Polaris A09BG50AA, A09BA50FA, A09BG50FA User Manual

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GENERAL INFORMATION

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

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

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

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

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

Specifications 1.4--1.5...........................

Standard Torque Specifications 1.6............

Tap Drill Charts 1.7..........................

Specs

Decimal Equivalent Chart 1.7.................

Unit of Measure Conversion Table 1.8..........

Glossary of Terms 1.9--1.10........................

1.1

GENERAL INFORMATION

MODEL IDENTIFICATION

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

Machine Model Number Identification

A09BG50AA

Emissions &

Year Designation

Basic Chassis Designation Engine Designation

Model Option

ENGINE DESIGNATION NUMBERS

EH500PLE Single, Liquid Cooled, SOHC 4 Stroke, Electric Start.................

VIN IDENTIFICATION

World Mfg. ID

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

Vehicle Descriptor

50A* P000000

Vehicle Identifier

Body Style

Powertrain

Emissions

Engine

Check Digit

Model Year

Plant No.

Individual Serial No.

* This could be either a number or a letter

ENGINE SERIAL NUMBER LOCATION

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

UNIT MODEL NUMBER AND SERIAL NUMBER LOCATION

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

Front

TRANSMISSION I.D. NUMBER LOCA

TION

1.2

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

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.

Shouldbothkeysbecomelost, ignition switch replacement is required.

GENERAL INFORMATION

Series # Part Number

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

31XX

KEY COVER

P/N 5433534

Key Series Number

PUBLICATION NUMBERS

Year Model Model No. Owner’s Manual Parts Manual

2009 Scrambler500 4x4 A09BG50AA, FA 9921777 9921778 2009 Scrambler500 2x4 A09BA50FA 9921777 9921778

When ordering service parts be sure to use the correct parts manual.

PAINT CODES

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

COLD WEATHER KITS FOR 4 CYCLE ATVS

Engine Heater -- (PN 2871507)

ACCESSORY ENGINE HEATER

1.3

GENERAL INFORMATION

MODEL: 2009 SCRAMBLER 500..........

MODEL NUMBER: A09BG50AA, FA / A09BA50FA.

( 4x4 / Intl’ ) (2x4 Intl’)

ENGINE MODEL: EH50PLE..

Category

Length 75 in./190.5 cm Width 46 in./116.8 cm Height 47 in./119.4 cm Wheel Base 48 in./121.9 cm Dry Weight 571 lbs./259 kg (4x4)

Gross Vehicle Weight 845 Lbs. / 383 kg (4x4)

Front Rack Capacity

(Accessory)

Rear Rack Capacity

(Accessory)

Tow Capacity 850 lbs./385.9 kg Tongue Weight 85 lbs./38.6 kg Body Style Gen III

Dimension / Capacity

571 lbs./259 kg (2x4)

845 Lbs. / 383 kg (2x4)

30 lbs./13.6 kg

60 lbs./27.2 kg

1.4

NOTE: 4x4 Model Shown

MODEL: 2009 SCRAMBLER 500..........

MODEL NUMBER: A09BG50AA, FA / A09BA50FA. ENGINE MODEL: EH50PLE..

Engine

Platform Fuji Single Cylinder Engine Model Number EH500PLE Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke 92 x 75 mm

3.6248I x 2.955I CompressionRatio 10.2:1 Compression Pressure 70--90 psi w/decompressor Engine Idle Speed 1200Rpm ± 100 Engine Max Operating Rpm 6500 Rpm ± 200 Cooling System / Capacity Liquid -- 2.25 qt / 2.1 ltr Overheat Warning HOT Indicator Lubrication PressurizedDry Sump Oil Requirements / Capacity Polaris 0W--40 2 qt. / 1.9 ltr Exhaust System Single Pipe

Carburetion

Carburetor model Mikuni BST 40mm Main Jet 155 Pilot Jet 40 Pilot Air Jet 160 Jet Needle -- Clip Position 6H25--94--3 Needle Jet Y--0M (896) Pilot Screw 2 Turns Out

(Set at factory, will vary on each vehicle)

Float Height 13 ± 1 mm / 0.51 ± 0.40“ Fuel Delivery Fuel Pump Fuel Capacity / Requirement 3.5 gal US / 13.2 ltr

87 Octane (minimum)

89 Oxygenated

Electrical

Alternator Output 250 w @ 5000 RPM Voltage Regulator 3--Phase-- LR--39 Lights : Head(Twin) 30 / 30 watts

Brake 8.26 watts

Tail 26.9 watts Ignition System CDI Ignition RPM Limit 6600 RPM Ignition Timing 30° BTDC @ 5000 RPM ± 250 Spark plug / Gap BKR6E/ .036 in./0.9 mm Battery / Model / Amp Hr Low Maintenance 14 Amp Hr Circuit Breakers Solid State in PDM Starting Electric

GENERAL INFORMATION

Drivetrain

Transmission Type H/N/Rev Transmission Capacity 32oz. / 945ml Front AWD Hub Capacity 2.5 oz. / 75ml Front Gearcase Capacity 4oz./118ml Gear Ratio : Low

Rev

High

Front Drive

Rear Drive / Chain Pitch Chain Type 520 O--ring PVT Type / Belt Non--EBS / 3211091

Steering / Suspension

Front Suspension / Shock A--arm / MacPherson Strut Front Travel 8.2 in. / 20.83 cm Rear Suspension / Shock Progressive Rate Swing Arm

Twin Tube Gas Charged Rear Travel 10.5 in. / 26.67 cm Ground Clearance 5.5 in. / 13.97 cm Shock Preload Adjustment

Front / Rear

Front --Non Adjustable.

Rear -- Cam Adjuster Turning Radius 83 in. / 210.8 cm unloaded Toe Out 1/8 -- 1/4 in / 3 -- 6.35 mm

Wheels / Brakes

Wheel Size / Pattern -- Front Steel 23x7--10 / 4--156 Wheel Size / Pattern -- Rear Steel 22x11--10 / 4--102 Front Tire Size 23x7--10 Rear Tire Size 22x11--10 Recommended Air Pressure

F/R Brake -- Front Dual Hydraulic Disc Brake -- Rear Single Hydraulic Disc

JETTING CHART

AMBIENT TEMPERATURE

Below 40°F

Below 5°C

160

152.5

Meters

(Feet)

Altitude

(0--6000)

above 1800

(above 6000)

0--1800

CLUTCH CHART

Shift

Weight

10 WH

PN 5630710

10 RH

PN 5630709

Spring

Blu/Grn

PN 7041157

Blu/Grn

PN 7041157

Meters

(Feet)

Altitude

0--1800

(0--6000)

1800--3700

(6000--12000)

n/a

4.74:1

3.06:1 2:1

13/36 76 Pitch

4 psi Front

3 psi Rear

+40°Fto+80°F

Drive

Driven

Spring

Silver

PN 7041499

Silver 1--1

PN 7041499

+5°Cto+28°C

155

147.5

Driven

Helix 40_

PN 5131446

40_

PN 5131446

1--1

1.5

GENERAL INFORMATION

STANDARD TORQUE SPECIFICATIONS

Thefollowing torquespecificationsare tobeused as a generalguideline. FOR SPECIFICTORQUE VALUESOF 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

T orque 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).............. ................ ..............

T o rque ft. lbs. (Nm)*

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

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

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

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

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

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

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

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

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

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

Metric

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

1.6

GENERAL INFORMATION

SAE TAP DRILL SIZES

Thread Size/Drill Size Thread Size/Drill Size

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

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

METRIC TAP DRILL SIZES

Tap Size Drill Size Decimal

Equiva-

lent

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

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

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3437

0.339

0.375

0.406

Nearest

Fraction

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

DECIMAL EQUIVALENTS

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

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

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

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

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

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

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

1/8. .1250...

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

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

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

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

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

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

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

1/4 .25....

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

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

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

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

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

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

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

3/8 .375....

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

45/64 .7031

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

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

3/4 .75....

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

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

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

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

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

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

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

7/8 .875....

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

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

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

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

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

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

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

11.0.....

18 mm = .7087″............... ...

1.7

GENERAL INFORMATION

CONVERSION TABLE

Unit of Measure Multiplied by Converts to

ft. lbs. x12 =in.lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 =Nm in. lbs. x .0115 =kg-m Nm x .7376 = ft.lbs. kg-m x 7.233 = ft. lbs. kg-m x 86.796 =in.lbs. kg-m x10 =Nm in. x 25.4 =mm mm x .03937 =in. in. x2.54 =cm mile (mi.) x1.6 =km km x .6214 = mile (mi.) Ounces (oz) x 28.35 = Grams (g) Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc) Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.) Grams (g) x 0.035 = Ounces (oz) lb. x .454 =kg kg x 2.2046 =lb. Cubic inches (cu in) x 16.387 = Cubic centimeters (cc) Cubic centimeters (cc) x 0.061 = Cubic inches (cu in) Imperial pints (Imp pt) x 0.568 = Liters (l) Liters (l) x1.76 = Imperial pints (Imp pt) Imperial quarts (Imp qt) x 1.137 = Liters (l) Liters (l) x0.88 = Imperial quarts (Imp qt) Imperial quarts (Imp qt) x 1.201 = US quarts (US qt) US quarts (US qt) x 0.833 = Imperial quarts (Imp qt) US quarts (US qt) x 0.946 = Liters (l) Liters (l) x 1.057 = US quarts (US qt) US gallons (US gal) x 3.785 =Liters (l) Liters (l) x 0.264 = US gallons (US gal) Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa) Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi) Kilopascals (kPa) x0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

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

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

1.8

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 transmit rotation of the clutch to the movable sheave in the drive and driven

clutch. ClutchOffset: Drive and drivenclutchesareoffsetso thatdrivebelt will stay nearlystraightasit movesalongtheclutch

face. Clutch Weights: Three levers in the driveclutch which relative to theirweight, profile and engine RPMcause thedrive

clutch to close.

Condenser/Capacitor: A storage reservoir for DC voltage. Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported

between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.

DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and

out-of-round in the cylinder bore.

Electrical Open: Open circuit. An electrical circuit which isn’t complete. Electrical Short: Short circuit. Anelectrical 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. HP: Horsepower. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.

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

lbs/in Left Side: Always referred to based on normal operating position of the driver.

: Kilograms per square centimeter.

: Pounds per square inch.

1.9

GENERAL INFORMATION

GLOSSARY OF TERMS

m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the

windings. Mechanical energy is converted to electrical energy in the stator.

mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040″. Nm: Newton meters. OD: Outside diameter . Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch System) qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM

increases.

Reservoir T ank: Thefill tank in the liquid cooling system. Resistance: Inthemechanicalsense,frictionorload. Intheelectricalsense, ohms. Bothresult inenergyconversionto

heat.

Right Side: Always referred to based on normal operating position of the driver. RPM: Revolutions per minute. Secondary Clutch: Driven clutch on chaincase or jackshaft. SeizedPiston: Gallingofthesidesof a piston. Usuallythereis a transferofaluminumfromthe pistonontothecylinder

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.

1.10

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

Lubricant and Maintenance Product Numbers 2.6

Pre-Ride Inspection 2.7......................

Pure Polaris Products for Your ATV 2.8.........

Lubrication Charts 2.9-2.11........................

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

Transmission Lubrication 4x4 2.12..............

MAINTENANCE

Transmission Linkage Adjustment (H/L/R) 2.13-2.14...

Throttle Operation / Choke Adjustment 2.14......

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

ETC Switch Operation 2.16-2.17....................

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

Compression Test 2.19........................

Battery Maintenance 2.19-2.21......................

Electrical 2.21-2.22................................

Coolant System Maintenance 2.23..............

Air Filter Service 2.24--2.25.........................

Air Box Sediment Tube Service 2.25............

Breather Filter 2.25...........................

Recoil Housing 2.26...........................

PVT Drying 2.26............................

Oil Change/Filter 2.26-2.29.........................

Valve Clearance 2.29-2.30.........................

Steering and Toe Alignment 2.30-2.32...............

Front Hub Maintenance (AWD Models) 2.32--2.33.....

Exhaust System Maintenance 2.33--2.34.............

Brake System Service 2.34-2.35....................

Drive Chain and Sprocket Service 2.35-2.36..........

Suspension Service / Controls 2.37-2.39.............

Wheel Removal / Installation 2.39-2.40...............

Tire Inspection 2.40...........................

2.1

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 speedofapproximately10 milesperhour. Vehiclessubjectedto severeuse mustbe inspectedandservicedmore frequently.

Severe Use Definition

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

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

Maintenance Chart Key

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

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

by an authorized Polaris dealer.

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

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

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

WARNING: Improperly performing the procedures marked with a

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

J could result in component failure and lead

2.2

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)

Steering

Front suspension

Rear suspension Tires

Brake fluid level

Brake lever travel Brake systems Drive Chain Wheels/fasteners Frame fasteners

Engine oil level

Air filter, pre-filter

Air box sediment

tube Coolant

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

Daily Daily

Daily

Make adjustments as needed.

Inspect; clean often Drain deposits when visible

Check level daily, change coolant every 2 years

(if applicable) Headlamp/tail

lamp

Air filter,

main element Recoil housing

Daily Weekly Weekly

Check operation; apply dielectric grease if replacing

Inspect; replace as needed Drain water as needed, check often if operating

in wet conditions

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

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

Front gearcase oil

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

(if equipped)

Middle gearcase

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

oil (if equipped)

Rear gearcase oil

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

(if equipped)

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

Remarks

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

2.3

MAINTENANCE

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Engine breather

filter (if equipped)

Engine oil change

(break-in)

General

25 H Monthly 155 (250) Inspect; replace if necessary 25 H 1M 155 (250) Perform a break-in oil change at one month 50 H 3M 310 (500) Lubricate all grease fittings, pivots, cables, etc.

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

Steering 50 H 6M 310 (500) Lubricate

Front suspension 50 H 6M 310 (500) Lubricate

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

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

bowl

Throttle Cable/

ETC Switch

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

E E

Carburetor air

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

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

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

(if applicable)

50 H 6M 310 (500) Inspect coolant strength

seasonally; pressure test system yearly

Engine oil change 100 H 6M 620

Oil filter change 100 H 6M 620

Oil tank vent hose 100 H 12 M 620

Valve clearance 100 H 12 M 620

(1000) (1000) (1000) (1000)

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

Replace with oil change Inspect routing, condition Inspect; adjust

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

2.4

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

Fuel system 100 H 12 M 620

Fuel filter 100 H 12 M 620

Radiator

100 H 12 M 620

(if applicable)

Cooling hoses

100 H 12 M 620

(if applicable)

Engine mounts 100 H 12 M 620 Exhaust muffler/

100 H 12 M 620

pipe

Spark plug 100 H 12 M 620

Ignition Timing 100 H 12 M 620

Wiring 100 H 12 M 620

Clutches (drive

100 H 12 M 620

and driven)

Front wheel

100 H 12 M 1000

bearings

Brake fluid 200 H 24 M 1240 Spark arrestor 300 H 36 M 1860

Idle speed

Toe adjustment

Auxiliary brake

Headlight aim

(Km)

(1000)

(1000) (1000) (1000) (1000) (1000) (1000) (1000) (1000)

(1000) (1600) (2000) (3000)

Remarks

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

Replace yearly Inspect; clean external

surfaces Inspect for leaks

Inspect Inspect Inspect; replace as needed Inspect Inspect for wear, routing,

security; apply dielectric grease to connectors subjected to water, mud, etc.

Inspect; clean; replace worn parts Inspect; replace as needed Change every two years Clean out Adjust as needed

Inspect periodically; adjust when parts are replaced

Inspect daily; adjust as needed Adjust as needed

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

2.5

MAINTENANCE

POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS

Part No. Description

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol) 2871281 Engine Oil (Quart)Premium 4 Synthetic

0W-- 40 (4-- Cycle) (12 Count)

2871844 Engine Oil (Gallon) Premium 4 Synthetic

0W-- 40 (4-- Cycle) (4 Count)

2871567 Engine Oil (16 Gallon) Premium 4

Synthetic 0W--40 (4 --Cycle)

Gearcase / Transmission Lubricants

2873602 Premium Synthetic AGL Gearcase Lube

(12 oz. bottle)(12 Count)

2873603 Premium Synthetic AGL Gearcase Lube

(1 Gal.) (4 Count)

2876160 Premium ATV Angle Drive Fluid

(32 oz.) (12 Count)

2872276 Premium ATV Angle Drive Fluid

(2.5 Gal) (2 Count)

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

(8 oz.) (12 Count)

Grease / Specialized Lubricants

2871322 Premium All Season Grease

(3 oz. cartridge)(24 Count)

2871423 Premium All Season Grease

(14 oz. cartridge)(10 Count)

2871460 Starter Drive Grease (12 Count) 2871515 Premium U-Joint Lube (3 oz.) (24 Count) 2871551 Premium U-Joint Lube (14 oz.) (10 Count) 2871312 GreaseGun Kit 2871329 Dielectric Grease (Nyogelt)

Coolant

2871323 60/40 Coolant (Gallon)(6 Count) 2871534 60/40 Coolant (Quart) (12 Count)

Part No. Description

Additives / Sealants / Thread Locking Agents /

Misc.

2874275 Loctitet Primer N, Aerosol 2871956 Loctitet Thread Sealant 565

(50 ml.)(6 Count)

2871949 Loctitet Threadlock 242

(50 ml.) (10 Count)

2871950 Loctitet Threadlock 242

(6 ml.)(12 Count)

2871951 Loctitet Threadlock 262

(50 ml.) (10 Count)

2871953 Loctitet Threadlock 271

(6 ml.)(12 Count)

2871954 Loctitet Threadlock 271

(36 ml.)(6 Count)

2870587 Loctitet 518 Gasket Eliminator/ Flange

Sealant (50 ml.) (10 Count)

2871326 Premium Carbon Clean

(12 oz.) (12 Count)

2870652 Fuel Stabilizer (16 oz.) (12 Count) 2871957 Black RTV Silicone Sealer

(3 oz. tube) (12 Count)

2871958 Black RTV Silicone Sealer

(11 oz. cartridge) (12 Count)

2870990 DOT3 Brake Fluid (12 Count) 2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)

NOTE: The number count indicated by each part

number in the table above indicates the number of units that are shipped with each order.

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

POLARIS LUBRICANT SYMBOL IDENTIFICATON

AGL

Polaris DOT 3 Brake Fluid

Polaris Sythetic Gearcase Lube

AGL

U--Joint

Polaris U--Joint Lube

2.6

0W/40

Polaris Sythetic OW-- 40 Oil

DHF

Polaris Demand Drive Hub Fluid

Polaris All Season Grease

ADF

Polaris ATV Angle Drive Fluid

MAINTENANCE

PRE-RIDE / DAILY INSPECTION

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

G Tires - check condition and pressures G Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank G All brakes - check operation (includes auxiliary brake) G Throttle - check for free operation G Headlight/Taillight/Brakelight - check operation of all indicator lights and switches G Engine stop switch - check for proper function G Wheels - check for loose wheel nuts G Air cleaner element - check for dirt or water; clean or replace G Steering - check for free operation, noting any unusual looseness in any area

G Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners G Engine coolant - check for proper level at the recovery bottle

COLD WEATHER KITS FOR 4 STROKE ATVS

Engine Heater -- (PN 2871507)

ACCESSORY ENGINE HEATER

2.7

MAINTENANCE

POLARIS LUBES/FLUIDS FOR SCRAMBLER 500 MODELS

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

2873554 -- ATV Oil Change Kit

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

-- Reservoir Gasket

--DrainPlugGasket

-- Instruction Sheet

2.8

LUBRICATION

MAINTENANCE

Ill.

Item Lube Rec. Method Frequency*

1 Engine Oil Polaris 0W--40

Synthetic

2 Transmission Polaris AGL

Gearcase Lubricant

3 Brake Fluid Polaris DOT 3

Brake Fluid

4 DriveChain Polaris Chain

Lube or O-Ring chain lube

5 FrontGear-

case

0W/40

ATV Angle Drive Fluid

Dipstick

Filter

1. Engine Oil and Filter

Add oil to proper level. Change after 1st month, 6 months or 100

hours thereafter; Change more often (25-50 hours) in extremely dirty conditions, or short trip cold weather operation.

Fill to bottom of fill hole. Approx. 32 oz.

Fill master cylinder reservoir to indicated level inside reservoir.

Apply to chain link plates and rollers.

Add to bottom of fill plug threads. Change annually©

AGL

Change annually ©

As required. Change fluid every 2 years.

As required*

Fill Plug

2. Transmission Fill Plug

Parking Brake Lock

3. Brake Fluid

Reservoir

4. Rear Drive Chain

Fill Plug

ADF

5. Front Gearcase

2.9

MAINTENANCE

LUBRICATION, CONT.

7. Tie Rod End

9. Swing Arm Bushings

10. Rear Concentric Housing

5. AWD Hubs

6. BallJoint

Ill.

5 AllWheel Drive

Hubs -- ATVs

6 Ball Joint Polaris All Season

7 Tie Rod Ends Polaris All Season

8 PropshaftYoke Premium U-Joint

9 Swing Arm Bush-

ings

10 Eccentric Housing Polaris All Season

Item Lube Rec. Method Frequency*

Polaris Demand Drive Hub Fluid

Grease¢

Grease Polaris All Season

Grease¢

4 or 8 O’clock position-

(end view)

Remove filler hole screw in hubs. Rotatewheels to 4 or 8 O’clock position. If lubricant is not visible add until it flows from filler hole. Reinstall screw.

Locate grease fitting on back side of struts and grease with grease gun.

Lift boot. Clean away dirt and grease. Apply fresh grease by hand and reassemble.

Locate fittings and grease - 3 pumps maximum Annually©

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

Locate grease fitting on eccentric housing and grease with grease gun.

DHF

8. Propshaft Yoke

(3 pumps max.)

Semi-annually

Annually©

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

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

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

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

Mobilegrease Special

2.10

MAINTENANCE

LUBRICATION / GREASE POINTS

As shown on Page 2.7, there are only five grease zerks on the Trail Blazer, two front ball joints, two on theswingarepivots, andoneontherearaxlehousing.

Swing Arm Pivot

Each Side

G Be sure vehicle is level before

proceeding.

G Check vent hose to be sure it is

routed properly and unobstructed.

G The correct gearcase lubricant to

use is ATV Angle Drive Fluid (PN

2871653), or an equivalent lubricant with a GL5 rating.

Make sure vent is unobstructed

Fill plug

ADF

Drain plug

Ball Joint Zerk

Each Side

Ball Joint Zerk

FRONT GEARCASE LUBRICATION

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

(4X4)

FRONT GEARCASE SPECIFICATIONS

Specified Lubricant:

ATV Angle Drive Fluid (PN 2871653)

Capacity: 4.0 Oz. (120ml.)

Drain Plug / Fill Plug T orque:

14 ft. lbs. (19.4 Nm)

To check the level:

1. Remove the fill plug. Inspect the level of lube. AddATVAngleDriveFluid(PN 2871653) until level of fluid is flush with the bottom of the fill plug threads.

To change lubricant:

1. Remove gearcase drain plug located on the bottom and drain oil. Catch and discard used oil properly.

2. Cleanand reinstall drainplug using a newsealing washer.

3. Remove fill plug.

4. Add proper amount of lubricant.

5. Install fill plug.

6. Check for leaks.

2.11

MAINTENANCE

TRANSMISSION LUBRICATION

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

G Be sure vehicle is level before

proceeding.

G Check vent hose to be sure it is

routed properly and unobstructed.

G Follow instructions on following

pages to check / change transmission lubricant.

TRANSMISSION SPECIFICATIONS

Specified Lubricant:

Polaris AGL Gearcase Lubricant (PN 2873603)

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

Capacity: 4x4 -- 32 oz. / 945 ml

Drain Plug / Fill Plug T orque:

14 ft. lbs. (19.4 Nm)

To change lubricant:

1. Removepropshaft shieldfromthe rightsideof the vehicle.

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

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

4. Remove fill plug.

5. Add Polaris AGL Gearcase Lubricant (PN

2873602) to proper level as described above.

6. Check for leaks.

7. Reinstall propshaft shield.

Right Side View of A TV

4x4 Models To check the level:

1. Removepropshaft shieldfromthe rightsideof the vehicle.

2. Remove fill plug and visually inspect the oil level. Level is correct when it reaches the bottom of the fill hole as shown below.

Oil Level

AGL

15/8″

View From Front

Transmission Fill Plug

Do not fill to bottom

of fillplug threads

2.12

MAINTENANCE

TRANSMISSION GEARSHIFT LINKAGE PRELIMINARY

Correctly Tightened

Jam Nut

G Ifshiftingproblems areencountered,

thetransmission linkagemayrequire adjustment.

G Visually check for contact of shift

lever to shifter opening in the front fender. Ensure shift linkage or shift lever is not contacting the frame or exhaust components.

G Tightenshiftlinkage rodendjam nuts

properly after adjustment. You should be able to rotate the linkage rod between 1/8 and 1/4 turn after both jam nuts are tight.

G The transmission shift linkage

should be periodically inspected for wear and parts replaced as required to remove excess play from shift linkage.

G Refer to Transmission chapter for

more information.

NOTE: Therod end must be held whentighteningthe jam nut to prevent damage to the rod end.

ADJUSTMENT,

INSPECTION

Linkage rod will rotate

1/8 -1/4 turn if rod ends

are tightened properly.

Parallel

Incorrectly Tightened

Jam Nut

SHIFT LINKAGE ADJUSTMENT

1. Inspect shift linkage tie rod ends, clevis and pivot bushings and replace if worn or damaged.

2. Place gear selector in neutral.

3. Loosen rod end adjuster jam nuts (A) on both ends of linkage rod. NOTE: The jam nut with yellow plating is Left Hand thread.

Gear Selector

Arm

Jam Nuts (A)

Linkage Rod

Ill. 1

4. Turn linkage rod (A) to shorten or lengthen rod until the shift lever is centered on hole in the fender.

2.13

MAINTENANCE

5. Hold rod end parallel to mounting surface and tighten jam nuts securely.

Center Lever

In Slot

THROTTLE OPERATION

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

PILOT SCREW

Thepilotsystem suppliesfuelduringengine 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 pilotscrew is calibratedatthe factoryto meetEPA/ CARB regulationsfor air qualitystandards 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 circuitcan be done only by a certifiedrepairshop to ensure air quality standards are not exceeded.

Pilot Screw location

1. Place the gear selector in neutral.

2. Set parking brake.

3. Start the engine and let it idle.

4. Turn handlebars from full right to full left. If idle speed increases at any point inthe turningrange, 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.

Brass Plug Installed

Brass Plug Removed

2.14

MAINTENANCE

PILOT SCREW ADJUSTMENT

FRONT (Engine)

Pilot Screw

View -- Right Cover Panel Removed

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

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

8. Re adjust idle speed if not within specification.

IDLE SPEED ADJUSTMENT

1. Start engine and warm it up thoroughly.

CV Carburetor

Pilot Screw

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

2. Turnpilot 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.

The pilot screw is set at the factory. Each carburetor will have a slightly different pilot screw setting, the adjustments below are the recommended settings, the settings may differ from these recommendations.

Pilot Screw Adjustment: Scrambler 500 -- 2 Turns Out

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

8712500).

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

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

Idle Screw

Idle Speed:

1200 +/-- 200 RPM

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

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

2.15

MAINTENANCE

THROTTLE CABLE / ELECTRONIC CONTROL (ETC

THROTTLE

SWITCH)

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

Direction

of travel

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

4. Withengine running, turn the handlebars fromfull 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.

1/16″ -1/8″

Freeplay

Lock-

nut

Boot

THROTTLE OPERATION

To remove the ETC cover:

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

2. Twistscrewdriver slightly while lifting onthecover to release snap.

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

Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding. Replace the throttle cable if worn, kinked, or damaged.

2.16

NOTE: When replacing the cover, check for correct placement of cover O-ring.

MAINTENANCE

CHOKE (ENRICHER) ADJUSTMENT

Boot

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

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

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

FUEL SYSTEM

WARNING

Gasoline is extremely flammable and explosive under certain conditions.

G Always stop the engine and refuel

outdoors or in a well ventilated area.

G Do not smoke or allow open flames

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

G Donot overfill the tank. Donot fill the

tank neck.

G If you get gasoline in your eyes or if

you swallow gasoline, seek medical attention immediately.

G If you spill gasoline on your skin or

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

G Never start the engine or let it run in

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

G Never drain the float bowl when the

engine is hot. Severe burns may result.

FUEL LINES

Fuel Lines

Pulse Line

Fuel Pump

Ill.1

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

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

3. Replace all fuel lines every two years.

Fuel Filter

2.17

MAINTENANCE

VENT LINES

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

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

FUEL FILTER

The fuel filter should be replaced in accordance with the Periodic Maintenance Chart.

1. Shut off fuel supply at fuel valve.

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

3. Remove fuel lines from filter.

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

Fuel Filter Located Close To Carburetor

1. Turn fuel valve to the off position.

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

Fuel Valve Location

RES

OFF

Arrow Indicates Direction of Flow

To Carburetor

5. Install clamps on fuel line.

6. Turn fuel valve ON.

7. Start engine and inspect for leaks.

CARBURETOR DRAINING

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

Drain tube

attached

here

Fuel Valve

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

4. Inspect the drained fuel for water or sediment.

5. Tighten drain screw.

6. Turnfuelvalveto“ON”.

7. Start machine and check for leaks.

NOTE: If there is a tube attached, it must be reattached as this will effect engine performance.

Drain Screw

NOTE: Thebowl drain screwis located onthebottom left side of the float bowl.

2.18

MAINTENANCE

COMPRESSION TEST

NOTE: This Polaris 4-Strokeengine is equipped with

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

70--90 psi

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

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

Cylinder Compression w/ decompressor

Cylinder Leakage

during a compression test.

Standard 70--90 PSI

BATTERY MAINTENANCE

WARNING

Battery electrolyte ispoisonous. Itcontains sulfuric acid. Serious burnscanresultfrom contact with skin, eyes or clothing. Antidote:

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

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

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

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

Service Limit: 10 %

(Inspect for cause if leakage exceeds 10%)

ENGINE MOUNTS

Inspect rubber engine mounts for cracks or damage.

ENGINE FASTENER TORQUE

Check engine fasteners and ensure they are tight.

SEALED LOW MAINTENANCE

BATTER

NOTE: All Low Maintenance batteries are fully charged and tested at the factory before installation. Expected shelf life varies on storage conditions. As a general rule before placing the battery into service, check the battery condition and charge accordingly .

Battery Check:

1. Check the date label on the side of the battery to calculate when to check voltage. The battery should be checked every 3 months.

2. Check the voltagewith a voltmeter or multimeter.

A fully charged battery should be 12.8 V higher

3. Ifthe voltage is below12.8V,the battery will need to be recharged.

2.19

MAINTENANCE

SEALED LOW MAINTENANCE

New Batteries: Batteries must be fully charged before use or battery life can be reduced by 10-30% of full potential. Charge battery for 3--5 hours using a variable rate charger. Do not use thealternator tochargeanew battery. A high rate battery charger can cause battery damage.

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 Maintena nc e batte r y. Doing so will damage the case and shorten the life of the battery. Refer to the Battery Activation and Maintenance Video (PN

9917987) for proper instruction on servicing Low Maintenance batteries.

NEVERattempt to add electrolyteor waterto a Low Maintena nc e batte r y. 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.

attempt to add electrolyte or water to a Low

BATTERY

If battery voltage is 12.8 V or less, the battery may need recharging. When using an automatic charger, refer to the charger manufacturer’s instructions for recharging. When using a constant current charger, use the following guidelines for recharging.

NOTE: Always verify battery condition beforeand 1-2 hours after the end of charging.

WARNING: An overheated battery could explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.

CHARGING

Battery Charging Reference Table

State of Charge

100% 12.8--13 V None,

75--100% 12.5--12.8 V May need

50--75% 12.0--12.5 V Needs

25--50% 11.5--12.0 V Needs

0--25% 11.5 V or

Voltage Action Charge

Time

note below)

None Re-

less

check voltage at 3 mos. after manufacture date

slight charge

Charge

Needs Charge

quired

3--6 hours

5--11 hours

At least 13 hours, verify state of charge

At least 20 hours

(*See

To service a Low Maintenance battery:

1. Remove battery from the vehicle

2. Test battery with a voltage meter or load tester to determine battery condition. This will determine thelengthof time requiredto chargethebatteryto full capacity. Refer to capacity table.

3. Charge battery using a variable rate charger.

2.20

MAINTENANCE

SEALED LOW MAINTENANCE BATTERY REMOV

The battery is located under the seat and right rear fender.

NOTE: New Batteries: Batteries must be fully charged before use or batterylifewill be reduced by 10-30%of full potential. Charge battery for3--5 hours at a current equivalent of 1/10 of the battery’sratedamp/hourcapacity. Do not usethe alternatorto chargea new battery.(Referto battery video PN 9917987)

INSPECTION/

Battery Location

SPARK PLUG

1. Removespark plug hightension lead. Cleanplug area so no dirt and debris can fall into engine when plug is removed.

2. Remove spark plug.

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

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

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

To remove the battery:

1. Disconnect holder strap and remove cover.

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

CAUTION

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

3. Remove the battery and recharge according to the charge chart.

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. Reinstallbattery,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.

Spark Plug Gap

.036″ (.9 mm)

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

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

8. Installsparkplug andtorqueto 14 ft. lbs. (19Nm).

Recommended Spark Plug:

NGK BKR6E

Spark Plug Torque: 14 Ft. Lbs.

(12--15 Nm)

2.21

MAINTENANCE

IGNITION TIMING

Refer to Electrical chapter for ignition timing procedure.

Ignition Timing:

30°±2° BTDC@5000RPM

ENGINE-TO -FRAME GROUND

Inspect engine-to-frame groundcableconnection. Be sure it is clean and tight.

COOLANT STRENGTH / TYPE

Test the strength of the coolant using an antifreeze hydrometer.

Antifreeze Hydrometer

G A 50/50 or 60/40 mixture of Polaris

Premium Coolant (PN 2871323) and distilled water will provide the optimum cooling, corrosion protection, andantifreezeprotection.

G Do not use tap water. Tap water

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

LIQUID COOLING SYSTEM OVER

Theengine coolant level iscontr olled ormaint ained by the recovery system. The recovery system components are t he recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding(heated)excesscoolant isforcedout ofthe radiatorpast the pressure capand int o the recovery bottle. Asenginecoolanttemperat ur edecreasesthe contracting ( c ooled)coolant isdrawn bac kupf r omthe tank past t he pressure cap and int o the radiator.

VIEW

G Some coolant level drop on new

machinesisnormalasthesystemis purging it s elfoftrapped air.Obser ve coolant levels often during t he break-in period.

G Overheating of engine could occur if

air is not fully purged from system.

G PolarisPremium60/40anti --freezeis

premixed and ready to use. Do not dilute wit h water.

Polaris 60/40 Anti-Freeze / Coolant

(PN 2871323)

COOLING SYSTEM HOSES

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

2.22

2. Check tightness of all hose clamps.

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

MAINTENANCE

RADIATOR

1. Check radiator air passages for restrictions or damage.

2. Carefully straighten any bent radiator fins.

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

COOLING SYSTEM PRESSURE

Refer to Page 3.6 for pressure test procedure.

TEST

COOLANT LEVEL INSPECTION

WARNING

Never remove the radiator pressure cap when the engineiswarmorhot. Escapingsteamandfluidcan causesevere burns. Theengine mustbe allowedto cool before removing the pressure cap.

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

3. Reinstall cap.

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

RADIATOR COOLANT LEVEL INSPECTION

NOTE: This procedure is only required if the cooling

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

WARNING

Never remove the radiator pressure cap when the engineiswarmorhot. Escapingsteamandfluidcan causesevere burns. Theengine mustbe allowedto cool before removing the pressure cap.

Ther ecov erybott le(A),locat edontheleftsideofthe machine,mustbemaint ainedbetweentheminimum and maxim um levels.

With the engine at operating temperature, the coolant level should be between the upper andlower marks on the coolant reservoir. If it is not:

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

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

To access the radiator pressure cap:

Remove front cover by placing your fingers under the front of the cover and pull upward.

Pressure Cap

2.23

MAINTENANCE

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.

G Never immerse the filter in water

since dirt can be transferred to the clean air side of the filter.

G If compressed air is used never

exceedapressureof 40PSI. Always use a dispersion type nozzle to prevent filter damageand clean from the inside to the outside.

G Replace the air filter every 50 hours,

and possibly more often in very dirty conditions.

AIR FILTER/PRE-FILTER SER

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

Theprefiltershould becleanedbeforeeachrideusing the following procedure:

1. Lift up on the rear of the seat.

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

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

VICE

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

cover. Inspect the gasket. Itshould adheretightly to the cover and seal all the way around.

4. Loosen clamp and remove air filter assembly.

Cover

Pre-filter

Main Element

Ill.1

Cleaning:

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

6. Rinse and dry thoroughly.

7. Inspect element for tears or damage.

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

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

Installation:

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

1 1. Reinstall filter on main filter mount. Place filter

clamp over the assembly and tighten.

Carb Boot

Gasket

2.24

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

Filter Clamp

Ill.2

Proper Filter Placement

Filter Support

Main Filter

MAINTENANCE

Sediment Tube

NOTE: Thesediment tube willrequire morefrequent

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.

Air Box

Ill.3

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

12. Install air box cover and secure with clips.

Front

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.

BREATHER FILTER INSPECTION

Polaris Four cycle ATV engines are equipped with a breather filter. The in-line filter is similar in appearanceto afuelfilter,andis visibleon the leftside (Location A).

Typical Breather Filter Location

In-Line Breather Filter

Location A

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

2.25

MAINTENANCE

BREATHER HOSE

1. Be sure breather line is routed properly and securedinplace. CAUTION: Makesurelinesare not kinked, pinched or has any sags that may collect and hold moisture.

RECOIL HOUSING

G Drain the housing periodically to

remove moisture.

Recoil Drain

G Drain the recoil housing after

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

G CAUTION: Make sure the manual

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

G Water will enter the recoil housing if

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

G After travelling in wet areas, the

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

G Do not open the crankcase drain

unless the engine has ingested water. Some engine oil will be lost if crankcase drain is opened.

G If recoil handle seal has been

damaged, the handle assembly should be replaced.

PVT DRAIN PLUG & DRYING

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

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

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

PVT Drain Plug & O--ring

Ill.3

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

ENGINE OIL LEVEL

The oil tank is located on the left side of the vehicle.

To check the oil level:

2.26

1. Set machine on a level surface.

MAINTENANCE

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

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

4. Reinstall dipstick, screwing into place.

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

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

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

Screw in completely to check

Recommended Engine Oil:

Polaris Premium 4 All Season

Synthetic, 0W--40, (PN 2871281)

NOTE: During cold weather operation, the oil level

should be monitored closely. Rising oil level, or milky looking oil between checks in cold weather driving, can indicate moisture collecting in the oil reservoir. If the oil level is over the full mark or milky looking, change the oil.

OIL AND FILTER CHANGE

WARNING

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

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

5. Allow oil to drain completely.

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

7. Reinstalldrainplug (B)and torque to14 ft. lbs. (19 Nm).

8. Loosen clamp (D) on oil hose.

9. Removeoil hosefromscreen fitting(C) onbottom of oil tank.

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

1 1. Apply Loctitet Thread Sealant 565 (PN

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

Install screen fitting (C)and rotate aminimum of2

12. 1/2 turns (clockwise) into the tank threads. Then rotate the screen fitting (C) clockwise until the nipple of the screen fitting (C) aligns with the marking on the tank (see Ill. 3).

Maximum torque for the screen fitting (C) is 25 ft.lbs. (34 Nm), do not overtighten.

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

NOTE:

NOTICE:

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

1. Place vehicle on a level surface.

2. Runenginetwoto three minutes until warm. Stop engine.

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

2.27

MAINTENANCE

Reference Mark on Tank

ILL. 3

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

NOTE: The sealing surfaces on the drain plug and

crankcase should be clean and free of burrs, nicks or scratches.

19. Reinstall drain plug.

20. Removedipstick and fill tank with 2 quarts (1.9 L) ofPolarisPremium4 SyntheticOil (PN2871844).

21. Placegearselector inPark andset parking brake.

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

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

23. Dispose of used filter and oil properly.

Oil Tank Drain Plug Torque:

14 ft. lb s. (19 Nm)

Crankcase Drain Plug Torque:

14 ft. lb s. (19 Nm)

15. Using acleandry cloth, cleanfilter sealingsurface on crankcase.

16. Lubricate O-ring on new filter with afilm ofengine oil. Check to make sure the O-ring is in good condition.

17. Installnew filter and turn by handuntilfiltergasket contacts the sealing surface, then turn and additional 1/2 turn.

Crankcase Drain

Engine Sump Drain Plug - Bottom View

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

Oil Filter Torque:

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

Oil Filter Wrench:

(PV--43527)

Oil Tank Screen Fitting Torque:

See Step 12

Recommended Engine Oil: Polaris Premium 4 All Season

Synthetic, 0W--40, (PN 2871281) Ambient Temperature Range:

-40° Fto120° F

OIL PUMP PRIMING PROCEDURE

NOTE: This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected or if the sump has been allowed to drain.

1. Clamp or pinch off vent line (A) approximately 2I from oil tank, between the end of oil tank vent fitting and the vent line’s pressure relief slit.

2.28

(A) Vent Hose to Air Box

Oil Lines To Engine

MAINTENANCE

5. Remove timing inspection plug from recoil housing.

CAUTION: Failure to position the crankshaft at TDC on compression stroke will result in improper valve adjustment.

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

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

Sprocket alignment pin facing up

Approx.

To Air Box

Oil Tank

Slit

Pinch Off

Vent Hose

2. Run engine for 10-20 seconds.

3. Shut engine off. Remove the vent line clamp. A rushof airshouldbe heard,indicatingtheoilpump is properly primed and ready for field operation.

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

VALVE CLEARANCE

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

Crankshaft-to-Camshaft Centerline

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

1. Remove the seat.

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

3. Remove the spark plug high tension lead and remove thesparkplug. CAUTION: Placea clean shop towel into the spark plug cavity to prevent dirt from entering.

4. Remove rocker cover bolts, cover and gasket. NOTE: It may be necessary to tap cover lightly

with a soft-faced hammer to loosen it from the cylinder head.

INTAKE VALVE CLEARANCE ADJUSTMENT

1. Insert a .006″ (.15mm) feelergauge betweenend of intake valve stem and clearance adjuster screw. Note: Do not stack more than one feeler gauge to make .006″.

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

2.29

MAINTENANCE

adjustment of each valve.

INTAKE VALVE CLEARANCE

.006″ (.15 mm)

3. Holdadjuster screw and tighten adjuster lock nut securely.

4. Re-check the valve clearance.

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

6. Repeat this step for the other intake valve.

EXHAUST VALVE CLEARANCE

NOTE: The exhaust valves share a common rocker

arm, and must be adjusted using two feeler gauges. Note: Do not stack more than one feeler gauge to make .006″.

1. Insert.006feeler gauges between endof exhaust valve stem and adjuster screws.

ADJUSTMENT

EXHAUST VALVE CLEARANCE

.006″ (.15 mm)

Valve Adjuster Tool: (PA--44689)

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

4. Re-check the valve clearance.

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

STEERING

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

Replace any worn or damaged steering components. Steering should move freely through entire range of travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism isnotrestricted orlimited. NOTE: Whenever steering components are replaced, checkfront endalignment. Use only genuine Polaris parts.

Feeler Gauge for Both Valves

2. Loosenlocknut(s)and turn adjuster screw(s) until there is a slight drag on feeler gauge(s). The Valve/Clutch Adjuster Tool (PA--44689) can be used to adjust the engine valves. NOTE: The feeler gauge(s) should remain inserted during

WARNING

Due to the critical nature of the procedures outlinedin this chapter, Polaris recommends steering componentrepair andadjustment beperformedbyan authorized Polaris Dealer. Onlya qualifiedtechnician 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 inthetie rod end, grasp the steering tie rod, pull in all directions feeling for movement.

G Repeat inspection for inner tie rod

end (on steering post).

2.30

MAINTENANCE

G Replace any worn steering

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

G Elevate front end of machine so front

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

WHEEL ALIGNMENT METHOD 1: STRAIGHTEDGE OR STRING

Be sure to keep handlebars centered. See notes below.

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

Measure

from string

to rim at

front and

rear of rim.

Rear rim

measure-

ment should

be 1/16″ to

1/8″ (.2to.3

cm) more

than front rim

measure-

ment.

Check for Loose Wheel or Hub

G If abnormal movement is detected,

inspect the hub and wheel assembly to determine the cause (loose wheel nuts, loose front hub nut (4x4).

G Refer to the Body/Steering or Final

Drive chapter for more information.

CAMBER AND CASTER

The camber and caster are non-adjustable.

NOTE: The steering post arm “frog” can be

used as an indicator of whether the handle-

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

WHEEL ALIGNMENT METHOD 2:

1. Place machine on a smooth level surface.

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

CHALK

2.31

MAINTENANCE

should always point straight back from the steering post.

3. Place a chalk mark on the center line of the front tires approximately 10″ (25.4 cm) fromthe 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. Callthis measurement “A”.

5. Rotatethetires180° bymovingvehicle forwardor backward. Position chalkmarks facing rearward, even with the hub/axle centerline.

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

To adjust toe

G Hold tie rod end to keep it from

G Loosenjamnuts atbothendof thetie

G Shorten or lengthen the tie rod until

G Important: When tightening the tie

Hold

Rod End

alignment:

rotating.

rod.

alignmentisasrequir ed to achieve the proper t oe set ting. M ethod 1 (1/16″ to 1/8″)or Method 2 (1/8″ to 1/4″).

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.

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.

Correctly

Tightened

Jam Nut

7. After alignment is complete, torque jam nuts to 12-14 ft. lbs. (16-19 Nm).

Incorrectly

Tightened

Jam Nut

FRONT AWD HUB FLUID LEVEL INSPECTION

To check front hub fluid:

1. Place vehicle on a level surface.

2. Turnwheeluntilfront hubfill/checkplugis in either the 4:00 or 8:00 position.

3. Remove fill/check plug.

(4X4)

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.

2.32

MAINTENANCE

4. Add Polaris Demand Drive Hub Fluid (PN

2871654) if necessary until fluid trickles out. NOTE: Do not force the fluid into the hub under

pressure or seal damage may occur.

5. Reinstall plug.

6. Repeat procedure for other hub.

AWD FRONT HUB FLUID CHANGE

1. Place a drain pan beneath the hub.

2. Remove check/fill plug.

3. Turnthe hubtothe6o’clock position anddrain the fluid into the drain pan.

4. Turnwheeluntilfront hubfill/checkplugis in either the 4 or 8 o’clock position.

5. Add Polaris Demand Drive Hub Fluid until fluid trickles out. NOTE: Donotforce the fluid into the hub under pressure or seal damage may occur.

(4X4)

EXHAUST PIPE

WARNING

G Do not perform clean out immediately

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

G T o reduce fire hazard, make sure that

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

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

hicle while purging the carbon from the spark arrestor.

G Never run the engine in an enclosed

area. Exhaust contains poisonous carbon monoxide gas.

G Do not go under the machine while it is

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

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

Polaris Demand Drive Hub Fluid:

(PN 2871654) - 8 oz..

(PN 2872277) - 2.5 gallon

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

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

Ill.1

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

3. If some carbon is expelled, cover the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times.

4. If particles are still suspected to be in the muffler, backthe machineonto an inclineso therear of the machine is one foot higher thanthe front. Set the hand brake and block the wheels. Make sure the machine is in neutral and repeat Steps 2 and 3.

SEE WARNING ABOVE

5. If particles are still suspected to be in the muffler, drive the machine onto the incline so the front of

Clean Out Plug

2.33

MAINTENANCE

the machine is one foot higher than the rear. Set the hand brake and block the wheels. Makesure the machine is in neutral and repeat Steps 2 and

3. SEE WARNING ABOVE

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

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

8. Reinstall the clean out plugs.

BRAKE SYSTEM INSPECTION

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

G Keepfluidlevel inthe master cylinder

reservoir to the indicated level inside reservoir.

G Use Polaris DOT 3 Brake Fluid (PN

2870990).

Sight Glass

Parking Brake Lock

BRAKE PAD INSPECTION

3/64″

(.1cm)

Minimum

Thickness

G Pads should be changed when

friction material is worn to 3/64″ (.1 cm),or aboutthethickness ofadime.

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.

Rear Master Cylinder Reservoir

Max Min

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

spongy feel.

G Check friction pads for wear,

damage or looseness.

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

frictionmaterial.

AUXILIARY BRAKE ADJUSTMENT

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

First, checkfootbrake effectiveness byapplying50lb. (approx.) downwardforce onthe pedal. The top of the pedal should be at least 1 inch, (25.4mm) above the surface of the footrest.

1/8, to 1/4, Free Play

(HYDRAULIC)

50 lbs

1″ or greater

Floorboard

2.34

MAINTENANCE

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

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

inch (3.2 - 6.35 mm).

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

Bleeding:

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

DRIVE CHAIN AND SPROCKET

Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers. The sprockets and outer rollers require periodic lubrication. Lubricate the chain with Polaris O-Ring Chain Lubricant (PN 2872073).

INSPECTION

SPROCKET INSPECTION

Inspect the sprocket for worn, broken or bent teeth. To check for wear, pull outward on the chain as

shown. Replacesprocket if chainmovementexceeds 1/4″ (.6 cm).

DRIVE CHAIN INSPECTION

The chain must be replaced when it reaches 3% elongation. The chain master link is a press--on that requires a chain pressing tool to install remove the

1. Stretch the chain tightly in a straight line.

2. Measurealength oftwentypitches(pins) from pin center to pin center, and compare to the specification. Replace the chain if the length exceeds the wear limit.

3. When replacing or reinstalling drive chain, install theclosed end ofthe splicelink clipasshown,with the closed end leading in forward operation.

link.

style

and

Inspect the drive chain for missing or damaged O-Rings, link plates, or rollers. Donotwashthechain with a high pressure washer, gasoline or solvents; do not use a wire brush to clean the chain as damage to the O-Rings may occur. Clean chain with hot soapy water and a soft bristled nylon brush.

Never allow battery acid to contact the drive chain.

Service Limit:

1/4″ (6mm)

Drive Chain Lubricant:

Polaris O-Ring Chain Lubricant

(PN 2872073)

Proper

Splicelink Clip

Opening

Position

Drive Chain Wear Limit-- 20 Pitch Length:

Std: 12.5″ (32 cm)

Wear Limit: 12.875″ (32.7 cm)

.003--.005”

(.076--.127 mm)

Gap after installation

2.35

MAINTENANCE

DRIVE CHAIN ADJUSTMENT, CONCENTRIC

CAUTION: Never adjust or operate the vehicle

with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result.

Break-In: Itis extremely importantto maintain proper chain tension to ensure the best possible chain life. There is a chain break-in period of approximately 100 miles or two (2) tanks of fuel. During this time chain tension should be watched very closely and loads to the chain should be kept light.

Checking Deflection: Inspect chain deflection by slowly moving theATV forward so any slack that may have previously been on the under part of the chain is now on the top side of the chain. The bottom part of the chain should be taught during inspection. Measure the chain deflection as shown in the diagram. Deflection should be approximately3/8 in. (10 mm). After inspection, again slowly move the ATVforward until all the chain slack is onthe top side of the chain and inspect the deflection. Repeat this procedure several times to check different spots on the chain.

The chain is correctly adjusted when the tightest portionof thechain itself hasapproximately3/8in.,(10 mm) ofdeflection. It’sa commoncharacteristic of any chain to have one or more tight spots in the chain. Therefore, it is extremely important to check chain deflection in several areas of the chain to ensure deflection is correct at the tightest point.

SWINGARM

3/8″ (10 mm) Deflection

2.36

ADJUSTMENT PROCEDURE CONCENTRIC REAR

AXLE

SWINGARM

Loosen Eccentric

clamp bolts (Step 2)

MAINTENANCE

Alternate Adjustment Method -- Pin Punch

(Step 5 and 6)

6. Roll the vehicle ahead or back to adjust chain slack to the proper dimension.

7. Tightenthe eccentric clampbolts tospecification.

Loosen (2) caliper

mounting bracket

bolts (Step 3 --

2004 models)

1. Loosen chain guard.

2. Loosen two eccentric clamp bolts.

3. 2004 Models -- Loosen caliper mounting bracket bolts.

4. Using a 2 1/2″ wrench, rotate the housing to adjust chain slack to the proper dimension, and then proceed to Step 7; or... follow Steps 5 and

6 for alternate method if 2 1/2″ wrench is not available.

Loosen

CAUTION: DO NOT OVER-TIGHTEN ECCENTRIC CLAMP BOLTS. PREMATURE BEARING FAILURE MAY RESULT.

Eccentric Clamp Bolt Torque Specs

Pinch Clamp Bolt Torque --

30 ft. lb s. (41 Nm)

Pinch Clamp Bolt Torque w/ Trailer Hitch -- 40 ft. lbs. (54 Nm)

Eccentric Clamp Without Hitch

Tighten

5. Insert a pin punch through the sprocket hub and into the eccentric axle housing.

30 ft.lbs. (41 Nm)

Without Trailer Hitch

2.37

MAINTENANCE

Eccentric Clamp With Hitch

Torque to 40 ft.lbs. (54 Nm)

Chain Guide

With Trailer Hitch

8. Remove the pin punch.

9. 2004 Models -- Tighten caliper mounting bracket bolts 10-12 ft. lbs. (14 - 17 Nm).

2004 Models: Caliper Mount Bracket

10-12 ft. lbs

10. Verify chain adjustment is correct after tightening eccentric clamp bolts to specification by rolling ATV forward and checking chain tension in several places on chain. The chain is adjusted

correctly when the tightest portion of the chain has approximately 3/8 in. (10 mm) of deflection.

1 1. Reinstall the chain guard (where applicable).

Reposition chain guide to allow 1/8″ (.3 cm) clearance between sprocket and guide.

SUSPENSION SPRING PRELOAD

Operator weight and v ehicle loading affect suspensionspringpreloadrequir ements.Adjus tas necessary.

ADJUSTMENT

FRONT SUSPENSION

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

Check all front suspension components for wear or damage.

Inspect front strut cartridges for leakage.

REAR SUSPENSION

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

Rear Spring

Adjustment Cam

2.38

G Check all rear suspension

components for wear or damage.

G Inspect shock for leakage.

REARSHOCK: Use the ShockSpanner Wrench(PN

2870872) to adjust the shock preload cam.

MAINTENANCE

CV SHAFT BOOT INSPECTION

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

Inspect Boots

CONTROLS

Check controls for proper oper ation, posit ioning and adjustment .

WHEEL, HUB, AND SPINDLE TORQUE T

Item Specification

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

Rear Wheel Nuts 50 Ft. Lbs. (68 Nm)

Front Spindle Nut Referto procedure listed in

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

ABLE

Chapter 7

WHEEL REMOVAL FRONT OR REAR

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.

Front Wheel

Front Spindle Nut

See Ch. 7

G Brake control and switch must be

positioned to allow brake lever to travel throughout entire range without contacting switch body.

WHEELS

Inspect all wheelsfor runout or damage. Checkwheel nuts and ensure they aretight. Donot over tightenthe wheel nuts.

Front Wheel Nuts (4)

27 ft. lbs. (34 Nm)

Rear Wheel

Rear Wheel Nuts (4)

50 ft. lbs. (68 Nm)

Taper end faces wheel for install.

Rear Hub Nut

80 ft. lbs. (108 Nm)

2.39

MAINTENANCE

WHEEL INSTALLATION

1. With the transmission in gear and the parking brake locked, place the wheel in the correct positiononthewheelhub. Besure thevalvestem is toward the outside and rotation arrows on the tire point toward forward rotation.

2. Attach the wheel nuts and finger tighten them.

3. Lower the vehicle to the ground.

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

CAUTION:

If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with taperedrear wheelnuts, makesuretaperedend ofnut goes into taper on wheel.

TIRE PRESSURE

Tire Pressure Inspection (PSI - Cold)

Front Rear

4 3

Tread

Depth 1/8I (3 mm)

WARNING

Operating an ATVwith worntires willincrease the possibility of the vehicle skidding and possible loss of control.

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

measures 1/8″ (.3 cm) or less.

FRAME, NUTS, BOLTS,

ASTENERS

TIRE INSPECTION

CAUTION:

G Maintain proper tire pressure. Refer

to the warning tire pressure decal applied to the vehicle.

G Impropertire inflationmayaffect ATV

maneuverability.

G When replacing a tire always use

original equipment size and type.

G Theuseof non-standard size or type

tires may affect ATV handling.

Tire Tread Depth

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

Periodically inspect the tightness 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.

2.40

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

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

Special Tools 3.5...............................

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

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

Cooling System Bleeding Procedure 3.6...........

Cooling System Tests/Routing/Specifications 3.7...

Engine Removal 3.8............................

Engine Installation Notes 3.8-3.9.....................

Cylinder Honing 3.9.............................

Crankshaft Runout Inspection/Straightening 3.10....

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

EH50PL Oil Pump Priming Procedure 3.11..........

EH50PL Lubrication/Oil Flow 3.11.................

EH50PL Engine Oil Flow charts 3.12...............

EH50PL Engine Exploded Views 3.13..............

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

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

EH50PL Cylinder Head Assembly 3.26-3.27.............

EH50PL Cylinder Service 3.27-3.31....................

EH50PL Engine Bottom End Disassembly 3.31-3.37......

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

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

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

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

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

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

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

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

ENGINE

3.1

ENGINE

TORQUE SPECIFICATIONS

Fastener Size EH50PLE

Ft. Lbs. (Nm)

Blind Plug (Oil Pressure) 1/8 Pipe

Thread Camshaft Sprocket 6mm 5-6.5 (7-9 Nm) Camshaft Chain T ensioner Lever 6mm 5-6.5 (7-9 Nm) Camshaft Chain T ensioner 6mm 5-6.5 (7-9 Nm) Camshaft Chain T ensioner Cap 11mm 14-19 (20-25 Nm) Carburetor Adaptor 8mm 12-14 (16-20 Nm) Crankcase 8mm 14-15 (19-21 Nm) Crankshaft Slotted Nut (Cam Chain Drive Sprocket) 28mm 35-51 (47-69 Nm) Cylinder Base Bolts 10mm

6mm

Cylinder Head Bolts 11mm

6mm

Drive Clutch Bolt 7/16 - 20 40 (55 Nm) Flywheel 16mm 58-72 (78-98 Nm) Oil Delivery Pipe 12mm 11-15 (15-21 Nm) Oil Drain Bolt (Crankcase) 14mm 14-17 (19-23 Nm) Oil Filter Pipe Fitting 20mm 36-43 (49-59 Nm) Oil Hose Fitting 1/8 Pipe

Thread Hard Metal Oil Line Banjo Fitting N/A 11--16 ft. lbs.

Oil Pump 6mm 5-6.5 (7-9 Nm) Oil Pump Case Screw 5mm 1.5-2 (2-3 Nm) One Way Valve 11mm 14-19 (20-25 Nm) Recoil Housing 6mm 5-6.5 (7-9 Nm) Rocker Cover 6mm 7-8 (9-11 Nm) Rocker Support 8mm 8-10 (1 1-13 Nm) Rocker Adjuster Screw 6mm 6-7 (8-10 Nm) Water Pump Impeller Nut 6mm 5-6.5 (7-9 Nm) Water Pump Housing Cover 6mm 5-6.5 (7-9 Nm) Stator Plate 6mm 5-6.5 (7-9 Nm) Starter Motor 6mm 5-6.5 (7-9 Nm) Spark Plug 14mm 9-11 (12-15 Nm) Thermistor -- -- 26 ± 2.1 (35 ± 3

6.5-11 (9-15 Nm)

45-49 (61-67 Nm)

6-8 (9-11 Nm)

Refer to Engine

Assembly for

torque procedure

6.5-11 (9-15 Nm)

(15--21 Nm)

Nm)

3.2

EH50PLE ENGINE SERVICE DATA

pgg

Cylinder Head / Valve EH50PLE10

Rocker Arm

Camshaft Cam lobe height In

Cylinder Head

Valve Seat Contacting width In

Valve Guide

Valve Margin thickness In

Valve

Valve Spring Overall length

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

ance

Camshaft journal OD

Camshaft journal bore ID

Camshaft Oil clearance

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

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

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

Stem oil clearance Std

Overall length

Squareness .075″ (1.9 mm)

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

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

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

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

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

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

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

Limit .0059″ (.15 mm)

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

ENGINE

3.3

ENGINE

g-p

groov

EH50PLE ENGINE SERVICE DATA

Cylinder / Piston / Connecting Rod EH50PLE10

Cylinder

Piston Outer diameter

Piston Pin

Piston Ring Piston ring installed Top

Piston Ring Standard clearance Top

Connecting Rod

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

Surface warpage limit (mating with cylinder head)

Cylinder bore Std 3.6221-3.6228″ (92.00-92.02 mm) Taper limit .0020″ (.050 mm) Out of round limit .0020″ (.050 mm) Piston clearance

Boring limit .020″ (.5 mm)

Std 3.6204-3.6215″ (91.970-91.985 mm) .0098″ (.25

mm) OS .0197″ (.50

mm) OS

Standard inner diameter of piston pin bore

Outer diameter .9053-.9055″ (22.994-23.0 mm) Standard clearance-piston pin to pin

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

gap

piston ring to ring

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

dial clearance Connecting rod big end side

clearance Connecting rod big end radial

clearance

ring Second

ring Oil ring

ring Second

ring

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

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

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

.0020″ (.05 mm)

3.6304-3.6310 (92.21-92.23 mm)

3.6403-3.6407 (92.46-92.47 mm) .9055-.9057″ (23.0-23.006 mm)

.0002-.0003″ (.004-.008 mm)

at 68° F(20° C)

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

3.4

ENGINE

SPECIAL TOOLS

PART NUMBER TOOL

DESCRIPTION

2872105 Water Pump

2200634 Valve Seat

2870390 Piston Support

2871043 Flywheel Puller 2871283 Crankshaft/Water

5131135 Water Pump

Mechanical Seal

Puller

ReconditioningKit

Block

Pump Seal Install

Kit

Install Kit

ENGINE FASTENER TORQUE

TTERNS

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

PISTON IDENTIFICATION

Thepistonmay havean identification mark or the piston may not piston placement. If the piston has an identification

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

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

Engine Model No.

EH50PLE10 .25

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

have an identification mark for

Oversize Available* (mm)

.50

Piston Length

72mm C

Standard Piston Identifier

6mm

Cylinder Head Cylinder Base

Pattern

Crankcase

Pattern

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

oversized

COOLING SYSTEM

WARNING: Neverremove radiator cap when engine

is warm or hot. Thecooling system is under pressure and serious burns may result. Allow the engine and cooling system to cool before servicing.

FLOW

Radiator

Thermostat

Cylinder

Head

Water

Pump

Cylinder

3.5

ENGINE

COOLING SYSTEM -- 4--STROKE BLEEDING PROCEDURE

Use this procedure when a unit overhea ts and no apparent leaks in the cooling system are found.

Note: If the coolant level is LOW in the radiator, or if there are leaks in the system, the coolant system will not draw coolant from the reservoir tank.

1. Park Machine on a flat surface. Remove radiator cap and top off coolant. Leave the cap off of the radiator. Start and idle machine for 5-10 minutes until steam is visible in the radiator cap area.

2. Stop the engine and let cool for a few minutes or until a bubble is seen at the filler neck or there is a dropping of the coolant level, indicating that coolant has been pulled into the system.

ImportantTips: Slowly squeezing the hose after the bend below the filler neck will aid in purging the system of air. Pump the hose using your hand several times as shown in the diagram. Elevating the rear of the ATV with a floor jack (rear tires 4-6, off the ground) also aids the purging of air from the system.

Squeeze Hose Here to Help Purge Air From System

Pump hose by hand to help purge system

3. Always add coolant to the radiator first, the neck to replace air that has been purged from the system. Fill the reservoir only after you have completely filled the coo ing system at the radiator filler neck

4. Repeat Steps 1 and 2 four or five times or until no more coolant is pulled into the system.

5. In some instances, Steps 1 and 2 may have to be performed with the radiator cap on to prevent coolant loss.

6. T o test, install the radiator cap and idle machine until fan comes on. Make sure the fan comes on before the hot light.

filling to the top of

Remote Filler Coo ling System

Polaris Premium Antifreeze

2871534 Quart 2871323 Gallon

3.6

ENGINE

RADIATOR CAP / SYSTEM PRESSURE

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

2. The radiator cap relief pressure is 13 lbs. for all models.

COOLING SYSTEM

TEST

Pressure test here with cap

in place

Radiator

Front

View

COOLING SYSTEM SPECIFICA

THERMISTOR READING DURING OPERA

Condition

Hot Light

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

Capacity

Radiator

Cap Relief

Pressure

TIONS

Thermistor

26 ± 2.1 ft.lbs.

(35 ± 3Nm)

Approx. Reading

(Min--Max)

178Ω -- 190Ω 215° F

2.25 Quarts (2.13L)

Temperature

(102° C)

13 PSI

TION

Vent hole inside cap

liner must be clear.

RECOMMENDED COOLANT

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

3.7

ENGINE

ACCESSIBLE COMPONENTS

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

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

Mechanical Seal*

The following components require engine removal for service:

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

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

ENGINE REMOVAL

1. Clean work area.

2. Thoroughly clean the ATV engine and chassis.

3. Disconnect battery negative (-) cable.

4. Remove the following parts as required.

S Seat S Left and Right Side Covers (Refer to

Chapter 5)

S Fuel T ankCover / Front Cab (Refer to

Chapter 5)

S Fuel T ank (Refer to Chapter 4)

5. Disconnect spark plug high tension lead.

6. Remove springs from exhaust pipe and remove pipe.

7. Drain coolant and engine oil.

8. Remove air pre-cleaner and duct.

9. Remove airbox.

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

1 1. Remove center chain guard on chain drive AWD

models.

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

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

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

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

16. Disconnect coolant temperature sensor wire.

17. Remove engine to chassis ground cable.

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

19. Remove engine through right side of frame.

ENGINE INSTALLATION NOTES

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

General Items

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

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

PVT System

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

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

3. Cleanclutchsheavesthoroughlyand inspectinlet and outlet ducts for proper routing and sealing. (Chapter 6)

Transmission

1. Inspecttransmissionoperation andadjust linkage if necessary. Refer to Chapter 2 and Chapter 8.

Exhaust

1. Replaceexhaust gaskets. Seal connections with high temp silicone sealant.

2. Checkto besureall springs are in goodcondition.

Bleed Cooling System

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

2. Fill coolant reservoir tank to full mark.

3.8

ENGINE

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

4. Againremoveradiator capandslowlyaddcoolant to top of fill neck.

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

Engine Break In Period

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

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

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

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

CYLINDER HONE SELECTION/HONING PROCEDURE

CAUTION:

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

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

piston-to-cylinder clearance specifications on Page

3.4 before honing. Complete the sizing with fine grit stones to provide the proper cross-hatch finish and required piston clearance.

EXAMPLE OF CROSS HATCH PATTERN

A finished cylinder should have a cross-hatch pattern toensurepiston ringseatingand toaid inthe retention of the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer’s instructions, or these guidelines:

S Use a motor speed of approximately

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

S Release the hone at regular intervals and

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

S After honing has been completed inspect

all port opening areas for rough or sharp edges. Applya slight chamfer to all ports to remove sharp edges or burrs, paying particular attention to the corners of the intake and exhaust ports.

HONING TO OVERSIZE

CAUTION: If cylinder wear or damage is excessive, it

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

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

CLEANING THE CYLINDER AFTER

It is very important that the cylinder be thoroughly cleanedafterhoning to remove allgritmaterial. Wash thecylinderin asolvent, then in hot, soapywater. Pay close attention to areas where the cylinder sleeve meets the aluminum casting(transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air , and oil the bore immediately with Polaris 4 Cycle Lubricant.

HONING

3.9

ENGINE

CRANKSHAFT STRAIGHTENING

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

2870569). Refer to the illustrations below.

Crankshaft Truing Stand

(PN 2870569)

NOTE: The rod pin position in relation to the dial

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

HIGH .004 (.1mm)

SUPPORT CRANKSHAFT HERE.

1. To correct a situation like the one shown in the illustration at right, strikethe shaft at pointA witha brass hammer.

HIGH .004 (.1mm)

HIGH .002 (.05mm)

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

NOTE: Maximum allowable runout is .0024I.

HIGH .005 (.13mm)

ENGINE LUBRICATION EH50PL

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

(PN 2871281)

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

Quarts (1.9 l)

Filter (PN 3084963)................

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

HIGH .002 (.05mm)

HIGH .005 (.13mm)

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

3.10

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

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

ENGINE

OIL PRESSURE TEST EH50PL

1. Remove blind plug on front left cylinder head.

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

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

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

Oil Pressure at 5500 RPM (Engine Hot):

Standard: 20 PSI Minimum: 12 PSI

OIL PUMP PRIMING PROCEDURE

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

Approx.

To Air Box

OIL FLOW -- EH50PL

The chart on Page 3.12 describes the flow of oil throughthe EH50PLengine. Beginningat the oiltank, the oil flows through a screen fitting in the bottom of the tank and into the oil supply hose. The feed side oftheoil pump drawsoil through the hose and into the crankcase oil gallery, and then pumps the oil through another passage to the one way valve. (When the engine is off, the one way valve closes to prevent oil in the tank from draining into the crankcase.) The oil ispumped through a delivery pipeto the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.

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

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

Oil Tank

Slit

Pinch Off

ent Hose

1. Clamp or pinch off vent line approximately 2I fromoil tankto avoidthe end ofoil tankvent fitting, and the vent line’s pressure relief slit

2. Run engine for 10--20 seconds.

3. Shut engine off. Remove the vent line clamp. A rushof airshouldbe heard,indicatingtheoilpump is properly primed and ready for field operation.

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

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

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

3.11

ENGINE

EH50PL OIL FLOW DIAGRAM

Internalpassage to camshaft (front left head bolt)

Oil filter

Oil feed to filter

From filter to crankshaft

One way v a lve

Oil Tank

EH50PL Oil Flo w Chart

Union Fitting (Upper)

Prevents oil from draining into crankcase with engine off

Oil Tank

Oil Hose

Crankcase Oil Gallery

Oil Pump (Feed)

One Way Valve

Bottom fitting is oil exhaust or return to tank

Top of Oil Tank

Oil Hose

Screen Fitting (Bottomof Tank)

Cam Shaft Journal

Union Fitting(Lower)

Crankcase Oil Gallery

Chain Room

Cam Lobe

Top fitting is oil feed or intake from bottom of tank

Oil Pump (Scavenging)

Sprocket Chain

Rocker Arm Rocker Shaft

Indirect Lubrication

Oil Strainer

Crankcase

Small End Bearing

Cylinder Sleeve

Main Bearing (PTO)

Large End Bearing

Delivery Pipe

Bypass Oil Filter

3.12

Cam Shaft Journal

Delivery Pipe

Through Cylinder Stud Front Left

Crankcase Oil Gallery

Metal

Oil Jet

Crank Pin

Crankshaft

EH50PL ENGINE EXPLODED VIEW

Crankcase Cylinder/

Cylinder Head

ENGINE

Crankshaft and Piston

Valve Train

3.13

ENGINE

ENGINE DISASSEMBLY

REFER TO PAGE 3.7 FOR ENGINE REMOVAL / INSTALLATION NOTES.

CAM CHAIN TENSIONER/ROCKER ARM/CAMSHAFT REMOV

1. Removeignitiontiming inspectionplug from recoil housing.

TDC “T” Mark

Rotation

should have clearance at this point.

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

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

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

Advance Marks

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

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

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

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

3.14

ENGINE

CAM CHAIN TENSIONER INSPECTION

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

2. Pushratchet pawl andholdit. Theplunger should move smoothly in and out of the tensioner body.

3. Releaseratchetpawl andpushinward onplunger. It should remain locked in position and not move inward.

ROCKER ARM/SHAFT INSPECTION

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

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

Tensioner Spring Free Length:

2.02I (5.13 cm)

4. Measurefree length of tensioner spring. Replace spring if excessively worn. Compare to specifications.

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

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

Rocker Shaft O.D.:

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

3.15

ENGINE

ROCKER ARM/SHAFT INSPECTION, CONT

Rocker Arm & Support I.D.:

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

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

Rocker Shaft Oil Clearance:

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

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

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

7. Inspectrocker adjuster screwsforwear,pitting,or damage to threads of the adjuster or locknut. Replace all worn or damaged parts. NOTE: The end of the adjuster screwis hardened and cannot be ground or re-faced.

CAMSHAFT REMOVAL

3.16

1. Remove thermostat housing.

2. Remove camshaft sprocket inspection cover.

ENGINE

3. Loosen three camshaft sprocket bolts.

4. Remove camshaft end cap and O-Ring.

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

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

Sprocket Teeth

Inspect for Areas of Tooth Wear or Damage

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

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

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

Decompressor Shaft

Decompressor Ball

Retainer Sleeve

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

AUTOMATIC COMPRESSION RELEASE REMOV

NOTE: The automatic compression release

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

AL/INSPECTION

3.17

ENGINE

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

2. Remove release lever shaft and return spring.

3. Inspect shaft for wear or galling.

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

If Camshaft Is Removed From Engine:

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

If Camshaft Is Installed In The Engine:

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

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

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

CAMSHAFT INSPECTION

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

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

AUTOMATIC COMPRESSION RELEASE INSTALLA

1. Slide spring onto shaft.

2. Apply engine oil to release lever shaft. The actuator ball must be held outward to allow

installation of the release lever shaft.

Stop pin

Spring in relaxed position

TION

Lubrication holes

Lobe height

Cam Lobe Height (Intake & Exhaust):

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

3.18

ENGINE

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

Journal O.D.

Journal

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

(37.935-37.950 mm)

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

5. Measure ID of camshaft journal bore.

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

(38.005-38.025 mm)

CYLINDER HEAD REMOVAL

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

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

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

4. Remove cylinder head and head gasket.

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

Camshaft Oil Clearance:

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

NOTE: Replace camshaft if damaged or if any part

is worn past the service limit. NOTE: Replace cylinder head if camshaft journal

bore is damaged or worn excessively.

3.19

ENGINE

CYLINDER HEAD EXPLODED VIEW, EH50PL

EH50PL

3.20

ENGINE

CYLINDER HEAD INSPECTION

(A)

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

CYLINDER HEAD WARPAGE

CYLINDER HEAD DISASSEMBL

WARNING: Wear eye protection or a face shield

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

location in the cylinder head.

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

Cylinder Head Warpage Limit:

.002″ (.05 mm)

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

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

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

3. Pushvalve out, keeping it inorder forreassembly in the same guide.

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

3.21

ENGINE

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

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

indicator.

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

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

Measure valve stem in several places.

VALVE INSPECTION

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

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

Valve Stem Diameter:

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

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

3.22

Valve Guide I.D.:

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

ENGINE

VALVE SEAT SERVICE

Valve Seat Inspection

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

3.25. If the valve seat is cracked the cylinder head

must be replaced.

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

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

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

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

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

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

COMBUSTION CHAMBER

Valve Guide Removal/Installation

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

2. Placenew valve guides in a freezer forat least15 minutes while heating cylinder head.

3. Heatcylinder head in an ovenor use a hot plateto bring cylinder head temperature to 212° F (100° C). CAUTION: Do not use a torch to heat cylinder head or warpage mayresultfromuneven heating. Head temperature can be checked with a pyrometer or a welding temperature stick.

VALVE SEAT RECONDITIONING

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

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

3.23

ENGINE

Reaming The Valve Guide

Too Wide

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

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

2. Using valve guide driver, drive guides out of the cylinder head from the combustionchamber side. Becarefulnot to damage guidebore or valve seat when removing guides.

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

Uneven

Good

Too Narrow

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

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

7. Install pilot into valve guide.

8. Apply cutting oil to valve seat and cutter.

Valve Guide Installed Height

Valve Guide Height:

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

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

3.24

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

10. Inspect the cut area of the seat. S If thecontact area is less than75% of the

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

S If the cutter now contacts the uncut

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

S If the contact area of the cutter is in the

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

S If the contact area of the initial cut is

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

(A)

ENGINE

Valve Seat Width: Intake Std: .028I (.7 mm)

Limit: .055I (1.4 mm)

Exhaust Std: .039I (1.0 mm)

Limit: .071I (1.8 mm)

Seat Width

1 1. Tocheck the contact area of the seat on the valve

face,apply athin coatingof PrussianBluetpaste to the valve seat. If using an interference angle (46°) apply black permanent marker to the entire valveface(A).

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

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

S If the indicated seat contact is at the

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

S If too low use the 60° or 75° cutterto

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

S If the seat is too wide or uneven, use

both top and bottom cutters to narrow the seat.

S If the seat is too narrow, widen using

the 45° cutter and re-check contact pointonthevalveface andseatwidth after each cut.

Bottom - 60° or 75°

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

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

15. Lubricate the valve guides with clean engine oil, andapply oil or water based lapping compound to the face of the valve. Lappingisnot requiredwith an interference angle.

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

17. Rotate the valve rapidly back and forth until the cutsounds smooth. Lift thevalve slightly offof the seat, rotate 1/4 turn, and repeat the lapping process. Dothis fourto fivetimesuntil the valveis fully seated, and repeat process for the other valve(s).

Seat - 45° or 46°

Top - 30°

3.25

ENGINE

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

19. If oil passage blind plug was removed, apply Crankcase Sealant (PN 2871557) or equivalent sealer to the threads and install, torquing to 8 ft. lbs. (11 Nm). CAUTION: Donot allow sealant to enter oil passage.

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

CYLINDER HEAD ASSEMBLY

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

maintain proper order.

1. Install new valve seals on valve guides.

2. Apply engine oil to valve guides and seats.

3. Coat valve stem with molybdenum disulfide grease.

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

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

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

7. Repeat procedure for remaining valve.

8. When all valves are installed, tap lightly with soft faced hammeron the endof the valvestoseat the split keepers.

3.26

VALVE SEALING TEST

1. Clean and dry the combustion chamber area.

2. Pour a small amount of clean, high flash point solvent intothe intake port and check for leakage aroundeachintakevalve. The valveseatsshould hold fluid with no seepage.

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

ENGINE

EXHAUST VALVE CLEARANCE

Feeler Gauge for Both Valves

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

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

2. Loosenlocknut(s)and turn adjuster screw(s) until there is a slight drag on feeler gauge(s). The Valve/Clutch Adjuster Tool (PA--44689) can be used to adjust the 500 engine valves. NOTE: Both feelergauges shouldremain insertedduring adjustment of each valve.

ADJUSTMENT

500 Engine

CYLINDER/PISTON REMOVAL AND

NOTE: Follow engine disassembly procedures to

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

1. Remove cam chain guide at front of cylinder.

INSPECTION

EXHAUST VALVE CLEARANCE

.006″ (.15 mm)

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

4. Re-check the valve clearance.

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

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

3.27

ENGINE

3. Loosen hose clamps and remove coolant inlet hose.

4. Remove the two 6 mm cylinder base bolts.

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

NOTE: The bolts are inside the water jacket.

PISTON REMOVAL

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

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

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

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

8. Remove dowel pins from crankcase.

3.28

3. Remove top compression ring.

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

ENGINE

2. Inspectthetop of the cylinder for warpageusing a straight edge and feeler gauge.

Cylinder Warpage:

.002″ (.05 mm)

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

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

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

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

6. Remove the expander.

CYLINDER INSPECTION

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

1/2″ Down From Top of Cylinder

1/2″ Up From Bottom

4. Inspect cylinder for taper and out of round with a telescoping gaugeor a dial bore gauge. Measure intwodifferentdirections,front toback andside to side, on three different levels (1/2″ down from top, in the middle, and 1/2″ up from bottom).

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

Cylinder Taper

Limit: .002 Max.

Cylinder Out of Round

Limit: .002 Max.

Standard Bore Size:

3.6221-3.6228I (92.00-92.012mm)

3.29

ENGINE

PISTON-TO-CYLINDER CLEARANCE

Piston

40 mm

Piston Pin

1. Measurepistonoutsidediameter atapoint 40mm down from the top of the piston at a right angle to the directionof the pistonpin.

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

Piston to Cylinder Clearance

1. Measure piston pin bore.

Piston Pin Measurement Locations

Piston Pin O.D. .9053-.9055I (22.994-23.0 mm)

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

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

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

PISTON/ROD INSPECTION

Piston Pin Bore

Piston Pin Bore: .9055-.9057I (23.0-23.006 mm)

3. Measure connecting rod small end ID.

Piston

Ring

Feeler Gauge

Piston Ring-to-Groove Clearance Top Ring Std: .0016-.0031I (.040-.080 mm)

Limit: .0059I (15 mm)

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

Limit: .0059I (15 mm)

3.30

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

ENGINE

PISTON RING INSTALLED GAP

1. Placeeach pistonring insidecylinderusing piston to push ring squarely into placeas shown at right.

Feeler Gauge

Cylinder

Piston Ring

Piston Ring Installed Gap Top Ring

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

Second Ring

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

Oil Ring

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

25-50mm

STARTER DRIVE REMOV

1. Remove recoil housing bolts and remove housing.

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

3. Inspectthethrustwasher for wearor damageand replace if necessary.

AL/INSPECTION

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

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

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

CRANKCASE DISASSEMBLY

NOTE: The recoilstarter,startermotor,starterdrive,

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

Std. Bushing ID:

.4735″-.4740″ (11.11-12.04 mm)

Std. Shaft OD:

.470″-.472″ (11.93-11.99 mm)

Starter Drive Bushing Clearance:

Std: .0015″-.004″ (.038-.102 mm)

Service Limit:

.008″ (.203 mm)

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

3.31

ENGINE

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

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

FLYWHEEL/STATOR REMOV

1. Remove flywheel nut and washer.

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

3. Markornote positionof stator plateoncrankcase.

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

AL/INSPECTION

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

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

CAM CHAIN/TENSIONER BLADE

5. Replace crankshaft seal (A).

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

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

3.32

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

Chain Service Limit:

5.407″ (13.7 cm)

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

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

6. Inspect sprocket teeth for wear or damage.

7. Inspect Woodruff key for wear.

8. Replace any worn or damaged parts.

ONE WAY VALVE

ENGINE

One Way Valve Spring Free Length: Std: 1.450″ (3.68 cm)

3. Inspect valve for wear.

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

CRANKCASE SEPARATION

Theoneway valvepreventsoilfromdrainingoutof the oil tank and into the crankcase when the engine is off. It must be clean and have adequate spring pressure in order to seal properly.

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

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

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

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

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

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

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

3.33

ENGINE

OIL PUMP REMOV

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

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

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

AL/INSPECTION

4. Removethree oil pumpretainingbolts andpump.

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

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

7. Clean screen thoroughly.

3.34

8. Remove pump body screw and feed chamber cover.

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

Pump End Clearance:

ENGINE

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

6. Tighten screw securely.

7. Install screen on pump body.

8. Installoilpump oncrankcase andtorquebolts to6 ft. lbs. (8 Nm).

Std: .001-.003 (.0254-.0762 mm) Wear Limit: .004 (.1016 mm)

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

Rotor Tip Clearance:

Oil Pump Attaching Bolt Torque:

6 ft. lbs. (8 Nm)

COUNTER BALANCER SHAFT REMOV

AL/INSPECTION

Std: .005 (.127 mm) Wear Limit: .008 (.2032 mm)

1 1. Measure rotor tip clearance with a feeler gauge.

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

13. Repeat measurements for scavenge rotor.

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

OIL PUMP ASSEMBLY

1. Clean and dry all parts thoroughly. Apply clean engineoiltoallparts. Donot usegasketsealer on the pump body mating surfaces or oil passages will become plugged.

2. Install pump shaft and scavenge rotor drive pin.

3. Installouter scavenge rotor,innerscavengerotor, and scavenge casing.

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

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

3.35

ENGINE

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

3. Turnthe shaftuntilbalancercounterweightsclear the crankshaft and remove the balancer shaft from the crankcase.

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

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

6. Inspect the balancer shaft bearings.

NOTE: Due to extremely close tolerances and minimal wear, the balancer shaft ball bearings must be inspected visually and by feel. Look for signs of discoloration, scoring or galling. Turn the inner race of each bearing. The bearings should turn smoothly and quietly. The outer race of each bearing should fit tightly inthecrankcase. The inner raceshouldbefirm withminimal sidetosidemovement andnodetectable up and down movement.

CRANKSHAFT REMOVAL/INSPECTION

1. Removetheshim washer(A) from thecrankshaft.

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

3.36

3. Useafeelergauge tomeasure theconnectingrod big end side clearance.

Connecting Rod Big End Side Clearance: Std: .0039-.0256I (.1-.65 mm)

Limit: .0315I (.80 mm)

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

Max Runout: .0024″ (.06 mm)

ENGINE

5. Measure the connecting rod big end radial clearance.

Big End Radial Clearance:

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

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

CRANKCASE BEARING INSPECTION

PUMP SHAFT OIL SEAL/ WATER PUMP SEAL

REMOV AL (ENGINE

MECHANICAL

DISASSEMBLED)

NOTE: The water pump mechanical seal can be

removedwithout removing theengine. Refer toWater Pump Mechanical Seal Installation.

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

1. Remove the seal from the PTO side crankcase.

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

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

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

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

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

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

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

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

the

CRANKCASE INSPECTION

1. Remove all traces of gasket sealer from the crankcase mating surfaces. Inspect thesurfaces closely for nicks, burrs or damage.

2. Check the oil pump and oil passage mating surfaces to be sure they are clean and not damaged.

3.37

ENGINE

BEARING INSTALLATION

NOTE: To ease bearing installation, warm the

crankcase until hot to the touch. Place the bearings in a freezer.

1. Install the bearings so the numbers are visible.

2. Drive or press new bearings into the crankcases, usingtheproperdriver. CAUTION: Pressonly on outer race of bearing to prevent bearing damage.

S 70 mm (2.755″) driver- For

crankshaft main bearings.

S 46mm (1.810″) For counterbalancer

bearings.

S 28 mm (1.100″) For pump shaft

bearing.

END PLAY INSPECTION/ADJUSTMENT

2. Measure the distance from the PTO crankcase mating surface to the main bearing using a dial caliper and a straight edge.

Before reassembling the crankcase,the following steps should be performed to determine the amount ofcrankshaft, counter balancer shaft, and pumpshaft endplay. Excessive endplaymay causeengine noise at idle and slow speeds. T oo little play will side load the bearings which may lead to premature bearing failure.

CRANKSHAFT END PLAY ADJUSTMENT

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

PTO Case Depth

1. Make sure all bearings are firmly seated in the both Mag and PTO crankcase.

3.38

ENGINE

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

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

Mag Case Depth

7. Measure the width of the crankshaft at the bearing seats with a micrometer or dial caliper and record.

Crankshaft Width

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

Total End Play

9. Subtract the thickness of the existing shim from theresultof Step8 to determine if a different shim is required. The result must be within the specified range listed at right.

Crankshaft End Play:

.008″-.016″ (.02-.04 cm)

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

Total Case Width

3.39

ENGINE

COUNTER BALANCER SHAFT END PLAY ADJUST

Step 2

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

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

Counter Balancer Shaft End Play:

.008″-.016″ (.02-.04 cm)

OIL PUMP SHAFT END PLAY ADJUSTMENT

1. Makesurethe pumpshaftbearingisfirmlyseated in the Magneto side crankcase.

Step3/4

3. Measure the distance from the Mag crankcase mating surface tothe balance shaft bearingusing a dial caliper and a straight edge. Subtract the thickness of the straightedge and record.

4. Measure the distance from the PTO crankcase mating surface to the bearing using the same method outlined in Step 1, 2, and-3.

5. Add the readings obtained in Step 3 and Step 4.

6. Subtract the counter balancer shaft width measured in Step 2 from the figure obtained in Step

7. Subtract the thickness of the existing shim from theresultof Step6 to determine if a different shim isneeded. Theresultmustbe withinthespecified range listed at below.

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

3. Install the gear on the oil pump and measure the width of the pump and gear. Subtract this measurement from the measurement recordedin Step 2.

4. Subtract the thickness of the existing shim from theresultof Step3 to determine if a different shim is needed. See Shaft End Play Spec. next page.

3.40

Pump Shaft End Play:

.008″-.016″ (.02-.04 cm)

PUMP SHAFT OIL SEAL INSTALLA

TION

ENGINE

difficult, installtwonuts onthe endof thethreaded rod and tighten against each other.

3. Install the proper shim on the magneto end of the crankshaft.

4. Place the balancer shaft in the PTO crankcase aligning the timing marks on the crankshaft and balancergears.Install the propershim washeron the shaft.

5. Inspect the oil pump sealing surface on the crankcase. Apply a light film of engine oil to the surface and install the oil pump.

NOTE: Do notuse gasketsealer onthe pumpmating surfaces.

NOTE: After engine is assembled and machine is readiedfor field operation, oil pump MUST be primed. Follow oil pump priming procedure on Page 3.10.

Oil Pump Bolt Torque:

6. ft. lbs. (8 Nm)

1. Install the seal from the outside of the crankcase (water pump side) with the spring facing inward, toward the pump shaft bearing.

2. Drive or press the seal into place using a 25 mm (.985″) seal driver, until flush with the outer edge of the seal bore.

3. Lubricate the seal lip with grease.

CRANKSHAFT/COUNTER BALANCE/OIL INSTALLA

Lubricate all bearings with clean engine oil before assembly.

Use the Crankshaft/Water Pump Installation Kit (PN

2871283) to prevent damage to the crankshaft and

main bearings during installation.

1. Install the crankshaft into the PTO side crankcase. Screw the threaded rod into the crankshaft until the threads are engaged a minimum of one inch (25.4mm).

2. Install the collar, washer, and nut onto the threaded rod. Hold thecrankshaft and tightenthe nut to draw the crankshaft into the main bearings until fully seated. Loosen the nut and remove the threaded rod from the crankshaft. If removal is

TION

PUMP

6. Alignthe drive gear with the drive pinon the pump shaft and install the gear. Besure the gear is fully seated and properly engaged.

7. Install the proper shimwasher onthe pump shaft.

CRANKCASE ASSEMBLY

1. Apply Crankcase Sealant (PN 2871557)tothe crankcase mating surfaces. Be sure the alignment pins are in place.

2. Set the crankcase in position carefully to avoid damaging the pump shaft seal, and install the magneto end crankshaft installation tool (follow instructions provided with the Crankshaft/Water Pump Installation Kit (PN 2871283).Drawthe crankcase halves together by tightening the nut on the tool and tapping lightly in the pump shaft area with a soft faced hammer to maintain alignment. Continually check alignment of the cases during installation, closing the gap equally until the surfaces are tightly seated.

3. Remove the tool.

3.41

ENGINE

4. Install the crankcase flange bolts and tighten in 3 steps following the pattern on Page 3.2 to specified torque.

Sealing Washer (Copper or Aluminum)

Sealing Washer

Crankcase Bolt Torque:

14 ft. lb s. (19 Nm)

Crankcase Sealant:

(PN 2871557)

WATER PUMP MECHANICAL SEAL INSTALLATION

1. Clean the seal cavity to remove all traces of old sealer.

2. Place a new mechanical seal in the seal drive collar, and install on the pump shaft.

3. Screw the guide onto the end of the pump shaft.

4. Installthewasherandnut andtightento drawseal into place until fully seated.

5. Remove the guide adaptor using the additional nut as a jam nut if necessary.

WATER PUMP MECHANICAL SEAL REMOVAL -

ENGINE

INSTALLED

Water Pump Mechanical Seal Puller: (PN 2872105)

Coolant Drain Bolt

Impeller

Ill. 1

1. After the coolant has been drained, remove the water pump cover, impeller and the sealing washer. (Ill. 1)

T-Handle

Ill. 2

2. Slide the main puller body over the outer portion of the mechanical seal as shown in Ill. 2 and turn T-Handle clockwise until it contacts water pump shaft. Continue rotating until outer portion of mechanical seal is separated from the metal seal body.

Mechanical Seal

Main Puller Body

Oil Seal

Replacement T--Handle: (PN 2872106)

This tool allows a technician to replace the mechanical water pump seal on EH50PL engines without removing the engine and splitting the cases.

CAUTION:

Improper or careless useof this tool or procedure can result in a bent water pump shaft. Pump shaft replacement requires engine removal and crankcase separation. Use caution while performing this procedure. Make sure that the puller is parallel to the shaft at alltimes. Do not placesideloads onthewater pump shaft or strike the puller or shaft in any way.

3.42

3. Insert the puller legs between the water pump drive shaft and the remaining portion of the mechanical seal. Attach the puller legs to the main puller body. Ill. 3

Main puller body

Position the split 90° to opening on main puller

Ill. 4

body

ENGINE

4. Ensure that the split between the puller legs is fully supported by the main body of the tool (Ill 4).

Hex Socket Screws

Puller Legs

Lip must grasp inside of mechanical seal.

Ill. 5

5. Tighten the hex socket screws on the puller legs sufficiently so the lip of the puller legs will grasp the mechanical seal. Ill. 5

ONE WAY VALVE INSTALLA

Install the one way valve plunger, spring, and plug using a new sealing washer.

One Way Valve Plug Torque:

16 ft. lb s. (22 Nm)

TION

CAM CHAIN DRIVE SPROCKET INST ALLA

TION

Ill. 6

6. Turn the puller T-Handle clockwise until it contacts thewaterpump shaft. Continuerotating untiltheremaining portion of mechanical seal has been removed from the cases. Ill. 6 Pump shaft oil seal can also be replaced at this time if necessary.

7. The Water Pump Install Kit (PN 5131135)is required to install the new mechanical seal. This tool is available separately and it is also included in the Crankshaft/Water Pump Seal Installation Kit (PN 2871283).

Tighten

1. Install the Woodruff key, drive sprocket, and slotted nut. Tighten the nut to the specified torque.

Slotted Nut Torque:

35-51 ft. lbs. (47-69 Nm)

3.43

ENGINE

TENSIONER BLADE INSTALLA

1. Install the tensioner blade and tighten the mounting bolt to specified torque.

Tensioner Blade Mounting Bolt Torque:

TION

6 ft. lbs. (8 Nm)

PISTON RING INSTALLATION

NOTE: Apply cleanengineoil toall ringsurfacesand

ring lands. Always check piston ring installed gap before rings are installed on piston. See Page 3.30. 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 expander 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.

NOTE: The top rail has a locating tab to prevent rotation. The tab must be positioned in the notch on the side of the piston as shown (A).

5. Install the top ring (chrome faced) with the “R” mark facing up and the end gap facing forward (toward the exhaust). (See ILL. 1).

6. Check to make sure the rings rotate freely in the groove when compressed.

Ring Profile

Top

Mark up

Second

Mark up

ILL. 1

PISTON INSTALLATION

1. Clean the gasket surfaces on the cylinder and crankcase. Remove all traces of old gasket material.

2. Make sure the cylinder mounting bolt holes are clean and free of debris.

3. Install the bottom rail with the gap at least 30° from the end of the expander on the side opposite the top rail gap.(See ILL. 1).

4. Installthesecondring withthe “R”markfacingup. Position the end gap toward the rear (intake) side of the piston.

3.44

Tang Outward

3. Install a new circlip on one side of the piston with the end gapfacing upor down, and tang outward.

CAUTION: Circlips become deformed during the removal process. Do not re-use old circlips. Do not

ENGINE

compress the new clip more than necessary upon installation to prevent loss of radial tension. Severe engine damage may result if circlips are re-used or deformed during installation.

4. Apply clean engine oil to the piston rings, ring lands, piston pin bore, piston pin, and pistonskirt. Lubricate the connecting rod (both ends), balancer drive gear, and crankshaft main bearing area.

Mag

5. Install the piston on the connecting rod with the arrow or : mark facing the magneto (RH) end of thecrankshaft. Thepiston pinshould bea pushfit in the piston.

6. Install the other circlip with the gap facing up or downandtang outward. (SeeCautionwith Step3 above). Push the piston pin in both directions to make sure the clips are properly seated in the groove.

3. Apply clean engine oil to the ring compressor (Snap Ont PN RCL30) and install the compressor following manufacturers instructions. CAUTION: Make sure the oil control ring upper rail tab is positioned properly in thenotch ofthe piston. Verifyallring end gaps are correctly located.

4. Applyclean engineoil liberallytothe cylinderbore and tapered area of the sleeve. Install the cylinder with a slight rocking motion until the rings are captive in the sleeve.

CYLINDER INSTALLATION

1. Placethedowelpins inthecrankcaseand installa new cylinder base gasket.

2. Position the Piston Support Block (PN 2870390) (A) beneath the piston skirt to support the piston during cylinder installation.

5. Remove the ring compressor and support block.

6. Push the cylinder downward until fully seated on the base gasket.

7. Apply a light film of oil to the threads and flange surface of the cylinder mounting bolts.

8. Install all four bolts finger tight. Rotate the engine and position the piston at BDC.

NOTE: If cam chain is installed, hold it up while rotatingtheengineto avoiddamageto the chain,drive sprocket teeth, or tensioner blade.

3.45

ENGINE

9. Tightenthe cylinder bolts in three steps in a criss cross pattern and torque to specifications.

10. Install the two 6 mm bolts.

Cylinder Bolt Torque: 10mm - 46 ft. lbs. (62 Nm)

6mm - 6 ft. lbs. (8 Nm)

CYLINDER HEAD INSTALLA

Clean the gasket surfaces on the cylinder head and cylinder. Remove all traces of old gasket material. Refer to disassembly photos.

1. Install the cam chain tensioner guide. Be sure bottom end of guide is located properly in crankcase.

2. Installthetwo dowel pins anda newcylinderhead gasket.

3. Place the cylinder head on the cylinder. Apply a film of engine oil to the cylinder head bolt threads and washers, and hand tighten the bolts.

The following procedure must be used to torque the cylinder head properly:

Torque all bolts evenly in a criss cross pattern

*Torque bolts to 22 ft. lbs. (30 Nm) *Torque bolts to 51 ft. lbs. (70 Nm) *Loosen bolts evenly 180° (1/2 turn) *Loosen bolts again another 180° (1/2

turn) *Torque bolts to 11 ft. lbs. (15 Nm)

TION

Guide in recess

CAM CHAIN/CAMSHAFT INSTALLATION

Install the cam chain over the crankshaft. CAUTION: Serious engine damage may result if the

camshaft is not properly timed to the crankshaft. IMPORTANT CAMSHAFT TIMING NOTE: In order

totimethecamshafttothecrankshaft,thepistonmust be precisely located at Top Dead Center (TDC).

CAMSHAFT TIMING

*From this point, tighten bolts evenly 90° (1/4 turn)

*Finally, tighten another 90° (1/4 turn) *Install two 6mm bolts and torque to 6

ft. lbs. (8 Nm)

3.46

1. Apply Polaris Premium Starter Drive Grease (PN

2871460) to the camshaft main journals and cam

lobes. Lubricate automatic compression release mechanism with clean engine oil. (To install the compression release mechanism, refer to Page

3.17).

2. Install the camshaft with the lobes facing downward and the sprocket alignment pin facing upward.

Single (TDC) Mark Aligned

3. Disconnect the wire from the cam chain and rotate the engine to align the single mark (Top Dead Center) on the flywheel with the notch in the timing inspection window. Be sure to usethe single TDC mark when installing thecam. Do not use the advance marks. See Ill. on next page.

(TDC ) timing

ENGINE

5. Before positioning the sprocket on the camshaft, check the position of the cam sprocket alignment pin. When the cam is positioned properly, the cam sprocket alignment pin (A) is directly in line with the crankshaft/camshaft centerline (B).

6. Install the sprocket on the camshaft. Apply Loctitet 242 (PN 2871949) to the cam sprocket bolts and torque to specifications.

Cam Sprocket Bolt Torque:

6 ft. lbs. (8 Nm)

4. Loopthe cam chain on the cam sprocket withthe dots on the sprocket facing outward and the alignment pin notch facing directly upward.

Single (TDC) Mark Aligned

7. V erify TDC mark in timing inspection hole and alignment pin is directly in line with crankshaft to camshaft centerline. Refer to Ill. on following page.

8. Apply Crankcase Sealant (PN 2871557)tothe camshaft end capand install using a newO-Ring.

9. Check all cam timing marks to verify proper cam timing, and install the cam chain tensioner body with a new gasket.

10. After tensioner installation, rotate engine at least two revolutions and re-check marks/timing.

3.47

ENGINE

CAMSHAFT TIMING

Dots

Crankshaft to Camshaft Centerline

Sprocket Alignment Pin

3.48

Single TDC Mark Aligned

TDC Mark

Rotation

Do Not Use Advance Marks

ENGINE

CAM CHAIN TENSIONER INSTALLA

1. Release the ratchet pawl (A) and push the tensioner plunger (B) all the way into the tensioner body.

2. Install the tensioner body with a new gasket and tighten the bolts.

Tensioner Bolt Torque:

TION

6 ft. lbs. (8 Nm)

2. Install a new O-Ring in the oil passage recess in the crankcase.

3. Apply 3 Bond 1215 (PN 2871557)oran equivalent sealer to the stator plate outer surface and install a new O-Ring.

4. Installthestatorplatebeingcareful not todamage the seal. Align timing reference marks on the plate and crankcase. Be sure the plate is fully seated. NOTE: Thisis a static timing mark. Strobe timing should be performed after start up.

5. Torque bolts evenly to specification.

3. Install the spring, new sealing washer, and tensioner plug.

Tensioner Plug Torque:

17 ft. lb s. (23 Nm)

4. Slowly rotate engine two to three revolutions and re-check cam timing.

STATOR, FLYWHEEL AND STARTER INSTALLA

NOTE: The stator, flywheel, starter drive, and recoil

can be assembled with the engine in the frame.

Stator

1. Applya light film of grease to the crankshaft seal. Apply molybdenum disulfide grease or assembly lubricant to the crankshaft bushing.

DRIVE

TION

Stator Plate Bolt Torque:

5-6.5 ft. lbs. (7-9 Nm)

6. Sealstator wire grommetwithCrankcaseSealant (PN 2871557) or equivalent sealer.

Flywheel

1. Installflywheel,washer, andnut. Torqueflywheel to specification.

Flywheel Nut Torque:

58-72 ft. lbs. (78-98 Nm)

3.49

ENGINE

Starter Drive

1. Be sure the washer is positioned on the back of the drive gear.

Apply StarterDrive Grease to Bushing

5. Besure thedowel pins arein placeand install the rocker shaft assembly.

6. Applya light film of engine oil to thethreads of the bolts and tighten evenly.

Rocker Shaft Support Tower Bolt Torque:

9 ft. lbs. (12 Nm)

Rocker Shaft Locating Bolt Torque:

6 ft. lbs. (8 Nm)

7. Adjust valves according to the valve adjustment procedure found in Chapter 2, Maintenance.

8. Apply clean engine oil liberally to the valve springs, cam chain, rocker arms, and camshaft.

9. Place a new rocker cover gasket on the cylinder head and install the cover and bolts.

Rocker Cover Bolt Torque:

2. Apply starter drive grease to the drive bushing in the crankcase and all moving surfaces of the starter drive mechanism. Install the starter drive.

3. Install recoil housing gasket and recoil housing.

Starter Drive Grease:

(PN 2871460)

ROCKER SHAFT/ROCKER ARM ASSEMBL INSTALLA

1. Assemble rocker arms, rocker shaft, and shaft supports.

2. Install and tighten rocker arm shaft locating bolt.

3. Apply starter drive grease to the cam lobes and cam follower surfaces.

4. Rotatethe engine untilthe camlobes arepointing downward.

TION

6 ft. lbs. (8 Nm)

THERMOSTAT INSTALLATION

Install the thermostat with one of the air bleed holes positioned next to the upper thermostat cover bolt hole as shown.

3.50

Polaris A09BG50AA, A09BA50FA, A09BG50FA User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual