Polaris Outlaw 500 Service Manual

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Page 1

Fix it like a Pro

Page 2

GENERAL INFORMATION

MAINTENANCE

ENGINE

FUEL SYSTEM

BODY / STEERING / SUSPENSION

BRAKES

ELECTRICAL

WIRE DIAGRAMS

Page 3

Page 4

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

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

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

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

VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

UNIT SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

2006-2007 OUTLAW 500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

‘WHERE USED’ TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

SPECIAL TOOL LISTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7

MISC. NUMBERS / CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

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

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

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

COVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11

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

1.1

Page 5

GENERAL INFORMATION

RepairPro Service Manual

VEHICLE IDENTIFICATION

Model Identification

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

Machine Model Number Identification

}

A 07 GP 50 AA

Year Designation

Basic Chassis Designation

Engine Designation Number

ES50PLE - Single, Water Cooled, Electric Start, 5-Speed

Manual, DOHC 4 Stroke.

VIN Identification

World

Mfg. ID

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

4 X A G P 5 0 A * 7 P 0 0 0 0 0 0

V ehicle Descriptor

}

Emissions

Engine

Body Style

Powertrain

Check Digit*

* -This could be either a number or a letter

Unit Serial Number (VIN) Location

Whenever corresponding with Polaris about a particular issue, the machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the left side of the frame tube. (1)

}

Engine Designation

Model

Year

Plant No*

}

Emissions & Model Option

Vehicle Identifier

}

Individual Serial Number

Engine Serial Number Location

This information can be found on the clutch housing on the right side of engine. (2)

VEHICLE INFORMATION

Paint Codes

PAINTED PART COLOR POLARIS

Frame Cloud Silver P-385 Frame Matte Black P-458

Replacement Keys

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

1.2

SERIES # PART NUMBER

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

Page 6

GENERAL INFORMATION

Standard Torque Specifications

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

in the steering, suspension, and engine sections.

1.3

Page 7

GENERAL INFORMATION

RepairPro Service Manual

SPECIFICATIONS

MODEL: 2006- 2007 OUTLAW 500

MODEL NUMBER: A06(07)GP50AA,AB ENGINE MODEL: ES500PLE041

Category Dimension

Length 71.5 in. / 182 cm Width 47.5 in. / 121 cm Height 45 in. / 114 cm Minimum Turing Radius 67 in . / 170 cm Wheel Base 51 in. / 130 cm Ground Clearance 11.5 in. / 29 cm Dry Weight 439 lbs. / 199 kg Gross Vehicle Weight 645 lbs. / 292 kg Oil Capacity 2 qts. / 1.9 ltr Coolant Capacity 2.25 qts. / 2.1 ltr Fuel Capacity 3.25 gal. / 12.3 ltr

1.4

Page 8

GENERAL INFORMATION

2006 - 2007 OUTLAW 500

MODEL NUMBER: A06(07)GP50AA,AB ENGINE MODEL: ES500PLE041

Engine

Platform Fuji DOHC 4 stroke Engine Model Number ES500PLE041 Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke (mm) 99.2 x 64.6 mm Compression Ratio 10.8:1 Compression Pressure 130 psi Engine Idle Speed 1600 Rpm Cooling System Liquid Thermostat Opening Temperature 160°F (71°C) Overheat Warning High Temp Light Lubrication Pressurized Dry Sump Oil Requirements PS-4 Synthetic Exhaust System 2 to 1 canister style

Carburetion

Carburetor model Mikuni BSR 42mm Main Jet 145 Pilot Jet 37.5 Jet Needle 6GL68-40-2 Needle Jet O-0 Pilot Screw 2.5 Turns Out (Reference Only) Float Height 13 mm (0.51") Fuel Delivery Fuel Pump Fuel Requirement 87 Octane (minimum)

Electrical

Alternator Output 200 w @ 3000 RPM Voltage Regulator 3-Phase Lights : Main Headlights Dual Beam 35 watts / 35 watts

Tail LED Brake 26.9 watts

Neutral / Hot / Reverse 1 watt (ea.) Ignition System DC/CDI Ignition RPM Limit 9100 ± 100 / Reverse 5000 ± 100 Ignition Timing 30o + 3o BTDC @ 3500 RPM Spark plug / Gap NGK DCPR8E/ .035 in./ 0.9 mm Battery / Model / Amp Hr Maintenance-Free 9 Amp Hr Circuit Breakers (Amps) Main-15 / Fan-10 / Ignition-5 Starting Electric - Standard Instrument Cluster N/A

Drivetrain

Transmission Type Manual 5 speed Main Sprocket - # Tooth 14 Rear Sprocket - # Tooth 38 Gear Ratio : 1st

2nd 3rd 4th 5th

Rev Chain Size / Deflection 520 O-ring / 1/4-3/8” (6-8mm) Clutch Type Wet Multi Plate Clutch Lever Freeplay 1/8” – 3/16” / 3.1 – 4.7 mm

2.43

1.61

1.29

1.09

0.92

2.07

Steering / Suspension

Front Suspension Style / Shock

Front Travel 10 in. / 25.4 cm Rear Suspension

Style / Shock Rear Travel 11 in. / 27.94 cm Ground Clearance 11.5 in. / 29 cm Shock Preload Adjustment

Front and Rear Turning Radius 67 in. / 170 cm Toe Out 0 - 1/16 in / .0 - .159 mm

Dual A-arm / RydeFX™ Shock

Independent A-Arm / RydeFX™

Compression Adjustable Shock

Threaded shock adjustment

with Spanner Wrench

Wheels / Brakes

Front Wheel Size / Offset / Bolt Pattern

Rear Wheel Size / Offset / Bolt Pattern

Front Tire Make / Model / Size

Rear Tire Make / Model / Size

Recommended Air Pressure F / R

Brake - Front Hydraulic Disc Brake - Rear Hydraulic Disc

10x5 / 28.3mm - 4/156

9x8 / 58.8mm - 4/110

Dunlop / Radial / 21x7-10

Dunlop / Radial / 20x10-9

5 psi Front 5 psi Rear

JETTING CHART

AMBIENT TEMPERATURE

Meters

(Feet)

Altitude

(0-6000)

above 1800

(above 6000)

0-1800

Below 40

Below 5

150 145

142.5 137.5

F + Above

+40

C + Above

1.5

Page 9

GENERAL INFORMATION

RepairPro Service Manual

SPECIAL TOOLS

‘Where Used’ Table

PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN

8712100 or 8712500 Tachometer 2,7

2200634 Valve Seat Reconditioning Kit 3 PU-45257 Valve Spring Compressor 3 PA-46075 Flywheel Puller 3 PA-46087 Crankcase Separator 3

2870390 Piston Support Block 3

2872105 Water Pump Mechanical Seal Puller 3 PA-45958 Cam Chain Tensioner Assembly Tool 3 PA-46076 MAG End Crankshaft Nut Remover/Installer 3 PA-46077 MAG End Crankshaft Installer 3

2871283 Crankshaft/Water Pump Seal Install Kit 3

5131135 Water Pump Install Kit 3 PA-46502 Valve Spring Compressor 3

2870975 Mity Vac™ Pressure Test Tool 3,4

2872314 Carburetor Float Adjustment Tool 4 PS-45259 Gas Fill Tool 5 PS-45261 IFP Positioning / Extraction Tool 5 PA-48282 Rear Hub Tool 5 PV-43568 Fluke™ 77 Digital Multimeter 7

2870630 Timing Light 7

*Special Tools can be ordered through a Polaris Dealer or SPX Corporation (1-800-328-6657).

1.6

Page 10

GENERAL INFORMATION

Special Tool Listing

Special Tools may be required while servicing your machine. Some of the tools listed are mandatory and other tools may be substituted with a similar tool, if available. Tools shown may not apply to a particular vehicle. Polaris recommends the use of Polaris special tools when servicing any Polaris product.

Standard Tools and Engine Tools

PU-45432 - Caliper or A Basic Caliper

Basic Micrometer

Standard Tools and Engine Tools

2870569 - Crankshaft True Kit

2870386 - Piston Pin Puller

PA-46076 Mag End Crank Nut Remover/Install

PA-46502 - Valve Spring Compressor

PA-46087 - Crankcase Separator

PA-46075 - Flywheel Puller

PA-45958 - Cam Chain Tensioner Tool

PA-46077 - Mag End Crankshaft Installer

PV-43527 Oil Filter Wrench

5131135 - Water Pump Install Tool

2870390 - Piston Support Block

1.7

Page 11

GENERAL INFORMATION

RepairPro Service Manual

Standard Tools and Engine Tools

2870303 - Hone Kit

2870305 - Stone Replacement Kit

2870588 - Hone Oil (12 OZ.)

2200634 - Valve Seat Reconditioning Kit

2871283 - Crank/Water Pump Seal Install Kit

Suspension Tools

PS-45261 - Shock IFP Positioning / Extraction Tool

PS-45259 - Gas Fill Tool

1.8

2870459 - Dial Indicator

PV-35667-A - Cylinder Leak down T ester

2872105 - Water Pump Seal Puller

Final Drive

PA-48282 Rear Hub Tool

Page 12

GENERAL INFORMATION

Fuel & Brake Systems

2870975 - Mity Vac™

Electrical Tools

PV-43568 - Fluke™ 77 Multimeter

Electrical Tools

2870630 - Timing Light

2871745 - Static Timing Light Harness

2460761 - Hall Sensor Probe Harness

PV-39617 - Current Clamp

2870836 - Battery Hydrometer

8712500 - PV-39951-A Tachometer T achometer

PV-39991 - Peak Reading Adapter

PV-37453 - Christie™ Se-Sulfating

Multi-Battery Charger

PV-63070 - Christie™ Multi-Battery Charger

1.9

Page 13

GENERAL INFORMATION

RepairPro Service Manual

MISC. NUMBERS / CHARTS

SAE Tap / Drill Sizes

Thread Size/ Drill Size Thread Size / Drill Size

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

#8-36 29 1 1/4-7 1 7/64 #10-24 24 1 1/4-12 1 11/64 #10-32 21 1 1/2-6 1 11/32 #12-24 17 1 1/2-12 1 27/64 #12-28 4.6mm 1 3/4-5 1 9/16

1/4-20 7 1 3/4-12 1 43/64

1/4-28 3 2-4 1/2 1 25/32 5/16-18 F 2-12 1 59/64 5/16-24 I 2 1/4-4 1/2 2 1/32

3/8-16 O 2 1/2-4 2 1/4

3/8-24 Q 2 3/4-4 2 1/2 7/16-14 U 3-4 2 3/4 7/16-20 25/64

Metric Tap / Drill Sizes

Tap Size Drill Size

3x.50 #39 0.0995 3/32 3x.60 3/32 0.0937 3/32 4x.70 #30 0.1285 1/8 4x.75 1/8 0.125 1/8 5x.80 #19 0.166 11/64 5x.90 #20 0.161 5/32

6x1.00 #9 0.196 13/64 7x1.00 16/64 0.234 15/64 8x1.00 J 0.277 9/32 8x1.25 17/64 0.265 17/64 9x1.00 5/16 0.3125 5/16

9x1.25 5/16 0.3125 5/16 10x1.25 11/32 0.3437 11/32 10x1.50 R 0.339 11/32

11 x 1.50 3/8 0.375 3/8

12x1.50 13/32 0.406 13/32 12x1.75 13/32 0.406 13/32

Decimal

Equivalent

Nearest

Fraction

Decimal Equivalents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

1 . . . . . . . . . . 1.0

. . . . . . . .8281

1.10

Page 14

Coversion Table

GENERAL INFORMATION

Unit of Measure Multiplied by Converts to

ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x.0115 = kg-m Nm x .7376 = ft. lbs. kg-m x 7.233 = ft. lbs. kg-m x 86.796 = in. lbs. kg-m x 9.807 = Nm in. x 25.4 =mm mm x .03937 = in. in. x 2.54 = cm mile (mi.) x 1.6 = km km x .6214 = mile (mi.) Ounces (oz.) x 28.35 = Grams (g) Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc) Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.) Grams (g) x 0.035 = Ounces (oz.) lb. x .454 = kg kg x 2.2046 = lb. Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc) Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in) Imperial pints (Imp pt.) x 0.568 = Liters (l) Liters (l) x 1.76 = Imperial pints (Imp pt.) Imperial quarts (Imp qt.) x 1.137 = Liters (l) Liters (l) x 0.88 = Imperial quarts (Imp qt.) Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.) US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.) US quarts (US qt.) x 0.946 = Liters (l) Liters (l) x 1.057 = US quarts (US qt.) US gallons (US gal) x 3.785 =Liters (l) Liters (l) x 0.264 = US gallons (US gal) Pounds - force per square inch (psi) x 6.895 = Kilo pascals (kPa) Kilo pascals (kPa) x 0.145 = Pounds - force per square inch (psi) Kilo pascals (kPa) x 0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1 = Kilo pascals (kPa) ð(3.14)xR2xH (height) = Cylinder Volume

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

1.11

Page 15

GENERAL INFORMATION

RepairPro Service Manual

Glossary of Terms

ABDC: After bottom dead center.

Alternating current voltage.

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

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

DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore. Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touch ing the

chassis).

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

: Kilograms per square centimeter.

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

: Pounds per square inch.

lbs/in Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy is

converted to electrical energy in the stator.

mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040". Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. PVT : Polaris Variable Transmission (Drive Clutch System) qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.

Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.

1.12

Page 16

MAINTENANCE

CHAPTER 2

MAINTENANCE

PERIODIC MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

PERIODIC MAINTENANCE OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

PRE-RIDE MAINTENANCE INTERVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4

RECOMMENDED PRE-RIDE FLUID LEVEL CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . .2.4

0 - 50 HOUR MAINTENANCE INTERVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

50 - 100 HOUR MAINTENANCE INTERVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

100 - 300 HOUR MAINTENANCE INTERVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8

LUBRICANTS AND SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . . 2.9

GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10

PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

FUEL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

CARBURETOR PILOT SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

THROTTLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL (ETC) ADJUSTMENT . .2.13

CHOKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

AIR FILTER AND PRE-FILTER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

AIR BOX DRAIN TUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

CRANKCASE BREATHER FILTER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

ENGINE AND TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

ENGINE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

ENGINE OIL AND FILTER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

OIL PUMP PRIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

EXHAUST PIPE / SPARK ARRESTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

ENGINE MOUNT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

LIQUID COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

COOLING SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

COOLANT STRENGTH / TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18

RADIATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

RECOVERY BOTTLE COOLANT LEVEL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .2.18

COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19

RADIATOR SCREEN REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

FINAL DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19

CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

REVERSE LOCK-OUT LEVER INSPECTION AND CABLE ADJUSTMENT. . . . . . . . . 2.19

SPROCKET INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

DRIVE CHAIN INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

DRIVE CHAIN TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

DRIVE CHAIN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

REAR DRIVESHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

REAR DRIVESHAFT BOOT “PRESSURE EQUALIZING”. . . . . . . . . . . . . . . . . . . . . . . 2.22

2.1

Page 17

MAINTENANCE

RepairPro Service Manual

ELECTRICAL AND IGNITION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

BATTERY INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

BATTERY TERMINALS / BOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

ENGINE- TO- FRAME GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

STEERING AND SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

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

WHEEL ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

STEERING INSPECTION / TIE ROD ENDS AND HUBS . . . . . . . . . . . . . . . . . . . . . . . 2.26

TOE ALIGNMENT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

SUSPENSION SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

REAR SHOCK COMPRESSION ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

BRAKE SYSTEM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

HOSE / FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

BRAKE TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

WHEEL REMOVAL: FRONT OR REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31

TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

2.2

Page 18

MAINTENANCE

PERIODIC MAINTENANCE CHART

Periodic Maintenance Overview

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

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

NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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

Maintenance Chart Key

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

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

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

(Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm use, prolonged low speed - heavy load operation or e xte nded idle. M ore preven tat ive maint ena nce is r equire d under these conditions. Fluid changes, cable, chain and chassis lu bricat i on are re quired more freque ntly. For engine oil, short trip cold weather riding also constitutes seve re 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 co uld result in component failure and lead to ser ious injury or death. Have an authorized Polaris dealer perform these services.

2.3

Page 19

MAINTENANCE

RepairPro Service Manual

Pre-Ride Maintenance Interval

Periodic Maintenance Chart

Maintenance Interval

Item

 Steering - Pre-Ride -

Front / Rear Suspension - Pre-Ride -



Tires - Pre-Ride -

 



Brake Fluid Level - Pre-Ride -

Brake Lever Travel - Pre-Ride -

Brake Systems - Pre-Ride -

Wheels / Fasteners - Pre-Ride -

Frame Fasteners - Pre-Ride -

Engine / Trans Oil Level - Pre-Ride -

Drive Chain - Pre-Ride -

Throttle - Pre-Ride - Check operation

Clutch - Pre-Ride - Check operation and adjustment

Engine Stop Switch - Pre-Ride - Check operation Air Filter / Pre-Filter - Pre-Ride - Inspect; clean often

Air Box Sediment Tube - Pre-Ride - Drain deposits when visible

Coolant - Pre-Ride -

Head Lamp / Tail Lamp - Pre-Ride -

A-arm Ball Joint - Pre-Ride

Rear Shaft Assembly -

(whichever comes first)

Hours Calendar

Pre-Ride

Post-Ride

Miles

(KM)

Remarks

Make adjustments as needed.

Check level daily,

change coolant every 2 years

Check operation;

apply dielectric grease if replacing

Check freeplay daily; have dealer replace if

wheel moves excessively

Check pre-ride for tears, punctures, leakin g.

Check post-ride for bulging / ballooning.

Replace if damaged. Burp if bulging.

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

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

Recommended Pre-Ride Fluid Level Checks

ITEM TYPE NOTES SEE PAGES

Engine / Trans Oil Polaris PS-4 Synthetic Engine Oil Add to proper level on dipstick 2.14

Coolant / Level

Brake Fluid Polaris DOT 3 or DOT 4 Brake Fluid

NOTE: Quick Reference Lubricants and maintenance product part numbers are listed on page 2.9

2.4

Polaris Premium 60/40 Pre–mixed

Antifreeze/Coolant or a 50/50

mixture high quality antifreeze/

coolant and distilled water

Allow engine and cooling system to cool completely

and check level in radiator. Fill to top of filler neck. If

reservoir was empty or extremely low, fill radiator

before filling reservoir tank to full line Fill to indicated level inside reservoir.

Use the sight glass to ensure the proper fluid level.

2.18

2.29

Page 20

MAINTENANCE

0 - 50 Hour Maintenance Interval

Periodic Maintenance Chart

Maintenance Interval

Item



E





E

 Valve Lash 50 H - -



Front / Rear Suspension 50 H 6M 500 (800)



E

E Choke Cable 50 H 6M 500 (800)

 Steering 50 H 6 M 500 (800) Lubricate

Air Filter,

Main Element

Engine / Trans Oil

Change (Break-In)

Engine / Trans

Oil Change

Oil Filter Change 10 H - 100 (160) Replace with oil change

Brake Pad Wear 10 H Monthly 100 (160) Inspect periodically

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

Engine Breather Filter (in air box)

General

Lubrication

Drive Chain 50 H 6M 500 (800)

Carburetor Float Bowl 50 H 6M 500 (800) Drain bowl periodically and prior to storage

Throttle Cable / ETC

Switch

Clutch cable 50 H 6 M 500 (800) Inspect, lubricate, adjust

Carburetor Air Intake /

Flange

Cooling System 50 H 6M 500 (800)

(whichever comes first)

Hours Calendar

- Weekly - Inspect; replace as needed

1 H - -

10 H - 100 (160) Check pre-ride level

20 H Monthly 200 (320) Inspect; replace if necessary

50 H 3M 500 (800)

50 H 6M 500 (800)

50 H 6M 500 (800) Inspect ducts for proper sealing / air leaks

Miles

(KM)

Perform a break-in oil change at 1 hour or 1

Check clearance. Re-shim only if out of

Lubricate all grease fittings, pivots, cables,

adjust and lubricate as needed

Inspect; tighten fasteners; grease

(especially after washing or driving in high

water levels) See page 2.6

Inspect coolant strength seasonally;

pressure test system yearly

Remarks

tank of gas

specification.

etc.

Inspect daily;

Inspect; adjust; lubricate;

replace if necessary

Inspect; adjust; lubricate;

replace if necessary

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

E Emission Control System Service (California)

 Have an authorized Polaris dealer perform these services.

2.5

Page 21

MAINTENANCE

RepairPro Service Manual

50 - 100 Hour Maintenance Interval

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar

Upper Steering Post (A) 50 H 3 M 500 (800)

Front A-arms (B) 50 H 3 M 500 (800)

Rear Control Arm

Bushings (C)





Stabilizer Bar (D) 50 H 6 M 500 (800) Grease

Rear Control Arm

Needle Bearings (E)

50 H 3 M 500 (800)

100 H 12 M 1000 (1600)

Miles

(Km)

Inspect; tighten fasteners; grease after washing

Disassemble, clean, inspect bearings and seals,

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

E Emission Control System Service (California)

 Have an authorized Polaris dealer perform these services.

Remarks

ATV or driving in water

Inspect; tighten fasteners; grease (also after

washing ATV or driving in water)

Inspect; tighten fasteners; grease (also after

washing ATV or driving in water)

grease, reassemble

2.6

Page 22

MAINTENANCE

100 - 300 Hour Maintenance Interval

Periodic Maintenance Chart

Maintenance Interval

Item







 





 Clutch Plates 100 H 12M 1000 (1600) Inspect; replace worn parts  Brake Fluid 200 H 24M 2000 (3200) Change every two years  Front Wheel Bearings 300 H 36M 3000 (4800) Inspect; replace as needed

E Idle Speed - Adjust as needed

 Toe Adjustment -

Oil Tank Vent Hose 100 H 12M 1000 (1600) Inspect routing, condition

Fuel System 100 H 12M 1000 (1600)



Fuel filter 100 H 12 M 1000 (1600) Replace yearly

Coolant System

Pressure Test

Radiator 100 H 12M 1000 (1600)

Cooling Hoses 100 H 12M 1000 (1600) Inspect for leaks Engine Mounts 100 H 12M 1000 (1600) Inspect

Exhaust Pipe 100 H 12M 1000 (1600) Inspect

Spark Plug 100 H 12M 1000 (1600) Inspect; replace as needed

Ignition Timing - 12M - Inspect

Wiring 100 H 12M 1000 (1600)

Spark Arrestor 300 H 36M 3000 (4800) Clean out as required

Headlight Aim - Adjust as needed

(whichever comes first)

Hours Calendar

100 H 12 M 1000 (1600) Pressure test system annually

Miles

(Km)

Check for leaks at tank cap, lines, fuel valve,

Inspect; clean external surfaces;

Inspect for wear, routing, security; apply

dielectric grease to connectors subjected to

adjust when parts are replaced

Remarks

filter, pump, carb uretor.

Replace lines every two years

change coolant every 2 years

water, mud, etc.

Inspect periodically;

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

E Emission Control System Service (California)

 Have an authorized Polaris dealer perform these services.

2.7

Page 23

MAINTENANCE

RepairPro Service Manual

Maintenance References

1. Engine Oil and Filter

2. Brake Fluid

(Right hand and Foot Brake Master Cylinder)

3. Rear Drive Chain

Sight

Glass

Fill to Indicated

Level

Oil Filter Location

III. # Item Lube Rec. Method Frequency*

2. Brake Fluid

3. Drive Chain Polaris Chain Lube

* More often under severe use, such as operation in mud, water, sand or under severe loads. ** Every 10 hours of operation (refer to Maintenance Schedule for additional information). Change more often in extremely dirty

conditions such as continuous operation in water, mud or sand, continuous hot, cold, or short trip cold weather operation.

NOTE: Excessive clutch plate residue will accelerate oil change intervals.

Engine Oil /

Transmission

Polaris PS-4 Synthetic

Polaris DOT 3 or DOT 4

Brake Fluid

Check dipstick and add to

proper level.

Fill master cylinder reservoirs

to indicated level inside

reservoir.

Apply to chain link plates and

rollers.

Perform break–in oil / filter

change at one hour; change oil

every 10hrs / 100mi. **

As required. Change fluid every

2 years or 200 hours. ***

As required *

*** Every 24 months or 200 hours of operation (refer to Maintenance Schedule for additional information). More often under severe conditions such as continuous operation in water, mud or sand.

2.8

Page 24

LUBRICANTS AND SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service Products

PART NO. DESCRIPTION

ENGINE LUBRICANT

2874414 Engine Oil (Quart) PS 4 Synthetic (4-Cycle) 2874415 Engine Oil (Gallon) PS 4 Synthetic (4-Cycle)

GREASE / SPECIALIZED LUBRICANTS

2871322 Premium All Season Grease (3 oz. cartridge) 2871423 Premium All Season Grease (14 oz. cartridge) 2876006 Rear Shaft Grease 2871460 Starter Drive Grease 2871312 Grease Gun Kit 2871329 Dielectric Grease 2872073 Chain Lube (Aerosol)

COOLANT

2871323 60/40 Coolant (Gallon) 2871534 60/40 Coolant (Quart)

ADDITIVES / SEALANTS / THREAD LOCKING AGENTS / MISC.

2870791 Fogging Oil (12 oz. Aerosol) 2871326 Premium Carbon Clean (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2870585 Loctite™ Primer N, Aerosol, 25 g 2870990 DOT 3 Brake Fluid 2872189 DOT 4 Brake Fluid 2871956 Loctite™ Thread Sealant 565 (50 ml.) 2871949 Loctite™ Threadlock 242 (50 ml.) 2871950 Loctite™ Threadlock 242 (6 ml.) 2871951 Loctite™ Threadlock 262 (50 ml.) 2871952 Loctite™ Threadlock 262 (6 ml.) 2871953 Loctite™ Threadlock 271 (6 ml.) 2871954 Loctite™ Threadlock 271 (36 ml.) 2870584 Loctite™ RC 680–Retaining Compound (10 ml.) 2870587 Loctite™ 518 Gasket Eliminator / Flange Sealant (50 ml.) 2871957 Black RTV Silicone Sealer (3 oz. tube) 2871958 Black RTV Silicone Sealer (11 oz. cartridge) 8560054 Silicone Sealer (14 oz. cartridge) 2871557 Crankcase Sealant, 3–Bond 1215 2872893 Engine Degreaser

MAINTENANCE

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GENERAL VEHICLE INSPECTION AND MAINTENANCE

Pre-Ride / Daily Inspection

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

• Tires – check condition and pressures

• Chain - Check tension, lubricate, adjust as needed

• Fuel and oil tanks – fill both tanks to their proper level; Do not overfill oil tank

• All brakes – check operation and adjustment (includes auxiliary brake

• Throttle – check for free operation

• Headlight/Taillig ht/Brakelight – check operation of all indicator lights and switches

• Engine stop switch – check for proper function

• Wheels – check for loose wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins

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

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

FUEL SYSTEM AND AIR INTAKE

Fuel System

WARNING

Gasoline is extremely flammable and

explosive under certain conditions.

• Always stop the engine and refuel outdoors or in a well ventilated area.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

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

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

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

• Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can result in loss of consciousness or death in a short period of time.

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

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

• Engine coolant – check for proper level at the recovery bottle

Frame, Nuts, Bolts, and Fasteners

Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in

place. Refer to specific fastener torques listed in each chapter.

Fuel Lines

Fuel Pump

Fuel Inlet

Fuel Outlet

Pulse Line

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

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

CAUTION

Make sure lines are not kinked or pinched.

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3. Replace all fuel lines every two years.

Vent Lines

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

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

CAUTION

Make sure lines are not kinked or pinched

Fuel Valve

6. Turn valve on, start engine and inspect for leaks.

Carburetor Draining

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

NOTE: The bowl drain screw is located on the bottom left side of the float bowl.

1. Turn fuel valve to the “Off” position.

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

3. Turn drain screw o ut two turns and allow fuel in t he float bowl and fuel line to drain completely.

4. Inspect the drained fuel for water or sediment.

5. Tighten drain screw.

6. Turn fuel valve to “On”.

7. Start machine and check for leaks.

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

Fuel Valve

The fuel system strains the fuel through screens located in the fuel valve. There is no fuel filter to service. To service the fuel valve:

1. Shut off fuel supply at fuel valve. Remove line clamps and fuel lines from the tank.

2. Remove the tank and drain remainder of fuel into a appropriate container.

3. Remove fuel valve by loosening the screws holding the valve to the tank.

4. Inspect the valve for damage or debris. Replace the valve if problems are found.

5. Reverse the procedures to install the fuel valve.

Drain Screw

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Carburetor Pilot Screw Adjustment

NOTE: The pilot screw is covered by a brass welsh plug per EPA requirements. Removal will be

required to perform these procedures.

FRONT

(Engine Side)

Pilot Screw Location

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

2. W ith engine off, turn pilot screw in (clockwise) until lightly seated. Turn screw out the specified number of turns.

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

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

8. Readjust idle speed to specification.

NOTE: Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.

Idle Speed Adjustment

NOTE: Adjusting the idle speed effects throttle cable freeplay and electronic throttle control (ETC) adjustment. Always check throttle cable freeplay

after adjusting idle speed and adjust if necessary.

BSR Carburetor

Idle Screw

Pilot Screw Initial Setting:

Outlaw 500 - 2.5 Turns Out

NOTE: Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be permanently damaged.

CAUTION

The pilot screw is calibrated at the factory to meet EPA / CARB regulations for air quality standards

and is sealed with a brass plug to prevent

tampering. Removal of the tamper proof plug is

not permitted. For service purposes, cleaning of

the pilot circuit can be done only by a certified

repair shop to ensure air quality standards

are not exceeded.

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). Start engine.

4. Set idle speed to 1600 RPM.

5. Slowly turn mixture screw clockwise using the pilot screw or an appropriate sized screwdriver until engine begins to miss.

1. Start engine and warm it up thoroughly.

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

Idle Speed

1600 ± 100 RPM

Throttle Inspection

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

1. Place the gear selector in neutral.

2. Set parking brake.

3. Start the engine and let it idle.

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

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

6. Inspect ETC cover seal and switch cavity by removing the cover. Verify that no dirt, water or mud is present.

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To remove the ETC cover:

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

2. Twist screwdriver slightly while lifting on the cover to release snap.

3. Repeat procedure at the other five locations as shown.

NOTE: Do not attempt to remove cover until all latch points are released.

Throttle Cable / Electronic Throttle Control (ETC) Adjustment

5. Turn adjuster until 1/16” to 1/8” (1-2mm) freeplay is

achieved at thumb lever. After making adjustments, quickly actuate the thumb lever several times and reverify freeplay.

Direction of Travel

Freeplay

1/16”-1/8”

(1-2mm)

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

7. T urn handlebars from left to right through the entire turning range. If idle speed increases, check for proper cable routing. If cable is routed properly and in good condition, repeat adjustment procedure.

Choke Adjustment

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

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

3. Start engine and set idle to 1600 RPM.

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

4. Loosen lock nut on in–line cable adjuster.

Lock Nut

Boot

Adjuster Sleeve

Boot

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

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.

Choke

Air Filter and Pre-filter Service

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

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

1. Unlatch and remove the seat.

2. Release the two air box cover clips (A) and rotate the cover rearward to remove it.

3. Remove the air filter retaining screw (B).

4. Loosen the filter clamp (C).

5. Remove the main air filter (D).

6. Remove the pre-filter (E) from the main filter element.

7. Remove the breather filter (F).

Air Box Drain Tube

Periodically check the air box drain tube located on the bottom side of the air box. Be sure the drain tube is not obstructed by mud or sand. Whenever deposits are visible, clean out the tube.

Drain Tube

NOTE: The drain tube will require more frequent inspection if the vehicle is operated in severe conditions.

Cleaning:

8. Wash the pre-filter (E) and breather filter (F) in soapy water, then rinse and let dry.

9. Wash the main filter element (D) without removing it from the internal filter cage. Rinse and let dry. When dry, apply a commercially available foam filter oil thoroughly on the element.

Installation:

10. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.

11. Reinstall crankcase breather filter, pre-filter and air filter into air box. Install the air filter retaining screw.

12. Reinstall the air box cover and secure the cover with the two clips.

Crankcase Breather Filter Inspection

Outlaw ATV engines are equipped with a crankcase breather filter in the air box. The filter is similar in appearance to a small foam block, and is visible on the left side (See Illustration to the left, Reference F).

The air breather filter should be inspected or replaced whenever the air filter is inspected.

ENGINE AND TRANSMISSION

Engine Oil Level Check

Check the oil level before each use of the vehicle. The dipstick is located on the left side of the ATV.

Dipstick

Location

Oil Level

Marks

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1. Position the ATV on a level surface.

2. Start the engine and let it idle for one minute.

3. Stop the engine and remove the dipstick. Wipe it dry with a clean cloth.

4. Reinstall the dipstick completely.

NOTE: The dipstick must be screwed completely in to keep the angle and depth of the stick consistent.

5. Remove the dipstick and check the oil level. Maintain the oil level in the safe range, between the full and add marks. Do not overfill.

6. Reinstall the dipstick.

Engine Oil and Filter Service

IMPORTANT: Polaris PS-4 Engine Oil is recommended for use in the Predator. PS-4 was specifically designed for the Predator’s engine and clutching system. Other oils do not contain the needed additives to prolong engine life and provide proper lubrication to the Predator clutch and transmission components.

1. Place the vehicle on a level surface.

2. Clean the area around the oil tank and crankcase drain plugs with clean shop towels.

8. Allow the oil to drain completely.

9. Replace the sealing washer and reinstall the plug. Torque

to 14 ft. lbs. (19 Nm).

10. Place shop towels beneath the oil filter cover.

11. Remove the three cover bolts and remove the cover.

72–78 in. lbs.

(8–9 Nm)

NOTE: A spring located behind the filter may pop out as the filter is removed. The spring must be reinstalled with the new filter.

12. Pull out the oil filter.

WARNING

Hot oil can cause serious burns to the skin.

Do not allow hot oil to contact skin.

3. Run the engine for two to three minutes until warm, then stop the engine.

4. Place a drain pan beneath the oil tank and remove the drain plug (1).

14 ft. lbs. (19 Nm)

5. Allow the oil to drain completely.

6. Replace the sealing washer and reinstall the plug. Torque to 14 ft. lbs. (19 Nm).

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

Oil Filter

Spring

13. Using a clean dry cloth, clean the filter sealing surfaces.

7. Place a drain pan beneath the crankcase and remove the drain plug (2).

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14. Replace the gasket in the cover.

Gasket

15. Lubricate the gasket on the new filter with a film of fresh engine oil.

16. Reinstall the spring and install the new filter with the open end facing outward.

17. Install the cover and torque the bolts to 72–78 in. lbs. (8– 9 Nm).

NOTE: The long bolt must be placed in the forward hole.

18. Remove the dipstick and fill the oil tank with 2.25 quarts (1.9 l) of Polaris PS-4 Engine Oil (PN 2874414).

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

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

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

22. Dispose of used filter and oil properly.

3. Shut off engine. Remove the vent line clamp. The oil pump should now be properly primed and ready for field operation.

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

Compression Test

NOTE: This engine has built-in decompression components. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about 85-90 psi @ 400 RPM during a compression test.

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

Cylinder Compression w / decompression

Standard: 85-90 PSI @ 400 RPM

Cylinder Leakdown

Service Limit: 10%

(Inspect for cause if leakage exceeds 10%)

Exhaust Pipe / Spark Arrestor

Oil Pump Priming Procedure

NOTE: The oil pump priming procedure should be performed as a safeguard against loss of pump prime when repairing oil tank, lines or engine.

1. Clamp or pinch off vent line approximately 2 tank (P), between the end of oil tank vent fitting and the vent line.

2. Run engine for 5-10 seconds at IDLE.

″ from oil

WARNING

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

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

• Wear eye protection.

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

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

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

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

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Periodically clean the spark arrestor to remove accumulated carbon.

Verify which type of spark arrestor your ATV is equipped with and follow the appropriate cleaning procedure below: (A) or (B)

Procedure A - End Cap Spark Arrestor

1. Remove the three screws (1) and remove the arrestor (2) from the end of the muffler.

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

3. Inspect the screen for wear and damage. Replace the arrestor is damage is found.

4. Remove and inspect the gasket (4). Replace if worn or damaged.

arrestor is damage is found.

Inspect the screen

4. Reinstall the arrestor and torque the bolt to 7 ft. lbs. (9.5 Nm)

Engine Mount Locations

Inspect engine mounts and frame for cracks or damage. Check engine fasteners and ensure they are tight.

Engine Mounting Locations

5. Reinstall the gasket and arrestor.

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

Procedure B - Set Screw Type Spark Arrestor

1. Remove the bolt and remove the arrestor from the end of the muffler.

Bolt

Spark Arrestor

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

3. Inspect the screen for wear and damage. Replace the

LIQUID COOLING SYSTEM

Cooling System Overview

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

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.

• Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels often during the break–in period.

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

• Polaris Premium 60/40 anti-freeze is premixed and ready to use. Do not dilute with water.

Coolant Strength / Type

T est the strength of the coolan t using an antifreeze hydrometer.

Antifreeze Hydrometer

• A 50/50 or 60/40 mixture of antifreeze and distilled water will provide the optimum cooling, corrosion protection, and antifreeze protection.

• 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.

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

Radiator

1. Check radiator external air flow passages fo r restrictions or damage.

2. Carefully straighten any bent radiator fins.

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

Recovery Bottle Coolant Level Inspection

WARNING

Never remove the radiator pressure cap when the

engine is warm or hot. Escaping stream and fluid can

cause severe burns. The engine must be allowed to

cool before removing the pressure cap.

The recovery bottle, is located on the right side of the vehicle under the front fender. The fluid level must be maintained between the FULL (A) and ADD (B) marks on the side panel (when the fluid is cool).

Polaris 60/40 Anti-Freeze / Coolant

(PN 2871323)

Cooling System Hoses

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

Recovery Bottle

If coolant is not between the FULL and ADD marks, perform the following steps:

1. Remove reservoir cap. Verify the breather foam is in place and the inner splash cap vent hole is clear and open.

1. Check tightness of all hose clamps.

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2. Fill reservoir to upper mark with Polaris Premium 60/40

Anti Freeze / Coolant (PN 2871323) or a mixture of antifreeze and distilled water as required for freeze protection in your area.

3. Reinstall cap.

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

Cooling System Pressure Test

See Chapter 3 for testing procedures.

Radiator Screen Removal

1. Remove the 4 screws retaining the radiator screen for access to the radiator fins when cleaning.

4. Squeeze the lever fully and release. Slightly squeeze the lever again until a slight resistance is felt. Measure the freeplay again. If necessary, repeat the adjustment procedure until proper freeplay is attained.

5. Replace the clutch perch pivot boot over the s crew and lock ring.

Reverse Lock-Out Lever Inspection and Cable Adjustment

Check for smooth lever operation and ensure that the lever returns freely without binding (1).

Adjust the reverse cable freeplay to .08”-.12” by adjusting the cable jam nuts (2).

FINAL DRIVE

Clutch Adjustment

1. Measure clutch lever freeplay between the perch and the lever (A). This distance should be 1/8” – 3/16” (3.1 mm –

4.7 mm)

CLUTCH LEVER FREEPLAY

2. If adjustment is required, slide the clutch perch pivot boot down the clutch cable to access the clutch adjustment screw (B) and lock ring (C).

3. Loosen the lock ring and turn the screw in (clockwise) to increase lever travel. Turn the screw out (counterclockwise) to decrease lever travel. Tighten the lock ring.

Sprocket Inspection

Inspect the sprocket for worn, broken or bent teeth.

To check for wear , pull upward on the chain at the area indicated (arrow). Replace sprocket if chain movement exceeds 1/4” (.6 cm).

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Drive Chain Inspection / Replacement

Inspect the drive chain for missing or damaged O–Rings, link plates, or rollers. Do not wash the chain 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.

If a gap is noticed between the outside edge of the master link and plate, back the plate out and close the gap.

Master Link

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 Chain Lubricant (PN 2872073).

Never allow battery acid to contact the drive chain. The chain must be replaced when it reaches 3% elongation.

1. Stretch the chain tightly in a straight line.

2. Measure the length of 21 pitches (pins) from pin center to pin center, and compare to the specification. Replace the chain if the length exceeds the wear limit.

Drive Chain Wear Limit, 21 Pitch Length:

Std: 12.5

Wear Limit: 12.875” (32.7 cm)

3. When replacing or reinstalling drive chain, install the closed end of the splice link clip as shown, with the closed end leading in forward operation. There should be a .003-

″ (.076-.127 mm) gap between the side plate of the

.005

chain and the splice link clip. See illustrations below.

Proper Spacelink Clip Opening Position

.003 - .005 (.076- .127 mm) Gap after installation

″

″(32 cm)

Do not press

plate in too far

Drive Chain Tension

CAUTION

Never adjust or operate the vehicle with the rear drive

chain too loose or too tight. Severe damage to the

transmission and drive components can result.

BREAK-IN: It is extremely important to 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 CHAIN TENSION:

2.20

Check the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the chain. At the center point of the top side of the chain there should be 1/4” - 3/ 8” (6-9 mm) deflection.

NOTE: The chain has a press-on master link. A chain tool must be used if it’s necessary to remove the chain for service.

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Drive Chain Adjustment

1. Loosen the upper and lower pivot mounting bolts (1).

2. Thread the chain adjusting bolt (2) inward or outward to adjust chain slack to the proper dimension.

Rear Driveshaft Boot Inspection

Before Operating

Inspect the boots before operating the vehicle. If a boot is torn, punctured or leaking fluid, replacement is required.

After Operating

Inspect the boots after operating the vehicle. If a boot is bulging or ballooned, perform the boot “burping” procedure.

3. Torque the pivot mounting bolts to 30 ft. lbs. (41 Nm).

4. Torque the chain adjusting bolt to 20 ft. lbs. (27 Nm).

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Rear Driveshaft Boot “Pressure Equalizing”

1. Using a needle nose pliers or boot clamp removal tool, remove the small boot clamp (1) from the inboard boot.

NOTE: Do not use any tools that may damage the boot.

2. Slide the free end of the boot two inches toward the center of the vehicle and lift the boot away from the shaft to allow excess air to escape.

ELECTRICAL AND IGNITION SYSTEM

Battery Maintenance

WARNING

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

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

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

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

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

3. Wipe excess grease from the shaft before returning the boot to the boot groove. Use caution not to allow excess air back into the system when reinstalling the boot.

4. Reinstall the boot clamp.

The battery is located under the front cab at the front of the A TV.

NOTE: The Outlaw battery is a Low Maintenance design and construction. Before placing the battery into service, check the battery condition and charge accordingly. Use of Conventional Lead-Acid batteries is not recommended.

New Batteries: Batteries must be fully charged before use or battery life will be reduced by 10–30% of full potential. Charge battery for 3-5 hours at a current equivalent of 1/10 of the battery’s rated amp/hour capacity (i.e. 9 amp hr x.10 =.9 amp charging). Do not use the alternator to charge a new battery.

Maintenance-Free batteries are sealed at the factory. The use of lead-calcium instead of lead-antimony allows the battery acid to be fully absorbed by the plates. Therefore, a Maintenance-Free battery case is opaque and the sealing caps are not removable, since there is no need to check electrolyte level.

IMPORTANT: Never attempt to add electrolyte or water to a Maintenance-Free battery. Doing so will damage the case and shorten the life of the battery.

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Battery Inspection / Removal

The battery is located under the front cab at the front of the A TV. Removal of the front cab assembly is required to access the battery. Refer to “Chapter 5” for front cab removal.

Battery

Location

To remove the battery:

1. Remove the front cab.

2. Disconnect holder strap.

3. Disconnect battery negative (–) (black) cable first, followed by the positive (+) (red) cables.

CAUTION

To redu c e th e ch a n ce of sparks: Whene ve r

removing the battery, disconnect the

negative (black) cable first. When reinst alling

the battery, install the negative cable last.

4. Remove the battery.

5. 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. Test battery for condition and charge accordingly.

6. If required, charge battery at 1/10 of its amp/hour rating. Example: 1/10 of 14 amp battery = 1.4 amp

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

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

2871329).

9. Reinstall battery cover, holder strap and front cab.

Off Season Storage

To prevent battery damage during extended periods of non–use, the following basic battery maintenance items must be performed:

• Remove the battery from the machine and wash the case and battery tray with a mild solution of baking soda and water. Rinse with fresh water after cleaning.

NOTE: Do not get any of the baking soda into the battery or the acid will be neutralized.

• Using a wire brush or knife, remove any corrosion from the cables and terminals.

• Never add water to a sealed maintenance free

battery.

• Charge at a rate no greater than 1/10 of the battery’s amp/hr capacity until the open circuit voltage is 12.9V or greater.

• Store the battery either in the machine with the cables disconnected, or store in a cool place.

Engine- To- Frame Ground

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

Charging Procedure

NOTE: Remote charging terminals have been provided to allow for battery charging without removal of the front cab.

1. Attach the Positive battery charging cable to the Red Charge Terminal (A); which is directly connected to the positive battery terminal. It is located just above the front right shock mount.

2. Attach the Negative battery charging cable to the free end of the Black Cable (B) under the right front cab (which is directly connected to the negative battery terminal).

Battery Terminals / Bolts

Ensure battery terminals are clean of corrosion. Use Polaris corrosion resistant Dielectric Grease (PN 2871329) on battery bolts.

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3. Charge with a charging output no larger than 1/10 of the battery's amp/hr rating. Charge as needed to raise the open circuit voltage to 12.9 V or greater.

WARNING

To avoid the possibility of explosion or sparks, connect positive (red) cable first and negative (black) cable last.

8. Remove spark plug. and inspect electrodes for wear and carbon buildup. The insulator tip should be a light tan color , indicating good combustion. Look for a sharp outer electrode edge with no rounding or erosion.

9. If needed, clean spark plug with electrical contact cleaner or a glass bead spark plug cleaner only.

NOTE: Wire brushes or coated abrasives should not be used.

10. Measure gap with a wi re gauge. Refer to specifications for proper spark plug type and gap. Adjust gap if necessary by bending the side electrode carefully.

11. If necessary, replace spark plug with proper type.

CAUTION

Severe engine damage may occur if the

incorrect spark plug is used.

12. Apply a small amount of anti–seize compound to the spark plug threads.

13. Install spark plug and torque to specification. Reverse steps as needed for reassembly.

Spark Plug Inspection

Spark Plug Removal and Replacement

1. Turn the fuel valve to OFF.

2. Remove the side panels and front cab.

3. Move the fuel valve hose clamp forward and gently remove the hose (1) from the fuel valve fitting on the gas tank.

4. Remove the vent hose (2) from the instrument panel, taking note of the hose routing for reinstallation.

5. Remove the tank mounting bolt (3) at the rear of the gas tank.

6. Move the tank rearward and upward over the engine. Slowly remove the tank, being careful not to catch any hoses, wires or other components. Place the tank on a stable surface or work bench to protect the valve from contamination or damage.

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

Recommended Spark Plug:

NGK DCPR8E

Spark Plug Torque:

14 Ft. Lbs. (19 Nm)

Spark Plug Gap

″ (0.9mm)

.035

Ignition Timing

Timing is non-adjustable. Refer to Chapter 7 for ignition timing inspection.

STEERING AND SUSPENSION

Steering

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

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MAINTENANCE

Replace any worn or damaged steering components. Steering should move freely through entire range of travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited.

NOTE: Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts.

WARNING

Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized

Polaris MSD certified technician when replacing

worn or damaged steering parts.

Use only genuine Polaris replacement parts.

Controls

Check controls for proper operation, positioning and adjustment.

Handlebars

If desired, the handlebars can be adjusted for rider preference.

Wheel Alignment

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 for procedure.

METHOD 1: USING A STRAIGHTEDGE OR STRING

WARNING

Severe injury or death can result from improper toe

alignment and adjustment.

1. Position the vehicle on a level surface.

NOTE: Always measure toe alignment on a flat ground surface.

2. Place the handlebars in a straight-ahead position. Use tie straps to secure the handlebars to the rear grab bar so they can’t move.

3. Place stands (1) in front of the vehicle, perpendicular to the rear tires. See illustration below.

WARNING

Improper adjustment of the handlebars or incorrect torquing of the adjuster lock bolts can cause limited

steering of the handle bars, which could result in

loss of control and serious injury or death.

1. Loosen the four bolts and adjust the handlebar to the desired height. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right.

11 ft. lbs.

(15 Nm)

2. Torque the rear two bolts to 11 ft. lbs. (15 Nm), then torque the front two bolts. A gap of up to 1/8” will remain at the rear bolts.

4. Tie an elastic string (2) around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle.

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5. Measure the distance between the string in front of the rear tires (A) and in front of the front tires (B). If the two measurements are not equal, adjust the string position until the measurements are equal.

6. Measure the distance from the string to the rim at the front and rear of the front rim (3). The difference between these two measurements should be between 0” and 1/16” toe out.

METHOD 2: USING A CHALK LINE

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 post arm “frog” can be used as an indicator of whether the handlebars are straight. The frog should be centered with equal clearance between the steering stops.

3. Place a chalk mark on the center line of the front tires as close to the hub/axle center line as possible, or measure to a specific distance from the floor. NOTE: It is important that the height of both marks be equally positioned in order to get an accurate measurement.

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

5. Rotate the tires 180 backward. Position chalk marks even with the hub/axle centerline or the specified floor measurement.

6. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 0 to 1/16” (0 to.0625 cm) toe out. This means the measurement at the front of the tire (A) is 0 to 1/16” (0 to.0625 cm) wider than the measurement at the rear (B).

by moving vehicle forward or

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

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

• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (possible loose wheel nuts or loose front hub components).

Chalk Line Measurement ‘A’

Steering Inspection / Tie Rod Ends and Hubs

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

2.26

Check for Loose Wheel or Hub

• Refer to the Body/Suspension Chapter 5 or Final Drive Chapter for service procedures.

Chalk Line

Measurement ‘B’

Page 42

MAINTENANCE

Toe Alignment Adjustment

If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting.

NOTE: Be sure handlebars are straight ahead before determining which tie rod(s) need adjustment.

CAUTION

During tie rod adjustment, it is very important that

the following precautions be taken when

tightening tie rod end jam nuts.

If the rod end is positioned incorrectly it will not

pivot, and may break.

To adjust toe alignment:

• Hold tie rod end to keep it from rotating.

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

• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in Method 1 or Method 2.

Suspension Spring Preload Adjustment

The front suspension preload may be adjusted to suit different conditions and operator weight.

WARNING

Uneven adjustment may cause poor handling of the ATV, which could result in an accident and serious injury or death. Always adjust both the left and right

spring preloads equally or have your Po laris

dealer perform the adjustments.

Front Suspension Set-Up

1. Position the vehicle on a level surface.

2. Stop the engine.

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

NOTE: The tires should be barely touching the ground and the suspension should be at full rebound.

4. Measure the distance from the ground to the bottom of the lower front bumper bolt. Note this measurement for later use.

• IMPORTANT: When tightening the tie rod end jam

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

• After alignment is complete, torque jam nuts to specification.

Hold Rod End Level While Nut Is Tightened

12–14 ft. lbs.

(16–19 Nm)

Correct Tie Rod End

Incorrect Tie Rod End

Camber and Caster

The camber and caster are non–adjustable.

5. Remove the support stand and have a rider sit comfortably on the seat with hands on the handlebars.

6. Place the transmission in neutral and slowly roll the machine forward and backward at least ten feet (3 m) without lifting or pushing down on the suspension.

7. Turn the handlebars fully to the left and right.

8. With the rider still on the vehicle, repeat the measurement performed in step 4.

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9. Subtract the step 8 measurement from the step 4 measurement. The difference should be between 3.75 and 4 inches (9.5 - 10.2 cm).

10. If the number is less than 3.75 inches (9.5 cm), decrease the front spring preload and repeat all steps (See “Front Spring Preload Adjustment”). If the number is higher than 4 inches (10.2 cm), increase spring preload and repeat all steps.

Front Spring Preload Adjustment

1. Raise and safely support the front of the ATV off the ground to allow the suspension to fully extend.

Preload adjustment tool

is included in tool kit

Rear Suspension Set-Up

1. Position the vehicle on a level surface.

2. Stop the engine.

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

NOTE: The tires should be barely touching the ground and the suspension should be at full rebound.

4. Measure the distance from the ground to the bottom of the rear lower control arm pivot bolt. Note this measurement for later use.

Figure 2-27

2. Turn the adjusting ring (1) clockwise to increase preload or counter-clockwise to decrease preload.

Decrease

Preload

Spring

Spacer

Increase

Preload

Ride-In

Spring

5. Remove the support stand and have a rider sit comfortably on the seat with hands on the handlebars.

6. Place the transmission in neutral and slowly roll the machine forward and backward at least ten feet (3 m) without lifting or pushing down on the suspension.

7. Turn the handlebars fully to the left and right.

8. With the rider still on the vehicle, repeat the measurement performed in step 4.

9. Subtract the step 8 measurement from the step 4 measurement. The difference should be between 4 and 4.25 inches (10.2 - 10.8 cm).

10. If the number is less than 4 inches (10.2 cm), decrease the rear spring preload on both shocks and repeat all steps. (See “Rear Spring Preload adjustment”) If the number is higher than 4.25 inches (10.8 cm), increase spring preload and repeat all steps.

Rear Spring Preload Adjustment

• The rear suspension spring preload and shock

compression damping may be adjusted to suit different riding conditions and operator weight.

2.28

1. Raise and safety support the rear of the ATV off the ground to allow the suspension to fully extend.

Page 44

2. Turn the adjusting ring (1) clockwise to increase preload or

counter-clockwise to decrease preload. See Figure 2-27 on previous page.

MAINTENANCE

Rear Compression Adjustments

Setting Compression Damping

Decrease

Preload

Spring

Spacer

Increase

Preload

Ride-In

Spring

Rear Shock Compression Adjustment

The compression damping adjustment is located on the bottom of each rear shock.

Use a flat blade screwdriver to make adjustments. There are 7 positions of compression adjustment.

Softest Position #1 - Full Counter-Clockwise Factory Position #4 - 3 Clicks from #1 Firmest Position #7 - 6 Clicks from #1

BRAKE SYSTEM

Brake System Inspection

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

• Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir.

• Use Polaris DOT 3 or DOT 4 Brake Fluid

Parking Brake

Lock

The softest adjustment is position #1. To obtain position #1, turn the adjuster counter-clockwise until it stops.

The firmest adjustment is position #7. To obtain position #7, start from position #1 and turn the adjuster clockwise 6 clicks.

The factory setting is position #4 or 3 clicks clockwise from position #1.

Softest - 1 Factory - 4 Firmest - 7

Position 1 - Full Counter-Clockwise. Position 7 - 6 Clicks Clockwise from

Compression Adjustment

7 Positions

Position 1.

Use a

screwdriver

to adjust

Location

Sight Glass

• Check brake system for fluid leaks.

• Check brake for excessive travel or spongy feel.

• Check friction pads for wear, damage or looseness.

Front Master Cylinder

Rear Master Cylinder

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MAINTENANCE

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• Check surface condition of the disc.

• Inspect thickness of brake pad friction material.

Hose / Fitting Inspection

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

Brake Pad Inspection

Pads should be changed when the friction material i s worn to 3/64” (.1 cm), or about the thickness of a U.S. dime.

3/64” (.1cm)

Minimum Thickness

Brake Testing

The foot brake should be checked for proper function.

Free Play:

Free play of the brake pedal should be 1/8 mm).

If free play is excessive, inspect pedal (1), linkage, and master cylinder (2) 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 auxiliary brake system in a conventional manner, following the

procedure outlined in the Brake Chapter.

″ – 1/4″ (3.2 – 6.35

WHEELS AND TIRES

Wheels

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

Wheel, Hub, and Spindle Torque Table

Item Specification

Front Wheel Nuts 30-35 Ft. Lbs. (41-47 Nm) Rear Wheel Nuts 30-35 Ft. Lbs. (41-47 Nm) Front Spindle Nut 40 Ft. Lbs. (55 Nm) Rear Hub Retaining Nut 90 Ft. Lbs. (108 Nm)

When applied, the brake power should be sufficient enough to stop the wheels under most conditions.

If brake operation is poor, two things must be examined:

Wheel Removal: Front or Rear

Wheel Removal

1. Stop the engine, place the tran smission in gear and lock the parking brake.

2. Loosen the wheel nuts slightly.

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

4. Remove the wheel nuts and remove the wheel.

Wheel Installation

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

2. Attach the wheel nuts and finger tighten them.

3. Lower the vehicle to the ground.

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MAINTENANCE

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

CAUTION

Improperly installed wheels could affect vehicle

handling and tire wear. On vehicles with flange wheel

nuts, make sure flat of nut goes onto wheel.

Flat side against wheel

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8 or less.

WARNING

Operating your ATV with worn tires, improperly

inflated tires, non - standard tires or improperly

installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the A TV

decal and in the owner’s manual.

Always use original equipment size and type

when replacing tires.

Make sure the wheels are installed properly.

1/8″ (.3 cm)

″ (3 mm)

Tire Pressure

CAUTION

Maintain proper tire pressure. Refer to the warning

tire pressure decal applied to the vehicle.

Tire Pressure (PSI - Cold)

Front Rear

Tire Inspection

• Improper tire inflation may affect ATV maneuverability.

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

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

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NOTES

2.32

Page 48

ENGINE

CHAPTER 3

ENGINE

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

ES50PL ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4

ES50PL ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

ENGINE FASTENER TORQUE PATTERNS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6

COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6

COOLANT TEMPERATURE SENSOR (THERMISTOR). . . . . . . . . . . . . . . . . . . . . . . . .3.7

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

RADIATOR CAP / SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7

COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7

ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .8

ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9

CRANKSHAFT STRAIGHTENING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

ES50PL ENGINE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10

OIL PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

OIL PUMP PRIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11

OIL FLOW - ES50PL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11

ES50PL OIL FLOW CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12

ES50PL ENGINE EXPLODED VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13

UPPER ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

CAM CHAIN TENSIONER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14

CAM CHAIN TENSIONER INSPECTION AND REASSEMBLY. . . . . . . . . . . . . . . . . . . 3.14

CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

AUTOMATIC COMPRESSION RELEASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . .3.15

CAMSHAFT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

CYLINDER AND PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17

PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17

PISTON AND ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18

LOWER ENGINE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19

CRANKCASE DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19

STARTER DRIVE GEARS REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . .3.19

FLYWHEEL / ONE-WAY STARTER CLUTCH REMOVAL AND INSPECTION. . . . . . .3.19

CRANKSHAFT NUT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20

CLUTCH COVER / CLUTCH REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . 3.20

SHIFTER COMPONENT REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 3.22

OIL PUMP REMOVAL AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23

CRANKSHAFT DRIVE AND CAM GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23

CAM CHAIN / TENSIONER BLADE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24

CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24

CRANKCASE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25

CRANKCASE BEARING INSPECTION / REMOVAL / INSTALLATION . . . . . . . . . . . .3.25

TRANSMISSION AND CRANKSHAFT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26

TRANSMISSION REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26

TRANSMISSION MAIN SHAFT DISASSEMBLY / ASSEMBLY. . . . . . . . . . . . . . . . . . . 3.26

TRANSMISSION REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27

CRANKSHAFT REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29

CRANKSHAFT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29

3.1

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ENGINE

RepairPro Service Manual

ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30

CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30

PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31

PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31

CYLINDER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32

CAM CHAIN INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32

CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32

PRIMARY DRIVE GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33

OUTLAW CAM TIMING EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

CYLINDER HEAD SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35

CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35

CYLINDER HEAD WARP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35

CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35

CYLINDER HEAD VALVE GUIDE / VALVE SEAT INSPECTION . . . . . . . . . . . . . . . . .3.36

VALVE GUIDE REMOVAL / INSTALLATION / REAM. . . . . . . . . . . . . . . . . . . . . . . . . .3.36

VALVE SEAT RECONDITIONING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37

VALVE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39

ES50PL ADJUSTING PAD SELECTION MATRIX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40

CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41

CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

PISTON–TO–CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43

CYLINDER HONE SELECTION AND HONING PROCEDURE. . . . . . . . . . . . . . . . . . . 3.43

HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43

PISTON RING INSTALLED GAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44

WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

OIL SEAL / MECHANICAL SEAL REMOVAL (ENGINE DISASSEMBLED) . . . . . . . . . 3.44

WATER PUMP MECHANICAL SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

MECHANICAL SEAL REMOVAL AND INSTALLATION (ENGINE ASSEMBLED) . . . . 3.45

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.46

SPARK PLUG FOULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.48

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48

3.2

Page 50

ENGINE

SPECIFICATIONS

Torque Specifications

ES50PL

Fastener Thread ES50PL: Ft. Lbs. (Nm)

Blind Plug (Crankcase) 1/8 PT 6.6–11.1 (9–15 Nm) Blind Plug (Oil Filter Cover) 1/4 PT 12.5–17 (17–23 Nm) Bearing Stop Plates 6mm 8.1–9.6 (11–13 Nm) Camshaft Chain Tensioner Blade Bolt 8mm 10–12.2 (13.5–16.5 Nm) Camshaft Chain Tensioner 6mm 6.6–8.1 (9–11 Nm) Camshaft Chain Tensioner Cap 6mm 6.6–8.1 (9–11 Nm) Camshaft Support 8mm 6.6–7.5 (9–10 Nm) Carburetor Adaptor 8mm 11.8–14.8 (16–20 Nm) Crankcase Cover 8mm 6.6–8.1 (9–11 Nm) Crankshaft Nut (Primary Drive Sprocket) 18mm 81–96 (110–130 Nm) Crankshaft Nut (Ball Bearing at Crankshaft) 32mm 66–81 (90–110 Nm)

Cylinder Base / Head Bolts Clutch Basket Nut 18mm 66–81 (90–110 Nm)

Clutch Cover 6mm 6.6–8.1 (9–11 Nm) Drive Sprocket and Sprocket Cover 6mm 6.6–8.1 (9–11 Nm) Flywheel (Apply engine oil to threads) 14mm 111–125 (150–170 Nm) Neutral Indicator Switch 5mm 2.2–3.7 (3–5 Nm) Oil Delivery Pipe 12mm 11.1–15.5 (15–21 Nm) Oil Drain Bolt (Crankcase) 14mm 14–17 (19–23 Nm) Oil Filter Cover Housing and Oil Pump Case 6mm 6.6–8.1 (9–11 Nm) Oil Hose Fittings 8mm 8.1–10.3 (11-14 Nm) One Way Valve Plug 11mm 11.1–15.5 (15-21 Nm) One Way Clutch Screws 6mm 9.6–11.1 (13–15 Nm) Pulser Coil (Apply PN2871557 to threads) 5mm 1.8–2.6 (2.5–3.5 Nm) Pressure Plate Screws 6mm 6.6–8.1 (9–11 Nm) Shift Cam 6mm 5.9–7.4 (8–10 Nm) Shift Lever 6mm 6.6–8.1 (9–11 Nm) Shift Detent Arm (Apply PN 2871557 to threads) 6mm 6.6–8.1 (9–11 Nm) Stator Housing Cover 6mm 6.6–8.1 (9–11 Nm) Stator Plate 5mm 4.1–5.8 (5.5–6.5 Nm) Starter Motor 6mm 6.6–8.1 (9–11 Nm) Spark Plug 12mm 11.1–14.8 (15–20 Nm) Timing Cover Plug (Center) 32mm 7.4–8.8 (10–12 Nm) Timing Cover Plug (Timing window) 14mm 2–4 (3–5 Nm) Thermo Cover 6mm 5.2–6.6 (7–9 Nm) Thermo Switch 3/8 NPT 23.6–28 (32–38 Nm) Valve Cover 6mm 6.6–8.1 (9–11 Nm) Water Pump Impeller 6mm 6.6–8.1 (9–11 Nm) Water Pump Housing Cover 6mm 6.6–8.1 (9–11 Nm) Radiator Thermistor -- 8 ±12 in.lbs. (0.8 ± 1.36 Nm)

11mm

6mm

Refer to Page 3.42

6–8 (9–11 Nm)

3.3

Page 51

ENGINE

RepairPro Service Manual

ES50PL Engine Service Data

Cylinder Head / Valve ES50PL

Camshaft

Cylinder Head

Va lve Seat

Valve Guide

Valve

Valve Spring

Cam lobe height

Camshaft journal OD

Camshaft journal bore ID

Camshaft Oil clearance

Surface warpage limit .0020” (.05 mm) Standard height 4.975” (126.4 mm)

Contacting width **Measure valve stem height

Inner diameter .2362- .2367” (6.0- 6.012 mm) Protrusion above head .535- .551” (13.6- 14.0 mm)

Margin thickness

Stem diameter

Stem oil clearance

Overall length

Valve Lash Overall length

Limit = -.079” (-2.0 mm) Squareness

Std Limit .0059” (.15 mm)

Std 1.667–1.671” (42.35–42.45 mm) Limit 1.655” (42.05 mm) Std 1.667–1.671” (42.35–42.45 mm) Limit 1.655” (42.05 mm) Mag .9821–.9828” (24.946–24.963 mm) PTO .8652–.8655” (21.976–21.985 mm) Mag .9842–.9851” (25.000–25.021 mm) PTO .8657–.8661” (21.990–22.000 mm) Mag .0014–.0029” (.037–.075 mm) PTO .0001–.0009” (.005–.024 mm) Limit .004” (.10 mm)

Std 1.5255” (38.75 mm) Limit 1.5425” (39.18 mm) Std 1.5255” (38.75 mm) Limit 1.5377” (39.06 mm)

Std .039” (1.0 mm) Limit .031” (.8 mm) Std .039” (1.0 mm) Limit .031” (.8 mm) In .2343–.2348” (5.950–5.965 mm) Ex .2341–.2346” (5.945–5.960 mm) In .0014–.0024” (.035–.062 mm) Ex .0016–.0026” (.040–.067 mm)

In 4.031” (102.4 mm) Ex 4.059” (103.1 mm) In .006” (.15 mm) +/- .0019” (.05 mm) Ex .010” (.27 mm) +/- .0019” (.05 mm) Inner 1.575” (40.0 mm) Outer 1.650” (41.9 mm) Inner .067-” (1.7 mm) Outer .071” (1.8 mm)

3.4

Page 52

ES50PL Engine Service Data

Cylinder / Piston / Connecting Rod / Crankshaft ES50PL

Surface warpage limit (mating with cylinder head) .002” (.05 mm) Cylinder bore Std 3.9055–3.9062” (99.20–99.22 mm)

ENGINE

Cylinder

Piston

Piston Pin

Piston Ring to ring groove clearance

Piston Ring installed gap

Taper limit .002” (.05 mm) Out of round limit .002” (.05 mm)

Piston clearance

Outer diameter Std 3.9037- 3.904” (99.155- 99.170 mm) Piston Pin Bore Standard I.D. .9055- .9057” (23.001- 23.007 mm) Outer diameter Std .9053- .9055” (23.001 - 23.007 mm) Piston pin to pin bore clearance .0002- .0004” (.001- .0011 mm)

Degree of fit

Top Ring

Second Ring

Top Ring

Second Ring

Std .0018- .0025” (.046- .065 mm) Limit .0039” (.10 mm)

Piston Pin must be a push (by hand) fit at 68

St d .0012–.0028” (.030–.070 mm) Limit .0059” (.15 mm) St d .0012–.0028” (.030–.070 mm) Limit .0059” (.15 mm) Std .008–.012” (.20–.30 mm) Limit .027” (.7 mm) Std .014–.019” (.35–.50 mm) Limit .031” (.8 mm)

F(20o C)

Oil Ring

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

clearance

Connecting Rod

Connecting rod big end side clearance

Connecting rod big end radial clearance

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

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

Std .004–.019” (.10–.50 mm) Limit .039” (1.0 mm)

Std .0003- .0009” (.007- .024 mm) Limit .0020” (.05 mm) Std .0035- .0196” (.09- .50 mm) Limit .0255” (.65 mm) Std .0004- .0015” (.011- .038 mm) Limit Same as standard

3.5

Page 53

ENGINE

RepairPro Service Manual

Special Tools

PART NUMBER TOOL DESCRIPTION

2872105

2200634

2870390 Piston Support Block

PA-45958

PA-46075 Flywheel Puller

PA - 46076

PA-46087 Crankcase Separator

PA-46077

2871283

5131135 Water Pump Install Kit

PA-46502 Valve Spring Compressor

Water Pump Mechanical

Seal Puller

Valve Seat Reconditioning

Kit

Cam Chain Tensioner

Assembly Tool

MAG End Crankshaft Nut

Remover/Installer

MAG End Crankshaft

Installer

Crankshaft/Water Pump

Seal Install Kit

Engine Fastener Torque Patterns

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

Cylinder Head & Cylinder Base

5 6

8 mm

GENERAL ENGINE SERVICE

Piston Identification

The piston may or may not have an identification mark for 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: Note the directional and identification marks when viewing the pistons from the top. Identifying marks such as “F”, “J”, “X“or positioned to the flywheel side of the engine. Other marks are used for identification as to diameter, length and design. Four stroke engine rings are a rectangular profile. See text for oil control ring rail installation. Use the information below to identify pistons and rings:

Compression Test

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

Cylinder Compression w / decompression

Standard: 85-90 PSI @ 400 RPM

Q must always be

3.6

Cylinder Leakdown

Service Limit: 10%

(Inspect for cause if leakage exceeds 10%)

Page 54

ENGINE

Coolant Temperature Sensor (Thermistor)

8-12 in. lbs. (.9-1.3 Nm)

Cooling System

FLOW

Radiator

Radiator Cap Pressure Test

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

2. The radiator cap relief pressure is 13 psi. for all models. Replace if cap releases at less than 13 psi.

Pressure test

From Thermostat

To Water Pump

Sensor

Coolant Flow Diagram

here with cap

in place

Thermostat

Cylinder Head

Water Pump

Cylinder

WARNING

Never remove radiator cap when engine is

warm or hot. The cooling system is under

pressure and serious burns may result.

Allow the engine and cooling system to cool

before servicing.

Radiator Cap / System Pressure Test

1. Remove recovery bottle hose from coolant filler neck.

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

Cooling System Specifications

Description Temperature

Fan Switch (Off) Fan Switch (On)

Hot Light On

System Capacity 2.25 Quarts (2.1 L)

Radiator Cap Relief

Pressure

Recommended Coolant Type

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.

IMPORTANT: 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 (PN 2871323) is re commended for use in all cooling systems and comes pre–mixed, ready to use.

F (65o C) ± 8

150 180o F (82o C) ± 7

221

F (105o C)

13 PSI

o o

3.7

Page 55

ENGINE

RepairPro Service Manual

Accessible Components

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

• Flywheel

• Alternator/Stator

• Starter Motor/Starter Drive

• Water Pump / Water Pump Mechanical Seal*

*Mechanical W ater Pump Seal Removal Tool (PN 2872105) is required to replace mechanical seal with engine in frame.

The following components require engine removal for service:

• Counterbalance Shaft or Bearing(s)

• Connecting Rod

•Crankshaft

• Crankshaft Main Bearings

• Cylinder Head

• Cylinder

• Piston/RIngs

• Camshaft

•Cams

• Cam Chain and Sprockets

• Transmission Gears and Bearings

Engine Removal

1. Thoroughly clean the ATV engine and chassis.

2. Clean work area.

3. Support the ATV with jackstands under the footrests at a height sufficient to raise the rear wheels off the floor at least 5 inches (12.7 cm).

4. Drain coolant and engine oil.

5. Remove the following components:

• Seat

• Side Panels

• Front Cab (Refer to Chapter 5)

• Fuel Tank (Refer to Chapter 4)

• RH footwell (Refer to Chapter 5)

6. Disconnect battery cables, starting with the negative (–) cable first.

7. Remove air in tak e du ct.

8. Remove carburetor. Caution: Fuel will leak if carb is turned upside down. In most instances, the carburetor will not have to be disconnected from the throttle cable, choke cable and fuel line for engine removal. Insert a shop towel into the carburetor flange to prevent dirt from entering the intake of the engine.

9. Disconnect all electrical connections to the engine (coolant sensor, neutral switch, plug wire, starter cable, ground cable). Remove the magneto side cover, leaving the electrical components attached, and secure out of the way.

10. Remove clutch and reverse cable linkage and secure out of the way.

11. Remove fasteners from exhaust pipe and remove header pipe.

12. Remove oil tank and hoses as an assembly. Dis connect vent line and secure out of the way.

13. Loosen chain, disconnect and remove. An acceptable alternative is to remove the transmission drive sprocket and roll chain off.

14. Remove all engine mount nuts and engine mount plates, starting at the rear with the combination engine / swing arm pivot mount first. Using a suitable tool, push the bolt out far enough to loosen the engine, but not drop the swing arm pivot. Use a jack under the bearing carrier to relieve tension from the pivot bolt for easier removal and installation.

15. With an assistant helping you, remove the engine by tilting forward and turning to exit through left side of frame.

3.8

To reinstall the engine, reverse the procedures. Refer to engine installation notes on Page 3.9.

Page 56

ENGINE

Engine Installation Notes

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

General Items

• Torque Rear Engine Lower Mount to 90 ft. lbs.

(122 Nm)

• Torque Front Engine Lower Mount to 27 ft. lbs. (33 Nm)

• Torque Top Engine Mount to 22 ft. lbs. (30 Nm)

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

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

• Verify clutch and lever freeplay according to procedures in Chapter 2.

• Adjust chain tension according to procedures in Chapter 2.

Exhaust

Engine Break In Period

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

New and rebuilt engines require a break-in oil change at 1 hour of engine run time.

OIL RECOMMENDATION

Polaris PS-4 All Season synthetic oil is specially

formulated for use with wet-clutch transmissions.

Never substitute or mix oil brands. Serious engine

damage and voiding of warranty can result.

For new or rebuilt engines, do not operate at full

throttle or high speeds for extended pe riods during the

first three hours of use. Excessive heat can build up

and cause damage to close fitted engine parts.

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

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

• Replace exhaust gaskets. Seal connections with high

temp silicone sealant if applicable.

• Verify all fasteners are in good condition and torqued

properly.

Bleed Cooling System

NOTE: Refer to Page 3.7 for hose routing. Bleeding generally is necessary after repairs to purge an y air that may remain in the system during filling.

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

2. Fill coolant reservoir tank to full mark.

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

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

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

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

ADD 8 OZ

SAFE

3. Drive slowly at first to gradually bring engine up to operating temperature.

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

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

6. Pull only light loads during initial break in.

7. Change break in oil and filter at 1 hour or 100 miles.

3.9

Page 57

ENGINE

RepairPro Service Manual

Crankshaft Straightening

Lubricate the bearings and clamp the crankshaft securely in the crankshaft alignment fixture. Refer to the illustrations below.

Crankshaft Alignment Fixture

(PN 2870569)

NOTE: The rod pin position in relation to the dial indicator position tells you what action is required to straighten the shaft.

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

HIGH .004 (.1 mm)

3. If the cran k rod pi n location is 180 (opposite that shown), it will be necessary to spread the crankshaft at position A as shown in the illustration below. When rebuilding and straightening a crankshaft, runout must be as close to zero as possible.

HIGH .002 (.05 mm)

NOTE: Maximum allowable runout is .0024”.

from the dial indicator

HIGH .005 (.13 mm)

ES50PL Engine Lubrication

SUPPORT CRANKSHAFT HERE

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

HIGH .002 (.05 mm)

HIGH .005 (.13 mm)

Oil Type:

Polaris PS-4 Synthetic (PN 2874414)

Capacity:

Approximately 2.25 U.S. Quarts (2.1L)

Filter:

(PN 3088036)

Drain Plug / Screen Fitting:

14.8 - 17 ft. lbs. (20-23 Nm) (If fitting is removed, follow oil pump priming procedure).

Oil Pressure Specification: 20 PSI @ 5500 RPM, Polaris PS-4 Synthetic (Engine Hot)

Oil Pressure Test

1. Remove bl ind plug on front right oil filter cover.

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

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

NOTE: Use only Polaris PS-4 Synthetic Engine Lubricant (PN 2874414).

3.10

Oil Pressure at 5500 RPM (Engine Hot):

Standard: 20 PSI Minimum: 12 PSI

Page 58

ENGINE

Oil Pump Priming Procedure

NOTE: The oil pump priming procedure should be performed as a safeguard against loss of pump prime when repairing oil tank, lines or engine.

1. Clamp or pinch off vent line approximately 2” from oil tank, between the end of oil tank vent fitting and the vent line.

2. Run engine for 5-10 seconds at IDLE.

IMPORTANT: Do not raise rpm or run for more than 10 seconds. Damage to tank may result.

3. Shut off engine. Remove the vent line clamp. The oil pump should now be properly primed and ready for field operation.

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

Oil Flow - ES50PL

The chart on Page 3.12 describes the flow of oil through the ES50PL engine. Beginning at the oil tank, the oil flows through a screen fitting in the bottom of the tank and into the oil supply hose. The feed side of the oil pump draws oil through the hose and into the crankcase oil gallery, pulling 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. Oil is then pumped to the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.

At this point, the oil is diverted in three directions. Oil is supplied to the crankshaft through a PTO side oil passage, lubricating the crank bearings, crank pin, piston, cylinder and connecting rod bearings. A delivery pipe supplies oil to the top of the cylinder head and the transmission main shaft. Oil is delivered though the pipe and enters the camshaft through the cam support oil gallery. The camshaft journals are lubricated through holes in the camshaft. Oil lubricates the cam chain sprockets and cam lobes via an oil jet, which drains to the crankcase.

Another oil path flows from the delivery pipe to the transmission main shaft. Here it passes through the oil gallery to lubricate the transmission gears, clutch and bearings.

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

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

3.11

Page 59

ENGINE

RepairPro Service Manual

ES50PL Oil Flow Chart

Top of Oil Tank

Oil Tank

Oil Hose

Crankcase (Mag Side)

Oil Gallery

Crankcase (Clutch Side)

Oil Gallery

Oil Pump

Prevents oil from

draining into crankcase with engine off

(Feed)

One Way Valve

Indirect Lubrication

Crankcase (Mag Side)

Oil Gallery

Cylinder

Piston

Connecting Rod

(Small End)

Large End

Bearing

Crankcase (Clutch Side)

Ball Bearing

(Mag Side)

Oil Gallery

Oil Jet

Crankcase

Cam Chain

Cam & Crank Sprocket

Chain Room

Cam Lobe Valve Lifter

Oil Pump

(Scavenging)

Oil Strainer

Cam Shaft

Journal

Bypass

3.12

Oil Filter

Delivery Pipe

Oil Shaft

Transmission

Main Shaft

Transmission Counter Shaft

Indirect Lubrication

Crank Pin

Crankshaft

Gears

Gears & Clutch

Gears

Cam Support

Oil Gallery

Cylinder Head

Oil Gallery

Page 60

ES50PL Engine Exploded Views

Crankcase / Transmission

ENGINE

Cylinder / Cylinder Head

Crankshaft and Piston

Valve Train

3.13

Page 61

ENGINE

RepairPro Service Manual

UPPER ENGINE DISASSEMBLY

Disassembly

REFER TO PAGE 3.8-3.9 FOR ENGINE REMOVAL / INSTALLATION NOTES

Cam Chain Tensioner Removal

1. Remove ignition timing inspection plug from recoil housing.

To position crankshaft at Top Dead Center (TDC) on the 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 for the camshaft sprocket marks and the indicator mark in the timing inspection hole.

TDC

Case Mark

6. If tensioner remains in place, tap lightly on tensioner body with a soft face hammer and remove tensioner.

CAUTION

The assembly is under spring tension.

Maintain inward pressure while removing.

7. For installation, retract the plunger using the special tool and reverse the installation procedures using a new gasket. Tighten bolts to specification. (Page 3.3)

Cam Chain Tensioner Inspection and Reassembly

NOTE: The cam tensioner assembly is not a serviceable item. Replace assembly if problems are found. Spring tension may be relieved using the special tool prior to removal, but is not necessary.

TDC Line

(Left of the “T”)

4. Align the indicator mark on flywheel with the indent in the inspection hole and the cam sprocket marks (facing upward) aligned with the dots at the 12 o’clock and 9 o’clock positions.

NOTE: The cam lobes should be laying flat and the valves have clearance at this point.

5. Remove the two 8 x 25 mm cam chain tensioner flange bolts.

A- Tool PN PA-45958

B- 10mm tensioner cap

1. When removed, the cam chain tensioner plunger should be extended outward to the end of its travel. Verify and inspect the plunger for wear or damage.

2. Push on the plunger. The plunger should not move in and out of the tensioner body.

3. To release the plunger tensi on and prepare for reassembly, remove the 10mm plug and insert the Cam Chain Tensioner Tool (PA-45958), lodging the tip of the tool into the spring

Tool PA-45958

IMPORTANT

Maintain Clearance

while rotating tool

3.14

Page 62

ENGINE

4. To retract the plunger, rotate the special tool clockwise while holding the tensioner stationary. You may also hold the special tool stationary and rotate the tensioner assembly counterclockwise if desired.

IMPORTANT: Do not grind edges of key flange into tensioner to prevent damage to the tool or locking guides during plunger retraction.

5. Once retraction is complete, lock the tool into the tensioner guides. This holds the spring and plunger in place for reassembly. Use caution not to disturb the tool during tensioner installation.

4. To free the cam assembly, lift one cam assembly and slightly rotate it while removing the chain from the cam gear. Repeat this procedure for the other cam.

NOTE: Do not allow cam chain to drop into the engine if no other disassembly is being performed.

5. Use a device to secure the cam chain, such as mechanic’s wire or nylon line, to prevent it from falling into the engine.

6. Inspect cam sprocket teeth for wear or damage. If damage is found, replace the camshaft assembly.

Inspect for Areas of Tooth

Wear or Damage

6. Reinstall the tensioner assembly, torquing the bolts to specification (Page 3.3). Remove the special tool and replace the tensioner cap.

Tensioner Bolt Torque

6.6- 8.1 ft lbs (9- 11 Nm)

Camshaft Removal

1. Remove the valve cover.

2. Remove the tensioner assembly.

3. Remove the 8 bolts securing the cam tower assembly and remove the cover.

Automatic Compression Release Inspection

NOTE: The automatic compression release mechanism cannot be serviced. The components are not replaceable. Replace the camshaft as an assembly if any part of the compression release is worn or damaged.

Note: Cam and compression release are

an assembly and not serviceable.

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

2. Inspect lobe on end of release cam for wear. Replace cam assembly if necessary.

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Camshaft Inspection

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

NOTE: Camshafts, gears and bearings are not serviceable. Replace camshaft as an assembly if problems are found.

2. Inspect the cam bearings for excess play or noise during rotation.

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

Camshaft Lobe Height

Limit: 1.6555ð (42.05 mm)

5. Measure ID of camshaft journal bore.

Camshaft Journal I.D.:

Mag End: .9842- .9851ð

(25.00- 25.021 mm)

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

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

Camshaft Oil Clearance

Limit: .0039ð (.10 mm)

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

Cylinder Head Removal

1. Remove the cam shafts.

2. Remove the two 8mm flange bolts (A) from cylinder head.

3. Loosen each of the four cylinder head bolts (B) with a 14mm 12-point socket, turning evenly 1/8 turn each time in a criss–cross pattern until loose.

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

Check for wear or roughness

Journal O.D.

Camshaft Journal O.D.:

Mag End: .9821- .9828ð

(24.946- 24.963 mm)

4. Remove bolts (B) and tap cylinder head lightly with a softface hammer until loose.

CAUTION

Tap only in reinforced areas or on thick parts of

cylinder head casting to avoid

damaging the head.

5. Remove cylinder head and head gasket.

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Cylinder and Piston Removal

NOTE: Follow engine disassembly procedures to remove valve cover, camshafts and cylinder head. Removal of clutch basket is required for this procedure.

1. Using a 9/32” (7mm) Allen wrench, remove the rear cam chain tensioner blade from the cylinder.

2. Loosen the 3 oil pipe banjo bolts, remove the bolts and sealing washers. Remove the pipes.

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

5. Remove dowel pins from crankcase.

Piston Removal

1. Remove circlip. Note piston directional aid that is pointing toward the left (stator) side of engine.

Directional Aid

2. Remove piston circlip and push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch to aid removal.

IMPORTANT: Do not apply heat to the piston rings. The ring may lose radial tension.

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

3. Remove top compression ring:

*Using a piston ring pliers: Carefully expand ring and lift it off the piston. *By hand: Placing both thumbs as shown, spread the ring open and push up on the opposite side. Take care to not scratch the ring lands.

IMPORTANT: Do not expand the ring more than the amount necessary to remove it from the p iston, or the ring may break.

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4. Repeat procedure for second ring.

5. The oil control ring is a three piece design consisting of a top and bottom steel rail and center expander section. Remove the top rail first followed by the bottom rail, then remove the expander. For installation, refer to Page 3.31.

Piston and Rod Inspection

1. Measure piston pin bore.

Piston Pin Bore

Piston Pin Bore:

.9055- .9057

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

″ (23.001- 23.007 mm)

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

Piston

Ring

Feeler Gauge

Piston Ring-to-Groove Clearance

Top Ring Limit: .0059

Second Ring Limit: .0059

4. Measure connecting rod small end ID.

″ (.15 mm)

3.18

Piston Pin Measurement Locations

Piston Pin O.D.

.9053- .9065

″ (22.994- 23 mm)

Small End I.D. :

Std: .9058- .9063

″ (23.007- 23.020 mm)

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LOWER ENGINE DISASSEMBLY

Crankcase Disassembly and Inspection

NOTE: The starter motor, starter drive gears, flywheel, stator, cam chain and sprockets can be serviced with the engine in the frame.

NOTE: Crankcase and transmission components cannot be serviced in the frame. Upper engine components, with the exception of the starter and stator removal, must be disassembled prior to performing these procedures.

Starter Drive Gears Removal and Inspection

1. Remove the starter.

2. Remove the 12 bolts holding the stator cover assembly.

5. Measure the ID of the bushing in the stator housing (A) and the crankcase and record. Measure in two directions 90° apart to determine if cover is out of round. Replace cover if clearance is determined to be excessive.

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

7. Installation: Reverse the removal procedures and install with a new gasket. Do not use sealant. Torque the bolts in a criss-cross pattern to 80–97 in. lbs. (9–11 Nm).

Flywheel / One-Way S tarter Clutch Removal and Inspection

3. Inspect the drive gears and shafts for wear or damage and replace if necessary.

4. Measure the OD of the starter drive shafts on both ends and record. Measure in two directions 90° apart to determine if components are out of round. Replace if components are worn or damaged.

1. Remove flywheel nut and washer.

2. Install Flywheel Puller (PA-46075) and remove fl ywheel.

IMPORTANT: Thread the puller onto the flywheel fully or flywheel threads may be damaged.

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3. Removing the flywheel exposes the starter drive main gear and one way clutch, which is mounted on the flywheel. Inspect the main gear and bearing for wear, broken teeth or other damage. Inspect the one-way clutch for wear or damage to the rollers, springs, etc. Replace one-way assembly if excessive wear or damage is found.

4. To replace the one-way starter clutch, remove the 8 screws (A) holding the assembly to the flywheel. Reinstall the screws and torque to 155-133 in. lbs. (13-15 Nm) in a crisscross pattern.

Crankshaft Nut Removal

1. Remove the stator-side crankshaft nut using MAG End

Crankshaft Nut Remover/Installer (PN PA-46076) while using a suitable holding fixture to keep the crankshaft from turning.

2. To reinstall, use a suitable holding fixture and MAG End Crankshaft Nut Remover/Installer (PN PA-46076) to torque the nut to 66-81 ft. lbs. (90–110 Nm).

Clutch Cover / Clutch Removal and Inspection

5. Installation: For installation of flywheel and starter gears, reverse the removal procedures. When installing the flywheel, apply engine oil to the crankshaft threads and torque the flywheel nut to 111-125 ft. lbs. (150-170 Nm).

1. Remove the 12 screws holding the clutch cover.

2. Remove the gasket. Clean the gasket surfaces prior to reassembly.

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3. Inspect or replace the crankshaft oil seal anytime the clutch cover is removed for service. Install with the seal lip pointed in toward the cover.

4. Remove the 6 screws holding the clutch pressure plate.

NOTE: The top clutch plate should rest in the towers.

CAUTION

Assembly is under spring pressure. Wear safety

glasses during removal.

NOTE: Top Clutch Plate Aligns In Basket Towers

6. Remove the clutch plates and friction discs, keeping them in order. Inspect the pressure plates for wear and warpage . Inspect the friction plates for wear or damage to friction material. If either are damaged or worn excessively, replace the components as a set.

NOTE: Replace clutch pack if measured thickness of friction material is less than .110” (2.8mm). The top plate has slightly different friction pads and should always be installed on top.

NOTE: Top Clutch Plate Aligns In Basket Towers

Top

7. To remove the clutch basket, remove the plunger from the center of the clutch and de-stake the nut to avoid damaging the threads upon removal.

5. Remove and inspect the clutch pressure plate for wear, cracks, etc. Check bearing for wear and smooth rotation. Replace either component if found to be damaged or worn.

NOTE: Nut is staked on flat of transmission shaft

8. Installation: Reverse the procedures. Using a new nut, torque the clutch basket retaining nut to 66-81 ft. lbs. (90110 Nm). Stake the nut at the flat on the transmission shaft. Install the clutch plates in order of removal. Reinsert the plunger into the shaft. Reinstall the cover, pressure plate screws and springs. Torque the screws to 80–97 in. lbs. (9–11 Nm).

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Shifter Component Removal and Inspection

1. With the clutch basket removed, remove the shift shaft assembly (A), guide plate (D), pawl assembly (B), and stopper arm / detent spring assembly (C).

CAUTION

Stopper arm (C) is under spring pressure.

Use care during removal.

3. Inspect the ratcher pawls (F), pawl plungers (G), plunger springs (H), shifter collar (J), shifter drum (K) and guide plate (L) for wear or damage. Replace if wear or damage is evident.

4. Installation: Reverse the procedures, paying close attention to the orientation of the ratcher pawls (F) during installation, as the surface must be flat when the pawls are installed correctly. The guide plat (L) should be installed with the “dot” facing upward. Torque the guide plate bolts, the detent spring assembly bolt and the shifter pin bolt (E) to 80–97 in. lbs. (9–11 Nm).

2. Remove the shift cam by loosening the shifter pin bolt (E).

Correct for installation - Flat Surface

Correct for installation

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Oil Pump Removal and Inspection

1. Remove the circlip holding the oil pump gear and remove the gear.

2. Remove the 3 bolts holding the oil pump cover. Inspect the inside of the cover for wear or scoring.

NOTE: Dowel pins for the inner pump body are loose and may become lost. Keep pins in a secure location.

5. Replace any component that is found to be damaged or worn.

OIL PUMP CLEARANCE

Limits are same as Standard

Body Feed / Scavenge .006-.008” .15 - .21mm

3. Remove the outer pump rotor assembly. Inspect for signs of scoring or excess wear.

NOTE: Cross pins for the pump rotors are loose and may become lost. Keep pins in a secure location.

4. Remove the inner pump chamber and pump rotor assembly. Inspect these components for wear or scoring.

Rotor Tip Feed / Scavenge Less than .006”

Rotor Side Feed .0007-.003” .02 - .08mm

Scavenge .002-.006” .05 - .16mm

6. Installation: Reverse the procedures. Use assembly lube or clean engine oil to coat the parts before assembly. Tighten the cover bolts to 80–97 in. lbs.(9–11 Nm). Verify the pump turns freely during and after torquin g bo lts.

Less than .15 mm

Crankshaft Drive and Cam Gear Removal

1. Remove the crankshaft nut, washer and drive gear. Note and white-mark the double spline on both g ears and shaft for ease of reassembly.

Double Spline

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2. Remove the cam gear and thrustwasher from the crankshaft for inspection. Replace if damage or excessive wear is present to the gear teeth or splines.

3. Installation: Reverse the procedures and torque nut to 81– 96 ft. lbs. (110–130 Nm).

Cam Chain / Tensioner Blade Removal

1. Remove bolt (A) securing tensioner pivot blade to crankcase . Inspect for cracks, wear, or damage.

2. Remove cam chain (B). Inspect chain for wear, 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 (pin) section of chain. Replace if worn past service limit.

Crankcase Separation

1. Remove the 13 flange bolts. 12 from the magneto side and

1 from the clutch side of the crankcase

cross pattern.

2. Remove the shifter assembly and shift cog that is attached to the shift drum (Items A-E).

evenly in a criss–

Chain Service Limit:

5.407” (13.7 cm)

3. Installation: Reverse the procedures and torque the pivot blade bolt to 10–12.2 ft. lbs. (13.5–16.5 Nm).

4. See Page 3.32 for Cam Timing.

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3. Separate crankcase by tapping with a soft faced hammer in reinforced areas. W atch the gap along the crankcase mating surface, making sure to separate the crankcase evenly. It may also be necessary to tap the clutch side of the crankshaft lightly to help separate the crankcase.

4. The crankshaft is designed to slip out of the P TO side upon disassembly. Once the crankcase halves are split apart, orientate the components into the stator side of the crankcase containing the crankshaft, balancer, oil gallery, the transmission gears and shift components for ease of service and reassembly.

Crankcase Inspection

1. Remove all traces of gasket sealer from the crankcase mating surfaces. Inspect the surfaces closely for nicks, burrs or damage.

2. Check the oil pump and oil passage mating surfaces to be sure they are clean and not damaged. Verify the oil pump screen is clean.

Crankcase Bearing Inspection / Removal / Installation

1. Inspect the crankshaft main bearings, balancer shaft bearings, output shaft, and pump shaft bearings.

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

Bearing Removal:

NOTE: To ease bearing removal, warm the bearing area, but not the bearing itself, until hot to the touch to expand the bearing cavity.

CAUTION

Wear the appropriate safety equipment during the

heating and removal process.

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

2. T o 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!

Bearing Installation:

NOTE: For ease of bearing installation, warm the crankcase until hot to the touch to expand the bearing cavity. Place the bearings in a freezer. This shrinks the bearing outer diameter slightly.

CAUTION

Wear the appropriate safety equipment during the

heating and installation process.

1. Install the bearings so the numbers are visible.

2. Drive or press new bearings into the crankcases, using the proper driver.

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

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RepairPro Service Manual

TRANSMISSION AND CRANKSHAFT SERVICE

Transmission Removal and Inspection

1. Remove the shift fork tubes, spring, shift forks, and shift drum from the transmission assembly.

2. Remove the main and output transmission shaft assemblies and disassemble, keeping the parts in order for ease of reassembly. Inspect the shift forks, shift drum, shift dogs, gear teeth and shaft splines for damage. If the mating surfaces on any of the components are found to be rounded, worn, or otherwise damaged, they must be replaced.

Main Shaft Assembly

3. Inspect the shaft support bearings in the crankcase halves. Replace if any roughness or wear is felt. See page 3.25 for crankcase bearing inspection / removal.

4. To reassemble, reverse the procedures using the photos for reference.

Transmission Main Shaft Disassembly / Assembly

CAUTION

These procedures require the use of a heat

source and hydraulic press to remove and install

components. Wear the proper protective and

safety gear to prevent injury.

1. Attach a bearing splitter to the reverse gear ONLY as shown. DO NOT apply a load to 4th gear, as damage will result. Place the assembly into a hydraulic press and using a suitable driver, press off the gear.

3.26

Output Shaft Assembly

2. Remove the parts from the shaft, keeping them in order for ease of reassembly. Inspect all the main shaft compon ents for signs of damage or wear. If the mating or rolling surfaces on any of the components are found to be rounded, worn, or otherwise damaged or rough, they must be replaced.

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ENGINE

3. T o reassemble the main shaft, install the components in the order removed.

4. Before pressing the reverse gear onto the main shaft, heat the reverse gear in an oil bath if desired. This will expand and ease pressing of the gear to the specified dimension.

CAUTION

This procedure requires the use of a heat source and

hydraulic press to install components. Wear the

proper protective and safety gear to prevent injury.

5. Support the mainshaft as shown with flat blocks. Press ONLY on the reverse gear until the total width of the gear set measures 120.4 ± .2mm (4.74 ± .008

″) as shown.

1. Insert t h e output shaft assembly, minus the outer gear the stator side casehalve. Do not insert outer gear or shift fork pins at this time.

2. Insert the reverse gear shaft assembly . Verify the alignment pin (A) has seated into the casehalf.

into

Main Shaft Gear Set Width

120.4 +

.2 mm (4.74 + .008″)

Transmission Reassembly

NOTE: Installation of the transmission assemblies can be facilitated by constantly rocking or moving them to reduce binding during assembly.

NOTE: Do not to allow transmission parts to fall from their assemblies during installation. Parts that are out of alignment will cause improper casehalf mating, resulting in transmission binding. Use of assembly lube to “stick” parts together for ease of installation is recommended.

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3. Install the main shaft assembly. The outer gear can now be installed. Verify the shallow side of the outer gear is facing out during installation.

5. Insert and rotate the shift drum so the alignment pin is approximately at the 5 o’clock position. Insert the fork pins into their respective cam followers, installing each fork shaft as they are assembled. Lifting of forks and gears wi ll be required to align pins into the shift drum.

Pin Position

NOTE: The output fork shaft contains a spring that must be inserted before assembly. See Photo.

Spring

4. Install the shift forks. Verify that each fork pin is pointed toward the shift drum.

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Crankshaft Removal / Installation

To remove crankshaft:

1. Remove the crankshaft retaining nut using Crankshaft Nut

Remover / Installer (PA-46076).

2. Remove the crankshaft bearing retainer screws using a impact driver at location (A).

NOTE: Screw threads contain locking agent. Heating of screws is required for removal. Use caution and wear the proper safety equipment while performing this procedure.

PTO side shown for clarity

3. Support the stator side crankcase in a stand to press the crankshaft out. Use care not to damage the crankcase mating surface or connecting rod. Applying heat to the crankcase bearing area to ease removal is acceptable.

4. Attach Crankcase Separator (PA-46087) to the casehalve. Turn the inner shaft clockwise while holding the outer shaft to press the crankshaft and bearing as an assembly out of the case.

PA-46087

Verify that all bolts are fully threaded to avoid damage to the case

6. Using MAG End Crankshaft Installer (PA-46077), draw

the crankshaft into the bearing assembly by sliding the collar and thrustwasher over the crankshaft end, threading the inner puller onto the crankshaft end. Turn the outer nut clockwise while holding the inner to pull the crankshaft into the bearing.

PA-46077

Inner Puller Outer Puller Thrust Washer

Collar

Crankshaft Inspection

NOTE: Larger than standard readings indicate excessive wear.

NOTE: Crankshaft components are press-fit and are serviceable.

1. Inspect the crankshaft connecting rod bearing journal for scoring and abnormal wear.

2. Use a feeler gauge to measure the connecting rod big end side clearance.

To install crankshaft:

5. Press the bearing into the crankcase at the outer edges with

an appropriate driver. Insert the bearing retainers and new screws, which have a pre-applied locking agent. T orque the screws to 8.1–9.6 ft. lbs. (11–13 Nm).

Connecting Rod Big End Side Clearance:

Limit: .0256

″ (.65 mm)

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3. Place the crankshaft in a truing stand or V–blocks and measure the runout on both ends with a dial indicator. See Crankshaft Straightening on Page 3.10.

Max Runout: .0012″ (.03 mm)

4. Measure the connecting rod big end radial clearance.

Big End Radial Clearance:

Limit: .0004- .0015

″ (.011- .038 mm)

3. Reassemble the crankcase halves. This is best accomplished with the stator side casehalve settled in a suitable fixture that allows it to lay flat. This allows easier installation without parts falling out of position. Make sure the oil gallery tube is oriented correctly and the balancer shaft groove aligns with the water pump shaft. Refer to photos.

NOTE: Some light tapping with a soft faced mallet may be required to bring the casehalves together. If for any reason the cases fail to mate, DO NOT FORCE. Reverify the transmission assemblies are fully seated in their respective case half and are not binding.

Align balancer shaft and water pump shaft grooves

5. Measure the connecting rod small end radial clearance.

Small End Radial Clearance:

Limit: .0020

6. Measure the connecting rod small end I.D.

Small End I.D. :

Std: .9058- .9063

″ (.05 mm)

″ (23.007- 23.020 mm)

ENGINE REASSEMBLY

Crankcase Reassembly

1. Apply a thin layer of Crankcase Sealer (PN 2871557) to all

sealing surfaces of the PTO case half, being careful not to over apply, as excessive sealant may clog oil passages or drip into the crankcase. Allow the sealer to set for a few minutes before assembling the two halves together.

2. Align the crankshaft and balancer timing marks and insert the components into the stator-side case halve. Then install the oil tube and transmission assemblies.

Verify pin is aligned with notch in case

4. Reinstal l the (12) stator side and (1) clutch side flange bolts, tightening in a criss-cross pattern. Stop occasionally and check that all rotating assemblies turn freely. Torque the flange bolts to 80–97 in. lbs. (9–11 Nm).

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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.

Gap should face up or down

3. Install a new circlip on one side of the piston with the end gap facing up or down.

CAUTION

Circlips become deformed during the removal

process. Do not re–use old circlips. Do not

compress the new clip more than necessary upon installation to prevent loss of radial tension. Severe engine damage may result if circlips ar e

re–used or deformed during installation.

Piston Ring Installation

NOTE: Apply clean engine oil to all ring surfaces and ring lands. Always check piston ring installed gap before rings are installed on piston. If the piston has been in service, clean any accumulated carbon from the ring grooves and oil control ring holes.

1. Place the oil control ring expander in oil ring groove with the end gap facing forward. The expander has no up or down marking and can be installed either way. The ends should butt squarely together and must not overlap. Install the bottom and top rails.

2. Install the second ring with the mark facing up.

3. Install the top ring with the mark facing up.

Ring Profile

Top - Chrome

Install with mark facing up

4. Apply clean engine oil to the piston rings, ring lands, piston pin bore, piston pin, and piston skirt. Lubricate the connecting rod (both ends), balancer drive gear, and crankshaft main bearing area.

Top Side of Piston

Identification Mark

Stator Side

5. Install the piston on the connecting rod with the identification mark facing the stator end of the crankshaft. The piston pin should be a push fit in the piston.

6. Install the other circlip with the gap facing up or down. (see Caution with Step 3 above). Push the piston pin in both directions to make sure the clips are properly seated in the groove.

Second - Cast

4. Check to make sure the rings rotate freely in the groove when compressed.

5. Orientate the rings for installation by rotating until the endgaps are 120 degrees apart.

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Cylinder Installation

1. Place the dowel pins in the crankcase and install a new cylinder base gasket.

PN 2870390

2. Position the Piston Support Block (P/N 2870390) beneath the piston skirt to support the piston during cylinder installation.

3. Apply clean engine oil to the ring compressor and install the compressor according to the manufacturer’s instructions.

IMPORTANT: Verify all ring end gaps are correctly located.

Cam Chain Installation

NOTE: The camshafts, crankshaft sprocket and clutch basket must be removed to perform this procedure.

1. Install the cam chain by dropping it down through the chain room and over the crankshaft sprocket.

2. Use a suitable device to hold the chain in place to keep it from dropping through the chain room, such as wire or a hammer handle.

Camshaft Timing

4. Apply clean engine oil liberally to the cylinder bore and tapered area of the sleeve. Install the cylinder with a slight rocking motion until the rings are captive in the sleeve.

5. Remove the ring compressor and support block.

6. Push the cylinder downward until fully seated on the base gasket.

7. Rotate the crankshaft and position the piston at TDC.

NOTE: If cam chain is installed, hold it up while rotating the engine to avoid damage to the chain, drive sprocket teeth, or tensioner blade.

CAUTION

Serious engine damage will result if the camshaft

is not properly timed to the crankshaft.

IMPORTANT: CAMSHAFT TIMING NOTE The Top Dead Center (TDC) mark is used to time the camshaft to the crankshaft. Follow the procedures outlined. Refer to the diagram.

1. Apply engine oil or assembly lube to the camshaft main journals, cam lobes and the automatic compression release mechanism.

2. Install the crankshaft cam sprocket onto the shaft. Note the double spline for ease of installation. The alignment mark should face outward.

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3. If not already at Top Dead Center, Loosely hold the cam chain and rotate the crankshaft until the crankshaft cam sprocket timing mark is aligned with the Top Dead Center (TDC) mark on the crankcase (see photo). Position the chain for correct timing by aligning the bottom cam timing mark with the brass colored bottom chain link. Keep tension on the chain so as to not lose chain alignment at the crankshaft sprocket during cam installation.

Align Brass Colored Link and Sprocket Mark with Top Dead Center (TDC) Mark

4. Install the camshafts one at a time. First, install the exhaust cam by looping the chain over the cam gear. At the same time, position the cam chain for correct timing by aligning the brass colored chain link with the 12 o’clock dot on the cam sprocket. The sprocket secondary mark should be at the 9 o’clock position. Keep tension on the chain so as to

not lose chain alignment at the crankshaft sprocket.

5. Next, install the intake cam, positioning the upper cam chain for correct timing by aligning the remaining brass colored chain link with the 12 o’clock dot on the cam sprocket. Timing is in phase when all three brass colored cam chain links align with all three sprocket timing marks and the secondary cam gear marks are at approximately the 9 o’clock position, with the exhaust cam timing mark slightly advanced. Refer to the diagram on Page 3.34.

NOTE: Failure to align marks in this fashion will cause valve-to-piston interference, resulting in engine damage.

Align Brass Colored Link and Sprocket Mark with Top Dead Center (TDC) Mark

6. Re-check all cam timing marks to verify proper cam timing, and install the cam tower. Tighten the bolts evenly in a criss-cross pattern to specification. Do not rotate engine

until the tensioner has been installed to avoid chain slip and loss of timing reference.

7. Install the tensioner assembly . ( raefer to Page 3. 14). Verify timing by rotating the crankshaft two full revolutions (720 degrees), checking for valve-to-piston interference which would indicate a problem with cam timing. If interference is noted, immediately stop rotation and reverify cam timing.

NOTE: Rotating the engine during verification will cause the timing alignment marks to rotate out of phase, and will take as many as 20 revolutions to come back into phase. To maintain alignment of the marks if needed, rotate the engine backward the same number of turns as forward.

8. W ith timing procedure completed, install the primary drive sprocket, washer and nut onto the crankshaft. Torque to specification.

Primary Drive Gear Installation

1. Install the cam sprocket with alignment mark outward.

2. W ith chain in place and cam timing having been performed, install the primary drive sprocket, washer and nut onto the crankshaft. Torque to 81–96 ft. lbs. (110–130 Nm).

Note exhaust cam is slightly advanced

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Outlaw Cam Timing Exploded View

3.34

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ENGINE

CYLINDER HEAD SERVICE

Cylinder Head Inspection

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

CAUTION

Use care not to damage sealing surface.

Cylinder Head Disassembly

WARNING

Wear eye protection during cylinder head

disassembly and reassembly.

1. Remove the valve buckets (A).

NOTE: Keep all parts in order with respect to their location in the cylinder head. Use care not to mar or damage the buckets upon removal.

Cylinder Head Warp

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

Cylinder Head Warp Limit:

.002

″ (.05 mm)

2. Under each bucket is a valve shim (B). Record and keep these shims oriented to each valve disassembled.

3. Using Valve Spring Compressor (A) (PA-46502), compress the valve springs and remove the split keepers.

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NOTE: To prevent loss of tension, do not compress the valve springs more than necessary.

4. Remove spring retainer , inner and outer springs and spring washer.

Spring Washer Located

Below Assembly

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

Cylinder Head Valve Guide / Valve Seat Inspection

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

valve seat is cracked the cylinder head must be replaced.

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.

NOTE: The valve springs should be positioned with the tightly wound coils against the cylinder head (B).

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

6. Measure free length of the inner and outer springs with a Vernier caliper. Check springs for squareness. Compare to specifications. Replace inner and outer springs as a set if either measurement is out of specification.

Inner 1.575” (40.0 mm) Outer 1.650” (41.9 mm)

7. Remove the valve seals.

CAUTION

Wear the proper safety equipment when

performing cylinder head service. Valve guide

replacement will require heating of the cylinder

head. Wear safety gloves to prevent burns.

Valve Guide Removal / Installation / Ream

1. Remove all carbon deposits from the combustion chamber, valve seat and valve guide area before attempting to remove valve guides.

IMPORTANT: Carbon deposits are extremely abrasive and may damage the valve guide bore when guides are removed.

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

3. Heat cylinder head in an oven or use a hot plate to bring cylinder head temperature to 212° F (100° C).

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IMPORTANT: Do not use a torch to heat cylinder head or warpage may result from uneven heating. Head temperature can be checked with a pyrometer or a welding temperature stick.

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

5. Using valve guide driver, drive guides out of the cylinder head from the combustion chamber side. Be careful not to damage guide bore or valve seat when removing guides.

6. Place cylinder head on cylinder head table.

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

7. Place a new guide in the valve guide installation tool and press guide in to proper depth. Check height of each guide above the cylinder head (A).

Valve Guide Installed Height

Valve Seat Reconditioning

1. Follow the manufacturers instructions provided with the

Valve Seat Reconditioning Kit (P/N 2200634). Abrasive stone seat reconditioning equipment can also be used. Keep all valves in order with their respective seat.

Valve Seat Wear Patterns

Too

Wide

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

Uneven

Good

Too

Narrow

Valve Guide Height:

.689- .709” (17.5 - 18.0 mm)

NOTE: The guide can also be inserted to the proper depth using a driver. Inspect the guide closely for cracks or damage if a driver is used.

8. Allow the 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.

9. Clean guides thoroughly with hot soapy water and a nylon brush. Rinse and dry with compressed air. Apply clean engine oil to guides.

2. Install pilot into valve guide.

3. Apply cutting oil to valve seat and cutter.

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

5. Inspect the cut area of the seat:

• If the contact area is less than 75% of the circumference of the seat, rotate the pilot 180° and make another light cut.

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

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

• If the contact area of the initial cut is greater than 75%, continue to cut the seat until all pits are removed and a new seat surface is evident.

NOTE: Remove only the amount of material necessary to repair the seat surface.

Seat Contact

Width

6. To check the contact area of the seat on the valve face, apply a thin coating of Prussian Blue™ paste to the valve seat. If using an interference angle (46°) apply black permanent marker to the entire valve face (A).

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

8. Remove valve and check where the Prussian Blue™ 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 (refer to the wear limits for proper seat width).

• If the indicated seat contact is at the top edge of the

valve face and contacts the margin area it is too high on the valve face. Use the 30° cutter to lower the valve seat.

• If too low use the 60° or 75° cutter to raise the seat.

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

• If the seat is too wide or uneven, use both top and

bottom cutters to narrow the seat.

• If the seat is too narrow, widen using the 45° cutter and

re–check contact point on the valve face and seat width after each cut.

Valve Seat Width:

Top 30o

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.

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

10. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve.

NOTE: Lapping is not required with an interference angle.

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

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

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

Seat 45o or 46

Bottom 60

or 75

Intake Std: .028” (.7 mm)

Limit: .055” (1.4 mm)

Exhaust Std: .039” (1.0 mm)

Limit: .071” (1.8 mm)

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Valve Inspection

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

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

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

ENGINE

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. Valves must be replaced if worn, bent, or damaged.

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

Measure valve stem in

several places

Valve Stem Diameter:

Intake: .2343- .2348

Exhaust: .2341- .2346

″ (5.950- 5.965 mm)

″ (5.945- 5.960 mm)

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ENGINE

RepairPro Service Manual

ES50PL Adjusting Pad Selection Matrix

1. Measure valve clearance at TDC (Compression Stroke) using thickness gauge with original adjusting pad installed.

2. Reference the measurement and the 3 digits marked on the existing adjusting pad on the matrix below.

3. Select a suitable adjusting pad from the matrix below and replace existing pad.

4. Measure and confirm that valve clearance is within the standard values.

5. If valve clearance is not within standard, reverify step#1 and repeat procedures again.

Example: Intake- Valve clearance before adjusting: 0.23mm(.009”)

Existing adjusting pad mark: 177 From “Intake Adjusting Pad Selection Matrix”, a suitable adjusting pad would be 185

Exhaust- Valve clearance before adjusting: 0.35mm(.0137”) Existing adjusting pad mark: 177 From “Intake Adjusting Pad Selection Matrix”, a suitable adjusting pad would be 185

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ENGINE

Cylinder Head Assembly

CAUTION

Wear eye protection during assembly.

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

1. Install new valve seals on valve guides.

2. Apply engine oil to valve guides and seats.

3. Coat valve stem with assembly lube.

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

5. Install spring washers. Dip valve springs and retainer in clean engine oil and install springs with closely spaced coils (B) toward the cylinder head.

Spring Washer Located

Below Assembly

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

7. Repeat procedure for remaining valves.

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

9. Install the shims and buckets for each valve in the order they were removed.

10. Check valve clearance with engine at Top Dead Center (TDC).

NOTE: Repairs such as valve grinding or valve replacement will require re-shimming for proper valve clearance. Use the chart provided on pa ge 3.40 to determine the appropriate shim thickness.

Valve Clearance (Engine Cold):

Intake: .006

Exhaust: .010” (.27 mm)

+/- .0019

″ (.15 mm)

″ (.05 mm)

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Cylinder Head Installation

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 guides. Be sure bottom end of guide is located properly in crankcase.

2. Install the two dowels and a new cylinder head 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

1. Torque bolts to 22 ft. lbs. (30 Nm)

2. Torque bolts to 51 ft. lbs. (70 Nm) Leave at this torque for 1 minute to allow

gaskets to seat for proper sealing.

3. Loosen bolts evenly 360

(1 turn)

CYLINDER SERVICE

Cylinder Inspection

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

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

Cylinder Warp

″ (.05 mm)

.002

4. Torque bolts to 29 ft. lbs. (35 Nm)

5. From this point, tighten bolts evenly 90 (1/4 turn)

6. Finally, tighten another 90

7. Install two 6 mm bolts and torque to 6 ft. lbs. (8 N

4. Install the two 6 mm bolts and torque to specification.

Cylinder 6 mm Bolt Torque:

6 ft. lbs. (8 Nm)

(1/4 turn)

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

1/2” Down From Top of Cylinder

1/2” Up From Bottom

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

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

Cylinder Taper

Limit: .002

Cylinder Out of Round

Limit: .002

Standard Bore Size:

3.9055- 3.9062

″ (.05 mm) Max.

″ (99.20- 99.22 mm)

Piston–to–Cylinder Clearance

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

Piston

Cylinder Hone Selection and Honing Procedure

CAUTION

A hone which will straighten as well as remove

material from the cylinder is very important.

Using a common spring loaded glaze breaker for

honing is not advised for nicasil cylinders.

Polaris recommends using a rigid hone

or arbor honing machine.

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

IMPORTANT: Clean the Cylinder After Honing

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

Piston Pin

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

Piston to Cylinder Clearance:

Std: .0018- .0025

Std: 3.9037- 3.9040

″ (.046- .065 mm)

Piston O.D.:

″ (99.155- 99.170 mm)

Honing To Deglaze

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

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

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

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

• After honing has been completed, inspect cylinder for thinning or peeling.

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

Piston Ring Installed Gap

1. Place each piston ring inside cylinder using piston to push ring squarely into place.

Feeler Gauge

Cylinder

3. If the bottom installed gap measurement exceeds the service limit, replace the rings. If ring gap is below specified limit, file ring ends until the gap is within the 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 oil immediately to prevent rust.

WATER PUMP SERVICE

Oil Seal / Mechanical Seal Removal (Engine Disassembled)

NOTE: The water pump mechanical seal can be removed without removing the engine. Refer to Water Pump Mechanical Seal Installation.

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

25-50 mm

Piston Ring

Piston Ring Installed Gap

Top Ring Std: .008- .012 Limit: .027” (.7 mm)

Second Ring Std: .014- .019 Limit: .031” (.8 mm)

Oil Ring Std: .004- .019 Limit: .039” (1.0 mm)

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

NOTE: A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round.

″ (.20- .30 mm)

″ (.35- .50 mm)

″ (.10- .50 mm)

1. Remove the pump shaft bearings from the PTO (right hand) side crankcase.

2. Drive the water pump mechanical seal out of the crankcase from inside to outside.

NOTE: The new mechanical seal must be installed using special tools. See Mechanical Seal Installation.

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 gu i de onto the end of the pump shaft.

4. Install the washer and nut and tighten to draw seal into place until fully seated.

5. Remove the guide adaptor using the additional nut as a jam nut if necessary.

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ENGINE

Mechanical Seal Removal and Installation (Engine Assembled)

The W ater Pump Mechanical Seal Puller allows a technicia n to replace the seal on ES50PL engines without removing the engine and splitting the cases.

NOTE: This removal process dismantles the seal, making it unusable for reinstallation.

Water Pump Mechanical Seal

Puller: (PN 2872105)

Replacement T-Handle:

(PN 2872106)

CAUTION

Improper or careless use of 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 the puller

is parallel to the shaft at all times.

Do not place side loads on the water pump shaft

or strike the puller or shaft in any way.

2. Slide the main puller body over the outer portion of the mechanical seal as shown in (Figure 3-45)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.

Figure 3-45

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. (Figure 3-46)

Main Puller Body

1. After the coolant has been drained, remove the water pump cover, impeller and the sealing washer.

Mechanical Seal

Sealing Washer

Impeller

Seal

4. Ensure that the split between the puller legs are fully supported by the main body of the tool (Figure 3-46).

5. T ighten the hex socket screws on the puller legs sufficiently so the lip of the puller legs will grasp the mechanical seal (Figure 3-47).

Hex Socket Screws

Puller Legs

Lip must grasp inside

Position the split 90° to opening

on main puller body

Figure 3-46

of mechanical seal.

Figure 3-47

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RepairPro Service Manual

6. Turn the puller T–Handle clock wise until it contacts the water pump shaft. Continue rotating until the remaining portion of mechanical seal has been removed from the case. (Figure 3-48)

Figure 3-48

7. Water Pump Install Kit (PN 5131135) is required to install the new mechanical seal. This tool is available separately as well as included in Crankshaft / Water Pump Seal Installation Kit (PN 2871283).

TROUBLESHOOTING

Engine

Engine Turns Over But Fails to Start

•No fuel

• Dirt in fuel line or filter

• Fuel will not pass through fuel valve

• Fuel pump inoperative/res tricted

• Tank vent plugged

• Carb starter circuit

• E ngine flooded

• Low compression (high cylinder leakage)

• No spark (Spark plug fouled)

Engine Does Not Turn Over

• Dead battery

• Starter motor does not turn

• E ngine seized, rusted, or mechanical failure

Engine Runs But Will Not Idle

• Restricted carburetor pilot system

• Carburetor misadjusted

• Choke not adjusted properly

• Low compression

• Crankcase breather restricted

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ENGINE

Engine Idles But Will Not Rev Up

• Spark plug fouled/weak spark

• Broken throttle cable

• Obstruction in air intake

• Air box removed (reinstall all intake components)

• Incorrect or restricted carbu retor jetting

• ETC switch limiting speed

• Reverse speed limiter limiting speed

• Carburetor vacuum slide sticking/diaphragm damaged

• Incorrect ignition timing

• Restricted exhaust system

Engine Has Low Power

• Spark plug fouled

• Cylinder, piston, ring, or valve wear or damage (check compression)

Low Compression

• Decompressor stuck

• Cylinder head gasket leak

• No valve clearance or incorrectly adjusted

• Cylinder or piston worn

• Pist on ri ngs worn, leaking, broken, or sticking

• Bent valve or stuck valve

• Valve spring broken or weak

• Valve not seating properly (bent or carbon accumulated on sealing surface)

• Rocker arm sticking

Backfiring

• ETC or speed limiter system malfunction

• Fouled spark plug or incorrect plug or plug gap

• Carburetion faulty – lean condition

• PVT not operating properly

• Restricted exhaust muffler

• Carburetor vacuum slide sticking/diaphragm damaged

• Dirty carburetor

Piston Failure – Scoring

• L ack of lubrication

• Dirt entering engine through cracks in air filter or ducts

• Engine oil dirty or contaminated

Excessive Smoke and Carbon Buildup

• Excessive piston–to–cylinder clearance

• Wet sumping

• Worn rings, piston, or cylinder

• Worn valve guides or seals

• R estricted breather

• Exhaust system air leaks

• Ignition system faulty:

Spark plug cap cracked / broken Ignition coil faulty Ignition or kill switch circuit faulty Ignition timing incorrect Sheared flywheel key

• Poor connections in ignition system

• System wiring wet

• Valve sticking

• Air leaks in intake

• Lean condition

• Air filter dirty or contaminated

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Spark Plug Fouling

• Spark plug cap loose or faulty

• Choke cable adjustment or plunger/cable sticking

• Fo reig n mat erial on choke plu nger seat or plunger

• Incorrect spark plug heat range or gap

• Carburetor inlet needle and seat worn

• Jet needle and/or needle jet worn or improperly adjusted

• Excessive carburetor vibration (loose or missing needle jet locating pins)

• Loose jets in carburetor or calibration incorrect for altitude/temperature

• Incorrect float level setting

• PVT system calibrated incorrectly or components worn or adjusted incorrectly

• Fuel quality poor (old) or octane too high

• Restricted system (mud or debris in radiator fins or restriction to air flow, passages blocked in radiator, lines, pump, or water jacket)

• Lean mixture (restricted jets, vents, fuel pump or fuel valve)

• Fuel pump output weak

• Restricted radiator (internally or cooling fins)

• Water pump failure

• Cooling system restriction

• Cooling fan inoperative or turning too slowly (perform current draw test)

• Ignition timing misadjusted

• Low oil level

• S park plug incorrect heat range

• Faulty hot light circuit

• Thermostat stuck closed or not opening completely

• L ow compression

• Restricted exhaust

• Weak ignition (loose coil groun d, faulty coil, stator, or ETC switch)

• E TC switch adjusted incorrectly

• Restricted air filter (main or pre–cleaner) or breather system

• Improperly assembled air intake system

• Restricted engine breather system

• Oil contaminated with fuel

• Restricted oil tank vent

Cooling System

Overheating

• Low coolant level

• Air in cooling system

Temperature Too Low

• T hermostat stuck open

Leak at Water Pump Weep Hole

• F aulty water pump mechanical seal (coolant leak)

• Faulty pump shaft oil seal (oil leak)

• Wrong type of coolant

• Faulty pressure cap or system leaks

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FUEL SYSTEM / CARBURETION

CHAPTER 4

FUEL SYSTEM / CARBURETION

FUEL SYSTEM AND CARBURETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

BSR 42 CARBURETOR EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2

FUEL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

JETTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

CARBURETOR JETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4

MIKUNI JET PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4

CV CARBURETOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

CARBURETOR FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

VENT SYSTEMS – CV CARBURETOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

MIKUNI CV CARBURETOR OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5

PILOT (IDLE AND SLOW) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6

STARTER SYSTEM (CHOKE OR ENRICHMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7

FLOAT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7

MAIN SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8

PILOT SCREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8

CARBURETOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

CARBURETOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10

CARBURETOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10

CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.11

FLOAT HEIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11

FUEL DELIVERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12

NEEDLE AND SEAT LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.12

FUEL LEVEL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12

FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13

FUEL PUMP DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13

FUEL PUMP INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13

FUEL STARVATION / LEAN MIXTURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13

RICH MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14

POOR IDLE / IDLE TOO HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14

IDLE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14

ERRATIC IDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14

4.1

Page 97

FUEL SYSTEM / CARBURETION

RepairPro Service Manual

FUEL SYSTEM AND CARBURETION

BSR 42 Carburetor Exploded View

Ref Description Ref Description Ref Description Ref Description

1 Cover, Diaphragm 16 Guide, Cable 31 A-Float 46 Asm., Plunger 2 Spring 17 O-ring 32 Jet, Main 47 Spring 3 Diaphragm 18 Cover 33 Ring 48 Holder, Guide 4 Valve, Piston 19 Screw 34Holder, Jet 49Screw 5 Holder 20 A-Shaft, Throttle 35 Jet, Needle 50 Cover 6 Spring 21 Screw 36 O-ring 51 Spring 7 Washer 22 Bolt 37 Needle Guide 52 Asm., Diaphragm 8 Washer 23 Spring, Idle Adjust 38 Screw 53 Filter

9 Jet, Needle 24 O-ring 39 Screw 54 Jet, Pilot Air 2 (1.3) 10 O-ring 25 Screw, Adjust 40 Jet, Pilot 55 Jet, Pilot Air 1 (110) 11 Case 26 Pin, Float 41 Jet, Starter (42.5) 56 Jet, Main Air (120) 12 Spring 27 O-ring 42 Asm., Carburetor 57 Ring 13 Seal 28 Body, Float 43 Packing 58 E-ring 14 Ring 29 Screw 44 E-ring 59 O-ring 15 Valve, Throttle (105) 30 Screw 45 Cap 60 Screw

Jet Needle

“E” Clip

Position

33 32

4.2

Refer to Page 4.4 for Optional Jet Part Numbers

Page 98

Fuel Tank Assembly

FUEL SYSTEM / CARBURETION

Tank Cap

Vent Line

Fuel Lines

Fuel Tank

Fuel Valve

Impulse Line

FUEL FLOW

*Fuel Pump

* Located on upper frame

In-Line

Filter

In-Line Filter

Fuel Pump

Fuel Tank Vent Fuel Tank

Fuel Screens

Fuel Valve

Carburetor Vent

Carburetor Engine

(Filter in Pickup)

4.3

Page 99

FUEL SYSTEM / CARBURETION

RepairPro Service Manual

Special Tools

PART NUMBER

2870975

2872314

Gasoline is extremely flammable and

explosive under certain conditions.

Always stop the engine and refuel outdoors or in a well ventilated area.

Do not overfill the tank. The tank is at full capacity when the fuel reaches the bottom of the filler neck. Leave room for expansion of fuel.

Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.

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

DESCRIPTION

Mity Vac

Carburetor Float Adjustment Tool

WARNING

TOOL

Pressure Test

Tool

Polaris A TV carburetors are calibrated for an altitude of 0–6000

ft. (0–1800 meters) and ambient temperatures above +40

C). Carburetors must be re–calibrated if operated outside

(+26 this temperature and/or altitude range. The jetting installed in production is not intended for all altitudes and/or temperatures. In addition, air screw / pilot screw adjustments may be required to suit operating conditions.

Carburetor Jetting

CAUTION

A main jet that is too small will cause a lean

operating condition resulting in

serious engine damage.

Select the correct main jet carefully for

elevation and temperature according to the

charts in the specifications sec tion or in the

Owner’s Manual for each particular model.

IMPORTANT: The following guidelines must be followed when establishing a main jet setting:

1. Select the lowest anticipated temperature at which the machine will be operated.

2. Determine the lowest approximate altitude at which the machine will be operated.

3. Select the correct main jet from the specifications chart in Chapter 1.

Mikuni Jet Part Numbers

Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

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

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

Jetting Guidelines

Changes in altitude and temperature affect air density , which is essentially the amount of oxygen available for combustion. In low elevations and cold temperatures, the air is more dense and has more oxygen. In higher elevations and higher temperatures, the air is less dense with reduced oxygen.

4.4

Main Jets Pilot Jets

Jet Number 130 3131537 25 3131538

132.5 3131536 27.5 3131539

135 3131535 30 3131540

137.5 3131534 32.5 3131541

140 3131522 35 3131542

142.5 3131523 37.5 3131543

145 3131524 40 3131544

147.5 3131525 42.5 3131545

152.5 3131526 47.5 3131546

155 3131527 50 3131547

157.5 3131528 52.5 3131548

160 3131529 55 3131549

162.5 3131530 57.5 3131550

165 3131531 60 3131551

167.5 3131532 65 3131552

170 3131533 70 3131553

Part Number Jet Number Part Number

Page 100

FUEL SYSTEM / CARBURETION

CV CARBURETOR SYSTEM

Carburetor Function

Carburetor Component Function

System

Float System

(Level Control)

Venting

Starter

(Choke /

Enrichment)

Main

Components

Inlet Pipe, Needle

and Seat, Float,

Float Pin

Passages in

carburetor; vent

lines to frame.

Choke Lever, Cable,

Plunger, Return

Spring, Carb

Passages (Starter

Jet, Starter Bleed

Pipe).

Main

Function

Maintains specified

fuel level in float

chamber

(carburetor float

bowl).

Supplies

atmospheric

pressure to float

chamber.

Supplies additional

fuel air mixture

necessary for cold

starting.

Main

Affect

All systems; all

throttle ranges

All systems; all throttle ranges.

All throttle

ranges.

Greatest effect

at low throttle

settings and

idle.

Vent Systems – CV Carburetor

The carburetor float bowl vent lines supply atmospheric pressure to the float bowl. The lines must be free of kinks, restrictions and be properly routed. This allows fuel to flow in the proper amount and prevents contaminants from entering the carburetor.

Mikuni CV Carburetor Operation

The constant velocity carburetor incorporates a mechanically operated throttle plate and a vacuum controlled slide valve (vacuum slide). The venturi cross–sectional area in the carburetor bore is increased or decreased automatically by the vacuum slide, which moves according to the amount of negative pressure (less than atmospheric) present in the venturi.

A diaphragm attached to the top of the vacuum slide is sealed to the slide and to the carburetor body forming two chambers. The chamber above the diaphragm is connected to the venturi area by a drilled orifice in the center of the vacuum slide. The chamber below the diaphragm is vented to atmospheric pressure by a passage on the air box side of the carburetor. A spring, installed in the center of the vacuum slide, dampens the slide movement and assists the return of the slide.

Pilot

(Idle System)

Main System

Pilot Jet / Passageways, Pilot–Mixture

Screw with Spring

Washer and Sealing

O–Ring, By-pass

Ports (Behind

Throttle Plate), Pilot

Air Jet, Pilot Outlet,

Throttle Plate.

Main Jet, Main Air

Jet, Main Air

Passage, Needle

Jet, Jet Needle,

Vacuum Slide, Throttle Plate.

Primarily supplies

fuel at idle and low

throttle positions.

Supplies fuel at

mid–range and high

throttle settings.

Mainly idle to

1/4 throttle.

Minimal effect

after 1/2

throttle.

1/4 to full

throttle.

Throttle Plate

Diaphragm

= Air Flow

Low Pressure From Venturi

Atmospheric

Pressure

Atmospheric

Air inlet

Vacuum

Slide

Venturi

= Low pressure

4.5