5

sure for original equi p

on oil case

ment

tires

. Aftermarket

ble3RECOMMENDED

PRESSURE

(COLD'

PSI

5 5

tires

may

require

diffe

LUBRICANTS

Lubricant Polari s

or 10W/40 Polaris synthetic gear case oil

Polaris

API GL5

Polaris

AND

FLU

fluid

type

Premium4Synthetic

motor

oil

front

gearcase

eo-so

demand

lube

gear lube

drive

hub flu id

or ATFType F

DOT 3 br ake

50:50 mi

coolantcompounded

and

Polaris all

xture

engines

season

flu

lgh

~quality

for

grease, or equ ivale

rent infl ation pressure.

IDS

10W/40

(part

ethylene g

alum

No. 2871478)

No. 2871653), or

(part

No. 2871654).

lycol-b

inumradiators

ased

Page 99

LUBRI

CATIO

Item

Engineoil

Transmission all

gear

Front

hubs

Front Coolant

case

N, M AI

(all years)

NTENANCE

AND

TUNE-UP

Table4CAPACITIES

1.89 L (2 U.S.

946.3 cc (32 U.S.oz.) 96 cc (3.25 U.S. oz.) 75 cc (2.5 U.S. oz.) Appro

uantity

x, 2.16 L (2.25 U.S.

qts

Table5MAINTENANCE

Item

Crankcase oil drain plug 19

Cylinderhead cover screws 8.2

Front gear case drain plug 9.4 Handlebar upper holder bolts

011

tank drainplug 19

Oil

lank

screen and fitting 20

AND

TUNE·UP

N'm

TORQUE

inAb

13·17 115-150

Valveadjusterlocknuts 6·7 53·62

Wheel lug

Front

Rear 21

Item

nuts

Tab

le6MAI

NTENA

NCE

AND TU

Specificat

NE·UP

SPECIF

ion

Discbrake pad thickness wear limit

All cali pers

3.81 mm (0.150 in.)

Valveclearance (cold)

Intake and exhaust

Spark plug

Heat range

1996·1997

1998~n

Gap

1996·1998 1999-0n

Idle speed

1996-1998 1999-0n

Ignition timing/speed

Carburetor pilot air screw

1996 1997·1998

1999-00

a ll pressure @S500 rpm

Standard

Minimum

0.15 mm (0.006 in.)

NGK BKR5ES NGK BKR5E

0.6-0.7 mm (0.024·0.028 in.)

0.7 mm (0.028 In.)

110(1.1300 100(1.1400rpm 30'

1 1/2

2 turn s out

25/8

138 kPa (20 psi) 83 kPa (12 psi)

e 3500

turns

rpm

out

SPECIFICATIONS

ICATIONS

ft.·lb

14 15

15 15

Page 100

CHAPTER FOUR

ENGINE

Th is chapter covers top end engi ne service and

repair procedur es. Specificat ions arc provided in

les 1-4 at the endofthe chapter.

The ATV is equipped with a liquid-cooled sing le

cylinder engine. The engine feature s a single over-

head camshaft (SOH C), which is chain driven from the cranksha ft and a four-valve cylinder head.Valve

actuation and adjustment is by means of adjustabl e

rocker arm s.

a ile

the most important aspects

engine overhaul is preparation. Read all of the proce-

dures before starting and review the information in

Chapter One regarding tools and methods. The accu-

rateuse of precision measuringequipmentis vital toa

successful overhaul. Before removing the engine and

disassembling the crankcase, degrease the engine and

frame. Have all the necessary hand and special tools available. Make sure

lit. Identify and store individual parts and assemblies

in appropriate storage containers (Fig

References

position the seal facin g on the work bench.

the part s as viewed by the rider siting on

ENGINE

Figure 2 explains f

the work area is clean and well

to the len and right sides

forw

ard, not how the engine may sit

PRINCIPLES

our

-stroke engine operation.

a successful

ure

I).

ref

er to the

TOP

END

ENGI

NE COO

A mixture

engine. The coolant is circulated through

and radiator by a shutt-drivcn pump. Refer to Chapter

Three for cooling system maintenance and to Chapter

Seven for service to the engine cooling system.

antifreezeand distilled watercools the

NOTE

Cooling is also assisted by the fins (A.

Figure 3) on the oil tank located on the

1((li

side. Some o

Jth

e hm t

LIN

jivm

the engine

is transferred 10 the oil. then radiated 10

theairflowingpastthecoo lingfins01 1 the

rese

rvoir

: Service to the lubrication

:sJ

tem is covered ill Chapter Five.