Polaris Sportsman 700 Efi (2005) Service manual

2005 SPORTSMAN 700 EFI
2005 SPORTSMAN 800 EFI

SERVICE MANUAL

PN 9919820

2005 SPORTSMAN 700/800 EFI

SERVICE MANUAL

Foreword

This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle
are from the operator’s perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, andshop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar
with service procedures before starting the work. Certain procedures require the use of special tools. Use
only the proper tools as specified.

This manual includes procedures for maintenance operations, component identification and unit repair, along
with service specifications for Polaris Sportsman 700/800 EFI ATVs. Comments or suggestions about this
manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota

55340.

Some Polaris factory manuals can be downloaded from www.polarisindustries.com or purchased from

www.purepolaris.com or contact your nearest Polaris dealer.

2005 Sportsman 700/800 EFI ATV Service Manual (PN 9919820)

ECopyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the
time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may
result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are
intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions
and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS

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

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

DANGER

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

WARNING

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

CAUTION:

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

NOTE:

A NOTE provides key information to clarify instructions.

Trademarks

Polaris acknowledges the following products mentioned in this manual:

Loctite, Registered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Ammco, Registered Trademark of Ammco Tools, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of the Warn Industries
HiPerWasht and Liquid Bufft are trademarks of HPC inc.

GENERAL

MAINTENANCE

ENGINE

ELECTRONIC FUEL INJECTION

BODY AND STEERING

CLUTCHING

FINAL DRIVE

TRANSMISSION

BRAKES

ELECTRICAL

GENERAL INFORMATION

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

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

2005 Sportsman EFI Dimensions 1.3...........

Specifications - Sportsman EFI 1.4--1.5............

Publication Numbers 1.6.....................

Paint Codes 1.6.............................

Specs

Replacement Keys 1.6.......................

Standard Torque Specifications 1.6............

Special Tools 1.7--1.10............................

Torque Table 1.11............................

Conversion Table 1.12........................

Tap Drill Charts 1.13..........................

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

Glossary of Terms 1.14........................

1.1

GENERAL INFORMATION

MODEL IDENTIFICATION

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

Machine Model Number Identification

A05MH68AU

Emissions &

Year Designation

Basic Chassis
Designation Engine Designation

Model Option

ENGINE DESIGNATION

EH068OLE Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start.................

EH076OLE Twin cylinder, Liquid Cooled, 4 Stroke, Electric Start.................

VIN IDENTIFICA

World Mfg. ID

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

Body Style

TION

Vehicle Description

Powertrain

ENGINE SERIAL NUMBER LOCA

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.

NUMBERS

68A* 4P0 00 0 00

Emissions

Engine

Check Digit

Model
Year

Plant No.

TION

MACHINE MODEL NUMBER AND

Vehicle Identifier

Individual Serial No.

A

* This could be either
a number or a letter

SERIAL NUMBER LOCATION

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

TRANSMISSION I.D.
LOCA

TION

NUMBER

1.2

Front

B

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

GENERAL INFORMATION

MODEL: 2005 SPORTSMAN 700 EFI..........

MODEL NUMBER: A05MH68AU.
ENGINE MODEL: EH068OLE22..

Category Dimension / Capacity

Length 83 in./205.74 cm

Width 48 in./116.8 cm

Height 48 in./119.4 cm

Seat Height 34 in./86.4 cm

Wheel Base 50.75 in./128.9 cm

Dry Weight 770 lbs./326.6 kg

Gross Vehicle Weight 1220 lbs. / 553 kg

Front Rack Capacity 100 lbs./45.4 kg

Rear Rack Capacity 200 lbs./90.7 kg

Towing Capacity 1500 lbs./454 kg

Hitch Tongue Capacity 150 lbs./68 kg

Body Style Spirit

MODEL: 2005 SPORTSMAN 800 EFI..........

MODEL NUMBER: A05MH86AU.
ENGINE MODEL: EH076OLE011..

Category

Length 83 in./205.74 cm

Width 48 in./116.8 cm

Height 48 in./119.4 cm

Seat Height 34 in./86.4 cm

Wheel Base 50.75 in./128.9 cm

Dry Weight 770 lbs./326.6 kg

Gross Vehicle Weight 1220 lbs. / 553 kg

Front Rack Capacity 100 lbs./45.4 kg

Rear Rack Capacity 200 lbs./90.7 kg

Towing Capacity 1500 lbs./454 kg

Hitch Tongue Capacity 150 lbs./68 kg

Body Style Spirit

Dimension / Capacity

1.3

MODEL: 2005 SPORTSMAN 700 EFI..........

MODEL NUMBER: A05MH68AU.
ENGINE MODEL: EH068OLE..

Engine

Platform Polaris Twin Cylinder

Engine Model Number EH0680LE022

Engine Displacement 683cc

Number of Cylinders 2

Bore & Stroke (mm) 80 x 68 mm

Compression Ratio 9.78:1

Compression Pressure 150--170 psi

Engine Idle Speed 1150 ± 100 RPM

Engine Max Operating Rpm 6500 Rpm ± 200 Rpm

Cooling System / Capacity Liquid -- 3.2 qt / 3 ltr

Overheat Warning HOT on Instrument Cluster

Lubrication Pressurized Wet Sump

Oil Requirements / Capacity Polaris 0W--40 2 qt. / 1.9 ltr

Exhaust System Single Pipe

Fuel System

Fuel System Electronic Fuel Injection (EFI)

Fuel Pump (in tank assembly) 25L per hour at 39 PSI

Fuel Filter(s) 30 Micron in Tank (not replaceable)

10 Micron In Line (replaceable)

Fuel Injector(s) Bosch

EFI Controller Bosch MSE 1.1 ECU

Fuel Capacity / Requirement 4.13 gal US / 15.6 ltr

87 Octane (minimum)

89 Oxygenated

Electrical

Alternator Output 500 w @ 6000 RPM

Lights : Pod 50 watts

Grill Two x 27 watts

Brake 8.26 watts

Ta il 26.9 watts

Ignition System DC/CDI Ignition

Operating RPM 6000 RPM

Ignition Timing 13° BTDC @ 1200 RPM

Spark plug / Gap RC7YC/ .035 in./0.9 mm

Battery / Model / Amp Hr Lead Acid / 30 Amp Hr

Circuit Breakers Fan20amp--Harness20amp

Fuel pump/ECU 15 amp

Instrument Cluster / Voltage

Regulator 6 amp

Starting Electric

Instrument Cluster LCD

GENERAL INFORMATION

Drivetrain

Transmission Type Drumshift -- H/L/N/Rev/Park

Transmission Capacity 15 oz. / 450m

Rear Gearcase Capacity 5 oz. / 150ml

Front Gearcase Capacity 5 oz. / 150ml

Gear Ratio : Low

Rev

High

Front Drive

Rear Drive

Clutch Type PVT w/EBS

Belt 3211091

Steering / Suspension

Front Suspension / Shock A-- arm / MacPherson Strut

Front Travel 8.2in./21cm

Rear Suspension / Shock Progressive Rate Independent

Rear Travel 9.5 in. / 24.13 cm

Ground Clearance 11.25 in. / 28.6 cm

Shock Preload Adjustment
Front / Rear

Turning Radius 76 in. / 193 cm unloaded

To e O u t 0 -- 1/16 in / .0 -- .159 mm

/Two x 2” Coil--over Shock

Rear -- Ratchet Style-- Std.

Wheels / Brakes

Wheel Size / Pattern -- Front Steel 25x8--12 / 4-- 156

Wheel Size / Pattern -- Rear Steel 25x11-- 12 / 4--156

Front Tire Size 25x8--12

Rear Tire Size 25x11-- 12

Recommended Air Pressure
F/R

Brake -- Front Dual Hydraulic Disc

Brake -- Rear Dual Hydraulic Disc

CLUTCH CHART EBS Models have no helix/s pring adjustment

Shift

Weight

20--56

(5631215)

20--54

(5631214)

Blu/Green

Blu/Green

Meters

(Feet)

Altitude

0--1800

(0--6000)

1800--3700

(6000--12000)

7.49:1

5.11:1

2.70:1

3.82:1

3.10:1

Front --Non Adjustable.

(205/80R--12)

(270/60R--12)

5 psi Front

5 psi Rear

Drive

Spring

(7041157)

(7041157) (3234199)

Driven

Spring

White

(3234199)

White

60--56--40

(3234208)

60--56--40

Driven

Helix

(3234208)

1.4

GENERAL INFORMATION

MODEL: 2005 SPORTSMAN 800 EFI..........

MODEL NUMBER: A05MH76AU/AW.
ENGINE MODEL: EH076OLE..

Engine

Platform Polaris Twin Cylinder

Engine Model Number EH0760LE011

Engine Displacement 760cc

Number of Cylinders 2

Bore & Stroke (mm) 80 x 68 mm

Compression Ratio 10:1

Compression Pressure 150-- 200 psi

Engine Idle Speed 1150 ± 100 RPM

Engine Max Operating Rpm 6500 Rpm ± 200 Rpm

Cooling System / Capacity Liquid -- 3.2 qt / 3 ltr

Overheat Warning HOT on Instrument Cluster

Lubrication Pressurized Wet Sump

Oil Requirements / Capacity Polaris 0W--40 2 qt. / 1.9 ltr

Exhaust System Dual Pipe / Silencer

Fuel System

Fuel System Electronic Fuel Injection (EFI)

Fuel Pump (in tank assembly) 25L per hour at 39 PSI

Fuel Filter(s) 30 Micron in Tank (not replaceable)

10 Micron In Line (replaceable)

Fuel Injector(s) Bosch

EFI Controller Bosch MSE 1.1 ECU

Fuel Capacity / Requirement 4.13 gal US / 15.6 ltr

87 Octane (minimum)

89 Oxygenated

Electrical

Alternator Output 500 w @ 6000 RPM

Lights : Pod 50 watts

Grill Two x 27 watts

Brake 8.26 watts

Ta il 26.9 watts

Ignition System DC/CDI Ignition

Operating RPM 6000 RPM

Ignition Timing 13° BTDC @ 1200 RPM

Spark plug / Gap RC7YC/ .035 in./0.9 mm

Battery / Model / Amp Hr Lead Acid / 30 Amp Hr

Circuit Breakers Fan20amp--Harness20amp

Fuel pump/ECU 15 amp

Instrument Cluster / Voltage

Regulator 6 amp

Starting Electric

Instrument Cluster LCD

Drivetrain

Transmission Type Drumshift -- H/L/N/Rev/Park

Transmission Capacity 15 oz. / 450m

Rear Gearcase Capacity 5 oz. / 150ml

Front Gearcase Capacity 5 oz. / 150ml

Gear Ratio : Low

Rev

High

Front Drive

Rear Drive

Clutch Type PVT w/EBS

Belt 3211106

7.49:1

5.11:1

2.70:1

3.82:1

3.10:1

Steering / Suspension

Front Suspension / Shock A-- arm / MacPherson Strut

Front Travel 6.7 in. / 17.02 cm

Rear Suspension / Shock Progressive Rate Independent

Rear Travel 9.5 in. / 24.13 cm

Ground Clearance 11.25 in. / 28.6 cm

Shock Preload Adjustment
Front / Rear

Turning Radius 76 in. / 193 cm unloaded

To e O u t 0 -- 1/16 in / .0 -- .159 mm

/Two x 2” Coil--over Shock

Front --Non Adjustable.

Rear -- Ratchet Style-- Std.

Wheels / Brakes

Wheel Size / Pattern -- Front Cast Alum. 26x8-- 12 / 4-- 156

Wheel Size / Pattern -- Rear Cast Alum. 26x11-- 12 / 4-- 156

Front Tire Size 26x8--12

Rear Tire Size 26x11-- 12

Recommended Air Pressure
F/R

Brake -- Front Dual Hydraulic Disc

Brake -- Rear Dual Hydraulic Disc

(205/80R--12)

(270/60R--12)

5 psi Front

5 psi Rear

CLUTCH CHART EBS Models have no helix/s pring adjustment

Meters

(Feet)

Altitude

0--1800

(0--6000)

1800--3700

(6000--12000)

Shift

Weight

20--60

(5631689)

20--58

(5631216)

Drive

Spring

Blu/Green

(7041157)

Blu/Green

(7041157)

Driven

Spring

3234233

3234233

Driven

Helix

3234234

3234234

1.5

PUBLICATION NUMBERS

GENERAL INFORMATION

Year

2005 Sportsman 700 EFI A05MH68AU 9919426 9919427 9919428

2005 Sportsman 800 EFI A05MH76AU 9917720 9917721 9917722

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

NOTE: Some Polaris factory publications can be found at www.polarisindustries.com or purchased from
www.purepolaris.com.

PAINT

PAINTED PART COLOR

FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147.
Order direct at www.polarisdealers.com (dealers only). Mix as directed.

REPLACEMENT

Replacement keys can be made from the original
key. To identify which series the key is, take the
first two digits on the original key and refer to the
chart to the right for the proper part number.

Should both keys become lost, ignition switch
replacement is required.

Model Model No. Owner’s

Manual

Parts

Manual PN

Parts

Micro Fiche

PN

CODES

DITZLER

DESCRIPTION

Frame Black 9440 P-067

NUMBER

POLARIS

NUMBER

KEYS

PN

31XX

Key Series
Number

700 ENGINE COLD WEATHER
FROST PLUG HEA

Frost Plug Heater for Sportsman 700/800 -- (PN 2873069)

TER

1.6

Series #

20 4010278

21 4010278

22 4010321

23 4010321

27 4010321

28 4010321

31 4110141

32 4110148

67 4010278

68 4010278

Part Number

GENERAL INFORMATION

SPECIAL TOOLS

Special Tools maybe required while servicing your
machine. Some of the tools listed are mandatory and
other tools maybe substituted with a similar tool, if
available. Polaris recommends the use of Polaris
special tools when servicing any Polaris product.

Standard Tools and Engine T

PU--45432 -- Caliper or
A Basic Caliper

Basic Micrometer

ools

Standard Tools and Engine Tools

PV--43527 Oil Filter Wrench

2870390 -- Piston Support Block

PA--44995 -- Water Pump Mechanical

Seal Install Tool

PU--45543 -- Universal Driver Handle

2871043 -- Flywheel Puller

2870773 -- C--Clip Install Tool

2870386 -- Piston Pin Puller

2871445 -- Piston Pin Puller Adapter

PA--45483 -- Main Seal Installer

PA--45658 -- Main Crank Seal Saver

PA--45401 -- Water Pump Seal Saver

PU--45778 -- Oil Pump Priming Tool

1.7

SPECIAL TOOLS

GENERAL INFORMATION

Standard Tools and Engine T

2870303 -- Hone Kit

2870305 -- Stone Replacement Kit

2870588 -- Hone Oil (12 oz.)

ools

Clutch (PVT) Tools

2870506 -- Drive Clutch Puller

2870913 -- Driven Clutch Puller

2872292 -- EBS Clutch Align Tool

2200634 -- Valve Seat

Reconditioning Kit

2870459 -- Dial Indicator

PV--35667--A -- Cylinder Leak

down Tester

9914177--A -- Drive Clutch Holding Tool

8700220 -- Clutch Compression Tool

2871358 -- Clutch Hold Fixture

2870341 -- Drive Clutch Spider

Removal Tool

1.8

GENERAL INFORMATION

Clutch (PVT) Tools

2871025 -- Clutch Bushing Replace

Tool Kit

2870910 -- Roll Pin Tool

Suspension Tools

2870871 -- ATV Ball Joint Tool Kit

2871071 -- Shock Body Holding Tool

2871226 -- Clutch Bushing

Replacement Kit

2201379 -- EBS Bushing

Replacement Kit

2870338 -- Spider Nut Socket

2871358 -- Clutch Holding Fixture

2870623 -- Shock Spring Compressor

2871572 -- Strut Rod Wrench

2871573 & 2871574 -- Strut

Spring Compressor

8700225 & 8700226 -- CV Boot

Clamp Pliers

1.9

GENERAL INFORMATION

Suspension Tools

2870872 -- Shock Spanner Wrench

2872608 -- Roll Pin Removal Tool

2871351 -- Shock IFP Depth Tool

Fuel & Brake Systems

Electrical Tools

2870630 -- Timing Light

2871745 --Static Timing Light Harness

2460761 -- Hall Sensor Probe Harness

PV--39991 -- Peak Reading Adapter

2870975 -- Mity Vac

Electrical T

PV--43568 --Fluke 77 Multimeter

PV--39617 -- Current Clamp

ools

PV--37453 -- Christie Se--Sulfating

Multi--Battery Charger

PV--63070 -- Christie Multi--Battery

Charger

2870836 -- Battery Hydrometer

RPM

8712500 -­Tachometer

PV--39951--A -­Tachometer

1.10

GENERAL INFORMATION

STANDARD TORQUE SPECIFICATIONS

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

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

Torque in. lbs. (Nm)

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

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

Torque ft. lbs. (Nm)

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

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

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

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

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

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

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

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

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

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

*

Metric

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

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

SPECIFIC TORQUE VALUES OF FASTENERS

Refer to exploded views in the appropriate section.

1.11

CONVERSION TABLE

GENERAL INFORMATION

Unit of Measure

ft. lbs. x12 =in.lbs.

in. lbs. x .0833 = ft. lbs.

ft. lbs. x 1.356 =Nm

in. lbs. x .0115 =kg-m

Nm x .7376 = ft.lbs.

kg-m x 7.233 = ft. lbs.

kg-m x 86.796 =in.lbs.

kg-m x10 =Nm

in. x 25.4 =mm

mm x .03937 =in.

in. x2.54 =cm

mile (mi.) x1.6 =km

km x .6214 = mile (mi.)

Ounces (oz) x 28.35 = Grams (g)

Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)

Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)

Grams (g) x 0.035 = Ounces (oz)

lb. x .454 =kg

kg x 2.2046 =lb.

Cubic inches (cu in) x 16.387 = Cubic centimeters (cc)

Cubic centimeters (cc) x 0.061 = Cubic inches (cu in)

Imperial pints (Imp pt) x 0.568 = Liters (l)

Liters (l) x1.76 = Imperial pints (Imp pt)

Imperial quarts (Imp qt) x 1.137 = Liters (l)

Liters (l) x0.88 = Imperial quarts (Imp qt)

Imperial quarts (Imp qt) x 1.201 = US quarts (US qt)

US quarts (US qt) x 0.833 = Imperial quarts (Imp qt)

US quarts (US qt) x 0.946 = Liters (l)

Liters (l) x 1.057 = US quarts (US qt)

US gallons (US gal) x 3.785 =Liters (l)

Liters (l) x 0.264 = US gallons (US gal)

Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)

Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)

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

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

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

Multiplied by Converts to

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

1.12

GENERAL INFORMATION

SAE TAP DRILL SIZES

Thread Size/Drill Size

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

Thread Size/Drill Size

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

METRIC TAP DRILL SIZES

Tap S ize

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

Drill Size Decimal

Equiva-

lent

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

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3125

0.3437

0.339

0.375

0.406

0.406

Nearest

Fraction

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

DECIMAL EQUIVALENTS

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

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

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

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

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

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

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

1/8. .1250...

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

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

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

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

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

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

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

1/4 .25....

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

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

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

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

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

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

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

3/8 .375....

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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 .8281...............

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

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

7/8 .875....

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

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

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

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

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

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

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

11.0.....

1.13

GENERAL INFORMATION

GLOSSARY OF TERMS

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

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

kg/cm2: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
lorltr: Liter.
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 magnetic field, a voltage will be generated in the windings.

Mechanical energy is converted to electrical energy in the stator.

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

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

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

1.14

MAINTENANCE

Periodic Maintenance Chart 2.2-2.5...............

Component Locations 2.6....................

Lubricant and Maintenance Product Numbers 2.7

Special Tools 2.8............................

Lubrication Charts 2.9-2.10........................

Front & Rear Gearcase Lubrication 2.11-2.12.........

Transmission Lubrication 2.13..................

Throttle Cable Adjustment 2.14.................

Transmission Linkage Inspection 2.15...........

Fuel System 2.15.............................

Compression Test 2.15-2.16........................

Battery Maintenance 2.16-2.17......................

Ignition 2.17..................................

Coolant System Maintenance 2.18-2.20..............

Radiator Screen Removal 2.20.................

Air Filter Service 2.20-2.21.........................

Air Box Sediment Tube Service 2.21............

Breather Filter 2.21-2.22...........................

PVT Drying & PVT Drain Plug 2.22..............

Oil Change/Filter 2.23-2.24.........................

Steering and Toe Alignment 2.25-2.27...............

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

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

Suspension Service 2.29-2.30......................

Controls 2.30.................................

Wheel/Tire --Removal/Installation/Inspection 2.31-2.32.

Warn® Winch Operation 2.33-2.34..................

Cleaning and Storage 2.35-2.36.....................

800 EFI Exhaust Canister Maintenance 2.36.....

2.1

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

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

Pay special attention to the oil level. A rise in oil level during cold weather can indicate 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 determine the cause or see your dealer.

procedures, have a qualified dealer perform these operations.

G Frequent immersion in mud, water or sand
G Racing or race-style high RPM use
G Prolonged low speed, heavy load operation
G Extended idle
G Short trip cold weather operation

Maintenance Chart Key

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

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

by an authorized Polaris dealer.

"= 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 extended idle. More preventative maintenance is
required under these conditions. Fluid changes, cable, chain and chassis lubrication are required more
frequently. For engine oil, short trip cold weather riding also constitutes severe use. Pay special attention
to oil level. 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

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

J could result in component failure and lead

2.2

MAINTENANCE

j

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)

J

Steering

"

Front suspension

"

Rear suspension
Tires

"

Brake fluid level

"

Brake lever travel
Brake systems
Wheels/fasteners
Frame fasteners

"

Engine oil level

E

"

Air filter, pre-filter

E

"

Air box sediment

E

tube
Coolant

--

--

--

--

--

--

--

--

--

--

--

--

--

Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride

Daily

Daily

Daily

--

--

--

--

--

--

--

--

--

--

--

--

--

Make adjustments as needed. See Pre-Ride
Checklist on Page 1.7.

Inspect; clean often

Drain deposits when visible

Check level daily, change coolant every 2 years

(if applicable)
Headlamp/tail

--

Daily

lamp

"

Air filter,

E

main element
Recoil housing

--

--

Weekly

Weekly

(if applicable)

"

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

J

--

Check operation; apply dielectric grease if re­placing

--

--

Inspect; replace as needed

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

Battery 20 H Monthly 125 (200) Check terminals; clean; test

"

Front gearcase oil

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

(if equipped)

"

Middle gearcase

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

oil (if equipped)

"

Rear gearcase oil

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

(if equipped)

"

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

" Perform these procedures more often for vehicles
subjected to severe use.
E Emission Control System Service (California)
J Have an authorized Polaris dealer perform these
services.

Remarks

2.3

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

MAINTENANCE

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

"

Engine breather

E

filter (if equipped)

"

Engine oil change

E

(break-in)

"

General

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

25 H 1M 155 (250) Perform a break-in oil change at one month

50 H 3M 310 (500) Lubricate all fittings, pivots, cables, etc.

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

J

Steering 50 H 6M 310 (500) Lubricate

"

Front suspension 50 H 6M 310 (500) Lubricate

"

Rear suspension 50 H 6M 310 (500) Lubricate

J

Throttle Cable/

E

ETC Switch

E

Air intake ducts/

50 H 6M 310 (500) Inspect; adjust; lubricate; replace if necessary

50 H 6M 310 (500) Inspect ducts for proper sealing/air leaks

flange
Drive belt 50 H 6M 310 (500) Inspect; adjust; replace as needed
Cooling system

(if applicable)

50 H 6M 310 (500) Inspect coolant strength

seasonally; pressure test
system yearly

"

Engine oil change 100 H 6M 620

E

"

Oil filter change 100 H 6M 620

E

"

Oil tank vent hose 100 H 12 M 620

E

J

Valve clearance 100 H 12 M 620

E

(1000)

(1000)

(1000)

(1000)

Perform a break-in oil change at 25 hours/one
month

Replace with oil change

Inspect routing, condition

Inspect;

" Perform these procedures more often for vehicles
subjected to severe use.
E Emission Control System Service (California)
J Have an authorized Polaris dealer perform these
services.

2.4

MAINTENANCE

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Hours Calendar Miles

J

Fuel system 100 H 12 M 620

E

J

Fuel filter 100 H 12 M 620

E

"

Radiator

100 H 12 M 620

(if applicable)

"

Cooling hoses

100 H 12 M 620

(if applicable)

"

Engine mounts 100 H 12 M 620

Exhaust muffler/

100 H 12 M 620

pipe

J

Spark plug 100 H 12 M 620

E

J

Ignition Timing 100 H 12 M 620

E

"

Wiring 100 H 12 M 620

J

Clutches (drive

100 H 12 M 620

and driven)

J

Front wheel

100 H 12 M 1000

bearings

J

Brake fluid 200 H 24 M 1240

Spark arrestor 300 H 36 M 1860

E

Idle speed

J

Toe adjustment

"

Auxiliary brake

J

Headlight aim

--

--

--

--

" Perform these procedures more often for vehicles
subjected to severe use.
E Emission Control System Service (California)
J Have an authorized Polaris dealer perform these
services.

(Km)

(1000)

(1000)

(1000)

(1000)

(1000)

(1000)

(1000)

(1000)

(1000)

(1000)

(1600)

(2000)

(3000)

Remarks

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

Replace yearly

Inspect; clean external
surfaces

Inspect for leaks

Inspect

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

Adjust as needed
Inspect periodically; adjust when parts are re-

placed
Inspect daily; adjust as needed

Adjust as needed

2.5

SPORTSMAN COMPONENT LOCATIONS

Brake Fluid Reservoir

Brake Lever

Light Control
& Run Switch

Reverse
Override

Work light

MAINTENANCE

Instrument Cluster

(Speedometer)

AWD Switch

Throttle

Front Storage
Compartment
&Rack

Front Gearcase

(Behind Radiator)

Oil Dipstick

Transmission

EFI Diagnostic
Plug Cover

PVT Cover Drain

Gas Cap

Gear Shifter

Ignition/Key

Rear Storage Compartment

2.6

Muffler

Right Side View

Front Drive Shafts

Front Prop Shaft

(Between Transmission

and Front Gearcase)

Auxiliary Brake

MAINTENANCE

POLARIS LUBRICANTS/FLUIDS FOR SPORTSMAN MODELS

Pure Polaris Lubricants and Maintenance Kits can be purchased at your local Polaris dealer.

ATV ANGLE DRIVE FLUID

2859066 -- Sportsman 600/700 Maintenance Kit

-- Oil Filter & 2 Qts. of 0W-- 40 oil

-- D r i v e B e l t

-- PVT Cover Seal

-- Spark Plug

-- Instruction Sheet

2202166 -- Sportsman 600/700 Oil Change Kit

-- Oil Filter & 2 Qts. of 0W-- 40 oil

-- Instruction Sheet

2.7

SPECIAL TOOLS

PART NUMBER

PV--43527 Oil Filter Wrench 2,3

2870872 Shock Spanner Wrench 2, 5

8712100 or 8712500 Tachometer 2,10

2200634 Valve Seat Reconditioning Kit 3

PU--45257 Valve Spring Compressor 3

PU--45652 Valve Pressure Hose 3

2871043 Flywheel Puller 3

2870390 Piston Support Block 3

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

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

PU--45498 Cam Spanner Wrench 3

PU--45838 Gear Holder 3

PA--44995 Water Pump Mechanical Seal Installer 3

PU--45543 Universal Drive Handle 3

PU--45483 Main Seal Installer 3

PU--45658 Main Crankshaft Seal Saver 3

PA--45401 Water Pump Seal Saver 3

PU--45778 Oil System Priming Tool 3

2870975 Mity Vact Pressure Test Tool 3, 9

PU--43506 Fuel Pressure Test Kit 4

PU--47082 Throttle Position Sensor Tester 4

2870871 Ball Joint Replacement Tool 5

2870623 Shock Absorber Spring Compression Tool 5

2871572 Strut Rod Wrench 5

2871573 LH Strut Spring Compressor 5

2871574 RH Strut Spring Compressor 5

2870506 Clutch Puller 6

9314177 Clutch Holding Wrench 6

2871358 Clutch Holding Fixture 6

2870341 Drive Clutch Spider Removal and Install Tool 6

2870913 Driven Clutch Puller 6

2870910 Roller Pin Tool 6

2871226 Clutch Bushing Replacement Tool Kit 6

2870386 Piston Pin Puller 6

2872292 EBS Clutch Alignment Tool 6

PU--47086 and 8700220 Clutch Compression Tool 6

2871025 Clutch Bushing Replacement Tool Kit 6

2872608 Roller Pin Removal Tool 7

8700226 CV Boot Clamp Pliers 7

PV--43568 Fluket77 Digital Multimeter 10

2870630 Timing Light 10

2870836 Battery Hydrometer 10

*Special Tools Can be ordered through SPX Corporation (www.polaris.spx.com)

TOOL DESCRIPTION CHAPTER TOOL USED IN

MAINTENANCE

2.8

MAINTENANCE

LUBRICATION

Dipstick/Fill Tube

0W/40

1. Engine Oil

DHF

Fill Plug

3. Front Gear Case Fill Plug

ADF

Fill / Check

Drain Plug

5. Brake Fluid (Left hand Master Cylinder)

Drain Plug

Fill / Check

2. Transmission

4. Rear Gear Case Fill Plug

Master Cylinder
Reservoir

Drain Plug

AGL

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

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

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

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

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

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

Mobilegrease Special

Ill.

#

1. Engine Oil Polaris 0W--40

2. Transmis-

3. Front Gear

4. Rear Gear

5. Brake Fluid Polaris Dot 3 Brake

Item Lube Rec. Method Frequency*

sion

Case

Case

Synthetic

Polaris AGL Gear-

case Lubricant

Premium Demand

Drive Hub Fluid

ATV Angle Drive

Fluid

Fluid

Check dipstick and add to

proper level.

Add lube to bottom of fill hole. Change annually ©

Drain completely. Add lube to spe-

cified quantity.

Drain completely. Add lube to spe-

cified quantity.

Fill master cylinder reservoir to in-

dicated level inside reservoir.

Change after 1st month, 6 months or 100

hours thereafter; Change more often

(25-50 hours) in extremely dirty condi-

tions, or short trip cold weather operation.

Change annually ©

Change annually ©

As required. Change fluid every 2 years

2.9

LUBRICATION, CONT.

MAINTENANCE

6. Front Prop Shaft
U-Joint

7. Front Hub strut

Front Hubstrut (All Models)

Ill.

#

6. Front Prop Shaft Polaris U-Joint

7. Front Hub strut Polaris All Season

Item Lube Rec. Method Frequency*

Grease¢

Grease¢

Locate grease fitting and

grease with grease gun.

Locate fitting and grease Semi-annually ¡

Semi-annually ¡

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

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

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

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

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

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

Mobilegrease Special

2.10

MAINTENANCE

FRONT GEARCASE LUBRICATION

The gearcase lubricant level should be checked and

changed in accordance with the maintenance

schedule.

G Be sure vehicle is level before proceeding and in

PARK.

G Check vent hose to be sure it is routed properly

and unobstructed.

G The correct front gearcase lubricant to use is

Polaris Premium Demand Hub Fluid.

FRONT GEARCASE SPECIFICATIONS

Specified Lubricant:

Premium Demand Drive Hub Fluid
(PN 2871654)

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

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

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

FRONT GEARCASE

Make sure vent is unobstructed

To change gearcase lubricant:

B
A

11 ft.lbs (15 Nm)

1. Remove gearcase drain plug (A) (11 mm) 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 Toque to 11 ft.lbs. (15 Nm).

Fill Plug

Fill plug

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

11 ft.lbs.
(15 Nm)

ILL. 1

Drain plug

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.

Left Side View Front Wheel

3. Remove fill plug (8 mm hex). Check the O-- ring.

4. Fill with the recommended fluid amount (5 oz.) or
to the bottom of the fill plughole threads. (See ILL.

3).

Front Gearcase

Plug Threads

Fill with 5 oz. lubricant
or bottom of fill plug
threads.

ILL. 3

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

2.11

MAINTENANCE

REAR GEARCASE
LUBRICA

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

G Be sure vehicle is level and in Park before

proceeding.

G Check vent hose to be sure it is routed properly

and unobstructed.

G The correct rear gearcase lubricant to use is

Polaris ATV Angle Drive Fluid.

REAR GEARCASE SPECIFICATIONS

Specified Lubricant:

ATV Angle Drive Fluid (PN 2871653)

Capacity: 5 Oz. (150 ml.)

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

To Check Lubricant Level:

Place the ATV on a level surface andin Park. The rear
gearcase fluid level should be level with the bottom of
the fill plug threads. Refer to the bottom illustration 2.

TION

and discard used oil properly.

B

A

2. Clean and reinstall drain plug (A) using a new
sealing washer (B).

3. Remove fill plug (C).

4. Fill with the recommended fluid amount or fill to
the bottom of the fill plug hole threads.

5. Install fill plug and check for leaks.

REAR

Make sure vent is unobstructed

GEARCASE

REAR

Fill to bottom of
fill plug threads

Ill. 2

To Change Lubricant:

1. Remove gearcase drain plug located on the
bottom of the gearcase and drain oil. (The drain
plug is accessible through the skid plate.) Catch

GEARCASE

(C) Fill Plug

ILL. 1

(A) Drain plug

2.12

MAINTENANCE

TRANSMISSION LUBRICATION

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

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

obstructed.

G Follow instructions to check / change transmission

lubricant.

To check the level:

1. Remove fill plug from the back of the transmission
and visually inspect the oil level. Level is correct
when it reaches the bottom of the fill hole as
shown at below.

To change lubricant:

1. Remove transmission drain plug to drain the oil.
Catch and discard used oil properly.

2. Clean and reinstall the drain plug. Torque to
specification.

3. Remove fill plug.

4. Add 15 oz. of Polaris AGL Gearcase Lubricant or
fill to top of the fill plug hole threads.

5. Check for leaks.

6. Reinstall fill plug and torque to 10--14 ft.lbs.
(14--19 Nm).

TRANSMISSION SPECIFICATIONS

Specified Lubricant:

Polaris AGL Gearcase Lubricant

(PN 2873603) (gal.) (PN 2873602) (12oz.)

Capacity: 15 oz. (450 ml.)

Drain Plug / Fill Plug Torque:

10--14 ft. lbs. (14--19 Nm)

Fill Plug

View From Back

Drain Plug

Transmission Fill Plug

Fill to the Bottom of Fill Plug Hole Threads

Proper Oil Level

2.13

MAINTENANCE

THROTTLE CABLE /
ELECTRONIC
CONTROL (ETC

THROTTLE

SWITCH)

ADJUSTMENT

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

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

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

Boot

Ill. 1

4. Turn adjuster until 1/16″ to 1/8″ freeplay is
achieved at thumb lever. (Ill. 2). After making
adjustments, quickly actuate the thumb lever
several times and reverify freeplay.

Adjuster
Sleeve

Lock­nut

Boot

THROTTLE

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

1. Place the gear selector in neutral.

2. Set parking brake.

3. Start the engine and let it idle.

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

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

To remove the ETC cover:

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

2. Twist screwdriver slightly while lifting on the cover
to release snap.

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

INSPECTION

Direction
of travel

Ill. 2

5. Tighten lock nut securely and slide boot
completely in place to ensure a water-tight 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 andin good condition, repeat adjustment
procedure.

1/16″ -1/8″

Freeplay

Ill. 1

3

6

6

2

1

5

5

4

ETC Cover

Removal Sequence

2.14

MAINTENANCE

SHIFT LINKAGE INSPECTION

NOTE: Shift rod is preset at time of manufacture.

Shift Linkage Rod

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

VENT LINES

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

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

FUEL FIL

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

TER

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

Shifter Mount

Shifter

Shift Linkage Rod

1. Relieve the pressure on the fuel rail. (See Ch. 4)

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

3. Remove fuel lines from filter.

4. Install new filter with arrow pointed in direction of
fuel flow.

5. Install clamps on fuel line.

6. Start engine and inspect for leaks.

COMPRESSION TEST

NOTE: This engine does NOT have decompression

components. Compression readings will vary in
proportion to cranking speed during the test. Average
compression (measured) is about 150-200 psi during
a compression test.

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

2.15

MAINTENANCE

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

Cylinder Compression

Standard: 150-200 PSI

Cylinder Leakdown

Service Limit 15 %

(Inspect for cause if leakage exceeds 15%)

ENGINE

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

Check engine fasteners and ensure they are tight.

MOUNTS

A

BATTERY MAINTENANCE

WARNING

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

External: Flush with water.

Internal: Drink large quantities of water or

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

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

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

Ill. 3

A

A

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

video PN 9917987)

The battery is located under the seat.

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

Maintain
between upper
and lower level
marks

Ill. 1

Batteries must be fully

2.16

MAINTENANCE

To remove the battery:

1. Disconnect holder strap and remove cover.

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

CAUTION

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

3. Disconnect the vent hose.

4. Remove the battery.

5. (Conventional Batteries Only) Remove the
filler caps and add distilled water only as needed
to bring each cell to the proper level. Do not
overfill the battery. Fully recharge after filling.

Use only distilled water. Tap water contains

minerals which are harmful to a battery.

Do not allow cleaning solution or tap water to

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

6. Reinstall the battery caps.

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

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

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

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

11. Reinstall battery cover and holder strap.

erosion of the electrodes.

Inspect electrode for
wear and buildup

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. (Illustration below)

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

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

8. Install spark plug and torque to specification.

Recommended Spark Plug:

Refer to Specifications Chapter 1

Spark Plug Torque:

18 Ft. Lbs. (24 Nm)

Spark Plug Gap

.036″ (0.9 mm)

SPARK

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

2. Remove spark plug.

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

PLUG

IGNITION

Refer to Chapter 10 for ignition timing procedures.

TIMING

2.17

MAINTENANCE

ENGINE-TO-FRAME GROUND

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

Typical Ground Cable

LIQUID COOLING SYSTEM
OVER

The engine coolant level is controlled ormaintained
by the recovery system. The recovery system
components are the recovery bottle, radiator filler
neck, radiator pressure cap and connecting hose.

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

VIEW

G Some coolant level drop on new

machinesis normalas the system is
purgingitselfoftrappedair. Observe
coolant levels often during the
break-in period.

G Overheating of engine could occur if

air is not fully purged from system.

G PolarisPremium60/40anti--freezeis

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

COOLANT STRENGTH /

Test the strength of the coolant using an antifreeze
hydrometer.

Antifreeze Hydrometer

G A 50/50 or 60/40 mixture of

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

G Do not use tap water. Tap water

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

Polaris 60/40 Anti-Freeze / Coolant

(PN 2871323)

TYPE

2.18

MAINTENANCE

COOLING SYSTEM HOSES

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

Upper Radiator

Hose

Lower Radiator Hose

1. Check tightness of all hose clamps.

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

Coolant Bottle

Fan

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

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

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

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

3. Reinstall cap.

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

Recovery Bottle
Accessible Under
Side Panel

RADIAT

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

2. Carefully straighten any bent radiator fins.

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

COOLING
PRESSURE

Refer to Chapter 3 for pressure test procedures.

COOLANT

OR

SYSTEM

TEST

LEVEL

INSPECTION

WARNING

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

Ill.1

RADIATOR COOLANT LEVEL
INSPECTION

WARNING

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

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

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

2.19

MAINTENANCE

To access the radiator pressure cap:

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

Remove
Cover

Radiator
Cap

RADIATOR
REMOV

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

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

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

SCREEN

AL

AIR FILTER/PRE-FILTER
SER

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

The pre filter should becleaned 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:

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

VICE

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

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

A

4. Loosen clamp and remove air filter
assembly.

Cover

Gasket

Pre-filter

Main Element

Ill.1

Cleaning:

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

6. Rinse and dry thoroughly.

7. Inspect element for tears or damage.

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

2.20

MAINTENANCE

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 purpose
grease to the sealing edges of the filter before
reinstalling.

Filter Clamp

AIR BOX SEDIMENT

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.

Ill.1

TUBE

Sediment Tube

Ill.2

Proper Filter Placement

Filter Support

Air Box

Ill.3

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

12. Install air box cover and secure with clips.

Main Filter

Front

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 HOSE

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

PVT DRYING & PVT DRAIN
PLUG

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

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

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

PVT Drain Plug & O--ring

Ill.3

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

2.22

MAINTENANCE

ENGINE OIL LEVEL

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

Dipstick

Ill.1

1. Set machine on a level surface.

2. Be sure the machine has sat for awhile before
removing the dipstick. Do not run the machine
and then check the dipstick.

3. Unlock the lever lock.(Ill. 2) Remove dipstick and
wipe dry with a clean cloth.

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

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

5. Remove dipstick and check to see that the oil
level is in the normal range. Add oil as indicated
by the level on the dipstick. Do not overfill. (See
NOTE below!)

NOTE: Due to the dipstick entry angle into the
crankcase, the oil level will read higher on the bottom
side of the dipstick. Proper level indication is
determined on the upper surface of the dipstick as it
is being removed, regardless of the level marks being
on top or on bottom. (See the next illustration)

Dipstick

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

Ill.2

Lever Lock

SAFE

Dipstick Location

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

Dipstick

ADD 8 OZ

2.23

MAINTENANCE

OIL AND FILTER CHANGE

1. Place vehicle on a level surface.

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

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

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

Crankcase Drain

Engine Oil Drain Plug - Bottom View

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

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

Oil Filter

(PN 2540006)

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

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

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

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

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

Recommended Engine Oil

Polaris Premium 4 All Season Synthetic,

0W--40 (PN 2871281)

Ambient Temperature Range:

_ Fto120_ F

-40

Crankcase Drain Plug Torque:

192 ± 24 in. lbs. (21.7 ± 2.7 Nm)

Oil Filter Torque:

Turn by hand until filter gasket

contacts sealing surface, then

turn an additional 1/2 turn

Oil Filter Wrench:

(PV--43527)

5. Allow oil to drain completely.

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

7. Reinstall drain plug and torque to 192 ± 24 in. lbs.
(21.7 ± 2.7 Nm).

2.24

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

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

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

16. Dispose of used filter and oil properly.

MAINTENANCE

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 orlimited. NOTE: Whenever steering
components are replaced, check front end alignment.
Use only genuine Polaris parts.

WARNING

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

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

G Replace any worn steering

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

G Elevate front end of machine so front

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

G If abnormal movement is detected,

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

TIE ROD END /

STEERING

INSPECTION

G To check for play in the tie rod end,

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

G Repeat inspection for inner tie rod

end on steering post.

Check for Loose Wheel or Hub

G Refer to the Body/Steering Chapter

5 or Final Drive Chapter 7 for service
procedures.

CAMBER AND

The camber and caster are non-adjustable.

CASTER

2.25

MAINTENANCE

WHEEL ALIGNMENT
METHOD 1:
STRAIGHTEDGE OR STRING

Be sure to keep handlebars centered. See notes
below.

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

Measure

from string

to rim at

front and

rear of rim.

Rear rim

measure-

ment should

be 1/16″ to

1/8″ (.2to.3

cm) more

than front rim

measure-

ment.

WHEEL ALIGNMENT
METHOD 2:

1. Place machine on a smooth level surface.

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

3. Place a chalk mark on the center line of the front
tires approximately 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° by moving vehicle forward or
backward. Position chalk marks facing rearward,
even with the hub/axle centerline.

6. Again measure the distance between the marks
and record. Call this measurement “B”. Subtract
measurement “B” from measurement “A”. The
difference between measurements “A” and “B” is
the vehicle toe alignment. The recommended
vehicle toe tolerance is 1/8″ to 1/4″ (.3to.6cm)
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).

CHALK

NOTE: The steering post arm “frog” can be

used as an indicator of whether the handle-

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

2.26

Ill.1

Chalk Line
Measurement
“A”

Measurement “B”

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

Incorrectly
Tightened
Jam Nut

Ill.2

Correctly
Tightened
Jam Nut

Ill.2

EXHAUST

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

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

Ill.1

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

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

PIPE

Clean Out Plug

To adjust toe

G Hold tie rod end to keep it from

G Loosen jam nuts at both end of the tie

G Shorten or lengthen the tie rod until

G IMPORTANT: When tightening the

G After alignment is complete, torque

alignment:

rotating.

rod.

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

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.

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

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

SEE WARNING

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

3. SEE WARNING

1ft.

2.27

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.

WARNING

G Do not perform clean out immediately

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

G To reduce fire hazard, make sure that

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

G Wear eye protection.
G Do not stand behind or in front of the ve-

hicle while purging the carbon from the
spark arrestor.

G Never run the engine in an enclosed

area. Exhaust contains poisonous car­bon monoxide gas.

G Do not go under the machine while it is

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

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

BRAKE SYSTEM

INSPECTION

MAINTENANCE

Rear Master Cylinder Reservoir

Max

Min.

Auxiliary Brake Reservoir

Located Under Seat

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

spongy feel.

G Check friction pads for wear,

damage or looseness.

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

friction material.

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

G Keep fluid level inthe master cylinder

reservoir to the indicated level inside
reservoir.

G Use Polaris DOT 3 Brake Fluid (PN

2870990).

Sight
Glass

Parking Brake
Lock

2.28

BRAKE PAD

Pads should be changed when the friction material is
worn to 3/64″ (.1 cm), or about thethickness of a dime.

INSPECTION

3/64″
(.1cm)

Minimum
Thickness

MAINTENANCE

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

The auxiliary brake should be checked for proper
function.

Auxiliary Brake

Support the rear wheels off the ground.

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

Auxiliary Foot Brake
Pedal

Full Height

TESTING

Full
Engagement

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.

1/8, to 1/4,
Free Play

50 lbs

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

Free Play:

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

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

Bleeding:

If free play is correct and brake pedal travel is still
excessive, air may be trapped somewhere in the
system. Bleed the hydraulic auxiliary brake system in
a conventional manner, following the procedure
outlined in Brake Chapter 9.

SUSPENSION:

SPRING

1″ or greater

Floorboard

Floor
Board Surface

AUXILIARY BRAKE
ADJUSTMENT

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

(HYDRAULIC)

PRELOAD

Operator weight and vehicle loading affect
suspensionspringpreloadrequirements.Adjustas
necessary.

Shock Spanner Wrench

ADJUSTMENT

(PN 2870872)

2.29

FRONT SUSPENSION

G Compress and release front suspension.

Damping should be smooth throughout
the range of travel.

G Check all front suspension components

for wear or damage.

G Inspect front strut cartridges for leakage.

MAINTENANCE

REAR

G Compress and release rear suspension.

G Check all rear suspension components

G Inspect shock for leakage.

SUSPENSION

Rear Spring
Adjustment Cam

Damping should be smooth throughout
the range of travel.

for wear or damage.

Inspect Boots

CONTROLS

Check controls for proper operation, positioning
and adjustment.

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,
or have you Polaris dealer replace the boot.

2.30

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

MAINTENANCE

WHEELS

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

WHEEL, HUB, T

Item

Steel -- Front Wheel Nuts

Steel -- Rear Wheel Nuts

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)

ORQUE

Specification

30 Ft. Lbs. (41 Nm)

30 Ft. Lbs. (41Nm)

90 Ft. Lbs. (122 Nm)

90 Ft. Lbs. (122 Nm)

WHEEL REMOVAL:
FRONT OR REAR

4. Remove the wheel nuts and remove the wheel.

WHEEL INSTALLA

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

2. Attach the wheel nuts and finger tighten them.

3. Lower the vehicle to the ground.

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

CAUTION:

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

Steel Wheel Aluminum Wheel

TION

Front & Rear Wheels

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

2. Loosen the wheel nuts slightly.

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

TIRE PRESSURE

CAUTION:

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

Tire Pressure Inspection (PSI - Cold)

Front Rear

5 5

A

2.31

MAINTENANCE

TIRE INSPECTION

G Improper tire inflation may affect ATV

maneuverability.

G When replacing a tire always use

original equipment size and type.

G The use of non-standard size or type

tires may affect ATV handling.

Tire Tread Depth

Always replace tires when tread depth is worn to
1/8″ (3 mm) or less.

Tread
Depth 1/8I (3 mm)

FRONT / REAR STORAGE
COMP

The front and rear 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 to the vertical position.

ARTMENTS

Front Storage -- Unlatched

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.

FRAME, NUTS, BOL
F

ASTENERS

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.

TS,

Front Storage -- Latched

Rear Storage -- Latched

2.32

MAINTENANCE

WARN® WINCH OPERATION

Equipped)

(If

This information is for Sportsman models equipped
with a 2500 lb. (2.5chi) Warn® Winch in the front.

Pre--Wired Warnt Winch Kits

2.5 ci -- PN 2875309

3.0 ci -- PN 2875308

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.

Mini--Rocker Switch

OUT

IN

Winch Handlebar Controls

The winch is located in the front bumper area.

Winch

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.

Control

FREESPOOL

ENGAGE

2.33

MAINTENANCE

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

Winch Connecting Wires Located
Under Right Front Cab Area

Winch Connecting Wires

The Red wire (6 Ga.) with the yellow crimp cover is
located under the left rear fender next to the starter
solenoid. The red wire connects to the battery.

Winch Connecting Wires

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

or

Contactor mounts for Splash Guard

Pic of quick connect and locations

Under Right Side Front Fender

2.34

MAINTENANCE

CLEANING & STORAGE OF

TV

A

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 ATV can
be cleaned much like an automobile.

Washing the ATV

The best and safest way to clean your ATV 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. Rinse 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. Avoid the use of harsh
cleaners since they can scratch the body finish.
Polaris offers a detailing kit for your ATV, see Page

2.7.

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

Storage Tips

See Page 2.7 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 high
pressure washers. Some detergents 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 15-20
minutes of operation for the stabilizer to disperse
through the fuel in the tank and carburetor. Turn the fuel
valve off and drain the carburetor bowl.

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 Tips

Polaris offers storage kits for you ATV, see Page 2.7
for the part numbers of Polaris products.

Fog the Engine

Use Polaris Fogging Oil, following the instructions as
directed.

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

1. Treat the fuel system with Polaris Carbon Clean.
Turn fuel petcock to ’OFF’.

2. To eliminate any fuel remaining in the carburetor,
run the engine until it stops. If Polaris fuel system
additive is not used, fuel tank, fuel lines, and
carburetor should be completely drained of
gasoline.

3. 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.

4. Remove the spark plug(s). Rotate the piston to
BDC and pour approximately two ounces of
Polaris oil into the cylinder.

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.

2.35

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

6. Turn the engine over several times to ensure
coverage of piston rings, cylinder walls and
crankshaft bearings.

7. Treat the fuel system with Polaris Carbon Clean.

8. If Polaris fuel system additive is not used, fuel
tank, fuel lines, and carburetor should be
completely drained of gasoline. To eliminate any
fuel remaining in the carburetor, run the engine
until it stops.

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.

MAINTENANCE

Engine Anti-Freeze

Test engine coolant strength and change if necessary.
Coolant should be replaced every two years. See
Page 2.18 for the proper test procedure.

Storage Area/Covers

Set the tire pressure and safely support the ATV with
the tires 1-2” 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 remove 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 thetransporting
unit securely using suitable straps or rope.

800 EFI Exhaust Canister Maintenance

The exhaust canisters on Polaris 800 EFIs are
ceramic coated. To maintain a beautiful finish and
prevent corrosion, periodic maintenence is required.

DO NOT use caustic chemicals to clean, as they
damage the

1. Wash any accumulated mud or debris from the
canisters with a soft brush and soapy water.

2. Use a cleaner, such as HPC HiPerWasht to
clean away any remaining grime, salts or oils.

3. If the canisters are stained from oils or other
fluids, use fine steel wool with HPC Liquid Bufft
Cleaner and Polish to remove the stain.

4. After removing the stains, polish using Liquid Buff
and a soft cloth.

Repeat this procedure as often as desired to maintain
the canister ’s finish.

finish.

may

2.36

Engine Exploded Views 3.2--3.7......................

Exhaust System View / Notes 3.8.................

Special Tools 3.9...............................

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

Torque Specifications 3.10........................

Engine Fastener Torque Patterns 3.11.............

Engine Service Data 3.12--3.14.........................

Cooling System Specifications 3.15................

Cooling System Test 3.15.........................

Engine Removal/Installation 3.16--3.17..................

Engine Installation Notes 3.17--3.18.....................

Cylinder Honing 3.19............................

Oil Flow 3.20....................................

Rocker Arm/Pushrod Inspection 3.21...............

Cylinder Head Disassembly/Inspection 3.21--3.23.........

Valve Inspection 3.24............................

Combustion Chamber 3.25.......................

Valve Seat Reconditioning 3.25--3.27....................

Cylinder Head Assembly. 3.27.....................

Valve Sealing Test 3.28...........................

Valve Train Exploded View. 3.28...................

Engine Head Reassembly 3.29--3.30....................

Cylinder Removal 3.31...........................

Valve Lifter Removal/Inspection 3.31...............

Piston Removal 3.31--3.32.............................

Cylinder Inspection 3.32--3.33..........................

Piston/Rod/Ring Service 3.33--3.35.....................

Starter Bendix Removal/Inspection 3.36............

Flywheel/Stator Removal/Inspection 3.37...........

Flywheel/Stator Installation 3.37--3.38...................

Engine Crankcase Disassembly/Inspection 3.38--3.46.....

Camshaft Inspection 3.47.........................

Engine Crankcase Assembly 3.47--3.58.................

Troubleshooting 3.59--3.60.............................

4--Stroke Coolant System Bleeding Procedure 3.61..

ENGINE

3.1

ENGINE

ENGINE EXPLODED VIEW

CRANKCASE

Journal Bearings

ML

ML

Camshaft

Thrust Plate

Flange Seal

WL

Crankshaft

60 ± 6in.lbs.

(6.8 ± .68 Nm)

Crankcase

Oil Pickup

O--ring

Woodruff Key

ML

Journal Bearings

Balance
Shaft

Washer

Oil Plug

115 ± 12 in. lbs.

(13 ± 1.35 Nm)

60 ± 6in.lbs.

(6.8 ± .68 Nm)

Baffle

NOTE: If needed, heat
the oil baffle bolts with a
heat gun to remove.

192 ± 24 in. lbs.

(21.7 ± 2.7 Nm)

Crankcase Bolts

242

22 ± 2 ft. lbs.

(30 ± 3Nm)

SEE PAGE 3.11 FOR CRANKCASE
BOLT TIGHTENING SEQUENCE

3.2

Apply Loctitet 242 to

242

the bolt threads.

Apply White

WL

Lithium Grease.

ML

Apply Moly
Lube Grease.

ENGINE EXPLODED VIEW

MAG SIDE

Split Gear

Washer

22 ± 2 ft. lbs.

Bolt

(30 ± 3Nm)

ENGINE

Counterbalance Gear

22 ± 2 ft. lbs.

(30 ± 3Nm)

1

4

3

2

Oil Pump Bolt Tighten Sequence

Washer

Bolt

84 ± 8in.lbs.

(9.5 ± .90 Nm)

Oil Pump

Oil rotor

Bolts

Gear/Stator Cover

*See Note

Wire Hold Down

OIL

Oil Pump

No Grease on this portion of gasket!

Mag Gasket Cover

Impeller

Washer

Nut

Gear/Stator Housing Bolt

96 ± 12 in. lbs.
(10.85 ± .35 Nm)

108 ± 12 in. lbs.

(6.8 ± .68 Nm)

*NOTE: Apply Corrosion Resistant

Grease to Stator Grommet Area

TIMING MARKS

GEAR TIMING AT TDC

3

4

Mag Cover Bolt Tighten Sequence

Apply Polaris 0W--40

OIL

oil to component.

Apply White

WL

Lithium Grease.

2

1

3.3

ENGINE

ENGINE EXPLODED VIEW

SG

Apply Polaris 0W--40
oil to seal.

OIL

Loctitet Pipe Sealant

(PN 2871956)

Bolts

(Tighten Top Bolt First)

84 ± 8 ft. lbs.

(9.50 ± 0.9 Nm)

Pos. Cable

Apply Polaris
Starter Grease.

Starter

1

2

Washer

Nut

108 ± 12 ft. lbs.
(12 ± 1.35 Nm)

Neg. Cable

MAG SIDE

SG

SG

Washer

Gasket

(NO Grease or Oil!)

Bendix

Washer

SG

Flywheel

Stator Cover

2

7

6

Water Pump Cover Bolt

Tighten Sequence

Water Pump

Cover
96 ± 12 in. lbs.

(10.85 ± 1.35 Nm)

Washer

Crankshaft Nut

65 ± 7 ft. lbs.

(88 ± 9.50 Nm)

55

4

1

3

Clamp

50 ± 5in.lbs.

(5.64 ± 0.56 Nm)

22 ± 2 ft.lbs.

(30 ± 3Nm)

Dowel

(Chamfer Side Down)

(5.65 ± 0.56 Nm)

Gasket

Oil Fill Tube

Spring

50 ± 5in.lbs.

Dipstick

O--ring

OIL

Hex Plug

216 ± 24 in. lbs.

(24.4 ± 2.71 Nm)

Oil Filter Nipple

35 ± 4 ft. lbs.

(47.5 ± 5.4 Nm)

Oil Filter

Bolts

96 ± 12 in. lbs.

(10.85 ± 1.35 Nm)

4

3

5

2

6

8

OIL

Stator Cover Bolt Tighten Sequence

7

2

1

9

3.4

ENGINE EXPLODED VIEW

ENGINE

TOP END

1 Lubricate threads and be-

tween washers and underside
of bolt heads with engine oil
Torque in sequence provided.

Apply Moly Lube

2

grease to valve tips.

Gasketfreeofoil.Verify

3

tabs are visible.

Apply thin film of 0W-- 40 to

4

25--55 mm of cylinder bore.

Apply0W--40topiston

5

pin or pin bore.

Apply 0W--40 to lifters.

6

Do not install expansion plug
more than 1.5 mm inward.

1.5 mm

Head Bolts

OIL

(Each Bolt
Threads)

2

ML

Bushing

Expansion
Plug

Initial: 15 ± 2 ft. lbs. (20.3 ± 2.7 Nm)

1

to seat gasket and back off 5 turns
Re--torque to 35 ± 4 ft. lbs (47.5 ±

5.5 Nm). Finalize sequence by tight­ening an additional 90° (1/4 turn)

3

1

6

Head Bolt Tighten Sequence

Rocker Arms

5

2

4

22 ± 2 ft. lbs.

(30 ± 3Nm)

Gasket

3

Pushrods

ML

0

Side View

Apply Polaris 0W--40 oil.

OIL

Apply Moly

ML

Lube Grease.

Cylinder

4

OIL

OIL

Piston Assembly

5

OIL

Circlip UP for Install

3Gasket

Hydraulic Lifter

OIL

3.5

ENGINE

ENGINE EXPLODED VIEW

OUTER COMPONENTS

3

6

2

20 ± 5in.lbs.

(2.5 ± 0.55 Nm)

216 ± 24 in. lbs.
(24.5 ± 2.7 Nm)

20 ± 5in.lbs.

(2.5 ± 0.55 Nm)

1

4

(*Apply Dielectric Grease Tips of Spark Plugs)

5

7

Breather Bolts

216 ± 24 in. lbs.

(24.5 ± 2.7 Nm)

Carburetor Boot

Bolts

Boot Clamp

Screws

84 ± 8in.lbs.

(9.5 ± 0.9 Nm)

Rocker Cover

Breather

O--ring Seal

Spark Plugs

*Apply Corrosion Resistant Grease

Gasket

Exhaust Manifold

Bolts

216 ± 24 in. lbs.
(24.5 ± 2.7 Nm)

Throttle Body

Thermistor

Thermostat

Crank Position

Sensor

84 ± 8in.lbs.

(9.5 ± 0.9 Nm)

200 ± 20 in. lbs.

(1.41 ± 0.14 Nm)

O--ring

Housing

Bolts

84 ± 8in.lbs.

(9.5 ± 0.9 Nm)

3.6

ENGINE EXPLODED VIEW

ELECTRICAL COMPONENTS

Fuel Injector

Fuel Rail

216 ± 24 in. lbs.

(24.5 ± 2.7 Nm)

EFI Harness

ENGINE

NOTE: See Chapter 4 for more information the EFI system.

3.7

ENGINE

EXHAUST SYSTEM

NOTE: Silencer Removal

Silencer removal requires replacement of the silencer grommets, item #24,
as they become damaged during removal.

1.

2.

3.

4.

26.

5.

6.

800 EFI Exhaust

Canister Maintenance

The exhaust canisters on Polaris 800
EFIs are ceramic coated. To maintain a

beautiful finish and prevent corrosion,
periodic maintenence is required. D

NOT use caustic chemicals to clean, a
they may damage the finish

1. Wash any accumulated mud or

debris from the canisters with a

soft brush and soapy water.

2. Use a cleaner, such as HPC

HiPerWasht to clean away any
remaining grime, salts or oils.

3. If the canisters are stained from

oils or other fluids, use fine steel
wool with HPC Liquid Bufft
Cleaner and Polish to remove the
stain.

4. After removing the stains, polish

using Liquid Buff and a soft cloth.

Repeat this procedure as often as de­sired to maintain the canister’s finish.

.

O

s

9.

7.

8.

22.

21.

10.

11.

12.

13.

14.

15.

16.

17.

25.

24.

23.

E 2004 Polaris Sales Inc.

15.

16.

18.

1.

2.

3.

4.

5.

7.

8.

20.

19.

Ref. Qty. Description

1. 2 Nut, Nylok

2. 2 Washer

3. 2 Bushing

4. 2 Washer, Rubber

5. 2 Bushing

6. 1 Bracket, Silencer, Frame

7. 2 Dampener, Vibration

8. 2 Bolt

9. 1 Exhaust, Silencer, RH

10. 1 Washer, Clean Out

11. 1 Bolt

12. 1 Seal, Exhaust Socket

13. 2 Spring

3.8

Ref. Qty. Description

14. 1 Exhaust, Pipe, Dual, Black

15. 4 Screw

16. 4 Washer

17. 1 Shield, Heat, Dual

18. 4 Screw

19. 1 Gasket

20. 1 Shield, Heat, Exhaust, Top

21. 1 Seal, Exhaust

22. 1 Clamp, Exhaust

23. 1 Exhaust, Silencer, LH

24. 2 Grommet, Silencer, Mount

25. 1 Bracket, Silencer, Mount

26. 1 Spring

SPECIAL TOOLS

PART NUMBER

PV--43527 Oil Filter Wrench

2200634 Valve Seat Reconditioning Kit

PU--45257 Valve Spring Compressor

PU--45652 Valve Pressure Hose

2871043 Flywheel Puller

2870390 Piston Support Block

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

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

PU--45498 Cam Spanner Wrench

PU--45838 Gear Holder

PA--44995 Water Pump Mechanical Seal Installer

PU--45543 Universal Driver Handle

PU--45483 Main Seal Installer

PU--45658 Main Crankshaft Seal Saver

PA--45401 Water Pump Seal Saver

2870975 Mity Vact Pressure Test Tool

PU--45778 Oil System Priming Tool

ENGINE

TOOL DESCRIPTION

ACCESSIBLE COMPONENTS

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

S Flywheel

S Alternator/Stator

S Starter Motor/Starter Drive

S Cylinder Head

S Cylinder

S Piston/RIngs

S Camshaft

S Rocker Arms

S Oil pump/Water Pump and Oil

Pump Drive Gear

S Gear Train Components

PISTON IDENTIFICA

Four stroke enginerings have a rectangular profile. See text on Page 3.29 for ring installation. Use theinformation
below to identify pistons and rings.

TION

The following components require engine
removal for service:

S Counterbalance Shaft or Bearing(s)

S Connecting Rod

S Crankshaft

S Crankshaft Main Bearings

S Crankcase

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

Engine Model No.

EH076OLE 80 mm None

EH068OLE 80 mm None

Piston Diameter Standard Piston Identification

3.9

ENGINE

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Fastener Size 700/800

in. Lbs. (Nm)

Camshaft Gear 8mm -- 22 ± 2(30± 3)

Camshaft Thrust Plate 6mm 115 ± 12 (13 ± 1.35) --

Carburetor Adaptor Bolts 8mm 216 ± 24 (24.5-± 2.7) --

Counterbalance Gear 8mm -- 22 ± 2(30± 3)

Crankcase Bolts 8mm -- *22 ± 2(30± 3)

Crankcase Breather 5mm 20 ± 5(2.5± 0.55) --

Cylinder Head Bolts 11 m m -- *35 ± 4 (47.5 ± 5.5)

Exhaust Manifold 8mm 216 ± 24 (24.5 ± 2.70) --

Flywheel 14 mm -- 65 ± 7(88± 9.50)

Magneto Cover 6mm *96 ± 12 (10.85 ± 0.35) --

Oil Baffle Weldment 5mm 60 ± 6(6.8± 0.68) --

Oil Drain Bolt (Crankcase) 12 mm 192 ± 24 (21.7 ± 2.7) --

Oil Fill Tube Bolt 5mm 50 ± 5 (5.64 ± 0.56) --

Oil Filter Pipe Fitting 20 mm -- 35 ± 4 (47.5 ± 5.4)

Oil Pick Up 5mm 60 ± 6(6.8± 0.68) --

Oil Pressure Relief Plug 10 mm 22 ± 2(30± 3) --

Oil Pump Housing Screw 6mm *84 ± 8 (9.50 ± 0.90) --

Rocker Arm 8mm -- *22 ± 2(30± 3)

Rocker Cover 6mm *84 ± 8(9.5± 0.9) --

Spark Plug 14 mm 216 ± 24 (24.5 ± 2.7) --

Starter Motor 6mm *84 ± 8(9.5± 0.9) --

Stator Assembly 6mm 96 ± 12 (10.85 ± 1.35) --

Stator Housing 6mm *96 ± 12 (10.85 ± 1.35) --

Temperature Switch 3/8 PT -- 25 ± 3(34± 4)

Thermostat Housing 6mm 84 ± 8(9.5± 0.9) --

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

Trigger Coil/Stator Wire Holddown 5mm *96 ± 12 (10.85 ± 1.35) --

Water Pump Housing Cover 6mm *96 ± 12 (10.85 ± 1.35) --

Water Pump Impeller Nut 8mm 108 ± 12 (12 ± 1.35) --

700/800

ft.lbs. (Nm)

* See exploded views for notes or torque sequences.

3.10

ENGINE

ENGINE FASTENER TORQUE PATTERNS

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

22 ± 2 ft. lbs.

(30 ± 3Nm)

CRANKCASE BOLT TIGHTEN

SEQUENCE

CYLINDER HEAD BOLT TIGHTEN SEQUENCE

Lubricate threads and between washer and underside of bolt with engine oil.
Torque in sequence to spec provided, allow the gasket to set for 1 minute,
then tighten in sequence 90° (1/4 turn).

35 ± 4 ft. lbs.

(47.5 ± 5.5 Nm)

3

6

+

90° (1/4 turn)

15

2

4

3.11

ENGINE

g

j

j

y

g

g

p

g

700/800 EFI ENGINE SERVICE DATA

**Cylinder Head / Valve

Camshaft Cam lobe height In

Ex

Camshaft journal OD

Camshaft journal
bore ID

Camshaft Oil
clearance

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

Counter
Balance

Cylinder
Head

Valve Seat Contacting width In

End Play 0.005” (0.127 mm)

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

EFI Engine No. -- EH680OLE / EH780OLE

Std 1.3334” (33.8674 mm)

Std 1.3334” (33.8674 mm)

Mag 1.654” ± 0.00039” (42 ± 0.010 mm)
Center 1.634” ± 0.00039” (41.50 ± 0.010 mm)
PTO 1.614” ± 0.00039” (41 ± 0.010 mm)
Mag 1.656” ± 0.00039” (42.07 ± 0.010 mm)
Center 1.637” ± 0.00039” (41.58 ± 0.010 mm)
PTO 1.617” ± 0.00039” (41.07 ± 0.010 mm)
Std 0.00276” ± 0.00079” (0.07 ± 0.02 mm)

Std 0.0472” + 0.00787” -- 0.0039”

(1.20 + 0.20 -- 0.10 mm)

Ex

Std 0.0591” + 0.00787” -- 0.0039”

Seat Angle Std 45.5 ± 0.25°

Val ve
Guide

Val ve Margin

Val ve
Spring

**denotes cylinder head with bronze valve guide

Inner diameter 0.2367” ± 0.00029” (6.012 ± 0.007 mm)
Protrusion above head 0.807” ± 0.0039” (20.50 ± 0.01 mm)

In

Std 0.79” (20.06mm)

Thickness

Ex

Std 0.80” (3.488 mm)

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

Ex 0.2351” ± 0.00039” (5.972 ± 0.01 mm)

Stem oil
clearance

Overall length

Overall length

Std

In 0.00228” ± 0.00098” (0.058 ± 0.025 mm)
Ex 0.00275” ± 0.00098” (0.0870± 0.025mm)

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

Length
Installed

Height

(1.50 + 0.20 -- 0.10 mm)

Max-- 0.98” (24.89mm) Min-- 0.59” (14.98mm)

Max-- 1.0” (25.4mm) Min-- 0.60” (15.24mm)

1.735” (46.069 mm)

Intake -- 1.4638” (37.18 mm)
Exhaust -- 1.4736” (37.43 mm)

3.12

700/800 EFI ENGINE SERVICE DATA

ENGINE

Cylinder / Piston / Connecting Rod

Cylinder

Lifter

Piston

Piston Pin

EFI Engine No.

EH680OLE

Surface warpage limit

0.004” (0.10 mm)

Same

(mating with cylinder head)
Cylinder bore Std 3.1495” (80 mm)
Taper limit 0.00031” (0.008 mm)
Out of round limit 0.00030” (0.0075 mm)
Piston clearance Std .040” ± .015”

Same

Same

Same

Same

(.041 ± .016 mm)
Boring limit N/A N/A
Outer Diameter Std 0.84245” ± 0.00025”

Same

(21.39 8± 0.00635 mm)
Block Bore Std 0.8438” ± 0.00062”

Same

(21.4322 ± 0.0157 mm)

Std 3.1477”± .000121”

(79.954± .003mm)
Standard inner diameter of piston pin

bore

0.78789” ± .00009I

(20.0125 ± 0.003 mm)
Outer diameter 0.7874” -- 0.7872”

(20 -- 19.995 mm)
Standard clearance-piston pin to pin

bore

0.00059” ± 0.0002”

(0.015 ± 0.005 mm)
Degree of fit Piston pin must be a push

3.14803” ± .00028I
(79.960 ± .007 mm)

0.70902” ± .00012I
(18.009 ± 0.003 mm)

0.70866” -- 0.70846”
(18 -- 17.995 mm)

0.00047” ± 0.00024”
(0.012 ± 0.006 mm)

Same

(by hand) fit at 68° F(20°

C)

EFI Engine No.

EH780OLE

3.13

ENGINE

ggp

g

pgg

g

g

Connectingrodbigendside

Connectingrodbigendradial

700/800 EFI ENGINE SERVICE DATA

Cylinder / Piston / Connecting Rod

Piston
Ring

Connect­ing Rod

EFI Engine No.

EH680OLE

Piston ring installed
gap

To p r ing

Second
ring

Oil ring

Std 0.0059-- 0.0138”

(0.15 ± 0.35 mm)

Limit

> 15% Leakdown > 15% Leakdown

Std 0.0098 -- 0.0197”

(0.25 ± 0.50 mm)

Limit

> 15% Leakdown > 15% Leakdown

Std 0.0196” ± .00984”

(0.50 ± 0.25 mm)

> 15% Leakdown > 15% Leakdown

(0.060 ± 0.020 mm)

> 15% Leakdown > 15% Leakdown

(0.070 ± 0.020 mm)

> 15% Leakdown > 15% Leakdown

Standard clearance
piston ring to ring
groove

To p r ing

Second
ring

Limit
Std 0.0024” ± 0.0008I

Limit
Std 0.0028” ± 0.0008I

Limit

Connecting rod small end ID .789 -- .78841”

(20.030 -- 20.015 mm)
Connecting rod small end ra-

dial clearance

Std 0.00098” ± 0.00039”

(0.025 ± 0.010 mm)

Connectingrod bigend side
clearance

Limit 0.01181” ± 0.00591” (0.30

± 0.15 mm)
Connectingrod bigend radial

clearance

Limit 0.00015” ± 0.00006”

(0.0038 ± 0.0015 mm)

EFI Engine No.

EH780OLE

0.0059 -- 0.0138”
(0.15 ± 0.35 mm)

0.0098 -- 0.0197”
(0.25 ± 0.50 mm)

0.0196” ± .00984”
(0.50 ± 0.25 mm)

0.0024” ± 0.0008I
(0.060 ± 0.020 mm)

0.0028” ± 0.0008I
(0.070 ± 0.020 mm)

.7096” ± 0.0003
(18.023± .008 mm)

Same

Same

Same

Crankshaft Crankshaft runout limit 0.00236” (0.060 mm)

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

3.14

Same

ENGINE

COOLING SYSTEM
SPECIFICA

Condition

Hot Light

On

Fan Off 296Ω -- 316Ω 180° F(82° C)

Fan On 236Ω -- 251Ω 195° F(91° C)

System

Capacity

Radiator

Cap Relief

Pressure

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 restrict coolant flow and
reduce heat dissipation, resulting in possible engine
damage. Polaris Premium 60/40 Antifreeze/Coolant is
recommended for use in all cooling systems and comes
pre-mixed, ready to use.

TIONS

Approx. Reading

(Min--Max)

178Ω -- 190Ω 215° F

2.25 Quarts

Temperature

(102° C)

(2.13L)

13 PSI

COOLING SYSTEM

WARNING

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

1. Remove front cover.

2. Remove recovery bottle hose from coolant filler
neck.

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

Radiator Cap Pressure Test

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

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

Upper Engine Hose

Filler Neck Assy.

Surge Tank

FLOW

Radiator

Thermostat

Cylinder
Head

Coolant Flow Diagram

To p

Bottom

Radiator
Left Side
View

Water
Pump

Cylinder

Fan

Shroud

Lower Engine
Hose

Exploded View

To W a te r P u m p

Hose

Radiator

Radiator
Front
View

3.15

ENGINE

ENGINE REMOVE & INSTALL

WARNING

Always wear safety glasses and proper shop
clothing when performing the procedures in this
manual. Failing to do so may lead to possible
injury or death.

1. Clean work area.

2. Thoroughly clean the ATV engine and chassis.

3. Disconnect battery negative (-) cable.

4. Remove the following parts as required:

S Seat
S Left and Right Side Covers (Refer to

Chapter 5)

S Fuel Tank Cover / Front Cab (Refer to

Chapter 5)

S Fuel Tank (Refer to Chapter 4)

5. Remove springs from exhaust pipe and remove
pipe.

6. Drain coolant and engine oil.

7. Remove air pre-cleaner and duct.

8. Remove airbox.

9. Disconnect the throttle body sensor (C) and the
T--map sensor (D). Remove throttle body (A).
Insert a shop towel into the engine intake to
prevent dirt from entering the intake port.

10. Relieve the fuel pressure in the fuel rail (refer to
Chapter 4, “FUEL INJECTION”) for proper
procedure. Carefully remove the fuel rail (B) and
injectors.

B

A

11. Disconnect spark plug high tension leads.

C

D

12. Remove the crank position sensor (E) located on
the mag cover.

E

13. Remove the air breather line .

F

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

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

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

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

18. Disconnect coolant temperature sensor wire
located on the cylinder.

19. Remove engine to chassis ground cable.

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

3.16

F

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

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

22. For engine installation, reverse procedures.

ENGINE

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.

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

Bleed Cooling System

NOTE: This cooling system contains vent lines to

help purge trapped air during filling. Refer to Page

3.15 for hose routing. Bleeding generally should not

be necessary.

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

2. Fill coolant reservoir tank to full mark.

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

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

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

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

ENGINE INSTALLATION NOTES

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

General Items

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

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

PVT System

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

3.17

ENGINE

Engine Break In Period

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

CAUTION

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

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

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

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

SAFE

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

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

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

6. Pull only light loads during initial break in.

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

ADD 8 OZ

3.18

CYLINDER HONE SELECTION

ENGINE

AND HONING

CAUTION:

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

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

HONING TO

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:

S Honing should be done with a

diamond hone. Cylinder could be
damaged if the hone is not hard
enough to scratch the nicasil lining.

S 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.

S Release the hone at regular intervals

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

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

S After honing has been completed,

inspect cylinder for thinning or
peeling.

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

PROCEDURE

DEGLAZE

EXAMPLE OF CROSS HATCH PATTERN

IMPORTANT: Clean the Cylinder After

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

ENGINE LUBRICA

Oil Type -- Polaris Premium 0W--40 Synthetic (PN

2871281)

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

Filter -- (PN 2540086)

Filter Wrench -- PV--43527 or equivalent

Oil Pressure Specification -- 35--39 PSI @ 5500

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

NOTE: See Chapter 1 for oil changekit part numbers.

OIL PRESSURE

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

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

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

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

Oil Pressure at 5500 RPM (Engine Hot):

Standard: 39 PSI
Minimum: 35 PSI

TION

TEST

Honing

3.19

ENGINE

OIL FLOW

This chart describes the flow of oil through the 600/700/800 engine. Beginning in the crankcase sump, the oil
is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the
oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. At this point,
the oil is supplied to the main oil galley through a crankcase passage. Oil is then diverted three ways from the
main oil galley, with the first path entering the camshaft bores, onto the rear balanceshaft journaland thendraining
back into the crankcase sump. The second oil path from the main oil galley feeds the lifter bores and then drains
back to the crankcase sump. The third oil path flows through a crankcase galley to the MAG side crankshaft
journal and also to the front balance shaft journal and onto the crankcase sump. The oil pressure switch is fed
off the main oil galley.

PTO

SIDE

Crankshaft

Main Bearing

Counterbalance
Bore

Camshaft

Bore

Crankcase

Sump

Rod

Bearings

Camshaft

Bore

Lifter Bores

Crankshaft

Main Bearing

Counterbalance
Bore

Camshaft

Bore

MAGNETO

SIDE

3.20

Oil Pressure

Relief

Main Oil Gallery

Pump

Filter

Crankcase

Sump

ENGINE

ROCKER ARM INSPECTION

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

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

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

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

PUSH ROD

INSPECTION

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

A

CYLINDER HEAD REMOVAL

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

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

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

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

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

WARNING

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

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

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

A

B

C

D

3.21

ENGINE

CYLINDER HEAD INSPECTION

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

CAUTION: Use care not to damage sealing surface.

CYLINDER HEAD WARP

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

A

AGE

WARNING

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

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

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

B

B

Measure at different points

on the surface.

Cylinder Head Warpage Limit:

004″ (.1016 mm) Max.

CYLINDER
DISASSEMBL

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

Valve Train Servicing

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

HEAD

Y

Bottom Side View

PU--45257

A

Valve Spring Compressor:

(PU--45257)

Valve Pressure Hose:

(PU--45652)

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

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

3. Remove spring retainer and spring.

4. The valve seals are now serviceable.

3.22

CYLINDER HEAD DISASSEMBLY, CONT.

ENGINE

NOTE: Carefully remove the cylinder components.

Place the hydraulic lifters (C), pushrods (D), and
rocker arms (E) in a safe, clean area.

D

C

Valve Spring Length:

Std: 1.735I (44.069 mm)

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

E

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

Valve Spring
Free Length

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

Mark the valves

3.23

ENGINE

VALVE INSPECTION

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

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

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

Valve Stem Diameter:

Intake: 0.2356” ± 0.00039”

(5.985

± 0.01 mm)

Exhaust: 0.2351” ± 0.00039”

(5.972

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

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

± 0.01 mm)

A

B

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

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

Valve Guide

Valve Guide I.D.:

0.23672” ± 0.000295”
(6.0617

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

± 0.0075 mm)

3.24

ENGINE

COMBUSTION CHAMBER

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

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

Combustion Area

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

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

To o
Wide

Uneven

Good

To o
Narrow

VALVE SEAT
RECONDITIONING

Cylinder Head Reconditioning

NOTE: Polaris recommends that the work be done

by a local machine shop that specializes in this area.

NOTE: The cylinder head valve guides cannot be
replaced.

WARNING

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

Valve Seat Inspection

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

head must be replaced.

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

1. Install pilot into valve guide.

2. Apply cutting oil to valve seat and cutter.

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

4. Inspect the cut area of the seat:

S If the contact area is less than 75%

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

S If the cutter now contacts the uncut

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

3.25

ENGINE

VALVE SEAT RECONDITIONING CONT’D

S If the contact area of the cutter is in

the same place, the valve guide is
distorted from improper installation.

S If the contact area of the initial cut is

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

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

(A)

S If the seat is too narrow, widen using

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

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

(B)

(A)

Proper Seat Contact On Valve Face

Bottom - 60°

Seat - 45°

To p - 3 0°

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

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

S If the indicated seat contact is at the

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

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

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

S If the seat is too wide or uneven, use

both top and bottom cutters to
narrow the seat.

Seat
Width

Valve Seat Width:

Intake Std: .028I (.7 mm)

Limit: .055I (1.4 mm)

Exhaust Std: .039I (1.0 mm)

Limit: .071I (1.8 mm)

3.26

VALVE SEAT RECONDITIONING CONT”D

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

WARNING

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

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

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

ENGINE

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

12. Thoroughly clean cylinder head and valves.

CYLINDER
REASSEMBL

NOTE: Assemble the valves one at a time tomaintain

proper order.

1. Apply engine oil to valve guides and seats.

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

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

4. Valve seals should be installed after the valves
are in the head to avoid valve seal damage. Install
new valve seals on valve guides.

HEAD

Y

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

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

(PU--45257)

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

3.27

ENGINE

VALVE SEALING TEST

1. Clean and dry the combustion chamber area (A).
Refer to Page 3.25 for cleaning tips.

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

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

VALVE TRAIN EXPLODED VIEW

A

ROCKER ARMS

SPRING RETAINERS

SPRINGS

SPRING SEATS

HEAD

VALVES

22 ± 2 ft. lbs.

(30 ± 3Nm)

RETAINER LOCKS

PUSH RODS

HYDRAULIC LIFTERS

3.28

ENGINE

ENGINE HEAD REASSEMBLY

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

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

A

B

2. Install cylinder head on cylinder.

3. Lubricate threads and top of washers underside
of bolt head with engine oil. Install head bolts (C).
Torque to
sequence provided (Pg.3.11). Allow the gasket to
set for 1 minute at this torque, then turn bolts 90°
(1/4 turn) in sequence . Refer to Page 3.11 for
tightening sequence.

35 ± 4 ft. lbs. (47.5 ± 5.5 Nm) in

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

D

5. Lubricate rockers (E) with engine oil.

E

C

Cylinder Head Bolt Torque:

35 ± 4 ft. lbs.

(47.5 ± 5.5 Nm)

Then turn additional 90° (1/4 turn)

-- Allow to set for 1 min.

*Torque Bolts In Sequence (Pg. 3.11)

6. Verify pushrods are engaged in lifters.

7. Install rockers. Be sure that tab of fulcrum (F) is

seated in head stand-off. Torque bolts to 22 ± 2

ft. lbs. (30 ± 3 Nm).

F

Rocker Arm Bolt Torque:

22 ± 2 ft. lbs.
(30 ± 3Nm)

3.29

ENGINE

ENGINE HEAD REASSEMBLY CONT’D

8. Install breather reed (G) into rocker cover (H).
Lightly apply black RTV sealant to the outer
edges of the breather reed. The reed has a tab
and will assemble one way only. Torque the
breather bolts to 20 ± 5in.lbs.(2.5± 0.55 Nm).

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

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

20 ± 5in.lbs.

(2.5 ± .55 Nm)

H

I

G

11. Install thermostat (J), new O--ring, and
thermostat housing. Torque thermostat housing
bolts to 84 ± 8in.lbs.(9.5± 0.9 Nm).

J

84 ± 8in.lbs.
(9.5 ± 0.9 Nm)

25 ± 3 ft. lbs.

(34 ± 4Nm)

Thermostat Housing Bolt Torque:

84 ± 8 in. lbs. (9.5 ± 0.9 Nm)

REMINDER: Before assembly, clean the bolts and

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

10. Install rocker cover. Torque bolts to 84 ± 8in.lbs.
(9.5 ± 0.9 Nm). See Page 3.6 for proper torque
sequence.

Rocker Cover Bolt Torque:

12. Install temperature sender (K) and torque to 200 ±
20 in. lbs. (1.4 ± .14 Nm).

K

200 ± 20 in. lbs.

± .14 Nm)

(1.4

K

84 ± 8 in. lbs. (9.5 ± 0.9 Nm)

*Torque In Proper Sequence (Pg. 3.6)

3.30

Temperature Sender Torque:

200 ± 20in.lbs.(1.4± .14 Nm)

ENGINE

CYLINDER REMOVAL

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

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

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

A

4. Check the lifters for wear or scores.

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

6. If the bottom surface has worn flat, it may be used
with the original camshaft only.

Inspect Hydraulic Lifter

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

VALVE
REMOV

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

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

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

LIFTER

AL/INSPECTION

Mark the Hydraulic Lifter

PISTON REMOV

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

Mark the piston

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

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

AL

A

3.31

ENGINE

2. Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston
slightly with a propane torch. CAUTION: Do not
apply heat to the piston rings. The ring may lose
radial tension.

3. Remove top compression ring:

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

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

CYLINDER INSPECTION

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

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

A

B

Measure at different points

Ill.1

To p V iew

on the surface.

B

4. Repeat procedure for second ring.

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

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

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

b) Remove the expander.

Compression

Rings

Oil Ring

B

A

C

Ill.2

Cylinder Warpage.

.004″ (0.1 mm) Max.

3.32

ENGINE

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

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 sideto
side, on three different levels (1/2″ down from top,
in the middle, and 1/2″ up from bottom).

1/2″ Down From Top of Cylinder

Y

X

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

Cylinder Taper

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

Cylinder Out of Round

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

Standard Bore Size (Both Cylinders):

Sportsman 700 / 800 : 3.1496I (80 mm)

PISTON-T

O-CYLINDER

CLEARANCE

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

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

Y

X

Y

X

1/2″ Up From Bottom

5mm

Piston

Piston Pin

Piston to Cylinder Clearance

Refer To Engine Service Data

Pg. 3.12 -- 3.14

Piston O.D.

Refer To Engine Service Data

Pg. 3.12 -- 3.14

3.33

ENGINE

PISTON/ROD INSPECTION

1. Measure piston pin bore.

Piston Pin Bore:

Refer To Engine Service

Data

Pg. 3.12 -- 3.14

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

3. Measure connecting rod small end ID.

Connecting Rod Small End I.D.

Refer To Engine Service Data

Pg. 3.12 -- 3.14

3.34

Piston Pin Measurement Locations

Piston Pin O.D.

Refer To Engine Service Data

Pg. 3.12 -- 3.14

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.

Piston

Ring

Feeler Gauge

Piston Ring-to-Ring Groove Clearance

ENGINE

Piston Ring Installed Gap

Refer To Engine Service Data

Pg. 3.12 -- 3.14

NOTE: Ring should be installed with the mark facing

upward.

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

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

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

Refer To Engine Service Data

Pg. 3.12 -- 3.14

PISTON RING INSTALLED GAP

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

C

B

A

25-50mm

3.35

ENGINE

STARTER DRIVE/BENDIX
REMOV

1. Remove stator housing bolts and remove
housing.

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

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

AL/INSPECTION

B

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

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

C

4. Inspect the thrust washer for wearor damageand
replace if necessary.

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

B

3.36

FLYWHEEL/STATOR
REMOV

AL/INSPECTION

ENGINE

E

C

1. Remove stator housing bolts and remove
housing.

Remove
Stator Cover

2. Remove flywheel nut and washer.

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

2871043

B

D

5. Remove the bendix (E) if necessary.

FLYWHEEL/STAT
INSTALLA

NOTE: Before assembly, clean the bolts and bolt

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

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

2. Properly place the stator wires under the wire
holddown and install the bolts. Inspect the bolts, if
new bolts are needed, replace them with new
bolts. The new bolts contain patch lock, so
Loctitet is not needed on the new bolts. Torque
bolts to 96 ± 12 in.lbs. (10.85 ± 0.35 Nm).

TION

OR

A

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

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

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

3. Install the starter bendix if removed.

4. Install woodruff key. Install the flywheel. Install
the flywheel washer and nut. Torque the flywheel
nut to 65 ± 7 ft.lbs. (88 ± 9.50 Nm)

3.37

ENGINE

Flywheel Nut Torque:

65 ± 7 ft. lbs. (88 ± 9.50 Nm)

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

Stator Housing Bolt Torque:

96 ± 12 in.lbs. (1.85 ± 1.35 Nm)

*Torque Bolts In Sequence 3.4)

ENGINE
DISASSEMBL

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

CRANKCASE

Y/INSPECTION

B

FLYWHEEL/STATOR INSTALLATION

6. Install stator housing with new O-rings. Torque
the bolts to 96 ± 12 in. lbs. (1.85 ± 1.35 Nm).
Follow bolt torque sequence on Pg. 3.4.

96±12 in.lbs.

A

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

E

D

C

3. Remove flywheel nut and washer.

3.38

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

2871043

F

ENGINE

J

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

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

I

G

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

H

Camshaft Gear

Crank Gear

8. Use a white pen to accent the timing marks on the
following gears: camshaft gear (K), crankshaft
gear (M), or counterbalance gear (N) This will
ensure proper gear alignment and timing during
reassembly of the gears.

Timing Marks

Counterbalance Gear

K

Water Pump Gear

M

N

3.39

ENGINE

NOTE: If replacing one of the gears, it is

recommended that all of the gears be replaced. A
gear kit is available in the parts book.

Cam Gear Removal

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

PU--45497--2

NOTE: Install the Cam Gear Tooth Alignment Tool

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

O

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

S Place the cam gear on a flat surface

with the timing mark side facing up.

S While holding both gears together,

lightly work a small flathead
screwdriver between the two gears.

S Remove the top gear. The springs

should stay in place.

CAUTION:

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

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

Cam Gear Alignment Tool:

(PU--45497--2)

Cam Gear Disassembly

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

3 Loaded Springs

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

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

Accent the Timing Marks

14. Inspect the gear teeth and the three tabs on the
gears for wear.

3.40

Inspect Teeth & Tabs

ENGINE

Replace Three Springs

Cam Gear Reassembly

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

Insert Springs

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

PU--45497--1

To assemble:

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

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

S Perform this procedure with all three

tapered pins.

S Do not push the pins too far

through or the springs will pop out.

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

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

PU--45497--1

3.41

ENGINE

Cam Gear Spring Installation Tool Kit:

(PU--45497)

Tapered Pin s:

(PU--45497--1)

Cam Gear Tooth Align Tool:

(PU--45497--2)

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

Align Timing Marks

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

(R) to align the teeth of the cam gears, as shown
in the picture.

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

PU--45497--2

NOTE: For ease of installing the Cam Gear

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

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

PU--45498

20. After the tapered pins are removed, be sure the
cam gear assembly is held together tightly. Place
the cam gear assembly on a flat surface. Use the
Cam Gear Tooth Alignment Tool (PU--45497-- 2)

3.42

P

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

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

balance shaft gear.

2871043

ENGINE

2871043

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

2871043).

Q

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

R

Water/Oil Pump Removal/Disassembly

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

S

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

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

Mark Rotors

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

3.43

ENGINE

Oil Rotor Clearance

28. Use a feeler gauge to measure the clearance
between the two rotors. Measure the gap
between the two rotor tips as shown below. The
clearance should not exceed 0.006” (0.15 mm).

0.006” (0.15 mm)

Max Tip Clearance

22 ± 2 ft.lbs.

(30 ± 3Nm)

Chamfered
end first

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

DISASSEMBLY OF WATER/OIL PUMP SHAFT

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

30. Reinstall the valve (dowel chamfered end first).
Install the spring, washer, and bolt. Torque the
bolt to 22 ± 2 ft. lbs. (30 ± 3 Nm).

WARNING

during this procedure. Protective gloves,
clothing and eyewear are required.

31. Carefully press the gear off the assembly while
supporting the housing assembly.

32. Remove the snap ring from the assembly. Place
the housing in a support and press out the
bearing/shaft assembly.

Wear appropriate safety gear

Press off gear

3.44

Press out
shaft and
bearing
assembly

Bearing

Retaining Ring

33. Place the shaft in a press to remove the bearing.

Bearing

ENGINE

WATER/OIL PUMP REASSEMBLY

34. Press new bearing onto the shaft.

Bearing

35. Press the bearing/shaft assembly using the
bearing’s outer race. Do not use the shaft to press

the assembly into the housing, as bearing
damage may result. Install retaining ring.

Press Bearing/Shaft
assembly using outer
race only

36. Press gear onto shaft while supporting the
housing.

3.45

ENGINE

CRANKCASE DISASSEMBLY CONT’D

37. Remove thrust plate (U).

U

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

Separate the
crankcase
halves

W

V

40. Remove balance shaft and crankshaft.

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

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

3.46

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

to replace the bearings anytime the engine is
disassembled.