The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a p roperly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some pro cedures ou tlined i n th is man ual re quire a sou nd kn owledge of me chanical t heory, to ol use, and sho p
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you ha ve any doubt as to yo ur ab ility to perform any of th e procedures outlined in th is Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in he lping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
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stries Inc. ATTN: Service Publications Department,
Publication Printed November 2011 (PN 9923523) Rev. 3
Throughout this manual, important information is brought to your attention by the following symbols:
SAFETY ALERT WARNING ind icates a po tential hazard that may result in severe injury or death to the o perator,
bystander or person(s) inspecting or servicing the vehicle.
SAFETY ALERT CAUTION indicates a potential h
vehicle.
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE provides key information by clarifying
IMPORTANT provides key reminders during disassembly
instructions.
azard that may r esult in min or personal in jury or damage to th e
NOTE:
IMPORTANT:
, assembly and inspection of components.
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of
Torx, Registered Trademark of Textron
Hilliard, Trademark of the H
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor
Some Pola ris factor y pu blications can be do wnload
www.purepolaris.com or by contacting the nearest Polaris dealer.
illiard Corporation
Neward Enterprises, Inc.
ed fro m www.polarisindustries.com, pu rchased fr om
NOTE: When ordering service parts be sure to use the correct parts manual.
NOTE: Polaris fa ctory pu blications c an be fo und a
www.purepolaris.com.
570R12VH57AD99235219923522
t www.pola risindustries.com or purchased f rom
Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the
original key and refer to the chart to the right for the proper part number.
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other
tools maybe su bstituted with a similar to ol, if ava ilable. Polaris recommends the use of Polaris Special Tools whe n
servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation,
by phone at 1-800-328-6657 or on-line at
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, ad just and replace parts as necessar
parts, use genuine Pure Polaris parts available from your Polaris dealer.
NOTE: Service a nd ad justments are critic al. If y ou’re no t fa miliar w ith sa fe s ervice a nd adjustment
procedures, have a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon aver
approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in m
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold we
Pay special attention to the oil level. A
oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to
rise, discontinue use and determine the cause or see your dealer.
ather operation
ud, water or sand
rise in oil level during cold weather can indicate contaminants collecting in the
y. When inspection r eveals the need for r eplacement
age riding conditions and an average vehicle speed of
Break-In Period
The break-in period consists of the first 25 hours of operation, or the time it takes to use 14 gallons (53 liters) of fuel.
Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these
components.
2
• Drive vehicle slowly at first while varying the thr
• Pull only light loads.
• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.
• Change both the engine oil and filter after 25 hours or one month.
• See “Owner’s Manual” for additional break-in information.
ottle position. Do not operate at sustained idle.
Maintenance Chart Key
The following symbols denote potential items to be aware of during maintenance:
= CAUTION: Due to the nature of these adjustments, it is recommended this service be p erformed by a n
authorized Polaris dealer.
= SEVERE USE ITEM: See information provided above.
E = Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
Improperly performing the procedures marked could result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
There are grease fittings at each A-arms pivot point, each front or rear stabilizer bushing, and on the front propshaft yoke.
Apply grease until all traces of water have been purged out at each of these areas.
ItemRecommended LubeMethodFrequency
Front Propshaft Yoke(s)
A-arm Pivot Bushings
Stabilizer Bar Bushings
Polaris Premium U-Joint Grease
Grease fittings every 500
mi
les (800 km).
Grease before long periods
of storage, and after
thoroughly washing or
submerging the vehicle.
Perform the following pre-ride inspection daily, and when
servicing the vehicle at each scheduled maintenance.
• Tires - check condition and pressures
• Fuel tank - fill to proper level
• All brakes - check operation and adjustment
• Throttle - check for free operation and closing
• Headlights/Taillights/Brakelights - also check
ope
ration of all indicator lights and switches
• Ignition switch - check for proper function
• Wheels - check for tightness of wheel nuts and
axle
nuts; check to be sure axle nuts are secured
by cotter pins
• Air cleaner element - check for dirt; replace if
necessary.
• Steering - check for free operation noting any
unu
sual looseness in any area
Shift Cable Inspection / Adjustment
Shift c able a djustment m ay be ne cessary if sy mptoms
include:
• No AWD or gear position display on instrument
er
clust
• Ratcheting noise on deceleration
• Inability to engage into a
• Excessive gear clash (noise)
• Gear selector moving out of desired range
1. Locate th e shift ca ble in th e rear r ight-hand whe el
w
ell area.
gear
• Loose parts - visually inspect vehicle for any
dam
aged or loose nuts, bolts or fasteners
• Engine coolant - check for proper level at the
recovery bottle
• Check all front and rear suspension components
for wear or damage.
Frame, Nuts, Bolts, and Fasteners
Periodically inspect the torque of all fasteners in
accordance with the maintenance schedule. Check that all
cotter pins are in place. Refer to specific fastener torques
listed in each chapter.
2. Inspect shift cable, clevis pin, pivot bushings, and dust
t. Replace if worn or damaged.
4. Adjust the shift cable so there is the same amount of
cable travel when shifting slightly past the detents of
HIGH (H) gear and PARK (P).
5. Thread jam nut (A) or (B) as required to obtain proper
ble adjustment.
ca
NOTE: This procedure may require a few attempts to
tain the proper adjustment.
ob
6. Once the p roper ad justment is obtained, place the
cable and jam nut (B) into the mount. Tighten jam
shift
nut (A) against the mount.
7. Start engine and shift through all gears to ensure the
cable is properly adjusted. If transmission still
shift
ratchets after cable adjustment, the transmission will
require service.
FUEL SYSTEM AND AIR INTAKE
Fuel System
Fuel Line
1. Check the quick-connect fu el line from th e en gine
fuel rail conn ection to th e fu el ta nk connection for
signs of wear, de terioration, da mage or leakag e.
Replace if necessary.
2
2. Be sure fuel line is routed and retained properly.
IMPORTANT: Make sure line is not kinked or pinched.
3. Replace fuel line every two years.
Gasoline is extremely flammable and explosive
under certain conditions.
Always stop the engine and refuel outdoors or in
a well ventilated area.
Do not smoke or allow open flames or sparks in
r near the area where refueling is performed or
o
where gasoline is stored.
Do not overfill the tank. Do not fill the tank
If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately.
If you spill gasoline on y
immediately wash it off with soap and water
and change clothing.
Never start the engine or let it run in an enclosed
The RZR 57 0 engine uses a se rviceable, hi gh-volume,
high-pressure, fuel pump that includes a preliminary filter
and a n in ternal fine filter located be fore th e p ump
regulator.
NOTE: Neither f ilter is se rvicable individua lly. Mu st
place the fuel pump as an assembly.
re
Vent Lines
1. Check fuel tan k, fr ont gearcase an d transmission
vent lines for signs of wear, deterioration, damage or
leakage. Replace every two years.
2. Be sure vent lines are routed and secured properly.
IMPORTANT: Ensure lines are not kinked or pinched.
Throttle Pedal Inspection
If the throttle pedal has excessive play due to cable stretch
or cab le misadju stment, 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.
NOTE: Refer to Chapter 4 for fuel pump replacement
a
nd all other information related to the EFI System.
It is recommended that the air filter be inspected as part of
pre-ride inspection. In extremely dusty conditions, air filter
replacement will be required more often.
The filter shou ld be inspected
procedure:
Removal
using the following
4. Inspect the air filter element and replace if necessary.
not attempt to clean the air filter.
Do
NOTE: If the filter has been soaked with fuel or oil it
st be replaced.
mu
NOTE: Service more frequently if vehicle is operated
cond itions o r at hig h th rottle ope ration f or
in wet
extended periods.
Installation
1. Clean the air box and air box cover thoroughly.
2. Place the filter into the air box with the air filter pleats
cing UP, as shown.
fa
NOTE: The air box is located underneath the cargo box
access panel.
1. Thoroughly clean the air box area to remove dirt and
ebris.
d
2. Loosen hose clamp (A) and remove the intake hose
from the air box cover.
3. Unlatch the (6) clips and carefully remove the air box
cover. Be sure not
air filter element during removal.
to let the air box cover contact the
3. Carefully install air box cover and secure with the (6)
clips.
4. Reinstall the clea n intake h ose a nd tigh ten ho se
c
This single cylinder engine is a wet-sump engine, meaning
the o il is co ntained in t he bo ttom of th e cr ankcase. To
check the oil level follow the procedure listed below:
IMPORTANT: Thoroughly clean engine around the oil
ain plug, oil filte r and oil dipstick to prevent
dr
contamination from entering the engine.
1. Position vehicle on a level surface.
2. Place the transmission in Park (P).
3. Be sure engine OFF has not been run for at lease 3
utes.
min
IMPORTANT: Do not run the machine and then
immediat
4. Locate the engine oil dipstick:
ely check the oil level.
• RZR 57
engine case; accessible through the righthand rear wheel well area.
0 - Located on the right-hand side of the
8. Unscrew and remove dipstick and verify the oil level
is in the SAFE (XX) range. Add oil as indicated by the
level on the dips tick. D o not overfill (see N OTE
below!).
NOTE: A rising oil level bet ween ch ecks in cool
ther driving can indicate contaminants suc h as
wea
gas or moisture collecting in the crankcase. If the oil
level is over t he f ull mar k, cha nge t he o il
immediately.
9. Reinstall the dipstick and hand tighten.
Engine Oil and Filter Service
Always change engine oil and filter at the intervals outlined
in the Periodic Maintenance Chart. Always change the oil
filter whenever changing the engine oil.
5. Thoroughly clean the engine around dipstick area.
6. Unscrew / remove dipstick and wipe dry with a clean
cloth.
7. Reinstall the dipstick completely.
NOTE: Make certain the dipstick is thr eaded all the
into the engine case.
way
IMPORTANT: Thoroughly clean engine around the oil
drain plug, oil f
contamination from entering the engine.
The engine is equipped with a breather hose. Inspect the
breather hose fo r po ssible kinks or we ar. The hose is
form fitted for a proper fit. Follow the breather hose from
the engine cr ankcase to the a ir intake baffle box on the
left-hand rear fender panel.
NOTE: Make sure line is not kinked or pinched.
Valve Clearance Inspection
IMPORTANT: Valve cl earance i nspection should be
performed on a cold engine, at room temperature.
1. Remove the seats and disconn ect th e negative ( -)
y cable.
batter
2. Remove the cargo box access panel.
3. Remove the spar k plug wire from the en gine an d
ove the spark plug. Place a clean shop towel into
rem
the spark plug tube to prevent debris from entering the
combustion chamber.
4. Remove the (3) T40 bolts retaining the valve cover.
5. Remove the valve cover fro m the engine out of the
t-hand rear wheel well area.
righ
Engine and Transmission Mounts
Periodically inspect engine and transmission mounts for
cracks or damage.
Refer to Chapter 3 “Engine Assembly
mounting fastener torque values.
and Installation” for
Compression Test Specification
NOTE: This en gine does ha ve decompression
components.
A smooth idle generally indicates good compression. Low
engine compression is rarely a factor in running condition
problems above idle speed.
Cylinder Compression:
80 - 120 psi (decompression)
6. Remove the outer PVT cover and drive belt as shown
7. Rotate th e drive clu tch co unter-clockwise until the
cam chain sprocket timing marks are aligned with the
gasket sur face as sho wn (see Ch apter 3 for mo re
TDC setting procedures).
IMPORTANT: Intake ca m s procket sh ould ha ve “I”
ks aligned with ga sket surface a nd the ex haust
mar
cam spr ocket shou ld have “E” ma rks aligned with
gasket surface.
Image for Reference Only
I
8. Measure the valve clearance of each valve using
thickness (feeler) gauge. Record the measurement if
clearance is out of specification.
I
E
E
9. If the valve clearance is out o
to “Valve Clearance Adjustment” (see Chapter 3).
f specification, proceed
= In. / mm.
Intake Valve Clearance (cold):
.005-.007 in. (0.125-0.175 mm)
= In. / mm.
Exhaust Valve Clearance (cold):
.008-.010 in. (0.152-0.254 mm)
10. Repeat steps 8- 9 u ntil all (4) valves h ave b een
inspected.
11. Inspect the valve cover seal and replace if necessary.
12. Install the valve cover and spark plug as o utlined in
a
Chapter
13. Install d rive b elt an d o uter clu tch cover a nd ( 8)
retaining screws (see Chapter 6)
3.
2
= T
Outer Clutch Cover Screws:
45-50 in. lbs. (5 Nm)
14. Connect the negative (-) battery cable to the battery.
15. Start the engine to ensure proper operation.
16. Reinstall the cargo box access panel and seats (see
Chapter
TransmissionAGL Plus Gearcase Lubricant44 oz. (1300 ml)10-14 ft. lbs. (14-19 Nm)
Transmission (INTL)AGL Plus Gearcase Lubricant41 oz. (1200 ml)10-14 ft. lbs. (14-19 Nm)
Front GearcaseDemand Drive Plus6.75 oz. (200 ml)8-10 ft. lbs. (11-14 Nm)
Transmission Lubrication
2
NOTE: It is important to f ollow t he t ransmission
maintenance inte rvals de scribed in the Periodic
Maintenance Chart. Regular lubricant level
inspections should be performed as well.
The transmission lubricant level shou ld be che cked and
nged in accordance with the maintenance schedule.
cha
• Be sur e ve hicle is po sitioned on a level su rface
en checking or changing the lubricant.
wh
• Check vent hose to be sure it
and unobstructed.
Transmission Lubricant Level Check
The fill plug is located on the rear portion of the
transmission gearcase. Access
the vehicle. Maintain lubricant level even with the bottom
of the fill plug hole.
1. Position vehicle on a level surface.
2. Remove the fill plug and check the lubricant level.
is routed properly
the fill plug at the rear of
3. If lubricant level is not even with the bottom threads,
dd the recommended lubricant as needed. Do n ot
NOTE: It is important to fo llow the fro nt gea rcase
maintenance inte rvals de scribed in the Periodic
Maintenance Chart . Regular fluid leve l ins pections
should be performed as well.
The fron t gearcase fluid le vel should be checked and
nged in accordance with the maintenance schedule.
cha
• Be sur e ve hicle is po sitioned on a level su rface
en checking or changing the fluid.
wh
• Check vent hose to be sure it
and unobstructed.
Front Gearcase Fluid Level Check
The fill plug is located on the bottom
gearcase. Access the fill plug through the right front wheel
well. Maintain fluid level even with the bottom of the fill plug
hole.
1. Position vehicle on a level surface.
2. Remove the fill plug and check the fluid level.
is routed properly
right side of the front
4. Reinstall the fill plug and torque to
Fill / Drain Plug Torque:
8-10 ft. lbs. (11-14 Nm)
Front Gearcase Fluid Change:
The d rain pl ug is locate d on th e bo ttom of th e fro nt
rcase. Access the drain plug through the access hole
gea
in the frame underneath the front gearcase.
1. Remove the fill plug (refer to “Front Gearcase Fluid
Level Chec
2. Place a drain pan under the front gearcase drain plug.
3. Remove th e dr ain plug and allo w fl uid to drain
completely
k”).
.
specification.
2
3. If fluid level is not even with the bottom threads, add
the recommended fluid
The engine coolant level is controlled, or maintained, by
the recovery system. The re covery system components
are the recovery bottle, radiator filler neck, radiator
pressure cap and connecting hose.
As coola nt op erating tem perature in creases, the
xpanding (heated) excess coola nt is for ced out of the
e
radiator past the pressure cap and into the recovery bottle.
As engine coolant temperature decreases the contracting
(cooled) coolant is drawn back up from the tank past the
pressure cap and into the radiator.
NOTE: Some coolant level drop on new machines is
rmal as the system is purging itself of trapped air.
no
Observe coolan t lev els of ten during the brea k-in
period.
NOTE: Overheating of engine could oc cur if air is
t fully purged from system.
no
Polaris Premium 60/40 is already premixed and ready to
e. Do not dilute with water.
us
Coolant Level Inspection
The pressure cap and recovery bottle are located under
the front hood of th e ve hicle. The coolant level must be
maintained between the minimum and maximum levels
indicated on the recovery bottle.
4. If the coolant level is below the MIN line, inspect the
co
olant level in the radiator.
NOTE: If o verheating is e vident, allow system to
cool comp letely and ch eck coolant leve l in th e
radiator and inspe ct f or s igns of trapped a ir in
system.
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.
5. Remove the pr essure ca p. Using a funnel, ad d
oolant to the top of the filler neck.
c
6. Reinstall the pressure cap.
NOTE: Use of a non-standard pressure ca p will not
allo
w the recovery system to function properly.
7. Remove recovery bottle cap and add coolant using a
funnel.
8. Fill recov ery bottle to M AX level w ith Polaris 60/40
premix Anti Freeze/Coolant or 50/50 or 60/40 mixture
of antifreeze and distilled water as required for freeze
protection in your area.
9. Reinstall the recovery bottle cap.
10. If co olant was re quired, sta rt eng ine an d check for
leaks. Ma ke su re radiator fins ar e clea n to prevent
overheating.
With the en gine at o perating temp
level should be between the upper and lower marks on the
coolant re covery bo ttle. If no t, per form the fo llowing
procedure:
Refer to Ch apter 3 fo r co oling sy stem pressure tes t
procedure.
MAINTENANCE
CA U T I O N
Antifreeze Hydrometer
WA RN I N G
Drain Here
Coolant Strength / Type
Test th e str ength of the co olant u sing a n an tifreeze
hydrometer.
• A 50/50 or 60/40 mixture of antifre
water will provide the optimum c ooling, corrosion
protection, and antifreeze protection.
• Do n ot use t ap water , stra ight a ntifreeze, or
straight water in th e system. T ap water co ntains
minerals an d impu rities wh ich build up in the
system.
• Straight water or antifreeze may cause the system
to freeze, corrode, or overheat.
Polaris Premium Antifreeze
2871534 - Quart
2871323 - Gallon
eze and distilled
Coolant Drain / Fill
Coolant Drain
1. Remove the hood from the front cab.
Never drain the coolant when the engine and
radiator are warm or hot. Hot coolant can cause
severe burns. Allow engine and radiator to cool.
2. Slowly remove the pressure cap to relieve any cooling
em pressure.
syst
3. Place a su itable drain pan underneath the rad iator
fitting on
4. Drain the coolant from the radiator by rem oving the
ower co olant ho se fro m the ra diator a s shown.
l
Properly dispose of the coolant.
the front right-hand side of the vehicle.
2
Cooling System
1. Inspect all hoses fo r cracks, d eterioration, a brasion
or leaks. Replace if necessary.
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).
2. Check tightness of all hose clamps.
5. Allow coolant to completely drain.
6. Place a su itable d rain pan underneath t he lo wer
ngine hose on the right-hand rear side of the vehicle.
Inspect the drive shaft boots for damage, tears, wear or
leaking grease. If the boots exhibit any of these symptoms,
they should be replaced. Refer to Chapter 7 for drive shaft
boot replacement.
ELECTRICAL AND IGNITION SYSTEM
Battery Maintenance
Keep battery terminals and connections free of corrosion.
If cleaning is necessary, remove the corrosion with a stiff
wire brush. Wash with a solution of one tablespoon baking
soda and one cup water. Rinse well with tap water and dry
off with c lean shop towels . Coat the terminals with
dielectric grease or petroleum jelly.
CALIFORNIA PROPOSITION 65 WARNING:
Batteries, battery posts, terminals and related
accessories contain lead and lead compounds,
and other chemicals known to the State of
California to cause cancer and birth defects or
other reproductive harm.
WASH HANDS AFTER HANDLING.
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:
Follow with milk of magnesia, beaten egg, or
Eyes: Flus
Ventilate when charging or using in an enclosed
NOTE: Batteries must be fully charged before use or
tery life will be re duced by 10 -30% of fu ll
bat
potential. Ch arge battery acc ording t o “Charging
Procedure” provided in Cha pter 1 0. Do not use the
vehicle’s stator/alternator to charge a new battery.
1. Remove the driver’s seat to access the battery.
2. Disconnect the (2) black (neg
3. Disconnect the (2) red (positive) battery cables.
4. Remove the ho ld-down strap and lift th e battery out
the vehicle.
of
ative) battery cables.
Battery Installation
IMPORTANT: Using a new battery that has not been
fully charged can damage the battery and result in a
shorter life. It can a lso hinder v ehicle pe rformance.
Follow the battery charging procedure in Chapter 10
“Electrical” before installing the battery.
1. Ensure the battery is fully charged.
2. Place the battery in the battery holder and secure with
old-down strap.
h
3. Coat the terminals with dielectric grease or petroleum
elly.
j
4. Connect and tighten the (2) re
5. Connect a nd tighten the ( 2) black ( negative) cable
last.
d (positive) cables first.
2
To reduce the chance of sparks: Whenever
removing the battery, disconnect the black
(negative) cable first. When reinstalling the
battery, install the black (negative) cable last.
rify that cables are properly routed and reinstall the
6.Ve
driver’s seat.
Battery Off Season Storage
Refer to Chap ter 10 “Electrical” for o ff sea son stor age
procedures.
Inspect ground cable connections. Be sure they are clean
and tight.
The engine ground cable runs from the upper starter motor
unting bolt to the chassis ground terminal.
mo
The Chassis ground is located under the drivers seat, near
starter solenoid.
the
STEERING
Steering Inspection
The steering components should be checked periodically
for lo ose fa steners, wor n tie ro d e nds, b all jo ints, and
damage. Also ch eck to make sure all cotter pin s ar e in
place. If cotte r p ins are re moved, they mu st not be re–
used. Always use new cotter pins.
Replace any wor n or da maged steer ing com ponents.
teering should mo ve freely through th e entire range of
S
travel without binding. Check routing of all cables, hoses,
and wirin g to b e sur e the steer ing mech anism i s n ot
restricted or limited.
Check t he st eering wh eel f or specified freeplay and
operation.
1. Position the vehicle on level ground.
2. Lightly turn the steering wheel left and right.
3. There should be 0.8”-1.0” (20-25 mm) of freeplay.
4. If there is exce ssive fr eeplay or the stee ring feels
rough, inspect the following components.
• Tie Rod Ends
• Steering Shaft U-Joints
• Steering Gearbox
Tie Rod End / Wheel Hub Inspection
• To check for play in the tie rod end, grasp the
steering tie rod, pull in all directions feeling for
movement.
• Replace any worn steering components. Steering
ld move freely through entire range of travel
shou
without binding.
• Elevate fr ont end of mach ine so front wheels are
off the ground. Che ck fo r a ny looseness in fr ont
hub/wheel assembly by g rasping the tire firmly at
top and bottom first, and then at front and rear. Try
to move the wheel and hub by pushing inward and
pulling outward.
• If abnormal movement is detected, inspect the hub
d whe el assemb ly to deter mine the cau se
an
(loose wheel nuts or loose front hub nut).
2.34
• Refer to Chap ter 7 “ Final Drive” for fro nt hu b
service procedures.
1. Place ma chine o n a smooth le vel su rface and set
steering wheel in a str aight ahead position. Secure
the steering wheel in this position.
2. Place a chalk mark on the cente
approximately 10” (25.4 cm) from the floor or as close
to the hub/axle center line as possible.
r line of the front tires
Wheel Toe Adjustment
If to e alig nment is inco rrect, mea sure th e dist ance
between vehicle center and each wheel. This will tell you
which tie rod needs adjusting.
2
NOTE: It is impor tant t he h eight of b oth mark s be
equally positioned to get an accurate measurement.
3. Measure the distance between the marks and record
measurement. Call this measurement “A”.
the
4. Rotate the tires 180
Position chalk marks facing rearward, even with the
hub/axle center line.
5. Again measure the distance between the marks and
cord. Call t his m easurement “ B”. Su btract
re
measurement “ B” from me asurement “ A”. The
difference between measurements “A” and “B” is the
vehicle toe alignment. The recommended vehicle toe
tolerance is 1/ 8”, t o 1/4”, ( .3 to .6 cm) toe out. This
means the measurement at the front of the tire (A) is
1/8”, to 1/4”, (.3 to .6 cm) wider than the measurement
at the rear (B).
(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)
° by moving the vehicle forward.
Wheel Toe-Out:
NOTE: Be sure st eering wheel is st raight ahead
ore determining which tie rod needs adjustment.
bef
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
• Shorten or lengthen the tie rod until alignment is as
re
quired to achieve the pr oper toe settin g as
specified in “Wheel Toe Alignment”.
• IMPORTANT: When tightening the tie rod end jam
nuts, the rod ends must be held parallel to prevent
rod e nd da mage and p remature wear. Dama ge
may not be immed iately app arent if done
incorrectly.
• After alignment is complete, torque jam nuts to
pecification.
s
Tie Rod Jam Nut Torque:
12-14 ft. lbs. (16-19 Nm)
SUSPENSION
Spring Preload Adjustment
The front and rear shock absorber springs are adjustable
by rotating the adjustment cam to change spring tension
preload.
Uneven adjustment may cause poor handling of the
vehicle, which could result in an accident and
serious injury or death. Always adjust both the left
and right spring preloads equally.
Suspension Spring Adjustment
1. Position the vehicle on a lev el surface and stop the
ine.
eng
2. Raise and safely su pport th e fr ont or rear of th e
vehicle off the ground to allow the suspension to fully
extend.
NOTE: The tires should not be touching the ground.
3. To adjust the suspension, rotate the
clockwise to incr ease spr ing ten sion or counterclockwise to decrease spring tension.
Shock Spanner Wrench
(PN 2871095)
4. Each notch of the adjustment will add 6% - 8% more
Always check the brake pedal travel and inspect the brake
fluid reservoir level before each operation. If the fluid level
is low, add DOT 4 brake fluid only.
Brake fluid should be changed every two years. The fluid
uld also be changed anytime th e fluid becomes
sho
contaminated, the fluid level is below the minimum level,
or if th e type and br and of th e fluid in the reservoir is
unknown.
The brake fluid master cylinder re
through the left front wheel well.
1. Position the vehicle on a level surface.
2. Place the transmission in PARK (P).
3. View the brake fluid level in the reservoir. The level
uld be between the MAX and MIN level lines.
sho
4. If the fluid level is lower than
brake fluid until it reaches the MAX level line.
servoir can be accessed
the MIN level line, add
Brake Pad / Disc Inspection
1. Check the brake pa ds for wear, dam age, or
looseness.
2. Inspect th e br ake p ad we ar su rface for e xcessive
wear.
3. Pads should be changed when the
worn to .040” (1 mm).
4. Check surface condition of the brake discs.
friction material is
2
5. Install th e re servoir ca p and apply the br ake pe dal
forcefully fo r a fe w se conds a nd ch eck for fluid
leakage around the master cylind er fittings an d the
brake caliper fittings.
5. Measure the th ickness of the front an d re ar bra ke
s.
disc
6. The disc(s) should be replaced if thickness is less than
.170” (4.32 mm).
Brake Hose and Fitting Inspection
Check b rake system hoses and fitting s for cracks,
deterioration, ab rasion, an d leaks. Tighten an y loo se
fittings and replace any worn or damaged parts.
When the parking brake is fully engaged and “BRAKE” is
displayed on the instrument clu ster, en gine spe ed is
limited to 1500 RPM while in gear. If throttle is applied, this
limiting fea ture pr events op eration, wh ich pr otects the
parking brake pads from excessive wear.
NOTE: Inspect the parking brake cable tension after
he first 25 hours of operation a nd ev ery 100 hours
t
of operation af terwards to ens ure prop er cab le
tension.
Loss of tension in the parking brake cable will caus
illumination of the parking brake indicator and activation of
the limiting feature. If this occurs, inspect an d a djust
parking brake cable tension. If performing this service is
difficult due to conditions o r location , temporarily
disconnect the parking brake switch electrical connector.
Reconnect th e co nnector as so on as practicable an d
adjust the parking brake cable to proper tension.
1. Pull back on the parking brake lever (located in dash).
2. After 3 t o 4 clic ks “BRAKE ” should display on the
nstrument cl uster a nd th e whe els of the vehicle
i
should not rotate when tur ning b y hand. After 8 full
clicks of lever travel, the vehicle should not roll while
parked.
3. If the vehicle moves, adjustment is necessary.
4. Adjust the pa rking brake cable wh ere th e ca ble
ttaches to the caliper mount / shift cable bracket. The
a
mount bracket is located on the right-hand side of the
transmission.
e
Parking Brake Pad Inspection (INTL)
Inspect t he p arking br ake ca liper br ake p ad thickness.
Replace brake pads if damaged or worn beyond service
limit. Replac e caliper ass embly if damage or excessive
wear is found. Refer to the following image for brake pad
specifications.
2. Remove pressure cap a nd pressure test the cooling
system using a commercially available pressure
tester.
3
Polaris Premium Antifreeze
2871534 - Quart
2871323 - Gallon
Recommended Coolant
Use only high quality antif re
distilled water in a 50/50 or 60/40 ratio, depending on
freeze protection required in your area.
CAUTION: Using
to a buildup of deposits which may restrict coolant flow and
reduce he at dissip ation, r esulting in p ossible engine
damage. Pola ris Pre mium 60 /40 An tifreeze/Coolant is
recommended for use in all cooling systems and comes
pre-mixed, ready to use.
tap water in the cooling system will lead
eze/coolant m ixed with
3. The system must maintain 10 psi for five minutes or
longer. If pressure loss is evident within five minutes,
check the filler neck, radiator, hoses, clamps and
water pump weep hole for leakage.
2. Remove the pr essure cap to reliev e any sys tem
pressure (see “Pressure Cap Test”).
3. Drain coolant to a level below the thermostat housing.
4. Remove the cargo box access panel.
5. Remove the spark plug wire from the engine.
6. Remove th e (2 ) bo lts (X) retai ning the th ermostat
cover.
Cooling System Bleeding Procedure
Always wear safety glasses and proper shop
clothing when performing the procedures in this
manual. Failing to do so may lead to possible
injury or death.
Use caution when performing these procedures.
Coolant may be hot and may cause
severe injury or burns.
NOTE: If the coolant level is LOW in the radiator, or
if there are lea ks in th e system, the coolant system
will not draw coolant from the reservoir tank.
NOTE: It may be ne cessary to safely raise the front
the vehicle 1 2” ( 30 c m) to blee d the c ooling
of
system.
1. Allow engine and cooling system to completely cool.
7. Lift the co ver from th e en gine a nd r emove the
rmostat.
the
8. Reverse th is p rocedure for in stallation. Re place
rmostat seal if worn or da maged. T orque
the
thermostat cover bolts to specification.
Thermostat Cover Bolts:
9. Be sure to properly fill and bleed cool
outlined in this chapter.
7.5 ft. lbs. (10 Nm)
ing system as
Be sure the engine has cooled and no pressure
is built up in the cooling system before removing
Be sure bearing is fully seated in cover or severe
3. Clean and de-grease the water pump drive shaft (H).
4. Press in th e wa ter pu mp dr ive shaft (H) into the
earing using PU-50869 Item #1.
b
w water pump drive sha ft b earing ( G)
engine damage may result.
5. Install the water pump drive shaft ho lding tool ( Item
#1) in kit PU-50869.
the as sembly u p-side-down so the special tool PU50869 is supporting the assembly.
14. While installing the stator cover to the engine, slightly
CA U T I O N
CA U T I O N
PA-49317
9 ft. lbs.
(12 Nm)
= T
= In. / mm.
Water Pump Drive Shaft
Mechanical Seal
Stator Cover
K
Finger Tighten
(Reverse Threads)
rotate the water pump impeller to verify the crankshaft
slot and the water pump drive shaft blade are properly
engaged. Verify the stator cover is laying flat on the
engine case.
The flywheel contains powerful magnets. Use
caution when installing the stator cover.
DO NOT place fingers between cover and
crankcase at any time during the removal and
installation process or injury could result.
ENGINE / COOLING SYSTEM
Stator Cover and Water Pump Cover
9 ft. lbs. (12 Nm)
16. Measure the installe d height of the new mechanical
seal a s sh own b elow. If not within sp ecification,
remove and discard the mechanical seal and properly
install new mechanical s eal as outlined in this
chapter.
3
If the water pump drive shaft blade and slot in the
crank shaft are not in alignment during the
installation process, severe engine damage may
result.
15. Install and to rque the stator cover fa steners in
sequenc
19. Install th e water pu mp co ver to the stator cover.
Torque all fasteners in sequence to specification.
20. Install the oil dipstick.
21. Install the coolant hose to the water pump cover and
ten hose clamp.
tigh
22. Connect the stator wir e connector and install a new
p securing the wiring to the front engine mount
tie stra
bracket.
23. Install the CPS sensor into the stator cover. Inspect
O-ring and replace if needed.
CPS
24. Install the right-hand rear wheel and torque the wheel
uts to specification. Safely lower vehicle.
n
ENGINE SERVICE
Accessible Engine Components
The following components can be serviced or re moved
with the engine installed:
• Camshaft
• Camshaft Sprockets
• Cylinder Head and Gaskets
• Cylinder and Gaskets
• Piston and Rings
• Flywheel
• Starter Motor / Idler Gear Asm
• Stator (Alternator)
• Thermostat
• Valve Cover
•Water Pump
• Camshaft Timing Chain and Guides
• Crankshaft Seal (PTO)
• Oil Pump / Oil Pump Sprocket or Chain
The following c omponents require e ngine re moval for
se
rvice:
• Counterbalance Shaft and Bearings
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)
25. Install both seats and the engine service panel.
26. Connect the (-) negative battery cable.
27. If the engine oil was contaminated during this service
procedure, perform an engine oil change as outlined
in Chapter 2. DO NOT run the engine until coolant has
been added to the cooling system.
28. Fill cooling system with rec
the system of air as outlined in this chapter.
ALL of the top-end engine components can be serviced
while the engine is mounted in the chassis.
ENGINE / COOLING SYSTEM
CA U T I O N
WA RN I N G
Spring Style
Clamp
Engine Removal
IMPORTANT: Some engine repair procedures can be
performed with out removing the engine as sembly
from th e ve hicle. Re fer to “Acc essible Engine
Components” for further information.
NOTE: The use of an overhead or port able engine
ist is the only recommended method for removing
ho
and installing the engine.
NOTE: Have an a ssistant help gu ide the eng ine in
nd out of the vehicle while using an engine hoist to
a
prevent pe rsonal injur y or damage to vehicle
components.
Correct Drive Clutch Puller P/N PA-48595
3. Drain the engine oil and engine coolant prior to engine
emoval (see Chapter 2).
r
4. Remove the sea ts an d en gine service pan el (see
apter 5).
Ch
5. Disconnect th e ( -) neg ative ba
battery.
6. Remove th e r ear bu mper and cargo b ox as a n
assembly (see Chapter 5).
ttery ca ble fr om the
3
Always wear safety glasses and proper shop
clothing when performing the procedures in
this Service Manual.
Failing to do so may lead to possible injury.
1. If vehicle was recently operated, allow it to cool down
before
2. Thoroughly clean the engine and chassis.
attempting to perform any work.
7. Loosen the (3) clam ps se curing th e int ake ba ffle
ssembly to the air box lid, inn er clutch cover and
a
engine crankcase vent. Remove the air intake baffle
/ intake ho ses / engine cran kcase vent tube an
assembly as shown below.
8. Elevate the rear of the vehicle off the ground using a
9. Remove the outer clutch cover, drive belt, drive clutch,
driven clutch and inner clutch cover (see Chapter 6).
Make note of hose and wire routings for reassembly.
IMPORTANT: Be sure to use the correct Drive Clutch
(PA-48595) to prevent damage to crankshaft.
Puller
10. Disconnect the stator wire connector and cut the tie
p secur ing the wir ing to th e front eng ine mou nt
stra
bracket. Replace tie strap for engine installation.
11. Remove the CPS sensor from the stator cover on the
ight-hand side of the engine. Plug CPS h ole with
r
clean shop towel. Inspect CPS O-ring and replace if
needed.
12. Disconnect the IAC valve (A), TPS (B), T-MAP sensor
(C), har
13. Disconnect the fuel injector harness lead (D) from the
fuel injector.
14. Properly relieve fuel pressure from the fuel rail.
15. Place a shop to beneath the fuel line quick connector
to
from the fuel rail by pressing in on the quick connector
tabs.
16. Move fue l line to th e left-h and sid e of th e en gine
co
installation.
ness leads from the throttle body.
catch any excess fuel. Disconnect the fuel line (E)
17. Disconnect the ignition coil har ness co nnector an d
ove the spark plug wire from the engine.
rem
ENGINE / COOLING SYSTEM
F
G
H
J
I
18. Remove t he ( 8) fa steners securing t he ( 2) b olt in
braces to the veh icle main fra me. Ma neuver the
braces for engine removal clearance. Note the routing
of the transmission breather hose and wire harness.
19. Remove (+) positive cable from the starter motor.
20. If desired, remov e the re maining s
and remove the starter motor from the engine.
21. Remove (-) negative cable from the starter mounting
lt.
bo
tarter motor bolt
22. Loosen the hose clamp (F) securing the throttle body
the air box. L ift air box up and rea rward a s an
to
assembly to disengage it from the throttle body.
23. Loosen the hose clamp (G) securing the throttle body
the engine intake boot. Remove throttle body from
to
the engine and wrap it with a clean shop towel. Place
throttle body on the left-hand side frame rail area.
IMPORTANT: Be sure dirt and debris do not enter the
ngine, a ir box or t hrottle bod y. Use clean sho p
e
towels to plug engine and air box intake holes.
3
24. Disconnect the upper en gine coo lant h ose ( H),
25. Remove the (3 ) he x bolts (K) secur ing th e exha ust
head pipe to the eng ine. Remo ve th e (3 ) r ubber
exhaust hangers (L) securing the exhaust system to
the main frame. Discard the exhaust seal and replace
with new for reassembly.
26. Maneuver the exhaust system towards the right-hand
of the vehicle to gain engine removal clearance.
side
Removal of the exhaust system from the chassis is not
needed.
27. Place a s upport in -between th e main fra me and
nsmission case. Do not pinch brake line.
tra
30. Remove the ( 8) b olts (N) securing th e cou pler
ckets to the engine and transmission.
bra
31. Loosen the (2) bolts and nuts (O) so the engine mount
cket can be slightly tilted away from engine.
bra
32. With the h elp of an assista nt an d the en gine hoist,
the engine vertically out of the vehicle frame.
raise
NOTE: Have a n ass istant help guide t he e ngine in
and out
prevent per sonal injury or dama ge t o th e ve hicle
components.
of the vehicle while using an engine hoist to
28. Use an overhead or portable engine hoist and suitable
gine s traps t o s ecure the engine in its cu rrent
en
position.
29. Remove the (4) bolts and nuts (M) securing the engine
7. In sequence, to rque the (8 ) e ngine cou pler br acket
fasteners to specification.
Rear Engine Coupler Fastener (In Sequence):
55 ft. lbs. (74.5 Nm)
8. In a criss-cross pattern, to
mount fasteners to specification.
rque the (4 ) fro nt eng ine
10. Remove the lifting str aps a nd over head or po rtable
engine hoist an d r emove th e sup port pr eviously
installed under the tra nsmission case du ring th e
engine removal process.
11. Reposition th e e xhaust system a nd insta ll the (3)
ber exhaust hangers, new exhaust seal and the (3)
rub
head p ipe bo lts. To rque he ad pipe b olts to
specification.
Front Engine Mount Fasteners:
40 ft. lbs. (54 Nm)
9. Torque th e (2) front center iso lator bolts to
ification.
spec
Isolator Center Bolt:
40 ft. lbs. (54 Nm)
Exhaust Head Pipe Bolts:
18 ft. lbs. (24.5 Nm)
12. Install the (3) coolant hoses onto the engine.
13. Install the throttle body and air box. Tighten the hose
mps that secure the throttle body to the intake boot
17. Connect the harness leads to the IAC valve (D), TPS
(E), T-MAP sensor (F). Verify routing is correct.
18. Connect the fuel injector harness lead (G) to the fuel
injector.
19. Connect the fuel line (H) to the fuel rail.
20. Install the (8) fasteners securing the (2) bolt in braces
to th e ve hicle m ain frame. Torque fas teners to
specification. Be sure the routing of the transmission
breather hose and wire harness is correct.
3
Rear Bolt in Brace Fastener Torque:
17 ft. lbs. (23 Nm)
Front Bolt in Brace Fastener Torque:
40 ft. lbs. (54 Nm)
21. Connect the ignition coil harness connector and install
e spark plug wire.
th
22. Install the CPS and mounting bolt into the stator cover
d torque to specification.
an
CPS Fastener Torque:
9 ft. lbs. (12 Nm)
23. Connect th e st ator wire connector and install a ne w
strap to secure the wiring to the front engine mount
tie
bracket.
24. Install the inner clutch cover as outlined in chapter 6.
25. Install the dr ive clutch, driven clutch, belt an d outer
ch cover as outlined in Chapter 6. Be sure all hose
clut
and wire routings are correct. Torque all fasteners to
specification as outlined in Chapter 6.
26. Install the in take ba ffle as sembly. Se cure the 3
mps that attach the a ssembly to the crankc ase
cla
vent, air box lid and inner clutch cover.
3.33
ENGINE / COOLING SYSTEM
= T
CA U T I ON
27. Install th e re ar bumper and cargo box assembly as
outlined in Chapter 5.
28. Install the left-hand rear wheel and torque wheel nuts
to specification.
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)
29. Remove the pressure cap and fill the
through the filler neck with properly mixed anti-freeze
/ coolant.
30. If the e ngine o il wa s com pletely d rained, a dd
roximately 2 quarts (1.9 L) of Polaris PS-4 Plus
app
Synthetic Engine Oil into the crankcase.
31. Install a new oil filter. Lubricate the seal with engine
rior to installation (see Chapter 2 “Maintenance”).
oil p
32. Connect the (-) negative battery cable to the battery.
33. Install the engine service panel and seats.
34. Follow the “Cooling System Bleeding Procedure” as
ed in this chapter.
outlin
35. Start engine and check for any oil or coolant leaks.
36. Check the engine oil level (see Chapter 2).
37. Refer customer to “En gine Bre ak-In Peri od” up on
urning vehicle to customer.
ret
cooling system
Engine Break-In Period
The break-in period con sists o f the first 25 h ours o f
operation, or the time it takes to use 15 gallons (57 liters)
of fuel. Careful treatment of a ne w e ngine a nd d rive
components will result in more efficient performance and
longer life for these components.
Use only Polaris PS-4 PLUS
Synthetic Engine Oil.
Never substitute or mix oil brands.
Serious engine damage and voiding of
w a r r a n t y c a n r e s u l t .
Do not operate at full throttle or high speeds for
extended periods during the first three hours of
use. Excessive heat can build up and cause
damage to close fitted engine parts.
1. Fill fuel tank with unleaded fuel which has a minimum
ump octane number of 87 = (R+ M)/2.
p
2. Refer to Chapter 2, “Engine Oil
indicated on oil tank dipstick. Add oil if necessary.
3. Drive slowly at first to gradually bring engine up to
erating temperature.
op
4. Vary throttle po sitions. Do no t operate at su stained
le or sustained high speed.
id
5. Perform regular checks on fluid le vels, con trols and
ll important bolt torques.
a
6. Change oil an d oil filter a fter br eak-in pe riod at 25
There ar e thre e ways to en sure the pisto n is at TDC.
Remove the outer clutch cover to access the drive clutch
to aid in engine ro tation (m anually tu rn the drive clu tch
counter clockwise).
1. With the CPS sensor removed, rotate the engine until
“V” mar ked o n the flywhee l is a ligned with the
the
CPS mounting ho le. This will se t TDC, but not
necessarily TDC o f t he compression st roke.
View the timing marks on the camshaft sprockets to
ensure the e ngine is at TDC of the co mpression
stroke.
2. With t he v alve cover a nd thermostat h ousing
emoved, ro tate th e en gine so the cam lobe s a re
r
facing ou tward a nd th e Cylin der Hold ing a nd
Camshaft Timing Plate (PU-50563) can be installed
into the slots of the camshafts as shown below. This
will set TDC of the compression stroke.
IMPORTANT: Intake c am spr ocket shou ld h ave “I”
rks aligned wit h g asket su rface and t he e xhaust
ma
cam s procket sh ould ha ve “E” mark s a ligned wit h
gasket surface.
3. With the stator cover and flywh
engine and position the piston at TDC by aligning the
timing ho le in cra nk case with a timing hole in th e
crankshaft.
Insert a 1 /4” dr ive socket exte nsion through th e
ankcase and into the crankshaft locating hole. This
cr
will s et TDC, but n ot necessarily TDC of the
compression stroke. View the timing marks on the
cam shaft sprockets to ensure the en gine is at TD C
of the compression stroke.
3. Remove the (2 ) bo lts r etaining th e fixed cam chain
guide (G) and remove the assembly from the engine.
Inspect the guide for wear and replace if necessary.
4. Remove th e re maining (6 ) b olts t hat r etain th e
camshaft carrier (H) and carefully lift the carrier off the
camshafts.
6. Mark the intake ( I) an d exha ust (J) camsh afts to
e proper assembly.
ensur
7. Lift up ward on the intake ca mshaft wh ile r otating it
ounter-clockwise. Walk the timing chain off of th e
c
sprocket. Carefully remove the intake camshaft from
the engine.
8. Remove the cam chain fro m the exha ust ca mshaft
rocket (J) and remove the exhaust camshaft from
sp
the engine.
NOTE: The crankcase has a lower guide t o prevent
the chain from falling off the crankshaft.
5. Attach a hook or other tool to the camshaft chain to
revent it from dropping down into the engine.
NOTE: Camshaft sprocket removal is n ot necessary
unless the replacement of the sprockets is required.
Inspect cam sprocket teeth for wear
timing chain and sprockets as a set if worn or damaged.
IMPORTANT: Replace camshaft sprocket bolts if they
are loosened or removed.
or damage. Replace
Camshaft / Camshaft Bore Inspection
Inspect a ll main journals a nd cam lo bes as de scribed
below and compare to specifications. Replace camshafts
or cylinde r he ad if wo rn beyond s ervice limit or if any
surface is pitted or damaged.
1. Visually inspect each cam lobe for wear or damage.
2. Measure the height of each cam lobe from the base
cle to highest point on the lobe using a micrometer.
cir
Compare to specification.
NOTE: Replace camshafts if damaged or if any part
worn past the service limit.
is
3
Camshaft Sprocket Bolts:
15 ft. lbs. (20 Nm)
Camshaft Lobe Height:
Intake: 1.5704" ± 0.0038" (39.89 ± 0.097 mm)
Exhaust: 1.5405" ± 0.0038" (39.13 ± 0.097 mm)
3. Visually insp ect each camsha ft journal for sco ring,
wear or damage.
4. Measure the diameter of the camshaft journals using
NOTE: The cy linder hea d ca n be se rviced with the
engine installed in the chassis.
IMPORTANT: Do not rotate hea d assembly up side-
wn until the valve buck ets and shims hav e been
do
removed.
1. Remove and discard the (2) outer M6 bolts (A) tha t
etain the cylinder head (B) and the cylinder.
r
2. Loosen the (4) cylinder head bolts (C) evenly 1/8 turn
60 degrees) at a time until all are loose.
(
3. Remove an d d iscard the cylin der h ead bo lts ( C).
Replace with new upon assembly.
4. Tap cylinder he ad lightly with a so ft faced hammer
til loose. Tap only in re inforced areas or on th ick
un
parts of the cylinder head casting.
5. Remove the cylinder head (B) and head gasket (D).
Cylinder Head Disassembly
Wear eye protection during cylinder head
disassembly and reassembly or when working
with the valve springs.
IMPORTANT: Keep mated parts together and in order
with respect to their location in the cylinder head for
assembly purposes. It is important to install cylinder
head components b ack in the same lo cation. M ark
each component or place them in an organized rack
as you remove them.
1. Remove the valve bu cket ( F) an d a djustment shim
G) from the cylinder head.
(
2. Compress the valve spring by hand using valve spring
Thoroughly clea n cylinde r h ead sur face to r emove a ll
traces of gasket material and carbon.
Use care not to damage gasket sealing surface.
All gasket surfaces must be clean, dry and free
of any oil or grease upon assembly. Clean
sealing surfaces with rubbing alcohol or
electrical contact cleaner. Do not touch sealing
surfaces of the new head gasket.
Cylinder Head Warp Inspection
1. Lay a s traight ed ge ( E) ac ross the s urface of th e
cylinder head at several different points and measure
warp by inserting a feeler gauge between the straight
edge and the cylinder head surface. If warp exceeds
the service limit, replace the cylinder head.
Valve Inspection
1. Remove all carbon from valves with a soft wire wheel
or brush.
2. Check valve face fo r exce s
burnt spots.
3. To chec k for bent v alve st em
blocks and measure with a dial indicator.
sive runout, pit ting, a nd
s, mo unt va lve in “V ”
4. Check the end of the valve stem for flaring, pitti ng,
wear or damage.
Cylinder Head Warp Limit:
.0024" (0.06 mm)
5. Inspect split keeper groove for wear or flaring in th e
keeper seat area.
NOTE: The valves can be re-faced or end ground, if
6. Measure diameter of valve stem with a micrometer in
three places, then rotate 90° and measure again (take
six measurements total). Compare to specifications.
Valve Stem Diameter:
Intake: 0.2155" - 0.2161" (5.475 - 5.490 mm)
Exhaust: 0.2147" -0.2153" (5.455 - 5.470 mm)
7. Measure valve guide inside dia
and end of the guide using a small hole gauge and a
micrometer. Measure in two directions.
meter at the top middle
Combustion Chamber Cleaning
Wear eye protection during combustion
chamber cleaning.
1. Clean a ll accumulated car bon dep osits fro m
combustion chambers and valve seat area.
NOTE: Carbon Clean Fu el Tre atment (2 871326) can
e used to help remove carbon deposits.
b
3
Valve Guide I.D.:
0.2165" - 0.2171" (5.500 - 5.515 mm)
8. Be su re to mea sure each guide a nd valve
combination indiv
NOTE: The valve guides cannot be replaced.
idually.
IMPORTANT: Do not u se a met al scr aper, a co arse
brush or abrasive cleaners to clean the cylinder
wire
head. Damage may result.
2. Visually inspe ct cylinde r head g asket su rface and
bustion chamber for cracks or damage. Pay close
com
attention to the ar eas a round sp ark p lug and va lve
seats.
Valve se at reconditioning should be pe rformed by a
technician pr oficient in cylinder hea d reco nditioning
techniques. Reconditioning techniques vary, so follow the
instructions pr ovided by the valve reco nditioning
equipment m anufacturer. D o not grind seats more t han
necessary t o provide p roper seat su rface, w idth, and
contact point on valve face.
Wear eye protection or a face shield during
cylinder head disassembly and reassembly.
Valve Seat Inspection
Inspect valve seat in cylinder head for pitting, burnt spots,
oughness, a nd u neven sur face. If a ny of the a bove
r
conditions exist, the valve seat must be reconditioned. If
the valve seat is cracked the cylinder head must be
replaced.
Valve seat width and point of contact on the valve face is
y important for proper sealing. The valve must contact
ver
the valve seat over the entire c ircumference 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 n arrow, heat tr ansfer from va lve to seat is r educed.
The valve may over heat an d warp , r esulting in burnt
valves.
* If the contact area is less than 75% of the circumference
seat, rotate the pilot 180° and make another light cut.
of the
* If the cutter now contacts the uncut portion of the sea t,
check the pilot. Look for burrs, nicks, or runout. If the pilot
is bent it must be replaced.
* If the contact area of the cutter is in the same place, the
valve guide is distorted from improper installation.
* 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 on ly t he a mount o f material
essary to repair the seat surface.
nec
5. To ch eck the con tact area of the seat on the valve
ce, apply a thin coating of Prussian Blue paste to the
fa
valve seat. If using an interference angle (46°) apply
black p
6. Insert valve into guide and tap v
a few times.
ermanent marker to the entire valve face (A).
alve lightly into place
Renewing Valve Seats
1. Install pilot into valve guide.
2. Apply cutting oil to valve seat and cutter.
3. Place 46° cutter on the pilot and make a light cut.
7. Remove valve an d check where the Pru ssian Blu e
indicate
seat should co ntact th e middle of th e valve face or
slightly above, and must be the proper width.
* If the indicated seat contact is at the
face and contacts the margin area (B) it is too high on the
valve face. Use the 30° cutter to lower the valve seat.
* If too lo w, use the 60° cutter to raise th e seat. When
contact area is centered on the valve face, measure seat
width.
* If the seat is too wide or uneven, use both top and bottom
cutters to narrow the seat.
* If the seat is too narrow, widen using the 45° cutter and
check contact p oint on the valve face and seat width
reafter each cut.
s seat contact o n the valve face . The valve
top edge of the valve
ENGINE / COOLING SYSTEM
B
A
Proper Seat Contact
on Valve Face
INTAKE
Seat Width
.039” (1.00 mm)
60°
45°
30°
= In. / mm.
EXHAUST
Seat Width
.059” (1.50 mm)
60°
45°
30°
NOTE: When us ing a n int erference a ngle, t he seat
contact point on the valve will be very narrow, and is
a normal condition. Look for an even and continuous
contact point all the way around the valve face (A).
Intake Seat Cutter Diameter: 1.567 in. (39.80 mm)
Exhaust Seat Cutter Diameter: 1.364 in. (34.65 mm)
3
Valve Seat Width:
Intake: .0393" (1.00 mm)
Service Limit: .0551" (1.4 mm)
8. Clean all filings from the area with hot s oapy water.
Rinse and dry with compressed air.
9. Lubricate valve guides with clean engine oil and apply
oil or water based lapping compound to the face of the
valve.
NOTE: Lapping is no t req uired if an interference
ngle reconditioning method is used.
a
10. Insert the valve into its respective guide and lap using
lapping tool or a section of fuel line connected to the
a
valve stem.
11. Rotate th e va lve rapidly ba ck and fo rth un til th e cu t
unds smooth. Lift the valve slightly off of the seat,
so
rotate 1/4 turn, and repeat the lapping process. Do this
four to f ive times until t he valve is fully seated, and
repeat process for the other valves.
3. Tap cylin der lig htly with a p lastic h ammer in th e
reinforced areas only until loose.
4. Rock cylinder forward and backward and lift it from the
ankcase, supporting piston and connecting rod.
cr
5. Remove the cylinder from the engine.
Cylinder Inspection
1. Remove all gasket material from the cylinder sealing
surfaces.
2. Inspect the top of the cylinder for war page using a
ight edge and feeler gauge.
stra
Cylinder Warpage:
.00098” (.025 mm)
6. Remove and discard cylinder base gasket.
3. Inspect cylinder for wear, s
4. Inspect cylinder for ta per an d ou t o f r ound with a
te
lescoping gauge or a dial bore gauge. Measure in
two different directions, front to back and side to side,
on three different levels (1 /2" down from top, in the
middle, and 1/2” up from bottom).