NOTE: Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts. Use only genuine Polaris components. One of two methods can be used to measure toe alignment. The string method and the chalk method. If adjustment is required, refer to following pages for procedure. G Replace any worn steering components. G Elevate front end of machine so front wheels are off the ground.
Try to move the wheel and hub by pushing inward and pulling outward. See notes below. NOTE: String should just touch side sur- face of rear tire on each side of machine. The frog should always point straight back from the steering post.
Place machine on a smooth level surface. If toe alignment is incorrect, measure the distance 2. Set handlebars in a straight ahead position and between vehicle center and each wheel. This will tell secure handlebars in this position. NOTE: The you which tie rod needs adjusting. The frog which tie rod s need adjustment. Place a chalk mark on the center line of the front when tightening tie rod end jam nuts.
NOTE: It is important that the height of both marks be equally positioned in order to get an Hold accurate measurement.
Rod End 4. Measure the distance between the marks and record the measurement. Again measure the distance between the marks Correctly Incorrectly and record. The recommended Ill. G Loosen jam nuts at both end of the tie rod. G Shorten or lengthen the tie rod until Ill.
Damage may not be immediately apparent if done incorrectly. See illustration 2. G After alignment is complete, torque Chalk Line jam nuts to ft. 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.
Make sure the machine is in neutral and repeat Steps 2 and G Do not perform clean out immediately 3. Repeat Steps 2 through 5 until no more particles haust system becomes very hot. Serious burns could result from contact with ex- are expelled when the engine is revved.
Stop the engine and allow the arrestor to cool. G To reduce fire hazard, make sure that 8. Reinstall the clean out plugs. G Do not stand behind or in front of the ve- The following checks are recommended to keep the hicle while purging the carbon from the brake system in good operating condition.
Service life spark arrestor. Inspect brakes in accordance with the area. Exhaust contains poisonous car- maintenance schedule and before each ride. G Keep fluid level in the master cylinder G Do not go under the machine while it is reservoir to the indicated level inside inclined. Set the hand brake and block reservoir.
Sight Parking Brake Glass Lock. 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. Rear Master Cylinder Reservoir. Place the transmission in neutral and start the Max Min. Purge accumulated carbon from the system by momentarily revving the engine several times.
If some carbon is expelled, cover the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more G Check brake system for fluid leaks. G Check brake for excessive travel or 4. If particles are still suspected to be in the muffler, spongy feel. Set the G Check friction pads for wear, hand brake and block the wheels. Make sure the damage or looseness. G Check surface condition of the disc. Full Full Height Engagement. Tighten any loose First, check foot brake effectiveness by applying 50 lb.
The top of the pedal should be at least 1 inch, Auxiliary Brake Floorboard. If free play is excessive, inspect pedal, linkage, and Support the rear wheels off the ground.
While turning the rear wheels by hand, apply the auxiliary foot brake. This brake should not stop the Bleeding: wheels from turning until the lever is half way between If free play is correct and brake pedal travel is still its rest position and bottoming on the footrest. Bleed the hydraulic auxiliary brake system in. Check controls for proper operation, positioning and adjustment. Adjustas necessary. Damping should be smooth throughout the range of travel.
G Inspect front strut cartridges for leakage. Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts. G Compress and release rear suspension. Stop the engine, place the transmission in gear for wear or damage. G Inspect shock for leakage. Loosen the wheel nuts slightly.
Elevate the side of the vehicle by placing a suitable stand under the footrest frame. Remove the wheel nuts and remove the wheel. G The use of non-standard size or type tires may affect ATV handling. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. Attach the wheel nuts and finger tighten them. Tread 3. Lower the vehicle to the ground. Securely tighten the wheel nuts to the proper torque listed in the table.
On vehicles with tapered rear wheel nuts, make sure tapered end of nut goes into taper on wheel. Flat side against wheel Worn tires can cause an accident. Check that all cotter pins are in place. Refer to specific Front Rear fastener torques listed in each chapter.
G When replacing a tire always use original equipment size and type. Engine Exploded Views. Valve Inspection. Gasket 4. Oil Pickup Bearings Crankcase Screws. Apply Loctitet to Thermostat Nm Cover. Thermostat Temperature Switch. Exhaust Exhaust Gasket Manifold ft. Cylinder Base Gasket Apply Loctitet to Carburetor Apply Loctitet to Pushrods Valve Woodruff Key Springs. Valve Seals Gears Cylinder Head. Apply Loctitet to ft.
Lifter Valve Oil Filter Oil Plug Nm ft. Oil Filter Nipple. Gerotor Oil Pressure ft. Relief Oil Pump Housing Nm. O--Ring Water Pump Seal. Apply Loctitet to Nm Starter 8. Bendix Nm. See text on Page 3. Use the information below to identify pistons and rings. Engine Model No. Counter End Play 0. Ex Std 0.
Seat Angle Std Stem diameter In 0. Piston Std 3. Crankshaft Crankshaft runout limit 0. The cooling system is under pressure and serious burns may result. Remove front cover. Pressure 2. The system must retain 10 psi for five minutes or Recommended Coolant longer.
Remove radiator cap and test cap using a buildup of deposits which may restrict coolant flow and commercially available cap tester. The radiator cap relief pressure is 13 lbs. Replace damage. Filler Neck Assy. Upper Engine Hose. Thermal Hose Sensor. Top Radiator Front View. Disconnect the coolant hoses. Properly dispose of any antifreeze from the engine or hoses. Clean work area.
Thoroughly clean the ATV engine and chassis. Disconnect battery negative - cable. When removing starter cables, note and mark 4. Remove cables. Remove transmission linkage rod from gear Chapter 5 selector and secure out of the way. Disconnect coolant temperature sensor wire. Chapter 5 Remove engine to chassis ground cable.
G Fuel Tank Refer to Chapter 4 Remove springs from exhaust pipe and remove mount plates. Remove the frame brace E from pipe. Drain coolant and engine oil. Remove air pre-cleaner and duct. Remove airbox. Remove the engine from the left side of the frame. Remove carburetor A. Insert a shop towel into the carburetor flange to prevent dirt from entering the intake port. Disconnect spark plug high tension lead B. Remove the air breather line C.
NOTE: Use caution when lifting the engine out of frame. Use an engine lift or other means if the engine is too heavy to be lifted manually. For engine installation, reverse these procedures. No single action on General Items your part is as important as a proper break in period.
Careful treatment of a new engine will result in more 1. Install previously removed components using efficient performance and longer life for the engine. Never substitute or PVT System mix oil brands. Serious engine damage and voiding of warranty can result. Adjust center distance of drive and driven clutch.
Do not operate at full throttle or high speeds for Chapter 6 extended periods during the first three hours of 2. Adjust clutch offset, alignment, and belt use. Excessive heat can build up and cause deflection. Chapter 6 damage to close fitted engine parts. Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing. Chapter 6 1. Refer to Chapter 2 and Chapter 8.
Check oil reservoir level indicated on dipstick. Exhaust Add oil if necessary. Replace exhaust gaskets. Seal connections with high temp silicone sealant. Check to be sure all springs are in good condition. Bleed Cooling System 3. Drive slowly at first to gradually bring engine up to NOTE: This cooling system contains vent lines to operating temperature.
Refer to page 3. Bleeding generally should not be 4. Vary throttle positions. Do not operate at necessary. Remove radiator cap and slowly add coolant to 5. Perform regular checks on fluid levels, controls and all important areas on the vehicle. Pull only light loads during initial break in.
Fill coolant reservoir tank to full mark. Change break in oil and filter at 20 hours or 3. Install radiator cap and gently squeeze coolant miles. Again, remove radiator cap and slowly add coolant to the bottom of fill neck if needed. Start engine and observe coolant level in the radiator. Allow air to purge and top off as necessary. Reinstall radiator cap and bring engine to operating temperature. After engine is cool, check level in reservoir tank and add coolant if necessary.
NOTE: Should the reservoir tank become empty, it will be necessary to refill at the radiator and repeat the bleeding procedure. 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. It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material.
Wash the cylinder in a solvent, then in hot, soapy water. Rinse thoroughly, dry with compressed air, A finished cylinder should have a cross-hatch pattern and oil the bore immediately with Polaris 4 Cycle to ensure piston ring seating and to aid in the retention Lubricant to prevent the formation of surface rust. Remember to Capacity -- Approximately 2 U. Quarts 1. If cylinder wear or damage is excessive, it will be 3. Start engine and allow it to reach operating necessary to replace the cylinder.
The cylinders are temperature, monitoring gauge indicator. Engine Lubricant. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.
At this point, the oil is supplied to the main oil galley through a crankcase passage. Oil is then diverted three ways from the main oil galley, with the first path entering the camshaft bores, onto the rear balance shaft journal and then draining back into the crankcase sump.
The second oil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump. The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump. The oil pressure switch is fed off the main oil galley. Crankshaft Crankcase Main Bearing Sump. Rod Crankshaft Bearings Main Bearing. Counterbalance Counterbalance Bore Bore.
If the push rod A is visibly bent, it should be replaced. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. Tap only in reinforced areas or on thick parts of 3. Check the rocker arm pad and fulcrum seat for cylinder head casting to avoid damaging the head excessive wear, cracks, nicks or burrs. Remove cylinder head B and head gasket C from the cylinder D. Clean push rods A in a suitable solvent. Blow dry push rods with compressed air.
Use compressed air to confirm the oil passage is clear in the center of the push rod. Always wear safety glasses when working with compressed air to prevent personal injury.
Check the ends of the push rods A for nicks, B grooves, roughness or excessive wear. The push rods A can be visually checked for straightness while they are installed in the engine by rotating them with the valve closed. Push rods C can also be checked with a dial indicator or rolled across a flat surface to check for straightness. Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon. Wear eye protection or a face shield during cylinder head disassembly and reassembly.
Install the Valve 1. Lay a straight edge A across the surface of the Pressure Hose PU into the spark plug cylinder head B at several different points and hole. Hook the hose to an air compressor and measure warpage by inserting a feeler gauge supply 50 to psi to the hose. This will seat the between the straight edge and the cylinder head valves during valve spring removal. Do not surface. If warpage exceeds the service limit, remove air from the hose at anytime until replace the cylinder head.
PU B. Measure at different points A on the surface. Bottom Side View. Remove spring retainer and spring. Valve Train Servicing 4. The valve seals are now serviceable. In some cases the valve train can be serviced while the cylinder head is still on the engine. Keep all parts in order with respect to their location in the cylinder head. The Std: 1. Place the Installed Height: 1. Remove valve guide seals. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.
Mark the valves with a white pen. Remove the valves from the cylinder head. This will ensure that the valves are properly placed during engine reassembly. E Mark the valves. Measure free length of spring with a Vernier caliper.
Compare to specifications. Replace spring if measurement is out of specification. Valve Spring Free Length. Remove all carbon from valves with a soft wire Intake: 0. Check valve face for runout, pitting, and burnt Exhaust: 0.
To check for bent valve stems, mount 5. Measure valve stem in several places. Rotate the valve 90 degrees and mea- sure for wear. Measure valve guide inside diameter at the top middle and end of the guide using a small hole 3. Check end of valve stem for flaring, pitting, wear gauge and a micrometer. Measure in two or damage A. Valve Guide A. Inspect split keeper groove for wear or flaring of the keeper seat area B. NOTE: The valves can be re-faced or end ground, if necessary.
They must be replaced if extensively worn, burnt, bent, or damaged. Measure diameter of valve stem with a Valve Guide I. Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance. NOTE: The valve guides cannot be replaced. Be sure to measure each guide and valve combination individually. Keep all valves in order with their respective seat. Clean all accumulated carbon deposits from NOTE: Valve seat width and point of contact on the combustion chamber and valve seat area with valve face is very important for proper sealing.
The carbon cleaner and a soft plastic scraper. If the seat is uneven, or abrasive cleaners to clean the bottom of the compression leakage will result. If the seat is too cylinder head. Extensive damage to the cylinder head wide, seat pressure is reduced, causing carbon may result.
Wear safety glasses during cleaning. If the seat is too narrow, heat transfer from valve to seat is reduced. The valve may overheat and warp, resulting Combustion Area in burnt valves. Install pilot into valve guide. NOTE: The cylinder head valve guides cannot be replaced.
Apply cutting oil to valve seat and cutter. Valve Seat Inspection 4. If the valve seat is cracked the cylinder another light cut. G If the cutter now contacts the uncut Follow the manufacturers instructions provided with portion of the seat, check the pilot. If the Reconditioning Kit PN Abrasive stone pilot is bent it must be replaced.
Be sure the cylinder head is at the proper NOTE: When using an interference angle, the seat temperature and replace the guide. Look for an even and continuous G If the contact area of the initial cut is contact point all the way around the valve face. To check the contact area of the seat on the valve face, apply a thin coating of Prussian Bluet paste to the valve seat. Insert valve into guide and tap valve lightly into place a few times.
Remove valve and check where the Prussian Bluet indicates seat contact on the valve face. The valve seat should contact the middle of the Seat valve face or slightly above, and must be the Width proper width. 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. When contact area is centered on the valve face, measure Intake Std:. Clean all filings from the area with hot soapy water, rinse, and dry with compressed air.
Wear eye protection or a face shield when working with compressed air during cylinder head disassembly and reassembly. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve.
NOTE: Lapping is not required with an interference angle valve job. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem. Dip valve spring and retainer in clean engine oil and install. Rotate the valve rapidly back and forth until the 6.
Place retainer on spring and install Valve Spring cut sounds smooth. Lift the valve slightly off of the Compressor PU NOTE: A small process. Do this four to five times until the valve is parts magnet can aid in installation of the fully seated, and repeat process for the other keepers. PU Thoroughly clean cylinder head and valves. Apply engine oil to valve guides and seats. Install new valve seals on valve guides. Coat valve stem with molybdenum disulfide grease or 0W Synthetic oil.
Install valve carefully with a rotating motion to avoid damaging valve seal. Repeat procedure for remaining valves. When all valves are installed, tap lightly with soft faced hammer on the end of the valves to seat the split keepers. NOTE: To prevent damage to the valve seals, do not compress the valve spring more than necessary to install the keepers.
Clean and dry the combustion chamber area A. Refer to Page 3. Pour a small amount of clean solvent onto the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage. Repeat for exhaust valves by pouring fluid into exhaust port. Lubricate push rods D and install into lifters. Before reassembly, clean the bolts and bolt holes with Primer N PN to remove any debris. This will ensure proper sealing when installing bolts and new Loctitet.
Install the head gasket A on the cylinder B. Lubricate rockers E with engine oil. Install cylinder head on cylinder. Install head bolts C. Torque bolts to ft. Verify pushrods are engaged in lifters. Install rockers. Be sure that tab of fulcrum F is seated in head stand-off. Rocker Arm Bolt Torque: ft. Install thermostat J. Out of these cookies, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website.
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You also have the option to opt-out of these cookies. But opting out of some of these cookies may have an effect on your browsing experience. Necessary Always Enabled. The Art of War Sun Tsu. Related Audiobooks Free with a 30 day trial from Scribd. Elizabeth Howell. Donnie Marsteller. Views Total views. Actions Shares. No notes for slide. Displacement cc. Bore 3. Stroke 2. Compression Ratio 9. Cooling Liquid. Lubrication Type Pressurized Wet Sump.
Main Jet Pilot Jet Jet Needle JFA Needle Jet P Throttle Valve Pilot Screw 1. Pilot Air Jet Valve Seat 1. Float Height Belt Belt Width Projected 1. Side Angle Overall 28 2. Outside Circumference Center Distance Clutch Offset 0. CDI Marking Coolant 3. Alternator Output Watts Transmission Tail 8.
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