Polaris SPORTSMAN 400 2003, SPORTSMAN 500 2003 Service Manual

The Way Out.

2003 SPORTSMAN 400 / 500

SERVICE MANUAL

PN 9918065

2003 SPORTSMAN 400/500

SERVICE MANUAL

Foreword

This manual is designed primarily for use by Polaris ATV service technicians in a properly equipped shop.
Persons usingthis manual should have asound knowledge of mechanical theory,tool use, and shop proce­dures in order to perform the work safely and correctly. The technician should read the text and be familiar
with service procedures before starting the work. Certain procedures require the use of special tools. Use
onlythepropertools, as specified. Cleanlinessofparts andtools aswellastheworkareaisofprimaryimpor­tance.

Allreferences to left andrightsideof the vehicle are from theoperator’sperspective when seated in a normal
riding position.

This manualincludesprocedures for maintenance operations, component identificationandunitrepair,along
with service specifications for the 2003 Polaris Sportsman ATVs. A table of contents is placed at the
beginningofeachchapter,andanalphabeticindexisprovidedattheendofthemanual for location ofspecific
page numbers and service information. Keep this manual available for reference in the shop area.

At the time of publication all information contained in this manual was technically correct. However, all
materials and specifications are subject to change without notice.

Comments or suggestions about this manual may be directed to: Polaris Sales Inc., Service Publications
Department, 2100 Hwy 55 Medina, Minnesota 55340.

2003 Sportsman 400/500 ATV Service Manual (PN 9918065)

ECopyright 2002 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the
time of publication. Due to constant improcvements in the design and quality of production components, some minor descrepancies
may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this
publication are intended for reference use only. No liability can be accepted for ommisions or inaccuracies. Any reprinting or reuse of
the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS

Throughout these instructions, important information is brought to your attention by the following symbols:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

DANGER

Failure to follow DANGER instructionswillresult in severeinjury ordeathtothe operator,bystander orperson
inspecting or servicing the ATV.

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or
person inspecting or servicing the ATV.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property
damage.

NOTE:

A NOTE provides key information to clarify instructions.

Trademarks

Polaris acknowledges the following products mentioned in this manual:

FLEXLOC, Registered Trademark of SPS Technologies
Loctite, Registered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
FOX, Registered Trademark of Fox Shox
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Ammco, Registered Trademark of Ammco Tools, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation

CHAPTER INDEX

CHAPTER 1 GENERAL

CHAPTER 2 MAINTENANCE

CHAPTER 3 ENGINE

CHAPTER 4 FUEL SYSTEM

CHAPTER 5 BODY/SUSPENSION

CHAPTER 6 PVT SYSTEM

CHAPTER 7 FINAL DRIVE

CHAPTER 8 TRANSMISSION

CHAPTER 9 BRAKES

CHAPTER 10 ELECTRICAL

CHAPTER 1

GENERAL INFORMATION

GENERAL INFORMA

Model Identification 1.1.......................

Serial Number Location 1.1...................

Machine Dimensions 1.2--1.4.....................

Specifications - Sportsman 400 1.5-1.6............

Specifications - Sportsman 500 H.O. 1.7-1.8........

Publication Numbers 1.9.....................

Paint Codes 1.9.............................

Replacement Keys 1.9.......................

Standard Torque Specifications 1.10............

Torque Conversion Table 1.11-1.12..................

Decimal Equivalent Chart 1.13.................

Conversion Table 1.14........................

Tap Drill Charts 1.15..........................

Glossary of Terms 1.16-1.17........................

TION

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

A 03 CH 50 AA

Emissions &

Year Designation

Basic Chassis
Designation Engine Designation

Model Option

ENGINE DESIGNATION NUMBERS

42 EH42PLE05 Single, L/C, SOHC 4 Stroke, Electric Start............

50 EH50PLE13 Single, L/C, SOHC 4 Stroke, Electric Start............

VIN IDENTIFICATION

World Mfg. ID

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

Body Style

Vehicle Descriptor

50A*2P000 000

Engine

Powertrain

Emissions

Check Digit

Model
Year

Plant No.

Vehicle Identifier

Individual Serial No.

* This could be either
a number or a letter

ENGINE SERIAL NUMBER LOCATION

Whenever corresponding about anengine, besure to refer to the engine model numberand serialnumber. This
information can be found on the sticker appliedto the recoil housing on the right side of engine.(A) An additional
number is stamped on the center top of crankcase beneath the cylinder coolant elbow.

MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION

Themachine modelnumber andserial numberare
important for vehicle identification. The machine
serial number is stamped on the lower left side of
the frame tube.(B)

A

TRANSMISSION I.D. NUMBER
LOCA

TION

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

1.2

Front

B

MACHINE DIMENSIONS

SPORTSMAN 400/500

GENERAL INFORMATION

47 in

114 cm

46 in

117 cm

400 --

500 --

11 in
28 cm

46 in
117 cm

81 in

205.7 cm
85 in

216 cm

51 in
128 cm

51 in

129.5 cm

1.3

GENERAL INFORMATION

ltitude

Below40

F

+40

Fan

dabov

e

Meter

s

0-180

0

(Feet

)

Above1800

Altitud

e

Meter

s

0-180

0

(Feet

)

180

0-370

0

MODEL: SPORTSMAN 400..........

MODEL NUMBER: A03CH42.
ENGINE MODEL: EH42PLE05..

CARBURETION

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

Main Jet 167.5............

Pilot Jet 40.............

Jet Needle 4GAC33--3...........

Needle Jet Q-0 (829)...........

Throttle Valve #100........

Pilot Screw 2 3/4 Turns Out..........

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

Valve Seat 1.5...........

Float Height 13.0mm (.51I)±1mm.........

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

89 Oxygenated

CLUTCH

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

Belt 3211069.....................

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

Side Angle (Overall) 26°......

Outside Circumference 40.86 ±.12I....

Center Distance 10±.12I (254.5mm)..........

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

Secondary Spring Black........

Driven Helix 44-36°.............

Spring Position (Helix) 2....

Spring Position (Sheave) 2..

JETTING CHART

Altitude

Meters

(Feet)

0-1800

(0-6000)

Above 1800

Above (6000)

CLUTCH CHART

A

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

AMBIENT TEMPERATURE

Below 40°F
Below +5°C

175 167.5

165 160

Shift

Weight Spring Spring Helix

10BH Blue/Green Black 2+2

16 Blue/Green Black 2+2

+40_F and above

+5_C and above

Clutch

Driven Cluthc

Driven

ENGINE

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

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

Bore 3.461I (87.9mm).......................

Stroke 2.756I (70mm).....................

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

Compression Ratio 9.2/1 Full Stroke..........

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

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

Operating RPM±200 6300 RPM.........

Idle RPM±200 (lights off) 1200 RPM.....

Compression Pressure (Std) ±15%.......

1.4

GENERAL INFORMATION

MODEL: SPORTSMAN 400............

MODEL NUMBER: A03CH42...

ENGINE MODEL: EH42PLE05....

ELECTRICAL FLUID Capacity Type

Flywheel I.D. FF95 Fuel Tank 5.25 gals. (19.9L)...... ..........

CDI Marking CU2557 Injector Oil N / A....... .......... .........

**Alternator Output 200 Watts / 250 Watts Coolant 2.25 qts. (2.1L) PP6*. ............

Ignition Timing 30° BTDC@5000RPM±2° Transmission 32 oz. PPS*..... ....... .......

Spark Plug / Gap NGK BKR5E / 0.036I (0.9mm) Gearcase Oil (Front) 4 oz. (120ml) 80-90 GL5... . .

Lights: Head Halogen Gearcase Oil (Center) N / A......

High Beam 50watts Gearcase Oil (Rear) N / A..

Low Beam 27 watts Engine Counter Bal. N / A. . .........

Tail 8.26 watts Engine Oil 2 qts. (1.9L) PP4*........ .......... ..

Brake 26.9 watts Brake (Hand) Dot 3...... .......

Voltage Regulator LR39 Brake (Foot) Dot 3.. ........

Electric Start Standard Front Hubs (AWD) 2.5 oz. (75ml) PDD*....... ...

**Early Build Units Have 200 Watt Altnerantor Shift Selector Box 1 oz. (30ml) PP4*... ..

Lubricant Key

*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style Gen IV Chain Type Shaft Drive........ .........

Front Suspension MacPherson Strut Gear Reduction-Low 6.69/1.. .

Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.17/1...... ..

Turning Radius 65I (165.1 cm) Gear Reduction-High 3.34/1.....

Toe Out 1/8I-1/4I (3-6.35 mm) Front Drive Ratio 2/1........... ....

Ground Clearance 11I (27.94 cm) Center Drive Ratio N / A.. ...

Front Vertical Travel 6.7I (17.02 cm) Final Drive Ratio 3.16/1....

Rear Suspension Progressive Rate Independent Brake (Hand) Single Lever, Hyd. Disc... .......

Rear Travel 9.5I (24.13cm) Brake (Auxiliary Foot) Hydraulic........

Rear Shock 2I Twin Tube........

Shock Adjustment Cam..

TIRES

Tire Size - Front 25 x 8 - 12....

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

Tire Size - Center N / A..
Tire Pressure - F/R 5/5 lbs.

Total Width 46I (116.84 cm)........

Total Length 81I (205.74 cm).......

Total Height 47I (119.38 cm)........

Wheel Base 50.50I (128.27 cm).......

Weight - Dry 697 lbs. (316.4 kg).......

LOAD CAPACITY

Front Rack (Std) 90 lbs......

Rear Rack (Std) 180 lbs.......

Tongue Weight 120 lbs.....

Tow Hitch Std...........

OPTIONAL SUSPENSION SPRINGS

SPRING TYPE SOFT STANDARD FIRM

Rear Compression Spring N/A 7041453-067

Front Strut Spring 7041238-067

Option 61 lb/in.

Standard 100 lb/in.

7041375-067

Standard 64/113 lb/in.

7041519-067

Option 140 lb/in.

7041450-067

Option 101 lb/in.

1.5

GENERAL INFORMATION

ltitude

Below40

F

+40

Fan

dabov

e

Meter

s

0-180

0

(Feet

)

Above1800

Altitud

e

Meter

s

0-180

0

(Feet

)

180

0-370

0

MODEL: SPORTSMAN 500 H.O...........

MODEL NUMBER: A03CH50.
ENGINE MODEL: EH50PLE13..

CARBURETION

Type BST 40 Mikuni................

Main Jet 152.5............

Pilot Jet 40.............

Jet Needle 6MGH1--94--3...........

Needle Jet X-6...........

Throttle Valve #120........

Pilot Screw 2 Turns Out..........

Pilot Air Jet 1.3..........

Valve Seat 1.5...........

Float Height 14.7mm (.58I)±1mm.........

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

89 Oxygenated

CLUTCH

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

Belt 3211069.....................

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

Side Angle (Overall) 26°......

Outside Circumference 40.86 ±.12I....

Center Distance 10±.12I (254.5mm)..........

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

Secondary Spring White/Yellow........

Driven Helix Compound (EBS).............

Spring Position (Helix) N/A....

Spring Position (Sheave) N/A..

JETTING CHART

Altitude

Meters

(Feet)

0-1800

(0-6000)

Above 1800

Above (6000)

AMBIENT TEMPERATURE

Below 40°F
Below +5°C

157.5 152.5

150 145

CLUTCH CHART

A

Meters

(Feet)

*EBS require no helix/spring adjustment

0-1800

(0-6000)

1800-3700

(6000-12000)

Shift

Weight Spring Spring Helix*

10WH Blue/Green White/Yellow EBS

16 Blue/Green White/Yellow EBS

+40_F and above

+5_C and above

Clutch

Driven Clutch

Driven

ENGINE

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

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

Bore 3.6248I (92mm).......................

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

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

Compression Ratio 10/2 Full Stroke..........

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

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

Operating RPM±200 6500 RPM.........

Idle RPM±200 (lights off) 1200 RPM.....

Compression Pressure (Std) ±15%.......

1.6

GENERAL INFORMATION

MODEL: SPORTSMAN 500 H.O.............

MODEL NUMBER: A03CH50...

ENGINE MODEL: EH50PLE13....

ELECTRICAL FLUID Capacity Type

Flywheel I.D. FF97 Fuel Tank 5.25 gals. (19.9L)...... ..........

CDI Marking CU2574 Injector Oil N / A....... .......... .........

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

Ignition Timing 30° BTDC@5000RPM±2° Transmission 32 oz. PPS*..... ....... .......

Spark Plug / Gap NGK BKR6E / 0.036I (0.9mm) Gearcase Oil (Front) 4 oz. (120ml) 80-90 GL5... . .

Lights: Head Halogen Gearcase Oil (Center) N / A......

High Beam 50watts Gearcase Oil (Rear) N / A..

Low Beam 27 watts Engine Counter Bal. N / A. . .........

Tail 8.26 watts Engine Oil 2 qts. (1.9L) PP4*........ .......... ..

Brake 26.9 watts Brake (Hand) Dot 3...... .......

Voltage Regulator LR39 Brake (Foot) Dot 3.. ........

Electric Start Standard Front Hubs (AWD) 2.5 oz. (75ml) PDD*....... ...

Shift Selector Box 1 oz. (30ml) PP4*... ..

Lubricant Key

*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W/40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style Gen IV Chain Type Shaft Drive........ .........

Front Suspension MacPherson Strut Gear Reduction-Low 6.69/1.. .

Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.17/1...... .

Turning Radius 65I (165.1 cm) Gear Reduction-High 3.34/1.....

Toe Out 1/8I-1/4I (3-6.35 mm) Front Drive Ratio 2/1........... ....

Ground Clearance 11I (27.94 cm) Center Drive Ratio N / A.. ...

Front Vertical Travel 6.7I (17.02 cm) Final Drive Ratio 3.16/1....

Rear Suspension Progressive Rate Independent Brake (Hand) Single Lever, Hyd. Disc... .......

Rear Travel 9.5I (24.13 cm) Brake ( Auxiliary Foot) Hydraulic........

Rear Shock 2I Twin Tube........

Shock Adjustment Cam..

TIRES

Tire Size - Front 25 x 8 - 12....

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

Tire Size - Center N / A..
Tire Pressure - F/R 5/5 lbs.

Total Width 46I (116.84 cm)........

Total Length 85I (215.9 cm).......

Total Height 47I (119.38 cm)........

Wheel Base 50.50I (128.27 cm).......

Weight - Dry 697 lbs. (316.4 kg).......

LOAD CAPACITY

Front Rack (Std) 90 lbs......

Rear Rack (Std) 180 lbs.......

Tongue Weight 120 lbs.....

Tow Hitch Std...........

OPTIONAL SUSPENSION SPRINGS

SPRING TYPE SOFT STANDARD FIRM

Rear Compression Spring N/A 7041453-067

Front Strut Spring 7041238-067

Option 61 lb/in.

Standard 100 lb/in.

7041375-067

Standard 64/113 lb/in.

7041519-067

Option 140 lb/in.

7041450-067

Option 101 lb/in.

1.7

GENERAL INFORMATION

PUBLICATION NUMBERS

Year Model Model No. Owner’s

Manual PN

2003 Sportsman400 A03CH42 9917492 9917537 9917538
2003 Sportsman500 A03CH50 9917492 9917541 9917542

When ordering service parts be sure to use the correct parts manual.
FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147.

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

Parts

Manual PN

Micro Fiche PN

COLD WEATHER KITS FOR 4 CYCLE ATVS

Oil Tank Cover -- (PN 2871874)
Engine Heater -- (PN 2871507)

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.

Parts

31XX

Key Series
Number

Series # Part Number

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

1.8

GENERAL INFORMATION

STANDARD TORQUE SPECIFICATIONS

The following torque specifications are to be used as a general guideline. There are exceptions in the steering,
suspension, and engine areas. Always consult the exploded views in each manual section for torque values of
fasteners before using standard torque.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

Torque in. lbs. (Nm)

#10 - 24 27 (3.1) 43 (5.0) 60 (6.9).............. ................ ..............

#10 - 32 31 (3.6) 49 (5.6) 68 (7.8).............. ................ ..............

Torque ft. lbs. (Nm)*

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

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

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

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

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

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

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

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

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

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

Metric

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

*To convert ft. lbs. to Nm multiply foot pounds by .1.382
*To convert Nm to ft. lbs. multiply Nm by .7376.

SPECIFIC TORQUE VALUES OF FASTENERS

Refer to exploded views in the appropriate sectionTorque Conversions

1.9

GENERAL INFORMATION

DECIMAL EQUIVALENTS

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

1/32 .0312 1 mm = .0394²................... ................

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

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

5/64 .0781 2 mm = .0787²......................... ................

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

7/64 .1094 3 mm = .1181²....................... ................

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

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

5/32 .1563 4 mm = .1575²................... ................

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

3/16 .1875 5 mm = .1969².............. ................

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

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

15/64 .2344 6 mm = .2362²........................ ................

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

17/64 .2656 7 mm = .2756²........................ ................

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

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

5/16 .3125 8 mm = .3150².............. ................

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

11/32 .3438 9 mm = .3543².................. ................

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

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

25/64 .3906 10 mm = .3937²........................ ................

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

27/64 .4219 11 mm = .4331²........................ ................

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

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

15/32 .4688 12 mm = .4724².................. ................

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

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

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

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

35/64 .5469 14 mm = .5512²........................ ................

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

37/64 .5781 15 mm = .5906²........................ ................

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

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

5/8 .625 16 mm = .6299².......... .................

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

21/32 .6563 17 mm = .6693².................. ................

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

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

45/64 .7031 18 mm = .7087²........................ ................

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

47/64 .7344 19 mm = .7480²........................ ................

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

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

25/32 .7813 20 mm = .7874².................. ................

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

13/16 .8125 21 mm = .8268²............. ................

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

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

55/64 .8594 22 mm = .8661²........................ ................

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

57/64 .8906 23 mm = .9055²........................ ................

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

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

15/16 .9375 24 mm = .9449²............. ................

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

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

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

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

1.10

GENERAL INFORMATION

CONVERSION TABLE

Unit of Measure Multiplied by Converts to

ft. lbs. x 12 = in. lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.356 = Nm
in. lbs. x .0115 = kg-m
Nm x .7376 = ft.lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 = in. lbs.
kg-m x 10 = Nm
in. x 25.4 =mm
mm x .03937 = in.
in. x 2.54 = cm
mile (mi.) x 1.6 = km
km x .6214 = mile (mi.)
Ounces (oz) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x 0.035 = Ounces (oz)
lb. x .454 = kg
kg x 2.2046 = lb.
Cubic inches (cu in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = Cubic inches (cu in)
Imperial pints (Imp pt) x 0.568 = Liters (l)
Liters (l) x 1.76 = Imperial pints (Imp pt)
Imperial quarts (Imp qt) x 1.137 = Liters (l)
Liters (l) x 0.88 = Imperial quarts (Imp qt)
Imperial quarts (Imp qt) x 1.201 = US quarts (US qt)
US quarts (US qt) x 0.833 = Imperial quarts (Imp qt)
US quarts (US qt) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt)
US gallons (US gal) x 3.785 =Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x 0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

p (3. 14) xR2x H (height) = Cylinder Volume

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

1.11

GENERAL INFORMATION

SAE TAP DRILL SIZES

Thread Size Drill Size Thread Size Drill Size

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

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

METRIC TAP DRILL SIZES

Tap Size Drill Size Decimal Equivalent Nearest Fraction

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

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

1.12

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3125

0.3437

0.339

0.375

0.406

0.406

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

GENERAL INFORMATION

GLOSSARY OF TERMS

ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8² or 1 cm). Polaris measures chain length in number of

pitches.

CI: Cubic inches.
Clutch Buttons: Plastic bushings which transmit rotation of the clutch to the movable sheave in thedrive and driven

clutch.
ClutchOffset: Driveand drivenclutches areoffset sothat drivebelt willstay nearlystraight asitmovesalongtheclutch

face.
Clutch Weights: Threelevers in the drive clutch which relative to their weight, profile and engine RPM causethe drive

clutch to close.

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

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

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

out-of-round in the cylinder bore.

Electrical Open: Open circuit. An electrical circuit which isn’t complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load.

(i.e. a bare wire touching the chassis).

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

kg/cm2: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.

lbs/in2: Pounds per square inch.
Left Side: Always referred to based on normal operating position of the driver.

1.13

GENERAL INFORMATION

GLOSSARY OF TERMS

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

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

mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040².
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch System)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM

increases.

Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: Inthemechanicalsense,friction or load. Intheelectricalsense, ohms. Bothresult inenergyconversionto

heat.

Right Side: Always referred to based on normal operating position of the driver.
RPM: Revolutions per minute.
Secondary Clutch: Driven clutch on chaincase or jackshaft.
SeizedPiston: Gallingofthesidesof a piston. Usuallythere is atransfer ofaluminumfrom the pistononto thecylinder

wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck
piston rings.

Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston’s most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the

circuit.

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

1.14

CHAPTER 2
MAINTENANCE

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

Pre-Ride Inspection 2.3......................

Recommended Lubricants and Capacities 2.4...
Lubricant and Maintenance Product Numbers 2.5

Special Tools 2.6--2.7............................

Lubrication Charts 2.7-2.8........................

Transmission Lubrication 2.9..................

Front Gearcase Lubrication 2.9--2.10................

Transmission Linkage Adjustment 2.10-2.11..........

Carburetor Adjustments 2.11-2.13...................

MAINTENANCE

2

Fuel System 2.13-2.14.............................

Compression Test 2.15........................

Battery Maintenance 2.15--2.16......................

Electrical 2.16................................

Coolant System Maintenance 2.17--2.18..............

Air Filter Service 2.18--2.20.........................

Air Box Sediment Tube Service 2.20............

Breather Filter 2.20...........................

Recoil Housing 2.20...........................

Oil Change/Filter 2.21-2.23.........................

Valve Clearance 2.23-2.24.........................

Steering and Toe Alignment 2.24-2.26...............

Front Hub Maintenance 2.26--2.27...................

Exhaust System Maintenance 2.27--2.28.............

Brake System Service 2.28-2.29....................

Suspension Service 2.29......................

Controls 2.29.................................

Wheel Removal/Installation 2.30................

Tire Inspection 2.31...........................

2.1

MAINTENANCE

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 tooil level. A rise in oil level in cold weather

can indicate moisture collecting in the oil tank (500). Change oil immediately if oil level begins to rise.

E Emission Control System Service (California).

Frequency

(Whichever comes first)

Item Hours Calendar Miles

(Km)

Engine Oil - Level/Change 100 hrs 6 months 1000 (1600) Check Level Daily; Break In service at 1 month

E"

Oil Filter 100 hrs 6 months 1000 (1600) Replace with oil change

E

Air Filter - Foam Pre-Cleaner Daily Daily Inspect-Clean & oil more often in dirty conditions.

E"

Air Filter - Main Element Weekly Weekly Inspect - Replace if necessary

E"

" Air Box Sediment Tube - Daily Drain deposits whenever visible
" Engine Breather Filter 20 hrs Monthly 200 (320) Inspect and replace if necessary
" Oil Tank Vent Hose 100 hrs 12 months 1000 (1600) Inspect hose routing /hose condition

Valve Clearance 100 hrs 12 months 1000 (1600) Inspect/Adjust

EH

Idle Speed As required As required Adjust

E

H Throttle Cable / ETC Switch 50 hrs 6 months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary

Choke (Enricher) Cable 50 hrs 6 months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary
Carburetor Float Bowl 50 hrs 6 months 500 (800) Drain bowl periodically and prior to storage
Carburetor Air Intake Ducts/Flange 50 hrs 6 months 500 (800) Inspect all ducts for proper sealing/air leaks
Fuel System 100 hrs 12 months 1000 (1600) Check for leaks at tank cap, lines, fuel valve, filter,

EH

Fuel Filter 100 hrs 12 months 1000 (1600) Replace filter annually

EH

Coolant/Level Inspection Daily Daily Replace engine coolant every 2 years
Coolant Strength / Pressure Test

System
Radiator 100 hrs 12 months 1000 (1600) Inspect / Clean external surface
Cooling System Hoses 100 hrs 12 months 1000 (1600) Inspect
Engine Mounts 100 hrs 12 months 1000 (1600) Inspect
Drain Recoil Housing Weekly Weekly More often if operating in wet environment
Exhaust Muffler / Pipe 100 hrs 12 months 1000 (1600)

100 hrs 6 months 1000 (1600) Inspect strength seasonally; Pressure test sys-

pump & carburetor. Replace lines every 2 years.

tem annually

ELECTRICAL

Spark Plug 100 hrs 12 months 1000 (1600) Inspect - Replace if necessary

E

Wiring 100 hrs 12 months 1000 (1600) Inspect for abrasion, routing, security
Ignition Timing 100 hrs 12 months 1000 (1600) Inspect
Battery 20 hrs Monthly 200 (320) Check terminals; Clean; Check fluid level
Headlight Aim As required As required Adjust if Necessary

Remarks

2.2

MAINTENANCE

Headlamp Inspection Daily Daily Check operation daily; Apply Nyogelt Grease

Tail Lamp Inspection Daily Daily Check Operation Daily; Apply Nyogelt Grease

to connector when lamp is replaced

to socket when lamp is replaced

CHASSIS

Frequency

(Whichever comes first)

Item Hours Calendar Miles

(Km)

" General Lubrication 50 hrs 3 months 500 (800) Lubricate All Fittings, Pivots, Cables, Etc.
" Front Hubs/Fluid Check 50 hrs 6 months 500 (800) Check monthly
" Front Hubs/Fluid Change 100hrs 12 months 1000 (1600) Check monthly
" Front Gearcase Lubricant 100 hrs 12 months 1000 (1600) Inspect Monthly; Change Annually

Drive Belt 50 hrs 6 months 500 (800) Inspect - Adjust, Replace if Necessary
Clutches (Drive And Driven) 100 hrs 12 months 1000 (1600) Inspect, Clean

" Transmission Oil Level 25 hrs Monthly 250 (400) Inspect Monthly; Change Annually

Shift Linkage 50 hrs 6 months 500 (800) Inspect,Lubricate, Adjust
Shift Selector Box 200 hrs 24 months 2000 (3200) Change Lubricant Every Two Years

H Steering 50 hrs 6 months 500 (800) Inspect Daily, Lubricate
H Toe Adjustment As required As required Periodic Inspection, Adjust When Parts are Re-

placed

" Front Suspension 50 hrs 6 months 500 (800) Inspect - Lubricate
" Rear Suspension 50 hrs 6 months 500 (800) Inspect - Lubricate

Tires Pre-ride Pre-ride Inspect Daily, Pre-Ride Inspection Item

H Brake Fluid 200 hrs 24 months 2000 (3200) Change Every Two Years
" Brake Fluid Level Pre-ride Pre-ride Inspect Daily, Pre-Ride Inspection Item
" Brake Lever Travel Pre-ride Pre-ride Inspect Daily, Pre-Ride Inspection Item

H Brake Pad Wear 10 hrs Monthly 100 (160) Inspect Periodically

Auxiliary Brake Adjustment As required As required Inspect Deflection Daily; Adjust
Brake System Pre-ride Pre-ride Pre-Ride Inspection Item
Wheels Pre-ride Pre-ride Pre-Ride Inspection Item
Frame Nuts, Bolts, Fasteners Pre-ride Pre-ride Pre-Ride Inspection Item

Remarks

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

2.3

MAINTENANCE

RECOMMENDED LUBRICANTS - QUICK REFERENCE

LUBRICANTS AND MAINTENANCE PRODUCT PART NUMBERS ARE LISTED ON PAGE 2.5

Item

Engine Oil Polaris Premium 4

Synthetic, 0W--40 (PN

2871567)

Transmission Polaris Synthetic Gear

Case Lubricant (PN

2871478)

Front Gear Case Premium Front Gearcase

Fluid (PN2871653) or GL5
80-90 Gear Lube

Gear Shift Selector
Box

Coolant Level Polaris Premium 60/40

Front Hubs Premium Demand Drive

Brake Fluid Polaris DOT 3 Brake Fluid

Polaris 0W--40 Synthetic
Engine Lubricant (PN

2871281)

Pre-mixed Antifreeze/
Coolant (PN 2871323) or
a 50/50 mixture high quali­ty antifreeze/coolant and
distilled water

Hub Fluid (PN 2871654)

(PN 2870990)

Type Notes See

Pages

Add to proper level on dipstick. 2.21--2.22

Refer to procedures outlined later in this
chapter.

Refer to procedures outlined later in this
chapter.

Oil in selector box should be at the center
line of the shift selector plungers. Do not
overfill or the selector may hydro-lock.

Fill reservoir tank to full line. Add if neces­sary. If reservoir was empty or extremely
low, allow engine and cooling system to
cool completely and check level in radia­tor. Fill to top of filler neck.

Fill hub at 4:00 or 8:00 position until fluid
trickles out. Do not force fluid into hub.

-Fill to indicated level inside reservoir. 2.28

2.9

2.9--2.10

8.4

2.18

2.27

COLD WEATHER KITS FOR 4 CYCLE ATV’S

Oil Tank Cover -- (PN 2871874)
Engine Heater -- (PN 2871507)

2.4

MAINTENANCE

POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS

Part No. Description

Engine Lubricant

2870791 Fogging Oil(12 oz. Aerosol)
2871098 Premium2 Cycle Engine Oil (Quart) (12

Count)

2871281 Engine Oil (Quart) Premium 4 Synthetic

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

2871844 Engine Oil (Gallon) Premium 4 Synthetic

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

2871567 Engine Oil (16 Gallon) Premium 4

Synthetic0W--40 (4--Cycle)

Gearcase / Transmission Lubricants

2873603 Premium Synthetic Gearcase Lubricant (1

Gal.)(4 Count)

2873602 Premium Synthetic Gearcase Lubricant

(12 oz. bottle) (12 Count)

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

Count)

2871653 Premium Front Gearcase Fluid(2.5 Gal)

(2 Count)

2870465 Oil Pump for 1 Gallon Jug
2871654 Premium Drive Hub Fluid (8 oz.) (12

Count)

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

Count)

2871653 Angle Drive Fluid (8 oz.)

Grease / Specialized Lubricants

2871322 Premium All Season Grease (3 oz.

cartridge) (24 Count)

2871423 Premium All Season Grease (14 oz.

cartridge) (10 Count)

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

Coolant

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

Additives / Sealants / Thread Locking Agents /

Misc.

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

Count)

2871949 Loctitet Threadlock242 (50ml.) (10

Count)

2871950 Loctitet Threadlock 242 (6 ml.) (12

Count)

2871951 Loctitet Threadlock262 (50ml.) (10

Count)

2871952 Loctitet Threadlock 262 (6 ml.) (12

Count)

2871953 Loctitet Threadlock 271 (6 ml.) (12

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.

2.5

MAINTENANCE

SPECIAL TOOLS

PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN

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 WaterPump Install Kit 3
2870569 Crankshaft Truing Stand 5
2872314 CarburetorFloat Adjustment Tool 4
2870975 Mity Vact Pressure TestTool 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
7052069 Charging Needle 5
2200421 Gas Shock Recharging Kit 5
2871352 Shock Rod Holding Tool 5
2871351 Foxt Shock IFP Depth Tool 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 OffsetAlignment Tool 6
2870913 Driven Clutch Puller 6
2870910 Roller Pin Tool 6
2871226 Clutch Bushing ReplacementTool Kit 6
2870386 Piston Pin Puller 6
2872292 EBS ClutchAlignment Tool 6
2201379 EBS Bushing Replacement Kit 6
8700220 Clutch Compression Tool 6
2871025 Clutch Bushing ReplacementTool Kit 6
2871199 Seal Sleeve Installation Tool Kit 5, 7
2870888 Hilliard Clutch Garter Spring Installation Tool 7
2872608 Roller Pin Removal Tool 7

8700226 CV Boot Clamp Pliers 7
2871701 (Part of 2871702 Kit) 2 1/8 inch Wrench 8
2871697 (Part of 2871702 Kit) Center Drive Bushing Tool 8
2871695 (Part of 2871702 Kit) Backlash Setting Tool 8
2871698 (Part of 2871702 Kit) Rear OutputSeal Driver 8
2871699 (Part of 2871702 Kit) Rear Driveshaft Seal Guide 8

2871282 BearingSeal Driver (50 mm) 8

PV--43568 Fluket77 DigitalMultimeter 10

2870630 TimingLight 10

2870836 Battery Hydrometer 10

2.6

MAINTENANCE

SPECIAL TOOLS, CONT’D

2460761 Hall Sensor Probe Harness 10

2871745 Static Timing Light Harness 10

NOTE: Polaris dealers can order the tools listed above through their Polaris Special Service Tools catalog.

LUBRICATION

Ill.

#

Item

1 Engine Oil

2 Transmis-

sion

3 Brake Fluid

4 Front Gear-

case Oil

Lube Required Method Frequency*

Polaris 0W--40
Synthetic (PN

2871567)

Polaris Synthetic
Gear Case Lubricant
(PN 2871478)

Polaris DOT 3 Brake
Fluid (PN 2870990)

Premium Front Gear­case Lube (PN

2871653)

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

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

Add lube to FULL level on dipstick. Change annually ©

Fill master cylinder reservoirto indi­cated level inside reservoir.

Add to bottom of fill plug threads. Change annually©

As required. Change fluidevery 2 years.

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

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

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

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

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

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

Mobilegrease Special

Transmission Dipstick

Dipstick

Filter

1. Engine Oil and Filter

Master Cylinder
Reservoir

3. Brake Fluid (Left hand Master Cylinder)

Full

OperatingRange

2. Transmission

Fill Plug

4. Front Gear Case Fill Plug

2.7

MAINTENANCE

LUBRICATION, CONT.

6. Front Drive
AxleU-Joint

5. Demand 4 Hubs

7. Front Prop Shaft
U-Joint

Ill.

#

Item Lube Required Method Frequency*

5 Demand 4 Hubs

- All Wheel Drive

6 Front Drive Axle

“U” Joints

7 U-Joints - Front

Prop Shaft

8 Propshaft Yoke

8. Propshaft Yoke
(3 pumps max.)

Polaris Demand
Drive Hub Fluid (PN

2871654)
Polaris U-Joint

Grease¢ (PN

2871551)
Premium U-Joint

Grease ¢
(PN 2871551)

Premium U-Joint
Grease ¢
(PN 2871551)

Remove filler hole screw in hubs. Rotate wheels to
4 or 8 O’clockposition. If lubricantis not visible add
until it flows from fillerhole. Reinstall screw.

Locate grease fittingand greasewith grease gun. Semi-annually

Locate Fittingsand Grease Semi-annual-

Locate fittings and grease - 3 pumps maximum Annually©

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

4 or 8 O’clock posi­tion- (end view)

Semi-annually

¡

¡

ly¡

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

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

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

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

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

Mobilegrease Special

2.8

MAINTENANCE

TRANSMISSION
LUBRICA

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

SPORTSMAN 400/500 TRANSMISSION

S Be sure vehicle is level before

proceeding.

S Check vent hose to be sure it is

routed properly and unobstructed.

TRANSMISSION SPECIFICATIONS

Specified Lubricant:

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

Capacity:

Drain Plug:

14 ft. lbs. (19.4 Nm)

TION

Dipstick Location

At change: Approx. 20 oz.....

To change lubricant:

1. Remove skid plate (if necessary).

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

3. Remove thedrain plugandwipethemagneticend
clean to remove accumulated metallic filings.

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 properlubricant through the dipstick hole
until the oil level is between the upper and lower
limits. Do not overfill.

6. Check for leaks.

7. Reinstall skid plate if removed in Step 1.

FRONT GEARCASE
LUBRICA

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

S Besurevehicleislevelbefore proceeding.
S Check vent hose to be sure it is routed

properly and unobstructed.

S The correct gearcase lubricant to use is

Polaris Premium GL5 80-90 Gear Lube
(PN 2871653)

FRONT GEARCASE SPECIFICATIONS

Specified Lubricant:

Polaris Front Gearcase Lube (PN

2871653)

Capacity:

(120ml.)

TION

...Or API GL5 80-90 Gearlube

4.0 Oz............

Full

To check the level:

1. Remove dipstick and wipe clean.

2. Reinstall dipstick completely, remove and check
the level. Add the proper lubricant as required to
bring level into operating range as shown.

Operating
Range

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

To check the level:

1. The front gearcase lubricant level

checked

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

To change lubricant:

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

with a dipstick or by visual reference.

cannot be

2.9

MAINTENANCE

2. Clean and reinstall drain plug using a newsealing
washer.

3. Remove fill plug.

4. Add proper amount of lubricant.

5. Install fill plug. Check for leaks.

Make sure vent
is unobstructed

Fill plug

Drain Plug

Drain plug

TRANSMISSION GEARSHIFT
LINKAGE
PRELIMINARY

ADJUSTMENT,

INSPECTION

SHIFT LINKAGE
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 ofdesired

range

NOTE: When adjusting linkage, always adjust both
linkage rods. The adjustment of one rod can prevent
proper adjustment of the other rod. Remove
necessary components to gain access to shift linkage
rodends (i.e.exhaust heat shield, exhaust pipe,etc.).

Low Range

Jam Nut

Gear Selector
Slides

Jam
Nut

Linkage rod will rotate
1/8 -1/4 turn if rod ends
are tightened properly.

Parallel

Correctly Tightened

Jam Nut

S Ifshifting problems are encountered,

the transmission linkage can be
adjusted.

S Tightenshiftlinkage rodend jam nuts

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

S The transmission shift linkage

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

S Refer to Transmission chapter for

more information.

Incorrectly Tightened

Jam Nut

NOTE: Rod end orientation, rod ends are
both down.

Ill. 1

1. Inspect shift linkage tie rod ends, clevis pins, and
pivot bushings and replace if worn or damaged.
Lubricate the tie rod ends with a light aerosol
lubricant or grease.

2. Loosen all rod end adjuster jam nuts see Ill. 1.

3. Note orientation of tie rod end studs with stud up
or down. Remove both rod end studs from
transmission bell cranks.

4. Be sure idle speed is adjusted properly.

both

NOTE: It is important to disconnect
from the transmission bell cranks. If one linkage rod
is incorrectly adjusted, it can affect the adjustment of
the other rod.

5. Place gear selector in neutral. Make sure the
transmission bell cranks are engaged in the

rod ends

2.10

MAINTENANCE

neutral position detents.

Adjust to align linkage rod end studs
with holes in bellcrank(s).

35 in. lbs.

(4 Nm)

35 in. lbs.

(4 Nm)

Ill. 2

6. Be sure the shift linkage rod ends are firmly
attached to the gear selector slides. Adjust the
low range (inside) rod so the rod end is centered
onthe transmission bellcrank. Install the lock nut
to the rod end and torque to 35 in. lbs. (4 Nm).

S Rotate rod both directions to

find points where resistance
is felt.

S Center the rod between the

Place
mark
on rod

points.

S Hold rod end parallel to

mounting surface and
tighten jam nut.

Parallel

tightened, the rod should rotate freely 1/4 turn
without binding.

11. Repeat Steps 7-10 for the High/Reverse rod.

THROTTLE INSPECTION

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

1. Place the gear selector in neutral.

2. Set parking brake.

3. Start the engine and let it idle.

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

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

3

6

2

1

565

4

Ill. 3

7. Rotate the linkage rod clockwise until resistance
is felt. Mark the rod so revolutions can be easily
counted. See Ill. 3 at right.

8. Rotate the linkage rod counterclockwise until the
same resistance is felt, counting the revolutions
as the rod is turned.

9. Turn the rod clockwise again one half of the
revolutions counted in Step 9.

10. Tighten the rod end jam nuts securely while
holding the rod end. The jam nuts must be
tightened with both front and rear rod ends
parallel to each other. If jam nuts are properly

ETC Cover

Ill. 1

To remove the ETC cover:

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

2. Twist screwdriver slightlywhile liftingon the cover
to release snap.

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

Removal Sequence

2.11