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

MAINTENANCE

GEARCASE LUBRICATION

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

G Be sure vehicle is level before proceeding.
G Check vent hose to be sure it is routed properly and unobstructed.
G The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid.
G The correct rear gearcase lubricant to use is Polaris Premium Gear Drive Fluid.

FRONT GEARCASE SPECIFICATIONS

Specified Lubricant:

Premium Demand Drive Hub Fluid
(PN 2871654)

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

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

To check the lubricant level:

The front and rear gearcases lubricant level cannot be
checked with a dipstick or by visual reference. The

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

To change gearcase lubricant:

1. Remove gearcase drain plug located on the bottom

of the gearcase and drain oil. (The drain plug is
accessible through the skid plate.) Catch and
discard used oil properly.

2. Clean and reinstall drain plug using a new sealing

washer.

3. Remove fill plug.

REAR GEARCASE SPECIFICATIONS

Specified Lubricant:

Polaris Gear Drive Fluid (PN 2871653)

Capacity: 5 Oz. (150 ml.)

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

FRONT GEARCASE

Make sure vent is unobstructed

Drain plug

4. Add proper amount of lubricant:
Front Gearcase: Fill with the recommended fluid

amount or fill to 0.75 in. (19 mm) below the threads of
the fill plug. (See ILL. 1 & ILL. 2)

Front Gearcase

Fill Plug Threads

Fill to 3/4 in.below

threads or fill

with 5 oz. lubricant.

Rear Gearcase: Fill with the recommended fluid
amount or fill to the bottom of the fill plug hole threads.
(See ILL.3)

5. Install fill plug and check for leaks.

ILL. 1

ILL. 2

ILL. 3

Fill plug

REAR GEARCASE

Make sure vent is unobstructed

Fill Plug

Drain plug

2.9

TRANSMISSION

MAINTENANCE

LUBRICA

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

G Be sure the vehicle is level before proceeding.
G Check vent hose to be sure it is not kinked or

obstructed.

G Follow instructions to check / change transmission

lubricant.

To check the level:

1. Remove propshaft shield from the right side of the

vehicle.

2. Remove fill plug and visually inspect the oil level.

Level is correct when it reaches the bottom of the
fill hole as shown at right.

To change lubricant:

1. Remove propshaft shield from the right side of the

vehicle .

2. Remove transmission drain plug to drain the oil.

Catch and discard used oil properly.

3. Clean and reinstall the drain plug with a new

sealing washer. Torque to specification.

4. Remove fill plug.

5. Add Polaris Premium Synthetic Gearcase

Lubricant to proper level as described above.

6. Check for leaks.

7. Reinstall propshaft shield.

TION

TRANSMISSION SPECIFICATIONS

Specified Lubricant:

Premium Synthetic Gearcase Lubricant

PN 2871477 (gal.) PN 2871478 (12oz.)

Capacity:

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

Oil Level

13.5 oz. (400 ml.)

15/8²

View From Front

Transmission Fill Plug

2.10

Do not fill to bottom
of fill plug threads

MAINTENANCE

SHIFT LINKAGE INPSECTION

NOTE: Shift rod is preset at time of manufacture.

Shift Linkage Rod

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.

4. Turn handlebars from full right to full left. If idle
speed increases at any point in the turning range,
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.

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 slightly while lifting on 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.

2

3

1

2. Note orientation of tie rod end studs with the ends
that are up down (vertical). Remove both rod end
bolts from transmission bell crank.

Shifter Mount

Shifter

Shift Linkage 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.

6

565

Ill. 1

4

ETC Cover

Removal Sequence

CHOKE (ENRICHER)
ADJUSTMENT

If the choke knob does not stay out when pulled,
adjust the choke tension by tightening (clockwise) the
jam nut under the rubber boot between the choke
knob and nut. Firmly grasp the rubber boot and
tighten until the choke slides freely but stays out when
pulled.

1. Place the gear selector in neutral.

2. Set parking brake.

3. Start the engine and let it idle.

2.11

MAINTENANCE

Verify free play of 1/16--3/16” (1.6--4.76 mm) and
smooth operation of choke cable.

If smooth choke operation is not obtainable, inspect
choke cable for kinks or sharp bends in routing.

Illustration of choke may vary with models.

Ill.1

Boot

CARBURETOR PILOT SCREW
ADJUSTMENT

4. Set idle speed to 1100 RPM. Always check
throttle cable freeplay after adjusting idle speed
and adjust if necessary.

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

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

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

8. Re adjust idle speed to specification.

IDLE SPEED ADJUSTMENT

CV Carburetor

FRONT
(Engine)

Ill.2

1. Start engine and warm it up to operating

2. Turn pilot screw in (clockwise) until

3. Connect an accurate tachometer that will read in

Pilot Screw

temperature (about 10 minutes).

lightly

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

Pilot Screw Adjustment

Refer to Specifications in Chapter 1

increments of + or -- 50 RPM such as the PET
2100DX (PN 8712100DX) or the PET 2500 (PN

8712500).

Ill.3

1. Start engine and warm it up thoroughly.

2. Adjust idle speed by turning the idle adjustment
screw in (clockwise) to increase or out
(counterclockwise) to decrease RPM. (Ill.3)

NOTE: Adjusting the idle speed affects throttle cable
freeplay and electronic throttle control (ETC)
adjustment. Always check throttle cable freeplay
after adjusting idle speed and adjust if necessary.

Idle Screw

Idle Speed:

1100 +/-- 200 RPM

THROTTLE CABLE /
ELECTRONIC
CONTROL (ETC

THROTTLE

SWITCH)

ADJUSTMENT

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

2. Place shift selector in neutral and set parking
brake.

2.12

MAINTENANCE

THROTTLE CABLE / ELECTRONIC THROTTLE
CONTROL (ETC SWITCH) ADJUSTMENT CONT’D

3. Start engine and set idle to specified RPM.

Boot

Ill. 1

NOTE: Be sure the engine is at operating
temperature. See Idle Speed Adjustment.

4. Loosen lock nut on in-line cable adjuster (Ill. 1).

5. Turn adjuster until 1/16² to 1/8² freeplay is
achieved at thumb lever. (Ill. 2). After making
adjustments, quickly actuate the thumb lever
several times and reverify freeplay.

Adjuster
Sleeve

Lock­nut

Boot

FUEL SYSTEM

WARNING

Gasoline is extremely flammable and explosive
under certain conditions.

G Always stop the engine and refuel

outdoors or in a well ventilated area.

G Do not smoke or allow open flames

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

G Do not overfill the tank. Do not fill the

tank neck.

G If you get gasoline in your eyes or if

you swallow gasoline, seek medical
attention immediately.

G If you spill gasoline on your skin or

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

G Never start the engine or let it run in

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

G Never drain the float bowl when the

engine is hot. Severe burns may
result.

Direction
of travel

Ill. 2

6. Tighten lock nut securely and slide boot
completely in place to ensure a water-tight seal.

7. Turn handlebars from left to right through the
entire turning range. If idle speed increases,
check for proper cable routing. If cable is routed
properly andin good condition, repeat adjustment
procedure.

1/16² -1/8²

Freeplay

FUEL LINES

Fuel Lines

Fuel Pump

Ill.1

1. Check fuel lines for signs of wear, deterioration,
damage or leakage. Replace if necessary.

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

3. Replace all fuel lines every two years.

Fuel Filter

2.13

MAINTENANCE

VENT LINES

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

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

FUEL FILTER

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

Arrow Indicates Direction
of Flow

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

4. Inspect the drained fuel for water or sediment.

5. Tighten drain screw.

6. Turn fuel valve to “ON”.

7. Start machine and check for leaks.

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

Drain tube
attached
here

Ill. 1

Drain Screw

RES

To Carburetor

Ill. 2

1. Shut off fuel supply at fuel valve.

2. Remove line clamps at both ends of the filter.

3. Remove fuel lines from filter.

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

5. Install clamps on fuel line.

6. Turn fuel valve “ON”.

7. Start engine and inspect for leaks.

CARBURETOR DRAINING

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

NOTE: The bowl drain screw is located on the bottom

left side of the float bowl.

1. Turn fuel valve to the off position.

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

OFF

ON

Ill. 2

COMPRESSION TEST

NOTE: This engine does NOT have decompression

components. Compression readings will vary in
proportion to cranking speed during the test. Average
compression (measured) is about 150-170 psi during
a compression test.

A smooth idle generally indicates good compression.
Low engine compression is rarely a factor in running
condition problems above idle speed. Abnormally
high compression can be caused by carbon deposits
in the combustion chamber or worn, damaged
exhaust cam lobes. Inspect camshaft and
combustion chamber if compression is abnormally
high.

2.14

MAINTENANCE

COMPRESSION TEST CONT’D

A cylinder leakdown test is the best indication of
engine condition. Follow manufacturer’s instructions
to perform a cylinder leakage test. (Never use high
pressure leakage testers, as crankshaft seals may
dislodge and leak).

Cylinder Compression

Standard: 150-170 PSI

Cylinder Leakdown

Service Limit 10 %

(Inspect for cause if leakage exceeds 10%)

ENGINE MOUNTS

Inspect rubber engine mounts (A) for cracks or
damage. (Ill.3)

Check engine fasteners and ensure they are tight.

A

BATTERY MAINTENANCE

WARNING

Battery electrolyte is poisonous. It contains
sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing. Anti­dote:

External: Flush with water.

Internal: Drink large quantities of water or

milk. Follow with milk of magnesia, beaten
egg, or vegetable oil. Call physician im­mediately.

Eyes: Flush with water for 15 minutes and
get prompt medical attention.

Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc. away. Venti­late when charging or using in an enclosed
space. Always shield eyes when working
near batteries. KEEP OUT OF REACH OF
CHILDREN.

Ill. 3

A

A

NOTE: New Batteries:
charged before use or battery life will be reduced
by 10-30% of full potential. Charge battery for 3--5
hours at a current equivalent of 1/10 of the
battery’srated amp/hour capacity. Do not use the
alternator to charge anew battery. (Refer to battery

video PN 9917987)

The battery is located under the left rear fender.

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

Maintain
between upper
and lower level
marks

Ill. 1

Batteries must be fully

2.15

MAINTENANCE

To remove the battery:

1. Disconnect holder strap and remove cover.

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

CAUTION

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

3. Disconnect the vent hose.

4. Remove the battery.

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

Use only distilled water. Tap water contains

minerals which are harmful to a battery.

Do not allow cleaning solution or tap water to

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

6. Reinstall the battery caps.

7. Clean battery cables andterminals with astiff wire
brush. Corrosion can be removed using a
solution of one cup water and one tablespoon
baking soda. Rinse well with clean water and dry
thoroughly.

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

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

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

11. Reinstall battery cover and holder strap.

distilled water only

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

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

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

8. Install spark plug and torque to specification.

Recommended Spark Plug:

Refer to Specifications Chapter 1

Spark Plug Torque:

14 Ft. Lbs. (19 Nm)

Spark Plug Gap

.036² (0.9 mm)

IGNITION TIMING

Refer to Chapter 10 for ignition timing procedures.

ENGINE-TO-FRAME GROUND

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

SPARK PLUG

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

2. Remove spark plug.

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

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

2.16

Ground Cable

MAINTENANCE

LIQUID COOLING SYSTEM
OVER

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

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

VIEW

G Some coolant level drop on new

machinesis normal as the system is
purgingitselfof trappedair. Observe
coolant levels often during the
break-in period.

G Overheating of engine could occur if

air is not fully purged from system.

G PolarisPremium60/40anti--freezeis

premixed and ready to use. Do not
dilute with water.

COOLING SYSTEM HOSES

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

1. Check tightness of all hose clamps.

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

COOLANT STRENGTH / TYPE

Test the strength of the coolant using an antifreeze
hydrometer.

Antifreeze Hydrometer

G A 50/50 or 60/40 mixture of

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

G Do not use tap water. Tap water

contains minerals and impurities
which build up in the system. Do not
add straight antifreeze or straight
water to the system. Straight water
or antifreeze may cause the system
to freeze, corrode, or overheat.

RADIATOR

1. Check radiator external air flow passages for
restrictions or damage.

2. Carefully straighten any bent radiator fins.

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

COOLING SYSTEM
PRESSURE

Refer to Chapter 3 for pressure test procedures.

TEST

Polaris 60/40 Anti-Freeze / Coolant

(PN 2871323)

2.17

MAINTENANCE

COOLANT LEVEL
INSPECTION

WARNING

Never remove the radiator pressure cap when the
engine is warm or hot. Escaping steam and fluid can
cause severe burns. The engine must be allowed to
cool before removing the pressure cap.

The recovery bottle, located on the left side of the
machine, must be maintained between the minimum
and maximum levels indicated. (Ill.1)

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

1. Remove reservoir cap. Verify the inner splash
cap vent hole is clear and open.

2. Fill reservoir to upper mark with Polaris Premium
60/40 Anti Freeze / Coolant (PN 2871323)ora
mixture of antifreeze and distilled water as
required for freeze protection in your area.

3. Reinstall cap.

NOTE: This procedure is only required if the cooling
system has been drained for maintenance and/or
repair. However, if the recovery bottle has run dry, or
if overheating is evident, the level in the radiator
should be inspected via the radiator cap first and
coolant added if necessary.

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

To access the radiator pressure cap:

Remove the four screws securing front rack. Turn
handle bars full left or right to provide more clearance.
Remove front cover by placing your fingers under the
front of the cover and pulling upward.

Front
Cover

Rack

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

Recovery
Bottle
Accessible
Under Side
Panel

Ill.1

RADIATOR COOLANT LEVEL
INSPECTION

WARNING

Never remove the radiator pressure cap when the
engine is warm or hot. Escaping steam and fluid can
cause severe burns. The engine must be allowed to
cool before removing the pressure cap.

Ill.2

RADIATOR SCREEN
REMOV

1. Pull out slightly on the top of the radiator screen.

2. With the top free, pull out on the bottom of the
screen to remove the screen.

3. To install the screen, simply press the tabs on the
screen back into the mounting grommets. Be
sure the screen is securely in place.

Ill.3

AL

2.18

MAINTENANCE

AIR FILTER/PRE-FILTER
SER

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

The pre filter should be cleanedbefore each ride using
the following procedure:

1. Lift up on the rear of the seat.

2. Pull the seat back and free of the tabs. NOTE:

3. Remove clips (6) from air box cover and remove

4. Loosen clamp and remove air filter

VICE

When reinstalling seat, make sure the slots in the
seat engage the tabs in the fuel tank.

cover. Inspect the gasket. It should adhere tightly
to the cover and seal all the way around.

assembly.

Cover

Gasket

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

Filter Clamp

Ill.2

Proper Filter Placement

Main Filter

Pre-filter

Main Element

Ill.1

Cleaning:

5. Slip the pre-filter element off of main element.
Clean the pre filter with high flash point solvent,
followed by hot soapy water.

6. Rinse and dry thoroughly.

7. Inspect element for tears or damage.

8. Apply foam filter oil or clean engine oil and
squeeze until excess oil is removed.

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

Installation:

10. Reinstall pre-filter element over main filter. Be
sure the element covers entire surface of main
filter without folds, creases, or gaps.

11. Reinstall filter on main filter mount. Place filter
clamp over the assembly and tighten.

Filter Support

Air Box

Ill.3

NOTE: The air filter should rest on the filter support.
Proper placement of the air filter is important to
prevent rattles and air leaks. See Illustration above.

12. Install air box cover and secure with clips.

Front

AIR BOX SEDIMENT TUBE

Periodically check the air box drain tube located
toward the rear of the machine. Drain whenever
deposits are visible in the clear tube.

1. Remove drain plug from end of sediment tube.

2. Drain tube.

2.19

MAINTENANCE

3. Reinstall drain plug.

Sediment Tube

Ill.1

NOTE: The sediment tube will require more frequent
service if the vehicle is operated in wet conditions or
at high throttle openings for extended periods.

BREATHER FILTER
INSPECTION

BREATHER HOSE

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

PVT DRYING & PVT DRAIN
PLUG

NOTE: If operating the ATV in or through water, be

sure to check the PVT cover and other components
for water ingestion. The ATV should be checked
immediately.

1. To release any water that maybe trapped in the
PVT cover, simply remove the PVT drain plug and
O-- ring located on the bottom of the PVT cover
and let the water drain out. The PVT drain plug is
shown below.

Four cycle ATV engines are equipped with a breather
filter. The in-line filter is similar in appearance to a fuel
filter, and is visible on the left side (Location A).

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

Typical Breather Filter Location

In-Line Breather
Filter Location A

View -- Under Left Front Fender

Ill.2

PVT Drain Plug & O--ring

Ill.3

2. To further expel water from the cover and to dry
out the PVT system, shift the transmission to
neutral and rev engine slightly to expel the
moisture and air-dry the belt and clutches. Allow
engine RPM to settle to idle speed, shift
transmission to lowest available range and test
for belt slippage. Operate ATV in lowest available
range for a short period of time until PVT system
is dry.

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

2.20

MAINTENANCE

ENGINE OIL LEVEL

The 600/700 engine is a wet--sump engine, meaning
the oil is contained in the bottom of the crankcase. To
check the oil level:

Dipstick

Ill.1

1. Set machine on a level surface.

2. Start and run engine for 20-30 seconds.

3. Stop engine and unlock the lever lock.(Ill. 2)

Remove dipstick and wipe dry with a clean cloth.

side of the dipstick. Proper level indication is
determined on the
is being removed, regardless of the level marks being
on top or on bottom. (See the next illustration)

Dipstick

NOTE: A rising oil level between checks in cool
weather driving can indicate contaminants such as
gas or moisture collecting in the crankcase. If the oil
level is over the full mark, change the oil immediately.

upper

Always read top side of dipstick to
properly check oil level in crankcase

surface of the dipstick as it

Lever Lock

Dipstick

Ill.2

4. Reinstall dipstick and push it into place. Do not
lock the dipstick.

NOTE: Make certain the dipstick is inserted all the
way into the filler tube to keep the angle and depth of
stick consistent. When reinstalling the dipstick, make
certain to seat the lever lock.

5. Remove dipstick and check to see that the oil

level is in the normal range. Add oil as indicated
by the level on the dipstick. Do not overfill. (See
NOTE below!)

SAFE

OIL AND FILTER CHANGE

1. Place vehicle on a level surface.

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

3. Clean area around drain plug at bottom of oil
engine.

4. Place a drain pan beneath crankcase and remove
drain plug.

Crankcase Drain

Engine Oil Drain Plug - Bottom View

NOTE: Due to the dipstick entry angle into the

crankcase, the oil level will read higher on the bottom

CAUTION: Oil may be hot. Do not allow hot oil to

come into contact with skin, as serious burns may
result.

2.21

Oil Filter

(PN 2540006)

5. Allow oil to drain completely.

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

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

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

9. Using a cleandry cloth, clean filter sealing surface
on crankcase.

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

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

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

MAINTENANCE

Recommended Engine Oil

Polaris Premium 4 All Season Synthetic,

0W-- 40 (PN 2871281)

Ambient Temperature Range:

-40

Fto120 F

Crankcase Drain Plug Torque:

20--22 ft. lbs. (27--30 Nm)

Oil Filter Torque:

Turn by hand until filter gasket

contacts sealing surface, then

turn an additional 1/2 turn

Oil Filter Wrench:

(PV--43527)

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

14. Start the engine and let it idle for one to two
minutes. Stop the engine and inspect for leaks.

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

16. Dispose of used filter and oil properly

.

STEERING

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

2.22

Replace any worn or damaged steering components.
Steering should move freely through entire range of
travel without binding. Check routing of all cables,
hoses, and wiring to be sure the steering mechanism
is not restricted or limited. NOTE: Whenever steering
components are replaced, check front end alignment.
Use only genuine Polaris parts.

MAINTENANCE

WARNING

Due to the critical nature of the procedures out­lined in this chapter, Polaris recommends
steering component repair and adjustment be
performed byan authorized Polaris MSD--certi­fied technician when replacing worn or dam­aged steering parts. Use only genuine Polaris
replacement parts.

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

TIE ROD END / STEERING
INSPECTION

G To check for play in the tie rod end,

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

G Repeat inspection for inner tie rod

end on steering post.

TIE ROD END/STEERING INSPECTION
CONT’D

G If abnormal movement is detected,

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

Check for Loose Wheel or Hub

G Replace any worn steering

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

G Elevate front end of machine so front

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

G Refer to the Body/Steering Chapter

5 or Final Drive Chapter 7 for service
procedures.

CAMBER AND CASTER

The camber and caster are non-adjustable.

2.23

WHEEL ALIGNMENT
METHOD 1:
STRAIGHTEDGE OR STRING

Be sure to keep handlebars centered. See notes
below.

NOTE: String should just touch side sur­face of rear tire on each side of machine.

MAINTENANCE

Measure

from string

to rim at

front and

rear of rim.

NOTE: The steering post arm “frog” can be

used as an indicator of whether the handle-

bars are straight. The frog should always
point straight back from the steering post.

Rear rim

measure-

ment should

be 1/16² to

1/8² (.2to.3

cm) more

than front rim

measure-

ment.

2.24

MAINTENANCE

WHEEL ALIGNMENT
METHOD 2:

1. Place machine on a smooth level surface.

2. Set handlebars in a straight ahead position and
secure handlebars in this position. NOTE: The
steering arm “frog” can be used as an indicator of
whether the handlebars are straight. The frog
should always point straight back from the
steering post.

3. Place a chalk mark on the center line of the front
tires approximately 10² (25.4 cm) from the floor or
as close to the hub/axle center line as possible.
NOTE: It is important that the height of both
marks be equally positioned in order to get an
accurate measurement.

4. Measure the distance between the marks and
record the measurement. Call this measurement
“A”.

5. Rotate thetires 180° by moving vehicle forward or
backward. Position chalk marks facing rearward,
even with the hub/axle centerline.

6. Again measure the distance between the marks
and record. Call this measurement “B”. Subtract
measurement “B” from measurement “A”.The
difference between measurements “A” and “B” is
the vehicle toe alignment. The recommended
vehicle toe tolerance is 1/8² to 1/4² (.3 to .6 cm)
toe out. This means the measurement at the front
of the tire (A) is 1/8² to 1/4² (.3 to .6 cm) wider than
the measurement at the rear (B).

Ill.1

Chalk Line
Measurement
“A”

CHALK

Measurement “B”

TOE ALIGNMENT
ADJUSTMENT

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

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

Hold
Rod End

Correctly
Tightened

Ill.2

To adjust toe

Jam Nut

Ill.2

alignment:

G Hold tie rod end to keep it from

rotating.

G Loosen jam nuts at both end of the tie

rod.

G Shorten or lengthen the tie rod until

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

G IMPORTANT: When tightening the

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

G After alignment is complete, torque

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

Incorrectly
Tightened
Jam Nut

2.25

MAINTENANCE

EXHAUST PIPE

WARNING

G Do not perform clean out immediately

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

G To reduce fire hazard, make sure that

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

G Wear eye protection.

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

hicle while purging the carbon from the
spark arrestor.

G Never run the engine in an enclosed

area. Exhaust contains poisonous car­bon monoxide gas.

G Do not go under the machine while it is

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

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

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

3. SEE WARNING

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

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

8. Reinstall the clean out plugs.

BRAKE SYSTEM INSPECTION

The following checks are recommended to keep the
brake system in good operating condition. Service life
of brake system components depends on operating
conditions. Inspect brakes in accordance with the
maintenance schedule and before each ride.

G Keep fluid level in the master cylinder

reservoir to the indicated level inside
reservoir.

G Use Polaris DOT 3 Brake Fluid (PN

2870990).

Sight
Glass

Parking Brake
Lock

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

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

Ill.1

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

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

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

SEE WARNING

Clean Out Plug

Rear Master Cylinder Reservoir

Max
Min

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

spongy feel.

G Check friction pads for wear,

damage or looseness.

G Check surface condition of the disc.
G Inspect thickness of brake pad

friction material.

2.26

MAINTENANCE

BRAKE PAD INSPECTION

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

3/64²
(.1cm)

Minimum
Thickness

Auxiliary Foot Brake
Pedal

Full Height

Floor
Board Surface

AUXILIARY BRAKE

Full
Engagement

HOSE/FITTING INSPECTION

Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
fittings and replace any worn or damaged parts.

AUXILIARY BRAKE TESTING

The auxiliary brake should be checked for proper
function.

Auxiliary Brake

ADJUSTMENT

Use the following procedure to inspect the hydraulic
auxiliary (foot) brake system and adjust or bleed if
necessary:

First, check foot brake effectiveness byapplying 50lb.
(approx.) downward force on the pedal. The top of the
pedal should be at least 1 inch, (25.4mm) above the
surface of the footrest.

1/8, to 1/4,
Free Play

If less than one inch, two things must be examined:

(HYDRAULIC)

50 lbs

1² or greater

Floorboard

Support the rear wheels off the ground.

While turning the rear wheels by hand, apply the
auxiliary foot brake. This brake should not stop the
wheels from turning until the lever is half way between
its rest position and bottoming on the footrest.

Free Play:

Free play of the brake pedal should be 1/8 - 1/4
inch (3.2 - 6.35 mm).

If free play is excessive, inspect pedal, linkage, and
master cylinder for wear or damage and replace any
parts as needed.

Bleeding:

If free play is correct and brake pedal travel is still
excessive, air may be trapped somewhere in the
system. Bleed the hydraulic auxiliary brake system in

2.27

MAINTENANCE

a conventional manner, following the procedure
outlined in Brake Chapter 9.

SUSPENSION: SPRING
PRELOAD

Operator weight and vehicle loading affect
suspensionspringpreloadrequirements.Adjustas
necessary.

Shock Spanner Wrench

ADJUSTMENT

(PN 2870872)

FRONT SUSPENSION

G Compress and release front suspension.

Damping should be smooth throughout
the range of travel.

G Check all front suspension components

for wear or damage.

G Inspect front strut cartridges for leakage.

REAR SUSPENSION

CONTROLS

Check controls for proper operation, positioning
and adjustment.

Brake control and switch must be positioned to allow
brake lever to travel throughout entire range without
contacting switch body.

WHEELS

Inspect allwheels for runout or damage. Check wheel
nuts and ensure they are tight. Do not over tighten the
wheel nuts. Apply Loctitet 271 (PN 2871954)tothe
wheel studs whenever reinstalling the wheel nuts.

Rear Spring
Adjustment Cam

G Compress and release rear suspension.

Damping should be smooth throughout
the range of travel.

G Check all rear suspension components

for wear or damage.

G Inspect shock for leakage.

2.28

WHEEL, HUB, AND SPINDLE
TORQUE T

Item Specification

Front Wheel Nuts 30 Ft. Lbs. (41 Nm)

Rear Wheel Nuts 30 Ft. Lbs. (41Nm)

Front Spindle Nut Refer to procedure listed in

Rear Hub Retaining Nut 80 Ft. Lbs. (108 Nm)

ABLE

Chapter 7

WHEEL REMOVAL:
FRONT OR REAR

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

2. Loosen the wheel nuts slightly.

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

MAINTENANCE

4. Remove the wheel nuts and remove the wheel.

WHEEL INSTALLATION

1. With the transmission in gear and the parking
brake locked, place the wheel in the correct
position on the wheel hub. Be sure the valve stem
is toward the outside and rotation arrows on the
tire point toward forward rotation.

2. Attach the wheel nuts and finger tighten them.

3. Lower the vehicle to the ground.

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

CAUTION:

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

G The use of non-standard size or type

tires may affect ATV handling.

Tire Tread Depth

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

Tread
Depth 1/8I (3 mm)

Flange Nuts:
Flat side against wheel

TIRE PRESSURE

CAUTION:

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

Tire Pressure Inspection (PSI - Cold)

Front Rear

5 5

TIRE INSPECTION

WARNING

Operating an ATV with worn tires will increase
the possibility of the vehicle skidding and pos­sible loss of control.

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

measures 1/8² (.3 cm) or less.

FRAME, NUTS, BOLTS,

ASTENERS

F

Periodically inspect the torque of all fasteners in
accordance with the maintenance schedule. Check
that all cotter pins are in place. Refer to specific
fastener torques listed in each chapter.

G Improper tire inflation may affect ATV

maneuverability.

G When replacing a tire always use

original equipment size and type.

2.29

MAINTENANCE

2.30

ENGINE

CHAPTER 3
ENGINE

Engine Exploded Views 3.2--3.6......................

Special Tools 3.7...............................

Torque Specifications 3.8........................

Engine Fastener Torque Patterns 3.9.............

Piston Identification 3.9..........................

Engine Service Data 3.10--3.13.........................

Cooling System Specifications 3.14................

Cooling System Pressure Tests 3.14...............

Engine Removal/Installation 3.15..................

Engine Installation Notes 3.16.....................

Cylinder Honing 3.17............................

Oil Flow 3.18....................................

Rocker Arm/Pushrod Inspection 3.19...............

Cylinder Head Disassembly/Inspection 3.19--3.21.........

Valve Inspection 3.22............................

Combustion Chamber 3.22.......................

Valve Seat Reconditioning 3.23--3.25....................

Cylinder Head Assembly. 3.25.....................

Valve Sealing Test 3.26...........................

Valve Train Exploded View. 3.26...................

Engine Head Reassembly 3.27--3.29....................

Cylinder Removal 3.29...........................

Valve Lifter Removal/Inspection 3.29...............

Piston Removal 3.29--3.30.............................

Cylinder Inspection 3.30--3.31..........................

Piston/Rod/Ring Service 3.31--3.33.....................

Starter Bendix Removal/Inspection 3.33--3.34............

Flywheel/Stator Removal/Inspection 3.34--3.35...........

Flywheel/Stator Installation 3.35--3.36...................

Engine Lower Disassembly/Inspection 3.36--3.44.........

Camshaft Inspection 3.44--3.45.........................

Engine Lower Assembly 3.45--3.55.....................

Troubleshooting 3.56--3.57.............................

700 Engine Exploded View (Back Book) 3.58........

3

3.1

ENGINE EXPLODED VIEW

ENGINE

Crankcase

Seal

Bearing

4.5-5.5 ft. lbs.
(6-7 Nm)

Bushing

Bearing

271

271

Crankcase

Assembly

Oil Pickup

20-24 ft. lbs.
(27-33 Nm)

Journal

Bearings

Oil Dipstick

Seals

4.5-5.5 ft. lbs.

271

(6-7 Nm)

O-- Ring

Gasket

262

Baffle

NOTE: Heat the oil
baffle bolts with a heat
gun to remove.

20-24 ft. lbs.

242

(27-33 Nm)

Magnetic Plug

20--22 ft. lbs.
(27-30 Nm)

Crankcase Screws

8.5-9.5 ft. lbs.

242

(12-13 Nm)

Gear/Stator Housing Cover

Apply Loctitet 262 to

262

the bolt threads.

Apply Loctitet 242 to

242

the bolt threads.

Apply Loctitet 271 to

271

the bolt threads.

3.2

ENGINE

ENGINE EXPLODED VIEW

Cylinder/
Cylinder Head

Breather Cover

271

27--33 in. lbs.

(3--4 Nm)

Reed

8.5-9.5 ft. lbs.
(12-13 Nm)

Rocker Cover

271

8.5-9.5 ft. lbs.

271

(12-13 Nm)

16-20 ft. lbs.

(22-27 Nm)

11-13 ft. lbs.

271

(15-18 Nm)

60--64 ft. lbs.

(81--87 Nm)

Thermostat

Cover

Frost Plug

Thermostat

Temperature

Switch

16--20 ft. lbs.

(22--27 Nm)

Exhaust

Gasket

Cylinder Head

Head Gasket

Cylinder

20-24 ft. lbs.

271

(27-33 Nm)

Exhaust

Manifold

Carburetor

Base Gasket

Apply Loctitet 242 to

242271

the bolt threads.

Apply Loctitet 271 to
the bolt threads.

3.3

ENGINE EXPLODED VIEW

ENGINE

Crankshaft and Pistons

Piston Assembly

Crankshaft

Woodruff Key

Valve Train

Thrust Plate

271

Val v e

Springs

Camshaft

4.5-5.5 ft. lbs.
(6--7 Nm)

26-30 ft. lbs.

242

(35-41 Nm)

Camshaft

Gears

20-24 ft. lbs.

(27-33 Nm)

Rocker Arms

Pushrods

Balance Shaft

Apply Loctitet 242 to

242271

the bolt threads.

Apply Loctitet 271 to
the bolt threads.

3.4

Gears

26-30 ft. lbs.

(35-41 Nm)

242

Val v e
Seals

Cylinder Head

Lifter Valve

Val v es

ENGINE

ENGINE EXPLODED VIEW

Water Pump / Oil Pump

Oil Plug

20-24 ft. lbs.

(27-33 Nm)

8.5-9.5 ft. lbs.
(12-13 Nm)

Oil Filter

33-37 ft. lbs.

(45-50 Nm)

Oil Filter

Nipple

Oil Pressure

Relief

Gerotor

Oil Pump

Housing

8.5-9.5 ft. lbs.
(12-13 Nm)

Gasket

Water/Oil

Shaft

242

Bearing

Water/Oil

Pump Gear

9-11 ft. lbs.
(12-15 Nm)

Impeller

Gear/Stator Housing

Apply Loctitet 242 to

242

the bolt threads.

Apply Loctitet 271 to

271

the bolt threads.

O-- Ring

Water Pump Seal

Water Pump Cover

8.5-9.5 ft. lbs.

271

(12-13 Nm)

3.5

ENGINE EXPLODED VIEW

Stator/Starter

Stator Wire Holddown

4.5-5.5 ft. lbs.

242

Stator

Bolts

(6-7 Nm)

8.5--9.5 ft. lbs.

242

(11.5--13 Nm)

80-100 ft. lbs.

242

(109-136 Nm)

ENGINE

8.5-9.5 ft. lbs.

271

(12-13 Nm)

Flywheel

Starter

Flywheel Nut

Stator Housing

O-- rings

Bendix

Sound Cover

Washers

Outer Cover

Timing Plug

7-9 ft. lbs.
(10-12 Nm)

8.5-9.5 ft. lbs.

242

(12-13 Nm)

3.6

Apply Loctitet 242 to

242271

the bolt threads.

Apply Loctitet 271 to
the bolt threads.

ENGINE

SPECIAL TOOLS

PART NUMBER TOOL DESCRIPTION

PV--43527 Oil Filter Wrench

2200634 Valve Seat Reconditioning Kit

PU--45257 Valve Spring Compressor

PU--45652 Valve Pressure Hose

2871043 Flywheel Puller

PU--44693 Valve Train Table

2870390 Piston Support Block

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

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

PU--45498 Cam Spanner Wrench

PU--45648 Gear Holder

PA--44995 Water Pump Mechanical Seal Installer

PU--45543 Universal Driver Handle

PU--45483 Main Seal Installer

PU--45658 Main Crankshaft Seal Saver

PA--45401 Water Pump Seal Saver

2870975 Mity Vact Pressure Test Tool

PU--45778 Oil System Priming Tool

ACCESSIBLE COMPONENTS

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

G Flywheel

G Alternator/Stator

G Starter Motor/Starter Drive

G Cylinder Head

G Cylinder

G Piston/RIngs

G Camshaft

G Rocker Arms

G Oil pump/Water Pump and Oil

Pump Drive Gear

G Gear Train Components

The following components require engine
removal for service:

G Counterbalance Shaft or Bearing(s)

G Connecting Rod

G Crankshaft

G Crankshaft Main Bearings

G Crankcase

3.7

ENGINE

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Fastener Size 600/700

Ft. Lbs. (Nm)

Camshaft Gear 8mm 26-30 (35-41 Nm)

Camshaft Thrust Plate 6mm 4.5-5.5 (6-7 Nm)

Carburetor Adaptor 8mm 11-13 (15-18 Nm)

Counterbalance Gear 8mm 26-30 (35-41 Nm)

Crankcase 8mm 20-24 (27-33 Nm)

Crankcase Breather 5mm 27--33 in.lbs.(3--4 Nm)

Cylinder Head Bolts 12 mm 60-64 (68-73 Nm)

Exhaust Manifold 8mm 20-24 (27-33 Nm)

Flywheel 14 mm 80-100 (109-136 Nm)

Magneto Cover 6mm 8.5-9.5 (12-13 Nm)

Oil Baffle Weldment 5mm 4.5-5.5 (6-7 Nm)

Oil Drain Bolt (Crankcase) 12 mm 20--22 (27-30 Nm)

Oil Fill Tube Bolt 5mm 4.5-5.5 (6-7 Nm)

Oil Filter Pipe Fitting 20 mm 33-37 (45-50 Nm)

Oil Pick Up 5mm 4.5-5.5 (6-7 Nm)

Oil Pressure Relief Plug 10 mm 20-24 (27-33 Nm)

Oil Pressure Switch 1/4-18 8.5-9.5 (12-13 Nm)

Oil Pump Housing Screw 6mm 8.5-9.5 (12-13 Nm)

Rocker Arm 8mm 20-24 (27-33 Nm)

Rocker Cover 6mm 8.5-9.5 (12-13 Nm)

Spark Plug 14 mm 16-20 (22-27 Nm)

Starter Motor 6mm 8.5-9.5 (12-13 Nm)

Stator Assembly 6mm 9-10 (12-14 Nm)

Stator Housing 6mm 8.5-9.5 (12-13 Nm)

Temperature Switch 3/8 PT 16-20 (22-27 Nm)

Thermostat Housing 6mm 8.5-9.5 (12-13 Nm)

Timing Plug 3/4-16 7-9 (10-12 Nm)

Trigger Coil/Stator Wire Holddown 5mm 4.5-5.5 (6-7 Nm)

Water Pump Housing Cover 6mm 8.5-9.5 (12-13 Nm)

Water Pump Impeller Nut 8mm 9-11 (12-15 Nm)

3.8

ENGINE

ENGINE FASTENER TORQUE PATTERNS

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

10

15

11

14

13

12

6

3

1

5

4

3

6

Cylinder Head

2

4

9

7

Crankcase

8

2

1

5

PISTON IDENTIFICATION

Four stroke engine rings have arectangular profile. See text on Page 3.27for ringinstallation. Use theinformation
below to identify pistons and rings.

NOTE: The pistons have no directional identification marks. New pistons are non--directional.

Engine Model No. Piston Length Standard Piston Identification

EH680ALE 80 mm None

EH590ALE 76.50 mm None

3.9

600 ENGINE SERVICE DATA

g

j

j

y

g

g

p

g

Cylinder Head / Valve Engine No. -- EH059OLE

Camshaft Cam lobe height In

Std 0 .2170” r 0.00236” (5.5118 r 0.060 mm)

Ex

Std 0 .2170” r 0.00236” (5.5118 r 0.060 mm)

ENGINE

Camshaft journal OD

Camshaft journal bore
ID

Camshaft Oil clear­ance

End Play 0.0135” r 0.0111” (0.3450 r 0.2825 mm)

Counter
Balance

Cylinder
Head

Valve Seat Contacting width In

Val v e
Guide

Val v e Margin thick- In

End Play 0.005” (0.127 mm)

Surface warpage limit 0.00394” (0.1 mm)
Standard height 3.478” (88.35 mm)

Ex

Seat Angle Std 44.75 r 0.25q
Inner diameter 0.2374” r 0.00059” (6.030 r 0.015 mm)
Protrusion above head 0.5610” r 0.00394” (14.25 r 0.10 mm)

ness

Ex

Mag 1.654” r 0.00039” (42 r 0.010 mm)
Center 1.634” r 0.00039” (41.50 r 0.010 mm)
PTO 1.614” r 0.00039” (41 r 0.010 mm)
Mag 1.656” r 0.00039” (42.07 r 0.010 mm)
Center 1.637” r 0.00039” (41.58 r 0.010 mm)
PTO 1.617” r 0.00039” (41.07 r 0.010 mm)
Std 0.00118” r 0.00079” (0.03 r 0.02 mm)

Std 0.0472” + 0.00787” -- 0.0039”

(1.20 + 0.20 -- 0.10 mm)

Std 0.0591” + 0.00787” -- 0.0039”

(1.50 + 0.20 -- 0.10 mm)

Std 0.1394” r 0.0065” (3.541 r 0.165 mm)

Std 0.1373” r 0.0065”(3.488 r 0.165 mm)

Stem diameter In 0.2356” r 0.00039” (5.985 r 0.01 mm)

Stem oil clear- Std
ance

Overall length

Val v e
Spring

Overall length

3.10

Ex 0.2346” r 0.00039” (5.96 r 0.01 mm)
In 0.00177” r 0.00098” (0.045 r 0.025 mm)
Ex 0.00334” r 0.00039” (0.085 r 0.010 mm)

In 4.51” r 0.01476” (114.5550 r 0.375 mm)
Ex 4.5453” r .01496” (115.45 r 0.38 mm)
Free

Length
Installed

Height

1.8267” (46.40 mm)

1.47” (37.34 mm)

ENGINE

Pistonclearance

g

g

Pisto

n

Pistonringinstalled

Topring

g

g

Secon

d

g

Oilring

p

g

Standardclearance-Topring

Secon

d

g

g

Connectingrodbigendside

g

Connectingrodbigendradial

600 ENGINE SERVICE DATA

Cylinder / Piston / Connecting Rod Engine No. -- EH590ALOE

Cylinder

Lifter

Surface warpage limit (mating with cyl­inder head)

Cylinder bore Std 3.0118” (76.5mm)
Taper limit 0.00031” (0.008 mm)
Out of round limit 0.00030” (0.0075 mm)
Piston clearance

Limit .0022” r .00067” (.055 r .017 mm)
Boring limit N/A
Outer Diameter Std 0.84245” r 0.00025” (21.39 8r 0.00635 mm)
Block Bore Std 0.8438” r 0.00062”(21.4322 r 0.0157 mm)

0.004” (0.10 mm)

Piston

Standard inner diameter of piston pin
bore

Piston Pin

Piston Piston rin
Ring

Connect­ing Rod

Outer diameter 0.7874” -- .0002” (20 -- .005 mm)
Standard clearance-piston pin to pin

bore
Degree of fit Piston pin must be a push (by hand) fit at 68q

gap

Standard clearance To

piston ring to ring
groove

Connecting rod small end ID 0.789” r 0.00059”. (20.030 r 0.015 mm)
Connecting rod small end ra-

dial clearance

Connectin
clearance

Connectin
clearance

Std 3.0096” r .00035I (76.445 r .009 mm)

installed Toprin

Second
ring

Oil rin

rin

Second
ring

rod bigend side

rod bigend radial

0.78757” r .00098I (20.0045 r 0.0025 mm)

0.00027” r 0.00019” (0.007 r 0.005 mm)

F(20q C)

Limit 0.01181” r 0.00039” (0.30 r 0.01 mm)

Limit 0.01476” r 0.00492” (0.375 r 0.125 mm)

Limit 0.00984” r .00393” (0.25 r 0.10 mm)

Limit 0.0019” r 0.00069” (0.0475 r 0.0175 mm)

Limit 0.0017” r 0.00049I (0.0425 r 0.0125 mm)

Std 0.00098” r 0.00039” (0.025 r 0.010 mm)

Limit 0.01181” r 0.00591” (0.30 r 0.15 mm)

Limit 0.00015” r 0.00006” (0.0038 r 0.0015 mm)

Crankshaft Crankshaft runout limit 0.00236” (0.060 mm)

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

3.11

700 ENGINE SERVICE DATA

g

j

j

y

g

g

p

g

Cylinder Head / Valve Engine No. -- EH68ALOE / EH068OLE

Camshaft Cam lobe height In

Std 0 .2170” r 0.00236” (5.5118 r 0.060 mm)

Ex

Std 0 .2170” r 0.00236” (5.5118 r 0.060 mm)

ENGINE

Camshaft journal OD

Camshaft journal bore
ID

Camshaft Oil clear­ance

End Play 0.0167” r 0.0098” (0.425 r 0.25 mm)

Counter
Balance

Cylinder
Head

Valve Seat Contacting width In

Val v e
Guide

Val v e Margin thick- In

End Play 0.005” (0.127 mm)

Surface warpage limit 0.00394” (0.1 mm)
Standard height 3.478” (88.35 mm)

Ex

Seat Angle Std 44.75 r 0.25q
Inner diameter 0.2374” r 0.00059” (6.030 r 0.015 mm)
Protrusion above head 0.5610” r 0.00394” (14.25 r 0.10 mm)

ness

Ex

Mag 1.654” r 0.00039” (42 r 0.010 mm)
Center 1.634” r 0.00039” (41.50 r 0.010 mm)
PTO 1.614” r 0.00039” (41 r 0.010 mm)
Mag 1.656” r 0.00039” (42.07 r 0.010 mm)
Center 1.637” r 0.00039” (41.58 r 0.010 mm)
PTO 1.617” r 0.00039” (41.07 r 0.010 mm)
Std 0.00118” r 0.00079” (0.03 r 0.02 mm)

Std 0.0472” + 0.00787” -- 0.0039”

(1.20 + 0.20 -- 0.10 mm)

Std 0.0591” + 0.00787” -- 0.0039”

(1.50 + 0.20 -- 0.10 mm)

Std 0.1394” r 0.0065” (3.541 r 0.165 mm)

Std 0.1373” r 0.0065”(3.488 r 0.165 mm)

Stem diameter In 0.2354” r 0.00065” (5.9785 r 0.0165 mm)

Stem oil clear- Std
ance

Overall length

Val v e
Spring

Overall length

3.12

Ex 0.2344” r 0.00065” (5.9535 r 0.0165 mm)
In 0.00203” r 0.00124” (0.0515 r 0.0315 mm)
Ex 0.0030” r 0.00124” (0.0765 r 0.0315 mm)

In 4.51” r 0.01476” (114.5550 r 0.375 mm)
Ex 4.5453” r .01496” (115.45 r 0.38 mm)
Free

Length
Installed

Height

1.8267” (46.40 mm)

1.47” (37.34 mm)

ENGINE

Pistonclearance

g

g

Pisto

n

Pistonringinstalled

Topring

g

g

Secon

d

g

Oilring

p

g

Standardclearance-Topring

Secon

d

g

g

Connectingrodbigendside

g

Connectingrodbigendradial

700 ENGINE SERVICE DATA

Cylinder / Piston / Connecting Rod Engine No. -- EH68ALOE / EH068OLE

Cylinder

Lifter

Surface warpage limit (mating with cyl­inder head)

Cylinder bore Std 3.1495” (80 mm)
Taper limit 0.00031” (0.008 mm)
Out of round limit 0.00030” (0.0075 mm)
Piston clearance

Limit .0016” r .00063” (.041 r .016 mm)
Boring limit N/A
Outer Diameter Std 0.84245” r 0.00025” (21.39 8r 0.00635 mm)
Block Bore Std 0.8438” r 0.00062”(21.4322 r 0.0157 mm)

0.004” (0.10 mm)

Piston

Standard inner diameter of piston pin
bore

Piston Pin

Piston Piston rin
Ring

Connect­ing Rod

Outer diameter 0.787” r .0002” (20 r .005 mm)
Standard clearance-piston pin to pin

bore
Degree of fit Piston pin must be a push (by hand) fit at 68q

gap

Standard clearance To

piston ring to ring
groove

Connecting rod small end ID 0.789” -- 0.00059”. (20.030 -- 0.015 mm)
Connecting rod small end ra-

dial clearance

Connectin
clearance

Connectin
clearance

Std 3.1477” r .00012I (79.954 r .003 mm)

installed Toprin

Second
ring

Oil rin

rin

Second
ring

rod bigend side

rod bigend radial

0.78789” r .0000098I (20.0125 r 0.0025 mm)

0.00059” r 0.0002” (0.015 r 0.005 mm)

F(20q C)

Limit 0.01083” r 0.00295” (0.275 r 0.075 mm)

Limit 0.0177” r 0.00394” (0.45 r 0.10 mm)

Limit 0.0177” r .00984” (0.45 r 0.25 mm)

Limit 0.0019” r 0.00069” (0.0475 r 0.0175 mm)

Limit 0.0017” r 0.00049I (0.0425 r 0.0125 mm)

Std 0.00098” r 0.00039” (0.025 r 0.010 mm)

Limit 0.01181” r 0.00591” (0.30 r 0.15 mm)

Limit 0.00015” r 0.00006” (0.0038 r 0.0015 mm)

Crankshaft Crankshaft runout limit 0.00236” (0.060 mm)

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

3.13

ENGINE

COOLING SYSTEM
SPECIFICA

Fan Switch (Off)
Fan Switch (On)

Hot Light On 221° F (105° C)

System Capacity 2.25 Quarts

Radiator Cap Relief

Pressure

Thermostat Starts opening 176° F

Recommended Coolant

Use only high quality antifreeze/coolant mixed with

distilled

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

water in a 50/50 or 60/40 ratio, depending on

TIONS

149° F(65° C) ± 8°
180° F(82° C) ± 3°

13 PSI

(80° C)

Open 8mm @ 205° F

(96° C)

COOLING SYSTEM

WARNING

Never remove radiator cap when engine is
warm or hot. The cooling system is under
pressure and serious burns may result. Allow
the engine and cooling system to cool before
servicing.

1. Remove front cover.

2. Remove recovery bottle hose from coolant filler
neck.

3. Connect a Mity Vact (PN 2870975) to the filler
neck nipple and pressurize system to 10 psi. The
system must retain 10 psi for five minutes or
longer. If pressure loss is evident within five
minutes, check the radiator, hoses, clamps and
water pump seals for leakage.

Radiator Cap Pressure Test

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

2. The radiator cap relief pressure is 13 lbs. Replace
cap if it does not meet this specification.

Filler Neck Assy.

Upper Engine

Hose

Surge Tank

FLOW

Radiator

Thermostat

Cylinder
Head

Coolant Flow Diagram

To p

Bottom

Water

Pump

Cylinder

Hose

Lower Engine
Hose

Exploded View

To W at e r P u mp

Thermal

Sensor

Fan

Shroud

Radiator

Radiator
Front
View

Radiator
Left Side
View

3.14

ENGINE

ENGINE REMOVE & INSTALL

1. Clean work area.

2. Thoroughly clean the ATV engine and chassis.

3. Disconnect battery negative (-) cable.

4. Remove the following parts as required:

G Seat
G Left and Right Side Covers (Refer to

Chapter 5)

G Fuel Tank Cover / Front Cab (Refer to

Chapter 5)

G Fuel Tank (Refer to Chapter 4)

5. Remove springs from exhaust pipe and remove
pipe.

6. Drain coolant and engine oil.

7. Remove air pre-cleaner and duct.

8. Remove airbox.

B

12. Disconnect the coolant hoses. Properly dispose
of any antifreeze from the engine or hoses.

13. Refer to PVT System Chapter 6 to remove outer
clutch cover, drive belt, drive clutch, driven clutch,
and inner cover (D).

14. When removing starter cables, note and mark
ground cable and positive(+) cable mounting
angle and locations . Remove cables.

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

16. Disconnect coolant temperature sensor wire.

17. Remove engine to chassis ground cable.

18. Remove all engine mount nuts and / or engine
mount plates. Remove the frame brace (E) from
the front left side of the frame.

C

A

9. Remove carburetor (A). Insert a shop towel into
the carburetor flange to prevent dirt from entering
the intake port.

10. Disconnect spark plug high tension lead (B).

11. Remove the air breather line (C).

D

E

19. Remove the engine from the left side of the frame.

NOTE: Use caution when lifting the engine out of
frame. Use an engine lift or other means if the engine
is too heavy to be lifted manually.

20. For engine installation, reverse these
procedures.

3.15

ENGINE

ENGINE INSTALLATION NOTES

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

General Items

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

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

PVT System

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

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

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

Transmission

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

Exhaust

Engine Break In Period

The break in period for a Polaris ATV engine is defined
as the first ten hours of operation, or the time it takes
to use two full tanks of gasoline. No single action on
your part is as important as a proper break in period.
Careful treatment of a new engine will result in more
efficient performance and longer life for the engine.
Perform the following procedures carefully.

CAUTION

Use only Polaris Premium 0--40W All Season
synthetic oil or equivalent. Never substitute or
mix oil brands. Serious engine damage and
voiding of warranty can result.

Do not operate at full throttle or high speeds for
extended periods during the first three hours of
use. Excessive heat can build up and cause
damage to close fitted engine parts.

1. Fill fuel tank with unleaded or leaded fuel which
has a minimum pump octane number of 87= (R+
M)/2.

2. Check oil reservoir level indicated on dipstick.
Add oil if necessary.

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

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

Bleed Cooling System

NOTE: This cooling system contains vent lines to

help purge trapped air during filling. Refer to page 3.6
for hose routing. Bleeding generally should not be
necessary.

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

2. Fill coolant reservoir tank to full mark.

3. Install radiator cap and gently squeeze coolant
hoses to force any trapped air out of system.

4. Again, remove radiator cap and slowly add
coolant to the bottom of fill neck if needed.

5. Start engine and observe coolant level in the
radiator. Allow air to purge and top off as
necessary. Reinstall radiator cap and bring
engine to operating temperature. After engine is
cool, check level inreservoir tank and addcoolant
if necessary.

NOTE: Should the reservoir tank become empty, it
will be necessary to refill at the radiator and repeat the
bleeding procedure.

SAFE

3. Drive slowly at first to gradually bring engine up to
operating temperature.

4. Vary throttle positions. Do not operate at
sustained idle or sustained high speed.

5. Perform regular checks on fluid levels, controls
and all important areas on the vehicle.

6. Pull only light loads during initial break in.

7. Change break in oil and filter at 20 hours or 200
miles.

ADD 8 OZ

3.16

ENGINE

CYLINDER HONE SELECTION
AND HONING

CAUTION:

A hone which will straighten as well as remove
material from the cylinder is very important. Using a
common spring loaded glaze breaker for honing is not
advised for nicasil cylinders. Polaris recommends
using a rigid hone or arbor honing machine.

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

PROCEDURE

HONING TO DEGLAZE

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

G Use a motor speed of approximately

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

G Release the hone at regular intervals

and inspect the bore to determine if
it has been sufficiently deglazed, and
to check for correct cross--hatch.

NOTE: Do not allow cylinder to
heat up during honing.

G After honing has been completed,

inspect cylinder for thinning or
peeling.

If cylinder wear or damage is excessive, it will be
necessary to replace the cylinder. The cylinders are
lined with a nicasil coating and are not repairable.
Hone only enough to deglaze the outer layer of the
cylinder bore.

EXAMPLE OF CROSS HATCH PATTERN

IMPORTANT: Clean the Cylinder After

It is very important that the cylinder be thoroughly
cleaned after honing to remove all grit material. Wash
the cylinder in a solvent, then in hot, soapywater. Use
electrical contact cleaner if necessary to clean these
areas. Rinse thoroughly, dry with compressed air,
and oil the bore immediately with Polaris 4 Cycle
Lubricant to prevent the formation of surface rust.

Honing

ENGINE LUBRICATION

Oil Type -- Polaris Premium 4 Synthetic (PN 2871281)

or API certified “SH” 5W30 oil

Capacity -- Approximately 2 U.S. Quarts (1.9 l)

Filter -- (PN 2540006)

Filter Wrench -- PV--43527 or equivalent

Oil Pressure Specification -- 25--34 PSI @ 5500

RPM, Polaris 0W--40 Synthetic , Engine at operating
temperature.

OIL PRESSURE TEST

1. Remove blind plug/sender from left side of
crankcase.

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

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

NOTE: Use only Polaris Premium 0--40W Synthetic
Engine Lubricant.

Oil Pressure at 5500 RPM (Engine Hot):

Standard: 34 PSI

Minimum: 25 PSI

3.17

ENGINE

OIL FLOW

This chart describes the flow of oil through the EH68 and the EH059 engine. Beginning in the crankcase sump,
the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter.
If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. At this
point, the oil is supplied to the main oil galley through a crankcase passage. Oil is then diverted three ways from
the main oil galley, with the first path entering the camshaft bores, onto the rear balance shaft journal and then
draining back into the crankcase sump. The second oil path from the main oil galley feeds the lifter bores and
then drains back to the crankcase sump. The third oil path flows through a crankcase galley to the MAG side
crankshaft journal and also to the front balance shaft journal and onto the crankcase sump. The oil pressure
switch is fed off the main oil galley.

PTO

SIDE

Crankshaft

Main Bearing

Counterbalance
Bore

Camshaft

Bore

Crankcase

Sump

Rod

Bearings

Camshaft

Bore

Lifter Bores

Crankshaft

Main Bearing

Counterbalance
Bore

Camshaft

Bore

MAGNETO

SIDE

Oil Pressure

Relief

Pump

Crankcase

Sump

3.18

Main Oil Gallery

Filter

ENGINE

ROCKER ARM INSPECTION

1. Mark or tag rocker arms in order of disassembly to
keep them in order for reassembly.

2. Inspect the wear pad at the valve end of the rocker
arm for indications of scuffing or abnormal wear.
If the pad is grooved, replace the rocker arm.

NOTE: Do not attempt to true this surface by
grinding.

3. Check the rocker arm pad and fulcrum seat for
excessive wear, cracks, nicks or burrs.

PUSH ROD INSPECTION

5. If the push rod (A) is visibly bent, it should be
replaced.

A

CYLINDER HEAD REMOVAL

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

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

3. Remove cylinder head (B) and head gasket (C)
from the cylinder (D).

1. Clean push rods (A) in a suitable solvent. Blow
dry push rods with compressed air.

2. Use compressed air to confirm the oil passage is
clear in the center of the push rod.

WARNING

Always wear safety glasses whenworking with
compressed air to prevent personal injury.

3. Check the ends of the push rods (A) for nicks,
grooves, roughness or excessive wear.

4. The push rods (A) can be visually checked for
straightness while they are installed in the engine
by rotating them with the valve closed. Push rods
can also be checked with a dial indicator or rolled
across a flat surface to check for straightness.

A

B

C

D

3.19

ENGINE

CYLINDER HEAD INSPECTION

1. Thoroughly clean cylinder head surface to
remove all traces of gasket material and carbon.

CAUTION: Use care not to damage sealing surface.

CYLINDER HEAD WARPAGE

1. Lay a straight edge (A) across the surface of the
cylinder head (B) at several different points and
measure warpage by inserting a feeler gauge
between the straight edge and the cylinder head
surface. If warpage exceeds the service limit,
replace the cylinder head.

A

WARNING

Wear eye protection or a face shield during
cylinder head disassembly and reassembly.

1. Having already removed the valve cover, rocker
arms and pushrods, align the cylinder to be
worked on at top dead center. Install the Valve
Pressure Hose (PU--45652) into the spark plug
hole. Hook the hose to an air compressor and
supply 50 to100 psi to the hose. This will seat the
valves during valve spring removal. Do not
remove air from the hose at anytime until
reassembly is completed.

2. Using the Valve Spring Compressor (PU--45257),
compress the valve spring and remove the valve
keepers. NOTE: A small parts magnet (A) can aid
in the removal of the retainers (B).

B

B

Measure at different points

on the surface.

Cylinder Head Warpage Limit:

004² (.1016 mm) Max.

Bottom Side View

CYLINDER HEAD
DISASSEMBL

NOTE: The following procedure is only for
servicing the top end of the valve train when
replacing valve springs or replacing valve seals.

Valve Train Servicing

In some cases the valve train can be serviced while
the cylinder head is still on the engine. Keep all parts
in order with respect to their location in the cylinder
head.

Y

PU--45257

A

Valve Spring Compressor:

(PU-- 45257)

Valve Pressure Hose:

(PU-- 45652)

NOTE: To prevent damage to the valve seals, do not

compress the valve spring more than is needed to
remove the valve keepers.

3. Remove spring retainer and spring.

4. The valve seals are now serviceable.

3.20

ENGINE

CYLINDER HEAD DISASSEMBLY, CONT.

NOTE: If working on the cylinder head while removed

from the engine assembly, use the Valve Train Table
(PU-- 44693) to perform cylinder head work. The
cylinder head attaches simply to the table. Place the
hydraulic lifters (C), pushrods (D), and rocker arms
(E) in a safe, clean area.

Valve Spring Length:

Std: 1.827I (46.40 mm)

Installed Height: 1.47” (37.34 mm)

PU--44693

D

C

6. Remove valve guide seals. IMPORTANT: It is
recommended to replace seals whenever the
cylinder head is disassembled. Hardened,
cracked or worn valve seals will cause excessive
oil consumption and carbon buildup.

7. Mark the valves with a white pen. Remove the
valves from the cylinder head. This will ensure
that the valves are properly placed during engine
reassembly.

E

5. Measure free length of spring with a Vernier caliper.
Compare to specifications. Replace spring if
measurement is out of specification.

Valve Spring
Free Length

Mark the valves

3.21

ENGINE

VALVE INSPECTION

1. Remove all carbon from valves with a soft wire
wheel or brush.

2. Check valve face for runout, pitting, and burnt
spots. To check for bent valve stems, mount
valve in a drill or use “V” blocks and a dial
indicator.

3. Check end of valve stem for flaring, pitting, wear
or damage (A).

Valve Stem Diameter:

Intake: 0.2356” r 0.00039”

(5.985 r 0.01 mm)

Exhaust: 0.2346”

(5.96

Measure valve stem in several places.
Rotate the valve 90 degrees and mea­sure for wear.

6. Measure valve guide inside diameter at the top
middle and end of the guide using a small hole
gauge and a micrometer. Measure in two
directions.

0.00039”

0.01 mm)

A

B

4. Inspect split keeper groove for wear or flaring of
the keeper seat area (B). NOTE: The valves can
be re-faced or end ground, if necessary. They
must be replaced if extensively worn, burnt, bent,
or damaged.

5. Measure diameter of valve stem with a
micrometer in three places, then rotate 90
degrees and measure again (six measurements
total). Compare to specifications.

Valve Guide

Valve Guide I.D.:

0.2374” r 0.00059” (6.030

7. Subtract valve stem measurement from the valve
guide measurement to obtain stem to guide
clearance. NOTE: The valve guides cannot be
replaced. Be sure to measure each guide and
valve combination individually.

0.015 mm)

3.22

ENGINE

COMBUSTION CHAMBER

1. Clean all accumulated carbon deposits from
combustion chamber and valve seat area with
carbon cleaner and a soft plastic scraper.

IMPORTANT: Do not use awire brush, metal scraper,
or abrasive cleaners to clean the bottom of the
cylinder head. Extensive damage to the cylinder head
may result. Wear safety glasses during cleaning.

Combustion Area

seat reconditioning equipment can also be used.
Keep all valves in order with their respective seat.

NOTE: Valve seat width and point of contact on the
valve face is very important for proper sealing. The
valve must contact the valve seat over the entire
circumference of the seat, and the seat must be the
proper width all the way around. If the seat is uneven,
compression leakage will result. If the seat is too
wide, seat pressure is reduced, causing carbon
accumulation and possible compression loss. If the
seat is too narrow, heat transfer from valve to seat is
reduced. The valve may overheat and warp, resulting
in burnt valves.

To o
Wide

Uneven

Good

To o
Narrow

VALVE SEAT
RECONDITIONING

Cylinder Head Reconditioning

NOTE: Polaris recommends that the work be done by

a local machine shop that specializes in this area.

NOTE: The cylinder head valve guides cannot be
replaced.

WARNING

Wear eye protection or a face shield during
cylinder head disassembly and reassembly.

Valve Seat Inspection

Inspect valve seat in cylinder head for pitting, burnt
spots, roughness, and uneven surface. If any of the
above conditions exist, the valve seat must be
reconditioned.

head must be replaced.

Follow the manufacturers instructions provided with
the valve seat cutters in the Cylinder Head
Reconditioning Kit (PN 2200634). Abrasive stone

If the valve seat is cracked the cylinder

1. Install pilot into valve guide.

2. Apply cutting oil to valve seat and cutter.

3. Place 46° cutter on the pilot and make a light cut.

4. Inspect the cut area of the seat:

G If the contact area is less than 75%

of the circumference of the seat,
rotate the pilot 180° and make
another light cut.

G If the cutter now contacts the uncut

portion of the seat, check the pilot.
Look for burrs, nicks, or runout. If the
pilot is bent it must be replaced.

3.23

ENGINE

VALVE SEAT RECONDITIONING CONT’D

G If the contact area of the cutter is in

the same place, the valve guide is
distorted from improper installation
and must be replaced. Be sure the
cylinder head is at the proper
temperature and replace the guide.

G If the contact area of the initial cut is

greater than 75%, continue to cut the
seat until all pits are removed and a
new seat surface is evident. NOTE:
Remove only the amount of material
necessary to repair the seat surface.

5. To check the contact area of the seat on the valve
face, applya thincoating of Prussian Bluet paste
to the valve seat. If using an interference angle
(46°) apply black permanent marker to the entire
valveface(A).

(A)

G If the seat is too narrow, widen using

the 45° cutter and re-check contact
point on the valve face and seat width
after each cut.

NOTE: When using an interference angle, the seat
contact point on the valve will be very narrow, and is
a normal condition. Look for an even and continuous
contact point all the way around the valve face. (B)

(B)

(A)

Proper Seat Contact On Valve Face

Bottom - 60°

Seat - 45°

To p - 3 0°

6. Insert valve into guide and tap valve lightly into
place a few times.

7. Remove valve and check where the Prussian
Bluet indicates seat contact on the valve face.
The valve seat should contact the middle of the
valve face or slightly above, and must be the
proper width.

G If the indicated seat contact is at the

top edge of the valve face and
contacts the margin area(B) it is too
high on the valve face. Use the 30°
cutter to lower the valve seat.

G If too low, use the 60° cutter to raise

the seat. When contact area is
centered on the valve face, measure
seat width.

G If the seat is too wide or uneven, use

both top and bottom cutters to
narrow the seat.

3.24

Seat
Width

Valve Seat Width:

Intake Std: .028I (.7 mm)

Limit: .055I (1.4 mm)

Exhaust Std: .039I (1.0 mm)

Limit: .071I (1.8 mm)

ENGINE

VALVE SEAT RECONDITIONING CONT”D

8. Clean all filings from the area with hot soapy
water, rinse, and dry with compressed air.

WARNING

Wear eye protection or a face shield when
working with compressed air during cylinder
head disassembly and reassembly.

9. Lubricate the valve guides with clean engine oil,
and apply oil or water based lapping compound to
the face of the valve. NOTE: Lapping is not
required with an interference angle valve job.

10. Insert the valve into its respective guide and lap
using a lapping tool or a section of fuel line
connected to the valve stem.

11. Rotate the valve rapidly back and forth until the
cut sounds smooth. Lift the valve slightly off of the
seat, rotate 1/4 turn, and repeat the lapping
process. Do this four to five times until the valve is
fully seated, and repeat process for the other
valve(s).

12. Thoroughly clean cylinder head and valves.

CYLINDER HEAD
REASSEMBL

NOTE: Assemble the valves one at a time to maintain

proper order.

1. Apply engine oil to valve guides and seats.

2. Install new valve seals on valve guides.

3. Coat valve stem with molybdenum disulfide
grease or 0W--40 Synthetic oil.

4. Install valve carefully with a rotating motion to
avoid damaging valve seal.

Y

5. Dip valve spring and retainer in clean engine oil
and install.

6. Place retainer on spring and install Valve Spring
Compressor (PU--45257). Install split keepers
with the gap even on both sides. NOTE: A small
parts magnet can aid in installation of the
keepers.

(PU-- 45257)

7. Repeat procedure for remaining valves. When all
valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the split
keepers. NOTE: To prevent damage to the valve
seals, do not compress the valve spring more
than necessary to install the keepers.

3.25

VALVE SEALING TEST

1. Clean and dry the combustion chamber area (A).
Refer to Page 3.23 for cleaning tips.

2. Pour a small amount of clean solvent onto the
intake port and check for leakage around each
intake valve. The valve seats should hold fluid
with no seepage.

3. Repeat for exhaust valves by pouring fluid into
exhaust port.

VALVE TRAIN EXPLODED VIEW

ENGINE

A

ROCKER ARMS

SPRING RETAINERS

SPRINGS

GUIDE SEALS

HEAD

VALVES

20--24 FT. LBS. (27--32.50 NM)

RETAINER LOCKS

PUSH RODS

HYDRAULIC LIFTERS

3.26

ENGINE

ENGINE HEAD REASSEMBLY

Before reassembly, clean the bolts and bolt holes with
Primer N (PN 2870585) to remove any debris. This
will ensure proper sealing when installing bolts and
new Loctitet.

1. Install the head gasket (A) on the cylinder (B).

A

B

2. Install cylinder head on cylinder.

3. Install headbolts (C). Torque bolts to 60-64 ft. lbs.
(81-87 Nm), following torque pattern on Page 3.9.

4. Lubricate push rods (D) and install into lifters.

D

5. Lubricate rockers (E) with engine oil.

E

C

Cylinder Head Bolt Torque:

60-64 ft. lbs. (81-87 Nm)

6. Verify pushrods are engaged in lifters.

7. Install rockers. Be sure that tab of fulcrum (F) is
seated in head stand-off. Torque bolts to 20-24 ft.
lbs. (27-33 Nm).

F

Rocker Arm Bolt Torque:

20-24 ft. lbs. (27-33 Nm)

3.27

ENGINE

ENGINE HEAD REASSEMBLY CONT’D

8. Install breather reed (G) into rocker cover (H).
Lightly apply black RTV sealant to the outer
edges of the breather reed. The reed has a tab
and will assemble one way only. Apply Loctitet
271 (PN 2871954) to the bolts. Torque the
breather bolts to 27-- 33 in. lbs. (3--4 Nm).

NOTE: When applying RTV, do not get any RTV
inside the reed assembly.

9. Place a new seal (I) into the bottom of the cover.
Be sure the seal is seated into the cover properly.

8.5-9.5 ft. lbs.

27--33 in.lbs.

(3--4 Nm)

G

(12-13 Nm)

H

I

11. Install thermostat (J). Apply Loctitet 271 (PN

2871954) to the bolts of the cover. Torque bolts to

8.5-9.5 ft. lbs. (12-13 Nm).

J

Thermostat Housing Bolt Torque:

8.5-9.5 ft. lbs. (12-13 Nm)

REMINDER: Before assembly, clean the bolts and

bolt holes with Primer N (PN 2870585) to remove any
debris. This will ensure proper sealing when installing
bolts and new Loctitet.

10. Install rocker cover. Apply Loctitet 271 (PN

2871954) to the bolts. Torque bolts to 8.5-9.5 ft.
lbs.12-13 Nm).

12. Apply pipe dope or Teflon tape to pipe threads of
temperature sender (K). Install and torque to
16-20 ft. lbs. (22-27 Nm).

K

Apply pipe dope or Teflon tape to threads.

Temperature Sender Torque:

16-20 ft. lbs. (22-27 Nm)

Rocker Cover Bolt Torque:

8.5-9.5 ft. lbs. (12-13 Nm)

3.28

ENGINE

CYLINDER REMOVAL

1. Follow engine disassembly procedures to
remove rocker cover and cylinder head.

2. Tap cylinder (A) lightly with a rubber mallet in the
reinforced areas only until loose.

3. Rock cylinder forward and backward while lifting it
from the crankcase, supporting pistons and
connecting rods. Support pistons with Piston
Support Block (PN 2870390).

A

4. Check the lifters for wear or scores.

5. Check the bottom end of lifter to make sure that it
has a slight convex.

6. If the bottom surface has wornflat, itmay be used
with the original camshaft only.

Inspect Hydraulic Lifter

NOTE: Lifters that are scored, worn, or if the bottom
is not smooth should be replaced with new lifters and
cam as an assembly. If replacing the lifters, the
camshaft should also be replaced.

VALVE LIFTER
REMOV

1. Remove the valve lifter’s by reaching into the
crankcase and pushing the lifter up through the
lifter bore by hand.

2. Thoroughly clean the lifters in cleaning solvent
and wipe them with a clean lint-free cloth.

3. Mark the lifters with a white pen if using the lifters
for reassembly. This will ensure that the lifters are
properly placed during engine reassembly.

AL/INSPECTION

Mark the Hydraulic Lifter

PISTON REMOVAL

1. Remove circlip (A). Mark the piston with a white
pen to ensure proper orientation (if reused) during
assembly.

Mark the piston

A

NOTE: If the pistons are to be reused, reassemble
the pistons in the same cylinder and direction from
which they were removed.

NOTE: New pistons are non--directional and can be
placed in either cylinder.

2. Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston

slightly

with a propane torch. CAUTION: Do not

3.29

ENGINE

apply heat to the piston rings. The ring may lose
radial tension.

3. Remove top compression ring:
*Using a piston ring pliers: Carefully expand ring

and lift it off the piston. CAUTION: Do not expand the
ring more than the amount necessary to remove it
from the piston, or the ring may break.

*Byhand: Placing both thumbs as shown, spread the
ring open and push up on the opposite side. Do not
scratch the ring lands.

b) Remove the expander.

Compression

Rings

Oil Ring

B

CYLINDER INSPECTION

1. Remove all gasket material from the cylinder
sealing surfaces.

2. Inspect the top of the cylinder (B) for warpage
using a straight edge (A) and feeler gauge (C).
Refer to Ill. 1 and Ill. 2.

4. Repeat procedure for second ring.

5. Remove the oil control ring.
The oil control ring is a three piece design consisting

of a top and bottom steel rail and a center expander
section. The top rail has a locating tab on the end
which fits into a notch (B) in the upper oil ring land of
the piston. To Remove:

a) Remove the top rail first followed by the bottom rail.

Ill.1

A

To p V ie w

B

Measure at different points
on the surface.

3.30

ENGINE

B

A

C

Ill.2

Cylinder Warpage.

.004s (0.1 mm) Max.

3. Inspect cylinder for wear, scratches, or damage.

1/2s Down From Top of Cylinder

Y

X

Y

X

Y

X

1/2s Up From Bottom

5. Record measurements. If cylinder is tapered or
out of round beyond .002, the cylinder must be
replaced.

Cylinder Taper

Limit: .002I (.05mm)Max.

Cylinder Out of Round

Limit: .002I (.05mm)Max.

4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure
in two different directions, front to back and side to
side, on three different levels (1/2s down from top,
in the middle, and 1/2s up from bottom).

Standard Bore Size (Both Cylinders):

Sportsman 700 : 3.1496I (80 mm)

Sportsman 600: 3.0018” (76.50 mm)

PISTON-TO-CYLINDER
CLEARANCE

Measure piston outside diameter at a point 5 mm up
from the bottom of the piston at a right angle to the
direction of the piston pin.

Subtract this measurement from the maximum
cylinder measurement obtained in Step 5.

3.31

5mm

Piston

ENGINE

2. Measure piston pin O.D. Replace piston and/or
piston pin if out of tolerance.

Piston Pin

Piston to Cylinder Clearance

600: .0022” r .00067” (.055

700: .0018” r .00063” (.041 r .016 mm)

Piston O.D.

600: 3.0096” r .00035I (76.445

700: 3.1477” r .00012I (79.954 r .003 mm)

.017 mm)

.009 mm)

PISTON/ROD INSPECTION

1. Measure piston pin bore.

Piston Pin Measurement Locations

Piston Pin O.D.

0.7874” -- .7872” (20 -- 19.995 mm)

3. Measure connecting rod small end ID.

Piston Pin Bore:

600: 0.00027” r 0.00019”

(0.007 r 0.005 mm)

700: 0.00059” r 0.0002”

(0.015 r 0.005 mm)

3.32

Connecting Rod Small End I.D.

.789” -- .78841”. (20.030 -- 20.015 mm)

4. Measure piston ring to groove clearance by
placing the ring in the ring land and measuring
with a thickness gauge. Replace piston and rings
if ring-to-groove clearance exceeds service
limits.

ENGINE

Piston

Ring

Piston Ring Installed Gap

600

Top Ring: 0.01181” r 0.00393”

(0.30 r 0.10 mm)

Second Ring Limit: 0.01476” r 0.00492”

(0.375 r 0.125 mm)

Oil Ring Limit: 0.00984” r .00393”

(0.25 r 0.10 mm)

700

Feeler Gauge

Piston Ring-to-Ring Groove Clearance

Top Ring Limit: 0.0019” r 0.00069”

(0.0475 r 0.0175 mm)

Second Ring Limit : 0.0017” r 0.00049”

(0.0425 r .0125 mm)

PISTON RING INSTALLED GAP

1. Place each piston ring (A) inside cylinder (B)
using piston to push ring squarely into place as
shown. (See next page)

C

Top Ring Limit: 0.01083” r 0.00295”

(0.275 r 0.075 mm)

Second Ring Limit: 0.0177” r 0.00394”

(0.45 r 0.10 mm)

Oil Ring Limit: 0.0177” r .00984”

(0.45 r 0.25 mm)

NOTE: Ring should be installed with the mark on the

ring facing upward.

2. Measure installed gap with a feeler gauge (C) at
both the top and bottom of the cylinder.
REMINDER: A difference in end gap indicates
cylinder taper. The cylinder should be measured
for excessive taper and out of round.

3. If the bottom installed gap measurement exceeds
the service limit, replace the rings. If ring gap is
smaller than the specified limit, file ring ends until
gap is within specified range.

NOTE: Always check piston ring installed gap after
re-boring a cylinder or when installing new rings. A
re-bored cylinder should always be scrubbed
thoroughly with hot soapy water, rinsed, and dried
completely. Wipe cylinder bore with oil immediately to
remove residue and prevent rust.

B

A

25-50mm

STARTER DRIVE/BENDIX
REMOV

1. Remove stator housing bolts and remove
housing.

2. Remove the flywheel nut and washer. Install
Flywheel Puller (PN 2871043) and remove
flywheel. CAUTION: Do not thread the puller
bolts into the flywheel more than 1/4s or stator
coils may be damaged.

3. Remove starter bendix assembly (A). Note the
thrust washers located on both sides of the
bendix.

AL/INSPECTION

3.33

B

4. Inspect the thrust washer for wear or damage and
replace if necessary.

ENGINE

C

FLYWHEEL/STATOR

5. After the bendix is removed, tap on the starter
assembly with a soft faced mallet to loosen the
starter from the crankcase.

B

6. Inspect gear teeth on starter drive (B). Replace
starter drive if gear teeth are cracked, worn, or
broken.

7. Inspect the bendix bushing (C) in the mag cover
for wear. Replace as needed.

REMOV

1. Remove stator housing bolts and remove
housing.

2. Remove flywheel nut and washer.

3. Install Flywheel Puller (PN 2871043) and remove
flywheel (A). CAUTION: Do not thread the puller
bolts into the flywheel more than 1/4² or stator
coils may be damaged. See next page.

AL/INSPECTION

3.34

ENGINE

2871043

A

4. Use caution when removing the wire holddown
(B), trigger coil (C), and the stator assembly (D).

Do not tap or bump the gear /stator housing
cover or the stator. This could cause the seal

around the gear/stator housing cover and the
crankcase to break, causing a leak.

E

C

B

lock, so Loctitet is not needed on the new bolts.
Torque bolts to 9--10 ft. lbs. (12--14 Nm).

3. Install the starter bendix if removed.

4. Install woodruff key. Install the flywheel. Install

the flywheel washer and nut. Apply Loctitet 242
(PN 2871949) onto the threads. Torque the
flywheel nut to 80--100 ft.lbs. (109--136 Nm)

Flywheel Nut Torque:

80--100 ft. lbs. (108.50--135.60 Nm)

D

5. Remove the bendix (E) if necessary.

FLYWHEEL/STATOR
INSTALLA

NOTE: Before assembly, clean the bolts and bolt

holes with Primer N (PN 2870585) to remove any
debris. This will ensure proper sealing when installing
bolts and new Loctitet.

1. Carefully install the stator and trigger coil to the
gear/stator housing cover. Do not tap on the
stator or the gear stator housing cover. This
may cause a leak in between the gear/stator
housing cover and the crankcase.

2. Properly place the stator wires under the wire
holddown and install the bolts. Apply
LocTitet242 (PN 2871949) onto the bolts.
Inspect the bolts, if new bolts are needed, replace
them with new bolts. The new bolts contain patch

TION

5. Inspect the mating surface around the gear/stator
housing cover and the crankcase for oil seepage.
If there is seepage between the mating surfaces,
then the gear/stator housing cover must be
resealed. Clean the gearcase surfaces and
reseal with a new gasket. Refer to the Lower
Engine Disassembly section and the Lower
Engine Assembly section for details. lnspect the
areas pointed out in the photograph for possible
oil seepage.

FLYWHEEL/STATOR INSTALLATION

6. Install stator housing with new O-rings. Apply
LocTitet271 (PN 2871954) onto the bolts.

3.35

Torque the bolts to 8.50--9.50 ft. lbs. (12--13 Nm).

Stator Housing Bolt Torque:

8.50-9.50 ft. lbs. (12-13 Nm)

ENGINE

E

D

C

3. Remove flywheel nut and washer.

4. Install Flywheel Puller (PN 2871043) and remove
flywheel (F). CAUTION: Do not thread the puller
bolts into the flywheel more than 1/4² or stator
coils may be damaged.

ENGINE LOWER
DISASSEMBL

1. Remove the stator cover (A) and water pump
cover (B).

A

2. Remove the nylok nut (C), washer (D), and water
pump impeller (E). Remove part of the water
pump seal behind the impeller.

Y/INSPECTION

B

2871043

F

5. Remove the starter bendix (G), wire holddown
plate (H), and the woodruff key (I) from the
crankshaft. The stator does not have to be
removed at this point.

I

3.36

G

H

ENGINE

ENGINE DISASSEMBLY CONT’D

6. Remove the gear/stator housing bolts and
remove the gear/stator housing cover (J) and
gasket from the crankcase. Be sure to catch the
excess oil from the crankcase.

J

7. Note the positions of the gears in the photo.

Water/oil pump Gear

Camshaft Gear

camshaft gear (K), water/oil pump gear (L),
crankshaft gear (M), or counterbalance gear (N).

Cam Gear Removal

9. Use the Cam Gear Tooth Alignment Tool
(PU--45497--2) (O) to align the cam split gear
assembly. With the split gear aligned, remove the
bolt and cam gear assembly.

PU--45497--2

NOTE: Install the Cam Gear Tooth Alignment Tool

(PU--45497--2) into the assembly hole counter
clockwise from the timing mark as shown.

O

Crank Gear

8. Use a white pen to accent the timing marks on the
gears. This will ensure proper gear alignment and
timing during reassembly of the gears.

Timing Marks

M

NOTE: It is recommended to replace all of the gears
if any of the following gears are to be replaced:

Counterbalance Gear

K

L

N

Cam Gear Alignment Tool:

(PU--45497--2)

Cam Gear Disassembly

10. Inspect the cam gear teeth and check to make
sure there is spring tension offsetting the teeth
between the two gears. If there is no tension,
check the springs inside of the cam gear
assembly.

3 Loaded Spring

11. The cam gear assembly contains three loaded
springs. To open the cam gear assembly:

3.37

G Place the cam gear on a flat surface

with the timing mark side facing up.

G While holding both gears together,

lightly work a small flathead
screwdriver between the two gears.

G Remove the top gear. The springs

should stay in place.

CAUTION:

WEAR SAFETY GLASSES AT ALL TIMES. USE
CAUTION WHEN WORKING WITH THE TOP
GEAR. THE SPRINGS COULD CAUSE INJURY OR
BECOME LOST SHOULD THEY POP OUT.

12. Remove all three springs using oneof the tapered
pins from the Tapered Pins (PU--45497--1).

ENGINE

Inspect Teeth & Tabs

Replace Three Springs

Cam Gear Reassembly

15. Install the new springs into the grooves of the cam
gear.

PU--45497--1PU--45497--1

13. With a white marking pen, accent the timing mark
on the gear that contains the springs.

Accent the Timing Marks

Insert Springs

16. Insert the pointed dowels from the Tapered Pins
(PU--45497--1) into the cam gear.

14. Inspect the gear teeth and the three tabs on the
gears for wear. It is recommended to replace the
springs whenever the gear is taken apart.

3.38

PU--45497--1

ENGINE

CAM GEAR REASSEMBLY CONT’D

To assemble:

G Hold the spring with one finger.
G Start the pointed end of the tapered

pin into the cam gear hole and slowly
push the dowel through the hole until
the end of the dowel is almost flush
with the spring.

G Perform this procedure with all three

tapered pins.

G Do not push the pins too far

through or the springs will pop out.

NOTE: Do not remove the tapered pins at this time.

17. Note in the photograph that the Tapered Pins
(PU--45497--1) are below flush with end of the
springs. This helps to align the three gear tabs
during the next step.

Align Timing Marks

19. Once the gears are pressed together, firmly hold
the gears together with one hand. Carefully
remove the Tapered Pins (PU--45497--1)by
pulling them out one at a time with the other hand.

PU--45497--1

Cam Gear Spring Installation Tool Kit:

(PU--45497)

Tapered Pins:

(PU--45497--1)

Cam Gear Tooth Align Tool:

(PU--45497--2)

18. Line up the two gears using the timing marks and
the three gear tabs that were referenced earlier.
Push the gears back together, using both hands
and hold securely.

20. After the tapered pins are removed, be sure the
cam gear assembly is held together tightly. Place
the cam gear assembly on a flat surface. Use the
Cam Gear Tooth Alignment Tool (PU--45497--2)
(R) to align the teeth of the cam gears, as shown
in the picture.

NOTE: Install the Cam Gear Alignment Tool
(PU--45497--2) into one assembly hole counter
clockwise from the timing mark.

3.39

PU--45497--2

NOTE: For ease of installing the Cam Gear

Alignment Tool (PU--45497--2) (R), use a twisting
motion when pushing down on the tool.

ENGINE DISASSEMBLY CONT’D

21. To remove the balance shaft gear, the flat side of
the camshaft (P) must face the balance shaft
gear. To rotate the camshaft, use the Cam
Spanner Wrench (PU--45498) to rotate the
camshaft so the flat side of the camshaft faces the
balance shaft gear.

ENGINE

2871043

23. Inspect the crankshaft gear (Q) for broken or worn
teeth. If the crankshaft gear does not need to
be replaced, it does not need to beremoved.If
the crankshaft gear is damaged, remove the
crankshaft gear with the Flywheel Puller (PN

2871043).

Q

PU--45498

P

NOTE: This Cam Spanner Wrench (PU--45498)is
only needed to rotate the camshaft when the entire
valve train is assembled. If the rocker arms are
removed, the cam--shaft can be turned by hand.

22. Remove the bolt and nut from the balance shaft
gear. Try to remove the balance shaft gear. If the
gear does not come off manually, use the
Flywheel Puller (PN 2871043) to remove the
balance shaft gear.

24. Install the two puller bolts (R). Tighten the puller
bolts up so that the bolts are at equal length.

R

25. Install the Flywheel Puller (PN 2871043) and
remove the flywheel, if needed.

3.40

ENGINE

2871043

Water/Oil Pump Removal/Disassembly

26. Rotate the water/oil pump gear (S), so that all four
bolts are visible though the gear. Remove the four
bolts with a hex wrench. Pull out the pump.

Mark Rotors

NOTE: If replacing the old rotors, new replacement
rotors will fit into the old oil/water pump housing.

28. Remove the oil pressure relief. The oil pressure
relief consists of a bolt, washer, spring, and valve
(dowel). Inspect the the valve (dowel) for signs of
possible obstructions. Use compressed air to
blow out any debris.

S

27. Inspect the oil pump rotors for wear. Mark the
rotors with a white pen to ensure upon
reassembly that the correct sides of the rotors are
installed and mesh with the same edges as
previously installed.

29. Reinstall the valve (dowel tapered end first).
Install the spring, washer, and bolt. Torque the
bolt to 20--24 ft. lbs. (27--33 Nm).

20--24 ft.lbs.

(27--33 Nm)

3.41

NOTE: Be sure to place the tapered end of the valve
(dowel) in first. If the valve is installed incorrectly, oil
pressure and oil priming problems will occur.

DISASSEMBLY OF WATER/OIL PUMP SHAFT

ENGINE

Press out gear

WARNING

during this procedure. Heat resistant gloves,
clothing and eyewear are required.

30. Heat oil/water pump drive housing (T). Remove
from shaft using a soft hammer.

31. Remove the gear shaft from the water/oil pump
housing.

Wear appropriate safety gear

T

Heat Housing

33. Press bearing from shaft. Replace the old
bearing with a new bearing during assembly.

Bearing

32. Press gear from shaft.

3.42

WATER/OIL PUMP REASSEMBLY

34. Press shaft into new gear. NOTE: Boss side of
gear faces out.

ENGINE

Gear Boss

35. Apply Loctitet 609 to the pump shaft to help

secure the bearing. Press on a new bearing.

clothing and eyewear are required.

37. Remove thrust plate (U).

U

38. Remove PTO end engine mount. Remove
crankcase bolts. Tap on the reinforced areas on
the cases using soft hammer. Carefully separate
the two crankcase halves.

36. Warm the housing. Apply Loctitet to bearing

outer race. Slide housing securely onto shaft and
bearing.

Warm the Housing

WARNING

during this procedure. Heat resistant gloves,

Wear appropriate safety gear

Separate the
crankcase
halves

NOTE: Only remove the oil baffle if the baffle is
damaged. When removing the oil baffle bolts, use a
heat gun to heat the bolts and loosen the Loctitet.
This will prevent any possible damage to the bolts or
to the crankcase casting.

3.43

ENGINE LOWER DISASSEMBLY/INSPECTION
CONT’D

39. Remove and clean oil pick up (V) and oil baffle
weldment (W).

W

ENGINE

V

40. Remove balance shaft and crankshaft.

41. Remove and inspect crankshaft main journal
bearings for abnormal wear. It is recommended

to replace the bearings anytime the engine is
disassembled.

CAMSHAFT INSPECTION

1. Thoroughly clean the cam shaft.

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

Lobe height

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

3.44

Cam Lobe Height (Intake & Exhaust):

Std: 0 .2170” ± 0.00236”

(5.5118 ± 0.060 mm)

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

ENGINE

Journal O.D.’s

B

A

Camshaft Journal O.D. :

A. (Mag): 1.654” ± .00039” (42 ± .010 mm)

B. (Ctr.): 1.634” ± .00039” (41.50 ± .010 mm)

C. (PTO): 1.614” ± .00039” (41 ± .010 mm)

5. Measure ID of camshaft journal bores.

C

ENGINE LOWER
REASSEMBL

WARNING: After any reassembly or
rebuild, the engine must be primed using
the Oil Priming Adapter (PU--45778) and
a 3/4--full oil filter before initial start--up.
Follow Steps 44--45 in this section to
properly prime the engine and to help aid
proper engine break in.

NOTE: Before assembly, clean the bolts and bolt

holes with Primer N (PN 2870585) to remove any
debris. This will ensure proper sealing when installing
bolts and new Loctitet.

1. Install oil pick up (A), if removed. Apply LocTitet
271 (PN 2871954). Torque bolt to 4.5-5.5 ft. lbs.
(6-7 Nm).

Y

B

Camshaft Journal Bore I.D.:

(Mag): 1.656” ± 0.00039” (42.07 ± 0.010 mm)

(Ctr.) 1.637” ± 0.00039” (41.58 ± 0.010 mm)

(PTO) 1.617” ± 0.00039” (41.07 ± 0.010 mm)

6. Calculate oil clearance by subtracting journal
O.D.’s from journal bore I.D.’s. Compare to
specifications.

Camshaft Oil Clearance:

Std: 0.00118” (.0299mm)

Limit: .0039” (.10 mm)

NOTE: Replace camshaft if damaged or if any part

is worn past the service limit.

NOTE: Replace engine block if camshaft journal
bores are damaged or worn excessively.

A

2. Install oil baffle weldment (B). Apply LocTitet

262 (PN 2871952). Torque bolts to 4.5-5.5 ft. lbs.
(6-7 Nm).

Oil Baffle Weldment Bolt Torque:

4.5-5.5 ft. lbs. (6-7 Nm)

Oil Pick Up Bolt Torque:

4.5-5.5 ft. lbs. (6-7 Nm)

3. Install the balance shaft. Inspect balance shaft
clearance (C) in both gearcase halves. Rotate

3.45

balance shaft to ensure that there is clearance
between it and oil baffle weldment.

NOTE: Always install new balance shaft bearings.

C

4. Apply Starter Drive Grease (PN 2871460)tocam
journals and balanceshaft bearing surfaces of the
MAG case halve. Install cam and balance shafts.

ENGINE

D

6. Apply Crankcase Sealant (PN 2871557)toPTO
gearcase halve.

E

5. Install crankshaft assembly and apply engine oil
to crank pins and rods (D). Apply Starter Drive
Grease (PN 2871460) to the main journals and
bearings.

NOTE: Do not apply sealant to cam relief hole (E).

7. Assemble the crankcase halves. Apply LocTitet

242 (PN 2871949). Torque bolts to 20-24 ft. lbs.
(27--33 Nm) following torque pattern on Page 3.2.

Crankcase Bolt Torque:

20-24 ft. lbs. (27-33 Nm)

8. Grease cam lobes and valve lifters with Polaris
Starter Drive Grease (PN 2871460).

3.46

ENGINE

Grease Cam Lobes

Grease Lifters

9. Lubricate lifters with engine oil and install in the
original order as removed in disassembly. Apply
Lubriplate to the ends of the lifters.

NOTE: Always replace the camshaft and lifters as
a set.

NOTE: Apply a small amount of grease to the cylinder

gasket to help hold it in place during cylinder
assembly. DO NOT USE SILICONE.

12. Install piston assemblies into cylinder aligning the
piston pin holes, to ensure proper alignment of the
pistons to the connecting rods upon assembly.
Partially install the piston pins into the pistons.

10. Lubricate connecting rods with engine oil.

11. Install new cylinder gasket on cylinder.

Cylinder Installation

NOTE: To help align the pistons, slide a rod that is
close to the same diameter as the wrist pin holes to
properly align them in the cylinder.

13. Position cylinder and piston assemblies onto the
connecting rods and push the piston pins through
the piston and pushrod.

3.47

Push in Piston Pins

ENGINE

NOTE: New bolts have patch lock on the threads and

do not require Loctitet.

G

14. Install the piston pin keepers (F). The pin keeper
ends should be installed at the 12 O’clock
position.

Place Pin Keeper (F)

in 12 O’clock position

NOTE: While installing in piston pins, cover all engine
passages. The clip could fall into the engine during
installation.

16. Assemble rotors as marked when disassembled.
Use a cleaner to remove the marks previously
made on the rotors.

Line Up Marks

17. Apply starter grease , lubriplate, or oil to the rotors
on the oil pump shaft.

NOTE: The application of oil or lubriplate aids in
priming the oil pump during initial engine start up.

Lubricate Rotors

15. Install camshaft thrust plate (G) with new bolts.
Torque bolts to 4.5-5.5 ft. lbs. (6-7 Nm).

3.48

F

18. Align the bolt holes and install oil pump assembly
into crankcase. Rotate the rotors in the housing
during installation, as this checks for binding if new
rotors are used.