Polaris 2005 Sportsman MV7 Service Manual

Download

Page 1

2005 SPORTSMAN MV7

SERVICE MANUAL

PN 9919963

Page 2

2005 SPORTSMAN MV7

SERVICE MANUAL

Foreword

This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position.

Some procedures outlined in this manualrequire asound knowledgeof mechanicaltheory, tool use, andshop procedures inorder to perform the work safely and correctly. Technicians shouldread the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified.

This manualincludes procedures for maintenanceoperations, component identification andunit repair, along with service specifications for 2005 Polaris Sportsman MV manual may bedirected to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota

55340.

2005 Sportsman MV7 Service Manual (PN 9919963)

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.

7 ATVs. Comments or suggestions about this

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 deathto the operator, bystander orperson inspecting or servicing the ATV.

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or person inspecting or servicing the ATV.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property damage.

NOTE:

A NOTE provides key information to clarify instructions.

Trademarks

Polaris acknowledges the following products mentioned in this manual:

FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity Vac, Registered Trademark of Neward Enterprises, Inc. Ammco, Registered Trademark of Ammco Tools, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation

Page 4

CHAPTER INDEX

CHAPTER 1 GENERAL

CHAPTER 2 MAINTENANCE

CHAPTER 3 ENGINE

CHAPTER 4 FUEL SYSTEM

CHAPTER 5 BODY/SUSPENSION

CHAPTER 6 PVT SYSTEM

CHAPTER 7 FINAL DRIVE

CHAPTER 8 TRANSMISSION

CHAPTER 9 BRAKES

CHAPTER 10 ELECTRICAL

Page 5

GENERAL INFORMATION

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

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

Publications Numbers / Replacement Keys 1.3..

2005 Sportsman MV7 / Dimensions 1.4--1.5.........

Specs

Special Tools 1.6--1.10............................

Standard Torque Specifications 1.11............

Conversion Table 1.12........................

Tap Drill Charts 1.13..........................

Decimal Equivalent Chart 1.13.................

Glossary of Terms 1.14........................

1.1

Page 6

GENERAL INFORMATION

MODEL IDENTIFICATION

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

Machine Model Number Identification

A05MH68AP

Emissions &

Year Designation

Basic Chassis Designation Engine Designation

Model Option

ENGINE DESIGNATION NUMBERS

EH068OLE Twin cylinder, Liquid Cooled, 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 4XAMH

Vehicle Description

68A*5P0 00 000

Vehicle Identifier

Body Style

Powertrain

Emissions

Engine

Check Digit

Model Year

Plant No.

ENGINE SERIAL NUMBER LOCATION

Be sure to refer to the engine model number and serialnumber whenever corresponding about an engine. This information can be found on the sticker applied to the top side of the crankcase (A). An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow.

MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION

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

TRANSMISSION I.D. NUMBER

Individual Serial No.

* This could be either a number or a letter

Front

LOCA

1.2

TION

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

Page 7

PUBLICATION NUMBERS

GENERAL INFORMATION

Year Model Model

No.

2005 Sportsman 700 MV A04MH68 9919959 9919960 9919961 9919934

NOTE: Military MV units utilize a different parts manual. Contact Polaris Industries customer service for the part

number at (763) 417--8650.

NOTE: Some publications can be foundat thePolaris website: www.polarisindustries.com or purchased from www.purepolaris.com.

Owner’s

Manual

Parts

Manual PN

Parts Micro

Fiche PN

Warn® Winch Guide

PAINT CODES

PAINTED PART COLOR

DESCRIPTION

Springs Black 9440 P-067

FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147. Order direct from Midwest Industrial Coatings (952-942-1840). Mix as directed.

DITZLER

NUMBER

POLARIS

NUMBER

REPLACEMENT KEYS

Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number.

Should both keys becomelost,ignition switch replacement is required.

Series # Part Number

20 4010278 21 4010278

31XX

Key Series Number

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

700 ENGINE COLD WEATHER FROST PLUG HEATER

Frost Plug Heater for Sportsman 600/700 -- (PN 2873069)

1.3

Page 8

GENERAL INFORMATION

MODEL: 2005 SPORTSMAN MV7..........

MODEL NUMBER: A05MH68. ENGINE MODEL: EH068OLE..

SPECIAL TOOLS

PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN

PV--43527 Oil Filter Wrench 2,3

2870872 Shock Spanner Wrench 2, 5

8712100 or 8712500 Tachometer 2,10

2200634 Valve Seat Reconditioning Kit 3

PU--45257 Valve Spring Compressor 3

2871043 Flywheel Puller 3

2870390 Piston Support Block 3 PU--45497--2 Cam Gear Tooth Alignment Tool 3 PU--45497--1 Cam Gear Spring Installation Kit (3 Tapered Pins) 3

PU--45498 Cam Spanner Wrench 3 PU--45838 Gear Holder 3

PA--44995 Water Pump Mechanical Seal Installer 3 PU--45543 Universal Drive Handle 3 PU--45483 Main Seal Installer 3 PU--45658 Main Crankshaft Seal Saver 3

PA--45401 Water Pump Seal Saver 3 PU--45778 OIl System Priming Tool 3

2870975 Mity Vact Pressure Test Tool 3, 4, 9 2872314 Carburetor Float Adjustment Tool 4 2870871 Ball Joint Replacement Tool 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 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 2872608 Roller Pin Removal Tool 7 8700226 CV Boot Clamp Pliers 7

PV--43568 Fluket77 Digital Multimeter 10

2870630 Timing Light 10 2870836 Battery Hydrometer 10

*Special Tools Can be ordered through SPX Corporation (1--800--328--6657).

1.6

Page 11

SPECIAL TOOLS

GENERAL INFORMATION

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 recommends 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

PV--43527 Oil Filter Wrench

2870390 -- Piston Support Block

PA--44995 -- Water Pump Mechanical

Seal Install Tool

PU--45543 -- Universal Driver Handle

ools

2871043 -- Flywheel Puller

2870773 -- C--Clip Install Tool

2870386 -- Piston Pin Puller

2871445 -- Piston Pin Puller Adapter

PA--45483 -- Main Seal Installer

PA--45658 -- Main Crank Seal Saver

PA--45401 -- Water Pump Seal Saver

PU--45778 -- Oil Pump Priming Tool

1.7

Page 12

GENERAL INFORMATION

SPECIAL TOOLS

Standard Tools and Engine Tools

2870303 -- Hone Kit

2870305 -- Stone Replacement Kit

2870588 -- Hone Oil (12 oz.)

Clutch (PVT) Tools

2870506 -- Drive Clutch Puller

2870913 -- Driven Clutch Puller

2872292 -- EBS Clutch Align Tool

2200634 -- Valve Seat

Reconditioning Kit

2870459 -- Dial Indicator

PV--35667--A -- Cylinder Leak

down Tester

9914177--A -- Drive Clutch Holding Tool

8700220 -- Clutch Compression Tool

2871358 -- Clutch Hold Fixture

2870341 -- Drive Clutch Spider

Removal Tool

1.8

Page 13

GENERAL INFORMATION

Clutch (PVT) Tools

2871025 -- Clutch Bushing Replace

Tool Kit

2870910 -- Roll Pin Tool

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

1.9

Page 14

GENERAL INFORMATION

Suspension Tools

2870872 -- Shock Spanner Wrench

2872608 -- Roll Pin Removal Tool

2871351 -- Shock IFP Depth Tool

Fuel & Brake Systems

Electrical Tools

2870630 -- Timing Light

2871745 --Static Timing Light Harness

2460761 -- Hall Sensor Probe Harness

2870975 -- Mity Vact

Electrical Tools

PV--43568 --Fluket 77 Multimeter

PV--39991 -- Peak Reading Adapter

PV--37453 -- Christie De--Sulfating

Multi--Battery Charger

PV--63070 -- Christie Multi--Battery

Charger

2870836 -- Battery Hydrometer

RPM

PV--39617 -- Current Clamp

1.10

8712500 -Tachometer

PV--39951--A -Tachometer

Page 15

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. (Nm)

#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).............. ................ .............

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 section.

1.11

Page 16

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 x10 =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

1.12

Page 17

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.....

1.13

Page 18

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. 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. 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/cm2: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. lorltr: Liter. Left 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. qt.: Quart/quarts. RPM: Revolutions per minute. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy

conversion to heat.

Right Side: Always referred to based on normal operating position of the driver. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder

wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.

Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston’s most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.

1.14

Page 19

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

Component Locations 2.6....................

Lubricant and Maintenance Product Numbers 2.7

Recommended Lubricants 2.8................

Lubrication Charts 2.9-2.10........................

Pre-Ride Inspection 2.10......................

Front Gearcase Lubrication 2.11................

Transmission Lubrication/Linkage Inspection 2.12

MAINTENANCE

Rear Gearcase Lubrication 2.13................

Lubrication / Grease Points 2.14................

Shift Linkage Adjustment 2.14..................

Carburetor Adjustments 2.14-2.16...................

Fuel System 2.17-2.18.............................

Compression Test 2.18--2.19........................

Battery Maintenance 2.19--2.20......................

Ignition 2.19-2.20..................................

Coolant System Maintenance 2.21--2.23..............

Air Box / Filter Service 2.23-2.24....................

Breather Filter / Line Inspection 2.24-2.25............

Recoil Housing 2.25...........................

PVT Drying & PVT Drain Plug 2.26..............

Oil Check/Change/Filter 2.26-2.28...................

Steering and Toe Alignment 2.28-2.30...............

Exhaust System Maintenance 2.30-2.31.............

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

Suspension Service 2.32-2.33......................

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

Wheel/Tire --Removal/Installation/Inspection 2.34-2.35.

® Winch Operation 2.36-2.37..................

Warn

Cleaning and Storage 2.38-2.39.....................

Maintenance Chart 2.40.......................

2.1

Page 20

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 miles perhour. Vehicles subjectedto severeuse must be inspected and serviced more frequently.

Severe Use Definition

G Frequent immersion in mud, water or sand G Racing or race-style high RPM use G Prolonged low speed, heavy load operation G Extended idle G 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 21

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 Page2.10.

Inspect; clean often

Drain deposits when visible

Check level daily, change coolant every 2 years

(if applicable) Headlamp/tail

Daily

lamp

Air filter,

main element Recoil housing

Weekly

(if applicable)

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

Check operation; apply dielectric grease if replacing

Inspect; replace as needed

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

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 22

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 23

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 24

MAINTENANCE

SPORTSMAN MV7 COMPONENT LOCATIONS

Gear Shifter

Winch Switch

Brake Lever

Light Control & Run Switch

Winch Selection Switch

Reverse Override

Choke

Front Storage Rack

Access Door

Instrument Cluster (Speedometer)

Ignition/Key

AWD Switch

Throttle

Fuel Valve

Rear Winch

Auxiliary Brake

Recoil Handle

Front Winch

Front Gearcase

(Behind Radiator)

Oil Dipstick

PVT Cover Drain Plug

Rear Rack

Gas Cap

Rear Gearcase

Transmission

Front Drive Shafts

2.6

Page 25

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.

POLARIS LUBRICANT SYMBOL IDENTIFICATION

0W/40

Polaris Synthetic OW--40 Oil

DHF

Polaris Demand Drive Hub Fluid

Polaris All Season Grease

ADF

Polaris ATV Angle Drive Fluid

Polaris DOT 3 Brake Fluid

AGL

Polaris Synthetic Gearcase Lube

AGL

U--Joint

Polaris U--Joint Lube

2.7

Page 26

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

2859066 -- Sportsman 600/700 Maintenance Kit

-- Oil Filter & 2 Qts. of 0W--40 oil

-- D r i v e B e l t

-- PVT Cover Seal

-- Spark Plug

-- Instruction Sheet

2202166 -- Sportsman 600/700 Oil Change Kit

-- Oil Filter & 2 Qts. of 0W--40 oil

-- Instruction Sheet

2.8

Page 27

LUBRICATION

Dipstick

MAINTENANCE

Fill / Check

0W/40

1. Engine Oil and Filter

Fill Plug

2. Transmission

DHF

Drain Plug

Fill plug

Drain Plug

3. Front Gear Case Fill Plug

5. Brake Fluid (Left hand Master Cylinder)

* 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)

4. Rear Gear Case Fill Plug

Master Cylinder Reservoir

AGL

ADF

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

Ill.

1. Engine Oil Polaris 0W--40

2. Transmis-

3. Front Gear

4. Rear Gear

5. Brake Fluid Polaris Dot 3 Brake

Item Lube Rec. Method Frequency*

sion

Case

Synthetic

Polaris AGL Gear-

case Lubricant

Premium Demand

Drive Hub Fluid

ATV Angle Drive

Fluid

Check dipstick and add to

proper level.

Add lube to bottom of fill hole. Change annually ©

Drain completely. Add lube to spe-

cified quantity.

Drain completely. Add lube to spe-

cified quantity.

Fill master cylinder reservoir to in-

dicated level inside reservoir.

Change after 1st month, 6 months or 100

hours thereafter; Change more often

(25-50 hours) in extremely dirty condi-

tions, or short trip cold weather operation.

Change annually ©

As required. Change fluid every 2 years

2.9

Page 28

MAINTENANCE

LUBRICATION, CONT.

6. Front Prop Shaft U-Joint

Front Hubstrut (All Models)

Ill.

6. Front Prop Shaft Polaris U-Joint

7. Front Hub strut Polaris All Season

* 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)

Item Lube Rec. Method Frequency*

Locate grease fitting and

Grease¢

grease with grease gun.

Locate fitting and grease Semi-annually ¡

7. Front Hub strut

Semi-annually ¡

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

Mobilegrease Special

PRE-RIDE / DAILY INSPECTION

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

G Tires - check condition and

pressures

G Fuel and oil tanks - fill both tanks to

their proper level; Do not overfill oil tank

G All brakes - check operation and

adjustment (includes auxiliary brake)

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

check operation of all indicator lights and switches

G Engine stop switch - check for

proper function

G Wheels - check for loose wheel nuts

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

G Air cleaner element - check for dirt

or water; clean or replace

G Steering - check for free operation,

noting any unusual looseness in any area

G Loose parts - visually inspect vehicle

for any damaged or loose nuts, bolts or fasteners

G Engine coolant - check for proper

level at the recovery bottle

2.10

Page 29

FRONT GEARCASE LUBRICATION

MAINTENANCE

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

G Be sure vehicle is level before proceeding and in

PARK.

G Check vent hose to be sure it is routed properly

and unobstructed.

G The correct front gearcase lubricant to use is

Polaris Premium Demand Hub Fluid.

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

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

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:

The front and rear gearcase lubricant level cannot be checked with a dipstick. The gearcase must be

drained and re-filled with the proper amount of lubricant. Refer to procedures.

Fill Plug

Left Side View Front Wheel

3. Remove fill plug (8 mm hex). Check the O--ring.

4. Fill with the recommended fluid amount (5 oz.) or to the bottom of thefill plughole threads.(See ILL.

3).

Front Gearcase

Plug Threads

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

ILL. 3

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

2.11

Page 30

MAINTENANCE

TRANSMISSION LUBRICATION

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

G Be sure the vehicle is level before proceeding. G Check vent hose to be sure it is not kinked or

obstructed.

G Follow instructions to check / change transmission

lubricant.

To check the level:

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

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

To change lubricant:

1. Remove transmission drain plug to drain the oil. Catch and discard used oil properly.

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

3. Remove fill plug.

4. Add 15 oz. (450 ml) of Polaris AGL Gearcase Lubricant or fill to top of the fill plug hole threads.

5. Check for leaks.

6. Reinstall fill plug and torque to 14 ft.lbs. (19 Nm).

TRANSMISSION SPECIFICATIONS

Specified Lubricant:

Polaris AGL Gearcase Lubricant

(PN 2873603) (gal.) (PN 2873602) (12oz.)

Capacity: 15 oz. (450 ml)

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19 Nm)

Fill Plug

View From Back

Transmission Fill Plug (5/16” Hex)

Fill to the Bottom of Fill Plug Hole Threads

Proper Oil Level

Drain Plug

2.12

Page 31

MAINTENANCE

REAR GEARCASE LUBRICA

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

G Be sure vehicle is level and in Park before

proceeding.

G Check vent hose to be sure it is routed properly

and unobstructed.

G The correct rear gearcase lubricant to use is

Polaris ATV Angle Drive Fluid.

REAR GEARCASE SPECIFICATIONS

Specified Lubricant:

ATV Angle Drive Fluid (PN 2871653)

Capacity: 10 Oz. (300 ml.)

Drain Plug / Fill Plug Torque:

14--18 ft. lbs. (19--24 Nm)

To Check Lubricant Level:

NOTE: The rear gearcase hastwo fill plugs. The rear

fill plug is located on the rear of the gearcase and is not easily accessible. The side fill plug is located on the left side of the gearcase. Use the side fill plug when checking or changing oil.

TION

To Change Lubricant:

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

2. Clean and reinstall drain plug (A) using a new sealing washer (B). Torque plug to 14--18 ft.lbs. (19--24 Nm).

3. Remove fill plug show in illustration 1.

4. Fill with the recommended fluid amount of 10 oz. (300 ml.) or to the bottom of the fill plug threads.

5. Install fill plug and check for leaks.

1. Position the vehicle on a level surface.

Fill Plug

ILL. 1

2. Remove the side fill plug and view the oil level through the fill plug hole.

3. Add lubricant as needed. The lubricant level should be at the bottom of the fill plug hole threads.

4. Reinstall fill plug and torque to 14 ft.lbs. (19 Nm).

Fill Plug Threads

Fill to bottom of fill plug threads

2.13

Page 32

MAINTENANCE

LUBRICATION / GREASE POINTS

As shownon Page2.10, there areonly 3grease zerks on the Sportsman MV, two front ball joints and rear prop shaft. The rear propshaft grease zerk is accessible through the auxiliary brake access hole on the right footwellor through the bottom of the footwell.

Ball Joint Zerk

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.

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

Ball Joint Zerk

View -- Right Footwell by Auxiliary Brake

Shifter Mount

Shift Linkage Rod

Shifter

THROTTLE INSPECTION

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

1. Place the gear selector in neutral.

2. 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 in the turning range, inspect throttle cable routing and condition. Adjust

2.14

Page 33

MAINTENANCE

cable tension as needed until lock--to--lock turning can be accomplished with no rise in engine rpm.

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

To remove 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 while lifting 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.

Illustration of choke may vary with models.

Ill.1

Boot

IDLE SPEED ADJUSTMENT

CV Carburetor

ETC Cover

Ill. 1

Removal Sequence

CHOKE (ENRICHER) ADJUSTMENT

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.

Verify free play of 1/16--3/16” (1.6--4.76 mm) and smooth operation of choke cable.

If smooth choke operation is not obtainable, inspect choke cable for kinks or sharp bends in routing.

Ill.3

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. (Ill.3)

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 Screw

Idle Speed:

2005: 1200 ± 50 RPM

2.15

Page 34

MAINTENANCE

PILOT SCREW

The pilot systemsupplies fuelduring 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 atthe factory 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

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.

THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL (ETC SWITCH) ADJUSTMENT CONTEND

3. Start engine and set idle to specified RPM.

Boot

Adjuster Sleeve

Locknut

Boot

Brass Plug Installed

Brass Plug Removed

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 reverify freeplay.

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 good condition, repeat adjustment procedure.

1/16″ -1/8″

Freeplay

2.16

Page 35

MAINTENANCE

FUEL SYSTEM

WARNING

Gasoline is extremely flammable and explosive under certain conditions.

G Always stop the engine and refuel

outdoors or in a well ventilated area.

G Do not smoke or allow open flames

or sparks in or near the area where refueling is performed or where gasoline is stored.

G Do not overfill the tank. Do not fill the

tank neck.

G If you get gasoline in your eyes or if

you swallow gasoline, seek medical attention immediately.

G If you spill gasoline on your skin or

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

G Never start the engine or let it run in

an enclosed area. Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time.

G Never drain the float bowl when the

engine is hot. Severe burns may result.

OFF

REAR TAN K

FRONT

TAN K

FUEL VALVE AND FUEL

ANKS

The fuel valve (1) is located on the left side panel. OFF: Turn the fuel valve off for vehicle storage and

when transporting. REAR TANK: It is recommended to use the rear tank

fuel supply first. Switch to the front tank when the rear tank is empty. It will be easierto monitorremaining fuel at the front tank gauge.

FRONT TANK: Use the front tank fuel supply when the rear tank is empty.

The front fuel tank filler cap (2) is located directly below the handlebar. The rear fuel tank and filler cap (3) are located behind the seat, under the rear rack.

FUEL LINES

Fuel Pump

Fuel Lines

Impulse Line

Fuel Filter

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

2. Besure fuellines arerouted 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.

2.17

Page 36

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.

Filter Located Between Pump and Carb

Arrow Indicates Direction of Flow

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.

Drain tube attached here

Ill. 1

Drain Screw

To Carburetor

1. Shut off fuel supply at fuel valve.

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

3. Remove fuel lines from filter.

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

5. Install clamps on fuel line.

6. Turn fuel valve “ON”.

7. Start engine and inspect for leaks.

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 is located on 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. Turn fuel valve to “Rear Tank” or “Front Tank”.

COMPRESSION TEST

NOTE: This engine does NOT have decompression

components. Compression readings will vary in proportion to cranking speed during thetest. Average compression (measured) is about 150-170 psi during a compression test.

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

2.18

Page 37

MAINTENANCE

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

Cylinder Compression

Standard: 150-170 PSI

Cylinder Leakdown

Service Limit 10 %

(Inspect for cause if leakage exceeds 10%)

ENGINE MOUNTS

Inspect rubber engine mounts (A) for cracks or damage. (Ill.3)

Check engine fasteners and ensure they are tight.

BATTERY MAINTENANCE

WARNING

Battery electrolyte ispoisonous. Itcontains 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. KEEPOUT OF REACH OF CHILDREN.

Ill. 3

NOTE: New Batteries: chargedbefore use or battery life willbe reduced by 10-30%of full potential. Chargebattery for 3--5 hours at a current equivalent of 1/10 of the battery’srated amp/hour capacity. Do not use the alternatorto charge a new battery. (Refer tobattery

video PN 9917987) The battery is located under the seat. Inspect the battery fluid level. When the electrolyte

nears the lower level, remove the battery and add distilled water only to the upper level line. (Ill.1)

Maintain between upper and lower level marks

Batteries must be fully

Ill. 1

2.19

Page 38

MAINTENANCE

To remove the battery:

1. Disconnect holder strap and remove cover.

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

CAUTION

To reduce the chance of sparks: Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, install the negative cable last.

3. Disconnect the vent hose.

4. Remove the battery.

5. Remove the fillercaps andadd distilled water only as needed to bring each cell to the proper level. Do not overfill the battery. Fully recharge after filling.

Use only distilled water. Tap water contains

minerals which are harmful to a battery.

Do not allow cleaning solution or tap water to

enter the battery, as it will shorten the life of the battery.

6. Reinstall the battery caps.

7. Cleanbattery cablesand terminalswith astiff wire brush. Corrosion can be removed using a solution of one cup water and one tablespoon baking soda. Rinse wellwith clean water and dry thoroughly.

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

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

10. Coat terminals and bolt threads with Dielectric Grease (PN 2871329).

11. Reinstall battery cover and holder strap.

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

Inspect electrode for wear and buildup

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. (Illustration below)

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:

Refer to Specifications Chapter 1

Spark Plug Torque:

18 Ft. Lbs. (24 Nm)

Spark Plug Gap

SPARK PLUG

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

2. Remove spark plug.

2.20

.036″ (0.9 mm)

Page 39

MAINTENANCE

ENGINE-TO-FRAME GROUND

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

Typical Ground Cable

LIQUID COOLING SYSTEM OVER

VIEW

COOLANT STRENGTH / TYPE

Test the strength of the coolant using an antifreeze hydrometer.

Antifreeze Hydrometer

G A 50/50 or 60/40 mixture of

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

G Do not use tap water. Tap water

contains minerals and impurities which build up in the system. Do not add straight antifreeze or straight water to the system. Straight water or antifreeze may cause the system to freeze, corrode, or overheat.

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

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

G Some coolant level drop on new

machinesisnormalasthe system is purgingitselfoftrappedair.Observe coolant levels often during the break-in period.

G Overheating of engine could occur if

air is not fully purged from system.

G PolarisPremium60/40anti--freezeis

premixed and ready to use. Do not dilute with water.

Polaris 60/40 Anti-Freeze / Coolant

(PN 2871323)

COOLING SYSTEM HOSES

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

Upper Radiator

Hose

Coolant Bottle

Lower Radiator Hose

Fan

2.21

Page 40

MAINTENANCE

1. Check tightness of all hose clamps.

2. Do not over-tighten hose clamps at radiator or radiator fitting may distort, causing a restriction or leak. Radiator hose clamp torque is 36 in. lbs. (4 Nm).

RADIATOR

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

2. To access the radiator, open the left side panel under the front rack. Pull outward on the access panel. NOTE: To remove the radiator, remove the front rack assembly (Refer to Chapter 5).

Access Panel

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

1. Remove the side panel. (Refer to Chapter 5)

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

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

4. Reinstall cap.

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

Recovery Bottle Accessible Under Side Panel

Ill.1

3. Carefully straighten any bent radiator fins.

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

COOLING SYSTEM PRESSURE

Refer to Chapter 3 for pressure test procedures.

TEST

COOLANT LEVEL INSPECTION

WARNING

Never remove the radiator pressure cap when the engine is warm or hot. Escaping steamand fluidcan cause severe burns. The engine mustbe allowed to cool before removing the pressure cap.

The recovery bottle, located on the left side of the machine, must bemaintainedbetween theminimum and maximum levels indicated. (Ill.1)

Ill.1

RADIATOR COOLANT LEVEL INSPECTION

WARNING

Never remove the radiator pressure cap when the engine is warm or hot. Escaping steamand fluidcan cause severe burns. The engine mustbe allowed to cool before removing the pressure cap.

NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, or if overheating is evident, the level in the radiator should be inspected via the radiator cap first and coolant added if necessary.

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

To access the radiator pressure cap:

1. Remove the bolts securing the front rack. See Chapter 5 for rack removal.

2. Remove the rack.

2.22

Page 41

3. Remove the pressure cap (1).

4. Using a funnel, slowly add coolant through the radiator filler neck.

5. Reinstall the pressure cap.

6. Reinstall the front rack.

MAINTENANCE

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

allow the recovery system to function properly. Contact your dealer for the correct replacement part.

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 filtershould becleaned beforeeach ride using the following procedure:

1. Lift up on the rear of the seat.

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

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 should adheretightly to the cover and seal all the way around.

4. Loosen clamp and remove air filter assembly.

Cover

Gasket

Pre-filter

Main Element

Ill.1

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 replaceif 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.

2.23

Page 42

MAINTENANCE

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

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

Filter Clamp

Ill.2

Proper Filter Placement

Main Filter

Filter Support

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. 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.

Air Box

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

BREATHER FILTER / LINES INSPECTION

Four cycle ATV engines are equipped with a breather filter. The in-line filter issimilar in appearance to afuel filter. The breather filter islocated behindthe fueltank foam on Sportsman MV models.

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

2.24

Page 43

MAINTENANCE

Breather Filter Orientation -- Arrow To Engine

RECOIL HOUSING

Recoil Drain Plug

Recoil Assembly Location

NOTE: In-line breather filter service life is extended when the foam air box pre-filter is in place and maintained properly. Never operate the engine without the pre-filter.

Breather Hose

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

NOTE: For recoil disassembly, refer to Chapter 3.

G Drain the housing periodically to remove

moisture.

G 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.

G 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.

G Water will enter the recoil housing if the

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

G After travelling in wet areas the recoil

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

G Do not open the crankcase drain unless

the engine has ingested water. Some

2.25

Page 44

MAINTENANCE

engine oil will be lost if crankcase drain is opened.

G If recoil handle (B) seal has been

damaged, the handle should be replaced.

PVT DRYING & PVT DRAIN PLUG

NOTE: If operating the ATV in or through water, be

sure to check the PVT cover and other components for water ingestion. The ATV should be checked immediately.

1. To release any water that maybe trapped in the PVT cover, simply removethe PVTdrain plug and O--ring located on the bottom of the PVT cover and let the water drain out. The PVT drain plug is shown below.

ENGINE OIL LEVEL

The 600/700 engine is a wet--sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level:

Dipstick

Ill.1

1. Set machine on a level surface.

2. Be sure the machine has sat for awhile before removing the dipstick. Do not run the machine and then check the dipstick.

3. Stop engine and unlock the lever lock.(Ill. 2) Remove dipstick and wipe dry with a clean cloth.

PVT Drain Plug & O--ring

Ill.3

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

Dipstick Location

Lever Lock

Dipstick

2.26

Ill.2

SAFE

ADD 8 OZ

Page 45

MAINTENANCE

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

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

5. Remove dipstick and check to see that the oil level is in the normal range. Add oil as indicated by the level on the dipstick. Do not overfill. (See NOTE below!)

NOTE: Due to the dipstick entry angle into the crankcase, the oil level will read higher on the bottom side of the dipstick. Proper level indication is determined on the upper surface of the dipstick as it is being removed, regardless of the level marks being on top or on bottom. (See the next illustration)

Dipstick

OIL AND FILTER CHANGE

1. Place vehicle on a level surface.

2. Run engine two to three minutes untilwarm. Stop engine.

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

4. Place a drainpan beneathcrankcase andremove drain plug.

Crankcase Drain

Engine Oil Drain Plug - Bottom View

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

NOTE: A rising oil level between checks in cool

weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full mark, change the oil immediately.

CAUTION: Oil may be hot. Do not allow hot oil to come into contact with skin, as serious burns may result.

Oil Filter

5. Allow oil to drain completely.

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

7. Reinstall drain plug and torque to 192 ± 24 in. lbs. (21.7 ± 2.7 Nm).

2.27

Page 46

MAINTENANCE

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

9. Usinga clean drycloth, cleanfilter sealingsurface on crankcase.

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

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

12. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris Premium 4 Synthetic Oil (PN 2871281).

Recommended Engine Oil

Polaris Premium 4 All Season Synthetic,

0W--40 (PN 2871281)

Ambient Temperature Range:

-40_ Fto120_ F

STEERING

The steering components should be checked periodically for loose fasteners, worn tierod 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 orlimited. NOTE: Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts.

WARNING

Due to thecriticalnature 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.

Crankcase Drain Plug Torque:

192 ± 24 in. lbs. (21.7 ± 2.7 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)

13. Place gear selector in neutral and set parking brake.

14. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks.

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

16. Dispose of used filter and oil properly

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

G To check for play in the tie rod end,

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

G Repeat inspection for inner tie rod

end on steering post.

2.28

Page 47

MAINTENANCE

WHEEL ALIGNMENT

G Replace any worn steering

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

G Elevate front end ofmachine 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.

G If abnormal movement is detected,

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

Check for Loose Wheel or Hub

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.

G Refer to the Body/Steering Chapter

5 or Final Drive Chapter 7 for service procedures.

CAMBER AND CASTER

The camber and caster are non-adjustable.

NOTE: The steering post tie rod mount can

be used as an indicator of whether the handle-

bars are straight. The mount should always

point straight back from the steering post.

2.29

Page 48

MAINTENANCE

WHEEL ALIGNMENT METHOD 2:

1. Place machine on a smooth level surface.

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) fromthe flooror 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 thetires 180° by movingvehicle 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 at the front of the tire (A) is1/8″ to 1/4″ (.3 to.6 cm) wider than the measurement at the rear (B).

Ill.1

Chalk Line Measurement “A”

CHALK

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

Hold Rod End

Correctly Tightened

Ill.2

To adjust toe

Jam Nut

Ill.2

alignment:

G Hold tie rod end to keep it from

rotating.

G Loosen jam nuts at both end of the tie

rod.

G Shorten or lengthen the tie rod until

alignment isas required to achieve the proper toe setting asspecified in Method 1 or Method 2.

G IMPORTANT: When tightening the

tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly. See illustration 2.

G After alignment is complete, torque

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

Incorrectly Tightened Jam Nut

2.30

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.

Page 49

Ill.1

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.

Clean Out Plug

MAINTENANCE

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

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

8. Reinstall the clean out plugs.

WARNING

G 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.

G To reduce fire hazard, make sure that

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

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

hicle while purging the carbon from the spark arrestor.

G Never run the engine in an enclosed

area. Exhaust contains poisonous carbon monoxide gas.

G Do not go under the machine while it is

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

4. If particles are still suspected to be in the muffler, back the machineonto an inclineso therear ofthe machine is one foot higher than the front. Set the hand brake and block the wheels. Make sure the machine is in Parkand repeat Steps 2 and 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

1ft.

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 ingood operating condition. Service life of brake system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride.

G Keep fluid level in themaster cylinder

reservoir to the indicated level inside reservoir.

G Use Polaris DOT 3 Brake Fluid (PN

2870990).

2.31

Page 50

MAINTENANCE

Sight Glass

Parking Brake Lock

Rear Master Cylinder Reservoir

Max

Min.

Brake Pad

Measure Thickness

Service Limit -- .180″ (4.6 mm)

Auxiliary Brake Reservoir

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

spongy feel.

G Check friction pads for wear,

damage or looseness.

G Check surface condition of the disc. G Inspect thickness of brake pad

friction material.

BRAKE PAD INSPECTION

Pads should be changed when the friction material is worn to .180” (4.6 mm). When the pad are new the thickness is .298 ± .007″ (7.56 ± .178 mm).

2.32

Page 51

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 Brake

Support the rear wheels off the ground. 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 waybetween its rest position and bottoming on the footrest.

Auxiliary Foot Brake Pedal

Full Height

Full Engagement

First, check foot brake effectiveness by applying50 lb. (approx.) downwardforce onthe pedal. Thetop ofthe 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:

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.

1″ or greater

Floorboard

SUSPENSION: SPRING

Floor Board Surface

AUXILIARY BRAKE ADJUSTMENT

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

(HYDRAULIC)

PRELOAD

Operator weight and vehicle loading affect suspensionspringpreloadrequirements.Adjustas necessary.

Shock Spanner Wrench

ADJUSTMENT

(PN 2870872)

2.33

Page 52

MAINTENANCE

FRONT SUSPENSION

G Compress and release front suspension.

Damping should be smooth throughout the range of travel.

G Check all front suspension components

for wear or damage.

G Inspect front strut cartridges for leakage.

REAR SUSPENSION

Inspect Boots

Rear Spring Adjustment Cam

G Compress and release rear suspension.

Damping should be smooth throughout the range of travel.

G Check all rear suspension components

for wear or damage.

G Inspect shock 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. Referto Chapter7 forCV bootreplacement, or have you Polaris dealer replace the boot.

CONTROLS

Check controls for proper operation, positioning and adjustment.

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

2.34

Page 53

MAINTENANCE

WHEELS

Inspect allwheels for runout or damage. Check wheel nuts andensure they are tight. Do not over tightenthe wheel nuts. Apply Loctitet 271 (PN 2871954)tothe wheel studs whenever reinstalling the wheel nuts.

WHEEL, HUB, AND SPINDLE TORQUE T

Item Specification

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

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

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

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

ABLE

WHEEL REMOVAL FRONT OR REAR

WHEEL INSTALLATION

1. With the transmission in Park and the parking brake locked, place the wheel in the correct position on thewheel hub. Be surethe 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:

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

TIRE PRESSURE

CAUTION:

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.

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

Tire Pressure Inspection (PSI - Cold)

Front Rear

5 5

4. Remove the wheel nuts and remove the wheel.

2.35

Page 54

MAINTENANCE

TIRE INSPECTION

G Improper tire inflation may affect ATV

maneuverability.

G When replacing a tire always use

original equipment size and type.

G The use of non-standard size or type

tires may affect ATV handling.

Tire Tread Depth

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

Tread Depth 1/8I (3 mm)

WARN® WINCH OPERATION

NOTE: See Chapter 5 for winch mounting. See

Chapter 10 for winch wiring information.

NOTE: For more information on winch operation and techniques, refer to the Warn® Winch Basic Guide to Winching.

The Sportsman MV is equipped with two reliable 2500 lb. (2.5ci) Warn® Winches. One winchin the frontand one in the rear of the MV.

Front Warn® Winch

WARNING

Operating an ATV with worn tires will increase the possibility ofthe vehicle skidding 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.

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.

Rear Warn® Winch

Warn® Winch Handlebar Controls

The winch selection switch located on the headlight pod gives the operator the ability to select the front or rear winch.

2.36

Selection Switch

Page 55

The mini--rocker switch or 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.

MAINTENANCE

ENGAGE

Mini--rocker Switch

OUT

Warn® Winch Control

FREESPOOL

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 controls 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 have to be in the OUT position.

2.37

Page 56

MAINTENANCE

CLEANING & STORAGE

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.

Storage Tips

See Chapter 1 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.

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 Chapter 1 for products.

Fog the Engine

Use Polaris Fogging Oil, following the instructions as directed.

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

1. Treat the fuel system with Polaris Carbon Clean. Turn fuel petcock to ’OFF’.

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

3. 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.

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.

2.38

Page 57

MAINTENANCE

4. Remove the spark plug(s). Rotate the pistons to BDC and pour approximately two ounces of Premium 4 Synthetic 0W--40 engine oil into each cylinder.

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

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

6. Reinstall the spark plugs. Apply dielectric grease to the inside of the spark plug cap and install the caps onto the plugs.

Lubricate

Inspect all cables and lubricate with Polaris Cable Lubricant. Follow lubrication guidelines in the maintenance section ofthe serviceor 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.

5. Always tie theframe ofthe ATVto thetransporting unit securely using suitable straps or rope.

Engine Anti-Freeze

Test engine coolant strength and change if necessary. Coolant should be replaced every two years. See “COOLANT STRENGTH/TYPE” in this chapter 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 machine with a genuine Polaris ATV cover. NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

Transporting the ATV

Follow these procedures when transporting the vehicle.

1. Turnoff the engine and removethe key toprevent loss during transporting.

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

3. Turn the fuel valve off.

4. Be surethe fuel cap, oil cap and seat are installed correctly.

2.39

Page 58

MAINTENANCE

MAINTENANCE SCHEDULE

Service Date Hours / Miles Service Performed Serviced By:

2.40

Page 59

Engine Exploded Views 3.2--3.6......................

Special Tools 3.7...............................

Piston Identification 3.7..........................

Torque Specifications 3.8........................

Engine Fastener Torque Patterns 3.9.............

Engine Service Data 3.10--3.13.........................

Cooling System Specifications 3.14................

Cooling System Test 3.14.........................

Engine Removal/Installation 3.15..................

Engine Installation Notes 3.16.....................

Cylinder Honing 3.17............................

Oil Flow 3.18....................................

Rocker Arm/Pushrod Inspection 3.19...............

Cylinder Head Disassembly/Inspection 3.19--3.21.........

Valve Inspection 3.22............................

Combustion Chamber 3.22.......................

Valve Seat Reconditioning 3.23--3.25....................

Cylinder Head Assembly. 3.25.....................

Valve Sealing Test 3.26...........................

Valve Train Exploded View. 3.26...................

Engine Head Reassembly 3.27--3.29....................

Cylinder Removal 3.29...........................

Valve Lifter Removal/Inspection 3.29...............

Piston Removal 3.29--3.30.............................

Cylinder Inspection 3.30--3.31..........................

Piston/Rod/Ring Service 3.31--3.33.....................

Starter Bendix Removal/Inspection 3.34............

Flywheel/Stator Removal/Inspection 3.35...........

Flywheel/Stator Installation 3.35--3.36...................

Engine Crankcase Disassembly/Inspection 3.37--3.45.....

Camshaft Inspection 3.45--3.46.........................

Engine Crankcase Assembly 3.46--3.57.................

Troubleshooting 3.58--3.59.............................

4--Stroke Coolant System Bleeding Procedure 3.60..

ENGINE

3.1

Page 60

ENGINE

ENGINE EXPLODED VIEW

CRANKCASE

Journal Bearings

Ball Bearing

Balance Shaft

Camshaft

Thrust Plate

115 ± 12 in. lbs.

(13 ± 1.35 Nm)

Flange Seal

60 ± 6in.lbs.

Bushing

Crankshaft

(6.8 ± .68 Nm)

Crankcase

Oil Pickup

O--ring

Woodruff Key

Journal Bearings

Oil Plug

Washer

60 ± 6in.lbs.

(6.8 ± .68 Nm)

Baffle

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

192 ± 24 in. lbs.

(21.7 ± 2.7 Nm)

3.2

Crankcase Bolts

242

22 ± 2 ft. lbs.

± 3Nm)

(30

Apply Loctitet 242 to

242

the bolt threads.

Apply White

Lithium Grease.

Apply Moly Lube Grease.

Page 61

ENGINE EXPLODED VIEW

MAG SIDE

Split Gear

Washer

22 ± 2 ft. lbs.

Bolt

(30

ENGINE

± 3Nm)

Counterbalance Gear

Washer

22 ± 2 ft. lbs.

± 3Nm)

(30

Oil Pump Bolt Tighten Sequence

Bolt

84 ± 8in.lbs.

(9.5 ± .90 Nm)

Oil Pump

Bolts

Gear/Stator Cover

Oil Gerotor

Oil Pump

Wire Hold Down

Gear/Stator Housing Bolt

OIL

No Grease on this portion of gasket!

Mag Gasket Cover

Impeller

Washer

96 ± 12 in. lbs. (10.85

± .35 Nm)

108 ± 12 in. lbs.

(6.8 ± .68 Nm)

Nut

TIMING MARKS

GEAR TIMING AT TDC

Mag Cover Bolt Tighten Sequence

Apply Polaris 0W--40

OIL

oil to component.

Apply White

Lithium Grease.

3.3

Page 62

ENGINE

ENGINE EXPLODED VIEW

Apply Polaris 0W--40 oil to seal.

OIL

Loctitet Pipe Sealant

(PN 2871956)

Bolts

(Tighten Top Bolt First)

± 8 ft. lbs.

(9.50

Pos. Cable

50 ± 5in.lbs.

(5.64

± 0.56 Nm)

Apply Polaris Starter Grease.

± 0.9 Nm)

Neg. Cable

Clamp

Starter

Washer

Nut

108 ± 12 ft. lbs. (12

± 1.35 Nm)

12 ± 1 ft. lbs.

(16 ± 1.35 Nm)

Oil Fill Tube

MAG SIDE

Recoil Pulley

Screw (3)

Recoil Lower Housing

Washer

Dipstick

Gasket

(NO Grease or Oil!)

Bendix

Washer

Flywheel

(BOTH SIDES)

Screws (12)

16 ± 2 ft. lbs.

(22 ± 2.7 Nm)

Recoil Housing

Water Pump Cover Bolt

Tighten Sequence

Water Pump

Cover

96 ± 12 in. lbs.

(10.85

Washer

Crankshaft Nut

65 ± 7 ft. lbs.

(88

Washer (2)

Screw (13)

± 1.35 Nm)

± 9.50 Nm)

Screw (2)

16 ± 2 ft. lbs.

(22 ± 2.7 Nm)

22 ± 2 ft.lbs.

(30

± 3Nm)

Dowel

(Chamfer Side Down)

3.4

50 ± 5in.lbs.

(5.65

± 0.56 Nm)

Spring

O--ring

216 ± 24 in. lbs.

(24.4

OIL

Stator Cover

Hex Plug

± 2.71 Nm)

Oil Filter Nipple

35 ± 4 ft. lbs.

(47.5

Oil Filter

± 5.4 Nm)

OIL

Standard Sportsman 700

Bolts

96 ± 12 in. lbs.

(10.85

Recoil Housing & Stator Cover Bolt Tighten Sequence

± 1.35 Nm)

Page 63

ENGINE EXPLODED VIEW

TOP END

1 Lubricate threads and be-

tween washers and underside of bolt heads with engine oil Torque in sequence provided, then tighten in sequence 90° (1/4 turn).

Apply Moly Lube

grease to valve tips.

Gasketfreeofoil.Verify

are visible.

tabs Apply thin film of 0W--40 to

25--55 mm of cylinder bore.

Apply0W--40topiston pin or pin bore.

Apply 0W--40 to lifters.

Do not expansion plug install more than 1.5 mm inward.

1.5 mm

OIL

(Each Bolt Threads)

Bushing

Expansion Plug

Head Bolts

35 ± 4 ft. lbs.

± 5.5 Nm)

(47.5

Head Bolt Tighten Sequence

Rocker Arms

Gasket

Pushrods

ENGINE

90° (1/4 turn)

(30

22 ± 2 ft. lbs.

± 3Nm)

Side View

Apply Polaris 0W--40 oil.

OIL

Apply Moly

Lube Grease.

Cylinder

OIL

Piston Assembly

OIL

Circlip UP for Install

3Gasket

Hydraulic Lifter

OIL

3.5

Page 64

ENGINE

ENGINE EXPLODED VIEW

OUTER COMPONENTS

20 ± 5in.lbs.

(2.5

216 ± 24 in. lbs. (24.5

20 ± 5in.lbs.

(2.5

± 0.55 Nm)

± 2.7 Nm)

Breather Bolts

216 ± 24 in. lbs.

(24.5

Carburetor Boot

Bolts

Boot Clamp

84 ± 8in.lbs.

(9.5

Spark Plugs

± 2.7 Nm)

Screws

± 0.9 Nm)

Rocker Cover

Breather

O--ring Seal

Exhaust Manifold

Bolts

216 ± 24 in. lbs. (24.5

± 2.7 Nm)

Gasket

BST34 Carburetor

Check Valve

Vent Line

Thermistor

O--ring

Thermostat

25 ± 3 ft. lbs.

(34

± 4Nm)

Housing

Bolts

84 ± 8in.lbs.

± 0.9 Nm)

(9.5

3.6

Page 65

SPECIAL TOOLS

PART NUMBER TOOL DESCRIPTION

PV--43527 Oil Filter Wrench

2200634 Valve Seat Reconditioning Kit PU--45257 Valve Spring Compressor PU--45652 Valve Pressure Hose

2871043 Flywheel Puller

2870390 Piston Support Block

PU--45497--2 Cam Gear Tooth Alignment Tool PU--45497--1 Cam Gear Spring Installation Kit (Tapered Pins)

PU--45498 Cam Spanner Wrench PU--45838 Gear Holder

PA--44995 Water Pump Mechanical Seal Installer PU--45543 Universal Driver Handle PU--45483 Main Seal Installer PU--45658 Main Crankshaft Seal Saver

PA--45401 Water Pump Seal Saver

2870975 Mity Vact Pressure Test Tool

PU--45778 Oil System Priming Tool

ENGINE

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 Oil pump/Water Pump and Oil

Pump Drive Gear

S Gear Train Components

The following components require engine removal for service:

S Counterbalance Shaft or Bearing(s) S Connecting Rod S Crankshaft S Crankshaft Main Bearings S Crankcase

PISTON IDENTIFICATION

Four stroke enginerings havea rectangular profile. See texton Page3.29 forring installation. Use theinformation below to identify pistons and rings.

NOTE: The pistons have no directional identification marks. New pistons are non--directional.

Engine Model No. Piston Diameter Standard Piston Identification

EH680ALE 80 mm None EH590ALE 76.50 mm None

3.7

Page 66

ENGINE

TORQUE SPECIFICATIONS

Fastener Size 600/700

in. Lbs. (Nm)

Camshaft Gear 8mm 22 ± 2(30± 3) Camshaft Thrust Plate 6mm 115-± 12 (13 ± 1.35) Carburetor Adaptor Bolts 8mm 216 ± 24 (24.5-± 2.7) Counterbalance Gear 8mm 22 ± 2(30± 3) Crankcase Bolts 8mm *22 ± 2(30± 3) Crankcase Breather 5mm 20 ± 5(2.5± 0.55) Cylinder Head Bolts 11 m m *35 ± 4 (47.5 ± 5.5) Exhaust Manifold 8mm 216 ± 24 (24.5 ± 2.70) Flywheel 14 mm 65 ± 7(88± 9.50) Magneto Cover 6mm *96 ± 12 (10.85 ± 0.35) Oil Baffle Weldment 5mm 60 ± 6(6.8± 0.68) Oil Drain Bolt (Crankcase) 12 mm 192 ± 24 (21.7 ± 2.7) Oil Fill Tube Bolt 5mm 50 ± 5 (5.64 ± 0.56) Oil Filter Pipe Fitting 20 mm 35 ± 4 (47.5 ± 5.4) Oil Pick Up 5mm 60 ± 6(6.8± 0.68) Oil Pressure Relief Plug 10 mm 22 ± 2(30± 3) Oil Pump Housing Screw 6mm *84 ± 8 (9.50 ± 0.90) Rocker Arm 8mm *22 ± 2(30± 3) Rocker Cover 6mm *84 ± 8(9.5± 0.9) Spark Plug 14 mm 216 ± 24 (24.5 ± 2.7) Starter Motor 6mm *84 ± 8(9.5± 0.9) Stator Assembly 6mm 96 ± 12 (10.85 ± 1.35) Stator Housing 6mm *96 ± 12 (10.85 ± 1.35) Thermistor 3/8 PT 25 ± 3(34± 4) Thermostat Housing 6mm 84 ± 8(9.5± 0.9) Timing Plug 3/4-16 7-9 (10-12 Nm) Trigger Coil/Stator Wire Holddown 5mm *96 ± 12 (10.85 ± 1.35) Water Pump Housing Cover 6mm *96 ± 12 (10.85 ± 1.35) Water Pump Impeller Nut 8mm 108 ± 12 (12 ± 1.35)

600/700

ft.lbs. (Nm)

* See exploded views for notes or torque sequences.

3.8

Page 67

ENGINE

ENGINE FASTENER TORQUE PATTERNS

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

CRANKCASE BOLT TIGHTEN SEQUENCE

22 ± 2 ft. lbs.

± 3Nm)

(30

CYLINDER HEAD BOLT TIGHTEN SEQUENCE

Lubricate threads and between washer and underside of bolt with engine oil. Torque in sequence to spec provided, allow the gasket to set for 1 minute, then tighten in sequence 90° (1/4 turn).

35 ± 4 ft. lbs.

± 5.5 Nm)

(47.5

90° (1/4 turn)

3.9

Page 68

ENGINE

600 ENGINE SERVICE DATA

Cylinder Head / Valve Engine No. -- EH059OLE

Camshaft Cam lobe height In

Std 1.3194” (33.5118 mm)

Camshaft journal OD

Camshaft journal bore ID

Camshaft Oil clearance

End Play 0.0135” ± 0.0111” (0.3450 ± 0.2825 mm)

Counter Balance

Cylinder Head

Valve Seat Contacting width In

Valve Guide

Valve Margin thick- In

End Play 0.005” (0.127 mm)

Surface warpage limit 0.00394” (0.1 mm) Standard height 3.478” (88.35 mm)

Seat Angle Std 44.75 ± 0.25° Inner diameter 0.2374” ± 0.00059” (6.030 ± 0.015 mm) Protrusion above head 0.5610” ± 0.00394” (14.25 ± 0.10 mm)

ness

Mag 1.654” ± 0.00039” (42 ± 0.010 mm) Center 1.634” ± 0.00039” (41.50 ± 0.010 mm) PTO 1.614” ± 0.00039” (41 ± 0.010 mm) Mag 1.656” ± 0.00039” (42.07 ± 0.010 mm) Center 1.637” ± 0.00039” (41.58 ± 0.010 mm) PTO 1.617” ± 0.00039” (41.07 ± 0.010 mm) Std 0.00118” ± 0.00079” (0.03 ± 0.02 mm)

Std 0.0472” + 0.00787” -- 0.0039”

(1.20 + 0.20 -- 0.10 mm)

Std 0.0591” + 0.00787” -- 0.0039”

(1.50 + 0.20 -- 0.10 mm)

Std 0.1394” ± 0.0065” (3.541 ± 0.165 mm)

Std 0.1373” ± 0.0065”(3.488 ± 0.165 mm)

Stem diameter In 0.2356” ± 0.00039” (5.985 ± 0.01 mm)

Ex 0.2346” ± 0.00039” (5.96 ± 0.01 mm)

Valve Spring

Stem oil clear- Std ance

Overall length

In 0.00177” ± 0.00098” (0.045 ± 0.025 mm) Ex 0.00334” ± 0.00039” (0.085 ± 0.010 mm)

In 4.51” ± 0.01476” (114.5550 ± 0.375 mm) Ex 4.5453” ± .01496” (115.45 ± 0.38 mm) Free

Length Installed

Height

1.8267” (46.40 mm)

1.47” (37.34 mm)

3.10

Page 69

600 ENGINE SERVICE DATA

Pistonclearance

Pisto

Pistonringinstalled

Topring

Secon

Oilring

Standardclearance-Topring

Secon

Connectingrodbigendside

Connectingrodbigendradial

Cylinder / Piston / Connecting Rod Engine No. -- EH590ALOE

Cylinder

Lifter

Surface warpage limit (mating with cylinder head)

Cylinder bore Std 3.0118” (76.5mm) Taper limit 0.00031” (0.008 mm) Out of round limit 0.00030” (0.0075 mm) Piston clearance

Limit .0022” ± .00067” (.055 ± .017 mm) Boring limit N/A Outer Diameter Std 0.84245” ± 0.00025” (21.39 8± 0.00635 mm) Block Bore Std 0.8438” ± 0.00062”(21.4322 ± 0.0157 mm)

ENGINE

0.004” (0.10 mm)

Piston

Standard inner diameter of piston pin bore

Piston Pin

Piston Piston ringinstalled Toprin Ring

Connecting Rod

Outer diameter 0.7874” -- .7872” (20 -- 19.995 mm) Standard clearance-piston pin to pin

bore Degree of fit Piston pin must be a push (by hand) fit at 68°

gap

Standard clearance Toprin

piston ring to ring groove

Connecting rod small end ID .789” -- .78841”. (20.030 -- 20.015 mm) Connecting rod small end ra-

dial clearance Connectingrod bigend side

clearance Connectingrod bigend radial

clearance

Std 3.0096” ± .00035I (76.445 ± .009 mm)

Second ring

Oil rin

Second ring

0.78757” ± .00098I (20.0045 ± 0.0025 mm)

0.00027” ± 0.00019” (0.007 ± 0.005 mm)

F(20° C)

Limit 0.01181” ± 0.00393” (0.30 ± 0.10 mm)

Limit 0.01476” ± 0.00492” (0.375 ± 0.125 mm)

Limit 0.00984” ± .00393” (0.25 ± 0.10 mm)

Limit 0.0019” ± 0.00069” (0.0475 ± 0.0175 mm)

Limit 0.0017” ± 0.00049I (0.0425 ± 0.0125 mm)

Std 0.00098” ± 0.00039” (0.025 ± 0.010 mm)

Limit 0.01181” ± 0.00591” (0.30 ± 0.15 mm)

Limit 0.00015” ± 0.00006” (0.0038 ± 0.0015 mm)

Crankshaft Crankshaft runout limit 0.00236” (0.060 mm)

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

3.11

Page 70

ENGINE

700 ENGINE SERVICE DATA

Cylinder Head / Valve Engine No. -- EH68ALOE / EH068OLE

Camshaft Cam lobe height In

Std 1.3194” (33.5118 mm)

Camshaft journal OD

Camshaft journal bore ID

Camshaft Oil clearance

End Play 0.0167” ± 0.0098” (0.425 ± 0.25 mm)

Counter Balance

Cylinder Head

Valve Seat Contacting width In

Valve Guide

Valve Margin thick- In

End Play 0.005” (0.127 mm)

Surface warpage limit 0.00394” (0.1 mm) Standard height 3.478” (88.35 mm)

Seat Angle Std 44.75 ± 0.25° Inner diameter 0.2374” ± 0.00059” (6.030 ± 0.015 mm) Protrusion above head 0.5610” ± 0.00394” (14.25 ± 0.10 mm)

ness

Std 0.0472” + 0.00787” -- 0.0039”

(1.20 + 0.20 -- 0.10 mm)

Std 0.0591” + 0.00787” -- 0.0039”

(1.50 + 0.20 -- 0.10 mm)

Std 0.1394” ± 0.0065” (3.541 ± 0.165 mm)

Std 0.1373” ± 0.0065”(3.488 ± 0.165 mm)

Stem diameter In 0.2356” ± 0.00039” (5.985 ± 0.01 mm)

Ex 0.2346” ± 0.00039” (5.96 ± 0.01 mm)

Valve Spring

Stem oil clear- Std ance

Overall length

In 0.00177” ± 0.00098” (0.045 ± 0.025 mm) Ex 0.00334” ± 0.00039” (0.085 ± 0.010 mm)

In 4.51” ± 0.01476” (114.5550 ± 0.375 mm) Ex 4.5453” ± .01496” (115.45 ± 0.38 mm) Free

Length Installed

Height

1.8267” (46.40 mm)

1.47” (37.34 mm)

3.12

Page 71

700 ENGINE SERVICE DATA

Pistonclearance

Pisto

Pistonringinstalled

Topring

Secon

Oilring

Standardclearance-Topring

Secon

Connectingrodbigendside

Connectingrodbigendradial

Cylinder / Piston / Connecting Rod Engine No. -- EH68ALOE / EH068OLE

Cylinder

Lifter

Surface warpage limit (mating with cylinder head)

Cylinder bore Std 3.1495” (80 mm) Taper limit 0.00031” (0.008 mm) Out of round limit 0.00030” (0.0075 mm) Piston clearance

Limit .0016” ± .00063” (.041 ± .016 mm) Boring limit N/A Outer Diameter Std 0.84245” ± 0.00025” (21.39 8± 0.00635 mm) Block Bore Std 0.8438” ± 0.00062”(21.4322 ± 0.0157 mm)

ENGINE

0.004” (0.10 mm)

Piston

Standard inner diameter of piston pin bore

Piston Pin

Piston Piston ringinstalled Toprin Ring

Connecting Rod

Outer diameter 0.7874” -- .7872” (20 -- 19.995 mm) Standard clearance-piston pin to pin

bore Degree of fit Piston pin must be a push (by hand) fit at 68°

gap

Standard clearance Toprin

piston ring to ring groove

Connecting rod small end ID .789” -- .78841”. (20.030 -- 20.015 mm) Connecting rod small end ra-

dial clearance Connectingrod bigend side

clearance Connectingrod bigend radial

clearance

Std 3.1477” ± .00012I (79.954 ± .003 mm)

Second ring

Oil rin

Second ring

0.78789” ± .0000098I (20.0125 ± 0.0025 mm)

0.00059” ± 0.0002” (0.015 ± 0.005 mm)

F(20° C)

Limit 0.01083” ± 0.00295” (0.275 ± 0.075 mm)

Limit 0.0177” ± 0.00394” (0.45 ± 0.10 mm)

Limit 0.0177” ± .00984” (0.45 ± 0.25 mm)

Limit 0.0019” ± 0.00069” (0.0475 ± 0.0175 mm)

Limit 0.0017” ± 0.00049I (0.0425 ± 0.0125 mm)

Std 0.00098” ± 0.00039” (0.025 ± 0.010 mm)

Limit 0.01181” ± 0.00591” (0.30 ± 0.15 mm)

Limit 0.00015” ± 0.00006” (0.0038 ± 0.0015 mm)

Crankshaft Crankshaft runout limit 0.00236” (0.060 mm)

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

3.13

Page 72

ENGINE

COOLING SYSTEM SPECIFICA

Condition Approx. Reading

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

Recommended Coolant

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

TIONS

Temperature

(Min--Max)

178Ω -- 190Ω 215° F

(102° C)

2.25 Quarts (2.13L)

13 PSI

COOLING SYSTEM

WARNING

Never remove radiator cap when engine is warm or hot. The cooling system is under pressure and serious burns may result. Allow the engine and cooling system to cool before servicing.

1. Remove front cover.

2. Remove recovery bottle hose from coolant filler neck.

3. Connect a Mity Vact (PN 2870975) to the filler neck nipple and pressurize system to 10 psi. The system must retain 10 psi for five minutes or longer. If pressure loss is evident within five minutes, check the radiator, hoses, clamps and water pump seals for leakage.

Radiator Cap Pressure Test

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

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

Upper Engine Hose

Filler Neck Assy.

Surge Tank

FLOW

Radiator

Thermostat

Cylinder Head

Coolant Flow Diagram

To p

Bottom

Water Pump

Cylinder

Fan

Shroud

Lower Engine Hose

Exploded View

To W a te r P u m p

Hose

Radiator

Radiator Front View

Radiator Left Side View

3.14

Page 73

ENGINE

ENGINE REMOVE & INSTALL

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 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. Remove springs from exhaust pipe and remove pipe.

6. Drain coolant and engine oil.

7. Remove air pre-cleaner and duct.

8. Remove airbox.

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

13. Refer to PVT System Chapter 6 to remove outer clutch cover, drivebelt, drive clutch, drivenclutch, and inner cover (D).

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

15. Remove transmission linkage rod 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. Remove the frame brace (E) from the front left side of the frame.

9. Remove carburetor (A). Insert a shop towel into the carburetor flange to prevent dirt from entering the intake port.

10. Disconnect spark plug high tension lead (B).

11. Remove the air breather line (C).

19. Removethe enginefrom the left sideof theframe.

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

20. For engine installation, reverse these procedures.

3.15

Page 74

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 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 clutchsheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing. (Chapter 6)

Transmission

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

Exhaust

Engine Break In Period

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

CAUTION

Use only Polaris Premium 0--40W All Season synthetic oil or equivalent. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Excessive heat can build up and cause damage to close fitted engine parts.

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

2. Check oil reservoir level indicated on dipstick. Add oil if necessary.

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

2. Check to be sure all springs are in good condition.

Bleed Cooling System NOTE: This cooling system contains vent lines to

help purge trapped air during filling. Refer to Page

3.14 for hose routing. Bleeding generally should not

be necessary.

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

2. Fill coolant reservoir tank to full mark.

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

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

5. Start engine and observe coolant level in the radiator. Allow air to purge and top off as necessary. Reinstall radiator cap and bring engine to operating temperature. After engine is cool, check level inreservoir tank and add coolant if necessary.

NOTE: Should the reservoir tank become empty, it will be necessary to refill at the radiator andrepeat the bleeding procedure.

SAFE

3. Drive slowly at first to gradually bringengine up to operating temperature.

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

5. Perform regular checks on fluid levels, controls and all important areas on the vehicle.

6. Pull only light loads during initial break in.

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

ADD 8 OZ

3.16

Page 75

CYLINDER HONE SELECTION

ENGINE

AND HONING

CAUTION:

A hone which will straighten as well as remove material from the cylinder is very important. Using a common spring loaded glaze breaker for honing is not advised for nicasil cylinders. Polaris recommends using a rigid hone or arbor honing machine.

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

PROCEDURE

HONING TO DEGLAZE

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

S Honing should be done with a

diamond hone. Cylinder could be damaged if the hone is not hard enough to scratch the nicasil lining.

S Use a motor speed of approximately

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

S Release the hone at regular intervals

and inspect the bore to determine if it hasbeen sufficiently deglazed, and to check for correct cross--hatch.

NOTE: Do not allow cylinder to heat up during honing.

S After honing has been completed,

inspect cylinder for thinning or peeling.

If cylinder wear or damage is excessive, it will be necessary to replace the cylinder. The cylinders are lined with a nicasil coating and are not repairable. Hone only enough to deglaze the outer layer of the cylinder bore.

EXAMPLE OF CROSS HATCH PATTERN

IMPORTANT: Clean the Cylinder After

It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder in asolvent, then in hot, soapy water. Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris 4 Cycle Lubricant to prevent the formation of surface rust.

Honing

ENGINE LUBRICATION

Oil Type -- Polaris Premium 0W--40 Synthetic (PN

2871281)

Capacity -- Approximately 2 U.S. Quarts (1.9 l) Filter -- (PN 2540086) Filter Wrench -- PV--43527 or equivalent Oil Pressure Specification -- 35--39 PSI @ 5500

RPM, Polaris 0W--40 Synthetic , Engine at operating temperature.

NOTE: See Chapter1 foroil changekit partnumbers.

OIL PRESSURE TEST

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

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

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

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

Oil Pressure at 5500 RPM (Engine Hot):

Standard: 39 PSI Minimum: 35 PSI

3.17

Page 76

ENGINE

OIL FLOW

This chart describes the flow of oil through the EH68 and the EH059 engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through 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 supplied to the main oil galley through a crankcase passage. Oil is then diverted three ways from the main oil galley, with the first path entering the camshaft bores, onto the rear balance shaft journal and then draining back into the crankcase sump. The second oil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump. The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump. The oil pressure switch is fed off the main oil galley.

PTO

SIDE

Crankshaft

Main Bearing

Counterbalance Bore

Camshaft

Bore

Crankcase

Sump

Rod

Bearings

Camshaft

Bore

Lifter Bores

Crankshaft

Main Bearing

Counterbalance Bore

Camshaft

Bore

MAGNETO

SIDE

3.18

Oil Pressure

Relief

Main Oil Gallery

Pump

Filter

Crankcase

Sump

Page 77

ENGINE

ROCKER ARM INSPECTION

1. Mark or tagrocker armsin order of disassembly to keep them in order for reassembly.

2. Inspect the wear padat thevalve endof therocker arm for indications of scuffing or abnormal wear. If the pad is grooved, replace the rocker arm.

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

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

PUSH ROD INSPECTION

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

CYLINDER HEAD REMOVAL

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

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

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

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

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

WARNING

Always wear safety glasses whenworking with compressed air to prevent personal injury.

3. Check the ends of the push rods (A) for nicks, grooves, roughness or excessive wear.

4. The push rods (A) can be visually checked for straightness while they are installed in the engine by rotating them with the valve closed. Push rods canalsobecheckedwithadialindicatororrolled across a flat surface to check for straightness.

3.19

Page 78

ENGINE

CYLINDER HEAD INSPECTION

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

CAUTION: Use care not to damage sealing surface.

CYLINDER HEAD WARPAGE

1. Lay a straight edge (A) across the surface of the cylinder head (B) 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.

WARNING

Wear eye protection or a face shield during cylinder head disassembly and reassembly.

1. Having already removed the valve cover, rocker arms and pushrods, align the cylinder to be worked on at top dead center. Install the Valve Pressure Hose (PU--45652) into the spark plug hole. Hook the hose to an air compressor and supply 50 to100 psi to the hose. This will seat the valves during valve spring removal. Do not remove air from the hose at anytime until reassembly is completed.

2. Using theValve SpringCompressor (PU--45257), compress the valve spring and remove the valve keepers. NOTE: A smallparts magnet(A) canaid in the removal of the retainers (B).

Measure at different points

on the surface.

Cylinder Head Warpage Limit:

004″ (.1016 mm) Max.

Bottom Side View

CYLINDER HEAD DISASSEMBL

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

Valve Train Servicing

In some cases the valve train can be serviced while the cylinder head is still on the engine. Keep all parts in order with respect to their location in the cylinder head.

PU--45257

Valve Spring Compressor:

(PU--45257)

Valve Pressure Hose:

(PU--45652)

NOTE: To prevent damage to the valve seals, do not

compress the valve spring more than is needed to remove the valve keepers.

3. Remove spring retainer and spring.

4. The valve seals are now serviceable.

3.20

Page 79

CYLINDER HEAD DISASSEMBLY, CONT.

NOTE: Carefully remove the cylinder components.

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

ENGINE

Valve Spring Length:

Std: 1.827I (46.40 mm)

Installed Height: 1.47” (37.34 mm)

6. Remove valve guide seals. IMPORTANT: It is recommended to replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.

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

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

Mark the valves

Valve Spring Free Length

3.21

Page 80

ENGINE

VALVE INSPECTION

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

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

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

Valve Stem Diameter:

Intake: 0.2356” ± 0.00039”

(5.985 ± 0.01 mm)

Exhaust: 0.2346” ± 0.00039”

(5.96 ± 0.01 mm)

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

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.

4. Inspect split keeper groove for wear or flaring of the keeper seat area (B). NOTE: The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent, or damaged.

5. Measure diameter of valve stem with a micrometer in three places, then rotate 90 degrees and measure again (six measurements total). Compare to specifications.

Valve Guide

Valve Guide I.D.:

0.2374” ± 0.00059” (6.030 ± 0.015 mm)

7. Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance. NOTE: The valveguides cannotbe replaced. Be sure to measure each guide and valve combination individually.

3.22

Page 81

ENGINE

COMBUSTION CHAMBER

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

IMPORTANT: Do notuse a wire brush, metal scraper, or abrasive cleaners to clean the bottom of the cylinder head. Extensive damageto the cylinderhead may result. Wear safety glasses during cleaning.

Combustion Area

seat reconditioning equipment can also be used. Keep all valves in order with their respective seat.

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

To o Wide

Uneven

Good

To o Narrow

VALVE SEAT RECONDITIONING

Cylinder Head Reconditioning NOTE: Polaris recommends that the work be done

by a local machine shop that specializes in this area. NOTE: The cylinder head valve guides cannot be

replaced.

WARNING

Wear eye protection or a face shield during cylinder head disassembly and reassembly.

Valve Seat Inspection

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

head must be replaced.

Follow the manufacturers instructions provided with the valve seat cutters in the Cylinder Head Reconditioning Kit (PN 2200634). Abrasive stone

1. Install pilot into valve guide.

2. Apply cutting oil to valve seat and cutter.

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

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

of the circumference of the 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, orrunout. Ifthe pilot is bent it must be replaced.

3.23

Page 82

ENGINE

VALVE SEAT RECONDITIONING CONT’D

S If the contact area of the cutter is in

the same place, the valve guide is distorted from improper installation.

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.

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

(A)

S If the seat is too narrow, widen using

the 45° cutter and re-check contact point on the valveface andseat width after each cut.

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

(B)

(A)

Proper Seat Contact On Valve Face

Bottom - 60°

Seat - 45°

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

7. 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° 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.

To p - 30°

Seat Width

Valve Seat Width:

Intake Std: .028I (.7 mm)

Limit: .055I (1.4 mm)

Exhaust Std: .039I (1.0 mm)

Limit: .071I (1.8 mm)

3.24

Page 83

VALVE SEAT RECONDITIONING CONT”D

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

WARNING

Wear eye protection or a face shield when working with compressed air during cylinder head disassembly and reassembly.

9. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve. NOTE: Lapping is not required with an interference angle valve job.

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

ENGINE

11. 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 thisfour to five times untilthe valveis fully seated, and repeat process for the other valve(s).

12. Thoroughly clean cylinder head and valves.

CYLINDER HEAD REASSEMBL

NOTE: Assemblethe valvesone at atime tomaintain

proper order.

1. Apply engine oil to valve guides and seats.

2. Coat valve stem with molybdenum disulfide grease or 0W--40 Synthetic oil.

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

4. Valve seals should be installed after the valves are in thehead to avoid valveseal damage. Install new valve seals on valve guides.

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

6. Place retainer on spring and install Valve Spring Compressor (PU--45257). Install split keepers with the gap even on both sides. NOTE: A small parts magnet can aid in installation of the keepers.

(PU--45257)

7. Repeat procedure for remaining valves. When all valves are installed, tap lightly with soft faced hammer on the end of the valves to seat the split keepers. NOTE: To prevent damage to the valve seals, do not compress the valve spring more than necessary to install the keepers.

3.25

Page 84

ENGINE

VALVE SEALING TEST

1. Clean and dry the combustion chamber area (A). Refer to Page 3.23 for cleaning tips.

2. Pour a small amount of clean solvent onto the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage.

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

VALVE TRAIN EXPLODED VIEW

ROCKER ARMS

SPRING RETAINERS

SPRINGS

GUIDE SEALS

HEAD

VALVES

22 ± 2 ft. lbs.

(30

± 3Nm)

RETAINER LOCKS

PUSH RODS

HYDRAULIC LIFTERS

3.26

Page 85

ENGINE

ENGINE HEAD REASSEMBLY

Before reassembly, cleanthe bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts.

1. Install the head gasket (A) on the cylinder (B).

2. Install cylinder head on cylinder.

3. Lubricate threads and top of washers underside of bolthead with engine oil. Install head bolts (C). Torque to sequence provided (Pg.3.9). Allow the gasket to set for 1 minute at this torque, then turn bolts 90° (1/4 turn) in sequence . Refer to Page 3.9 for tightening sequence.

35 ± 4 ft. lbs. (47.5 ± 5.5 Nm) in

4. Lubricate push rods (D) and install into lifters.

5. Lubricate rockers (E) with engine oil.

Cylinder Head Bolt Torque:

± 4 ft. lbs.

(47.5

± 5.5 Nm)

Then turn additional 90° (1/4 turn)

-- Allow to set for 1 min.

*Torque Bolts In Sequence (Pg. 3.9)

6. Verify pushrods are engaged in lifters.

7. Install rockers. Be sure that tab of fulcrum (F) is seated in head stand-off. Torque bolts to

ft. lbs.

(30 ± 3 Nm).

Rocker Arm Bolt Torque:

22 ± 2

22 ± 2 ft. lbs. (30

± 3Nm)

3.27

Page 86

ENGINE

ENGINE HEAD REASSEMBLY CONT’D

8. Install breather reed (G) into rocker cover (H). Lightly apply black RTV sealant to the outer edges of the breather reed. The reed has a tab and will assemble one way only. Torque the breather bolts to 20 ± 5in.lbs.(2.5± 0.55 Nm).

NOTE: When applying RTV, do not get any RTV inside the reed assembly.

9. Place a new seal (I) into the bottom of the cover. Be sure the seal is seated into the cover properly.

20 ± 5in.lbs.

(2.5 ± .55 Nm)

11. Install thermostat (J), new O--ring, and thermostat housing. Torque thermostat housing bolts to 84 ± 8in.lbs.(9.5± 0.9 Nm).

84 ± 8in.lbs. (9.5 ± 0.9 Nm)

25 ± 3 ft. lbs.

(34 ± 4Nm)

Thermostat Housing Bolt Torque:

84 ± 8 in. lbs. (9.5 ± 0.9 Nm)

REMINDER: Before assembly, clean the bolts and

bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts.

10. Install rocker cover. Torque bolts to 84 ± 8in.lbs. (9.5 ± 0.9 Nm). See Page 3.6 for proper torque sequence.

12. Apply pipe dope or Teflon tape to pipe threads of coolant thermistor (K). Install andtorque to 25 ± 3 ft. lbs. (34 ± 4 Nm). See Pg. 3.6 for placement.

Apply pipe sealant or Teflon tape to threads.

Thermistor Location

Rocker Cover Bolt Torque:

84 ± 8 in. lbs. (9.5 ± 0.9 Nm)

*Torque In Proper Sequence (Pg. 3.6)

3.28

Thermistor Torque:

25 ± 3 ft. lbs. (34 ± 4Nm)

Page 87

ENGINE

CYLINDER REMOVAL

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

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

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

4. Check the lifters for wear or scores.

5. Check the bottom end of lifter to make sure that it has a slight convex.

6. If the bottom surface has worn flat, it may be used with the original camshaft only.

Inspect Hydraulic Lifter

NOTE: Lifters that are scored, worn, or if the bottom is not smooth should be replaced with new lifters and cam as an assembly. If replacing the lifters, the camshaft should also be replaced.

VALVE LIFTER REMOV

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

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

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

AL/INSPECTION

Mark the Hydraulic Lifter

PISTON REMOVAL

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

Mark the piston

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

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

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

3.29

Page 88

ENGINE

apply heat to the piston rings. The ring may lose radial tension.

3. Remove top compression ring: *Using a piston ring pliers: Carefully expand ring

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

*Byhand: Placing boththumbs asshown, spreadthe ring open and push up on the opposite side. Do not scratch the ring lands.

b) Remove the expander.

Compression

Rings

Oil Ring

CYLINDER INSPECTION

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

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

4. Repeat procedure for second ring.

5. Remove the oil control ring. The oil control ring is a three piece design consisting

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

a) Remove the toprail first followed bythe bottom rail.

Ill.1

To p V iew

Measure at different points

on the surface.

3.30

Page 89

ENGINE

Ill.2

Cylinder Warpage.

.004″ (0.1 mm) Max.

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

1/2″ Down From Top of Cylinder

1/2″ Up From Bottom

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

Cylinder Taper

Limit: .002I (.05mm)Max.

Cylinder Out of Round

Limit: .002I (.05mm)Max.

4. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure in twodifferent directions, frontto backand sideto side, onthree different levels (1/2″ down from top, in the middle, and 1/2″ up from bottom).

Standard Bore Size (Both Cylinders):

Sportsman 700 : 3.1496I (80 mm)

Sportsman 600: 3.0018” (76.50 mm)

PISTON-TO-CYLINDER CLEARANCE

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

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

3.31

Page 90

ENGINE

5mm

Piston

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

Piston Pin

Piston to Cylinder Clearance

600: .0022” ± .00067” (.055 ± .017 mm)

700: .0016” ± .00063” (.041 ± .016 mm)

Piston O.D.

600: 3.0096” ± .00035I (76.445 ± .009 mm)

700: 3.1477” ± .00012I (79.954 ± .003 mm)

PISTON/ROD INSPECTION

1. Measure piston pin bore.

Piston Pin Measurement Locations

Piston Pin O.D.

0.7874” -- .7872” (20 -- 19.995 mm)

3. Measure connecting rod small end ID.

3.32

Piston Pin Bore:

600: 0.00027” ± 0.00019”

(0.007 ± 0.005 mm)

700: 0.00059” ± 0.0002”

(0.015 ± 0.005 mm)

Connecting Rod Small End I.D.

.789” -- .78841”. (20.030 -- 20.015 mm)

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

Page 91

Piston

Ring

ENGINE

Piston Ring Installed Gap

600

Top Ring: 0.01181” ± 0.00393”

(0.30 ± 0.10 mm)

Second Ring Limit: 0.01476” ± 0.00492”

(0.375 ± 0.125 mm)

Oil Ring Limit: 0.00984” ± .00393”

(0.25 ± 0.10 mm)

700

Feeler Gauge

Piston Ring-to-Ring Groove Clearance

Top Ring Limit: 0.0019” ± 0.00069”

(0.0475 ± 0.0175 mm)

Second Ring Limit : 0.0017” ± 0.00049”

(0.0425 ± .0125 mm)

PISTON RING INSTALLED GAP

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

Top Ring Limit: 0.01083” ± 0.00295”

(0.275 ± 0.075 mm)

Second Ring Limit: 0.0177” ± 0.00394”

(0.45 ± 0.10 mm)

Oil Ring Limit: 0.0177” ± .00984”

(0.45 ± 0.25 mm)

NOTE: Ring should be installed with the mark on the

ring facing upward.

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

3. If thebottominstalled gap measurement exceeds the service limit, replace the rings. If ring gap is smaller than the specified limit, file ring ends until gap is within specified range.

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

25-50mm

3.33

Page 92

ENGINE

STARTER DRIVE/BENDIX REMOV

1. Remove stator housing bolts and remove housing.

2. Remove the flywheel nut and washer. 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. Remove starter bendix assembly (A). Note the thrust washers located on both sides of the bendix.

AL/INSPECTION

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

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

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

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

3.34

Page 93

FLYWHEEL/STATOR

ENGINE

REMOV

1. Remove the recoil housing bolts on the Sportsman MV. Then remove the lower recoil housing and recoil pulley. Refer to the “RECOIL DISASSEMBLY/INSPECTION” section later in this chapter to disassemble the recoil.

CAUTION:

The recoil is under spring tension. A face shield and eye protection is required duing the procedure.

Recoil Pulley

3Screws

AL/INSPECTION

Sportsman MV with Recoil

Remove Recoil Housing

2871043

5. Use caution when removing the wire holddown (B), trigger coil (C), and the stator assembly (D).

Do not tap or bump the gear /stator housing cover or the stator. This could cause the seal

around the gear/stator housing cover and the crankcase to break, causing a leak.

12 Screws

Lower Recoil Housing

2. On a standard Sportsman 700, remove stator housing bolts and remove housing .

3. Remove flywheel nut and washer.

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

13 Screws

Standard Sportsman 700 --

No Recoil

2Screws

Remove Stator Cover

6. Remove the bendix (E) if necessary.

FLYWHEEL/STATOR INSTALLA

NOTE: Before assembly, clean the bolts and bolt

holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts.

1. Carefully install the stator and trigger coil to the gear/stator housing cover. Do not tap on the stator or the gear stator housing cover. This may cause a leak in between the gear/stator housing cover and the crankcase.

2. Properly place the stator wires under the wire holddown and installthe bolts. Inspectthe bolts, if new bolts are needed, replace them with new bolts. The new bolts contain patch lock, so Loctitet is not needed on the new bolts. Torque

TION

3.35

Page 94

ENGINE

bolts to 96 ± 12 in.lbs. (10.85 ± 0.35 Nm).

3. Install the starter bendix if removed.

4. Install woodruff key. Install the flywheel. Install the flywheel washer and nut. Torque the flywheel nut to 65 ± 7 ft.lbs. (88 ± 9.50 Nm)

Flywheel Nut Torque:

65 ± 7 ft. lbs. (88 ± 9.50 Nm)

FLYWHEEL/STATOR INSTALLATION Sportsman MV Models

6. Install recoil pulley and 3 screws. Torque screws to 12 ± 1 ft. lbs. (16 ± 1.5 Nm).

7. Clean the areas of the lower recoil housing that have sealant on them before reinstallation. After the areas are clean and dry apply Loctite Pipe Sealant (PN 2871956) to the same areas. Install lower recoil housing and torque screws accordingto the pattern on Page 3.4 to 16 ± 2 ft.lbs. (22 ± 2.7 Nm).

8. Install the outer recoil housing. Torque the screws to 16 ± 2 ft.lbs. (22 ± 2.7 Nm). Refer to the exploded view at the beginning of the chapter.

9. Test the recoil by slowly pullingthe rope out until you feel pressure and let it return slowly, this will bring the engine to the compressionstroke. Then pull the rope with a regular pull.

12 ± 1 ft. lbs.

(16 ± 1.35 Nm)

Sportsman MV Models

12 Screws

5. Inspect themating surface around the gear/stator housing cover and the crankcase for oil seepage. If there is seepage between the mating surfaces, then the gear/stator housing cover must be resealed. Clean the gearcase surfaces and reseal with a new gasket. Refer to the Lower Engine Disassembly section and the Lower Engine Assembly section for details. lnspect the areas pointed out in the illustration for possible oil seepage.

Clean areas of Lower Recoil Housing

16 ± 2 ft. lbs.

(22 ± 2.7 Nm)

13 Screws

2Screws

16 ± 2 ft. lbs. (22 ± 2.7 Nm)

*Torque in Proper Sequence (Pg. 3.4)

Standard Sportsman 700

10. Install stator housing with new O-rings. Torque the bolts to 96 ± 12 in. lbs. (1.85 ± 1.35 Nm). Follow bolt torque sequence on Pg. 3.4.

Standard Sportsman 700

96±12 in.lbs.

3.36

See Bolt Tightening Sequence Pg. 3.4

Page 95

ENGINE CRANKCASE

ENGINE

DISASSEMBL

CAUTION:

The recoil is under spring tension. A face shield and eye protection is required duing the procedure.

Recoil Pulley

3Screws

Y/INSPECTION

Sportsman MV with Recoil

Remove Recoil Housing

4. Remove flywheel nut and washer.

5. Install Flywheel Puller (PN 2871043) and remove flywheel (F). CAUTION: Do notthread the puller bolts into the flywheel more than 1/4″ or stator coils may be damaged.

PN 2871043

12 Screws

Lower Recoil Housing

2. On a standard Sportsman 700, remove thestator cover (A) and water pump cover (B).

13 Screws

Standard Sportsman 700

2Screws

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

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

3.37

Page 96

ENGINE

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

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

Camshaft Gear

Timing Marks

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

Water Pump Gear

Cam Gear Removal

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

PU--45497--2

Crank Gear

9. Use a white pen to accent the timingmarks on the following gears: camshaft gear (K), crankshaft gear (M), or counterbalance gear (N) This will ensure proper gear alignment and timing during reassembly of the gears.

Counterbalance Gear

3.38

NOTE: Install the Cam Gear Tooth Alignment Tool

(PU--45497--2) into the assembly hole counter clockwise from the timing mark as shown.

Cam Gear Alignment Tool:

(PU--45497--2)

Cam Gear Disassembly

Page 97

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

3 Loaded Springs

ENGINE

Accent the Timing Marks

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

12. The cam gear assembly contains three loaded springs. To open the cam gear assembly:

S Place the cam gear on a flat surface

with the timing mark side facing up.

S While holding both gears together,

lightly work a small flathead screwdriver between the two gears.

S Remove the top gear. The springs

should stay in place.

CAUTION:

WEAR SAFETY GLASSES AT ALL TIMES. USE CAUTION WHEN WORKING WITH THE TOP GEAR. THE SPRINGS COULD CAUSE INJURY OR BECOME LOST SHOULD THEY POP OUT.

13. Remove all three springs using one of the tapered pins from the Tapered Pins (PU--45497--1).

Inspect Teeth & Tabs

Replace Three Springs

Cam Gear Reassembly

16. Install the newsprings intothe grooves of the cam gear.

Insert Springs

PU--45497--1PU--45497--1

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

17. Insert the pointed dowels from the Tapered Pins (PU--45497--1) into the cam gear.

3.39

Page 98

ENGINE

PU--45497--1

To assemble:

S Hold the spring with one finger. S Start the pointed end of the tapered

pin into the cam gear hole andslowly push the dowel through the hole until the end of the dowel is almost flush with the spring.

S Perform this procedure with all three

tapered pins.

S Do not push the pins too far

through or the springs will popout.

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

Cam Gear Spring Installation Tool Kit:

(PU--45497)

Tapered Pins:

(PU--45497--1)

Cam Gear Tooth Align Tool:

(PU--45497--2)

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

Align Timing Marks

18. Note in the photograph that the Tapered Pins (PU--45497--1) are below flush with end of the springs. This helps to align the three gear tabs during the next step.

PU--45497--1

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

21. After the tapered pins are removed, be sure the cam gearassembly is held together tightly. Place the cam gear assembly on a flat surface. Use the Cam Gear Tooth Alignment Tool (PU--45497--2)

3.40

Page 99

ENGINE

(R) to align the teeth of the cam gears, as shown in the picture.

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

PU--45497--2

NOTE: For ease of installing the Cam Gear

Alignment Tool (PU--45497--2) (R), use a twisting motion when pushing down on the tool.

balance shaft gear.

2871043

24. Inspect thecrankshaft gear(Q) for broken orworn teeth. If the crankshaft gear does not need to be replaced, itdoes not needto beremoved.If the crankshaft gear is damaged, remove the crankshaft gear with the Flywheel Puller (PN

2871043).

22. To remove the balance shaft gear, the flat side of the camshaft (P) must face the balance shaft gear. To rotate the camshaft, use the Cam Spanner Wrench (PU--45498) to rotate the camshaft sothe flat sideof the camshaft facesthe balance shaft gear.

PU--45498

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

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

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

26. Install the Flywheel Puller (PN 2871043) and remove the crankshaft gear, if needed.

3.41

Page 100

ENGINE

2871043

Water/Oil Pump Removal/Disassembly

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

Oil Rotor Clearance

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

0.006” (0.15 mm) Max Tip Clearance

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

28. Inspect the oil pump rotors for wear. Mark the rotors with a white pen to ensure upon reassembly that the correct sides of the rotorsare installed and mesh with the same edges as previously installed.

Mark Rotors

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

3.42

31. Reinstall the valve (dowel chamfered end first). Install the spring, washer, and bolt. Torque the bolt to 22 ± 2 ft. lbs. (30 ± 3 Nm).

22 ± 2 ft.lbs.

(30 ± 3Nm)

Chamfered end first