Polaris Trail Boss 330 2003, TRAIL BOSS 2003 Service Manual

PN 9918061
Printed in USA

2003 TRAIL BOSS SERVICE MANUAL PN 9918061

2003 TRAIL BOSS

SERVICE MANUAL

PN 9918061

59173 03 TrailBoss Cover 8/23/02 8:47 PM Page 1

2003 TRAIL BOSS 330

SERVICE MANUAL

Foreword

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

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

This manual includes procedures for maintenance operations, component identification and unit repair, along
with service specifications for 2003 Polaris Trail Boss ATVs.Comments or suggestions about this manual may
be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.

2003 Trail Boss 330 ATV Service Manual (PN 9918061)

ECopyright 2002 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of
publication. Due to constant improcvements in the design and quality of production components, some minor descrepancies may result
between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended
for reference use only. No liability can be accepted for ommisions or inaccuracies. Any reprinting or reuse of the depictions and/or
procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS

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

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

DANGER

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

WARNING

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

CAUTION:

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

NOTE:

A NOTE provides key information to clarify instructions.

Trademarks

Polaris acknowledges the following products mentioned in this manual:

FLEXLOC, Registered Trademark of SPS Technologies
Loctite, Registered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
FOX, Registered Trademark of Fox Shox
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Ammco, Registered Trademark of Ammco Tools, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation

CHAPTER INDEX

CHAPTER 1 GENERAL

CHAPTER 2 MAINTENANCE

CHAPTER 3 ENGINE

CHAPTER 4 FUEL SYSTEM

CHAPTER 5 BODY/SUSPENSION

CHAPTER 6 PVT SYSTEM

CHAPTER 7 FINAL DRIVE

CHAPTER 8 TRANSMISSION

CHAPTER 9 BRAKES

CHAPTER 10 ELECTRICAL

GENERAL INFORMATION

CHAPTER 1
GENERAL INFORMA TION
MAINTENANC

2003 Model Identification 1.2..................

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

2003 Trailboss Model 1.3.....................

Replacement Keys 1.4.......................

Machine Dimensions 1.5.....................

Specifications - 2003 Trail Boss 330 1.6-1.7........

Publication Numbers 1.8.....................

Paint Codes 1.8.............................

Standard Torque Specifications 1.8............

Tap Drill Charts 1.9..........................

Decimal Equivalent Chart 1.9.................

Unit of Measure Conversion Table 1.10..........

Glossary of Terms 1.11........................

E

/

1

1.1

GENERAL INFORMATION

MODEL IDENTIFICATION

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

Machine Model Number Identification

A03CA32AA

Emissions &

Year Designation

Basic Chassis
Designation Engine Designation

Model Option

ENGINE DESIGNATION NUMBERS

32 ES32PFE10 Single, Air Cooled, SOHC 4 Stroke, Electric Start............

VIN IDENTIFICA TION

World Mfg. ID

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

Vehicle Descriptor

32A*3P000000

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 LOCA TION

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

A

Front

B

TRANSMISSION I.D. NUMBER
LOCA

TION

1.2

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

GENERAL INFORMATION

2003 TRAILBOSS MODEL

2003 TRAILBOSS 330

1.3

REPLACEMENT KEYS

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

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

31XX

Key Series
Number

GENERAL INFORMATION

Series # Part Number

20 4010278

21 4010278

22 4010321

23 4010321

27 4010321

28 4010321

31 4110141

32 4110148

67 4010278

68 4010278

1.4

GENERAL INFORMATION

MACHINE DIMENSIONS

46 in
117 cm

FRONT

34 in
86 cm

46 in
117 cm

75 in
191 cm

SIDE

49.5 in
126 cm

1.5

MODEL: 2003 TRAIL BOSS 330..........

Altitud

e

Below40

F

+40Fto+80

F

(Feet

)

above1800

Altitud

e

Meter

s

0-180

0

(Feet

)

180

0-370

0

MODEL NUMBER: A03CA32.
ENGINE MODEL: ES32PFE10..

GENERAL INFORMATION

CARBURETION

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

Main Jet 122.5............

Pilot Jet 42.5.............

Jet Needle 4HB48--2...........

Needle Jet P-0M...........

Pilot Screw 2 Turns Out..........

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

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

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

89 Oxygenated

CLUTCH

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

Belt 321 1077.....................

Belt Width (Projected) 1.1882 (30.18mm).....

Side Angle (Overall) 26°......

Outside Circumference 40.86 ±.122....

Center Distance 10±.122 (254.5mm)..........

Clutch Offset 0.52 (12.7mm)............

Drive Spring Grey.............

Driven Spring Black............

Driven Helix 2+2.............

JETTING CHART

Altitude

Meters

(Feet)

0-1800

(0-6000)

above 1800

(above 6000)

CLUTCH CHART

Meters

(Feet)

*40E helix, black driven spring

0-1800

(0-6000)

1800-3700

(6000-12000)

AMBIENT TEMPERATURE

Below 40°F

Below 5°C

117.5 122.5

120 115

Shift

Weight Spring Spring Helix

20-- 40 Blue/Grey Black 2+2

20-- 38 Blue/Grey Black 2+2

+40EFto+80EF

+5ECto+26EC

Drive Clutch

Driven Clutch

Driven

ENGINE

Type 4 Cycle, Single Cyl........................

Displacement 329 cc...............

Bore 3.0912 (78.5mm).......................

Stroke 2.6792 (68mm).....................

Valve Clearance In & Ex 0.006 ± 0.00082 (0.15 ± 0.02 mm) BTDC on compression......

Cooling Air with fan assisted oil cooler....................

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

Piston Marking None..............

Operating RPM±200 6300 RPM.........

Idle RPM ± 50 (lights off) 1300 RPM.....

Compression Ratio 9.2:1..........

Compression Pressure 70--90 PSI.......

1.6

GENERAL INFORMATION

MODEL: 2003 TRAIL BOSS 330............

MODEL NUMBER: A03CA32...

ENGINE MODEL: ES32PFE10....

ELECTRICAL FLUID Capacity Type

Flywheel I.D. None Fuel Tank 3.25 gals. (12.30 L)...... ..........

CDI Part Number 4010697 Transmission 11.3 oz. (335 ml) PPS*... .......

Alternator Output 210 watts Engine Oil 1.5 qts (1.4 L) PP4*... .........

Ignition Timing 30°±2° BTDC@5000RPM Brake (Hand) Dot 3..... .....................

Spark Plug / Gap NGK BKR6E / 0.0362 (0.9 mm) Brake (Foot) Dot 3... ......................

Lights: Head (2) Dual Beam 30/30 watts......

Tail 8.26 watts........

Brake 26.9 watts......

Indicator 1.0 watts...

Electric Start Standard.......

Electronic Speedo N/A..

Polaris Lubricants

*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W--40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid

SUSPENSION / CHASSIS DRIVE TRAIN

Body Style Gen IV Chain Type 520 O-Ring........ .........

Front Suspension MacPherson Strut Gear Reduction-Rev 3.05/1.. .

Tow Capacity 850 lbs. (385.9 kg) Gear Reduction-High 2.68/1......

Turning Radius 752 (191 cm) Final Drive Ratio 11/40 78P..... ....

Toe Out 1/82-1/42 (3-6.35 mm) Brake (Hand) Single Lever, Hyd. Disc........... .......

Ground Clearance 5.52 (13.97 cm) Brake ( Auxiliary Foot) Hydraulic..
Front Vertical Travel 6.72 (17.02 cm)
Rear Suspension Progressive Rate Swing Arm...

Rear Travel 9.02 (22.86 cm)........

Rear Shock 22 Gas Charged Twin Tube........

Shock Adjustment Cam..

TIRES

Tire Size - Front 23 x 7 - 10....

Tire Size - Rear 22 x 11 - 10....

Tire Pressure - F/R 4/3 lbs..

Total Width 462 (117 cm)........

Total Length 752 (191 cm).......

Total Height 462 (117 cm)........

Wheel Base 49.52 (125.73 cm).......

Weight - Dry 505 lbs. (230 kg).......

LOAD CAPACITY

Front Rack (Accy) 75 lbs. (34 kg)....

Rear Rack (Std) 125 lbs. (57 kg)......

Tongue Weight 85 lbs. (14 kg).......

Tow Hitch Std...........

OPTIONAL SUSPENSION SPRINGS

SPRING TYPE SOFT STANDARD FIRM

Rear Compression Spring

Front Strut Spring N/A 7041850-067

N/A

7041518-067

130 --165 lb/in.

41 lb/in.

7041303-067

250 lb/in.

7041375-067

64 - 113 lb/in.

1.7

PUBLICATION NUMBERS

2003TrailB

330A03CA32AA991749299178629917863

GENERAL INFORMATION

Year Model Model No. Owner’s

Manual PN

oss

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

Parts

Manual PN

Parts

Micro Fich e PN

PAINT CODES

PAINTED PART COLOR

DESCRIPTION

Springs Silver -- -- P-385

Rims Bright White 2185 P-133

Rack(s) Black 9440 P-067

Frame Black 9440 P-067

FRAME COLOR - P067 Medium Gloss Black 9440 / 8520147.
Order direct from Midwest Industrial Coatings 952--252--2000 See Quick Reference Manual for ordering info.

DITZLER
NUMBER

POLARIS
NUMBER

STANDARD TORQUE SPECIFICATIONS

The following torque specifications are to be used as a general guideline. FOR SPECIF IC TORQUE VALUES OF
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.

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

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

Torque ft. lbs. (Nm)*

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

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

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

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

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

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

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

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

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

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

Metric / Torque

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

(Nm)

1.8

GENERAL INFORMATION

SAE TAP DRILL SIZES

Thread Size/Drill Size Thread Size/Drill Size

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

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

METRIC TAP DRILL SIZES

Tap Size Drill Size Decimal

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

0.3125

0.3437

0.339

0.375

0.406

0.406

Nearest

Fraction

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

DECIMAL EQUIVALENTS

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

1/32 .0312 1 mm = .0394²........... ...

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

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

5/64 .0781 2 mm = .0787²................ ...

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

7/64 .1094 3 mm = .1181².............. ...

1/8. .1250...

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

5/32 .1563 4 mm = .1575²........... ...

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

3/16 .1875 5 mm = .1969²........... ...

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

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

15/64 .2344 6 mm = .2362²............... ...

1/4 .25....

17/64 .2656 7 mm = .2756²............... ...

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

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

5/16 .3125 8 mm = .3150²........... ...

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

11/32 .3438 9 mm = .3543².......... ...

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

3/8 .375....

25/64 .3906 10 mm = .3937²............... ...

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

27/64 .4219 11 mm = .4331²............... ...

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

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

15/32 .4688 12 mm = .4724²......... ...

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

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

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

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

35/64 .5469 14 mm = .5512²............... ...

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

37/64 .5781 15 mm = .5906²............... ...

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

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

5/8 .625 16 mm = .6299².... ............

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

21/32 .6563 17 mm = .6693²......... ...

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

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

45/64 .7031 18 mm = .7087²............... ...

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

47/64 .7344 19 mm = .7480²............... ...

3/4 .75....

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

25/32 .7813 20 mm = .7874²......... ...

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

13/16 .8125 21 mm = .8268²......... ...

53/64 .8281...............

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

55/64 .8594 22 mm = .8661²............... ...

7/8 .875....

57/64 .8906 23 mm = .9055²............... ...

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

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

15/16 .9375 24 mm = .9449²......... ...

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

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

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

11.0.....

1.9

GENERAL INFORMATION

CONVERSION TABLE

Unit of Measure Multiplied by Converts to

ft. lbs. x12 =in.lbs.

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

ft. lbs. x 1.356 =Nm

in. lbs. x .0115 =kg-m

Nm x .7376 = ft.lbs.

kg-m x 7.233 = ft. lbs.

kg-m x 86.796 =in.lbs.

kg-m x10 =Nm

in. x 25.4 =mm

mm x .03937 =in.

in. x2.54 =cm

mile (mi.) x1.6 =km

km x .6214 = mile (mi.)

Ounces (oz) x 28.35 = Grams (g)

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

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

Grams (g) x 0.035 = Ounces (oz)

lb. x .454 =kg

kg x 2.2046 =lb.

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

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

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

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

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

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

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

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

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

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

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

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

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

Kilopascals (kPa) x 0.145 = 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)

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

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

1.10

GENERAL INFORMATION

GLOSSARY OF TERMS

ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8² or 1 cm). Polaris measures chain length in number of pitches.
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive

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. An electrical circuit which is completed before the current reaches the intended load.

(i.e. a bare wire touching the chassis).

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

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

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 .040².
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch System)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.

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

Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston’s most outward travel from crankshaft.
Vol t: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.

1.11

NOTES

GENERAL INFORMATION

1.12

MAINTENANCE

CHAPTER 2
MAINTENANCE

Periodic Maintenance Chart 2.2-2.3...............

Pre-Ride Inspection 2.3......................

Recommended Maintenance Products 2.4......

Lubricant and Maintenance Quick Reference 2.5-2.6

Special Tools 2.7............................

Transmission Lubrication 2.8..................

Transmission Linkage Adjustment 2.9..........

Throttle Operation / Choke Adjustment 2.10......

Carburetor Adjustments 2.10-2.11...................

2

ETC Switch Adjustment 2.11...................

Fuel System 2.12.............................

Compression Test 2.13........................

Battery Maintenance 2.13-2.14......................

Electrical 2.14-2.15................................

Oil Cooler Maintenance 2.15...................

Air Filter Service 2.15.........................

Air Box Sediment Tube Service 2.16............

Breather Filter 2.16...........................

Recoil Housing/PVT Drying 2.16-2.17................

Oil Level/Change/Filter 2.17-2.18....................

Valve Clearance 2.19-2.20.........................

Steering and Toe Alignment 2.20-2.22...............

Exhaust System Maintenance 2.22.............

Brake System Service 2.23-2.24....................

Drive Chain and Sprocket Service 2.24-2.26..........

Suspension Service / Controls 2.26-2.27.............

Wheel Removal / Installation 2.27...............

Tire Inspection 2.28...........................

2.1

MAINTENANCE

PERIODIC MAINTENANCE CHART

Inspection, adjustment and lubrication intervals of important components is listed in the following chart.
Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 mph.
Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for
replacement parts. Always use genuine Polaris parts

H = CAUTION: Due to the nature of these adjustments, it is recommended that service be performed by
an authorized Polaris dealer.

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

prolonged idle) should be inspected and serviced more frequently. For engine oil, short trip cold
weather riding also constitutes severe use. Pay special attention to oil level. A rise in oil level in cold weather

can indicate moisture collecting in the oil tank. Change oil immediately if oil level begins to rise.
E = Emission Control System Service (California).

(Whichever comes first)

Item Hours Calendar Miles

Engine Oil - Level/Change 100 hrs 6 months 1000 (1600) Check Level Daily; Break In service at 1 month

E"

Oil Filter 100 hrs 6 months 1000 (1600) Replace with oil change

E

Air Filter - Foam Pre-Cleaner Daily Daily Inspect-Clean & oil more often in dirty conditions.

E"

Air Filter - Main Element Weekly Weekly Inspect - Replace if necessary

E"

" Air Box Sediment Tube - Daily Drain deposits whenever visible

" Engine Breather Filter 20 hrs Monthly 200 (320) Inspect and replace if necessary

" Oil Tank Vent Hose 100 hrs 12 months 1000 (1600) Inspect hose routing /hose condition

Valve Clearance 100 hrs 12 months 1000 (1600) Inspect/Adjust

EH

Idle Speed As required As required Adjust

E

H Throttle Cable / ETC Switch 50 hrs 6 months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary

Choke (Enricher) Cable 50 hrs 6 months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary

Carburetor Float Bowl 50 hrs 6 months 500 (800) Drain bowl periodically and prior to storage

Carburetor Air Intake Ducts/Flange 50 hrs 6 months 500 (800) Inspect all ducts for proper sealing/air leaks

Fuel System 100 hrs 12 months 1000 (1600) Check for leaks at tank cap, lines, fuel valve, filter,

EH

Fuel Filter 100 hrs 12 months 1000 (1600) Replace filter annually

EH

Coolant/Level Inspection Daily Daily Replace engine coolant every 2 years

Coolant Strength / Pressure Test
System

Radiator 100 hrs 12 months 1000 (1600) Inspect / Clean external surface

Cooling System Hoses 100 hrs 12 months 1000 (1600) Inspect

Engine Mounts 100 hrs 12 months 1000 (1600) Inspect

Drain Recoil Housing Weekly Weekly More often if operating in wet environment

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

Spark Plug 100 hrs 12 months 1000 (1600) Inspect - Replace if necessary

E

Wiring 100 hrs 12 months 1000 (1600) Inspect for abrasion, routing, security

Ignition Timing 100 hrs 12 months 1000 (1600) Inspect

Battery 20 hrs Monthly 200 (320) Check terminals; Clean; Check fluid level

Headlight Aim As required As required Adjust if Necessary

Headlamp Inspection Daily Daily Check operation daily; Apply Nyogelt Grease

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

100 hrs 6 months 1000 (1600) Inspect strength seasonally; Pressure test sys-

.

Frequency

Remarks

(Km)

pump & carburetor. Replace lines every 2 years.

tem annually

ELECTRICAL

to connector when lamp is replaced

to socket when lamp is replaced

2.2

MAINTENANCE

PERIODIC MAINTENANCE CHART, CONT.

CHASSIS

Frequency

(Whichever comes first)

Item Hours Calendar Miles

(Km)

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

" Front Hubs/Fluid Check 50 hrs 6 months 500 (800) Check monthly

" Front Hubs/Fluid Change 100 hrs 12 months 1000 (1600) Check monthly

H Front Wheel Bearings (2x4) Annually 12 months Inspect and replace if necessary

H Front Hub Spindle Nut Torque

(AWD Models)

Drive Belt 50 hrs 6 months 500 (800) Inspect - Adjust, Replace if Necessary

Clutches (Drive And Driven) 100 hrs 12 months 1000 (1600) Inspect, Clean

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

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

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

H Toe Adjustment As required As required Periodic Inspection, Adjust When Parts are Re-

" Rear Axle 50 hrs 6 months 500 (800) Inspect Bearings, Grease Fitting

" Front Suspension 50 hrs 6 months 500 (800) Inspect - Lubricate

" Rear Suspension 50 hrs 6 months 500 (800) Inspect - Lubricate

Drive Chain 50 hrs 6 months 500 (800) Inspect Daily, Adjust and Lubricate if Needed

Tires Pre-ride Pre-ride Inspect Daily, Pre-Ride Inspection Item

H Brake Fluid 200 hrs 24 months 2000 (3200) Change Every Two Years

" Brake Fluid Level Pre-ride Pre-ride Inspect Daily, Pre-Ride Inspection Item

" Brake Lever Travel Pre-ride Pre-ride Inspect Daily, Pre-Ride Inspection Item

H Brake Pad Wear 10 hrs Monthly 100 (160) Inspect Periodically

Auxiliary Brake Adjustment As required As required Inspect Deflection Daily; Adjust

Output Shaft Bearing Monthly Monthly Grease Monthly

Brake Sys tem Pre-ride Pre-ride Pre-Ride Inspection Item

Wheels Pre-ride Pre-ride Pre-Ride Inspection Item

Frame Nuts, Bolts, Fasteners Pre-ride Pre-ride Pre-Ride Inspection Item

Annually 12 months Inspect Torque and Locking Fastener and re-

place if necessary

placed

Remarks

PRE-RIDE / DAIL Y INSPECTION

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

G Tires - check condition and pressures
G Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank
G All brakes - check operation and adjustment (includes auxiliary brake)
G Throttle - check for free operation and closing
G Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
G Engine stop switch - check for proper function
G Wheels - check for tightness of wheel nuts and axle nuts; be sure axle nuts are secured by cotter pins
G Drive chain - condition and slack; refer to drive chain adjustment
G Air cleaner element - check for dirt; clean or replace
G Steering - check for free operation noting any unusual looseness in any area
G Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
G Engine coolant - check for proper level at the recovery bottle

2.3

MAINTENANCE

POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS

Part No. Description

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol)

2871281 Engine Oil (Quart) Premium 4 Synthetic

0W--40 (4--Cycle) (12 Count)

2871844 Engine Oil (Gallon) Premium 4 Synthetic

0W--40 (4--Cycle) (4 Count)

2871567 Engine Oil (16 Gallon) Premium 4

Synthetic 0W-- 40 (4--Cycle)

Gearcase / Transmission Lubricants

2873603 Premium Synthetic Gearcase Lubricant (1

Gal.) (4 Count)

2873602 Premium Synthetic Gearcase Lubricant

(12 oz. bottle) (12 Count)

2871653 Premium Front Gearcase Fluid (8 oz.) (12

Count)

2871653 Premium Front Gearcase Fluid (2.5 Gal)

(2 Count)

2870465 Oil Pump for 1 Gallon Jug

2871654 Premium Drive Hub Fluid (8 oz.) (12

Count)

2872277 Premium Drive Hub Fluid (2.5 gal.) (2

Count)

2871653 AngleDriveFluid(8oz.)

Grease / Specialized Lubricants

2871322 Premium All Season Grease (3 oz.

cartridge) (24 Count)

2871423 Premium All Season Grease (14 oz.

cartridge) (10 Count)

2871460 Starter Drive Grease (12 Count)

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

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

2871312 Grease Gun Kit

2871329 Dielectric Grease (Nyogel)

Coolant

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

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

Additives / Sealants / Thread Locking Agents /

Misc.

2870585 Loctite Primer N, Aerosol, 25 g

2871956 Loctite Thread Sealant 565 (50 ml.) (6

Count)

2871949 Loctite Threadlock 242 (50 ml.) (10

Count)

2871950 Loctite Threadlock 242 (6 ml.) (12

Count)

2871951 Loctite Threadlock 262 (50 ml.) (10

Count)

2871952 Loctite Threadlock 262 (6 ml.) (12

Count)

2871953 Loctite Threadlock 271 (6 ml.) (12

Count)

2871954 Loctite Threadlock 271 (36 ml.) (6

Count)

2870584 Loctite 680-Retaining Compound (10

ml.)

2870587 Loctite 518 Gasket Eliminator / Flange

Sealant (50 ml.) (10 Count)

2872113 Disk Brake Quiet (12 oz.) (12 Count)

2871326 Premium Carbon Clean (12 oz.) (12

Count)

2870652 Fuel Stabilizer (16 oz.) (12 Count)

2871957 Black RTV Silicone Sealer (3 oz. tube)

(12 Count)

2871958 Black RTV Silicone Sealer (11 oz.

cartridge) (12 Count)

2870990 DOT3 Brake Fluid (12 Count)

2872113 Disc Brake Quiet, Aerosol, (9 oz.) (12

Count)

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

2872893 Engine Degreaser (12oz.) (12 Count)

NOTE: The number count indicated by each part
number in the table above indicates the number of
units that are shipped with each order.

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

2.4

MAINTENANCE

RECOMMENDED MAINTENANCE PRODUCTS - QUICK
REFERENCE

Item Typ e Notes See

Pages

Engine Oil Polaris Premium 4

Add to proper level on dipstick. 2.17-2.18

Synthetic, 0W--40

Transmission Polaris Synthetic Gear

Case Lubricant

Refer to procedures outlined later in this
chapter.

2.8

Brake Fluid Polaris DOT 3 Brake Fluid Fill to indicated level inside reservoir. 2.23

MAINTENANCE QUICK REFERENCE

Ill.

#

1 Engine Oil Polaris 0W-- 40

2 Transmission Polaris Synthet-

3 Brake Fluid Polaris DOT 3

4 Drive Chain Polaris Chain

Item Lube Rec. Method Frequency*

Synthetic

ic Gear Case
Lubricant

Brake Fluid

Lube or O-Ring
chain lube

Dipstick

1. Engine Oil

Add oil to proper level. Change after 1st month, 6 months or 100

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

Add lube to FULL level on dip­stick.

Fill master cylinder reservoir to in­dicated level inside reservoir. See
Page 2.23.

Apply to chain link plates and roll­ers.

Change annually ©

As required. Change fluid every 2 years.

As required*

Transmission
Dipstick

Operating
Range

Full

2. Transmission

Parking Brake Lock

3. Brake Fluid

Reservoir

4. Rear Drive Chain

2.5

MAINTENANCE QUICK REFERENCE CONT’D

8. Rear Axle Bearings

7. Tie Rod End

5. Front
Wheel
Bearings

MAINTENANCE

9. Swing Arm
Bushings

6. Ball Joint

Ill.

#

5 Front Wheel Bear-

ings

6 Ball Joint Polaris All Season

7 Tie Rod Ends Polaris All Season

8 Rear Axle Bearings Polaris All Season

9 Swing Arm Bush-

ings

Item Lube Rec. Method Frequency*

Sealed; Replace Inspect and replace bearings if necessary Annually ©

Grease¢

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 eccentric and grease with
grease gun.

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

Semi-annually

¡

Semi-annually

¡

Semi-annually

¡

Semi-annually

¡

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

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

© 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

2.6

MAINTENANCE

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 Flywheel Puller 3

2871293 Slotted Nut Socke t 3

PV--43527 OIl Filter Wrench 3

2872314 Carburetor Float Adjustment Tool 4

2870975 Mity Vac Pressure Test Tool 4, 9

2870871 Ball Joint Replacement Tool 5

2870623 Shock Absorber Spring Compression Tool 5

2871572 Strut Rod Wrench 5

2871573 LH Strut Spring Compressor 5

2871574 RH Strut Spring Compressor 5

2870506 Clutch Puller 6

9314177 Clutch Holding Wrench 6

2871358 Clutch Holding Fixture 6

2870341 Drive Clutch Spider Removal and Install Tool 6

2870654 Clutch Offset Alignment Tool 6

2870913 Driven Clutch Puller 6

2870910 Roller Pin Tool 6

2871226 Clutch Bushing Replacement Tool Kit 6

2870386 Piston Pin Puller 6

8700220 Clutch Compression Tool 6

2871710 10” Center Distance Tool 8

PV--43568 Fluke77 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 Tools catalog.

2.7

MAINTENANCE

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 Premium Synthetic Gearcase Lubricant

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

Capacity: 11.3 oz. (335 ml)

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

TRANSMISSION FLUID
CHANGE/TORQUE ST

OP

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. Remove the drain plug and wipe the magnetic end
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

B

Drain Plug

Transmission

Dipstick

To check the level:

1. Remove dipstick and wipe clean.

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

Full

Operating

Range

Forward

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

9. Add the proper lubricant through the dipstick hole
until the oil level is between the upper and lower
limits. Do not overfill.

10. Check for leaks.

11. ReinstallskidplateifremovedinStep1.

A

2.8

MAINTENANCE

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 If shifting problems are encountered,

the transmission linkage may require
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 Tighten shift linkage rod end jam 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.

NOTE: The rod end must be held when tightening the
jam nut to prevent damage to the rod end.

Incorrectly Tightened

Jam Nut

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

4. Turn linkage rod (A) to shorten or lengthen rod

until the shift lever is centered on hole in the fender.

A

5. Hold rod end parallel to mounting surface and

tighten jam nuts securely.

2.9

MAINTENANCE

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 in the turning range,
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

PILOT SCREW (IDLE
MIXTURE)

NOTE: These procedures are intended as reference
only. Actual final settings may be different depending
on the atmospheric conditions in your area.

1. Turn pilot 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.

FRONT

(Engine)

Pilot Screw

ADJUSTMENT

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 the choke 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.

Pilot Screw Adjustment:

2.0 Turns

2. 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).

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

4. Set idle speed to 1300 RPM. Always check
throttle cable freeplay after adjusting idle speed
and adjust if necessary.

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

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

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

8. Re adjust idle speed if not within specification.

2.10

MAINTENANCE

IDLE SPEED ADJUSTMENT

1. Start engine and warm it up thoroughly.

CV Carburetor

Idle Screw

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

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 1/16² -1/8²
freeplay is achieved at the thumb lever. After
making any adjustment, “flip” the lever slightly to
confirm adjustment.

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

4. With engine running, turn the handlebars from full
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.

THROTTLE OPERATION

To remove the ETC cover:

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

3

6

5

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

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

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
damaged.

2

1

4

Boot

Adjuster

Sleeve

Direction

of travel

1/16² -1/8²

Freeplay

Lock-

nut

Boot

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

2.11

MAINTENANCE

FUEL SYSTEM

WARNING

Gasoline is extremely flammable and explosive
under certain conditions.

G Always stop the engine and refuel

outdoors or in a well ventilated area.

G Do not smoke or allow open flames

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

G Do not overfill the tank. Do not fill the

tank neck.

G If you get gasoline in your eyes or if

you swallow gasoline, seek medical
attention immediately .

G If you spill gasoline on your skin or

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

G Never start the engine or let it run in

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

G Never drain the float bowl when the

engine is hot. Severe burns may
result.

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.

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.

Arrow Indicates Direction

of Flow

To Carburetor

FUEL LINES

Fuel Lines

Pulse Line

Fuel Pump

Ill.1

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

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

3. Replace all fuel lines every two years.

Fuel Filter

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

2.12

MAINTENANCE

NOTE: The bowl drain screw is located on the bottom

left side of the float bowl.

1. Turn fuel valve to the off position.

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

RES

Cylinder Compression

Standard 70--90 PSI

Cylinder Leakage

Service Limit: 10 %

(Inspect for cause if leakage exceeds 10%)

OFF

ON

Fuel Valve

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-Stroke engine 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 is the best indication of engine
condition on models with automatic decompression.
Follow tester manufacturer’s instructions to perform
a cylinder leakage test. (Never use high pressure
leakage testers as crankshaft seals may dislodge and
leak).

during a compression test.

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

External: Flush with water.

Internal: Drink large quantities of water or

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

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

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

NOTE: All 2003 Trail Boss ATV batteries are
Maintenance-- Free design and construction. All
Maintenance--Free batteries are fully charged and
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 .

2.13

MAINTENANCE

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 instruction on servicing Mainte nance--Free
batteries.

The battery is located under the left rear fender.

B

A

SPARK PLUG

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

2. Remove spark plug.

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

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

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

Spark Plug Gap

.036² (.9 mm)

Battery

To remove the battery:

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

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

CAUTION

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

3. Remove the battery.

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

5. Reinstall battery, 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.

6. If necessary, replace spark plug with proper type.

CAUTION: Severe engine damage may occur if
the incorrect spark plug is used.

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

8. Install spark plug and torque to 14 ft. lbs.

Recommended Spark Plug:

NGK BKR6E

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

IGNITION TIMING

Refer to Electrical chapter for ignition timing
procedure.

Ignition Timing:

30°°°°±±±±2°°°° BTDC@5000RPM

2.14

MAINTENANCE

ENGINE-TO-FRAME GROUND

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

Engine Ground Strap

MAIN AIR FILTER CLEANING

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.

AIR FILTER/PRE-FILTER
SER

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

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

1. Lift up on the rear of the seat.

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

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

4. Loosen clamp and remove air filter assembly (B &

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.

C).

C

B

A

E

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

exceed a pressure of 40 PSI. Always
use a dispersion type nozzle to
prevent filter damage and clean from
the inside to the outside.

G Replace the air filter every 50 hours,

and possibly more often in very dirty
conditions.

Ill.1

Cleaning:

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

6. Rinse and dry thoroughly.

7. Inspect element for tears or damage.

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

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

Installation:

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

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

2.15

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

Filter Clamp

MAINTENANCE

Sediment Tube

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.

Main Filter

Front

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

1. Remove drain plug from end of sediment tube.

2. Drain tube.

3. Reinstall drain plug.

RECOIL HOUSING

0 Drain the housing periodically to

remove moisture.

Crankcase Drain

Recoil Drain

1. Install air box cover and secure with clips.

AIR BOX SEDIMENT TUBE

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

2.16

0 Drain the recoil housing after

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

0 CAUTION: Make sure the manual

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

MAINTENANCE

sealed properly, water may enter the
recoil housing and damage
components.

G Water will enter the recoil housing if

the starter handle 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 ATV should be checked
immediately.

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 the bottom crosshatched area
and the bottom of the top crosshatched area. Add
oil as indicated by the level on the dipstick. Do not
overfill.

Normal Oil Operating
Range is between crosshatch.

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

PVT Drain Plug & O--ring

Ill.3

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

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.

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

Recommended Engine Oil:

Polaris Premium 4 All Season
Synthetic, 0W-40 (PN 2871281)

Ambient Temperature Range:

-40° Fto120° F

2.17

MAINTENANCE

OIL AND FILTER CHANGE

1. Place vehicle on a level surface.

2. Clean area around drain plug at bottom of oil pan.

3. Run engine two to 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. Replace sealing washer (A) on drain plug. NOTE:
The sealing surfaces on drain plug and oil tank
should be clean and free of burrs, nicks or
scratches.

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

8. The oil filter is located on the right side of the
machine. Place shop towels beneath oil filter.
Using an oil filter wrench, turn filter
counterclockwise to remove.

Filter

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

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

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

Drain plug located under the engine.

Crankcase Drain

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)
of Polaris Premium 4 Synthetic Oil (PN 2871281).

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. lbs. (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)

Engine Sump Drain Plug - Bottom View

2.18

MAINTENANCE

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 the spark plug. CAUTION: Place a clean
shop towel into the spark plug cavity to prevent
dirt from entering.

4. Remove plastic valve plugs.

330 Valve Plugs

INTAKE VALVE CLEARANCE
ADJUSTMENT

1. Insert a .006² (.15mm) feeler gauge between end
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.

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 to open, continue to rotate until the “T” aligns with
pointer. The camshaft lobes should be pointing
downward.

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

INTAKE VALVE CLEARANCE:

0.006±0.0008I (0.15±0.02 mm)

BTDC on compression

330 Engine

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

4. Re-check the valve clearance.

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

EXHAUST V ALVE
CLEARANCE

ADJUSTMENT

NOTE: The exhaust valve is adjusted the same as the
intake valve.

2.19

MAINTENANCE

1. Insert .006² feeler gauge between end of exhaust
valve stem and adjuster screw.

EXHAUST VALVE CLEARANCE:

0.006±0.0008I (0.15±

BTDC on compression

2. Loosen locknut and turn adjuster screw until there
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. Reinstall fuel tank and any body panels that were
removed to gain access.

0.02 mm)

STEERING

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

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

TIE ROD END / STEERING
INSPECTION

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

G Repeat inspection for inner tie rod

end (on steering post).

G Replace any worn steering

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

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

WARNING

NOTE: Due to the critical nature of the procedures
outlined in this chapter, Polaris recommends steering
component repair and adjustment be performed by an
authorized Polaris Dealer. Only a qualified technician
should replace worn or damaged steering parts. Use
only genuine Polaris replacement parts.

G Elevate front end of machine so front

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

2.20

Check for Loose Wheel or Hub

MAINTENANCE

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.

Measure

from string

to rim at

front and

rear of rim.

1/8² (.2to.3

than front rim

STRING

Rear rim

measure-

ment should

be 1/16² to

cm) more

measure-

ment.

WHEEL ALIGNMENT
METHOD 2:

1. Place machine on a smooth level surface.

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

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

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

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

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

CHALK

NOTE: The steering post arm “frog” can be

used as an indicator of whether the handle-

bars are straight. The frog should always

point straight back from the steering post.

Chalk Line

Measurement

“A”

Measurement “B”

2.21

MAINTENANCE

TOE ALIGNMENT
ADJUSTMENT

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

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

To adjust toe

G Hold tie rod end to keep it from

rotating.

G Loosen jam nuts at both end of the tie

rod.

G Shorten or lengthen the tie rod until

alignment is as required to achieve
the proper toe s etting. Method 1
(1/16² to 1/8²) or Method 2 (1/8² to
1/4²).

G Important: When tightening the tie

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

Hold

Rod End

alignment:

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 To reduce fire hazard, make sure that

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

G Wear eye protection.

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

hicle while purging the carbon from the
spark arrestor.

G Never run the engine in an enclosed

area. Exhaust contains poisonous car­bon monoxide gas.

G Do not go under the machine while it is

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

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

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.

Correctly

Tightened

Jam Nut

Incorrectly

Tightened

2.22

Jam Nut

Ill.1

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

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

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

SEE WARNING ABOVE

Clean Out Plug

MAINTENANCE

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

3. SEE 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
brake system in good operating condition. Service life
of brake system components depends on operating
conditions. Inspect brakes in accordance with the
maintenance schedule and before each ride.

G Keep fluid level in the master cylinder

reservoir to the indicated level inside
reservoir.

G Use Polaris DOT 3 Brake Fluid (PN

2870990).

BRAKE PAD INSPECTION

3/64²

(.1cm)

Minimum

Thickness

Pads should be changed when friction material is
worn to 3/64² (.1 cm), or about the thickness of a dime.

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.

Sight
Glass

Rear Master Cylinder Reservoir

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

friction material.

Max

Min

Parking Brake
Lock

AUXILIARY BRAKE
ADJUSTMENT

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

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

1/8, to 1/4,
Free Play

(HYDRAULIC)

50 lbs

1² or greater

Floorboard

2.23

MAINTENANCE

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

Free Play:

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

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

Bleeding:

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

DRIVE CHAIN AND
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. Do not wash the chain
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

To check for wear, pull outward on the chain as
shown. Replace sprocket if chain movement exceeds
1/4² (.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. Measure a length of twenty pitches (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
the closed end of the splice link clip as shown, with
the closed end leading in forward operation.

Proper

Splicelink Clip

Opening

Position

Drive Chain Wear Limit--20 Pitch Length:

Std: 12.5² (32 cm)

Wear Limit: 12.875² (32.7 cm)

Never allow battery acid to contact the drive chain.

Service Limit:

1/4² (6mm)

Drive Chain Lubricant:

Polaris O-Ring Chain Lubricant

(PN 2872073)

SPROCKET INSPECTION

Inspect the sprocket for worn, broken or bent teeth.

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: It is extremely important to 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 the ATV 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 approximately 3/8

in. (10 mm).

SWINGARM

2.24

MAINTENANCE

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.

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
any chain to have one or more tight spots in the chain.
Therefore, it is extremely important to check chain
deflection in several areas of the chain to ensure
deflection is correct at the tightest point.

Loosen Eccentric

clamp bolts (Step 2)

Loosen (2) caliper

mounting bracket

bolts (Step 3)

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

5. Move the ATV forward or back to move the
eccentric housing and adjust to the proper tension
(Approximately: 3/8” , or 10 mm)

Pin Punch

3/8² (10 mm) Deflection

ADJUSTMENT PROCEDURE ­CONCENTRIC

1. Loosen chain guide.

2. Loosen the two (2) eccentric clamp bolts.

3. Loosen caliper mounting bracket bolts located
under the axle.

See illustration for bolt locations.

SWINGARM

6. Tighten the eccentric clamp bolts to specification.

Eccentric Clamp With Hitch

Torque the nut

WITH TRAILER HITCH - 45 ft. lbs. (61 Nm)

2.25

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

Eccentric Clamp Without Hitch

MAINTENANCE

Loosen

Tighten

Torque the nut

WITHOUT TRAILER HITCH - 30 ft. lbs. (41 Nm)

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

Caliper Mount Bracket

10-12 ft. lbs

8. Remove pin punch.

9. Roll ATV forward checking chain tension at the
same point in several places around the chain.

The chain is adjusted correctly when the
tightest portion of the chain has
approximately 3/8 in. (10 mm) of deflection.

10. Position chain guide to allow 1/8” (3.175 mm),
clearance and tighten retaining bolt to 5 ft.lbs (7
Nm).

The chain can also be adjusted by loosening the rear
eccentric housing as described previously and using
a 2 1/2” (63.5 mm) wrench on the flats of the eccentric.
Turn the eccentric with the wrench until chain tension
is to specification.

SUSPENSION SPRING
PRELOAD

Operator weight and vehicle loading affect
suspensionspringpreloadrequirement s. Adjustas
necessary to avoid bottoming of the shocks.

ADJUSTMENT

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

G Check all rear suspension

components for wear or damage.

G Inspect shock for leakage.

Shock Spanner Wrench

2.26

(PN 2870872)

MAINTENANCE

CONTROLS

Check contr ols for proper operation, positioning
and adjustment.

G Brake control and switch must be

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

4. Remove the wheel nuts and remove the wheel.

Tapered nuts - install with

tapered side against wheel

WHEELS

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

WHEEL, HUB, AND SPINDLE
TORQUE T

Item Specification

Front Wheel Nuts 20 Ft. Lbs. (27 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

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.

Flange Nuts:

Flat side against wheel

WHEEL INSTALLATION

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

2. Attach the wheel nuts and finger tighten them.

3. Lower the vehicle to the ground.

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

CAUTION:

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

2.27

MAINTENANCE

TIRE PRESSURE

Tire Pressure Inspection (PSI - Cold)

Front Rear

4 3

TIRE INSPECTION

WARNING

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

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

measures 1/8² (.3 cm) or less.

FRAME, NUTS, BOLTS,

ASTENERS

F

Periodically inspect the 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.

CAUTION:

G Maintain proper tire pressure. Refer

to the warning tire pressure decal
applied to the vehicle.

G Improper tire inflation may affect ATV

maneuverability.

G When replacing a tire always use

original equipment size and type.

G The use of non-standard size or type

tires may affect ATV handling.

Tire Tread Depth

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

Tread

Depth 1/8I (3 mm)

2.28

CHAPTER 3
ENGINE

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

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 3.33-3.42..................

Recoil Disassembly/Inspecti on/Reassembly 3.42-3.44....

Spark Plug Fouling Checklist 3.45..................

Troubleshooting 3.45-3.46.............................

ENGINE

3

3.1

ENGINE

g

j

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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

Val v e Margin thickness In

Val v e

Valve Spring Free length

Rocker arm ID .8669-.8678² (22.020-22.041 mm)
Rocker shaft OD .8656-.8661² (21.987-22.0 mm)
Rocker shaft Oil Clearance

Camshaft journal OD

Camshaft journal bore ID

Camshaft Oil clearance

Surface warpage limit .0020² (.05 mm)
Standard height 2.908² (73.8 mm)

Inner diameter .2362-.2367² (6.000-6.012 mm)
Protrusion above head .681-.689² (17.3-17.5 mm)

Stem diameter In .2343-.2348² (5.950-5.965 mm)

Stem oil clearance Std

Overall length

Squareness 0.075² (1.9 mm)

Std .0008-.0021² (.020-.054 mm)
Limit .0039² (.10 mm)
Std 1.3001--1.3041² (33.023-33.123 mm)
Limit 1.2883² (32.723 mm)

Ex

Std 1.3007-1.3047² (33.039-33.139 mm)
Limit 1.2889² (32.739 mm)
Mag 1.4935-1.4941² (37.935-37.950 mm)
PTO 1.4935-1.4941² (37.935-37.950 mm)
Mag 1.4963-1.4970² (38.005-38.025 mm)
PTO 1.4963-1.4970² (38.005-38.025 mm)
Std .0022-.0035² (.055-.090 mm)
Limit .0039² (.10 mm)

Std .039² (1.0 mm)
Limit .055² (1.4 mm)

Ex

Std .059² (1.5 mm)
Limit .071² (1.8 mm)

Std .039² (1.0 mm)
Limit .032² (0.8 mm)

Ex

Std .047² (1.2 mm)
Limit .032² (0.8 mm)

Ex .2341-.2346² (5.945-5.960 mm)
In 0.0014-0.0024² (0.035-0.062mm)
Ex 0.0016-0.0026² (0.040-0.067mm)

Limit .0059² (0.15 mm)

In 3.979² (101.0 mm)
Ex 3.987² (101.2 mm)
Std 1.673² (42.5 mm)
Limit -- -- --

A

3.2

ENGINE

gggpp

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g

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p

g

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ES32PFE10 ENGINE SER
DAT

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

A

Cylinder / Piston / Connecting Rod ES32PFE10

Cylinder

Piston Outer diameter

Piston Pin

Piston Ring Piston ring installed gap Top r i ng

Piston Ring Standard clearance -

Connecting Rod

Crankshaft

Surface warpage limit (mating with cylinder
head)

Cylinder bore Std 3.0906-3.0913² (78.50-78.520 mm)
Taper limit .0020² (0.050 mm)
Out of round limit .0020² (0.050 mm)
Piston clearance

Boring limit .0020² (0.5 mm)

Standard inner diameter of piston pin bore .7095-.7097² (18.007-18.013 mm)
Outer diameter .7092--.7095² (18.001-18.007 mm)
Standard clearance-piston pin to pin bore 0.0-.0005² (0.0-0.012 mm)
Degree of fit Piston pin must be a push (by hand) fit at 68°

piston ring to ring groove

Connecting rod small end ID .7095-.7101² (18.007-18.023 mm)
Connecting rod small end radial

clearance

Connecting rod big end side clear­ance

Connecting rod big end bearing
clearance

Crankshaft runout limit (PTO end) 0.0024² (0.060 mm)
Crankshaft end play 0.002-0.008² (0.05-0.20 mm)

VICE

Std 3.0881-3.0891² (78.438-78.462 mm)
.0098² (.25 mm)OS3.0980-3.0989² (78.688-78.712 mm)

.0197² (.50 mm)OS3.1078-3.1087² (78.938-78.962 mm)

Second
ring

Oil ring

Top r i ng

Second
ring

.0020² (0.050 mm)

Std .0015-.0032² (0.038-0.082 mm)
Limit .004² (0.11 mm)

F(20° C)
Std .0079-.0118² (0.20-0.30 mm)
Limit .039² (1.0 mm)
Std .0138-.0197² (0.35-0.50 mm)
Limit .039² (1.0 mm)
Std .0079-.0236² (0.20-0.60 mm)
Limit .059² (1.5 mm)
Std .0014-.0030² (0.035-0.075 mm)
Limit .0059² (0.15 mm)
Std .0010-.0026² (0.025-0.065 mm)
Limit .0059² (0.15 mm)

Std 0.0-.0009² (0.0-0.022 mm)
Limit .0012² (0.03 mm)
Std .0028-.0118² (0.07-0.30 mm)
Limit .0138² (0.35 mm)
Std 0.0007-0.0021² (0.019-0.053 mm)
Limit 0.0026² (0.065 mm)

3.3

ENGINE

SPECIAL T

PART NUMBER TOOL

PV--43527 Oil Filter Wrench

OOLS

DESCRIPTION

2200634 Valve Seat

Reconditioning Kit

2870390 Piston Support

Block

2870159 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 Fit­tings

Oil Delivery Pi­pe

Oil Drain Bolt
(Crankcase)

Oil Filter Pipe
Fitting (Con­nector)

6mm 5-6.5 (7-9 Nm)

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 Cov­er

Oil Relief Valve
Plug

Recoil Housing 6mm 5-6.5 (7-9 Nm)

Rocker Cover 6mm 7-8 (9-11 Nm)

Rocker Cover
Block Plug

Rocker Adjus­ter Screw Lock
Nut

Stator Plate 6mm 5-6.5 (7-9 Nm)

Starter Motor 6mm 5-6.5 (7-9 Nm)

Spark Plug 14mm 9-11 (12-15 Nm)

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

PA

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

23

1

Cylinder Head
Cylinder Base

7

3

4

5

1

2

4

Crankcase

5

6mm

6

9

11

10

8

6

3.4

ENGINE

PISTON IDENTIFICA

The piston may have an 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
numbers or letters on all rings (except oil control rings)
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 ank Cover / Front Cab (Refer to

Chapter 5)

G Fuel Tank (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 entering the
intake port.

11. Loosen auxiliary brake master cylinder mount if
necessary for clearance.

12. Refer to PVT System Chapter 6 to remove outer
clutch cover, drive belt, drive clutch, driven clutch,
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.

3.5

ENGINE

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
the daily 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 Clean clutch sheaves thoroughly and

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

6)

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

Season Synthetic Oil, or API certified
“SH” oil.

G Use fuel with a minimum octane of 87

(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 spring loaded glaze breaker for honing is not
advised for nicasil cylinders. Polaris recommends
using a rigid hone or arbor honing machine.

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

HONING TO DEGLAZE

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

G Use a motor speed of approximately

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

G Release the hone at regular intervals

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

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

G After honing has been completed,

inspect cylinder for thinning or
peeling.

IMPORTANT: Clean the Cylinder After

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

Honing

3.6

ENGINE

If cylinder wear or damage is excessive, it will be
necessary to replace the cylinder. Hone only 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. This may be accomplished
by either boring the cylinder and then finish honing to
the final bore size, or by rough honing followed by
finish honing.

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 - .003² (.05 - .07 mm) for
finish honing. Refer to piston-to-cylinder clearance
specifications on Page 3.2 before honing. Complete the
sizing with fine grit stones to provide the proper
cross-hatch finish and required piston clearance.

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

G Use a motor speed of approximately

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

G Release the hone at regular intervals

and inspect the bore to determine if
it has been 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

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

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

Honing

ENGINE LUBRICATION ­ES32PF10

Oil Type Polaris Premium 0--40W Synthetic.....

(PN 2871281)

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 0W--40 Synthetic
(Oil temp at 122_F50_C)

OIL PRESSURE TEST
ES32PF10

WARNING: Oil temperature and pressure can cause
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.

3.7

ENGINE

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

Top Bracket

To Engine

Inlet Hose

Hose Clamps

NOTE: Use Polaris Premium 0--40W Synthetic
Engine Lubricant (PN 2871281).

Fan Motor

Screws

Shroud

Thermistor

Oil Cooler

Lower Bracket

Rubber

Mounts

U--Clips

3.8

ENGINE

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

In

Engine Sump

Oil Pickup

Screen

Pressure Relief

Oil Pump

Crankcase

Oil Passage

Bypass

Out

Oil Filter

Crankcase

Oil Passage

Oil Cooler

3.9

ENGINE

ES32PFE ENGINE EXPLODED

Crankcase

ES32PF

VIEW

Cylinder/

Cylinder Head

Crankshaft
and Piston

Valve Train

3.10

ENGINE

ENGINE REMOV

AL

REFER TO PAGE 3.5 - 3.6 FOR ENGINE

REMOVAL / INSTALLATION

NOTES.

CAM CHAIN TENSIONER
REMOV

1. Remove ignition timing inspection plug 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.

AL

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.

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 align with gasket surface and the
cam lobes should be pointing down and valves
should have clearance at this point.

Sprocket marks

align with gasket

surface

CAM CHAIN TENSIONER
INSPECTION

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

B

A

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

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

3.11

ENGINE

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

Tensioner Spring Free Length:

2.06² (5.23 cm) Std.

1.92² (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.:

ENGINE

CAMSHAFT REMOVAL

1. Remove cam shaft end plug (A).

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

4. Remove sprocket from camshaft and chain.

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

3.13

ENGINE

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. Inspect lobe on end of release lever shaft for wear
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)

3.14

ENGINE

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.

A

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.

3.15

ENGINE

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.

A

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

3. Push valve out, keeping it in order for reassembly
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 split keeper. NOTE:
To prevent loss of tension, do not compress the
valve spring more than necessary.

Y

Valve Spring

Free Length

Ill.1

Coil Fatigue/

Squareness

Ill.2

Valve Spring Length:

Std: 1.673I (42.5 mm)

Squareness:

.075I (1.9 mm)

3.16

5. Remove valve seals. CAUTION: Replace seals

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

VALVE INSPECTION

ENGINE

A

B

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). Compare to
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.

3.17

ENGINE

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

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

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: If valve guides are replaced, valve seats must

be reconditioned. Refer to Valve Seat 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 V alve 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. Remove all carbon deposits from the combustion
chamber, valve seat and valve guide area before
attempting to remove valve guides. CAUTION:
Carbon deposits are extremely abrasive and may
damage the valve guide bore when guides are
removed.

2. Place new valve guides in a freezer for at least 15
minutes while heating cylinder head.

3. Heat cylinder head in an oven or use a hot plate to
bring cylinder head temperature to 212° F (100°
C). CAUTION: Do not use a torch to heat
cylinder head or warpage may result from uneven
heating. Head temperature can be checked with
a pyrometer or a welding temperature stick.

Uneven

Good

Too

Narrow

3.18

ENGINE

4. Follow the manufacturers instructions provided
with the valve seat cutters in the Valve Seat
Reconditioning Kit (PN 2200634). Abrasive stone
seat reconditioning equipment can also be used.
Keep valves in order with their respective seat.

NOTE: Valve seat width and point of contact on the
valve face is very important for proper sealing. The
valve must contact the valve seat over the entire
circumference of the seat, and the seat must be the
proper width all the way around. If the seat is uneven,
compression leakage will result. If the seat is too
wide, seat pressure is reduced, causing carbon
accumulation and possible compression loss. If the
seat is too narrow, heat transfer from valve to seat is
reduced 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 combustion chamber side.
Be careful not to damage guide bore 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
proper depth. Inspect the guide closely 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 guides thoroughly with hot soapy water and
a nylon brush. Rinse and dry with compressed
air. Apply clean engine oil to guides.

VALVE SEAT
RECONDITIONING

1. Install pilot into valve guide.

A

Valve Guide Installed Height

Valve Guide Height:

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

2. Apply cutting oil to valve seat and cutter.

3.19

ENGINE

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.
Look for burrs, nicks, or runout. If the
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%, continue to cut the
seat until all pits are removed and a
new seat surface is evident. NOTE:
Remove only the amount of material
necessary to repair the seat surface.

5. To check the contact area of the seat on the valve

face, apply a thin coating of Prussian Bluet paste
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° cutter to

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

G If the seat is too wide or uneven, use

both top and bottom cutters to
narrow the seat.

G If the seat is too narrow, widen using

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

Bottom - 60° or 75°

Seat - 45° or 46°

Top - 30 °

3.20

(A)

ENGINE

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,
and apply oil or water based lapping compound to
the face of the valve. Lapping is not required with
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.

A

13. Spray electrical contact cleaner into oil passage
a

nd dry using compressed air.

CYLINDER HEAD ASSEMBLY

CAUTION: Wear eye protection during assembly.

NOTE: Assemble the valves one at a time to maintain

proper order.

1. Install new valve seals on valve guides.

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

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.

3.21

ENGINE

CYLINDER HEAD ASSEMBLY CONT’D

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

Y

7. Repeat procedure for remaining valve.

8. When all valves are installed, tap lightly with soft
faced hammer on the end of the valves to seat the
split keepers.

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.

A

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.

3.22

ENGINE

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.

AL

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. Inspect the top of the cylinder for warpage using a
straight edge and feeler gauge.

Cylinder Warpage:

*Using a piston ring pliers: Carefully expand ring

and lift it off the piston. CAUTION: Do not expand the
ring more than the amount necessary to remove it
from the piston, or the ring may break.
*By hand: Placing both thumbs as shown, spread the
ring open and push up on the opposite side. Do not
scratch the ring lands.

4. Repeat procedure for second ring.

.0020² (.05 mm) MAX

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

4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure
in two different directions, front to back and side to
side, on three different levels (1/2² down from top,
in the middle, and 1/2² up from bottom).

1/2² Down From Top of Cylinder

Y

X

Y

X

Y

X

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

1/2² Up From Bottom

3.23

ENGINE

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.

Standard Bore Size:

3.0906-3.0913I (78.50-78.520 mm)

PISTON INSPECTION

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

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)

3.24

ENGINE

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 a thickness gauge. Replace piston and rings
if ring-to-groove clearance exceeds service
limits.

Ring to groove clearance

Piston

Ring

PISTON RING INSTALLED
GAP

1. Place each piston ring inside cylinder using piston
to push ring squarely into place as shown.

Piston ring end gap installed

Feeler Gauge

Cylinder

Piston Ring

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

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

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

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)

Piston Ring Installed Gap

Top Ring

Std: .0079-.0138I (.20-.36 mm)

Limit: .039I (1.0 mm)

Second Ring

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

Limit: .039I (1.0 mm)

Oil Ring

Std: .0079-.0276I (.20-.70 mm)

Limit: .059I (1.5 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.

3.25

ENGINE

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

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

DRIVE

AL/INSPECTION

Starter Drive Bushing Clearance:

Std: .0015²-.004² (.038-.102 mm)

Service Limit:

008² (.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

A

Std. Bushing ID:

.4735²-.4740² (11.11-12.04 mm)

Std. Shaft OD:

.470²-.472² (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. Replace bushing if clearance exceeds
the service limit.

A

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

3. Mark or note position of stator plate on crankcase.

4. Remove bolts and carefully remove stator
assembly, being careful not to damage crankshaft
bushing on stator plate.

3.26

ENGINE

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).

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.

B

A

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

Chain Service Limit:

5.407² (13.7 cm)

Inspect for Areas of

Tooth Wear or Damage

4. Inspect Woodruff key for wear.

5. Replace any worn or damaged parts.

Slotted Nut Socket

(PN 2871293)

3.27

ENGINE

PRESSURE RELIEF VAL

The pressure relief valve opens to relieve 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.

VE

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: 2.175² (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.

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
engine oil to all parts. Do not use gasket sealer 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. Install oil pump on crankcase and torque bolts to 6
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. Support the MAG side crankcase and crankshaft;
press the crankshaft out. Be careful not to
damage the crankcase mating surface or
connecting rod.

3.29

ENGINE

2. Use a feeler gauge to measure the connecting rod
big end side clearance.

Connecting Rod Big End Side Clearance:

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

Limit: .0138 (.35 mm)

2. Measure the width of the connecting rod at the big
end.

Connecting Rod Width:

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

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

4. Measure the O.D. of the crankshaft rod journal in
four places and in two directions away from the oil
hole. Replace the crankshaft if it measures below
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 be aligned 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: 1.6556-1.6560I (41.989-42.000 mm)

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

Oil passage

3.30

CRANKSHAFT
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. Turn the outer race of each bearing.
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 PlastigaugeÒto
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. Place a 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.

Ò

INSPECTION

Ò

across the complete

Ò

.

. 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.

Ò

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

Ò

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
race should fit tightly in the crankcase. The inner race
should be firm with minimal side to side movement
and no detectable up and down movement.

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

3.31

ENGINE

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: To ease crankshaft bearing installation, warm
the crankcase until hot to the t ouch. Place the bearing
in a freezer.

1. Install the crankshaft bearing so the 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 (2.755²) 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____________________

3.32

ENGINE

4. Measure the width of the crankshaft at the

bearing seats or, if PTO bearings are installed, the
width from MAG side bearing seat to the outside
race of the PTO bearings with a micrometer or dial
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
the result of Step 5 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 of connecting rod and cap. Ensure that 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:

008²-.016² (.02-.04 cm)

3.33

ENGINE

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. Remove bolt securing oil strainer to the 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 torque in 3 steps according to the torque
pattern. See Page 3.4.

2. Install oil pump cover . Torque screws to specified
torque.

Oil Pump Cover Screw Torque:

4-5 ft. lbs. (5-7 Nm)

NOTE: Do not use gasket sealer on the pump mating

surfaces.

OILRELIEFVALVE
INSTALLA

Install the oil relief valve, spring, and plug using 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)

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 .

3.34

SPROCKET INSTALLA

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

2871293), tighten the nut to the specified torque.

B

A

Tighten

Slotted Nut Torque:

45 ft. lbs. (61 Nm)

TION

ENGINE

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: Apply clean engine 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 oil ring top rail with the 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. Install the second ring with the “R” mark facing up.
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.

3.35

ENGINE

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

5. Install the piston on the connecting rod with

the pin casting notch facing the rear of engine
(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. (See Caution with Step 3 above). Push the
piston pin in both directions to make sure the clips
are properly seated in the groove.

7. Place the dowel pins in the crankcase and install a
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 gaps are 120
degrees apart from each other before installation.

2. Apply clean engine oil liberally to the cylinder bore
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
rotating the engine to avoid damage to 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.

A

3.36

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. Install the two dowel pins and a new cylinder head
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.

ENGINE

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
to timethe camshaft to the crankshaft,the piston must
be precisely located at T op 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 to time the camshaft and the
dot on the cam chain drive sprocket to establish TDC
(see below, Method 1). It is important to note that this
method can only be used when the stator is removed
and the cam chain drive sprocket is in view. The plate
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)

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.

When the stator assembly is installed, use Method 2.
This method establishes accurate Top Dead Center
(TDC) by aligning the single mark on the flywheel with
the notch in the timing inspection 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 In stallation - Timing Method 1
Refer to Illustration Page 3.39

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

chain drive sprocket is aligned with the crankcase
projection (mark facing downward).

2. Align the single plated link on the cam chain with

the marked tooth of the cam chain drive sprocket.
Use a wire to pull the chain up through the cylinder
and cylinder head, and secure it to hold the chain
in place.

3.37

ENGINE

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,
aligning the plated link on the chain with the dot on
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 Method 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
use the single TDC mark when installing the cam.
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

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: The plate links will not align after engine is
rotated.

3.38

7. Check all cam timing marks to verify proper cam
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.

ENGINE

CAMSHAFT TIMING - METHOD

Method 1 - Camshaft Timing with Stator Removed

Single Plated

Link and Dot on

Cam Sprocket

1

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

Crankcase Projection

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

3.39

ENGINE

CAMSHAFT TIMING - METHOD

Method 2 - Camshaft Timing Using Flywheel TDC Mark

Do not use dot on sprocket

for cam timing

2

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

Advance Marks

Cam Timing

(View through timing inspection hole)

Position crankshaft at TDC

3.40

Do Not Use

Advance Marks

For Cam Timing

Do Not Use

ENGINE

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

B

A

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. Apply a 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. Torque plug to specification.

Tensioner Plug Torque:

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

3. Install the stator plate being careful not to damage
the seal. Align timing reference marks on the
plate and crankcase. Be sure the plate is fully
seated.
NOTE: This is 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. Seal stator wire grommet with Crankcase Sealant
(PN 2871557).

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

3.41

ENGINE

FLYWHEEL INSTALLA

1. Install flywheel, washer , and nut. Torque flywheel
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. Apply engine assembly lube to the cam lobes and
cam follower surfaces.

4. Rotate the engine until the cam lobes are pointing
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. lbs. (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.

3. Install recoil housing.

9. Adjust valves according to the valve adjustment
procedure found in Chapter 2, Maintenance.

10. Install rocker cover block plug.

Rocker Cover Block Plug Torque:

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

11. Install valve adjustment caps with new o-rings.
Tighten securely.

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
12-18².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: The handle must seal tightly on the recoil
housing to prevent water and dirt from entering.

Y/INSPECTION

3.42

ENGINE

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

A

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.

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

6. Hold reel firmly in housing. Pull rope handle until
12-18² of rope is exposed, and hold reel in place.

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.

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.

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

A

9. Unwind rope and inspect for cuts or abrasions.

10. Inspect drive tab on hub return spring for 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.

11. Pull knot out of of recoil reel. Untie knot. Remove
rope from reel.

3.43

ENGINE

RECOIL ASSEMBL

CAUTION: Recoil is under spring tension. A face
shield or eye protection is required during this
procedure.

To install a new spring:

1. Place spring in housing with the end positioned so
the spring spirals inward in a counterclockwise
direction. See photo.

2. Hold spring in place and cut retaining wire.

To reinstall an old spring:

1. Hook outer tab in place in recoil housing and wind
spring in a 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:

Y

Open end here

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 more pre-wind is required, place rope
in notch and add additional turns of pre-wind.

8. Install ratchet pawl and return spring, with long leg
of spring engaged in reel.

9. Reinstall friction plate.
NOTE: The friction plate must be positioned 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.

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.

3.44

ENGINE

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 Loose jets in carburetor or calibration

incorrect for altitude/temperature

G Incorrect float level setting
G PVT system calibrated incorrectly 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

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 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

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

3.45

ENGINE

TROUBLESHOOTING

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 rings worn, 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

Backfiring

G ETC or speed limiter system

malfunction

G Fouled spark plug or incorrect 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

3.46

FUEL SYSTEM/CARBURETION

CHAPTER 4
FUEL SYSTEM/CARBURETION

Exploded View, Mikuni BST 34 Carburetor 4.2...

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

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

Fuel F low Diagram 4.4.......................

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

Carburetor Jetting 4.5........................

Main Jet / Pilot Jet Par t Numbers 4.5...........

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

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

CV Carburetor Operation 4.6-4.7..................

Disassembly Notes, CV Carburetor 4.8-4.9.........

Cleaning, CV Carburetor 4.9..................

Inspection, CV Carburetor 4.10.................

Assembly, CV Carburetor 4.10-4.11.................

Float Adjustment, CV Carburetor 4.11...........

Needle & Seat Leakage Test 4.11...............

Fuel Level 4.12...............................

Fuel Pump Service 4.12.......................

Troubleshooting 4.13..........................

4

4.1

FUEL SYSTEM/CARBURETION

BST 34 CARBURETOR EXPLODED VIEW

8

9

30

10

7

11

44
43

5

29
28

16

18

19

20

33

51

Refer to Page 4.5 for Jet Part Numbers

50

36

35

34

21

39

45

1

23

6

27

24

26
25

52

37

4

40

41

42

13

12

38

14

15

17

2

16

3

47

48

49

31

1

22

3

5

32

Jet Needle
“E” Clip Position

4.2

46

1. Carburetor Assembly

2. Screw

3. Throttle V alve

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

2

42. Plunger Assembly

43. Spring Washer

4

44. Screw

45. Air Jet

46. Cable Guide

47. Spring

48. Ring

49. Adjust Screw

50. Screw and Washer Assy.

51 Plate

52 Screw

FUEL PUMP EXPLODED VIEW

FUEL SYSTEM/CARBURETION

4

5

3

8

5

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

2

1

7

6

4.3

FUEL SYSTEM/CARBURETION

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

L

Fuel Pump

4.4

Fuel Tank Vent

Filter

Carburetor Vent

Carburetor

Fuel Tank

Fitting Screens

Fuel Valve

Engine

FUEL SYSTEM/CARBURETION

SPECIAL TOOLS

PART NUMBER TOOL

DESCRIPTION

2870975 Mity Vac 

Pressure Test Tool

2872314 Carburetor Float

Adjustment Tool

WARNING

Gasoline is extremely flammable and explosive under
certain conditions.

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 the engine

is hot. Severe burns may result.

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
/ 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’s Safety and Maintenance Manual for each
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 main jet 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.

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

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

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

JETTING GUIDELINES

Changes in altitude and temperature affect air density,
which is essentially the amount of oxygen available for
combustion. In low elevations and cold temperatures,
the air is more dense and has more oxygen. In higher
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

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

4.5

FUEL SYSTEM/CARBURETION

CV CARBURETOR SYSTEM
FUNCTION

Carburetor Component Function

System Main

Components

Float

System

(Level Control)

Venting Passages in

Starter
(Choke/En­richment)

Pilot
(Idle System)

Main
System

Inlet Pipe,

Needle and

Seat, Float,

Float Pin

Carburetor,

Vent lines

to frame

Choke Lever,

Cable, Plung-

er, Return

Spring, Carb

Passages

(Starter Jet,

Starter Bleed

Pipe)

Pilot Jet/

Passage-

ways, Pilot-

Mixture

Screw with

Spring

Washer and

Sealing O-

Ring, By-

pass 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 (carbu­retor float
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 systems
All throttle
ranges

All throttle
ranges
Greatest
effect at
low throttle
settings
and idle

Mainly idle
to 1/4
throttle
Minimal ef­fect after
1/2 throttle

1/4tofull
throttle

VENT SYSTEMS - CV
CARBURET

The carburetor float bowl vent lines supply
atmospheric pressure to the float bowl. The lines
must be free of kinks, restrictions and be properly
routed. This allows fuel to flow in the proper amount
and prevents contaminants from entering the
carburetor.

OR

MIKUNI CV CARB
OPERA

The constant velocity carburetor incorporates a
mechanically operated throttle plate and a vacuum
controlled slide valve (vacuum slide). The venturi
cross-sectional area in the carburetor bore is
increased or decreased automatically by the vacuum
slide, which moves according to the amount of
negative pressure (less than atmospheric) present in
the venturi.

A diaphragm attached to the top of the vacuum slide
is sealed to the slide and to the carburetor body
forming two chambers. The chamber above the
diaphragm is connected to the venturi area by a drilled
orifice in the center of the vacuum slide. The chamber
below the diaphragm is vented to atmospheric
pressure by a passage on the air box side of the
carburetor. A spring, installed in the center of the
vacuum slide, dampens the slide movement and
assists the return of the slide.

Throttle
Plate

TION

Diaphragm

Low Pressure
From Venturi

Vacuum
Slide

Air Box
Pressure

From
Air Box

4.6

=AirFlow

Venturi

= Low Pressure

CARBURETOR OPERATION CONT’D

When the throttle plate is opened and engine speed
begins to increase, the pressure in the venturi (and
therefore in the chamber above the diaphragm)
becomes significantly lower than atmospheric.
Atmospheric pressure in the chamber below the
diaphragm forces the diaphragm upward, raising the
slide against spring pressure. When the pressure
above and below the diaphragm are nearly equal, the
slide moves downward under spring pressure.
Raising or lowering the slide increases or decreases
the cross sectional area in the venturi, and therefore
the air velocity in the venturi is kept relatively constant.
This provides improved fuel atomization and optimum
fuel/air ratio.

Diaphragm

Low Pressure
From Venturi

Vacuum
Slide

FUEL SYSTEM/CARBURETION

4

1

6

7

5

2

3

From
Air Box

Throttle
Plate

Venturi

=AirFlow

Note: Diagrams are for explanation of theory only, and are not true
representations of Mikuni BST carburetor.

= Low Pressure

PILOT (IDLE AND SLOW)
SYSTEM

This system supplies fuel during engine operation
with throttle valve closed (1) or slightly opened. The
fuel from float chamber (2) is metered by pilot jet (3)
where it mixes with air coming in through pilot air jet
(4). The mixture then goes up through pilot passage
to pilot screw (5). A part of the mixture is discharged
into the main bore out of bypass ports (6). The
remainder is then metered by pilot screw and
discharged into the main bore through pilot outlet (7).

STARTER SYSTEM (CHOKE

ENRICHMENT)

OR

When the choke cable (1) is activated, the starter
plunger (5) is lifted off the seat.

8

7

3

Fuel is drawn into the starter circuit from the float
chamber (2) through the starter jet (3). Starter jet
meters this fuel, which then flows into starter pipe (4)
and mixes with the air (7) coming from the float
chamber. The mixture, rich in fuel content, reaches
starter plunger and mixes again with the air coming
through a passage (8) extending from underneath the
diaphragm. The rich fuel/air mixture for starting is
discharged through starter outlet (6) in the the main
bore.

5

1

6

4

2

4.7

FUEL SYSTEM/CARBURETION

FLOAT SYSTEM

Fuel enters the float chamber (3) by means of the inlet
pipe and passage, through a screen on the back of the
inlet needle seat (4), and around the inlet needle (2).
As the fuel fills the float chamber, the float (1) rises and
forces the inlet needle against the seat, shutting off
the orifice in the seat. When fuel level is up in float
chamber, floats are up and needle valve remains
pushed up against valve seat. Under this condition,
no fuel enters the float chamber. As the fuel level falls,
floats go down and needle valve unseats itself to
admit fuel into the chamber. In this manner, the
needle valve admits and shuts off fuel alternately to
maintain a practically constant fuel level inside the
float chamber.

1

2

7

A

6

Inlet
Pipe

1

4

3

2

MAIN SYSTEM

As throttle valve (1) is opened, engine speed rises,
and this increases negative pressure in the venturi.
Consequently the vacuum slide (2) moves upward.
The fuel in float chamber (3) is metered by main jet (4),
and the metered fuel enters needle jet (5), in which it
mixes with the air admitted through main air jet (6) to
form an emulsion. The emulsified fuel then passes
through the clearance between needle jet (5) and jet
needle (7), and is discharged into the venturi (A).
Mixture proportioning is accomplished in needle jet
(5); the clearance through which the emulsified fuel
must flow is determined ultimately by throttle position
and vacuum slide height.

5

4

3

CARBURETOR
DISASSEMBLY - MIKUNI

Use the following disassembly, assembly, and
inspection techniques to service a CV carburetor.

1. Remove carburetor diaphragm chamber cover
with a ratchet style screwdriver. DO NOT use an
impact driver to remove the screws or carburetor
may be permanently damaged.

CV

4.8

FUEL SYSTEM/CARBURETION

CARBURETOR DISASSEMBLY CONT’D

2. Remove float bowl and carefully remove the
pressed float pin.

Support Here

NOTE: Be careful not to damage the float pin tower
during the float pin removal. Support the float pin
tower while removing the float pin. This helps to
prevent the float pin towers from breaking off.

3. Remove inlet needle seat retaining screw along
with plate, and carefully remove needle seat.
NOTE: Do not use a pliers to remove the seat or
permanent damage may occur.

4. Remove the pilot mixture screw, spring, flat
washer, and O-Ring. If an anti-tamper plug is
installed over the pilot screw cavity, it must be
removed for access.

O-Ring

Washer

Spring

Pilot Screw

NOTE: The starter jet is not removeable. Upon
disassembly, place the parts in a container for safe
keeping.

Pilot Screw

Starter Jet

CARBURETOR CLEANING

WARNING

Protect eyes from contact with cleaner. Ta ke
appropriate safety measures during these
procedures. Safety glasses and chemical resistant
gloves are required. Should you get cleaner in your
eyes or if you swallow cleaner, seek medical attention
immediately.

Carburetor cleaners can be extremely caustic.
Extended periods of soaking can loosen the adhesive
sealer on the passage drill-way plugs. Do not soak
rubber or plastic components (such as the vacuum
slide diaphragm, needle seat screen, or O-Rings in
caustic cleaning solutions. Irreparable damage may
occur. Do not use agitator--type carburetor cleaning
equipment. Rubber parts must be cleaned with mild
detergent and hot water only.

1. Thoroughly clean the carburetor body , jets, and
all passages with carburetor cleaner or electrical
contact cleaner.

2. If the carburetor is extremely dirty or
contaminated with fuel residue and varnish, soak
for short periods only in carburetor cleaner, and
rinse in hot water.

3. Replace the jets if they have a buildup of fuel
residue or bacterial growth that cannot be
removed. Even a small amount of residue will
reduce the flow characteristics of the jet.

4. V erify all passages and jets are unobstructed by
spraying electrical contact cleaner through the
passages. CAUTION: Do not use wire or welding
tip cleaners as the orifice size may be altered.

5. Use low pressure air to dry carburetor body and
all components.

4.9