Polaris Trail Boss 330 (2009) Service manual

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Page 1

GENERAL INFORMATION

PartShark.com

877-999-5686

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

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

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

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

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

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

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

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

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

Specs

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

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

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

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

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

1.1

Page 2

GENERAL INFORMATION

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MODEL IDENTIFICATION

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

Machine Model Number Identification

A09CA32AA

Emissions &

Year Designation

Basic Chassis Designation Engine Designation

Model Option

ENGINE DESIGNATION

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

VIN IDENTIFICA

World Mfg. ID

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

Body Style

TION

Vehicle Descriptor

Powertrain

ENGINE SERIAL NUMBER LOCA

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

UNIT MODEL NUMBER AND SERIAL NUMBER LOCA

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)

NUMBERS

Vehicle Identifier

32A* 9P 0 00 000

Emissions

Engine

Check Digit

Model Year

Plant No.

Individual Serial No.

TION

* This could be either a number or a letter

TION

Front

TRANSMISSION I.D. LOCA

TION

NUMBER

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

1.2

Page 3

PUBLICATION NUMBERS

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GENERAL INFORMATION

Year Model Model No. Owner’s

Manual PN

2009 Trail Boss 330 A09CA32AA 9921784 9921774

2009 Trail Blazer 330 A09BA32AA 9921773 9921787

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

NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com or purchased from www.purepolaris.com.

PAINT

FRAME COLOR - P067 Medium Gloss Black 9440 / 8520147.

REPLACEMENT

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

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

CODES

31XX

KEY COVER

P/N 5433534

Key Series Number

KEYS

Series #

20 4010278

21 4010278

22 4010321

23 4010321

27 4010321

28 4010321

31 4110141

32 4110148

67 4010278

68 4010278

Part Number

Parts

Manual PN

1.3

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GENERAL INFORMATION

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

MODEL NUMBER: A09CA32AA. ENGINE MODEL: ES32PFE..

Category Dimension

Length 75 in./191 cm

Width 46 in./117 cm

Height 46 in./117 cm

Wheel Base 49.5 in./125.73 cm

Ground Clearance 5.5./13.97 cm

Dry Weight 505 lbs./230 kg

Gross Vehicle Weight 845 lbs./383 kg

Front Rack Capacity

Rear Rack Capacity

Towing Capacity

Hitch Tongue Weight

Body Style

75 lbs./34 kg

125 lbs./57 kg

850 lbs./385 kg

85 lbs./14 kg

Gen IV

1.4

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

MODEL NUMBER: A09CA32AA. ENGINE MODEL: ES32PFE..

Engine

Platform Fuji 4 stroke, Single Cylinder

Engine Model Number EH32PFE

Engine Displacement 329cc

Number of Cylinders 1

Bore & Stroke (mm) 78.5 x 68 mm

Compression Ratio 9.2:1

Compression Pressure 70--90 psi

Engine Idle Speed 1300 ± 100 Rpm

Cooling System/Capacity Oil/ Air w/ fan assist

Overheat Warning HOT Light on Panel

Lubrication Wet Sump

Oil Requirements Polaris 2W--50

Exhaust System USFS Approved

1.9qts./1.8 ltr

Carburetion

Carburetor model Mikuni BST 34mm

Main Jet 122.5

Pilot Jet 42.5

Jet Needle 4HB48--3

Needle Jet P--4 (829)

Pilot Screw 2 Turns Out

Pilot Air Jet 160

Float Height 13 ± 1 mm (0.51 ± 0.40“)

Fuel Delivery Fuel Pump

Fuel Capacity / Requirement 3.25 gal. (12.3 L)

(Initial starting point, may vary

for each ATV)

87 Octane (minimum)

89 Oxygenated

Electrical

Alternator Output 200 w @ 5000 RPM

Voltage Regulator 3--Phase

Lights : High Beam 2x30 watts

Low Beam 2x30 watts

Brake 26.9 watts

Ta il 8.26 watts

Ignition System DC/CDI Ignition

Ignition Timing 30°±2° BTDC @ 5000 RPM

Spark plug / Gap NGK BKR6E/ .036 in./0.9mm

Battery / Model / Amp Hr Maintenance--Free -- 14 Amp Hr

Circuit Breakers Harness 20 amp

Starting Electric / Recoil Backup

Indicator Panel Standard

Drivetrain

Transmission Type Inline H/N/R

Transmission Capacity 11.3 oz. (335 ml)

Gear Ratio : High

Rev.

Final

Chain Type 520 O-- Ring

Clutch Type PVT Non EBS

Belt 3211077

2.68/1

3.05/1

11/40 78P

Steering / Suspension

Front Suspension / Shock A--arm / MacPherson Strut

Front Travel 8.2 in. / 20.83 cm

Rear Suspension Style / Shock

Rear Travel 10.5 in. / 26.67 cm

Ground Clearance 5.5 in. / 13.97 cm

Shock Preload Adjustment Front / Rear

Turning Radius 83in./211cm

To e O u t 1/8 -- 1/4 in / 3 -- 6.35 mm

Progressive Rate Swingarm /

Twin Tube Gas Charged

Front -- n/a

Rear -- Cam

Wheels / Brakes

Wheel Size -- Front / Pattern 23 x 7 -- 10 / 4-- 156

Wheel Size -- Rear / Pattern 22 x 11 -- 10 / 4-- 102

Air Press. F/R Tires 4 psi Front / 3 psi Rear

Brake -- Front Dual Hydraulic Disc

Brake -- Rear Single Hydraulic Disc

Brake Fluid Polaris DOT 4 Brake Fluid

JETTING CHART

Altitude

Meters

(Feet)

0--1800

(0--6000)

above 1800

(above 6000)

AMBIENT TEMPERATURE

Below 40°F

Below 5°C

127.5 122.5

120

+40°Fto+80°F

+5°Cto+28°C

115

CLUTCH CHART

Driven

Helix

(5131446)

Meters

(Feet)

Altitude

0--1800

(0--6000)

1800--3700

(6000--12000)

Shift

Weight

10 RH

(5630709)

20--40

(5631356)

Drive

Spring

Blu/Grn

(7041157)

Blu/Grn

Driven

Spring

Black

(7041782)

Black

(7041782)(7041157)

45°

2--2

45°

2--2

1.5

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GENERAL INFORMATION

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

MODEL NUMBER: A09BA32AA. ENGINE MODEL: ES32PFE..

Category Dimension

Length 75 in./191 cm

Width 46 in./117 cm

Height 46 in./117 cm

Wheel Base 48 in./121.9 cm

Ground Clearance 5.5./13.97 cm

Dry Weight 488 lbs./221 kg

Gross Vehicle Weight 830 lbs./377 kg

Front Rack Capacity (Accessory)

Rear Rack Capacity (Accessory)

Towing Capacity

Hitch Tongue Weight (Accessory)

Body Style

30 lbs./13.6 kg

60 lbs./27.2 kg

850 lbs./385 kg

85 lbs./14 kg

Gen III

1.6

Page 7

GENERAL INFORMATION

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

MODEL NUMBER: A09BA32AA. ENGINE MODEL: ES32PFE..

Engine

Platform Fuji 4 stroke, Single Cylinder

Engine Model Number ES32PFE

Engine Displacement 329cc

Number of Cylinders 1

Bore & Stroke (mm) 78.5 x 68 mm

Compression Ratio 9.2:1

Compression Pressure 70--90 psi

Engine Idle Speed 1300 ± 100 Rpm

Cooling System/Capacity Oil/ Air w/ fan assist

Overheat Warning HOT Light on Panel

Lubrication Wet Sump

Oil Requirements Polaris 2W--50

Exhaust System USFS Approved

1.9qts./1.8 ltr

Carburetion

Carburetor model Mikuni BST 34mm

Main Jet 122.5

Pilot Jet 42.5

Jet Needle 4HB48--3

Needle Jet P--4 (829)

Pilot Screw 2 Turns Out

Pilot Air Jet 160

Float Height 13 ± 1 mm (0.51 ± 0.40“)

Fuel Delivery Fuel Pump

Fuel Capacity / Requirement 3.25 gal. (12.3 L)

(Initial starting point, may vary

for each ATV)

87 Octane (minimum)

89 Oxygenated

Electrical

Alternator Output 200 w @ 5000 RPM

Voltage Regulator 3--Phase

Lights : Head 55 watts

Brake 26.9 watts

Ta il 8.26 watts

Ignition System DC/CDI Ignition

Ignition Timing 30°±2° BTDC @ 5000 RPM

Spark plug / Gap NGK BKR6E/ .036 in./0.9mm

Battery / Model / Amp Hr Maintenance--Free -- 14 Amp Hr

Circuit Breakers Harness 20 amp

Starting Electric / Recoil Backup

Indicator Panel Standard

Drivetrain

Transmission Type Inline H/N/R

Transmission Capacity 11.3 oz. (335 ml)

Gear Ratio : High

Rev.

Final

Chain Type 520 O-- Ring

Clutch Type PVT Non EBS

Belt 3211077

2.68/1

3.05/1

11/40 78P

Steering / Suspension

Front Suspension / Shock A--arm / MacPherson Strut

Front Travel 8.2 in. / 20.83 cm

Rear Suspension Style / Shock

Rear Travel 10.5 in. / 26.67 cm

Ground Clearance 5.5 in. / 13.97 cm

Shock Preload Adjustment Front / Rear

Turning Radius 83in./211cm

To e O u t 1/8 -- 1/4 in / 3 -- 6.35 mm

Progressive Rate Swingarm /

Twin Tube Gas Charged

Front -- n/a

Rear -- Cam

Wheels / Brakes

Wheel Size -- Front / Pattern 23 x 7 -- 10 / 4-- 156

Wheel Size -- Rear / Pattern 22 x 11 -- 10 / 4-- 102

Air Press. F/R Tires 4 psi Front / 3 psi Rear

Brake -- Front Dual Hydraulic Disc

Brake -- Rear Single Hydraulic Disc

Brake Fluid Polaris DOT 4 Brake Fluid

JETTING CHART

Altitude

Meters

(Feet)

0--1800

(0--6000)

above 1800

(above 6000)

AMBIENT TEMPERATURE

Below 40°F

Below 5°C

127.5 122.5

120

+40°Fto+80°F

+5°Cto+28°C

115

CLUTCH CHART

Driven

Helix

(5131446)

Meters

(Feet)

Altitude

0--1800

(0--6000)

1800--3700

(6000--12000)

Shift

Weight

10 RH

(5630709)

20--40

(5631356)

Drive

Spring

Blu/Grn

(7041157)

Blu/Grn

Driven

Spring

Black

(7041782)

Black

(7041782)(7041157)

45°

2--2

45°

2--2

1.7

Page 8

GENERAL INFORMATION

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SPECIAL TOOLS

PART NUMBER

PA --44689 Valve Clutch Adjuster 2

2870872 Shock Spanner Wrench 2, 5

8712100DX or 8712500 Tachometer 2,10

2200634 Valve Seat Reconditioning Kit 3

2870390 Piston Support Block 3

2870159 Flywheel Puller 3

2871293 Slotted Nut Socket 3

PV-- 43527 OIl Filter Wrench 3

2872314 Carburetor Float Adjustment Tool 4

2870975 Mity Vact Pressure Test Tool 4, 9

2870871 Ball Joint Replacement Tool 5

2870623 Shock Absorber Spring Compression Tool 5

2871573 LH Strut Spring Compressor 5

2871574 RH Strut Spring Compressor 5

2870506 Clutch Puller 6

9314177 Clutch Holding Wrench 6

2871358 Clutch Holding Fixture 6

2870341 Drive Clutch Spider Removal and Install Tool 6

2870654 Clutch Offset Alignment Tool 6

2870913 Driven Clutch Puller 6

2870910 Roller Pin Tool 6

2871226 Clutch Bushing Replacement Tool Kit 6

2870386 Piston Pin Puller 6

8700220 Clutch Compression Tool 6

2871710 10” Center Distance Tool 8

PV-- 43568 Fluket 77 Digital Multimeter 10

2870630 Timing Light 10

2870836 Battery Hydrometer 10

8712100 or 8712500 Tachometer 10

TOOL DESCRIPTION CHAPTER TOOL USED IN

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

1.8

Page 9

GENERAL INFORMATION

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STANDARD TORQUE SPECIFICATIONS

The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering,

suspension, and engine sections.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

Torque 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 / Torque

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

1.9

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GENERAL INFORMATION

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SAE TAP DRILL SIZES

Thread Size/Drill Size

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

Thread Size/Drill Size

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

METRIC TAP DRILL SIZES

Tap Size

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

Drill Size Decimal

Equiva-

lent

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

0.0995

0.0937

0.1285

0.125

0.166

0.161

0.196

0.234

0.277

0.265

0.3125

0.3437

0.339

0.375

0.406

Nearest

Fraction

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

DECIMAL EQUIVALENTS

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

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

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

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

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

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

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

1/8. .1250...

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

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

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

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

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

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

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

1/4 .25....

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

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

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

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

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

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

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

3/8 .375....

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3/4 .75....

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

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

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

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

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

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

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

7/8 .875....

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

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

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

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

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

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

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

11.0.....

1.10

Page 11

CONVERSION TABLE

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877-999-5686

GENERAL INFORMATION

Unit of Measure

ft. lbs. x12 =in.lbs.

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

ft. lbs. x 1.356 =Nm

in. lbs. x .0115 =kg-m

Nm x .7376 = ft.lbs.

kg-m x 7.233 = ft. lbs.

kg-m x 86.796 =in.lbs.

kg-m x10 =Nm

in. x 25.4 =mm

mm x .03937 =in.

in. x2.54 =cm

mile (mi.) x1.6 =km

km x .6214 = mile (mi.)

Ounces (oz) x 28.35 = Grams (g)

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

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

Grams (g) x 0.035 = Ounces (oz)

lb. x .454 =kg

kg x 2.2046 =lb.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Multiplied by Converts to

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

1.11

Page 12

GENERAL INFORMATION

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GLOSSARY OF TERMS

ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8″ or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as itmoves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive

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

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

out-of-round in the cylinder bore.

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

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

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

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

lbs/in2: Pounds per square inch. Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the

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

mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040″. Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch System) qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. SeizedPiston: Galling of the sides of a piston. Usually there is a transferof aluminum from the piston ontothe cylinder wall.

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

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

1.12

Page 13

MAINTENANCE

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877-999-5686

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

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

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

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

Lubricant and Maintenance Quick Reference 2.10-2.11

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2.1

Page 14

MAINTENANCE

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PERIODIC MAINTENANCE CHART

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

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

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

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

Severe Use Definition

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

Maintenance Chart Key

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

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

by an authorized Polaris dealer.

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

(Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race - style high rpm use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is required under these conditions. Fluid changes, cable, chain and chassis lubrication are required more frequently. For engine oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A rising oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.)

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

procedures, have a qualified dealer perform these operations.

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

WARNING: Improperly performing the procedures marked with a to serious injury or death. Have an authorized Polaris dealer perform these services.

J could result in component failure and lead

2.2

Page 15

MAINTENANCE AND LUBRICATION

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Periodic Maintenance Chart

MAINTENANCE

Item

Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)

Steering

Front suspension

Rear suspension Tires

Brake fluid level

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

Engine oil level

Air filter, pre-filter

Air box sediment

tube Coolant

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

Daily

Make adjustments as needed.

Inspect; clean often

Drain deposits when visible

Check level daily, change coolant every 2 years

(if applicable) Headlamp/tail

lamp

Air filter,

main element Recoil housing

Daily

Weekly

Check operation; apply dielectric grease if replacing

Inspect; replace as needed

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

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

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

Front gearcase oil

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

(if equipped)

Middle gearcase

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

oil (if equipped)

Rear gearcase oil

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

(if equipped)

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

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

Remarks

2.3

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item

Engine breather

filter (if equipped)

Engine oil change

(break-in)

General lubrication

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

Steering 50 H 6M 310 (500) Lubricate

Front suspension 50 H 6M 310 (500) Lubricate

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

bowl

Throttle Cable/

ETC Switch

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

E E

Carburetor air intake ducts/ flange

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

(if applicable)

Engine oil change 100 H 6M 620

Oil filter change 100 H 6M 620

Oil tank vent hose 100 H 12 M 620

Valve clearance 100 H 12 M 620

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

Maintenance Interval

(whichever comes first)

Hours Calendar Miles

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

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

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

50 H 6M 310 (500) Drain bowl periodically and prior to storage

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

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

50 H 6M 310 (500) Inspect coolant strength

(Km)

(1000)

seasonally; pressure test system yearly

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

Replace with oil change

Inspect routing, condition

Inspect; adjust

Remarks

2.4

Page 17

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Periodic Maintenance Chart

MAINTENANCE

Item

Fuel system 100 H 12 M 620

Fuel filter 100 H 12 M 620

Radiator (if applicable)

Cooling hoses (if applicable)

Engine mounts 100 H 12 M 620

Exhaust muffler/ pipe

Spark plug 100 H 12 M 620

Ignition Timing 100 H 12 M 620

Wiring 100 H 12 M 620

Clutches (drive and driven)

Front wheel bearings

Brake fluid 200 H 24 M 1240

Spark arrestor 300 H 36 M 1860

Idle speed

Toe adjustment

Auxiliary brake

Headlight aim

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

Maintenance Interval

(whichever comes first)

Hours Calendar Miles

100 H 12 M 620

100 H 12 M 1000

(Km)

(1000)

(1600)

(2000)

(3000)

Remarks

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

Replace yearly

Inspect; clean external surfaces

Inspect for leaks

Inspect

Inspect; replace as needed

Inspect

Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

Inspect; clean; replace worn parts

Inspect; replace as needed

Change every two years

Clean out

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

placed Inspect daily; adjust as needed

Adjust as needed

2.5

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POLARIS LUBES/FLUIDS FOR TRAILBOSS 330 MODELS

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

2.6

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POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS

Part No.

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol)

2876244 Engine Oil (Quart) Premium 4 Synthetic

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

2876245 Engine Oil (Gallon) Premium 4 Synthetic

Gearcase / Transmission Lubricants

2873602 Premium Synthetic AGL Gearcase Lube

2873603 Premium Synthetic AGL Gearcase Lube

2876160 Premium ATV Angle Drive Fluid

2872276 Premium ATV Angle Drive Fluid

2870465 Oil Pump for 1 Gallon Jug

2871654 Premium Demand Drive Hub Fluid

Grease / Specialized Lubricants

2871322 Premium All Season Grease

2871423 Premium All Season Grease

(14 oz. cartridge) (10 Count)

2871460 Starter Drive Grease (12 Count)

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

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

2871312 Grease Gun Kit

2871329 Dielectric Grease (Nyogelt )

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

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

Description

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

(12 oz. bottle) (12 Count)

(1 Gal.) (4 Count)

(32 oz.) (12 Count)

(2.5 Gal) (2 Count)

(8 oz.) (12 Count)

(3 oz. cartridge) (24 Count)

Coolant

Part No.

Additives / Sealants / Thread Locking Agents /

2874275 Loctitet Primer N, Aerosol

2871956 Loctitet Thread Sealant 565

2871950 Loctitet Threadlock 242

2871951 Loctitet Threadlock 262

2871953 Loctitet Threadlock 271

2871326 Premium Carbon Clean

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

2871957 Black RTV Silicone Sealer

2871958 Black RTV Silicone Sealer

(11 oz. cartridge) (12 Count)

2872189 DOT 4 Brake Fluid (12 Count)

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

NOTE: The number count indicated by each part

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

Description

Misc.

(50 ml.) (6 Count)

(6 ml.) (12 Count)

(50 ml.) (10 Count)

(6 ml.) (12 Count)

(12 oz.) (12 Count)

(3 oz. tube) (12 Count)

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

POLARIS LUBRICANT SYMBOL IDENTIFICAT

2W/50

Polaris Sythetic OW--40 Oil

DHF

Polaris Demand Drive Hub Fluid

Polaris DOT 4 Brake Fluid

AGL

Polaris Sythetic Gearcase Lube

AGL

ADF

Polaris ATV Angle Drive Fluid

U--Joint

Polaris U-- Joint Lube

Polaris All Season Grease

2.7

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PRE-RIDE / DAILY INSPECTION

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

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

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

COLD WEATHER KITS FOR 4 STROKE A

Engine Heater -- (PN 2871507)

ACCESSORY ENGINE HEATER

TVS

2.8

Page 21

TRAIL BOSS 330 COMPONENT LOCATIONS

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Brake Fluid Reservoir

Brake Lever

Light Control & Run Switch

Fuel Valve

Front Rack

Reverse Override

Rear Axle & Drive Sprocket

Choke

MAINTENANCE

Display

Throttle

Ignition/Key

Headlights

Transmission

Engine Recoil

Right Side View

Oil Dipstick

Muffler

Auxiliary Brake

PVT Cover

Gear Shifter

Front Rack

Engine

2.9

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MAINTENANCE QUICK REFERENCE

Ill.

1 Engine Oil Polaris 2W--50

2 Transmission Polaris AGL Lu-

3 Brake Fluid Polaris DOT 3

4 Drive Chain Polaris Chain

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

Item Lube Rec. Method Frequency*

Synthetic

bricant

Brake Fluid

Lube or O-Ring chain lube

Dipstick

2W/50

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

Add lube to FULL level on dipstick.

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

Apply to chain link plates and rollers.

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

Change annually ©

As required. Change fluid every 2 years.

As required*

Transmission Dipstick

AGL

Operating Range

Full

1. Engine Oil

Parking Brake Lock

Reservoir

3. Brake Fluid

2. Transmission

4. Rear Drive Chain

2.10

Page 23

MAINTENANCE QUICK REFERENCE CONT’D

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MAINTENANCE

5. Ball Joint

8. Axle Housing

4. Front Wheel Bearings

6. Tie Rod Ends

7. Swingarm Pivots

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

Ill.

4 Front Wheel Bear-

ings

5 Ball Joint Polaris All Season

6 Tie Rod Ends Polaris All Season

7 Swing Arm Bush-

ings

8 Rear Axle Housing Polaris All Season

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

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

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

Mobilegrease Special

Item Lube Rec. Method Frequency*

Sealed; Replace Inspect and replace bearings if necessary Annually ©

Grease¢

Polaris All Season Grease¢

Grease¢

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

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

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

Locate grease fitting on eccentric and grease with grease gun.

Semi-annually

2.11

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TRANSMISSION LUBRICATION

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

G Be sure vehicle is level before

proceeding.

G Check vent hose to be sure it is

routed properly and unobstructed.

G Follow instructions on following

pages to check / change transmission lubricant.

TRANSMISSION SPECIFICATIONS

Specified Lubricant:

Polaris AGL Gearcase Lubricant:

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

Capacity: 11.3 oz. (335 ml)

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

Transmission

Dipstick

Full

Operating

Range

TRANSMISSION FLUID CHANGE/TORQUE ST

ADJUSTMENT

1. Remove skid plate (if necessary).

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

3. Loosen jam nut (A).

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

5. Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings.

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

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

PVT Cover

To check the level:

1. Remove dipstick and wipe clean.

Forward

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

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

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

2.12

limits. Do not overfill.

10. Check for leaks.

11. ReinstallskidplateifremovedinStep1.

Drain Plug

Page 25

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LUBRICATION / GREASE POINTS

As shown on Page 2.8, there are only five grease zerks on the Trail Boss, two front ball joints, two on the swing are pivots, and one on the rear axle housing.

Swing Arm Pivot

Each Side

Ball Joint Zerk

Each Side

Ball Joint Zerk

TRANSMISSION GEARSHIFT LINKAGE

ADJUSTMENT/

INSPECTION

Linkage rod will rotate

1/8 -1/4 turn if rod ends

are tightened properly.

Parallel

Correctly Tightened

Jam Nut

G If shifting problems are encountered,

the transmission linkage may require adjustment.

G Visually check for contact of shift

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

G Tighten shift linkage rod end jam nuts

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

G The transmission shift linkage

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

G Refer to Transmission chapter for

more information.

Incorrectly Tightened

Jam Nut

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

2.13

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SHIFT LINKAGE ADJUSTMENT

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

2. Place gear selector in neutral.

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

Jam Nuts (A)

Linkage Rod

Ill. 1

THROTTLE OPERATION -

ALL

MODELS

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

1. Place the gear selector in neutral.

2. Set parking brake.

3. Start the engine and let it idle.

4. Turn handlebars from full right to full left. If idle speed increases at any point in the turning range, inspect throttle cable routing and condition. If cable is routed properly and in good condition, repeat adjustment procedure.

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

CHOKE

(ENRICHER)

ADJUSTMENT

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

Boot

If the choke knob does not stay out when pulled, adjust the choke tension by tightening the tensioner located under the rubber boot between the choke

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

knob and nut. Firmly grasp the rubber boot and tighten until the choke slides freely but stays out when pulled.

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

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

2.14

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PILOT SCREW

The pilot system supplies fuel during engineoperation with the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet.

CAUTION:

The pilot screw is calibrated at the factory to meet EPA / CARB regulations for air quality standards and is sealed with a brass plug to prevent tampering. Removal of the tamper proof plug is not permitted. For service purposes, cleaning of the pilot circuit can be done only by a certified repair shop to ensure air quality standards are not exceeded.

Pilot Screw location

PILOT SCREW ADJUSTMENT

FRONT (Engine)

Pilot Screw

View -- Right Cover Panel Removed

Pilot Screw

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

Brass Plug Installed

Brass Plug Removed

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

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

Pilot Screw Adjustment: Trailboss 330 -- 2 Turns Out

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

8712500).

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

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

2.15

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

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

8. Re adjust idle speed if not within specification.

IDLE SPEED

1. Start engine and warm it up thoroughly.

CV Carburetor

ADJUSTMENT

Idle Screw

Idle Speed:

1300 ± 100 RPM

confirm adjustment.

Boot

Adjuster

Sleeve

Direction

of travel

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

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

THROTTLE OPERA

To remove the ETC cover:

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

Lock-

nut

1/16″ -1/8″

Freeplay

TION

Boot

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

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

ELECTRONIC CONTROL (ETC THROTTLE ADJUSTMENT

1. Slide the boots off inline cable adjuster sleeve.

Loosen adjuster locknut.

2. With handlebars centered and wheels pointing

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

THROTTLE

SWITCH)/

CABLE

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

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

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

2.16

Page 29

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damaged.

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

FUEL

Gasoline is extremely flammable and explosive under certain conditions.

SYSTEM

WARNING

G Always stop the engine and refuel

outdoors or in a well ventilated area.

G Do not smoke or allow open flames

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

G Do not overfill the tank. Do not fill the

tank neck.

G If you get gasoline in your eyes or if

you swallow gasoline, seek medical attention immediately.

G If you spill gasoline on your skin or

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

G Never start the engine or let it run in

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

G Never drain the float bowl when the

engine is hot. Severe burns may result.

FUEL

Fuel Pump

Ill.1

1. Check fuel lines for signs of wear, deterioration,

2. Be sure fuel lines are routed properly and secured

3. Replace all fuel lines every two years.

VENT

1. Check fuel tank, oil tank, carburetor, battery and

2. Be sure vent lines are routed properly and

FUEL FIL

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

1. Shut off fuel supply at fuel valve.

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

3. Remove fuel lines from filter.

4. Install new filter and clamps onto fuel lines with

LINES

Fuel Lines

Pulse Line

damage or leakage. Replace if necessary.

with cable ties. CAUTION: Make sure lines are not kinked or pinched.

LINES

transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years.

secured with cable ties. CAUTION: Make sure lines are not kinked or pinched.

TER

arrow pointed in direction of fuel flow.

2.17

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Arrow Indicates Direction

of Flow

RES

OFF

To Carburetor

Fuel Valve

5. Install clamps on fuel line.

6. Turn fuel valve ON.

7. Start engine and inspect for leaks.

CARBURETOR

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

Drain tube

attached

here

Drain Screw

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

1. Turn fuel valve to the off position.

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

DRAINING

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

4. Inspect the drained fuel for water or sediment.

5. Tighten drain screw.

6. Turnfuelvalveto“ON”.

7. Start machine and check for leaks.

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

COMPRESSION

NOTE: This Polaris 4-Stroke engine is equipped with

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

70--90 psi

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

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

during a compression test.

TEST

Cylinder Compression

Standard 70--90 PSI

Cylinder Leakage

Service Limit: 10 %

(Inspect for cause if leakage exceeds 10%)

2.18

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ENGINE MOUNTS

Inspect rubber engine mounts for cracks or damage.

ENGINE FASTENER T

Check engine fasteners and ensure they are tight.

BATTERY

MAINTENANCE

ORQUE

WARNING

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

External: Flush with water.

Internal: Drink large quantities of water or

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

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

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

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

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

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

NEVER attempt to add electrolyte or water to a Maintenance--Free battery. Doing so will damage the case and shorten the life of the battery. Refer to the Battery Maintenance Video (PN 9917987) for proper instruction on servicing Maintenance--Free batteries.

The battery is located under the left rear fender.

Battery

To remove the battery:

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

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

CAUTION

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

3. Remove the battery.

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

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

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

7. Reinstall battery cover and holder strap.

2.19

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SPARK PLUG

330 Engine

Recommended Spark Plug:

NGK BKR6E

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

(12--14 Nm)

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.

Inpsect electrode for wear and buildup

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

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

IGNITION

Refer to Electrical chapter for ignition timing procedure.

ENGINE-TO-FRAME

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

TIMING

Ignition Timing:

30°±2° BTDC@5000RPM

GROUND

Engine Ground Strap

MAIN AIR FILTER CLEANING

Spark Plug Gap

.036″ (.9 mm)

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

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

8. Install spark plug and torque to 9--11 ft. lbs(12--14 Nm).

2.20

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

G Never immerse the filter in water

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

G If compressed air is used never

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

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G Replace the air filter every 50 hours,

and possibly more often in very dirty conditions.

AIR FILTER/PRE-FIL SER

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

The pre filter shouldbe cleaned before eachride using the following procedure:

1. Lift up on the rear of the seat.

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

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

VICE

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

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

TER

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

Installation:

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

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

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

Filter Clamp

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

Ill.1

Cleaning:

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

6. Rinse and dry thoroughly.

7. Inspect element for tears or damage.

ILL.1

Proper Filter Placement

Filter Support

Air Box

Ill.3

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

11. Install air box cover and secure with clips.

Main Filter

Front

2.21

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AIR BOX SEDIMENT TUBE

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

Sediment Tube

NOTE: The sediment tube will require more frequent

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

1. Remove drain plug from end of sediment tube.

2. Drain tube.

3. Reinstall drain plug.

RECOIL HOUSING

G Drain the housing periodically to

remove moisture.

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

G Water will enter the recoil housing if

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

G After travelling in wet areas, the

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

G Do not open the crankcase drain

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

G If recoil handle seal has been

damaged, the handle assembly should be replaced.

PVT DRAIN PLUG & DR

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

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

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

YING

Recoil Drain

G 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.

G CAUTION: Make sure the manual

start handle (B) is fully seated on the

2.22

Ill.3

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

PVT Drain Plug & O--ring

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ENGINE OIL LEVEL

To check the oil level:

1. Set machine on a level surface.

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

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

4. Reinstall dipstick, screwing into place.

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

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

Normal Oil Operating Range is between crosshatch.

OIL AND FILTER

1. Place vehicle on a level surface.

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

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

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

5. Allow oil to drain completely.

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

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

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

CHANGE

Crosshatch Areas of Dipstick

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

Drain plug located under the engine.

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

Recommended Engine Oil:

Polaris Premium 4 All Season

Synthetic, 2W--50

Engine Sump Drain Plug - Bottom View

Crankcase Drain

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

2.23

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

Filter

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

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

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

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

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

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

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

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

16. Dispose of used filter and oil properly.

Crankcase Drain Plug Torque:

14 ft. lbs. (19 Nm)

Oil Filter Torque:

Turn by hand until filter gasket contacts sealing surface, then turn an additional 1/2 turn

VALVE

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

1. Remove the seat.

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

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

4. Remove plastic valve plugs.

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” alignswith pointer. The camshaft lobes should be pointing downward.

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

CLEARANCE

330 Valve Plugs

Oil Filter Wrench:

(PV--43527)

INTAKE VALVE CLEARANCE:

0.006±0.0008I (0.15±0.02 mm) BTDC on compression

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

EXHAUST VALVE CLEARANCE:

INTAKE VALVE CLEARANCE ADJUSTMENT

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

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

330 Engine

0.006±0.0008 BTDC on compression

2. Loosen locknut and turn adjuster screw until there is a slight drag on feeler gauge.

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

4. Re-check the valve clearance.

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

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

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

I (0.15±0.02 mm)

STEERING

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

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

WARNING

NOTE: Due to the critical nature of the procedures

outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an

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

4. Re-check the valve clearance.

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

EXHAUST VAL CLEARANCE

NOTE: The exhaust valve is adjusted the same as the

intake valve.

ADJUSTMENT

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.

2.25

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TIE ROD END / STEERING INSPECTION

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

G Repeat inspection for inner tie rod

end (on steering post).

G Replace any worn steering

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

G If abnormal movement is detected,

inspect the hub and wheel assembly to determine the cause.

G Refer to the Body/Steering or Final

Drive chapter for more information.

CAMBER AND

The camber and caster are non-adjustable.

CASTER

WHEEL ALIGNMENT METHOD: STRAIGHTEDGE OR

Be sure to keep handlebars centered. See notes below.

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

STRING

G Elevate front end of machine so front

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

Check for Loose Wheel or Hub

Measure

from string

to rim at

front and

rear of rim.

NOTE: Thesteeringpostarmcanbeused

as an indicator of whether the handlebars

are straight. The frog should always point

straight back from the steering post.

Rear rim

measure-

ment should

be 1/16″ to

1/8″ (.2to.3

cm) more

than front rim

measure-

ment.

2.26

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WHEEL ALIGNMENT METHOD 2:

1. Place machine on a smooth level surface.

2. Set handlebars in a straight ahead position and secure handlebars in this position. NOTE: The steeringarmcanbeusedasanindicatorof whether the handlebars are straight. The arm should always point straight back from the steering post.

3. Place a chalk mark on the center line of the front tires approximately 10″ (25.4 cm) from the floor or as close to the hub/axle center line as possible. NOTE: It is important that the height of both marks be equally positioned in order to get an accurate measurement.

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

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

6. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8″ to 1/4″ (.3to.6cm) toe out. This means the measurement at the front of the tire (A) is 1/8″ to 1/4″ (.3 to .6 cm) wider than the measurement at the rear (B).

CHALK

TOE ALIGNMENT ADJUSTMENT

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

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

To adjust toe

G Hold tie rod end to keep it from

G Loosen jam nuts atboth end of the tie

G Shorten or lengthen the tie rod until

G Important: When tightening the tie

Rod End

alignment:

rotating.

rod.

alignment is as required to achieve the proper toe setting. Method 1 (1/16″ to 1/8″) or Method 2 (1/8″ to 1/4″).

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

Hold

Correctly

Tightened

Jam Nut

Chalk Line

Measurement

“A”

Measurement “B”

Incorrectly

Tightened

Jam Nut

2.27

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EXHAUST CLEANING

WARNING

G Do not perform clean out immediately

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

G To reduce fire hazard, make sure that

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

G Wear eye protection.

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

hicle while purging the carbon from the spark arrestor.

G Never run the engine in an enclosed

area. Exhaust contains poisonous carbon monoxide gas.

G Do not go under the machine while it is

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

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

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

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

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

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

SEE WARNING ABOVE

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

3. SEE PREVIOUS WARNING

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

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

8. Reinstall the clean out plugs.

BRAKE SYSTEM

INSPECTION

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

Ill.1

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

Clean Out Plug

maintenance schedule and before each ride.

G Keep fluid level in the master cylinder

reservoir to the indicated level inside reservoir.

G Use Polaris DOT 4 Brake Fluid

(PN 2872189).

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Sight Glass

Auxiliary Brake Master Cylinder

G Check brake system for fluid leaks,

excessive travel or spongy feel.

G Check friction pads for wear,

damage or looseness.

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

friction material.

BRAKE PAD

INSPECTION

Parking Brake Lock

AUXILIARY ADJUSTMENT

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

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

1/8, to 1/4, Free Play

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

Free Play:

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

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

Bleeding:

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

BRAKE

(HYDRAULIC)

50 lbs

1″ or greater

Floorboard

DRIVE CHAIN

3/64″

(.1cm)

Minimum

Thickness

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

HOSE/FITTING

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

INSPECTION

SPROCKET

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

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

AND

INSPECTION

2.29

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Never allow battery acid to contact the drive chain.

Service Limit:

1/4″ (6mm)

Proper

Splicelink Clip

Opening

Position

Drive Chain Wear Limit--20 Pitch Length:

Std: 12.5″ (32 cm)

Wear Limit: 12.875″ (32.7 cm)

Drive Chain Lubricant:

Polaris O-Ring Chain Lubricant

(PN 2872073)

SPROCKET

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 1/4″ (.6 cm).

DRIVE CHAIN

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.

INSPECTION

DRIVE CHAIN ADJUSTMENT CONCENTRIC

CAUTION: Never adjust or operate the vehicle

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

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

Checking Deflection: Inspect chain deflection by slowly moving the ATV forward so any slack that may have previously been on the under part of the chain is now on the top side of the chain. The bottom part of the chain should be taught during inspection. Measure the chain deflection as shown in the diagram. Deflection should be approximately 3/8

in. (10 mm).

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

SWINGARM

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

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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.

2. Loosen two eccentric clamp bolts.

3. 2004 Models -- Loosen caliper mounting bracket

bolts.

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

6 for alternate method if 2 1/2 available.

Loosen

Tighten

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

″ wrench is not

Alternate Adjustment Method -- Pin Punch

(Step 5 and 6)

3/8″ (10 mm) Deflection

ADJUSTMENT PROCEDURE CONCENTRIC REAR

AXLE

Loosen (2) caliper

mounting bracket

bolts (Step 3 --

SWINGARM

Loosen Eccentric

clamp bolts (Step 2)

2004 models)

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

7. Tighten the eccentric clamp bolts to specification.

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

Eccentric Clamp Bolt Torque Specs

Pinch Clamp Bolt Torque --

30 ft. lbs. (41 Nm)

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

1. Loosen chain guard.

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Eccentric Clamp Without Hitch

30 ft.lbs. (41 Nm)

Without Trailer Hitch

Eccentric Clamp With Hitch

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

11. Reinstall the chain guard (where applicable). Reposition chain guide to allow 1/8″ (.3 cm) clearance between sprocket and guide.

Chain Guide

SUSPENSION SPRING PRELOAD

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

ADJUSTMENT

Torque to 40 ft.lbs. (54 Nm)

With Trailer Hitch

8. Remove the pin punch.

9. 2004 Models -- Tighten caliper mounting bracket

bolts 10-12 ft. lbs. (14 - 17 Nm).

2004 Models: Caliper Mount Bracket

FRONT SUSPENSION

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

Check all front suspension components for wear or damage.

Inspect front strut cartridges for leakage.

REAR SUSPENSION

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

Rear Spring

Adjustment Ring

10-12 ft. lbs

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

correctly when the tightest portion of the

G Check all rear suspension

components for wear or damage.

G Inspect shock for leakage.

2.32

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Shock Spanner Wrench

(PN 2870872)

CONTROLS

Check controls for proper operation, positioning and adjustment.

WHEEL REMOVAL FRONT OR REAR

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

2. Loosen the wheel nuts slightly.

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

4. Remove the wheel nuts and remove the wheel.

Front Wheel

Front Wheel Nuts (4)

27 ft. lbs. (37 Nm)

Front Spindle Nut

40 ft. lbs. (54 Nm)

G Brake control and switch must be

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

Rear Wheel

Rear Wheel Nuts (4)

50 ft. lbs. (68 Nm)

WHEELS

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

WHEEL, HUB, AND SPINDLE TORQUE T

Item

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

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

Front Spindle Nut 40 Ft Lbs. (54Nm)

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

ABLE

Specification

WHEEL INSTALLATION

1. With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheelhub. 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.

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

Rear Hub Nut

80 ft. lbs. (108 Nm)

Taper end faces wheel for install.

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3. Lower the vehicle to the ground.

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

CAUTION:

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

Tread

Depth 1/8I (3 mm)

TIRE

PRESSURE

Tire Pressure Inspection (PSI - Cold)

Front Rear

4 3

TIRE INSPECTION

WARNING

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

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

measures 1/8″ (.3 cm) or less.

FRAME, NUTS, BOLTS,

ASTENERS

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

CAUTION:

G Maintain proper tire pressure. Refer

to the warning tire pressure decal applied to the vehicle.

G Improper tire inflation may affect ATV

maneuverability.

G When replacing a tire always use

original equipment size and type.

G The use of non-standard size or type

tires may affect ATV handling.

Tire Tread Depth

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

2.34

Page 47

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ENGINE

3.1

Page 48

ENGINE

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ES32PFE10 ENGINE SERVICE DAT

Cylinder Head / Valve

Rocker Arm

Camshaft Cam lobe height In

Cylinder Head

Valve Seat Contacting width In

Valve Guide

Val ve Margin thickness In

Val ve

Valve Spring Free length

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

Camshaft journal OD

Camshaft journal bore ID

Camshaft Oil clearance

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

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

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

Stem oil clearance Std

Overall length

Squareness 0.075″ (1.9 mm)

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

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

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

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

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

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

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

Limit .0059″ (0.15 mm)

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

ES32PFE10

3.2

Page 49

ES32PFE10 ENGINE SERVICE DATA

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ENGINE

Cylinder / Piston / Connecting Rod

Cylinder

Piston Outer diameter

Piston Pin

Piston Ring Piston ring installed gap To p ri ng

Piston Ring Standard clearance -

Connecting Rod

Crankshaft

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

Surface warpage limit (mating with cylinder head)

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

Boring limit .0020″ (0.5 mm)

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

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

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

Second ring

Oil ring

To p rin g

piston ring to ring groove

Second ring

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

clearance

Connecting rod big end side clearance

Connecting rod big end bearing clearance

Crankshaft runout limit (PTO end) 0.0024″ (0.060 mm) Crankshaft end play 0.002-0.008″ (0.05-0.20 mm)

ES32PFE10

.0020″ (0.050 mm)

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

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

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

3.3

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ENGINE

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SPECIAL T

PART NUMBER

PV-- 43527 Oil Filter Wrench

OOLS

TOOL

DESCRIPTION

2200634 Valve Seat

Reconditioning Kit

2870390 Piston Support

Block

2871043 Flywheel Puller

2871293 Slotted Nut Socket

TORQUE SPECIFICATIONS

ENGINE TORQUE SPECIFICATIONS

Fastener Size 330

ES32PFE10

Ft. Lbs. (Nm)

Camshaft Chain Tensioner Lever

Camshaft Chain Tensioner

Camshaft Chain Tensioner Cap

Camshaft Sprocket

Carburetor Adaptor

Connecting Rod

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

Crankshaft Slotted Nut (Drive Sprocket)

Cylinder Base Bolts

Cylinder Head Bolts

Drive Clutch Bolt

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

Oil Hose Fittings

Oil Delivery Pipe

Oil Drain Bolt (Crankcase)

Oil Filter Pipe Fitting (Connector)

6mm 5-6.5 (7-9 Nm)

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

10mm 25-29 (34-40 Nm)

8mm 12-14 (16-20 Nm)

8.5mm 29-33 (39-45 Nm)

28mm 35-51 (47-69 Nm)

6mm 5-7 (7-9 Nm)

10mm Refer to Engine

Assembly for torque pro-

cedure

7/16 - 20 40 (55 Nm)

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

12mm 11-15 (15-21 Nm)

14mm 14-17 (19-23 Nm)

20mm 36-43 (49-59 Nm)

Oil Line Fitting 20 (27 Nm)

Oil Pump Cover

Oil Relief Valve Plug

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

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

Rocker Cover Block Plug

Rocker Adjuster Screw Lock Nut

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

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

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

Thermistor 3--3.6 (4--5 Nm)

6mm 4-5 (5-7 Nm)

14mm 14.5-16.5 (20-23 Nm)

28mm 39-44 (53-59)

6mm 6-7 (8-10 Nm)

ENGINE FASTENER TORQUE

TTERNS

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

Cylinder Head Cylinder Base

Crankcase

6mm

3.4

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ENGINE

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PISTON IDENTIFICATION

The piston may piston may not piston placement. If the piston has an identification

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

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

Engine

Model No.

ES32PFE .25

have an identification mark or the

have an identification mark for

Oversize

Available*

(mm)

.50

Standard

Piston

Identification

None

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

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

ACCESSIBLE

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

G Flywheel

G Alternator/Stator

G Starter Motor/Starter Drive

G Cylinder Head

G Cylinder

G Piston/RIngs

G Oil pump

G Rocker Arms

G Cam Chain and Sprockets

COMPONENTS

The following components require engine removal for service:

G Camshaft

G Connecting Rod

G Crankshaft

G Crankshaft Main Bearings

G Crankcase

ENGINE REMOV

1. Clean work area.

2. Thoroughly clean the ATV engine and chassis.

3. Disconnect battery negative (-) cable.

4. Remove the following parts as required.

G Seat G Left and Right Side Covers (Refer to

Chapter 5)

G Fuel Tank Cover / Front Cab (Refer to

Chapter 5)

G Fuel Tank (Refer to Chapter 4)

5. Disconnect spark plug high tension lead.

6. Disconnect all electrical wires from the engine.

7. Remove springs from exhaust pipe and remove pipe.

8. Drain engine oil.

9. Remove airbox.

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

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

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

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

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

15. Remove engine to chassis ground cable.

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

17. Remove engine through right side of frame.

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ENGINE

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ENGINE INSTALLA

TION

NOTES

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

General Items

G Install previously removed

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

G Perform regular checks on fluid

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

PVT System

G Adjust center distance of drive and

driven clutch. (Chapter 6)

G Adjust clutch offset, alignment, and

belt deflection. (Chapter 6)

G Clean clutch sheaves thoroughly and

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

Transmission

G Inspect transmission operation and

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

Exhaust

G Replace exhaust gaskets. Seal

connections with high temp silicone sealant.

G Check to be sure all springs are in

good condition.

Engine Break In Period

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

G Use only Polaris Premium 4 All

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

G Use fuel with a minimum octane of 87

(R+M)/2 method.

G Change break-in oil and filter at 20

hours or 500 miles, whichever comes first.

CYLINDER

HONE SELECTION/HONING PROCEDURE

CAUTION:

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

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

HONING TO

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

G Use a motor speed of approximately

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

G Release the hone at regular intervals

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

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

G After honing has been completed,

inspect cylinder for thinning or peeling.

IMPORTANT: Clean the Cylinder After

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

DEGLAZE

Honing

3.6

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ENGINE

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

EXAMPLE OF CROSS HATCH PATTERN

HONING TO

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 - .003″ (.05 - .07 mm) for finish honing. Refer to piston-to-cylinder clearance specifications on Page 3.2 before honing. Complete the sizing with fine grit stones to provide the proper cross-hatch finish and required piston clearance.

OVERSIZE

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

IMPORTANT: Clean the Cylinder After

ENGINE LUBRICATION

Honing

ES32PF10

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

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

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

OIl Filter Wrench PV--43527...

Drain Plug/

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

Oil Pressure Specification

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

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

OIL PRESSURE

TEST

G Use a motor speed of approximately

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

G Release the hone at regular intervals

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

G After honing has been completed

inspect all port opening areas for

ES32PF10

WARNING: Oil temperature and pressure can cause

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

1. Remove lower blind plug behind oil filter on

crankcase.

2. Insert a 1/8” NPT oil pressure gauge adaptor into

the crankcase and attach gauge.

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ENGINE

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

ES32PF10

Oil Pressure at 3000 RPM (Engine Hot):

Standard: 71-99 PSI

Minimum: 20 PSI at idle

OIL COOLER ASSEMBL

330 Engine

Lower Bracket

Rubber Mounts

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

Top Bracket

Screws

U--Clips

Shroud

Oil Cooler

36--44 in.lbs.

Thermistor

(4--5 Nm)

Fan Motor

Threaded Cooler Hose

Oil Flow To and From Cooler

3.8

Page 55

OIL FLOW DIAGRAM - ES32PF

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ENGINE

Engine Sump

Oil Pickup

Screen

Small End

Bearing

Cylinder Sleeve

Main Bearing

Large End

Bearing

Crank Pin

Crankshaft

Pressure Relief

Oil Pump

Piston

Oil Jet

(Fixed)

Connecting Rod

Crankcase

Oil Passage

Cam Shaft

Journal

Cam Lobe

Crankcase

Oil Passage

Chain Room

Rocker Arm /

Rocker Shaft /

Sprocket /

Cam Shaft

Oil Passage In

Bypass

Crankcase

Oil Passage

Chain

Journal

Cylinder

Crankcase

Oil Passage

Oil Filter

Indirect

Lubrication

Through Front Right

Cylinder Head Bolt

Passage

Oil Hoses

Out

Oil Cooler

3.9

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ENGINE

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ES32PFE ENGINE EXPLODED

Crankcase

ES32PF

VIEW

Cylinder/

Cylinder Head

Crankshaft and Piston

Valve Train

3.10

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ENGINE

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ENGINE REMOVAL

REFER TO PAGE 3.5 - 3.6 FOR

REMOVAL / INSTALLATION

CAM CHAIN REMOV

1. Remove ignition timing inspection plug from recoil housing.

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

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

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

TDC Mark

TENSIONER

Single TDC Mark Aligned

ENGINE

NOTES.

5. Remove cam chain tensioner plug, sealing

washer, spring and pin. CAUTION: The plug is under spring tension. Maintain inward pressure while removing.

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

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

CAM CHAIN TENSIONER

Rotation

Do Not Use

Advance Marks

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

Sprocket marks

align with gasket

surface

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 plungershould move smoothly in and out of the tensioner body.

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

3.11

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ENGINE

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877-999-5686

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

Tensioner Spring Free Length:

2.02″ (5.13 cm) Std.

1.92″ (4.88 cm) Limit

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

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

Cylinder block

plug

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

ROCKER

ARM/SHAFT

INSPECTION

1. Remove rocker cover.

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

Wave

washer

Inspect surface

of followers

PTO

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

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

Rocker Shaft O.D.:

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

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ENGINE

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Rocker Arm & Support I.D.:

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

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

CAMSHAFT REMOV

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.

Rocker Shaft Oil Clearance:

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

Limit: .0039I (.10 mm)

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

4. Remove sprocket from camshaft and chain.

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

3.13

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ENGINE

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CAMSHAFT REMOVAL CONT’D

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

Inspect for Areas of

Tooth Wear or Damage

7. Remove camshaft.

Lobe

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

3. Inspect shaft for wear or galling.

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

COMPRESSION

TION

INSPECTION

Return spring (spacer)

Release lever

Dowel pin

AUTOMATIC RELEASE INSTALLA

1. Slide spring onto shaft.

2. Apply engine oil to release lever shaft.

CAMSHAFT

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

AUTOMATIC COMPRESSION RELEASE REMOV

AL/

Lubrication holes

INSPECTION

NOTE: The automatic compression release

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

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

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

Limit: 1.2883I (32.723 mm)

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

Limit: 1.2889I (32.739 mm)

Lobe height

Cam Lobe Height

Intake

Exhaust

3.14

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ENGINE

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

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

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

Journal O.D.

Journal

Camshaft Journal O.D.:

Mag & PTO End: 1.4935-1.4941I

(37.935-37.950 mm)

CYLINDER HEAD REMOV

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

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

3. Remove cylinder head and head gasket.

5. Measure ID of camshaft journal bore.

Camshaft Journal I.D.:

Mag & PTO End: 1.4963-1.4970I

(38.005-38.025 mm)

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

Camshaft Oil Clearance:

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

Limit: .0039I (.10 mm)

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

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

CYLINDER HEAD INSPECTION

1. Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon. CAUTION: Use care not to damage sealing surface.

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ENGINE

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CYLINDER HEAD WARP

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

Cylinder Head Warpage Limit:

.002” (.05mm)

AGE

2. Remove spring retainer and spring.

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

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

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

CYLINDER HEAD DISASSEMBL

WARNING: Wear eye protection or a face shield

during cylinder head disassembly and reassembly.

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

1. Using a valve spring compressor, compress the

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

Ill.1

Ill.2

Valve Spring Length:

Std: 1.673I (42.5 mm)

Squareness:

.075I (1.9 mm)

Valve Spring

Free Length

Coil Fatigue/

Squareness

3.16

Page 63

5. Remove valve seals. CAUTION: Replace seals

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

VALVE INSPECTION

ENGINE

4. Inspect split keeper groove for wear or flaring of

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

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

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

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

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

Measure valve stem in

several places.

Valve Stem Diameter:

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

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

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

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7. Subtract valve stem measurement to obtain stem

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

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

VALVE SEAT RECONDITIONING

Valve Seat Inspection

Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be reconditioned. See Valve Seat Reconditioning, Page

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

head must be replaced.

Valve Guide I.D.:

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

NOTE: If valve guides are replaced, valve seats must

be reconditioned. Refer to Valve Seat Reconditioning for procedure.

COMBUSTION

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

CHAMBER

To o

Wide

Cylinder Head Reconditioning

NOTE: Servicing the valve guides and valve seats

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

2200634).

CAUTION: Wear eye protection when performing

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

Valve Guide Removal/Installation

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

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

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

Uneven

Good

To o

Narrow

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

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

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

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

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

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

Reaming The Valve Guide

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

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

VALVE SEA

RECONDITIONING

1. Install pilot into valve guide.

Valve Guide Installed Height

Valve Guide Height:

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

2. Apply cutting oil to valve seat and cutter.

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VALVE SEAT RECONDITIONING CONT’D

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

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

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

G If the cutter now contacts the uncut

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

G If the contact area of the cutter is in

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

G If the contact area of the initial cut is

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

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

face, applya thin coating of Prussian Bluet paste to the valve seat. If using an interference angle (46°) apply black marker to the entire valve face (A).

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

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

(B)

(A)

Proper Seat Contact On Valve Face

G If the indicated seat contact is at the

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

G If too low use the 60° or 75° cutter to

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

G If the seat is too wide or uneven, use

both top and bottom cutters to narrow the seat.

G If the seat is too narrow, widen using

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

Bottom - 60° or 75°

Seat - 45° or 46°

To p - 3 0°

(A)

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

Seat

Width

Valve Seat Width:

Intake Std: .039I (1.0 mm)

Limit: .055I (1.4 mm)

Exhaust Std: .059I (1.4 mm)

Limit: .071I (1.8 mm)

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

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

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

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

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

CYLINDER HEAD ASSEMBL

CAUTION: Wear eye protection during assembly.

NOTE: Assemble the valves oneat 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.

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

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CYLINDER HEAD ASSEMBLY CONT’D

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

Closely spaced

coils toward

cylinder head

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

ENGINE BOTTOM DISASSEMBL

Cylinder Removal

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

1. Remove cam chain guide at front of cylinder.

2. Remove the two 6 mm cylinder base bolts.

END

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

7. Repeat procedure for remaining valve.

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

VALVE SEALING

1. Clean and dry the combustion chamber area.

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

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

TEST

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

5. Remove dowel pins from crankcase.

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PISTON 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.

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

6. Remove the expander.

CYLINDER INSPECTION

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

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

Cylinder Warpage:

.0020″ (.05 mm) MAX

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

4. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure in two different directions, front to back and side to side, on three different levels (1/2″ down from top, in the middle, and 1/2″ up from bottom).

1/2″ Down From Top of Cylinder

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

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.

1/2″ Up From Bottom

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CYLINDER INSPECTION CONT’D

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

Cylinder Taper

Limit: .002 Max.

Cylinder Out of Round

Limit: .002 Max.

Cylinder Standard Bore Size:

3.0906-3.0913I (78.50-78.520 mm)

PISTON

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.

INSPECTION

3. Measure piston pin bore.

Piston Pin Bore:

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

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

5mm

Piston

Piston Pin

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

Piston to Cylinder Clearance

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

Limit: .004I (.11 mm)

Piston O.D.:

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

Piston Pin Measurement Locations

Piston Pin O.D.

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

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5. Measure connecting rod small end ID.

Connecting Rod Small End I.D.

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

6. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Replace piston and rings if ring-to-groove clearance exceeds service limits.

Ring to groove clearance

Piston

Ring

PISTON RING INST

ALLED

GAP

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

Piston ring end gap installed

Feeler Gauge

Cylinder

Piston Ring

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

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

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

25-50mm

Piston Ring Installed Gap

Feeler Gauge

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

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

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)

CRANKCASE DISASSEMBL

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

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

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

Top Ring

Limit: .039I (1.0 mm)

Second Ring

Limit: .039I (1.0 mm)

Oil Ring

Limit: .059I (1.5 mm)

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STARTER REMOV

1. Remove recoil housing bolts and remove housing.

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

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

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

DRIVE

AL/INSPECTION

Starter Drive Bushing Clearance:

Std: .0015″-.004″ (.038-.102 mm)

Service Limit:

008″ (.203 mm)

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

FLYWHEEL/STAT REMOV

1. Remove flywheel nut and washer.

AL/INSPECTION

Std. Bushing ID:

.4735″-.4740″ (11.11-12.04 mm)

Std. Shaft OD:

.470″-.472″ (11.93-11.99 mm)

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

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

3. 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.

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5. Replace crankshaft seal.

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

CAM

CHAIN/TENSIONER

BLADE

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

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

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

DRIVE SPROCKET REMOV

INSPECTION

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

Remove

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

3. Inspect sprocket teeth for wear or damage.

Measure 20

Pitch Length

4. Inspect Woodruff key for wear.

5. Replace any worn or damaged parts.

Chain Service Limit:

5.407″ (13.7 cm)

Inspect for Areas of

Tooth Wear or Damage

Slotted Nut Socket

(PN 2871293)

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PRESSURE RELIEF VAL

The pressure relief valve opens 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.

Outer Feed Rotor to Crankcase Clearance:

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

Wear Limit: .004 (.1016 mm)

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

Relief Valve Spring Free Length:

Std: 2.175″ (5.52 cm)

3. Inspect valve for wear.

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

OIL PUMP REMOV

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

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

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

AL/INSPECTION

Pump End Clearance:

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

Wear Limit: .004 (.1016 mm)

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5. Measure rotor tip clearance with a feeler gauge.

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Rotor Tip Clearance:

Std: .005 (.127 mm)

Wear Limit: .008 (.2032 mm)

ENGINE

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

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

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

OIL PUMP ASSEMBL

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 SEPARA

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

TION

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.

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

Connecting Rod Big End Side Clearance:

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

Limit: .0138 (.35 mm)

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.

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

Connecting Rod Width:

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

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

4. Measure the O.D. of the crankshaft rod journal in four places and in two directions away from the oil hole. Replace the crankshaft if it measures below the service limit, or if the journal is out of round.

Rod Bearing Journal O.D.:

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

1. Measure the width of the rod bearing journal.

INSPECTION

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

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

Oil passage

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MAIN BEARING INSPECTION

1. Inspect the crankshaft main bearings.

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

2. Replace bearings if they fail visual inspection.

CONNECTING ROD

BEARING

INSPECTION

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

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

ENGINE

NOTE: Use the widest part of the Plastigauge®to

determine the oil clearance.

Connecting Rod To Crankshaft Clearance:

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

Limit: .0026 (.065 mm)

CONNECTING ROD CLEARANCE

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

2. Place a strip of Plastigauge width of the crank pin.

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

4. Torque the rod nuts to specification.

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

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

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

this procedure.

INSPECTION

Rod Nut Torque:

. The rod must not turn during

BEARING

across the complete

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

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

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

CRANKCASE

BEARING

INSPECTION

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

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

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

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

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

from bearing

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CRANKCASE

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

BEARING INSTALLA

NOTE: To ease crankshaft bearing installation, warm

the crankcase until hot to t he t ouch. Place the bearing in a freezer.

1. Install the crankshaft bearing so the numbers are visible.

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

G Use a 70mm (2.755″) driver- For

crankshaft main bearings.

END PLA

INSPECTION

TION

INSPECTION/ADJUSTMENT

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

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

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

Crankshaft End Play Adjustment

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

MAG Case Depth

+ PTO Case Depth____________________

= Total Case Width____________________

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4. Measure the width of the crankshaft at the bearing seats or, if PTO bearings are installed, the width from MAG side bearing seat to the outside race of the PTO bearings with amicrometer or dial caliper and record.

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

Crankshaft Width

ENGINE ASSEMBLY/ CONNECTING INSTALLA

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

2. Install bearing inserts onto connecting rod and cap.

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

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

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

TION

ROD

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

Total End Play

6. Subtract the thickness of the existing shim from the result of Step 5 to determine if a different shim is required. The result must be within the specified range listed below. Increase or decrease shim thickness as required to bring end play within range.

Marks

NOTE: Procedure during disassembly called for marking of connecting rod and cap. Ensure that each part is installed in its original location by noting the marks placed on the parts during disassembly.

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

Rod Nut Torque:

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

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

Crankshaft End Play:

008″-.016″ (.02-.04 cm)

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CRANKSHAFT INSTALLA

Lubricate all bearings with clean engine oil before assembly.

1. Install the crankshaft into the PTO side crankcase.

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

CRANKCASE OIL

TION

STRAINER

INSPECTION

1. Remove bolt securing oil strainer to the MAG side crankcase.

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

3. Replace oil strainer if it fails visual inspection.

CRANKCASE REASSEMBL

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

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

3. Install the crankcase flange bolts and tighten to specified torque in 3 steps according to the torque pattern. See Page 3.4.

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

Oil Pump Cover Screw Torque:

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

NOTE: Do not use gasket sealer on the pump mating

surfaces.

OILRELIEFVAL INSTALLA

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

Oil Relief Valve Plug Torque:

TION

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

CAM CHAIN DRIVE

Crankcase Bolt Torque:

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

Crankcase Sealant :

(PN 2871557)

OIL PUMP INSTALLA

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

3.34

TION

SPROCKET INSTALLA

1. Install the Woodruff key, drive sprocket, and

slotted nut. Using the Slotted Nut Socket (PN

2871293), tighten the nut to the specified torque.

Tighten

Slotted Nut Torque:

45 ft. lbs. (61 Nm)

TION

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ENGINE

INSTALLA

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

Tensioner Blade Mounting Bolt Torque:

OIL FILTER INSTALLA

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

Oil Filter Connector Torque:

PISTON RING INSTALLA

NOTE: Apply clean engine oil to all ring surfaces and

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

TION

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

TION

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

TION

Ring Profile

To p

“R1” Mark up

“R” Mark up

4. Install the second ring withthe “R” mark facing up. Position the end gap toward the rear (intake) side of the piston.

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

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

Second

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

2. Install the oil ring top rail with the end gap at least 30° from the end of the expander.

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

PISTON INSTALLA

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

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

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

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

TION

3.35

Page 82

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

5. Install the piston on the connecting rod with

the pin casting notch facing the rear of engine (starter side). The piston pin should be a push fit in the piston.

6. Install the other circlip with the gap facing up or down. (See Caution with Step 3 above). Push the piston pin in both directions to make sure the clips are properly seated in the groove.

7. Place the dowel pins in the crankcase and install a new cylinder base gasket.

8. Lubricate the piston and rings with assembly lube and install a sleeve--type ring compressor on the piston assembly. Verify that the ring gaps are120 degrees apart from each other before installation.

2. Apply clean engine oilliberally to the cylinder bore and tapered area of the sleeve. Install the cylinder with a slight rocking motion until the rings are captive in the sleeve.

3. Remove the ring compressor and support block.

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

NOTE: If cam chain is installed, hold it up while rotating theengine to avoiddamage to the chain, drive sprocket teeth, or tensioner blade.

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

CYLINDER INSTALLA

HEAD

TION

CYLINDER INSTALLA

1. Position the Piston Support Block (PN 2870390)

(A) beneath the piston skirt to support the piston during cylinder installation.

TION

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

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

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

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

3.36

Page 83

ENGINE

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

Torque in cross

pattern per procedure

Torque

5-6.5 ft. lbs.

(7--9 Nm)

Torque all bolts evenly in a cross

pattern. Apply oil to bolt threads

Install the cam chain over the crankshaft.

Plated

Link

Sprocket

Mark

Crankcase

Projection

IMPORTANT CAMSHAFT TIMING NOTE: In order to time the camshaft to the crankshaft, the piston must be precisely located at Top Dead Center (TDC). This can be accomplished using one of two methods.

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

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

*Loosen bolts evenly 180° (1/2 turn)

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

*From this point, tighten bolts evenly

90° (1/4 turn)

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

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

(7--9Nm)

CAM

CHAIN/CAMSHAFT

INSTALLATION

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

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

Camshaft Installation - Timing Method 1 Refer to Illustration Page 3.39

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

1. Rotate the crankshaft until the mark on the cam chain drive sprocket is aligned with the crankcase projection (mark facing downward).

2. Align the single plated link on the cam chain with the marked tooth of the cam chain drivesprocket. Use a wire to pull the chain up through the cylinder and cylinder head, and secure it to hold the chain in place.

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3. Apply Polaris Low Temp Grease (PN 2870577),

or engine assembly lubricant to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil. (To install the compression release mechanism, refer to Page 3.14).

Plate link

aligned w/dot

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

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

6. Loop the cam chain over the cam sprocket, aligning the plated link on thechain with the dot on the sprocket.

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

Camshaft Installation - Timing Method 2 Refer to Page 3.40

1. Apply Polaris Low Temp Grease (PN 2870577),

or molybdenum disulfide grease to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil. (To install the compression release mechanism, refer to Page 3.18).

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

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

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

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

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

Cam Sprocket Bolt Torque:

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

(TDC ) timing

7. Check all cam timing marks to verify proper cam

Cam Sprocket Bolt Torque:

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

8. Check all cam timing marks to verify proper cam timing, and install the cam chain tensioner. See Cam Chain Tensioner Installation Page 3.41. NOTE: The platelinks willnot align after engine is rotated.

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

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

3.38

Page 85

CAMSHAFT TIMING - METHOD 1

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Method 1 - Camshaft Timing with Stator Removed

Single Plated

Link and Dot on

Cam Sprocket

ENGINE

Crankshaft to Camshaft Centerline

Sprocket marks aligned with

gasket surface at TDC on

compression stroke (cam

lobes facing downward)

Single Plated

Link and

Rectangular

Mark

on Cam

Chain Drive

Sprocket

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

Crankcase Projection

3.39

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ENGINE

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CAMSHAFT TIMING - METHOD

Method 2 - Camshaft Timing Using Flywheel TDC Mark

Do not use dot on sprocket

for cam timing

Crankshaft to Camshaft Centerline

Decompressor arm stop pin UP

(Cam lobes DOWN)

Sprocket marks aligned with

gasket surface at TDC on compression stroke (cam

lobes facing downward, de-

compressor arm stop pin UP)

Single TDC Mark Aligned

TDC Mark

Rotation

Do Not Use

Advance Marks

Cam Timing

(View through timing inspection hole)

3.40

Position crankshaft at TDC

Do Not Use

Advance Marks

For Cam Timing

Page 87

ENGINE

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CAM CHAIN TENSIONER INSTALLA

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

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

TION

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

STATOR INSTALLA

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

can be assembled with the engine in the frame.

Stator

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

TION

Timing Marks

Tensioner Bolt Torque:

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

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

Tensioner Plug Torque:

2. Apply Crankcase Sealant (PN 2871557)tothe

stator plate outer surface and install a new O-Ring.

3. Install the stator plate being careful not to damage the seal. Align timing reference marks on the plate and crankcase. Be sure the plate is fully seated. NOTE: This is a static timing mark. Strobe timing should be performed after start up.

4. Torque bolts evenly to specification.

Stator Plate Bolt Torque:

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

5. Seal stator wire grommet with Crankcase Sealant (PN 2871557).

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

3.41

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FLYWHEEL INSTALLA

1. Install flywheel, washer, and nut. Torque flywheel to specification.

Flywheel Nut Torque:

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

STARTER DRIVE ASSEMBL

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

TION

ROCKER INSTALLA

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

2. Install and tighten rocker shaft block plug.

3. Apply engine assembly lube to the cam lobes and cam follower surfaces.

4. Rotate the engine until the cam lobes are pointing downward.

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

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

7. Install the rocker cover assembly.

8. Install rocker cover bolts and torque to specifications.

SHAFT/ARM

TION

Rocker Cover Bolt Torque:

7-8 ft. lbs. (9-11 Nm)

Starter Drive Grease:

(PN 2871460)

2. Apply Starter Drive Grease (PN 2871460)tothe

drive bushing in the crankcase and all moving surfaces of the starter drive mechanism. Install the starter drive.

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

10. Install rocker cover block plug.

Rocker Cover Block Plug Torque:

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

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

3. Install recoil housing.

3.42

Page 89

INTAKE VALVE CLEARANCE

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ADJUSTMENT

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

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

330 Engine

ENGINE

VALVE CLEARANCE

330 Engines

.006″ (.15 mm)

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

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

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

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

10. Install the spark plug high tension lead.

11. Install parts removed for access.

330 Engine

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

Valve Adjuster Tool: PA--44689

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

4. Re-check the valve clearance.

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

EXHAUST VAL CLEARANCE

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

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

NOTE: The 330 exhaust valve is adjusted the same as the intake valve. The Valve/Clutch Adjuster Tool (PN PA--44689) can be used to adjust the 330 engines valves.

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

4. Re-check the valve clearance.

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

ADJUSTMENT

3.43

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RECOIL DISASSEMBL

CAUTION: Recoil is under spring tension. A face

shield or eye protection is required during this procedure.

Replace any parts found to be worn or damaged.

1. Remove bolts and recoil housing from engine.

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

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

Y/INSPECTION

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

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

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

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

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

3.44

Page 91

ENGINE

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

9. Unwind rope and inspect for cuts or abrasions.

10. Inspect drive tab onhub return spring for damage. To remove hub return spring, hold outer coils in place with one hand and slowly remove spring one coil at a time from the inside out.

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

To reinstall an old spring:

1. Hook outer tab in place in recoil housing and wind spring in a counterclockwise direction one coil at a time while holding the installed coils in place.

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

To complete recoil assembly:

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

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

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

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

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

Open end here

RECOIL ASSEMBL

CAUTION: Recoil is under spring tension. A face

shield or eye protection is required during this procedure.

To install a new spring:

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

2. Hold spring in place and cut retaining wire.

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

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

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

9. Reinstall friction plate. NOTE: The friction plate must be positioned with both end tabs of the friction spring opposite the ratchet pawl.

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

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

3.45

Page 92

ENGINE

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SPARK PLUG

FOULING

TROUBLESHOOTING

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

plunger/cable sticking

G Foreign material on choke plunger

seat or plunger

G Incorrect spark plug heat range or

gap

G Carburetor inlet needle and seat

worn

G Jet needle and/or needle jet worn or

improperly adjusted

G Excessive carburetor vibration

(loose or missing needle jet locating pins)

G Loose jets in carburetor or calibration

incorrect for altitude/temperature

G Incorrect float level setting G PVT system calibrated incorrectly or

components worn or mis-adjusted

G Fuel quality poor (old) or octane too

high

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

faulty coil, stator, or ETC switch)

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

pre-cleaner) or breather system

G Improperly assembled air intake

system

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

G Engine flooded G Low compression (high cylinder

leakage)

G No spark (Spark plug fouled)

Engine Does Not Turn Over

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

mechanical failure

G Recoil components damaged

Engine Runs But Will Not Idle

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

Engine Idles But Will Not Rev Up

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

components)

G Incorrect or restricted carburetor

jetting

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

sticking/diaphragm damaged

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

Engine Has Low Power

TROUBLESHOOTING

Engine Turns Over But Fails to Start

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

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

or damage (check compression)

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

sticking/diaphragm damaged

G Dirty carburetor G Cam lobe worn

3.46

Page 93

TROUBLESHOOTING

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Piston Failure - Scoring

G Lack of lubrication G Dirt entering engine through cracks

in air filter or ducts

G Engine oil dirty or contaminated

Excessive Smoke and Carbon Buildup

G Excessive piston-to-cylinder

clearance

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

Low Compression

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

adjusted

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

sticking

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

carbon accumulated on valve area)

G Rocker arm sticking

ENGINE

Backfiring

G ETC or speed limiter system

malfunction

G Fouled spark plug or incorrect plugor

plug gap

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

G Spark plug cap cracked/broken G Ignition coil faulty G Ignition or kill switch circuit

faulty

G Ignition timing incorrect

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

3.47

Page 94

ENGINE

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NOTES

3.48

Page 95

FUEL SYSTEM/CARBURETION

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Exploded View, Mikuni BST 34 Carburetor 4.2...

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

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

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

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

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

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

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

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

CV Carburetor Operation 4.7-4.9..................

Pilot Screw 4.9..............................

Disassembly, CV Carburetor 4.10...............

Cleaning, CV Carburetor 4.11..................

Inspection, CV Carburetor 4.11.................

Assembly, CV Carburetor 4.12.................

Float Adjustment, CV Carburetor 4.13...........

Needle & Seat Leakage Test 4.13...............

Fuel Level 4.14...............................

Fuel Pump Service 4.14.......................

Troubleshooting 4.15..........................

4.1

Page 96

FUEL SYSTEM/CARBURETION

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1. Carburetor Assembly

BST 34 CARBURETOR EXPLODED VIEW

29 28

4.2

44 43

Refer to Page 4.5 for Jet Part Numbers

26 25

Jet Needle “E” Clip Position

2. Screw

3. Throttle Valve

4. Cover, Diaphragm

5. Jet Block Assembly

6. Spring

7. Diaphragm Assembly

8. Ring

9. “E” Ring

10. Ring

11. Needle Jet

12. Cover

13. O-Ring

14. Throttle Shaft Assembly

15. Ring

16. Seal

17. Spring

18. Packing

19. “E” Ring

20. Cap

21. Screw

22. Drain Screw

23. O-Ring

24. Washer

25. Adjuster

26. Spring

27. Pilot Jet

28. Main Jet

29. Washer

30. Jet Needle

31. Float Assembly

32. Float Body Assembly

33. Float Pin

34. Needle Valve

35. O-Ring

36. O-Ring

37. Plug

38. Screw

39. Screw

40. Guide Holder

41. Spring

42. Plunger Assembly

43. Spring Washer

44. Screw

45. Air Jet

46. Cable Guide

47. Spring

48. Ring

49. Adjust Screw

50. Screw and Washer Assy.

51 Plate

52 Screw

Page 97

FUEL PUMP EXPLODED VIEW

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FUEL SYSTEM/CARBURETION

1. Fuel Pump Assembly

2. Diaphragm, Gasket Set

3. Screw and Washer Assembly

4. Screw and Washer Assembly

5. Screw and Washer Assembly

6. Pressure Regulator

7. Fuel Inlet

8. Fuel Outlet

4.3

Page 98

FUEL SYSTEM/CARBURETION

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FUEL TANK ASSEMBLY

Forward

Vent line routed smoothly into center of steering post

Tank to fuel valve connection -Gold fitting (tall stand pipe) to “ON”

90 Degree Fuel

Reserve Outlet Fitting

(Marked “2” on fuel valve)

Fuel Line

“2 (Reserve)”

90 Degree Fuel

Outlet Fitting

(Marked 1) on fuel valve)

“1 (ON)”

Gas Tank Mounting

Hardware

Fuel Filter

Fuel Valve

FUEL FLOW DIAGRAM

L Located Above Coolant Reservoir

Above LH Front Tire

Fuel Pump

Carburetor Vent

4.4

Fuel Tank Vent

Filter

Carburetor

Fuel Tank

Fitting Screens

Fuel Valve

Engine

Page 99

FUEL SYSTEM/CARBURETION

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FUEL SYSTEM COMPONENT OVERVIEW

Fuel Tank

Fuel Pump

Tank to Pump Line

Impulse Line

Fuel Pump to Carburetor Line

SPECIAL TOOLS

PART NUMBER

2870975 Mity Vact

2872314 Carburetor Float

WARNING

Gasoline is extremely flammable and explosive under certain conditions.

TOOL

DESCRIPTION

Pressure Test Tool

Adjustment Tool

Vent Line

Carburetor

Fuel Filter

Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

If you get gasoline in your eyes or if you should swallow gasoline, seek medical attention immediately.

If you spill gasolineon your skin or clothing, immediately wash with soap and water and change clothing.

Always stop the engine and refuel

outdoors or in a well ventilated area.

Do not overfill the tank. The tank is at

full capacity when the fuel reaches the bottom of the filler neck. Leave room for expansion of fuel.

Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.

Never drain the float bowl when the engine

is hot. Severe burns may result.

JETTING GUIDELINES

Changes in altitude and temperature affect air density, which is essentially the amount of oxygen availablefor combustion. In low elevations and cold temperatures, the air is more dense and has more oxygen. In higher elevations and higher temperatures, the air is less dense with reduced oxygen.

Polaris ATV Carburetors are calibrated for an altitude of 0-6000 ft. (0-1800 meters) and ambient temperatures between +40 and +80° F(+5° to +26° C). Carburetors must be re-calibrated if operated outside this temperature and/or altitude range. The jetting installed in production is not intended for all altitudes and/or temperatures. In addition, air screw

4.5

Page 100

FUEL SYSTEM/CARBURETION

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/ pilot screw adjustments and PVT adjustments may be required to suit operating conditions.

CV CARBURETOR

SYSTEM

FUNCTION

CARBURETOR

CAUTION:

A main jet that is too small will cause a lean operating condition resulting in serious engine damage. Select the correct main jet carefully for elevation and temperature according to the charts in the Specifications section or in the Owner’s Safety and Maintenance Manual for each particular model.

IMPORTANT: The following guidelines must be

followed when establishing a main jet setting:

1. Select the lowest anticipated temperature at which the machine will be operated.

2. Determine the lowest approximate altitude at which the machine will be operated.

3. Select the correct main jet from the chart on page on the Specifications page.

4. Clutching changes may also be required for changes in elevation. Refer to clutching chart in the Specifications section for recommendations.

MIKUNI JET PART

Main Jets

Jet Number Part Number

112.5 3130554 115 3130555

117.5 3130556 120 3130557

122.5 3130558 125 3130559

127.5 3130560 130 3130561

132.5 3130562 135 3130563

137.5 3130564 140 3130527

142.5 3130566 145 3130567

147.5 3130568 150 3130569

152.5 3130570 155 3130571

157.5 3130572 160 3131141

162.5 3131142 165 3131143

167.5 3131144 170 3131145

JETTING

NUMBERS

Pilot Jets

Jet Number

40.0 3130624

42.5 3130526

50.0 3131132

Part Number

Carburetor Component Function

System Main

Float

System

(Level Control)

Venting Passages in

Starter (Choke/Enrichment)

Pilot (Idle System)

Main System

Components

Inlet Pipe, Needle and Seat, Float, Float Pin

Carburetor, Vent lines to frame

Choke Lever, Cable, Plunger, Return Spring, Carb Passages (Starter Jet, Starter Bleed Pipe)

Pilot Jet/ Passageways, PilotMixture Screw with Spring Washer and Sealing ORing, Bypass Ports (Behind Throttle Plate), Pilot Air Jet, Pilot Outlet, Throttle Plate

Main Jet, Main Air Jet, Main Air Passage, Needle Jet, Jet Needle, Vacuum Slide, Throttle Plate

Main

Function

Maintains specified fuel level in float chamber (carburetor float bowl)

Supplies atmospheric pressure to float chamber

Supplies additional fuel air mixture necessary for cold starting

Primarily supplies fuel at idle and low throttle positions

Supplies fuel at midrange and high throttle settings.

Main

Affect

All systems All throttle ranges

All throttle ranges Greatest effect at low throttle settings and idle

Mainly idle to 1/4 throttle Minimal effect after 1/2 throttle

1/4tofull throttle

4.6