Polaris TRAIL BOSS 325 2001 User Manual

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CHAPTER 1 GENERAL INFORMA

Model Identification 1.1...........................

Serial Number Location 1.1.......................

Machine Dimensions 1.2-1.3..........................

Specifications 1.4-1.5................................

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

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

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

Standard Torque Specifications 1.7................

Torque Conversion Table 1.8-1.9......................

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

Conversion Table 1.11.............................

Tap Drill Charts 1.12...............................

Glossary of Terms 1.13-1.14............................

TION

GENERAL INFORMATION

MODEL IDENTIFICATION

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

Machine Model Number Identification

A01AA32AA

Emissions &

Year Designation

Basic Chassis Designation Engine Designation

Model Option

ENGINE DESIGNATION NUMBERS

32 ES32PFE06/07/08 Single, Air Cooled, SOHC 4 Stroke, Electric Start..............

VIN IDENTIFICATION

World Mfg. ID

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

Body Style

Vehicle Descriptor

32A*1P 0 00 000

Engine

Powertrain

Emissions

Check Digit

Model Year

Plant No.

Vehicle Identifier

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.

MACHINE 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)

TRANSMISSION I.D. NUMBER LOCA

TION

The transmission I.D. number is located on top of the transmission case below the shifting bellcranks.

Front

1.1

GENERAL INFORMATION

MACHINE DIMENSIONS

36.25 in 92 cm

FRONT

35.5 in

90.1 cm

45.5 in

115.6 cm

72 in

182.8 cm

1.2

SIDE

13 in

33.02 cm

9.75 in

23.5 cm

48.75 in

123.8 cm

13.5 in

34.2 cm

MACHINE DIMENSIONS

GENERAL INFORMATION

40.6 in

103.1 cm

45.5 in

115.6 cm

REAR

Hitch

10.5 in

26.67 cm

Rock Guard

5.5 in

13.9 cm

34.75 in

88.27 cm

44.6 in

113.3 cm

1.3

GENERAL INFORMATION

Altitud

Below40

+40Fto+80

Meter

0-180

(Feet

)

above1800

Altitud

Below40

+40Fto+80

Meter

0-180

(Feet

)

above1800

Altitud

Meter

0-180

(Feet

)

180

0-370

MODEL: 2001 TRAIL BOSS 325..........

MODEL NUMBER: A01AA32AA. ENGINE MODEL: ES32PFE06/07/08..

CARBURETION

Type BST 31 Mikuni................

Main Jet 145 (06/07)............

Main Jet 120 (08)............

Pilot Jet 50.............

Jet Needle 5F14--3 (06/07)...........

Jet Needle 5F14--2 (08)...........

Needle Jet P-2(829)...........

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

Pilot Air Jet 175..........

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

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

89 Oxygenated

JETTING CHART 06/07

Altitude

Meters

(Feet)

0-1800

(0-6000)

above 1800

(above 6000)

AMBIENT TEMPERATURE

Below 40qF

Below 5qC

150 145

142.5 137.5

JETTING CHART 08

Altitude

Meters

(Feet)

0-1800

(0-6000)

above 1800

(above 6000)

AMBIENT TEMPERATURE

Below 40qF

Below 5qC

115 120

117.5 112.5

+40_Fto+80_F

+5_Cto+26_C

+40_Fto+80_F

+5_Cto+26_C

CLUTCH

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

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

Belt Width (Projected) 1.188I (30.18mm).....

Side Angle (Overall) 26q......

Outside Circumference 40.86 r.12I....

Center Distance 10r.12I (254.5mm)..........

Clutch Offset 0.5I (12.7mm)............

Secondary Spring Black........

Driven Helix 40q.............

ENGINE

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

Displacement 324 cc...............

Bore 3.073I (78mm).......................

Stroke 2.679I (68mm).....................

Valve Clearance In/Ex 0.006/0.006I @ BTDC on compression.......

Cooling Air w/fan assisted oil cooler....................

Lubrication Type Dry Sump............

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

Operating RPMr200 6000 RPM.........

Idle RPMr200 (lights off) 1300 RPM.....

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

Compression Pressure (Std) r15%.......

CLUTCH CHART

Meters

(Feet)

*40_ helix, black driven spring

0-1800

(0-6000)

1800-3700

(6000-12000)

Shift

Weight Spring Helix

10RH Blue/Green 2-2

16 Mod Blue/Green 2-2

Clutch

Driven

1.4

GENERAL INFORMATION

MODEL: 2001 TRAIL BOSS 325............

MODEL NUMBER: A01AA32AA...

ENGINE MODEL: ES32PFE06/07/08....

ELECTRICAL FLUID Capacity Type

Flywheel I.D. None Fuel Tank 3.7 gals. (14.2L)...... ..........

CDI Marking F8T19271 Injector Oil N / A....... .......... .........

Alternator Output 200 Watts Coolant N / A... ............ .........

Ignition Timing 30qr2qBTDC@5000RPM Transmission 11.3 oz. (335 ml)PPS*..... .......

Spark Plug / Gap NGK BKR6E / 0.036I(0.9mm) Gearcase Oil (Front) N / A... .

Lights: Head Dual Beam 60/60 watts Gearcase Oil (Center) N / A......

Tail 8.26 watts Gearcase Oil (Rear) N / A........ .

Brake 26.9 watts Engine Counter Bal. N / A...... . .........

Voltage Regulator LR35 Engine Oil (06/07) 1.9 qts. (1.8L) PP4*.. ...

Electric Start Standard Engine Oil (08) 2.4 qts (2.3L) PP4*....... ...... .

Electronic Speedo N/A Brake (Hand) Dot 3.. .....................

Brake (Foot) Dot 3......................

Front Hubs (AWD) N / A... Shift Selector Box N / A...

*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 II Chain Type 520 O-Ring........ .........

Front Suspension MacPherson Strut Gear Reduction-Low N / A.. .

Tow Capacity 850 lbs. (385.9kg) Gear Reduction-Rev 3.05/1...... .

Turning Radius 60I (152.4cm) Gear Reduction-High 2.68/1.....

Toe Out 1/8I-1/4I (3-6.35mm) Front Drive Ratio N / A........... ....

Ground Clearance 5.5I (13.97cm) Center Drive Ratio N / A.. ...

Front Vertical Travel 6.7I (17.02cm) Final Drive Ratio 1 1/42 80P....

Rear Suspension Progressive Rate Swing Arm Brake (Hand) Single Lever, Hyd. Disc... .......

Rear Travel 9.0I (22.86cm) Brake ( Auxiliary Foot) Hydraulic........

Rear Shock 2I Gas Charged Twin Tube........

Shock Adjustment Cam..

TIRES

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

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

Tire Size - Center N / A.. Tire Pressure - F/R 4/3 lbs..

Total Width 45.5I (115.6cm)........

Total Length 71.5I (181.61cm).......

Total Height 46I (116.84cm)........

Wheel Base 49.5I (125.73cm).......

Weight - Dry 509 lbs. (231 kgs).......

LOAD CAPACITY

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

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

Tongue Weight 30 lbs........

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

OPTIONAL SUSPENSION SPRINGS

SOFT STANDARD FIRM

Rear Compression Spring

Front Strut Spring N/A 7041850-067

7041518-067

175 lb/in.

7041518-067

175 lb/in.

41 lb/in.

7041303-067

250 lb/in.

7041375-067

64 - 113 lb/in.

1.5

GENERAL INFORMATION

TrailB

A01A

A32A

PUBLICATION NUMBERS

Year Model Model No. Owner’s Manual

2001

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

oss 325

9915754 9916381 9916382

Parts

Manual PN

PAINT CODES

PAINTED PART COLOR

DESCRIPTION

Springs Fire Red 72060 P-093

Rims Bright White 2185 P-133

Rack(s) Fire Red 72060 P-093

Fenders, Tank & Tool Box Covers

Bumper Caps, Front Cover, Headlight Pod, Seat and Side Panel

FRAME COLOR - P067 Medium Gloss Black 9440 / 8520147. Order direct from Midwest Industrial Coatings (952-942-1840). Mix as directed.

Bright White 2185 P-133

Porsche Red N/A P-136

DITZLER

NUMBER

Parts

Micro Fiche PN

POLARIS

NUMBER

REPLACEMENT KEYS

Replacement keys can be made from the original key. T o 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.

31XX

Key Series Number

Series # Part Number

31 4110141

32 4110148

67 4010278

68 4010278

27 4010321

28 4010321

1.6

GENERAL INFORMATION

STANDARD TORQUE SPECIFICA TIONS

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

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

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).............. ................ .............

(Nm)

Metric

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

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

SPECIFIC TORQUE VALUES OF FASTENERS

Refer to exploded views in the appropriate section.

1.7

GENERAL INFORMATION

TORQUE CONVERSIONS

Newton Metre to Pound Foot and Pound Inch

1.8

TORQUE CONVERSIONS

Newton Metre to Pound Foot and Pound Inch

GENERAL INFORMATION

1.9

GENERAL INFORMATION

DECIMAL EQUIVALENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

27/64 .4219 1 1 mm = .4331s........................ ................

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

43/64 .6719

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

11.0............

1.10

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 1.383 =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)

S  xR2x H (height) = Cylinder Volume

qCtoqF: 9 (qC + 40) y 5-40=qF qFtoqC: 5 (qF + 40) y 9-40=qC

1.11

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

METRIC TAP DRILL SIZES

Tap S i z e Drill Size Decimal Equivalent Nearest Fraction

3x.50 3x.60 4x.70 4x.75 5x.80 5x.90 6 x 1.00 7 x 1.00 8 x 1.00 8 x 1.25 9 x 1.00 9 x 1.25 10 x 1.25 10 x 1.50 11 x 1. 5 0 12 x 1.50 12 x 1.75

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

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3437

0.339

0.375

0.406

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

1.12

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 = 3/8s or 1 cm). Polaris measures chain length in number of

pitches.

CI: Cubic inches. Clutch Buttons: Plastic bushings which transmit rotation of the clutch to the movable sheave in the drive and driven

clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch

face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive

clutch to close.

Condenser/Capacitor: A storage reservoir for DC voltage. Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported

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

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

out-of-round in the cylinder bore.

Electrical Open: Open circuit. An electrical circuit which isn’t complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load.

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

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

kg/cm 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/in Left Side: Always referred to based on normal operating position of the driver.

: Kilograms per square centimeter.

: Pounds per square inch.

1.13

GENERAL INFORMATION

GLOSSARY OF TERMS

m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the

windings. Mechanical energy is converted to electrical energy in the stator.

mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040s. 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. RPM: Revolutions per minute. 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. Both result in energy conversion to

heat.

Right Side: Always referred to based on normal operating position of the driver. RPM: Revolutions per minute. Secondary Clutch: Driven clutch on chaincase or jackshaft. SeizedPiston: Galling of the sides of 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.

1.14

CHAPTER 2 MAINTENANCE

Periodic Maintenance Chart 2.1-2.2....................

Pre-Ride Inspection 2.2...........................

Recommended Lubricants 2.3.....................

Lubricant and Maintenance Product Numbers 2.4....

Lubrication Charts 2.5-2.6............................

Transmission Lubrication 2.7......................

Torque Stop Adjustment 2.7.......................

Transmission Linkage Inspection 2.8...............

Carburetor Adjustments 2.8-2.11.......................

Fuel System 2.12-2.13.................................

Compression Test 2.14............................

Battery Maintenance 2.15..........................

Electrical 2.16....................................

Air Filter Service 2.17..............................

Air Box Sediment Tube Service 2.17.................

Recoil Housing 2.18...............................

Oil Change/Filter 2.19-2.20.............................

Valve Clearance 2.21-2.22..............................

Steering and Toe Allignment 2.23-2.25...................

Exhaust System Service 2.26.......................

Brake System Service 2.27-2.28.........................

Drive Chain Service 2.29-2.32...........................

Suspension Service 2.33...........................

Wheel Removal/Installation 2.34....................

Tire Inspection 2.35...............................

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. More frequent maintenance is required if vehicle is used for utility work at speeds averaging less than 10 mph. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. HCAUTION: 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. Change oil immediately if oil level begins to rise.

E Emission Control System Service (California).

PERIODIC MAINTENANCE - ENGINE

Frequency

(Whichever comes first)

Item Hours Calendar Miles

(Km)

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

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

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

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

" Air Box Sediment Tube - Daily Drain deposits whenever visible

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

Idle Speed As required As required Adjust

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,

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

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

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)

pump & carburetor. Replace lines every 2 years.

ELECTRICAL

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

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 Polaris Dielectric

Tail Lamp Inspection Daily Daily Check Operation Daily; Apply Polaris Dielectric

Grease to connector when lamp is replaced

Grease to socket when lamp is replaced

Remarks

2.1

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.

H Front Wheel Bearings Annually 12 months Inspect and replace if necessary

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-

placed

" 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/Pedal T ravel Pre-ride Pre-ride Inspect Daily, Pre-Ride Inspection Item

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

Brake System Pre-ride Pre-ride Pre-Ride Inspection Item

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

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

Remarks

PRE-RIDE / DAILY INSPECTION

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

S Tires - check condition and pressures S Fuel and engine oil level S All brakes - check operation and adjustment (includes auxiliary brake) S Throttle - check for free operation and closing S Headlight/Taillight/Brakelight - check operation of all indicator lights and switches S Engine stop switch - check for proper function S Wheels - check for tightness of wheel nuts and axle nuts; check to be sure axle nuts are se-

cured by cotter pins

S Drive chain - condition and slack; refer to drive chain adjustment S Inspect vehicle for any visible signs of oil leakage S Air cleaner element - check for dirt; clean or replace S Steering - check for free operation noting any unusual looseness in any area S Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners

2.2

MAINTENANCE

RECOMMENDED LUBRICANTS - QUICK REFERENCE

LUBRICANTS AND MAINTENANCE PRODUCT PART NUMBERS ARE LISTED ON PAGE 2.4. REFER

TO SPECIFICATIONS CHAPTER 1 FOR CAPACITY INFORMA

Item

Engine Oil Polaris Premium 4

Synthetic, 0W/40

Transmission Polaris Synthetic Gear

Case Lubricant

Brake Fluid Polaris DOT 3 Brake Fluid Fill to indicated level inside reservoir. 2.29

Typ e Notes See

Add to proper level on dipstick. 2.21

Refer to procedures outlined later in this chapter.

TION.

Page

2.7

COLD WEATHER KITS FOR 4 STROKE ATVS

Engine Heater -- PN 2871507

2.3

MAINTENANCE

POLARIS PREMIUM LUBRICANT AND MAINTENANCE PRODUCT PART

Part No. Description

2870791 Fogging Oil

2871281 Engine Oil (Quart) Premium 4 Synthetic 0-W40 (4-Cycle)

2871567 Engine Oil (16 Gallon) Premium 4 Synthetic 0-W40 (4-Cycle)

2871477 Premium Synthetic Gearcase Lubricant (1 Gal.)

2871478 Premium Synthetic Gearcase Lubricant (12 oz.. bottle)

2870465 Oil Pump for Gearcase Oil

2871322 Premium All Season Grease (3 oz.. cartridge)

2871423 Premium All Season Grease (14 oz.. cartridge)

2871460 Starter Drive Grease

2871312 Grease Gun Kit 2871329 Dielectric Grease (Nyogelt)

2870585 Loctitet Primer N, Aerosol, 25g 2871949 Loctitet Threadlock 242 (50ml.) 2871950 Loctitet Threadlock 242 (6ml.) 2871951 Loctitet Threadlock 262 (50ml.) 2871952 Loctitet Threadlock 262 (6ml.) 2871953 Loctitet Threadlock 271 (6ml.) 2871954 Loctitet Threadlock 271 (36ml.) 2870584 Loctitet RC 680-Retaining Compound (10ml. ) 2870587 Loctitet 518 Gasket Eliminator / Flange Sealant (50ml.)

2871326 Premium Carbon Clean 12 oz..

2870652 Fuel Stabilizer 16 oz..

2871957 Black RTV Silicone Sealer (3 oz.. tube)

2871958 Black RTV Silicone Sealer (11 oz.. cartridge)

8560054 Marine Grade Silicone Sealer (14 oz.. cartridge)

2870990 DOT3 Brake Fluid

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

2871557 Crankcase Sealant, 3-Bond 1215

NUMBERS

Engine Lubricant

Gearcase / Transmission Lubricants

Grease / Specialized Lubricants

Additives / Sealants / Thread Locking Agents / Misc.

2.4

LUBRICATION

Apply

4DriveChainPolarisChain

Applytochainlinkplatesandroll

Asrequire

ubeoO

MAINTENANCE

Ill.

Item Lube Rec. Method Frequency*

1 Engine Oil Polaris 0W/40

Synthetic

2 Transmission Polaris Synthet-

ic Gear Case Lubricant

3 Brake Fluid Polaris DOT 3

Brake Fluid

4 Drive Chain Polaris Chain

Lube or O-Ring chain lube

Dipstick

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 Change annually

Fill master cylinder reservoir to indicated level inside reservoir. See page 2.29 .

to chain linkplates and roll-Asrequired

ers

As required. Change fluid every 2 years.

Transmission Dipstick

Full

1. Engine Oil

Parking Brake Lock

3. Brake Fluid

2. Transmission

4. Rear Drive Chain

Operating Range

2.5

MAINTENANCE

LUBRICATION

9. Steering Post

10. Rear Axle Bearings

8. Tie Rod End

11. Swing A rm

5. Front Wheel Bearings

Bushings

7. Front A-Arm Pivot Shaft

Ill.

5 Front Wheel Bear-

ings

6 Ball Joint Polaris All Season

7 Front A-Arm Pivot

Shaft

8 Tie Rod Ends Polaris All Season

9 Steering Post Bush-

ings

10 Rear Axle Bearings Polaris All Season

11 Swing Arm Bush-

ings

Item Lube Rec. Method Frequency*

Sealed; Replace Inspect and replace bearings if necessary Annually ©

Grease¢

Polaris All Season Grease¢

Grease¢

All Season Grease¢

Grease¢

Polaris All Season Grease¢

6. Ball Joint

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

Locate grease fitting on pivot shaft and grease with grease gun.

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

Locate fittings on upper and lower steering post and grease with grease gun.

Locate grease fitting on eccentric and grease with grease gun.

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

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)

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

Mobilegrease Special

2.6

MAINTENANCE

TRANSMISSION LUBRICATION

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

S Be sure vehicle is level before proceeding. S Check vent hose to be sure it is routed properly and unobstructed. S 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:

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

1 1.3 oz. (335 ml)....

TRANSMISSION LEVEL CHECK/CHANGE

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.

TRANSMISSION FLUID CHANGE/TORQUE STOP

AD-

JUSTMENT

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. T orque 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.

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.

Forward

Full

PVT Cover

Transmission Dipstick

Operating Range

Drain Plug

2.7

MAINTENANCE

TRANSMISSION GEARSHIFT LINKAGE ADJUSTMENT, PRELIMINARY

S If shifting problems are encountered, the transmis-

sion linkage should be adjusted.

S 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. Clevis or rod end should be parallel to mounting surface.

S The transmission shift linkage should be periodically

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

S Refer to Transmission chapter for more information.

INSPECTION

CHOKE (ENRICHER) ADJUSTMENT

With the choke control pushed in, the choke plunger must be seated on the fuel passage way in the carburetor. If the plunger is not seated on the fuel passage way inside the carburetor (not enough cable freeplay), the engine will flood or run too rich, causing plug fouling and poor performance.

Linkage rod will rotate 1/8 -1/4 turn if rod ends are tightened properly.

Correctly Tightened

Jam Nut

Parallel

Incorrectly Tightened

Jam Nut

If cable slack is excessive, the choke fuel passage will not open far enough, which may cause cold starting difficulty. Also, the half-choke position used for intermittent applications will not function properly.

1. Locate the boot behind the choke knob and pull it back.

Loosen the friction nut 1 turn or until choke slides freely. Re-install boot.

2. Push the choke knob in to the full off position.

3. Slide boots off in-line cable adjuster and loosen

adjustment locknut.

4. Turn adjuster until the choke knob pulls out over 1/4s.

5. Push on the choke knob lightly while turning the

adjuster the opposite way.

6. Turn the adjuster until the knob contacts the boot.

7. Tighten adjuster nut.

8. Slide boots back over cable adjuster sleeve until they

touch at the middle point of the adjuster.

9. Pull back the choke knob boot and tighten the friction

nut until the choke will maintain a set position. Re-install boot.

Boot

Adjuster Sleeve

Locknut

Boot

2.8

IDLE SPEED ADJUSTMENT

MAINTENANCE

1. Start engine and warm it up thoroughly.

2. Adjust idle speed by turning the idle adjustment screw

in (clockwise) to increase or out (counterclockwise) to decrease RPM. (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.

Idle Speed:

1300 RPM r 200

CV Carburetor

Idle Screw

PILOT SCREW (IDLE MIXTURE) ADJUSTMENT NOTES

Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be permanently dam-

aged.

Start engine and warm it up to operating temperature (about 10 minutes). This is a very important step.

PILOT SCREW ADJUSTMENT

IMPORTANT NOTE: Idle speed is specified with the lights OFF. On the idle speed will drop between 100-150 RPM when the lights are turned on.

1. Connect an accurate tachometer such as the PET

2100DX (P/N 8712100DX) or the PET 2500 (P/N

8712500).

2. Adjust idle speed using the idle speed screw to about

1600 RPM.

3. Turn the pilot screw (mixture screw) in or out slowly

using the pilot screw wrench to obtain the highest idle RPM.

4. Re-adjust idle speed to specified RPM (1300 r100).

5. Again turn the pilot screw in or out slowly to obtain the

highest idle RPM.

6. Turn the pilot screw out (counterclockwise) 1/8 to 1/4

turn.

7. Re-adjust idle speed to specified RPM (1300 r100).

FRONT (Engine)

Pilot Screw

2.9

MAINTENANCE

THROTTLE CABLE FREEPLAY/ ELECTRONIC THROTTLE CONTROL (ETC SWITCH)

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. Slide boot off throttle cable adjuster and jam nut.

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

3. Start engine and set idle to specified RPM.

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

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

5. Turn cable adjuster out until engine RPM begins to

increase.

6. Turn cable adjuster back in until throttle lever has

1/16s (.16 cm) of travel before engine RPM increases (Ill. 2).

7. Tightenlock nut securely and slide boot completely in

place to ensure a water-tight seal.

ADJUSTMENT

Ill. 1

Boot

Adjuster Sleeve

Locknut

Throttle Cable Adjuster

Lock Nut

Boot

Ill. 2

Ill. 3

Direction of travel

1/16s -1/8s

Freeplay

2.10

MAINTENANCE

THROTTLE CABLE FREEPLAY/ ELECTRONIC THROTTLE CONTROL (ETC SWITCH) ADJUSTMENT, CONT

8. Turn handlebars from left to right through the entire

turning range. If idle speed increases, check for proper cable routing. If cable is routed properly and in good condition, repeat adjustment procedure.

ETC switch contacts are closed in fault condition (throttle cable slack).

Switch contacts are open during normal operation

2.11

MAINTENANCE

FUEL SYSTEM

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 smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

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

If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.

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

Never start the engine or let it run in an enclosed area. 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.

FUEL LINES

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.

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 or whenever sediment is visible in the filter.

1. Shut off fuel supply at fuel valve.

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

3. Remove fuel lines from filter.

4. Install new filter and clamps onto fuel lines with arrow

pointed in direction of fuel flow.

5. Install clamps on fuel line.

6. Turn fuel valve ON.

7. Start engine and inspect for leaks.

8. Reinstall fuel tank.

Arrow Indicates Direction of Flow

To Carburetor

2.12

CARBURETOR DRAINING

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

NOTE: The bowl drain screw is located on the bottom left side of the float bowl.

MAINTENANCE

1. Turn fuel valve to the off position.

2. Place a clean container beneath the bowl drain spigot

or bowl drain hose.

3. Turn drain screw out two turns and allow fuel in the

float bowl and fuel line to drain completely.

4. Inspect the drained fuel for water or sediment.

5. Tighten drain screw securely.

6. Turn fuel valve to “on”.

7. Start machine and check for leaks.

8. Replace vent line if removed.

Drain tube attached here

Drain Screw

RES

OFF

Fuel Valve

2.13

MAINTENANCE

COMPRESSION TEST

NOTE: 4-Stroke engines are equipped with an automatic decompressor. Compression readings will vary in pro-

portion to cranking speed during the test. Average compression (measured) is about 50-90 psi during a compression test.

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

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

Cylinder Leakage

Service Limit: 10 % (Inspect for cause if leakage exceeds 10%)

ENGINE MOUNTS

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

FASTENER TORQUE - ENGINE

Check engine fasteners and ensure they are tight.

2.14

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.

The battery is located under the left rear fender.

MAINTENANCE

Inspect the battery fluid level. When the battery fluid nears the lower level, the battery should be removed and distilled water should be added to the upper level line. To remove the battery:

1. Disconnect holder strap and remove cover.

2. Disconnect battery negative (-) (black) cable first,

followed by the positive (+) (red) cable.

CAUTION

Whenever removing or reinstalling the battery , disconnect the negative (black) cable first and reinstall the negative cable last!

3. Disconnect the vent hose.

4. Remove the battery.

5. Remove the filler caps and add distilled water only as needed to bring each cell to the proper level. Do not

overfill the battery.

To refill use only distilled water. T ap water contains minerals which are harmful to a battery.

Do not allow cleaning solution or tap water to enter the battery. It will shorten the life of the battery.

6. Reinstall the battery caps.

7. 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.

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

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

10. Coat terminals and bolt threads with Polaris dielectric grease. 1 1. Reinstall battery cover and holder strap.

Maintain between upper and lower level marks

NOTE: New Battery:

of batterys’ full potential.

Battery must be fully charged before use or battery life will be significantly reduced 10-30%

2.15

MAINTENANCE

SPARK PLUG

1. Remove spark plug high tension lead. Clean plug area

so no dirt and debris can fall into engine when plug is removed.

2. Remove spark plug.

3. Inspect electrodes for wear and carbon buildup. Look

for a sharp outer edge with no rounding or erosion of the electrodes.

4. Clean with electrical contact cleaner or a glass bead

spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used.

5. Measure gap with a wire gauge. Refer to

specifications for proper spark plug type and gap. Adjust gap if necessary by bending the side electrode carefully.

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.

IGNITION TIMING

Recommended Spark Plug:

Refer to Specifications

Spark Plug Torque: 14 Ft. Lbs.

(19 Nm)

Spark Plug Gap

.032 - .036s¢.8 - .9 mm)

Refer to Electrical chapter for ignition timing procedure.

ENGINE-TO-FRAME GROUND

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

Engine Ground Strap

2.16

PREFILTERANDAIRFILTERSERVICE

1. Remove seat.

2. Remove spring clamps securing the airbox lid and

remove lid.

3. Pull foam breather filter out.

4. Loosen clamp and remove filter.

5. Remove foam or mesh pre-filter from main filter.

6. Carefully wash the pre-filter in soapy water and dry

it thoroughly. Replace the pre-filter if the element is torn or damaged.

7. Install dry pre-filter over new main filter and

reinstall.

Mesh Pre-filter

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.

MAINTENANCE

Main Filter

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.

BREATHER HOSE

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

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

Sediment Tube

2.17

MAINTENANCE

RECOIL HOUSING

S Drain the housing periodically to remove moisture. S 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.

S CAUTION: Make sure the manual start handle is ful-

ly 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.

S Water will enter the recoil housing if the starter handle

is disengaged from the rope guide when under water.

S After travelling in wet areas the recoil housing and

starter should always be drained completely by removing the recoil.

S Do not open the crankcase drain unless the engine

has ingested water.

Crankcase Drain

Recoil Drain (above front propshaft)

2.18

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.

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

5. Remove dipstick and check to see that the oil level is in

the normal range. Add oil as indicated by the level on the dipstick. Do not overfill.

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.

OIL AND FILTER CHANGE

MAINTENANCE

1. Place vehicle on a level surface.

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

engine.

3. Clean area around drain plug.

4. Place a drain pan beneath engine crankcase and

remove drain plug. 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.

6. Replace sealing washer on drain plug. NOTE: The

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

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

Recommended Engine Oil:

Polaris Premium 4 All Season Synthetic, 0W-40

Ambient Temperature Range:

-40q Fto120q F

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

Screw in completely to check

Crankcase Drain

Engine Sump Drain Plug - Bottom View

2.19

MAINTENANCE

OIL AND FILTER CHANGE, CONT.

8. Place shop towels beneath oil filter. Using an oil

filter wrench, turn filter counterclockwise to remove.

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

on crankcase.

10. Lubricate O-ring on new filter with a film of engine

oil. Check to make sure the O-ring is in good condition.

1 1. Install new filter and turn by hand until filter gasket

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

12. Remove dipstick and fill sump with 2 quarts (1.9 l) of

Polaris Premium 4 synthetic oil.

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:

Snap Ont PN YA997 or 2 1/2 inch

2.20

VALVE CLEARANCE

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

1. Remove the seat.

MAINTENANCE

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.

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.

325 Valve Plugs

2.21

MAINTENANCE

INTAKE VALVE CLEARANCE ADJUSTMENT

1. Insert a .006s(.15mm) feeler gauge between end of

intake valve stem and clearance adjuster screw.

2. Using a 10 mm wrench and a screwdriver, loosen

adjuster lock nut and turn adjusting screw until there is a slight drag on the feeler gauge.

3. Hold adjuster screw and tighten adjuster lock nut

securely.

4. Re-check the valve clearance.

5. Repeat adjustment procedure if necessary until

clearance is correct with locknut secured.

INTAKE VAL VE CLEARANCE

.006s (.15 mm)

EXHAUST VALVE CLEARANCE ADJUSTMENT

NOTE: The exhaust valve is adjusted the same as the in-

take valve.

1. Insert .006s feeler gauge between end of exhaust

valve stem and adjuster screw.

2. Loosen locknut and turn adjuster screw until there is a

slight drag on feeler gauge.

EXHAUST VALVE CLEARANCE

.006s (.15 mm)

3. When clearance is correct, hold adjuster screw and

tighten locknut securely

4. Re-check the valve clearance.

5. Repeat adjustment procedure if necessary until

clearance is correct with locknut secured.

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.

2.22

MAINTENANCE

STEERING

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

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

WARNING

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

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

TIE ROD END / STEERING INSPECTION

S To check for play in the tie rod end, grasp the steering

tie rod, pull in all directions feeling for movement.

S Repeat inspection for inner tie rod end (on steering

post).

S Replace any worn steering components. Steering

should move freely through entire range of travel without binding.

S 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. T ry to move the wheel and hub by pushing inward and pulling outward.

S If abnormal movement is detected, inspect the hub and

wheel assembly to determine the cause (loose wheel nuts, and spindle nut).

S Refer to the Body/Steering or Final Drive chapter for

more information.

CAMBER AND CASTER

The camber and caster are non-adjustable.

Check for Loose Wheel or Hub

2.23

MAINTENANCE

TOE ALIGNMENT - METHOD 1: STRAIGHTEDGE OR STRING

Be sure to keep handlebars centered. See note below.

NOTE: String

should just touch

side surface of rear

tire on each side of

machine.

Measure from string to rim at front and rear of rim.

Rear rim measurement should be 1/16s to 1/8s (.2 to .3 cm) more than front rim measurement.

NOTE: The steering post 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.

2.24

MAINTENANCE

TOE ALIGNMENT - METHOD 2: CHALK

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 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 face of the front tires

approximately 10s(25.4 cm) from the floor as close to the hub/axle center line as possible. NOTE: It is important that both marks be equally positioned from the ground 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 180q 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 1/8s to 1/4s (.3 to .6 cm) toe out. This means the measurement at the front of the tire (A) is 1/8s to 1/4s (.3 to .6 cm) wider than the measurement at the rear (B).

Chalk Line Measurement “A”

Measurement “B”

TOE ALIGNMENT ADJUSTMENT

7. 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

S Hold tie rod end to keep it from rotating.

S Loosen jam nuts at both ends of the tie rod.

S Shorten or lengthen the tie rod until alignment is as re-

S When the tie rod end jam nuts are tightened, be sure

8. After alignment is complete, torque jam nuts to 12-14 ft. lbs.

(16.6-19.3 Nm).

alignment:

quired t o ac hieve the pr oper toesett ing as s pecified

inMet hod 1(1/16s to 1/8s) or Method 2(1/ 8sto 1/4s).

rod ends are held parallel with steering arm and do not

allow the rod end to contact the arm or damage will oc-

cur to the rod end, and will severely shorten tie rod end

life.

Hold Rod End

Correctly Tightened Jam Nut

Incorrectly Tightened Jam Nut

2.25

MAINTENANCE

EXHAUST PIPE

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 at right.

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 parking brake and block the wheels. Make sure the machine is in neutral and repeat steps 2 and 3. WARNING: SEE BELOW.

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 parking brake and block the wheels. Make sure the machine is in neutral and repeat steps 2 and 3. WARNING: SEE BELOW.

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.

Clean Out Plug

WARNING

S Do not perform this operation immediately after the engine has

been run because the exhaust system becomes very hot.

S Because of the increased fire hazard, make sure that there are

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

S Wear eye protection.

S Do not stand behind or in front of the vehicle while purging the

carbon from the spark arrestor.

S Never run the engine in an enclosed area. The exhaust con-

tains poisonous carbon monoxide gas.

S Do not go under the machine while it is inclined.

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

2.26

MAINTENANCE

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 accordancewith the maintenance schedule and before each ride.

S Keep fluid level in the master cylinder reservoir to the in-

dicated level inside reservoir at all times.

S Use Polaris DOT 3 brake fluid (PN 2870990).

S Check brake system for fluid leaks.

S Check brake for excessive travel or spongy feel.

S Check friction pads for wear, damage and looseness.

S Check surface condition of the disc.

S Inspect thickness of brake pad friction material.

Sight Glass

Max Min

Parking Brake Lock

BRAKE P AD INSPECTION

S Pads should be changed when friction material is worn

to 3/64s (.1 cm), or about the thickness of a dime.

HOSE/FITTING INSPECTION

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

3/64s (.1cm)

Minimum Thickness

2.27

MAINTENANCE

AUXILIARY BRAKE ADJUSTMENT (HYDRAULIC)

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

1. First check foot brake effectiveness by applying a 50

lb. (approx.) downward force on the pedal. The top of the pedal should be at least 1, (25.4mm) above the surface of the footrest (see Ill. 1).

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 worn parts.

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 the Brake chapter.

1/8sto 1/4 Free Play

Ill. 1

50 lbs

1sor greater

Floorboard

2.28

MAINTENANCE

DRIVE CHAIN AND SPROCKET INSPECTION

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

2871079). 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.

Never allow battery acid to contact the drive chain.

SPROCKET INSPECTION

Inspect the sprocket for worn, broken or bent teeth.

To check for wear, pull outward on the chain as shown. Replace sprocket if chain movement exceeds 1/4s (.6 cm).

Drive Chain Lubricant:

Polaris O-Ring Chain Lubricant PN 2871079

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.

Drive Chain Wear Limit, 20 Pitch Length:

Std: 12.5s (32 cm) Wear Limit: 12.875s (32.7 cm)

Service Limit: 1/4s (6mm)

Proper Splicelink Clip Opening Position

Rear Chain Shown

2.29

MAINTENANCE

DRIVE CHAIN ADJUSTMENT, CONCENTRIC SWINGARM

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 importantto maintain proper chain tensionto ensure the bestpossible 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.

be approximately 3/8,(10 mm).

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, (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.

After inspection, again slowly move the ATV forward until all the chain slack is

Delfection should

3/8s (10 mm) Deflection

ADJUSTMENT PROCEDURE - CONCENTRIC SWINGARM

1. Loosen chain guide.

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

3. Loosen caliper mounting bracket bolts located

under the axle.

Loosen Eccentric clamp bolts (Step 2)

2.30

Loosen (2) caliper mounting bracket bolts (Step 3)

MAINTENANCE

ADJUSTMENT PROCEDURE - CONCENTRIC SWINGARM, CONT.

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 (approx. 3/8s, or 10 mm)

Pin Punch

6. Tighten the eccentric clamp bolts to specification.

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

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

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

Eccentric Clamp With Hitch

Torque the nut

Eccentric Clamp Without Hitch

Torque the nut

2.31

MAINTENANCE

ADJUSTMENT PROCEDURE - CONCENTRIC SWINGARM, CONT.

7. Tightencaliper mounting bracket bolts 10-12 ft. lbs.

(14 - 17 Nm)

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 tightestportion of the chain has approximately 3/8, (10 mm) of deflection.

10. Position chain guide to allow 1/8, clearance and

tighten retaining bolt to 5 ft.lbs (7 Nm)

1 1. Re--install chain guards if removed.

Caliper Mount Bracket

10-12 ft. lbs

2.32

SUSPENSION SPRING PRELOAD ADJUSTMENT

Operator weight and vehic le loading aff ect suspension spring preload requir ements . Adjust as necessary.

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.

Check all rear suspension components for wear or damage.

Rear Spring Adjustment Cam

MAINTENANCE

Inspect shock for leakage.

Shock Spanner Wrench

PN 2870872

CONTROLS

Checkcontr ols for pr oper operat ion, positioning and adjustment.

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

Spacer T ab

2.33

MAINTENANCE

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 TABLE

Item Specification

Front Wheel Nuts 20 Ft. Lbs.

Rear Wheel Nuts 50 Ft. Lbs.

Front Spindle Nut 40 Ft. Lbs.

Rear Hub Retaining Nut 80 Ft. Lbs.

WHEEL REMOVAL

1. Stop the engine, place the transmission in gear

and lock the parking brake.

2. Loosen the wheel nuts slightly.

3. Elevate the side of the vehicle by placing a

suitable stand under the footrest frame.

4. Remove the wheel nuts and remove the wheel.

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. Install

as shown at right for front or rear wheels.

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 rear wheel nuts, make sure tapered end of nut goes into taper on wheel.

Front

Flange Nuts: Flat side against wheel

Rear

Tapered nuts - install with tapered side against wheel

2.34

TIRE PRESSURE

Tire Pressure Inspection (PSI - Cold)

Front Rear

4 3

TIRE INSPECTION

CAUTION:

S Maintain proper tire pressure. Refer to the warning tire

pressure decal applied to the vehicle.

MAINTENANCE

S Improper tire inflation may affect ATV maneuverability.

S When replacing a tire always use original equipment

size and type.

S The use of non-standard size or type tires may affect

ATV handling.

Tire Tread Depth

Always replac e t ires when tread depth is wornto 1/8s(3 mm) or less.

WARNING

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

Worn tires can cause an accident. Always replace tires when the tread depth measures 1/8s (.3 cm)

or less.

FRAME, NUTS, BOLTS, FASTENERS

Tread Depth 1/8I (3 mm)

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.

2.35

NOTES

CHAPTER 3 ENGINE

Torque Specifications 3.1.............................

Torque Patterns 3.2.................................

Piston Identification 3.2..............................

Engine Service Data 3.3-3.4.............................

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

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

Cylinder Honing 3.7.................................

Engine Lubrication 3.8...............................

Oil Pressure Test 3.8................................

Lubrication/Oil Flow 3.9-3.10..............................

Engine Exploded View 3.11............................

Engine Top End Disassembly 3.12-3.24......................

Valve Seat Service 3.25-3.30...............................

Engine Bottom End Disassembly 3.31-3.46..................

Crankcase & Bearing Assembly 3.47...................

Crankshaft End Play Inspection 3.47-3.48....................

Engine Assembly/Inspection 3.49-3.62......................

Sealed Recoil Disassembly/Inspection 3.63-3.64..............

Sealed Recoil Assembly 3.65..........................

Spark Plug Fouling Checklist 3.66......................

Troubleshooting 3.67-3.68.................................

ENGINE

TORQUE SPECIFICATIONS

ENGINE TORQUE SPECIFICATIONS

Fastener Size 325

ES32PFE

Ft. Lbs. (Nm)

Camshaft Chain Tensioner Lever 6mm 5-6.5 (7-9 Nm)

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

Camshaft Chain Tensioner Cap 11mm 14-19 (20-25 Nm)

Camshaft Sprocket 10mm 25-29 (34-40 Nm)

Carburetor Adaptor 8mm 12-14 (16-20 Nm)

Connecting Rod 8.5mm 29-33 (39-45 Nm)

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

Crankshaft Slotted Nut (Drive Sprocket) 28mm 35-51 (47-69 Nm)

Cylinder Base Bolts 6mm 5-7 (7-9 Nm)

Cylinder Head Bolts 10mm Refer to Engine

Assembly for torque pro-

cedure

Drive Clutch Bolt 7/16 - 20 40 (55 Nm)

Flywheel 16mm 58-72 (78-98 Nm)

Oil Hose Fittings 1/2 & 9/16 20 (27 Nm)

Oil Delivery Pipe 12mm 11-15 (15-21 Nm)

Oil Drain Bolt (Crankcase) 14mm 14-17 (19-23 Nm)

Oil Filter Pipe Fitting (Connector) 20mm 36-43 (49-59 Nm)

Oil Line Fitting 20 (27 Nm)

Oil Pump Cover 6mm 4-5 (5-7 Nm)

Oil Relief Valve Plug 14mm 14.5-16.5 (20-23 Nm)

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

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

Rocker Cover Block Plug 28mm 39-44 (53-59)

Rocker Adjuster Screw Lock Nut 6mm 6-7 (8-10 Nm)

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)

3.1

ENGINE

ENGINE FASTENER TORQUE PATTERNS

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

6mm

Cylinder Head

Cylinder Base

Crankcase

PISTON IDENTIFICATION

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. Oversize Available*

(mm)

ES32PFE .25

.50

Pistons and rings marked 25 equal .25mm (.010I)oversized Pistons and rings marked 50 equal .50mm (.020I)oversized

3.2

Piston Length Standard Piston

Identification

mm None

ES32PFE ENGINE SERVICE DATA

pgg

Cylinder Head / Valve ES32PFE

Rocker Arm

Camshaft Cam lobe height In

Cylinder Head

Valve Seat Contacting width In

Valve Guide

Valve Margin thickness In

Valve

Valve Spring Free length

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

Rocker shaft OD .8656-.8661s (21.987-22.0 mm)

Rocker shaft Oil Clearance

Camshaft journal OD

Camshaft journal bore ID

Camshaft Oil clearance

Surface warpage limit .0020s (.05 mm)

Standard height 2.908s (73.8 mm)

Inner diameter .2362-.2367s (6.000-6.012 mm)

Protrusion above head .690-.709s (17.5-18.0 mm)

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

Stem oil clearance Std

Overall length

Squareness .059s (1.5 mm)

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

Limit .0039s (.10 mm)

Std 1.2955-1.2995s (32.881-32.981 mm)

Limit 1.2837s (32.581 mm)

Std 1.2955-1.2995s (32.881-32.981 mm)

Limit 1.2837s (32.581 mm)

Mag 1.4935-1.4941s (37.935-37.950 mm)

PTO 1.4935-1.4941s (37.935-37.950 mm)

Mag 1.4963-1.4970s (38.005-38.025 mm)

PTO 1.4963-1.4970s (38.005-38.025 mm)

Std .0022-.0035s (.055-.090 mm)

Limit .0039s (.10 mm)

Std .039s (1.0 mm)

Limit .055s (1.4 mm)

Std .059s (1.5 mm)

Limit .071s (1.8 mm)

Std .039s (1.0 mm)

Limit .032s (0.8 mm)

Std .047s (1.2 mm)

Limit .032s (0.8 mm)

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

In 0.0014-0.0024s (0.035-0.062mm)

Ex 0.0016-0.0026s (0.040-0.067mm)

Limit .0059s (0.15 mm)

In 3.979s (101.0 mm)

Ex 3.987s (101.2 mm)

Std 1.655s (42.0 mm)

Limit 1.576s (40.0 mm)

ENGINE

3.3

ENGINE

gggpp

ggg

ES32PFE ENGINE SERVICE DATA

Cylinder / Piston / Connecting Rod ES32PFE

Cylinder

Piston Outer diameter

Piston Pin

Piston Ring Piston ring installed gap To p r i ng

Piston Ring Standard clearance -

Connecting Rod

Crankshaft

Surface warpage limit (mating with cylinder head) .0020s (0.050 mm)

Cylinder bore Std 3.0732-3.0740s (78.000-78.020 mm)

Taper limit .0020s (0.050 mm)

Out of round limit .0020s (0.050 mm)

Piston clearance

Boring limit .0020s (0.5 mm)

Std 3.0707-3.0717s (77.938-77.962 mm)

.0098s (.25 mm) OS 3.0806-3.0815s (78.188-78.212 mm)

.0197s (.50 mm) OS 3.0905-3.0914s (78.438-78.462 mm)

Standard inner diameter of piston pin bore .7095-.7097s (18.007-18.013 mm)

Outer diameter .7092--.7095s (18.001-18.007 mm)

Standard clearance-piston pin to pin bore 0.0-.0005s (0.0-0.012 mm)

Degree of fit Piston pin must be a push (by hand)

Second ring

Oil ring

Top r ing

pistonringtoringgroove

Second ring

Connecting rod small end ID .7095-.7101s (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) 0.0024s (0.060 mm)

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

Std .0015-.0032s (0.038-0.082 mm)

Limit .004s (0.11 mm)

fitat68q F(20q C)

Std .0079-.0138s (0.20-0.35 mm)

Limit .039s (1.0 mm)

Std .0138-.0197s (0.35-0.50 mm)

Limit .039s (1.0 mm)

Std .0079-.0276s (0.20-0.70 mm)

Limit .059s (1.5 mm)

Std .0014-.0030s (0.035-0.075 mm)

Limit .0059s (0.15 mm)

Std .0010-.0026s (0.025-0.065 mm)

Limit .0059s (0.15 mm)

Std 0.0-.0009s (0.0-0.022 mm)

Limit .0012s (0.03 mm)

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

Limit .0138s (0.35 mm)

Std 0.0007-0.0021s (0.019-0.053 mm)

Limit 0.0026s (0.065 mm)

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

3.4

ENGINE

ACCESSIBLE COMPONENTS

The following components can be serviced or The following components require engine removed with the engine installed in the frame: removal for service:

SFlywheel SConnecting Rod

SAlternator/Stator SCrankshaft

SStarter Motor/Starter Drive SCrankshaft Main Bearings

SCylinder Head SCrankcase

SCylinder

SPiston/RIngs

SOil pump

SCamshaft

SRocker Arms

SCam Chain and Sprockets

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.

SSeat SLeft and Right Side Covers (Refer to Chapter 5) SFuel T ank Cover / Front Cab (Refer to Chapter 5) SFuel Tank (Refer to Chapter 4)

5. Disconnect spark plug high tension lead.

6. Remove springs from exhaust pipe and remove pipe.

7. Drain engine oil.

8. Remove airbox.

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

10. Loosen auxiliary brake master cylinder mount, if necessary for clearance.

1 1. Refer to PVT System to remove outer clutch cover, drive belt, drive clutch, driven clutch, and inner

cover.

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

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

14. Remove engine to chassis ground cable.

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

16. Remove engine through right side of frame.

3.5

ENGINE

ENGINE INSTALLATION NOTES

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

General Items

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

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

PVT System

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

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

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

Transmission

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

Exhaust

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

2. 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.

1. Use only Polaris Premium 4 All Season synthetic oil, or API certified “SH” oil.

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

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

3.6

ENGINE

CYLINDER HONE SELECTION/HONING PROCEDURE

Selecting a hone which will straighten as well as remove material from the cylinder is very important. Using a common spring loaded finger type glaze breaker for honing is never advised. Polaris recommends using a rigid hone or arbor honing machine which also has the capability of oversizing.

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

CAUTION:

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 - .003s (.05 - .07 mm) for finish honing. Refer to piston-to-cylinder clearancespecifications on page 3.4 before honing. Complete the sizing with fine grit stones to provide the proper cross-hatch finish and required piston clearance.

EXAMPLE OF CROSS HATCH PATTERN

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

SUse 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 1/2s (1.3 cm) beyond the bore at the end of each stroke.

SRelease the hone at regular intervals and inspect the bore to determine if it has been cleared, and to check

piston fit.

IMPORTANT:

CLEANING THE CYLINDER AFTER HONING

It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder in a solvent, then in hot, soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting. Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris Premium 4 Synthetic 0-W40 lubricant.

3.7

ENGINE

ENGINE LUBRICATION - ES32PF

Oil Type Polaris Premium 4 Synthetic (PN 2871281); or API certified “SH” 5W30...........................

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

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

Filter Wrench Snap On PN YA997 or equivalent......................

Drain Plug / Screen Fitting 14 ft. lbs. (19 Nm)..........

Oil Pressure Specification (ES32PF) 71-99 PSI @ 3000 RPM, Polaris 0W/40 Synthetic..

(Oil temp at 122_F-50_C)

OIL PRESSURE TEST - ES32PF

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

Blind Plug

NOTE:Use Polaris Premium 4 Synthetic Engine Lubricant.

ES32PF

Oil Pressure at 3000 RPM (Engine Hot):

Standard: 71-99 PSI Minimum: 20 PSI

3.8

ENGINE

OIL FLOW -- ES32PF

The ES32PF engine is equipped with a thermostatically controlled valve that directs oil returning to the engine through a cooler when the oil is hot. V alve operation is described below. The chart on page 3.10 describes the flow of oil through the ES32PF engine and oil cooler. Beginning at the engine sump, the oil flows through a screen in the bottom of the crankcase into the feed side of the oil pump. Oil then passes through the crankcase oil passage to the inlet hose, and on to the oil cooler thermo valve. The thermo valve directs oil back to the crankcase if oil temperature is low. If oil temperature is hot, the thermo valve directs oil through the oil cooler first, and then back to the crankcase. After passing through the crankcase passage, oil is pumped through to the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.

At this point, the oil is diverted in two directions. Oil is supplied to the camshaft through the right front cylinder head bolt passage and into the camshaft through the camshaft journal. The camshaft journals, cam lobes, and rocker arms are lubricated through holes in the camshaft. Splashed oil lubricates the cam chain, sprocket, and valve springs, and drains to the sump.

The other oil path from the filter leads to the crankcase main oil passage, which leads to the crankshaft. An oil seal on the stator plate prevents oil from entering the stator/flywheel area. Oil travels through the crankshaft to the crank pin, lubricating the connecting rod large end bearing directly. Oil also passes through an oil jet (drilled orifice) in the end of the crank pin to the PTO end main bearings.

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

NOTE:The oil lines and clamps are designed for high pressure. DO NOT SUBSTITUTE. Use genuine Polaris oil lines and clamps.

Oil Cooler Mounted Thermo Valve

3.9

ENGINE

OIL FLOW DIAGRAM - ES32PF

Small End Bearing

Cylinder Sleeve

Main Bearing

Large End Bearing

Crank Pin

Crankshaft

Piston

Oil Jet (Fixed)

Connecting Rod

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

Bypass

Indirect Lubrication

Through Front Right Cylinder Head Bolt Passage

Engine Sump

Oil Pickup Screen

3.10

Pressure Relief

Oil Pump

Crankcase Oil Passage

Oil Filter

Crankcase Oil Passage

Out

Oil Hoses

Thermo Valve

Oil Cooler

ES32PFE ENGINE EXPLODED VIEW

ENGINE

Crankcase

ES32PFE06/07/08

EARLY ES32PFE06

Cylinder/ Cylinder Head

Crankshaft and Piston

Valve Train

3.11

ENGINE

ENGINE REMOVAL

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

CAM CHAIN TENSIONER REMOVAL

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.

TDC Mark

Rotation

Single TDC Mark Aligned

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.

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.

Sprocket marks align with gasket surface

3.12

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.

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.

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

ENGINE

Tensioner Spring Free Length:

2.06s (5.23 cm) Std.

1.92s (4.88 cm) Limit

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

3.13

ENGINE

ROCKER ARM/SHAFT INSPECTION

1. Remove breather box.

2. Remove rocker cover.

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

4. 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.

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

Wave washer

Inspect surface of followers

PTO

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

Rocker Shaft O.D.:

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

Cylinder block plug

3.14

ROCKER ARM/SHAFT INSPECTION, CONT.

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

Rocker Arm & Support I.D.:

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

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

ENGINE

Rocker Shaft Oil Clearance:

Std: .0008-.0021I (.020-.054 mm) Limit: .0039I (.10 mm)

9. 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.

3.15

ENGINE

CAMSHAFT REMOVAL

1. Remove cam shaft end plug (A).

2. Remove camshaft sprocket flange bolt and washer.

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

4. Remove sprocket from camshaft and chain.

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

3.16

CAMSHAFT REMOVAL, CONT.

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

7. Remove camshaft.

ENGINE

Inspect for Areas of Tooth Wear or Damage

Return spring (spacer)

Release lever

Dowel pin

3.17

ENGINE

AUTOMATIC COMPRESSION RELEASE REMOVAL/INSPECTION

NOTE: The automatic compression release mecha-

nism 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.

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.

Lobe

AUTOMATIC COMPRESSION RELEASE INSTALLATION

1. Slide spring onto shaft.

2. Apply engine oil to release lever shaft.

3.18

CAMSHAFT INSPECTION

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

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

3. Measure height of each cam lobe using a micrometer.

Compare to specifications.

ENGINE

Cam Lobe Height (Intake & Exhaust):

Std: 1.2955-1.2995I (32.881-32.981 mm) Limit: 1.2837I (32.581 mm)

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

Camshaft Journal O.D.:

Mag & PTO End: 1.4935-1.4941I (37.935-37.950 mm)

5. Measure ID of camshaft journal bore.

Camshaft Journal I.D.:

Mag & PTO End: 1.4963-1.4970I (38.005-38.025 mm)

Lubrication holes

Lobe height

Journal O.D.

Journal

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.

3.19

ENGINE

CYLINDER HEAD REMOVAL

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

8. 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.

9. Remove cylinder head and head gasket.

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.

3.20

CYLINDER HEAD WARPAGE

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:

.002s (.05 mm)

CYLINDER HEAD DISASSEMBLY

ENGINE

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.

2. Remove spring retainer and spring.

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

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

3.21

ENGINE

CYLINDER HEAD DISASSEMBLY, CONT.

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.

Valve Spring Length:

Std: 1.654I (42.0 mm) Limit: 1.575I (40.0 mm)

Squareness:

.059I (1.5 mm)

Valve Spring Free Length

Ill.1

Coil Fatigue/ Squareness

Ill.2

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.

3.22

VALVE INSPECTION

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

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

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

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

ENGINE

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

Valve Stem Diameter:

Intake: .2343-.2348I (5.950-5.965 mm) Exhaust: .2341-.2346I (5.945-5.960 mm)

Measure valve stem in several places.

3.23

ENGINE

VALVE INSPECTION, CONT.

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

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

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

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.

3.24

ENGINE

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 3.26. If the valve

seat is cracked the cylinder head must be replaced.

Cylinder Head Reconditioning

NOTE: Servicing the valve guides and valve seats requires special tools and a thorough knowledge of recondi-

tioning techniques. Follow the instructions provided in the cylinder head service tool 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 212q F (100q 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.

3.25

ENGINE

VALVE SEAT RECONDITIONING, CONT.

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

NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. The valve must contact the valve seat over the entire circumference of the seat, and the seat must be the proper width all the way around. If the seat is uneven, compression leakage will result. If the seat istoo 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.

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

2. Using valve guide driver, drive guides out of the cylinder head from the combustion chamber side. Be careful not to damage guide bore or valve seat when removing guides.

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

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

Too Wide

Uneven

Good

Too Narrow

Valve Guide Height:

.689-.709I (17.5-18.0 mm)

Reaming The Valve Guide

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

6. Clean guides thoroughly with hot soapy water and a nylon brush. Rinse and dry with compressed air. Apply clean engine oil to guides.

Valve Guide Installed Height

3.26

VALVE SEAT RECONDITIONING, CONT.

1. Install pilot into valve guide.

2. Apply cutting oil to valve seat and cutter.

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

4. Inspect the cut area of the seat. SIf the contact area is less than 75% of the circum-

ference of the seat, rotate the pilot 180q and make another light cut.

SIf 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.

SIf 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.

SIf 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 Blue¥ pasteto the valve seat. If using an interference angle (46q) apply black permanent marker to the entire valve face (A).

6. Insert valve into guide and tap valve lightly into place afewtimes.

ENGINE

(A)

3.27

ENGINE

VALVE SEAT RECONDITIONING, CONT.

7. Remove valve and check where the Prussian Blue¥ 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).

SIf 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 30q cutter to lower the valve seat.

SIf too low use the 60q or 75q cutter to raise the seat.

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

SIf the seat is too wide or uneven, use both top and bot-

tom cutters to narrow the seat.

SIf the seat is too narrow, widen using the 45q cutter

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

(B)

(A)

Proper Seat Contact On Valve Face

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.

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.

Bottom - 60q or 75q

Seat Width

Seat - 45q or 46q

Top - 3 0q

3.28

VALVE SEAT RECONDITIONING, CONT.

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.

1 1. 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.

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

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

ENGINE

CYLINDER HEAD ASSEMBL Y

CAUTION: Wear eye protection during assembly.

NOTE: Assemble the valves one at a time to maintain

proper order.

1. Install new valve seals on valve guides.

2. Apply engine oil to valve guides and seats.

3. Coat valve stem with molybdenum disulfide grease.

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

3.29

ENGINE

CYLINDER HEAD ASSEMBLY, CONT.

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

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.

Closely spaced coils toward cylinder head

VALVE SEALING TEST

1. Clean and dry the combustion chamber area.

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

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

3.30

ENGINE BOTTOM END DISASSEMBLY

ENGINE

CYLINDER REMOV

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.

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

4. Rock cylinder forward and backward and lift it from the crankcase, supporting piston and connecting rod. Support piston with piston support block PN 2870390.

5. Remove dowel pins from crankcase.

3.31

ENGINE

PISTON REMOVAL

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.

*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.

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

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

6. Remove the expander.

3.32

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:

.002s (.05 mm)

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 (1/2s down from top, in the middle, and 1/2s up from bottom).

ENGINE

1/2s Down From Top of Cylinder

1/2s Up From Bottom

3.33

ENGINE

CYLINDER INSPECTION, CONT.

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:

3.0732-3.0740I (78.000-78.020 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.

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

Piston to Cylinder Clearance

Std: .0015-.0032I (.038-.082 mm) Limit: .004I (.11 mm)

Piston O.D.:

Std: 3.0707-3.0717I (77.938-77.962 mm)

5mm

Piston

Piston Pin

3.34

PISTON INSPECTION, CONT.

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.

ENGINE

Piston Pin O.D.

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

5. Measure connecting rod small end ID.

Connecting Rod Small End I.D.

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

Piston Pin Measurement Locations

3.35

ENGINE

PISTON INSPECTION, CONT.

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.

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

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

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 reboring a cylinder or when installing new rings. A rebored 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.

Cylinder

Ring to groove clearance

Piston

Ring

Feeler Gauge

Piston ring end gap installed

Feeler Gauge

25-50mm

Piston Ring

3.36

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.

STARTER DRIVE REMOVAL/INSPECTION

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.

ENGINE

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

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

Std. Bushing ID:

.4735s-.4740s (11.11-12.04 mm)

Std. Shaft OD:

.470s-.472s (11.93-11.99 mm)

Starter Drive Bushing Clearance:

Std: .0015s-.004s (.038-.102 mm)

Service Limit:

.008s (.203 mm)

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

3.37

ENGINE

FLYWHEEL/STATOR REMOVAL/INSPECTION

1. Remove flywheel nut and washer.

2. Install flywheel puller (PN 2870159) and remove flywheel. CAUTION: Do not thread the puller bolts into the flywheel more than 1/4s or stator coils may be damaged.

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

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

5. Replace crankshaft seal.

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

3.38

CAM CHAIN/TENSIONER BLADE

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

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

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

ENGINE

Measure 20 Pitch Length

Chain Service Limit:

5.407s (13.7 cm)

3.39

ENGINE

DRIVE SPROCKET REMOVAL / INSPECTION

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

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

3. Inspect sprocket teeth for wear or damage.

4. Inspect Woodruff key for wear.

5. Replace any worn or damaged parts.

Slotted Nut Socket

PN 2871293

Remove

PRESSURE RELIEF VALVE

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.

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

Relief Valve Spring Free Length:

Std: 2.175s (5.52 cm)

3. Inspect valve for wear.

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

Inspect for Areas of Tooth Wear or Damage

3.40

OIL PUMP REMOVAL/INSPECTION

1. Remove the five screws on the oil pump cover with an impact driver.

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.

Pump End Clearance:

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

Wear Limit: .004 (.1016 mm)

ENGINE

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

Outer Feed Rotor to Crankcase Clearance:

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

Wear Limit: .004 (.1016 mm)

5. Measure rotor tip clearance with a feeler gauge.

Rotor Tip Clearance:

Std: .005 (.127 mm)

Wear Limit: .008 (.2032 mm)

3.41

ENGINE

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.

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.

3.42

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.

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

Connecting Rod Big End Side Clearance:

ENGINE

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

Limit: .0138 (.35 mm)

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.

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

Connecting Rod Width:

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

3.43

ENGINE

CRANKSHAFT INSPECTION, CONT.

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.

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.

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.

Oil passage

2. Replace bearings if they fail visual inspection.

3.44

Polaris TRAIL BOSS 325 2001 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual