Polaris Hawkeye, 2006 HAWKEYE 2x4, 2006 Hawkeye 4x4 Repair Manual

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Page 1

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

VEHICLE IDENTIFICATION NUMBER (VIN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . .1.2

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

MODEL:2006 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

MODEL: 2006 HAWKEYE 4X4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

MODEL:2006 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4

MODEL:2006 HAWKEYE 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7

STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9

SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11

GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

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Page 2

GENERAL INFORMATION

VEHICLE IDENTIFICATION

Model Identification

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

Machine Model Number Identification

A 0 6 LB 2 7 A A

Year Designation

Basic Chassis

Designation

Engine Designation Number

ES30PFE ............................................................Single, Air Cooled, SOHC 4 Stroke, Electric Start

Vehicle Identification Number (VIN)

World

Mfg. ID

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A P B 2 0 A * 5 P 0 0 0 0 0 0

Vehicle Descriptor

}

Vehicle Identifier

}

Emissions & Model Option

Engine Designation

}

Body Style

Vehicle and Engine Serial Number Locations

Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional num ber is stamped on the center top of crankcase beneath the cylinder coolant elbow.

The machine serial number (1- lower frame rail) and engine number (2- right side engine) are important for

vehicle identification.

Engine

Powertrain

Emissions

Model

Year

Check Digit

Plant No

Individual Serial Number

* This could be either

a number or a letter

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Page 3

SPECIFICATIONS

MODEL: 2006 HAWKEYE 2x4

MODEL NUMBER: . . . . . . . . .A06LB27AA

ENGINE MODEL: . . . . . . . . . .ES30PFE

Category Dimension

Length 74 in./188 cm Width 42 in./107 cm Height 45.5 in./116 cm Wheel Base 46 in./117 cm Ground Clearance 8 in./20.3 cm Dry Weight 525 lbs./238 kg Gross Vehicle Weight 930 lbs./422 kg Front Rack Capacity 70 lbs./31.75 kg Rear Rack Capacity 100 lbs./45 kg Towing Capacity 750 lbs./340 kg Hitch Tongue Weight 75 lbs./34 kg Body Style Recreational/Utility

GENERAL INFORMATION

MODEL: . . . . . . . . . . . . 2006 HAWKEYE 4x4

MODEL NUMBER: . . . . . . . . .A06LD27AA

ENGINE MODEL: . . . . . . . . . .ES30PFE

Category Dimension

Length 74 in./188 cm Width 42 in./107 cm Height 45.5 in./116 cm Wheel Base 46 in./117 cm Ground Clearance 8 in./20.3 cm Dry Weight 550 lbs./250 kg Gross Vehicle Weight 930 lbs./422 kg Front Rack Capacity 70 lbs./31.75 kg Rear Rack Capacity 100 lbs./45 kg Towing Capacity 750 lbs./340 kg Hitch Tongue Weight 75 lbs./34 kg Body Style Recreational/Utility

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Page 4

GENERAL INFORMATION

MODEL: 2006 HAWKEYE 2x4

MODEL NUMBER: A06LB27AA ENGINE MODEL: ES30PFE

Engine

Platform Fuji 4 stroke, Single Cylinder Engine Model Number ES300PFE010 Engine Displacement 299cc Number of Cylinders 1 Bore & Stroke (mm) 78.5 x 68 mm Compression Ratio 9.2:1 Full Stroke Compression Pressure Compression Relase 60-90 psi Engine Idle Speed Cooling System/Capacity Air/Oil Cooled Overheat Warning Lubrication Wet Sump Oil Requirements Polaris 0W-50 / 2 qts (1.9L) Exhaust System Single Pipe - USFS Approved

Carburetion

Carburetor model Mikuni BST 34mm Main Jet 147.5 Pilot Jet 42.5 Jet Needle 4HB42-5 Needle Jet 0-4m Pilot/Air Screw 2.5 Turns Out (Initial setting)

Float Height 13mm from carburetor body Fuel Delivery Fuel Pump Fuel Capacity /

Requirement

Electrical

Alternator Output 250 watt / 18.6 Amp @ 6000 Voltage Regulator 3-phase Lights : High Beam --

Low Beam 37.5 watts Brake 12V / 26.9 watts

Tail 12V / 8.26 watts Ignition System DC CDI Ignition Timing BTDC 30+/-2deg. @ 5000 RPM Spark plug / Gap NGK CR8E

Battery / Model / Amp Hr Conventional 14 Amp/hr Circuit Breakers

Fusible Link / 15 amp Main / 15 Amp Accsy

Starting Electric / Recoil Back-up Indicator Panel LCD / Indicator lights

1300 RPM

None

4.5 gal. (17 L)

87 Octane (minimum)

89 Oxygenated

.031 in. / .8 mm

Drivetrain

Transmission Type H-N-R Transmission Capacity 15.2 oz. (450 ml) Gear Ratio : Foward

Reverse

15.18:1

14.05:1 Clutch Type CVT w/EBS Belt 3211108

Steering / Suspension

Front Suspension / Shock Mac Pherson Strut Front Travel 7 in. / 17.8 cm Rear Suspension

Style / Shock

Independent

Coil-over Adjustable Rear Travel 8 in. / 20.3 cm Ground Clearance 8 in. / 20.3 cm Shock Preload Adjustment

Front / Rear

Front - Cam

Rear - Cam Turning Radius 62.5 in. (159 cm) unloaded Toe Out 0-1/16 in. (0-.159 mm)

Wheels / Brakes

Tire/Rim Size - Front 22 x 7-12 Tire/Rim Size - Rear 22 x 10-12 Air Press. F/R Tires 3-5 psi Brake - Front Single Control Hydraulic Disc Brake - Rear Single Control Hydraulic Disc Brake Fluid Polaris DOT 3 or 4 Brake Fluid

JETTING CHART

Altitude

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

AMBIENT TEMPERATURE

Below 40o F

Below 5

152.5 147.5

147.5 142.5

Above +40

Above +5

CLUTCH CHART

Altitude Shift Weight

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000 - 12000)

14 g (Yellow)

5412989

12 g (Red)

5412987

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Page 5

GENERAL INFORMATION

MODEL: 2006 HAWKEYE 4x4

MODEL NUMBER: A06LD27AA ENGINE MODEL: ES30PFE

Engine

Carburetion

Carburetor model Mikuni BST 34mm Main Jet 147.5 Pilot Jet 42.5 Jet Needle 4HB42-5 Needle Jet 0-4m Pilot/Air Screw 2.5 Turns Out (Initial setting)

Float Height 13mm from carburetor body Fuel Delivery Fuel Pump Fuel Capacity /

Requirement

Electrical

Alternator Output 250 watt / 18.6 Amp @ 6000 Voltage Regulator 3-phase Lights : High Beam --

Low Beam 37.5 watts Brake 12V / 26.9 watts

Tail 12V / 8.26 watts Ignition System DC CDI Ignition Timing BTDC 30+/-2deg. @ 5000 RPM Spark plug / Gap NGK CR8E

Battery / Model / Amp Hr Conventional 14 Amp/hr Circuit Breakers

Fusible Link / 15 amp Main / 15 Amp Accsy

Starting Electric / Recoil Back-up Indicator Panel LCD / Indicator lights

1300 RPM

None

4.5 gal. (17 L)

87 Octane (minimum)

89 Oxygenated

.031 in. / .8 mm

Drivetrain

Transmission Type H-N-R Transmission Capacity 15.2 oz. (450 ml) Gear Ratio : Front Output

Rear Output

Fwd 5.17:1 / Rev 4.79:1

Fwd 15.18:1 / Rev 14.05:1 Clutch Type CVT w/EBS Belt 3211108

Steering / Suspension

Front Suspension / Shock Mac Pherson Strut Front Travel 7 in. / 17.8 cm Rear Suspension

Style / Shock

Independent

Coil-over Adjustable Rear Travel 8 in. / 20.3 cm Ground Clearance 8 in. / 20.3 cm Shock Preload Adjustment

Front / Rear

Front - Cam

Rear - Cam Turning Radius 62.5 in. (159 cm) unloaded Toe Out 0-1/16 in. (0-.159 mm)

Wheels / Brakes

JETTING CHART

Altitude

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

AMBIENT TEMPERATURE

Below 40o F

Below 5

152.5 147.5

147.5 142.5

Above +40

Above +5

CLUTCH CHART

Altitude Shift Weight

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000 - 12000)

14 g (Yellow)

5412989

12 g (Red)

5412987

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GENERAL INFORMATION

PUBLICATION NUMBERS

Year Model Model No. Owner’s Manual PNParts Manual

2006 Hawkeye 2x4 A06LB27AA 9920202 9920207 9920208 2006 Hawkeye 4x4 A06LD27AB,AC 9920202 9920207 9920208

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

www.purepolaris.com.

Parts Micro

Fiche PN

REPLACEMENT KEYS

Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is necessary.

Series # Part Number

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

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GENERAL INFORMATION

SPECIAL TOOLS

Special Tools may be required while servicing your machine. Some of the tools listed are mandatory and other tools may be 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

2871293 - B - Crankshaft

Slotted Nut Socket

PA - 47344 - Balance Shaft

Slotted Nut Socket

Standard Tools and Engine Tools

2870569 - Crankshaft True Kit

PV - 35667 - A - Cylinder Leakdown Tester

PU - 45432 - Caliper or A Basic Caliper

2870975 - Mity Vac

2870773 - C - Clip Install Tool

2870390 - Piston Support Block

PA-47478 - Drive Clutch Holder

Suspension Tools

2870871 - ATV Ball Joint Tool Kit

2870623 - Shock Spring Compressor

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GENERAL INFORMATION

Standard Tools and Engine Tools

2870303- Hone Kit

2870305 - Stone Replacement Kit

Electrical Tools

PV -43568 - FlukeTM 77 Multimeter

PV-39617 - Current Clamp

2870836 - Battery Hydrometer

2870588 - Hone Oil (12 OZ.)

2200634 - Valve Seat Reconditioning Kit

2870459 - Dial Indicator

8712500 - PV-39951-A

Tachometer Tachometer

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GENERAL INFORMATION

STANDARD TORQUE SPECIFICATIONS

The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections.

Bolt Size Threads/In Grade 2 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 / Torque

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

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GENERAL INFORMATION

SAE TAP DRILL SIZES

Thread Size/ Drill Size Thread Size / Drill Size

#0-80 3/64 1/2-13 27/64 #1-64 53 1/2-20 29/64 #1-72 53 9/16-12 31/64 #2-56 51 9/16-18 33/64 #2-64 50 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 45 3/4-10 21/32 #4-40 43 3/4-16 11/16 #4-48 42 7/8-9 49/64 #5-40 38 7/8-14 13/16 #5-44 37 1-8 7/8 #6-32 36 1-12 59/64 #6-40 33 1 1/8-7 63/64 #8-32 29 1 1/8-12 1 3/64 #8-36 29 1 1/4-7 1 7/64 #10-24 24 1 1/4-12 1 11/64 #10-32 21 1 1/2-6 1 11/32 #12-24 17 1 1/2-12 1 27/64 #12-28 4.6mm 1 3/4-5 1 9/16 1/4-20 7 1 3/4-12 1 43/64 1/4-28 3 2-4 1/2 1 25/32 5/16-18 F 2-12 1 59/64 5/16-24 I 2 1/4-4 1/2 2 1/32 3/8-16 O 2 1/2-4 2 1/4 3/8-24 Q 2 3/4-4 2 1/2 7/16-14 U 3-4 2 3/4 7/16-20 25/64

METRIC TAP DRILL SIZES

Tap Size Drill Size Decimal

Equivalent

3x.50 #39 0.0995 3/32 3x.60 3/32 0.0937 3/32 4x.70 #30 0.1285 1/8 4x.75 1/8 0.125 1/8 5x.80 #19 0.166 11/64 5x.90 #20 0.161 5/32 6x1.00 #9 0.196 13/64 7x1.00 16/64 0.234 15/64 8x1.00 J 0.277 9/32 8x1.25 17/64 0.265 17/64 9x1.00 5/16 0.3125 5/16 9x1.25 5/16 0.3125 5/16 10x1.25 11/32 0.3437 11/32 10x1.50 R 0.339 11/32 11x1.50 3/8 0.375 3/8 12x1.50 13/32 0.406 13/32 12x1.75 13/32 0.406 13/32

Nearest Fraction

DECIMAL EQUIVALENTS

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

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

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

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

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

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

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

1/8. . . . . . . . .1250

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

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

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

3/16. . . . . . .. . . . . . . .1875 . . .5mm= .1969"

13/64 . . . . . . . . . .. . . . . . . .2031

7/32. . . . . . .. . . . . . . .2188

15/64 . . . . . . . . . .. . . . . . . .2344 . . .6 mm = .2362"

1/4. . . . . . . . .25

17/64 . . . . . . . . . .. . . . . . . .2656 . . .7 mm = .2756"

9/32. . . . . . .. . . . . . . .2813

19/64 . . . . . . . . . .. . . . . . . .2969

5/16. . . . . . .. . . . . . . .3125 . . .8mm= .3150"

21/64 . . . . . . . . . .. . . . . . . .3281

11/32. . . . . .. . . . . . . .3438 . . .9 mm = .3543"

23/64 . . . . . . . . . .. . . . . . . .3594

3/8. . . . . . . . .375

25/64 . . . . . . . . . .. . . . . . . .3906 . . .10 mm = .3937"

13/32. . . . . .. . . . . . . .4063

27/64 . . . . . . . . . .. . . . . . . .4219 . . .11 mm =.4331"

7/16. . . . . . .. . . . . . . .4375

29/64 . . . . . . . . . .. . . . . . . .4531

15/32. . . . . .. . . . . . . .4688 . . .12 mm = .4724"

31/64 . . . . . . . . . .. . . . . . . .4844

1/2. . . . . . . . .5 . . . . . . . . . . . .13mm = .5118"

33/64 . . . . . . . . . .. . . . . . . .5156

17/32. . . . . .. . . . . . . .5313

35/64 . . . . . . . . . .. . . . . . . .5469 . . .14 mm = .5512"

9/16. . . . . . .. . . . . . . .5625

37/64 . . . . . . . . . .. . . . . . . .5781 . . .15 mm = .5906"

19/32. . . . . .. . . . . . . .5938

39/64 . . . . . . . . . .. . . . . . . .6094

5/8. . . . . . . . .625 . . . . . . . . . .16mm=. 6299"

41/64 . . . . . . . . . .. . . . . . . .6406

21/32. . . . . .. . . . . . . .6563 . . .17 mm =.6693"

43/64 . . . . . . . . . .. . . . . . . .6719

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

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

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

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

3/4. . . . . . . . .75

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

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

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

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

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

27/32

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

7/8. . . . . . . . .875

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

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

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

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

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

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

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

1 . . . . . . . . . 1.0

. . . . . . . .8281

. . . . . . . .8438

. . . . . .

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GENERAL INFORMATION

CONVERSION TABLE

Unit of Measure Multiplied by Converts to

ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m Nm x .7376 = ft. lbs. kg-m x 7.233 = ft. lbs. kg-m x 86.796 = in. lbs. kg-m x 10 = Nm in. x 25.4 =mm mm x .03937 = in. in. x 2.54 = cm mile (mi.) x 1.6 = km km x .6214 = mile (mi.) Ounces (oz.) x 28.3 5 = 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 = Ounc es (oz.) lb. x .454 = kg kg x 2.2046 = lb. Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc) Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in) Imperial pints (Imp pt.) x 0.568 = Liters (l) Liters (l) x 1.76 = Imperial pints (Imp pt.) Imperial quarts (Imp qt.) x 1.137 = Liters (l) Liters (l) x 0.88 = Imperial quarts (Imp qt.) Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.) US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.) US quarts (US qt.) x 0.946 = Liters (l) Liters (l) x 1.057 = US quarts (US qt.) US gallons (US gal) x 3.785 =Liters (l) Liters (l) x 0.264 = US gallons (US gal) Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa) Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi) Kilopascals (kPa) x 0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

π(3.14)xR

x H (height) = Cylinder Volume

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

÷ 9 - 40 = °C

1.11

Page 12

GENERAL INFORMATION

GLOSSARY OF TERMS

ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center.

BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch . Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and

grip the drive belt. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.

CVT: Centrifugal Variable Transmission (Drive Clutch System)

DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder

bore.

Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire

touching the chassis).

End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt . ft.: Foot/feet. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.

: Kilograms per square centimeter.

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

: Pounds per square inch.

lbs/in Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage 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. 1 mm = 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. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts.

WOT: Wide open throttle.

1.12

Page 13

CHAPTER 2

MAINTENANCE

MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2

MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2

MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

LUBRICANTS / FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

POLARIS LUBES/FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6

POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS. . . . . . . . . . . . . 2.7

POLARIS LUBRICANT SYMBOL IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8

VEHICLE INSPECTION / MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8

HAWKEYE HANDLEBAR COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . .2.9

MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9

TRANSMISSION LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

FRONT GEARCASE LUBRICATION (4X4 ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

LUBRICATION / GREASE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

THROTTLE OPERATION - ALL MODELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

CHOKE (ENRICHER) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

PILOT SCREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

PILOT SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

ELECTRONIC THROTTLE CONTROL (ETC SWITCH)/THROTTLE CABLE ADJUSTMENT2.14

FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

ENGINE FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

SPARK PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

MAIN AIR FILTER CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

AIR FILTER/PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

AIR BOX SEDIMENT TUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

CVT DRAIN PLUG & DRYING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

ENGINE OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

TIE ROD END/STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

TOE ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

TOE ALIGNMENT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

EXHAUST CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

BRAKE SYSTEM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

HOSE/FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

BRAKE FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

SUSPENSION SPRING FRONT / REAR PRELOAD ADJUSTMENT. . . . . . . . . . . . . . 2.24

FRONT SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

REAR SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

WHEEL, HUB, AND SPINDLE

TORQUE TABLE2.25

WHEEL REMOVAL/INSTALL- FRONT OR REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

2.1

Page 14

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 per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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

Maintenance Chart Key

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

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

authorized Polaris dealer.

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

(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 o peration or exten ded idle . Mor e prev entat ive main tenanc e is required under these conditions. Fluid changes, cable, chain and chass is lubrication a re requ ired more f requent ly. 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

2.2

Improperly performing the procedures marked with

 could result in component failure and lead to

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

Page 15

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(KM)

Steering - Pre-Ride - Check for free operation. Front-suspension - Pre-Ride -



Rear-suspension - Pre-Ride -



Tires - Pre-Ride Engine Stop Switch - Check Operation

Brake fluid level - Pre-Ride -



Brake lever travel - Pre-Ride -



Brake systems - Pre-Ride Throttle - Pre-Ride - Check Operation Wheels /fasteners - Pre-Ride Frame Fasteners - Pre-Ride -



Engine oil level - Pre-Ride -



Air filter, pre-filter - Daily - Inspect;clean often



Air box sediment tube - Daily - Drain deposits when visible

Coolant (if applicable)

Headlamp/tail lamp - Daily Air filter,



main element

Recoil housing (if equipped)



Brake pad wear 10 H Monthly 100 (160) Inspect periodically



Battery 20 H Monthly 200 (320) Check terminals; clean; test Engine oil change



(break-in)

Front gearcase oil (if



equipped)



Middle gearcase oil (if equipped)

Rear gearcase oil



(if equipped) Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly



- Daily -

- Weekly - Inspect; replace as needed

-Weekly -

20 H 1M 10 0 (1 60 )

25 H Monthly 250 (400) Inspect level; change yearly

Make adjustments as needed. See PreRide Checklist on Page 2.8.

Make adjustments as needed. See PreRide Checklist on Page 2.8

Check level daily, change coolant every 2 years Check operation; apply dielectric grease if replacing

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

Perform a break-in oil change at one month

Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services.

MAINTENANCE

Remarks

2.3

Page 16

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(KM)

Engine breather



filter (if equipped)

Engine breather hose General



lubrication Shift Linkage 50 H 6 M 500 (800) Inspect, lubricate, adjust



Steering 50 H 6 M 500 (800) Inspect daily, Lubricate



Front suspension 50 H 6 M 500 (800)



Rear suspension 50 H 6 M 500 (800)



Carburetor float bowl



Throttle Cable/

ETC Switch



Choke cable 50 H 6 M 500 (800)

Carburetor air

intake ducts/flange Drive belt 100 H 12 M 1000 (1600) Inspect; adjust; replace as needed Cooling system (if applicable) Engine oil change *Severe Duty



**Normal Duty Engine oil change

*Severe Duty

25 H Monthly 250 (400) Inspect; replace if necessary

100 H 6 M 1000 (1600) Inspect

50 H 3 M 500 (800)

50 H 6 M 500 (800) 50 H 6 M 500 (800)

50 H 6 M 500 (800)

500

25 H 50 H

25 H

6 M

12 M

6 M

(800) 1000

(1600)

500

(800)

Lubricate all grease fittings, pivots, cables, etc.

Inspect, Lubricate, Tighten Fasteners Inspect, Lubricate, Tighten

Fasteners Drain bowl periodically and prior to storage Inspect; adjust; lubricate; replace if necessary Inspect; adjust; lubricate; replace if necessary Inspect ducts for proper sealing/air leaks

Inspect coolant strength seasonally; pressure test system yearly

Perform a break-in oil change at 20

hours/one month, change more

frequently during cold weather

Replace at oil change

Remarks

**Normal Duty Oil filter change 100 H 6 M 1000 (1600) Replace with oil change



Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust



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

50 H

12 M

1000

(1600)

2.4

Page 17

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)



Fuel system 100 H 12M



Fuel Filter 100 H 12M

Radiator



(if applicable) Cooling hoses



(if applicable) Engine mounts 100 H 12M



Exhaust muffler / pipe



Spark plug 100 H 12M



Ignition Timing 100 H 12M

Wiring 100 H 12M



Clutches (drive



and driven) Front wheel



bearings

 Brake fluid 200 H 24M

Spark arrestor 300 H 36M

E Idle Speed - Adjust as needed

 Toe adjustment - Inspect periodica lly; adjust when part s are replaced



Auxiliary brake Pre- Ride Inspect daily; adjust as needed



Headlight aim - Adjust as needed

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

100 H 12M

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

1000

(1600)

2000

(3200)

3000

(4800)

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 die lectric

grease to connectors subjected to water, mud, etc. Inspect;clean; replace worn parts

Inspect; replace as needed

Change every two years

Clean out

Remarks

2.5

Page 18

MAINTENANCE

LUBRICANTS / FLUIDS

POLARIS LUBES/FLUIDS

ATV Angle Drive Fluid

0W/40

2874865 - Quarts 2874867 - 55 Gallon Drum

2.6

Page 19

MAINTENANCE

POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS

Part No. Description

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol) 2874865 0W-50 Quarts 2874867 0W-50 55 Gallon Drum

Gearcase / Tra nsmission Lubricants

2873602

2873603

2871653

2872276

2870465 Oil Pump for 1 Gallon Jug

2871322

2871423

2871460 Starter Drive Grease (12 Count) 2871312 Grease Gun Kit 2871329 Dielectric Grease (Nyogel™)

Premium Synthetic AGL Gearcase Lube

(12 oz. bottle) (12 Count)

Premium Synthetic AGL Gearcase Lube

(1 Gal.) (4 Count)

Premium ATV Angle Drive Fluid

(8 oz.) (12 Count)

Premium ATV Angle Drive Fluid

(2.5 Gal) (2 Count)

Grease / Specialized Lubricants

Premium All Season Grease

(3 oz. cartridge) (24 Count)

Premium All Season Grease (14 oz. cartridge) (10 Count)

Part No. Description

Additives / Sealants / Thread Locking Agents /

Misc.

2870585 Loctite™ Primer N, Aerosol, 25 g

2871956

2871949

2871950

2871951

2871952

2871953

2871954

2870584

2870587

2871326

2870652 Fuel Stabilizer (16 oz.) (12 Count)

2871957

2871958

Loctite™ Thread Sealant 565

(50 ml.) (6 Count)

Loctite™ Threadlock 242

(50 ml.) (10 Count)

Loctite™ Threadlock 242

(6 ml.) (12 Count)

Loctite™ Threadlock 262

(50 ml.) (10 Count)

Loctite™ Threadlock 262

(6 ml.) (12 Count)

Loctite™ Threadlock 271

(6 ml.) (12 Count)

Loctite™ Threadlock 271

(36 ml.) (6 Count)

Loctite™ 680-Retaining Compound

(10 ml.)

Loctite™ 518 Gasket Eliminator / Flang e

Sealant (50 ml.) (10 Count)

Premium Carbon Clean

(12 oz.) (12 Count)

Black RTV Silicone Sealer

(3 oz. tube) (12 Count)

Black RTV Silicone Sealer

(11 oz. cartridge) (12 Count)

NOTE: Each item can be purchased separately at your local Polaris dealer.

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.

2.7

Page 20

MAINTENANCE

POLARIS LUBRICANT SYMBOL IDENTIFICATION

NOTE: The symbols are used to properly identify the correct lube or grease to use in the maintenance section.

Polaris DOT 3 Brake Fluid

Polaris Synthetic Gearcase Lube

Polaris Synthetic OW-50 Oil

Polaris All Season Grease

Polaris ATV Angle Drive Fluid

VEHICLE INSPECTION / MAINTENANCE

PRE-RIDE / DAILY INSPECTION

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

• Tires - check condition and pressures

• Fuel and oil - fill both to their proper level; Do not overfill

• All brakes - check operation(includes auxiliary brake)

• Throttle - check for free operation

• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches

• Engine stop switch - check for proper function

• Wheels - check for loose wheel nuts

• Air cleaner element - check for dirt or water; clean or replace

• Steering - check for free operation, noting any unusual looseness in any area

• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners

• Engine coolant(if applicable) - check for proper level at the recovery bottle

2.8

Page 21

HAWKEYE HANDLEBAR COMPONENT LOCATIONS

4x4 switch

Indicator Lights

Front Brake

Speedo

MAINTENANCE

(if applicable)

Light Control & Run Switch

Choke

Ignition/S tart Key

Reverse Override

MAINTENANCE QUICK REFERENCE

III. # Item Lube Rec. Method Frequency*

Change after 1st month (25 hours), 50 hours thereafter;

2 Transmission

Engine Oil Polaris 0W-50

Synthetic

Polaris AGL Lubricant

Add oil to proper level.

See procedure. Change annually2

Change more often (25 hours) in severe duty conditions, or short trip cold weather operation.

Throttle

3Brake Fluid

* More often under severe use, such as operated in water or under severe loads.

1 Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) 2 Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) 3 Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special.

Rear Gearcase

A-Arm Bushings

Polaris DOT 3 Brake Fluid

Polaris A TV Angle Drive Fluid

Polaris All Season Grease 3

Fill master cylinder reservoir to indicated level inside reservoir.

Drain and refill with premeasured amount of lubricant.

Locate grease fitting on swing arm and grease with grease gun.

As required. Change fluid every 2 years.

As required*

Semi-annually 1

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MAINTENANCE

NOTE: Refer to Page 2.6-2.8 for the Polaris Lubricant Identification table.

1. Engine Oil

Reservoir Level

3. Brake Fluid

5. Bottom Rear Lower Control Arm Lower Rear Bearing Carrier Pivot Prop Shaft

2. Transmission Oil

4. Rear Gearcase Oil

2.10

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MAINTENANCE

TRANSMISSION LUBRICATION

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

• Be sure vehicle is level before proceeding.

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

TRANSMISSION SPECIFICATIONS

Specified Lubricant:

Polaris AGSL Gearcase Lubricant:

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

Capacity:

Even with fill plug

Drain Plug and Fill Plug Torque:

15 ft. lbs. (20 Nm)

To change / check transmission fluid:

1. Place a drain pan beneath oil pan and remove drain plug from the crankcase. Allow oil to drain completely.

FRONT GEARCASE LUBRICATION (4X4 ONLY)

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

• Be sure vehicle is level before proceeding.

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

FRONT GEARCASE SPECIFICATIONS

Specified Lubricant:

Polaris Premium Demand Drive Hub Fluid: (PN 2872277) (2.5 gallon) (PN 2871654) (8 oz.)

Capacity:

Even with fill plug

Drain Plug Torque:

8-10 ft. lbs. (11-13 Nm)

Fill / Check Plug Torque:

8-10 ft. lbs. (11-13 Nm)

2. Reinstall the drain pl ug . Tighten to specification.

3. Add the proper amount of lubricant to bring level into operating range as shown. Do not over fill.

Drain Plug

Gearcase oil flush with the bottom of thread area.

4. Verify fluid level is correct and no leaks are present.

Oil Level Check

1. Position the vehicle on a level surface.

2. Remove the check/fill plug (A) and view the oil level. The oil level should be at the bottom of the check plug (B) threads.

3. Reinstall the check/fill plug (A). Torque to specification.

4. Reinstall the check plug (A) and a new sealing washer. Torque to specification.

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MAINTENANCE

5. Check for leaks.

Oil Change

1. Remove the drain plug (C). Drain the oil into an appropriate container. Discard used oil properly

2. Clean and reinstall the drain plug with a new sealing washer. Torque to specification.

3. Remove the check plug (A).

4. Remove the fill plug (B) and add a pre-measured amount of Polaris Angle Drive Fluid. The fluid should not be above the bottom of the check plug (A) threads.

5. Reinstall the fill plug (B) and check plug (A). Torque to specification.

6. Check for leaks.

LUBRICATION / GREASE POINTS

There are grease zerks rear lower control arm inner pivots, lower rear bearing carrier pivots, and the prop shaft. Apply grease until it is visible on the ends of the pivot points.

THROTTLE OPERATION - ALL MODELS

Check for smooth throttle opening and closing in all han dlebar 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.

Verify free play of 1/16-3/16” (1.6-4.76 mm) and smooth operation of choke cable.Adjustments to the freeplay can be made by loosening the choke cable adjustment in or out to gain the desired freeplay.

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

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 “ON”.

7. Start machine and check for leaks.

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

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. If cable is routed properly and in good condition, repeat adjustment procedure.

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

CHOKE (ENRICHER) ADJUSTMENT

CHOKE

2.12

Drain tube attached here

III. 1

Drain Screw

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MAINTENANCE

PILOT SCREW

The pilot system supplies fuel during en gine operatio n wi th 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 screw is calibrated at the factory to m eet 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 ADJUSTMENT

FRONT

(Engine)

Pilot Screw

Pilot Screw Location

Brass Plug Installed

Brass Plug Removed

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

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

Pilot screws are calibrated at the factory. Each carburetor has a slightly different pilot screw setting. The specifications may require additional tuning to achieve the desired results.

3. Connect an accurate tachometer that will read in increments of + or - 50 RPM such as the PET 2100DX (PN 8712100DX) or the PET 2500 (PN 8712500).

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

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

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MAINTENANCE

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

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

8. Re adjust idle speed if not within specification.

ELECTRONIC THROTTLE CONTROL (ETC SWITCH)/THROTTLE CABLE ADJUSTMENT

1. Slide the boots off inline cable adjuster sleeve. Loosen adjuster locknut.

2. With handlebars centered and wheels pointing forward, turn adjuster sleeve until 1/16” - 1/8” freeplay is achieved at the thumb lever. After making any adjustment, “flip” the lever slightly to confirm adjustment.

Boot

Adjuster Sleeve

Locknut

Boot

• Do not overfill the tank. Do not fill the tank neck.

• If you get gasoline in your eyes or if you swallow gasoline, seek medical attention immediately.

• If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.

• 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.

• Never drain the float bowl when the engine is hot. Severe burns may result.

FUEL LINES

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

2. Be sure fuel lines are routed properly and secured with cable ties.

CAUTION

Make sure lines are not kinked or pinched

Direction of travel

3. Tighten locknut and slide boots over cable adjuster until they touch at the middle point of the adjuster.

4. With engine running, turn the handlebars from full left to full right with transmission in neutral. Engine RPM should not change and the engine should not die. If either of these occur, return to the first step.

NOTE: If the throttle cable is adjusted too tight, the ETC will limit operation at low throttle positions.

1/16” to 1/8” Freeplay

FUEL SYSTEM

WARNING

Gasoline is extremely flammable and explosive under certain conditions.

• Always stop the engine and refuel outdoors or in a

well ventilated area.

• Do not smoke or allow open flames or sparks in or

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

3. Replace all fuel lines every two years.

VENT LINES

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

2. Verify 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. The fuel filter is located between the fuel tank and carburetor.

1. Clamp fuel lines

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.

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MAINTENANCE

BATTERY MAINTENANCE

WARNING

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

Fuel Filter

To Carburetor

5. Install clamps on fuel line.

6. Start engine and inspect for leaks.

7. Remove clamps

COMPRESSION TEST

NOTE: This 4-Stroke engine is equipped with an

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

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

A cylinder leakage test is the best indication of engine condition on models with automatic decompression. Follow tester 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: 90PSI

Cylinder Leakage

Service Limit: 10%

(Inspect for cause if leakage exceeds 10%)

during a

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

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

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

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

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

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

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

ENGINE MOUNTS

Inspect rubber engine mounts for cracks or damage.

ENGINE FASTENER TORQUE

Check engine fasteners and ensure they are tight

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MAINTENANCE

The battery is located under front rack.

To remove the battery:

1. Disconnect holder strap.

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 reinst alling the battery, install the negative cable last.

SPARK PLUG

1. Remove the seat and left hand side panel.

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

3. Remove spark plug.

4. 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

Spark Plug Gap

3. Remove the battery.

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

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

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

2871329).

7. Reinstall battery cover and holder strap.

5. Clean with electrical contact cleaner or a glass bead spark

plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used.

6. 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.

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

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

9. Install spark plug and torque to 9-11 ft. lbs (12-14 Nm).

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MAINTENANCE

10. Replace side panel and seat.

Recommended Spark Plug:

NGK R7HSA

Spark Plug Torque: 9-11 Ft. Lbs.

(12 - 14 Nm)

IGNITION TIMING

Timing is CDI controlled and has no adjustment procedure.

Ignition Timing:

+ 2o BTDC@3000RPM

MAIN AIR FILTER CLEANING

It is advisable to replace the filter when it is dirty. However, in an emergency it is permissible to clean the main filter if you observe the following practices.

• Never immerse the filter in water since dirt can be transferred to the clean air side of the filter.

• If compressed air is used never exceed a pressure of 40 PSI. Always use a dispersion type nozzle to prevent filter damage and clean from the inside to the outside.

• Replace the air filter every 50 hours, and possibly more often in very dirty conditions.

AIR FILTER/PRE-FILTER SERVICE

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

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

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

3. Inspect the gasket. It should adhere tightly to the cover and seal all the way around.

4. Remove air filter assembly.

Cleaning:

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

6. Rinse and dry thoroughly.

7. Inspect element for tears or damage.

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

Installation:

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

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

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

1. Remove the seat.

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MAINTENANCE

Proper Filter Placement

Filter Support

Air Box

Main Filter

CVT DRAIN PLUG & DRYING

NOTE: If operating the ATV through water, be sure to

check the CVT and other components for water ingestion. The ATV should be checked immediately.

1. To release any water that maybe trapped in the CVT cover, simply remove the CVT drain plug and O-ring located on the bottom of the CVT cover and let the water drain out.

III. 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.

11. Install air box cover and secure with clips.

Rear

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.

Sediment Tube

2. To further expel water from the cover and to dry out the CVT 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 CVT system is dry.

ENGINE OIL LEVEL

To check the oil level:

1. Set machine on a level surface.

2. Place the transmission in neutral.

3. Lock the parking brake.

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.

1. Remove drain plug from end of sediment tube.

2. Drain Tube.

3. Reinstall drain plug.

2.18

4. Start the engine. Allow it to idle for 30 seconds.

5. Turn the engine off.

6. The oil dipstick and fill hole are located behind the recoil on

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MAINTENANCE

the right side of the ATV.

7. Remove the dipstick and wipe it clean.

8. Reinstall the dipstick completely

9. Remove the dipstick an check the oil level.

10. Add oil as needed to bring the level between the minimum and maximum marks. Do not over fill.

11. Reinstall the dipstick.

6. Clean the area around the drain plug.

CAUTION

Hot oil may result in serious burns. Do not allow hot oil to contact skin.

7. Place a drain pan under the vehicle.

8. Remove the drain plug. Use a 6mm Allen wrench.

9. Drain the oil.

OIL AND FILTER CHANGE

1. Set machine on a level surface.

2. Place the transmission in neutral.

3. Lock the parking brake.

4. Start the engine. Allow it to idle for two to three minuets.

5. Turn the engine off.

10. Reinstall the drain plug with a new sealing washer.

11. Torque to 14 ft-lb (19Nm).

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

12. Place towels under the oil filter.

13. Using an oil filter wrench, turn the filter counter clockwise to remove it.

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MAINTENANCE

14. Clean the filter sealing area on the engine.

15. Lubricate the filter o-ring. Check to make sure the o-ring is in good condition.

16. Install the new oil filter, After the filter contacts the engine surface turn it 1/2 turn by hand.

VALVE CLEARANCE ADJUSTMENT

INTAKE VALVE CLEARANCE

1. Verify cam lobes are pointed down.

2. Insert a .006” (.15 mm) feeler gauge between end of intake valve stem and adjuster screw.

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

4. Re-check the valve clearance.

17. Remove the dipstick.

18. Add 0W/50 oil.

19. Reinstall the dipstick.

20. Start the engine and allow it to idle for two minuets.

21. Turn off the engine. Check for oil leaks.

22. Check the oil level. Add oil as needed to bring the level between the min. and max marks. Do not overfill.

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

INTAKE/ EXHAUST VALVE CLEARANCE

.006” (.15 mm)

EXHAUST VALVE CLEARANCE

1. Verify cam lobes are pointed down.

2. Insert an .006” (.15 mm) feeler gauge between end of exhaust valve stem and adjuster screw.

3. Loosen locknut and turn adjuster screw until there is a slight drag on feeler gauge.

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

5. Re-check the valve clearance.

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

STEERING

23. Discard used oil and filter properly.

2.20

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

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MAINTENANCE

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

WARNING

Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris Dealer. Only a qualified technician should replace worn or damaged steering parts. Use only genuine Polaris replacement parts.

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

TIE ROD END/STEERING INSPECTION

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

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

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

first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward.

Check for Loose Wheel or Hub

• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause.

CAMBER AND CASTER

The camber and caster are non-adjustable.

TOE ALIGNMENT

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 can be used as an indicator of whether the handlebars are straight. The arm should always point straight back from the steering post.

• Elevate front end of machine so front wheels are off the ground. Check for any looseness in front hub / wheel assembly by grasping the tire firmly at top and bottom

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

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

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

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

by moving vehicle forward or

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MAINTENANCE

measurement at the rear (B).

Chalk Line Measurement “A”

Measurement “B”

TOE ALIGNMENT ADJUSTMENT

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

CAUTION

During tie rod adjustment, it is very important that the following precautions be taken when tightening tie rod end jam nuts. If the rod end is positioned incorrectly it will not pivot, and may break

To adjust toe alignment:

• Hold tie rod end to keep it from rotating.

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

• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting - (1/8” to 1/4”).

• 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.

Hold Rod End

Correctly Tightened

Jam Nut

Incorrectly Tightened

Jam Nut

EXHAUST CLEANING

WARNING

• Do not perform clean out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with exhaust components.

• To reduce fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor.

• Wear eye protection.

• Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor.

• Never run the engine in an enclosed area.Exhaust contains poisonous carbon monoxide gas.

• Do not go under the machine while it is inclined.Set the hand brake and block the wheels to prevent roll back.

2.22

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

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

1. Allow the muffler to cool if hot.

2. Remove the fastener (1) and remove the arrestor from the

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MAINTENANCE

end of the muffler.

Arrestor

3. Use a non-synthetic brush to clean the arrestor screen. A synthetic brush may melt if components are warm. If necessary, blow debris from the screen with compressed air.

4. Inspect the screen for wear and damage. Replace if necessary.

5. Remove and inspect the gasket. Replace if worn or damaged.

6. Reinstall the gasket and arrestor.

• Use Polaris DOT 3 or DOT 4 Brake Fluid

• Check brake system for fluid leaks, excessive travel or spongy feel.

• Check brake pads for wear, damage or looseness.

• Check surface condition of the disc.

• Inspect thickness of brake pad friction material.

SIGHT GLASS

BRAKE PAD INSPECTION

Front Brake Pads

7. Use a wire brush to clean the arrestor screen. (NOTE: A synthetic brush may melt if components are warm.) If necessary, blow debris from the screen with compressed air.

8. Reinstall the clean out plug and arrestor.

9. Torque screws to 50 in. lbs. (5.6 Nm).

BRAKE SYSTEM INSPECTION

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

• Keep fluid level in the master cylinder reservoir to

the indicated level inside reservoir.

• Check the fluid level “eye”. If it is clear, it is an indication that fluid is needed or the brake pads may be worn, which can reduce the fluid level.

Brake Pad

Service Limit - .059” (1.5 mm)

Brake pads should be changed when friction material is worn to .59” (1.5 mm).

Measure Thickness

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.

BRAKE FREEPLAY

Hand Brake Lever

1. Check the brake lever, and foot brake for loose connections, free play, and damage.

2. Measure the hand brake lever freeplay. Freeplay should be

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MAINTENANCE

0.40-0.80 in. (10-20 mm).

3. If excessive free play exists, inspect brake pads, pedal, linkage springs, and hoses for wear or damage and replace any parts as needed.

.40” - .80” (10-20 mm)

Hand Brake Lever Free Play

Rear Foot Brake

• If free play is excessive: Inspect brake pads, pedal, linkage springs, and hoses for wear or damage and replace any parts as needed.

SUSPENSION SPRING FRONT / REAR PRELOAD ADJUSTMENT

Operator weight and vehicle loading affect suspension spring preload requirements. Using Spanner Wrench (PN 2870872) adjust as necessary to avoid bottoming of the shocks.

Rear Brake

4. Check foot brake effectiveness by applying approximately 50 lb. (23 kg) downward force on the pedal. The top of the pedal should travel not more than 1 inch (25.4mm).

50 lbs

5. If more than one inch, two things must be examined:

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

inch (3.2 - 6.35 mm).

1” or greater

Floorboard

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MAINTENANCE

FRONT SUSPENSION INSPECTION

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

Check all front suspension components for wear or damage. Inspect front shocks for leakage.

REAR SUSPENSION INSPECTION

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

• Check all rear suspension components for wear or damage.

• Inspect shock for leakage.

Shock Spanner Wrench

(PN 2870872)

CONTROLS

Check controls for proper operation, positioning and adjustment.

WHEEL REMOVAL/INSTALL- FRONT OR REAR

Wheel Removal

1. Stop the engine, place the transmission in gear 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.

4. Remove the wheel nuts and remove the wheel.

Wheel Installation

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

NOTE:Apply an anti-seize compound on the front wheel spindle before hub/wheel installation.

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

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

WHEELS

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

WHEEL, HUB, AND SPINDLE TORQUE TABLE

Item Specification

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

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

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

Improperly installed wheels could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure t apered end of nut g oes into taper on wheel.

Wheel

Wheel Nuts (4) 27 ft. lbs. (37 Nm)

Cotter Key

Hub Retaining Nut 80 ft. lbs. (108 Nm)

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MAINTENANCE

WHEEL INSTALLATION

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. Be sure to properly torque and install all wheel nuts.

TIRE PRESSURE

Tire Pressure Inspection (PSI - Cold)

Front Rear

Tire Tread Depth

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

Tread

Depth 1/8” (3 mm)

FRAME, NUTS, BOLTS, FASTENERS

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.

TIRE INSPECTION

WARNING

Operating an ATV with worn tires will increase the possibility of the vehicle skidding and possible loss of control.

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

sures 1/8” (.3 cm) or less.

CAUTION

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

• Improper tire inflation may affect ATV maneuverability.

2.26

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

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

Page 39

ENGINE

CHAPTER 3 ENGINE

TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2

TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

ENGINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2

TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4

GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

ENGINE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5

ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6

ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7

OIL FLOW DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9

PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10

PISTON RING IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10

ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10

ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13

TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14

TRANSMISSION INSTALLATION NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15

ENGINE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

OIL FLOW / PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

ENGINE BREATHER / OIL SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

CAM CHAIN TENSIONER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17

ROCKER ARM/SHAFT DISASSEMBLY AND INSPECTION. . . . . . . . . . . . . . . . . . . . .3.17

CAMSHAFT REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18

CAMSHAFT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19

CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19

CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20

COMBUSTION CHAMBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20

CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20

VALVE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21

VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21

CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24

VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24

ENGINE BOTTOM END DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25

CAM CHAIN GUIDE AND TESIONER BLADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25

PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25

CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26

CYLINDER HONE SELECTION/ HONING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . .3.26

HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26

PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27

PISTON RING INSTALLED GAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28

FLYWHEEL REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28

STARTER DRIVE CLUTCH REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . .3.29

CAM CHAIN DRIVE SPROCKET REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . .3.29

OIL PUMP INSPECTION / REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.30

STARTING CLUTCH AND ENGINE BRAKING CLUTCH REMOVAL /INSPECTION . . 3.30

STARTING CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31

CRANKCASE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.32

CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.32

CRANKSHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33

CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION. . . . . . . . . . . . . . . . . . . . . .3.33

CRANKCASE OIL PASSAGES & PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . .3.34

3.1

Page 40

ENGINE

CAMSHAFT CHAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

BALANCE SHAFT BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

CRANKCASE OIL PICKUP STRAINER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

BEARING /SEAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

END PLAY INSPECTION/ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35

CRANKSHAFT END PLAY ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35

COUNTER BALANCER SHAFT END PLAY ADJUST. . . . . . . . . . . . . . . . . . . . . . . . . . 3.36

CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37

CAM CHAIN, OIL PUMP, & TENSIONER BLADE INSTALLATION . . . . . . . . . . . . . . . 3.38

PISTON RING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39

PISTON INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39

CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40

CYLINDER HEAD AND CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 3.40

CAMSHAFT INSTALLATION & TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41

CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

ROCKER ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

STARTER DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43

SPARK PLUG FOULING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43

ENGINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

3.2

Page 41

ENGINE

TOOLS

SPECIAL TOOLS

PART NUMBER TOOL DESCRIPTION

2200634

2870390 Piston Support Block PA-47308 Flywheel Puller PA-47457 Star ting Clutch Holder

2871293-B

Va lve Seat

Reconditioning Kit

Crankshaft Slotted Nut

Socket

TORQUE SPECIFICATIONS

ENGINE TORQUE SPECIFICATIONS

Fastener

Camshaft Chain Tensioner Lever

Camshaft Chain Tensioner Body

Camshaft Chain Tensioner Cap

Camshaft Sprocket Cover

Thread

Size

6mm 5-6.5 (7-9 Nm)

6mm 6.5-8.0 (9-11 Nm)

8mm 6-7.5 (8-10 Nm)

6mm 6.5-8.0 (9-11 Nm)

ES300PFE010

Ft. Lbs. (Nm)

Oil Pressure Blind Plug 1/4 NPT 20-24 (27-33 Nm) Oil Pressure Relief

Valve Plug Recoil Housing 6mm 7-8 (9-11 Nm)

Rocker Adjuster Screw 5mm 3.5-5 (5-7 Nm) Rocker Cover 6mm 5-6.5 (7-9 Nm)

Rocker Adjuster Screw Lock Nut

Stator Plate to Crankcase

Stator to Stator Plate Screws

Starter Motor 6mm 5-6.5 (7-9 Nm) Starting Clutch Cover 8mm 14-15.5 (19-21Nm)

Starting Clutch Nut 16mm

Spark Plug (New) 12mm 7.5-9 (10-12 Nm)

Spark Plug (Used) 12mm

14 mm 15-17 (20-23 Nm)

5mm 3.7-5.0 (5-7 Nm)

6mm 7-8 (9-11 Nm)

5mm 5-6.5 (7-9 Nm)

103-118

(140-160 Nm)

Tighten 30-45

degrees after

gasket contact

Camshaft S procket Bolt 10mm 30-34 (40-46 Nm) Carburetor

Adaptor Cylinder Head Bolts 10mm

Cylinder & Head 6mm Bolts

Crankcase 6mm 6.5-8.0 (9-11 Nm) Crankshaft Sprocket

Slotted Nut Flywheel Nut 16mm 66-81 (90-110 Nm) Oil Drain Bolt

(Crankcase) Oil Filter Pipe Fitting

(Crankcase)

8mm 12-14 (16-20 Nm)

Refer to Torque

Procedure

6mm 5-7 (7-9 Nm)

25mm 34 (46 Nm)

14mm 13-16 (18-22 Nm)

20mm 9.5-12 (13-16 Nm)

3.3

Page 42

ENGINE

TORQUE PATTERNS

Tightening method for cylinder head nuts:

1) Apply engine oil to washer and threads of 10mm bolts.

2) Tighten 10mm bolt s in pattern below to 18.5 f t. lbs. (25 Nm)

3) Loosen 180 degrees

4) Tighten to 11 ft. lbs. (15 Nm)

5) Tighten 90 degrees

6) Tighten 60 degrees

7) Tighten 6mm head and base bolts to 8 ft. lbs. (11 Nm)

Cylinder Head / Cylinder Base

6 mm

3.4

Page 43

GENERAL ENGINE SERVICE

ENGINE EXPLODED VIEW

Crankcase

8 ft. lbs.

15 ft. lbs.

ENGINE

Cylinder/ Cylinder Head

6 ft. lbs.

15 ft. lbs.

Crankshaft and Piston

SEE PROCEDURE

12-14 ft. lbs.

5.5 ft. lbs.

16 ft. lbs.

5.5 ft. lbs.

Valve Train

3.5 ft. lbs.

7 ft. lbs.

6 ft. lbs.

34 ft. lbs.

6 ft. lbs.

30-34 ft. lbs.

3.5

Page 44

ENGINE

ENGINE SERVICE DATA

Cylinder Head / Valvetrain ES300PFE010

Camshaft Lobe Height In Std

Limit

Ex Std

Limit Journal O.D. PTO 1.0998-1.1004" (27.935-27.950mm) Journal O.D. MAG 1.5328-1.5334" (38.935-38.950mm) Journal Bore I.D. PTO 1.1025-1.1033" (28.005-28.025mm) Journal Bore I.D. MAG 1.5356-1.5364" (39.005-39.025mm)

Camshaft Journal Oil Clearance

Camshaft Chain Cylinder Head Surface Warpage Limit .0020” (.05 mm)

Rocker Arm/Shaft Rocker arm ID .8669-.8677" (22.02-22.04 mm)

Rocker shaft OD .8656-.866 1" (21.987-22.00 mm) Oil Clearance (Limit) .0039" (.10 mm)

Valve Clearance

Valve Seat Angle Contacting Width In Std

Valve Stem Diameter In

Stem Length

Margin

Valve Guide Inner Diameter In

Stem to Guide Oil Clearance Limit .006" (.15 mm)

Valve Spring Free Length

Squareness 0.075” (1.9 mm)

In Std .006" (.15 mm) Ex Std .006" (.15 mm)

Ex Std

In Limit .031" (.8mm) Ex Limit .031" (.8mm)

Std

Limit

Limit .1921" (4.9 mm)

1.2938-1.2977" (32.863 - 32.963mm)

1.2820" (32.563 mm)

1.2938-1.2977" (32.863 - 32.963mm)

1.2820" (32.563 mm)

.0021-.0035" (.055 - .090mm) .0039" (.10mm)

Install new as a part of any crankshaft removal

.039" (1.0 mm) .055" (1.4 mm) .059" (1.5 mm) .070" (1.8 mm) .2342-.2348" (5.950-5.965 mm) .2340-.2346" (5.945-5.960 mm)

3.976" (101.0mm)

3.984" (101.2mm)

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

1.640" (41.66 mm)

1.377" (35.0 mm)

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

PTO: Power Take Off

3.6

Page 45

ENGINE SERVICE DATA

Cylinder / Piston / Connecting Rod ES300PFE010

Cylinder Surface warpage limit (mating with cylinder

head) Cylinder bore Std

Taper or Out-of-Round Limit Limit .002” (0.05 mm)

Piston to cylinder clearance Std

Limit

Boring Limit

Piston Outer diameter

Pin Bore - Inner Diameter

Piston Pin

Piston Ring Piston Ring Installed Gap Top ring Std

Connecting Rod Connecting rod small end ID

Pin outer diameter clearance in piston Degree of fit

Piston Ring to Ring Groove Clearance

Connecting rod small end radial clearance (to piston pin)

Connecting rod big end axial (side) clearance

St d 3.0566-3.0575" (77.638-77.662 mm) 1st O.S. .0098" (.25 mm) Oversize 2nd O.S. .0197" (.50 mm) Oversize

Limit

Second ring

Oil ring Std

Top ring Std

Second ring

Oil ring Std

Std Limit

Limit

Limit Std Limit

Limit

Std Limit Std

Limit

.002” (0.05 mm)

3.0590-3.0598" (77.70-77.72 mm)

.0015-.0032" (0.038-0.082 mm) .0043" (0.11 mm)

1st O.S. + .0098” (.25 mm) 2nd O.S. + .0197” (.50 mm)

.7089-.7094" (18.007-18.020 mm) .00015- .00047” (.004- .012 mm)

Push (by hand) fit @ 68 clearance 0-.0005" (0-.012mm)

.008-.0012" (.2-.3 mm) .032" (.8 mm) .018-.019" (.35-.50 mm) .039" (1.0mm) .0079-.0275" (.2-.7 mm) .059" (1.5 mm)

.0006-.0029" (.015.-.074 mm) .006" (.15 mm) .0009-.0025" (.025-.065 mm) .006" (0.15 mm) .002-.0057" (.055-.145 mm)

N/A

.7089-.7094" (18.007-18.020 mm) 0 - .0007" (0 - 0.019 mm) .0011" (.03 mm)

.0035-.0196" (.09-.50 mm)

.023" (.60 mm)

F (20o C) (Standard

ENGINE

Connecting rod big end radial clearance

Std

Limit

0.0004-.0014" (.011-0.038 mm)

.0019" (.05 mm)

3.7

Page 46

ENGINE

Crankshaft / Counter Balancer / Oil Pump ES300PFE010

Crankshaft

Crankshaft End Runout Limit 0.0024" (0.06 mm)

Crankshaft End Play

Counter Balancer Counter Balancer Shaft End Play

Oil Pump

Oil Pump Shaft End Play N/A

Oil Pump End Clearance

Pump Rotor Tip Clearance

Pump Feed Rotor to Pump Body Clearance

Oil Pressure (Polaris 0W-50 @ Normal Operating T emperature @ Idle Speed)

Std 0.006-.012" (.15 - .30 mm) Limit N/A Std 0.004-.029" (0.1 - .74 mm) Limit N/A

Std 0.0027-.0051" (.070 - .130 mm)

Limit N/A

Std 0.0047" (.12 mm)

Limit N/A

Std 0.006 - 008" (.15 - .21 mm)

Limit N/A

Std Above 9 PSI

Limit Below 9 PSI

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

PTO: Power Take Off.

3.8

Page 47

OIL FLOW DIAGRAM

ES300PFE010

ENGINE

Rocker Arm Rocker Shaft Valve Springs

Chain Room

Connecting Rod Small End Piston Skirt / Rings

Counter Balance Gear Connecting Rod Big End

Main Bearing

PTO SIDE

Nozzle

Starting Clutch One Way Clutch

Starting Clutch

Main Bearing

Crankcase

Oil Passage

Oil Cooler / Filter

Crankcase

Oil Passage

Cylinder Head

(RH Cam Journal)

Crankshaft

Stator Plate

Crankcase

Oil Passage

Oil Pressure Inspection & Accy Oil Cooler Fitting Location

Camshaft Sprocket & Chain

Right Rear

Cylinder Bolt

MAG SIDE

OIL FLOW DIAGRAM KEY

Direct

Indirect

Oil Pump

Crankcase

Oil Passage

Oil Pickup Screen

Engine Sump

3.9

Page 48

ENGINE

PISTON IDENTIFICATION

The piston is identified by the marking ES30A.

Note the directional and identification marks when viewing the pistons from the top. The letters “IN” must always be toward the intake side of the engine.

Piston rings must be installed correctly to ensure engine performance. The numbers or letters on all rings (except oil control rings) must be positioned upward. See text for oil control ring upper rail installation. Use the information below to identify pistons and rings.

Engine Model

No.

ES300PFE010

Oversize

Available (mm)

.25mm .50mm

Standard

Piston

Identification

Valve Pocket to

Rear

(Intake Side)

PISTON RING IDENTIFICATION

The piston ring profile is shown below. Install top and second ring with marking UP. Refer to text for oil control

ring installation.

Piston Ring

TOP RING Mark Faces UP

SECOND RING Mark Faces UP

Installation

Note

Profile

Inner Bevel;

Barrel Face

Undercut;

Taper Face

• Cylinder Head

•Valves

• Carburetor

• Piston/RIngs

The following components require engine removal for service:

• Starting Clutch (transmission removal required)

• One-Way Clutch (engine braking)

• Crankshaft

• Crankshaft Main Bearings

• Counter Balance Shaft or Bearings

• Crankcase

• Transmission

NOTE: Crankshaft components are not serviceable. Replace crankshaft as an assembly.

ENGINE SERVICE

ENGINE REMOVAL

NOTE: The engine removal procedure described below removes the engine and transmission as an assembly, and the engine is then removed from the transmission case. The transmission can be removed separately from the engine (see Transmission Removal procedure in this chapter).

1. Clean work area.

2. Thoroughly clean the ATV engine and chassis.

ACCESSIBLE COMPONENTS

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

•Flywheel

• Alternator/Stator

• Starter Motor/Starter Drive

• Oil pump

• Rocker Arms / Rocker Shaft

• Camshaft

• Cam Chain and Sprockets

• Cylinder

3.10

3. Disconnect battery cables at battery.

4. Drain engine oil.

5. Disconnect spark plug high tension lead.

6. Remove the following parts:

•Seat

• Left and Right Side Covers

• Rear cab

7. Remove CVT cover and both clutches (refer to CVT

Page 49

ENGINE

Chapter 8)

8. Front prop shaft (4x4 models) (Drive pin out at front gearcase, pull shaft back, then forward. Refer to Drive Chapter)

13. CVT air intake and exhaust ducts

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

15. Remove exhaust head pipe.

16. Starter motor positive (+) and negative (-) cables at starter motor.

9. Remove transmission linkage rod (A) and vent hose (B)

10. Disconnect gear indicator switch harness (at transmission)

11. Disconnect speed sensor from transmission (left rear side).

12. Rea r fuel ta nk br acket

3.11

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ENGINE

17. Recoil housing, flywheel and stator (or if front cab is removed, remove front cab and disconnect wires.) See “Flywheel Removal / Inspection” on page 3.28. for flywheel removal procedure.

NOTE: If front cab is already removed, the stator wires can be disconnected. Disregard the steps to remove recoil cover, flywheel, and stator from the engine.

18. Front engine mount

19. Support lower sub-frame with a stable platform jack.

20. Rear lower engine mount

21. Sub frame bolts (2 each side)

23. Top rear shock bolts.

24. Top bolt s fro m swa y ba r br ac ket .

25. Lower the jack and pull engine / transmission assembly out the rear.

Rear mount

22. Rear wheel (left side) and brake caliper. Re-install rear wheel after caliper removal.

2 both sides

3.12

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ENGINE

26. Support engine and remove (9) transmission-toengine bolts.

IMPORTANT: DO NOT LIFT ENGINE BY THE STARTING CLUTCH SHAFT!

ENGINE INSTALLATION NOTES

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

General Items

Engine Break In Period

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

• Use only Polaris Premium 4 All Season Synthetic Oil, or API certified “SH” oil.

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

• Change break-in oil and filter at 20 hours or 100 miles, whichever comes first.

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

• Perform 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).

CVT System

• Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing.

• Inspect drive and driven clutch as described in chapter 8.

Transmission

• Inspect transmission operation.

Exhaust

• Replace exhaust gaskets. Seal connections if necessary with high temp sealant.

• After running the engine, verify all bolted exhaust connections are tight and in good condition.

Engine Mount Torque

• Inspect all engine mount fasteners and verify they are tightened properly

3.13

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ENGINE

TRANSMISSION REMOVAL

NOTE: The transmission can be removed separately from the engine. Follow this procedure if engine removal is not required.

1. Clean work area.

2. Thoroughly clean the ATV engine and chassis.

3. Disconnect battery cables at battery.

4. Drain transmission oil.

5. Remove the following parts:

• Seat

• Left and Right Side Covers

• Rear cab

6. Remove CVT cover and both clutches (refer to CVT Chapter 8)

8. Remove transmission linkage rod (A) and vent hose (B)

9. Disconnect gear indicator switch harness (at transmission)

10. Disconnect speed sensor at transmission (left rear side).

11. Rear fuel tank bracket.

12. CVT air inlet duct.

7. Front prop shaft (4x4 models) (Drive pin out at front gearcase, pull shaft back, then forward. Refer to Drive Chapter)

3.14

13. Support frame under engine with a stable platform jack.

14. Rear wheels and brake caliper.

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ENGINE

15. Remove rear plate (lower control arm bolts) and upper control arm bolts.

16. Remove rear shocks.

17. Remove rear suspension (both sides) with drive shafts.

18. Rear lower engine mount

19. Sub frame bolts (2 each side)

22. Loosen, but do not remove the 4 bolts from the rear transmission hanger bracket.

23. Remove (9) transmission-to-engine bolts.

24. Remove the top 2 rear bracket bolts.

25. Carefully lower the transmission jack until rear bracket is clear of frame.

26. Slide transmission to the left until alignment pins in cover are release from engine case.

27. Remove transmission out to the left side.

28. Remove sway bar bracket from transmission.

29. Refer to transmission disassembly in CVT/ Transmission Chapter 8.

TRANSMISSION INSTALLATION NOTES

1. Install new gasket on engine

2. Install transmission to engine until alignment pins are engaged, and screw in 4 bolts to hold in place but do not completely tighten at this time.

3. Loosely install upper frame mount bolts and all subframe bolts.

4. Install all remaining transmission-to-engine crankcase bolts and tighten all in 2 steps to specified torque following a cross pattern.

5. Tighten subframe to main frame bolts (4) and rear engine mount bolts.

6. Tighten rear upper bra cket bolts.

7. Tighten rear upper bra cket bolts.

Rear mount

20. Remove sub frame.

21. Support transmission with another jack.

2 both sides

3.15

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ENGINE

ENGINE LUBRICATION

Oil Type:. . . . . . . .Polaris Premium 0W-50 Synthetic

Capacity (DRY):

1.64-1.95 U.S. Quarts (1.55-1.85 l)

Capacity (OIL/FILTER/COOLING BLOCK CHANGE):

1.4-1.7 U.S. Quarts (1.3-1.6 l)

Drain Plug:. . . . . .14-18 ft. lbs. (19-24.4 Nm)

Oil Pressure Specification:

(Using Polaris 0W-50 Synthetic @ Operating Temperature @ Idle) Any pressure reading above 9 PSI.

OIL FLOW / PRESSURE TEST

WARNING

Oil temperature can cause serious injury and damage. Wear the proper safety gear when performin g these procedures.

NOTE: Due to the engine assembly having a majority of roller bearings, oil pressure readings hot or cold will be very low. Low oil pressure is not an indication of a oil delivery problem.

1. Remove plug from the crankcase. See Page 3.6

2. Insert a 1/4 Pipe Thread oil pressure gauge adaptor into the crankcase and attach an oil pressure gauge.

3. Start engine and allow it to reach operating temperature while monitoring gauge indicator. Any pressure above 9 PSI is an indication of good oil flow.

CAM CHAIN TENSIONER REMOVAL

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

4. Remove the valve cover.

5. Rotate engine in normal direction and watch the intake valve open and begin to close.

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

Single TDC Mark Aligned

TDC Mark

Rotation

7. Align single (T) mark on flywheel with in the inspection hole, and the cam sprocket pin (facing upward) aligned with the camshaft to crankshaft center line. NOTE: The sprocket marks align with gasket surface, the cam lobes should be pointing down and the valves should have clearance at this point.

ENGINE BREATHER / OIL SEPARATOR

The breather / oil separator is locate d behind the gas t ank on the left side. The breather provides ventilation for the valve cover and crankcase through the air box.

BREATHER FITTING

3.16

Dot

Marks Aligned

8. Remove the cam chain tensioner end cap. CAUTION: The plunger is under spring tension. Maintain inward pressure while removing.

9. Remove 2 cam chain tensioner bolts.

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ENGINE

10. Tap lightly on tensioner body with a soft face hammer to loosen and remove tensioner if required.

CAM CHAIN TENSIONER INSPECTION

1. Pull cam chain tensioner plunger (A) out to the end of its travel and inspect ratchet teeth on plunger and pawl. Inspect spring (B) for wear or damage.

ROCKER ARM/SHAFT DISASSEMBLY AND INSPECTION

NOTE: Orientation of the components is important for

reassembly. Mark all components before disassembly.

1. Remove the valve cover . Be sure engine is positioned at TDC on the compression stroke (there should be clearance on both rocker arm adjusters).

2. Mark the rocker arms to keep them in order for assembly.

3. Slide the rocker shaft out and be prepared to catch the wave washer (A) positioned on the PTO end of the shaft between the casting and the intake rocker arm.

2. Hold the ratchet open and slide the plung er in and o ut of the tensioner body. The plunger should move smoothly throughout the travel range.

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

4. Inspect each rocker arm cam follower surface. If there is any damage or uneven wear, replace the rocker arm. NOTE: Always replace camshaft if lobe of either rocker arm is worn or damaged.

Inspect surface of followers

3.17

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ENGINE

5. Inspect the rocker arm shaft and the shaft bore in the cylinder head for wear or signs of scoring.

6. Measure I.D. of each rock er arm (A) for out-of-round and visually inspect the I.D. surface. Replace arm if excessive wear is evident.

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

8. Measure O.D. of rocker shafts for out-of -round. Inspect them for wear or damage. Replace if excessive wear is evident. NOTE: Orientation of the rocker shafts is important for reassembly.

4. If not removing the cylinder for other service, secure the cam chain with a wire to prevent it from falling into the crankcase.

5. Inspect cam sprocket teeth for wear or damage.

6. Inspect the automatic compression release mechanism. Replace the cam if parts are worn.

CAMSHAFT REMOVAL AND INSPECTION

NOTE: Cam chain tensioner must be removed before

performing this procedure.

1. Remove the camshaft end cover.

2. Remove the sprocket bolt.

3. Slip the chain over the sprocket and remove sprocket.

Compression Release-one-way operation

3.18

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ENGINE

CAMSHAFT INSPECTION

1. Thoroughly clean the camshaft.

2. Visually inspect each cam lobe and bearing journal for wear, scoring, or damage. Verify oil delivery passages are clean.

3. Check the automatic decompressor spring legs and replace if broken. Spring preload is very light (about 45 degrees).

4. Measure the height of the cam lobes with a micrometer and compare to specification. Replace cam if worn below minimum height (service limit).

2. Loosen each of the four cylinder head bolts evenly 1/4 turn each time in a cross pattern until loose.

3. Remove bolts (A) and tap the cam support tower with a plastic hammer until loose. Remove.

4. After removing the camshaft and securing the cam chain, tap cylinder head lightly with a plastic hammer until loose. CAUTION: Tap only in reinforced areas or on thick parts of cylinder head casting.

5. Remove cylinder head, gasket, front chain guide and dowel pins.

Cam Lobe Height

Intake & Exhaust

Std: 1.2938”-1.2977 (32.863-32.963 mm)

Limit: 1.2820” (32.563 mm)

CYLINDER HEAD REMOVAL

NOTE: Cam chain and tensioner must be removed. If no

crankshaft service is being performed, secure cam chain with wire to avoid dropping chain into the crankcase.

1. Remove the (two) 6mm screws on the cylinder head and the two on the cylinder base.

CYLINDER HEAD INSPECTION

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

CAUTION

Use care not to damage sealing surface. If there is damage found on the cylinder head combustion chamber, it is recommended the component be replaced.

3.19

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ENGINE

CYLINDER HEAD WARP INSPECTION

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

Cylinder Head Warp Limit:

.002” (.05 mm)

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

4. Measure free length of the inner and outer springs with a Vernier caliper, Ill.1. Check spring for squareness as shown in Ill.2. Replace spring if measurements are out of specification.

Valve Spring Free Length

III.1

Coil fatigue/ Squareness

COMBUSTION CHAMBER INSPECTION

Clean all accumulated carbon deposits from combustion chamber and valve seat area with a soft wire brush. Inspect the combustion chamber for cracks and/or damage from foreign debris.

CYLINDER HEAD DISASSEMBLY

WARNING

Wear eye protection or a face shield during cylinder head disassembly and reassembly. Cylinder head service should be performed by a technician knowledgeable in cylinder head reconditioning in a properly equipped shop.

NOTE: Keep all parts in order with respect to their location in the cylinder head.

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

III.2

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

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

tightly wound coils (A) against the cylinder head.

3.20

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ENGINE

VALVE INSPECTION

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

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

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

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

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

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

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

4. Inspect split keeper groove for wear or flaring of the keeper seat area (B). NOTE: The valve s cannot be refaced or end ground. Valves must be replaced if worn, bent, or damaged.

5. Measure diameter o f valve st em with a micro meter in three places and in two different directions (six measurements total). Replace if excessive wear is evident.

Measure valve stem in several places

VALVE SEAT RECONDITIONING

Valve Seat Inspection

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

the valve seat is cracked the cylinder head must be replaced.

Too Wide

Uneven

Good Too

Narrow

3.21

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ENGINE

Cylinder Head Reconditioning NOTE: Servicing the valve guides and valve seats

requires special tools and a thorough knowledge of reconditioning techniques. Follow the instructions provided in the Valve Seat Reconditioning Kit (PN

2200634).

CAUTION

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

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

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

1. Install pilot into valve guide.

3. Place 46

4. Inspect the cut area of the seat.

• If the contact area is less than 75% of the circumference of the seat, rotate the pilot 180

make another light cut.

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

• If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation and must be replaced. Be sure the cylinder head is at the proper temperature and replace the guide.

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

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

cutter on the pilot and make a light cut.

)apply black marker to the entire valve face (A).

and

2. Apply cutting oil to valve seat and cutter.

3.22

(A)

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

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ENGINE

7. Remove valve and check where the Prussian Blue™ or black marker indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, an d must be the proper width (A).

(B)

(A)

Proper Seat Contact On Valve Face

• 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.

• If too low use the 60

or 75o cutter to raise the seat. When contact area is centered on the valve face, measure seat width.

• If the seat is too wide or uneven, use both top and bottom cutters to narrow the seat.

• If the seat is too narrow, widen using the 45

cutter and re-check contact point on the valve face and se at width after each cut.

Bottom 60o or 75

Seat - 45o or 46

Top - 30

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

Seat Width

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

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

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

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

12. Clean cylinder head, valves, and camshaft oil supply passages thoroughly.

13. Spray electrical contact cleaner into oil passages and dry using compressed air.

3.23

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ENGINE

CYLINDER HEAD ASSEMBLY

CAUTION

Wear eye protection during assembly.

NOTE: Assemble the valves one at a time to maintain proper order.

1. Install new valve seals on valve guides.

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

7. Repeat procedure for remaining valve.

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

VALVE SEALING TEST

1. Clean and dry the combustion chamber area.

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

2. Apply engine oil to valve guides and seats.

3. Coat valve stem with molybdenum disulfide grease.

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

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

Closely spaced coils toward cylinder head

3.24

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ENGINE

ENGINE BOTTOM END DISASSEMBLY

Cylinder Removal

Follow engine disassembly procedures to remove valve cover, camshaft and rocker arms, and cylinder head.

1. Lift to remove cam chain guide at front of cylinder.

2. Remove the two 6 mm cylinder base bolts.

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

4. Rock cylinder forward and backward and lif t it from the crankcase, supporting piston and connecting rod. Support piston with Piston Support Block (PN

2870390).

CAM CHAIN GUIDE AND TESIONER BLADE

1. The guide can be removed after cylinder head is removed by pulling it upward out of the channel in the crankcase.

2. Remove blade and insp ect. Replace if worn., cracked, or damaged.

3. Tensioner blade removal req uires recoil, flywheel, and stator plate removal. Refer to lower end service procedures to access the bolt securing the tensioner blade to the crankcase.

PISTON REMOVAL

1. Remove one circlip. Note valve pocket on intake side of piston for installation.

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

3. Remove the compression rings, starting with the top ring.

*Using a piston ring pliers: Carefully expand ring and lif t 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.

*By hand: Placing both thumbs at end gap, carefully spread the ring open and lift ring over piston at the opposite side. Use care to not scratch the ring lands.

4. Repeat procedure for second ring.

5. The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section. Remove the top rail first followed by the bottom rail and expander.

3.25

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ENGINE

CYLINDER INSPECTION

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

2. Inspect the top of the cylinder for warpage using a straight edge and feeler gauge.

Cylinder Warp:

.002” (.05 mm) MAX

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

4. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure in two different directions, front to back and side to side, on three different levels (1/2” down from top, in the middle, and 1/2” up from bottom).

1/2” Down From Top of Cylinder

CYLINDER HONE SELECTION/ HONING PROCEDURE

CAUTION

A hone which will straighten as well as remove material from the cylinder is very important. Using a common spring loaded glaze breaker for honing is not advised. 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.

HONING TO DEGLAZE

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

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

• Release the hone at regular intervals and inspect the bore to determine if it has been sufficiently deglazed, and to check for correct cross-hatch.

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

1/2” Up From Bottom

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

Cylinder Taper

Limit: .002” (.05 mm) Max.

Cylinder Out of Round

Limit: .002” (.05 mm) Max.

3.26

• After honing has been completed, THOROUGHLY clean the cylinder to remove all honing residue.

IMPORTANT: Clean the Cylinder After Honing

Wash the cylinder in a solvent, then in hot, soapy water. Use electrical contact cleaner if necessary to clean areas that cannot be scrubbed. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris 4 Cycle Lubricant to prevent the formation of surface rust.

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ENGINE

If cylinder wear or damage is excessive, it will be necessary to replace the cylinder. Hone only enough to deglaze the outer layer of the cylinder bore.

EXAMPLE OF CROSS HATCH PATTERN

PISTON INSPECTION

1. Measure piston outside diameter at a point 7 mm up from the bottom of the p iston at a right angle to the direction of the piston pin.

3. Measure piston pin bore. Replace piston if out-ofround

Piston Pin Bore

4. Measure piston pin O.D. Replace piston pin if out-ofround.

Piston Pin Measurement Locations

7mm

Piston

Piston Pin

2. Subtract this measurement from the maximum cylinder measurement obtained earlier.

Piston to Cylinder Clearance

Std: .0015- .0032” (0.038- 0.082 mm)

Limit: .0043” (.11 mm)

5. Measure connecting rod small end ID. Replace crankshaft if out-of-round.

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ENGINE

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

Piston

Ring

Feeler Gauge

PISTON RING INSTALLED GAP

1. Place each piston ring inside cylin der using piston to push ring squarely into place as shown.

Piston ring installed end gap

cylinder should be measured for excessive taper and out of round.

3. If the installed gap measurement exceeds the limit, replace the rings. If using new rings and the measurement is too small, file the ring ends to achieve the proper gap.

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

FLYWHEEL REMOVAL / INSPECTION

CAUTION

The crankshaft end cont ai ns an o il passage plunge joint (A) as shown below . The plunger must be able to move in and out freely. Avoid damage to the crankshaft end or plunge joint and spring, which can cause loss of oil pressure, resulting in severe engine damage.

Feeler Gauge

Cylinder

Piston Ring

Piston Ring Installed Gap

Top Ring

Std: .008- .012” (.2- .3 mm)

Limit: .032” (0.8 mm)

Second Ring

Std: .014- .020” (0.35- 0.50 mm)

Limit: .039” (1.0 mm)

Oil Ring

Std: .008- .028” (0.2- 0.7 mm)

Limit: .059” (1.5 mm)

2. Measure the gap with a feeler gauge at both the top and bottom of the cylinder.

25-50 mm

1. Remove the recoil housing, re coil hub, and flywheel nut.

2. Install Flywheel Puller (PN PA-47308) and remove flywheel. CAUTION: Do not hammer or strike the tool while attached to the crankshaft end.

NOTE: Measure at two points in the cylinder A difference in end gap indicates cylinder taper. The

3.28

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ENGINE

STARTER DRIVE CLUTCH REMOVAL/ INSPECTION

1. Remove recoil housing bolts and remove housing.

2. Remove the starter drive clutch and washer by pulling the shaft and tilting the gear slightly.

3. Measure the OD of the starter drive shaft on both ends for out-of-round.

4. Measure the ID of the bushings in the recoil housing and in the crankcase (A) in two directions 90 determine if out-of-round. Replace worn bushings.

apart to

CAM CHAIN DRIVE SPROCKET REMOVAL / INSPECTION

1. Remove recoil housing, flywheel, flywheel key, and stator.

2. Using the Slotted Nut Socket, remove the crankshaft slotted nut by turning it clockwise. NOTE: Slotted nut is left hand thread.

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

REMOVE

Slotted Nut Socket

(PN 2871293-A)

3. Remove cam chain drive sprocket and Woodruff key from crankshaft.

4. Inspect sprocket teeth for wear or damage.

Visually inspect for

tooth wear or damage

5. Inspect Woodruff key for wear.

3.29

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ENGINE

OIL PUMP INSPECTION / REMOVAL

NOTE: Mark the oil pump gero ters to keep parts mated

for assembly.

1. Remove recoil housing, flywheel, flywheel key, and stator.

2. Use a feeler gauge to check oil pump rotor tip clearance at “A”, and pump body clearance at “B”. Compare to specifications. Replace the oil pump assembly if any parts are damaged, scored, or measure beyond the service limit.

3. Mark the oil pump geroters and shaft and carefully lift the geroters from the housing.

STARTING CLUTCH AND ENGINE BRAKING CLUTCH REMOVAL /INSPECTION

NOTE: The transmission must be removed from the engine to access the starting clutch and one-way engine braking clutch.

1. Inspect the starting clutch drum bearing in the housing. The shaft must turn smoothly (by hand) without binding in the clockwise direction, and should not turn by hand in the counter clockwise direction. Minimal movement in the shaft is NORMAL with engine removed due to the lack of clutch cover bearing support on the free end of the shaft (approximately 0-.060” (0-1.5mm). Press the shaft out of the housing and replace the bearing if worn or rough.

DO NOT LIFT ENGINE WITH CLUTCH SHAFT

2. Remove all screws from the starting clutch housing.

3. Remove the one-way clutch from the starting clutch drum with a twisting motion. Note direction of installation with flange toward drum for assembly.

Inspect Drum For Wear or Damage

Flange toward drum

4. Inspect the one-way clutch closely for cracks or damage on the sprag shoes and the cage.

3.30

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ENGINE

5. Open the staked portion of the nut (A) with a center punch. Inspect the one-way clutch hub surface on the starting clutch (B). The hub must be smooth without any nicks or burrs. Replace the starting clutch assembly if the one-way clutch hub is uneven or damaged

Inspect entire surface of one-way clutch hub.

6. Install the starting clutch holder (PA-47457) onto the starting clutch and engage the tabs (C).

8. Inspect the shoes and springs of the starting clutch. Measure the thickness of the friction material on the shoes as shown, from the bottom of the friction material to the top at the thinnest point.

Standard Thickness: .100” (2.54mm)

LIMIT: .039” (1.00mm)

STARTING CLUTCH ASSEMBLY

1. Clean the mating surfaces of the crankcase and clutch starting clutch housing to remove all gasket material.

2. Install the starting clutch on the shaft.

3. Start a NEW stake nut on the shaft.

4. Install the starting clutch holder on the clutch.

5. Torque the nut to specification.

7. Remove the nut (counterclockwise). This is a standard thread.

Starting Clutch Stake Nut:

103-118 ft. lbs. (140-160 Nm)

6. Use a center punch or a pin punch to thoroughly stake the nut at the depression in the shaft.

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ENGINE

7. If drum bearing was replaced in the starting clutch housing, press the drum/shaft into the housing until fully seated.

8. Clean the inside of the starting clutch drum and lubricate the drum and one-way clutch with engine oil.

9. Install one-way clutch in starting clutch drum with the flanged side toward the hub, using a rotating motion.

Flange side toward hub

10. Install a new housing gasket.

11. Install the drum / housing assembly onto the case, install the housing bolts and torque in two steps using a cross pattern to specification.

CRANKCASE DISASSEMBLY

NOTE: Engine must be removed from the frame to

perform any crankcase or crankshaft removal. NOTE: The starter, starter drive, flywheel, stator, oil

pump and transmission can be serviced with the engine in the frame.

CRANKCASE SEPARATION

NOTE: Stator housing, flywheel and gears have are

previously removed for this procedure. Use care during the removal process to avoid damage to the cam chain.

NOTE: Valvetrain and cylinder removal must be performed prior to this procedure.

1. Remove all bolts and the pressure re lief valve (A) from the magneto side crankcase.

Starting Clutch Drum

Housing:

14-15.5 ft. lbs. (19-21 Nm)

12. CHECK the clutch shaft to be sure it rotates smoothly in the clockwise direction and will not rotate in the counterclockwise direction. If binding is evident, or if the shaft rotates in both directions (without turning the engine over) disassemble and inspect the one-way clutch and hub.

2. Tap carefully on reinforced areas of the cases to separate the halves. Watch the gap along the crankcase mating surface and separate the crankcase evenly.

3. Lift the right case half off of the left, leaving the crankshaft and balance shaft in the left case.

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ENGINE

CRANKSHAFT REMOVAL

1. Lift the crankshaft and balance shaft from the left case.

2. Note the number and thickness of any shims installed on either shaft.

NOTE: Crankshaft and balance shaft end play must be measured and adjusted with shims if any new components are installed (bearings, crankcase, crankshaft, or balance shaft. See procedure this chapter.

CRANKSHAFT / CAM CHAIN /

visual inspection.

3. The connecting rod utilizes a roller bearing. Clearance can be measured with a dial indicator to check radial clearance. Visually inspect the connecting rod, crank pin, and thrust washers for scoring, damage, excessive wear, or signs of overheating. Check for roughness or noise when rotating the connecting rod on the crank pin. Replace crankshaft if it fails visual inspection, or if any up and down movement is detectable in the connecting rod.

Connecting Rod Big End

Radial Clearance:

.0004-.0014” (.011-.038 mm)

LIMIT: .0019” (.05mm)

SPROCKET INSPECTION

1. Inspect the crankshaft main bearings for wear or damage.

NOTE: Due to extremely close tolerances and minimal movement, the ball bearings must be inspected visually, and by feel. Look for signs of discoloration, scoring or galling. Turn the outer race of each bearing. The bearings should turn smoothly and quietly. The inner race of PTO bearing each bearing should fit tightly on the crankshaft. The outer race should be firm with minimal side to side movement and no detectable up and down movement. The MAG end bearing usually stays in the case. Check the inner race of the MAG bearing in the same manner.

2. Replace the main bearings if the components fail

4. Check connecting rod side clearance with a feeler gauge.

5. Refer to piston inspection in this chapter to inspect the connecting rod small end.

Connecting Rod Side

Clearance:

.0035-.0196” (.09-.50mm)

Limit: .023” (.60mm)

6. Clean crankshaft oil passages by running a stream of clean solvent through the crankshaft. Be sure all passages are clear and free of nicks or scratches.

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ENGINE

CRANKCASE OIL PASSAGES & PRESSURE RELIEF VALVE

1. Remove the pressure relief valve assembly from the case.

2. Clean all crankcase oil passages with a stream of clean solvent.

CAMSHAFT CHAIN

1. Replace the cam chain as part of any crankshaft repair.

2. The cam chain can be removed by removing the engine top end, the recoil assembly, flywheel and flywheel key, stator plate, and slotted nut.

3. Lift the sprocket slightly until chain clears the crankcase to remove.

ote: Install new chain as a part of crankshaft rep

Turn the inner race of bearing. The bearing should turn smoothly and quietly. The outer race should fit tightly in the crankcase. The inner race should be firm with minimal side to side movement and no detectable up and down movement.

2. To remove balance shaft bearings, use a blind hole bearing puller.

NOTE: Bearings are stressed during the removal procedure and should not be re-used.

CRANKCASE OIL PICKUP STRAINER INSPECTION

1. Pull the strainer screen (A) from the case carefully and clean or replace it if heavily clogged, or if damaged.

BEARING /SEAL INSTALLATION

NOTE: To ease crankcase bearing installation, warm the

crankcase until hot to the touch. Placing the bearing in a freezer prior to installation will assist the assembly process.

1. Install the bearing so the numbers are visible.

2. Drive or press the new bearing into the crankcase, using the proper driver.

BALANCE SHAFT BEARING INSPECTION

NOTE: Replace all seals whenever the crankcase is

disassembled.

1. Inspect the balance shaft bearings in the crankcase. NOTE: Due to extremely close tolerances and minimal movement, the bearing must be inspected visually and by feel. Look for signs of discoloration, scoring or galling.

3.34

CAUTION

Press only on outer race of bearing to prevent bearing damage.

3. Install new seals with the lip facing in.

CAUTION

Press only on outer diameter to prevent damage.

Page 73

ENGINE

END PLAY INSPECTION/ADJUSTMENT

Before reassembling the crankcase, the following steps should be performed to determine the amount of crankshaft, counter balancer shaft, and pump shaft end play. Excessive end play may cause engine noise at idle and slow speeds. Too little play will side load the bearings which may lead to premature bearing failure.

CRANKSHAFT END PLAY ADJUSTMENT

NOTE: The method described here is shown with the PTO main bearing on the crankshaft, which is the most common situation. If the bearing is in the case, the procedure is the same, but the photo examples will differ.

1. Make sure all bearings are firmly seated in the crankcase.

3. Subtract the thickness of the straightedge from the measurement obtained in Step 2 and record.

PTO Case Depth_________________________

4. Measure the distance from the Magneto crankcase mating surface to the main bearing using the sa me method and record.

2. Lay a straightedge on the left (PTO) crankcase and measure the distance from the straightedge to the bottom of the main bearing bore (if bearing is still on the crankshaft) or to the bearing race (if the bearing is installed in the case) using a dial caliper.

5. Subtract the thickness of the straightedge from the measurement obtained in Step 4 and record.

Mag Case Depth_______________

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ENGINE

6. Add the readings recorded in Step 3 and Step 5 and record below.

To tal Case Width_________________

7. Measure the width of the crankshaft at the bearing seats (or to the outside of bear ing if bear ing is on the crankshaft as shown) with a micrometer or dial caliper and record.

COUNTER BALANCER SHAFT END PLAY ADJUST.

NOTE: The counterbalance shaft end play measurement procedure is the same as th at outlined for the crankshaft. The exception is that measurements are taken to the balance shaft bearings in the case, rather than the crankshaft main bearings, and the width of the balance shaft is measured, not the crankshaft.

1. Make sure the counterbalance shaft bearings are firmly seated in each crankcase.

Measure to balance shaft bearing race

2. Measure the distance from the Mag crankcase mating surface to the balance shaft bearing using a dial caliper and a straight edge. Subtract the thickness of the straightedge and record.

Crankshaft Width____________

8. Subtract the Crankshaft Width measured in Step 7 from the Total Case Width recorded in Step 6, and record below.

To tal End Play_____________

9. Subtract the thickness of the existing shim from the result of Step 8 to determine if a different shim is required. The result must be within the specified range listed below.

Crankshaft End Play: .006-.012” (.15-.30 mm)

MAG Case Depth_________________________

3. Measure the distance from the PTO crankcase mating surface to the bearing using the same method outlined for the MAG side.

PTO Case Depth_________________________

4. Measure the width of the c ounter balancer shaft at the bearing seats with a dial caliper or micrometer, and record reading.

5. Add the readings obtained in Step 2 and Step 3.

6. Subtract the counter balancer shaft width measured in Step 4 from the result obtained in Step 5.

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ENGINE

7. Subtract the thickness of the existing shim from the result of Step 6 to determine if a different shim is needed. The result must be within the sp ecified ra nge listed at below.

8. Add or subtract shims or change shim thickness as required and install them upon assembly.

Counter Balance Shaft End Play:

.004”-.029” (.1-.74 mm)

CRANKCASE REASSEMBLY

Crankshaft Installation

Lubricate all bearings with clean engine oil before assembly. Be sure crankcase mating surfaces are clean and free from oil or grease.

1. Place the required shims on the crankshaft and balance shaft.

3. Be sure balance dots on gear teeth are aligned.

4. Apply a thin coat of crankcase sealant to the outer mating surface of the left crankcase. Sealant is not required on the inner mating surfaces (A).

2. Support the PT O side cran kcase on blocks. Insta ll the crankshaft and balance shaft in the case, aligning the balance dots on the gears.

Crankcase Sealant

PN 2871557

5. Install the mag side case and tap with a soft faced hammer to seat.

6. Install case screws and torque in a cross pattern to specification.

Crankcase Bolt Torque:

6.5-8.0 ft. lbs. (9-11 Nm)

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Page 76

ENGINE

CAM CHAIN, OIL PUMP, & TENSIONER BLADE INSTALLATION

1. Install the cam chain over the drive sprocket.

2. Lubricate and install the oil pump geroters, aligning the marks made during disassembly. Clean the marks off the geroters.

Geroters

3. Install the tensioner blade and tighten the mounting bolt to specified torque.

it with Loctite 242 (blue) before installation.

This screw must be sealed

7. Torque the screws to specification.

Stator Plate Screw Torque:

6.5-8.0 ft. lbs. (9-11 Nm)

8. Install the flywheel key and flywheel.

Flywheel Nut:

67-81 ft. lbs. (90-110 Nm)

Tensioner Blade Mounting Bolt Torque:

5-6.5 ft. lbs. (7-9 Nm)

4. Install a new O-ring on the stator plate.

5. Lubricate the stator plate seal and bushing with engine oil and install the stator plate.

6. IMPORTANT! Be sure the sealed screw is placed in the hole that aligns with the cam chain cavity or an oil leak may result. If you are installing the old screw seal

Recoil Drive Hub:

12-14 ft. lbs. (17-19 Nm)

3.38

Page 77

ENGINE

PISTON RING INSTALLATION

NOTE: Apply clean engine oil to all ring surfaces and ring

lands. Always check piston ring installed gap before rings are installed on piston. If the piston has been in service, clean any accumulated carbon from the ring grooves and oil control ring holes.

1. Place the oil control ring expander in oil ring groove with the end gap facing forward. The exp ander has no up or down marking and can be installed either way.

The ends should butt squarely together and must not overlap.

2. Install the oil ring top rail with the end gap at least 30 from the end of the expander.

3. Install the bottom rail with the gap at least 30 end of the expander on the side opposite the top rail gap.

4. Install the second ring with the mark facing up. The second ring has an undercut with a tapered face. Position the end gap toward the rear (intake) side of the piston.

5. Install the top ring with the marking facing up. The top ring has an inner bevel with a barrel face.

Top Ring:

Bevel on Inner Edge

Install with mark UP

from the

piston pin bore, piston pin, and piston skirt. Lubricate the connecting rod (both ends) and crankshaft main bearing area.

3. IMPORTANT- Install the piston on the conne cting

rod with the valve pocket facing the intake side of engine. The piston pin should be a push fit into the piston.

Pocket

4. Install the other circlip with the gap facing up or down. Push the piston pin in both directions to make sure the clips are properly seated in the groove.

5. Lubricate the piston and rings with engine oil and install a ring compressor on the piston assembly. Verify that the ring gaps are 120 each other before installation.

- 180o apart from

Second Ring Mark Faces UP

6. Verify proper installation of rings by checking to be sure the top and second rings rotate freely in the groove when compressed by hand.

PISTON INSTALLATION

CAUTION

Do not re-use circlips. Circlips become deformed during the removal process. Do not compress the new clip more than necessary to prevent loss of radial tension. Severe engine damage may result if circlips are re-used or deformed during installation.

1. Install a new circlip on one side of the piston with the end gap facing up or down.

2. Apply clean engine oil to the piston rings, ring lands,

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Page 78

ENGINE

CYLINDER INSTALLATION

NOTE: Clean the gasket surfaces on the crankcase and

cylinder. Remove all traces of old gasket material or sealant. The surfaces must be oil-free!

1. Apply a small amount of crankcase sealant at the case parting lines (A). Do not allow sealant to dry. Assemble the top end immediately.

2. Install the dowel pin(s).

3. Install a new base gasket onto the mating surface and position the Piston Support Block (PN 2870390) beneath the piston skirt to support the piston during cylinder installation.

4. Apply clean engine oil liberally to the bore and tapered area of the cylinder. Place the cylinder on to the studs.

NOTE: Route cam chain through the cylinder chain room and secure it, holding it up to avoid damage to the chain, drive sprocket teeth or tensioner blade.

5. Loop the cam chain through the cylinder chain room and secure with mechanic’s wire.

8. Install the cam chain guide and dowel pins into the cylinder. Verify the bottom end of the guide is seated properly in the crankcase.

CYLINDER HEAD AND CAMSHAFT INSTALLATION

NOTE: Clean the gasket surfaces on the cylinder head

and cylinder. Remove all traces of old gasket material. The surfaces must be oil-free!

1. Install the dowel pin(s) and a new cylinder head gasket.

2. Pull the cam chain through the cylinder head chain room and secure with mechanic’s wire.

3. Place the cylinder head on the cylinder.

4. Install the two 6 mm bolts on cylinder base and on the head, but do not tighten.

6. Install cylinder carefully with a front to back rocking motion until rings are fully captive in the sleeve, then remove the compressor and support block.

7. Seat the cylinder firmly onto the base gasket.

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ENGINE

5. Lubricate the washers and the threads of the cylinder head bolts and install the bolts with washers.

6. Torque the cylinder head following the procedure a nd pattern below.

Cylinder Head / Cylinder Base

6 mm

timing mark on the flywheel is aligned with the mar k in the timing inspection window of the recoil housing. Be sure to use the correct mark when installing the cam. Do not use any advance timing marks.

2. Apply engine oil or starter drive grease (molybdenum disulfide paste) to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil.

Starter Drive Grease:

(PN 2871460)

3. Orient the camshaft with the lobes facin g down ward , and install the cam into the cylinder head.

Forward

• Tighten M10 bolts to 18.5 ft. lbs. (25 Nm)

• Loosen 180 degrees

• Tighten to 11 ft. lbs. (15 Nm)

• Tighten 90 degrees

• Tighten 60 degrees

• Tighten 6mm head & base bolts to 8 ft.lbs.(11 Nm)

CAMSHAFT INSTALLATION & TIMING

CAUTION

Serious engine damage will result if the camshaft is not properly timed to the crankshaft.

IMPORTANT CAMSHAFT TIMING NOTE: In order to time the camshaft to the crankshaft, the piston must be precisely located at Top Dead Center (TDC). If flywheel key and flywheel are not installed, install them at this time. The recoil housing must also be temporarily installed to use the timing inspection hole.

4. Disconnect the wire or tie strap securing the cam chain (if used).

5. Be sure the pin on the camshaft is pointing DOWN.

1. Rotate the crankshaft until the “T” (Top Dead Center)

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ENGINE

6. Loop the cam chain over the sprocket and shift the chain on the sprocket until it can be installed onto the camshaft.

7. VERIFY the following:

• “T” Mark on flywheel is aligned with the projection in the timing hole of the recoil housing.

• The mark (A) on the camshaft sprocket is aligned with the projection (B) in the camshaft cover window as shown above.

8. Verify all marks are aligned. Install the cam sprocket bolt and torque to specification.

Camshaft Sprocket Bolt

35.5-50 ft. lbs. (48-70 Nm)

CAM CHAIN TENSIONER INSTALLATION

1. Hold the tensioner ratchet pawl (A) open and push the plunger (B) in to the fully retracted position.

assembly with a new gasket and tighten the bolts to specification.

Tensioner Bolt Torque:

5-6.5 ft. lbs. (7-9 Nm)

3. Install the pin, spring, and tensioner cap with a new sealing washer. Torque cap to specification.

Tensioner Cap Torque:

6-7.5 ft. lbs. (8-10 Nm)

4. Slowly rotate engine two to three revolutions in the direction of rotation and re-check cam timing.

ROCKER ARM INSTALLATION

1. Lubricate the rocker arms and shaft with engine oil. Apply a light film of starter grease (mo ly grease) to the cam follower pad on the rocker arms.

Starter Drive Grease:

2. With the plunger retracted, install the tensioner

3.42

(PN 2871460)

Page 81

ENGINE

2. Slide the shaft through the tower just enough to install the wave washer (A).

NOTE: The flats of the wave washer are positioned against the intake rocker arm.

3. Install the rocker arms in the same position as marked during disassembly.

STARTER DRIVE ASSEMBLY

1. Be sure the washer is positioned on the back of the drive gear.

Starter Drive Grease:

(PN 2871460)

2. Apply Starter Drive Grease (PN 2871460) to the drive bushings in the cases and all moving surfaces of the starter drive gears and install.

3. Install recoil housing and torque bolts to specification.

4. Turn the engine through several revolutions to be sure parts rotate freely and smoothly.

5. Adjust valve clearance as outlined in the maintenance section.

TROUBLESHOOTING

SPARK PLUG FOULING TROUBLESHOOTING

• Restricted air filter (main or pre-cleaner), or air inlet ducts.

• Choke cable adjustment or plunger/cable sticking

• Foreign material on choke plunger seat or plunger

• Incorrect spark plug heat range or gap

• Jet needle and/or needle jet worn or improperly adjusted

• Excessive carburetor vibration (check all engine and carburetor mounts)

• Oil contaminated with fuel

• ETC switch mis-adjusted

• Low compression

• Spark plug cap loose or faulty

• Loose jets in carburetor or calibration incorrect for altitude/temperature

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ENGINE

• Incorrect float level setting

• Carburetor inlet needle and seat worn

• CVT system calibrated incorrectly or components worn or mis-adjusted

• Fuel quality poor (old)

• Restricted exhaust

• Restricted crankcase breather system

• Weak ignition (loose coil ground, faulty coil, sta tor, engine to chassis ground, or ETC switch)

• Improperly assembled air intake system

ENGINE Troubleshooting

Engine Turns Over But Fails to Start

• No fuel

• Dirt in fuel line or filter

• Fuel will not pass through fuel valve

• Fuel pump inoperative/restricted

• Fuel tank vent plugged

• Carburetor starter circuit restricted

• Engine flooded

• Low compression (high cylinder leakage)

• No spark (Spark plug fouled)

Engine Idles But Will Not Rev Up

• Spark plug fouled/weak spark

• Broken throttle cable

• Obstruction in air intake

• Air box removed (reinstall all intake components)

• Incorrect or restricted carburetor jetting

• ETC switch limiting speed

• Reverse speed limiter limiting speed

• Carburetor vacuum slide sticking/diaphragm damaged

• Incorrect ignition timing

• Restricted exhaust system

• Camshaft lobes worn

• Flywheel key sheared

Engine Has Low Power

• Spark plug fouled

• Cylinder, piston, ring, or valve wear or damage (check compression)

• CVT not operating properly

• Restricted exhaust muffler

• Dirty carburetor

Engine Does Not Turn Over

• Dead battery

• Starter motor does not turn

• Engine seized, rusted, or mechanical failure

Engine Runs But Will Not Idle

• Idle speed set too low

• Faulty ETC system

• Restricted carburetor pilot system

• Carburetor misadjusted

• Choke not adjusted properly or sticking plunger

• Low compression

• Crankcase breather restricted

• Air filter restriction

3.44

• Cam lobe worn

Piston Failure - Scoring

• Lack of lubrication

• Dirt entering engine through cracks in air filter or ducts

• Engine oil dirty or contaminated

Excessive Smoke and Carbon Buildup

• Oil level too high

• Excessive piston-to-cylinder clearance

• Worn rings, piston, or cylinder

• Worn valves, guides or seals

• Restricted crankcase vent

• Air filter dirty or contaminated

Page 83

Low Compression

• Decompressor stuck

• Cylinder head gasket leak

• No valve clearance or incorrectly adjusted

• Cylinder or piston worn

• Piston rings worn, leaking, broken, or sticking

• Bent valve or stuck valve

• Valve spring broken or weak

• Valve not seating properly (bent or carbon accumulated on valve area)

• Rocker arm sticking

Backfiring

• ETC or speed limiter system malfunction

• Fouled spark plug or incorrect plug or plug gap

ENGINE

• Carburetion faulty - lean condition

• Intake / Exhaust system air leaks

• Ignition system faulty:

•Spark plug cap cracked/broken

•Ignition coil faulty

•Ignition or kill switch circuit faulty

•Ignition timing incorrect

•Sheared flywheel key

• Poor connections in ignition system

• System wiring wet

• Cam lobe worn or Valve sticking

• Lean condition

3.45

Page 84

ENGINE

NOTES

3.46

Page 85

FUEL SYSTEM / CARBURETION

CHAPTER 4

FUEL SYSTEM / CARBURETION

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2

CARBURETITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

BST 34 CARBURETOR EXPLODED VIEW 1 OF 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3

BST 34 CARBURETOR EXPLODED VIEW 2 OF 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4

CARBURETOR VENTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5

CARBURETOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6

CARBURETOR JETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6

MIKUNI JET PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6

CV CARBURETOR SYSTEM FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6

CARBURETOR VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7

MIKUNI CV CARB OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7

STARTER SYSTEM (CHOKE OR ENRICHMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.8

PILOT (IDLE AND SLOW) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.8

MAIN SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.9

FLOAT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.9

PILOT SCREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10

AIR/FUEL MIXTURE RATIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10

JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.11

NEEDLE JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.11

THROTTLE OPENING VS. FUEL FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.11

CARBURETOR DISASSEMBLY – MIKUNI CV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.12

CARBURETOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13

CARBURETOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13

CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14

FLOAT HEIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14

NEEDLE AND SEAT LEAKAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.15

FUEL LEVEL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.15

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16

AIR INTAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17

AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.17

FUEL TANK/FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18

FUEL TANK / FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18

EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19

EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19

4.1

Page 86

FUEL SYSTEM / CARBURETION

SPECIAL TOOLS

PART NUMBER

2870975

2872314

Mity Vac

WARNING

Gasoline is extremely flammable and explosive

under certain conditions.

Always stop the engine and refuel outdoors or in a well ventilated area.

Do not overfill the tank. The tank is at full capacity when the fuel reaches the bottom of the filler neck. Leave room for expansion of fuel.

TOOL

DESCRIPTION

Tool

Carburetor Float

Adjustment Tool

NOTE: It is strongly recommended that Polaris Carbon Clean be added regularly as directed to the fuel systems of all Polaris ATVs. Carbon Clean stabilizes the fuel, preventing clogging of the small passages and orifices common to ATV carburetors, and ensures constant

performance, reliability and easier starting.

Pressure Test

Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.

Never drain the float bowl when the engine is hot. Severe burns may result.

Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

If you get gasoline in your eyes or if you should swallow gasoline, seek medical attention immediately.

If you spill gasoline on your skin or clothing, immediately wash with soap and water and change clothing.

4.2

Page 87

CARBURETITION

BST 34 Carburetor Exploded View 1 of 2

FUEL SYSTEM / CARBURETION

Table 4-1: Carburetor Components

Reference Description Reference Description

A Jet Needle J Throttle Control Cover Plate

B Diaphragm Assembly K Carburetor Body

C Needle Jet L Enrichment Plunger

D Jet Block Assembly M Enrichment Spring

E Washer N Cable guide

F Main jet P Pilot Air Jet

GCover

H Spring

4.3

Page 88

FUEL SYSTEM / CARBURETION

BST 34 Carburetor Exploded View 2 of 2

Table 4-2: Carburetor Components

Reference Description Reference Description

A Throttle Plate Shaft Retaining Components J Float Bowl O Ring

B Pilot Jet K Float Bowl

C Needle Valve Assembly L Float Bowl Drain Screw

D Throttle Plate M Throttle Shaft

E Idle RPM Speed Adjustment Screw N Throttle Shaft Return Spring

FSpring

G Needle Valve Retaining Plate

HFloats

4.4

Page 89

Carburetor Venting System

FUEL SYSTEM / CARBURETION

Table 4-3: Carburetor Venting System

Reference Description

ACheck Valve

B Hose (Float Bowl Drain)

C Hose (Vents)

DTee Fitting

E Filter

4.5

Page 90

FUEL SYSTEM / CARBURETION

CARBURETOR SPECIFICATIONS

2006 Hawkeye 2x4 / 4x4

(Domestic and International)

Altitude

Feet

(Meters)

Ambient

Temperature

0-6000

(0-1800)

6000-12000

(1800-3700)

Below 40F

(Below 5C)

152.5 147.5

147.5 142.5

(Above 5C)

Above 40F

CARBURETOR JETTING

IMPORTANT: The following guidelines must be followed

when establishing a main jet setting:

1. Select the lowest anticipated temperature and altitude at which the machine will be operated.

2. Select the correct main jet according to the engines fuel/performance requirements.

CAUTION

CV CARBURETOR SYSTEM FUNCTION

Carburetor Component Function

System

Float

System

(Level

Control)

Venting Passages in

Starter (Choke/ Enrichment)

Main

Components

Inlet Pipe, Needle and Seat, Float, Float Pin

Carburetor , Vent lines to frame

Choke Lever, Cable, Plunger, Return Spring, Carb Passages (Starter Jet, St arter Bleed Pipe)

Main

Function

Maintains specified fuel level in float chamber (carburetor float bowl)

Supplies atmospheric pressure to float chamber

Supplies additional fuel air mixture necessary for cold starting

All systems All throttle ranges

All throttle ranges Greatest effect at low throttle settings and idle

Main

Affect

A main jet that is too small will cause a lean operating condition resulting in serious engine damage. Select the correct main jet carefully for elevation and temperature according to the charts in the Specifications section or in the Owner’s Sa fety and Maintenance Manual for each particular model.

MIKUNI JET PART NUMBERS

Main Jets - BST 34 Pilot Jets - BST 34

Jet Number 130 3130561 25 n/a

132.5 3130562 27.5 n/a

135 3130563 30 n/a

137.5 3130564 32.5 n/a

140 3130527 35 n/a

142.5 3130566 37.5 n/a

145 3130567 40 3130624

147.5 3130568 42.5 3130526

152.5 3130570 45 3131397

155 3130571 47.7 3131226

157.5 3130572 50 3131132

160 3131141 55 n/a

162.5 3131142 57.5 n/a

165 3131143 60 n/a

167.5 3131144 65 n/a

170 3131145 70 n/a

Part Number Jet Number Part Number

Pilot (Idle System)

Main System

Pilot Jet/ Passage-ways, Pilot–Mixture Screw with Spring Washer and Sealing O– Ring, By-pass Ports (Behind Throttle Plate), Pilot Air Jet, Pilot Outlet, Throttle Plate

Main Jet, Main Air Jet, Main Air Passage, Needle Jet, Jet Needle, V acuum Slide, Throttle Plate

Primarily supplies fuel at idle and low throttle positions

Supplies fuel at mid–range and high throttle settings.

Mainly idle to 1/4 throttle Minimal effect after 1/2 throttle

1/4 to full throttle

4.6

Page 91

FUEL SYSTEM / CARBURETION

CARBURETOR VENTING

The carburetor float bowl vent lines supply atmospheric pressure to the float bowl. The lines must be free o f kink s, restrictions and be properly routed. This allows fuel to flow in the proper amount and prevents contaminants from entering the carburetor.

MIKUNI CV CARB OPERATION

The constant velocity carburetor incorporates a mechanically operated throttle plate and a vacuum controlled slid e valve (vacuum slide). The venturi cross–sectional area in the carburetor bore is increased or decreased automatically by the vacuum slide, which moves according to the amount of negative pressure (less than atmospheric) present in the venturi.

A diaphragm attached to the top of the vacuum slide is sealed to the slide and to the carburetor body forming two chambers. The chamber above the diaphragm is connected to the venturi area by a drilled orifice in the center of the vacuum slide. The chamber below the diaphragm is vented to atmospheric pressure by a passage on the air box side of the carburetor. A spring, installed in the center of the vacuum slide, dampens the slide movement and assists the return of the slide.

When the throttle plate is opened and engine speed begins to increase, the pressure in the venturi (and therefore in the chamber above the diaphragm) becomes significantly lower than atmospheric. Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward, raising the slide against spring pressure. When the pressure above and below the diaphragm are nearly equal, the slide moves downward under spring pressure. Raising or lowering the slide increases or decreases the cross sectional area in the venturi, and therefore the air velocity in the venturi is kept relatively constant. This provides improved fuel atomization and optimum fuel/air ratio.

Diaphragm

Throttle Plate

= Air Flow

Low Pressure From Venturi

Atmospheric

Pressure

Atmospheric

Air inlet

Vacuum

Slide

Venturi

= Low pressure

Note: Diagrams are for explanation of theory only, and are not true representations of Mikini BST carburetor.

4.7

Page 92

FUEL SYSTEM / CARBURETION

STARTER SYSTEM (CHOKE OR ENRICHMENT)

When the choke cable (1) is activated, the starter plunger (5) is lifted off the seat.

Fuel is drawn into the starter circuit from the float chamber (2) through the starter jet (3). Starter jet meters this fuel, which then flows into starter pipe (4) and mixes with the air (7) coming from the float chamber. The mixture, rich in fuel content, reaches starter plunger and mixes again with the air coming through a passage (8) extending from underneath the diaphragm. The rich fuel/ air mixture for starting is discharged through starter outlet (6) in the main bore.

PILOT (IDLE AND SLOW) SYSTEM

This system supplies fuel during engine operation with throttle valve closed (1) or slightly opened. The fuel from float chamber (2) is metered by pilot jet (3) where it mixes with air coming in through pilot air jet (4). The mixture then goes up through pilot passage to pilot screw (5). A part of the mixture is discharged into the main bore out of bypass ports (6). The remainder is then metered by pilot screw and discharged into the main bore through pilot outlet (7).

4.8

Page 93

FUEL SYSTEM / CARBURETION

MAIN SYSTEM

As throttle valve (1) is opened, engine speed rises, and this increases negative pressure in the venturi. Consequently the vacuum slide (2) moves upward. The fuel in float chamber (3) is metered by main jet (4), and the metered fuel enters needle jet (5), in which it mixes with the air admitted through main air jet (6) to form an emulsion. The emulsified fuel then passes through the clearance between needle jet (5) and jet needle (7), and is discharged into the venturi (A). Mixture proportioning is accomplished in needle jet (5); the clearance through which the emulsified fuel must flow is determined ultimately by throttle position and vacuum slide height.

FLOAT SYSTEM

Fuel enters the float chamber (3) by means of the inlet pipe and passage, through a scree n on the back of the inlet needle seat (4), and around the inlet needle (2). As the fuel fills the float chamber, the float (1) rises and forces the inlet needle agains t the seat, shutting off the orifice in the seat. When fuel level is up in float chamber, floats are up and needle valve remains pushed up against valve seat. Under this condition, no fuel enters the float chamber. As the fuel level falls, floats go down and needle valve unseats itself to allow fuel into the chamber. In this manner, the needle valve releases and shuts off fuel alternately to maintain a constant fuel level inside the float chamber.

Inlet

Pipe

4.9

Page 94

FUEL SYSTEM / CARBURETION

PILOT SCREW

The pilot system supplies fuel during engine operation 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 screw is calibrated at the 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

AIR/FUEL MIXTURE RATIO

E-Clip Position vs. Fuel Flow

2 3 4

Throttle Valve Opening

A carburetor with a slide type throttle valve is also called a variable venturi type carburetor. In this type of carburetor, the needle jet and jet needle serve to control proper air/ fuel mixture ratio at the medium throttle valve opening (between 1/4 and 3/4 opening).

100%

4.10

Brass Plug Installed

Brass Plug Removed

Having the proper needle jet and jet needle has a major impact on engine performance at partial load. The jet needle tapers off at one end and the clearance between the jet needle and the needle jet increases as the throttle valve opening gets wider. The air/fuel mixture ratio is controlled by the height of the “E” clip inserted into one of the five slots provided in the head of th e jet needle. The previous chart shows the variation of fuel flow based on the height of the “E” clip.

Page 95

FUEL SYSTEM / CARBURETION

JET NEEDLE

The jet needle has five adjustment gro oves cut into the upper portion, and is tapered from approximately the middle of the needle to the lower end. The top is fixed to the center of the throttle valve by the needle clip, and the tapered end extends into the needle jet. Fuel flows through the space between the needle jet and jet needle. This space does not vary until the throttle reaches the 1/4 open point. At that time the tapered portion of the needle begins to move out of the jet, affecting fuel flow as the opening enlarges. If the needle clip is changed from the standard position to a lower groove, the needle taper starts coming out of the jet sooner, resulting in a richer mixture. Moving the clip higher produces a leaner mixture. If the taper is worn due to vibration, fuel flow may be significantly affected.

Jet Needle

Leaner

Position#

Richer

NEEDLE JET

The needle jet works in conjunction with the jet needle to regulate fuel flow rate. An air bleed opening in the side of the needle jet brings in air measured by the air jet. This air initiates the mixing and atomizing process inside the needle jet.

Needle Jet

Main Jet

THROTTLE OPENING VS. FUEL FLOW

In a full throttle condition the cross sectioned area between the jet needle and the needle jet is larger than the cross sectioned area of the main jet. The main jet therefore has greater control over fuel flow.

Closed Throttle

Small Clearance

One-half Throttle

Medium Clearance

Full Throttle

Large Clearance

4.11

Page 96

FUEL SYSTEM / CARBURETION

CARBURETOR DISASSEMBLY – MIKUNI CV

Use the following disassembly, assembly, and inspection techniques to service a CV carburetor.

1. Remove carburetor diap hragm chamber cove r with a ratchet style screwdriver. DO NOT use an impact driver to remove the screws or carburetor may be permanently damaged.

2. Remove float bowl. Remove the float pin screw. The float and float pin can be removed.

3. Remove inlet needle seat retaining screw along with plate, and carefully remove needle seat. NOTE: Do not use a pliers to remove the seat or permanent damage may occur.

Remove Screw

4. Remove the pilot mixture screw, spring, flat washer, and O–Ring. If an anti–tamper plug is installed over the pilot screw cavity, it must be removed for access.

O-Ring

Washer

Spring

Pilot Screw

NOTE: The starter jet is removable. Upon disassembly, place the parts in a container for safe keeping.

4.12

Page 97

FUEL SYSTEM / CARBURETION

CARBURETOR CLEANING

WARNING

Protect eyes from contact with cleaner. T a ke appropriate safety measures during these procedures. Safety glasses and chemical resistant gloves are required. Should you get cleaner in your eyes or if you swallow cleaner, seek medical attention immediately. Carburetor cleaners can be ex tremely caustic. Extended periods of soaking can loosen th e a dhesive sealer on the passage drill-way plugs. Do not soak rubber or plastic components (such as the vacuum slide diaphragm, needle seat screen, or O-Rings in caustic cleaning solutions. Irrepara ble damage may occur. Do not use agitator-type carburetor cleaning equipment. Rubber parts must be cle aned with mild detergent and hot water only.

1. Thoroughly clean the carburetor body, jets, and all passages with carburetor cleaner or electrical contact cleaner.

2. If the carburetor is extremely dirty or contaminated with fuel residue and varnish, soak for short periods only in carburetor cleaner, and rinse in hot water.

3. Replace the jets if they have a buildup of fuel residue or bacterial growth that cannot be removed. Even a small amount of residue will reduce the flow characteristics of the jet.

4. Verify all passages and jets are unobstructed by spraying electrical contact cleaner through the passages. CAUTION: Do not use wire or welding tip cleaners as the orifice size may be altered.

5. Use low pressure air to dry carburetor body and all components.

CARBURETOR INSPECTION

1. Inspect jet needle and needle jet for wear. Look for discoloration, shiny spots, or an area that looks different than the rest of the needle. The middle to upper portion of the needle contact s the needle jet and is the most likely wear point. If jet needle shows signs of wear replace both the needle and needle jet to prevent a rich condition. TIP: A worn needle jet is difficult to spot. To check, slide a slightly larger new jet needle into the needle jet and hold it to a light source. Light will be visible between the needle and needle jet if it is worn.

Jet Needle

Inspect this area

2. Inspect the inlet needle tapered surface for any sign of wear or damage. Be sure the spring loaded pin is free moving and returns freely when pushed. The inlet needle and seat should be pressure tested after assembly.

Good Condition

Seat

Worn, Deposits

Needle Jet

Needle

Wear areas

4.13

Page 98

FUEL SYSTEM / CARBURETION

CARBURETOR ASSEMBLY

Inspect the diaphragm (A) for holes, deterioration, or damage. Make sure the diaphragm is pliable but not swollen. The diaphragm should fit properly in the carburetor body. Replace diaphragm assembly if diaphragm is damaged.

damage the O–ring during installation. Turn the screw in until it lightly contacts the seat. Back out the specified number of turns. NOTE: Th e fina l p ilot ( idle ) mixture must be adjusted with the engine running. Refer to Page 2.10.

Pilot Screw Base Setting

(Set at Factory)

Factory Specification: 2.5 Turns Out

FLOAT HEIGHT ADJUSTMENT

1. Illustration 1: Place the throttle side of the carburetor on a level surface to remove weight from float arm. In this position, the float tongue will rest slightly outward.

1. Replace parts in proper order. The spring seat (B) is stepped and must be placed on TOP of “E” Clip (C). Spacer washer (D) must be inst alled below the E–Clip. Refer to parts manual for more information.

2. Be sure the tab (E) on outer edge of diaphragm is positioned properly in the carburetor body.

FRONT (Engine)

Pilot Screw

3. Install the pilot mixture screw, spring, washer, and O– ring as an assembly. Lubricate the O–Ring with oil or light grease before installation. CAUTION: Do not

2. Illustration 2: With the carburetor still resting on the level surface, use one hand to slightly tilt the carburetor back. The float will then fall into the correct position, with the float tongue resting lightly on the inlet needle valve pin without compressing the spring. The bottom of the float should be parallel with the floa t bowl mating surface. Illustration 3: NOTE: If the float is past parallel with the mating surface, the carburetor has been tilted back too far and the float tongue is likely compressing the needle valve pin.

Float parallel with float bowl mating surface

4.14

Page 99

FUEL SYSTEM / CARBURETION

3. Measure the height from the float bowl mating surface to the top of step of the float as shown in Illustration 2. Both sides of float should be parallel to each other. The measurement should be made at the mid–point on top of the float using Float Adjustment Tool (PN

2872314) or a vernier caliper. When measuring the height, be sure the inlet needle valve spring is not compressed.

Float Bowl Height: 13-14 mm

4. If adjustment is necessary, bend the tongue slightly. Be sure float measurement is even on left and right side.

FUEL LEVEL TEST

A fuel level test can be performed on some models if the drain hose fitting is accessible. Be sure to re–attach the bowl drain hose after performing th e test. A fuel level t est allows you to observe the height of the fuel in the float bowl without removing the carburetor. The fuel level can be observed with the engine either running or shut off, however, engine must run briefly to allow fuel level to stabilize.

1. Attach a clear line to drain fitting. Be sure line fits tightly on fitting. Position hose along side of carburetor as shown.

1.5 mm .060 in.

Bowl Mating Surface

NEEDLE AND SEAT LEAKAGE TEST

1. Install the float bowl. Invert the carburetor an d install a Mity–V ac™ (PN 2870975) to the fue l inlet fitting. Apply 5 PSI pressure to inlet fitting. The needle and seat should hold pressure indefinitely . If not, inspect ne edle and seat and seat O–ring.

Mity VacTM (PN 2870975)

2. Open bowl drain screw by turning counterclockwise approximately two turns. Start and run engine for 3 to 5 seconds to allow fuel level to stabilize in the line. If level is out of specification, remove carburetor and inspect inlet needle and seat, float height, passages, etc.

NOTE: If a line was removed to perform this procedure, it must be replaced.

4.15

Page 100

FUEL SYSTEM / CARBURETION

TROUBLESHOOTING

FUEL STARVATION/LEAN MIXTURE Symptoms: Hard start or no start, bog, backfire, popping

through intake / exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle speed erratic.

• No fuel in tank

• Restricted tank vent, or routed improperly

• Fuel lines or fuel valve restricted

• Fuel filter plugged

• Carburetor vent line(s) restricted

• Plugged or restricted inlet needle and seat screen or inlet passage

• Clogged jets or passages

• Float stuck, holding inlet needle closed or inlet needle stuck

• Float level too low

• Intake air leak ( throttle shaft, intake duct s, airbox or air cleaner cover)

• Jet needle position incorrect

• Incorrect pilot screw adjustment

POOR IDLE Idle Too High

• Idle adjusted improperly/idle mixture screw damaged

• Sticky vacuum slide

• Throttle cable sticking, improperly adjusted, routed incorrectly

• Choke cable sticking, improperly adjusted, routed incorrectly

• Plugged or restricted idle jet

Idle Too Low

• Choke cable bending or incorrectly adjusted

• Idle speed set incorrectly

• Idle mixture screw misadjusted or damaged

• Belt dragging

• Ignition timing incorrect

• Worn jet needle/needle jet

• Plugged or restricted idle jet

Erratic Idle

• Choke cable bending or incorrectly adjusted

• Throttle cable incorrectly adjusted

RICH MIXTURE

Symptoms: Fouls spark plugs, black, sooty exhaust

smoke, rough idle, poor fuel economy, engine runs rough/ misses, poor performance, bog, engine loads up, backfire.

• Air intake restricted (inspect intake duct)

• Air filter dirty/plugged

• Electric choke inoperative

• Incorrect pilot air/fuel screw adjustment

• Faulty inlet needle and seat

• Faulty inlet needle seat O-Ring

• Float level too high

• Poor fuel quality (old fuel)

•Loose jets

• Worn jet needle/needle jet or other carburetor parts

• Dirty carburetor (air bleed passages or jets)

• Air leaks, dirty carburetor passages (pilot circuit)

• Pilot mixture screw damaged or adjusted incorrectly

• Tight valves

• Ignition timing incorrect

• Belt dragging

• Dirty air cleaner

• Engine worn

• Spark plug fouled

• Idle speed set incorrectly (speed limiter)

• Worn jet needle/needle jet

• Plugged or restricted idle jet

4.16