Polaris SPORTSMAN 600 2003, SPORTSMAN 700 2003, SPORTSMAN 700 2002 Service Manual

2003 SPORTSMAN 600

2002-2003 SPORTSMAN 700

SERVICE MANUAL

PN 9918066

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 instructions will result in severe injury or death to the 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

2003 SPORTSMAN 600/700

SERVICE MANUAL

Foreword

This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
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 procedures outlined inthis manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar
with service procedures before starting the work. Certain procedures require the use of special tools. Use
only the proper tools as specified.

This manual includes procedures for maintenance operations, component identification and unit repair, along
with service specifications for 2003 Polaris Sportsman 600/700 ATVs. Comments or suggestions about this
manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota

55340.

2002 Sportsman 600/700 ATV Service Manual (PN 9918066)

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 improvements 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 omissions 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.

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

GENERAL INFORMATION

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

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

2003 Sportsman Models 1.3..................

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

Specifications - 2002 Sportsman 700 1.6-1.7.......

Specifications - 2003 Sportsman 600 1.8-1.9.......

Specifications - 2003 Sportsman 700 1.10-1.11.......

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

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

CHAPTER 1
GENERAL INFORMATION

1

Replacement Keys 1.12.......................

Standard Torque Specifications 1.13............

Decimal Equivalent Chart 1.14.................

Conversion Table 1.15........................

Tap Drill Charts 1.16..........................

Glossary of Terms 1.17-1.18........................

1.1

GENERAL INFORMATION

MODEL IDENTIFICA

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

TION

Machine Model Number Identification

A03CH68AA

Emissions &

Year Designation

ENGINE DESIGNATION

EH068OLE11 Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start...............

EH059OLE11 Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start...............

VIN IDENTIFICA

World Mfg. ID

1

2

4XA C H

Body Style

3

TION

Vehicle Description

5

4

Powertrain

6

68A* 2P0 00 0 00

Engine

Basic Chassis
Designation Engine Designation

NUMBERS

Vehicle Identifier

8

7

Emissions

9

Model
Year

Check Digit

10 1

Plant No.

13

12

1

Individual Serial No.

Model Option

14

15

16

17

* This could be either
a number or a letter

ENGINE SERIAL NUMBER LOCA

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

TION

MACHINE MODEL NUMBER AND

SERIAL NUMBER LOCA

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

TRANSMISSION I.D.

LOCA

TION

TION

NUMBER

A

Front

B

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

1.2

GENERAL INFORMATION

2003 SPRORTSMAN 600 & 700 MODELS

SPORTSMAN 600

SPORTSMAN 700

NOTE: MODELS WILL VARY IN COLOR.

1.3

MACHINE DIMENSIONS

GENERAL INFORMATION

FRONT

46 in

116.84 cm

85 in

215.90 cm

1.4

SIDE

50.75 in

128.90 cm

GENERAL INFORMATION

MACHINE DIMENSIONS

46 in

116.84 cm

47 in

119.38 cm

REAR

11 in

27.94 cm

46 in

116.84 cm

1.5

MODEL: 2002 SPORTSMAN 700..........

ltitude

Below40

F

+40

Fan

dabov

e

Meter

s

0-180

0

(Feet

)

Above1800

Altitud

e

ue/

Gre

e

Meter

s

0-180

0

Blue/Gree

n

(Feet

)

ue/

Gre

e

180

0-370

0

Blue/Gree

n

MODEL NUMBER: A02CH68AA/CA.
ENGINE MODEL: EH68ALOE1..

CARBURETION

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

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

Pilot Jet 45.............

Jet Needle 4BH41--4...........

Needle Jet P-6...........

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

Pilot Screw 1.5 Turns Out..........

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

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 3211091.....................

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

Side Angle (Overall) 28°±2°......

Outside Circumference 40.875 ±.188I....

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

*EBS require no helix/spring adjustment

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

AMBIENT TEMPERATURE

Below 40 °F
Below +5°C

167.5 162.5

160 155

SAShift

Weight Spring Spring Helix

20--56

20--54

Drive Clutch

Bl

(5631215)

Bl

(5631214)

+40_F and above

+5_C and above

Driven Clutch

n

White/Yellow EBS

n

White/Yellow EBS

Driven

ENGINE

Type 4 Cycle, Twin Cyl........................

Displacement 683 cc...............

Bore 3.149I (80 mm).......................

Stroke 2.677I (68 mm).....................

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

Compression Ratio 9.78/1 Full Stroke..........

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

Lubrication Type Pressurized Wet Sump............

Operating RPM±200 6000 RPM.........

Idle RPM±200 (lights off) 1100 RPM.....

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

1.6

GENERAL INFORMATION

MODEL: 2002 SPORTSMAN 700............

MODEL NUMBER: A02CH68AA/CA...

ENGINE MODEL: EH68ALOE1....

ELECTRICAL FLUID Capacity Type

Flywheel I.D. 4060152 Fuel Tank 4.75 gals. (17.9 L)...... ..........

CDI Marking 4010364 Coolant 3.2 qts. (3 L) *PP6....... ............ .

Alternator Output 300 Watts Transmission 13.50 oz. *PPS... ....... ....

Ignition Timing 25° BTDC@3000±500RPM Gearcase Oil (Front).. 5 oz. (150 ml)...*PDD.....

Spark Plug / Gap RC7YC -- 0.036I (0.9mm) Gearcase Oil (Rear) 5oz. (150 ml) 80--90 GL5... . .

Lights: Head 50 Watt Quartz Engine Oil 2 qts. (1.9L) *PP4...... .......... ..

Grill (2) 27 Watts Quartz Brake (Hand) Dot 3.... .......

Tail 8.26 watts Brake (Foot) Dot 3........ ........

Brake 26.9 watts......

Voltage Regulator LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant..

Electric Start Standard *PPS Polaris Premium Synthetic Gear Case Oi.......

Instrument Cluster LCD *PP4 Polaris 0W--40 Synthetic Engine Lubricant..

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style Gen IV 4 Wheel Independent Shaft Drive........

Front Suspension MacPherson Strut Gear Reduction-Low 7.5/1.. .

Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.11/1...... .

Turning Radius 76I (181.61 cm) Gear Reduction-High 3.09/1.....

Toe Out 1/8I-1/4I (3-6.35 mm) Front Drive Ratio 3.82/1........... ....

Ground Clearance 11I (27.94 cm) Final Drive Ratio 3.10/1.. ....

Front Vertical Travel 6.7I (17.02 cm) Brake (Hand) Single Lever, Hyd. Disc.......

Rear Suspension Progressive Rate Independent Brake (Auxiliary Foot) Hydraulic...

Rear Travel 9.5I (24.13 cm) Transmission Park Lock........

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

Shock Adjustment Cam..

Lubricant Key

*PDD Premium Demand Drive Hub Fluid

TIRES

TireSize-Front 25x8-12....

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

Tire Pressure - F/R 5/5 lbs.

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

Total Length 85I (215.90 cm).......

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

Wheel Base 50.75I (128.90 cm).......

Weight - Dry 740 lbs. (335.60 kg).......

LOAD CAPACITY

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

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

Tongue Weight 150 lbs.....

Hitch Towing Capacity...1500 lbs.

1.7

MODEL: 2003 SPORTSMAN 600..........

Altitud

e

Below40

F

+40Fandabov

e

Meter

s

0-180

0

(Feet

)

Above1800

Altitud

e

ue/

Gre

e

Meter

s

0-180

0

Blue/Gree

n

(Feet

)

ue/

Gre

e

180

0-370

0

Blue/Gree

n

MODEL NUMBER: A03CH59.
ENGINE MODEL: EH059OLE..

CARBURETION

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

Main Jet 155............

Pilot Jet 45.............

Jet Needle J8--4FA01--3...........

Needle Jet P-4...........

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

Pilot Screw 1.5 Turns Out..........

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

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

Float Height 14.7mm (.58I)r1mm.........

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

89 Oxygenated

CLUTCH

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

Belt 321 1091.....................

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

Side Angle (Overall) 28qr2q......

Outside Circumference 40.875 r.188I....

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

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

Secondary Spring White/Y ellow........

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

*EBS require no helix/spring adjustment

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

AMBIENT TEMPERATURE

Below 40 qF
Below +5qC

162.5 155

150 145

Shift

Weight Spring Spring Helix

10 MH

10 WH

Drive Clu tch

Bl

(5631215)

Bl

(5631214)

+40_F and above

+5_C and above

Driven Clutch

n

White/Yellow EBS

n

White/Yellow EBS

Driven

ENGINE

Type 4 Cycle, Twin Cyl........................

Displacement 597 cc...............

Bore 3.012I (76.5 mm).......................

Stroke 2.559I (65 mm).....................

Compression Ratio 9.35/1 Full Stroke..........

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

Lubrication Type Pressurized Wet Sump............

Operating RPMr200 6000 RPM.........

Idle RPM r 100 (lights off) 1 100 RPM....

Compression Pressure 150--170psi r15%.......

1.8

GENERAL INFORMATION

MODEL: 2003 SPORTSMAN 600............

MODEL NUMBER: A03CH59...

ENGINE MODEL: EH059OLE....

ELECTRICAL FLUID Capacity Type

Flywheel I.D. 4060152 Fuel Tank 4.75 gals. (17.9 L)...... ..........

CDI Marking 4010785 Coolant 3.2 qts. (3 L) *PP6....... ............ .

Alternator Output 300Watts Transmission 13.50 oz. *PPS... ....... ....

Ignition Timing 25q BTDC@3000RPMr500 Gearcase Oil (Front).. 5 oz. (150 ml)...*PDD.....

Spark Plug / Gap RC7YC -- 0.035I (0.9mm) Gearcase Oil (Rear) 5oz. (150 ml) 80--90 GL5... . .

Lights: Head 50 Watt Quartz Engine Oil 2 qts. (1.9L) *PP4...... .......... ..

Grill (2) 27 Watts Quartz Brake (Hand) Dot 3.... .......

Tail 8.26 watts Brake (Foot) Dot 3........ ........

Brake 26.9 watts......

Voltage Regulator LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant..

Electric Start Standard *PPS Polaris Premium Synthetic Gear Case Lube.......

Instrument Cluster LCD *PP4 Polaris 0W--40 Synthetic Engine Lubricant..

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style Gen IV 4 Wheel Independent Shaft Drive........

Front Suspension MacPherson Strut Gear Reduction-Low 7.49:1.. .

Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.11:1...... .

Turning Radius 76I (181.61 cm) Gear Reduction-High 2.89:1.....

Toe O u t 1/ 8 I-1/4I (3-6.35 mm) Front Drive Ratio 3.82:1........... ....

Ground Clearance 11I (27.94 cm) Final Drive Ratio 3.10:1.. ....

Front Vertical Travel 6.7I (17.02 cm) Brake (Hand) Single Lever, Hyd. Disc.......

Rear Suspension Progressive Rate Independent Brake (Auxiliary Foot) Hydraulic...

Rear Travel 9.5I (24.13 cm) Transmission Park Lock........

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

Shock Adjustment Cam..

Lubricant Key

*PDD Premium Demand Drive Hub Fluid

TIRES

TireSize-Front 25x8-12....

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

Tire Pressure - F/R 5/5 lbs.

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

Total Length 85I (215.90 cm).......

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

Wheel Base 50.75I (128.90 cm).......

Weight - Dry 740 lbs. (335.60 kg).......

LOAD CAPACITY

Front Rack (Std) 90 lbs. (41 kg).....

Rear Rack (Std) 200 lbs. (91 kg)......

Tongue Weight 150 lbs. (68 kg)....

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

1.9

MODEL: 2003 SPORTSMAN 700..........

Altitud

e

Below40

F

+40Fandabov

e

Meter

s

0-180

0

(Feet

)

Above1800

Altitud

e

ue/

Gre

e

Meter

s

0-180

0

Blue/Gree

n

(Feet

)

ue/

Gre

e

180

0-370

0

Blue/Gree

n

MODEL NUMBER: A03CH68.
ENGINE MODEL: EH068OLE..

CARBURETION

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

Main Jet 155............

Pilot Jet 47.5.............

Jet Needle J8--4FA01--3...........

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

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

Pilot Screw 1.5 Turns Out..........

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

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

Float Height 14.7mm (.58I)r1mm.........

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

89 Oxygenated

CLUTCH

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

Belt 321 1091.....................

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

Side Angle (Overall) 28qr2q......

Outside Circumference 40.875 r.188I....

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

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

Secondary Spring White/Y ellow........

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

*EBS require no helix/spring adjustment

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

AMBIENT TEMPERATURE

Below 40 qF
Below +5qC

160 155

147.5 142.5

Shift

Weight Spring Spring Helix

20--56

20--54

Drive Clu tch

Bl

(5631215)

Bl

(5631214)

+40_F and above

+5_C and above

Driven Clutch

n

White/Yellow EBS

n

White/Yellow EBS

Driven

ENGINE

Type 4 Cycle, Twin Cyl........................

Displacement 683 cc...............

Bore 3.149I (80 mm).......................

Stroke 2.677I (68 mm).....................

Compression Ratio 9.78/1 Full Stroke..........

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

Lubrication Type Pressurized Wet Sump............

Operating RPMr200 6000 RPM.........

Idle RPMr100 (lights off) 1100 RPM.....

Compression Pressure 150--170psi r15%.......

1.10

GENERAL INFORMATION

MODEL: 2003 SPORTSMAN 700............

MODEL NUMBER: A03CH68...

ENGINE MODEL: EH068OLE....

ELECTRICAL FLUID Capacity Type

Flywheel I.D. 4060152 Fuel Tank 4.75 gals. (17.9 L)...... ..........

CDI Marking 4010364 Coolant 3.2 qts. (3 L) *PP6....... ............ .

Alternator Output 300 Watts Transmission 13.50 oz. *PPS... ....... ....

Ignition Timing 32q BTDC@5760RPMr200 Gearcase Oil (Front).. 5 oz. (150 ml)...*PDD.....

Spark Plug / Gap RC7YC -- 0.036I (0.9mm) Gearcase Oil (Rear) 5oz. (150 ml) 80--90 GL5... . .

Lights: Head 50 Watt Quartz Engine Oil 2 qts. (1.9L) *PP4...... .......... ..

Grill (2) 27 Watts Quartz Brake (Hand) Dot 3.... .......

Tail 8.26 watts Brake (Foot) Dot 3........ ........

Brake 26.9 watts......

Voltage Regulator LR39 *PP6 Polaris Premium 60/40 Antifreeze/Coolant..

Electric Start Standard *PPS Polaris Premium Synthetic Gear Case Lube.......

Instrument Cluster LCD *PP4 Polaris 0W--40 Synthetic Engine Lubricant..

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style Gen IV 4 Wheel Independent Shaft Drive........

Front Suspension MacPherson Strut Gear Reduction-Low 7.49:1.. .

Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.1:1...... .

Turning Radius 76I (181.61 cm) Gear Reduction-High 2.89:1.....

Toe O u t 1/ 8 I-1/4I (3-6.35 mm) Front Drive Ratio 3.82:1........... ....

Ground Clearance 11I (27.94 cm) Final Drive Ratio 3.10:1.. ....

Front Vertical Travel 6.7I (17.02 cm) Brake (Hand) Single Lever, Hyd. Disc.......

Rear Suspension Progressive Rate Independent Brake (Auxiliary Foot) Hydraulic...

Rear Travel 9.5I (24.13 cm) Transmission Park Lock........

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

Shock Adjustment Cam..

Lubricant Key

*PDD Premium Demand Drive Hub Fluid

TIRES

TireSize-Front 25x8-12....

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

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 50.75I (128.90 cm).......

Weight - Dry 740 lbs. (335.60 kg).......

LOAD CAPACITY

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

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

Tongue Weight 150 lbs.....

Hitch Towing Capacity...1500 lbs.

1.11

PUBLICATION NUMBERS

GENERAL INFORMATION

Year Model Model No. Owner’s

Manual

PN

2003 Sportsman 600/700 A03CH59 / A03CH68 9918213 9917718 9917719

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

Parts

Manual PN

Parts

Micro Fiche

PN

PAINT CODES

PAINTED PART COLOR

DESCRIPTION

Springs Black 9440 P-067

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

REPLACEMENT KEYS

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

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

1.12

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 section.

1.13

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........................

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

GENERAL INFORMATION

1.14

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

Kilopascals (kPa) x0.01 = Kilograms - force per square cm

Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

p (3.14) xR

2

x H (height) = Cylinder Volume

= Pounds - force per square inch (psi)

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

1.15

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

1.16

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 alternating current voltage.
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 the drive and driven

clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch

faces.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile andengine RPM cause the 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 end.

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.

1.17

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: In the mechanical sense,friction orload. In theelectrical sense, ohms. Both result in energy conversion to

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 of the sides of apiston. Usually there is atransfer of aluminum from the pistononto the cylinder

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

Stator Plate: The plate mounted under the flywheel supporting the battery and ignition charging coils.
TDC: Top dead center. Piston’s most outward travel from crankshaft.
Vol t: 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.

1.18

MAINTENANCE

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............................

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

Front & Rear Gearcase Lubrication 2.9.........

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

Transmission Linkage Inspection 2.11...........

Carburetor Adjustments 2.12-2.13...................

2

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

Compression Test 2.14--2.15........................

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

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

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

Radiator Screen Removal 2.18.................

Air Filter Service 2.19.........................

Air Box Sediment Tube Service 2.19............

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

PVT Drying & PVT Drain Plug 2.20..............

Oil Change/Filter 2.21-2.22.........................

Steering and Toe Alignment 2.22-2.25...............

Exhaust System Maintenance 2.26.............

Brake System Service 2.26-2.27....................

Suspension Service 2.28......................

Controls 2.28.................................

Wheel Removal/Installation 2.29................

Tire Inspection 2.29...........................

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

H= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed

by an authorized Polaris dealer.

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

operation, prolonged idle) should be inspected and serviced more frequently. For engine oil,
short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A
rise in oil level in cold weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if oil level begins to rise.

E= Emission Control System Service (California).

PERIODIC MAINTENANCE - ENGINE

Item Maintenance Interval

(Whichever comes first)

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 - Screen Pre-Cleaner Daily Daily -- Ins pect-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

Idle Speed As required As required -- Adjust as required

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

Exhaust Muffler / Pipe 100 hrs 12 months 1000 (1600) Inspect

100 hrs 6 months 1000 (1600) Inspect strength seasonally;

pump & carburetor. Replace lines every 2 years.

Pressure test system 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

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

Grease to connector when lamp is replaced

Grease to socket when lamp is replaced

Remarks

2.2

MAINTENANCE

PERIODIC MAINTENANCE CHART, CONT.

CHASSIS

Item Maintenance Interval

(Whichever comes first)

Hours Calendar Miles

(Km)

" General Lubrication 50 hrs 3 months 500 (800) Lubricate All Fittings, Pivots, Cables, Etc.

" 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

Check/Drain PVT Housing Weekly Weekly More often if operating in wet environment

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

Shift Linkage 50 hrs 6 months 500 (800) Inspect, Lubricate, Adjust

H Steering 50 hrs 6 months 500 (800) Inspect Daily, Lubricate

H Toe Adjustment As required As required -- Periodic Inspection, Adjust When

" 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

Parts are Replaced

PRE-RIDE / DAILY INSPECTION

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

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

cotter pins

G Air cleaner element - check for dirt; clean or replace
G Steering - check for free operation noting any unusual looseness in any area

G Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
G Engine coolant - check for proper level at the recovery bottle

2.3

MAINTENANCE

RECOMMENDED LUBRICANTS -

Item Type Notes See

Pages

Engine Oil Polaris Premium 4

Synthetic 0W--40

Transmission Polaris Synthetic

Gear Case Lubricant

Front Gear Case Polaris Premium Demand

Drive Hub Fluid

Coolant Level Polaris Premium 60/40

Pre-mixed Antifreeze/

Coolant or a 50/50 mixture

high quality antifreeze/

coolant and distilled water

Brake Fluid Polaris DOT 3 Brake Fluid Fill to indicated level inside reservoir. 2.26

NOTE: Quick Reference Lubricants and maintenance product part numbers are listed on page 2.5

Add to proper level on dipstick. 2.21

Refer to procedures outlined in this chapter. 2.10

Refer to procedures outlined in this chapter. 2.9

Allow engine and cooling system to

cool completely and check level in ra-

diator. Fill to top of filler neck. If reser-

voir was empty or extremely low, fill

reservoir tank to full line if necessary.

2.18

2.4

MAINTENANCE

POLARIS LUBRICANTS,MAINTENANCE AND SERVICE

Part No. Description

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol)

2871098 Premium 2 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

Synthetic 0W--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 Gear Drive 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 AngleDriveFluid(8oz.)

Grease / Specialized Lubricants

2871322 Premium All Season Grease (3 oz.

cartridge) (24 Count)

2871423 Premium All Season Grease (14 oz.

cartridge) (10 Count)

2871460 Starter Drive Grease (12 Count)

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

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

2871312 Grease Gun Kit
2871329 Dielectric Grease (Nyogelt)

Coolant

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

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

Additives / Sealants / Thread Locking Agents /

Misc.

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

Count)

2871949 Loctitet Threadlock 242 (50 ml.) (10

Count)

2871950 Loctitet Threadlock 242 (6 ml.) (12

Count)

2871951 Loctitet Threadlock 262 (50 ml.) (10

Count)

2871952 Loctitet Threadlock 262 (6 ml.) (12

Count)

2871953 Loctitet Threadlock 271 (6 ml.) (12

Count)

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.

PRODUCTS

2.5

SPECIAL TOOLS

PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN

PV--43527 Oil Filter Wrench 2,3

2870872 Shock Spanner Wrench 2, 5

8712100 or 8712500 Tachometer 2,10

2200634 Valve Seat Reconditioning Kit 3

PU--45257 Valve Spring Compressor 3

PU--45652 Valve Pressure Hose 3

2871043 Flywheel Puller 3

PU--44693 Valve Train Table 3

2870390 Piston Support Block 3

PU--45497--2 Cam Gear Tooth Alignment Tool 3

PU--45497--1 Cam Gear Spring Installation Kit (3 Tapered Pins) 3

PU--45498 Cam Spanner Wrench 3

PU--45838 Gear Holder 3

PA--44995 Water Pump Mechanical Seal Installer 3

PU--45543 Universal Drive Handle 3

PU--45483 Main Seal Installer 3

PU--45658 Main Crankshaft Seal Saver 3

PA--45401 Water Pump Seal Saver 3

PU--45778 OIl System Priming Tool 3

2870975 Mity Vact Pressure Test Tool 3, 4, 9

2872314 Carburetor Float Adjustment Tool 4

2870871 Ball Joint Replacement Tool 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

2870913 Driven Clutch Puller 6

2870910 Roller Pin Tool 6

2871226 Clutch Bushing Replacement Tool Kit 6

2870386 Piston Pin Puller 6

2872292 EBS Clutch Alignment Tool 6

2201379 EBS Bushing Replacement Kit 6

8700220 Clutch Compression Tool 6

2871025 Clutch Bushing Replacement Tool Kit 6

2872608 Roller Pin Removal Tool 7

8700226 CV Boot Clamp Pliers 7

PV--43568 Fluket77 Digital Multimeter 10

2870630 Timing Light 10

2870836 Battery Hydrometer 10

*Special Tools Can be ordered through SPX Corporation (1--800--328--6657).

MAINTENANCE

2.6

MAINTENANCE

LUBRICATION

Dipstick

Fill Plug

3. Front Gear Case Fill Plug

Transmission

Plug

2. Transmission1. Engine Oil and Filter

Fill plug

4. Rear Gear Case Fill Plug

Master Cylinder
Reservoir

5. Brake Fluid (Left hand Master Cylinder)

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

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

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

Ill.

#

1. Engine OIl Polaris 0W--40

2. Transmis-

3. Front Gear

4. Rear Gear

5. Brake Fluid Polaris Dot 3 Brake

Item Lube Rec. Method Frequency*

sion

Case

Case

Synthetic

Polaris Synthetic

Gear Case Lubricant

Premium Demand

Drive Hub Fluid

Polaris Gear Drive

Fluid

Fluid

Check dipstick and add to

proper level.

Add lube to bottom of fill hole. Change annually ©

Drain completely. Add lube to spe-

cified quantity.

Drain completely. Add lube to spe-

cified quantity.

Fill master cylinder reservoir to in-

dicated level inside reservoir.

Change after 1st month, 6 months or 100

hours thereafter; Change more often

(25-50 hours) in extremely dirty condi-

tions, or short trip cold weather operation.

Change annually ©

Change annually ©

As required. Change fluid every 2 years

2.7

LUBRICATION, CONT.

6. Front Drive
Axle U-Joint

8. Rear Wheel Hub Bear­ing Carrier

MAINTENANCE

7. Front Prop Shaft
U-Joint

9. Front Hub strut

Ill.

#

6. Front Drive Axle “U” Joints Polaris U-Joint

7. Front Prop Shaft Polaris U-Joint

8. Rear Wheel Hub Bearing Carrier Polaris All Season

9. Front Hub strut Polaris All Season

Item Lube Rec. Method Frequency*

Grease¢

Grease¢

Grease¢

Grease¢

Locate grease fitting and

grease with grease gun.

Locate grease fitting and

grease with grease gun.

Locate fittings and grease Semi-annually ¡

Locate fittings and grease Semi-annually ¡

Semi-annually ¡

Semi-annually ¡

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

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

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