POLARIS TRAIL BOSS User Manual

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GENERAL INFORMATION

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

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

Replacement Keys 1.3.......................

Machine Dimensions 1.3.....................

Publication Numbers 1.3.....................

Paint Codes 1.3.............................

Specifications - Trail Boss 330 1.4--1.5.............

Specifications - Trail Blazer 330 1.6--1.7............

Specs

Special Tools 1.8............................

Standard Torque Specifications 1.9............

Tap / Drill Charts 1.10.........................

Decimal Equivalent Chart 1.10.................

Unit of Measure Conversion Table 1.11..........

Glossary of Terms 1.12........................

1.1

GENERAL INFORMATION

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MODEL IDENTIFICATION

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

Machine Model Number Identification

A09CA32AA

Emissions &

Year Designation

Basic Chassis Designation Engine Designation

Model Option

ENGINE DESIGNATION NUMBERS

ES32PFE Single, Air Cooled, SOHC 4 Stroke, Electric Start..................

VIN IDENTIFICATION

World Mfg. ID

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

Vehicle Descriptor

32A*9P0 00000

Vehicle Identifier

Body Style

Powertrain

Emissions

Engine

Check Digit

Model Year

Plant No.

Individual Serial No.

* This could be either a number or a letter

ENGINE SERIAL NUMBER LOCATION

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

UNIT MODEL NUMBER AND SERIAL NUMBER LOCATION

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

Front

TRANSMISSION I.D. NUMBER LOCA

TION

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

1.2

PUBLICATION NUMBERS

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GENERAL INFORMATION

Year Model Model No. Owner’s

Manual PN

2009 Trail Boss 330 A09CA32AA 9921784 9921774 2009 Trail Blazer 330 A09BA32AA 9921773 9921787

NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com or purchased from

www.purepolaris.com.

Parts

Manual PN

PAINT CODES

FRAME COLOR - P067 Medium Gloss Black 9440 / 8520147.

REPLACEMENT KEYS

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

Shouldbothkeysbecomelost, ignition switch replacement is required.

Series # Part Number

20 4010278

31XX

KEY COVER

P/N 5433534

Key Series Number

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

1.3

GENERAL INFORMATION

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MODEL: 2009 TRAILBOSS 330..........

MODEL NUMBER: A09CA32AA. ENGINE MODEL: ES32PFE..

Category

Length 75 in./191 cm Width 46 in./117 cm Height 46 in./117 cm Wheel Base 48 in./121.9 cm Ground Clearance 5.5./13.97 cm Dry Weight 488 lbs./221 kg Gross Vehicle Weight 830 lbs./377 kg

Front Rack Capacity (Accessory)

Rear Rack Capacity (Accessory)

Towing Capacity Hitch TongueWeight

(Accessory) Body Style

Dimension

30 lbs./13.6 kg

60 lbs./27.2 kg

850 lbs./385 kg

85 lbs./14 kg

Gen III

1.6

MODEL: 2009 TRAILBLAZER 330..........

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MODEL NUMBER: A09BA32AA. ENGINE MODEL: ES32PFE..

Engine

Platform Fuji 4 stroke, Single Cylinder Engine Model Number ES32PFE Engine Displacement 329cc Number of Cylinders 1 Bore & Stroke (mm) 78.5 x 68 mm CompressionRatio 9.2:1 Compression Pressure 70--90 psi Engine Idle Speed 1300 ± 100 Rpm Cooling System/Capacity Oil/ Air w/ fan assist

1.9qts./1.8 ltr Overheat Warning HOT Light on Panel Lubrication Wet Sump Oil Requirements Polaris 2W--50 Exhaust System USFS Approved

Carburetion

Carburetor model Mikuni BST 34mm Main Jet 122.5 Pilot Jet 42.5 Jet Needle 4HB48--3 Needle Jet P--4 (829) Pilot Screw 2 Turns Out

(Initial starting point, may vary

for each ATV) Pilot Air Jet 160 Float Height 13 ± 1 mm (0.51 ± 0.40“) Fuel Delivery Fuel Pump Fuel Capacity / Requirement 3.25 gal. (12.3 L)

87 Octane (minimum)

89 Oxygenated

Electrical

Alternator Output 200 w @ 5000 RPM Voltage Regulator 3--Phase Lights : Head 55 watts

Brake 26.9 watts

GENERAL INFORMATION

Drivetrain

Transmission Type Inline H/N/R Transmission Capacity 11.3 oz. (335 ml) Gear Ratio : High

Rev. Final

Chain Type 520 O--Ring Clutch Type PVT Non EBS Belt 3211077

Steering / Suspension

Front Suspension / Shock A--arm / MacPherson Strut Front Travel 8.2 in. / 20.83 cm Rear Suspension

Style / Shock Rear Travel 10.5 in. / 26.67 cm Ground Clearance 5.5in. / 13.97 cm Shock Preload Adjustment

Front / Rear Turning Radius 83in./211cm Toe Out 1/8 -- 1/4 in / 3 -- 6.35 mm

Progressive Rate Swingarm /

Twin Tube Gas Charged

Wheels / Brakes

JETTING CHART

Altitude

Meters

(Feet)

0--1800

(0--6000)

above 1800

(above 6000)

AMBIENT TEMPERATURE

Below 40°F

Below 5°C

127.5 122.5

120

CLUTCH CHART

Shift

Weight 10 RH

(5630709)

20--40

(5631356)

Blu/Grn

Meters

(Feet)

Altitude

0--1800

(0--6000)

1800--3700

(6000--12000)

Drive

Spring

(7041157)

2.68/1

3.05/1

11/40 78P

Front -- n/a

Rear -- Cam

+40°Fto+80°F

+5°Cto+28°C

Driven Spring

Black

(7041782)

Black

(7041782)(7041157)

115

Driven

Helix

(5131446)

45°

2--2

45°

2--2

1.7

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SPECIAL TOOLS

PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN

PA--44689 Valve Clutch Adjuster 2

2870872 Shock Spanner Wrench 2, 5

8712100DX or 8712500 Tachometer 2,10

2200634 Valve Seat Reconditioning Kit 3 2870390 Piston Support Block 3 2870159 FlywheelPuller 3 2871293 Slotted Nut Socket 3

PV--43527 OIl Filter Wrench 3

2872314 CarburetorFloat Adjustment Tool 4 2870975 Mity Vact Pressure Test Tool 4, 9 2870871 BallJoint Replacement Tool 5 2870623 Shock Absorber Spring Compression Tool 5 2871573 LH Strut Spring Compressor 5 2871574 RH Strut Spring Compressor 5 2870506 Clutch Puller 6 9314177 Clutch Holding Wrench 6 2871358 ClutchHolding Fixture 6 2870341 Drive Clutch Spider Removal and Install Tool 6 2870654 Clutch Offset Alignment Tool 6 2870913 Driven Clutch Puller 6 2870910 Roller Pin Tool 6 2871226 ClutchBushing Replacement Tool Kit 6 2870386 Piston Pin Puller 6 8700220 Clutch Compression Tool 6 2871710 10” Center Distance Tool 8

PV--43568 Fluket77 Digital Multimeter 10

2870630 Timing Light 10 2870836 Battery Hydrometer 10

8712100 or 8712500 Tachometer 10

NOTE: Polaris dealers can order the tools listed above through the SPX Service T ools catalog.

1.8

GENERAL INFORMATION

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STANDARD TORQUE SPECIFICATIONS

Thefollowing torquespecificationsare tobeused as a generalguideline. FOR SPECIFICTORQUE VALUESOF FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering,

suspension, and engine sections.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

T orque in. lbs. (Nm)

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

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

T o rque ft. lbs. (Nm)*

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

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

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

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

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

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

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

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

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

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

Metric / Torque

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

1.9

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SAE TAP DRILL SIZES

Thread Size/Drill Size Thread Size/Drill Size

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

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

METRIC TAP DRILL SIZES

Tap Size Drill Size Decimal

Equiva-

lent

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

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

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3437

0.339

0.375

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

1/16 .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.....

1.10

GENERAL INFORMATION

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CONVERSION TABLE

Unit of Measure Multiplied by Converts to

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

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

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

1.11

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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″ or1 cm). Polaris measures chainlength in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. ClutchOffset: Drive anddriven clutchesare offset sothatdrive beltwill staynearly straightas it movesalong the clutchface. Clutch Weights: Three levers in the driveclutch which relative to theirweight, profile and engine RPMcause thedrive

clutch to close and grip the drive belt. Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.

DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and

out-of-round in the cylinder bore.

Electrical Open: Open circuit. An electrical circuit which isn’t complete. Electrical Short: Short circuit. Anelectrical 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.

lbs/in2: Pounds per square inch. Left or Right 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. PVT: Polaris Variable Transmission (Drive Clutch System) qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir T ank: Thefill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. SeizedPiston: Gallingofthe sides ofa piston. Usuallythereis atransferofaluminumfromthepistonontothecylinderwall.

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.

1.12

MAINTENANCE

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

Recommended Maintenance Products 2.6--2.7......

Pre-Ride Inspection 2.8......................

ATV Component Locations 2.9................

Lubricant and Maintenance Quick Reference 2.10-2.11

Transmission Lubrication 2.12..................

Lubrications/Grease Points 2.13................

Transmission Linkage Adjustment 2.13..........

Throttle Operation / Choke Adjustment 2.14......

Carburetor Adjustments 2.15-2.16...................

ETC Switch Adjustment 2.16--2.17...................

Fuel System 2.17-2.18.............................

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

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

Ignition / Sparkplug 2.20.......................

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

Air Box Sediment Tube Service 2.22............

Recoil Housing/PVT Drying 2.22................

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

Valve Clearance 2.24-2.25.........................

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

Exhaust System Maintenance 2.28.............

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

Drive Chain and Sprocket Service 2.29-2.32..........

Suspension Service / Controls 2.32-2.33.............

Wheel Removal / Installation 2.33--2.34...............

Tire Inspection 2.34...........................

2.1

MAINTENANCE

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PERIODIC MAINTENANCE CHART

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

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

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

procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speedofapproximately10 milesperhour. Vehiclessubjectedto severeuse mustbe inspectedandservicedmore frequently.

Severe Use Definition

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

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.

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 AND LUBRICATION

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Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)

Steering

Front suspension

Rear suspension Tires

Brake fluid level

Brake lever travel Brake systems Drive Chain Wheels/fasteners Frame fasteners

Engine oil level

Air filter, pre-filter

Air box sediment

tube Coolant

Pre-Ride 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.

Inspect; clean often Drain deposits when visible

Check level daily, change coolant every 2 years

(if applicable) Headlamp/tail

lamp

Air filter,

main element Recoil housing

Daily Weekly Weekly

Check operation; apply dielectric grease if replacing

Inspect; replace as needed Drain water as needed, check often if operating

in wet conditions

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

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

Remarks

" 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.

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MAINTENANCE

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

Hours Calendar Miles

Engine breather

filter (if equipped)

Engine oil change

(break-in)

General lubrication

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

Steering 50 H 6M 310 (500) Lubricate

Front suspension 50 H 6M 310 (500) Lubricate

Rear suspension 50 H 6M 310 (500) Lubricate Carburetor float

bowl

Throttle Cable/

ETC Switch

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

E E

Carburetor air intake ducts/ flange

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

(if applicable)

Engine oil change 100 H 6M 620

Oil filter change 100 H 6M 620

Oil tank vent hose 100 H 12 M 620

Valve clearance 100 H 12 M 620

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 grease fittings, pivots, cables, etc.

50 H 6M 310 (500) Drain bowl periodically and prior to storage 50 H 6M 310 (500) Inspect; adjust; lubricate; replace if necessary

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

50 H 6M 310 (500) Inspect coolant strength

(whichever comes first)

(Km)

(1000) (1000) (1000) (1000)

seasonally; pressure test system yearly

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

Replace with oil change Inspect routing, condition Inspect; adjust

Remarks

" 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.

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Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

Hours Calendar Miles

Fuel system 100 H 12 M 620

Fuel filter 100 H 12 M 620

Radiator (if applicable)

Cooling hoses (if applicable)

Engine mounts 100 H 12 M 620 Exhaust muffler/

pipe

Spark plug 100 H 12 M 620

Ignition Timing 100 H 12 M 620

Wiring 100 H 12 M 620

Clutches (drive and driven)

Front wheel bearings

Brake fluid 200 H 24 M 1240 Spark arrestor 300 H 36 M 1860

Idle speed

Toe adjustment

Auxiliary brake

Headlight aim

100 H 12 M 620 100 H 12 M 620

100 H 12 M 620

100 H 12 M 620 100 H 12 M 1000

(whichever comes first)

(Km)

(1000)

(1000) (1000) (1000) (1000) (1000) (1000) (1000) (1000)

(1000) (1600) (2000) (3000)

Remarks

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

Replace yearly Inspect; clean external

surfaces Inspect for leaks

Inspect Inspect 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 replaced

Inspect daily; adjust as needed Adjust as needed

" 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.

2.5

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POLARIS LUBES/FLUIDS FOR TRAILBOSS 330 MODELS

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

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POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS

Part No. Description

Engine Lubricant

2870791 FoggingOil (12 oz. Aerosol) 2876244 Engine Oil (Quart)Premium 4 Synthetic

2W--50 (4--Cycle) (12 Count)

2876245 Engine Oil (Gallon) Premium 4 Synthetic

2W--50 (4--Cycle) (4 Count)

Gearcase / Transmission Lubricants

2873602 Premium Synthetic AGL Gearcase Lube

(12 oz. bottle)(12 Count)

2873603 Premium Synthetic AGL Gearcase Lube

(1 Gal.) (4 Count)

2876160 Premium ATV Angle Drive Fluid

(32 oz.) (12 Count)

2872276 Premium ATVAngle Drive Fluid

(2.5 Gal) (2 Count)

2870465 Oil Pump for 1 Gallon Jug 2871654 Premium Demand Drive Hub Fluid

(8 oz.) (12 Count)

Grease / Specialized Lubricants

2871322 Premium All Season Grease

(3 oz. cartridge)(24 Count)

2871423 Premium All Season Grease

(14 oz. cartridge)(10 Count)

2871460 StarterDrive Grease (12 Count) 2871515 Premium U-Joint Lube (3 oz.) (24 Count) 2871551 Premium U-Joint Lube (14 oz.) (10 Count) 2871312 Grease Gun Kit 2871329 DielectricGrease (Nyogelt)

Coolant

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

Part No. Description

Additives / Sealants / Thread Locking Agents /

Misc.

2874275 Loctitet Primer N, Aerosol 2871956 Loctitet Thread Sealant 565

(50 ml.)(6 Count)

2871950 Loctitet Threadlock 242

(6 ml.)(12 Count)

2871951 Loctitet Threadlock 262

(50 ml.) (10 Count)

2871953 Loctitet Threadlock 271

(6 ml.)(12 Count)

2871326 Premium Carbon Clean

(12 oz.) (12 Count)

2870652 Fuel Stabilizer (16 oz.) (12 Count) 2871957 Black RTV Silicone Sealer

(3 oz. tube) (12 Count)

2871958 Black RTV Silicone Sealer

(11 oz. cartridge) (12 Count)

2872189 DOT 4 Brake Fluid (12 Count) 2871557 CrankcaseSealant, 3-Bond 1215 (5oz.)

NOTE: The number count indicated by each part

number in the table above indicates the number of units that are shipped with each order.

NOTE: Each item can be purchased separately at your local Polaris dealer.

POLARIS LUBRICANT SYMBOL IDENTIFICATON

AGL

Polaris DOT 4 Brake Fluid

Polaris Sythetic Gearcase Lube

AGL

U--Joint

Polaris U--Joint Lube

2W/50

Polaris Sythetic OW--40 Oil

DHF

Polaris Demand Drive Hub Fluid

Polaris All Season Grease

ADF

Polaris ATV Angle Drive Fluid

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PRE-RIDE / DAILY INSPECTION

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

G Tires - check condition and pressures G Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank G All brakes - check operation (includes auxiliary brake) G Throttle - check for free operation G Headlight/Taillight/Brakelight - check operation of all indicator lights and switches G Engine stop switch - check for proper function G Wheels - check for loose wheel nuts G Air cleaner element - check for dirt or water; clean or replace G Steering - check for free operation, noting any unusual looseness in any area

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

COLD WEATHER KITS FOR 4 STROKE ATVS

Engine Heater -- (PN 2871507)

ACCESSORY ENGINE HEATER

2.8

TRAIL BOSS 330 COMPONENT LOCATIONS

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Brake Fluid Reservoir

Brake Lever

Light Control & Run Switch

Fuel Valve

Front Rack

Reverse Override

Choke

Rear Axle & Drive Sprocket

MAINTENANCE

Display

Throttle

Ignition/Key

Headlights

Transmission

Engine Recoil

Right Side View

Oil Dipstick

Muffler

Auxiliary Brake

PVT Cover

Gear Shifter

Front Rack

Engine

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MAINTENANCE QUICK REFERENCE

Ill.

1 Engine Oil Polaris 2W--50

2 Transmission PolarisAGL Lu-

3 Brake Fluid Polaris DOT 3

4 DriveChain Polaris Chain

NOTE: Refer to Page 2.6 for the Polaris Lubricant Identification table.

Item Lube Rec. Method Frequency*

Add oil to proper level. Change after1st month, 6 months or 100

Synthetic

Add lube to FULL level on dip-

bricant

Brake Fluid

Lube or O-Ring chain lube

Dipstick

2W/50

stick. Fill master cylinder reservoir to in-

dicated level inside reservoir. See Page 2.29.

Apply to chain link plates and rollers.

hours thereafter; Change more often (25-50 hours) in extremely dirty conditions, or short trip cold weather operation.

Change annually ©

As required. Change fluid every 2 years.

As required*

Transmission Dipstick

AGL

Operating Range

Full

1. Engine Oil

Parking Brake Lock

3. Brake Fluid

2. Transmission

Reservoir

4. Rear Drive Chain

2.10

MAINTENANCE QUICK REFERENCE CONT’D

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MAINTENANCE

5. Ball Joint

8. Axle Housing

4. Front Wheel Bearings

6. Tie Rod Ends

7. Swingarm Pivots

NOTE: Refer to Page 2.6 for the Polaris Lubricant Identification table.

Ill.

4 FrontWheel Bear-

ings

5 Ball Joint Polaris All Season

6 Tie Rod Ends Polaris All Season

7 Swing Arm Bush-

ings

8 Rear Axle Housing Polaris All Season

* 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) © Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) ¢ Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or

Mobilegrease Special

Item Lube Rec. Method Frequency*

Sealed; Replace Inspect and replace bearings if necessary Annually ©

Grease¢

Grease¢ Polaris All Season

Grease¢

Locate grease fitting on back side of struts and grease with grease gun.

Lift boot. Clean away dirt and grease. Apply fresh grease by hand and reassemble.

Locate grease fitting on swing arm and grease with grease gun.

Locate grease fitting on eccentric and grease with grease gun.

Semi-annually

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TRANSMISSION LUBRICATION

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

G Be sure vehicle is level before

proceeding.

G Check vent hose to be sure it is

routed properly and unobstructed.

G Follow instructions on following

pages to check / change transmission lubricant.

TRANSMISSION SPECIFICATIONS

Specified Lubricant:

Polaris AGL Gearcase Lubricant:

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

Capacity: 11.3 oz. (335 ml) Drain Plug / Fill Plug T orque:

14 ft. lbs. (19.4 Nm)

Transmission

Dipstick

Full

Operating

Range

TRANSMISSION FLUID CHANGE/TORQUE ST

ADJUSTMENT

1. Remove skid plate (if necessary).

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

3. Loosen jam nut (A).

4. Turn adjuster bolt (B) in to allow the removal of drain plug.

5. Removethedrainplug andwipethe magneticend clean to remove accumulated metallic filings.

6. After the oil has drained completely, install a new sealing washer and install the drain plug. Torque to 14 ft. lbs. (19.3 Nm).

7. Turn adjuster bolt (B) out until it touches the frame, and then an additional 1/2 turn.

PVT Cover

To check the level:

1. Remove dipstick and wipe clean.

Forward

8. Tighten the jam nut securely while holding the adjuster bolt.

9. Addthe proper lubricant through the dipstick hole until the oil level is between the upper and lower

2. Reinstall dipstick completely, remove and check the level. Add the proper lubricant as required to bring level into operating range as shown.

limits. Do not overfill.

10. Check for leaks.

11.ReinstallskidplateifremovedinStep1.

Drain Plug

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LUBRICATION / GREASE POINTS

As shown on Page 2.8, there are only five grease zerks onthe TrailBoss,two front balljoints,two onthe swing are pivots, and one on the rear axle housing.

Swing Arm Pivot

Each Side

Ball Joint Zerk

Each Side

Ball Joint Zerk

TRANSMISSION GEARSHIFT LINKAGE

ADJUSTMENT/

INSPECTION

Linkage rod will rotate

1/8 -1/4 turn if rod ends

are tightened properly.

Parallel

Correctly Tightened

Jam Nut

G Ifshiftingproblems areencountered,

thetransmission linkagemayrequire adjustment.

G Visually check for contact of shift

lever to shifter opening in the front fender. Ensure shift linkage or shift lever is not contacting the frame or exhaust components.

G Tightenshiftlinkage rodendjam nuts

properly after adjustment. You should be able to rotate the linkage rod between 1/8 and 1/4 turn after both jam nuts are tight.

G The transmission shift linkage

should be periodically inspected for wear and parts replaced as required to remove excess play from shift linkage.

G Refer to Transmission chapter for

more information.

Incorrectly Tightened

Jam Nut

NOTE: Therod end must be held whentighteningthe jam nut to prevent damage to the rod end.

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SHIFT LINKAGE ADJUSTMENT

1. Inspect shift linkage tie rod ends, clevis and pivot bushings and replace if worn or damaged.

2. Place gear selector in neutral.

3. Loosen rod end adjuster jam nuts (A) on both ends of linkage rod. NOTE: The jam nut closest to the knurled end is Left Hand thread.

Jam Nuts (A)

Linkage Rod

Ill. 1

THROTTLE OPERATION - ALL MODELS

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 inthe turningrange, inspect throttle cable routing and condition. If cable is routed properly and in good condition, repeat adjustment procedure.

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

CHOKE (ENRICHER) ADJUSTMENT

4. Turn linkage rod (A) to shorten or lengthen rod until the shift lever is centered on hole in the fender.

5. Hold rod end parallel to mounting surface and tighten jam nuts securely.

Boot

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

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

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

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PILOT SCREW

Thepilotsystem suppliesfuelduringengine operation with the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet.

CAUTION:

The pilotscrew is calibratedatthe factoryto meetEPA/ CARB regulationsfor air qualitystandards and is sealed with a brass plug to prevent tampering. Removal of the tamper proof plug is not permitted. For service purposes, cleaning of the pilot circuitcan be done only by a certifiedrepairshop to ensure air quality standards are not exceeded.

Pilot Screw location

PILOT SCREW ADJUSTMENT

FRONT (Engine)

Pilot Screw

View -- Right Cover Panel Removed

Pilot Screw

1. Start engine and warm it up to operating temperature (about 10 minutes).

Brass Plug Installed

Brass Plug Removed

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

The pilot screw is set at the factory. Each carburetor will have a slightly different pilot screw setting, the adjustments below are the recommended settings, the settings may differ from these recommendations.

Pilot Screw Adjustment: Trailboss 330 -- 2 Turns Out

3. Connect an accurate tachometer that will read in increments of + or -- 50 RPM such as the PET 2100DX (PN 8712100DX) or the PET 2500 (PN

8712500).

4. Set idle speed to 1200 RPM. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.

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

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

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

8. Re adjust idle speed if not within specification.

IDLE SPEED ADJUSTMENT

1. Start engine and warm it up thoroughly.

CV Carburetor

Idle Screw

confirm adjustment.

Boot

Adjuster

Sleeve

Direction

of travel

3. Tighten locknut and slide boots over cable adjuster until they touch at the middle point of the adjuster.

4. Withengine running, turn the handlebars fromfull left to full right with transmission in neutral. Engine RPM should not change and the engine should not die. If either of these occur, return to the first step.

Lock-

nut

1/16″ -1/8″

Freeplay

Boot

THROTTLE OPERATION

To remove the ETC cover:

Idle Speed:

1300 ± 100 RPM

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

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

ELECTRONIC THROTTLE CONTROL (ETC THROTTLE

CABLE

SWITCH)/

ADJUSTMENT

1. Slide the boots off inline cable adjuster sleeve.

Loosen adjuster locknut.

2. With handlebars centered and wheels pointing

forward, turn adjuster sleeve until 1/16″ -1/8″ freeplay is achieved at the thumb lever. After making any adjustment, “flip” the lever slightly to

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

2. Twistscrewdriver slightly while lifting onthecover 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.

Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding. Replace the throttle cable if worn, kinked, or

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damaged.

NOTE: When replacing the cover, check for correct placement of cover O-ring.

FUEL SYSTEM

WARNING

Gasoline is extremely flammable and explosive under certain conditions.

FUEL LINES

Fuel Lines

Fuel Pump

Pulse Line

Ill.1

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

2. Besurefuel linesare routed properly andsecured with cable ties. CAUTION: Make sure lines are not kinked or pinched.

3. Replace all fuel lines every two years.

G Always stop the engine and refuel

outdoors or in a well ventilated area.

G Do not smoke or allow open flames

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

G Donot overfill the tank. Donot fill the

tank neck.

G If you get gasoline in your eyes or if

you swallow gasoline, seek medical attention immediately.

G If you spill gasoline on your skin or

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

G Never start the engine or let it run in

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

G Never drain the float bowl when the

engine is hot. Severe burns may result.

VENT LINES

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

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

FUEL FILTER

The fuel filter should be replaced in accordance with the Periodic Maintenance Chart. The fuel filter is located between the fuel pump and carburetor.

1. Shut off fuel supply at fuel valve.

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

3. Remove fuel lines from filter.

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

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Arrow Indicates Direction

of Flow

RES

OFF

To Carburetor

Fuel Valve

5. Install clamps on fuel line.

6. Turn fuel valve ON.

7. Start engine and inspect for leaks.

CARBURETOR DRAINING

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

Drain tube

attached

here

Drain Screw

NOTE: Thebowl drain screwis located onthebottom left side of the float bowl.

1. Turn fuel valve to the off position.

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

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

4. Inspect the drained fuel for water or sediment.

5. Tighten drain screw.

6. Turnfuelvalveto“ON”.

7. Start machine and check for leaks.

NOTE: If there is a tube attached, it must be reattached as this will effect engine performance.

COMPRESSION TEST

NOTE: This Polaris 4-Strokeengine is equipped with

an automatic decompressor. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about

70--90 psi

Smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition problems above idle speed. Abnormally high compression can be caused by a decompressor malfunction, or worn or damaged exhaust cam lobes. Inspect camshaft and automatic decompression mechanism if compression is abnormally high.

A cylinder leakage test isthe best indication ofengine condition on models with automatic decompression. Follow tester manufacturer’s instructions to perform a cylinder leakage test. (Never use high pressure leakagetesters ascrankshaft seals may dislodgeand leak).

during a compression test.

Cylinder Compression

Standard 70--90 PSI

Cylinder Leakage

Service Limit: 10 %

(Inspect for cause if leakage exceeds 10%)

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ENGINE MOUNTS

Inspect rubber engine mounts for cracks or damage.

ENGINE FASTENER TORQUE

Check engine fasteners and ensure they are tight.

BATTERY MAINTENANCE

WARNING

Battery electrolyte ispoisonous. Itcontains sulfuric acid. Serious burnscanresultfrom 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 nearbatteries. KEEPOUTOF REACH OF CHILDREN.

NOTE: All Trail Boss ATV batteries are Maintenance -- Free design and construction. All Maintenance--Free batteries arefully chargedand tested at the factory before installation. Expected shelf life is 6 --8 months depending on storage conditions. As a general rule before placing the battery into service, check the battery condition and charge accordingly .

Maintenance -- Free batteries are permanently sealed at the time of manufacture. The use of lead--calcium and AGM technology instead of lead--antimony allows the battery acid to be fully absorbed. For this reason, a Maintenance--Free

battery case is dark and the cell caps are not removable, since there is no need to check electrolyte level.

NEVER attempt to add electrolyte or water to a Maintena nc e--Free battery. Doing so will damage the case and shorten the life of the battery. Refer to the Battery Maintenance Video (PN 9917987) for proper instruc tion on serv ic ing Maintenance--Free batteries.

The battery is located under the left rear fender.

Battery

To remove the battery:

1. Disconnect holder strap (A) and remove cover (B).

2. Disconnect battery negative (-)(black) cablefirst, 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. Remove the battery.

4. Cleanbatterycables andterminalswitha stiffwire 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.

5. Reinstallbattery,attaching positive(+)(red) cable first and then the negative (-) (black) cable.

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

7. Reinstall battery cover and holder strap.

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SPARK PLUG

330 Engine

1. Removespark plug hightension lead. Cleanplug area so no dirt and debris can fall into engine when plug is removed.

2. Remove spark plug.

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

Inpsect electrode for wear and buildup

Recommended Spark Plug:

NGK BKR6E

Spark Plug Torque: 9--11 Ft. Lbs.

(12--14 Nm)

IGNITION TIMING

Refer to Electrical chapter for ignition timing procedure.

Ignition Timing:

30°±2° BTDC@5000RPM

ENGINE-TO-FRAME GROUND

Inspect engine-to-frame groundcableconnection. Be sure it is clean and tight.

Engine Ground Strap

4. Clean with electrical contact cleaner or a glass bead spark plugcleaner 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 andgap. Adjust gap if necessary by bending the side electrode carefully.

MAIN AIR FILTER CLEANING

Spark Plug Gap

.036″ (.9 mm)

6. If necessary,replacespark 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. Installsparkplug andtorqueto 9--11ft. lbs(12--14 Nm).

It is advisable to replace the filter when it is dirty. However, in an emergency it is permissible to clean the main filter if you observe the following practices.

G Never immerse the filter in water

since dirt can be transferred to the clean air side of the filter.

G If compressed air is used never

exceedapressureof 40PSI. Always use a dispersion type nozzle to prevent filter damageand clean from the inside to the outside.

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G Replace the air filter every 50 hours,

and possibly more often in very dirty conditions.

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.

Theprefiltershould becleanedbeforeeachrideusing 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 from air box cover (A) and remove

VICE

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

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

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

Installation:

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

10. 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

4. Loosenclamp andremoveair filter assembly (B& C).

Ill.1

Cleaning:

5. Slipthe pre-filter element (C) off of main element. Clean the pre filter with hot soapy water.

6. Rinse and dry thoroughly.

7. Inspect element for tears or damage.

ILL.1

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.

1 1. Install air box cover and secure with clips.

Main Filter

Front

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AIR BOX SEDIMENT TUBE

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

Sediment Tube

NOTE: Thesediment tube willrequire morefrequent

service if the vehicle is operated in wet conditions or at high throttle openings for extended periods.

1. Remove drain plug from end of sediment tube.

2. Drain tube.

3. Reinstall drain plug.

RECOIL HOUSING

G Drain the housing periodically to

remove moisture.

recoil housing, especially when travelling in wet areas. If it is not sealed properly, water may enter the recoil housing and damage components.

G Water will enter the recoil housing if

the starter handle (B) is disengaged from the rope guide when under water.

G After travelling in wet areas, the

recoil housing and starter should always be drained completely by removing the recoil.

G Do not open the crankcase drain

unless the engine has ingested water. Some engine oil will be lost if crankcase drain is opened.

G If recoil handle seal has been

damaged, the handle assembly should be replaced.

PVT DRAIN PLUG & DRYING

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

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

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

Recoil Drain

G Drain the recoil housing after

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

G CAUTION: Make sure the manual

start handle (B) is fully seated on the

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. OperateATVin lowestavailable range for a short period of time until PVT system is dry.

PVT Drain Plug & O--ring

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ENGINE OIL LEVEL

To check the oil level:

1. Set machine on a level surface.

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

3. Stop engine, remove dipstick and wipe dry with a clean cloth.

4. Reinstall dipstick, screwing into place.

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

6. Remove dipstick and check to see that the oil level is in the normal range. The oil should be between the top of thebottom crosshatched area andthebottomof thetop crosshatchedarea. Add oilas indicated by thelevel onthe dipstick. Donot overfill.

Normal Oil Operating Range is between crosshatch.

OIL AND FILTER CHANGE

1. Place vehicle on a level surface.

2. Cleanarea around drain plug at bottomof oil pan.

3. Runenginetwoto three minutes until warm. Stop engine.

4. Place a drain pan beneath oil pan and remove drain plug from under the crankcase. CAUTION: Oil may be hot. Do not allow hot oil to come into contact with skin as serious burns may result.

5. Allow oil to drain completely.

NOTE: It is not necessary to drain the oil from the oil cooler, unless contaminants, water, or debris are found in the crankcase oil.

6. Replacesealingwasher(A)ondrainplug. NOTE: The sealing surfaces on drain plug and oil tank should be clean and free of burrs, nicks or scratches.

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

Crosshatch Areas of Dipstick

NOTE: Do not fill the over the normal oil operating range. Filling over the normal operating range could cause a mist of oil to enter the air box.

Drain plug located under the engine. NOTE: Rising oil level between checks in cool weatherdriving, canindicatemoisture collectinginthe oil reservoir. If the oil level is over the full mark, change the oil.

Recommended Engine Oil:

Polaris Premium 4 All Season

Synthetic, 2W--50

Engine Sump Drain Plug - Bottom View

8. The oil filter is located on the right side of the machine. Place shop towels beneath oil filter.

Crankcase Drain

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Using an oil filter wrench, turn filter counterclockwise to remove.

Filter

9. Usingacleandry cloth,cleanfilter sealingsurface on crankcase.

10. Lubricate O-ring on new filter with afilm ofengine oil. Check to make sure the O-ring is in good condition.

1 1. Install newfilterand turnby handuntilfiltergasket

contacts the sealing surface, then turn and additional 1/2 turn.

VALVE CLEARANCE

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

1. Remove the seat.

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

3. Remove the spark plug high tension lead and remove thesparkplug. CAUTION: Placea clean shop towel into the spark plug cavity to prevent dirt from entering.

4. Remove plastic valve plugs.

330 V alve Plugs

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

12. Remove dipstick and fill tank with 2 quarts (1.9 l) ofPolarisPremium4 SyntheticOil (PN2871281).

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.

Crankcase Drain Plug Torque:

14 ft. lb s. (19 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. Remove timing inspection plug from recoil housing.

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

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

NOTE: Observe the intake valve closing and then start toopen, continueto rotate until the“T” aligns with pointer. The camshaft lobes should be pointing downward.

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

INTAKE VALVE CLEARANCE:

0.006±0.0008I (0.15±0.02 mm)

BTDC on compression

2.24

INTAKE VALVE CLEARANCE

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ADJUSTMENT

1. Insert a .006″ (.15mm) feelergauge betweenend of intake valve stem and clearance adjuster screw.

2. Using Valve/Clutch Adjuster (PA--44689), loosen adjuster lock nut and turn adjusting knob until there is a slight drag on the feeler gauge.

330 Engine

MAINTENANCE

1. Insert.006″ feelergauge between end of exhaust valve stem and adjuster screw.

EXHAUST VALVE CLEARANCE:

0.006±0.0008I (0.15±0.02 mm)

BTDC on compression

2. Loosenlocknutandturnadjusterscrew untilthere is a slight drag on feeler gauge.

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

4. Re-check the valve clearance.

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

6. Inspect o-rings on the plastic valve plugs, replace if damaged. Securely fasten valve plugs.

7. Reinstallfuel tank and any body panels that were removed to gain access.

STEERING

The steering components should be checked periodicallyfor loose fasteners, worn tierod 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 isnotrestricted orlimited. NOTE: Whenever steering components are replaced, checkfront endalignment. Use only genuine Polaris parts.

WARNING

NOTE: Due to the critical nature of the procedures

outlined in this chapter,Polaris recommends steering componentrepair andadjustment beperformedbyan

3. Holdadjuster screw and tighten adjuster lock nut securely.

4. Re-check the valve clearance.

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

authorized Polaris Dealer. Onlya qualifiedtechnician should replace 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.

EXHAUST VALVE CLEARANCE

NOTE: Theexhaust valveis adjustedthesameasthe

intake valve.

ADJUSTMENT

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TIE ROD END / STEERING INSPECTION

To check for play inthetie 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).

G Replace any worn steering

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

G If abnormal movement is detected,

inspect the hub and wheel assembly to determine the cause.

G Refer to the Body/Steering or Final

Drive chapter for more information.

CAMBER AND CASTER

The camber and caster are non-adjustable.

WHEEL ALIGNMENT METHOD: STRAIGHTEDGE OR

Be sure to keep handlebars centered. See notes below.

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

STRING

G Elevate front end of machine so front

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

Check for Loose Wheel or Hub

Measure

from string

to rim at

front and

rear of rim.

NOTE: Thesteeringpostarmcanbeused

as an indicator of whether the handlebars

are straight. The frog should always point

straight back from the steering post.

Rear rim

measure-

ment should

be 1/16″ to

1/8″ (.2to.3

cm) more

than front rim

measure-

ment.

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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 steeringarmcanbeusedasanindicatorof whether the handlebars are straight. The arm 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) fromthe 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. Callthis measurement “A”.

5. Rotatethetires180° bymovingvehicle forwardor backward. Position chalkmarks facing rearward, even with the hub/axle centerline.

6. Again measure the distance between the marks and record. Callthis 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) toeout. This means themeasurementat the front ofthe tire (A)is 1/8″ to 1/4″ (.3to .6 cm)wider than the measurement at the rear (B).

CHALK

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.

To adjust toe

G Hold tie rod end to keep it from

G Loosenjamnuts atbothendof thetie

G Shorten or lengthen the tie rod until

G Important: When tightening the tie

alignment:

rotating.

rod.

alignmentisasrequir ed to achieve the proper t oe set ting. M ethod 1 (1/16″ to 1/8″)or Method 2 (1/8″ to 1/4″).

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.

Hold

Rod End

Correctly

Tightened

Jam Nut

Chalk Line

Measurement

“A”

Measurement “B”

Incorrectly

Tightened

Jam Nut

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EXHAUST CLEANING

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 T o 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.

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.

3. If some carbon is expelled, cover the exhaust outlet and lightly tap on the pipearound the clean out plugs while revving the engine several more times.

4. If particles are still suspected to be in the muffler, backthe machineonto an inclineso therear of the machine is one foot higher thanthe front. Set the hand brake and block the wheels. Make sure the machine is in neutral and repeat Steps 2 and 3.

SEE WARNING ABOVE

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. Makesure the machine is in neutral and repeat Steps 2 and

3. SEE PREVIOUS WARNING

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

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

8. Reinstall the clean out plugs.

BRAKE SYSTEM INSPECTION

The following checks are recommended to keep the brakesystemin goodoperating condition. Service life of brake system components depends on operating conditions. Inspect brakes in accordance with the

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.

Clean Out Plug

maintenance schedule and before each ride.

G Keepfluidlevel inthe master cylinder

reservoir to the indicated level inside reservoir.

G Use Polaris DOT 4 Brake Fluid

(PN 2872189).

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Sight Glass

Auxiliary Brake Master Cylinder

G Check brake system for fluid leaks,

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

frictionmaterial.

Parking Brake Lock

BRAKE PAD INSPECTION

AUXILIARY BRAKE ADJUSTMENT

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

First, checkfootbrake effectiveness byapplying50lb. (approx.) downwardforce onthe pedal. The top of the pedal should be at least 1 inch, (25.4mm) above the surface of the footrest.

1/8, to 1/4, Free Play

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

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:

(HYDRAULIC)

50 lbs

1″ or greater

Floorboard

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

DRIVE CHAIN AND

3/64″

(.1cm)

Minimum

Thickness

Pads should be changed when friction material is wornto3/64″ (.1cm), orabout thethicknessof adime.

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.

SPROCKET

Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers. The sprockets and outer rollers require periodic lubrication. Lubricate the chain with Polaris O-Ring Chain Lubricant (PN 2872073).

Inspect the drive chain for missing or damaged O-Rings, link plates, or rollers. Donotwashthechain with a high pressure washer, gasoline or solvents; do not use a wire brush to clean the chain as damage to the O-Rings may occur. Clean chain with hot soapy water and a soft bristled nylon brush.

INSPECTION

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Never allow battery acid to contact the drive chain.

Service Limit:

1/4″ (6mm)

Proper

Splicelink Clip

Opening

Position

Drive Chain Wear Limit-- 20 Pitch Length:

Std: 12.5″ (32 cm)

Wear Limit: 12.875″ (32.7 cm)

Drive Chain Lubricant:

Polaris O-Ring Chain Lubricant

(PN 2872073)

SPROCKET INSPECTION

Inspect the sprocket for worn, broken or bent teeth. To check for wear, pull outward on the chain as

shown. Replacesprocket if chainmovementexceeds 1/4″ (.6 cm).

DRIVE CHAIN INSPECTION

The chain must be replaced when it reaches 3% elongation.

1. Stretch the chain tightly in a straight line.

2. Measurealength oftwentypitches(pins) from pin center to pin center, and compare to the specification. Replace the chain if the length exceeds the wear limit.

3. When replacing or reinstalling drive chain, install theclosed end ofthe splicelink clipasshown,with the closed end leading in forward operation.

DRIVE CHAIN ADJUSTMENT, CONCENTRIC

CAUTION: Never adjust or operate the vehicle

with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result.

Break-In: Itis extremely importantto maintain proper chain tension to ensure the best possible chain life. There is a chain break-in period of approximately 100 miles or two (2) tanks of fuel. During this time chain tension should be watched very closely and loads to the chain should be kept light.

Checking Deflection: Inspect chain deflection by slowly moving theATV forward so any slack that may have previously been on the under part of the chain is now on the top side of the chain. The bottom part of the chain should be taught during inspection. Measure the chain deflection as shown in the diagram. Deflection should be approximately3/8

in. (10 mm).

After inspection, again slowly move the ATV forward until all the chain slack is on the top side of the chain and inspect the deflection. Repeat this procedure several times to check different spots on the chain.

SWINGARM

The chain is correctly adjusted when the tightest portion of the chain itself has approximately 3/8 in., (10 mm) of deflection. It’s a common characteristic of

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anychain to have oneor moretight spotsin thechain. Therefore, it is extremely important to check chain deflection in several areas of the chain to ensure deflection is correct at the tightest point.

2. Loosen two eccentric clamp bolts.

3. 2004 Models -- Loosen caliper mounting bracket bolts.

4. Using a 2 1/2″ wrench, rotate the housing to adjust chain slack to the proper dimension, and then proceed to Step 7; or... follow Steps 5 and

6 for alternate method if 2 1/2″ wrench is not available.

Loosen

Tighten

5. Insert a pin punch through the sprocket hub and into the eccentric axle housing.

3/8″ (10 mm) Deflection

ADJUSTMENT PROCEDURE CONCENTRIC REAR

AXLE

Loosen (2) caliper

mounting bracket

bolts (Step 3 --

2004 models)

SWINGARM

Loosen Eccentric

clamp bolts (Step 2)

Alternate Adjustment Method -- Pin Punch

(Step 5 and 6)

6. Roll the vehicle ahead or back to adjust chain slack to the proper dimension.

7. Tightenthe eccentric clampbolts tospecification.

CAUTION: DO NOT OVER-TIGHTEN ECCENTRIC CLAMP BOLTS. PREMATURE BEARING FAILURE MAY RESULT.

Eccentric Clamp Bolt Torque Specs

Pinch Clamp Bolt Torque --

30 ft. lb s. (41 Nm)

Pinch Clamp Bolt Torque w/ Trailer Hitch -- 40 ft. lbs. (54 Nm)

1. Loosen chain guard.

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Eccentric Clamp Without Hitch

30 ft.lbs. (41 Nm)

Without Trailer Hitch

Eccentric Clamp With Hitch

chain has approximately 3/8 in. (10 mm) of deflection.

1 1. Reinstall the chain guard (where applicable).

Reposition chain guide to allow 1/8″ (.3 cm) clearance between sprocket and guide.

Chain Guide

SUSPENSION SPRING PRELOAD

ADJUSTMENT

Torque to 40 ft.lbs. (54 Nm)

With Trailer Hitch

8. Remove the pin punch.

9. 2004 Models -- Tighten caliper mounting bracket bolts 10-12 ft. lbs. (14 - 17 Nm).

2004 Models: Caliper Mount Bracket

10-12 ft. lbs

Operator weight and vehicle loading affect suspension spring preload requirements. Adjust as necessary to avoid bottoming of the shocks.

FRONT SUSPENSION

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

Check all front suspension components for wear or damage.

Inspect front strut cartridges for leakage.

REAR SUSPENSION

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

Rear Spring

Adjustment Ring

10. Verify chain adjustment is correct after tightening eccentric clamp bolts to specification by rolling ATV forward and checking chain tension in several places on chain. The chain is adjusted

correctly when the tightest portion of the

G Check all rear suspension

components for wear or damage.

G Inspect shock for leakage.

2.32

Shock Spanner Wrench

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(PN 2870872)

CONTROLS

Check controls for proper oper ation, posit ioning and adjustment .

MAINTENANCE

WHEEL REMOVAL FRONT OR REAR

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

2. Loosen the wheel nuts slightly.

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

4. Remove the wheel nuts and remove the wheel.

Front Wheel

Front Wheel Nuts (4)

27 ft. lbs. (37 Nm)

Front Spindle Nut

40 ft. lbs. (54 Nm)

G Brake control and switch must be

positioned to allow brake lever to travel throughout entire range without contacting switch body.

WHEELS

Inspect all wheelsfor runout or damage. Checkwheel nuts and ensure they aretight. Donot over tightenthe wheel nuts.

WHEEL, HUB, AND SPINDLE TORQUE T

Item Specification

Front Wheel Nuts 27 Ft. lbs. (37 Nm)

Rear Wheel Nuts 50 Ft. Lbs. (68 Nm)

Front Spindle Nut 40 Ft Lbs. (54Nm)

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

ABLE

Rear Wheel

Rear Wheel Nuts (4)

50 ft. lbs. (68 Nm)

Taper end faces wheel for install.

Rear Hub Nut

80 ft. lbs. (108 Nm)

WHEEL INSTALLATION

1. With the transmission in gear and the parking brake locked, place the wheel in the correct positiononthewheelhub. Besure thevalvestem is toward the outside and rotation arrows on the tire point toward forward rotation.

2. Attach the wheel nuts and finger tighten them.

NOTE: Install the tapered end of the rear wheel nut goes into the taper of the wheel. See illustration above.

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3. Lower the vehicle to the ground.

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

CAUTION:

If wheels are improperly installed it could affect vehicle handling and tire wear. Be sure to properly torque and install all wheel nuts.

TIRE PRESSURE

Tire Pressure Inspection (PSI - Cold)

Front Rear

4 3

TIRE INSPECTION

Tread

Depth 1/8I (3 mm)

FRAME, NUTS, BOLTS,

ASTENERS

Periodically inspect the tightness 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.

WARNING

Operating anATVwithworn tires will increase the possibility of the vehicleskidding 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.

CAUTION:

G Maintain proper tire pressure. Refer

to the warning tire pressure decal applied to the vehicle.

G Impropertire inflationmayaffect ATV

maneuverability.

G When replacing a tire always use

original equipment size and type.

G Theuseof non-standard size or type

tires may affect ATV handling.

Tire Tread Depth

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

2.34

Engine Service Data 3.2-3.3.........................

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Special Tools and Torque Specifications 3.4........

Torque Patterns 3.4.............................

Piston Identification 3.5..........................

Engine Removal 3.5............................

Engine Installation Notes 3.6.....................

Cylinder Honing 3.6-3.7.............................

Engine Lubrication 3.7...........................

Oil Pressure Test 3.7-3.8............................

Lubrication/Oil Flow 3.8-3.9..........................

Engine Exploded View 3.10.......................

Engine Top End Disassembly 3.11 -3.18.................

Valve/ Valve Seat Service 3.18-3.22....................

Engine Bottom End Disassembly 3.22-3.32..............

Crankcase & Bearing Assembly 3.32...............

Crankshaft End Play Inspection 3.32-3.33...............

Engine Assembly/Inspection/Adjustments 3.33-3.43......

Recoil Disassembly/Inspection/Reassembly 3.44-3.45....

Spark Plug Fouling Checklist 3.46..................

Troubleshooting 3.46-3.47.............................

ENGINE

3.1

ENGINE

pgg

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ES32PFE10 ENGINE SERVICE DAT

Cylinder Head / Valve ES32PFE10

Rocker Arm

Camshaft Cam lobe height In

Cylinder Head

Valve Seat Contacting width In

Valve Guide

Valve Margin thickness In

Valve

Valve Spring Free length

Rocker arm ID .8669-.8678″ (22.020-22.041 mm) Rocker shaft OD .8656-.8661″ (21.987-22.0 mm) Rocker shaft Oil Clearance

Camshaft journal OD

Camshaft journal bore ID

Camshaft Oil clearance

Surface warpage limit .0020″ (.05 mm) Standard height 2.908″ (73.8 mm)

Inner diameter .2362-.2367″ (6.000-6.012 mm) Protrusion above head .681-.689″ (17.3-17.5 mm)

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

Stem oil clearance Std

Overall length

Squareness 0.075″ (1.9 mm)

Std .0008-.0021″ (.020-.054 mm) Limit .0039″ (.10 mm) Std 1.3001--1.3041″ (33.023-33.123 mm) Limit 1.2883″ (32.723 mm)

Std 1.3007-1.3047″ (33.039-33.139 mm) Limit 1.2889″ (32.739 mm) Mag 1.4935-1.4941″ (37.935-37.950 mm) PTO 1.4935-1.4941″ (37.935-37.950 mm) Mag 1.4963-1.4970″ (38.005-38.025 mm) PTO 1.4963-1.4970″ (38.005-38.025 mm) Std .0022-.0035″ (.055-.090 mm) Limit .0039″ (.10 mm)

Std .039″ (1.0 mm) Limit .055″ (1.4 mm)

Std .059″ (1.5 mm) Limit .071″ (1.8 mm)

Std .039″ (1.0 mm) Limit .032″ (0.8 mm)

Std .047″ (1.2 mm) Limit .032″ (0.8 mm)

Ex .2341-.2346″ (5.945-5.960 mm) In 0.0014-0.0024″ (0.035-0.062mm) Ex 0.0016-0.0026″ (0.040-0.067mm)

Limit .0059″ (0.15 mm)

In 3.979″ (101.0 mm) Ex 3.987″ (101.2 mm) Std 1.673″ (42.5 mm) Limit -- -- --

3.2

ENGINE

gggpp

ggg

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ES32PFE10 ENGINE SERVICE DAT

Cylinder / Piston / Connecting Rod ES32PFE10

Cylinder

Piston Outer diameter

Piston Pin

Piston Ring Piston ring installed gap Top ring

Piston Ring Standard clearance -

Connecting Rod

Crankshaft

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

Surface warpage limit (mating with cylinder head)

Cylinder bore Std 3.0906-3.0913″ (78.50-78.520 mm) Taper limit .0020″ (0.050 mm) Out of round limit .0020″ (0.050 mm) Piston clearance

Boring limit .0020″ (0.5 mm)

Std 3.0881-3.0891″ (78.438-78.462 mm) .0098″ (.25 mm)OS3.0980-3.0989″ (78.688-78.712 mm)

.0197″ (.50 mm)OS3.1078-3.1087″ (78.938-78.962 mm)

Standard inner diameter of piston pin bore .7095-.7097″ (18.007-18.013 mm) Outer diameter .7092--.7095″ (18.001-18.007 mm) Standard clearance-piston pin to pin bore 0.0-.0005″ (0.0-0.012 mm) Degree of fit Piston pin must be a push (by hand) fit at 68°

Second ring

Oil ring

Top ring

piston ring to ring groove

Second ring

Connecting rod small end ID .7095-.7101″ (18.007-18.023 mm) Connecting rod small end radial

clearance Connecting rod big end side clear-

ance Connecting rod big end bearing

clearance Crankshaft runout limit (PTO end) 0.0024″ (0.060 mm)

Crankshaft end play 0.002-0.008″ (0.05-0.20 mm)

.0020″ (0.050 mm)

Std .0015-.0032″ (0.038-0.082 mm) Limit .004″ (0.11 mm)

F(20° C) Std .0079-.0118″ (0.20-0.30 mm) Limit .039″ (1.0 mm) Std .0138-.0197″ (0.35-0.50 mm) Limit .039″ (1.0 mm) Std .0079-.0236″ (0.20-0.60 mm) Limit .059″ (1.5 mm) Std .0014-.0030″ (0.035-0.075 mm) Limit .0059″ (0.15 mm) Std .0010-.0026″ (0.025-0.065 mm) Limit .0059″ (0.15 mm)

Std 0.0-.0009″ (0.0-0.022 mm) Limit .0012″ (0.03 mm) Std .0028-.0118″ (0.07-0.30 mm) Limit .0138″ (0.35 mm) Std 0.0007-0.0021″ (0.019-0.053 mm) Limit 0.0026″ (0.065 mm)

3.3

ENGINE

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SPECIAL T

PART NUMBER TOOL

PV--43527 Oil Filter Wrench

OOLS

DESCRIPTION

2200634 Valve Seat

ReconditioningKit

2870390 Piston Support

Block

2871043 Flywheel Puller 2871293 Slotted Nut Socket

TORQUE SPECIFICATIONS

ENGINE TORQUE SPECIFICATIONS

Fastener Size 330

ES32PFE10

Ft. Lbs. (Nm)

Camshaft Chain Tensioner Lever

Camshaft Chain Tensioner

Camshaft Chain Tensioner Cap

Camshaft Sprocket

Carburetor Adaptor

Connecting Rod

Crankcase 8mm 14-15 (19-21 Nm) Crankshaft

Slotted Nut (Drive Sprocket)

Cylinder Base Bolts

Cylinder Head Bolts

Drive Clutch Bolt

Flywheel 16mm 58-72 (78-98 Nm) Oil Hose Fit-

tings Oil Delivery Pi-

pe Oil Drain Bolt

(Crankcase) Oil Filter Pipe

Fitting(Connector)

6mm 5-6.5 (7-9 Nm)

11mm 8--10 (11--14 Nm)

10mm 25-29 (34-40 Nm)

8mm 12-14 (16-20 Nm)

8.5mm 29-33 (39-45 Nm)

28mm 35-51 (47-69 Nm)

6mm 5-7 (7-9 Nm)

10mm Refer to Engine

Assembly for torque pro-

cedure

7/16 - 20 40 (55 Nm)

1/2 & 9/16 20 (27 Nm)

12mm 11-15 (15-21 Nm)

14mm 14-17 (19-23 Nm)

20mm 36-43 (49-59 Nm)

Oil Line Fitting 20 (27 Nm) Oil Pump Cov-

er Oil Relief Valve

Plug Recoil Hous ing 6mm 5-6.5 (7-9 Nm) Rocker Cover 6mm 7-8 (9-11 Nm) Rocker Cover

Block Plug Rocker Adjus-

ter Screw Lock Nut

Stator Plate 6mm 5-6.5 (7-9 Nm) StarterMotor 6mm 5-6.5 (7-9 Nm) Spark Plug 14mm 9-11 (12-15 Nm) Thermistor 3-- 3.6(4--5 Nm)

6mm 4-5 (5-7 Nm)

14mm 14.5-16.5 (20-23 Nm)

28mm 39-44 (53-59)

6mm 6-7 (8-10 Nm)

ENGINE FASTENER TORQUE

TTERNS

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

Cylinder Head Cylinder Base

Crankcase

6mm

3.4

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PISTON IDENTIFICA

Thepistonmay havean identification mark or the piston may not piston placement. If the piston has an identification

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

Note the directional and identification marks when viewing the pistons from the top. The letter “F”, “ ! ”, “ "”or: must always be toward the flywheel side of the engine. The other numbers are used for identification as to diameter, length and design. Four stroke engine rings are rectangular profile. The numbersor letters onallrings(exceptoil controlrings) must be positioned upward. See text for oil control ring upper rail installation. Use the information below to identify pistons and rings.

Engine

Model No.

ES32PFE .25

have an identification mark for

Oversize

Available*

(mm)

.50

TION

Standard

Piston

Identification

None

*Pistons and rings marked 25 are .25mm (.010I)

oversized. Pistons and rings marked 50 are .50mm (.020I)oversized

ACCESSIBLE COMPONENTS

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

G Flywheel G Alternator/Stator G Starter Motor/Starter Drive G Cylinder Head G Cylinder G Piston/RIngs G Oil pump G Rocker Arms G Cam Chain and Sprockets

The following components require engine removal for service:

G Camshaft G Connecting Rod G Crankshaft G Crankshaft Main Bearings G Crankcase

ENGINE REMOVAL

1. Clean work area.

2. Thoroughly clean the ATV engine and chassis.

3. Disconnect battery negative (-) cable.

4. Remove the following parts as required.

G Seat G Left and Right Side Covers (Refer to

Chapter 5)

G Fuel T ankCover / Front Cab (Refer to

Chapter 5)

G Fuel T ank (Refer to Chapter 4)

5. Disconnect spark plug high tension lead.

6. Disconnect all electrical wires from the engine.

7. Remove springs from exhaust pipe and remove pipe.

8. Drain engine oil.

9. Remove airbox.

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

1 1. Loosen auxiliary brake master cylinder mount if

necessary for clearance.

12. Refer to PVT System Chapter 6 to remove outer clutch cover,drive belt, driveclutch,drivenclutch, and inner cover.

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

14. Remove transmission linkage rod(s) from gear selector and secure out of the way .

15. Remove engine to chassis ground cable.

16. Remove all engine mount nuts and / or engine mount plates.

17. Remove engine through right side of frame.

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ENGINE

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ENGINE INSTALLA

TION

NOTES

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

General Items

G Install previously removed

components using new gaskets, seals, and fasteners where applicable.

G Perform regular checks on fluid

levels, controls, and all important areas on the vehicle as outlined in thedaily pre-ride inspection checklist (refer to Chapter 2).

PVT System

G Adjust center distance of drive and

driven clutch. (Chapter 6)

G Adjust clutch offset, alignment, and

belt deflection. (Chapter 6)

G Cleanclutchsheavesthoroughlyand

inspect inlet and outlet ducts for proper routing and sealing. (Chapter

Transmission

G Inspect transmission operation and

adjust linkage if necessary. Refer to Chapter 2 and Chapter 8.

Exhaust

G Replace exhaust gaskets. Seal

connections with high temp silicone sealant.

G Check to be sure all springs are in

good condition.

Engine Break In Period

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

G Use only Polaris Premium 4 All

SeasonSyntheticOil, or APIcertified “SH” oil.

G Usefuelwithaminimumoctane of87

(R+M)/2 method.

G Change break-in oil and filter at 20

hours or 500 miles, whichever comes first.

CYLINDER HONE SELECTION/HONING PROCEDURE

CAUTION:

A hone which will straighten as well as remove material from the cylinder is very important. Using a common springloaded glaze breaker for honing isnot 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 DEGLAZE

A finished cylinder should have a cross-hatch pattern toensurepiston ringseatingand toaid inthe retention of the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer’s instructions, or these guidelines:

G Use a motor speed of approximately

300-500 RPM, run the hone in and outof the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered (orcylindercenteredon arbor)and to bring the stones approximately 1/2″ (1.3 cm)above and belowtheboreat the end of each stroke.

G Release the honeat regularintervals

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

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

G After honing has been completed,

inspect cylinder for thinning or peeling.

IMPORTANT: Clean the Cylinder After

It is very important that the cylinder be thoroughly cleanedafterhoning to remove allgritmaterial. Wash thecylinderin a solvent,then inhot, 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.

Honing

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If cylinder wear or damage is excessive, it will be necessary to replace the cylinder. Honeonly enough to deglaze the outer layer of the cylinder bore.

EXAMPLE OF CROSS HATCH PATTERN

HONING TO OVERSIZE

If cylinder wear or damage is excessive, it will be necessary to oversize the cylinder using a new oversize piston and rings. Thismay be accomplished by either boring the cylinder and then finish honing to the final bore size, or by rough honing followed by finish honing.

For oversize honing always wet hone using honing oil and a coarse roughing stone. Measure the piston (see piston measurement) and rough hone to the size of the piston. Always leave .002 - .003″ (.05 - .07 mm) for finish honing. Refer to piston-to-cylinder clearance specifications on Page3.2 before honing. Completethe sizing with fine grit stones to provide the proper cross-hatch finish and required piston clearance.

rough or sharp edges. Apply a slight chamfer to all ports to remove sharp edges or burrs, paying particular attention to the corners of the intake and exhaust ports.

IMPORTANT: Clean the Cylinder After

Honing

ENGINE LUBRICATION ES32PF10

Oil Type Polaris Premium 2W--50 Synthetic.....

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

Filter PN 3084963...............

OIl Filter Wrench PV--43527... Drain Plug/

Screen Fitting 14 ft. lbs. (19 Nm)......

Oil Pressure Specification

(ES32PF10) 71-99 PSI @ 3000 RPM,.........

Polaris 2W--50 Synthetic (Oil temp at 122_F50_C)

OIL PRESSURE TEST

G Use a motor speed of approximately

300-500 RPM, run the hone in and outof the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered (orcylindercenteredon arbor)and to bring the stone approximately 1/2″ (1.3 cm) beyond the bore at the end of each stroke.

G Release the honeat regularintervals

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

G After honing has been completed

inspect all port opening areas for

ES32PF10

WARNING: Oiltemperature andpressure cancause

serious injury and damage. Wear the proper safety gear when performing these procedures.

1. Remove lower blind plug behind oil filter on crankcase.

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

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

ES32PF10

Oil Pressure at 3000 RPM (Engine Hot):

Standard: 71-99 PSI

Minimum: 20 PSI at idle

OIL COOLER ASSEMBLY

330 Engine

Lower Bracket

Rubber

Mounts

NOTE: Use Polaris Premium 2W--50 Synthetic Engine Lubricant.

Top Bracket

Screws

U--Clips

Shroud

Oil Cooler

36--44 in.lbs.

Thermistor (4--5 Nm)

Threaded Cooler Hose

Fan Motor

Oil Flow To and From Cooler

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OIL FLOW DIAGRAM -

Small End

Bearing

Cylinder Sleeve

Connecting Rod

Main Bearing

Large End

Bearing

Crank Pin

Crankshaft

ES32PF

Piston

Oil Jet

(Fixed)

Cam Shaft

Journal

Cam Lobe

Crankcase

Oil Passage

Chain Room

Rocker Arm /

Rocker Shaft /

Sprocket /

Chain

Cam Shaft

Journal

Oil Passage In

Cylinder

Crankcase

Oil Passage

Indirect

Lubrication

Through Front Right

Cylinder Head Bolt

Passage

Oil Hoses

Engine Sump

Oil Pickup

Screen

Pressure Relief

Oil Pump

Crankcase

Oil Passage

Bypass

Out

Oil Filter

Crankcase

Oil Passage

Oil Cooler

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ES32PFE ENGINE EXPLODED

Crankcase

ES32PF

VIEW

Cylinder/

Cylinder Head

Crankshaft and Piston

Valve Train

3.10

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ENGINE REMOV

REFER TO PAGE 3.5 - 3.6 FOR ENGINE REMOVAL / INSTALLATION NOTES.

CAM CHAIN TENSIONER REMOV

1. Removeignitiontiming inspectionplug from recoil housing.

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

2. Rotate engine slowly in the direction of rotation watching intake valves open and start to close.

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

Single TDC Mark Aligned

TDC Mark

5. Remove cam chain tensioner plug, sealing washer, spring and pin. CAUTION: The plug is under spring tension. Maintain inward pressure while removing.

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

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

CAM CHAIN TENSIONER

Rotation

Do Not Use

Advance Marks

4. Align single (TDC) mark on flywheel with projection in inspection hole, and the cam sprocket pin (facing upward) aligned with the camshaft to crankshaft center line. NOTE: The sprocket marks alignwith gasketsurface and the cam lobes should be pointing down and valves should have clearance at this point.

Sprocket marks

align with gasket

surface

INSPECTION

1. Pull cam chain tensioner plunger outward to the end of its travel. Inspectteeth onratchet pawl(A) and plunger teeth (B) for wear or damage.

2. Pushratchet pawl andholdit. Theplunger should move smoothly in and out of the tensioner body.

3. Releaseratchetpawl andpushinward onplunger. It should remain locked in position and not move inward.

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4. Measurefree length of tensioner spring. Replace spring if excessively worn.

Tensioner Spring Free Length:

2.02″ (5.13 cm) Std.

1.92″ (4.88 cm) Limit

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

4. Remove cylinder block plug using a 14 mm hex head wrench.

Cylinder block

plug

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

ROCKER ARM/SHAFT INSPECTION

1. Remove rocker cover.

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

Wave

washer

Inspect surface

of followers

PTO

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

Rocker Shaft O.D.:

.8656-.8661I (21.987-22.0 mm)

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

3.12

Rocker Arm & Support I.D.:

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ENGINE

CAMSHAFT REMOVAL

1. Remove cam shaft end plug (A).

.8669-.8678I (22.020-22.041 mm)

7. Measure I.D. of both rocker arm shaft support areas and visually inspect surface. Compare to specifications.

2. Remove camshaft sprocket flange bolt and washer.

3. Place a clean shop towel in the area below cam chain sprocket.

Rocker Shaft Oil Clearance:

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

Limit: .0039I (.10 mm)

8. Inspectrocker adjuster screwsforwear,pitting,or damage to threads of the adjuster or locknut. Replace all worn or damaged parts. NOTE: The end of the adjuster screwis hardened and cannot be ground or re-faced.

4. Remove sprocket from camshaft and chain.

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

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CAMSHAFT REMOV AL CONT’D

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

Inspect for Areas of

Tooth Wear or Damage

7. Remove camshaft.

Lobe

2. Remove release lever shaft and return spring (spacer).

3. Inspect shaft for wear or galling.

4. Inspectlobe on endof release levershaft forwear and replace if necessary.

Return spring (spacer)

Release lever

Dowel pin

AUTOMATIC COMPRESSION RELEASE REMOV

AL/

INSPECTION

NOTE: The automatic compression release

mechanism can be inspected and serviced without removing the camshaft from the cylinder head.

1. Check release lever shaft for smooth operation throughout the entire range of rotation.

AUTOMATIC COMPRESSION RELEASE INSTALLA

1. Slide spring onto shaft.

2. Apply engine oil to release lever shaft.

TION

CAMSHAFT INSPECTION

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

Lubrication holes

Lobe height

Cam Lobe Height

Intake

Std: 1.3001-1.3041I (33.023-33.123 mm)

Limit: 1.2883I (32.723 mm)

Exhaust

Std: 1.3007-1.3047I (33.039-33.139 mm)

Limit: 1.2889I (32.739 mm)

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

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

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

Journal O.D.

Journal

Camshaft Journal O.D.:

Mag & PTO End: 1.4935-1.4941I

(37.935-37.950 mm)

CYLINDER HEAD REMOVAL

1. Loosen each of the four cylinder head bolts evenly 1/8 turn each time in a cross pattern until loose.

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

3. Remove cylinder head and head gasket.

5. Measure ID of camshaft journal bore.

Camshaft Journal I.D.:

Mag & PTO End: 1.4963-1.4970I

(38.005-38.025 mm)

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

Camshaft Oil Clearance:

Std: .0022-.0035I (.055-.090 mm)

Limit: .0039I (.10 mm)

Replace camshaft if damaged or if any part is worn past the service limit.

Replace cylinder head if camshaft journal bore is damaged or worn excessively.

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.

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CYLINDER HEAD WARP

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

Cylinder Head Warpage Limit:

.002” (.05mm)

AGE

2. Remove spring retainer and spring.

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

3. Pushvalve out, keeping it inorder forreassembly in the same guide.

4. Measure free length of spring with a Vernier caliper, Ill.1. Check spring for squareness as shown in Ill.2. Compare to specifications. Replace spring if either measurement is out of specification.

CYLINDER HEAD DISASSEMBL

WARNING: Wear eye protection or a face shield

during cylinder head disassembly and reassembly. NOTE: Keep all parts in order with respect to their

location in the cylinder head.

1. Using a valve spring compressor, compress the valve spring and remove the splitkeeper. NOTE: To prevent loss of tension, do not compress the valve spring more than necessary .

Ill.1

Ill.2

Valve Spring Length:

Std: 1.673I (42.5 mm)

Squareness:

.075I (1.9 mm)

Valve Spring

Free Length

Coil Fatigue/

Squareness

3.16

5. Remove valve seals. CAUTION: Replace seals

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

VALVE INSPECTION

ENGINE

4. Inspect split keeper groove for wear or flaring of the keeper seat area (B). NOTE: The valves cannot be re-faced or end ground. They must be replaced if worn, bent, or damaged.

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

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

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

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

Measure valve stem in

several places.

Valve Stem Diameter:

Intake: .2343-.2348I (5.950-5.965 mm)

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

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

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7. Subtract valvestem measurement to obtainstem to guide clearance. NOTE: Be sure to measure each guide and valve combination individually.

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

VALVE SEAT RECONDITIONING

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. See Valve Seat Reconditioning, Page

3.19--3.21. If the valve seat is cracked the cylinder

head must be replaced.

Valve Guide I.D.:

.2362-.2367I (6.0-6.012 mm)

NOTE: Ifvalveguides are replaced,valveseats must

bereconditioned. Refer to ValveSeat Reconditioning for procedure.

COMBUSTION CHAMBER

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

Too

Wide

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

requires special tools and a thorough knowledge of reconditioning techniques. Follow the instructions provided in the Valve Seat Reconditioning Kit (PN

2200634). CAUTION: Wear eye protection when performing

cylinder head service. Valve guide replacement will require heating of the cylinder head. Wear gloves to prevent burns.

Valve Guide Removal/Installation

1. Removeall carbon deposits from the combustion chamber, valve seat and valve guide area before attempting to remove valve guides. CAUTION: Carbon deposits are extremely abrasiveand may damage the valve guide bore when guides are removed.

2. Placenew valve guides in a freezer forat least15 minutes while heating cylinder head.

3. Heatcylinder head in an ovenor use a hot plateto bring cylinder head temperature to 212° F (100° C). CAUTION: Do not use a torch to heat cylinder head or warpage mayresultfromuneven heating. Head temperature can be checked with a pyrometer or a welding temperature stick.

Uneven

Good

Too

Narrow

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4. Follow the manufacturers instructions provided with the valve seat cutters in the Valve Seat ReconditioningKit (PN 2200634). Abrasivestone seat reconditioning equipment can also be used. Keep 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 properwidth all the way around. If theseat isuneven, 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 and the valve may overheat and warp, resulting in burnt valves.

5. Once thoroughly heated, place cylinder head on blocks of wood which will allow the old guides to be removed.

6. Using valve guide driver, drive guides out of the cylinder head from the combustionchamber side. Becarefulnot to damage guidebore or valve seat when removing guides.

7. Place cylinder head on cylinder head table. NOTE: Be sure cylinder head is still at 212° F (100° C) before installing new guides.

8. Place a new guide in the valve guide installation tool and press guide in to proper depth. Check height of each guide above the cylinder head(A). Refer to specifications. NOTE: Theguidecanalsobedrivenintothe properdepth. Inspect the guideclosely for cracks or damage if a driver is used.

Reaming The Valve Guide

9. Allow cylinder head to cool to room temperature. Apply cutting oil to the reamer. Guides should be reamed from the valve spring side of the cylinder head. Ream each guide to size by turning the reamer clockwise continually. Continue to rotate reamer clockwise during removal of the tool.

10. Clean guidesthoroughly withhot soapy waterand a nylon brush. Rinse and dry with compressed air. Apply clean engine oil to guides.

VALVE SEAT RECONDITIONING

1. Install pilot into valve guide.

Valve Guide Installed Height

Valve Guide Height:

.681-.689I (17.3-17.5 mm)

2. Apply cutting oil to valve seat and cutter.

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VALVE SEAT RECONDITIONING CONT’D

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

4. Inspect the cut area of the seat. G If the contact area is less than 75%

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

G If the cutter now contacts the uncut

portion of the seat, check the pilot. Lookfor burrs, nicks,or runout. Ifthe pilot is bent it must be replaced.

G If the contact area of the cutter is in

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

G If the contact area of the initial cut is

greater than 75%, continueto 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,apply athin coatingof PrussianBluetpaste to the valve seat. If using an interference angle (46°) apply black marker to the entire valve face (A).

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

7. Remove valve and check where the Prussian Bluet or black marker 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 (A).

(B)

(A)

Proper Seat Contact On Valve Face

G If the indicated seat contact is at the

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

G If too low use the 60° or 75° cutterto

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

G If the seat is too wide or uneven, use

both top and bottom cutters to narrow the seat.

G If the seat is too narrow, widen using

the 45° cutter and re-check contact pointonthevalveface andseatwidth after each cut.

Bottom - 60° or 75°

Seat - 45° or 46°

Top - 30°

(A)

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

Seat

Width

Valve Seat Width:

Intake Std: .039I (1.0 mm)

Limit: .055I (1.4 mm)

Exhaust Std: .059I (1.4 mm)

Limit: .071I (1.8 mm)

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

9. Lubricate the valve guides with clean engine oil, andapply oil or water based lapping compound to the face of the valve. Lappingisnot requiredwith an interference angle.

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.

12. Clean cylinder head, valves, and camshaft oil supply passage (A) thoroughly.

13. Spray electrical contact cleaner into oil passage and dry using compressed air.

CYLINDER HEAD ASSEMBLY

CAUTION: Wear eye protection during assembly. NOTE: Assemblethe valves one at atime tomaintain

proper order.

1. Install new valve seals on valve guides.

2. Apply engine oil to valve guides and seats.

3. Coat valve stem with molybdenum disulfide grease.

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

1 1. Rotate the valve rapidly back and forth until the

cutsounds smooth. Lift thevalve slightly offof the seat, rotate 1/4 turn, and repeat the lapping process. Dothis fourto fivetimesuntil the valveis fully seated, and repeat process for the other valve.

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CYLINDER HEAD ASSEMBLY CONT’D

5. Dip valve spring and retainer in clean engine oil andinstall spring with closely spaced coils toward the cylinder head.

Closely spaced

coils toward

cylinder head

6. Place retainer on spring and install valve spring compressor. Compress spring only enough to allow split keeper installation to prevent loss of spring tension. Install split keepers with the gap even on both sides.

ENGINE BOTTOM END DISASSEMBL

Cylinder Removal

Follow engine disassembly procedures to remove valve cover, camshaft and rocker arms, and cylinder head.

1. Remove cam chain guide at front of cylinder.

2. Remove the two 6 mm cylinder base bolts.

7. Repeat procedure for remaining valve.

8. When all valves are installed, tap lightly with soft faced hammeron the endof the valvestoseat the split keepers.

VALVE SEALING TEST

1. Clean and dry the combustion chamber area.

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

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

3. Tap cylinder lightly with a plastic hammer in the reinforced areas only until loose.

4. Rock cylinder forward and backward and lift it from the crankcase, supporting piston and connecting rod. Support piston with Piston Support Block (PN 2870390)(A).

5. Remove dowel pins from crankcase.

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PISTON REMOV

1. Remove circlip. Note that opening for circlip access is on the intake side.

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.

5. Remove the top rail first followed by the bottom rail.

6. Remove the expander.

CYLINDER INSPECTION

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

2. Inspectthetop of the cylinder for warpageusing a straight edge and feeler gauge.

Cylinder Warpage:

*Using a piston ring pliers: Carefully expand ring

andlift it off the piston. CAUTION: Do notexpandthe ring more than the amount necessary to remove it from the piston, or the ring may break. *Byhand: Placingboththumbsasshown, spread the ring open and push up on the opposite side. Do not scratch the ring lands.

4. Repeat procedure for second ring.

.0020″ (.05 mm) MAX

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

4. Inspect cylinder for taper and out of round with a telescoping gaugeor a dial bore gauge. Measure intwodifferentdirections,front toback andside to 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

The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section.

1/2″ Up From Bottom

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CYLINDER INSPECTION CONT’D

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

Cylinder Taper

Limit: .002 Max.

Cylinder Out of Round

Limit: .002 Max.

Cylinder Standard Bore Size:

3.0906-3.0913I (78.50-78.520 mm)

PISTON INSPECTION

1. Measure piston outside diameter at a point 5 mm upfrom thebottom of the piston at a right angle to the directionof the pistonpin.

3. Measure piston pin bore.

Piston Pin Bore:

.7095-.7097I (18.007-18.013 mm)

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

5mm

Piston

Piston Pin

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

Piston to Cylinder Clearance

Std: .0015-.0032I (.038-.082 mm)

Limit: .004I (.11 mm)

Piston O.D.:

Std: 3.0881-3.0891I (78.438-77.462 mm)

Piston Pin Measurement Locations

Piston Pin O.D.

.7092-.7095I (18.001-18.007 mm)

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5. Measure connecting rod small end ID.

Connecting Rod Small End I.D.

.7095-.7101I (18.007-18.023 mm)

6. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with athickness gauge. Replacepiston andrings if ring-to-groove clearance exceeds service limits.

Ring to groove clearance

Piston

Ring

PISTON RING INSTALLED GAP

1. Placeeach pistonring insidecylinderusing piston to push ring squarely into place as shown.

Piston ring end gap installed

Feeler Gauge

Cylinder

Piston Ring

2. Measureinstalled gap with a feeler gauge at both the top and bottom of the cylinder. NOTE: Adifference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round.

3. If thebottominstalled gap measurement exceeds the service limit, replace the rings.

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 an oil rag immediately to remove residue and prevent rust.

25-50mm

Piston Ring Installed Gap

Feeler Gauge

Piston Ring-to-Groove Clearance

Top Ring Std: .0014-.0030I (.035-.075 mm)

Limit: .0059I (.15 mm)

Second Ring Std: .0010-.0026I (.025-.065

mm)

Limit: .0059I (.15 mm)

Std: .0079-.0118I (.20-.36 mm)

Std: .0138-.0197I (.35-.50 mm)

Std: .0079-.0236I (.20-.70 mm)

CRANKCASE DISASSEMBLY

NOTE: The recoil starter, starter motor, starter drive,

flywheel, stator, cam chain and sprockets can be serviced with the engine in the frame.

Top Ring

Limit: .039I (1.0 mm)

Second Ring

Limit: .039I (1.0 mm)

Oil Ring

Limit: .059I (1.5 mm)

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STARTER REMOV

1. Remove recoil housing bolts and remove housing.

2. Remove starter drive assembly. Note the thrust washer located at the rear of the drive mechanism.

3. Inspectthethrustwasher for wearor damageand replace if necessary.

4. Measurethe OD of the starter drive shaft on both ends and record.

DRIVE

AL/INSPECTION

Starter Drive Bushing Clearance:

Std: .0015″-.004″ (.038-.102 mm)

Service Limit:

008″ (.203 mm)

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

FLYWHEEL/STATOR REMOV

1. Remove flywheel nut and washer.

AL/INSPECTION

Std. Bushing ID:

.4735″-.4740″ (11.11-12.04 mm)

Std. Shaft OD:

.470″-.472″ (11.93-11.99 mm)

5. Measure the ID of the bushing in the recoil housing (A) and in the crankcase and record. Measure in two directions 90° apart to determine if bushing is out of round. Calculate bushing clearance. Replacebushingif clearanceexceeds the service limit.

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

3. Markornote positionof stator plateoncrankcase.

4. Remove bolts and carefully remove stator assembly,beingcareful not todamagecrankshaft bushing on stator plate.

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5. Replace crankshaft seal.

6. Remove large sealing O-Ring from outer edge of stator plate.

CAM CHAIN/TENSIONER BLADE

1. Remove bolt securing tensioner blade to crankcase (A).

2. Remove blade and inspect for cracks, wear, or damage.

3. Remove cam chain. Inspect chain for worn or missing rollers or damage. Stretch chain tight on a flat surface and apply a 10 lb. (4.53 kg) load. Measure length of a 20 pitch section of chain. Replace if worn past service limit.

DRIVE SPROCKET REMOVAL

INSPECTION

1. Using the Slotted Nut Socket (PN 2871293), remove the crankshaft slotted nut (A). NOTE: The slotted nut is a left hand thread.

Remove

2. Remove cam chain drive sprocket (B) and Woodruff key from crankshaft.

3. Inspect sprocket teeth for wear or damage.

Measure 20

Pitch Length

4. Inspect Woodruff key for wear.

5. Replace any worn or damaged parts.

Chain Service Limit:

5.407″ (13.7 cm)

Inspect for Areas of

Tooth Wear or Damage

Slotted Nut Socket

(PN 2871293)

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PRESSURE RELIEF VAL

The pressure relief valve opens torelieve any excess pressure from the oil pump if oil pressure reaches approximately 71 psi. It must be clean and have adequate spring pressure in order to seal properly .

1. Remove cap bolt, sealing washer, spring, and relief valve from MAG side crankcase.

Outer Feed Rotor to Crankcase Clearance:

Std: .001-.003 (.0254-.0762 mm)

Wear Limit: .004 (.1016 mm)

4. Measure clearance between outer feed rotor and crankcase pocket with a feeler gauge.

2. Inspect free length of spring and check coils for distortion.

Relief Valve Spring Free Length:

Std: 2.175″ (5.52 cm)

3. Inspect valve for wear.

4. Check seat area for nicks or foreign material that may prevent proper sealing of valve.

OIL PUMP REMOV

1. Remove the five screws on the oil pump cover withanimpactdriver.

2. Inspect rotors and mating surface of oil pump cover. Check for nicks, burrs, or surface irregularities.

3. Measure pump end clearance using a feeler gauge and straight edge.

AL/INSPECTION

Pump End Clearance:

Std: .001-.003 (.0254-.0762 mm)

Wear Limit: .004 (.1016 mm)

3.28

5. Measure rotor tip clearance with a feeler gauge.

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Rotor Tip Clearance:

Std: .005 (.127 mm)

Wear Limit: .008 (.2032 mm)

ENGINE

2. Separate crankcase by tapping with a soft faced hammer in reinforced areas.

3. Watch the gap along the crankcase mating surface and separate the crankcase evenly.

4. Remove the Mag (RH) crankcase from the PTO case.

OIL PUMP ASSEMBLY

1. Clean and dry all parts thoroughly. Apply clean engineoiltoallparts. Donot usegasketsealer on the pump cover mating surfaces or clearances will be incorrect, and oil passages may become plugged.

2. Install outer feed rotor and inner feed rotor drive pin.

3. Install inner feed rotor and feed chamber cover with screw.

4. Tighten screw securely.

5. Installoilpump oncrankcase andtorquebolts to6 ft. lbs. (8 Nm).

Oil Pump Attaching Bolt Torque:

6 ft. lbs. (8 Nm)

CRANKCASE SEPARATION

1. Remove flange bolts (11) from magneto side crankcase evenly in a criss-cross pattern.

CRANKSHAFT REMOVAL/INSPECTION

1. Supportthe MAG side crankcase and crankshaft; press the crankshaft out. Be careful not to damage the crankcase mating surface or connecting rod.

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2. Useafeelergauge tomeasure theconnectingrod big end side clearance.

Connecting Rod Big End Side Clearance:

Std: .0028-.0118 (0.07-0.30 mm)

Limit: .0138 (.35 mm)

2. Measurethe width of theconnectingrodat thebig end.

Connecting Rod Width:

Std: .8233-.8252I (20.88-20.93 mm)

3. Visually inspect bearing journal for scoring, damageor excessive wear. Replace crankshaft if it fails visual inspection.

4. Measure the O.D. of the crankshaft rod journal in four placesand intwodirectionsaway from the oil hole. Replace the crankshaft if itmeasuresbelow the service limit, or if the journal is out of round.

3. If the clearance exceeds the service limit, either the crankshaft, connecting rod or both need to be replaced. Refer to Steps 1 & 2 under crankshaft inspection to determine which part(s) are outside of specifications.

NOTE: Markings on connecting rod and cap that must bealigned for assembly. If marks are not clearly visible, mark the rod and cap with a permanent marker.

4. Remove the connecting rod nuts and connecting rod bearing cap.

NOTE: It may be necessary to lightly tap on the side of the cap with a plastic mallet to loosen it.

CRANKSHAFT INSPECTION

1. Measure the width of the rod bearing journal.

Rod Bearing Journal O.D.:

Std: 1.6531-1.6535I (41.989-42.000 mm)

5. Check oil passage to make sure it is clear.

Oil passage

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MAIN BEARING INSPECTION

1. Inspect the crankshaft main bearings.

NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. Look for signs of discoloration, scoring or galling. Turnthe outerraceof eachbearing. The bearings should turn smoothly and quietly. The inner race of each bearing should fit tightly in the crankshaft. The outer race should be firm with minimal side to side movement and no detectable up and down movement.

2. Replace bearings if they fail visual inspection.

CONNECTING ROD BEARING INSPECTION

1. Inspect bearing inserts for unusual wear,peeling, scoring, damage etc. Replace as necessary.

NOTE: If one insert requires replacement, replace both connecting rod bearing inserts as a set.

ENGINE

NOTE: Use the widest part of the Plastigauge®to

determine the oil clearance.

Connecting Rod To Crankshaft Clearance:

Std: .0007-.0021 (.019-.053 mm)

Limit: .0026 (.065 mm)

CONNECTING ROD BEARING CLEARANCE

1. Clean all oil from bearing inserts and crank pin.

2. Placea strip of Plastigauge width of the crank pin.

3. Install the connecting rod and bearing cap in the correct orientation.

4. Torque the rod nuts to specification.

Rod Nut Torque:

29-33 ft. lbs. (39-45 Nm)

5. Remove the bearing cap being careful not to disturb the Plastigauge

6. Use the measuring scale on the Plastigauge wrapper to measure the thickness of the Plastigauge

this procedure.

INSPECTION

across thecomplete

. The rod must not turn during

7. If oil clearance is not within specification, install new rod bearings and recheck the oil clearance.

8. If service limit is still exceeded, determine if the crankshaft or connecting rod needs to be replaced per Crankshaft Inspection and Connecting Rod Inspection.

9. At completion of measurement procedure; remove all traces of Plastigauge and crankshaft.

from bearing

CRANKCASE BEARING INSPECTION

1. Inspect the crankshaft main bearing in the MAG side crankcase.

NOTE: Due to extremely close tolerances and minimal side wear, the bearing must be inspected visually and by feel. Look for signs of discoloration,

scoring or galling. Turn the inner race of bearing. The bearing should turn smoothly and quietly. The outer raceshould fit tightlyin the crankcase. Theinner race should be firm with minimal side to side movement and no detectable up and down movement.

2. To remove crankshaft bearing, use a blind hole bearing puller.

NOTE: Bearings are stressed during the removal procedure and should not be re-used

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CRANKCASE

1. Remove all traces of gasket sealer from the crankcase mating surfaces. Inspect the surfaces closely for nicks, burrs or damage.

INSPECTION

BEARING INSTALLATION

NOTE: Toeasecrankshaft bearing installation, warm

the crankcase until hot to the touch. Place the bearing in a freezer.

1. Install the crankshaft bearing sothe numbers are visible.

2. Drive or press the new bearing into the crankcase, using the proper driver. CAUTION: Press only on outer race of bearing to prevent bearing damage.

G Use a 70mm (2.755″) driver- For

crankshaft main bearings.

END PLAY INSPECTION/ADJUSTMENT

Before reassembling the crankcase,the following steps should be performed to determine the amount of crankshaft end play. Excessive end play may cause engine noise at idle and slow speeds. Too little play will side load the bearings which may lead to premature bearing failure.

2. Measure the distance from the MAG side crankcase mating surface to the main bearing using a dial caliper and a straight edge.

3. Subtract the thickness of the straightedge from the measurement obtained in Step 2 and record. Repeat Step 2 and 3 for the PTO case. If PTO bearings are not installed in the crankcase, measure to the bearing seat in the case.

Crankshaft End Play Adjustment

1. Make sure crankshaft bearing is firmly seated in the MAG side crankcase.

MAG Case Depth + PTO Case Depth____________________ = Total Case Width____________________

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4. Measure the width of the crankshaft at the bearingseats or,ifPTO bearingsare installed,the width from MAG side bearing seat to the outside raceof thePTO bearingswith amicrometerordial caliper and record.

NOTE: If PTO bearings are not installed, measure the width of the bearings and add to crankshaft width.

ENGINE ASSEMBLY/ CONNECTING INSTALLA

1. Clean all oil off connecting rod, connecting rod cap and bearing inserts.

2. Install bearing inserts onto connecting rod and cap.

NOTE: First, install bearing tab into groove, then press the rest of the bearing into place.

3. Apply assembly lube onto the connecting rod bearings and crank pin.

4. Install rod and cap onto the crankshaft. Ensure that I.D. marks are aligned.

TION

ROD

Crankshaft Width

5. Subtract the Crankshaft Width measured in Step 4 from the Total Case Width recorded in Step 3, and record below.

Total End Play

6. Subtract the thickness of the existing shim from theresultof Step5 to determine if a different shim is required. The result must be within the specified range listed below. Increase or decrease shim thickness as required to bring end play within range.

Marks

NOTE: Procedure during disassembly called for marking ofconnectingrod and cap. Ensurethat each part is installed in its original location by noting the marks placed on the parts during disassembly.

5. Tighten rod cap nuts to 1/2 torque specification, then full torque.

Rod Nut Torque:

29-33 ft. lbs. (39-45 Nm)

6. V erify that the connecting rod is free to rotate on the crankshaft journal.

Crankshaft End Play:

008″-.016″ (.02-.04 cm)

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CRANKSHAFT INSTALLA

Lubricate all bearings with clean engine oil before assembly.

1. Install the crankshaft into the PTO side crankcase.

2. Install the proper shim on the magneto end of the crankshaft.

TION

CRANKCASE OIL STRAINER INSPECTION

1. Removebolt securing oilstrainer tothe MAG side crankcase.

2. Remove oil strainer and visually inspect for any rips, tears or obstructions in screen.

3. Replace oil strainer if it fails visual inspection.

CRANKCASE REASSEMBLY

1. Apply Crankcase Sealant (PN 2871557)tothe crankcase mating surfaces. Be sure the alignment pins are in place.

2. Set the crankcase in position carefully. Mate the crankcase halves by tapping lightly with a soft faced hammer. Continually check alignment of the cases during installation, closing the gap equally until the surfaces are tightly sealed.

3. Install the crankcase flange bolts and tighten to specified torquein 3steps accordingto thetorque pattern. See Page 3.4.

2. Installoil pump cover. T orquescrews to specified torque.

Oil Pump Cover Screw Torque:

4-5 ft. lb s. (5-7 Nm)

NOTE: Donot use gasket sealer on the pump mating

surfaces.

OILRELIEFVALVE INSTALLA

Install the oil relief valve, spring, and plugusing a new sealing washer.

Oil Relief Valve Plug Torque:

TION

14-17 ft. lbs. (19-23 Nm)

CAM CHAIN DRIVE

Crankcase Bolt Torque:

14-15 ft. lbs. (19-21 Nm)

Crankcase Sealant :

(PN 2871557)

SPROCKET INST ALLA

1. Install the Woodruff key, drive sprocket, and slotted nut. Using the Slotted Nut Socket (PN

2871293), tighten the nut to the specified torque.

TION

OIL PUMP INSTALLATION

1. Inspect the oil pump sealing surface on the crankcase. Apply a light film of engine oil to the surfaces. Install outer and inner rotors over crankshaft .

Slotted Nut Torque:

Tighten

45 ft. lb s. (61 Nm)

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TENSIONER INSTALLA

1. Install the tensioner blade and tighten the mounting bolt to specified torque.

Tensioner Blade Mounting Bolt Torque:

5-6.5 ft. lbs. (7-9 Nm)

BLADE

TION

OIL FILTER INSTALLATION

1. Apply clean engine oil to oil filter gasket. Install filter until gasket lightly touches seat and then tighten an additional 3/4 of a turn.

Oil Filter Connector Torque:

36-43 ft. lbs. (49-59 Nm)

Ring Profile

“R1” Mark up

“R” Mark up

Top

Second

PISTON RING INSTALLATION

NOTE: Applycleanengine oil to all ring surfaces and

ring lands. Always check piston ring installed gap before rings are installed on piston. See Page 3.36. If the piston has been in service clean any accumulated carbon from the ring grooves and oil control ring holes.

1. Place the oil control ring expander in oil ring groove with the end gap facing forward. The expander has no up or down marking and can be installed either way. The ends should butt squarely together and must not overlap.

2. Install the oilring top rail withthe end gap at least 30° from the end of the expander.

3. Install the bottom rail with the gap at least 30° from the end of the expander on the side opposite the top rail gap.

4. Installthesecondring withthe “R”markfacingup. Position the end gap toward the rear (intake) side of the piston.

5. Install the top ring (chrome faced) with the “R1” mark facing up and the end gap facing forward (toward the exhaust).

6. Check to make sure the rings rotate freely in the groove when compressed.

PISTON INSTALLATION

1. Clean the gasket surfaces on the cylinder and crankcase. Remove all traces of old gasket material.

2. Make sure the cylinder mounting bolt holes are clean and free of debris.

3. Install a new circlip on one side of the piston with the end gap facing up or down.

CAUTION: Circlips become deformed during the removal process. Do not re-use old circlips. Do not compress the new clip more than necessary upon installation to prevent loss of radial tension. Severe engine damage may result if circlips are re-used or deformed during installation.

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4. Apply clean engine oil to the piston rings, ring lands, piston pin bore, piston pin, and pistonskirt. Lubricate the connecting rod (both ends) and crankshaft main bearing area.

5. Install the piston on the connecting rod with

thepincastingnotchfacing therear ofengine (starter side). The piston pin should be a push fit in the piston.

6. Install the other circlip with the gap facing up or down. (SeeCautionwith Step3 above). Pushthe piston pin in both directions to make surethe clips are properly seated in the groove.

7. Placethedowelpins inthecrankcaseand installa new cylinder base gasket.

8. Lubricate the piston and rings with assembly lube and install a sleeve--type ring compressor on the piston assembly. Verify that the ring gapsare 120 degreesapartfromeach other before installation.

2. Applyclean engineoil liberallytothe cylinderbore and tapered area of the sleeve. Install the cylinder with a slight rocking motion until the rings are captive in the sleeve.

3. Remove the ring compressor and support block.

4. Push the cylinder downward until fully seated on the base gasket.

NOTE: If cam chain is installed, hold it up while rotatingtheengineto avoiddamageto the chain,drive sprocket teeth, or tensioner blade.

5. Install the two 6 mm bolts, but do not tighten.

CYLINDER HEAD INSTALLA

TION

CYLINDER INSTALLATION

1. Position the Piston Support Block (PN 2870390) (A) beneath the piston skirt to support the piston during cylinder installation.

Clean the gasket surfaces on the cylinder head and cylinder. Remove all traces of old gasket material.

1. Install the cam chain tensioner guide. Be sure bottom end of guide is located properly in crankcase.

2. Installthetwo dowel pins anda newcylinderhead gasket.

3. Place the cylinder head on the cylinder. Apply a film of engine oil to the cylinder head bolt threads and washers, and hand tighten the bolts.

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The following procedure must be used to torque the cylinder head properly:

Torque in cross

pattern per procedure

Torque

5-6.5 ft. lbs.

(7--9 Nm)

Torque all bolts evenly in a cross

pattern. Apply oil to bolt threads

Install the cam chain over the crankshaft.

Plated

Link

Sprocket

Mark

Crankcase

Projection

IMPORTANT CAMSHAFT TIMING NOTE: In order totimethecamshafttothecrankshaft,thepistonmust be precisely located at Top Dead Center (TDC). This can be accomplished using one of two methods.

When the stator assembly is removed, follow the procedure outlined in Method 1. This method uses the cam chain plate links totime the camshaft and the dot on the cam chain drive sprocket to establish TDC (see below,Method 1). Itis important to note that this method can only be used when the stator is removed andthe cam chain drivesprocket isin view. Theplate links are not used to time the camshaft when the flywheel is installed.

*Torque bolts to 18 ft. lbs. (24.5 Nm)

*Loosen bolts evenly 180° (1/2 turn)

*Torque bolts to 11 ft. lbs. (14.7 Nm)

*From this point, tighten bolts evenly

90° (1/4 turn)

*Finally, tighten another 60° (1/6 turn)

When the stator assembly is installed, use Method 2. This method establishes accurate Top Dead Center (TDC) by aligningthesinglemark on the flywheelwith the notch in the timinginspection hole (see Method 2, Page 3.40). The camshaft sprocket alignment marks are parallel to the gasket surface, the alignment pin faces to the intake side, and camshaft lobes are pointing down.

Camshaft Installation -Timing Method 1 Refer to Illustration Page 3.39

Torque 6mm case bolts to 5--6.5 ft. lbs.

(7--9Nm)

CAM CHAIN/CAMSHAFT INSTALLATION

CAUTION: Serious engine damage may result if the camshaft is not properly timed to the crankshaft.

If the stator assembly is removed: NOTE: Use this method only when the stator is removed and cam chain drive sprocket is in view.

1. Rotate the crankshaft until the mark on the cam chaindrive sprocketis aligned with thecrankcase projection (mark facing downward).

2. Align the single plated link on the cam chain with themarkedtooth of thecam chaindrive sprocket. Useawire topullthechainupthroughthe cylinder and cylinder head, and secure it to hold the chain in place.

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3. Apply Polaris Low Temp Grease (PN 2870577), or engine assembly lubricant to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil. (To install the compression release mechanism, refer to Page 3.14).

Plate link

aligned w/dot

4. Install the camshaft with the lobes facing downward and the sprocket alignment pin facing toward intake.

5. Disconnect the wire from the cam chain and install the cam sprocket with the dot facing outward.

6. Loop the cam chain over the cam sprocket, aligningtheplated link on the chainwiththe doton the sprocket.

7. Install the sprocket on the camshaft. Apply Loctitet 242 (PN 2871949 to the cam sprocket bolt and torque to specifications.

Camshaft Installation - Timing Metho d 2 Refer to Page 3.40

1. Apply Polaris Low Temp Grease (PN 2870577), or molybdenum disulfide grease to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil. (To install the compression release mechanism, refer to Page 3.18).

2. Install the camshaft with the lobes facing downward and the sprocket alignment pin facing toward intake.

3. Disconnect the wire from the cam chain and rotate the engine to align the single mark (Top Dead Center) on the flywheel with the notch in the timing inspection window. Be sure to usethe single TDC mark when installing thecam. Do not use the advance marks.

4. Loop the cam chain onto the cam sprocket with the dot on the sprocket facing outward and the alignment marks parallel with gasket surface.

5. Before positioning the sprocket on the camshaft, check the position of the cam sprocket alignment pin. When the cam is positioned properly, the cam sprocket alignment pin is facing to the intake side.

6. Install the sprocket on the camshaft. Apply Loctitet 242 (PN 2871949) to the cam sprocket bolt and torque to specifications.

Cam Sprocket Bolt Torque:

25-29 ft. lbs. (34-40 Nm)

(TDC ) timing

7. Check all cam timing marks to verify proper cam

Cam Sprocket Bolt Torque:

25-29 ft. lbs. (34-40 Nm)

8. Check all cam timing marks to verify proper cam timing, and install the cam chain tensioner. See Cam Chain Tensioner Installation Page 3.41. NOTE: Theplate linkswillnot align after engineis rotated.

timing, and install the cam chain tensioner body with a new gasket.

8. After tensioner installation, rotate engine at least two revolutions and re-check marks/timing.

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CAMSHAFT TIMING - METHOD

Method 1 - Camshaft Timing with Stator Removed

Single Plated

Link and Dot on

Cam Sprocket

Crankshaft to Camshaft Centerline

Sprocket marks aligned with

gasket surface at TDC on

compression stroke (cam

lobes facing downward)

Single Plated

Link and

Rectangular

Mark

on Cam

Chain Drive

Sprocket

NOTE: Plated links will not align after engine is rotated.

Crankcase Projection

3.39

ENGINE

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CAMSHAFT TIMING - METHOD

Method 2 - Camshaft Timing Using Flywheel TDC Mark

Do not use dot on sprocket

for cam timing

Crankshaft to Camshaft Centerline

Decompressor arm stop pin UP

(Cam lobes DOWN)

Sprocket marks aligned with

gasket surface at TDC on compression stroke (cam

lobes facing downward, de-

compressor arm stop pin UP)

Single TDC Mark Aligned

TDC Mark

Rotation

Do Not Use

Advance Marks

Cam Timing

(View through timing inspection hole)

Position crankshaft at TDC

Do Not Use

Advance Marks

For Cam Timing

3.40

ENGINE

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CAM CHAIN INSTALLA

1. Release the ratchet pawl (A) and push the tensioner plunger (B) all the way into the tensioner body.

2. Install the tensioner body with a new gasket and tighten the bolts to specification.

TENSIONER

TION

4. Slowly rotate engine two to three revolutions and re-check cam timing once chain is tight.

STATOR INSTALLATION

NOTE: The stator, flywheel, starter drive, and recoil

can be assembled with the engine in the frame.

Stator

1. Applya light film of grease to the crankshaft seal. Apply molybdenum disulfide grease or assembly lubricant to the crankshaft bushing.

Timing Marks

Tensioner Bolt Torque: 8--10 ft. lbs. (11--14 Nm)

3. Install the spring, pin, new sealing washer, and tensioner plug. T orque plug to specification.

Tensioner Plug Torque:

2. Apply Crankcase Sealant (PN 2871557)tothe stator plate outer surface and install a new O-Ring.

3. Installthestatorplatebeingcareful not todamage the seal. Align timing reference marks on the plate and crankcase. Be sure the plate is fully seated. NOTE: Thisis a static timing mark. Strobe timing should be performed after start up.

4. Torque bolts evenly to specification.

Stator Plate Bolt Torque:

5-6.5 ft. lbs. (7-9 Nm)

5. Sealstator wire grommetwithCrankcaseSealant (PN 2871557).

14-19 ft. lbs. (20-25 Nm)

3.41

ENGINE

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FLYWHEEL INSTALLA

1. Installflywheel,washer, andnut. Torqueflywheel to specification.

Flywheel Nut Torque:

58-72 ft. lbs. (78-98 Nm)

TION

STARTER DRIVE ASSEMBLY

1. Be sure the washer is positioned on the back of the drive gear.

ROCKER SHAFT/ARM INSTALLA

1. Assemble rocker arms, rocker shaft and wave washer into rocker cover.

2. Install and tighten rocker shaft block plug.

3. Applyengine assembly lubeto thecam lobes and cam follower surfaces.

4. Rotatethe engine untilthe camlobes arepointing downward.

5. Apply clean engine oil liberally to the valve springs, cam chain, rocker arms, and camshaft.

6. Apply Crankcase Sealant (PN 2871557)tothe rocker cover mating surfaces. Be sure the alignment pins are in place.

7. Install the rocker cover assembly.

8. Install rocker cover bolts and torque to specifications.

TION

Rocker Cover Bolt Torque:

7-8 ft. lb s. (9-11 Nm)

Starter Drive Grease:

(PN 2871460)

2. Apply Starter Drive Grease (PN 2871460)tothe drive bushing in the crankcase and all moving surfaces of the starter drive mechanism. Install the starter drive.

9. Adjust valves according to the “INTAKE VAL VE CLEARANCE PROCEDURE” on next page.

10. Install rocker cover block plug.

Rocker Cover Block Plug Torque:

39-44 ft. lbs. (53-59 Nm)

1 1. Install valve adjustment caps with new o-rings.

Tighten securely.

3. Install recoil housing.

3.42

ENGINE

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INTAKE VALVE

CLEARANCE

ADJUSTMENT

1. Insert a .006″ (.15mm) feelergauge betweenend of intake valve stem and clearance adjuster screw.

2. Using Valve/Clutch Adjuster T ool (PN PA--44689), loosen adjuster lock nut and turn adjusting knob until there is a slight drag on the feeler gauge.

330 Engine

VALVE CLEARANCE

330 Engines

.006″ (.15 mm)

6. 330: Inspect o-rings on the plastic valve plugs, replace if damaged. Securely fasten valveplugs.

7. Scrape gasket surfaces to remove all traces of the old gasket.

8. Remove the shop towel from the spark plug cavity.

9. Install the spark plug. Torque to 14 ft. lbs. (19 Nm).

10. Install the spark plug high tension lead.

1 1. Install parts removed for access.

330 Engine

Spark Plug Torque: 14 ft. lbs. (19 Nm)

Valve Adjuster Tool: PA--44689

3. Holdadjuster screw and tighten adjuster lock nut securely.

4. Re-check the valve clearance.

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

EXHAUST VALVE CLEARANCE

1. Insert .006″ feeler gauge(s) between end of exhaust valve stem and adjuster screw(s).

2. Loosenlocknut(s)and turn adjuster screw(s) until there is a slight drag on feeler gauge(s).

NOTE: The 330 exhaust valve is adjusted the same as the intake valve. The V alve/Clutch Adjuster Tool (PNPA--44689) canbe usedtoadjustthe330 engines valves.

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

4. Re-check the valve clearance.

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

ADJUSTMENT

3.43

ENGINE

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RECOIL DISASSEMBL

CAUTION: Recoil is under spring tension. A face

shield or eye protection is required during this procedure.

Replace any parts found to be worn or damaged.

1. Remove bolts and recoil housing from engine.

2. Pull recoil rope so it is extended approximately 12-18″.Check handle c-ring for proper tension and the handle for cracks or damage which may allow water or dirt to enter the recoil housing. NOTE: Thehandle must seal tightly on the recoil housing to prevent water and dirt from entering.

3. Remove center bolt from recoil friction plate (A).

Y/INSPECTION

5. Remove ratchet pawl with spring and inspect. Replace spring or ratchet pawl if worn, broken, or damaged.

NOTE: Long arm of spring engages reel. Short end rests against pawl.

6. Holdreel firmly in housing. Pull rope handle until 12-18″ of rope is exposed, and hold reel in place.

4. Inspect plate for wear or damage. Inspect plate friction spring for wear, damage, and proper tension. The spring should fit tightly on friction plate.

7. Place rope in notch on outer edge of reel. Release tension on hub and allow reel to unwind approximately 6-7 turns until spring tension is released.

3.44

ENGINE

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8. Slowly and carefully remove reel from recoil housing making sure the spring remains in the housing. Inspect the reel hub and bushing (A) for wear.

9. Unwind rope and inspect for cuts or abrasions.

10. Inspectdrive tabon hub return springfor damage. To remove hub return spring, hold outer coils in place with one hand and slowly remove spring one coil at a time from the inside out.

1 1. Pullknot out of of recoilreel. Untie knot. Remove

rope from reel.

To reinstall an old spring:

1. Hookouter tabin place in recoil housing andwind springina counterclockwise direction one coil at a time while holding the installed coils in place.

2. Lubricate the spring with light lubricant such as Premium All Season Grease.

To complete recoil assembly:

1. Route rope through guide bushing in recoil housing and into reel. Tie a secure knot in end of the rope.

2. Wind rope counterclockwise onto the reel, as viewed from ratchet side of reel.

3. Lock rope into notch on outer edge of reel.

4. Apply a small amount of grease or equivalent to the center post of the housing and the bushing.

5. Install reel into housing making sure the spring drive tab on the reel engages the spring and the reel is fully seated in the housing.

Open end here

RECOIL ASSEMBLY

CAUTION: Recoil is under spring tension. A face

shield or eye protection is required during this procedure.

To install a new spring:

1. Placespringin housingwiththe endpositionedso the spring spirals inward in a counterclockwise direction. See photo.

2. Hold spring in place and cut retaining wire.

6. Apply downward pressure on the reel and rotate counterclockwise approximately 6-7 turns to pre-wind the spring. Continue rotating counterclockwise until rope on outer edge aligns with rope guide bushing.

7. Release rope from notch and allow reel to rewind completely. If morepre-wind is required, place rope in notch and add additional turns of pre-wind.

8. Installratchet pawlandreturnspring, withlong leg of spring engaged in reel.

9. Reinstall friction plate. NOTE: Thefriction plate must bepositioned with both end tabs of the friction spring opposite the ratchet pawl.

10. Torque friction plate retaining bolt to 5-6 ft. lbs. (7-9 Nm).

11. Apply Crankcase Sealant (PN 2871557)tothe recoil housing outer edge. Reinstall recoil housing. Seal stator wire harness grommet with RTV silicone.

3.45

ENGINE

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SPARK PLUG

FOULING

TROUBLESHOOTING

G Spark plug cap loose or faulty G Choke cable adjustment or

plunger/cable sticking

G Foreign material on choke plunger

seat or plunger

G Incorrect spark plug heat range or

gap

G Carburetor inlet needle and seat

worn

G Jet needle and/or needle jet worn or

improperly adjusted

G Excessive carburetor vibration

(loose or missing needle jet locating pins)

G Loosejetsincarburetor orcalibration

incorrect for altitude/temperature

G Incorrect float level setting G PVT system calibratedincorrectly or

components worn or mis-adjusted

G Fuel quality poor (old) or octane too

high

G Low compression G Restricted exhaust G Weak ignition (loose coil ground,

faulty coil, stator, or ETC switch)

G ETC switch mis-adjusted G Restricted air filter (main or

pre-cleaner) or breather system

G Improperly assembled air intake

system

G Restricted engine breather system G Oil contaminated with fuel G Restricted oil tank vent

G Engine flooded G Low compression (high cylinder

leakage)

G No spark (Spark plug fouled)

Engine Does Not Turn Over

G Dead battery G Starter motor does not turn G Engine seized, rusted, or

mechanical failure

G Recoil components damaged

Engine Runs But Will Not Idle

G Restricted carburetor pilot system G Carburetor misadjusted G Choke not adjusted properly G Low compression G Crankcase breather restricted G Air filter restriction

Engine Idles But Will Not Rev Up

G Spark plug fouled/weak spark G Broken throttle cable G Obstruction in air intake G Air box removed (reinstall all intake

components)

G Incorrect or restricted carburetor

jetting

G ETC switch limiting speed G Reverse speed limiter limiting speed G Carburetor vacuum slide

sticking/diaphragm damaged

G Incorrect ignition timing G Restricted exhaust system G Cam Lobe worn

Engine Has Low Power

TROUBLESHOOTING

Engine Turns Over But Fails to Start

G No fuel G Dirt in fuel line or filter G Fuel will not pass through fuel valve G Fuel pump inoperative/restricted G Tank vent plugged G Carb starter circuit

G Spark plug fouled G Cylinder, piston, ring, or valve wear

or damage (check compression)

G PVT not operating properly G Restricted exhaust muffler G Carburetor vacuum slide

sticking/diaphragm damaged

G Dirty carburetor G Cam lobe worn

3.46

TROUBLESHOOTING

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Piston Failure - Scoring

G Lack of lubrication G Dirt entering engine through cracks

in air filter or ducts

G Engine oil dirty or contaminated

Excessive Smoke and Carbon Buildup

G Excessive piston-to-cylinder

clearance

G Worn rings, piston, or cylinder G Worn valves, guides or seals G Restricted breather G Air filter dirty or contaminated

Low Compression

G Decompressor stuck G Cylinder head gasket leak G No valve clearance or incorrectly

adjusted

G Cylinder or piston worn G Piston ringsworn, leaking, broken, or

sticking

G Bent valve or stuck valve G Valvespringbrokenorweak G Valve not seating properly (bent or

carbon accumulated on valve area)

G Rocker arm sticking

ENGINE

Backfiring

G ETC or speed limiter system

malfunction

G Fouledsparkplug orincorrect plug or

plug gap

G Carburetion faulty - lean condition G Intake / Exhaust system air leaks G Ignition system faulty:

GSpark plug cap cracked/broken GIgnition coil faulty GIgnition or kill switch circuit

faulty

GIgnition timing incorrect

GSheared flywheel key G Poor connections in ignition system G System wiring wet G Cam lobe worn or Valve sticking G Lean condition

3.47

ENGINE

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NOTES

3.48

FUEL SYSTEM/CARBURETION

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Exploded View, Mikuni BST 34 Carburetor 4.2...

Fuel Pump Exploded View 4.3.................

Fuel Tank Asm. Exploded View 4.4............

Fuel Flow Diagram 4.4.......................

Special Tools & Jetting Guidelines 4.5.........

Carburetor Jetting 4.6........................

Main Jet / Pilot Jet Part Numbers 4.6...........

CV Carburetor System Function (4 Cycle) 4.6...

CV Carburetor Vent System (4 Cycle) 4.7.......

CV Carburetor Operation 4.7-4.9..................

Pilot Screw 4.9..............................

Disassembly, CV Carburetor 4.10...............

Cleaning, CV Carburetor 4.11..................

Inspection, CV Carburetor 4.11.................

Assembly, CV Carburetor 4.12.................

Float Adjustment, CV Carburetor 4.13...........

Needle & Seat Leakage Test 4.13...............

Fuel Level 4.14...............................

Fuel Pump Service 4.14.......................

Troubleshooting 4.15..........................

4.1

FUEL SYSTEM/CARBURETION

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1. Carburetor Assembly

BST 34 CARBURETOR EXPLODED VIEW

29 28

44 43

Refer to Page 4.5 for Jet Part Numbers

27 24

26 25

Jet Needle “E” Clip Position

2. Screw

3. Throttle Valve

4. Cover, Diaphragm

5. Jet Block Assembly

6. Spring

7. Diaphragm Assembly

8. Ring

9. “E” Ring

10. Ring

11. Needle Jet

12. Cover

13. O-Ring

14. Throttle Shaft Assembly

15. Ring

16. Seal

17. Spring

18. Packing

19. “E” Ring

20. Cap

21. Screw

22. Drain Screw

23. O-Ring

24. Washer

25. Adjuster

26. Spring

27. Pilot Jet

28. Main Jet

29. Washer

30. Jet Needle

31. Float Assembly

32. Float Body Assembly

33. Float Pin

34. Needle Valve

35. O-Ring

36. O-Ring

37. Plug

38. Screw

39. Screw

40. Guide Holder

41. Spring

42. Plunger Assembly

43. Spring Washer

44. Screw

45. Air Jet

46. Cable Guide

47. Spring

48. Ring

49. Adjust Screw

50. Screw and Washer Assy. 51 Plate 52 Screw

4.2

FUEL PUMP EXPLODED VIEW

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FUEL SYSTEM/CARBURETION

1. Fuel Pump Assembly

2. Diaphragm, Gasket Set

3. Screw and Washer Assembly

4. Screw and Washer Assembly

5. Screw and Washer Assembly

6. Pressure Regulator

7. Fuel Inlet

8. Fuel Outlet

4.3

FUEL SYSTEM/CARBURETION

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FUEL TANK ASSEMBLY

Forward

Vent line routed smoothly into center of steering post

Tank to fuel valve connection -Gold fitting (tall stand pipe) to “ON”

90 Degree Fuel

Reserve Outlet Fitting

(Marked “2” on fuel valve)

Fuel Line

“2 (Reserve)”

90 Degree Fuel

Outlet Fitting

(Marked 1) on fuel valve)

“1 (ON)”

Gas Tank Mounting

Hardware

Fuel Filter

Fuel Valve

FUEL FLOW DIAGRAM

L Located Above Coolant Reservoir

Above LH Front Tire

Fuel Pump

Fuel Tank Vent

Filter

Carburetor Vent

Carburetor

Fuel Tank

Fitting Screens

Fuel Valve

Engine

4.4

FUEL SYSTEM/CARBURETION

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FUEL SYSTEM COMPONENT OVERVIEW

Fuel Tank

Fuel Pump

Tank to Pump Line

Impulse Line

Fuel Pump to Carburetor Line

SPECIAL TOOLS

PART NUMBER TOOL

DESCRIPTION

2870975 Mity Vact

Pressure TestTool

2872314 Carburetor Float

AdjustmentTool

WARNING

Gasoline is extremely flammable and explosive under certain conditions.

Vent Line

Carburetor

Fuel Filter

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

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

Ifyou spillgasoline onyour skin orclothing, immediately wash with soap and water and change clothing.

Always stop the engine and refuel

outdoors or in a well ventilated area.

Do not overfill the tank. The tank is at

full capacity when the fuel reaches the bottom of the filler neck. Leave room for expansion of fuel.

Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.

Never drain the float bowl when theengine

is hot. Severe burns may result.

JETTING GUIDELINES

Changesinaltitudeandtemperatureaffect airdensity, whichisessentiallythe amountof oxygenavailablefor combustion. Inlow elevations andcold temperatures, the air is more dense and has more oxygen. Inhigher elevations and higher temperatures, the air is less dense with reduced oxygen.

Polaris ATV Carburetors are calibrated for an altitude of 0-6000 ft. (0-1800 meters) and ambient temperatures between +40 and +80° F(+5° to +26° C). Carburetors must be re-calibrated if operated outside this temperature and/or altitude range. The jetting installed in production is not intended for all altitudes and/or temperatures. In addition, air screw

4.5

FUEL SYSTEM/CARBURETION

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/ pilot screw adjustments and PVT adjustments may be required to suit operating conditions.

CARBURETOR JETTING

CAUTION:

A main jet that is too small will cause a lean operating condition resulting in serious engine damage. Select the correct main jet carefully for elevation and temperature according to the charts in the Specifications section or in the Owner’sSafety and Maintenance Manual foreach particular model.

IMPORTANT: The following guidelines must be

followed when establishing a main jet setting:

1. Select the lowest anticipated temperature at which the machine will be operated.

2. Determine the lowest approximate altitude at which the machine will be operated.

3. Select the correct mainjet from the chart on page on the Specifications page.

4. Clutching changes may also be required for changes in elevation. Refer to clutching chart in the Specifications section for recommendations.

MIKUNI JET PART NUMBERS

Main Jets

Jet Number Part Number

112.5 3130554 115 3130555

117.5 3130556 120 3130557

122.5 3130558 125 3130559

127.5 3130560 130 3130561

132.5 3130562 135 3130563

137.5 3130564 140 3130527

142.5 3130566 145 3130567

147.5 3130568 150 3130569

152.5 3130570 155 3130571

157.5 3130572 160 3131141

162.5 3131142 165 3131143

167.5 3131144 170 3131145

Pilot Jets

Jet Number Part Number

40.0 3130624

42.5 3130526

50.0 3131132

CV CARBURETOR SYSTEM FUNCTION

CarburetorComponent Function

System Main

Components

Float

System

(Level Control)

Venting Passages in

Starter (Choke/Enrichment)

Pilot (IdleSystem)

Main System

Inlet Pipe, Needle and Seat, Float, Float Pin

Carburetor, Ventlines to frame

Choke Lever, Cable, Plunger,Return Spring, Carb Passages (Starter Jet, StarterBleed Pipe)

Pilot Jet/ Passageways, PilotMixture Screw with Spring Washer and Sealing ORing, Bypass Ports (Behind Throttle Plate),Pilot Air Jet, Pilot Outlet, Throttle Plate

Main Jet, Main Air Jet, Main Air Passage, Needle Jet, Jet Needle, Vacuum Slide, Throttle Plate

Main

Function

Maintains specified fuel level in float chamber (carburetorfloat bowl)

Supplies atmospheric pressure to float chamber

Supplies additional fuel air mixture necessary for cold starting

Primarily supplies fuel at idle and low throttle positions

Supplies fuel at midrange and high throttle settings.

Main

Affect

All systems All throttle ranges

All throttle ranges Greatest effectat low throttle settings and idle

Mainly idle to 1/4 throttle Minimal effect after 1/2 throttle

1/4tofull throttle

4.6

POLARIS TRAIL BOSS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual