Polaris Sportsman 400, Sportsman 500, Sportsman 500 H.O., SPORTSMAN 500 DUSE Service Manual

CHAPTER INDEX

CHAPTER 1 GENERAL

CHAPTER 2 MAINTENANCE

CHAPTER 3 ENGINE

CHAPTER 4 FUEL SYSTEM/CARBURETION

CHAPTER 5 BODY / SUSPENSION

CHAPTER 6 PVT SYSTEM

CHAPTER 7 FINAL DRIVE

CHAPTER 8 TRANSMISSION

CHAPTER 9 BRAKES

CHAPTER 10 ELECTRICAL

CHAPTER 1
GENERAL INFORMA

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

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

Replacement Keys 1.2............................

Model Color Identification 1.3-1.7......................

Machine Dimensions 1.8-1.10..........................

Specifications - Sportsman 400 1.11-1.12.................

Specifications - Sportsman 500 DUSE 1.13-1.14..........

Specifications - Sportsman 500 H.O. 1.15-1.16............

Publication Numbers 1.17..........................

Paint Codes 1.17.................................

Standard Torque Specifications 1.18................

Torque Conversion Table 1.19-1.20......................

Decimal Equivalent Chart 1.21......................

Conversion Table 1.22.............................

Tap Drill Charts 1.23...............................

Glossary of Terms 1.24-1.25............................

TION

1

GENERAL INFORMATION

MODEL IDENTIFICATION

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

Machine Model Number Identification

A01CH50AA

Emissions &

Year Designation

Basic Chassis
Designation Engine Designation

Model Option

ENGINE DESIGNATION NUMBERS

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

50 EH50PLE09/13 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*1P0 00000

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

MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION

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

A

TRANSMISSION I.D. NUMBER
LOCA

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

TION

Front

B

1.1

GENERAL INFORMATION

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.

31XX

Key Series
Number

Series # Part Number

31 41 10141
32 41 10148
67 4010278
68 4010278
27 4010321
28 4010321

1.2

MODEL COLOR IDENTIFICA TION

GENERAL INFORMATION

SPORTSMAN 400 -

A01CH42AA

SPORTSMAN 400 - A01CH42AB

1.3

GENERAL INFORMATION

MODEL COLOR IDENTIFICA TION

SPORTSMAN 400 - A01CH42AC

1.4

MODEL COLOR IDENTIFICA TION

GENERAL INFORMATION

SPORTSMAN 500 H.O. -

A01CH50AA

SPORTSMAN 500 H.O. - A01CH50AB

1.5

GENERAL INFORMATION

MODEL COLOR IDENTIFICA TION

SPORTSMAN 500 DUSE - A01CH50AD

SPORTSMAN 500 H.O. -

A01CH50AE

1.6

MODEL COLOR IDENTIFICA TION

SPORTSMAN 500 H.O. DUSE - A01CH50AF

GENERAL INFORMATION

SPORTSMAN 500 H.O. RSE - A01CH50AJ

1.7

GENERAL INFORMATION

MACHINE DIMENSIONS

SPORTSMAN

30 in

76.2 cm

400

22 in

55.8 cm

41 in

104.1 cm

45 in

114.3 cm

SPORTSMAN 500

32 in

81.2 cm

22 in

55.8 cm

42 in

106.6 cm

46 in

116.8 cm

1.8

MACHINE DIMENSIONS

SPORTSMAN 400

35 in
89 cm

GENERAL INFORMATION

81 in

205.7 cm

13.5 in

34.29 cm

SPORTSMAN

34 in

86.3 cm

51 in

129.5 cm

500

81 in

205.7 cm

15 in

38.1 cm

50.5 in

128.2 cm

1.9

GENERAL INFORMATION

MACHINE DIMENSIONS

SPORTSMAN 400

45 in

114.3 cm

46 in

116.8 cm

9.25 in

23.5 cm

38 in

96.5 cm
47 in

119.4 cm

SPORTSMAN

500

45 in

114.3 cm

48 in

121.9 cm

10 in

25.4 cm

37 in

93.9 cm
47 in

119.3 cm

1.10

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

Altitud

e

Below40

F

+40Fandabov

e

Meter

s

0-180

0

(Feet

)

Above1800

Altitud

e

Meter

s

0-180

0

(Feet

)

180

0-370

0

MODEL NUMBER: A01CH42AA/AB/AC.
ENGINE MODEL: EH42PLE05..

CARBURETION

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

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

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

Jet Needle JF-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 321 1069.....................

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..

GENERAL INFORMATION

JETTING CHART

Altitude

Meters

(Feet)

CLUTCH CHART

Meters

(Feet)

0-1800

(0-6000)

Above 1800

Above (6000)

0-1800

(0-6000)

1800-3700

(6000-12000)

AMBIENT TEMPERATURE

Below 40°F
Below +5°C

175 167.5

165 160

Shift

Weight Spring Helix

10BH Blue/Green 2+2

10WH Blue/Green 2+2

+40_F andabove

+5_C andabove

Clutch

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.......

CompressionRatio 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%.......

1.11

GENERAL INFORMATION

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

MODEL NUMBER: A01CH42AA/AB/AC...

ENGINE MODEL: EH42PLE05....

ELECTRICAL FLUID Capacity Type

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

CDI Marking CU2565 Injector Oil N / A....... .......... .........

Alternator Output 200 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 60/60 watts Gearcase Oil (Center) N / A......

Tail 8.26 watts Gearcase Oil (Rear) N / A........ .

Brake 26.9 watts Engine Counter Bal. N / A...... . .........

Voltage Regulator LR39 Engine Oil 2 qts. (1.9L) PP4*.. .......... ..

Electric Start Standard Brake (Hand) Dot 3....... .......

Brake (Foot) Dot 3........

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 850 lbs. (385.6kg) Gear Reduction-Rev 5.17/1...... .

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

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

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

Front Vertical Travel 6.7I (17.02cm) 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 - 10....

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

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

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

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

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

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

LOAD CAPACITY

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

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

Tongue Weight 30 lbs.....

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

OPTIONAL SUSPENSION SPRINGS

SOFT STANDARD FIRM

Rear Compression Spring

Front Strut Spring 7041238-067

N/A 7041453-067

Option 61 lb/in.

1.12

Standard 100 lb/in.

7041375-067

Standard 64/113 lb/in.

7041519-067

Option 140 lb/in.

7041450-067

Option 101 lb/in.

MODEL: SPORTSMAN 500DUSE..........

Altitud

e

Below40

F

+40Fandabov

e

Meter

s

0-180

0

(Feet

)

Above1800

Altitud

e

Meter

s

0-180

0

(Feet

)

180

0-370

0

MODEL NUMBER: A01CH50AD.
ENGINE MODEL: EH50PLE09..

CARBURETION

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

Main Jet 162.5............

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

Jet Needle 4HB41-3...........

Needle Jet Q-0 (513)...........

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

Pilot Screw 2 5/8 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 321 1069.....................

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/Green........

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

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

Spring Position (Sheave) N/A..

GENERAL INFORMATION

JETTING CHART

Altitude

Meters

(Feet)

0-1800

(0-6000)

Above 1800

Above (6000)

CLUTCH CHART

Meters

(Feet)

*EBS require no helix/spring adjustment

0-1800

(0-6000)

1800-3700

(6000-12000)

AMBIENT TEMPERATURE

Below 40°F
Below +5°C

170 162.5

160 155

Shift

Weight Spring Helix*

10MH Blue/Green EBS

10WH Blue/Green EBS

+40_F and above

+5_C and above

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 6000 RPM.........

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

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

1.13

GENERAL INFORMATION

MODEL: SPORTSMAN 500 DUSE............

MODEL NUMBER: A01CH50AD...

ENGINE MODEL: EH50PLE09....

ELECTRICAL FLUID Capacity Type

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

CDI Marking CU2570 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 BKR5E / 0.036I (0.9mm) Gearcase Oil (Front) 4 oz. (120ml) 80-90 GL5... . .

Lights: Head Halogen 60/60 watts Gearcase Oil (Center) N / A......

Tail 8.26 watts Gearcase Oil (Rear) N / A........ .

Brake 26.9 watts Engine Counter Bal. N / A...... . .........

Voltage Regulator LR39 Engine Oil 2 qts. (1.9L) PP4*.. .......... ..

Electric Start Standard Brake (Hand) Dot 3....... .......

Brake (Foot) Dot 3........

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. (555.6kg) Gear Reduction-Rev 5.17/1...... .

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

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

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

Front Vertical Travel 6.7I (17.02cm) 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 - 10....

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

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

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

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

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

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

LOAD CAPACITY

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

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

Tongue Weight 35 lbs.....

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

OPTIONAL SUSPENSION SPRINGS

SOFT STANDARD FIRM

Rear Compression Spring

Front Strut Spring 7041238-067

N/A 7041453-067

Option 61 lb/in.

1.14

Standard 100 lb/in.

7041375-067

Standard 64/113 lb/in.

7041519-067

Option 140 lb/in.

7041450-067

Option 101 lb/in.

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

Altitud

e

Below40

F

+40Fandabov

e

Meter

s

0-180

0

(Feet

)

Above1800

Altitud

e

Meter

s

0-180

0

(Feet

)

180

0-370

0

MODEL NUMBER: A01CH50AA/AB/AE/AF/AJ.
ENGINE MODEL: EH50PLE13..

CARBURETION

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

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

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

Jet Needle KE-3 (683)...........

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

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

Pilot Screw 2 1/2 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 321 1069.....................

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..

GENERAL INFORMATION

JETTING CHART

Altitude

Meters

(Feet)

0-1800

(0-6000)

Above 1800

Above (6000)

CLUTCH CHART

Meters

(Feet)

*EBS require no helix/spring adjustment

0-1800

(0-6000)

1800-3700

(6000-12000)

AMBIENT TEMPERATURE

Below 40°F
Below +5°C

157.5 152.5

150 145

Shift

Weight Spring Helix*

10WH Blue/Green EBS

10RH Blue/Green EBS

+40_F and above

+5_C and above

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%.......

1.15

GENERAL INFORMATION

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

MODEL NUMBER: A01CH50AA/AB/AE/AF/AJ...

ENGINE MODEL: EH50PLE13....

ELECTRICAL FLUID Capacity Type

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

CDI Marking CU2570 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 BKR5E / 0.036I (0.9mm) Gearcase Oil (Front) 4 oz. (120ml) 80-90 GL5... . .

Lights: Head Halogen 60/60 watts Gearcase Oil (Center) N / A......

Tail 8.26 watts Gearcase Oil (Rear) N / A........ .

Brake 26.9 watts Engine Counter Bal. N / A...... . .........

Voltage Regulator LR39 Engine Oil 2 qts. (1.9L) PP4*.. .......... ..

Electric Start Standard Brake (Hand) Dot 3....... .......

Brake (Foot) Dot 3........

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. (555.6kg) Gear Reduction-Rev 5.17/1...... .

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

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

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

Front Vertical Travel 6.7I (17.02cm) 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 - 10....

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

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

Total Length 81I (205.74cm) (AA/AB/AE).......

85I (215.9cm) (AF/AJ)...................

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

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

Weight - Dry 697 lbs. (316.4kg) (AA/AB/AE).......

750 lbs. (340kg) (AF/AJ)...................

LOAD CAPACITY

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

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

Tongue Weight 35 lbs.....

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

OPTIONAL SUSPENSION SPRINGS

SOFT STANDARD FIRM

Rear Compression Spring

Front Strut Spring 7041238-067

N/A 7041453-067

Option 61 lb/in.

1.16

Standard 100 lb/in.

7041375-067

Standard 64/113 lb/in.

7041519-067

Option 140 lb/in.

7041450-067

Option 101 lb/in.

PUBLICATION NUMBERS

GENERAL INFORMATION

Year Model Model No. Owner’s Manual

PN

2001 Sportsman 400 A01CH42AA/AB/AC 9915754 9916443 9916444
2001 Sportsman 500 DUSE A01CH50AD 9915754 9916002 9916003
2001 Sportsman 500 H.O. A01CH50AA/AB/AE/

AF/AJ

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

9915754 9916446 9916447

Parts

Manual PN

Micro Fiche PN

PAINT CODES

PAINTED PART COLOR

DESCRIPTION

(400) Springs/Rims Black 9440 P-067
(500) Springs/Rims Black 9440 P-067
(500) Opt. B Springs Black 9440 P-067
(500) Opt. B Rims Brushed Aluminum N/A P-117

FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147.
Order direct from Midwest Industrial Coatings (952-942-1840). Mix as directed.

DITZLER

NUMBER

POLARIS

NUMBER

Parts

1.17

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

T orque in. lbs. (Nm)

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

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

T o rque ft. lbs. (Nm)*

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

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

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

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

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

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

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

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

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

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

Metric

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

*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 section.

1.18

TORQUE CONVERSIONS

Newton Meter to Pound Foot and Pound Inch

GENERAL INFORMATION

1.19

GENERAL INFORMATION

TORQUE CONVERSIONS

Newton Meter to Pound Foot and Pound Inch

1.20

DECIMAL EQUIVALENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

27/64 .4219 1 1mm = .4331″........................ ................

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

1 1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

11.0............

GENERAL INFORMATION

1.21

GENERAL INFORMATION

CONVERSION TABLE

Unit of Measure Multiplied by Converts to

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

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

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

1.22

GENERAL INFORMATION

SAE TAP DRILL SIZES

Thread Size Drill Size Thread Size Drill Size

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

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

METRIC TAP DRILL SIZES

Tap Size Drill Size Decimal Equivalent Nearest Fraction

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

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

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3125

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

1.23

GENERAL INFORMATION

GLOSSARY OF TERMS

ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8″ or 1 cm). Polaris measures chain length in number of

pitches.

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

clutch.
ClutchOffset: Driveand drivenclutchesareoffsetsothat drive beltwillstaynearlystraightasit movesalongtheclutch

face.
Clutch Weights: Three levers in the drive clutchwhich relative totheir weight, profile andengine 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.
lorltr: Liter.

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

1.24

GENERAL INFORMATION

GLOSSARY OF TERMS

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

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

mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040″.
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch System)
qt.: Quart/quarts.
RPM: Revolutions per minute.
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,frictionor load. Inthe electricalsense, ohms. Bothresultinenergy conversionto

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: Galling ofthesidesofa piston. Usually thereis atransferof aluminumfromthepistononto thecylinder

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

Stator Plate: Theplate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston’s most outward travel from crankshaft.
Volt: Theunit 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.

1.25

CHAPTER 2

MAINTENANCE

Periodic Maintenance Chart 2.1-2.2....................

Pre-Ride Inspection 2.2...........................

Recommended Lubricants and Capacities 2.3.......

Lubricant and Maintenance Product Numbers 2.4....

Lubrication Charts 2.5-2.8............................

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

Transmission Lubrication 2.10......................

Transmission LInkage Adjustment 2.11-2.12..............

Carburetor Adjustments 2.13-2.15.......................

Fuel System 2.16-2.17.................................

Compression Test 2.18............................

Battery Maintenance 2.19..........................

Electrical 2.20....................................

Coolant System Maintenance 2.21-2.22..................

Air Filter Service 2.23..............................

Air Box Sediment Tube Service 2.24.................

Breather Filter 2.24................................

Recoil Housing 2.25...............................

Oil Change/Filter 2.26-2.27.............................

Valve Clearance 2.28-2.29..............................

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

Front Hub Maintenance 2.33.......................

Exhaust System Maintenance 2.34..................

Brake System Service 2.35-2.36.........................

Suspension Service 2.37...........................

Controls 2.38.....................................

Wheel Removal/Installation 2.39....................

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

2

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.
HCAUTION: 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 specialattention to oil level. Arise in oil level in coldweather can indicate moisturecollect­ing in the oil tank. Change oil immediately if oil level begins to rise.

E Emission Control System Service (California).

PERIODIC MAINTENANCE - ENGINE

Frequency

(Whichever comes first)

Item Hours Calendar Miles

(Km)

Engine Oil - Level/Change 100 hrs 6 months 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
CoolingSystemHoses 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
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

Remarks

2.1

MAINTENANCE

PERIODIC MAINTENANCE CHART, CONT.

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 100 hrs 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 200hrs 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 se-

cured by cotte r 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

2.2