Polaris RANGER 2x4 User guide

GENERAL INFORMATION

CHAPTER 1
GENERAL INFORMATION

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

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

Models Numbers / Replacement Key 1.3.......

Machine Dimensions 1.4-1.5.....................

Specifications - RANGER 2X4 1.6-1.7.............

Specifications - RANGER 4X4 1.8-1.9.............

Specifications - RANGER 6X6 1.10-1.11.............

Publication Numbers 1.12.....................

Paint Codes 1.12.............................

Starting the RANGER 1.12.....................

1

1.1

GENERAL INFORMATION

MODEL IDENTIFICATION

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

Machine Model Number Identification

A11RF50AB

Emissions &

Series Designation

Basic Chassis
Designation Engine Designation

Model Option

Engine Designation

42 EH42PLE06 Single, L/C, SOHC 4 Stroke, Electric Start
50 EH50PLE16 Single, L/C, SOHC 4 Stroke, Electric Start

Number

VIN Identification

World Mfg. ID

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

Body Style

ENGINE SERIAL NUMBER LOCA

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

Vehicle Description

50A* 1P 0 00 0 00

Engine

Powertrain

Emissions

Check Digit

Model
Year

Plant No.

TION

Vehicle Identifier

Individual Serial No.

A

* This could be either
a number or a letter

TRANSMISSION I.D.
LOCA

TION

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

1.2

NUMBER

GENERAL INFORMATION

MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION

The machine model number and serial number are
important for vehicle identification. The machine
serial number (A) is stamped on the lower frame
rail close to the front drive wheel. The model and
serial number (B) are also located on a sticker on
the hood liner.

B

A

REPLACEMENT

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

31XX

KEYS

Key Series
Number

Series #

20 4010278

21 4010278

22 4010321

23 4010321

27 4010321

28 4010321

31 4110141

32 4110148

67 4010278

68 4010278

Part Number

1.3

GENERAL INFORMATION

MACHINE DIMENSIONS

75 in

190.50 cm

(Front of Box)

1.4

13 in
23 cm

7.2 in

18 cm

58 in

147 cm

MACHINE DIMENSIONS

GENERAL INFORMATION

120 in

305 cm

48 in

152 cm

229 cm

113 i n
33 cm

7.2 in

18.25 cm

90 in

42 in

107 cm

76 in

193 cm

1.5

GENERAL INFORMATION

MODEL SPECIFICATIONS

MODEL: RANGER 2X4............

MODEL NUMBER: A11RB42AA...

ENGINE MODEL: EH42PLE06....

ELECTRICAL FLUID Capacity Type

Flywheel I.D. FF97 Fuel Tank 8.5 gals. (32.2L)...... ..........

CDI Marking CU2570 Injector Oil N / A....... ..........

Alternator Output 250 Watts Coolant 2.25 qts. (2.1L) PP6*... ............ ..

Ignition Timing 30qBTDC@5000RPMrqTransmission 27 oz (800 ml) PPS*..... .......

Spark Plug / Gap NGK BKR5E / 0.036I (0.9mm) Gearcase Oil (Front) N/A... .

Lights: Head Dual Beam (2)--35 watt quartz Gearcase Oil (Rear) 10 oz (300 ml) ....80-90...... .

Tail 5 watts Gearcase Oil (Middle) N/A........

Brake 5 watts Engine Oil 2 qts. (1.9L) PP4*...... .......... ......

Indicator ....1watt Brake(Foot) D.O.T. 3..........................

Voltage Regulator LR39..

Start System Electric start.......

DC Outlet Dash Receptacle *PPS Polaris Premium Synthetic Gear Case Oil.........

Battery........... 30Amp(12Volt) *PP4 Polaris 0W--40 Synthetic Engine Lubricant

Lubricant Key

*PDD Premium Demand Drive Hub Fluid
*PP6 Polaris Premium 60/40 Antifreeze/Coolant

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style Series 11 Transmission Dual Sensing Automatic PVT........ .......

Front Suspension MacPherson Strut Gear Reduction-Low 8.66:1.. .
MIddle Suspension MacPherson Strut Gear Reduction-Rev 5.91:1..

Turning Radius 186I (472 cm) Gear Reduction-Hi 3.81:1..... ...

Toe Out 1/8I-1/4I (3-6.35 mm) Front Drive Ratio N/A........... ....

Ground Clearance 7.2I (180 mm) Middle Drive Ratio N/A.. ...

Front Vertical Travel 6.7I (170 mm) Final Drive Ratio 3.70:1....

Center Vertical Travel 5.25” (133 mm) Shift Type .........InLine EZShift Hi/Lo/Reverse

Rear Suspension Swing Arm w/Dual Shocks Brake Type: Hydraulic Foot Pedal... ........

Rear Travel 6.25I (158 mm) Parking Brake Foot Actuated (Mechanical)........ .......

Shock . . . (2)--2” Twin Tubes Front & Rear Brake Fixed Disc, Hydraulic....... ..

Shock Adjustment Cam Floating Caliper..

LOAD CAPACITY

Cargo Box Dimensions 58x42 x13 in...........

TIRES

Tire Size - Front 25 x 10 - 12....

Tire Size - Rear 25 x 11 - 12....

Tire Pressure - F/R 8--12 psi.

Total Width 60I (152.40 cm)........

Total Length 113I (287 cm).......

Total Height 75I (190.50 cm)........

Wheel Base 76I (193 cm).......

Weight - Dry 1105 lbs. (412 kgs).......

Cargo Box Load Capacity 850 lbs (317 kgs)......

Tow Hitch Receiver Hitch.....................

Hitch Tongue Capacity 75 lbs (28 kgs)..........

Hitch Towing Capacity 1400 lbs (523 kgs)..........

*Vehicle Payload 1500 lbs (681 kgs)...............

*Payload Includes: One driver and two passengers

1.6

MODEL SPECIFICATIONS

Altitud

e

Below40

F

+40to+80F

Meter

s

0--180

0

(Feet

)

180

0--above

Altitud

e

p

g

ue/

Gre

e

a

c

Meter

s

0--180

0

10B

H

Blue/Gree

n

Black

4

1--3

7

(Feet

)

ue/

Gre

e

a

c

180

0-370

0

10R

H

Blue/Gree

n

Black

4

1--3

7

MODEL: RANGER 2X4..........

MODEL NUMBER: A11RB42AA.
ENGINE MODEL: EH42PLE06..

CARBURETION

Type BST 34 Mikuni CV................

Main Jet 135............

Pilot Jet 42.5.............

Jet Needle 4LC38--3...........

Needle Jet P--6 (829)...........

Pilot Screw 2.25 Turns..........

Pilot Air Jet 160..........

Valve Seat 1.2 Viton...........

Float Height 13mm (.51I).........

Fuel Octane (R+M/2) 87 Non-Oxygenated or.

89 Oxygenated

CLUTCH

Type PVT....................

Belt 3211077.....................

Belt Width (Projected) 1.188I (30.18mm).....

Drive Belt Deflection 1.125 “ (28.57 mm)......

Side Angle (Overall) 26q......

Outside Circumference 40.86 r.12I....

Center Distance 10” (254.5mm)..........

Clutch Offset 0.5I (12.7mm)............

Secondary Spring Black........

Driven Helix 41--37.............

Spring Position (Helix) .... 2

Spring Position (Sheave) 2..

GENERAL INFORMATION

JETTING CHART

Altitude

Meters

(Feet)

CLUTCH CHART

Meters

(Feet)

0--1800

(0-- 6000)

1800--abov e

(6000-- above)

0--1800

(0-- 6000)

1800-3700

(6000-12000)

AMBIENT TEMPERATURE

Below 40 qF

Below +5qC

140 135

132.5 127.5

Shift

Weight Sp ring Spring

10BH Bl

(5630511)

10RH Bl

(5630515)

+40_to +80 _F
+5_ to +26_C

Drive Clutch

(7041157)

(7041157)

Drriven Clutch

n Bl

(7041782)

n Bl

(7041782)

Helix Spring

Angle

k 41--37

(5132344)

k 41--37

(5132344)

ENGINE

Type 4 Cycle, Single Cyl........................

Displacement 425 cc...............

Bore 3.46I (92mm).......................

Stroke 2.76I (75mm).....................

Valve Clearance In/Ex 0.006/0.006I @ TDC on compression.......

Compression Ratio 9.2 :1..........

Cooling Liquid....................

Lubrication Type Dry Sump............

Operating RPMr200 5250 RPM.........

Idle RPMr200 (lights off) 1200 RPM.....

Compression Pressure 70--90 psi.......

1.7

GENERAL INFORMATION

MODEL SPECIFICATIONS

MODEL: RANGER 4x4............

MODEL NUMBER: A11RD50AA...

ENGINE MODEL: EH50PLE16....

ELECTRICAL FLUID Capacity Type

Flywheel I.D. FF97 Fuel Tank 8.5 gals. (32.2L)...... ..........

CDI Marking CU2570 Injector Oil N / A....... ..........

Alternator Output 250 Watts Coolant 2.25 qts. (2.1L) PP6*... ............ ..

Ignition Timing 30qBTDC@5000RPMrqTransmission 13.5 oz (400 ml) PPS*..... ....... ..

Spark Plug / Gap NGK BKR5E / 0.036I (0.9mm) GearcaseOil(Front) 5oz(150ml).... PDD*... .

Lights: Head Dual Beam (2)--35 watt quartz Gearcase Oil (Rear) 10 oz (300 ml) ....80-90...... .

Tail 5 watts Gearcase Oil (Middle) N/A........

Brake 5 watts Engine Oil 2 qts. (1.9L) PP4*...... .......... ......

Indicator ....1watt Brake(Foot) D.O.T. 3..........................

Voltage Regulator LR39..

Start System Electric start.......

DC Outlet Dash Receptacle *PPS Polaris Premium Synthetic Gear Case Oil.........

Battery........... 30Amp(12Volt) *PP4 Polaris 0W--40 Synthetic Engine Lubricant

Lubricant Key

*PDD Premium Demand Drive Hub Fluid
*PP6 Polaris Premium 60/40 Antifreeze/Coolant

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style Series 11 Transmission Dual Sensing Automatic PVT........ .......

Front Suspension MacPherson Strut Gear Reduction-Low 8.66:1.. .
MIddle Suspension MacPherson Strut Gear Reduction-Rev 5.91:1..

Tow Capacity 1500 lbs. (680 kg) Gear Reduction-Hi 3.81:1...... ...

Turning Radius 150I (381 cm) Front Drive Ratio 3.83:1..... ....

Toe Out 1/8I-1/4I (3-6.35 mm) Middle Drive Ratio N/A........... ...

Ground Clearance 7.2I (180 mm) Final Drive Ratio 3.70:1.. ....

Front Vertical Travel 6.7I (170mm) ShiftType.........InLine EZShift Hi/Lo/Reverse

Center Vertical Travel 5.25” (133 mm) Brake Type: Hydraulic Foot Pedal........

Rear Suspension Swing Arm w/Dual Shocks Parking Brake Foot Actuated (Mechanical)... .......

Rear Travel 6.25I (158 mm) Front & Rear Brake Fixed Disc, Hydraulic........ ..

Shock . . . (2)--2” Twin Tubes Floating Caliper.......

Shock Adjustment Cam..

LOAD CAPACITY

Cargo Box Dimensions 58x428x13 in..........

TIRES

Tire Size - Front 25 x 10 - 12....

Tire Size - Rear 25 x 11 - 12....

Tire Pressure - F/R 8--12 psi.

Total Width 60I (152.40 cm)........

Total Length 113I (287 cm).......

Total Height 75I (190.50 cm)........

Wheel Base 76I (193 cm).......

Weight - Dry 1185 lbs. (442 kg).......

Cargo Box Load Capacity 1000 lbs (454 kgs)......

Tow Hitch Receiver Hitch.....................

Hitch Tongue Capacity 75 lbs (28 kgs)..........

Hitch Towing Capacity 1500 lbs (681 kgs)..........

*Vehicle Payload 1500 lbs (681 kgs)...............

*Payload Includes: One driver and two passengers

1.8

MODEL SPECIFICATIONS

Altitud

e

Below40

F

+40to+80F

Meter

s

0--180

0

(Feet

)

180

0--above

Altitud

e

p

g

ue/

Gre

e

a

c

0

Meter

s

0--180

0

10M

H

Blue/Gree

n

Black

4

0

(Feet

)

ue/

Gre

e

a

c

0

180

0-370

0

10W

H

Blue/Gree

n

Black

4

0

MODEL: RANGER 4X4..........

MODEL NUMBER: A11RD50AB.
ENGINE MODEL: EH50PLE16..

CARBURETION

Type BST 34 Mikuni CV................

Main Jet 142.5............

Pilot Jet 42.5.............

Jet Needle 4MB32--3...........

Needle Jet P--8...........

Pilot Screw 2.5 Turns..........

Pilot Air Jet 160..........

Valve Seat 1.2 Viton...........

Float Height 13mm (.51I).........

Fuel Octane (R+M/2) 87 Non-Oxygenated or.

89 Oxygenated

CLUTCH

Type PVT....................

Belt 3211077.....................

Belt Width (Projected) 1.188I (30.18mm).....

Drive Belt Deflection 1.125 “ (28.57 mm)......

Side Angle (Overall) 26q......

Outside Circumference 40.86 r.12I....

Center Distance 10” (254.5mm)..........

Clutch Offset 0.5I (12.7mm)............

Secondary Spring Black........

Driven Helix 40.............

Spring Position (Helix) .... 2

Spring Position (Sheave) 2..

GENERAL INFORMATION

JETTING CHART

Altitude

Meters

(Feet)

CLUTCH CHART

Meters

(Feet)

0--1800

(0-- 6000)

1800--abov e

(6000-- above)

0--1800

(0-- 6000)

1800-3700

(6000-12000)

AMBIENT TEMPERATURE

Below 40 qF

Below +5qC

140 142.5

132.5 127.5

Shift

Weight Sp ring Spring

10MH Bl

(5630513)

10WH Bl

(5630515)

+40_to +80 _F
+5_ to +26_C

Drive Clutch

(7041157)

(7041157)

Drriven Clutch

n Bl

(7041782)

n Bl

(7041782)

Helix Spring

k 4

(5131446)

k 4

(5131446)

Angle

ENGINE

Type 4 Cycle, Single Cyl........................

Displacement 499 cc...............

Bore 3.625I (92mm).......................

Stroke 2.955I (75mm).....................

Valve Clearance In/Ex 0.006/0.006I @ TDC on compression.......

Compression Ratio 10.2:1..........

Cooling Liquid....................

Lubrication Type Dry Sump............

Operating RPMr200 5250 RPM.........

Idle RPMr200 (lights off) 1200 RPM.....

Compression Pressure 70--90 psi.......

1.9

GENERAL INFORMATION

MODEL SPECIFICATIONS

MODEL: RANGER 6x6............

MODEL NUMBER: A11RF50AA...

ENGINE MODEL: EH50PLE16....

ELECTRICAL FLUID Capacity Type

Flywheel I.D. FF97 Fuel Tank 8.5 gals. (32.2L)...... ..........

CDI Marking CU2570 Injector Oil N / A....... ..........

Alternator Output 250 Watts Coolant 2.25 qts. (2.1L) PP6*... ............ ..

Ignition Timing 30qBTDC@5000RPMrqTransmission 13.5 oz (400 ml) PPS*..... ....... ..

Spark Plug / Gap NGK BKR5E / 0.036I (0.9mm) GearcaseOil(Front) 5oz(150ml).... PDD*... .

Lights: Head Dual Beam (2)--35 watt quartz Gearcase Oil (Rear) 10 oz (300 ml) . . . 80-90...... .

Tail 5 watts Gearcase Oil (Middle) 6.75 oz (200 ml) 80--90........ ..

Brake 5 watts Engine Oil 2 qts. (1.9L) PP4*...... .......... ......

Indicator ....1watt Brake(Foot) D.O.T. 3..........................

Voltage Regulator LR39..

Start System Electric start.......

DC Outlet Dash Receptacle *PPS Polaris Premium Synthetic Gear Case Oil.........

Battery........... 30Amp(12Volt) *PP4 Polaris 0W--40 Synthetic Engine Lubricant

Lubricant Key

*PDD Premium Demand Drive Hub Fluid
*PP6 Polaris Premium 60/40 Antifreeze/Coolant

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style Series 11 Transmission Dual Sensing Automatic PVT........ .......

Front Suspension MacPherson Strut Gear Reduction-Low 8.66:1.. .
MIddle Suspension MacPherson Strut Gear Reduction-Rev 5.91:1..

Tow Capacity 1500 lbs. (680 kg) Gear Reduction-Hi 3.81:1...... ...

Turning Radius 150I (381 cm) Front Drive Ratio 3.83:1..... ....

Toe Out 1/8I-1/4I (3-6.35 mm) Middle Drive Ratio 3.70:1........... ...

Ground Clearance 7.2I (180 mm) Final Drive Ratio 3.70:1.. ....

Front Vertical Travel 6.7I (170mm) ShiftType.........InLine EZShift Hi/Lo/Reverse

Center Vertical Travel 5.25” (133 mm) Brake Type: Hydraulic Foot Pedal........

Rear Suspension Swing Arm w/Dual Shocks Parking Brake Foot Actuated (Mechanical)... .......

Rear Travel 6.25I (158 mm) Front & Rear Brake Fixed Disc, Hydraulic........ ..

Shock . . . (2)--2” Twin Tubes Floating Caliper.......

Shock Adjustment Cam..

LOAD CAPACITY

Cargo Box Dimensions 58x48x13 in...........

TIRES

Tire Size - Front 25 x 10 - 12....

Tire Size - Rear 25 x 11 - 12....

Tire Pressure - F/R 8--12 psi.

Total Width 60I (152.40 cm)........

Total Length 120I (305 cm).......

Total Height 75I (190.50 cm)........

Wheel Base 90I (229 cm).......

Dry Weight. 1410 lbs. ( 526 kg).......

Cargo Box Load Capacity 1000 lbs (454 kgs)......

Tow Hitch Receiver Hitch.....................

Hitch Tongue Capacity 75 lbs (28 kgs)..........

Hitch Towing Capacity 1500 lbs (681 kgs)..........

*Vehicle Payload 1500 lbs (681 kgs)...............

*Payload Includes: One driver and two passengers

1.10

MODEL SPECIFICATIONS

Altitud

e

Below40

F

+40to+80F

Meter

s

0--180

0

(Feet

)

180

0--above

Altitud

e

p

g

GBlue/

Gre

enS

Meter

s

0--180

0

G

Blue/Gree

n

Silve

r

4

1--3

7

(Feet

)

ue/

Gre

enS

180

0-370

0

F

Blue/Gree

n

Silve

r

4

1--3

7

MODEL: RANGER 6x6..........

MODEL NUMBER: A11RF50AA.
ENGINE MODEL: EH50PLE16..

CARBURETION

Type BST 34 Mikuni CV................

Main Jet 142.5............

Pilot Jet 42.5.............

Jet Needle 4MB32--3...........

Needle Jet P--8...........

Pilot Screw 2.5 Turns..........

Pilot Air Jet 160..........

Valve Seat 1.2 Viton...........

Float Height 13mm (.51I).........

Fuel Octane (R+M/2) 87 Non-Oxygenated or.

89 Oxygenated

CLUTCH

Type PVT....................

Belt 3211077.....................

Belt Width (Projected) 1.188I (30.18mm).....

Side Angle (Overall) 26q......

Outside Circumference 40.86 r.12I....

Drive Belt Deflection 1.125 “ (28.57 mm)......

Center Distance 10” (254.5mm)..........

Clutch Offset 0.5I (12.7mm)............

Secondary Spring Silver........

Driven Helix 41--37.............

Spring Position (Helix) ....1

Spring Position (Sheave) 1..

GENERAL INFORMATION

JETTING CHART

Altitude

Meters

(Feet)

CLUTCH CHART

Meters

(Feet)

0--1800

(0-- 6000)

1800--abov e

(6000-- above)

0--1800

(0-- 6000)

1800-3700

(6000-12000)

AMBIENT TEMPERATURE

Below 40 qF

Below +5qC

140 142.5

132.5 127.5

Shift

Weight Sp ring Spring

(5630514)

F Bl

(5630515)

+40_to +80 _F
+5_ to +26_C

Drive Clutch

(7041157)

(7041157)

Drriven Clutch

(7041499)

(7041499)

Helix Spring

Angle

ilver 41--37

ilver 41--37

(5132344)

(5132344)

ENGINE

Type 4 Cycle, Single Cyl........................

Displacement 498 cc...............

Bore 3.625I (92mm).......................

Stroke 2.955I (75mm).....................

Valve Clearance In/Ex 0.006/0.006I @ TDC on compression.......

Compression Ratio 10.2:1..........

Cooling Liquid....................

Lubrication Type Dry Sump............

Operating RPMr200 5250 RPM.........

Idle RPMr200 (lights off) 1200 RPM.....

Compression Pressure 70--90 psi.......

1.11

GENERAL INFORMATION

PUBLICATION NUMBERS

Model

RANGER 2x4
RANGER 4x4
RANGER 6x6

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

PAINT

Springs Medium Gloss Black 9440 P--067

Hood/Dash Eddie Bauer Green 44931 P--195

Frame/Cab Medium Gloss Black 9440 / 8520147 P--067

Order direct from Midwest Industrial Coatings (952--942--1840). Mix as directed.

CODES

PAINTED

PART

STARTING THE

NOTICE: To start the Series 11 RANGER, the foot

brake must be depressed to start the machine. The
RANGER utilizes this safety feature to help prevent
any possible injury or accidents that may occur dur­ing initial machine startup.

Model No. Owner’s

Manual PN

A11RB42AA
A11RD50AA
A11RF50AA

9918176 99118179 9918071 9918180

COLOR

DESCRIPTION

RANGER

Parts

Manual PN

DITZLER

NUMBER

Service

Manual PN

Parts

Micro Fiche

PN

POLARIS
NUMBER

1.12

Brake

Ignition Key

1. Press down on the foot brake. 2. Turn the ignition key to start the Ranger.

GENERAL INFORMATION

CHAPTER 2
MAINTENANCE

Periodic Maintenance Chart 2.2--2.3...............

Polaris Lubricant and Service Part Numbers 2.4.

Special Tools 2.5............................

Pre-Ride Inspection 2.5......................

Lubrication Charts 2.6-2.8........................

Front Gearcase Lubrication 2.9................

Middle Gearcase Lubrication 2.9--2.10..............

Rear Gearcase Lubrication 2.10--2.11................

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

Shift Linkage Adjustment 2.13..................

2

Throttle Pedal Inspection 2.14..................

Fuel System 2.14--2.17.............................

Battery Maintenance 2.17--2.18......................

Spark Plug / Electrical 2.18--2.19....................

Engine Coolant System 2.19--2.22...................

Air Filter / Breather Filter 2.22--2.24..................

Flywheel Housing 2.24........................

Oil Level and Filter Change 2.25--2.26................

Oil Pump Priming Procedure 2.26...............

Valve Adjustment 2.27--2.28.........................

Steering and Toe Alignment 2.28--2.29...............

Exhaust Pipe 2.30............................

Brake System 2.30--2.31............................

Wheel and Tire 2.31--2.32..........................

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

2.1

GENERAL INFORMATION

PERIODIC MAINTENANCE CHART

Inspection, adjustment and lubrication intervals of important components is listed in the following chart.
Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 mph.
Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for
replacement parts. Always use genuine Polaris parts.

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

" Vehicles subjected to severe use (operation in wet or dusty areas, low speed heavy load operation,

prolonged idle) should be inspected and serviced more frequently. For engine oil, short trip cold
weather riding also constitutes severe use. Pay special attention to oil level. A rise in oil level in cold weather

can indicate moisture collecting in the oil tank. Change oil immediately if oil level begins to rise.

E Emission Control System Service
(California).

PERIODIC MAINTENANCE - ENGINE

Frequency

(Whichever comes first)

Item Hours Calendar Miles

(Km)

Engine Oil - Level/Change 100 hrs 6 months N/A Check Level Daily; Break In service at 1 month

E"

Oil Filter 100 hrs 6 months N/A Replace with oil change

E

Air Filter - Main Element Weekly Weekly N/A Inspect - Replace if necessary

E"

" Air Box Sediment Tube - Daily N/A Drain deposits whenever visible

" Engine Breather Filter 25 hrs Monthly N/A Inspect and replace if necessary

" Oil Tank Vent Hose 100 hrs 12 months N/A Inspect hose routing /hose condition

Valve Clearance 100 hrs 12 months N/A Inspect/Adjust

EH

Idle Speed As required As required N/A Adjust

E

Choke (Enricher) Cable 50 hrs 6 months N/A Inspect -Adjust, Lubricate, Replace if necessary

Carburetor Float Bowl 50 hrs 6 months N/A Drain bowl periodically and prior to storage

Carburetor Air Intake Ducts/Flange 50 hrs 6 months N/A Inspect all ducts for proper sealing/air leaks

Fuel System 100 hrs 12 months N/A Check for leaks at tank cap, lines, filter, pump &

EH

carburetor. Replace lines every 2 years.

Remarks

CHASSIS

Frequency

(Whichever comes first)

Item Hours Calendar Miles

Remarks

(Km)

Fuel Filter 100 hrs 12 months N/A Replace filter annually

EH

Coolant/Level Inspection Daily Daily N/A Replace engine coolant every 2 years

Coolant Strength / Pressure Test
System

Radiator 100 hrs 12 months N/A Inspect / Clean external surface

Cooling System Hoses 100 hrs 12 months N/A Inspect

Engine Mounts 100 hrs 12 months N/A Inspect

Drain Recoil Housing Weekly Weekly N/A More often if operating in wet environment

Exhaust Muffler / Pipe 100 hrs 12 months N/A

100 hrs 6 months N/A Inspect strength seasonally; Pressure test sys-

tem annually

ELECTRICAL

Spark Plug 100 hrs 12 months N/A Inspect - Replace if necessary

E

Wiring 100 hrs 12 months N/A Inspect for abrasion, routing, security

2.2

GENERAL INFORMATION

CHASSIS

Frequency

(Whichever comes first)

Item Hours Calendar Miles

(Km)

Ignition Timing 100 hrs 12 months N/A Inspect

Battery 25 hrs Monthly N/A Check terminals; Clean; Check fluid level

Headlight Aim As required As required N/A Adjust if Necessary

Headlamp Inspection Daily Daily N/A Check operation daily; Apply Nyogelt Grease

to connector when lamp is replaced

Tail Lamp Inspection Daily Daily N/A Check Operation Daily; Apply Nyogelt Grease

to socket when lamp is replaced

" General Lubrication 50 hrs 3 months N/A Lubricate All Fittings, Pivots, Cables, Etc.

" Front Gearcase Lubricant 100 hrs 12 months N/A Inspect Monthly; Change Annually

" Middle Gearcase Lubricant 100 hrs 12 months N/A Inspect Monthly; Change Annually

" Rear Gearcase Lubricant 100 hrs 12 months N/A Inspect Monthly; Change Annually

Drive Belt 50 hrs 6 months N/A Inspect - Adjust, Replace if Necessary

Clutches (Drive And Driven) 100 hrs 12 months N/A Inspect, Clean

" Transmission Oil Level 25 hrs Monthly N/A Inspect Monthly; Change Annually

Shift Linkage 50 hrs 6 months N/A Inspect,Lubricate, Adjust

H Steering 50 hrs 6 months N/A Inspect Daily, Lubricate

H Toe Adjustment As required As required N/A Periodic Inspection, Adjust When Parts are Re-

placed

" Front Suspension 50 hrs 6 months N/A Inspect - Lubricate

" Rear Suspension 50 hrs 6 months N/A Inspect - Lubricate

Tires Pre-ride Pre-ride N/A Inspect Daily, Pre-Ride Inspection Item

H Brake Fluid 200 hrs 24 months N/A Change Every Two Years

" Brake Fluid Level Pre-ride Pre-ride N/A Inspect Daily, Pre-Ride Inspection Item

" Brake Lever Travel Pre-ride Pre-ride N/A Inspect Daily, Pre-Ride Inspection Item

H Brake Pad Wear 25 hrs Monthly N/A Inspect Periodically

Auxiliary Brake Adjustment As required As required N/A Inspect Deflection Daily; Adjust

Brake System Pre-ride Pre-ride N/A Pre-Ride Inspection Item

Wheels Pre-ride Pre-ride N/A Pre-Ride Inspection Item

Frame Nuts, Bolts, Fasteners Pre-ride Pre-ride N/A Pre-Ride Inspection Item

Remarks

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

" Vehicles subjected to severe use (operation in wet or dusty areas, low speed heavy load operation,

prolonged idle) should be inspected and serviced more frequently. For engine oil, short trip cold
weather riding also constitutes severe use. Pay special attention to oil level. A rise in oil level in cold weather

can indicate moisture collecting in the oil tank. Change oil immediately if oil level begins to rise.

E Emission Control System Service
(California).

2.3

GENERAL INFORMATION

POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS

Part No.

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol)

2871098 Premium 2 Cycle Engine Oil (Quart) (12

2871281 Engine Oil (Quart) Premium 4 Synthetic

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

2871844 Engine Oil (Gallon) Premium 4 Synthetic

2871567 Engine Oil (16 Gallon) Premium 4

Gearcase / Transmission Lubricants

2873603 Premium Synthetic Gearcase Lubricant (1

2873602 Premium Synthetic Gearcase Lubricant

2871653 Premium Front Gearcase Fluid (8 oz.) (12

2871653 Premium Front Gearcase Fluid (2.5 Gal)

2870465 Oil Pump for 1 Gallon Jug

2871654 Premium Drive Hub Fluid (8 oz.) (12

2872277 Premium Drive Hub Fluid (2.5 gal.) (2

2871653 AngleDriveFluid(8oz.)

Grease / Specialized Lubricants

2871322 Premium All Season Grease (3 oz.

2871423 Premium All Season Grease (14 oz.

2871460 Starter Drive Grease (12 Count)

2871515 Premium U-Joint Lube (3 oz.) (24 Count)

2871551 Premium U-Joint Lube (14 oz.) (10 Count)

2871312 Grease Gun Kit
2871329 Dielectric Grease (Nyogelt)

2871323 60/40 Coolant (Gallon) (6 Count)

2871534 60/40 Coolant (Quart) (12 Count)

Additives / Sealants / Thread Locking Agents /

2870585 Loctitet Primer N, Aerosol, 25 g
2871956 Loctitet Thread Sealant 565 (50 ml.) (6

2871949 Loctitet Threadlock 242 (50 ml.) (10

2871950 Loctitet Threadlock 242 (6 ml.) (12

2871951 Loctitet Threadlock 262 (50 ml.) (10

2871952 Loctitet Threadlock 262 (6 ml.) (12

2871953 Loctitet Threadlock 271 (6 ml.) (12

Description

Count)

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

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

Gal.) (4 Count)

(12 oz. bottle) (12 Count)

Count)

(2 Count)

Count)

Count)

cartridge) (24 Count)

cartridge) (10 Count)

Coolant

Misc.

Count)

Count)

Count)

Count)

Count)

Count)

Part No. Description
2871954 Loctitet Threadlock 271 (36 ml.) (6

Count)

2870584 Loctitet 680-Retaining Compound (10

ml.)

2870587 Loctitet 518 Gasket Eliminator / Flange

Sealant (50 ml.) (10 Count)

2872113 Disk Brake Quiet (12 oz.) (12 Count)

2871326 Premium Carbon Clean (12 oz.) (12

Count)

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

2871957 Black RTV Silicone Sealer (3 oz. tube)

(12 Count)

2871958 Black RTV Silicone Sealer (11 oz.

cartridge) (12 Count)

2870990 DOT3 Brake Fluid (12 Count)

2872113 Disc Brake Quiet, Aerosol, (9 oz.) (12

Count)

2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)

2872893 Engine Degreaser (12oz.) (12 Count)

NOTE: The number count indicated by each part

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

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

2.4

SPECIAL TOOLS

PART NUMBER

PA-- 44689 Valve Clutch Adjuster 2

2872105 Water Pump Mechanical Seal Puller 2

8712100 or 8712500 Tachometer 2,10

2200634 Valve Seat Reconditioning Kit 3

2870390 Piston Support Block 3

2871043 Flywheel Puller 3

2871283 Crankshaft/Water Pump Seal Install Kit 3

5131135 Water Pump Install Kit 3

2870569 Crankshaft Truing Stand 5

2872314 Carburetor Float Adjustment Tool 4
2870975 Mity Vact Pressure Test Tool 3, 4, 9

2870871 Ball Joint Replacement Tool 5

2870872 Shock Spanner Wrench 2, 5

2870623 Shock Absorber Spring Compression Tool 5

2871572 Strut Rod Wrench 5

2871573 LH Strut Spring Compressor 5

2871574 RH Strut Spring Compressor 5

2870506 Clutch Puller 6

9314177 Clutch Holding Wrench 6

2871358 Clutch Holding Fixture 6

2870341 Drive Clutch Spider Removal and Install Tool 6

2870654 Clutch Offset Alignment Tool 6

2870913 Driven Clutch Puller 6

2870910 Roller Pin Tool 6

2871226 Clutch Bushing Replacement Tool Kit 6

2870386 Piston Pin Puller 6

8700220 Clutch Compression Tool 6

2871025 Clutch Bushing Replacement Tool Kit 6

2872608 Roller Pin Removal Tool 7

8700226 CV Boot Clamp Pliers 7

PV--43568 Fluket77 Digital Multimeter 10

2870630 Timing Light 10

2870836 Battery Hydrometer 10

GENERAL INFORMATION

TOOL DESCRIPTION CHAPTER TOOL USED IN

PRE-RIDE / DAILY INSPECTION

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

S Tires - check condition and pressures
S Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank
S All brakes - check operation and adjustment (includes auxiliary brake)
S Throttle - check for free operation and closing
S Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
S Engine stop switch - check for proper function
S Wheels - check for tightness of wheel nuts and axle nuts; check to be sure axle nuts are

secured by cotter pins

S Air cleaner element - check for dirt; clean or replace
S Steering - check for free operation noting any unusual looseness in any area
S Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
S Engine coolant - check for proper level at the recovery bottle

2.5

GENERAL INFORMATION

LUBRICATION

Item

1. Engine Oil
4-Strokes

2. Transmission Polaris Synthet-

3. Brake Fluid DOT 3 (PN

Lube Rec. Method Frequency*

Polaris 0W--40
Synthetic (PN

2871281)

ic Gear Case
Lubricant (PN

2871477)

2870990)or

Dot 4

1. Oil Filter

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

Add lube to bottom of fill plug
threads.

Fill reservoir between MAX and
Min lines.

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

Change annually. Change more often if used
in severe conditions.

As required. Change fluid every 2 years.

1. Dipstick

Engine Oil and Filter

2. Fill Plug

Transmission

Engine OIl Tank

3. Reservoir

Brake Master Cylinder

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

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

© Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)

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

Mobilegrease Special

2.6

GENERAL INFORMATION

LUBRICATION, CONT.

Item

4. Front Gearcase Polaris Demand Drive Hub Fluid

5. Rear Gearcase Polaris Gear Drive Fluid

6. Rear Prop
Shaft U--Joints

7. Rear Prop

Shaft Yoke

8. Front Prop

Shaft U--Joints

9. Front Prop

Shaft Yoke

10. Middle Gearcase Polaris Gear Drive Fluid

(PN 2871654)

(PN 2871477)

Polaris Premium U--Joint Lube
(PN 2871551)

Polaris Premium U--Joint Lube
(PN 2871551)

Polaris Premium U--Joint Lube
(PN 2871551)

Polaris Premium U--Joint Lube
(PN 2871551)

(PN 2871477)

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

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

© Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)

Lube Rec. Method Frequency*

Drain completely. Add lube to spe­cified quantity.

Drain completely. Add lube to spe­cified quantity.

Locate fittings and grease and
grease with grease gun.

Locate fittings and grease with
grease gun.

Locate fittings and grease with
grease gun.

Drain completely. Add lube to spe­cified quantity.

Polaris Gear Drive Fluid Semi-- annually¡

Change annually©

Change annually©

Semi--annually¡

Semi--annually¡

Semi--annually¡

Semi--annually¡

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

Mobilegrease Special

4. Fill Plug

5. Fill Plug

Drain Plug Drain Plug

Front Gearcase (4x4 & 6x6) Rear Gearcase (All Models)

10. Fill Plug

Drain Plug

MIddle Gearcase (6x6 )

6. U--Joints

7. Yoke 8. U--Joints

9. Yoke

Rear Prop Shaft Front Prop Shaft (4x4 & 6x6)

2.7

GENERAL INFORMATION

LUBRICATION, CONT.

11. Hub Strut
Assembly

Front Hubstrut

13. Swing
Arm

Pivot

12. Mid Axle Drive Shaft

Mid Angle Driveshaft (6x6)

Swingarm

Item Lube Rec. Method Frequency*

11. Hubsrut As­sembly (Both
Sides)

12. Mid Axle
Drive Shaft (Both
Driveshafts) (6x6)

13. Swing Arm
Pivot

Polaris All Season Grease
(PN 2871423)

Polaris All Season Grease
(PN 2871423)

Polaris All Season Grease
(PN 2871423)

Locate grease fitting on the underside of the hub­strut assembly and grease with grease gun.

Locate grease two grease fittings on both ends
joints of driveshaft and grease with grease gun.

Locate grease fitting in center of driveshaft and
grease with grease gun.

Locate grease fitting on inside of the swing arm
pivot.

Semi Annually¡

Semi Annually¡

Semi Annually¡

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

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

© Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)

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

Mobilegrease Special

2.8

GENERAL INFORMATION

FRONT GEARCASE

LUBRICATION (4X4,
MODELS ONL

FRONT GEARCASE SPECIFICATIONS

Specified Lubricant:

Premium Demand Drive Hub Fluid
(PN 2871654)

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

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

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

S Be sure vehicle is level before

proceeding.

S Check vent hose to be sure it is

routed properly and unobstructed.

S The correct front gearcase lubricant

to use is Polaris Premium Demand
Hub Fluid.

Y)

6X6

7. Install fill plug. Check for leaks.

FRONT GEARCASE (4X4, 6X6)

Make sure vent is unobstructed

Fill plug

Drain plug

Fill Plug Threads

Fill to 3/4” below

threads or fill

with 5 oz. lubricant.

To check the lubricant level:

The gearcase must be drained and re-filled with the
proper amount of lubricant. Refer to the procedure
below.

To change front gearcase lubricant:

1. With the RANGER on a level surface, remove the
fill plug and check the lubricant level. Lubricant
should be kept at the specified level, according to
the proper gearcase specifications listed.

2. Support the vehicle securely with a jackstand and
remove the front tire on the driver’s side.

3. Remove gearcase drain plug located on the
bottom of the gearcase and drain oil. (The drain
plug is accesible through the skid plate.) Catch
and discard used oil properly.

4. Clean and reinstall drain plug using a new sealing
washer.

5. Remove fill plug.

6. Fill with the recommended fluid amount or fill to

0.75 in. (19 mm) below the threads of the fill plug.

MIDDLE GEARCASE

LUBRICATION (6X6 ONL

MIDDLE GEARCASE SPECIFICATIONS

Specified Lubricant:

Polaris Gear Drive Fluid (PN 2871653)

Capacity:........6.75 Oz. (200 ml.)

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

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

S Be sure vehicle is level before

proceeding.

S Check vent hose to be sure it is

routed properly and unobstructed.

S The correct middle gearcase

lubricant to use is Polaris Gear Drive
Fluid

Y)

2.9

GENERAL INFORMATION

To check the lubricant level:

The gearcase must be drained and re-filled with the
proper amount of lubricant. Refer to the procedure
below.

To change middle gearcase lubricant:

1. With the RANGER on a level surface, remove the
fill plug and check the lubricant level. Lubricant
should be kept at the specified level, according to
the proper gearcase specifications listed.

2. Support the vehicle securely with a jackstand and
remove the front tire on the driver’s side.

3. Remove gearcase drain plug located on the
bottom of the gearcase and drain oil. (The drain
plug is accesible through the skid plate.) Catch
and discard used oil properly.

4. Clean and reinstall drain plug using a new sealing
washer.

5. Remove fill plug.

6. Fill with the recommended fluid amount or fill to
the bottom of the threads of the fill plug hole.

7. Install fill plug. Check for leaks.

MIDDLE GEARCASE

Make sure vent is unobstructed

(6X6)

Fill Plug

Drain Plug

Fill to bottom

of fill plug hole

threads or 6.75 oz.

REAR GEARCASE
LUBRICATION (ALL

REAR GEARCASE SPECIFICATIONS

Specified Lubricant:

Polaris Gear Drive Fluid (PN 2871653)

Capacity: 10 Oz. (300 ml.)

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

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

S Be sure vehicle is level before

proceeding.

S Check vent hose to be sure it is routed

properly and unobstructed.

S The correct rear gearcase lubricant to

use is Polaris Gear Drive Lube

To check the lubricant level:

The gearcase must be drained and re-filled with the
proper amount of lubricant. Refer to the procedure
below.

To change rear gearcase lubricant:

1. With the vehicle on a level surface, remove the fill
plug and check the lubricant level. Lubricant
should be kept at the specified level, according to
the proper gearcase specifications listed.

2. Support the vehicle securely with a jackstand and
remove the front tire on the driver’s side.

3. Remove gearcase drain plug located on the
bottom of the gearcase and drain oil. (The drain
plug is accesible through the skid plate.) Catch
and discard used oil properly.

MODELS)

Fill Plug
Threads

2.10

View of Fill Plug Area

GENERAL INFORMATION

4. Clean and reinstall drain plug using a new sealing
washer.

REAR GEARCASE (All

Make sure vent is unobstructed

Drain plug

5. Remove fill plug (A).

Models)

Fill plug

TRANSMISSION SPECIFICATIONS

Specified Lubricant:

Polaris Premium Synthetic Gearcase Lubricant
(PN 2871477) (Gallon) (PN 2871478) (12 oz.)

Approximate Capacity at Change:

4x4 & 6x6: 13.50 oz. (400 ml.)

2x4: 27 oz. (800 ml.)

Drain Plug Torque: 14 ft. lbs. (19.4 Nm)

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

S Be sure vehicle is level before

proceeding.

S Check vent hose to be sure it is

routed properly and unobstructed.

To check the level:

1. Remove transmission plug and wipe clean.

A

6. Fill with the recommended fluid amount or fill to
the bottom of the threads of the fill plug hole.

7. Install fill plug. Check for leaks.

TRANSMISSION
LUBRICA

NOTE: It is very important to follow a regular

transmission fluid check/change schedule. The
service manual of the RANGER recommends the
level be checked every twenty- five (25) hours of
operation, and changed once (1) a year.

TION

Transmission Fill Plug

2. To check the level, use a light colored and non
absorbent measuring instrument (Exp: white zip
tie). The fluid level of the 2x4 models is 3/4” (19

mm) below the top thread of the fill plug. The 4x4
and 6x6 models should measure 1 1/2” (38 mm)

below the top thread of the fill plug. See ILL. 2 on
next page.

Simply modify the measuring instrument to the
specified distance. Dip the measuring instrument
into the gearcase, the fluid level should just touch
the bottom portion of the measuring instrument.
Fill or drain the transmission until the specified
quantities are reached. Sell ILL. 3 and ILL. 4.

ILL. 1

2.11

GENERAL INFORMATION

Examples of Measuring Instruments

2x4 Model

4x4 & 6x6 Models

4x4 & 6x6 T

Measuring Instrument

ransmission

Top Fill Plug Thread

3/4” (19 mm)
Below top thread
of fill plug.

2x4 Transmission

Measuring Instrument

3/4”

1 1/2” (38 mm)
Below top thread
of fill plug.

ILL. 2

Top Fill Plug Thread

11/2”

Fluid Level

1 1/2” (38 mm) Below Top Fill Plug HoleThread

Inside View of Transmission Fluid Level

ILL. 4

To change lubricant:

1. Remove skid plate (if necessary).

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

3. Remove the drain plug and wipe the magnetic end
clean to remove accumulated metallic filings.

Fluid Level

3/4” (19 mm) Below Top Fill Plug HoleThread

Inside View of Transmission Fluid Level

ILL. 3

Transmission

Drain Plug

ILL.5

4. After the oil has drained completely, install a new
sealing washer and install the drain plug. Torque
to 14 ft. lbs. (19 Nm).

5. Add the proper lubricant through the dipstick hole
until the oil level is between the upper and lower
limits. Do not overfill. Refer to Illustration 2 for
proper fluid level depending on the RANGER
model.

6. Check for leaks.

7. Reinstall skid plate if removed in Step 1.

2.12

GENERAL INFORMATION

SHIFT LINKAGE
INSPECTION/ADJUSTMENT

Linkage rod adjustment is necessary when symptoms
include:

S No All Wheel Drive light
S Noise on deceleration
S Inability to engage a gear
S Excessive gear clash (noise)
S Shift selectors moving out of desired

range

NOTE: Remove necessary components to gain
access to shift linkage cable ends (i.e. exhaust heat
shield, exhaust pipe, etc.).

end, also.

Inside Jam Nut

Transmission Cable Adjustment

5. After turning the outside jam nut 1 1/2 turns. Hold
the outside jam nut with a wrench and tighten the
inside jam nut clockwise, until it is tight against the
bracket.

6. Repeat Step 4 and Step 5 until the proper
adjustment
is made for the transmission cable.

7. Use this procedure to loosen or tighten the shift
linkage cable as needed.

Outside Jam Nut

1. Inspect shift linkage cable, clevis pins, and pivot
bushings and replace if worn or damaged.

2. Be sure idle speed is adjusted properly.

3. Place gear selector in neutral. Make sure the
transmission bell crank is engaged in the neutral
position detents.

4. With two wrenches loosen the outside jam nut
counterclockwise. Turn the outside jam nut 1 1/2
turns. Perform this procedure on the shift lever

Clockwise

Counterclockwise

Shift Lever Cable Adjustment

Inside Jam Nut

Outside Jam Nut

2.13

GENERAL INFORMATION

THROTTLE PEDAL
INSPECTION

Throttle Freeplay

Parking

Brake

Throttle Pedal

If the throttle pedal has excessive play due to cable
stretch or cable misadjustment, it will cause a delay in
throttle speed. Also, the throttle may not open fully.
If the throttle pedal has no play, the throttle may be
hard to control, and the idle speed may be erratic.
Check the throttle pedal play periodically in
accordance with the Periodic Maintenance Chart and
adjust the play if necessary.

Throttle Freeplay Inspection

Boot

Adjuster
Sleeve

Lock­nut

Boot

THROTTLE CABLE
ADJUSTMENT

NOTE: If the proper freeplay cannot be obtained with

the throttle block adjuster, adjust the cable at the
carburetor using the following procedure.

1. Remove seat.

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

3. Loosen lock nut and turn adjuster until proper
throttle lever freeplay is obtained.

4. Tighten locknut and slide boot back over adjuster.

5. Reinstall seat.

6. Check for proper throttle operation and correct
freeplay in all handlebar positions.

1. Apply the parking brake.

2. Put the gear shift lever in the N (Neutral) position.

3. Start the engine, and warm it up thoroughly.

4. Measure the distance the throttle pedal moves
before the engine begins to pick up speed. Free
play should be 1/16 - 1/8 inches.

Adjustment

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

2. Turn adjuster until 1/16, to 1/8, freeplay is
achieved pedal. NOTE: While adjusting freeplay,
it is important you flip the throttle lever back and
forth.

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

Throttle Cable
Adjuster

Lock Nut

CHOKE (ENRICHER)
ADJUSTMENT

With the choke control pushed in, the choke plunger
must be seated on the fuel passage way in the
carburetor. If the plunger is not seated on the fuel
passage way inside the carburetor (not enough cable
freeplay), the engine will flood or run too rich, causing
plug fouling and poor performance.

2.14

If cable slack is excessive, the choke fuel passage will
not open far enough, which may cause cold starting
difficulty. Also, the half-choke position used for
intermittent applications will not function properly.

GENERAL INFORMATION

A

1. Locate the boot by the carburetor and pull it back.
Loosen the friction nut 1 turn or until choke slides
freely. Re-install boot.

2. Push the choke knob (A) in to the full off position.

3. Slide boots off in-line cable adjuster and loosen
adjustment locknut.

4. Turn adjuster until the choke knob pulls out over
1/4².

5. Push on the choke knob lightly while turning the
adjuster the opposite way.

Boot

6. Turn the adjuster until the knob contacts the boot.

7. Tighten adjuster nut.

8. Slide boots back over cable adjuster sleeve until
they touch at the middle point of the adjuster.

9. Pull back the choke knob boot and tighten the
friction nut until the choke will maintain a set
position. Re-install boot.

Adjuster
Sleeve

Lock­nut

Boot

FRONT
(Engine)

Pilot Screw

Pilot Screw Adjustment

Refer to Specifications

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

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

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

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

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

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

8. Re adjust idle speed if not within specification.

PILOT SCREW

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

ADJUSTMENT

2.15

GENERAL INFORMATION

IDLE SPEED ADJUSTMENT

1. Start engine and warm it up thoroughly.

CV Carburetor

Idle Screw

Idle Speed:

1200 +/-- 200 RPM

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

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

S Never start the engine or let it run

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

S Never drain the float bowl when

the engine is hot. Severe burns
may result.

FUEL

1. Check fuel lines for signs of wear, deterioration,

2. Be sure fuel lines are routed properly and secured

3. Replace all fuel lines every two years.

LINES

damage or leakage. Replace if necessary.

with cable ties. CAUTION: Make sure lines are
not kinked or pinched.

VENT LINES

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

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

FUEL FIL

TER

FUEL

Gasoline is extremely flammable and explosive
under certain conditions.

SYSTEM

WARNING

S Always stop the engine and refuel

outdoors or in a well ventilated
area.

S Do not smoke or allow open

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

S Do not overfill the tank. Do not fill

the tank neck.

S If you get gasoline in your eyes or

if you swallow gasoline, seek
medical attention immediately.

S If you spill gasoline on your skin

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

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

1. Remove line clamps at both ends of the filter (A).

2. Remove fuel lines from filter (A).

Fuel Flow

Fuel Pump

A

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

4. Install clamps on fuel line.

2.16

GENERAL INFORMATION

5. Start engine and inspect for leaks.

CARBURETOR

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

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

1. Turn fuel valve to the off position.

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

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

4. Inspect the drained fuel for water or sediment.

5. Tighten drain screw.

6. Turn fuel valve to “ON”.

7. Start machine and check for leaks.

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

DRAINING

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.

Ill. 1

Drain tube
attached
here

Drain Screw

NOTE: New Batteries:
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. Do not use the
alternator to charge a new battery. (Refer to Battery

Activation and Maintenance video PN 9917987)

The battery is located under the left rear fender.

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

Maintain
between upper
and lower level
marks

Ill. 1

Batteries must be fully

2.17

GENERAL INFORMATION

To remove the battery:

1. Disconnect holder strap and remove cover.

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

CAUTION

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

3. Disconnect the vent hose.

4. Remove the battery.

5. Remove the filler caps and add distilled water only
as needed to bring each cell to the proper level.
Do not overfill the battery. Fully recharge after
filling.

Use only distilled water. Tap water contains

minerals which are harmful to a battery.

Do not allow cleaning solution or tap water to

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

6. Reinstall the battery caps.

7. 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.

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

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

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

11. Reinstall battery cover and holder strap.

SPARK

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

2. Remove spark plug.

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

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

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

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

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

8. Install spark plug and torque to specification.

PLUG

Recommended Spark Plug:

Refer to Specifications

Spark Plug Torque:

14 Ft. Lbs. (19 Nm)

Spark Plug Gap

.036² (0.9 mm)

2.18

IGNITION TIMING

Refer to Chapter 10 for ignition timing procedures.

Ignition Timing 425/500 Engines:

30°±2° BTDC@5000RPM

GENERAL INFORMATION

ENGINE TO FRAM GROUND

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

Ground

LIQUID COOLING SYSTEM
OVER

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

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

Some coolant level drop on new machines is normal
asthe system is purgingitself of trappedair. Observe
coolant levels often during the break-in period.

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

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

VIEW

COOLANT STRENGTH /

Test the strength of the coolant using an antifreeze
hydrometer.

Antifreeze Hydrometer

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

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

S Do not use tap water, straight antifreeze,

or straight water in the system. Tapwater
contains minerals and impurities which
build up in the system.

S Straight water or antifreeze may cause

the system to freeze, corrode, or
overheat.

Polaris 60/40 Anti-Freeze / Coolant

(PN 2871323)

COOLANT

LEVEL

TYPE

INSPECTION

The recovery bottle, located on the left side of the
machine, must be maintained between the minimum
andmaximumlevelsindicatedontherecoverybottle.

Surge Tank Cap

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

2.19

GENERAL INFORMATION

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

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

3. Reinstall cap.

Surge Tank

Radiator Cap

WARNING Never remove the pressure cap

when the engine is warm or hot. Escaping steam can
cause severe burns. The engine must be cool before
removing the pressure cap.

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

RADIATOR COOLANT LEVEL
INSPECTION

NOTE: This procedure is only required if the cooling

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

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

To access the radiator pressure cap raise the front
hood.
The radiator cap is located on the drivers side.

COOLING SYSTEM

Coolant Lines

Fan

Radiator

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

2. Check tightness of all hose clamps.

HOSES

2.20

GENERAL INFORMATION

CAUTION:

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

COOLING
PRESSURE

Refer to Page 3.5 for pressure test procedure.

RADIAT

1. Check radiator (A) air passages for restrictions or
damage.

2. Carefully straighten any bent radiator fins.

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

SYSTEM

TEST

OR

A

the frame.

Bolts

Wheel Well

Bolts

2. Remove two mounting screws that secure the top
of the radiator to the frame. Remove the radiator
cap. Pull the radiator out of the frame at an angle.

NOTE: If you have trouble reaching the top radiator
bolts, remove four screws from the top front of the
hood liner. Prop the front of the hood up 1.5 inches
(38.10 mm) to help remove the top bolts that secure
the radiator to the frame.

3. Remove the drain plug and drain the coolant from
the radiator. Drain the coolant into a suitable
container and properly dispose of the coolant.

4. Remove the outlet radiator hose, inlet radiator
hose, surge tank hose, and overflow hose from
the radiator.

5. Unplug the thermal sensor harness and the fan
harness.

COOLANT DRAIN/RADIAT
REMOV

1. Remove the front bumper. Remove three bolts
that secure the bumper to the bottom of the
frame. Remove six screws (both sides) that
secure the wheel well panel to the frame.
Remove two bolts that secure the top bumper to

AL

OR

2.21

GENERAL INFORMATION

6. Remove the radiator.

Inlet Radiator Hose

Cap

Surge Tank

Hose

Outlet Radiator

Hose

Mounting

Screws

Temp. Sensor Plug

AIR FILTER/ BREATHER
FILTER SER

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

The filter should be inspected periodically before each
ride, using the following procedure.

1. Lift the box to access the filter box cover.

2. Remove clips (2) from air box cover and remove
cover. Inspect the gasket. It should adhere tightly
to the cover and seal all the way around.

3. Remove air filter assembly. Do not clean the main
filter, the filter should be replaced.

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

VICE

Breather Filter

Cover Seal

Filter

Cover

Installation

1. Reinstall the filter into the air box container. Be
sure the filter fits tightly in the air box.

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

2. Check air box. If oil or water deposits are found,
drain them into a suitable container.

NOTE: Service more frequently if vehicle is operated
in wet conditions or at high throttle openings for
extended periods.

3. Install air box cover and secure with clips.

2.22

BREATHER FILTER INSPECTION

The engines are equipped with a breather filter. The
in-line filter is similar in appearance to a fuel filter, and
is visible on the left side (Location A). Follow right
hand breather line out of the side of the airbox and
locate filter. Blow through gently in direction of arrow
on filter to check for clogging. Replace as needed.

A

GENERAL INFORMATION

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

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

BREATHER

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

HOSE

2.23

GENERAL INFORMATION

AIR INTAKE INSPECTION

Foam

Air Baffling

Box

1. Lift the hood.

2. Inspect the foam inserts in the air baffle boxes. If
the foam inserts are dirty, clean the foam with a
high flash point solvent, followed by hot soapy
water.

3. Rinse and dry the foam thoroughly.

4. Inspect the foam for tears or damage. Replace if
necessary.

5. Reinstall the foam inserts into the air baffle boxes.

Air Box

Engine Intake

Duct

FLYWHEEL

S Drain the housing periodically to remove moisture.

S Drain the flywheel housing after

operating the vehicle in very wet
conditions. This should also be done
before storing the vehicle. The drain
screw is located at the bottom of the
flywheel housing. Remove the plug.
Reinstall the plug once housing has
been drained.

S After travelling in wet areas the

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

S Do not open the crankcase drain

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

HOUSING

Gasket

Plug

2.24

GENERAL INFORMATION

ENGINE OIL LEVEL

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

1. Set machine on a level surface.

2. Start and run engine for 20-30 seconds. This will
return oil to its true level in the oil tank. About a
cup of oil will remain in the crankcase.

3. Stop engine, remove the bench seat.

4. The oil tank is located on the driver side. Remove
dipstick and wipe dry with a clean cloth.

Dipstick

5. Reinstall dipstick, screwing into place.

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

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

OIL AND FILTER

CHANGE

WARNING

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

NOTICE:

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

RECOMMENDED ENGINE OIL:

Poaris Premium Synthetic OW--40

(PN 2871281) (Quart)

Ambient Temperature Range:

-- 4 0 ° F to 120° F

1. Place vehicle on a level surface.

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

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

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

5. Allow oil to drain completely.

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

Screw in completely to check

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

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

D

A

B

7. Reinstall drain plug and torque to 14 ft. lbs. (19
Nm).

8. Loosen clamp (D).

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

C

2.25

GENERAL INFORMATION

10. Remove screen fitting (C).

11. Clean screen thoroughly.

12. Apply Loctitet 565 Thread Sealant (PN

2871956) to the clean and oil free threads of the
fitting.

13. Install the fitting (C) and tighten.

14. Install oil hose on fitting and install clamp.

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

Oil Filter

25. Dispose of used filter and oil
properly.

Oil Tank Drain Plug Torque:

14 ft. lbs. (19 Nm)

Crankcase Drain Plug Torque:

14 ft. lbs. (19 Nm)

Oil Filter Torque:

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

Oil Filter Wrench:

PV--43527

Oil Tank Screen Fitting Torque:

14-17 ft. lbs. (19 Nm)

OIL
PRIMING

PUMP

PROCEDURE

16. Using a clean dry cloth, clean filter sealing surface
on crankcase.

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

18. Install new filter and turn by hand until filter gasket
contacts the sealing surface, then turn and
additional 1/2 turn.

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

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

20. Reinstall drain plug.

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

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

23. Prime oil pump using procedure below.Stop
the engine and inspect for leaks.

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

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

1. Clamp or pinch off vent line approximately 2I

from oil tank to avoid the end of oil tank vent fitting,
and before the vent line’s pressure relief slit

2. Run engine for 45-60 seconds.

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

Approx.

To Ai r Bo x

2I

Oil Tank

Slit

Pinch Off

Vent Hose

2.26

VALVE CLEARANCE

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

1. Remove the seat.

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

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

4. Remove rocker cover bolts, cover and gasket.

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

5. Remove timing inspection plug from recoil
housing.

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

Sprocket alignment pin facing up

GENERAL INFORMATION

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

INTAKE VALVE

CLEARANCE

ADJUSTMENT

1. Insert a .006² (.15mm) feeler gauge between end
of intake valve stem and clearance adjuster
screw.

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

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

4. Re-check the valve clearance.

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

6. Repeat this step for the other intake valve.

Crankshaft-to-Camshaft Centerline

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

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

INTAKE VALVE CLEARANCE

.006² (.15 mm)

2.27

GENERAL INFORMATION

EXHAUST VALVE
CLEARANCE

Feeler Gauge for Both Valves

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

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

2. Loosen locknut(s) and turn adjuster screw(s) until
there is a slight drag on feeler gauge(s). The
Valve/Clutch Adjuster Tool (PA--44689) can be
used to adjust the 425/500 engines valves.
NOTE: Both feeler gauges should remain
inserted during adjustment of each valve.

ADJUSTMENT

500 Engine

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.

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

TIE ROD END /

STEERING

INSPECTION

S To check for play in the tie rod end,

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

S Repeat inspection for inner tie rod

end (on steering post).

S Replace any worn steering

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

EXHAUST VALVE CLEARANCE

.006² (.15 mm)

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

4. Re-check the valve clearance.

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

STEERING

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

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

S Elevate front end of machine so front

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

2.28

Hold
Rod End

GENERAL INFORMATION

Check for Loose Wheel or Hub

S If abnormal movement is detected,

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

S Refer to the Body/Steering or Final

Drive chapter for more information.

CAMBER AND

The camber and caster are non-adjustable.

TOE

ALIGNMENT

CASTER

ADJUSTMENT

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

Correctly
Tightened

Ill.2

To adjust toe

Jam Nut

Ill.2

alignment:

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

alignment is as required to achieve the
proper toe setting as specified in
Method 1 or Method 2.

S IMPORTANT: When tightening the tie

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

S After alignment is complete, torque jam

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

Incorrectly
Tightened
Jam Nut

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

2.29

GENERAL INFORMATION

EXHAUST PIPE

WARNING

S Do not perform clean out immediately

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

S To reduce fire hazard, make sure that

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

S Wear eye protection.

S Do not stand behind or in front of the ve-

hicle while purging the carbon from the
spark arrestor.

S Never run the engine in an enclosed

area. Exhaust contains poisonous car­bon monoxide gas.

S Do not go under the machine while it is

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

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

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

3. SEE WARNING

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

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

8. Reinstall the clean out plugs.

BRAKE SYSTEM

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.

INSPECTION

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

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

Ill.1

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

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

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

SEE WARNING

Clean Out Plug

S Keep fluid level in the master cylinder

reservoir to the indicated level inside
reservoir.

S Use Polaris DOT 3 Brake Fluid (PN

2870990) or DOT 4 Brake Fluid.

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

spongy feel.

S Check friction pads for wear,

damage or looseness.

S Check surface condition of the disc.

2.30

GENERAL INFORMATION

BRAKE PAD INSPECTION

Pads should be changed when the friction material is
wornto3/64² (.1 cm), or about the thickness of a dime.

3/64²
(.1cm)

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.

WHEEL, HUB, AND

Minimum
Thickness

SPINDLE

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

2. Loosen the wheel nuts slightly.

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

4. Remove the wheel nuts and remove the wheel.

WHEEL INSTALLA

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.

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

CAUTION:

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

TION

TORQUE T

Item

Front Wheel Nuts 35 Ft. Lbs. (47 Nm)

Rear Wheel Nuts 35 Ft. Lbs. (47 Nm)

Front Spindle Nut 40 Ft. Lbs. (55 Nm)

Rear & Center Hub Retain-

ing Nut

ABLE

Specification

110 Ft. Lbs. (150 Nm)

WHEEL REMOVAL FRONT OR
REAR

Flange Nuts:
Flat side against wheel

2.31

GENERAL INFORMATION

TIRE PRESSURE

CAUTION:

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

Tire Pressure Inspection (PSI - Cold)

Front Center & Rear

10 10

TIRE INSPECTION

S Improper tire inflation may affect

vehicle maneuverability.

S When replacing a tire always use

original equipment size and type.

S The use of non-standard size or type

tires may affect vehicle handling.

Tire Tread Depth

Always replace tires when tread depth is worn to
1/8² (3 mm) or less.

that all cotter pins are in place. Refer to specific
fastener torques listed in each chapter.

S Check all rear suspension components

for wear or damage.

FRONT

Rear Spring
Adjustment Cam

SUSPENSION

Shock Spanner Wrench

Tread
Depth 1/8I (3 mm)

WARNING

Operating a RANGER with worn tires
will increase the possibility of the vehicle
skidding easily with possible loss of con­trol.

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

depth measures 1/8² (.3 cm) or less.

FRAME, NUTS, BOL

(PN 2870872)

S Compress and release front suspension.

Damping should be smooth throughout
the range of travel.

S Check all front suspension components

for wear or damage.

S Inspect front strut cartridges for leakage.

TS,

F

ASTENERS

Periodically inspect the torque of all fasteners in
accordance with the maintenance schedule. Check

2.32

REAR SUSPENSION

GENERAL INFORMATION

Rear Suspension

Swing Arm

U--Bolt

Washer & Bolt

Pivot Bolt Lock

Frame

Rear Axle

S Compress and release rear suspension.

Damping should be smooth throughout
the range of travel.

S Check all rear suspension components

for wear or damage.

S Inspect shock for leakage.

Bushings

Coil Over

Shock

Pivot Bolt

2.33

GENERAL INFORMATION

NOTES

2.34

CHAPTER 3
ENGINE

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Counter Balancer End Play Inspection. 3.40.........

Oil Pump Shaft End Play Inspection 3.40--3.41...........

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

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

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

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

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

ENGINE

3

3.1

ENGINE

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Fastener Size EH42PLE/

EH50PLE

Ft. Lbs. (Nm)

Blind Plug (Oil
Pressure)

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

Camshaft Chain
Tensioner Lever

Camshaft Chain
Tensioner

Camshaft Chain
Tensioner Cap

Carburetor Adaptor 8mm 12-14 (16-20 Nm)

Crankcase 8mm 14-15 (19-21 Nm)

Crankshaft Slotted
Nut (Cam Chain
Drive Sprocket)

Cylinder Base
Bolts

Cylinder Head
Bolts

Drive Clutch Bolt 7/16 -

Flywheel 16mm 58-72 (78-98 Nm)

Oil Delivery Pipe 12mm 11-15 (15-21 Nm)

Oil Drain Bolt
(Crankcase)

Oil Filter Pipe Fit­ting

Oil Hose Fitting 1/8 Pipe

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

OilPumpCase
Screw

One Way Valve 11mm 14-19 (20-25 Nm)

Recoil Housing 6mm 5-6.5 (7-9 Nm)

Rocker Cover 6mm 7-8 (9-11 Nm)

Rocker Support 8mm 8-10 (11-13 Nm)

Rocker Adjuster
Screw

Water Pump Impel­ler Nut

1/8 PT
(28tpi)

6mm 5-6.5 (7-9 Nm)

6mm 5-6.5 (7-9 Nm)

11mm 14-19 (20-25 Nm)

28mm 35-51 (47-69 Nm)

10mm

6mm

11mm

6mm

20

14mm 14-17 (19-23 Nm)

20mm 36-43 (49-59 Nm)

Thread

5mm 1.5-2 (2-3 Nm)

6mm 6-7 (8-10 Nm)

6mm 5-6.5 (7-9 Nm)

6.5-11 (9-15 Nm)

45-49 (61-67 Nm)

6-8 (9-11 Nm)

Refer to Engine

Assembly for

torque procedure

40 (55 Nm)

6.5-11 (9-15 Nm)

Water Pump
Housing Cover

Stator Plate 6mm 5-6.5 (7-9 Nm)

Starter Motor 6mm 5-6.5 (7-9 Nm)

Spark Plug 14mm 9-11 (12-15 Nm)

6mm 5-6.5 (7-9 Nm)

SPECIAL TOOLS

PART NUMBER

2200634 Valve Seat

2870390 Piston Support

2871043 Flywheel Puller

2871283 Crankshaft/Water

5131135 Water Pump

2870569 Crankshaft Truing

2870975 Mity Vact

PV--43527 OIl Filter Wrench

TOOL

DESCRIPTION

Reconditioning Kit

Block

Pump Seal Install

Kit

Install Kit

Stand

Pressure Test Tool

3.2

ENGINE SERVICE DATA

g

j

j

y

g

g

g

pgg

ENGINE

Cylinder Head / Valve

Rocker Arm

Camshaft Cam lobe height In

Cylinder Head

Valve Seat Contacting width In

Valve Guide

Valve Margin thickness In

Valve

Valve Spring Overall length

Rocker arm ID .8669-.8678² (22.020-22.041 mm) .8669-.8678² (22.020-22.041 mm)

Rocker shaft OD .8656-.8661² (21.987-22.0 mm) .8656-.8661² (21.987-22.0 mm)

Rocker shaft Oil Clearance

Camshaft journal OD

Camshaft journal bore ID

Camshaft Oil clearance

Surface warpage limit .0020² (.05 mm) .0020² (.05 mm)

Standard height 3.870² (98.3 mm) 3.870² (98.3 mm)

Inner diameter .2362-.2367² (6.0-6.012 mm) .2362-.2367² (6.0-6.012 mm)

Protrusion above head .689-.709² (17.5-18.0 mm) .689-.709² (17.5-18.0 mm)

Stem diameter In .2343-.2348² (5.950-5.965 mm) .2343-.2348² (5.950-5.965 mm)

Stem oil clearance Std

Overall length

Squareness .075² (1.9 mm) .075² (1.9 mm)

EH42PLE EH50PLE

Std .0008-.0021² (.020-.054 mm) .0008-.0021² (.020-.054 mm)

Limit .0039² (.10 mm) .0039² (.10 mm)

Std 1.2884-1.2924² (32.726-32.826 mm) 1.2884-1.2924² (32.726-32.826 mm)

Limit 1.2766² (32.426 mm) 1.2766² (32.426 mm)

Ex

Std 1.2884-1.2924² (32.726-32.826 mm) 1.2884-1.2924² (32.726-32.826 mm)

Limit 1.2766² (32.426 mm) 1.2766² (32.426 mm)

Mag 1.4935-1.4941² (37.935-37.950 mm) 1.4935-1.4941² (37.935-37.950 mm)

PTO 1.4935-1.4941² (37.935-37.950 mm) 1.4935-1.4941² (37.935-37.950 mm)

Mag 1.4963-1.4970² (38.005-38.025 mm) 1.4963-1.4970² (38.005-38.025 mm)

PTO 1.4963-1.4970² (38.005-38.025 mm) 1.4963-1.4970² (38.005-38.025 mm)

Std .0022-.0035² (.055-.090 mm) .0022-.0035² (.055-.090 mm)

Limit .0039² (.10 mm) .0039² (.10 mm)

Std .028² (.7 mm) .028² (.7 mm)

Limit .055² (1.4 mm) .055² (1.4 mm)

Ex

Std .039² (1.0 mm) .039² (1.0 mm)

Limit .071² (1.8 mm) .071² (1.8 mm)

Std .039² (1.0 mm) .039² (1.0 mm)

Limit .031² (.8 mm) .031² (.8 mm)

Ex

Std .047² (1.2 mm) .047² (1.2 mm)

Limit .031² (.8 mm) .031² (.8 mm)

Ex .2341-.2346² (5.945-5.960 mm) .2341-.2346² (5.945-5.960 mm)

In .0014-.0024² (.035-.062 mm) .0014-.0024² (.035-.062 mm)

Ex .0016-.0026² (.040-.067 mm) .0016-.0026² (.040-.067 mm)

Limit .0059² (.15 mm) .0059² (.15 mm)

In 3.976² (101.0 mm) 3.976² (101.0 mm)

Ex 3.984² (101.2 mm) 3.984² (101.2 mm)

Std 1.654² (42.0 mm) 1.654² (42.0 mm)

Limit 1.575² (40.0 mm) 1.575² (40.0 mm)

3.3

ENGINE

y

gggpp

g

g

g

p

g

g

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g

g

g

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ENGINE SERVICE DATA

Cylinder / Piston / Connecting Rod

Cylinder

Piston Outer diameter

Piston Pin

Piston Ring Piston ring installed gap To p ring

Piston Ring Standard clearance -

Connecting
Rod

Crankshaft Crankshaft runout limit .0024² (.06 mm) .0024² (.06 mm)

Surface warpage limit (mating with cylinder head) .0020² (.05 mm) .0020² (.05 mm)

Cylinder bore Std 3.4606-3.614² (87.900-87.920 mm) 3.6221-3.6228² (92.00-92.02 mm)

Taper limit .0020² (.050 mm) .0020² (.050 mm)

Out of round limit .0020² (.050 mm) .0020² (.050 mm)

Piston clearance

Boring limit .020² (.5 mm) .020² (.5 mm)

Std 3.4596-3.4600² (87.875-87.885 mm) 3.6204-3.6215² (91.970-91.985 mm)

.0098² (.25 mm) OS 3.4695-3.4699² (88.125-88.135 mm) 3.6304-3.6310² (92.21-92.23 mm)

.0197² (.50 mm) OS 3.4793-3.4797² (88.375-88.385 mm) 3.6403-3.6407² (92.46-92.47 mm)

Standard inner diameter of piston pin bore .9055-.9057² (23.0-23.006 mm) .9055-.9057² (23.0-23.006 mm)

Outer diameter .9053-.9055² (22.994-23.0 mm) .9053-.9055² (22.994-23.0 mm)

Standard clearance-piston pin to pin bore .0002-.0003² (.004-.008 mm) .0002-.0003² (.004-.008 mm)

Degree of fit Piston pin must be a push (by hand) fit at 68° F(20° C)

Second
ring

Oil ring

Top ri n g

pistonringtoringgroove

Second
ring

Connecting rod small end ID .9058-.9063² (23.007-23.020 mm) .9058-.9063² (23.007-23.020 mm)

Connecting rod small end radial clear­ance

Connecting rod big end side clearance

Connecting rod big end radial clear­ance

Std .0006-.0018² (.015-.045 mm) .0006-.0018² (.015-.045 mm)

Limit .0024² (.060 mm) .0024² (.060 mm)

Std .0079-.0138² (.20-.36 mm) .0079-.0138² (.20-.36 mm)

Limit .039² (1.0 mm) .039² (1.0 mm)

Std .0079-.0138² (.20-.36 mm) .0079-.0138² (.20-.36 mm)

Limit .039² (1.0 mm) .039² (1.0 mm)

Std .0079-.0276² (.20-.70 mm) .0079-.0276² (.20-.70 mm)

Limit .059² (1.5 mm) .059² (1.5 mm)

Std .0016-.0031² (.040-.080 mm) .0016-.0031² (.040-.080 mm)

Limit .0059² (.15 mm) .0059² (.15 mm)

Std .0012-.0028² (.030-.070 mm) .0012-.0028² (.030-.070 mm)

Limit .0059² (.15 mm) .0059² (.15 mm)

Std .0003-.0010² (.007-.026 mm) .0003-.0010² (.007-.026 mm)

Limit .0020² (.05 mm) .0020² (.05 mm)

Std .0039-.0256² (.1-.65 mm) .0039-.0256² (.1-.65 mm)

Limit .0315² (.80 mm) .0315² (.80 mm)

Std .0004-.0015² (.011-.038 mm) .0004-.0015² (.011-.038 mm)

Limit .0020² (.05 mm) .0020² (.05 mm)

EH42PLE EH50PLE

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

3.4

ENGINE

ENGINE FASTENER TORQUE

TTERNS

PA

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

6mm

23

1

Cylinder Head

Cylinder Base

4

Pattern

7

3

1

5

6

5

9

10

Engine
Model
No.

EH50PLE .25

EH42PLE 25

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

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

oversized

Oversize
Available*
(mm)

.50

.50

Piston
Length

72 mm C

66 mm B

Standard
Piston Iden­tification

8

2

4

6

Crankcase

Pattern

PISTON IDENTIFICATION

The piston may
the piston may not
piston placement. If the piston has an identification

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

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

have an indentification mark or

have an identification mark for

3.5

ENGINE

COOLING SYSTEM

WARNING: Never remove radiator cap when engine

is warm or hot. The cooling system is under pressure

FLOW

Radiator

Thermostat

Cylinder
Head

Water
Pump

Cylinder

and serious burns may result. Allow the engine and

cooling system to cool before servicing.

System Pressure Test

1. Remove front cover.

2. Remove recovery bottle hose from coolant
filler.

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

Radiator Cap Pressure Test

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

2. The radiator cap relief pressure is 13 lbs.

3.6

Top

Bottom

Radiator
Left Side
View

Radiator
Front
View

ENGINE

RECOMMENDED COOLANT

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

COOLING
SPECIFICA

Fan Switch (Off)
Fan Switch (On)

Hot Light On 221° F (105° C)

System Capacity 2.25 Quarts

Radiator Cap Relief

Pressure

Thermostat Starts opening 176° F

SYSTEM

TIONS

149° F(65° C) ± 8°
180° F(82° C) ± 3°

13 PSI

(80° C)

Open 8mm @ 205° F

(96° C)

ACCESSIBLE COMPONENTS

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

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

Mechanical Seal*

The following components require engine removal for
service:

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

S Crankshaft Main Bearings
S Crankcase

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

ENGINE REMOVAL

1. Clean work area.

2. Thoroughly clean the ATV engine and chassis.

3. Disconnect battery negative (-) cable.

4. Remove the following parts as required.

S Seat
S Left and Right Side Covers (Refer to

Chapter 5)

S Fuel Tank Cover / Front Cab (Refer to

Chapter 5)

S Fuel Tank (Refer to Chapter 4)

5. Disconnect spark plug high tension lead.

6. Remove springs from exhaust pipe and remove
pipe.

7. Drain coolant and engine oil.

8. Remove air pre-cleaner and duct.

9. Remove airbox.

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

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

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

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

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

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

16. Disconnect coolant temperature sensor wire.

17. Remove engine to chassis ground cable.

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

19. Remove engine through right side of frame.

(TYPICAL)

3.7

ENGINE

ENGINE INSTALLATION
NOTES

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

General Items

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

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

PVT System

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

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

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

Transmission

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

Exhaust

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

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

Bleed Cooling System

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

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

CYLINDER

HONE
SELECTION/HONING
PROCEDURE

CAUTION:

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

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

NOTE: See next page for more information on
honing.

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

2. Fill coolant reservoir tank to full mark.

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

4. Again remove radiator cap and slowly add coolant
to top of fill neck.

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

Engine Break In Period

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

1. Use only Polaris Premium 4 All Season synthetic
oil. Never substitute or mix oil brands. Serious
engine damage can result.

3.8

HONING TO OVERSIZE

ENGINE

CAUTION: If cylinder wear or damage is excessive,

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

CAUTION: For oversize honing always wet hone
using honing oil and a coarse roughing stone.
Measure the piston (see piston measurement) and
rough hone to the size of the piston. Always leave
.002 - .003² (.05 - .07 mm) for finish honing. Refer to
piston-to-cylinder clearance specifications on Page

3.4 before honing. Complete the sizing with fine grit

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

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

CLEANING THE
AFTER

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. Pay
close attention to areas where the cylinder sleeve
meets the aluminum casting (transfer port area). Use
electrical contact cleaner if necessary to clean these
areas. Rinse thoroughly, dry with compressed air,
and oil the bore immediately with Polaris 2 Cycle
Lubricant.

HONING

CYLINDER

CRANKSHAFT
STRAIGHTENING

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

2870569). Refer to the illustrations below.

EXAMPLE OF CROSS HATCH PATTERN

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

S Use a motor speed of approximately

300-500 RPM, run the hone in and out of
the cylinder rapidly until cutting tension
decreases. Remember to keep the hone
drive shaft centered (or cylinder centered
on arbor) and to bring the stone
approximately 1/2² (1.3 cm) beyond the
bore at the end of each stroke.

S Release the hone at regular intervals and

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

S After honing has been completed inspect

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

Crankshaft Truing Stand

(PN 2870569)

NOTE: The rod pin position in relation to the dial

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

HIGH .004 (.1mm)

A

B

SUPPORT CRANKSHAFT
HERE.

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

HIGH .004 (.1mm)

3.9

ENGINE

HIGH .002 (.05mm)

HIGH .005 (.13mm)

AA

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

HIGH .002 (.05mm)

A

A

HIGH .005 (.13mm)

OIL PRESSURE TEST

-

EH42PL/EH50PL

1. Remove blind plug on front left cylinder head.

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

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

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

Oil Pressure at 5500 RPM (Engine Hot):

Standard: 20 PSI
Minimum: 12 PSI

OIL PUMP

PRIMING

3. If the crank rod pin location is 180_ from the dial

indicator (opposite that shown above), it will be
necessary to spread the crankshaft at position A
as shown in the illustration at right. When
rebuilding and straightening a crankshaft, runout
must be as close to zero as possible.

NOTE: Maximum allowable runout is .0024I.

ENGINE LUBRICATION

-

EH42PL/EH50PL

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

(PN 2871281)

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

Quarts (1.9 l)

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

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

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

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

PROCEDURE

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

Approx.

2I

Oil Tank

Vent Hose

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

2. Run engine for 45-60 seconds.

3. Remove the vent line clamp. Note: If the line is
bled properly you should hear air release, if you
do not hear air the line has not bled. The oil pump
will now be properly primed and ready for field
operation.

To Ai r Bo x

Slit

Pinch Off

3.10

OIL FLOW -- EH42PL/EH50PL

The chart on Page 3.12 describes the flow of oil
through the EH42PL/EH50PL 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, and then pumps the
oil through another passage to the one way valve.
(When the engine is off, the one way valve closes to
prevent oil in the tank from draining into the
crankcase.) The oil is pumped through a delivery pipe
to the oil filter. If the oil filter is obstructed, a bypass
valve contained in the filter allows oil to bypass the
filter element.

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

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

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

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

ENGINE

3.11

ENGINE

EH42PL/EH50PL OIL FLOW DIAGRAM

Internal passage to
camshaft (front left
head bolt)

Oil filter

Oil feed to
filter

From filter
to crankshaft

One way valve

Oil Tank

Oil Flow Chart

Union Fitting
(Upper)

Prevents oil
from draining
into crankcase
with engine off

Oil Tank

Oil Hose

Crankcase
Oil Gallery

Oil Pump
(Feed)

One Way Valve

Bottom fitting is oil
exhaust or return
to tank

Top o f O il Ta n k

Oil Hose

Screen Fitting
(Bottom of Tank)

Cam Shaft
Journal

Union Fitting (Lower)

Crankcase
Oil Gallery

Chain Room

Cam Lobe

Top fitting is oil
feed or intake
from bottom of
tank

Oil Pump
(Scavenging)

Sprocket
Chain

Rocker Arm
Rocker Shaft

Indirect
Lubrication

Oil Strainer

Crankcase

Small End
Bearing

Cylinder Sleeve

Main Bearing
(PTO)

Large End
Bearing

3.12

Delivery Pipe

Bypass Oil Filter

Cam Shaft
Journal

Delivery Pipe

Delivery Pipe

Through Cylinder
Stud Front Left

Crankcase
Oil Gallery

Metal

Oil Jet

Crank Pin

Crankshaft

EH42PL/EH50PL ENGINE EXPLODED VIEW

Crankcase Cylinder/

Cylinder
Head

A

ENGINE

Crankshaft
and Piston

Valve Train

3.13

ENGINE

ENGINE REMOVAL

REFER TO PAGE 3.7--3.8 FOR

REMOVAL / INSTALLATION

CAM

CHAIN

ENGINE

NOTES.

TENSIONER/ROCKER
ARM/CAMSHAFT REMOV

1. Remove ignition timing inspection plug from recoil
housing.

TDC “T” Mark

Rotation

AL

should have clearance at this point.

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

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

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

Advance Marks

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

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

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

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

3.14

ENGINE

CAM CHAIN TENSIONER
INSPECTION

B

A

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

2. Push ratchet pawl and hold it. The plunger should
move smoothly in and out of the tensioner body.

3. Release ratchet pawl and push inward onplunger.
It should remain locked in position and not move
inward.

ROCKER

ARM/SHAFT

INSPECTION

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

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

Tensioner Spring Free Length:

2.320I (5.9 cm)

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

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

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

Rocker Shaft O.D.:

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

3.15

ENGINE

ROCKER ARM/SHAFT
INSPECTION, CONT

Rocker Arm & Support I.D.:

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

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

.

Rocker Shaft Oil Clearance:

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

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

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

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

CAMSHAFT REMOV

AL

3.16

1. Remove thermostat housing.

2. Remove camshaft sprocket inspection cover.

ENGINE

3. Loosen three camshaft sprocket bolts.

4. Remove camshaft end cap and O-Ring.

7. Slide camshaft inward to allow removal of cam
sprocket and remove sprocket from camshaft and
chain.

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

Sprocket Teeth

Inspect for Areas of Tooth
Wear or Damage

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

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

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

Decompressor Shaft

Decompressor Ball

Retainer Sleeve

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

AUTOMATIC

COMPRESSION
RELEASE
REMOV

NOTE: The automatic compression release

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

AL/INSPECTION

3.17

ENGINE

C

A

B

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

2. Remove release lever shaft and return spring.

3. Inspect shaft for wear or galling.

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

AUTOMATIC
RELEASE INSTALLA

1. Slide spring onto shaft.

2. Apply engine oil to release lever shaft.

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

COMPRESSION

TION

Stop pin

Spring in relaxed position

If Camshaft Is Removed From Engine:

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

If Camshaft Is Installed In The Engine:

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

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

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

3.18

CAMSHAFT

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

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

INSPECTION

Camshaft Oil Clearance:

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

ENGINE

Lubrication holes

Lobe height

Cam Lobe Height (Intake & Exhaust):

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

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

Journal O.D.

Journal

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

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

CYLINDER HEAD
VIEW,

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

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

EH42PL/EH50PL

EXPLODED

B

Camshaft Journal O.D.:

Mag & PTO End: 1.4935-1.4941I
(37.935-37.950 mm)

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

5. Measure ID of camshaft journal bore.

Camshaft Journal I.D.:

Mag & PTO End: 1.4963-1.4970I
(38.005-38.025 mm)

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

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

4. Remove cylinder head and head gasket.

3.19

ENGINE

CYLINDER HEAD EXPLODED VIEW, EH42PL/EH50PL

EH42PL/EH50PL

3.20

A

ENGINE

CYLINDER HEAD
INSPECTION

(A)

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

CYLINDER HEAD WARP

AGE

CYLINDER
DISASSEMBL

WARNING: Wear eye protection or a face shield

during cylinder head disassembly and reassembly.

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

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

HEAD

Y

A

Cylinder Head Warpage Limit:

.002² (.05 mm)

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

A

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

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

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

3.21

ENGINE

4. Measure free length of spring with a Vernier
caliper. Check spring for squareness. Compare
to specifications. Replace spring if either
measurement is out of specification

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

indicator.

A

B

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

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

Measure valve stem in
several places.

VALVE

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

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

INSPECTION

Valve Stem Diameter:

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

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

3.22

ENGINE

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

Valve Guide I.D.:

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

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

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

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

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

COMBUSTION

CHAMBER

VALVE SEA

T

RECONDITIONING

Valve Seat Inspection

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

3.25. If the valve seat is cracked the cylinder head

must be replaced.

Cylinder Head Reconditioning

NOTE: Servicing the valve guides and valve seats

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

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

Valve Guide Removal/Installation

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

VALVE SEA
RECONDITIONING, CONT

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

T

.

3.23

ENGINE

Reaming The Valve Guide

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, and the seat must be the
proper width all the way around. If the seat is uneven,
compression leakage will result. If the seat is too
wide, seat pressure is reduced, causing carbon
accumulation and possible compression loss. If the
seat is too narrow, heat transfer from valve to seat is
reduced and the valve may overheat and warp,
resulting in burnt valves.

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

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

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

Uneven

Good

Too
Narrow

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

6. Clean guides thoroughly with hot soapy water and
a nylon brush. Rinse and dry with compressed
air. Apply clean engine oil to guides.

7. Install pilot into valve guide.

8. Apply cutting oil to valve seat and cutter.

A

Valve Guide Installed Height

Valve Guide Height:

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

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

3.24

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

10. Inspect the cut area of the seat.

S If the contact area is less than 75% of the

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

S If the cutter now contacts the uncut

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

S If the contact area of the cutter is in the

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

S If the contact area of the initial cut is

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

(A)

ENGINE

Valve Seat Width:

Intake Std: .028I (.7 mm)

Limit: .055I (1.4 mm)

Exhaust Std: .039I (1.0 mm)

Limit: .071I (1.8 mm)

Seat
Width

11. To check the contact area of the seat on the valve

face, apply a thin coating of Prussian Bluet paste
to the valve seat. If using an interference angle
(46°) apply black permanent marker to the entire
valveface(A).

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

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

S If the indicated seat contact is at the

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

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

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

S If the seat is too wide or uneven, use

both top and bottom cutters to
narrow the seat.

S If the seat is too narrow, widen using

the 45° cutter and re-check contact
point on the valve face and seat width
after each cut.

Bottom - 60° or 75°

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

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

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

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

17. Rotate the valve rapidly back and forth until the
cut sounds smooth. Lift 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).

Seat - 45° or 46°

Top - 30 °

or

31°

3.25

ENGINE

A

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

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

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

CYLINDER HEAD ASSEMBL

CAUTION: Wear eye protection during assembly.

NOTE: Assemble the valves one at a time to maintain

proper order.

Y

1. Install new valve seals on valve guides.

2. Apply engine oil to valve guides and seats.

3. Coat valve stem with molybdenum disulfide
grease.

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

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

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

7. Repeat procedure for remaining valve.

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

3.26

VALVE SEALING

1. Clean and dry the combustion chamber area.

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

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

TEST

EXHAUST VALVE

ENGINE

CLEARANCE

Feeler Gauge for Both Valves

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

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

2. Loosen locknut(s) and turn adjuster screw(s) until
there is a slight drag on feeler gauge(s). The
Valve/Clutch Adjuster Tool (PA--44689) can be
used to adjust the 425/500 engines valves.
NOTE: Both feeler gauges should remain
inserted during adjustment of each valve.

ADJUSTMENT

425/500 Engine

1. Remove cam chain guide at front of cylinder.

EXHAUST VALVE CLEARANCE

.006² (.15 mm)

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

4. Re-check the valve clearance.

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

CYLINDER/PISTON REMOV
AND

NOTE: Follow engine disassembly procedures to

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

INSPECTION

AL

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

3.27

ENGINE

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

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

8. Remove dowel pins from crankcase.

3. Loosen hose clamps and remove coolant inlet
hose.

4. Remove the two 6 mm cylinder base bolts.

PISTON REMOV

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

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

AL

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

NOTE: The bolts are inside the water jacket.

3.28

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

ENGINE

scratch the ring lands.

A

4. Repeat procedure for second ring.

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

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

6. Remove the expander.

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

Cylinder Warpage:

.002² (.05 mm)

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

1/2² Down From Top of Cylinder

X

X

X

Y

Y

Y

CYLINDER

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

INSPECTION

1/2² 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 (1/2² down from top,
in the middle, and 1/2² up from bottom).

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

Cylinder Taper

Limit: .002 Max.

Cylinder Out of Round

Limit: .002 Max.

Standard Bore Size:

3.6221-3.6228I (92.00-92.012mm)

3.29

ENGINE

PISTON-TO-CYLINDER
CLEARANCE

Piston

40 mm

Piston Pin

1. 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.

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

Piston to Cylinder Clearance

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

Piston O.D.:

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

Piston Pin Measurement Locations

Piston Pin O.D.

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

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

PISTON/ROD

Piston Pin Bore:

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

1. Measure piston pin bore.

INSPECTION

Piston Pin Bore

3.30

3. Measure connecting rod small end ID.

Piston

Ring

Feeler Gauge

Piston Ring-to-Groove Clearance

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

Limit: .0059I (15 mm)

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

Limit: .0059I (15 mm)

ENGINE

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

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

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

PISTON RING INST

ALLED

GAP

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

Feeler Gauge

Cylinder

Piston Ring

25-50mm

CRANKCASE DISASSEMBL

NOTE: The recoil starter, starter motor, starter drive,

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

STARTER
REMOV

1. Remove recoil housing bolts and remove
housing.

DRIVE

AL/INSPECTION

Y

Piston Ring Installed Gap

Top Ring

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

Second Ring

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

Oil Ring

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

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

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

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

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

A

3.31

ENGINE

Std. Bushing ID:

.4735²-.4740² (11.11-12.04 mm)

5. Replace crankshaft seal (A).

Std. Shaft OD:

.470²-.472² (11.93-11.99 mm)

Starter Drive Bushing Clearance:

Std: .0015²-.004² (.038-.102 mm)

Service Limit:

.008² (.203 mm)

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

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

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

FLYWHEEL/STAT
REMOV

AL/INSPECTION

OR

B

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

1. Remove flywheel nut and washer.

2. Install Flywheel Puller (PN 2871043) and remove
flywheel. CAUTION: Do not thread the puller
bolts into the flywheel more than 1/4² or stator
coils may be damaged.

3. Mark or note position of stator plate on crankcase.

4. Remove bolts and carefully remove stator
assembly, being careful not to damage crankshaft
bushing on stator plate.

A

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

CAM CHAIN/TENSIONER
BLADE

A

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

3.32

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

ENGINE

B

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

Chain Service Limit:

5.407² (13.7 cm)

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

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

6. Inspect sprocket teeth for wear or damage.

7. Inspect Woodruff key for wear.

8. Replace any worn or damaged parts.

CD

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

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

One Way Valve Spring Free Length:

Std: 1.450² (3.68 cm)

3. Inspect valve for wear.

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

B

CRANKCASE SEPARA

A

TION

ONE WAY VAL

The one way valve prevents oil from draining out of the
oil tank and into the crankcase when the engine is off.
It must be clean and have adequate spring pressure
in order to seal properly.

VE

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

3.33

ENGINE

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

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

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

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

OIL PUMP

4. Remove three oil pump retaining bolts and pump.

REMOV

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

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

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

AL/INSPECTION

C

B

A

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

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

7. Clean screen thoroughly.

3.34

ENGINE

8. Remove pump body screw and feed chamber
cover.

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

Pump End Clearance:

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

Wear Limit: .004 (.1016 mm)

11. Measure rotor tip clearance with a feeler gauge.

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

13. Repeat measurements for scavenge rotor.

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

OIL PUMP ASSEMBL

1. Clean and dry all parts thoroughly. Apply clean
engine oil to all parts. Donot use gasket sealer on
the pump body mating surfaces or oil passages
will become plugged.

2. Install pump shaft and scavenge rotor drive pin.

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

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

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

6. Tighten screw securely.

7. Install screen on pump body.

8. Install oil pump on crankcase and torque bolts to 6
ft. lbs. (8 Nm).

Y

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

Rotor Tip Clearance:

Std: .005 (.127 mm)

Wear Limit: .008 (.2032 mm)

Oil Pump Attaching Bolt Torque:

6 ft. lbs. (8 Nm)

COUNTER
REMOV

A

BALANCERSHAFT

AL/INSPECTION

3.35

ENGINE

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

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

CRANKSHAFT
REMOVAL/INSPECTION

A

1. Remove the shim washer (A) from the crankshaft.

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

3. Turnthe shaft until balancer counter weights clear
the crankshaft and remove the balancer shaft
from the crankcase.

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

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

6. Inspect the balancer shaft bearings.

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

3.36

3. Use a feeler gauge to measure the connecting rod
big end side clearance.

Connecting Rod Big End Side Clearance:

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

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

Max Runout: .0024² (.06 mm)

ENGINE

5. Measure the connecting rod big end radial
clearance.

Big End Radial Clearance:

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

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

CRANKCASE

BEARING

INSPECTION

PUMP SHAFT OIL
WATER PUMP
SEAL

REMOVAL (ENGINE

SEAL/

MECHANICAL

DISASSEMBLED)

NOTE: The water pump mechanical seal can be

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

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

1. Remove the seal from the PTO side crankcase.

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

NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. Look for signs of discoloration,
scoring 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.

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

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

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

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

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

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

CRANKCASE

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.

INSPECTION

the

3.37

ENGINE

BEARING INSTALLATION

NOTE: To ease bearing installation, warm the

crankcase until hot to the t ouch. Place the bearings in
a freezer.

1. Install the bearings so the numbers are visible.

2. Drive or press new bearings into the crankcases,
using the proper driver. CAUTION: Press only on
outer race of bearing to prevent bearing damage.

S 70 mm (2.755²) driver- For

crankshaft main bearings.

S 46 mm (1.810²) For counter balancer

bearings.

S 28 mm (1.100²) For pump shaft

bearing.

END PLA

Y

INSPECTION/ADJUSTMENT

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

2. Measure the distance from the PTO crankcase
mating surface to the main bearing using a dial
caliper and a straight edge.

CRANKSHAFT END PLA

Y

ADJUSTMENT

1. Make sure all bearings are firmly seated in the
both Mag and PTO crankcase.

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

PTO Case Depth

3.38

ENGINE

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

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

Mag Case Depth

7. Measure the width of the crankshaft at the
bearing seats with a micrometer or dial caliper
and record.

Crankshaft Width

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

Total End Play

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

Crankshaft End Play:

.008²-.016² (.02-.04 cm)

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

Total Case Width

3.39

ENGINE

COUNTER BALANCER
SHAFT END PLAY ADJUST

Step 2

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

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

Step3/4

.

Counter Balancer Shaft End Play:

.008²-.016² (.02-.04 cm)

OIL PUMP SHAFT END PLA

Y

ADJUSTMENT

1. Make sure the pump shaft bearing is firmly seated
in the Magneto side crankcase.

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

4. Measure the distance from the PTO crankcase
mating surface to the bearing using the same
method outlined in Step 1, 2, and-3.

5. Add the readings obtained in Step 3 and Step 4.

6. Subtract the counter balancer shaft width
measured in Step 2 from the figure obtained in Step

5.

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

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

3. Install the gear on the oil pump and measure the
width of the pump and gear. Subtract this
measurement from the measurement recorded in
Step 2.

4. Subtract the thickness of the existing shim from
the result of Step 3 to determine if a different shim
is needed. See Shaft End Play Spec. next page.

3.40

Pump Shaft End Play:

.008²-.016² (.02-.04 cm)

PUMP SHAFT OIL
INSTALLA

TION

SEAL

ENGINE

difficult, install two nuts on the end of the threaded
rod and tighten against each other.

3. Install the proper shim on the magneto end of the
crankshaft.

4. Place the balancer shaft in the PTO crankcase
aligning the timing marks on the crankshaft and
balancer gears. Install the proper shim washer on
the shaft.

5. Inspect the oil pump sealing surface on the
crankcase. Apply a light film of engine oil to the
surface and install the oil pump.

NOTE: Do not use gasket sealer on the pump mating
surfaces.

NOTE: After engine is assembled and machine is
readied for field operation, oil pump MUST be primed.
Follow oil pump priming procedure on Page 3.10.

Oil Pump Bolt Torque:

6. ft. lbs. (8 Nm)

1. Install the seal from the outside of the crankcase
(water pump side) with the spring facing inward,
toward the pump shaft bearing.

2. Drive or press the seal into place using a 25 mm
(.985²) seal driver, until flush with the outer edge
of the seal bore.

3. Lubricate the seal lip with grease.

CRANKSHAFT/COUNTER
BALANCE/OIL
INSTALLA

Lubricate all bearings with clean engine oil before
assembly.

Use the Crankshaft/Water Pump Installation Kit (PN

2871283) to prevent damage to the crankshaft and

main bearings during installation.

1. Install the crankshaft into the PTO side
crankcase. Screw the threaded rod into the
crankshaft until the threads are engaged a
minimum of one inch (25.4mm).

2. Install the collar, washer, and nut onto the
threaded rod. Hold the crankshaft and tighten the
nut to draw the crankshaft into the main bearings
until fully seated. Loosen the nut and remove the
threaded rod from the crankshaft. If removal is

TION

PUMP

6. Align the drive gear with the drive pin on the pump
shaft and install the gear. Be sure the gear is fully
seated and properly engaged.

7. Install the proper shim washer on the pump shaft.

CRANKCASE ASSEMBL

1. Apply Crankcase Sealant (PN 2871557)tothe
crankcase mating surfaces. Be sure the
alignment pins are in place.

2. Set the crankcase in position carefully to avoid
damaging the pump shaft seal, and install the
magneto end crankshaft installation tool (follow
instructions provided with the Crankshaft/Water
Pump Installation Kit (PN 2871283).Drawthe
crankcase halves together by tightening the nut
on the tool and tapping lightly in the pump shaft
area with a soft faced hammer to maintain
alignment. Continually check alignment of the
cases during installation, closing the gap equally
until the surfaces are tightly seated.

3. Remove the tool.

4. Install the crankcase flange bolts and tighten in 3
steps following the pattern on Page 3.4 to
specified torque.

Crankcase Bolt Torque:

14 ft. lbs. (19 Nm)

Y

3.41

ENGINE

Crankcase Sealant:

(PN 2871557)

WATER PUMP

MECHANICAL

SEAL INSTALLATION

1. Clean the seal cavity to remove all traces of old
sealer.

2. Place a new mechanical seal in the seal drive
collar, and install on the pump shaft.

3. Screw the guide onto the end of the pump shaft.

4. 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.

WATER PUMP
SEAL REMOVAL -

MECHANICAL

ENGINE

INSTALLED

Sealing Washer
(Copper or Aluminum)

Coolant Drain
Bolt

Ill. 1

1. After the coolant has been drained, remove the
water pump cover, impeller and the sealing
washer. (Ill. 1)

T-Handle

Sealing Washer

Oil
Seal

Impeller

Mechanical Seal

Water Pump Mechanical Seal
Puller: (PN 2872105)

Replacement T --Handle:
(PN 2872106)

This tool allows a technician to replace the
mechanical water pump seal on EH50PL engines
without removing the engine and splitting the cases.

CAUTION:

Improper or careless 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 that 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.

Main Puller Body

Ill. 2

2. Slide the main puller body over the outer portion
of the mechanical seal as shown in Ill. 2 and turn
T-Handle clockwise until it contacts water pump
shaft. Continue rotating until outer portion of
mechanical seal is separated from the metal seal
body.

3. nsert the puller legs between the water pump
drive shaft and the remaining portion of the
mechanical seal. Attach the puller legs to the
main puller body. Ill. 3

3.42

Main puller
body

ENGINE

7. The Water Pump Install Kit (PN 5131135)is
required to install the new mechanical seal. This
tool is available separately and it is also included
in the Crankshaft/Water Pump Seal Installation
Kit (PN 2871283).

Position the split
90° to opening
on main puller

Ill. 4

4. Ensure that the split between the puller legs is
fully supported by the main body of the tool (Ill 4).

Hex Socket Screws

Puller Legs

Lip must grasp inside
of mechanical seal.

Ill. 5

body

ONE WAY VAL
INSTALLA

Install the one way valve plunger, spring, and plug
using a new sealing washer.

One Way Valve Plug Torque:

16 ft. lbs. (22 Nm)

TION

CAM CHAIN
SPROCKET INSTALLA

A

VE

DRIVE

TION

B

5. Tighten the hex socket screws on the puller legs
sufficiently so the lip of the puller legs will grasp
the mechanical seal. Ill. 5

Ill. 6

6. Turn the puller T-Handle clockwise until it
contacts the water pump shaft. Continue rotating
until the remaining portion of mechanical seal has
been removed from the cases. Ill. 6 Pump shaft
oil seal can also be replaced at this time if
necessary.

Tighten

1. Install the Woodruff key, drive sprocket, and
slotted nut. Tighten the nut to the specified
torque.

Slotted Nut Torque:

35-51 ft. lbs. (4.71-6.86 kg-m)

3.43

ENGINE

TENSIONER BLADE
INSTALLA

1. Install the tensioner blade and tighten the
mounting bolt to specified torque.

Tensioner Blade Mounting Bolt Torque:

PISTON RING INSTALLA

NOTE: Apply clean engine oil to all ring surfaces and

ring lands. Always check piston ring installed gap
before rings are installed on piston. See Page 3.30.
If the piston has been in service clean any
accumulated carbon from the ring grooves and oil
control ring holes.

1. Place the oil control ring expander in oil ring
groove with the end gap facing forward. The
expander has no up or down marking and can be
installed either way. The ends should butt
squarely together and must not overlap.

2. Install the oil ring top rail.

NOTE: The top rail has a locating tab to prevent
rotation. The tab must be positioned in the notch on
the side of the piston as shown (A).

TION

6 ft. lbs. (8 Nm)

TION

5. Install the top ring (chrome faced) with the “R”
mark facing up and the end gap facing forward
(toward the exhaust). (See ILL. 1).

6. Check to make sure the rings rotate freely in the
groove when
compressed.

Ring Profile

Mark up

Mark up

ILL. 1

PISTON INSTALLA

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.

TION

Top

Second

A

3. Install the bottom rail with the gap at least 30°
from the end of the expander on the side opposite
the top rail gap.(See ILL. 1).

4. Install the second ring with the “R” mark facing up.
Position the end gap toward the rear (intake) side
of the piston.

3.44

Tang Outward

3. Install a new circlip on one side of the piston with
the end gap facing up or down, and tang outward.

CAUTION: Circlips become deformed during the
removal process. Do not re-use old circlips. Do not

ENGINE

compress the new clip more than necessary upon
installation to prevent loss of radial tension. Severe
engine damage may result if circlips are re-used or
deformed during installation.

4. Apply clean engine oil to the piston rings, ring
lands, piston pin bore, piston pin, and piston skirt.
Lubricate the connecting rod (both ends),
balancer drive gear, and crankshaft main bearing
area.

Mag

or

:

5. Install the piston on the connecting rod with the
arrow or : mark facing the magneto (RH) 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 and tang outward. (See Caution with Step 3
above). Push the piston pin in both directions to
make sure the clips are properly seated in the
groove.

3. Apply clean engine oil to the ring compressor

(Snap Ont PN RCL30) and install the
compressor following manufacturers
instructions. CAUTION: Make sure the oil
control ring upper rail tab is positioned properly in
the notch of the piston. Verify all ring end gaps are
correctly located.

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.

CYLINDER INSTALLA

1. Place the dowel pins in the crankcase and install a
new cylinder base gasket.

A

2. Position the Piston Support Block (PN 2870390)
(A) beneath the piston skirt to support the piston
during cylinder installation.

TION

5. Remove the ring compressor and support block.

6. Push the cylinder downward until fully seated on
the base gasket.

7. Apply a light film of oil to the threads and flange
surface of the cylinder mounting bolts.

8. Install all four bolts finger tight. Rotate the engine
and position the piston at BDC.

NOTE: If cam chain is installed, hold it up while
rotating the engine to avoid damage to the chain, drive
sprocket teeth, or tensioner blade.

3.45

ENGINE

9. Tighten the cylinder bolts in three steps in a criss
cross pattern and torque to specifications.

10. Install the two 6 mm bolts.

Cylinder Bolt Torque:

10mm - 46 ft. lbs. (62 Nm)
6mm - 6 ft. lbs. (8 Nm)

CYLINDER
INSTALLA

Clean the gasket surfaces on the cylinder head and
cylinder. Remove all traces of old gasket material.
Refer to disassembly photos.

1. Install the cam chain tensioner guide. Be sure
bottom end of guide is located properly in
crankcase.

2. Install the two dowel pins 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

*Torque bolts to 22 ft. lbs. (30 Nm)

*Torque bolts to 51 ft. lbs. (70 Nm)

*Loosen bolts evenly 180° (1/2 turn)

*Loosen bolts again another 180° (1/2
turn)

*Torque bolts to 11 ft. lbs. (15 Nm)

HEAD

TION

Guide in
recess

CAM CHAIN/CAMSHAFT
INSTALLATION

Install the cam chain over the crankshaft.

CAUTION: Serious engine damage may result if the
camshaft is not properly timed to the crankshaft.

IMPORTANT CAMSHAFT TIMING NOTE: In order
to time the camshaft to the crankshaft, the piston must
be precisely located at Top Dead Center (TDC).

CAMSHAFT

TIMING

*From this point, tighten bolts evenly
90° (1/4 turn)

*Finally, tighten another 90° (1/4 turn)

*Install two 6mm bolts and torque to 6
ft. lbs. (8 Nm)

3.46

1. Apply Polaris Premium Starter Drive Grease (PN

2871460) to the camshaft main journals and cam

lobes. Lubricate automatic compression release
mechanism with clean engine oil. (To install the
compression release mechanism, refer to Page

3.21).

2. Install the camshaft with the lobes facing
downward and the sprocket alignment pin facing
upward.

Single (TDC)
Mark Aligned

3. Disconnect the wire from the cam chain and
rotate the engine to align the single
mark (Top Dead Center) on the flywheel with the
notch in the timing inspection window. Be sure to
use the single TDC mark when installing the cam.
Do not use the advance marks. See Ill. on next
page.

(TDC ) timing

ENGINE

B

A

5. Before positioning the sprocket on the camshaft,
check the position of the cam sprocket alignment
pin. When the cam is positioned properly, the
cam sprocket alignment pin (A) is directly in line
with the crankshaft/camshaft centerline (B).

6. Install the sprocket on the camshaft. Apply
Loctitet 242 (PN 2871949) to the cam sprocket
bolts and torque to specifications.

Cam Sprocket Bolt Torque:

6 ft. lbs. (8 Nm)

A

4. Loop the cam chain on the cam sprocket with the
dots on the sprocket facing outward and the
alignment pin notch facing directly upward.

Single (TDC)
Mark Aligned

7. Verify TDC mark in timing inspection hole and
alignment pin is directly in line with crankshaft to
camshaft centerline. Refer to Ill. on following
page.

8. Apply Crankcase Sealant (PN 2871557)tothe
camshaft end cap and install using a new O-Ring.

9. Check all cam timing marks to verify proper cam
timing, and install the cam chain tensioner body
with a new gasket.

10. After tensioner installation, rotate engine at least
two revolutions and re-check marks/timing.

3.47

ENGINE

CAMSHAFT TIMING

Dots

Crankshaft to Camshaft Centerline

Sprocket Alignment Pin

3.48

Single TDC Mark Aligned

TDC Mark

Rotation

Do Not Use
Advance Marks

ENGINE

CAM CHAIN TENSIONER
INSTALLA

1. Release the ratchet pawl (A) and push the
tensioner plunger (B) all the way into the
tensioner body.

2. Install the tensioner body with a new gasket and
tighten the bolts.

TION

B

A

1. Apply a light film of grease to the crankshaft seal.
Apply molybdenum disulfide grease or assembly
lubricant to the crankshaft bushing.

2. Install a new O-Ring in the oil passage recess in
the crankcase.

3. Apply Crankcase Sealant (PN 2871557)oran
equivalent sealer to the stator plate outer surface
and install a new O-Ring.

Tensioner Bolt Torque:

6 ft. lbs. (8 Nm)

3. Install the spring, new sealing washer, and
tensioner plug.

Tensioner Plug Torque:

17 ft. lbs. (23 Nm)

4. Slowly rotate engine two to three revolutions and
re-check cam timing.

STATOR, FLYWHEEL AND
STARTER
INSTALLA

NOTE: The stator, flywheel, starter drive, and recoil

can be assembled with the engine in the frame.

Stator

DRIVE

TION

4. Install the stator plate being careful not to damage
the seal. Align timing reference marks on the
plate and crankcase. Be sure the plate is fully
seated.
NOTE: This is a static timing mark. Strobe timing
should be performed after start up.

5. Torque bolts evenly to specification.

Stator Plate Bolt Torque:

5-6.5 ft. lbs. (7-9 Nm)

6. Seal stator wire grommet with Crankcase Sealant
(PN 2871557) or equivalent sealer.

Flywheel

1. Install flywheel, washer, and nut. Torque flywheel
to specification.

Flywheel Nut Torque:

58-72 ft. lbs. (78-98 Nm)

3.49

ENGINE

Starter Drive

1. Be sure the washer is positioned on the back of
the drive gear.

Apply Starter Drive

Grease to Bushing

5. Be sure the dowel pins are in place and install the
rocker shaft assembly.

6. Apply a light film of engine oil to the threads of the
bolts and tighten evenly.

Rocker Shaft Support Tower Bolt Torque:

9 ft. lbs. (12 Nm)

Rocker Shaft Locating Bolt Torque:

6 ft. lbs. (8 Nm)

7. Adjust valves according to the valve adjustment
procedure found in Chapter 2, Maintenance.

8. Apply clean engine oil liberally to the valve
springs, cam chain, rocker arms, and camshaft.

9. Place a new rocker cover gasket on the cylinder
head and install the cover and bolts.

Rocker Cover Bolt Torque:

6 ft. lbs. (8 Nm)

2. Apply starter drive grease to the drive bushing in
the crankcase and all moving surfaces of the
starter drive mechanism. Install the starter drive.

3. Install recoil housing gasket and recoil housing.

Starter Drive Grease:

(PN 2871460)

ROCKER
ARM ASSEMBL
INSTALLA

1. Assemble rocker arms, rocker shaft, and shaft
supports.

2. Install and tighten rocker arm shaft locating bolt.

3. Apply starter drive grease to the cam lobes and
cam follower surfaces.

4. Rotate the engine until the cam lobes are pointing
downward.

SHAFT/ROCKER

Y

TION

THERMOSTAT INSTALLA

Install the thermostat with one of the air bleed holes
positioned next to the upper thermostat cover bolt
hole as shown.

TION

3.50

ENGINE

OIL PIPES

Install the oil pipes with new sealing washers. Tighten
all bolts evenly to specified torque.

Oil Pipe Bolt Torque:

20 ft. lbs. (27 Nm)

RECOIL
DISASSEMBL

CAUTION: The recoil is under spring tension. A face

shield and eye protection is required during this
procedure.

Replace any parts found to be worn or damaged.

REMOVE BOLTS
RECOIL

HOUSING

Y/INSPECTION

AND

11. Remove center bolt from recoil friction plate (A).

12. Inspect plate for wear or damage. Inspect plate
friction spring for wear, damage, and proper
tension. The spring should fit tightly on friction
plate.

A

10. Pull recoil rope so it is extended approximately
12-18². Check handle c-ring for proper tension,
and the handle for cracks or damage which may
allow water or dirt to enter the recoil housing
through the rope. NOTE: The handle must seal
tightly on the recoil housing to prevent water from
entering.

13. Remove ratchet pawl with spring and inspect.
Replace spring or ratchet pawl if worn, broken, or
damaged.

NOTE: Long arm of spring engages reel. Short end
against pawl.

14. Hold reel firmly in housing. Pull rope handle until
12-18² of rope is exposed, and hold reel in place.

15. Place rope in notch on outer edge of reel.
Release tension on hub and allow reel to unwind
approximately 6-7 turns until spring tension is
released.

3.51

ENGINE

A

16. Slowly and carefully remove reel from recoil
housing making sure the spring remains in the
housing. Inspect the reel hub and bushing (A) for
wear.

17. Unwind rope and inspect for cuts or abrasions.

18. Inspect drive tab on hub return spring for damage.
To remove hub return spring, hold outer coils in
place with one hand and slowly remove spring
one coil at a time from the inside out.

19. Pull knot out of of recoil reel. Untie knot. Remove
rope from reel.

1. Hook outer tab in place in recoil housing and wind
spring in a counterclockwise direction one coil at a
time while holding the installed coils in place.

2. Lubricate the spring with light lubricant such as
Premium All Season Grease (PN 2871423).

To complete recoil assembly:

1. Route rope through guide bushing in recoil
housing and into reel. Tie a secure knot in end of
the rope.

2. Wind rope counterclockwise onto the reel, as
viewed from ratchet side of reel.

3. Lock rope into notch on outer edge of reel.

4. Apply a small amount of grease or equivalent to
the center post of the housing and the bushing.

Open end here

RECOIL ASSEMBL

CAUTION: Be sure to wear a face shield and eye

protection when performing this procedure.

To install a new spring:

1. Place spring in housing with the end positioned so
the spring spirals inward in a counterclockwise
direction. See photo at right.

2. Hold spring in place and cut retaining wire.

To reinstall an old spring:

Y

5. Install reel into housing making sure the spring
drive tab on the reel engages the spring and the
reel is fully seated in the housing.

6. Apply downward pressure on the reel and rotate
counterclockwise approximately 6-7 turns to
pre-wind the spring. Continue rotating
counterclockwise until rope on outer edge aligns
with rope guide bushing.

7. Release rope from notch and allow reel to rewind
completely. If more pre-wind is required, place rope
in notch and add additional turns of pre-wind.

8. Install ratchet pawl and return spring, with long leg
of spring engaged in reel.

9. Reinstall friction plate. NOTE: The friction plate
must be positioned with both end tabs of the
friction spring opposite the ratchet pawl.

10. Torque friction plate retaining bolt to 5-6 ft. lbs.
(7-9 Nm).

11. Reinstall recoil housing using a new gasket. Seal
stator wire harness grommet with RTV silicone.

3.52

ENGINE

SPARK PLUG FOULING

S Spark plug cap loose or faulty
S Choke cable adjustment or

plunger/cable sticking

S Foreign material on choke plunger

seat or plunger

S Incorrect spark plug heat range or

gap

S Carburetor inlet needle and seat

worn

S Jet needle and/or needle jet worn or

improperly adjusted

S Excessive carburetor vibration

(loose or missing needle jet locating
pins)

S Loose jets in carburetor or calibration

incorrect for altitude/temperature

S Incorrect float level setting
S PVT system calibrated incorrectly or

components worn or mis-adjusted

S Fuel quality poor (old) or octane too

high

S Low compression
S Restricted exhaust
S Weak ignition (loose coil ground,

faulty coil, stator, or ETC switch)

S ETC switch mis-adjusted
S Restricted air filter (main or

pre-cleaner) or breather system

S Improperly assembled air intake

system

S Restricted engine breather system
S Oil contaminated with fuel
S Restricted oil tank vent

TROUBLESHOOTING

Engine Turns Over But Fails to Start

S No fuel
S Dirt in fuel line or filter
S Fuel will not pass through fuel valve
S Fuel pump inoperative/restricted
S Tank vent plugged
S Carb starter circuit
S Engine flooded
S Low compression (high cylinder

leakage)

S No spark (Spark plug fouled)

Engine Does Not Turn Over

S Dead battery
S Starter motor does not turn
S Engine seized, rusted, or

mechanical failure

Engine Runs But Will Not Idle

S Restricted carburetor pilot system
S Carburetor misadjusted
S Choke not adjusted properly
S Low compression
S Crankcase breather restricted

Engine Idles But Will Not Rev Up

S Spark plug fouled/weak spark
S Broken throttle cable
S Obstruction in air intake
S Air box removed (reinstall all intake

components)

S Incorrect or restricted carburetor jetting
S ETC switch limiting speed
S Reverse speed limiter limiting speed
S Carburetor vacuum slide

sticking/diaphragm damaged

S Incorrect ignition timing
S Restricted exhaust system

Engine Has Low Power

S Spark plug fouled
S Cylinder, piston, ring, or valve wear or

damage (check compression)

S PVT not operating properly
S Restricted exhaust muffler
S Carburetor vacuum slide

sticking/diaphragm damaged

S Dirty carburetor

Piston Failure - Scoring

S Lack of lubrication
S Dirt entering engine through cracks in air

filter or ducts

S Engine oil dirty or contaminated

Excessive Smoke and Carbon Buildup

S Excessive piston-to-cylinder clearance
S Wet sumping
S Worn rings, piston, or cylinder
S Worn valve guides or seals
S Restricted breather
S Air filter dirty or contaminated

Low Compression

Decompressor stuck

S

3.53

ENGINE

S Cylinder head gasket leak
S No valve clearance or incorrectly

adjusted

S Cylinder or piston worn
S Piston rings worn, leaking, broken, or

sticking

S Bent valve or stuck valve
S Valvespringbrokenorweak
S Valve not seating properly (bent or

carbon accumulated on sealing surface)

S Rocker arm sticking

Backfiring

S ETC or speed limiter system malfunction
S Fouled spark plug or incorrect plug or

plug gap

S Carburetion faulty - lean condition
S Exhaust system air leaks
S Ignition system faulty:

Spark plug cap cracked/broken
Ignition coil faulty
Ignition or kill switch circuit faulty
Ignition timing incorrect
Sheared flywheel key

S Poor connections in ignition system
S System wiring wet
S Valve sticking
S Air leaks in intake
S Lean condition

S Ignition timing misadjusted
S Low oil level
S Spark plug incorrect heat range
S Faulty hot light circuit
S Thermostat stuck closed or not opening

completely

Temperature Too Low

S Thermostat stuck open

Leak at Water Pump Weep Hole

S Faulty water pump mechanical seal

(coolant leak)

S Faulty pump shaft oil seal (oil leak)

COOLING SYSTEM
TROUBLESHOOTING

Overheating

S Low coolant level
S Air in cooling system
S Wrong type of coolant
S Faulty pressure cap or system leaks
S Restricted system (mud or debris in

radiator fins or restriction to air flow,
passages blocked in radiator, lines,
pump, or water jacket)

S Lean mixture (restricted jets, vents, fuel

pump or fuel valve)

S Fuel pump output weak
S Restricted radiator (internally or cooling

fins)

S Water pump failure
S Cooling system restriction
S Cooling fan inoperative or turning too

slowly (perform current draw test)

3.54