Polaris 2005 SPORTSMAN 500, 2005 SPORTSMAN 400 Servise Manual

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SPORTSMAN 400/500

6(59,&(0$18$/

3199194

319919425

6(59,&(0$18$/

319919425

3199194

Page 2

2005 SPORTSMAN 400/500

SERVICE MANUAL

Foreword

This manual is designed primarily for use by Polaris ATV service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. The technician 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 propertools, as specified. Cleanliness of parts and tools as well as the work areaisof primary importance.

All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position.

This manualincludes procedures for maintenanceoperations, component identification andunit repair, along with service specifications for the 2005 Polaris Sportsman ATVs. A table of contents is placed at the beginning of each chapter, andan alphabetic index is provided at the endof the manual for location ofspecific page numbers and service information. Keep this manual available for reference in the shop area.

At the time of publication all information contained in this manual was technically correct. However, all materials and specifications are subject to change without notice.

Comments or suggestions about this manual may be directed to: Polaris Sales Inc., Service Publications Department, 2100 Hwy 55 Medina, Minnesota 55340.

2005 Sportsman 400/500 ATV Service Manual (PN 9919425)

ECopyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies 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 omissions 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.

Page 3

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 insevere 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 Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of the Warn Industries

Some Polaris factory publications can be downloaded from www.polarisindustries.comor purchased from

www.purepolaris.com or contact your nearest Polaris dealer.

Page 4

GENERAL

MAINTENANCE

ENGINE

CARBURETION

BODY AND STEERING

CLUTCHING

FINAL DRIVE

TRANSMISSION

BRAKES

ELECTRICAL

Page 5

GENERAL INFORMATION

Model Identification 1.2.......................

Serial Number Location 1.2...................

Publication Numbers 1.3.....................

Paint Codes 1.3.............................

Replacement Keys 1.3.......................

General Specifications - Sportsman 400/500 1.4-1.6.

Special Tools 1.7--1.12............................

Standard Torque Specifications 1.13............

Specs

Decimal Equivalent Chart 1.14.................

Conversion Table 1.15........................

Glossary of Terms 1.16........................

1.1

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GENERAL INFORMATION

MODEL IDENTIFICATION

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

Machine Model Number Identification

A05MH50AA

Year Designation

Basic Chassis Designation Engine Designation

Model Option

ENGINE DESIGNATION NUMBERS

42 EH42PLE Single, L/C, SOHC 4 Stroke, Electric Start...............

50 EH50PLE Single, L/C, SOHC 4 Stroke, Electric Start...............

VIN IDENTIFICATION

World Mfg. ID

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4XA MH

Body Style

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.

Vehicle Descriptor

50A* 5P0 00 000

Engine

Powertrain

Emissions

Check Digit

Model Year

Plant No.

Vehicle Identifier

Individual Serial No.

* This could be either a number or a letter

MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION

Engine model numberison recoilhousing (A). 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)

TRANSMISSION I.D. NUMBER LOCA

TION

The transmission I.D. number is located on top of the transmission snorkel, right side of machine.

1.2

Front

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PUBLICATION NUMBERS

GENERAL INFORMATION

Year Model Owner’s Manual PN Parts

Manual PN

2005 Sportsman 400 9919412 9919413 9919414 2005 Sportsman 500 9919412 9919416 9919417

NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com

Parts

Micro Fiche PN

ATV PAINT INFORMATION

FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147.

COLD WEATHER KITS FOR 4 CYCLE ATVS

Engine Heater -- (PN 2871507)

ACCESSORY ENGINE HEATER

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.

31XX

Key Series Number

Series # Part Number

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

1.3

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GENERAL INFORMATION

MODEL: 2005 Sportsman 400..........

MODEL NUMBER: A05MH42. ENGINE MODEL: 425..

SPECIAL TOOLS

PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN

PA--44689 Valve Clutch Adjuster 2

2872105 Water Pump Mechanical Seal Puller 2

8712100 or 8712500 Tachometer 2,10

2200634 Valve Seat Reconditioning Kit 3 2870390 Piston Support Block 3 2871043 Flywheel Puller 3 2871283 Crankshaft/Water Pump Seal Install Kit 3 5131135 Water Pump Install Kit 3 2870569 Crankshaft Truing Stand 5 2872314 Carburetor Float Adjustment Tool 4 2870975 Mity Vact Pressure Test Tool 3, 4, 9 2870871 Ball Joint Replacement Tool 5 2870872 Shock Spanner Wrench 2, 5 2870623 Shock Absorber Spring Compression Tool 5 2871572 Strut Rod Wrench 5 2871573 LH Strut Spring Compressor 5 2871574 RH Strut Spring Compressor 5 7052069 Charging Needle 5 2200421 Gas Shock Recharging Kit 5 2871352 Shock Rod Holding Tool 5 2871351 Foxt Shock IFP Depth Tool 5 2870506 Clutch Puller 6 9314177 Clutch Holding Wrench 6 2871358 Clutch Holding Fixture 6 2870341 Drive Clutch Spider Removal and Install Tool 6 2870654 Clutch Offset Alignment Tool 6 2870913 Driven Clutch Puller 6 2870910 Roller Pin Tool 6 2871226 Clutch Bushing Replacement Tool Kit 6 2870386 Piston Pin Puller 6 2872292 EBS Clutch Alignment Tool 6 2201379 EBS Bushing Replacement Kit 6 8700220 Clutch Compression Tool 6 2871025 Clutch Bushing Replacement Tool Kit 6 2871199 Seal Sleeve Installation Tool Kit 5, 7 2870888 Hilliard Clutch Garter Spring Installation Tool 7 2872608 Roller Pin Removal Tool 7

8700226 CV Boot Clamp Pliers 7 2871701 (Part of 2871702 Kit) 2 1/8 inch Wrench 8 2871697 (Part of 2871702 Kit) Center Drive Bushing Tool 8 2871695 (Part of 2871702 Kit) Backlash Setting Tool 8 2871698 (Part of 2871702 Kit) Rear Output Seal Driver 8 2871699 (Part of 2871702 Kit) Rear Driveshaft Seal Guide 8

2871282 Bearing Seal Driver (50 mm) 8

PV--43568 Fluket77 Digital Multimeter 10

2870630 Timing Light 10

2870836 Battery Hydrometer 10

1.7

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GENERAL INFORMATION

SPECIAL TOOLS, CONT’D

2460761 Hall Sensor Probe Harness 10

2871745 Static Timing Light Harness 10

NOTE: Polaris dealers can order the tools listed above through their Polaris Special Service Tools catalog.

SPECIAL TOOLS

Special Tools maybe required while servicing your machine. Some of the tools listed are mandatory and other tools maybe substituted with a similar tool, if available. Polaris reccommends the use of Polaris special tools when servicing any Polaris product.

Standard Tools and Engine Tools

PU--45432 -- Caliper or A Basic Caliper

Basic Micrometer

Standard Tools and Engine T

ools

2870569 -- Crankshaft True Kit

2870386 -- Piston Pin Puller

2871445 -- Piston Pin Puller Adapter

2871043 -- Flywheel Puller

2870773 -- C--Clip Install Tool

2870967 -- Slotted Nut Socket

8700229 -- Flywheel Holder & Adapter

1.8

2870968 -- Counter Balance Puller

PV--43527 Oil Filter Wrench

PA--44689 -- Valve/Clutch Adjuster

2870390 -- Piston Support Block

Page 13

Standard Tools and Engine Tools

GENERAL INFORMATION

2870303 -- Hone Kit

2870305 -- Stone Replacement Kit

2870588 -- Hone Oil (12 oz.)

2200634 -- Valve Seat

Reconditioning Kit

2871283 -- Crank/Water Pump Seal

Install Kit

Clutch (PVT) T

2870506 -- Drive Clutch Puller

2870913 -- Driven Clutch Puller

2870654 -- ATV Clutch Align Tool

ools

2870459 -- Dial Indicator

PV--35667--A -- Cylinder Leak

down Tester

2872105 -- Water Pump Seal Puller

2872292 -- EBS Clutch Align Tool

9914177--A -- Drive Clutch Holding Tool

8700220 -- Clutch Compression Tool

1.9

Page 14

GENERAL INFORMATION

Clutch (PVT) Tools

2870341 -- Drive Clutch Spider

Removal Tool

2870910 -- Roll Pin Tool

2871025 -- Clutch Bushing Replace

Tool Kit

Suspension Tools

2870871 -- ATV Ball Joint Tool Kit

2871071 -- Shock Body Holding Tool

2871226 -- Clutch Bushing

Replacement Kit

2201379 -- EBS Bushing

Replacement Kit

2870338 -- Spider Nut Socket

2870623 -- Shock Spring Compressor

2871572 -- Strut Rod Wrench

2871573 & 2871574 -- Strut

Spring Compressor

8700225 & 8700226 -- CV Boot

Clamp Pliers

2871358 -- Clutch Holding Fixture

1.10

Page 15

GENERAL INFORMATION

Suspension Tools

2870872 -- Shock Spanner Wrench

2872608 -- Roll Pin Removal Tool

2871351 -- Shock IFP Depth Tool

Transmission Tools

Fuel & Brake Systems

2870975 -- Mity Vac

Electrical T

PV--43568 --Fluke 77 Multimeter

ools

2871702 -- Shaft Drive Transmission

& Front Gearcase Tool Kit

2871282 -- Bearing/Seal Driver

(50 mm)

PV--39617 -- Current Clamp

2870836 -- Battery Hydrometer

RPM

8712500 -Tachometer

PV--39951--A -Tachometer

1.11

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GENERAL INFORMATION

Electrical Tools

2870630 -- Timing Light

2871745 --Static Timing Light Harness

2460761 -- Hall Sensor Probe Harness

PV--39991 -- Peak Reading Adapter

PV--37453 -- Christie Se--Sulfating

Multi--Battery Charger

PV--63070 -- Christie Multi--Battery

Charger

1.12

Page 17

GENERAL INFORMATION

STANDARD TORQUE SPECIFICATIONS

The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

Torque in. lbs.

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

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

Torque ft. lbs. (Nm)*

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

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

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

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

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

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

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

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

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

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

(Nm)

Metric

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

*To convert ft. lbs. to Nm multiply foot pounds by .1.382 *To convert Nm to ft. lbs. multiply Nm by .7376.

SPECIFIC TORQUE VALUES OF FASTENERS

Refer to exploded views in the appropriate sectionTorque Conversions

1.13

Page 18

GENERAL INFORMATION

SAE TAP DRILL SIZES

Thread Size/Drill Size Thread Size/Drill Size

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

1/2-13 27/64 1/2-20 29/64 9/16-12 31/64 9/16-18 33/64 5/8-11 17/32 5/8-18 37/64 3/4-10 21/32 3/4-16 11/16 7/8-9 49/64 7/8-14 13/16 1-8 7/8 1-12 59/64 1 1/8-7 63/64 1 1/8-12 1 3/64 11/4-7 17/64 1 1/4-12 1 11/64 11/2-6 111/32 1 1/2-12 1 27/64 13/4-5 19/16 1 3/4-12 1 43/64 2-4 1/2 1 25/32 2-12 1 59/64 2 1/4-4 1/2 2 1/32 21/2-4 21/4 23/4-4 21/2 3-4 2 3/4

METRIC TAP DRILL SIZES

Tap Size Drill Size Decimal

Equiva-

lent

3x.50 3x.60 4x.70 4x.75 5x.80 5x.90 6 x 1.00 7 x 1.00 8 x 1.00 8 x 1.25 9 x 1.00 9 x 1.25 10 x 1.25 10 x 1.50 11 x 1.50 12 x 1.50 12 x 1.75

#39 3/32 #30 1/8 #19 #20 #9 16/64 J 17/64 5/16 5/16 11/32 R 3/8 13/32 13/32

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3437

0.339

0.375

0.406

Nearest

Fraction

3/32 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32

DECIMAL EQUIVALENTS

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

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

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

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

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

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

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

1/8. .1250...

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

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

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

3/16 .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

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

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

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

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

53/64 .8281...............

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

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

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

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

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

..............

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

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

3/4 .75....

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

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

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

7/8 .875....

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

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

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

11.0.....

1.14

Page 19

GENERAL INFORMATION

CONVERSION TABLE

Unit of Measure Multiplied by Converts to

ft. lbs. x12 =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 9.807 =Nm in. x 25.4 =mm mm x .03937 =in. in. x2.54 =cm mile (mi.) x1.6 =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) x1.76 = Imperial pints (Imp pt) Imperial quarts (Imp qt) x 1.137 = Liters (l) Liters (l) x0.88 = 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) x0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

π (3.14) xR2x H (height) = Cylinder Volume

°Cto°F: 9 (°C + 40) ÷ 5-40=°F °Fto°C: 5 (°F + 40) ÷ 9-40=°C

1.15

Page 20

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 drivenclutches are offset so thatdrive belt will staynearly straight as itmoves along the clutchface. Clutch Weights: Three levers in thedrive clutch which relative totheirweight,profile andengine RPM cause thedrive

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.

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

lbs/in Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage 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. SeizedPiston: Galling of thesides of a piston. Usually there isa transfer of aluminum fromthe pistononto 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.

: Kilograms per square centimeter.

: Pounds per square inch.

1.16

Page 21

MAINTENANCE

Periodic Maintenance Chart 2.2-2.5...............

Lubricant and Maintenance Product Numbers 2.6--2.7

ATV Component Locations 2.8................

Lubrication Charts 2.9........................

Front Gearcase Lubrication 2.10-2.11................

Transmission Lubrication 2.11-2.12..................

Lubrications Points 2.12--2.13.......................

Transmission Linkage Adjustment 2.13..........

Carburetor / Throttle Adjustments 2.13-2.16..........

Fuel System 2.16-2.17.............................

Compression Test 2.18........................

Battery Maintenance 2.19......................

Coolant System Maintenance 2.19-2.21..............

Air Filter Service 2.21-2.22.........................

Air Box Sediment Tube Service 2.22............

Breather Filter 2.23...........................

Recoil Housing 2.23...........................

Oil Change/Filter 2.24-2.26.........................

Valve Clearance 2.26-2.27.........................

Steering and Toe Alignment 2.27-2.30...............

Exhaust System Maintenance 2.31.............

Brake System Service 2.31-2.32....................

Suspension Service 2.33......................

Controls 2.33.................................

Wheel Removal/Installation 2.34................

Tire Inspection 2.34...........................

Compartment Storage 2.35....................

Warnt Winch Operation 2.36--2.37..................

Cleaning and Storage of ATV 2.38--2.39..............

2.1

Page 22

MAINTENANCE

PERIODIC MAINTENANCE CHART

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

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

NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment

procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 milesperhour. Vehiclessubjected tosevereuse must be inspected and serviced more frequently.

Severe Use Definition

S Frequent immersion in mud, water or sand S Racing or race-style high RPM use S Prolonged low speed, heavy load operation S Extended idle S Short trip cold weather operation

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

Maintenance Chart Key

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

H= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed

by an authorized Polaris dealer.

"= SEVERE USE ITEM ----If vehicle is subjected to severe use, decrease interval by 50%

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

E= Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING: Improperly performing the procedures marked with a

to serious injury or death. Have an authorized Polaris dealer perform these services.

J could result in component failure and lead

2.2

Page 23

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)

Steering

Front suspension

Rear suspension Tires

Brake fluid level

Brake lever travel Brake systems Wheels/fasteners Frame fasteners

Engine oil level

Air filter, pre-filter

Air box sediment

tube Coolant

Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride

Daily

Make adjustments as needed. See Pre-Ride Checklist on Page 1.7.

Inspect; clean often

Drain deposits when visible

Check level daily, change coolant every 2 years

(if applicable) Headlamp/tail

lamp

Air filter,

main element Recoil housing

Daily

Weekly

Check operation; apply dielectric grease if replacing

Inspect; replace as needed

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

Brake pad wear 10 H Monthly 60 (100) Inspect periodically

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

Front gearcase oil

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

(if equipped)

Middle gearcase

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

oil (if equipped)

Rear gearcase oil

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

(if equipped)

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

Remarks

" Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.

2.3

Page 24

MAINTENANCE

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Engine breather

filter (if equipped)

Engine oil change

(break-in)

General

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

25 H 1M 155 (250) Perform a break-in oil change at one month

50 H 3M 310 (500) Lubricate all fittings, pivots, cables, etc.

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

Steering 50 H 6M 310 (500) Lubricate

Front suspension 50 H 6M 310 (500) Lubricate

Rear suspension 50 H 6M 310 (500) Lubricate Carburetor float

50 H 6M 310 (500) Drain bowl periodically and prior to storage

bowl

Throttle Cable/

ETC Switch

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

E E

Carburetor air

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

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

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

(if applicable)

50 H 6M 310 (500) Inspect coolant strength

seasonally; pressure test system yearly

Engine oil change 100 H 6M 620

Oil filter change 100 H 6M 620

Oil tank vent hose 100 H 12 M 620

Valve clearance 100 H 12 M 620

(1000)

Perform a break-in oil change at 25 hours/one month

Replace with oil change

Inspect routing, condition

Inspect; adjust

" Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.

2.4

Page 25

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

Fuel system 100 H 12 M 620

Fuel filter 100 H 12 M 620

Radiator

100 H 12 M 620

(if applicable)

Cooling hoses

100 H 12 M 620

(if applicable)

Engine mounts 100 H 12 M 620

Exhaust muffler/

100 H 12 M 620

pipe

Spark plug 100 H 12 M 620

Ignition Timing 100 H 12 M 620

Wiring 100 H 12 M 620

Clutches (drive

100 H 12 M 620

and driven)

Front wheel

100 H 12 M 1000

bearings

Brake fluid 200 H 24 M 1240

Spark arrestor 300 H 36 M 1860

Idle speed

Toe adjustment

Auxiliary brake

Headlight aim

(Km)

(1000)

(1600)

(2000)

(3000)

Remarks

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

Replace yearly

Inspect; clean external surfaces

Inspect for leaks

Inspect

Inspect; replace as needed

Inspect

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

Inspect; clean; replace worn parts

Inspect; replace as needed

Change every two years

Clean out

Adjust as needed Inspect periodically; adjust when parts are re-

placed Inspect daily; adjust as needed

Adjust as needed

" Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.

2.5

Page 26

MAINTENANCE

POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS

Part No. Description

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2 Cycle Engine Oil (Quart) (12

Count)

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

2873602 Premium Synthetic AGL Gearcase Lube

(12 oz. bottle) (12 Count)

2873603 Premium Synthetic AGL Gearcase Lube

(1 Gal.) (4 Count)

2871653 Premium ATV Angle Drive Fluid

(8 oz.) (12 Count)

2872276 Premium ATV Angle Drive Fluid

(2.5 Gal) (2 Count)

2870465 Oil Pump for 1 Gallon Jug 2871654 Premium Demand Drive Hub Fluid

(8 oz.) (12 Count)

2872277 Premium Demand Drive Hub Fluid

(2.5 gal.) (2 Count)

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)

Part No. Description

Additives / Sealants / Thread Locking Agents /

Misc.

2870585 Loctitet Primer N, Aerosol, 25 g 2871956 Loctitet Thread Sealant 565

(50 ml.) (6 Count)

2871949 Loctitet Threadlock 242

(50 ml.) (10 Count)

2871950 Loctitet Threadlock 242

(6 ml.) (12 Count)

2871951 Loctitet 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)

2870584 Loctitet 680-Retaining Compound

(10 ml.)

2870587 Loctitet 518 Gasket Eliminator / Flange

Sealant (50 ml.) (10 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) 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.

POLARIS LUBRICANT SYMBOL IDENTIFICATION

0W/40

Polaris Synthetic OW--40 Oil

DHF

Polaris Demand Drive Hub Fluid

Polaris All Season Grease

Polaris DOT 3 Brake Fluid

AGL

Polaris Synthetic Gearcase Lube

AGL

U--Joint

Polaris U--Joint Lube

2.6

ADF

Polaris ATV Angle Drive Fluid

Page 27

MAINTENANCE

POLARIS LUBRICANTS/FLUIDS FOR SPORTSMAN MODELS

Pure Polaris Lubricants and Maintenance Kits can be purchased at your local Polaris dealer.

ATV Angle Drive Fluid

2859061 -- Sportsman 500 Maintenance Kit

-- Oil Filter & 3 Qts. of 0W--40 oil

-- EBS Drive Belt

-- PVT Cover Seal

-- Spark Plug

-- Instruction Sheet

2873554 -- Sportsman 400/500 Oil Change Kit

-- Oil Filter & 3 Qts. of 0W--40 oil

-- Reservoir Gasket

--DrainPlugGasket

-- Instruction Sheet

2.7

Page 28

MAINTENANCE

SPORTSMAN 400/500 COMPONENT LOCATIONS

Instrument Cluster

Brake Fluid Reservoir

Brake Lever

Light Control & Run Switch

Worklight

Reverse Override

(Speedometer)

AWD Switch

Throttle

Front Storage Compartment &Rack

Front Gearcase

(Behind Radiator)

Fuel Valve

Oil Dipstick

PVT Cover

Gas Cap

Choke

Ignition/Key

Rear Storage Compartment

2.8

Gear Shifter

Muffler

Transmission

Right Side View

Front Drive Shafts

Front Prop Shaft

(Between Transmission

and Front Gearcase)

Engine Recoil

Auxiliary Brake

Page 29

LUBRICATION

MAINTENANCE

Ill.

Item

1 Engine Oil

2 Transmis-

sion

3 Brake Fluid

4 Front Gear-

case

5 Ball Joints

6 Propshaft

Yoke

Lube Required Method Frequency*

Polaris 0W--40 Synthetic (PN

2871567)

AGL Gearcase Lubricant (PN 2873602)

Polaris DOT 3 Brake Fluid (PN 2870990)

Polaris Demand Drive Hub Fluid (PN

2871654) All Purpose Grease Locate fittings and grease - 3

Premium U-Joint Grease ¢ (PN 2871551)

Add oil to proper level, see procedure.

Add lube to bottom of fill plug hole threads.

Fill master cylinder reservoir to indicated level inside reservoir.

Add oil to proper level, see procedure.

pumps maximum Locate fittings and grease - 3

pumps maximum

Change after 1st month, 6 months or 100 hours thereafter; Change more often (25-50 hours) in extremely dirty conditions, or short trip cold weather operation.

Change annually ©

As required. Change fluid every 2 years.

Change annually ©

Annually©

NOTE: Refer to Page 2.6 for the Polaris Lubricant Identification table. * More often under severe use, such as operated in water or under severe loads.

¡ Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)

More often under severe conditions (operating in water or hauling heavy loads)

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

Mobilegrease Special

0W/40

Oil Filter

Dipstick

Oil Fill Plug

1. Engine Oil and Filter

Master Cylinder Reservoir

AGL

DHF

3 Transmission

Fill Plug

Drain

3. Brake Fluid (Left hand Master Cylinder)

Plug

4. Front Gearcase

(Centralized Hilliard)

5. Hub Strut

6. Propshaft Yoke (3 pumps max.)

2.9

Page 30

MAINTENANCE

PRE-RIDE / DAILY INSPECTION

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

S Tires - check condition and pressures S Fuel and oil tanks - fill both tanks to their

proper level; Do not overfill oil tank

S All brakes - check operation and adjustment

(includes auxiliary brake)

S Throttle - check for free operation S Headlight/Taillight/Brakelight - check operation

of all indicator lights and switches

S Engine stop switch - check for proper function S Wheels - check for loose wheel nuts and axle

nuts; check to be sure axle nuts are secured by cotter pins

S Air cleaner element - check for dirt or water;

clean or replace

S Steering - check for free operation, noting any

unusual looseness in any area

S Loose parts - visually inspect vehicle for any

damaged or loose nuts, bolts or fasteners

S Engine coolant - check for proper level at the

recovery bottle

FRONT GEARCASE SPECIFICATIONS

Specified Lubricant:

Premium Demand Drive Hub Fluid (PN 2871654)

Capacity:.........5.0 Oz. (150 ml.)

Fill Plug Torque: 8--10 ft.lbs. (11--14 Nm) Drain Plug Torque: 11 ft. lbs. (15 Nm)

FRONT GEARCASE

Make sure vent is unobstructed

Fill plug

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

11 ft.lbs. (15 Nm)

ILL. 1

Drain plug

To check the lubricant level:

FRONT GEARCASE LUBRICA

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

S Be sure vehicle is level before proceeding and in

PARK.

S Check vent hose to be sure it is routed properly

and unobstructed.

S The correct front gearcase lubricant to use is

Polaris Premium Demand Drive Hub Fluid.

TION

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

2.10

Page 31

MAINTENANCE

To change gearcase lubricant:

11 ft.lbs (15 Nm)

View Under Front of ATV

1. Remove gearcase drain plug (A) (11 mm) located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly.

2. Clean and reinstall drain plug (A) using a new sealing washer toque to 11 ft.lbs. (15 Nm).

Drain Plug

TRANSMISSION LUBRICA

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

SPORTSMAN 400/500 TRANSMISSION

TION

Drain Plug

Location: Left Rear Wheel Area

Fill Plug

Left Side View Front Wheel

3. Remove fill plug (8 mm hex).

4. Fill with the recommended fluid amount (5 oz.) or to the bottom of the fillplughole threads. (SeeILL.

3).

Front Gearcase

Plug Threads

Fill with 5 oz. lubricant or bottom of fill plug threads.

5. Install fill plug and check for leaks.

DHF

ILL. 3

Location: Right Side Footwell

Drain Plug

S Be sure vehicle is level before

proceeding.

S Check vent hose to be sure it is

routed properly and unobstructed.

2.11

Page 32

MAINTENANCE

TRANSMISSION SPECIFICATIONS

Specified Lubricant:

AGL Gearcase Lubricant: (PN 2873603) (Gallon) (PN 2873602) (12 oz.)

Capacity: At change: Approx. 32 oz.....

Drain Plug & Fill Plug:

22 ft. lbs. (30 Nm)

To check the level:

(948 ml)

1. Remove fill plug.

2. Fluid should be filled to bottom of fill plug hole threads. Add the proper lubricant as required to bring level into operating range as shown.

Oil Fill Plug

AGL

Oil Fill Level--

Bottom Fill Plug

Hole Threads

To change lubricant:

2. Remove thedrainplug andwipe the magnetic end clean to remove accumulated metallic filings.

3. After the oil has drained completely, install a new sealing washer (if installed) and install the drain plug. Torque to 22 ft.lbs. (30 Nm).

4. Add the proper lubricant through the fill plug hole until the oil levelis tothe bottom of the fill plughole threads (See Illustration above). Do not overfill.

5. Check for leaks.

6. Reinstall skid plate if removed in Step 1.

LUBRICATIONS / GREASE POINTS

As shown on Page 2.7, there are 3 grease zerks on the Sportsman, two front ball joints and front prop shaft.

1. Place a drain pan beneath the transmission oil drain plug area.

S Elevate the front of the machine

using a proper lifting device or automotive approved ramps.

S This will ensure that the oil in the

transmission is properly drained.

2.12

Ball Joint Zerk

Page 33

Ball Joint Zerk

View -- Right Side Under Recoil Housing

MAINTENANCE

2. Note orientation of tie rodend studs with the ends that are up down (vertical). Remove both rod end bolts from transmission bell crank.

Shifter Mount

Shifter

SHIFT LINKAGE INSPECTION

NOTE: Shift rod is preset at time of manufacture.

Shift Linkage Rod

1. Inspect shift linkage tie rod ends, clevis pins, and pivot bushings and replace if worn or damaged. Lubricate the tie rod ends with a light aerosol lubricant or grease.

Shift Linkage Rod

THROTTLE INSPECTION

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

1. Place the gear selector in Park.

2. Set parking brake.

3. Start the engine and let it idle.

4. Turn handlebars from full right to full left. If idle speed increases at any point inthe turning range, inspect throttle cable routing and condition. Adjust cable tension as needed until lock--to--lock turning can be accomplished with no rise in engine rpm.

5. Replace the throttle cable if worn, kinked, or damaged.

Ill. 1

ETC Cover

Removal Sequence

2.13

Page 34

MAINTENANCE

To remove the ETC cover:

1. Use a medium flat blade screwdriver and insert blade into the pocket of the cover starting on the #1 position.

2. Twist screwdriver slightly whilelifting on the cover to release snap.

3. Repeat procedure at the other five locations as shown. NOTE: Do not attempt to remove cover until all latch points are released.

CHOKE (ENRICHER) ADJUSTMENT

PILOT SCREW

The pilotsystemsuppliesfuelduring engineoperation with the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet.

CAUTION:

The pilot screwis calibrated at thefactory to meet EPA / CARB regulations for air quality standards and is sealed with a brass plug to prevent tampering. Removal of the tamper proof plug is not permitted. For service purposes, cleaning of the pilot circuit can be done only by a certified repair shop to ensure air quality standards are not exceeded.

Pilot Screw location

Boot

If the choke knob does not stay out when pulled, adjust the choke tension by tightening (clockwise) the jam nut under the rubber boot between the choke knob and nut. Firmly grasp the rubber boot and tighten until the choke slides freely but stays out when pulled.

Brass Plug Installed

Brass Plug Removed

2.14

Page 35

MAINTENANCE

PILOT SCREW ADJUSTMENT

FRONT (Engine)

Pilot Screw

View -- Right Sise Panel Removed

6. Slowly turn mixture screw counterclockwise until idle speed increases to maximum RPM. Continue turning counterclockwise until idle RPM begins to drop.

7. Center the pilot screw between the points in Step 5 and 6.

8. Re adjust idle speed if not within specification.

IDLE SPEED ADJUSTMENT

CV Carburetor

Idle Screw

Pilot Screw

1. Start engine and warm it up to operating temperature (about 10 minutes).

2. Turn pilot screw in (clockwise) until lightly seated. Turn screw out the specified number of turns. NOTE: Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be permanently damaged.

Pilot screws are calibrated at the factory. Each carburetor has a slightly different pilot screw setting. The specifications below are the “base” recommended setting, and may require additional tuning to achieve the desired results.

Pilot Screw Adjustment: Sportsman 400 -- 2 3/4 Turn Out Sportsman 500 -- 2 Turns Out

3. Connect an accurate tachometer that will read in increments of + or -- 50 RPM such as the PET 2100DX (PN 8712100DX) or the PET 2500 (PN

8712500).

4. Set idle speed to 1200 RPM. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.

5. Slowly turn mixture screw clockwise using the pilot screw wrench until engine begins to miss.

1. Start engine and warm it up thoroughly.

2. Adjust idle speed by turning the idle adjustment screw in (clockwise) to increase or out (counterclockwise) to decrease RPM. (Refer to Ill. at right).

NOTE: Adjusting the idle speed affects throttle cable freeplay and electronic throttle control (ETC) adjustment. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.

Idle Speed:

1100 +/-- 200 RPM

2.15

Page 36

MAINTENANCE

THROTTLE CABLE / ELECTRONIC CONTROL (ETC

THROTTLE

SWITCH)

ADJUSTMENT

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

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

3. Start engine and set idle to specified RPM.

Boot

Ill. 1

NOTE: Be sure the engine is at operating temperature. See Idle Speed Adjustment.

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

5. Turn adjuster until 1/16″ to 1/8″ freeplay is achieved at thumb lever. (Ill. 2). After making adjustments, quickly actuate the thumb lever several times and verify freeplay.

Adjuster Sleeve

Locknut

Boot

FUEL SYSTEM

WARNING

Gasoline is extremely flammable and explosive under certain conditions.

S Always stop the engine and refuel

outdoors or in a well ventilated area.

S Do not smoke or allow open

flames or sparks in or near the area where refueling is performed orwheregasolineisstored.

S Do not overfill the tank. Do not fill

the tank neck.

S If you get gasoline in your eyes or

if you swallow gasoline, seek medical attention immediately.

S If you spill gasoline on your skin

or clothing, immediately wash it off with soap and water and change clothing.

S Never start the engine or let it run

in an enclosed area. Engine exhaust fumesare poisonousand can result loss of consciousness or death in a short time.

S Never drain the float bowl when

the engine is hot. Severe burns may result.

FUEL LINES

Direction of travel

Ill. 2

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

7. Turn handlebars from left to right through the entire turning range. If idle speed increases, check for proper cable routing. If cable is routed properly andin goodcondition, repeatadjustment procedure.

1/16″ -1/8″

Freeplay

2.16

Fuel Pump

Inspect

Fuel Lines

Inspect

1. Check fuel lines for signs of wear, deterioration, damage or leakage. Replace if necessary.

2. Besurefuel lines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked or pinched.

3. Replace all fuel lines every two years.

NOTE: See Chapter 4 for fuel line routing diagram.

Page 37

MAINTENANCE

VENT LINES

Check fuel tank, oil tank, carburetor, battery and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years.

Be sure vent lines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked or pinched.

FUEL FILTER

The fuel filter should be replaced in accordance with the Periodic Maintenance Chart or whenever sediment is visible in the filter.

Arrow Indicates Direction of Flow

Ill. 2

To Carburetor

CARBURETOR DRAINING

The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl, or before extended periods of storage.

NOTE: The bowl drain screw islocatedon the bottom left side of the float bowl.

1. Turn fuel valve to the OFF position.

2. Place a clean container beneath the bowl drain spigot or bowl drain hose.

3. Turn drain screw out two turns and allow fuel in the float bowl and fuel line to drain completely.

4. Inspect the drained fuel for water or sediment.

5. Tighten drain screw.

6. Turnfuelvalveto“ON”.

7. Start machine and check for leaks.

NOTE: All tubes attached to the carburetor must be check for pinching or blockage, as this will effect engine performance

General Fuel Filter Location

1. Shut off fuel supply at fuel valve.

2. Remove seat and locate filter on right side of atv. NOTE: Remove side panel if necessary.

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

4. Remove fuel lines from filter.

5. Install new filter and clamps onto fuel lines with arrow pointed in direction of fuel flow.

6. Install clamps on fuel line.

7. Turn fuel valve “ON”.

8. Start engine and inspect for leaks.

Drain tube attached here

Ill. 1

Fuel Valve Located Left Side Panel

OFF

Drain Screw

2.17

Page 38

MAINTENANCE

COMPRESSION TEST

NOTE: 4-Stroke 500 and 425 engines are equipped

with an automatic decompressor. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about 50-90 psi

Smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition problems above idle speed. Abnormally high compression can be caused by a decompressor malfunction, or worn or damaged exhaust cam lobes. Inspect camshaft and automatic decompression mechanism if compression is abnormally high.

A cylinder leakage test isthe best indication ofengine condition on models with automatic decompression. Follow manufacturer’s instructions to perform a cylinder leakage test. (Never use high pressure leakage tester as crankshaft seals may dislodge and leak).

Cylinder Compression Standard 50-90 PSI

Cylinder Leakage Service Limit 10 %

(Inspect for cause if leakage exceeds 10%)

during a compression test.

ENGINE MOUNTS

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

SPARK PLUG

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

2. Remove spark plug.

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

4. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used.

5. Measure gap with a wire gauge. Refer to specifications for proper spark plug type and gap. Adjust gap if necessary by bending the side electrode carefully. (Ill. 1)

6. If necessary, replace spark plug with proper type. CAUTION: Severe engine damage may occur if the incorrect spark plug is used.

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

8. Install spark plug and torque to specification.

Recommended Spark Plug:

NGK BKR5E

2.18

Spark Plug Torque:

14 Ft. Lbs. (19 Nm)

Spark Plug Gap

.036″ (0.9 mm)

Page 39

MAINTENANCE

BATTERY MAINTENANCE

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote:

External: Flush with water. Internal: Drink large quantities of water or

milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

hours at a current equivalent of 1/10 of the battery’s rated amp/hour capacity (i.e. 12amp hr x .10 = 1.2 amp charging). Do not use the alternator to charge a new battery.

Low--Maintenance batteries are permanently sealed at the time of manufacture. The use of lead--calcium and AGM technology instead of lead--antimony allows the battery acid to be fully absorbed. For this reason, a Low--Maintenance battery case is dark and the cell caps are not removable, since there is no need to check electrolyte level.

NEVER Low--Maintenance battery. Doing so will damage the case and shorten the life of the battery. Refer to the Battery Maintenance Video (PN 9917987) for proper instruction on servicing batteries.

NOTE: New Batteries: charged before useorbatterylifewillbe reduced by 10-30%of full potential. Charge battery for 3--5 hours at a current equivalent of 1/10 of the battery’srated amp/hourcapacity. Do not usethe alternator to charge anew battery.(Referto Battery Activation and Maintenance video PN 9917987)

attempt to add electrolyte or water to a

Batteries must be fully

The battery is located under the left rear fender.

Battery Location

NOTE: All 2005 Sportsman 400/500 ATV batteries areLowMaintenance indesign and construction. All Low Maintenance batteries are fully charged and tested at the factory before installation. Expected shelf life is 6--8 months depending on storage conditions. As a general rule before placing the battery into service, check the battery condition and charge accordingly.

New Batteries: before use or battery life can be reduced by 10-30% of full potential. Charge battery for 3--5

Batteries must be fully charged

LIQUID COOLING SYSTEM OVER

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

As coolant operating temperature increases, the expanding(heated)excesscoolantisforcedoutofthe radiator past the pressure cap and into the recovery bottle. Asenginecoolanttemperaturedecreasesthe contracting(cooled)coolantisdrawnbackupfromthe tank past the pressure cap and into the radiator.

Some coolant level droponnew machines is normal asthesystemispurgingitselfoftrappedair. Observe coolant levels often during the break-in period.

Overheating of engine could occur if air is not fully purged from system.

PolarisPremium60/40isalreadypremixedandready to use. Do not dilute with water.

VIEW

COOLANT STRENGTH / TYPE

Test the strength of the coolant using an antifreeze hydrometer.

2.19

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MAINTENANCE

Antifreeze Hydrometer

S A 50/50 or 60/40 mixture of antifreeze

and distilled water will provide the optimum cooling, corrosion protection, and antifreeze protection.

S Do not use tap water, straight antifreeze,

or straightwater inthesystem. Tapwater contains minerals and impurities which build up in the system.

S Straight water or antifreeze may cause

the system to freeze, corrode, or overheat.

Polaris 60/40 Anti-Freeze / Coolant

(PN 2871323)

RADIATOR/GRILL SCREEN

1. Check radiator (A) air passages for restrictions or damage. Check and clean the radiator screen (B).

2. Carefully straighten any bent radiator fins.

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

COOLING SYSTEM HOSES

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

2. Check tightness of all hose clamps.

CAUTION:

COOLING SYSTEM PRESSURE

Refer to Page 3.6 for pressure test procedure.

TEST

COOLANT LEVEL INSPECTION

The recovery bottle, located on the left side of the machine, mustbe maintainedbetween theminimum andmaximumlevelsindicatedontherecoverybottle.

Recovery Bottle Accessible Under Side Panel

Do not over-tighten hose clamps at radiator, or radiator fitting may distort, causing a restriction to coolant flow. Radiator hose clamp torque is36 in. lbs. (4 Nm).

2.20

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

Page 41

MAINTENANCE

1. Remove reservoir cap. Inner splash cap vent hole must be clear and open.

2. Fill reservoir to upper mark with Polaris Premium 60/40 Anti Freeze / Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.

3. Reinstall cap.

NOTE: If overheating isevident, allowsystem to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system.

RADIATOR SCREEN REMOV

1. Pull out slightly on the top of the radiator screen.

2. With the top free, pull out on the bottom of the screen to remove the screen.

3. To install the screen, simply press the tabs on the screen back into the mounting grommets. Be sure the screen is securely in place.

RADIATOR COOLANT LEVEL INSPECTION

NOTE: This procedure is only required if the cooling

system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, or if overheating is evident, the level in the radiator should be inspected and coolant added if necessary.

WARNING Never remove the pressure cap

when the engine is warm or hot. Escaping steam can cause severeburns. The engine mustbecool before removing the pressure cap.

NOTE: Use of a non-standard pressure cap will not

allow the recovery system to function properly.

Remove Cover

Radiator Cap

To access the radiator pressure cap:

1. Open the front cargo storage.

2. Remove the inside cover over the radiator cap.

AIR FILTER/PRE-FILTER SER

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

The pre filter should becleaned beforeeachride using the following procedure:

1. Lift up on the rear of the seat.

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

3. Remove clips (A) from air box cover and remove

VICE

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

cover. Inspect the gasket. It shouldadheretightly to the cover and seal all the way around.

2.21

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MAINTENANCE

NOTE: Apply a small amount of general purpose

grease to the sealing edges of the filter before reinstalling.

4. Loosen clamp and remove air filter assembly.

Cover

Pre-filter

Ill.1

Main Element

Carb Boot

Gasket

Filter Clamp

Ill.2

Proper Filter Placement

Main Filter

Filter Support

Air Box

Cleaning:

5. Slip the pre-filter element off of main element. Clean the pre filter with high flash point solvent, followed by hot soapy water.

6. Rinse and dry thoroughly.

7. Inspect element for tears or damage.

8. Apply foam filter oil or clean engine oil and squeeze until excess oil is removed.

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

Installation:

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

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

Ill.3

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

12. Install air box cover and secure with clips.

Front

AIR BOX SEDIMENT TUBE

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

1. Remove drain plug from end of sediment tube.

2.22

Page 43

MAINTENANCE

2. Drain tube.

3. Reinstall drain plug.

Sediment Tube

Ill.1

NOTE: The sediment tube will require more frequent service if the vehicle is operated in wet conditions or at high throttle openings for extended periods.

BREATHER FILTER INSPECTION

Four cycle ATV engines are equipped with a breather filter. The in-line filter is similar inappearance to afuel filter, and is visible on the left side (Location A).

maintained properly. Never operate the engine without the pre-filter.

RECOIL HOUSING

Recoil Drain

Recoil Handle Location

In-line breather filters should be installed with the arrow pointing toward the engine (away from the air box).

Typical Breather Filter Location

In-Line Breather Filter Location A

BREATHER HOSE

1. Be sure breather line is routed properly and securedin place. CAUTION: Make sure lines are not kinked or pinched.

NOTE: In-line breather filter service life is extended when the foam air box pre-filter is in place and

S Drain the housing periodically to remove

moisture.

S Drain the recoil housing after operating

the ATV in very wet conditions. This should also be done before storing the ATV. The drain screw is located at the bottom of the recoil housing. Remove the screw with a 10 mm wrench. Reinstall screw once housing has been drained.

S CAUTION: Make sure the manual start

handle (B) is fully seated on the recoil housing, especially when travelling in wet areas. If it is not sealed properly, water may enter the recoil housing and damage components.

S Water will enter the recoil housing if the

starter handle (B) is disengaged from the rope guide when under water.

S After travelling in wet areas the recoil

housing and starter should always be drained completely by removing the recoil.

S Do not open the crankcase drain unless

the engine has ingested water. Some

2.23

Page 44

MAINTENANCE

engine oil will be lost if crankcase drain is opened.

S If recoil handle (B) seal has been

damaged, the handle should be replaced.

ENGINE OIL LEVEL

0W/40

The oil tank is located on the left side of the vehicle. To check the oil level:

1. Set machine on a level surface.

2. Start and run engine for 20-30 seconds. This will return oil to its true level in the oil tank.

3. Stop engine, remove dipstick (A) and wipe dry with a clean cloth.

4. Reinstall dipstick, screw the dipstick into place.

NOTE: The dipstick must be screwed completely in to ensure accurate measurement.

ADD 8 OZ. NORMAL FULL

5. Remove dipstick and check to see that the oil level is in the normal range. The oil should be between the top line and the bottom line on the dipstick. Add oil as indicated by the level on the dipstick. Do not overfill.

NOTE: Rising oil level between checks in cool weather driving, can indicate moisture collecting inthe oil reservoir. If the oil level is over the full mark, change the oil.

OIL AND FILTER CHANGE

WARNING

Personal injury can occur when handling used oil. Hot oil can cause burns or skin damage.

NOTICE:

Care must be taken to ensure that fluids are contained. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembly any component containing fluids.

1. Place vehicle on a level surface.

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

3. Clean area around drain plug (B) at bottom of oil tank. Remove drain plug (B).

4. Place a drain pan beneath oil tank and remove drain plug. CAUTION: Oil may be hot. Do not allow hot oil to come into contact with skin as serious burns may result.

Maintain Oil Level In Normal Range

Screw Dipstick in completely to check

2.24

5. Allow oil to drain completely.

6. Replace sealing washer (A) on drain plug (B). NOTE: The sealing surfaces on drainplugand oil tank should be clean and free of burrs, nicks or scratches.

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MAINTENANCE

7. Reinstall drainplug(B) and torque to 14 ft. lbs. (19 Nm).

8. Loosen clamp (D).

9. Remove oil hose from screen fitting (C) onbottom of oil tank.

10. Remove screen fitting (C) and clean the screen.

11. Apply Loctitet Thread Sealant 565 (PN

2871956) or an equivalent pipe thread sealant or PTFE sealant tape to clean, oil free threads of fitting (C).

12. Installfitting (C)and torque to 14-17 ft.lbs.(19--23 Nm). Be sure to align the fitting (C) with the mark on the back side of the tank.

13. Install oil hose on fitting (C) and re--install clamp (D).

17. Install newfilter and turn by handuntil filter gasket contacts the sealing surface, then turn and additional 1/2 turn.

Crankcase Drain

Engine Sump Drain Plug - Bottom View

18. Approximately 1 cup of engine oil will remain in the crankcase. Todrain, remove drain plug found on lower right side of crankcase.

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

19. Reinstall drain plug.

20. Remove dipstick and fill tank with 2 quarts (1.9 L) of Polaris Premium 4 Synthetic Oil(PN2871844).

21. Place gear selector inPark andset parking brake.

14. Place shop towels beneath oil filter (E) . Use Oil Filter Wrench (PV--43527), turn filter counterclockwise to remove.

15. Using aclean drycloth, cleanfilter sealingsurface on crankcase.

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

NOTE: Clamp or pinch off the vent line 2” from the oil tank as shown below in the Oil Pump Priming Procedure for the 400/500 engine.

22. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

2.25

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MAINTENANCE

A)V

23. Dispose of used filter and oil properly.

Oil Tank Drain Plug Torque:

14 ft. lbs. (19 Nm)

Crankcase Drain Plug Torque:

14 ft. lbs. (19 Nm)

Oil Filter Torque:

Turn by hand until filter gasket contacts sealing surface, then turn an additional 1/2 turn

Oil Filter Wrench:

(PV--43527)

Oil Tank Screen Fitting Torque:

14-17 ft. lbs. (19 Nm --23 Nm)

Recommended Engine Oil:

Polaris Premium 4 All Season Synthetic, 0W--40, (PN 2871281)

Ambient Temperature Range:

-40° Fto120° F

Oil Lines To Engine

Oil Tank

(A) Vent Hose to Air Box

Approx.

To A ir B ox

Pinch Off

ent Hose

(

Slit

OIL PUMP PRIMING PROCEDURE

NOTE: This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.

1. Clamp or pinch off vent line (A) approximately 2I from oil tank to avoidthe endofoil tankventfitting, and the vent line’s pressure relief slit

2. Run engine at IDLE for 10--20 seconds.

3. Remove the vent line clamp. The oil pump will now be properly primed and ready for field operation. Note: If the system is primed properly

you should hear some air release. If you do not, the system has not primed. Repeat the process if necessary.

(400/500)

VALVE CLEARANCE

Inspect and adjust valve clearance while the engine is cold and the piston positioned at Top Dead Center (TDC) on compression stroke.

1. Remove the seat.

2. Remove body panels and fuel tank as necessary to gain access to valve cover.

3. Remove the spark plug high tension lead and remove the sparkplug. CAUTION: Place aclean shop towel into the spark plug cavity to prevent dirt from entering.

4. Remove rocker cover bolts, cover and gasket.

NOTE: It may be necessary to tap cover lightly with a soft-faced hammer to loosen it from the cylinder head.

5. Remove timing inspection plug from recoil housing.

2.26

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MAINTENANCE

CAUTION: Failure to position the crankshaft at TDC

on compression stroke will result in improper valve adjustment.

Sprocket alignment pin facing up

Crankshaft-to-Camshaft Centerline

6. Rotate engine slowly with recoil rope, watching the intake valve(s) open and close.

NOTE: At this point watch the camshaft sprocket locating pin and slowly rotate engine until locating pin is facing upward, directly in line with the crankshaft to camshaft center line as shown. The camshaft lobes should be pointing downward.

INTAKE VALVE CLEARANCE ADJUSTMENT

1. Insert a .006″ (.15mm) feeler gauge between end of intake valve stem and clearance adjuster screw.

2. Using a 10 mm wrench and a screwdriver, loosen adjuster lock nut and turn adjusting screw until there is a slight drag on the feeler gauge.

3. Hold adjuster screw and tighten adjuster lock nut securely.

4. Re-check the valve clearance.

5. Repeat adjustment procedure if necessary until clearance is correct with locknut secured.

6. Repeat this step for the other intake valve.

INTAKE VALVE CLEARANCE

.006″ (.15 mm)

EXHAUST VALVE CLEARANCE

ADJUSTMENT

7. Verify accurate TDC positioning by observing the “T” mark aligned with the pointer in the timing inspection hole. In this position there should be clearance on all valves.

500 Engine

Feeler Gauge for Both Valves

NOTE: The exhaust valves share a common rocker arm, and must be adjusted using two feeler gauges.

1. Insert .006 feeler gauge(s) between end of exhaust valve stem and adjuster screw(s).

2. Loosen locknut(s) andturn adjuster screw(s) until there is a slight drag on feeler gauge(s). The Valve/Clutch Adjuster Tool (PA--44689) can be used to adjust the engines valves. NOTE: Both feeler gauges should remain inserted during adjustment of each valve.

2.27

Page 48

MAINTENANCE

EXHAUST VALVE CLEARANCE

.006″ (.15 mm)

3. When clearance is correct, hold adjuster screw and tighten locknut securely

4. Re-check the valve clearance.

5. Repeat adjustment procedure if necessary until clearance is correct with locknut secured.

STEERING

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

Replace any worn or damaged steering components. Steering should move freely through entire range of travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited. NOTE: Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts.

WARNING

Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed byan authorizedPolaris MSD--certified technician when replacing worn or damaged steering parts. Use only genuine Polaris replacement parts.

S Repeat inspection for inner tie rod

end on steering post.

S Replace any worn steering

components. Steering should move freely through entire range of travel without binding.

S Elevate front end of machine so front

wheels are off the ground. Check for any looseness in front hub / wheel assembly by grasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward.

S If abnormal movement is detected,

inspect the hub and wheel assembly to determine the cause ( possible loose wheel nuts or loose front hub components).

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

TIE ROD END / STEERING INSPECTION

S To check for play in the tie rod end,

grasp the steering tie rod, pull in all directions feeling for movement.

2.28

Check for Loose Wheel or Hub

S Refer to the Body/Steering Chapter

5 or Final Drive Chapter 7 for service procedures.

Page 49

MAINTENANCE

CAMBER AND CASTER

The camber and caster are non-adjustable.

WHEEL ALIGNMENT METHOD 1: STRAIGHTEDGE OR STRING

Be sure to keep handlebars centered. See notes below.

NOTE: String should just touch side surface of rear tire on each side of machine.

Measure

from string

to rim at

front and

rear of rim.

Rear rim

measure-

ment should

be 1/16″ to

1/8″ (.2to.3

cm) more

than front rim

measure-

ment.

2. Set handlebars in a straight ahead position and secure handlebars in this position. NOTE: The steering arm “frog” can be used as an indicator of whether the handlebars are straight. The frog should always point straight back from the steering post.

3. Place a chalk mark on the center line of the front tires approximately 10″ (25.4 cm) from the floor or as close to the hub/axle center line as possible. NOTE: It is important that the height of both marks be equally positioned in order to get an accurate measurement.

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

5. Rotate the tires 180° by moving vehicle forward or backward. Position chalk marks facing rearward, even with the hub/axle centerline.

6. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8″ to 1/4″ (.3to.6cm) toe out. This meansthe measurement atthefront of the tire (A) is1/8″ to 1/4″ (.3 to .6 cm) wider than the measurement at the rear (B)

Ill.1

NOTE: The steering post arm “frog” can be

used as an indicator of whether the handle-

bars are straight. The frog should always point straight back from the steering post.

WHEEL ALIGNMENT METHOD 2:

1. Place machine on a smooth level surface.

CHALK

Chalk Line Measurement “A”

Measurement “B”

TOE ALIGNMENT ADJUSTMENT

If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting. NOTE: Be sure handlebars are straight ahead before determining which tie rod(s) need adjustment.

CAUTION: During tie rod adjustment, it is very important that the following precautions be taken when tightening tie rod end jam nuts. If the rod end

2.29

Page 50

MAINTENANCE

is positioned incorrectly it will not pivot, and may break.

Hold Rod End

Incorrectly Tightened Jam Nut

Ill.2

Correctly Tightened Jam Nut

Ill.2

To adjust toe alignment:

S Hold tie rod end to keep it from rotating. S Loosen jam nuts at both end of the tie rod. S Shorten or lengthen the tie rod until alignment

is as required to achieve the proper toe setting asspecifiedin Method 1 orMethod

S IMPORTANT: When tightening the tie rod

end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparentif doneincorrectly. See illustration 2.

S After alignment is complete, torque jam nuts

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

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

3. If some carbon is expelled, cover the exhaust outlet and lightly tap on the pipe around the clean out plugs with a rubber mallet while revving the engine several more times.

4. If particles are still suspected to be in the muffler, back the machine ontoanincline sotherear of the machine is one foot higher than the front. Set the hand brake and block the wheels. Make sure the machine is inParkand repeat Steps 2and 3. SEE

WARNING

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

SEE WARNING

EXHAUST PIPE

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

1. Remove the clean out plugs located on the bottom of the muffler as shown in illustration 1.

Ill.1

Clean Out Plug

2.30

1ft.

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

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

Page 51

8. Reinstall the clean out plugs.

WARNING

MAINTENANCE

Rear Master Cylinder Reservoir

S Do not perform clean out immediately

after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with exhaust components.

S To reduce fire hazard, make sure that

there are no combustible materials in the area when purging the spark arrestor.

S Wear eye protection. S Do not stand behind or in front of the ve-

hicle while purging the carbon from the spark arrestor.

S Never run the engine in an enclosed

area. Exhaust contains poisonous carbon monoxide gas.

S Do not go under the machine while it is

inclined. Set the hand brake and block the wheels to prevent roll back.

Failure to heed these warnings could result in serious personal injury or death.

BRAKE SYSTEM INSPECTION

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

S Keep fluid level in the master cylinder

reservoir to the indicated level inside reservoir.

S Use Polaris DOT 3 Brake Fluid (PN

2870990).

Sight Glass

Parking Brake Lock

Max Min

Auxiliary Brake Reservoir

Located Under Seat

S Check brake system for fluid leaks. S Check brake for excessive travel or

spongy feel.

S Check friction pads for wear,

damage or looseness.

S Check surface condition of the disc.

BRAKE PAD INSPECTION

Pads should be changed when the friction material is worn to 3/64″ (.1 cm), or about thethickness ofadime.

3/64″ (.1cm)

Minimum Thickness

2.31

Page 52

MAINTENANCE

HOSE/FITTING INSPECTION

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

AUXILIARY BRAKE TESTING

The auxiliary brake should be checked for proper function.

Auxiliary Foot Brake Pedal

Full Height

Floor Board Surface

Full Engagement

First, check foot brakeeffectiveness by applying50lb. (approx.) downwardforce on the pedal. The top of the pedal should be at least 1 inch, (25.4mm) above the surface of the footrest.

1/8, to 1/4, Free Play

50 lbs

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

Free Play: Free play of the brake pedal should be 1/8 - 1/4

inch (3.2 - 6.35 mm).

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

Bleeding:

1″ or greater

Floorboard

1. Support the rear wheels off the ground.

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

AUXILIARY BRAKE ADJUSTMENT

Auxiliary Brake

(HYDRAULIC)

If free play is correct and brake pedal travel is still excessive, air may be trapped somewhere in the system. Bleed the hydraulic auxiliarybrake system in a conventional manner, following the procedure outlined in Brake Chapter 9.

SUSPENSION SPRING PRELOAD

Center Spring Adjustment Ring

Shock Spanner Wrench

ADJUSTMENT

(PN 2871095)

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

2.32

Operator weight and vehicle loading affect suspensionspringpreloadrequirements.Adjustas necessary,using the spannerwrench(2)supplied in your ATV tool kit toturntheadjustment cam (1).

Page 53

MAINTENANCE

FRONT SUSPENSION

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

Check all front suspension components for wear or damage.

Inspect front strut cartridges for leakage.

CV SHAFT BOOT INSPECTION

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

contacting switch body.

Throttle assembly clamp

Align clamp edge with knurl

Align throttle control assembly clamp with knurl on handlebar

WHEELS

Inspect allwheels for runout or damage. Check wheel nuts andensure they are tight. Do notover tighten the wheel nuts.

Inspect Boots

CONTROLS

Check controls for proper operation, positioning and adjustment.

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

WARNING

Operating anATV with worntires will increase the possibility of the vehicle skidding and possible loss of control.

Worn tires can cause an accident. Always replace tires when the tread depth

measures 1/8″ (.3 cm) or less.

WHEELS

Inspect allwheels for runout or damage. Check wheel nuts andensure they are tight. Do notover tighten the wheel nuts.

WHEEL,HUB,ANDSPINDLE TORQUE T

Item Specification

Front Wheel Nuts 27 Ft. Lbs. (37 Nm)

Rear Wheel Nuts 27 Ft. Lbs. (37 Nm)

Front Spindle Nut 70 Ft. Lbs. (95 Nm)

Rear Hub Retaining Nut 80 Ft. Lbs. (108 Nm)

ABLE

2.33

Page 54

MAINTENANCE

WHEEL REMOVAL FRONT OR REAR

Front & Rear Wheels

Front & Rear Wheel Nuts (4)

27 ft. lbs. (37 Nm)

Front Hub Nut

70 ft. lbs. (95 Nm)

Rear Hub Nut

80 ft. lbs. (108 Nm)

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

2. Loosen the wheel nuts slightly.

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

TIRE PRESSURE

CAUTION:

Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the vehicle.

Tire Pressure Inspection (PSI - Cold)

Front Rear

5 5

TIRE INSPECTION

S Improper tire inflation mayaffect ATV

maneuverability.

S When replacing a tire always use

original equipment size and type.

S The use of non-standard size or type

tires may affect ATV handling.

Tire Tread Depth

4. Remove the wheel nuts and remove the wheel.

WHEEL INSTALLATION

1. With the transmission in Park and the parking brake locked, place the wheel in the correct position on the wheelhub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.

2. Attach the wheel nuts and finger tighten them.

3. Lower the vehicle to the ground.

4. Securely tighten the wheel nuts to the proper torque listed in the table .

CAUTION:

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

Tread Depth 1/8I (3 mm)

WARNING

Operating an ATV with worn tires will increase the possibility of the vehicleskidding easily with possible loss of control.

Worn tires can cause an accident. Always replace tires when the tread

depth measures 1/8″ (.3 cm) or less.

If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make suretaperedendof nut goes into taper on wheel.

2.34

Page 55

FRAME, NUTS, BOLTS,

ASTENERS

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

FRONT / REAR STORAGE

MAINTENANCE

COMP

The front and rear storage compartments are easily accessible. To open the front compartment turn the latch handle to the horizontal position on both sides. To close the storage compartment turn the latch handles just past the vertical position. Use the arrow located on top of the latch as a reference.

ARTMENTS

Reference Arrow

Front Storage -- Unlatched

Rear Storage -- Latched

Front Storage -- Latched

2.35

Page 56

MAINTENANCE

WARNt WINCH OPERATION

The 2005 Sportsmans are pre--wired with the proper Warnt winch wiring for quick and easy installation of aWarnt Winch in the front. Refer to the installation instructions with the winch kit for more details on proper installation.

Mini--Rocker Switch

Pre--Wired Warnt Winch Kits

2.5 ci -- PN 2875309

3.0 ci -- PN 2875308

Winch Handlebar Controls

The winch is located in the front bumper area.

OUT

Winch Control

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

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

When the winch is FREESPOOL, the winch allows the cable to be pulled out freely. NOTE: The switch on the handlebar does not need to be pushed OUT when using FREESPOOL.

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

2.36

FREESPOOL

ENGAGE

Page 57

Winch Wire Locations

MAINTENANCE

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

Winch Connecting Wires Located Under Right Front Cab Area

Winch Connecting Wires

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

Contactor mounts on Splash Guard

Pic of quick connect and locations

Under Right Side Front Fender

The Red wire (6 Ga.) with the yellow crimp cover is located under the left rear fender next to the starter solenoid. The red wire connects to the battery.

2.37

Page 58

MAINTENANCE

CLEANING & STORAGE OF YOUR A

Cleaning the ATV

Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile.

Washing the ATV

The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning and safety labels are damaged, contact your a Polaris dealer for free replacement.

Polaris does not recommend the use of a high pressure type car wash system for washing the ATV. If a high pressure system is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels. NOTE: Grease all zerk fittings immediately after washing, and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system.

Waxing the ATV

Your ATV can be waxed with any non-abrasive automotive paste wax. Avoid the use of harsh cleaners since they can scratch the body finish. Polaris offers a detailing kit for your ATV, see Page

2.7.

CAUTION: Certain products, including insect repellants and chemicals, will damage plastic surfaces. Use caution when using these products near plastic surfaces.

Storage Tips

See Page 2.7 for the part numbers of Polaris products.

CAUTION: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period.

Clean the Exterior

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

Stabilize the Fuel

Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. (Carbon clean will also reduce the possibility of bacterial growth in the fuel system.) Allow 15-20 minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor. Turn the fuel valve off and drain the carburetor bowl.

Oil and Filter

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

Air Filter / Air Box

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

Breather Filter

Inspect and clean or replace the breather filter.

Fluid Levels

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

Drain the Recoil Housing

Remove the recoil housing drain plug and drain any moisture.

Storage Tips

Polaris offers storage kits for you ATV, see Page 2.7 for the part numbers of Polaris products.

Fog the Engine

Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W--40 engine oil. To access the plug hole, use a section of clear 1/4” hose and a small plastic squeeze bottle filled with the pre-measured amount of oil. Note: Do this carefully! If you miss the plug hole, oil will drain from the spark plug cavity into the hole at the front of the cylinder head, and appear to be an oilleak. Install the spark plug and pullthe engineover slowly with the recoil starter. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.

If you choose not to use Polaris Fogging Oil, perform the following procedure.

1. Support the front end of the machine so the engine is level or tilted slightly rearward.

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

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

2.38

Page 59

4. Turn the engine over several times to ensure coverage of piston rings, cylinder walls and crankshaft bearings.

5. Treat the fuel system with Polaris Carbon Clean.

6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline. To eliminate any fuel remaining in the carburetor, run the engine until it stops.

Lubricate

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

Storage Tips

Battery Storage

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

MAINTENANCE

Engine Anti-Freeze

Test engine coolant strength andchange ifnecessary. Coolant should be replaced every two years. See Page 2.19 for the proper test procedure.

Storage Area/Covers

Set the tire pressure and safely support the ATV with the tires 1-2” off the ground. Be sure the storage area is well ventilated, and cover the machinewith a genuine Polaris ATV cover. NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

Transporting the ATV

Follow these procedures when transporting the vehicle.

1. Turnoff the engine and remove thekey to prevent loss during transporting.

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

3. Turn the fuel valve off.

4. Be sure the fuel cap, oil cap andseat are installed correctly.

5. Always tietheframe of the ATV to thetransporting unit securely using suitable straps or rope.

2.39

Page 60

MAINTENANCE

MAINTENANCE SCHEDULE

Service Date Hours / Miles Service Performed Serviced By:

2.40

Page 61

Torque Specifications 3.2........................

Special Tools 3.2...............................

EH50PL Service Data 3.3-3.4........................

Torque Patterns 3.5.............................

Piston Identification 3.5..........................

Cooling System Pressure Test 3.6--3.7................

Cooling System Specifications 3.7................

Engine Removal 3.7............................

Engine Installation Notes 3.8.....................

Cylinder Honing 3.8--3.9.............................

Crankshaft Runout Inspection 3.9--3.10.................

EH50PL Engine Lubrication 3.10..................

EH50PL Oil Pump Priming Procedure 3.10..........

EH50PL Lubrication/Oil Flow 3.11-3.12.................

EH50PL Engine Exploded View 3.13...............

EH50PL Engine Top End Disassembly 3.14-3.23.........

EH50PL Valve Seat Service 3.23-3.26..................

EH50PL Cylinder Head Assembly 3.26-3.31.............

EH50PL Engine Bottom End Disassembly 3.31-3.36......

EH50PL Crankcase & Bearing Assembly 3.37--3.38.......

EH50PL Crankshaft End Play Inspection 3.38-3.39.......

EH50PL Counter Balancer End Play Inspection. 3.40. EH50PL Oil Pump Shaft End Play Inspection 3.40--3.41...

EH50PL Engine Assembly/Inspection 3.41-3.51..........

Sealed Recoil Disassembly/Inspection 3.51--3.52.........

Sealed Recoil Assembly 3.52.....................

Spark Plug Fouling Checklist 3.53.................

Troubleshooting 3.53--3.54.............................

ENGINE

3.1

Page 62

ENGINE

TORQUE SPECIFICATIONS

Fastener Size EH42PLE/

EH50PLE

Ft. Lbs. (Nm)

Blind Plug (Oil Pressure)

Camshaft Sprocket 6mm 5-6.5 (7-9 Nm) Camshaft Chain

Tensioner Lever Camshaft Chain

Tensioner Camshaft Chain

Tensioner Cap Carburetor Adaptor 8mm 12-14 (16-20 Nm) Crankcase 8mm 14-15 (19-21 Nm) Crankshaft Slotted

Nut (Cam Chain Drive Sprocket)

Cylinder Base Bolts

Cylinder Head Bolts

Drive Clutch Bolt 7/16 -

Flywheel 16mm 58-72 (78-98 Nm) Oil Delivery Pipe 12mm 11-15 (15-21 Nm) Oil Drain Bolt

(Crankcase) Oil Filter Pipe Fit-

ting Oil Hose Fitting 1/8 Pipe

Hard Metal Oil Line Banjo Fitting

Oil Pump 6mm 5-6.5 (7-9 Nm) Oil Pump Case

Screw One Way Valve 11m m 14-19 (20-25 Nm) Recoil Housing 6mm 5-6.5 (7-9 Nm) Rocker Cover 6mm 7-8 (9-11 Nm) Rocker Support 8mm 8-10 (11-13 Nm) Rocker Adjuster

Screw Water Pump Impel-

ler Nut

1/8 PT (28tpi)

6mm 5-6.5 (7-9 Nm)

11mm 14-19 (20-25 Nm)

28mm 35-51 (47-69 Nm)

10mm

6mm

11mm

6mm

14mm 14-17 (19-23 Nm)

20mm 36-43 (49-59 Nm)

Thread

N/A 11--16 ft.lbs.

5mm 1.5-2 (2-3 Nm)

6mm 6-7 (8-10 Nm)

6mm 5-6.5 (7-9 Nm)

6.5-11 (9-15 Nm)

45-49 (61-67 Nm)

6-8 (9-11 Nm)

Refer to Engine

Assembly for

torque procedure

40 (55 Nm)

6.5-11 (9-15 Nm)

(15--21 Nm)

Water Pump Housing Cover

Stator Plate 6mm 5-6.5 (7-9 Nm) Starter Motor 6mm 5-6.5 (7-9 Nm) Spark Plug 14mm 9-11 (12-15 Nm) Thermistor -- -- 26 ± 2.1 (35 ± 3

6mm 5-6.5 (7-9 Nm)

Nm)

SPECIAL TOOLS

PART NUMBER TOOL

DESCRIPTION

2200634 Valve Seat

2870390 Piston Support

2871043 Flywheel Puller 2871283 Crankshaft/Water

5131135 Water Pump

2870569 Crankshaft Truing

2870975 Mity Vact

PV--43527 OIl Filter Wrench

Reconditioning Kit

Block

Pump Seal Install

Kit

Install Kit

Stand

Pressure Test Tool

3.2

Page 63

ENGINE SERVICE DATA

pgg

Cylinder Head / Valve EH42PLE EH50PLE

Rocker Arm

Camshaft Cam lobe height In

Cylinder Head

Valve Seat Contacting width In

Valve Guide

Valve Margin thickness In

Valve

Valve Spring Overall length

Rocker arm ID .8669-.8678″ (22.020-22.041 mm) .8669-.8678″ (22.020-22.041 mm) Rocker shaft OD .8656-.8661″ (21.987-22.0 mm) .8656-.8661″ (21.987-22.0 mm) Rocker shaft Oil Clearance

Camshaft journal OD

Camshaft journal bore ID

Camshaft Oil clearance

Surface warpage limit .0020″ (.05 mm) .0020″ (.05 mm) Standard height 3.870″ (98.3 mm) 3.870″ (98.3 mm)

Inner diameter .2362-.2367″ (6.0-6.012 mm) .2362-.2367″ (6.0-6.012 mm) Protrusion above head .689-.709″ (17.5-18.0 mm) .689-.709″ (17.5-18.0 mm)

Stem diameter In .2343-.2348″ (5.950-5.965 mm) .2343-.2348″ (5.950-5.965 mm)

Stem oil clearance Std

Overall length

Squareness .075″ (1.9 mm) .075″ (1.9 mm)

Std .0008-.0021″ (.020-.054 mm) .0008-.0021″ (.020-.054 mm) Limit .0039″ (.10 mm) .0039″ (.10 mm) Std 1.2884-1.2924″ (32.726-32.826 mm) 1.2884-1.2924″ (32.726-32.826 mm) Limit 1.2766″ (32.426 mm) 1.2766″ (32.426 mm)

Std 1.2884-1.2924″ (32.726-32.826 mm) 1.2884-1.2924″ (32.726-32.826 mm) Limit 1.2766″ (32.426 mm) 1.2766″ (32.426 mm) Mag 1.4935-1.4941″ (37.935-37.950 mm) 1.4935-1.4941″ (37.935-37.950 mm) PTO 1.4935-1.4941″ (37.935-37.950 mm) 1.4935-1.4941″ (37.935-37.950 mm) Mag 1.4963-1.4970″ (38.005-38.025 mm) 1.4963-1.4970″ (38.005-38.025 mm) PTO 1.4963-1.4970″ (38.005-38.025 mm) 1.4963-1.4970″ (38.005-38.025 mm) Std .0022-.0035″ (.055-.090 mm) .0022-.0035″ (.055-.090 mm) Limit .0039″ (.10 mm) .0039″ (.10 mm)

Std .028″ (.7 mm) .028″ (.7 mm) Limit .055″ (1.4 mm) .055″ (1.4 mm)

Std .039″ (1.0 mm) .039″ (1.0 mm) Limit .071″ (1.8 mm) .071″ (1.8 mm)

Std .039″ (1.0 mm) .039″ (1.0 mm) Limit .031″ (.8 mm) .031″ (.8 mm)

Std .047″ (1.2 mm) .047″ (1.2 mm) Limit .031″ (.8 mm) .031″ (.8 mm)

Ex .2341-.2346″ (5.945-5.960 mm) .2341-.2346″ (5.945-5.960 mm) In .0014-.0024″ (.035-.062 mm) .0014-.0024″ (.035-.062 mm) Ex .0016-.0026″ (.040-.067 mm) .0016-.0026″ (.040-.067 mm)

Limit .0059″ (.15 mm) .0059″ (.15 mm)

In 3.976″ (101.0 mm) 3.976″ (101.0 mm) Ex 3.984″ (101.2 mm) 3.984″ (101.2 mm) Std 1.654″ (42.0 mm) 1.654″ (42.0 mm) Limit 1.575″ (40.0 mm) 1.575″ (40.0 mm)

ENGINE

3.3

Page 64

ENGINE

gggpp

ENGINE SERVICE DATA

Cylinder / Piston / Connecting Rod EH42PLE EH50PLE

Cylinder

Piston Outer diameter

Piston Pin

Piston Ring Piston ring installed gap To p r i ng

Piston Ring Standard clearance -

Connecting Rod

Crankshaft Crankshaft runout limit .0024″ (.06 mm) .0024″ (.06 mm)

KEY - Std: Standard;OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power Take Off Side

Surface warpage limit (mating with cylinder head) .0020″ (.05 mm) .0020″ (.05 mm) Cylinder bore Std 3.4606-3.614″ (87.900-87.920 mm) 3.6221-3.6228″ (92.00-92.02 mm) Taper limit .0020″ (.050 mm) .0020″ (.050 mm) Out of round limit .0020″ (.050 mm) .0020″ (.050 mm) Piston clearance

Boring limit .020″ (.5 mm) .020″ (.5 mm)

Std 3.4596-3.4600″ (87.875-87.885 mm) 3.6204-3.6215″ (91.970-91.985 mm) .0098″ (.25 mm) OS 3.4695-3.4699″ (88.125-88.135 mm) 3.6304-3.6310″ (92.21-92.23 mm)

.0197″ (.50 mm) OS 3.4793-3.4797″ (88.375-88.385 mm) 3.6403-3.6407″ (92.46-92.47 mm) Standard inner diameter of piston pin bore .9055-.9057″ (23.0-23.006 mm) .9055-.9057″ (23.0-23.006 mm) Outer diameter .9053-.9055″ (22.994-23.0 mm) .9053-.9055″ (22.994-23.0 mm) Standard clearance-piston pin to pin bore .0002-.0003″ (.004-.008 mm) .0002-.0003″ (.004-.008 mm) Degree of fit Piston pin must be a push (by hand) fit at 68° F(20° C)

Second

ring

Oil ring

To p r in g piston ring to ring groove

Second

ring

Connecting rod small end ID .9058-.9063″ (23.007-23.020 mm) .9058-.9063″ (23.007-23.020 mm) Connecting rod small end radial clear-

ance

Connecting rod big end side clearance

Connecting rod big end radial clearance

Std .0006-.0018″ (.015-.045 mm) .0006-.0018″ (.015-.045 mm) Limit .0024″ (.060 mm) .0024″ (.060 mm)

Std .0079-.0138″ (.20-.36 mm) .0079-.0138″ (.20-.36 mm) Limit .039″ (1.0 mm) .039″ (1.0 mm) Std .0079-.0138″ (.20-.36 mm) .0079-.0138″ (.20-.36 mm) Limit .039″ (1.0 mm) .039″ (1.0 mm) Std .0079-.0276″ (.20-.70 mm) .0079-.0276″ (.20-.70 mm) Limit .059″ (1.5 mm) .059″ (1.5 mm) Std .0016-.0031″ (.040-.080 mm) .0016-.0031″ (.040-.080 mm) Limit .0059″ (.15 mm) .0059″ (.15 mm) Std .0012-.0028″ (.030-.070 mm) .0012-.0028″ (.030-.070 mm) Limit .0059″ (.15 mm) .0059″ (.15 mm)

Std .0003-.0010″ (.007-.026 mm) .0003-.0010″ (.007-.026 mm) Limit .0020″ (.05 mm) .0020″ (.05 mm) Std .0039-.0256″ (.1-.65 mm) .0039-.0256″ (.1-.65 mm) Limit .0315″ (.80 mm) .0315″ (.80 mm) Std .0004-.0015″ (.011-.038 mm) .0004-.0015″ (.011-.038 mm) Limit .0020″ (.05 mm) .0020″ (.05 mm)

3.4

Page 65

ENGINE

ENGINE FASTENER TORQUE

TTERNS

Tighten cylinder head, cylinder base, and crankcase fasteners in 3 steps following the sequence outlined below.

6mm

Cylinder Head Cylinder Base

Pattern

Engine Model No.

EH50PLE .25

EH42PLE 25

*Pistons and rings marked 25 equal .25mm (.010I) oversized

Pistons and rings marked 50 equal .50mm (.020I)

oversized

Oversize Available* (mm)

.50

Piston Length

72 mm C

66 mm B

Standard Piston Identification

COOLING SYSTEM SPECIFICA

TIONS

Thermistor

26 ± 2.1 ft.lbs.

(35 ± 3Nm)

Crankcase

Pattern

PISTON IDENTIFICATION

The pistonmay have an identification mark or the piston may not piston placement. If the piston has an identification

mark, follow the directions for piston placement below. If the piston does not have an identification mark, the direction for placement of the piston does not matter.

Note the directional and identification marks when viewing the pistons from the top. The letter “F”, “ ! ”, “ "”or: must always be toward the flywheel side of the engine. The other numbers are used for identification as to diameter, length and design. Four stroke engine rings are rectangular profile. See text for oil control ring upper rail installation. Use the information below to identify pistons and rings.

have an identification mark for

THERMISTOR READING DURING OPERA

Condition

Hot Light

On Fan Off 296Ω -- 316Ω 180° F(82° C) Fan On 236Ω -- 251Ω 195° F(91° C) System

Capacity

Radiator

Cap Relief

Pressure

Approx. Reading

(Min--Max)

178Ω -- 190Ω 215° F

2.25 Quarts (2.13L)

13 PSI

Temperature

(102° C)

TION

3.5

Page 66

ENGINE

COOLING SYSTEM

WARNING: Never remove radiator cap when engine

is warm or hot. The cooling system is under pressure

FLOW

Radiator

Thermostat

Cylinder Head

Water Pump

Cylinder

and serious burns may result. Allow the engine and cooling system to cool before servicing.

System Pressure Test

1. Remove radiator cap cover located in storage box.

2. Remove recovery bottle hose from coolant filler.

3. Connect a Mity Vact (PN 2870975) to radiator and pressurize system to 10 PSI. The system must retain 10 lbs of pressure for five minutes or longer. If pressure loss is evident within five minutes, check radiator, all cooling system hoses and clamps, or water pump seal.

Radiator Cap Pressure Test

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

2. The radiator cap relief pressure is 13 lbs.

Fan

Upper Hose

Lower Hose

Overflow Bottle

Radiator

To p

Bottom

Filler Neck

Radiator Left Side View

Radiator Front View

3.6

Page 67

ENGINE

RECOMMENDED COOLANT

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

ACCESSIBLE COMPONENTS

The following components can be serviced or removed with the engine installed in the frame:

S Flywheel S Alternator/Stator S Starter Motor/Starter Drive S Cylinder Head S Cylinder S Piston/Rings S Camshaft S Rocker Arms S Cam Chain and Sprockets S Water Pump / Water Pump

Mechanical Seal*

The following components require engine removal for service:

S Oil pump / Oil Pump Drive Gear S Counterbalance Shaft or Bearing(s) S Connecting Rod S Crankshaft

S Left and Right Side Covers (Refer to

Chapter 5)

S Fuel Tank Cover / Front Cab (Refer to

Chapter 5)

S Fuel Tank (Refer to Chapter 4)

5. Disconnect spark plug high tension lead.

6. Remove springs from exhaust pipe and remove pipe.

7. Drain coolant and engine oil.

8. Remove air pre-cleaner and duct.

9. Remove airbox.

10. Remove carburetor. Insert a shop towel into the carburetor flange to prevent dirt from entering the intake port.

11. Remove center chain guard on chain drive AWD models.

12. Remove center drive and driven sprocket bolts and remove chainand sprockets as an assembly.

13. Refer to PVT System to remove outer clutch cover, drive belt, drive clutch, driven clutch, and inner cover.

14. Starter motor. Note ground cable location. Mark positive (+) cable mounting angle and remove cable.

15. Remove transmission linkage rod(s) from gear selector and secure out of the way.

16. Disconnect coolant temperature sensor wire.

17. Remove engine to chassis ground cable.

18. Remove all engine mount nuts and / or engine mount plates.

19. Remove engine through right side of frame.

S Crankshaft Main Bearings S Crankcase

*It may be necessary to loosen engine mounts and move engine slightly to access water pump. Use the Water Pump Mechanical Seal Puller (PN 2872105)to replace mechanical seal with engine in frame.

ENGINE REMOVAL (TYPICAL)

1. Clean work area.

2. Thoroughly clean the ATV engine and chassis.

3. Disconnect battery negative (-) cable.

4. Remove the following parts as required. S Seat

3.7

Page 68

ENGINE

ENGINE INSTALLATION NOTES

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

General Items

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

2. Perform regular checks on fluid levels, controls, and all important areas on the vehicle as outlined in the daily pre-ride inspection checklist (refer to Chapter 2 or the Owner’s Safety and Maintenance Manual).

PVT System

1. Adjust center distance of drive and driven clutch. (Chapter 6)

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

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

Transmission

1. Inspect transmission operationand adjustlinkage if necessary. Refer to Chapter 2 and Chapter 8.

Exhaust

2. Use fuel with a minimum octane of 87 (R+M)/2 method.

3. Change break-in oil and filter at 20 hours or 500 miles, whichever comes first.

CYLINDER HONE SELECTION/HONING PROCEDURE

CAUTION:

Selecting a hone which will straighten as well as remove material from the cylinder is very important. Using a common spring loaded finger type glaze breaker for honing is never advised. Polaris recommends using a rigid hone or arbor honing machine which also has the capability of oversizing.

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

NOTE: See next page for more information on honing.

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

2. Check to be sure all springs areingoodcondition.

Bleed Cooling System

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

2. Fill coolant reservoir tank to full mark.

3. Install radiator cap and squeeze coolant lines to force air out of system.

4. Againremoveradiatorcapand slowly addcoolant to top of fill neck.

5. Start engine and observe coolant level in the radiator. Allow air to purge and top off as necessary. Reinstall radiator cap and bring engine to operating temp. Check level in reservoir tank after engineis coolandadd coolant if necessary.

Engine Break In Period

4 Cycle Engine Break-In Period is defined as the first 10 hours of engine operation, or 2 full tanks of fuel.

1. Use only Polaris Premium 4 All Season synthetic oil, or API certified “SH” oil. Never substitute or mix oil brands. Serious engine damage can result.

3.8

Page 69

HONING TO OVERSIZE

ENGINE

CAUTION: If cylinder wear or damage is excessive,

it will be necessary to oversize the cylinder using a new oversize piston and rings. This may be accomplished by either boring the cylinder and then finish honing to the final bore size, or by rough honing followed by finish honing.

CAUTION: For oversize honing always wet hone using honing oil and a coarse roughing stone. Measure the piston (see piston measurement) and rough hone to the size of the piston. Always leave .002 - .003″ (.05 - .07 mm) for finish honing. Refer to piston-to-cylinder clearance specifications on Page

3.4 before honing. Complete the sizing with fine grit

stones to provide the proper cross-hatch finish and required piston clearance.

to remove sharp edges or burrs, paying particular attention to the corners of the intake and exhaust ports.

CLEANING THE CYLINDER AFTER

It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder inasolvent, then in hot, soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris 2 Cycle Lubricant.

HONING

CRANKSHAFT STRAIGHTENING

Lubricate the bearings and clamp the crankshaft securely in the Crankshaft Truing Stand (PN

2870569). Refer to the illustrations below.

EXAMPLE OF CROSS HATCH PATTERN

A finished cylinder should have a cross-hatch pattern to ensurepiston ringseating andto aid in theretention of the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer’s instructions, or these guidelines:

S Use a motor speed of approximately

300-500 RPM, run the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered (or cylindercentered on arbor) and to bring the stone approximately 1/2″ (1.3 cm) beyond the bore at the end of each stroke.

S Release the hone at regular intervals and

inspect the bore to determine if it has been cleared, and to check piston fit. NOTE: Do not allow cylinder to heat up during honing. The thinner areas of the liner around the ports will expandcausing uneven bore.

S After honing hasbeen completed inspect

all port opening areas for rough or sharp edges. Apply a slight chamfer to all ports

Crankshaft Truing Stand

(PN 2870569)

NOTE: The rod pin position in relation to the dial

indicator position tells you what action is required to straighten the shaft.

HIGH .004 (.1mm)

SUPPORT CRANKSHAFT HERE.

1. To correct a situation like the one shown in the illustration atright, strikethe shaft at point A with a brass hammer.

HIGH .004 (.1mm)

3.9

Page 70

ENGINE

OIL PRESSURE TEST -

HIGH .002 (.05mm)

HIGH .005 (.13mm)

2. To correct a situation like the one shown in the illustration at right, squeeze the crankshaft at point A. (Use tool from alignment kit).

HIGH .002 (.05mm)

HIGH .005 (.13mm)

EH50PL

1. Remove blind plug on front left cylinder head.

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

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

NOTE: Use Polaris Premium 4 Synthetic Engine Lubricant (PN 2871281).

Oil Pressure at 5500 RPM (Engine Hot):

Standard: 20 PSI Minimum: 12 PSI

3. If the crank rod pin location is 180_ from the dial indicator (opposite that shown above), it will be necessary to spread the crankshaft at position A as shown in the illustration at right. When rebuilding and straightening a crankshaft, runout must be as close to zero as possible.

NOTE: Maximum allowable runout is .0024I.

ENGINE LUBRICATION EH50PL

Oil Type Polaris Premium 4 Synthetic.............

(PN 2871281); or API certified “SH” 5W30 oil

Capacity Approximately 2 U.S.............

Quarts (1.9 l)

Filter PN 3084963................

Filter Wrench (PV--43527)........

*Drain Plug / Screen Fitting 14 ft. lbs. (19 Nm) (If.. fitting is removed, follow oil pump priming procedure).

*Oil Pressure Specification 20 PSI @ 5500... RPM, Polaris 0W--40 Synthetic (Engine Hot)

3.10

Page 71

ENGINE

OIL PUMP PRIMING PROCEDURE

NOTE: This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.

(A) Vent Hose to Air Box

Oil Lines To Engine

Approx.

Oil Tank

(A) Vent Hose

1. Clamp or pinch off vent line (A) approximately 2I

from oil tank to avoidthe endofoil tankventfitting, and the vent line’s pressure relief slit

2. Run engine for 10--20 seconds.

3. Remove the vent line clamp. A rush of air should

be heard, indicating the oil pump is properly primed andready for fieldoperation. Note: If the

line is bled properly you should hearair release, if you do not hear air the line has not bled. The oil pump will now be properly primed and ready for field operation.

To A ir B ox

Slit

Pinch Off

OIL FLOW -- EH50PL

The chart on Page 3.12 describes the flow of oil through the EH50PL engine. Beginning atthe oiltank, the oil flows through a screen fitting in the bottom of the tank and into the oil supply hose. The feed side of theoilpumpdraws oil through the hoseand into the crankcase oil gallery, and then pumps the oil through another passage to the one way valve. (When the engine is off, the one way valve closes to prevent oil in the tank from draining into the crankcase.) The oil is pumped throughadelivery pipe to the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.

At this point, the oil is diverted in two directions. Oil is supplied to the camshaft through the left front cylinder stud, and an oil passage in the head. Oil enters the camshaft through the PTO (L) journal. The camshaft journals, cam lobes, and rocker arms are lubricated through holes in the camshaft. The oil lubricates the cam chain and sprocket and drains to the sump.

The other oil path from the filter leads through a delivery pipe to the crankcase main oil gallery, which leads to the stator plate oil passage. Here it passes through the slotted friction bearing (located in the stator plate) into the crankshaft. An oil seal on the stator plate prevents oil from entering the stator/flywheel area. Oil travels through the crankshaft to the crank pin, lubricating theconnecting rod large endbearing directly. Oil also passes through an oil jet (drilled orifice) in the end of the crank pin to the PTO end main bearings and counterbalancer gears.

Residual oil from the lubrication of the crankshaft and connecting rod indirectly lubricates the cylinder wall, piston, rings,connecting rod small end bearing, piston pin, oil/water pump drive gears, cam chain and drive sprocket, and Magneto end crankshaft main bearing.

The one-way valve is located on the front left (PTO) side of the crankcase. The valve prevents oil in the tank from draining into the engine sump when the engine is off. The valve mechanism consists of a plunger, return spring, guide plug, and sealing washer. When the engine is running, oil pressure lifts the plunger off the seat, allowing oil flow. When the engine is off, spring pressure forces the plunger against the oil passage seat, preventing oil flow from the tank to the sump. The one-way valve requires very little maintenance. If engine oil drains into the sump whenthe engine is off, inspect the valve sealing surface for debris or damage. Inspect the return spring for distortion or damage.

3.11

Page 72

ENGINE

EH50PL OIL FLOW DIAGRAM

Vent Hose

Oil Tank

Internal passage to camshaft (front left head bolt)

EH50PL Oil Flow Chart

Oil Tank

Union Fitting (Upper)

Oil Hose

Bottom fitting is oil exhaust or return to tank

To p of O il Ta nk

Oil Hose

Screen Fitting (Bottom of Tank)

Top fitting is oil feed or intake from bottom of tank

Union Fitting (Lower)

Crankcase Oil Gallery

Oil filter

Oil feed to filter

One way valve

Oil Pump (Scavenging)

From filter to crankshaft

Oil Strainer

Crankcase

Prevents oil from draining into crankcase with engine off

Crankcase Oil Gallery

Oil Pump (Feed)

One Way Valve

Delivery Pipe

Bypass Oil Filter

Chain Room

Cam Shaft Journal

Cam Lobe

Cam Shaft Journal

Delivery Pipe

Sprocket Chain

Rocker Arm Rocker Shaft

Through Cylinder Stud Front Left

Crankcase Oil Gallery

Metal

Indirect Lubrication

Small End Bearing

Cylinder Sleeve

Main Bearing (PTO)

Large End Bearing

Oil Jet

Crank Pin

Crankshaft

3.12

Page 73

EH50PL ENGINE EXPLODED VIEW

Crankcase Cylinder/

ENGINE

Cylinder Head

Crankshaft and Piston

Valvetrain

3.13

Page 74

ENGINE

ENGINE REMOVAL

REFER TO PAGE 3.7--3.8 FOR ENGINE REMOVAL / INSTALLATION

NOTES.

CAM CHAIN TENSIONER/ROCKER ARM/CAMSHAFT REMOV

1. Remove ignitiontiminginspection plug from recoil

housing.

TDC “T” Mark

Rotation

should have clearance at this point.

5. Remove cam chain tensioner plug, sealing washer, and spring. CAUTION: The plug is under spring tension. Maintain inward pressure while removing.

6. Remove the two 6x25 mm cam chain tensioner flange bolts.

7. Tap lightly on tensioner body with a soft face hammer and remove tensioner.

Advance Marks

To position crankshaft at Top Dead Center (TDC) on compression stroke:

2. Rotate engine slowly in the direction of rotation watching intake valves open and start to close.

3. Continue to rotate engine slowly, watching camshaft sprocket marks and the mark in the timing inspection hole.

4. Align single (TDC) mark on flywheel with projection in inspection hole, and the cam sprocket pin (facing upward) aligned with the camshaft to crankshaft center line. NOTE: The cam lobe should be pointing down and valves

3.14

Page 75

ENGINE

CAM CHAIN TENSIONER INSPECTION

1. Pull cam chain tensioner plunger outward to the end of its travel. Inspect teeth onratchet pawl(A) and plunger teeth (B) for wear or damage.

2. Push ratchet pawland holdit. The plungershould move smoothly in and out of the tensioner body.

3. Releaseratchet pawland pushinward onplunger. It should remain locked in position and not move inward.

ROCKER ARM/SHAFT INSPECTION

1. Mark or tag rocker arms to keep them in order for assembly.

2. Inspect each rocker arm cam follower surface. If there is any damage or uneven wear, replace the rocker arm. NOTE: Always inspect camshaft lobe if rocker arms are worn or damaged.

Tensioner Spring Free Length:

2.320I (5.9 cm)

4. Measure free lengthof tensioner spring. Replace spring if excessively worn. Compare to specifications.

5. Replace entire tensioner assembly if any part is worn or damaged.

3. Measure O.D. of rocker shaft. Inspect it for wear or damage. Compare to specifications.

Rocker Shaft O.D.:

.8656-.8661I (21.987-22.0 mm)

3.15

Page 76

ENGINE

ROCKER ARM/SHAFT INSPECTION, CONT

Rocker Arm & Support I.D.:

.8669-.8678I (22.020-22.041 mm)

4. Measure I.D. of each rocker arm and compare to specifications.

Rocker Shaft Oil Clearance:

Std: .0008-.0021I (.020-.054 mm) Limit: .0039I (.10 mm)

5. Measure I.D. of both rocker arm shaft supports and visually inspect surface. Compare to specifications.

6. Subtract rocker shaft O.D. from rocker arm & shaft support I.D. This is the oil clearance. Compare to specifications.

7. Inspect rocker adjuster screws for wear, pitting, or damage to threads of the adjuster or locknut. Replace all worn or damaged parts. NOTE: The end of the adjuster screw is hardened and cannot be ground or re-faced.

CAMSHAFT REMOVAL

3.16

1. Remove thermostat housing.

2. Remove camshaft sprocket inspection cover.

Page 77

ENGINE

3. Loosen three camshaft sprocket bolts.

4. Remove camshaft end cap and O-Ring.

7. Slide camshaft inward to allow removal of cam sprocketandremove sprocketfrom camshaftand chain.

8. Secure cam chain with a wire to prevent it from falling into the crankcase.

Sprocket Teeth

Inspect for Areas of Tooth Wear or Damage

9. Inspect cam sprocket teeth for wear or damage. Replace if necessary.

5. Inspect camshaft end cap (thrust face) for wear. Replace if worn or damaged.

6. Place a clean shop towel in the area below cam chain sprocket and remove sprocket retaining bolts.

Decompressor Shaft

Decompressor Ball

Retainer Sleeve

10. Slide camshaft out the PTO side of the cylinder head.

AUTOMATIC COMPRESSION RELEASE REMOV

NOTE: The automatic compression release

mechanism can be inspected and serviced without removing the camshaft from the cylinder head. The actuator ball in the camshaft is not replaceable. Replace the camshaft as an assembly if the actuator ball is worn or damaged.

AL/INSPECTION

3.17

Page 78

ENGINE

1. Check release lever shaft (A) for smooth operation throughout the entire range of rotation. The spring (B) should hold the shaft weight against the stop pin. In this position, the actuator ball (C) will be held outward in the compression release mode.

2. Remove release lever shaft and return spring.

3. Inspect shaft for wear or galling.

4. Inspect lobe on end of release lever shaft and actuator ball for wear and replace if necessary.

AUTOMATIC COMPRESSION RELEASE INSTALLA

1. Slide spring onto shaft.

2. Apply engine oil to release lever shaft.

The actuator ball must be held outward to allow installation of the release lever shaft.

TION

Stop pin

Spring in relaxed position

If Camshaft Is Removed From Engine:

3. Turn the camshaft until the actuator ball is in the lowest position andinstall the release lever shaft.

If Camshaft Is Installed In The Engine:

4. Use a small magnet to draw the actuator ball outward, or rotate the engine until the cam lobes face upward and install release lever shaft.

5. Position camshaft as shown at bottom of illustration at right.

6. Place arm of spring under stop pin as shown and push release lever inward until fully seated. Do not pre-wind the spring one full turn or the compression release will not disengage whenthe engine starts. Check operation of mechanism as outlined in Step 1 of Removal (above). NOTE: When shaft is properly installed, actuator ball will be held inthe “out” position. It isimportant to note that spring pressure is very light.

3.18

CAMSHAFT INSPECTION

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

2. Thoroughly clean the cam shaft, making sure the oil feed holes are not obstructed.

Page 79

Camshaft Oil Clearance:

Std: .0022-.0035I (.055-.090 mm) Limit: .0039I (.10 mm)

ENGINE

Lubrication holes

Lobe height

Cam Lobe Height (Intake & Exhaust):

Std: 1.2884-1.2924I (32.726-32.826 mm) Limit: 1.2766I (32.426 mm)

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

Journal O.D.

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

NOTE: Replace cylinder head if camshaft journal bore is damaged or worn excessively.

CYLINDER HEAD EXPLODED VIEW,

1. Remove the two 6mm flange bolts (A) from cylinder head. See next exploded view on next page.

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

EH50PL

Journal

Camshaft Journal O.D.: Mag & PTO End: 1.4935-1.4941I

(37.935-37.950 mm)

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

5. Measure ID of camshaft journal bore.

Camshaft Journal I.D.: Mag & PTO End: 1.4963-1.4970I

(38.005-38.025 mm)

Calculate oil clearance by subtracting journal OD from journal bore ID. Compare to specifications.

3. Remove bolts (B) and tap cylinder head lightly with a plastic hammer until loose. CAUTION: Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging the thread.

4. Remove cylinder head and head gasket.

3.19

Page 80

ENGINE

CYLINDER HEAD EXPLODED VIEW, EH50PL

EH50PL

3.20

Page 81

ENGINE

CYLINDER HEAD INSPECTION

(A)

1. Thoroughly clean cylinder head (A) surface to remove all traces of gasket material and carbon. CAUTION: Use care not to damage sealing surface.

CYLINDER HEAD WARPAGE

CYLINDER HEAD DISASSEMBL

WARNING: Wear eye protection or a face shield

during cylinder head disassembly and reassembly. NOTE: Keep all parts in order with respect to their

location in the cylinder head.

1. Using a valve spring compressor (A), compress the valve spring and remove the split keeper. NOTE: To prevent loss of tension, do not compress the valve spring more than necessary.

Cylinder Head Warpage Limit:

.002″ (.05 mm)

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

2. Remove spring retainer and spring. NOTE: The valve springs should be positioned with

the tightly wound coils against the cylinder head on progressively wound springs (A).

3. Push valve out, keepingit in order for reassembly in the same guide.

4. Measure free length of spring with a Vernier caliper. Check spring for squareness. Compare

3.21

Page 82

ENGINE

to specifications. Replace spring if either measurement is out of specification

5. Remove valve seals. CAUTION: Replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.

indicator.

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

4. Inspect split keeper groove for wear or flaring of the keeper seat area (B). NOTE: The valves cannot be re-faced or end ground. They must be replaced if worn, bent, or damaged.

Measure valve stem in several places.

VALVE INSPECTION

1. Remove all carbon from valve with a soft wire wheel.

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

Valve Stem Diameter:

Intake: .2343-.2348I (5.950-5.965 mm) Exhaust: .2341-.2346I (5.945-5.960 mm)

5. Measure diameter of valve stem with a micrometer in three places and in two different directions (six measurements total). Compare to specifications.

3.22

Page 83

ENGINE

Clean all accumulated carbon deposits from combustion chamber and valve seat area with a soft wire brush.

VALVE SEAT RECONDITIONING

Valve Seat Inspection

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

3.25. If the valve seat is cracked the cylinder head

must be replaced.

Cylinder Head Reconditioning

Valve Guide I.D.:

.2362-.2367I (6.0-6.012 mm)

6. Measure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer. Measure in two directions, front to back and side to side.

7. Subtract valve stem measurement to obtainstem to guide clearance. NOTE: Be sure to measure each guide and valve combination individually.

8. Replace valve and/or guide if clearance is excessive. Compare to specifications.

NOTE: If valve guides are replaced, valve seats must be reconditioned. Refer to Valve Seat Reconditioning for procedure.

COMBUSTION CHAMBER

NOTE: Servicing the valve guides and valve seats

requires special tools and a thorough knowledge of reconditioning techniques. Follow the instructions provided in the cylinder head service tool kit.

CAUTION: Wear eye protection when performing cylinder head service. Valve guide replacement will require heating of the cylinder head. Wear gloves to prevent burns.

Valve Guide Removal/Installation

1. Remove all carbon deposits from the combustion chamber, valve seat and valve guide area before attempting to remove valve guides. CAUTION: Carbon deposits are extremely abrasive andmay damage the valve guide bore when guides are removed.

2. Place new valve guides in afreezer for at least 15 minutes while heating cylinder head.

3. Heat cylinder head in an oven or use a hot plateto bring cylinder head temperature to 212° F (100° C). CAUTION: Do not use a torch to heat cylinder heador warpage may result from uneven heating. Head temperature can be checked with a pyrometer or a welding temperature stick.

VALVE SEAT RECONDITIONING, CONT

Follow the manufacturers instructions provided with the valve seat cutters in the Valve Seat Reconditioning Kit (PN 2200634). Abrasive stone seat reconditioning equipment can also be used. Keep all valves in order with their respective seat.

3.23

Page 84

ENGINE

Reaming The Valve Guide

To o Wide

NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. The valve must contact the valve seat over the entire circumference of the seat, and the seat must be the proper width all the way around. If the seat is uneven, compression leakage will result. If the seat is too wide, seat pressure is reduced, causing carbon accumulation and possible compression loss. If the seat is too narrow, heat transfer from valve to seat is reduced and the valve may overheat and warp, resulting in burnt valves.

1. When thoroughly heated, place cylinder head on blocks of wood which will allow the old guides to be removed.

2. Using valve guide driver, drive guides out of the cylinder headfrom thecombustion chamber side. Be careful not to damage guide bore or valve seat when removing guides.

3. Place cylinder head on cylinder head table. NOTE: Be sure cylinder head is still at 212° F (100° C) before installing new guides.

Uneven

Good

To o Narrow

5. Allow cylinder head to cool to room temperature. Apply cutting oil to the reamer. Guides should be reamed from the valve spring side of the cylinder head. Ream each guide to size by turning the reamer clockwise continually. Continue to rotate reamer clockwise during removal of the tool.

6. Cleanguides thoroughly with hotsoapy water and a nylon brush. Rinse and dry with compressed air. Apply clean engine oil to guides.

7. Install pilot into valve guide.

8. Apply cutting oil to valve seat and cutter.

Valve Guide Installed Height

Valve Guide Height:

.689-.709I (17.5-18.0 mm)

4. Place a new guide in the valve guide installation tool and press guide in to proper depth. Check height ofeachguide above the cylinder head (A). NOTE: Theguidecanalsobedrivenintothe proper depth. Inspect theguideclosely for cracks or damage if a driver is used.

3.24

9. Place 46° cutter on the pilot and make a light cut.

10. Inspect the cut area of the seat. S If the contact area is less than 75% of the

circumference ofthe seat, rotate the pilot 180° and make another light cut.

S If the cutter now contacts the uncut

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

Page 85

S If the contact area of the cutter is in the

same place, the valve guide is distorted from improper installation and must be replaced. Be sure the cylinder head is at the proper temperature and replace the guide.

S If the contact area of the initial cut is

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

(A)

ENGINE

Valve Seat Width:

Intake Std: .028I (.7 mm)

Limit: .055I (1.4 mm)

Exhaust Std: .039I (1.0 mm)

Limit: .071I (1.8 mm)

Seat Width

11. To check the contact area of the seat on the valve face, applya thincoating ofPrussian Bluetpaste to the valve seat. If using an interference angle (46°) apply black permanent marker to the entire valveface(A).

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

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

S If the indicated seat contact is at the

top edge of the valve face and contacts the margin area(B) it is too high on the valve face. Use the 30° cutter to lower the valve seat.

S If too low use the 60° or 75° cutter to

raise the seat. When contact area is centered on the valve face, measure seat width.

S If the seat is too wide or uneven, use

both top and bottom cutters to narrow the seat.

S If the seat is too narrow, widen using

the 45° cutter and re-check contact point on thevalveface andseatwidth after each cut.

Bottom - 60° or 75°

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

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

15. Lubricate the valve guides with clean engine oil, and apply oil or water basedlapping compound to the face of the valve. Lapping is not required with an interference angle.

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

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

Seat - 45° or 46°

To p - 30 °

3.25

Page 86

ENGINE

18. Clean cylinder head, valves, and camshaft oil supply passage (A) thoroughly.

19. If oil passage blind plug was removed, apply Crankcase Sealant (PN 2871557) or equivalent sealer to the threads and install, torquing to 8 ft. lbs. (11 Nm). CAUTION: Do not allow sealant to enter oil passage.

20. Spray electrical contact cleaner into oil passage and dry using compressed air.

CYLINDER HEAD ASSEMBLY

CAUTION: Wear eye protection during assembly. NOTE: Assemble the valves one at a time to

maintain proper order.

1. Install new valve seals on valve guides.

2. Apply engine oil to valve guides and seats.

3. Coat valve stem with molybdenum disulfide grease.

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

5. Dip valve spring and retainer in clean engine oil and install springwith closely spaced coils toward the cylinder head.

6. Place retainer on spring and install valve spring compressor. Compress spring only enough to allow split keeper installation to prevent loss of spring tension. Install split keepers with the gap even on both sides.

7. Repeat procedure for remaining valve.

8. When all valves are installed, tap lightly with soft faced hammer on the end of the valves to seat the split keepers.

3.26

VALVE SEALING TEST

1. Clean and dry the combustion chamber area.

2. Pour a small amount of clean, high flash point solvent into the intake port and check for leakage around each intakevalve. The valve seats should hold fluid with no seepage.

3. Repeat for exhaust valves by pouring fluid into exhaust port.

Page 87

EXHAUST VALVE

ENGINE

CLEARANCE

Feeler Gauge for Both Valves

NOTE: The exhaust valves share a common rocker arm, and must be adjusted using two feeler gauges.

1. Insert .006 feeler gauge(s) between end of exhaust valve stem and adjuster screw(s).

2. Loosen locknut(s) andturn adjuster screw(s) until there is a slight drag on feeler gauge(s). The Valve/Clutch Adjuster Tool (PA--44689) can be used to adjust the 500 engines valves. NOTE: Both feeler gauges should remain inserted during adjustment of each valve.

ADJUSTMENT

500 Engine

1. Remove cam chain guide at front of cylinder.

EXHAUST VALVE CLEARANCE

.006″ (.15 mm)

3. When clearance is correct, hold adjuster screw and tighten locknut securely

4. Re-check the valve clearance.

5. Repeat adjustment procedure if necessary until clearance is correct with locknut secured.

CYLINDER/PISTON REMOVAL AND

NOTE: Follow engine disassembly procedures to

remove valve cover, camshaft and rocker arms, and cylinder head.

INSPECTION

2. Loosen all four oil pipe banjo bolts and then remove the bolts and eight sealing washers. Remove the pipes.

3.27

Page 88

ENGINE

3. Loosen hose clamps and remove coolant inlet hose.

4. Remove the two 6 mm cylinder base bolts.

6. Tap cylinder lightly with a plastic hammer in the reinforced areas only until loose.

7. Rock cylinder forward and backward and lift it from the crankcase, supporting piston and connecting rod. Support piston with Piston Support Block (PN 2870390).

8. Remove dowel pins from crankcase.

PISTON REMOVAL

5. Loosen each of the four large cylinder base bolts 1/4 turn at a time in a criss-cross pattern until loose and remove bolts.

NOTE: The bolts are inside the water jacket.

1. Remove circlip. Note piston directional arrow pointing toward the right (Mag) side of engine.

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

3. Remove top compression ring.

*Using a piston ring pliers: Carefully expand ring and lift it off the piston. CAUTION: Do notexpandthe ring more than the amount necessary to remove it from the piston, or the ring may break. *Byhand: Placing both thumbs asshown, spread the ring open and push up on the opposite side. Do not

3.28

Page 89

ENGINE

scratch the ring lands.

4. Repeat procedure for second ring. The oil control ring is a three piece design consisting

of a top and bottom steel rail and a center expander section. The top rail has a locating tab on the end which fits into a notch (A) in the upper oil ring land of the piston.

5. Remove the top rail first followed by the bottom rail.

6. Remove the expander.

2. Inspect thetop of the cylinder for warpage usinga straight edge and feeler gauge.

Cylinder Warpage:

.002″ (.05 mm)

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

1/2″ Down From Top of Cylinder

CYLINDER INSPECTION

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

1/2″ Up From Bottom

4. Inspect cylinder for taper and out of round with a telescoping gaugeor a dial bore gauge. Measure in two different directions, front to back and side to side, onthree different levels (1/2″ downfromtop, in the middle, and 1/2″ up from bottom).

5. Record measurements. If cylinder is tapered or out of round beyond .002, the cylinder must be re-bored oversize, or replaced.

Cylinder Taper

Limit: .002 Max.

Cylinder Out of Round

Limit: .002 Max.

Standard Bore Size:

3.6221-3.6228I (92.00-92.012mm)

3.29

Page 90

ENGINE

PISTON-TO-CYLINDER CLEARANCE

Piston

40 mm

Piston Pin

1. Measure piston outside diameter atapoint 40mm down from the top of the piston at a right angle to the direction of the piston pin.

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

Piston to Cylinder Clearance

Std: .0006-.0018I (.015-.045 mm)

Piston O.D.:

Std: 3.6204-3.6215I (91.970-91.985 mm)

Piston Pin Measurement Locations

Piston Pin O.D.

.9053-.9055I (22.994-23.0 mm)

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

PISTON/ROD INSPECTION

Piston Pin Bore

Piston Pin Bore:

.9055-.9057I (23.0-23.006 mm)

1. Measure piston pin bore.

3.30

3. Measure connecting rod small end ID.

Piston

Ring

Feeler Gauge

Page 91

Piston Ring-to-Groove Clearance

Top Ring Std: .0016-.0031I (.040-.080 mm)

Limit: .0059I (15 mm)

Second Ring Std: .0012-.0028I (.030-.070 mm)

Limit: .0059I (15 mm)

ENGINE

below specified limit, file ring ends until gap is within specified range.

NOTE: Always check piston ring installed gap after re-boring a cylinder or when installing new rings. A re-bored cylinder should always be scrubbed thoroughly with hot soapy water, rinsed, and dried completely. Wipe cylinder bore with an oil rag immediately to remove residue and prevent rust.

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

PISTON RING INSTALLED GAP

1. Place each piston ring inside cylinder using piston to push ring squarely into place as shown at right.

Feeler Gauge

Cylinder

Piston Ring

25-50mm

CRANKCASE DISASSEMBLY

NOTE: The recoilstarter, starter motor,starter drive,

flywheel, stator, cam chain and sprockets can be serviced with the engine in the frame.

STARTER DRIVE REMOV

1. Remove recoil housing bolts and remove housing.

AL/INSPECTION

Piston Ring Installed Gap

Top Ring

Std: .0079-.0138I (.20-.36 mm) Limit: .039I (1.0 mm)

Second Ring

Std: .0079-.0138I (.20-.36 mm) Limit: .039I (1.0 mm)

Oil Ring

Std: .0079-.0276I (.20-.70 mm) Limit: .059I (1.5 mm)

2. Measure installed gap with a feeler gauge at both the top and bottom of the cylinder. NOTE: A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round.

3. If thebottom installed gap measurement exceeds the service limit, replace the rings. If ring gap is

2. Remove starter drive assembly. Note the thrust washer located at the rear of the drive mechanism.

3. Inspect thethrust washer for wear or damage and replace if necessary.

3.31

Page 92

ENGINE

Std. Bushing ID:

.4735″-.4740″ (11.11-12.04 mm)

5. Replace crankshaft seal (A).

Std. Shaft OD:

.470″-.472″ (11.93-11.99 mm)

Starter Drive Bushing Clearance:

Std: .0015″-.004″ (.038-.102 mm)

Service Limit:

.008″ (.203 mm)

4. Measure the OD of the starter drive shaft on both ends and record.

5. Measure the ID of the bushing in the recoil housing (A) and in the crankcase and record. Measure in two directions 90° apart to determine if bushing is out of round. Calculate bushing clearance. Replace bushing if clearance exceeds the service limit.

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

FLYWHEEL/STATOR REMOV

AL/INSPECTION

6. Remove oil passage O-Ring (B).

1. Remove flywheel nut and washer.

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

3. Mark ornoteposition of stator plate oncrankcase.

4. Remove bolts and carefully remove stator assembly,beingcareful not todamagecrankshaft bushing on stator plate.

7. Remove large sealing O-Ring from outer edge of stator plate.

CAM CHAIN/TENSIONER BLADE

1. Remove bolt securing tensioner blade to crankcase (A).

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2. Remove blade and inspect for cracks, wear, or damage.

ENGINE

3. Remove cam chain (B). Inspect chain for wornor missing rollers or damage. Stretch chain tight on a flat surface and apply a 10 lb. (4.53 kg) load. Measure length of a 20 pitch section of chain. Replace if worn past service limit.

Chain Service Limit:

5.407″ (13.7 cm)

1. Remove cap bolt (A), sealing washer (B), spring (C), and one way valve (D) from PTO side crankcase.

2. Inspect free length of spring and check coils for distortion.

One Way Valve Spring Free Length:

Std: 1.450″ (3.68 cm)

4. Using the special socket, remove the crankshaft slotted nut (A). NOTE: The slotted nut is a left hand thread.

5. Remove cam chain drive sprocket (B) and Woodruff key from crankshaft.

6. Inspect sprocket teeth for wear or damage.

7. Inspect Woodruff key for wear.

8. Replace any worn or damaged parts.

ONE WAY VALVE

The one wayvalve prevents oil from drainingout ofthe oil tank and into the crankcase when the engine is off. It must be clean and have adequate spring pressure in order to seal properly.

3. Inspect valve for wear.

4. Check seat area for nicks or foreign material that may prevent proper sealing of valve.

CRANKCASE SEPARATION

1. Remove flange bolts (10) from magneto side crankcase evenly in a criss-cross pattern.

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ENGINE

2. Separate crankcase by tapping with a soft faced hammer in reinforced areas.

3. Tap lightly on balancer gear with a brass drift through the hole in the crankcase if necessary, to ensure the balancer shaft stays in the PTO side crankcase. Watch the gap along the crankcase mating surface and separate the crankcase evenly. It may also be necessary to tap the oil pump shaft lightly to separate the crankcase.

CAUTION: Do not strike the oil pump shaft at an angle or the shaft may bend, causing irreparable damage. Tap only lightly on the pump shaft if necessary.

4. Remove the Mag (RH) crankcase from the PTO case.

OIL PUMP

4. Remove three oil pump retaining bolts andpump.

REMOV

1. Remove pump shaft bearing (A) and thrust washer (B) from pump shaft.

2. Remove (2) bolts holding pump drive gear (C).

3. Inspect drive gear teeth for cracks, damage or excessive wear.

AL/INSPECTION

5. Inspect mating surface of crankcase and oil pump. Check for nicks, burrs, or surface irregularities.

6. Remove the three screws and strainer screen from pump.

7. Clean screen thoroughly.

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ENGINE

8. Remove pump body screw and feed chamber cover.

9. Measure pump end clearance using a feeler gauge and straight edge.

Pump End Clearance:

Std: .001-.003 (.0254-.0762 mm)

Wear Limit: .004 (.1016 mm)

12. Remove inner and outer feed rotor and pump chamber body.

13. Repeat measurements for scavenge rotor.

14. Remove inner and outer scavenge rotor and inspect pump shaft for wear.

OIL PUMP ASSEMBLY

1. Clean and dry all parts thoroughly. Apply clean engine oil toallparts. Do not use gasket sealer on the pump body mating surfaces or oil passages will become plugged.

2. Install pump shaft and scavenge rotor drive pin.

3. Install outer scavenge rotor, inner scavenge rotor, and scavenge casing.

4. Install outer feed rotor and inner feed rotor drive pin.

5. Install inner feed rotor and feed chamber cover with screw.

6. Tighten screw securely.

7. Install screen on pump body.

8. Install oilpumpon crankcase and torque bolts to 6 ft. lbs. (8 Nm).

10. Measure clearance between outer feed rotor and pump body with a feeler gauge.

Rotor Tip Clearance:

Std: .005 (.127 mm)

Wear Limit: .008 (.2032 mm)

Oil Pump Attaching Bolt Torque:

6 ft. lbs. (8 Nm)

COUNTER BALANCER SHAFT REMOV

AL/INSPECTION

11. Measure rotor tip clearance with a feeler gauge.

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ENGINE

1. Remove the shim washer (A) from the counter balancer shaft.

2. Note the alignment dots on the balancer and crankshaft gears, the marks must be aligned during reassembly.

CRANKSHAFT REMOVAL/INSPECTION

1. Remove theshimwasher (A) from the crankshaft.

2. Support the PTO side crankcase and crankshaft; press the crankshaft out. Be careful not to damage the crankcase mating surface or connecting rod.

3. Turnthe shaft untilbalancercounter weightsclear the crankshaft and remove the balancer shaft from the crankcase.

4. Inspect the balancer drive gear and pump shaft drive gear.

5. Replace the shaft if gear teeth are abnormally worn or damaged.

6. Inspect the balancer shaft bearings.

NOTE: Due to extremely close tolerances and minimal wear, the balancer shaft ball bearings must be inspected visually and by feel. Look for signs of discoloration, scoring or galling. Turn the inner race of each bearing. The bearings should turn smoothly and quietly. The outer race of each bearing should fit tightly in the crankcase. The inner race should be firm with minimal side tosidemovement and nodetectable up and down movement.

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3. Useafeeler gaugeto measure theconnecting rod big end side clearance.

Connecting Rod Big End Side Clearance:

Std: .0039-.0256I (.1-.65 mm) Limit: .0315I (.80 mm)

4. Place the crankshaft in a truing stand or V-blocks and measure the runout on both ends with a dial indicator.

Max Runout: .0024″ (.06 mm)

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ENGINE

5. Measure the connecting rod big end radial clearance.

Big End Radial Clearance:

Std: .0004-.0015I (.011-.038 mm) Limit: .0020I (.05 mm)

6. Inspect the crankshaft main bearing journals for scoring and abnormal wear.

CRANKCASE BEARING INSPECTION

PUMP SHAFT OIL SEAL/ WATER PUMP SEAL

REMOVAL (ENGINE

MECHANICAL

DISASSEMBLED)

NOTE: The water pump mechanical seal can be

removed without removing the engine. Refer to Water Pump Mechanical Seal Installation.

Replace the pump shaft seal and water pump mechanical seal whenever the crankcase is disassembled.

1. Remove the seal from the PTO side crankcase.

2. Inspect the crankshaft main bearings, balancer shaft bearings, and pump shaft bearing.

NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. Look for signs of discoloration, scoring orgalling. Turn theinner race of each bearing. The bearings should turn smoothly and quietly. The outer race of each bearing should fit tightly in the crankcase. The inner race should be firm with minimal side to side movement and no detectable up and down movement.

3. Support the crankcase and drive or press the main bearings out of each crankcase.

4. To remove balancer shaft bearings and pump shaft bearing use a blind hole bearing puller.

NOTE: Bearings are stressed during the removal process and should not be re-used!

1. Remove the pump shaft bearing from the Magneto (right hand) side crankcase.

2. Pry out the oil seal, noting the direction of installation with the spring side facing IN (toward inside of case).

3. Drive the water pump mechanical seal out of the crankcase from inside to outside. Note: The new mechanical seal must be installed after crankcases are assembled, using a special tool. See Mechanical Seal Installation.

the

CRANKCASE INSPECTION

1. Remove all traces of gasket sealer from the crankcase mating surfaces. Inspect the surfaces closely for nicks, burrs or damage.

2. Check the oil pump and oil passage mating surfaces to be sure they are clean and not damaged.

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ENGINE

BEARING INSTALLATION

NOTE: To ease bearing installation, warm the

crankcase until hot to the touch. Place the bearings in a freezer.

1. Install the bearings so the numbers are visible.

2. Drive or press new bearings into the crankcases, using the proper driver. CAUTION: Press only on outer race of bearing to prevent bearing damage.

S 70 mm (2.755″) driver- For

crankshaft main bearings.

S 46 mm (1.810″)For counter balancer

bearings.

S 28 mm (1.100″) For pump shaft

bearing.

END PLAY INSPECTION/ADJUSTMENT

2. Measure the distance from the PTO crankcase mating surface to the main bearing using a dial caliper and a straight edge.

Before reassembling the crankcase,the following steps should be performed to determine the amount of crankshaft, counter balancer shaft, and pump shaft end play. Excessive end play maycauseengine noise at idle and slow speeds. Too little play will side load the bearings which may lead to premature bearing failure.

CRANKSHAFT END PLAY ADJUSTMENT

3. Subtract the thickness of the straightedge from the measurement obtained in Step 2 and record.

PTO Case Depth

1. Make sure all bearings are firmly seated in the both Mag and PTO crankcase.

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ENGINE

4. Measure the distance from the Magneto crankcase mating surface to the main bearing using the same method and record.

5. Subtract the thickness of the straightedge from the measurement obtained in Step 4 and record.

Mag Case Depth

7. Measure the width of the crankshaft at the bearing seats with a micrometer or dial caliper and record.

Crankshaft Width

8. Subtract the Crankshaft Width measured in Step 7 from the Total Case Width recorded in Step 6, and record below.

Total End Play

9. Subtract the thickness of the existing shim from the result of Step 8 to determine if a different shim is required. The result must be within the specified range listed at right.

Crankshaft End Play:

.008″-.016″ (.02-.04 cm)

6. Add the readings recorded in Step 3 and Step 5 and record below.

Total Case Width

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ENGINE

COUNTER BALANCER SHAFT END PLAY ADJUST

Step 2

1. Make sure all bearings are firmly seated in the crankcase.

2. Measure the width of the counter balancer shaft at the bearing seats with a dial caliper or micrometer, and record reading.

Counter Balancer Shaft End Play:

.008″-.016″ (.02-.04 cm)

OIL PUMP SHAFT END PLAY ADJUSTMENT

1. Make surethe pumpshaft bearingis firmly seated in the Magneto side crankcase.

Step3/4

3. Measure the distance from the Mag crankcase mating surface to the balance shaft bearing using a dial caliper and a straight edge. Subtract the thickness of the straightedge and record.

4. Measure the distance from the PTO crankcase mating surface to the bearing using the same method outlined in Step 1, 2, and-3.

5. Add the readings obtained in Step 3 and Step 4.

6. Subtract the counter balancer shaft width measured in Step 2 from the figure obtained in Step

7. Subtract the thickness of the existing shim from the result of Step 6 to determine if a different shim is needed. The result must bewithin thespecified range listed at below.

2. Measure the distance from the magneto crankcase mating surface to the bearing using a dial caliper and a straight edge. Subtract the thickness of the straightedge and record.

3. Install the gear on the oil pump and measure the width of the pump and gear. Subtract this measurement from the measurement recorded in Step 2.

4. Subtract the thickness of the existing shim from the result of Step 3 to determine if a different shim is needed. See Shaft End Play Spec. next page.

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