9918061 PN MANUAL SERVICE BOSS TRAIL 2003
2003 TRAIL BOSS
SERVICE MANUAL
PN 9918061
PN 9918061
Printed in USA
2003 TRAIL BOSS 330 SERVICE MANUAL
Foreword
This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified.
This manual includes procedures for maintenance operations, component identification and unit repair, along with service specifications for 2003 Polaris Trail Boss ATVs.Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.
2003 Trail Boss 330 ATV Service Manual (PN 9918061)
ECopyright 2002 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improcvements in the design and quality of production components, some minor descrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for ommisions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
Throughout these instructions, important information is brought to your attention by the following symbols:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
DANGER
Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person inspecting or servicing the ATV.
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or person inspecting or servicing the ATV.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property damage.
NOTE:
A NOTE provides key information to clarify instructions.
Trademarks
Polaris acknowledges the following products mentioned in this manual:
FLEXLOC, Registered Trademark of SPS Technologies
Loctite, Registered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
FOX, Registered Trademark of Fox Shox
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Ammco, Registered Trademark of Ammco Tools, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
CHAPTER INDEX
CHAPTER 1 |
GENERAL |
CHAPTER 2 |
MAINTENANCE |
CHAPTER 3 |
ENGINE |
CHAPTER 4 |
FUEL SYSTEM |
CHAPTER 5 |
BODY/SUSPENSION |
CHAPTER 6 |
PVT SYSTEM |
CHAPTER 7 |
FINAL DRIVE |
CHAPTER 8 |
TRANSMISSION |
CHAPTER 9 |
BRAKES |
CHAPTER 10 |
ELECTRICAL |
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION/
MAINTENANCE
2003 Model Identification . . . . . . . . . . . . . . . . . . 1.2
Serial Number Location . . . . . . . . . . . . . . . . . . . 1.2
2003 Trailboss Model . . . . . . . . . . . . . . . . . . . . . 1.3
Replacement Keys . . . . . . . . . . . . . . . . . . . . . . . 1.4
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . 1.5
Specifications - 2003 Trail Boss 330 . . . . . . . . 1.6-1.7
Publication Numbers . . . . . . . . . . . . . . . . . . . . . 1.8
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Standard Torque Specifications . . . . . . . . . . . . 1.8
Tap Drill Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . 1.9
Unit of Measure Conversion Table . . . . . . . . . . 1.10
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . 1.11
1
1.1
GENERAL INFORMATION
MODEL IDENTIFICATION
The machine model number must be used with any correspondence regarding warranty or service.
Machine Model Number Identification
A |
0 3 C A |
3 2 A A |
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Emissions & |
Year Designation |
Basic Chassis |
Model Option |
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Designation |
Engine Designation |
ENGINE DESIGNATION NUMBERS
32 ES32PFE10 . . . . . . . . . . . . Single, Air Cooled, SOHC 4 Stroke, Electric Start
VIN IDENTIFICATION
World Mfg. ID |
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Vehicle Descriptor |
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Vehicle Identifier |
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1 |
2 |
3 |
4 |
5 |
6 |
7 |
8 |
9 |
10 |
11 |
12 |
13 |
14 |
15 |
16 |
17 |
4 |
X A A A 3 |
2 A * 3 P 0 0 0 0 0 0 |
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Body Style |
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Emissions |
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Model |
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Year |
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Individual Serial No. |
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Engine |
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Powertrain |
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Check Digit |
Plant No. |
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* This could be either a number or a letter
ENGINE SERIAL NUMBER LOCATION
Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional number is stamped on the center top of crankcase beneath the cylinder coolant elbow.
UNIT MODEL NUMBER AND SERIAL NUMBER LOCATION
The machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the lower left side of the frame tube.(B)
A
Front
TRANSMISSION I.D. NUMBER LOCATION
The transmission I.D. number is located on top of the transmission, right side of machine. 
1.2
GENERAL INFORMATION
2003 TRAILBOSS MODEL
2003 TRAILBOSS 330
1.3
GENERAL INFORMATION
REPLACEMENT KEYS
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number.
Should both keys become lost, ignition switch replacement is required.
31XX
Key Series
Number
Series # |
Part Number |
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20 |
4010278 |
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21 |
4010278 |
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22 |
4010321 |
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23 |
4010321 |
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27 |
4010321 |
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28 |
4010321 |
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31 |
4110141 |
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32 |
4110148 |
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67 |
4010278 |
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68 |
4010278 |
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1.4
GENERAL INFORMATION
MACHINE DIMENSIONS
46 in
117 cm
FRONT
46 in
117cm
75 in
191 cm
34 in
86 cm
SIDE
49.5 in
126 cm
1.5
GENERAL INFORMATION
MODEL: . . . . . . . . . . 2003 TRAIL BOSS 330
MODEL NUMBER: . A03CA32
ENGINE MODEL: . . ES32PFE10
CARBURETION |
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JETTING CHART |
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Type . . . . . . . . . . . . . . . |
BST 34 Mikuni. |
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AMBIENT TEMPERATURE |
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Altitude |
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Below 40 F |
+40EF to +80EF |
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Main Jet |
122.5 |
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Below 5 C |
+5EC to +26EC |
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. . . . . . . . . . . .Pilot Jet |
. 42.5 |
Meters |
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0-1800 |
117.5 |
122.5 |
Jet Needle |
4HB48--2 |
(Feet) |
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(0-6000) |
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Needle Jet . . . . . . . . . . |
P-0M. |
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above 1800 |
120 |
115 |
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(above 6000) |
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Pilot Screw |
2 Turns Out |
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Pilot Air Jet . . . . . . . . . |
. 160 |
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Valve Seat . . . . . . . . . . |
. 1.5 |
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Fuel Octane (R+M/2) |
. 87 Non-Oxygenated or |
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89 Oxygenated |
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CLUTCH |
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CLUTCH CHART |
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Altitude |
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Shift |
Drive Clutch |
Driven Clutch |
Driven |
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Type |
PVT |
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Weight |
Spring |
Spring |
Helix |
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Meters |
0-1800 |
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Belt |
3211077 |
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20 40 |
Blue/Grey |
Black |
2+2 |
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(Feet) |
(0-6000) |
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Belt Width (Projected) |
1.1882 (30.18mm) |
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1800-3700 |
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20 38 |
Blue/Grey |
Black |
2+2 |
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Side Angle (Overall) |
26 |
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(6000-12000) |
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* 40E helix, black driven spring |
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Outside Circumference |
40.86 .122 |
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Center Distance . . . . . . . . |
. . 10 .122 (254.5mm) |
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Clutch Offset . . . . . . . . . . |
. . 0.52 (12.7mm) |
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Drive Spring . . . . . . . . . . . |
. . Grey |
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Driven Spring . . . . . . . . . . |
. . Black |
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Driven Helix . . . . . . . . . . . |
. . 2+2 |
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ENGINE |
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Type . . . . . . . . . . . . . . . . . . . |
. . . . 4 Cycle, Single Cyl. |
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Displacement . . . . . . . . . . . |
. . . . 329 cc |
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Bore . . . . . . . . . . . . . . . . . . . |
. . . . 3.0912 (78.5mm) |
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Stroke . . . . . . . . . . . . . . . . . |
. . . . 2.6792 (68mm) |
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Valve Clearance In & Ex . . |
. . . . 0.006 0.00082 (0.15 0.02 mm) BTDC on compression |
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Cooling . . . . . . . . . . . . . . . . |
. . . . Air with fan assisted oil cooler |
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Lubrication Type . . . . . . . . |
. . . . Wet Sump |
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Piston Marking . . . . . . . . . . |
. . . . None |
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Operating RPM 200 . . . . . |
. . . . 6300 RPM |
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Idle RPM 50 (lights off) |
. . . . . 1300 RPM |
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Compression Ratio . . . . . . |
. . . . 9.2:1 |
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Compression Pressure . . . |
. . . . 70--90 PSI |
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1.6
GENERAL INFORMATION
MODEL: . . . . . . . . . . . . 2003 TRAIL BOSS 330
MODEL NUMBER: . . . A03CA32
ENGINE MODEL: . . . . ES32PFE10
ELECTRICAL |
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FLUID |
Capacity |
Type |
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Flywheel I.D. . . . . . . |
None |
Fuel Tank . . . . . . . |
. . . 3.25 gals. (12.30 L) |
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CDI Part Number . . . |
4010697 |
Transmission . . . . |
. . . 11.3 oz. (335 ml) PPS* |
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Alternator Output . . . |
210 |
watts |
Engine Oil . . . . . . |
. . . 1.5 qts (1.4 L) |
PP4* |
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Ignition Timing . . . . . |
30 2 BTDC@5000RPM |
Brake (Hand) . . . . |
. . . . . . . . . . . . . . . . . |
Dot 3 |
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Spark Plug / Gap . . . |
NGK BKR6E / 0.0362 (0.9 mm) |
Brake (Foot) . . . . . |
. . . . . . . . . . . . . . . . . |
Dot 3 |
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Lights: Head . . . . . . |
(2) Dual Beam 30/30 watts |
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Tail . . . . . . . . |
8.26 |
watts |
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Brake . . . . . . |
26.9 |
watts |
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Indicator . . . |
1.0 |
watts |
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Electric Start . . . . . . . |
Standard |
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Electronic Speedo . . |
N/A |
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Polaris Lubricants |
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*PP6 |
Polaris Premium 60/40 Antifreeze/Coolant |
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*PPS |
Polaris Premium Synthetic Gear Case Oil |
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*PP4 |
Polaris 0W-- |
40 Synthetic Engine Lubricant |
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*PDD |
Premium Demand Drive Hub Fluid |
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SUSPENSION / CHASSIS
Body Style . . . . . . . . |
Gen IV |
Front Suspension . . |
MacPherson Strut |
Tow Capacity . . . . . . |
850 lbs. (385.9 kg) |
Turning Radius . . . . . |
752 (191 cm) |
Toe Out . . . . . . . . . . . |
1/82-1/42 (3-6.35 mm) |
Ground Clearance . . |
5.52 (13.97 cm) |
Front Vertical Travel |
6.72 (17.02 cm) |
Rear Suspension . . . |
Progressive Rate Swing Arm |
Rear Travel . . . . . . . . |
9.02 (22.86 cm) |
Rear Shock . . . . . . . . |
22 Gas Charged Twin Tube |
Shock Adjustment . . |
Cam |
TIRES
Tire Size - Front . . . . 23 x 7 - 10 Tire Size - Rear . . . . 22 x 11 - 10 Tire Pressure - F/R . 4/3 lbs.
Total Width . . . . . . . . 462 (117 cm) Total Length . . . . . . . 752 (191 cm) Total Height . . . . . . . . 462 (117 cm)
Wheel Base . . . . . . . 49.52 (125.73 cm) Weight - Dry . . . . . . . 505 lbs. (230 kg)
DRIVE TRAIN
Chain Type . . . . . . . . . 520 O-Ring
Gear Reduction-Rev . 3.05/1
Gear Reduction-High 2.68/1
Final Drive Ratio . . . . 11/40 78P
Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Brake ( Auxiliary Foot) Hydraulic
LOAD CAPACITY
Front Rack (Accy) . . . . 75 lbs. (34 kg) Rear Rack (Std) . . . . . . 125 lbs. (57 kg)
Tongue Weight . . . . . . . 85 lbs. (14 kg) Tow Hitch . . . . . . . . . . . Std
OPTIONAL SUSPENSION SPRINGS
SPRING TYPE |
SOFT |
STANDARD |
FIRM |
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Rear Compression Spring |
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7041518-067 |
7041303-067 |
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N / A |
130 --165 lb/in. |
250 lb/in. |
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Front Strut Spring |
N / A |
7041850-067 |
7041375-067 |
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41 lb/in. |
64 - 113 lb/in. |
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1.7
GENERAL INFORMATION
PUBLICATION NUMBERS
Year |
Model |
Model No. |
Owner’s |
Parts |
Parts |
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Manual PN |
Manual PN |
Micro Fiche PN |
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2003 |
Trail Boss 330 |
A03CA32AA |
9917492 |
9917862 |
9917863 |
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NOTE: When ordering service parts be sure to use the correct parts manual. |
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PAINT CODES
PAINTED PART |
COLOR |
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DITZLER |
POLARIS |
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DESCRIPTION |
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NUMBER |
NUMBER |
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Springs |
Silver |
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---- |
P-385 |
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Rims |
Bright White |
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2185 |
P-133 |
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Rack(s) |
Black |
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9440 |
P-067 |
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Frame |
Black |
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9440 |
P-067 |
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FRAME COLOR - P067 Medium Gloss Black 9440 / 8520147. |
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Order direct from Midwest Industrial Coatings 952--252--2000 |
See Quick Reference Manual for ordering info. |
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STANDARD TORQUE SPECIFICATIONS
The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections.
Bolt Size |
Threads/In |
Grade 2 |
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Grade 5 |
Grade 8 |
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Torque in. lbs. (Nm) |
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#10 |
- |
24 . . . . . . . . . . |
. . . . 27 |
(3.1) . . . . . |
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43 |
(5.0) . . . . . . . . . . . . . . |
60 |
(6.9) |
#10 |
- |
32 . . . . . . . . . . |
. . . . 31 |
(3.6) . . . . . . |
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49 |
(5.6) . . . . . . . . . . . . . . |
68 |
(7.8) |
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Torque ft. lbs. (Nm)* |
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1/4 |
- |
20 . . . . . . . . . . |
. . . . 5 (7) . . . . . . . . |
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8 (11) . . . . . . . . . . . . . . . . |
12 |
(16) |
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1/4 |
- |
28 . . . . . . . . . . |
. . . . 6 (8) . . . . . . . . |
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10 |
(14) . . . . . . . . . . . . . . |
14 |
(19) |
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5/16 |
- |
18 . . . . . . . . . . |
. . . . 11 (15) . . . . . . |
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17 |
(23) . . . . . . . . . . . . . . |
25 |
(35) |
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5/16 |
- |
24 . . . . . . . . . . |
. . . . 12 |
(16) . . . . . . |
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19 |
(26) . . . . . . . . . . . . . . |
29 |
(40) |
3/8 |
- |
16 . . . . . . . . . . |
. . . . 20 |
(27) . . . . . . |
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30 |
(40) . . . . . . . . . . . . . . |
45 |
(62) |
3/8 |
- |
24 . . . . . . . . . . |
. . . . 23 |
(32) . . . . . . |
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35 |
(48) . . . . . . . . . . . . . . |
50 |
(69) |
7/16 |
- |
14 . . . . . . . . . . |
. . . . 30 |
(40) . . . . . . |
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50 |
(69) . . . . . . . . . . . . . . |
70 |
(97) |
7/16 |
- |
20 . . . . . . . . . . |
. . . . 35 |
(48) . . . . . . |
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55 |
(76) . . . . . . . . . . . . . . |
80 |
(110) |
1/2 |
- |
13 . . . . . . . . . . |
. . . . 50 |
(69) . . . . . . |
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75 |
(104) . . . . . . . . . . . . . |
110 (152) |
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1/2 |
- |
20 . . . . . . . . . . |
. . . . 55 |
(76) . . . . . . |
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90 |
(124) . . . . . . . . . . . . . |
120 (166) |
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Metric / Torque |
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6 x 1.0 |
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72-78 In. lbs. |
. . . . 8 x 1.25 |
14-18 ft. lbs. |
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. . . . 10 x 1.25 |
26-30 ft. lbs. |
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1.8
GENERAL INFORMATION
SAE TAP DRILL SIZES
Thread Size/Drill Size |
Thread Size/Drill Size |
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#0-80 |
3/64 |
1/2-13 |
27/64 |
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#1-64 |
53 |
1/2-20 |
29/64 |
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#1-72 |
53 |
9/16-12 |
31/64 |
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#2-56 |
51 |
9/16-18 |
33/64 |
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#2-64 |
50 |
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5/8-11 |
17/32 |
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#3-48 |
5/64 |
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5/8-18 |
37/64 |
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#3-56 |
45 |
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3/4-10 |
21/32 |
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#4-40 |
43 |
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3/4-16 |
11/16 |
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#4-48 |
42 |
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7/8-9 |
49/64 |
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#5-40 |
38 |
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#5-44 |
37 |
7/8-14 |
13/16 |
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#6-32 |
36 |
1-8 |
7/8 |
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#6-40 |
33 |
1-12 |
59/64 |
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#8-32 |
29 |
1 |
1/8-7 |
63/64 |
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#8-36 |
29 |
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1 |
1/8-12 |
1 |
3/64 |
|||
#10-24 |
24 |
|||||
1 |
1/4-7 |
1 |
7/64 |
|||
#10-32 |
21 |
|||||
1 |
1/4-12 |
1 |
11/64 |
|||
#12-24 |
17 |
|||||
1 |
1/2-6 |
1 |
11/32 |
|||
#12-28 |
4.6mm |
|||||
1 |
1/2-12 |
1 |
27/64 |
|||
1/4-20 |
7 |
|||||
|
|
|
|
|||
1/4-28 |
3 |
1 |
3/4-5 |
1 |
9/16 |
|
5/16-18 |
F |
1 |
3/4-12 |
1 |
43/64 |
|
5/16-24 |
I |
2-4 1/2 |
1 |
25/32 |
||
3/8-16 |
O |
2-12 |
1 |
59/64 |
||
3/8-24 |
Q |
2 |
1/4-4 1/2 |
2 |
1/32 |
|
7/16-14 |
U |
|||||
2 |
1/2-4 |
2 |
1/4 |
|||
7/16-20 |
25/64 |
|||||
2 |
3/4-4 |
2 |
1/2 |
|||
|
|
|||||
|
|
3-4 |
2 |
3/4 |
||
|
|
|
|
|
|
|
METRIC TAP DRILL SIZES
Tap Size |
Drill Size |
Decimal |
Nearest |
|
|
Equiva- |
Fraction |
|
|
lent |
|
|
|
|
|
3 x .50 |
#39 |
0.0995 |
3/32 |
3 x .60 |
3/32 |
0.0937 |
3/32 |
4 x .70 |
#30 |
0.1285 |
1/8 |
4 x .75 |
1/8 |
0.125 |
1/8 |
5 x .80 |
#19 |
0.166 |
11/64 |
5 x .90 |
#20 |
0.161 |
5/32 |
6 x 1.00 |
#9 |
0.196 |
13/64 |
7 x 1.00 |
16/64 |
0.234 |
15/64 |
8 x 1.00 |
J |
0.277 |
9/32 |
8 x 1.25 |
17/64 |
0.265 |
17/64 |
9 x 1.00 |
5/16 |
0.3125 |
5/16 |
9 x 1.25 |
5/16 |
0.3125 |
5/16 |
10 x 1.25 |
11/32 |
0.3437 |
11/32 |
10 x 1.50 |
R |
0.339 |
11/32 |
11 x 1.50 |
3/8 |
0.375 |
3/8 |
12 x 1.50 |
13/32 |
0.406 |
13/32 |
12 x 1.75 |
13/32 |
0.406 |
13/32 |
|
|
|
|
DECIMAL EQUIVALENTS
1/64 . . . . . . . . . |
. . . . . . . .0156 |
|
1/32 . . . . |
. . . . . . . .0312 . . . |
1 mm = .0394 |
3/64 . . . . . . . . . |
. . . . . . . .0469 |
|
1/16 . . . . |
. . . . . . . .0625 |
|
5/64 . . . . . . . . . |
. . . . . . . .0781 . . . |
2 mm = .0787 |
3/32 . . . . |
. . . . . . . .0938 |
|
7/64 . . . . . . . |
. . . . . . . .1094 . . . |
3 mm = .1181 |
1/8. . . . .1250 |
|
|
9/64 . . . . . . . . . |
. . . . . . . .1406 |
|
5/32 . . . . |
. . . . . . . .1563 . . . |
4 mm = .1575 |
11/64 . . . . . . . . |
. . . . . . . .1719 |
|
3/16 . . . . |
. . . . . . . .1875 . . . |
5 mm = .1969 |
13/64 . . . . . . . . |
. . . . . . . .2031 |
|
7/32 . . . . |
. . . . . . . .2188 |
|
15/64 . . . . . . . . |
. . . . . . . .2344 . . . |
6 mm = .2362 |
1/4 . . . . |
.25 |
|
17/64 . . . . . . . . |
. . . . . . . .2656 . . . |
7 mm = .2756 |
9/32 . . . . |
. . . . . . . .2813 |
|
19/64 . . . . . . . . |
. . . . . . . .2969 |
|
5/16 . . . . |
. . . . . . . .3125 . . . |
8 mm = .3150 |
21/64 . . . . . . . . |
. . . . . . . .3281 |
|
11/32 . . . |
. . . . . . . .3438 . . . |
9 mm = .3543 |
23/64 . . . . . . . . |
. . . . . . . .3594 |
|
3/8 . . . . |
.375 |
|
25/64 . . . . . . . . |
. . . . . . . .3906 . . . |
10 mm = .3937 |
13/32 . . |
. . . . . . . .4063 |
|
27/64 . . . . . . . . |
. . . . . . . .4219 . . . |
11 mm = .4331 |
7/16 . . . . |
. . . . . . . .4375 |
|
29/64 . . . . . . . . |
. . . . . . . .4531 |
|
15/32 . . |
. . . . . . . .4688 . . . |
12 mm = .4724 |
31/64 . . . . . . . . |
. . . . . . . .4844 |
|
1/2 . . . . |
.5 . . . . . . . . . . . . . . |
13 mm = .5118 |
33/64 . . . . . . . . |
. . . . . . . .5156 |
|
17/32 . . |
. . . . . . . .5313 |
|
35/64 . . . . . . . . |
. . . . . . . .5469 . . . |
14 mm = .5512 |
9/16 . . . . |
. . . . . . . .5625 |
|
37/64 . . . . . . . . |
. . . . . . . .5781 . . . |
15 mm = .5906 |
19/32 . . |
. . . . . . . .5938 |
|
39/64 . . . . . . . . |
. . . . . . . .6094 |
|
5/8 . . . . |
.625 . . . . . . . . . . . . |
16 mm = .6299 |
41/64 . . . . . . . . |
. . . . . . . .6406 |
|
21/32 . . |
. . . . . . . .6563 . . . |
17 mm = .6693 |
43/64 . . . . . . . |
. . . . . . . .6719 |
|
11/16 . . . |
. . . . . . . .6875 |
|
45/64 . . . . . . . . |
. . . . . . . .7031 . . . |
18 mm = .7087 |
23/32 . . |
. . . . . . . .7188 |
|
47/64 . . . . . . . . |
. . . . . . . .7344 . . . |
19 mm = .7480 |
3/4 . . . . |
.75 |
|
49/64 . . . . . . . . |
. . . . . . . .7656 |
|
25/32 . . |
. . . . . . . .7813 . . . |
20 mm = .7874 |
51/64 . . . . . . . . |
. . . . . . . .7969 |
|
13/16 . . |
. . . . . . . .8125 . . . |
21 mm = .8268 |
53/64 . . . . . . . . |
. . . . . . . .8281 |
|
27/32 . . |
. . . . . . . .8438 |
|
55/64 . . . . . . . . |
. . . . . . . .8594 . . . |
22 mm = .8661 |
7/8 . . . . |
.875 |
|
57/64 . . . . . . . . |
. . . . . . . .8906 . . . |
23 mm = .9055 |
29/32 . . |
. . . . . . . .9063 |
|
59/64 . . . . . . . |
. . . . . . . .9219 |
|
15/16 . . |
. . . . . . . .9375 . . . |
24 mm = .9449 |
61/64 . . . . . . . . |
. . . . . . . .9531 |
|
31/32 . . |
. . . . . . . .9688 . . . |
25 mm = .9843 |
63/64 . . . . . . . . |
. . . . . . . .9844 |
|
1 . . . . . 1.0 |
1.9 |
|
|
|
|
|
|
|
|
|
GENERAL INFORMATION |
|
|
CONVERSION TABLE |
|
|
|
|
|
||
|
|
|
|
|
|
||
|
|
Unit of Measure |
Multiplied by |
|
Converts to |
||
|
|
|
|
|
|||
ft. lbs. |
|
x 12 |
|
= in. lbs. |
|||
|
|
|
|
|
|||
in. lbs. |
|
x .0833 |
|
= ft. lbs. |
|||
|
|
|
|
|
|||
ft. lbs. |
|
x 1.356 |
|
= Nm |
|||
|
|
|
|
|
|||
in. lbs. |
|
x .0115 |
|
= kg-m |
|||
|
|
|
|
|
|||
Nm |
|
x .7376 |
|
= ft.lbs. |
|||
|
|
|
|
|
|||
kg-m |
|
x 7.233 |
|
= ft. lbs. |
|||
|
|
|
|
|
|||
kg-m |
|
x 86.796 |
|
= in. lbs. |
|||
|
|
|
|
|
|||
kg-m |
|
x 10 |
|
= Nm |
|||
|
|
|
|
|
|||
in. |
|
x 25.4 |
|
=mm |
|||
|
|
|
|
|
|||
mm |
|
x .03937 |
|
= in. |
|||
|
|
|
|
|
|||
in. |
|
x 2.54 |
|
= cm |
|||
|
|
|
|
||||
mile (mi.) |
x 1.6 |
|
= km |
||||
|
|
|
|
|
|||
km |
|
x .6214 |
|
= mile (mi.) |
|||
|
|
|
|
||||
Ounces (oz) |
x 28.35 |
|
= Grams (g) |
||||
|
|
|
|
||||
Fluid Ounces (fl. oz.) |
x 29.57 |
|
= Cubic Centimeters (cc) |
||||
|
|
|
|
||||
Cubic Centimeters (cc) |
x .03381 |
|
= Fluid Ounces (fl. oz.) |
||||
|
|
|
|
||||
Grams (g) |
x 0.035 |
|
= Ounces (oz) |
||||
|
|
|
|
|
|||
lb. |
|
x .454 |
|
= kg |
|||
|
|
|
|
|
|||
kg |
|
x 2.2046 |
|
= lb. |
|||
|
|
|
|
||||
Cubic inches (cu in) |
x 16.387 |
|
= Cubic centimeters (cc) |
||||
|
|
|
|
||||
Cubic centimeters (cc) |
x 0.061 |
|
= Cubic inches (cu in) |
||||
|
|
|
|
||||
Imperial pints (Imp pt) |
x 0.568 |
|
= Liters (l) |
||||
|
|
|
|
|
|||
Liters (l) |
|
x 1.76 |
|
= Imperial pints (Imp pt) |
|||
|
|
|
|
||||
Imperial quarts (Imp qt) |
x 1.137 |
|
= Liters (l) |
||||
|
|
|
|
|
|||
Liters (l) |
|
x 0.88 |
|
= Imperial quarts (Imp qt) |
|||
|
|
|
|
||||
Imperial quarts (Imp qt) |
x 1.201 |
|
= US quarts (US qt) |
||||
|
|
|
|
||||
US quarts (US qt) |
x 0.833 |
|
= Imperial quarts (Imp qt) |
||||
|
|
|
|
||||
US quarts (US qt) |
x 0.946 |
|
= Liters (l) |
||||
|
|
|
|
|
|||
Liters (l) |
|
x 1.057 |
|
= US quarts (US qt) |
|||
|
|
|
|
||||
US gallons (US gal) |
x 3.785 |
|
=Liters (l) |
||||
|
|
|
|
|
|||
Liters (l) |
|
x 0.264 |
|
= US gallons (US gal) |
|||
|
|
|
|
||||
Pounds - force per square inch (psi) |
x 6.895 |
|
= Kilopascals (kPa) |
||||
|
|
|
|
||||
Kilopascals (kPa) |
x 0.145 |
|
= Pounds - force per square inch (psi) |
||||
|
|
|
|
||||
Kilopascals (kPa) |
x 0.01 |
|
= Kilograms - force per square cm |
||||
|
|
|
|
||||
Kilograms - force per square cm |
x 98.1 |
|
= Kilopascals (kPa) |
||||
|
|
|
|
|
|||
x R2 x H (height) |
|
|
|
= Cylinder Volume |
|||
C to F: |
9 ( C + 40) 5 - 40 = F |
|
|
|
|
|
|
F to C: |
5 ( F + 40) 9 - 40 = C |
|
|
|
|
|
|
1.10
GENERAL INFORMATION
GLOSSARY OF TERMS
ABDC: After bottom dead center. ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center.
BBDC: Before bottom dead center. BDC: Bottom dead center.
BTDC: Before top dead center. CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8 or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and grip the drive belt.
Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore.
Electrical Open: Open circuit. An electrical circuit which isn’t complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter. in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
2
kg/cm : Kilograms per square centimeter. kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter.
2
lbs/in : Pounds per square inch.
Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040 . Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch System) qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston’s most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
1.11
GENERAL INFORMATION
NOTES
1.12
MAINTENANCE
CHAPTER 2
MAINTENANCE
Periodic Maintenance Chart . . . . . . . . . . . . . . . |
2.2-2.3 |
|
Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . |
2.3 |
|
. . . . . .Recommended Maintenance Products |
2.4 |
|
Lubricant and Maintenance Quick Reference |
2.5-2.6 |
|
Special Tools |
2.7 |
2 |
|
||
Transmission Lubrication . . . . . . . . . . . . . . . . . . |
2.8 |
|
. . . . . . . . . .Transmission Linkage Adjustment |
2.9 |
|
Throttle Operation / Choke Adjustment . . . . . . |
2.10 |
|
. . . . . . . . . . . . . . . . . . .Carburetor Adjustments |
2.10-2.11 |
|
ETC Switch Adjustment . . . . . . . . . . . . . . . . . . . |
2.11 |
|
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2.12 |
|
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . |
2.13 |
|
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . |
2.13-2.14 |
|
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2.14-2.15 |
|
Oil Cooler Maintenance . . . . . . . . . . . . . . . . . . . |
2.15 |
|
Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . |
2.15 |
|
Air Box Sediment Tube Service . . . . . . . . . . . . |
2.16 |
|
Breather Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2.16 |
|
Recoil Housing/PVT Drying . . . . . . . . . . . . . . . . |
2.16-2.17 |
|
Oil Level/Change/Filter . . . . . . . . . . . . . . . . . . . . |
2.17-2.18 |
|
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . |
2.19-2.20 |
|
Steering and Toe Alignment . . . . . . . . . . . . . . . |
2.20-2.22 |
|
Exhaust System Maintenance . . . . . . . . . . . . . |
2.22 |
|
Brake System Service . . . . . . . . . . . . . . . . . . . . |
2.23-2.24 |
|
Drive Chain and Sprocket Service . . . . . . . . . . |
2.24-2.26 |
|
Suspension Service / Controls . . . . . . . . . . . . . |
2.26-2.27 |
|
Wheel Removal / Installation . . . . . . . . . . . . . . . |
2.27 |
|
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2.28 |
|
2.1
MAINTENANCE
PERIODIC MAINTENANCE CHART
Inspection, adjustment and lubrication intervals of important components is listed in the following chart. Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 mph. Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
H = CAUTION: Due to the nature of these adjustments, it is recommended that service be performed by an authorized Polaris dealer.
" = Vehicles subjected to severe use (operation in wet or dusty areas, low speed heavy load operation, prolonged idle) should be inspected and serviced more frequently. For engine oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A rise in oil level in cold weather can indicate moisture collecting in the oil tank. Change oil immediately if oil level begins to rise.
E = |
Emission Control System Service (California). |
|
|
||
|
|
|
|
|
|
|
|
|
Frequency |
|
|
|
|
(Whichever comes first) |
|
||
|
|
|
|
|
|
|
Item |
Hours |
Calendar |
Miles |
Remarks |
|
|
|
|
(Km) |
|
|
|
|
|
|
|
E" |
Engine Oil - Level/Change |
100 hrs |
6 months |
1000 (1600) |
Check Level Daily; Break In service at 1 month |
|
|
|
|
|
|
E |
Oil Filter |
100 hrs |
6 months |
1000 (1600) |
Replace with oil change |
|
|
|
|
|
|
E" |
Air Filter - Foam Pre-Cleaner |
Daily |
Daily |
|
Inspect-Clean & oil more often in dirty conditions. |
|
|
|
|
|
|
E" |
Air Filter - Main Element |
Weekly |
Weekly |
|
Inspect - Replace if necessary |
|
|
|
|
|
|
" |
Air Box Sediment Tube |
- |
Daily |
|
Drain deposits whenever visible |
|
|
|
|
|
|
" |
Engine Breather Filter |
20 hrs |
Monthly |
200 (320) |
Inspect and replace if necessary |
|
|
|
|
|
|
" |
Oil Tank Vent Hose |
100 hrs |
12 months |
1000 (1600) |
Inspect hose routing /hose condition |
|
|
|
|
|
|
EH |
Valve Clearance |
100 hrs |
12 months |
1000 (1600) |
Inspect/Adjust |
|
|
|
|
|
|
E |
Idle Speed |
As required |
As required |
|
Adjust |
|
|
|
|
|
|
H |
Throttle Cable / ETC Switch |
50 hrs |
6 months |
500 (800) |
Inspect -Adjust, Lubricate, Replace if necessary |
|
|
|
|
|
|
|
Choke (Enricher) Cable |
50 hrs |
6 months |
500 (800) |
Inspect -Adjust, Lubricate, Replace if necessary |
|
|
|
|
|
|
|
Carburetor Float Bowl |
50 hrs |
6 months |
500 (800) |
Drain bowl periodically and prior to storage |
|
|
|
|
|
|
|
Carburetor Air Intake Ducts/Flange |
50 hrs |
6 months |
500 (800) |
Inspect all ducts for proper sealing/air leaks |
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|
EH |
Fuel System |
100 hrs |
12 months |
1000 (1600) |
Check for leaks at tank cap, lines, fuel valve, filter, |
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pump & carburetor. Replace lines every 2 years. |
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EH |
Fuel Filter |
100 hrs |
12 months |
1000 (1600) |
Replace filter annually |
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|
Coolant/Level Inspection |
Daily |
Daily |
|
Replace engine coolant every 2 years |
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|
Coolant Strength / Pressure Test |
100 hrs |
6 months |
1000 (1600) |
Inspect strength seasonally; Pressure test sys- |
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System |
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tem annually |
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|
Radiator |
100 hrs |
12 months |
1000 (1600) |
Inspect / Clean external surface |
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|
Cooling System Hoses |
100 hrs |
12 months |
1000 (1600) |
Inspect |
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Engine Mounts |
100 hrs |
12 months |
1000 (1600) |
Inspect |
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Drain Recoil Housing |
Weekly |
Weekly |
|
More often if operating in wet environment |
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Exhaust Muffler / Pipe |
100 hrs |
12 months |
1000 (1600) |
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ELECTRICAL |
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E |
Spark Plug |
100 hrs |
12 months |
1000 (1600) |
Inspect - Replace if necessary |
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Wiring |
100 hrs |
12 months |
1000 (1600) |
Inspect for abrasion, routing, security |
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Ignition Timing |
100 hrs |
12 months |
1000 (1600) |
Inspect |
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Battery |
20 hrs |
Monthly |
200 (320) |
Check terminals; Clean; Check fluid level |
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Headlight Aim |
As required |
As required |
|
Adjust if Necessary |
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Headlamp Inspection |
Daily |
Daily |
|
Check operation daily; Apply Nyogelt Grease |
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to connector when lamp is replaced |
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Tail Lamp Inspection |
Daily |
Daily |
|
Check Operation Daily; Apply Nyogelt Grease |
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to socket when lamp is replaced |
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2.2
MAINTENANCE
PERIODIC MAINTENANCE CHART, CONT.
CHASSIS
|
|
|
Frequency |
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|
(Whichever comes first) |
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||
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Item |
Hours |
Calendar |
Miles |
Remarks |
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|
(Km) |
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|
" |
General Lubrication |
50 hrs |
3 months |
500 (800) |
Lubricate All Fittings, Pivots, Cables, Etc. |
|
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|
|
" |
Front Hubs/Fluid Check |
50 hrs |
6 months |
500 (800) |
Check monthly |
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|
" |
Front Hubs/Fluid Change |
100 hrs |
12 months |
1000 (1600) |
Check monthly |
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|
H |
Front Wheel Bearings (2x4) |
Annually |
12 months |
|
Inspect and replace if necessary |
|
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|
H |
Front Hub Spindle Nut Torque |
Annually |
12 months |
|
Inspect Torque and Locking Fastener and re- |
|
(AWD Models) |
|
|
|
place if necessary |
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|
Drive Belt |
50 hrs |
6 months |
500 (800) |
Inspect - Adjust, Replace if Necessary |
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|
|
Clutches (Drive And Driven) |
100 hrs |
12 months |
1000 (1600) |
Inspect, Clean |
|
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|
" |
Transmission Oil Level |
25 hrs |
Monthly |
250 (400) |
Inspect Monthly; Change Annually |
|
|
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|
|
Shift Linkage |
50 hrs |
6 months |
500 (800) |
Inspect,Lubricate, Adjust |
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|
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|
|
H |
Steering |
50 hrs |
6 months |
500 (800) |
Inspect Daily, Lubricate |
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|
H |
Toe Adjustment |
As required |
As required |
|
Periodic Inspection, Adjust When Parts are Re- |
|
|
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|
placed |
|
|
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|
|
|
" |
Rear Axle |
50 hrs |
6 months |
500 (800) |
Inspect Bearings, Grease Fitting |
|
|
|
|
|
|
" |
Front Suspension |
50 hrs |
6 months |
500 (800) |
Inspect - Lubricate |
|
|
|
|
|
|
" |
Rear Suspension |
50 hrs |
6 months |
500 (800) |
Inspect - Lubricate |
|
|
|
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|
|
Drive Chain |
50 hrs |
6 months |
500 (800) |
Inspect Daily, Adjust and Lubricate if Needed |
|
|
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|
|
|
Tires |
Pre-ride |
Pre-ride |
|
Inspect Daily, Pre-Ride Inspection Item |
|
|
|
|
|
|
H |
Brake Fluid |
200 hrs |
24 months |
2000 (3200) |
Change Every Two Years |
|
|
|
|
|
|
" |
Brake Fluid Level |
Pre-ride |
Pre-ride |
|
Inspect Daily, Pre-Ride Inspection Item |
|
|
|
|
|
|
" |
Brake Lever Travel |
Pre-ride |
Pre-ride |
|
Inspect Daily, Pre-Ride Inspection Item |
|
|
|
|
|
|
H |
Brake Pad Wear |
10 hrs |
Monthly |
100 (160) |
Inspect Periodically |
|
|
|
|
|
|
|
Auxiliary Brake Adjustment |
As required |
As required |
|
Inspect Deflection Daily; Adjust |
|
|
|
|
|
|
|
Output Shaft Bearing |
Monthly |
Monthly |
|
Grease Monthly |
|
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|
Brake System |
Pre-ride |
Pre-ride |
|
Pre-Ride Inspection Item |
|
|
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|
Wheels |
Pre-ride |
Pre-ride |
|
Pre-Ride Inspection Item |
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|
Frame Nuts, Bolts, Fasteners |
Pre-ride |
Pre-ride |
|
Pre-Ride Inspection Item |
|
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|
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|
PRE-RIDE / DAILY INSPECTION
Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
GTires - check condition and pressures
GFuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank
GAll brakes - check operation and adjustment (includes auxiliary brake)
GThrottle - check for free operation and closing
GHeadlight/Taillight/Brakelight - check operation of all indicator lights and switches
GEngine stop switch - check for proper function
GWheels - check for tightness of wheel nuts and axle nuts; be sure axle nuts are secured by cotter pins
GDrive chain - condition and slack; refer to drive chain adjustment
GAir cleaner element - check for dirt; clean or replace
GSteering - check for free operation noting any unusual looseness in any area
GLoose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
GEngine coolant - check for proper level at the recovery bottle
2.3
MAINTENANCE
POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS
Part No. |
Description |
|
|
|
Engine Lubricant |
|
|
2870791 |
Fogging Oil (12 oz. Aerosol) |
|
|
2871281 |
Engine Oil (Quart) Premium 4 Synthetic |
|
0W--40 (4--Cycle) (12 Count) |
|
|
2871844 |
Engine Oil (Gallon) Premium 4 Synthetic |
|
0W--40 (4--Cycle) (4 Count) |
|
|
2871567 |
Engine Oil (16 Gallon) Premium 4 |
|
Synthetic 0W--40 (4--Cycle) |
|
|
Gearcase / Transmission Lubricants
2873603 Premium Synthetic Gearcase Lubricant (1
Gal.) (4 Count)
2873602 Premium Synthetic Gearcase Lubricant
(12 oz. bottle) (12 Count)
2871653 Premium Front Gearcase Fluid (8 oz.) (12 Count)
2871653 Premium Front Gearcase Fluid (2.5 Gal)
(2 Count)
2870465 |
Oil Pump for 1 Gallon Jug |
2871654 Premium Drive Hub Fluid (8 oz.) (12 Count)
2872277 Premium Drive Hub Fluid (2.5 gal.) (2 Count)
2871653 |
Angle Drive Fluid (8 oz.) |
Grease / Specialized Lubricants
2871322 |
Premium All Season Grease (3 oz. |
|
cartridge) (24 Count) |
|
|
2871423 |
Premium All Season Grease (14 oz. |
|
cartridge) (10 Count) |
|
|
2871460 |
Starter Drive Grease (12 Count) |
|
|
2871515 |
Premium U-Joint Lube (3 oz.) (24 Count) |
|
|
2871551 |
Premium U-Joint Lube (14 oz.) (10 Count) |
|
|
2871312 |
Grease Gun Kit |
|
|
2871329 |
Dielectric Grease (Nyogelt) |
|
|
|
Coolant |
|
|
2871323 |
60/40 Coolant (Gallon) (6 Count) |
|
|
2871534 |
60/40 Coolant (Quart) (12 Count) |
|
|
Additives / Sealants / Thread Locking Agents / |
|
|
Misc. |
|
|
2870585 |
Loctitet Primer N, Aerosol, 25 g |
|
|
2871956 |
Loctitet Thread Sealant 565 (50 ml.) (6 |
|
Count) |
|
|
2871949 |
Loctitet Threadlock 242 (50 ml.) (10 |
|
Count) |
|
|
2871950 |
Loctitet Threadlock 242 (6 ml.) (12 |
|
Count) |
|
|
2871951 |
Loctitet Threadlock 262 (50 ml.) (10 |
|
Count) |
|
|
2871952 |
Loctitet Threadlock 262 (6 ml.) (12 |
|
Count) |
|
|
2871953 |
Loctitet Threadlock 271 (6 ml.) (12 |
|
Count) |
|
|
2871954 |
Loctitet Threadlock 271 (36 ml.) (6 |
|
Count) |
|
|
2.4
2870584 Loctitet 680-Retaining Compound (10
ml.)
2870587 Loctitet 518 Gasket Eliminator / Flange Sealant (50 ml.) (10 Count)
2872113 Disk Brake Quiet (12 oz.) (12 Count)
2871326 Premium Carbon Clean (12 oz.) (12 Count)
2870652 Fuel Stabilizer (16 oz.) (12 Count)
2871957 Black RTV Silicone Sealer (3 oz. tube)
(12 Count)
2871958 Black RTV Silicone Sealer (11 oz. cartridge) (12 Count)
2870990 |
DOT3 Brake Fluid (12 Count) |
2872113 Disc Brake Quiet, Aerosol, (9 oz.) (12 Count)
2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)
2872893 Engine Degreaser (12oz.) (12 Count)
NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.
NOTE: Each item can be purchased separately at your local Polaris dealer.
MAINTENANCE
RECOMMENDED MAINTENANCE PRODUCTS - QUICK REFERENCE
Item |
Type |
Notes |
See |
|
|
|
Pages |
|
|
|
|
Engine Oil |
Polaris Premium 4 |
Add to proper level on dipstick. |
2.17-2.18 |
|
Synthetic, 0W--40 |
|
|
|
|
|
|
Transmission |
Polaris Synthetic Gear |
Refer to procedures outlined later in this |
2.8 |
|
Case Lubricant |
chapter. |
|
|
|
|
|
Brake Fluid |
Polaris DOT 3 Brake Fluid |
Fill to indicated level inside reservoir. |
2.23 |
|
|
|
|
MAINTENANCE QUICK REFERENCE
|
Ill. |
Item |
Lube Rec. |
Method |
Frequency* |
|
# |
|
|
|
|
|
|
|
|
|
|
|
1 |
Engine Oil |
Polaris 0W--40 |
Add oil to proper level. |
Change after 1st month, 6 months or 100 |
|
|
|
Synthetic |
|
hours thereafter; Change more often (25-50 |
|
|
|
|
|
hours) in extremely dirty conditions, or short |
|
|
|
|
|
trip cold weather operation. |
|
|
|
|
|
|
|
2 |
Transmission |
Polaris Synthet- |
Add lube to FULL level on dip- |
Change annually © |
|
|
|
ic Gear Case |
stick. |
|
|
|
|
Lubricant |
|
|
|
|
|
|
|
|
|
3 |
Brake Fluid |
Polaris DOT 3 |
Fill master cylinder reservoir to in- |
As required. Change fluid every 2 years. |
|
|
|
Brake Fluid |
dicated level inside reservoir. See |
|
|
|
|
|
Page 2.23. |
|
|
|
|
|
|
|
|
4 |
Drive Chain |
Polaris Chain |
Apply to chain link plates and roll- |
As required* |
|
|
|
Lube or O-Ring |
ers. |
|
|
|
|
chain lube |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Transmission |
|
|
|
|
|
Dipstick |
Dipstick
Operating |
Full |
Range |
|
1. Engine Oil |
2. Transmission |
Parking Brake Lock
Reservoir
4. Rear Drive Chain
2.5
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