Polaris SPORTSMAN 700 EFI User Manual

2007 SPORTSMAN 450 / 500 EFI / 500 X2 EFI

SERVICE MANUAL

FOREWORD

This service manual is designed prim arily for use by ce rtified Polaris Mas ter 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 in this 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 pro cedur es require the use of special tools. Use only the proper tools as specified.

Comments or suggestions about this manual may be d irected to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.

2007 Sportsman 450 / 500 EFI / 500 X2 EFI Service Manual PN 9920560

© Copyright 2006 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 component s, some minor discrep ancies may result between t he actual vehicle and the inf ormation presented in t his

publication. Depictions and/or procedures in this publ ication are intended f or reference use only. No liability can be accepted for omission s or inaccuracies. Any r eprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS

Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle.

CAUTION

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE:

NOTE provides key information by clarifying instructions.

IMPORTANT:

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or

by contacting the nearest Polaris dealer.

GENERAL

MAINTENENCE

ENGINE

FUEL SYSTEM

BODY / SUSPENSION

CLUTCH

TRANSMISSION

FINAL DRIVE

BRAKES

ELECTRICAL

INTERNATIONAL

NOTES

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

ENGINE DESIGNATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

VEHICLE IDENTIFICATION NUMBER (VIN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

TRANSMISSION I.D. LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

ENGINE AND MACHINE SERIAL NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

SPORTSMAN ‘DELUXE’ AND ‘STANDARD’ MODEL COMPONENT COMPARISON . .1.4 SPORTSMAN X2 ‘DELUXE’ AND ‘STANDARD’ MODEL COMPONENT COMPARISON1.5

2007 SPORTSMAN 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

MODEL NUMBER: A07MH46AA, AZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6

2007 SPORTSMAN 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

MODEL NUMBER: A07MH50AX, AY, AZ / A07MN50AQ, AF / A07MH50FC. . . . . . . . .1.8

2007 SPORTSMAN X-2 500 EFI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

MODEL NUMBER: A07TH50AU, AZ / A07TN50AF, AQ / A07TH50EA . . . . . . . . . . . .1.10

MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14

GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15

1.1

GENERAL INFORMATION

MODEL NUMBER INFORMATION

Model Number

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

A07 MN 50 AU

Engine Designation Numbers

EH50PLE - Single Cylinder, Liquid Cooled,4 Stroke, Electric Start

V ehicle Identification Number (VIN)

World

Mfg. ID

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A M N 5 0 A * 7 P 0 0 0 0 0 0

Vehicle Descriptor

}

Vehicle Identifier



Body Style

Transmission I.d. Location

Engine And Machine Serial Numbers

The machine model number and serial number are important for vehicle identification. Be sure to refer to the engine model number and serial number whenever corresponding about an engine. 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.

Engine

Powertrain

Emissions

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

Model

Year

Check Digit

Plant No

Individual Serial Number

* This could be either

a number or a letter

The machine serial number is stamped on the lower left side of the frame tube (B).

1.2

Publications

GENERAL INFORMATION

Table 1-1: Publications

Year Model Model No.

A07MN50A

2007 Sportsman 500 EFI

2007 Sportsman X2 500 EFI

2007 Sportsman 450 EFI A07MH46A 9920629 9920557 N/A

2007

Sportsman X2 500 EFI

Quadricycle

A07MH50A (Standard)

A07MH50F (Standard Intl’)

A07TN50A

A07TH50A (Standard)

A07MH46E 9920650 9920899 N/A

(Deluxe)

Owner's

Manual PN

9920364 9920365 N/A

9920632 9920902 N/A

Parts

Manual PN

Paint Codes

Table 1-2: Paint Codes

PAINTED PART

Sportsman Frame Black 9440 P-067

COLOR

DESCRIPTION

DITZLER NUMBER

Replacement Keys

Parts

Micro Fiche PN

POLARIS NUMBER

Replacement keys can be made from the original key (Phoenix excluded). 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.

Table 1-3: Key Numbers

Series # Part Number

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

Key Cover PN 5433534

1.3

GENERAL INFORMATION

Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison

For Model Year 2007, a Sportsman ‘Deluxe’ and ‘Standard’ model were offered. Use the following table as a guide:

SPORTSMAN ‘DELUXE’ MODEL Item Location SPORTSMAN ‘STANDARD’ MODEL

Winch 1 No Winch

PXT Tires 2 Titan Tires

PVT w/EBS 3 Non-EBS (X2 excluded)

Rear Work Lights 4 No Work Lights

Front Drive w/ Active Descent Control (ADC) 5 No Active Descent Control (ADC)

Speed Sensor Wiring for ADC 6 No Sensor Wiring Change

Rear Rack Extension 7 No Rack Extension

Cast Aluminum Wheels 8 Steel Wheels

Single Exhaust 9 Single Exhaust

Wire Harness w/ Active Descent Control (ADC) 10 Standard Wire Harness

PDM w/ Active Descent Control (ADC) 10 Standard PDM

Deluxe Model Pictured

1.4

GENERAL INFORMATION

Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison

For Model Year 2007, an X2 ‘Deluxe’ and ‘Standard’ model were offered. Use the following table as a guide:

X2 ‘DELUXE’ MODEL Item Location X2 ‘STANDARD’ MODEL

Winch 1 No Winch

Rear Work Lights 2 No Work Lights

Front Drive w/ Active Descent Control (ADC) 3 No Active Descent Control (ADC)

Cast Aluminum Wheels 4 Steel Wheels

Standard Model Pictured

1.5

GENERAL INFORMATION

2007 SPORTSMAN 450

Model Number: A07MH46AA, AZ Engine Model: EH46PLE

Table 1-4: Sportsman 450 General

Specifications

Category Dimension / Capacity Length 83 in./211 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 50.5 in./128.3 cm Ground Clearance 11 in./27.94 cm Dry Weight 715 lbs./324 kg Gross Vehicle Weight 1210 lbs./549 kg Front Rack Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Body Style Spirit Hitch Tongue Capacity 120 lbs./54.4 kg

1.6

GENERAL INFORMATION

Table 1-5: Sportsman 450

ENGINE

Platform Fuji Single Cylinder Engine Model Number EH46PL E010 Engine Displacement 455cc Number of Cylinders 1 Bore & Stroke (mm) 87.9 x 75 mm Compression Ratio 9.8:1 Compression Pressure 50-90 psi Engine Idle Speed

Engine Max Operating Rpm Cooling System / Capacity Liquid - 2.25 qt / 2.1 ltr

Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 ltr Exhaust System Single Pipe USFS Approved

Fuel System

Carburetor Mikuni BST 34mm Main Jet 167.5 Pilot Jet 42.5 Jet Needle / Clip Position 4IB33 - 3 Needle Jet P-6M (829)

Pilot Screw 2 3/4 Turns Out (initial) Pilot Air Jet 1.3 Float Height Fuel Delivery Fuel Pump

Fuel Capacity / Requirement 4.25 gal US / 19.9 liters

Electrical

Alternator Output 260 w @ 3000 RPM

Voltage Regulator 3-phase - PDM

Lights : Pod 50 watts Grill 2 x 37 watts Brake 26.9 watts Tail 8.26 watts Worklight 13 watts Indicator 1 watt

Operating RPM Ignition System DC/CDI Ignition Ignition Timing Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery / Amp Hr Maintenance-Free / 12 Amp Hr.

Circuit Protection Solid State - PDM

Starting Electric / Recoil Instrument Cluster Analog Speedo w/ LCD

6000 RPM

W/Compression Release

1100

 50 RPM

6000 Rpm

13mm 

87 Octane (minimum)

 200 Rpm

1 (.51  0.40")

or 89 Oxygenated

°2° BTDC @ 5000 RPM

Table 1-6: Sportsman 450

Drivetrain

Transmission Type Drumshift - H/L/N/R/P Transmission Capacity 32 oz. / 948 ml Front Gearcase Capacity 8.97 oz. / 265 ml Gear Ratio : Low

Rev High Front Drive

Clutch Type PVT Non-EBS Belt 3211077

23.91:1

16.30:1

10.49:1

3.82:1

Steering / Suspension

Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Independent -

w/ 2

" Coil-over shock

Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11 in. / 27.94 cm Shock Preload Adjustment

Front / Rear Turning Radius 65 in./165.10 cm unloaded Toe Out 0-1/16 in / .0 - .159 mm

Front -Non Adjustable.

Rear - Ratchet Style- Std.

Wheels / Brakes

Wheel / Tire Size / Pattern - Front Steel 25x8 - 12 / 4-156 Wheel / Tire Size / Pattern - Rear Steel 25x11 - 12 / 4-156 Recommended Air Pressure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Single Hydraulic Disc Brake Fluid DOT - approved only

Table 1-7: Sportsman 450 Jetting

AMBIENT TEMPERATURE

M e t e r s

(Feet)

Altitude

0-1800

(0-6000)

1800-3700

(6000-12000)

Below 40

Below 5 ° C

° F

+40 to +80 ° F

+5 to +28 ° C

175 167.5

162.5 157.5

Table 1-8: Sportsman 450 Clutching

M e t e r s

(Feet)

Altitude

0-1800

(0-6000)

1800-3700

(6000-12000)

Shift

Weight

10 WH

(5630710)

20-40

(5631356)

Drive Clutch Spring

Blu/Grey

(7042202)

Blu/Grey

(7042202)

Driven Clutch Spring

Black

(7041782)

Black

(7041782)

Driven-

Helix

40 2+2

(5131446)

40 2+2

(5131446)

1.7

GENERAL INFORMATION

2007 SPORTSMAN 500 EFI

Model Number: A07MH50AX, AY, AZ, AQ / A07MN50AL, AF / A07MH50FC

(Standard Models) (Deluxe Models) (International)

Engine Model: EH50PLE

Table 1-9: Sportsman 500 EFI General

Specifications

Category Dimension / Capacity Length 83 in./211 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 50.5 in./128.3 cm Ground Clearance 11.25 in./28.6 cm Dry Weight 715 lbs./324 kg Gross Vehicle Weight 1200 lbs./544 kg Front Rack Capacity 90 lbs./40.8 kg Rear Box Capacity 180 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Body Style Spirit Hitch Tongue Capacity 120 lbs./54.4 kg

1.8

GENERAL INFORMATION

Table 1-10: Sportsman 500 EFI

ENGINE

Platform Fuji Single Cylinder Engine Model Number EH50PL E210 Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio

Compression Pressure 50-90 psi W/Compression Release Engine Idle Speed

Engine Max Operating Rpm Cooling System / Capacity Liquid - 2.5 qt / 2.4 ltr Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 ltr Exhaust System Single Pipe USFS Approved

Fuel System

Fuel System Electronic Fuel Injection (EFI) Fuel Pump (in tank assembly) 25L per hr. at 39 psi Fuel Filter(s) 10 micron in-line

30 micron in tank Fuel Injector(s) Visteon EFI Controller Visteon VP5U1U-12A650-AA Fuel Capacity / Requirement 6 gal US / 22.7 liters

Electrical

Alternator Output 350 w @ 6000 RPM Lights : Pod 50 watts Grill 2 x 37 watts Brake 2 x 8.26 watts Tail 2 x 26.9 watts Worklight 2 x 13 watts Indicator 1 watt

Operating RPM Ignition System DC/CDI Ignition

Ignition Timing Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery / Amp Hr Lead Acid / 30 Amp Hr. Circuit Breakers Fan 12 amp / Switched Power 10

Starting Electric / Recoil Instrument Cluster Analog Speedo w/ LCD

6000 RPM

amp / Fuel Pump 10 amp / ECU

15 amp / Ignition Coil 10 amp /

Accessory Power 10 amp /

10.2:1

1100

 200 RPM

6000 Rpm

87 Octane (minimum)

 200 Rpm

(not replaceable)

or 89 Oxygenated

° BTDC @ 1150 RPM

Lights 20 Amp

Table 1-11: Sportsman 500 EFI

Drivetrain

Transmission Type Drumshift - H/L/N/R/P Transmission Capacity 32 oz. / 948 ml Front Gearcase Capacity- CH 8.97 / 265 ml Front Gearcase Capacity- ADC 9.3 / 275 ml Gear Ratio : Low

Rev High Front Drive

Clutch Type PVT (Standard Models)

PVT w/EBS (Deluxe Models)

Belt 3211113 EBS

23.91:1

21.74:1

10.57:1

3.82:1

3211077 Non-EBS

Steering / Suspension

Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Independent -

Coil - over shock Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11 in. / 27.94 cm Shock Preload Adjustment

Front / Rear Turning Radius 65 in./165.10 cm unloaded Toe Out 0-1/16 in / .0 - .159 mm

Front -Non Adjustable.

Rear - Ratchet Style- Std.

Wheels / Brakes

Wheel/Tire Size / Pattern - Front 26 x 8 - 12 / 4-156 Wheel/Tire Size / Pattern - Rear 26 x 11 - 12 / 4-156 Recommended Air Pressure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Single Hydraulic Disc Brake Fluid DOT - approved only

Table 1-12: Sportsman 500 EFI Clutching

Altitude Shift

M e t e r s

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

Weight

10 WH

(5630710)

10 RH

(5630709)

Drive Clutch Spring

Blu/Green (7041157)

Driven Clutch Spring

White/Yel (7041635)

Helix*

*No

Adjustment

EBS

(5131674)

EBS

(5131674)

1.9

GENERAL INFORMATION

2007 SPORTSMAN X-2 500 EFI

Model Number: A07TH50AU, AZ, AQ / A07TN50AF / A07TH50EA

(Standard Models) (Deluxe Model) (Intl’ Quadricycle)

Engine Model: EH50PLE

Table 1-13: Sportsman X-2 500 EFI General

Specifications

Category Dimension / Capacity Length 93 in./236 cm Width 48 in./122 cm Height 48 in./122 cm Wheel Base 57 in./145 cm Ground Clearance 11 in./28 cm Dry Weight 798 lbs./362 kg Gross Vehicle Weight 1500 lbs./680 kg Front Rack Capacity 90 lbs./40.8 kg Rear Box Capacity 400 lbs./81.6 kg Towing Capacity 1225 lbs./555.6 kg Body Style Spirit Hitch Tongue Capacity 120 lbs./54.4 kg

Rear box capacity and tongue weight

not to exceed 400 lbs./181kg

1.10

GENERAL INFORMATION

Table 1-14: Sportsman X2 500 EFI

ENGINE

Platform Fuji Single Cylinder Engine Model Number EH50PL E210 Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 60-90 psi Engine Idle Speed

Engine Max Operating Rpm Cooling System / Capacity Liquid - 2.5 qt / 2.4 ltr

Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 ltr Exhaust System Single Pipe USFS Approved

Fuel System

Fuel System Electronic Fuel Injection (EFI) Fuel Pump (in tank assembly) 25L per hr. at 39 psi Fuel Filter(s) 10 micron in-line

30 micron in tank Fuel Injector(s) Visteon EFI Controller Visteon VP5U1U-12A650-AA Fuel Capacity / Requirement 6 gal US / 22.7 liters

Electrical

Alternator Output 350 w @ 6000 RPM Lights : Pod 50 watts Grill 2 x 37 watts Brake 2 x 8.26 watts Tail 2 x 26.9 watts Worklight 2 x 13 watts Indicator 1 watt Operating RPM

Ignition System DC/CDI Ignition Ignition Timing

Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery / Amp Hr Lead Acid / 30 Amp Hr. Circuit Breakers Fan 12 amp / Switched Power 10

Starting Electric / Recoil Instrument Cluster Analog Speedo w/ LCD

6000 RPM

amp / Fuel Pump 10 amp / ECU

15 amp / Ignition Coil 10 amp /

W/Compression Release

1150

 50 RPM

6000 Rpm

87 Octane (minimum)

 200 Rpm

(not replaceable)

or 89 Oxygenated

° BTDC @ 1150 RPM

Accessory Power 10 amp /

Lights 20 Amp

Table 1-15: Sportsman X2 500 EFI

Drivetrain

Transmission Type Drumshift - H/L/N/Rev/Park Transmission Capacity 32 oz. / 948 ml Front Gearcase Capacity- CH 8.97 / 265 ml Front Gearcase Capacity- ADC 9.3 / 275 ml Gear Ratio : Low

Rev High Front Drive

Clutch Type PVT w/EBS Belt 3211113

23.91:1

21.74:1

10.57:1

3.82:1

Steering / Suspension

Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Independent -

Coil - over shock Rear Travel 8.75 in. / 22.2 cm Ground Clearance 11 in. / 28 cm Shock Preload Adjustment

Front / Rear Turning Radius 82 in./208 cm unlocked Toe Out 0-1/16 in / .0 - .159 mm

Front -Non Adjustable.

Rear - Ratchet Style- Std.

Wheels / Brakes

Wheel Size / Pattern - Front Steel 12x6 / 4-156 Wheel Size / Pattern - Rear Steel 12x8 / 4-156 Front Tire Size 25x8-12 Rear Tire Size 25x11-12 Recommended Air Pressure Front & Rear - 5 psi Brake - Front Dual Hydraulic Disc Brake - Rear Dual Hydraulic Disc

Table 1-16: Sportsman X2 500 EFI

Altitude Shift

M e t e r s

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

Weight

10 WH

(5630710)

10 RH

(5630709)

Drive Clutch Spring

Blu/Green (7041157)

Driven Clutch Spring

White/Yel (7041635)

Helix*

*No

Adjustment

EBS

(5131674)

EBS

(5131674)

1.11

GENERAL INFORMATION

MISC. NUMBERS/CHARTS

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.

1.12

GENERAL INFORMATION

SAE Tap Drill Sizes

Thread Size/ Drill Size Thread Size / Drill Size

#0-80 3/64 1/2-13 27/64 #1-64 53 1/2-20 29/64 #1-72 53 9/16-12 31/64 #2-56 51 9/16-18 33/64 #2-64 50 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 45 3/4-10 21/32 #4-40 43 3/4-16 11/16 #4-48 42 7/8-9 49/64 #5-40 38 7/8-14 13/16 #5-44 37 1-8 7/8 #6-32 36 1-12 59/64 #6-40 33 1 1/8-7 63/64 #8-32 29 1 1/8-12 1 3/64 #8-36 29 1 1/4-7 1 7/64 #10-24 24 1 1/4-12 1 11/64 #10-32 21 1 1/2-6 1 11/32 #12-24 17 1 1/2-12 1 27/64 #12-28 4.6mm 1 3/4-5 1 9/16 1/4-20 7 1 3/4-12 1 43/64 1/4-28 3 2-4 1/2 1 25/32 5/16-18 F 2-12 1 59/64 5/16-24 I 2 1/4-4 1/2 2 1/32 3/8-16 O 2 1/2-4 2 1/4 3/8-24 Q 2 3/4-4 2 1/2 7/16-14 U 3-4 2 3/4 7/16-20 25/64

Metric Tap Drill Sizes

Tap Size Drill Size

3x.50 #39 0.0995 3/32 3x.60 3/32 0.0937 3/32 4x.70 #30 0.1285 1/8 4x.75 1/8 0.125 1/8 5x.80 #19 0.166 11/64 5x.90 #20 0.161 5/32 6x1.00 #9 0.196 13/64 7x1.00 16/64 0.234 15/64 8x1.00 J 0.277 9/32 8x1.25 17/64 0.265 17/64 9x1.00 5/16 0.3125 5/16 9x1.25 5/16 0.3125 5/16 10x1.25 11/32 0.3437 11/32 10x1.50 R 0.339 11/32 11x1.50 3/8 0.375 3/8 12x1.50 13/32 0.406 13/32 12x1.75 13/32 0.406 13/32

Decimal Equivalent

Nearest Fraction

Decimal Equivalents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

27/64 . . . . . . . . . . .. . . . . . . .4219 . . 11 mm =.4331"

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

. . . . . . . .8281

1.13

GENERAL INFORMATION

Conversion Table

Unit of Measure Multiplied by Converts to

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

(3.14)xR

x H (height) = Cylinder Volume

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

 9 - 40 = °C

1.14

Glossary Of Terms

GENERAL INFORMATION

ABDC: After bottom dead center. ACV: Alternating current voltage.

ADC: Active Descent Control. Alternator: Electrical generator producing voltage alternating current.

ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8, or 1 cm). Polaris measures chain length in number of pitches. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between

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

DCV: Direct current voltage. 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).

Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Ft. lb. / Foot Pound: 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. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. kg/cm: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter. Left Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a m agnetic field, a voltage will be generated in the windings.

Mechanical energy is converted to electrical energy in the stator.

mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040,. Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. PDM: Power Distribution Module. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. qt.: Quart/quarts. RPM:

Revolutions per minute.

Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Resistance: In the mechanical sense, friction or load. In the electrical 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. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylin der wall.

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

Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.

1.15

GENERAL INFORMATION

NOTES

1.16

MAINTENANCE

CHAPTER 2

MAINTENANCE

MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4

LUBRICATION / FLUIDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

SPORTSMAN COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 .7

SPORTSMAN X2 COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . .2.9

POLARIS LUBRICANT SYMBOL IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

LUBRICATION COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

FRONT GEARCASE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

TRANSMISSION LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

ADC DIFFERENTIAL HYDRAULIC CIRCUIT FLUID CHANGE. . . . . . . . . . . . . . . . . . .2.14

VEHICLE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

SHIFT LINK ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

THROTTLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL ADJUSTMENT . . . . . . .2.15

FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

SPARK PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

ACTIVE DESCENT CONTROL (ADC) RESERVOIR LEVEL. . . . . . . . . . . . . . . . . . . . . 2.18

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

LIQUID COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

COOLANT STRENGTH / TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

RADIATOR/GRILL SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

RADIATOR COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

AIR FILTER/PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

AIR BOX SEDIMENT TUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

BREATHER FILTER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

BREATHER HOSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

RECOIL HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

ENGINE OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

OIL PUMP PRIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

INTAKE VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

EXHAUST VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

TIE ROD END/STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

WHEEL ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

TOE ALIGNMENT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

BRAKE SYSTEM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29

BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

HOSE/FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

2.1

MAINTENANCE

AUXILIARY BRAKE TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

AUXILIARY BRAKE ADJUSTMENT (HYDRAULIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

SUSPENSION SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

FRONT SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31

WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32

WHEEL REMOVAL FRONT OR REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33

STORAGE COMPARTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

WINCH OPERATION (IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34

ATV CLEANING & STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36

MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38

2.2

MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer.

NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a

qualified dealer perform these operatio ns.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can ind icate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determin e th e cau se or se e you r dea ler.

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance : = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an

authorized Polaris dealer.

= SEVERE USE ITEM --If vehicle is subjected to severe use, decrease interval by 50%

(Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm use, prolonged low speed - heavy load operation or e xte nded idle. M ore preven tat ive maint ena nce is r equire d under these conditions. Fluid changes, cable and chassis lubrication are required more frequently. For engine oil, short trip cold weather riding also constitutes se vere use. Pay specia l attention to oil lev el. A rising oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.)

E= Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING

Improperly performing the procedures marked with a

 could result in component failure and lead to

serious injury or death. Have an authorized Polaris dealer perform these services.

2.3

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(KM)

 Steering - Pre-Ride -

Front-suspension - Pre-Ride -



Rear-suspension - Pre-Ride -



Tires - Pre-Ride Brake fluid level - Pre-Ride -



Brake lever travel - Pre-Ride -



Brake systems - Pre-Ride Wheels /fasteners - Pre-Ride Frame fasteners - Pre-Ride -



Engine oil level - Pre-Ride -

Passenger Seat Lock Out - Pre-Ride - Verify Seat is secured Dump Box Operation - Pre-Ride - Verify Box is latched



Air filter, pre-filter - Daily - Inspect; clean often



Air box sediment tube - Daily - Drain deposits when visible

Coolant - Daily -

Headlamp/tail lamp - Daily Air filter,



main element

Recoil housing - Weekly -



Brake pad wear 10 H Monthly 60 (100) Inspect periodically



Battery 20 H Monthly 125 (200) Check terminals; clean; test Front gearcase oil (if



equipped) Middle gearcase oil (if



equipped) Rear gearcase oil



(if equipped) Transmission oil 25 H Monthly 155 (250) Inspect level; change yearly



- Weekly - Inspect; replace as needed

25 H Monthly 155 (250) Inspect level; change yearly

Make adjustments as needed.

Check level daily, change coolant every 2 years Check operation; apply dielectric grease if replacing

Drain water as needed, check often if operating in wet conditions

Remarks

Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.

2.4

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(KM)

Engine breather



filter (if equipped)

Engine oil change



(break-in)

General



lubrication Shift Linkage 50 H 6 M 310 (500) Inspect, lubricate, adjust

 Steering 50 H 6 M 310 (500) Lubricate

Front suspension 50 H 6 M 310 (500) Lubricate



Rear suspension 50 H 6 M 310 (500) Lubricate





Throttle Cable/ETC

Switch Air intake ducts/

flange Drive belt 50 H 6 M 310 (500) Inspect; adjust; replace as needed Cooling system (if applicable) Engine oil change



Oil filter change 100 H 6 M 620 (1000) Replace with oil change



Oil tank vent hose 100 H 12 M 620 (1000) Inspect routing, condition



Valve clearance 100 H 12 M 620 (1000) Inspect; adjust

25 H Monthly 155 (250) Inspect; replace if necessary

25 H 1 M 155 (250)

50 H 3 M 310 (500)

50 H 6 M 310 (500) 50 H 6 M 310 (500)

50 H 6 M 310 (500)

100 H 6 M 620 (1000)

Perform a break-in oil change at one month

Lubricate all grease fittings, pivots, cables, etc.

Inspect; adjust; lubricate; replace if necessary Inspect ducts for proper sealing/air leaks

Inspect coolant strength seasonally; pressure test system yearly Perform a break-in oil change at 25 hours/one month

Remarks

Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)

Have an authorized Polaris dealer perform these services.

2.5

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)



Fuel system 100 H 12M



Fuel Filter 100 H 12M

Radiator



(if applicable) Cooling hoses



(if applicable) Engine mounts 100 H 12M



Exhaust muffler / pipe



Spark plug 100 H 12M



Ignition Timing 100 H 12M

Wiring 100 H 12M



Clutches (drive



and driven) Front wheel



bearings

 Brake fluid 200 H 24M

Spark arrestor 300 H 36M

 Toe adjustment - Inspect periodically; adjust when part s are replaced



Auxiliary brake - Inspect daily; adjust as needed



Headlight aim - Adjust as needed

100 H 12M

620

(1000)

620

(1000)

620

(1000)

620

(1000)

620

(1000)

620

(1000)

620

(1000)

620

(1000)

620

(1000)

620

(1000)

1000

(1600)

1240

(2000)

1860

(3000)

Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every two years

Replace yearly

Inspect; clean external surfaces

Inspect for leaks

Inspect

Inspect; replace as needed

Inspect Inspect for wear, routing, security; apply dielectric

grease to connectors subjected to water, mud, etc. Inspect; clean; replace worn parts

Inspect; replace as needed

Change every two years

Clean out

Remarks

Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)

Have an authorized Polaris dealer perform these services.

2.6

LUBRICATION / FLUIDS

SPORTSMAN Component Locations

MAINTENANCE

(Deluxe)

(Sportsman Only)

2.7

MAINTENANCE

SPORTSMAN X2 Component locations

Brake Fluid Reservoir

Brake Lever

Worklight

Instrument Cluster

(Speedometer)

AWD/Turf Switch

Diagnostic Port (under access panel)

Front St orage Compartment & Rack

Front Demand

Drive Unit

(Behind Radiator)

Light Control & Run Switch

Oil Dipstick

PVT Cover

Gear Shifter

Reverse Override

Gas Cap

Throttle

Ignition/Key

Rear Dump Box / Passenger Area

Battery (Under Tank)

2.8

Transmission

Rear Drive CV Shafts

Right Side View

Muffler

Auxiliary Brake

Front Prop Shaft

(Between Transmission and Front Gearcase)

Front Drive CV Shafts

MAINTENANCE

Polaris Lubricants, Maintenance and Service Products

Table 2-1:

PART

NUMBER

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol) 2871281

2871844

2871567

Gearcase / Transmission Lubricants 2876251 Demand Drive L T Premium Hub Fluid 3234438 Polaris ADC Hydraulic Fluid

2873602

2873603

2876160

2872276 2870465 Oil Pump for 1 Gallon Jug

2871322

2871423 2871460 Starter Drive Grease (12 count) 2871515

2871551 2871312 Grease Gun Kit

2871329

Engine Oil (Quart) Premium Synthetic

Engine Oil (Gallon) Premium Synthetic

Engine Oil (16 Gallon) Premium 4

Premium Synthetic AGL Gearcase Lube

Premium ATV Angle Drive Fluid

Grease / Specialized Lubricants

DESCRIPTION

0W-40 (4-cycle) (12 count)

0W-40 (4-cycle) (4 count)

Synthetic 0W-40 (4-cycle)

(12 oz. bottle) (12 count)

(1 Gal. bottle) (4 count)

(32 oz.) (12 count)

(2.5 Gal.) (2 count)

Premium All Season Grease

(3 oz. cartridge) (24 count)

Premium All Season Grease (14 oz. cartridge) (10 count)

Premium U-Joint Lube

(3 oz.) (24 Count)

Premium U-Joint Lube

(14 oz.) (10 count)

Dielectric Grease (Nyogel



Table 2-1:

PART

NUMBER

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

Additives / Sealants / Thread Locking Agents / Misc.

2874275 2871956

2871950

2871951

2871953

2871557

2871326 2870652 Fuel Stabilizer (16 oz.) (12 count) 2871957

2871958 2870990 DOT 3 Brake Fluid (12 count)

2871557 Crankcase Sealant, 3 Bond 1215 (5 oz.)

DESCRIPTION

Coolant

Loctite

Primer N, Aerosol

Loctite

Thread Sealant 565

(50 ml.) (6 count)

Loctite

 Threadlock 242

(6 ml.) (12 count)

Loctite

 Threadlock 262

(50 ml.) (10 count)

Loctite

 Threadlock 271

(6 ml.) (12 count)

3-Bond 1215

Premium Carbon Clean

(12 oz.) (12 count)

Black RTV Silicone Sealer

(3 oz. tube ) (12 count)

Black RTV Silicone Sealer

(11 oz. cartridge) (12 count)

Sealant

(5 oz.)

2.9

MAINTENANCE

Polaris Lubricant Symbol Identification

NOTE: The symbols used are for quick reference in identifying which lubricant/grease to use on each component.

Polaris DOT Brake Fluid

Polaris ADC

Hydraulic Fluid

Polaris Synthetic

0W/40

Polaris ATV Angle Drive Fluid

Polaris Synthetic AGL

Gearcase Lube

Polaris 60/40

Coolant

Polaris Demand Drive

LT Hub Fluid

Pre-ride / Daily Inspection

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

• Verify seat lock-out operation

• Verify box lock-out operation

• Tires - check condition and pressures

• Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank

• All brakes - check operation and adjustment (includes auxiliary brake)

• Throttle -check for free operation

• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches

• Engine stop switch - check for proper function

• Wheels - check for loose wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins

• Air cleaner element - check for dirt or water; clean or replace

• Steering - check for free operation, noting any unusual looseness in any area

• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners

Polaris U-Joint Lube

Polaris All

Season Grease

• Engine coolant - check for proper level at the recovery bottle

• ADC Fluid Level - check for proper level

2.10

Lubrication Components

1. Engine Oil

3. Front Gearcase

2. Transmission Fluid

5. Brake Fluid

8. Front Propshaft

MAINTENANCE

4. Rear Gearcase

6. Front A-Arm

7. Rear A-Arm

1. Engine Oil Polaris 0W/40

2. Transmission

3A. 3B.

4. Rear Gearcase ATV Angle Drive Fluid

5. Brake Fluid Polaris Dot 3 Brake Fluid

6. Front A-Arm Polaris All Season Grease Locate fitting and grease.

7. Rear A-Arm Polaris All Season Grease Locate fitting and grease

5. Front Propshaft

* More often under severe use, such as operated in water or under severe loads. 1 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) 2 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) 3 Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or

Mobilegrease Special

TEM LUBE METHOD

Check dipstick and add to

Front Gearcase

ADC Fluid

Polaris AGL Synthetic

Gearcase Lube

Demand Drive LT

Premium

Polaris ADC Hydraulic

Polaris U-Joint Grease

Add lube to bottom fill hole.

Drain completely . Add l ube to

specified quantity.

Drain completely . Add l ube to

specified quantity.

Fill master cylinder reservoir

Locate fitting and grease.

proper level.

to indicated level

FREQUENCY*

Change after 1st month, 6 months, or 100

hours thereafter; Change more often (25-50

hours) in extremely dirty conditions, or short

trip cold weather operation.

Change annually

Gearcase - Change annually

ADC - Change fluid every 2 years

Change annually

As required, change fluid every 2 years

Semi-annually Semi-annually Semi-annually

n n n

2.11

MAINTENANCE

Front Gearcase Lubrication

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

• Be sure vehicle is level before proceeding and in PARK

• Check vent hose to be sure it is routed properly and unobstructed

• The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid.

FRONT GEARCASE

Fill Plug 8-10 ft.lbs. (11-14 Nm)

Drain Plug

11 ft.lbs. (15 Nm)

To Change Gearcase Lubricant:

Drain Plug

1. Remove gearcase drain plug (A) 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 (A) using a new sealing washer (B). Torque to specification.

Specified Lubricant:

Demand Drive LT Premium Hub Fluid

(PN 2876251)

CH Gearcase Capacity: 8.97 oz. (265 ml.) ADC Gearcase Capacity: 9.3 oz. (275 ml.)

= T

Fill Plug Torque: 8-10 ft.lbs. (11-14 Nm)

Drain Plug Torque: 11 ft.lbs. (15 Nm)

To Check the Lubricant Level:

The front and rear gearcase lubricant level cannot be checked with a dipstick. The gearcase must be drained and re-filled with the proper amount of lubricant or be filled to the bottom of the fill plug hole threads. Refer to procedures.

Fill Plug

Left Side View

3. Remove fill plug. Inspect the O-ring.

4. Fill with th e recommended fluid amount or to the bottom of the fill plug hole threads. (See Illustration below).

Front Gearcase

Fill - Demand Drive LT

Premium

Hub Fluid

2.12

5. Install / torque fill plug and check for leaks.

MAINTENANCE

Transmission Lubrication

Transmission - Specified Lubricant:

Polaris AGL Gearcase Lubricant

(Gallon - PN 2873603) (12 oz. - PN 2873602)

Transmission - Capacity:

32 oz. (948 ml)

= T

Transmission Drain / Fill Plug Torque:

20-25 ft.lbs. (27-34 Nm)

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

To check the level:

1. Be sure vehicle is level before proceeding

2. Clean around fill plug area.

3. Remove fill plug located on the left side of the ATV.

4. Fluid should be fil led to bottom of fill plug hole threads. Add the proper lubricant as required to bring level into operating range as shown.

To change lubricant:

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

2. Clean around the drain plug and remove the drain plug and wipe the magnetic end clean to remove all accumulated metallic filings.

Drain Plug

3. After the oil h as drained completel y, install a new sealing washer (if installed) and install the drain plug. Torque to specification.

4. Add the proper lubricant through the fill plug hole until the oil level is to the bottom of the fill plug hole threads. Do not overfill.

Oil Fill Plug

Oil Fill LevelBottom Fill Plug

Hole Threads

5. Install the check plug and torque it to specification

Oil Fill Plug

Oil Fill LevelBottom Fill Plug

Hole Threads

5. Check for leaks.

2.13

MAINTENANCE

ADC Differential Hydraulic Circuit Fluid Change

1. Make sure vehicle is parked on flat ground and allowed to sit at least 30 minutes prior to bleeding hydraulic circuit.

2. Thoroughly clean area around and on remote reservoir and bleeder valves.

3. Remove reservoir cap and diaphragm assembly.

4. Make sure hydraulic oil inside reservoir is free of debris. If any debris is found, use clean rag or suction device to remove from the reservoir.

NOTE: Debris in reservoir may block porting and produce inadequate bleeding of the system. Decreased performance may be encountered with inadequate bleed of the hydraulic circuit.

5. Begin the bleeding process by filli ng reservoir to ‘MAX’ line with clean Polaris ADC hyrdraulic fluid. (AW ISO 10 hydraulic fluid equivalent).

6. Locate bleeder valves found on either side of differential and remove the protective caps.

7. Turn bleeder valves counter-clockwise to loosen. Loosen bleeder screw slowly, allowing oil and any trapped air to flow out of fitting.

IMPORTANT: Do not allow hydraulic fluid in reservoir to drain below minimum fill line. Close bleeder valve before oil level falls below minimum fill line. Refilling empty reservoir will result in air pockets becoming trapped.

VEHICLE INSPECTION

Shift Link Rod Inspection

NOTE: Shift rod is preset at time of manufacturer.

1. Inspect shift link tie rod ends and replace if worn or damaged. Lubricate pivot points with a light aerosol lubricant or grease if desired.

Shift Mount

Shifter

Shift Link Rod

NOTE: If empty reservoir is encountered, filling of fluid is still possible. Verify air is not trapped before proceeding with step 7.

8. Continue steps 6 -8 on both sides in sequence until clean fluid is seen when bleeding occurs.

9. Re-torque both bleeder valves to specification and reinstall cover caps.

= T

Bleeder Valve Torque:

80 in. lbs. (9 Nm)

10. Fill reservoir with to a level midway between ‘MAX’ and ‘MIN’ fill lines. Verify no debris is found in reservoir oil.

11. Replace reservoir cap securely and wipe clean any residue.

2.14

MAINTENANCE

Throttle Inspection

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

1. Place the gear selector in Park.

2. Set parking brake.

3. Start the engine and let it idle.

4. Turn handlebars from full right to full left. If idle speed increases at 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.

ETC Cover

Removal Sequence

III. 1

Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment

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

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

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

Boot

Adjuster Sleeve

4. Turn adjuster until specified freeplay is achieved at thumb lever. (see illustration). After making adjustments, quickly actuate the thumb lever several times and reverify freeplay.

Lock Nut

Boot

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 show n.

NOTE: Do not attempt to remove cover until all latch points are released.

Direction of Travel

1/16-1/8” Freeplay

= In. / mm.

Throttle Freeplay:

.0625 - .1250" (1.58 - 3.17mm)

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

6. 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 and in good condition, repeat adjustment procedure

2.15

MAINTENANCE

Fuel System

WARNING

* Gasoline is extremely flammable and explosive

under certain conditions. * EFI components are under high pressure. Verify system pressure has been relieved before disassembly. * Never drain the fuel system when the engine is hot . Sev ere burn s may res u lt * Do not overfill the tank. The tank is at full capacity when the fuel reaches the bottom of the filler neck. Leave room for expansion of fuel. * Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time. * Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. * If you get gasoline in your eyes or if you should swallow gasoline, seek medical attention immediately. * If you spill gasoline on your skin or clothing, immediately wash with soap and water and change clothing. * Always stop the engine and refuel outdoors or in a well ventilated area.Keep away from open flames and electrical components when removing fuel filter.

• Always stop the engine and refuel outdoors or in a well ventilated area.

Fuel Lines

EFI Example

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

2. Be sure fuel lines are routed properly, the connectors latched and the lines secured with cable ties.

CAUTION

Make sure lines are not kinked or pinched

3. Replace all fuel lines every two years.

NOTE: See Chapter 4 for fuel line routing diagram.

Vent Lines

Check fuel tank, oil tank, crankcase, 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.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If you get gasoline in your eyes or if you swallow gasoline, seek medical attention immediately.

• If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.

• 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.

• Never drain the system when the engine is hot.

Severe burns may result.

2.16

CAUTION

Make sure lines are not kinked or pinched

MAINTENANCE

Fuel Filter

The fuel filter should be replaced in accordance with the Periodic Maintenance Chart.

EFI Example

1. Locate filter at the front of the ATV. NOTE: Remove

access panels if necessary.

2. Remove fuel lines from filter.

3. Install new filter onto fuel lines with arrow pointed in direction of fuel flow.

4. Install clamps on fu el line (if required).

5. Turn ignition to “ON”.

6. Start engine and inspect for leaks.

Compression Test

NOTE: 450/500 4-Stroke engines are equipped with an

automatic decompressor. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about 60-90 psi during a compression test.

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 a decompressor malfunction, or worn or damaged exhaust cam lobes. Inspect camshaft and automatic decompression mechanism if compression is abnormally high.

A cylinder leakage test is the best indication of engine condition on models with automatic decompression. 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 60-90 PSI

Cylinder Leakage

Service Limit: 10%

(Inspect for cause if leakage exceeds 10%)

Engine Mounts

Inspect rubber engine mounts (A) for cracks or damage. Check engine fasteners and ensure they are tight.

2.17

MAINTENANCE

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.

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.

Spark Plug Gap

Active Descent Control (ADC) Reservoir Level

The Active Descent Control reservoir (DELUXE Models Only) is located by the radiator fill cap. Check the level and verify it is between the ‘MAX’ and ‘MIN’ lines. Add only Polaris ADC fluid when required.

Battery Maintenance

Complete battery servicing information for both conventinoal and sealed batteries can be found in Chapter 10 of this manual.

.036” (0.9 mm)

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.

= T

Recommended Spark Plug

Refer to the Specifications page in

Chapter 1 for spark plug type.

Spark Plug Torque: 14 Ft. Lbs. (19 Nm)

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.

NOTE: Expected battery shelf life is 6-8 months depending on storage conditions. As a general rule before placing the battery into service, check the battery condition and charge accordingly.

2.18

MAINTENANCE

New Batteries: Batteries must be fully charged before use or battery life can be reduced by 10-30% of full potential. Charge battery for 3-5 hours at a current equivalent of 1/10 of the battery’s rated amp/ hour capacity (i.e. 12amp hr x .10 = 1.2 amp charging). Do not use the alternator to charge a new battery.

Liquid Cooling System Overview

The engine coolant level is controlled 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) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.

Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels often during the break-in period.

Overheating of engine could occur if air is not fully purged from system.

Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water.

Coolant Strength / Type

Cooling System Hoses

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

2. Check tightness of all hose clamps.

CAUTION

Do not over-tighten hose clamps at radiator,

or radiator fitting may distort,

causing a restriction to coolant flow.

Radiator hose clamp torque is 36 in. lbs. (4 Nm).

T est the strength of the coolant using an antifreeze hydrometer.

Antifreeze Hydrometer

• A 50/50 or 60/40 mixture of antifreeze and distilled water will provide the optimum cooling, corrosion protection, and antifreeze protection.

• Do not use tap water, straight antifreeze, or straight water in the system. Tap water contains minerals and impurities which build up in the system.

• Straight water or antifreeze may cause the system to freeze, corrode, or overheat.

Polaris 60/40 Anti-Freeze/ Coolant

(PN 2871323)

Radiator/Grill Screen

1. Check radiator (A) air passages for restrictions or damage . Check and clean the radiator screen (B).

2. Carefully straighten any bent radiator fins.

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

2.19

MAINTENANCE

Cooling System Pressure Test

Refer to Chapter 3 for pressure test procedure.

Coolant Level Inspection

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

Recovery Bottle

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

1. Remove reservoir cap. Inner splash cap vent hole must be clear and open.

2. Fill reservoir to upper ma rk with Polaris Premium 60/40 Anti Freeze / Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.

3. Reinstall cap.

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

Remove Cover

Radiator Cap

To access the radiator pressure cap:

1. Open the front cargo storage.

2. Remove the inside cover over the radiator cap.

Air Filter/Pre-Filter Service

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 cleaned before 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: When

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

3. Remove clips (A ) from air box cover and remove cover. Inspect the gasket. It should adhere tightly to the cover and seal all the way around.

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

Radiator Coolant Level Inspection

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 radia to r sh ou ld be inspected and coolant added if necessary.

WARNING

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

2.20

4. Loosen clamp and remove air filter assembly.

Cover

Pre-Filter

Gasket

Main Element

Proper Filter Placement

Filter Support

Air Box

MAINTENANCE

Main Filter

Carb Boot

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.

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

Filter Clamp

Front

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.

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.

3. Reinstall drain plug.

Sediment Tube

Drain Plug

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.

2.21

MAINTENANCE

Breather Filter Inspection

Four-cycle A TV 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 can be installed in either direction.

Typical Breather Filter Location

In-Line Breather Filter Location A

Breather Hose

Recoil Housing

Recoil Drain

• Drain the housing periodically to remove moisture.

• Drain the recoil housing after operating the ATV in very wet conditions. This should also be done before storing the ATV. The drain screw is located at the bottom of the recoil housing. Remove the screw with a 10 mm wrench. Reinstall screw once housing has been drained.

1. Be sure breather line is routed properly and secured in

place. CAUTION: Make sure lines are not kinked or pinched.

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.

• CAUTION: Make sure the manual start handle (B) is fully seated on the recoil housing, especially when travelling in wet areas. If it is not sealed properly, water may enter the recoil housing and damage components.

• Water will enter the recoil housing if the starter handle (B) is disengaged from the rope guide when under water.

• After travelling in wet areas the recoil housing and starter should always be drained completely by removing the recoil.

• Do not open the crankcase drain unless the engine has ingested water. Some engine oil will be lost if crankcase drain is opened.

• If recoil handle (B) seal has been damaged, the handle should be replaced.

2.22

MAINTENANCE

Engine Oil Level

The oil tank is located on the left side of the vehicle. To check the oil level:

1. Set machine on a level surface.

2. Clean the area around the dip stick.

3. Start and run engine for 20-30 seconds. This will return oil to its true level in the oil tank.

4. Stop engine, remove dipstick (A) and wipe dry with a clean cloth.

5. Reinstall dipstick, screw the dipstick into place.

NOTE: The dipstick must be screwed completely in to ensure accurate measurement.

ADD 8 OZ.

Maintain Oil Level In Normal range

Screw Dipstick in completely to check

NORMAL

FULL

Oil and Filter Change

Oil Filter Torque:

Turn by hand until filter gasket

contacts sealing surface, then

turn an additional 1/2 turn

Oil Filter Wrench:

(PV-43527)

Oil Tank Screen Fitting Torque:

25 ft-lb (34Nm)

Recommended Engine Oil:

Polaris Premium 4 All Season

Synthetic, 0W-40

WARNING

Personal injury can occur when handling used oil. Hot oil can cause burns or skin damage.

NOTICE: Care must be taken to ensure that the fluids are contained. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembly of any component containing fluids.

1. Place vehicle on a level surface.

2. Clean area around drain plug (A) at bottom of oil tank.

3. Run engine two to three minutes until the engine is warm.

4. After two or three minutes stop the engine.

6. Remove dipstick and check to see that the oil level is in the normal range. The oil should be between the top line and the bottom line on the dipstick. Add oil as indicated by the level on the dipstick. Do not overfill.

NOTE: Rising oil level between checks in cool weather driving, can indicate moisture collecting in the oil reservoir. If the oil level is over the full mark, change the oil.

2.23

MAINTENANCE

5. Place a drain pan beneath oil tank and remove the drain plug

(A). CAUTION: Oil m ay be hot. Do not allow hot oil to come into contact with skin as serious burns may result.

Reference mark

6. Allow oil to drain completely.

7. Replace sealing washer (B) on drain plug (A).

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

8. Reinstall the drain plug (A) and torqu e it to sp ecification.

= T

Oil Tank Drain Plug Torque:

14 ft. lbs. (19 Nm)

14. Install oil hose (E) on fitting (C) and re-install clamp (D).

15. Place shop towels beneath oil filter. Use Oil Filter Wrench

(PV-43527), turn filter counterclockwise to remove.

Oil Filter

16. Using a clean dry cloth, clean filter sealing surface on the crankcase.

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

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

19. Approximately 1 cup of engine oil will remain in the crankcase. To drain, remove drain plug found on lower right side of crankcase.

Crankcase Drain Plug Torque:

14 ft. lbs. (19 Nm)

9. Loosen clamp (D).

10. Remove oil hose (E) from screen fitting (C) on bottom of oil tank.

11. Remove screen fitting (C) and clean the screen.

12. Apply Loctite™ thread sealant 505 or an equivalent pipe thread sealant or PTFE sealant tape to clean, oil free threads of fitting (C).

13. Install screen fitting (C) and rotate a minimum of 2 1/2 turns (clockwise) into the tank threads. Then rotate the screen fitting clockwise until the nipple of the screen fitting aligns with the reference marking on the tank.

CAUTION

Maximum torque for the screen fitting

is 25 ft-lb (34Nm), do not over tighten.

NOTE: Maximum torque for the screen fitting is 25 ft-lb (34Nm), do not over tighte n.

Engine Sump Drain

Engine Sump Drain Plug- Bottom View

NOTE: The sealing surfaces on the drain plug and

crankcase should be clean and free of burrs, nicks or scratches.

20. Reinstall drain plug and torque to specification.

21. Remove dipstick and fill tank with 2 quarts (1.9 L) of Polaris Premium 4 Synthetic Oil.

22. Place gear selector in Park and set parking brake.

NOTE: Clamp or pinch off the vent line 2” from the oil tank as shown in the Oil Pump Priming Procedure for th e 450/500 engine.

2.24

MAINTENANCE

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

24. Dispose of used filter and oil properly.

Oil Pump Priming Procedure

NOTE: This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.

1. Clamp or pinch off vent line (A) approximately 2” from oil tank to avoid the end of oil tank vent fi tting, and the vent line’s pressure relief slit

Slit

(A)

Valve Clearance

Inspect and adjust valve clearance while the engine is cold and the piston positioned at Top Dead Center (TDC) on compression stroke.

1. Remove the seat.

2. Remove body panels and fu el tank as necessary to gain access to valve cover.

3. Remove the spark plu g high tension lead and remove the spark plug. CAUTION: Place a clean shop towel into the spark plug cavity to prevent dirt from entering.

4. Remove rocker cover bolts, cover and gasket.

NOTE: It may be necessary to tap cover lightly with a soft-faced hammer to loosen it from the cylinder head.

5. Remove timing inspection plug from recoil housing.

CAUTION

Failure to position the crankshaft at TDC on compression stroke will result in improper valve adjustment.

Sprocket alignment pin facing up

2. Run engine at IDLE for 10-20 seconds.

3. Remove the vent line clamp. The oil pump wil l now be

properly primed and ready for field operation. Note: If the

system is primed properly you should hear some air release. If you do not, the system has not primed. Repeat the process if necessary.

(A) Vent Hose to Air Box

Oil Lines To Engine

Crankshaft-to-Camshaft Centerline

6. Rotate engine slowly with recoil rope, watching the intake valve(s) open and close.

NOTE: At this point watch the camshaft sprocket locating pin and slowly rotate engine until locating pin is facing upward, directly in line with the crankshaft to camshaft center line as shown. The camshaft lobes should be pointing downward.

2.25

MAINTENANCE

7. Verify accurate TDC positioning by observing the “T” mark aligned with the pointer in the timing inspection hole. In this position there should be clearance on all valves.

Intake Valve Clearance Adjustment

1. Insert a .006" (.15mm) feeler gauge between end of intake valve stem and clearance adjuster screw.

2. Using a 10 mm wrench and a screwdriver, loosen adjuster lock nut and turn adjusting screw until there is a slight drag on the feeler gauge.

3. Hold adjuster screw and tighten adjuster lock nut securely.

4. Re-check the valve clearance.

5. Repeat adjustment procedure if necessary until clearance is correct with locknut secured.

6. Repeat this step for the other intake valve.

INTAKE VALVE CLEARANCE

1. Insert a .006" (.15mm) feeler gauge between end of exhaust valve stem and adjuster screw(s).

2. Loosen locknut(s) and turn adjuster screw(s) until there is a slight drag on feeler gauge(s). The V alve/Clutch Adjuster Tool (PA-44689) can be used to adjust the engines valves.

NOTE: Both feeler gauges should remain inserted during adjustment of each valve.

EXHAUST VALVE CLEARANCE

.006” (.15 mm)

3. When clearance is correct, hold adjuster screw and tighten locknut securely.

4. Re-check the valve clearance.

5. Repeat adjustment procedure if necessary until clearance is correct with locknut secured.

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.

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.

.006” (.15 mm)

Exhaust Valve Clearance Adjustment

Feeler gauge for both valves

NOTE: The exhaust valves share a common rocker arm, and must be adjusted using two feeler gauges.

WARNING

Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering com ponent repair and adjustment be performed by a n authorized

MSD-certified technician when replacing worn or

damaged steering parts.

Use only genuine Polaris replacement parts.

2.26

MAINTENANCE

Tie Rod End/Steering Inspection

• To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement.

• Repeat inspection for inner tie rod end on steering post.

• Replace any worn steering components. Steering should move freely through entire range of travel without binding.

• 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.

• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause ( possible loose wheel nuts or loose front hub components).

Wheel Alignment

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 center section can be used as an indicator of whether the handlebars are straight. The center section should always point straight back from the steering post.

3. Place a chalk mark on the center line of the front tires approximately 10" (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 the tires 180 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 1/8" to 1/4" (.3 to.6 cm) toe out. This means the measurement at the front of the tire (A) is 1/8" to 1/4" (.3 to .6 cm) wider than the measurement at the rear (B)

III. 1

by moving vehicle forward or

Check for Loose Wheel or Hub

• 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.

Chalk Line Measurement “A”

(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)

Measurement “B”

= In. / mm.

Wheel Toe-Out:

2.27

MAINTENANCE

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 Jam Nut

III. 2

Incorrectly Tightened Jam Nut

Exhaust Pipe

WARNING

• 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.

• To reduce fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor.

• Wear eye protection.

• Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor.

• Never run the engine in an enclosed area.Exhaust contains poisonous carbon monoxide gas.

• 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.

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.

To adjust toe alignment:

• Hold tie rod end to keep it from rotating.

• Loosen jam nuts at both end of the tie rod.

• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in Method 1 or Method 2.

• 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.

• After alignment is complete, torque jam nuts to specification.

= T

Tie Rod Jam Nut Torque:

12-14 ft. lbs. (16-19 Nm)

Clean Out Plug

III. 1

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

2.28

MAINTENANCE

3. If some carbon is expelled, cover the exhaust outlet and lightly tap on the pipe around the clean out plugs with a rubber mallet 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 Park and repeat Steps 2 and 3. SEE WARNING

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 Park and repeat Steps 2 and 3. SEE WARNING

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.

• Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir.

• Use Polaris DOT 3 Brake Fluid

Sight Glass

Parking Lock Brake

• Use Polaris DOT 3 Brake Fluid

1 ft.

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.

• Check brake for excessive travel or spongy feel.

• Check brake system for fluid leaks.

• Check friction pads for wear, damage or looseness.

• Check surface condition of the disc.

2.29

MAINTENANCE

Brake Pad Inspection

Pads should be changed when the friction material i s worn to

.180” / 4.6 mm, or about the thickness of a dime.

.180” / 4.6 mm,

Minimum

Thickness

= In. / mm.

Brake Pad Service Limit:

.180" (4.6 mm)

2. 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.

Auxiliary Foot Brake Pedal

Full Height

Floor Board Surface

Full Engagement

Auxiliary Brake Adjustment (Hydraulic)

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

First, check foot brake effectiveness by applying 50 lb. (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.

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

1. Support the rear wheels off the ground.

1/8, to 1/4, Free Play

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

Free Play:

50 lbs

1” or greater

Floorboard

= In. / mm.

Foot Brake Freeplay:

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

2.30

MAINTENANCE

Suspension Spring Preload Adjustment

Center Spring Adjustment Ring

Shock Spanner Wrench

(PN 2871095)

Operator weight and vehicle loading affect suspension spring preload requirements. Adjust as necessary, using the spanner wrench (2) to turn the adjustment cam (1).

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.

Throttle assembly clamp

Front Suspension

Compress and release front suspension. Damping should be smooth throughout the range of travel.

Check all front suspension components for wear or damage. Inspect front strut cartridges for leakage.

CV Shaft Boot Inspection

Inspect the CV shaft boots in the front and rear of the ATV for damage, tears, wear, or leaking grease. If the rubber boot exhibits any of these symptoms, replace the boot. Refer to Chapter 7 for CV boot replacement.

Inspect Boots

Align clamp edge with knurl

Align throttle control assembly clamp with knurl on handlebar.

Wheels

Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts.

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 1/8” (.3 cm) or less.

Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts.

2.31

MAINTENANCE

Wheel, Hub, And Spindle Torque Ta ble

Item Specification

Steel - Front Wheel Nuts 27 Ft. Lbs. (37 Nm)

Steel - Rear Wheel Nut s 27 Ft. Lbs. (37Nm)

Aluminum

Front Wheel Nuts

Aluminum

Rear Wheel Nuts

Front Hub Retaining Nut 70 ft.lbs. (90 Nm)

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

90 Ft. Lbs. (122 Nm)

Wheel Removal Front or Rear

Front & Rear Wheels

Front & Rear

Wheel Nuts (4)

See table Below

Wheel Installation

1. With the transmission in Park 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 nu ts to th e proper torqu e li sted in the table.

Steel Wheel Aluminium Wheel

Front Hub Nut 70 ft. lbs. (95 Nm)

Rear Hub Nut

80 ft. lbs. (108 Nm)

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

2. Loosen the wheel nuts slightly.

• Elevate the side of the vehicle by placing a suitable

stand under the footrest frame.

CAUTION

If wheels are improperly installed it 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.

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

3. Remove the wheel nuts and remove the wheel.

2.32

MAINTENANCE

Tire Inspection

• Improper tire inflation may affect ATV maneuverability.

• When replacing a tire always use original equipment size and type.

• 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 1/8" (3 mm) or less.

Tread Depth 1/8” (3 mm)

Storage Compartments

The storage compartments are easily accessible. To open the front compartment turn the latch handle to the horizontal position on both sides. To close the storage compartment turn the latch handles just past the vertical position. Use the arrow located on top of the latch as a reference.

Unlatch

WARNING

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

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

measures 1/8” (.3 cm) or less.

Frame, Nuts, Bolts, Fasteners

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

Latch

2.33

MAINTENANCE

Winch Operation (If Equipped)

This information is for Sportsman models equipped with a winch in the front.

Winch Handlebar Control

The winch is located in the front bumper area.

The mini-rocker (IN/OUT) control controls the direction of the cable for the winch. IN pulls the cable into the winch and OUT feeds the cable out of the winch.

Winch Control

The winch control located on the side of the winch gives the operator easy access to switch between ENGAGED and FREESPOOL.

When the winch is ENGAGED, the winch only allows the cable to be pulled IN or released OUT via the mini-rocker switch on the handlebar.

When the winch is FREESPOOL, the winch allows the cable to be pulled out freely.

NOTE: The switch on the handlebar does not have to be in the OUT position.

FREESPOOL

ENGAGE

Winch Wire Locations

The winch wires can be located under the front cab area. Locate the wires, remove the cap and hook up to winch the Blue an d

2.34

MAINTENANCE

Yellow (6 Ga.) wires to the winch. Refer to the installation instructions for more details.

Winch Connector

Splash Guard for Contactor mount

Winch Connecting Harness

The Orange/White wires are located under the front cover (under headlight pod). The Orange/White wires supply the control power to the winch.

Right Side Front Fender

Locate the Red wire (6 Ga.) with the yellow crimp cover is located in the rear fender area. The red wire connects to the battery.

Winch Connecting Wire

2.35

MAINTENANCE

ATV Cleaning & Storage

Cleaning the ATV

Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your A TV can be cleaned much like an automobile.

Washing the ATV

The best and safest way to clean your A TV is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. tRinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning and safety labels are damaged, contact your a Polaris dealer for free replacement.

Polaris does not recommend the use of a high pressure type car wash system for washing the ATV. If a high pressure system is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels. NOTE: Grease all zerk fittings immediately after washing, and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system.

Waxing the ATV

Your ATV can be waxed with any non-abrasive automotive paste wax. A void the use of harsh cleaners since they can scratch the body finish. Polaris offers a detailing kit for ATVs.

CAUTION

Certain products, including insect repellents and chemicals, will damage plastic surfaces. Use caution when using these products near plastic surfaces.

Storage Tips

See Page 2.9 for the part numbers of Polaris products .

CAUTION

Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period.

Clean the Exterior

Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime. Don’t use harsh detergents or hig h pressure washers. Some deter gents deteriorate rubber parts. Use dish soap type cleaners only . High pressure washers may force water past seals.

Stabilize the Fuel

Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer . Follow the instructions on the container for the recommended amount. (Carbon clean will also reduce the possibility of bacterial growth in the fuel system). Allow 1520 minutes of operation for the stabilizer to disperse through the fuel in the tank and EFI sytem / carburetor. Turn the fuel valve off and drain the carburetor bowl (450 only).

Oil and Filter

Warm the engine and change the oil and filter. Follow the procedure in this chapter for proper oil change.

Air Filter / Air Box

Inspect and clean or replace the pre-cleaner and air filter. Clean the air box and drain the sediment tube.

Breather Filter

Inspect and clean or replace the breather filter.

Fluid Levels

Inspect the following fluid levels and change if necessary: front gearcase; transmission; brake fluid (change every two years or as required if fluid looks dark or contaminated).

Drain the Recoil Housing

Remove the recoil housing drain plug and drain any moisture.

Storage Kits

Polaris offers storage kits for ATVs. See a Polaris dealer or visit www.purepolaris.com.

Fog the Engine

To properly store the engine, us e Polaris Fogging Oil according to the directions.

If you choose not to use Polaris Fogging Oil, perform the following procedure:

1. Support the front end of the machine so the engine is level or tilted slightly rearward.

2. Treat the fuel system with Polaris Carbon Clean according to the directions.

3. Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W-40 engine oil. To access the plug hole, use a section of clear 1/4” hose and a small plastic squeeze bottle filled with the pre-measured amount of oil.

Note: Do this carefully! If you miss the plug hole, oil will drain from the spark plug cavity into the hole at the front of the cylinder head, and appear to be an oil leak. Install

the spark plug and pull the engine over slowly with the recoil starter. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.

4. Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug.

2.36

MAINTENANCE

5. Turn the engine over sev eral ti mes with the recoil only to

ensure coverage of piston rings, cylinder walls and crankshaft bearings.

6. If Polaris fuel system additive is not used, fuel tank, and fuel lines should be completely drained of gasoline.

Lubricate

Inspect all cables and lubricate with Polaris Cable Lubricant. Follow lubrication guidelines in the maintenance section of the service or owner’s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease.

Storage Tips Battery Storage

Remove the battery from the vehicle and ensure that it’s fully charged before placing it in storage. See Chapter 10 for instructions.

Engine Anti-Freeze

Test engine coolant strength and change if necessary. Coolant should be replaced every two years.

Storage Ar ea/Covers

Set the tire pressure and safely support the A TV with the tires 12” off the ground. Be sure the storage area is well ventilated, and cover the machine with a genuine Polaris ATV cover. NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

Transporting the ATV

Follow these procedures when transporting the vehicle.

1. Turn off the engine and rem ove the key to prevent loss during transporting.

2. Always place the transmission in park and lock the parking brake.

3. Turn the fuel valve off.

4. Be sure the fuel cap, oil cap and seat are installed correctly.

5. Always tie the frame of the ATV to the transporting unit

securely using suitable straps or rope.

2.37

MAINTENANCE

Maintenance Schedule

Service Date Hours / Miles Service Performed Serviced By:

2.38

ENGINE

CHAPTER 3

ENGINE

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3

ENGINE FASTENER TORQUE PATTERNS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3

ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4

ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5

GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6

COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7

ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8

ENGINE REMOVAL (TYPICAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8

ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9

CYLINDER HONE SELECTION/ HONING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . .3.9

HONING TO OVERSIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9

CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10

CRANKSHAFT STRAIGHTENING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10

ENGINE LUBRICATION - EH 50PL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11

OIL PRESSURE TEST - EH 50PL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11

OIL PUMP PRIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11

OIL FLOW - EH50PL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11

EH50PL OIL FLOW DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12

EH50PL ENGINE EXPLODED VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13

ENGINE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

CAM CHAIN TENSIONER/ROCKER ARM/ CAMSHAFT REMOVAL . . . . . . . . . . . . . .3.14

CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14

ROCKER ARM/SHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15

CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

AUTOMATIC COMPRESSION RELEASE REMOVAL/INSPECTION . . . . . . . . . . . . . .3.17

AUTOMATIC COMPRESSION RELEASE INSTALLATION. . . . . . . . . . . . . . . . . . . . . .3.18

CAMSHAFT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19

CYLINDER HEAD EXPLODED VIEW, EH50PL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20

CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21

CYLINDER HEAD WARP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21

CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21

VALVE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22

COMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23

VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23

CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26

VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26

VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26

CYLINDER/PISTON REMOVAL AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . .3.27

PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28

CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28

PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29

PISTON/ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29

PISTON RING INSTALLED GAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.30

CRANKCASE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.30

STARTER DRIVE REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31

FLYWHEEL/STATOR REMOVAL/INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31

CAM CHAIN/TENSIONER BLADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.32

ONE WAY VALVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.32

CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33

3.1

ENGINE

OIL PUMP REMOVAL/INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33

OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

COUNTER BALANCER SHAFT REMOVAL/INSPECTION. . . . . . . . . . . . . . . . . . . . . . 3.34

CRANKSHAFT REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35

CRANKCASE BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36

PUMP SHAFT OIL SEAL/WATER PUMP MECHANICAL SEAL REMOVAL . . . . . . . . 3.36

CRANKCASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36

BEARING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37

END PLAY INSPECTION/ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37

CRANKSHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37

COUNTER BALANCER SHAFT END PLAY ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . 3.38

OIL PUMP SHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39

ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40

PUMP SHAFT OIL SEAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40

CRANKSHAFT/COUNTER BALANCE/OIL PUMP INSTALLATION . . . . . . . . . . . . . . . 3.40

CRANKCASE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41

WATER PUMP MECHANICAL SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 3.41

WATER PUMP MECHANICAL SEAL REMOVAL - ENGINE INSTALLED . . . . . . . . . .3.41

ONE WAY VALVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

CAM CHAIN DRIVE SPROCKET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43

TENSIONER BLADE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43

PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43

PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

CYLINDER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45

CAM CHAIN/CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45

CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46

CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48

CAM CHAIN TENSIONER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49

STATOR, FLYWHEEL AND STARTER DRIVE INSTALLATION. . . . . . . . . . . . . . . . . .3.49

ROCKER SHAFT/ROCKER ARM ASSEMBLY INSTALLATION. . . . . . . . . . . . . . . . . . 3.50

THERMOSTAT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.50

OIL PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.50

RECOIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51

RECOIL DISASSEMBLY/INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.51

RECOIL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53

SPARK PLUG FOULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.53

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.53

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.54

3.2

ENGINE

SPECIFICATIONS

Torque Specifications

TORQUE SPECIFICATIONS

Fastener Size EH50PLE

Ft. Lbs. (Nm)

Blind Plug (Oil Pressure)

Camshaft S procket 6mm 5-6.5 (7-9 Nm) Camshaft Chain

Tensioner Lever Camshaft Chain Tensioner Camshaft Chain Tensioner Cap Carburetor Adaptor 8mm 12-14 (16-20 Nm) Crankcase 8mm 14-15 (19-21 Nm) Crankshaft Slotted Nut (Cam Chain Drive Sprocket) Cylinder Base Bolts 10mm

Cylinder Head Bolts 11mm

Drive Clutch Bolt 7/16 - 20 40 (55 Nm) Flywheel 16mm 58-72 (78-98 Nm) Oil Delivery Pipe 12mm 11-15 (15-21 Nm) Oil Drain Bolt

(Crankcase) Oil Filter Pipe Fitting 20mm 36-43 (49-59 Nm) Oil Hose Fitting 1/8 Pipe

Hard Metal Oil Line Banjo Fitting

Oil Pump 6mm 5-6.5 (7-9 Nm) Oil Pump Case Screw 5mm 1.5-2 (2-3 Nm) One Way Valve 11mm 14-19 (20-25 Nm) Recoil Housing 6mm 5-6.5 (7-9 Nm) Rocker Cover 6mm 7-8 (9-11 Nm) Rocker Support 8mm 8-10 (11-13 Nm) Rocker Adjuster Screw 6mm 6-7 (8-10 Nm) Water Pump Impeller

Nut Water Pump Housing Cover Stator Plate 6mm 5- 6.5 (7-9 Nm) Starter Motor 6mm 5-6.5 (7-9 Nm) Spark Plug 14mm 9-11 (12-15 Nm) Thermistor -- 26 ± 2.1 (35 ± 3 Nm)

1/8 PT (28tpi)

6mm 5-6.5 (7-9 Nm)

11mm 14-19 (20-25 Nm)

28mm 35-51 (47- 69 Nm)

6mm

14mm 14-17 (19- 23 Nm)

Thread

N/A 11-16 ft.lbs. (15-21

6mm 5-6.5 (7-9 Nm)

6.5-11 (9-15 Nm)

45-49 (61-67 Nm)

6-8 (9-11 Nm)

Refer to Engine

Assembly for torque

procedure

6.5-11 (9-15 Nm)

Nm)

Special Tools

PART NUMBER TOOL DESCRIPTION

2200634 2870390 Piston Support Block

2871043 Flywheel Puller 2871283 5131135 Water Pump Install Kit

2870569 Crankshaft Truing Stand 2870975

PV-43527 OIl Filter Wrench

Valve Seat Reconditioning

Kit

Crankshaft/Water Pump

Seal Install Kit

Mity Vac™ Pressure Test

Tool

Engine Fastener Torque Patterns

Tighten cylinder head, cylinder base, and crankcase fasteners in 3 steps following the sequence outlined.

6mm

Cylinder Head Cylinder Base

Pattern

Crankcase Pattern

3.3

ENGINE

Engine Service Data

Cylinder Head / Valve

Rocker Arm Rocker arm ID .8669-.8678" (22.020-22.041 mm)

Rocker shaft OD .86 56-.8661" (21.987-22.0 mm) Rocker shaft Oil Clearance Std .0008-.0021" (.020-.054 mm)

Limit .0039" (.10 mm)

Camshaft Cam lobe height In Std 1.2884-1.2924” (32.726-32.826 mm)

Limit 1.2766" (32.426 mm)

Ex Std 1.2884-1.2924” (32.726-32.826 mm)

Limit 1.2766" (32.426 mm)

Camshaft journal OD Mag 1.4935-1.4941” (37.935-37.950 mm)

PTO 1.4935-1.4941” (37.935-37.950 mm)

Camshaft journal bore ID Mag 1.4 963-1.4970” (38.005-38.025 mm)

PTO 1.4963-1.4970” (38.005-38.025 mm)

Camshaft Oil clearance Std .022-.0035”(.055-.090 mm)

Limit .0039" (.10 mm)

Cylinder Head Surface warpage limit .0020" (.05 mm)

Standard Height 3.870" (98.3 mm)

Valve Seat Contacting width In Std .028" (.7 mm)

Limit .055" (1.4 mm)

Ex Std .039" (1.0 mm)

Limit .071" (1.8 mm)

Valve Guide Inner diameter .2362-.2367" (6.0-6.012 mm)

Protrusion above head .689-.709" (17.5-18.0 mm)

Valve Margin Thickness In Std .039" (1.0 mm)

Limit .031" (.8 mm)

Ex Std .047" (1.2 mm)

Limit .031" (.8 mm)

Valve Stem diameter In .2343-.2348" (5.950-5.965 mm)

Ex .2341-.2346" (5.945-5.960 mm)

Stem Oil Clearance Std In .0014-.0024" (.035-.062 mm)

Ex .0016-.0026" (.040-.067 mm)

Limit .0059" (.15 mm)

Overall length In 3.976" (101.0 mm)

Ex 3.984" (101.2 mm)

Valve Spring Overall Length Std 1.654" (42.0 mm)

Limit 1.575" (40.0 mm)

Squareness .075” (1.9 mm)

EH50PLE

3.4

Engine Service Data

Cylinder / Piston / Connecting Rod EH50PLE

Cylinder Surface warpage limit (mating with cylinder

head) Cylinder bore Std 3.6221-3.6228” (92.00-92.02 mm) Tap er limit .0020” (0.05 mm) Out of round limit .0020” (0.05 mm) Piston clearance Std .0006-.0018" (0.015-0.045 mm)

Boring Limit .020” (.5 mm)

Piston Outer diameter Std 3.6204-3.6215” (91.970-91.985mm)

Standard inner diameter of piston pin bore .9055-.9057” (23.0-23.006 mm)

Piston Pin Outer diameter .9053-.9055” (22.994-23.0 mm)

Standard clearance-piston pin to pin bore .0002-.0003” (.004-.008 mm) Degree of fit

Piston Ring Piston Ring Installed

gap

.0020” (0.05 mm)

Limit .0024” (0.060 mm)

.0098" (.25 mm) OS 3.6304-3.6310” (92.21-92.23 mm) .0197" (.50 mm) OS 3.6403-3.6407” (92.46-92.47 mm)

Piston Pin must be a push (by hand) fit at 68

Top ring Std .0079-.0138" (.20-.36 mm)

Limit .039” (1.0 mm)

ENGINE

F (20o

Second ring

Oil ring Std .0079-.0276" (0.20-0.70 mm)

Piston Ring Standard clearance -

piston ring to ring groove

Connecting Rod

Crankshaft Crankshaft runout limit .0024” (.06 mm)

Connecting rod small end ID .9058- .9063” (23.007 - 23.020 mm) Connecting rod small end radial

clearance

Connecting rod big end side clearance

Connecting rod big end radial clearance

Top ring Std .0016-.0031" (0.040.-080 mm)

Second ring

Std .0079-.0138" (.20-.36 mm) Limit .039” (1.0 mm)

Limit .059" (1.5 mm)

Limit .0059" (.15 mm) Std .0012-.0028" (0.030-0.070 mm) Limit .0059" (.15 mm)

Std .0003-.0010” (.007-.026 mm) Limit .0020 (.05 mm) Std .0039-.0256” (.1-.65 mm) Limit .0315” (.80 mm) Std .0004-.0015” (.011-.038 mm) Limit .0020” (.05 mm)

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

PTO: Power Take Off.

3.5

ENGINE

GENERAL ENGINE SERVICE

Piston Identification

The piston may have an identification mark or the piston may not have an identification mark for piston placement. If the piston has an identification mark, follow the directions for piston placement below. If the piston does not have an identification mark, the direction for placement of the piston does not matter.

Note the directional and identification marks when viewing the pistons from the top. The letter “F”, “ be toward the flywheel side of the engine. The other numbers are

used for identification as to diameter, length and design. Four stroke engine rings are rectangular profile. See text for oil control ring upper rail installation. Use the information below to identify pistons and rings.

Engine Model No.

EH50PLE .25

EH42PLE .25

*Pistons and rings marked 25 equal .25mm (.010”) oversized

*Pistons and rings marked 50 equal .50mm (.020”) oversized

Oversize Available* (mm)

.50

J ”,“ X” or : must always

Piston Length

72 mm C

66 mm B

Standard Piston Identification

Cooling System Specifications

Sensor

18.5 +

ft. lbs.

(25 Nm)

THERMISTOR READING DURING OPERATION

Condition

Temperature 37.3 - 39.2 k Ω 68° F (20° C)

System

Capacity

Radiator Cap

Relief

Pressure

Approx. Reading

(Min-Max)

2.25 Quarts (2.13L)

13 PSI (89.6 kpa)

Temperature

3.6

ENGINE

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.

FLOW

Radiator

Thermostat

Cylinder

Head

Water Pump

Cylinder

System Pressure Test

1. Remove radiator cap cover located in storage box.

2. Remove recovery bottle hose from coolant filler.

3. Connect a Mity Vac™ (PN 2870975) to radiator and pressurize system to 10 PSI (68.9 kpa). The system must retain 10 lbs of pressure for five minutes or longer. If pressure loss is evident within five minutes, check radiator, all cooling system hoses and clamps, or water pump seal.

Radiator Cap Pressure Test

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

2. The radiator cap relief pressure is 13 lbs (89.6 kpa).

Fan

Lower Hose

Overflow Bottle

Upper Hose

Filler Neck

Radiator

To p

Bottom

Radiator Left Side View

Radiator Front View

3.7

ENGINE

RECOMMENDED COOLANT

Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area..

CAUTION

Using tap water in the cooling system will lead to a

buildup of deposits which may restr ict co olant flow

and reduce heat dissipation, resulting in possible

engine damage. Polaris Premium 60/40 Antifree ze/

Coolant is recommended for use in all cooling systems, and comes pre-mixed, ready to use.

Accessible Components

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

• Flywheel

• Alternator/Stator

• Starter Motor/Starter Drive

• Cylinder Head

• Cylinder

• Piston/RIngs

• Camshaft

• Rocker Arms

• Cam Chain and Sprockets

• Water Pump / Water Pump Mechanical Seal*

The following components require engine removal for service:

Engine Removal (TYPICAL)

1. Clean work area.

2. Thoroughly clean the ATV engine and chassis.

3. Disconnect battery negative(-) cable.

4. Remove the following parts as required.

•Seat

• Left and Right Side Covers (Refer to Chapter 5)

• Fuel Tank Cover / Front Cab (Refer to Chapter 5)

• Fuel Tank (Refer to Chapter 4)

5. Disconnect spark plug high tension lead.

6. Remove springs from exhaust pipe and remove pipe.

7. Drain coolant and engine oil.

8. Remove air pre-cleaner and duct.

9. Remove airbox.

10. Remove carburetor. Insert a shop towel into the carburetor flange to prevent dirt from entering the intake port.

11. Remove center chain guard on chain drive AWD models.

12. Remove center drive and driven sprocket bolts and remove chain and sprockets as an assembly.

13. R efer to PVT System to remove outer clutch cover, drive belt, drive clutch, driven clutch, and inner cover.

14. Starter motor. Note ground cable location. Mark positive (+) cable mounting angle and remove cable.

15. Remove transmission linkage rod(s) 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.

19. Remove engine through right side of frame.

• Oil pump / Oil Pump Drive Gear

• Counterbalance Shaft or Bearing(s)

• Connecting Rod

• Crankshaft

• Crankshaft Main Bearings

• Crankcase

*It may be necessary to loosen engine mounts and move engine slightly to access water pump. Use the Water Pump Mechanical Seal Puller (PN 2872105) to replace mechanical seal with engine in frame.

3.8

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 preride inspection checklist (refer to Chapter 2 or the Owner’s Safety and Maintenance Manual).

PVT System

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

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

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

2. Check to be sure all springs are in good cond ition.

Cylinder Hone Selection/ Honing Procedure

CAUTION

Selecting a hone which will straighten as well as

remove material from the cylinder is very important.

Using a common spring loaded finger type glaze

breaker for honing is never advised. Polaris

recommends using a rigid hone or arbor honing

machine which also has the capability of oversizing.

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.

NOTE: See next page for more information on honing.

Honing To Oversize

CAUTION

If cylinder wear or damage is excessive, it will be

necessary to oversize the cylinder using a new oversize

piston and rings. This may be accomplished by either

boring the cylinder and then finish honing to the final bore

size, or by rough honing followed by finish honing.

Bleed Cooling System

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

2. Fill coolant reservoir tank to ful l mark.

3. Install radiator cap and squeeze coolant lines to force air out of system.

4. Again remove radi ator cap and slowly add coolant to top of fill neck.

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 temp. Check level in reservoir tank after engine is cool and add coolant if necessary.

Engine Break In Period

4 Cycle Engine Break-In Period is defined as the first 10 hours of engine operation or 2 full tanks of fuel.

1. Use only Polaris Premium 4 Al l Season synthetic oil, or API certified “SH” oil.Never substitute or mix oil brands. Serious engine damage can result.

2. Use fuel with a minimum octane of 87 (R+M)/2 met hod.

3. Change break-in oil and filter at 20 hours or 500 miles, whichever comes first.

CAUTION

For oversize honing, always wet hone using honing oil and a coarse roughing stone. Measure the piston (see

piston measurement) and rough hone to the size of the

piston. Always leave .002 - .003" (.05 - .07 mm) for finish

honing. Refer to piston-to-cylinder clearance

specifications before honing. Complete the sizing with

fine grit stones to provide the proper cross-hatch finish

and required piston clearance.

EXAMPLE OF CROSS HATCH PATTERN

3.9

ENGINE

)

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:

• 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 1/2” (1.3 cm) above and below the bore at the end of each stroke.

• Release the hone at regular intervals and inspect the bore to determine if it has been cleared, and to check piston fit. NOTE: Do not allow cylinder to heat up during honing. The thinner areas of the liner around the ports will expand causing uneven bore.

• After honing has been completed inspect all port opening areas for rough or sh arp edges. Apply a slight chamfer to all ports to remove shar p edges or burrs, paying particular attention to the corners of the intake and exhaust ports.

Cleaning the Cylinder After Honing

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, soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris 2 Cycle Lubricant.

Crankshaft Straightening

Lubricate the bearings and clamp the crankshaft securely in the Crankshaft Truing Stand (PN 2870569). Refer to the illustrations below.

Crankshaft Truing Stand

(PN 2870569)

NOTE: The rod pin position in relation to the dial

indicator position tells you what action is required to straighten the shaft.

HIGH .004 (.1 mm) HIGH .004 (.1 mm)

SUPPORT CRANKSHAFT

1. To correct a situation like the one shown in the illustration, strike the shaft at point A with a brass hammer.

HERE

HIGH .002 (.05 mm)

HIGH .005 (.13 mm

2. To correct a situation like the one shown in the illustration, squeeze the crankshaft at points A. (Use tool from alignment kit).

HIGH .002 (.05 mm)

HIGH .005 (.13 mm)

3.10

ENGINE

3. If the crank rod pin location is 180o from the dial indicator (opposite that shown above), it will be necessary to spread the crankshaft at position A as shown in the illustration at right. When rebuilding and straightening a crankshaft, runout must be as close to zero as possible.

NOTE: Maximum allowable runout is .0024”.

Engine LubricationEH 50PL

Oil Type:Polaris Premium 4 Synthetic (PN 2871281); or API certified “SH” 0-40W oil

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

Filter Wrench . . . .(PV-43527)

*Drain Plug / Screen Fitting...14 ft. lbs. (19 Nm) (If fitting is removed, follow oil pump priming procedure).

*Oil Pressure Specification...20 PSI @ 5500 RPM, Polaris 0W-40 Synthetic (Engine Hot)

Oil Pressure Test - EH 50PL

1. Remove blind plug on front left cyl ind er head.

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

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

NOTE: Use only Polaris Premium 4 Synthetic Engine Lubricant (PN 2871281).

Oil Pressure at 5500 RPM (Engine Hot):

Standard: 20 PSI Minimum: 12 PSI

Oil Pump Priming Procedure

See “Oil Pump Priming Procedure” on page 2.25.

Oil Flow - EH50PL

The following chart describes the flow of oil through the EH50PL engine. Beginning at the oil tank, the oil flows through a screen fitting in the bottom of the tank and into the oil supply hose. The feed side of the oil pump draws oil through the hose and into the crankcase oil gallery, and then pumps the oil through another passage to the one way valve. (When the engine is off, the one way valve closes to prevent oil in the tank from draining into the crankcase.) The oil is pumped through a delivery pipe to 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 diverted in two directions. Oil is supplied to the camshaft through the left front cylinder stud, and an oil passage in the head. Oil enters the camshaft through the PTO (L) journal. The camshaft journals, cam lobes, and rocker arms are lubricated through holes in the camshaft. The oil lubricates the cam chain and sprocket and drains to the sump.

The other oil path from the filter leads through a del ivery pipe to the crankcase main oil gallery, which leads to the stator plate oil passage. Here it passes through the slotted friction bearing (located in the stator plate) into the crankshaft. An oil seal on the stator plate prevents oil from entering the stator/flywheel area. Oil travels through the crankshaft to the crank pin, lubricating the connecting rod large end bearing directly. Oil also passes through an oil jet (drilled orifice) in the end of the crank pin to the PTO end main bearings and counterbalancer gears.

Residual oil from the lubrication of the crankshaft and connecting rod indirectly lubricates the cylinder wall, piston, rings, connecting rod small end bearing, piston pin, oil/water pump drive gears, cam chain and drive sprocket, and Magneto end crankshaft main bearing.

The one-way valve is located on the front left (PTO) side of the crankcase. The valve prevents oil in the tank from draining into the engine sump when the engine is off. The valve mechanism consists of a plunger, return spring, guide plug, and sealing washer. When the engine is running, oil pressure lifts the plunger off the seat, allowing oil flow. When the engine is off, spring pressure forces the plunger against the oil passage seat, preventing oil flow from the tank to the sump. The one-way valve requires very little maintenance. If engine oil drains into the sump when the engine is off, inspect the valve sealing surface for debris or damage. Inspect the return spring for distortion or damage.

3.11

ENGINE

EH50PL Oil Flow Diagram

Internal passage to camshaft (front left head bolt)

Vent Hose

Oil Filter

Oil feed to filter

From filter to crankshaft

Oil Tank

EH50PL Oil Flow Chart

Oil Tank

Union Fitting (Upper)

Oil Hose

Crankcase

Oil Gallery

Oil Pump

Prevents oil from draining into crankcase with engine off

(Feed)

One Way Valve

Top of Oil Tank

Oil Hose

Screen Fitting (Bottom of Tank)

Cam Shaft Journal

Bottom fitting is oil exhaust or return to tank

Union Fitting (Lower)

Crankcase

Oil Gallery

Chain Room

Rocker Arm Rocker Shaft

Cam Lobe

One way valve

Top fitting is oil feed or intake from bottom of tank

Oil Pump

(Scavenging)

Sprocket Chain

Indirect Lubrication

Oil Strainer

Crankcase

Small End Bearing

Cylinder Sleeve

Main Bearing (PTO)

3.12

Bypass

Delivery Pipe

Oil Filter

Cam Shaft Journal

Through Cylinder

Stud Front Lef t Delivery Pipe Delivery Pipe

Crankcase

Oil Gallery

Metal

Large End Bearing

Oil Jet

Crank Pin

Crankshaft

EH50PL Engine Exploded Views

ENGINE

Crankcase

Cylinder/ Cylinder Head

Crankshaft and Piston

Valvetrain

3.13

ENGINE

ENGINE DISASSEMBLY

Cam Chain Tensioner/ROCKER ARM/ CAMSHAFT Removal

1. Remove ignition timing inspection plug from recoil housing.

TDC “T” Mark

Rotation

To position crankshaft at Top Dead Center (TDC) on compression stroke:

2. Rotate engine slowly in the direction o f rotation watch ing intake valves open and start to close.

3. Continue to rotate engine slowly, watching camshaft sprocket marks and the mark in the timing inspection hole.

Advance Marks

NOTE: The cam lobe should be pointing down and valves should have clearance at this point.

5. Remove cam chain tensioner plug, sealing washer, and spring.

CAUTION

The plug is under spring tension. Maintain inward

pressure while removing.

6. Remove the two 6x25 mm cam chain tensioner flange bolts.

7. Tap lightly on tensioner body with a soft face hammer to loosen and remove tensioner.

4. Align single (TDC) m ark on flywheel with projection in inspection hole, and the cam sprocket pin (facing upward) aligned with the camshaft to crankshaft center line.

Cam Chain Tensioner Inspection

1. Pull cam chain tensioner plunger outw ard to the end of its travel. Inspect teeth on ratchet pawl (A) and plunger teeth (B) for wear or damage.

3.14

ENGINE

2. Push ratchet pawl and h old it. The plunger should move smoothly in and out of the tensioner body.

3. Release ratchet pawl and push inward on plunger. It should remain locked in position and not move inward.

Tensioner Spring Free Length:

2.02” (5.13 cm)

Limit 1.92 (4.88cm)

4. Measure free length of tensioner spring. Replace spring if excessively worn. Compare to specifications.

5. Replace entire tensioner assembly if any part is worn or damaged.

2. Inspect each rocker arm cam follower surface. If there is any damage or uneven wear, replace the rocker arm. NOTE: Always inspect camshaft lobe if rocker arms are worn or damaged.

3. Measure O.D. of rocker shaft. Inspect it for wear or damage. Compare to specifications.

Rocker Shaft O.D.:

.8656 - .8661 (21.987-22.0 mm)

Rocker Arm/Shaft Inspection

1. Mark or tag rocker arms to keep them in order for assembly.

Rocker Arm & Support I.D.:

.8669 - .8678 (22.020-22.041 mm)

3.15

ENGINE

4. Measure I.D. of each rocker arm and compare to specifications.

Rocker Shaft Oil Clearance:

Std: .0008 - .0021 (.020-.054 mm)

Limit: .0039” (.10 mm)

5. Measure I.D. of both rocker arm shaft supports and visually inspect surface. Compare to specifications.

6. Subtract rocker shaft O.D. from rocker arm & shaft support I.D. This is the oil clearance. Compare to specifications.

7. Inspect rocker adjuster screws for wear, pitting, or damage to threads of the adjuster or locknut. Replace all worn or damaged parts. NOTE: The end of the adjuster screw is hardened and cannot be ground or re-faced.

Camshaft Removal

1. Remove thermostat housing.

3. Loosen three camshaft sprocket bolts.

4. Remove camshaft end cap and O-Ring.

5. Inspect camshaft end cap (thrust face) for wear. Replace if worn or damaged.

6. Place a clean shop towel in the area below cam chain sprocket and remove sprocket retaining bolts.

2. Remove camshaft sprocket inspection cover.

3.16

7. Slide camshaft inward to allow removal of cam sprocket and remove sprocket from camshaft and chain.

ENGINE

8. Secure cam chain with a wire to prevent it from falling into the crankcase.

Sprocket Teeth

Inspect for Areas of Tooth Wear or Damage

9. Inspect cam sprocket teeth for wear or damage. Replace if necessary.

Decompressor Shaft

Decompressor Ball Retainer Sleeve

Automatic Compression Release Removal/ Inspection

NOTE: The automatic compression release mechanism can be inspected and serviced without removing the camshaft from the cylinder head. The actuator ball (C) in the camshaft is not replaceable. Replace the camshaft as an assembly if the actuator ball is worn or damaged.

1. Check release lever shaft (A) for smooth operation throughout the entire range of rotation. The spring (B) should hold the shaft weight against the stop pin. In this position, the actuator ball (C) will be held outward in the compression release mode.

2. Remove release lever shaft and return spring.

3. Inspect shaft for wear or galling.

4. Inspect lobe on end of release lever shaft and actuator ball for wear and replace if necessary.

10. Slide camshaft out the PTO side of the cylinder head.

3.17

ENGINE

Automatic Compression Release Installation

1. Slide spring onto shaft.

2. Apply engine oil to release lever shaft.

The actuator ball must be held outward to allow inst allation of the release lever shaft.

Stop Pin

Spring in relaxed position

If Camshaft Is Removed From Engine:

3. Turn the camshaft until the actuator ball is in the lowest position and install the release lever shaft.

Camshaft Inspection

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

2. Thoroughly clean the cam shaft, making sure the oil feed holes are not obstructed.

Lubrication holes

Lobe Height

Cam Lobe Height (Intake & Exhaust)

Std: 1.2884-102924” (32.726-32.826 mm)

Limit: 1.2766” (32.426 mm)

If Camshaft Is Installed In The Engine:

4. Use a small magnet to draw the actuator ball outward, or rotate the engine until the cam lobes face upward and install release lever shaft.

5. Position camshaft as shown at bottom of illustration at right.

6. Place arm of spring under stop pin as shown and push release lever inward until fully seated. Do not pre-wind the spring one full turn or the compression release will not disengage when the engine starts. Check operation of mechanism as outlined in Step 1 of Removal (above).

NOTE: When shaft is properly installed, actuator ball will be held in the “out” position. It is important to note that spring pressure is very light.

3.18

ENGINE

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

Journal O.D

Journal

Camshaft Journal O.D.:

Mag & PTO End: 1.4935-1.4941”

(37.935- 37.950 mm)

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

5. Measure ID of camshaft journal bore.

Camshaft Journal I.D.:

Mag & PTO End: 1.4963-1.4970”

(38.005- 38.025 mm)

Cylinder Head Removal

1. Remove the two 6mm flange bolts (A) from cylinder head. See next exploded view on next page.

2. Loosen each of the four cylinder head bolts (B) evenly 1/8 turn each time in a criss-cross pattern until loose.

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

4. Remove cylinder head and head gasket.

Calculate oil clearance by subtracting journal OD from journal bore ID. Compare to specifications.

Camshaft Oil Clearance:

Std: .0022-.0035” (.055-.090 mm)

Limit: .0039” (.10 mm)

NOTE: Replace camshaft if damaged or if any part is

worn past the service limit. NOTE: Replace cylinder head if camshaft jo urnal bore is

damaged or worn excessively.

3.19

ENGINE

Cylinder Head Exploded View, EH50PL

EH50PL

3.20

ENGINE

Cylinder Head Inspection

(A)

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

CAUTION

Use care not to damage sealing surface.

Cylinder Head Warp

Cylinder Head Disassembly

WARNING

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

NOTE: Keep all parts in order with respect to their location in the cylinder head.

1. Using a valve spring compressor (A ), compress the valve

springs and remove the split keeper. NOTE: To prevent loss of tension, do not compress the valve spring more than necessary.

Cylinder Head Warp Limit:

.002” (.05 mm)

1. Lay a straight edge across the surface of the cylinder head 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.

2. Remove spring retainer and spring.

NOTE: The valve springs should be positioned with the tightly wound coils against the cylinder head on progressively wound springs (A).

3. Push valve out, keepin g it in order for reassembly in the same guide.

3.21

ENGINE

4. Measure free length of spring with a Vernier caliper. Check spring for squareness. Compare to specifications. Replace spring if either measurement is out of specification

5. Remove valve seals. CAUTION: Replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.

seat area (B). NOTE: The valves cannot be re-faced or end ground. V alves must be replaced if worn, bent, or damaged.

Measure valve stem in several places

Intake: .2343-.2348” (5.950-5.965 mm)

Exhaust: .2341-.2346” (5.945-5.960 mm)

5. Measure diameter of valve stem with a micrometer in three places and in two different directions (six measurements total). Compare to specifications.

Valve Stem Diameter:

Valve Inspection

1. Remove all carbon from valve with a soft wire wheel.

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 use a dial indicator.

Valve Guide I.D.:

.2362-.2367” (6.0-6.012 mm)

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, front to back and side to side.

7. Subtract valve stem measurement to obtain stem to guide clearance.

NOTE: Be sure to measure each guide and valve combination individually

8. Replace valve and/or guide if clearance is excessive.Compare to specifications.

NOTE: If valve guides are replaced, valve seats must be reconditioned. Refer to Valve Seat Reconditioning for procedure.

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

4. Inspect split keeper groove for wear or flaring of the keeper

3.22

ENGINE

Combustion Chamber

Clean all accumulated carbon deposits from combustion chamber and valve seat area with a soft wire brush.

Valve Seat ReconditionING

Valve Seat Inspection

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

the valve seat is cracked the cylinder head must be replaced.

Cylinder Head Reconditioning NOTE: Servicing the valve guides and valve seats

requires special tools and a thorough knowledge of reconditioning techniques. Follow the instructions provided in the cylinder head service tool kit.

CAUTION

3. Heat cylinder head in an oven or use a hot plate to bring cylinder head temperature to 212

F (100o C).

CAUTION

Do not use a torch to heat cylinder head or warpage m ay

result from uneven heating. Head temperature can be

checked with a pyrometer or a welding temperature

stick. Wear the appropriate safety equipment for

working with heated metal.

Follow the manufacturers instructions provided with the valve seat cutters in the Valve Seat Reconditioning Kit (PN

2200634). Abrasive stone seat reconditioning equipment

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

Too Uneven Good Too

Wide

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, ca using carbon accumulation and possible compression loss. If the seat is too narrow, heat transfer from valve to seat is reduced and the valve may overheat and warp, resulting in burnt valves.

Narrow

Wear eye protection when performing cylinder head

service. Valve guide replacement will require heating of

the cylinder head. Wear gloves to prevent burns.

Valve Guide Removal/Installation

1. Remove all carbon deposits from the combustion chamber, valve seat and valve guide area before attempting to remove valve guides.

CAUTION

Carbon deposits are extremely abrasive and may

damage the valve guide bore when guides are re moved.

2. Place new valve guides in a freezer for at least 15 minutes while heating cylinder head.

1. When thoroughly heated, place cylinder head on blocks of wood which will allow the old guides to be removed.

2. Using valve guide driver, drive guides out of the cylinder head from the combustion chamber side. Be careful not to damage guide bore or valve seat when removing guides.

3.23

ENGINE

3. Place cylinder head on cylinder head table. NOTE: Be sure

cylinder head is still at 212 new guides.

Valve Guide Installed Height

Valve Guide Height:

.689-.709” (17.5-18.0 mm)

4. Place a new guide in the valve guide installation tool and press guide in to proper depth. Check height of each guide above the cylinder head (A). NOTE: The guide can also be driven in to the proper depth. Inspect the guide closely for cracks or damage if a driver is used.

Reaming The Valve Guide

F (100o C) before installing

8. Apply cutting oil to valve seat and cutter.

9. Place 46

10. Inspect the cut area of the seat.

• If the contact area is less than 75% of the

• If the cutter now contacts the uncut portion of the

• If the contact area of the cutter is in the same

cutter on the pilot and make a light cut.

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

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

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.

and

5. Allow cylinder head to cool to room temperature. Apply cutting oil to the reamer. Guides should be reamed from the valve spring side of the cylinder head. Ream each guide to size by turning the reamer clockwise continually. Continue to rotate reamer clockwise during removal of the tool.

6. Clean guides thoroughly with hot soapy water and a nylon brush. Rinse and dry with compressed air. Apply clean engine oil to guides.

7. Install pilot in to valve guide.

• 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.

(A)

11. To check the contact area of the seat on the valve face, apply a thin coating of Prussian Blue™ paste to the valve seat. If using an interference angle (46 marker to the entire valve face (A).

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

) apply black permanent

3.24

ENGINE

13. Remove valve and check where the Prussian Blue™ 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.

• 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

lower the valve seat.

• If too low use the 60

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

• If the seat is too wide or uneven, use both top and

bottom cutters to narrow the seat.

• If the seat is too narrow, widen using the 45

and re-check contact point on the va lve face and seat width after each cut.

Valve Seat Width:

Intake Std: .028” (.7 mm)

Limit: .055” (1.4 mm)

Exhaust Std: .039” (1.0 mm)

Limit: .071” (1.8 mm)

or 75o cutter to raise the

cutter to

cutter

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 on the black marker, all the way around the valve face.

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

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

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

17. 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 ti mes until the valve is fully seated, and repeat process for the other valve(s).

Bottom - 60o or 75o

Seat Width

Seat - 45

or 46

Top - 30

18. Clean cylinder head, valves, and camshaft oil supply passage (A) thoroughly.

19. If oil passage blind plug was removed, apply Crankcase

Sealant (PN 2871557) or equivalent sealer to the threads and install, torquing to 8 ft. lbs. (11 Nm).

CAUTION

Do not allow sealant to enter oil passage.

20. Spray electrical contact cleaner into oil passage and dry using compressed air.

3.25

ENGINE

Cylinder Head Assembly

CAUTION

Wear eye protection during assembly.

NOTE: Assemble the valves one at a time to maintain proper order.

1. Install new valve seals on valve guides.

2. Apply engine oil to valve guides and seats.

3. Coat valve stem with molybdenum disulfide grease.

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

5. Dip valve spring and retainer in clean engine oil and install spring with closely spaced coils toward the cylinder head.

Valve Sealing Test

1. Clean and dry the combustion chamber area.

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

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

Valve Clearance Adjustment

Feeler gauge for both valves

NOTE: The valves share a common rocker arm, and

must be adjusted using two feeler gauges.

1. Insert .006 feeler gauge(s) between end of exhaust valve stem and adjuster screw(s).

2. Loosen locknut(s) and turn adjuster screw(s) until there is a slight drag on feeler gauge(s). The Valve/Clutch Adjuster Tool (PA-44689) can be used to adjust the 500 engines valves.

NOTE: Both feeler gauges should remain inserted during adjustment of each valve

6. Place retainer on springs and install valve spring compressor. Compress spring only enough to allow split keeper installation and prevent loss of spring tension. Install split keepers with the gap even on both sides.

7. Repeat procedure for remaining valve.

8. When all valves are installed, tap lightly with soft faced hammer on the end of the valves to seat the split keepers.

3.26

VALVE CLEARANCE

.006” (.15 mm)

3. When clearance is correct, hold adjuster screw and tighten locknut securely

4. Re-check the valve clearance.

5. Repeat adjustment procedure if necessary until clearance is correct with locknut secured.

ENGINE

Cylinder/Piston Removal and Inspection

NOTE: Follow engine disassembly procedures to

remove valve cover, camshaft and rocker arms, and cylinder head.

1. Remove cam chain guide at front of cylinder.

4. Remove the two 6 mm cylinder base bolts.

5. Loosen each of the four large cylinder base bolts 1/4 turn at a time in a criss-cross pattern until loose and remove bolts.

NOTE: The bolts are inside the water jacket.

2. Loosen all four oil pipe banjo bolts and then rem ove the bolts and eight sealing washers. Remove the pipes.

3. Loosen hose clamps and remove coolant in let hose.

6. Tap cylinder lightly with a plastic hammer in the reinforced areas only until loose.

7. Rock cylinder forward and backward and lift it from the crankcase, supporting piston and connecting rod. Support piston with Piston Support Block (PN 2870390).

8. Remove dowel pins from crankcase.

3.27

ENGINE

Piston Removal

1. Remove circlip. Note piston directional arrow pointing toward the right (Mag) side of engine.

1. Remove piston circlip and push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch.

2. Remove top compression ring.

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

3. Repeat procedure for second 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 (A) in the upper oil ring land of the piston.

4. Remove the top rai l first followed by the bottom rail.

5. Remove the expander.

CAUTION

Do not apply heat to the piston rings. The ring may

lose radial tension

*Using a piston ring pliers: Carefully expand ring and lift it off the piston.

CAUTION

Cylinder Inspection

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

2. Inspect the top of the cylinder for warpage using a straight edge and feeler gauge.

Cylinder Warp Limit:

.002” (.05 mm)

Do not expand the ring more than necessary to remove it from the piston or the ring may break

3.28

ENGINE

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

1/2” Down From Top of Cylinder

1/2” Up From Bottom

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 (1/2” down from top, in the middle, and 1/ 2” up from bottom).

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

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

Piston to Cylinder Clearance

Std: .0006- .0018” (.015- .045 mm)

Piston O.D.:

Std: 3.6204- 3.6215” (91.970-91.985 mm)

Piston/Rod Inspection

Piston Pin Bore

Piston Pin Bore:

Cylinder Taper

Limit: .002 Max.

Cylinder Out of Round

Limit: .002 Max.

Standard Bore Size:

3.6221-3.6228” (92.00 - 92.012 mm)

Piston-to-Cylinder Clearance

Piston

40 mm

Piston Pin

1. Measure piston outside diameter at a point 40 mm down from the top of the piston at a right angle to the direction of the piston pin.

.9055-.9057” (23.0-23.006 mm)

1. Measure piston pin bore.

Piston Pin Measurement Locations

Piston Pin O.D.

.9053-.9055” (22.994-23.0 mm)

3.29

ENGINE

Piston Ring Installed Gap

1. Place each piston ring inside cylinder using piston to push ring squarely into place as shown at right.

Feeler Gauge

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

3. Measure connecting rod small end ID.

Piston

Ring

Feeler Gauge

Piston Ring-to-Groove Clearance

Top Ring Std: .0016-.0031” (.040-.080 mm)

Limit: .0059” (15 mm)

Second Ring Std: .0012-.0028” (.030-.070 mm)

Limit: .0059” (15 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

Cylinder

Piston Ring

Piston Ring Installed Gap

Top Ring

Std: .0079- .0138” (.20- .36 mm)

Limit: .039” (1.0 mm)

Second Ring

Std: .0079- .0138” (.20- .36 mm)

Limit: .039” (1.0 mm)

Oil Ring

Std: .0079- .0276” (.20- .70 mm)

Limit: .059” (1.5 mm)

2. Measure installed gap with a feeler gauge at both the top and bottom of the cylinder.

NOTE: 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 below specified limit, file ring ends until gap is within specifi ed range.

NOTE: Always check piston ring installed gap after reboring 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 an oil rag immediately to remove residue and prevent rust.

25-50 mm

3.30

Crankcase Disassembly

NOTE: The recoil starter, starter motor , starte r drive, flywheel, stator, cam chain and sprockets can be serviced with the engine in the frame.

ENGINE

Starter Drive Removal/Inspection

1. Remove recoil housing bol ts and rem ove housing.

2. Remove starter drive assembly. Note the thrust washer located at the rear of the drive mechanism.

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

5. Measure the ID of the bushing in the recoil housing (A) and in the crankcase and record. Measure in two directions 90 apart to determine if bushing is out of round. Calculate bushing clearance. Replace bushing if clearance exceeds the service limit.

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

Flywheel/Stator Removal/Inspection

1. Remove flywheel nut and washer.

2. Install Flywheel Puller (PN 2871043) and remove flywheel.

CAUTION

Do not thread the puller bolts into the flywheel more

than 1/4" or stator coils may be damaged

3. Mark or note position of stator plate on crankcase.

4. Remove bolts and carefully remove stator assembly, being careful not to damage crankshaft bushing on stator plate.

5. Replace crankshaft seal (A).

.4735”-.4740” (11.11-12.04 mm)

Std. Bushing ID:

Std. Shaft OD:

.470”-.472” (11.93-11.99 mm)

Starter Drive Bushing Clearance:

Std: .0015-.004” (.038-.102 mm)

Service Limit:

.008” (.203 mm)

4. Measure the OD of the starter drive shaft on both ends and record.

6. Remove oil passage O-Ring (B).

3.31

ENGINE

7. Remove large sealing O-Ring from outer edge of stator plate.

Cam Chain/Tensioner Blade

1. Remove bolt securing tensioner blade to crankcase (A).

section of chain. Replace if worn past service limit.

Chain Service Limit: 5.407” (13.7 cm)

4. Using the special socket, remove the crankshaft slotted nut.

NOTE: The cran ksh a ft slot te d nu t is a left-hand thread.

5. Remove cam chain drive sprocket and woodruff key from crankshaft.

6. Inspect sprocket teeth for wear or damage.

7. Inspect woodruff key for wear.

8. Replace any worn or damaged parts.

One Way Valve Removal

The one way valve prevents oil from draining ou t of the oil tank and into the crankcase when the engine is off. It must be clean and have adequate spring pressure in order to seal properly.

2. Remove blade and inspect for cracks, wear, or damage.

20 Pitch Section

3. Remove cam chain (B ). Inspect chain for worn or missing rollers or damage. Stretch chain tight on a flat surface and apply a 10 lb. (4.53 kg) load. Measure length of a 20 pitch

1. Remove cap bolt (A), sealin g washer (B), spring (C), and one way valve (D) from PTO side crankcase.

2. Inspect free length of spring and check coils for distortion.

One Way Valve Spring Free Length:

Std: 1.450” (3.68 cm)

3. Inspect valve for wear.

4. Check seat area for nicks or foreign material that may prevent proper sealing of valve.

3.32

ENGINE

Crankcase Separation

1. Remove flange bolts (10) from magneto side crankcase evenly in a criss-cross pattern.

2. Separate crankcase by tapping with a soft faced hammer in reinforced areas.

3. Tap lightly on balancer gear with a brass drift through th e hole in the crankcase if necessary, to ensure the balancer shaft stays in the PTO side crankcase. Watch the gap along the crankcase mating surface and separate the crankcase evenly. It may also be necessary to tap the oil pump shaft lightly to separate the crankcase.

3. Inspect drive gear teeth for cracks, damage or excessive wear.

4. Remove three oil pump retai ning bolts and pump.

5. Inspect mating surface of crankcase and oil pump. Check for nicks, burrs, or surface irregularities.

CAUTION

Do not strike the oil pump shaft at an angle or the

shaft may bend, causing irreparable damage. Tap

only lightly on the pump shaft if necessary.

4. Remove the Mag (RH) crankcase from the PTO case.

Oil Pump Removal/Inspection

1. Remove pump shaft bearing (A) and thrust washer (B) from pump shaft.

2. Remove (2) bolts holding pump drive gear (C).

6. Remove the three screws and strainer screen from pump.

7. Clean screen thoroughly.

8. Remove pump body screw and feed chamber cover.

3.33

ENGINE

9. Measure pump end clearance using a feeler gauge and straight edge.

Pump End Clearance:

Std: .001 -.003 (.0254-.0762 mm)

Wear Limit: .004 (.1016 mm)

10. Measure clearance between outer feed rotor and pump body with a feeler gauge.

Oil Pump Assembly

1. Clean and dry all parts thoroughly. Apply clean engine oil to all parts. Do not use gasket sealer on the pump body mating surfaces or oil passages will become plugged.

2. Install pump shaft and scavenge rotor drive pin.

3. Install outer scavenge rotor, inner scavenge rotor, and scavenge casing.

4. Install outer feed rotor and inner feed rotor drive pin.

5. Install inner feed rotor and feed chamber cover with screw.

6. Tighten screw securely.

7. Install screen on pump body.

8. Install oil pump on crankcase and torque bolts to 6 ft . lbs. (8 Nm).

Oil Pump Attaching Bolt Torque:

6 ft. lbs. (8 Nm)

Counter Balancer Shaft Removal/Inspection

1. Remove the shim washer (A) from the counter balancer shaft.

Rotor Tip Clearance:

Std: .005 (.127 mm)

Wear Limit: .008 (.2032 mm)

11. Measure rotor tip clearance with a feeler gauge.

12. Remove inner and outer feed rotor and pump chamber body.

13. Repeat measurements for scavenge rotor.

14. Remove inner and outer scavenge rotor and inspect pump shaft for wear.

3.34

2. Note the alignment dots on the balancer and crankshaft gears, the marks must be aligned during reassembly.

ENGINE

3. Turn the shaft until balancer counter weights clear the crankshaft and remove the balancer shaft from the crankcase.

4. Inspect the balancer drive gear and pump shaft drive gear.

5. Replace the shaft if gear teeth are abnormally worn or damaged.

6. Inspect the balancer shaft bearings.

NOTE: Due to extremely close tolerances and minimal wear, the balancer shaft ball bearings must be inspected visually and by feel. Look for signs of discoloration, scoring or galling. Turn the inner race of each bearing. The bearings should turn smoothly and quietly. The outer race of each bearing should fit tightly in the crankcase. The inner race should be firm with minimal side to side movement and no detectable up and down movement.

Crankshaft Removal/Inspection

8. Support the PTO side crankcase and crankshaft; press the crankshaft out. Be careful not to damage the crankcase mating surface or connecting rod.

9. Use a feeler gauge to measure the connecting rod big end side clearance.

Connecting Rod Big End Side Clearance:

Std: .0039-.0256” (.1-.65 mm)

Limit: .0315” (.80 mm)

10. Place the crankshaft in a truing stand or V-blocks and measure the runout on both ends with a dial indicator.

Max Runout: .0024” (.06 mm)

11. Measure the connecting rod big end radial clearance.

Big End Radial Clearance:

Std: .0004-.0015” (.011-.038 mm)

Limit: .0020” (.05 mm)

7. Remove the shim washer (A) from the crankshaft.

12. Inspect the crankshaft main bearing journals for scoring and abnormal wear.

3.35

ENGINE

Crankcase Bearing Inspection

1. Remove the seal from the PTO side crankcase.

2. Inspect the crankshaft main bearings, balancer shaft bearings, and pump shaft bearing.

NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. Look for signs of discoloration, scoring or galling. Turn the inner race of each bearing. The bearings should turn smoothly and quietly . The outer race of e ach bearing should fit tightly in the crankcase. The inner race should be firm with minimal side to side movement and no detectable up and down movement.

3. Support the crankcase and drive or press the main bearings out of each crankcase.

4. To remove balancer shaft bearings and pump shaft bearing use a blind hole bearing puller.

NOTE: Bearings are stressed during the removal process and should not be re-used!

Pump Shaft Oil Seal/W ater Pump Mechanical Seal Removal (Engine Disassembled)

NOTE: The water pump mechanical seal can be

removed without removing the engine. Refer to Water Pump Mechanical Seal Installation.

Replace the pump shaft seal and water pump mechanical seal whenever the crankcase is disassembled.

1. Remove the pump shaft bearing from the Magneto (right hand) side crankcase.

2. Pry out the oil seal, noting the direction of installation with the spring side facing IN (toward inside of case).

3. Drive the water pump mechanical seal out of the crankcase from inside to outside. Note: The new mechanical seal must be installed after special tool. See Mechanical Seal Installation.

the crankcases are assembled, using a

Crankcase Inspection

1. Remove all traces of gasket sealer from the crankcase mating surfaces. Inspect the surfaces closely for nicks, burrs or damage.

2. Check the oil pump and oil passage mating surfaces to be sure they are clean and not damaged.

3.36

ENGINE

Bearing Installation

NOTE: To ease bearing installation, warm the

crankcase until hot to the touch. Place the bearings in a freezer.

1. Install the bearings so the numbers are visible.

2. Drive or press new bearings into the crankcases, using the proper driver.

CAUTION

Press only on outer race of bearing

to prevent bearing damage

• 70 mm (2.755") driver- For crankshaft main

bearings.

• 46 mm (1.810") For counter balancer bearings.

• 28 mm (1.100") For pump shaft bearing.

End Play Inspection/Adjustment

Before reassembling the crankcase,the following steps should be performed to determine the amount of crankshaft, counter balancer shaft, and pump shaft end play . Excessive end play may cause engine noise at idle and slow speeds. Too little play will side load the bearings which may lead to premature bearing failure.

4. Measure the distance from the PTO crankcase mating surface to the main bearing using a dial caliper and a straight edge.

5. Subtract the thickness of the straightedge from the measurement obtained in Step 2 and record.

Crankshaft End Play Adjustment

3. Make sure all bearings are firmly seated in the both Mag and PTO crankcase.

PTO Case Depth_________________________

3.37

ENGINE

6. Measure the distance from the Magneto crankcase mating surface to the main bearing using the same method and record.

7. Subtract the thickness of the straightedge from the measurement obtained in Step 4 and record.

Mag Case Depth_______________

10. Subtract the Crankshaft Width measured in S tep 7 from the Total Case Width recorded in Step 6, and record below.

Total End Play_____________

11. Subtract the thickness of the existing shim from the result of Step 8 to determine if a different shim is required. The result must be within the specified range listed.

Crankshaft End Play: .008-.016” (.02-.04 cm)

Counter Balancer Shaft End Play Adjustment.

8. Add the readings recorded in Step 3 and Step 5 and record below.

Total Case Width_________________

9. Measure the width of the crankshaft at the bearing seats with a micrometer or dial caliper and record.

12. Make sure all bearings are firmly seated in the crankcase.

13. Measure the width of the counter balancer shaft at the bearing seats with a dial caliper or micrometer, and record reading.

Crankshaft Width____________

3.38

ENGINE

14. Measure the distance from the Mag crankcase mating surface to the balance shaft bearing using a dial caliper and a straight edge. Subtract the thickness of the straightedge and record.

15. Measure the distance from the PTO crankcase mating surface to the bearing using the same method outlined in Step 1, 2, and-3.

16. Add the readings obtained in Step 3 and Step 4.

17. Subtract the counter balancer shaft width measured in Step 2 from the figure obtained in Step 5.

18. Subtract the thickness of the existing shim from the result of Step 6 to determine if a different shim is needed. The result must be within the specified range listed at below.

Counter Balance Shaft End Play:

.008”-.016” (.02-.04 cm)

Oil Pump Shaft End Play Adjustment

1. Make sure the pump shaft bearing is firm ly seated in the Magneto side crankcase.

3. Install the gear on the oil pump and measure the width of the pump and gear. Subtract this measurement from the measurement recorded in Step 2.

4. Subtract the thickness o f the ex isting shim from th e result of Step 3 to determine if a different shim is needed. See Shaft End Play Spec.

Oil Pump Shaft End Play:

.008”-.016” (.02-.04 cm)

2. Measure the distance from the magneto crankcase mating surface to the bearing using a dial caliper and a straight edge. Subtract the thickness of the straightedge and record.

3.39

ENGINE

ENGINE REASSEMBLY

Pump Shaft Oil Seal Inst allation

1. Install the seal from the outside of the crankcase (water pump side) with the spring facing inward, toward the pump shaft bearing.

2. Drive or press the seal into place using a 25 mm (.985") seal driver, until flush with the outer edge of the seal bore.

3. Lubricate the seal lip with grease.

Crankshaft/Counter Balance/Oil Pump Installation

Lubricate all bearings with clean engine oil before assembly.

Use the Crankshaft/Water Pump Installation Kit (PN

2871283) to prevent damage to the crankshaft and main bearings during installation.

1. Install the crankshaft into the PTO side crankcase. Screw the threaded rod into the crankshaft until the threads are engaged a minimum of one inch (25.4mm).

2. Install the collar, washer, and nut onto the threaded rod. Hold the crankshaft and tighten the nut to draw the crankshaft into the main bearings until fully seated. Loosen the nut and remove the threaded rod from the crankshaft. If removal is difficult, install two nuts on the end of the threaded rod and tighten against each other.

3. Install the proper shim on the magneto end of the crankshaft.

4. Place the balancer shaft in the PTO crankcase aligning the timing marks on the crankshaft and balancer gears. Install the proper shim washer on the shaft.

5. Inspect the oil pump sealing surface on the crankcase. Apply a light film of engine oil to the surface and install the oil pump.

NOTE: Do not use gasket sealer on the pump mating surfaces.

NOTE: After engine is assembled and machine is readied for field operation, oil pump MUST be primed. Follow oil pump priming procedure.

Oil Pump Bolt Torque:

6 ft. lbs. (8 Nm)

6. Align the drive gear with the drive pin on the pump shaft and install the gear. Be sure the gear is fully seated and properly engaged.

7. Install the proper shim washer on the pump shaft.

3.40

ENGINE

Crankcase Assembly

1. Apply Crankcase Sealant (PN 2871557 ) to the crankcase

mating surfaces. Be sure the alignment pins are in place.

2. Set the crankcase in position carefully to avoid damaging the pump shaft seal, and install the magneto end crankshaft installation tool (follow instructions provided with the Crankshaft/Water Pump Installation Kit (PN 2871283). Draw the crankcase halves together by tightening the nut on the tool and tapping lightly in the pump shaft area with a soft faced hammer to maintain alignment. Continually check alignment of the cases during installation, closing the gap equally until the surfaces are tightly seated.

3. Remove the tool.

4. Install the crankcase flange bolts and tighten in 3 steps following the pattern to specified torque.

Crankcase Bolt Torque:

14 ft. lbs. (19 Nm)

Crankcase Sealant:

(PN 2871557)

Water Pump Mechanical Seal Installation

Water Pump Mechanical Seal Removal Engine Installed

Water Pump Mechanical Seal

Puller: (PN 2872105)

Replacement T-Handle:

(PN 2872106)

This tool allows a technician to replace the mechanical water pump seal on EH50PL engines without removing the engine and splitting the cases.

CAUTION

Improper or careless use of this tool or procedure

can result in a bent water pump shaft.Pump shaft

replacement requires engine removal and crankcase separation. Use caution while performing this procedure. Make sure that the puller is parallel

to the shaft at all times. Do not place side loads on the water pump shaft or strike the puller or shaft in

any way.

1. After the coolant has been drained, remove the water pump cover, impeller and the sealing washer. (Ill. 1).

Sealing Washer

5. Clean the seal cavity to remove all traces of old sealer.

6. Place a new mechanical seal in the seal drive collar, and install on the pump shaft.

7. Screw the guide onto the end of the pump shaft.

8. Install the washer and nut and tighten to draw seal into place until fully seated.

9. Remove the guide adaptor using the additional nut as a jam nut if necessary.

Sealing Washer (Copper or Aluminium)

Coolant Drain Bolt

III. 1

Oil Seal

Impeller

Mechanical Seal

3.41

ENGINE

2. Slide the main puller body over the outer portion of the mechanical seal as shown in Ill. 2 and turn T-Handle clockwise until it contacts water pump shaft. Continue rotating until outer portion of mechanical seal is separated from the metal seal body.

T-Handle

Main Puller Body

III. 2

3. Insert the puller legs between the water pump drive sh aft and the remaining portion of the mechanical seal. Attach the puller legs to the main puller body. Ill. 3

Main puller

body

5. Tighten the hex socket screws on the puller legs sufficiently so the lip of the puller legs will grasp the mechanical seal. Ill. 5.

T-Handle

Main Puller Body

III. 5

6. Turn the puller T-Handle clockwise unti l it contacts the water pump shaft. Continue rotating until the remaining portion of mechanical seal has been removed from the cases. Ill. 6 Pump shaft oil seal can also be replaced at this time if necessary.

7. The Water Pump Install Kit (PN 5131135) is required to install the new mechanical seal. This tool is available separately and it is also included in the Crankshaft/Water Pump Seal Installation Kit (PN 2871283).

Position the split

to opening

90 on main puller

body

III.3

4. Ensure that the split between the puller legs are fully supported by the main body of the tool (Ill 4).

Hex Socket Screws

Puller Legs

One Way Valve Installation

Install the one way valve plung er , spring, and plug using a new sealing washer.

One Way Valve Plug Torque:

16 ft. lbs. (22 Nm)

III. 4

3.42

Lip must grasp inside of mechanical seal

Polaris SPORTSMAN 700 EFI User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS

TRADEMARKS

MODEL NUMBER INFORMATION

Model Number

Engine Designation Numbers

V ehicle Identification Number (VIN)

Transmission I.d. Location

Engine And Machine Serial Numbers

Publications

Paint Codes

Replacement Keys

Sportsman ‘Deluxe’ and ‘Standard’ Model Component Comparison

Sportsman X2 ‘Deluxe’ and ‘Standard’ Model Component Comparison

2007 SPORTSMAN 450

2007 SPORTSMAN 500 EFI

2007 SPORTSMAN X-2 500 EFI

MISC. NUMBERS/CHARTS

Standard Torque Specifications

SAE Tap Drill Sizes

Metric Tap Drill Sizes

Decimal Equivalents

Conversion Table

Glossary Of Terms

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

Periodic Maintenance Chart

LUBRICATION / FLUIDS

SPORTSMAN Component Locations

SPORTSMAN X2 Component locations

Polaris Lubricants, Maintenance and Service Products

Polaris Lubricant Symbol Identification

Pre-ride / Daily Inspection

Lubrication Components

Front Gearcase Lubrication

Transmission Lubrication

ADC Differential Hydraulic Circuit Fluid Change

VEHICLE INSPECTION

Shift Link Rod Inspection

Throttle Inspection

Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment

Fuel System

Fuel Lines

Vent Lines

Fuel Filter

Compression Test

Engine Mounts

Spark Plug

Active Descent Control (ADC) Reservoir Level

Battery Maintenance

Liquid Cooling System Overview

Coolant Strength / Type

Cooling System Hoses

Radiator/Grill Screen

Cooling System Pressure Test

Coolant Level Inspection

Air Filter/Pre-Filter Service

Radiator Coolant Level Inspection

Air Box Sediment Tube

Breather Filter Inspection

Breather Hose

Recoil Housing

Engine Oil Level

Oil and Filter Change

Oil Pump Priming Procedure

Valve Clearance

Intake Valve Clearance Adjustment

Steering

Exhaust Valve Clearance Adjustment

Tie Rod End/Steering Inspection

Wheel Alignment

Camber and Caster

Toe Alignment Adjustment

Exhaust Pipe

Brake System Inspection