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2006 Hawkeye Chapter 1 - General Information

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July 2018
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[email protected] GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MODEL:2006 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MODEL: 2006 HAWKEYE 4X4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MODEL:2006 HAWKEYE 2X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 MODEL:2006 HAWKEYE 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 1.1 1 [email protected] GENERAL INFORMATION VEHICLE IDENTIFICATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification 27 AA } } } } A 0 6 LB Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation Engine Designation Number ES30PFE ............................................................Single, Air Cooled, SOHC 4 Stroke, Electric Start Vehicle Identification Number (VIN) World Mfg. ID Vehicle Identifier Vehicle Descriptor 4 5 6 7 8 9 10 11 12 13 14 15 16 17 P B 2 0 A * 5 P 0 0 0 0 0 0 Engine Body Style } } 1 2 3 4 X A Model Year Plant No Emissions Powertrain Check Digit Individual Serial Number * This could be either a number or a letter Vehicle and Engine Serial Number Locations 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. The machine serial number (1- lower frame rail) and engine number (2- right side engine) are important for 2 vehicle identification. 1 1.2 [email protected] GENERAL INFORMATION SPECIFICATIONS MODEL: 2006 HAWKEYE 2x4 MODEL NUMBER: . . . . . . . . . A06LB27AA ENGINE MODEL: . . . . . . . . . . ES30PFE Category Length Dimension 74 in./188 cm Width 42 in./107 cm Height 45.5 in./116 cm Wheel Base 46 in./117 cm Ground Clearance 8 in./20.3 cm Dry Weight 525 lbs./238 kg Gross Vehicle Weight 930 lbs./422 kg Front Rack Capacity 70 lbs./31.75 kg Rear Rack Capacity 100 lbs./45 kg Towing Capacity 750 lbs./340 kg Hitch Tongue Weight Body Style 75 lbs./34 kg Recreational/Utility MODEL: . . . . . . . . . . . . 2006 HAWKEYE MODEL NUMBER: . . . . . . . . . A06LD27AA ENGINE MODEL: . . . . . . . . . . ES30PFE Category Length Dimension 74 in./188 cm Width 42 in./107 cm Height 45.5 in./116 cm Wheel Base 46 in./117 cm Ground Clearance 8 in./20.3 cm Dry Weight 550 lbs./250 kg Gross Vehicle Weight 930 lbs./422 kg Front Rack Capacity 70 lbs./31.75 kg Rear Rack Capacity 100 lbs./45 kg Towing Capacity 750 lbs./340 kg Hitch Tongue Weight Body Style 4x4 75 lbs./34 kg Recreational/Utility 1.3 [email protected] GENERAL INFORMATION MODEL: 2006 HAWKEYE 2x4 Transmission Type MODEL NUMBER: A06LB27AA ENGINE MODEL: ES30PFE Transmission Capacity Gear Ratio : Engine Platform Fuji 4 stroke, Single Cylinder Engine Model Number ES300PFE010 Engine Displacement 299cc Number of Cylinders 1 Bore & Stroke (mm) 78.5 x 68 mm Compression Ratio 9.2:1 Full Stroke Compression Pressure Engine Idle Speed Cooling System/Capacity Overheat Warning Lubrication Compression Relase 60-90 psi 1300 RPM Air/Oil Cooled None Wet Sump Oil Requirements Polaris 0W-50 / 2 qts (1.9L) Exhaust System Single Pipe - USFS Approved Carburetion Carburetor model Main Jet Pilot Jet 147.5 42.5 4HB42-5 Needle Jet 0-4m Pilot/Air Screw 2.5 Turns Out (Initial setting) Float Height 13mm from carburetor body Fuel Delivery Fuel Pump 4.5 gal. (17 L) 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 250 watt / 18.6 Amp @ 6000 Voltage Regulator 3-phase Lights : High Beam -- Low Beam 12V / 26.9 watts Tail 12V / 8.26 watts Ignition System DC CDI Ignition Timing BTDC 30+/-2deg. @ 5000 RPM Battery / Model / Amp Hr Circuit Breakers Starting Indicator Panel 1.4 15.2 oz. (450 ml) Foward Reverse 15.18:1 14.05:1 Clutch Type CVT w/EBS Belt 3211108 Steering / Suspension Front Suspension / Shock Mac Pherson Strut Front Travel 7 in. / 17.8 cm Rear Suspension Style / Shock Independent Coil-over Adjustable Rear Travel 8 in. / 20.3 cm Ground Clearance 8 in. / 20.3 cm Shock Preload Adjustment Front / Rear Turning Radius Toe Out Front - Cam Rear - Cam 62.5 in. (159 cm) unloaded 0-1/16 in. (0-.159 mm) Tire/Rim Size - Front 22 x 7-12 Tire/Rim Size - Rear 22 x 10-12 Air Press. F/R Tires 3-5 psi Brake - Front Single Control Hydraulic Disc Brake - Rear Single Control Hydraulic Disc Brake Fluid Polaris DOT 3 or 4 Brake Fluid JETTING CHART Altitude Meters (Feet) 0-1800 (0-6000) 1800-3700 (6000-12000) AMBIENT TEMPERATURE Above +40o F Below 40o F Below 5o C Above +5o C 152.5 147.5 147.5 142.5 CLUTCH CHART 37.5 watts Brake Spark plug / Gap H-N-R Wheels / Brakes Mikuni BST 34mm Jet Needle Fuel Capacity / Requirement Drivetrain NGK CR8E .031 in. / .8 mm Conventional 14 Amp/hr Fusible Link / 15 amp Main / 15 Amp Accsy Electric / Recoil Back-up LCD / Indicator lights Altitude Meters (Feet) Shift Weight 0-1800 (0-6000) 14 g (Yellow) 5412989 1800-3700 (6000 - 12000) 12 g (Red) 5412987 [email protected] GENERAL INFORMATION MODEL: 2006 HAWKEYE 4x4 Transmission Type MODEL NUMBER: A06LD27AA ENGINE MODEL: ES30PFE Gear Ratio : Fuji 4 stroke, Single Cylinder Engine Model Number ES300PFE010 Engine Displacement 299cc Number of Cylinders 1 Bore & Stroke (mm) 78.5 x 68 mm Compression Ratio 9.2:1 Full Stroke Compression Pressure Engine Idle Speed Cooling System/Capacity Overheat Warning Lubrication Compression Relase 60-90 psi 1300 RPM Air/Oil Cooled None Wet Sump Oil Requirements Polaris 0W-50 / 2 qts (1.9L) Exhaust System Single Pipe - USFS Approved Carburetion Carburetor model Main Jet Pilot Jet 147.5 42.5 4HB42-5 Needle Jet 0-4m Pilot/Air Screw 2.5 Turns Out (Initial setting) Float Height 13mm from carburetor body Fuel Delivery Fuel Pump 4.5 gal. (17 L) 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 250 watt / 18.6 Amp @ 6000 Voltage Regulator 3-phase Lights : High Beam -- Low Beam Brake Tail BTDC 30+/-2deg. @ 5000 RPM Starting Indicator Panel CVT w/EBS Belt 3211108 Steering / Suspension Front Suspension / Shock Mac Pherson Strut Front Travel 7 in. / 17.8 cm Rear Suspension Style / Shock Independent Coil-over Adjustable Rear Travel 8 in. / 20.3 cm Ground Clearance 8 in. / 20.3 cm Shock Preload Adjustment Front / Rear Turning Radius Toe Out Front - Cam Rear - Cam 62.5 in. (159 cm) unloaded 0-1/16 in. (0-.159 mm) Tire/Rim Size - Front 22 x 7-12 Tire/Rim Size - Rear 22 x 10-12 Air Press. F/R Tires 3-5 psi Brake - Front Single Control Hydraulic Disc Brake - Rear Single Control Hydraulic Disc Brake Fluid Polaris DOT 3 or 4 Brake Fluid JETTING CHART Altitude Meters (Feet) 0-1800 (0-6000) 1800-3700 (6000-12000) AMBIENT TEMPERATURE Above +40o F Below 40o F Below 5o C Above +5o C 152.5 147.5 147.5 142.5 CLUTCH CHART Altitude 12V / 8.26 watts Ignition Timing Circuit Breakers Clutch Type 12V / 26.9 watts DC CDI Battery / Model / Amp Hr Fwd 5.17:1 / Rev 4.79:1 Fwd 15.18:1 / Rev 14.05:1 37.5 watts Ignition System Spark plug / Gap Front Output Rear Output 15.2 oz. (450 ml) Wheels / Brakes Mikuni BST 34mm Jet Needle Fuel Capacity / Requirement H-N-R Transmission Capacity Engine Platform Drivetrain Meters (Feet) Shift Weight 0-1800 (0-6000) 14 g (Yellow) 5412989 1800-3700 (6000 - 12000) 12 g (Red) 5412987 NGK CR8E .031 in. / .8 mm Conventional 14 Amp/hr Fusible Link / 15 amp Main / 15 Amp Accsy Electric / Recoil Back-up LCD / Indicator lights 1.5 [email protected] GENERAL INFORMATION GENERAL INFORMATION PUBLICATION NUMBERS Year Model Model No. Owner’s Manual PN Parts Manual PN Parts Micro Fiche PN 2006 Hawkeye 2x4 A06LB27AA 9920202 9920207 9920208 2006 Hawkeye 4x4 A06LD27AB,AC 9920202 9920207 9920208 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. REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is necessary. 1.6 Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 [email protected] GENERAL INFORMATION SPECIAL TOOLS Standard Tools and Engine Tools Special Tools may be required while servicing your machine. Some of the tools listed are mandatory and other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris special tools when servicing any Polaris product. Standard Tools and Engine Tools 2871293 - B - Crankshaft Slotted Nut Socket PA - 47344 - Balance Shaft Slotted Nut Socket 2870569 - Crankshaft True Kit PV - 35667 - A - Cylinder Leakdown Tester PU - 45432 - Caliper or A Basic Caliper Suspension Tools 2870975 - Mity VacTM 2870871 - ATV Ball Joint Tool Kit 2870773 - C - Clip Install Tool 2870390 - Piston Support Block 2870623 - Shock Spring Compressor PA-47478 - Drive Clutch Holder 1.7 [email protected] GENERAL INFORMATION Standard Tools and Engine Tools Electrical Tools PV-43568 - FlukeTM 77 Multimeter 2870303- Hone Kit PV-39617 - Current Clamp 2870305 - Stone Replacement Kit 2870836 - Battery Hydrometer 2870588 - Hone Oil (12 OZ.) 2200634 - Valve Seat Reconditioning Kit 2870459 - Dial Indicator 1.8 8712500 Tachometer PV-39951-A Tachometer [email protected] GENERAL INFORMATION 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 #10 #10 - 24 32 1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 - 20 28 18 24 16 24 14 20 13 20 Grade 2 Grade 5 Grade 8 Torque in. lbs. (Nm) . . . . . . . . . . . . . . . . . 27 (3.1) . . . . . . . . . 43 (5.0) . . . . . . . . . 60 (6.9) . . . . . . . . . . . . . . . . . 31 (3.6) . . . . . . . . . 49 (5.6) . . . . . . . . . 68 (7.8) Torque ft. lbs. (Nm)* . . . . . . . . . . . . . . . . . 5 (7). . . . . . . . . . . . 8 (11). . . . . . . . . . . 12 (16) . . . . . . . . . . . . . . . . . 6 (8). . . . . . . . . . . . 10 (14) . . . . . . . . . 14 (19) . . . . . . . . . . . . . . . . . 11(15) . . . . . . . . . . 17 (23) . . . . . . . . . 25 (35) . . . . . . . . . . . . . . . . . 12(16) . . . . . . . . . . 19 (26) . . . . . . . . . 29 (40) . . . . . . . . . . . . . . . . . 20(27) . . . . . . . . . . 30 (40) . . . . . . . . . 45 (62) . . . . . . . . . . . . . . . . . 23(32) . . . . . . . . . . 35 (48) . . . . . . . . . 50 (69) . . . . . . . . . . . . . . . . . 30(40) . . . . . . . . . . 50 (69) . . . . . . . . . 70 (97) . . . . . . . . . . . . . . . . . 35(48) . . . . . . . . . . 55 (76) . . . . . . . . . 80 (110) . . . . . . . . . . . . . . . . . 50(69) . . . . . . . . . . 75 (104) . . . . . . . . 110 (152) . . . . . . . . . . . . . . . . . 55(76) . . . . . . . . . . 90 (124) . . . . . . . . 120 (166) Metric / Torque 6 x 1.0. . . . . . . . . . . 72-78 In.lbs.. . . . . . . . . 8 x 1.25 14-18 ft.lbs . . . . 10 x 1.25 26-30 ft.lbs. 1.9 [email protected] GENERAL INFORMATION 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 DECIMAL EQUIVALENTS 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 1 1/4-7 1 7/64 1 1/4-12 1 11/64 1 1/2-6 1 11/32 1 1/2-12 1 27/64 1 3/4-5 1 9/16 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 2 1/2-4 2 1/4 2 3/4-4 2 1/2 3-4 2 3/4 METRIC TAP DRILL SIZES Tap Size Drill Size 3x.50 3x.60 4x.70 4x.75 5x.80 5x.90 6x1.00 7x1.00 8x1.00 8x1.25 9x1.00 9x1.25 10x1.25 10x1.50 11x1.50 12x1.50 12x1.75 #39 3/32 #30 1/8 #19 #20 #9 16/64 J 17/64 5/16 5/16 11/32 R 3/8 13/32 13/32 1.10 Decimal Equivalent 0.0995 0.0937 0.1285 0.125 0.166 0.161 0.196 0.234 0.277 0.265 0.3125 0.3125 0.3437 0.339 0.375 0.406 0.406 Nearest Fraction 3/32 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32 1/64 3/64 5/64 7/64 9/64 11/64 13/64 15/64 17/64 19/64 21/64 23/64 25/64 27/64 29/64 31/64 33/64 35/64 37/64 39/64 41/64 43/64 45/64 47/64 49/64 51/64 53/64 55/64 57/64 59/64 61/64 63/64 ................ 1/32 . . . . . . . . . . . . . ................ 1/16 . . . . . . . . . . . . . ................ 3/32 . . . . . . . . . . . . . ................ 1/8 . . . . . . . . .1250 ................ 5/32 . . . . . . . . . . . . . ................ 3/16 . . . . . . . . . . . . . ................ 7/32 . . . . . . . . . . . . . ................ 1/4 . . . . . . . . .25 ................ 9/32 . . . . . . . . . . . . . ................ 5/16 . . . . . . . . . . . . . ................ 11/32 . . . . . . . . . . . . ................ 3/8 . . . . . . . . .375 ................ 13/32 . . . . . . . . . . . . ................ 7/16 . . . . . . . . . . . . . ................ 15/32 . . . . . . . . . . . . ................ 1/2 . . . . . . . . .5. . . . ................ 17/32 . . . . . . . . . . . . ................ 9/16 . . . . . . . . . . . . . ................ 19/32 . . . . . . . . . . . . ................ 5/8 . . . . . . . . .625. . ................ 21/32 . . . . . . . . . . . . ................ 11/16 . . . . . . . . . . . . ................ 23/32 . . . . . . . . . . . . ................ 3/4 . . . . . . . . .75 ................ 25/32 . . . . . . . . . . . . ................ 13/16 . . . . . . . . . . . . ................ 27/32 . . . . . . . . . . . . ................ 7/8 . . . . . . . . .875 ................ 29/32 . . . . . . . . . . . . ................ 15/16 . . . . . . . . . . . . ................ 31/32 . . . . . . . . . . . . ................ 1 . . . . . . . . . 1.0 .0156 .0312 . . .1 mm= .0394" .0469 .0625 .0781 . . .2 mm = .0787" .0938 .1094 . . .3 mm =.1181" .1406 .1563 . . .4 mm = .1575" .1719 .1875 . . .5mm= .1969" .2031 .2188 .2344 . . .6 mm = .2362" .2656 . . .7 mm = .2756" .2813 .2969 .3125 . . .8mm= .3150" .3281 .3438 . . .9 mm = .3543" .3594 .3906 . . .10 mm = .3937" .4063 .4219 . . .11 mm =.4331" .4375 .4531 .4688 . . .12 mm = .4724" .4844 . . . . . . . .13mm = .5118" .5156 .5313 .5469 . . .14 mm = .5512" .5625 .5781 . . .15 mm = .5906" .5938 .6094 . . . . . . . .16mm=. 6299" .6406 .6563 . . .17 mm =.6693" .6719 .6875 .7031 . . .18 mm = .7087" .7188 .7344 . . .19 mm = .7480" .7656 .7813 . . .20 mm = .7874" .7969 .8125 . . .21 mm =.8268" .8281 .8438 .8594 . . .22 mm = .8661" .8906 . . .23 mm = .9055" .9063 .9219 .9375 . . .24 mm = .9449" .9531 .9688 . . .25 mm = .9843" .9844 [email protected] GENERAL INFORMATION CONVERSION TABLE Unit of Measure Multiplied by Converts to ft. lbs. x 12 = 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 x 10 = Nm in. x 25.4 =mm mm x .03937 = in. in. x 2.54 = cm mile (mi.) x 1.6 = 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) x 1.76 = Imperial pints (Imp pt.) Imperial quarts (Imp qt.) x 1.137 = Liters (l) Liters (l) x 0.88 = 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) x 0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1 = Kilopascals (kPa) π(3.14)xR2x H (height) = Cylinder Volume °C to °F: 9 (°C + 40) ÷ 5 - 40 = °F °F to °C: 5 (°F + 40) ÷ 9 - 40 = °C 1.11 [email protected] GENERAL INFORMATION GLOSSARY OF TERMS ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" 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 it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and grip the drive belt. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO. CVT: Centrifugal Variable Transmission (Drive Clutch System) 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. l or ltr: 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. 1 mm = 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. qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. 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 [email protected] MAINTENANCE CHAPTER 2 MAINTENANCE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 LUBRICANTS / FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 POLARIS LUBES/FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS. . . . . . . . . . . . . 2.7 POLARIS LUBRICANT SYMBOL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 VEHICLE INSPECTION / MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 HAWKEYE HANDLEBAR COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 FRONT GEARCASE LUBRICATION (4X4 ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 LUBRICATION / GREASE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 THROTTLE OPERATION - ALL MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 CHOKE (ENRICHER) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 PILOT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 PILOT SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 ELECTRONIC THROTTLE CONTROL (ETC SWITCH)/THROTTLE CABLE ADJUSTMENT2.14 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 ENGINE FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16 IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 MAIN AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 AIR FILTER/PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 AIR BOX SEDIMENT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18 CVT DRAIN PLUG & DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18 ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18 OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19 VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 TIE ROD END/STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 TOE ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 TOE ALIGNMENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 EXHAUST CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 BRAKE SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23 BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23 HOSE/FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23 BRAKE FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23 SUSPENSION SPRING FRONT / REAR PRELOAD ADJUSTMENT. . . . . . . . . . . . . . 2.24 FRONT SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 REAR SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 WHEEL, HUB, AND SPINDLE TORQUE TABLE2.25 WHEEL REMOVAL/INSTALL- FRONT OR REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 2.1 2 [email protected] MAINTENANCE MAINTENANCE PERIODIC MAINTENANCE CHART Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition • Frequent immersion in mud, water or sand • Racing or race-style high RPM use • Prolonged low speed, heavy load operation • Extended idle • Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer. Maintenance Chart Key The following symbols denote potential items to be aware of during maintenance: = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized Polaris dealer. = SEVERE USE ITEM --If vehicle is subjected to severe use, decrease interval by 50% (Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is required under these conditions. Fluid changes, cable, chain and chassis lubrication are required more frequently. For engine oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A rising oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.) E= Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. 2.2 [email protected] MAINTENANCE MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Steering Front-suspension Rear-suspension Tires Engine Stop Switch Maintenance Interval (whichever comes first) Hours Calendar Miles (KM) Pre-Ride Pre-Ride - Pre-Ride Pre-Ride - Remarks Check for free operation. Make adjustments as needed. See PreRide Checklist on Page 2.8. Check Operation Make adjustments as needed. See PreRide Checklist on Page 2.8 Make adjustments as needed. See PreRide Checklist on Page 2.8 Check Operation Make adjustments as needed. See PreRide Checklist on Page 2.8 Make adjustments as needed. See PreRide Checklist on Page 2.8 Brake fluid level - Pre-Ride - Brake lever travel - Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride - Engine oil level - Pre-Ride - Air filter, pre-filter - Daily - Inspect;clean often Air box sediment tube - Daily - Drain deposits when visible Coolant (if applicable) - Daily - Headlamp/tail lamp - Daily - - Weekly - Inspect; replace as needed - Weekly - Drain water as needed, check often if operating in wet conditions Brake pad wear 10 H Monthly 100 (160) Inspect periodically Battery Engine oil change E (break-in) Front gearcase oil (if equipped) 20 H Monthly 200 (320) 20 H 1M 100 (160) Check terminals; clean; test Perform a break-in oil change at one month 25 H Monthly 250 (400) Inspect level; change yearly 25 H Monthly 250 (400) Inspect level; change yearly Brake systems Throttle Wheels /fasteners Frame Fasteners E E E Air filter, E main element Recoil housing (if equipped) Middle gearcase oil (if equipped) Check level daily, change coolant every 2 years Check operation; apply dielectric grease if replacing Rear gearcase oil 25 H Monthly 250 (400) Inspect level; change yearly (if equipped) 25 H Monthly 250 (400) Inspect level; change yearly Transmission oil Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services. 2.3 [email protected] MAINTENANCE Item Hours Engine breather E filter (if equipped) Engine breather hose General lubrication Shift Linkage Maintenance Interval (whichever comes first) Calendar Miles (KM) 25 H Monthly 250 (400) 100 H 6M 1000 (1600) 50 H 3M 500 (800) 50 H 6M 500 (800) Lubricate all grease fittings, pivots, cables, etc. Inspect, lubricate, adjust Inspect daily, Lubricate Steering 50 H 6M 500 (800) Front suspension 50 H 6M 500 (800) Rear suspension 50 H 6M 500 (800) 50 H 6M 500 (800) 50 H 6M 500 (800) 50 H 6M 500 (800) 50 H 6M 500 (800) 100 H 12 M 1000 (1600) 50 H 6M 500 (800) 25 H 6M 500 (800) **Normal Duty 50 H 12 M Engine oil change *Severe Duty 25 H 6M **Normal Duty 50 H 12 M 100 H 100 H E E E E Carburetor float bowl Throttle Cable/ ETC Switch Choke cable Carburetor air intake ducts/flange Drive belt Cooling system (if applicable) Engine oil change *Severe Duty Oil filter change Remarks 1000 (1600) 500 (800) Inspect; replace if necessary Inspect Inspect, Lubricate, Tighten Fasteners Inspect, Lubricate, Tighten Fasteners Drain bowl periodically and prior to storage Inspect; adjust; lubricate; replace if necessary Inspect; adjust; lubricate; replace if necessary Inspect ducts for proper sealing/air leaks Inspect; adjust; replace as needed Inspect coolant strength seasonally; pressure test system yearly Perform a break-in oil change at 20 hours/one month, change more frequently during cold weather Replace at oil change 6M 1000 (1600) 1000 (1600) Replace with oil change 12 M 1000 (1600) Inspect; adjust E Valve clearance E Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services 2.4 [email protected] MAINTENANCE Item E E Fuel system Fuel Filter Radiator (if applicable) Cooling hoses (if applicable) Engine mounts Exhaust muffler / pipe E E Spark plug Ignition Timing Wiring Clutches (drive and driven) Front wheel bearings Brake fluid Spark arrestor E Idle Speed Toe adjustment Auxiliary brake Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) 1000 100 H 12M (1600) 1000 100 H 12M (1600) 1000 100 H 12M (1600) 1000 100 H 12M (1600) 1000 100 H 12M (1600) 1000 100 H 12M (1600) 1000 100 H 12M (1600) 1000 100 H 12M (1600) 1000 100 H 12M (1600) 1000 100 H 12M (1600) 1000 100 H 12M (1600) 2000 200 H 24M (3200) 3000 300 H 36M (4800) Pre- Ride Remarks Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor, replace lines every two years Replace yearly Inspect; clean external surfaces Inspect for leaks Inspect Inspect Inspect; replace as needed Inspect Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc. Inspect;clean; replace worn parts Inspect; replace as needed Change every two years Clean out Adjust as needed Inspect periodically; adjust when parts are replaced Inspect daily; adjust as needed Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services. 2.5 [email protected] MAINTENANCE LUBRICANTS / FLUIDS POLARIS LUBES/FLUIDS 0W/40 2874865 - Quarts 2874867 - 55 Gallon Drum ATV Angle Drive Fluid 2.6 [email protected] MAINTENANCE POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS Part No. Description Additives / Sealants / Thread Locking Agents / Misc. 2870585 Loctite™ Primer N, Aerosol, 25 g 2871956 Loctite™ Thread Sealant 565 (50 ml.) (6 Count) 2871949 Loctite™ Threadlock 242 (50 ml.) (10 Count) 2871950 Loctite™ Threadlock 242 (6 ml.) (12 Count) 2873602 Premium Synthetic AGL Gearcase Lube (12 oz. bottle) (12 Count) 2871951 Loctite™ Threadlock 262 (50 ml.) (10 Count) 2873603 Premium Synthetic AGL Gearcase Lube (1 Gal.) (4 Count) 2871952 Loctite™ Threadlock 262 (6 ml.) (12 Count) 2871653 Premium ATV Angle Drive Fluid (8 oz.) (12 Count) 2871953 Loctite™ Threadlock 271 (6 ml.) (12 Count) 2872276 Premium ATV Angle Drive Fluid (2.5 Gal) (2 Count) 2871954 Loctite™ Threadlock 271 (36 ml.) (6 Count) 2870465 Oil Pump for 1 Gallon Jug 2870584 Loctite™ 680-Retaining Compound (10 ml.) 2870587 Loctite™ 518 Gasket Eliminator / Flange Sealant (50 ml.) (10 Count) 2871326 Premium Carbon Clean (12 oz.) (12 Count) 2870652 Fuel Stabilizer (16 oz.) (12 Count) 2871957 Black RTV Silicone Sealer (3 oz. tube) (12 Count) 2871958 Black RTV Silicone Sealer (11 oz. cartridge) (12 Count) 2870990 DOT3 Brake Fluid (12 Count) 2871557 Crankcase Sealant, 3-Bond 1215 (5oz.) 2872893 Engine Degreaser (12oz.) (12 Count) Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2874865 0W-50 Quarts 2874867 0W-50 55 Gallon Drum Gearcase / Transmission Lubricants Grease / Specialized Lubricants 2871322 2871423 2871460 Premium All Season Grease (3 oz. cartridge) (24 Count) Premium All Season Grease (14 oz. cartridge) (10 Count) Starter Drive Grease (12 Count) 2871312 Grease Gun Kit 2871329 Dielectric Grease (Nyogel™) NOTE: Each item can be purchased separately at your local Polaris dealer. NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order. 2.7 [email protected] MAINTENANCE POLARIS LUBRICANT SYMBOL IDENTIFICATION NOTE: The symbols are used to properly identify the correct lube or grease to use in the maintenance section. Polaris DOT 3 Brake Fluid Polaris Synthetic Gearcase Lube Polaris Synthetic OW-50 Oil Polaris All Season Grease Polaris ATV Angle Drive Fluid VEHICLE INSPECTION / MAINTENANCE PRE-RIDE / DAILY INSPECTION Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. • Tires - check condition and pressures • Fuel and oil - fill both to their proper level; Do not overfill • All brakes - check operation(includes auxiliary brake) • Throttle - check for free operation • Headlight/Taillight/Brakelight - check operation of all indicator lights and switches • Engine stop switch - check for proper function • Wheels - check for loose wheel nuts • Air cleaner element - check for dirt or water; clean or replace • Steering - check for free operation, noting any unusual looseness in any area • Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners • Engine coolant(if applicable) - check for proper level at the recovery bottle 2.8 [email protected] MAINTENANCE HAWKEYE HANDLEBAR COMPONENT LOCATIONS 4x4 switch (if applicable) Indicator Lights Speedo Front Brake Throttle Light Control & Run Switch Choke Ignition/Start Key Reverse Override MAINTENANCE QUICK REFERENCE III. # 1 Item Engine Oil Lube Rec. Method Frequency* Polaris 0W-50 Synthetic Add oil to proper level. Change after 1st month (25 hours), 50 hours thereafter; Change more often (25 hours) in severe duty conditions, or short trip cold weather operation. 2 Transmission Polaris AGL Lubricant See procedure. Change annually2 3 Brake Fluid Polaris DOT 3 Brake Fluid Fill master cylinder reservoir to indicated level inside reservoir. As required. Change fluid every 2 years. 4 Rear Gearcase Polaris ATV Angle Drive Fluid Drain and refill with premeasured amount of lubricant. As required* 5 A-Arm Bushings Polaris All Season Grease 3 Locate grease fitting on swing arm and grease with grease gun. Semi-annually 1 * More often under severe use, such as operated in water or under severe loads. 1 Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) 2 Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) 3 Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special. 2.9 [email protected] MAINTENANCE NOTE: Refer to Page 2.6-2.8 for the Polaris Lubricant Identification table. 1. Engine Oil 2. Transmission Oil Reservoir Level 3. Brake Fluid 5. Bottom Rear Lower Control Arm Lower Rear Bearing Carrier Pivot Prop Shaft 2.10 4. Rear Gearcase Oil [email protected] MAINTENANCE TRANSMISSION LUBRICATION FRONT GEARCASE LUBRICATION (4X4 The transmission lubricant level should be checked and ONLY) changed in accordance with the maintenance schedule. • Be sure vehicle is level before proceeding. The front gearcase lubricant level should be checked and changed in accordance with the maintenance schedule. • Be sure vehicle is level before proceeding. • Check vent hose to be sure it is routed properly and unobstructed. • Check vent hose to be sure it is routed properly and unobstructed. TRANSMISSION SPECIFICATIONS FRONT GEARCASE SPECIFICATIONS Specified Lubricant: Polaris AGSL Gearcase Lubricant: (PN 2873603) (Gallon) (PN 2873602) (12 oz.) Specified Lubricant: Polaris Premium Demand Drive Hub Fluid: (PN 2872277) (2.5 gallon) (PN 2871654) (8 oz.) Capacity: Even with fill plug Capacity: Even with fill plug Drain Plug and Fill Plug Torque: 15 ft. lbs. (20 Nm) Drain Plug Torque: 8-10 ft. lbs. (11-13 Nm) To change / check transmission fluid: 1. Place a drain pan beneath oil pan and remove drain plug from the crankcase. Allow oil to drain completely. 2. Reinstall the drain plug. Tighten to specification. 3. Add the proper amount of lubricant to bring level into operating range as shown. Do not over fill. Fill / Check Plug Torque: 8-10 ft. lbs. (11-13 Nm) A B C Drain Plug Gearcase oil flush with the bottom of thread area. 4. Oil Level Check 1. Position the vehicle on a level surface. 2. Remove the check/fill plug (A) and view the oil level. The oil level should be at the bottom of the check plug (B) threads. 3. Reinstall the check/fill plug (A). Torque to specification. 4. Reinstall the check plug (A) and a new sealing washer. Torque to specification. Verify fluid level is correct and no leaks are present. 2.11 [email protected] MAINTENANCE 5. Check for leaks. Oil Change 1. Remove the drain plug (C). Drain the oil into an appropriate container. Discard used oil properly 2. Clean and reinstall the drain plug with a new sealing washer. Torque to specification. 3. Remove the check plug (A). 4. Remove the fill plug (B) and add a pre-measured amount of Polaris Angle Drive Fluid. The fluid should not be above the bottom of the check plug (A) threads. 5. Reinstall the fill plug (B) and check plug (A). Torque to specification. 6. Check for leaks. Verify free play of 1/16-3/16” (1.6-4.76 mm) and smooth operation of choke cable.Adjustments to the freeplay can be made by loosening the choke cable adjustment in or out to gain the desired freeplay. If smooth choke operation is not obtainable, inspect choke cable for kinks or sharp bends in routing. CARBURETOR DRAINING The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl, or before extended periods of storage. NOTE: The bowl drain screw is located on the bottom left side of the float bowl. 1. Turn fuel valve to the OFF position. LUBRICATION / GREASE POINTS 2. There are grease zerks rear lower control arm inner pivots, lower rear bearing carrier pivots, and the prop shaft. Apply grease until it is visible on the ends of the pivot points. Place a clean container beneath the bowl drain spigot or bowl drain hose. 3. Turn drain screw out two turns and allow fuel in the float bowl and fuel line to drain completely. 4. Inspect the drained fuel for water or sediment. 5. Tighten drain screw. 6. Turn fuel valve to “ON”. 7. Start machine and check for leaks. 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 NOTE: All tubes attached to the carburetor must be check for pinching or blockage, as this will effect engine performance Drain tube attached here III. 1 CHOKE 2.12 Drain Screw [email protected] MAINTENANCE PILOT SCREW PILOT SCREW ADJUSTMENT The pilot system supplies fuel during engine operation with the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet. CAUTION FRONT (Engine) 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 Pilot Screw Location 1. Start engine and warm it up to operating temperature (about 10 minutes). 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. Brass Plug Installed Pilot screws are calibrated at the factory. Each carburetor has a slightly different pilot screw setting. The specifications may require additional tuning to achieve the desired results. Brass Plug Removed 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. 2.13 [email protected] MAINTENANCE 6. • Do not overfill the tank. Do not fill the tank neck. 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. • If you get gasoline in your eyes or if you swallow gasoline, seek medical attention immediately. • If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing. ELECTRONIC THROTTLE CONTROL (ETC SWITCH)/THROTTLE CABLE 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 confirm adjustment. Boot Locknut • 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. • Never drain the float bowl when the engine is hot. Severe burns may result. FUEL LINES 1. Check fuel lines for signs of wear, deterioration, damage, or leakage. Replace if necessary. 2. Be sure fuel lines are routed properly and secured with cable ties. CAUTION Boot Adjuster Sleeve Make sure lines are not kinked or pinched 3. Direction of travel 1/16” to 1/8” Freeplay 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. VENT LINES 1. Check fuel tank, crankcase, carburetor, battery and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years. 2. Verify vent lines are routed properly and secured with cable ties. CAUTION NOTE: If the throttle cable is adjusted too tight, the ETC will limit operation at low throttle positions. Make sure lines are not kinked or pinched FUEL FILTER FUEL SYSTEM WARNING Gasoline is extremely flammable and explosive under certain conditions. • Always stop the engine and refuel outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. 2.14 Replace all fuel lines every two years. The fuel filter should be replaced in accordance with the Periodic Maintenance Chart. The fuel filter is located between the fuel tank and carburetor. 1. Clamp fuel lines 2. Remove line clamps at both ends of the filter. 3. Remove fuel lines from filter. 4. Install new filter and clamps onto fuel lines with arrow pointed in direction of fuel flow. [email protected] MAINTENANCE BATTERY MAINTENANCE WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: Fuel Filter External: Flush with water. To Carburetor Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. 5. Install clamps on fuel line. 6. Start engine and inspect for leaks. 7. Remove clamps COMPRESSION TEST NOTE: This 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 90 psi during a compression test. 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). Cylinder Compression Standard: 90PSI Cylinder Leakage Service Limit: 10% (Inspect for cause if leakage exceeds 10%) 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 Hawkeye batteries are Low Maintenance design and construction. All Low Maintenance 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. Low Maintenance 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 Low Maintenance 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 Low Maintenance 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 Low Maintenance batteries. ENGINE MOUNTS Inspect rubber engine mounts for cracks or damage. ENGINE FASTENER TORQUE Check engine fasteners and ensure they are tight 2.15 [email protected] MAINTENANCE The battery is located under front rack. SPARK PLUG To remove the battery: 1. Remove the seat and left hand side panel. 1. Disconnect holder strap. 2. 2. Disconnect battery negative (-) (black) cable first, followed by the positive (+) (red) cable. Remove spark plug high tension lead. Clean plug area so no dirt and debris can fall into engine when plug is removed. 3. Remove spark plug. 4. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes. CAUTION To reduce the chance of sparks: Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, install the negative cable last. 3. Remove the battery. 4. Clean battery cables and terminals with a stiff wire brush. Corrosion can be removed using a solution of one cup water and one tablespoon baking soda. Rinse well with clean water and dry thoroughly. 5. Reinstall battery, attaching positive (+) (red) cable first and then the negative (-) (black) cable. 6. Coat terminals and bolt threads with Dielectric Grease (PN 2871329). 7. Reinstall battery cover and holder strap. 2.16 Inspect electrode for wear and buildup Spark Plug Gap 5. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used. 6. 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. 7. If necessary, replace spark plug with proper type. CAUTION: Severe engine damage may occur if the incorrect spark plug is used. 8. Apply a small amount of anti-seize compound to the spark plug threads. 9. Install spark plug and torque to 9-11 ft. lbs (12-14 Nm). [email protected] MAINTENANCE 10. Replace side panel and seat. 2. Remove clips from air box cover (A) and remove cover. Recommended Spark Plug: A NGK R7HSA Spark Plug Torque: 9-11 Ft. Lbs. (12 - 14 Nm) IGNITION TIMING Timing is CDI controlled and has no adjustment procedure. Ignition Timing: 32o + 2o BTDC@3000RPM MAIN AIR FILTER CLEANING It is advisable to replace the filter when it is dirty. However, in an emergency it is permissible to clean the main filter if you observe the following practices. • Never immerse the filter in water since dirt can be transferred to the clean air side of the filter. • If compressed air is used never exceed a pressure of 40 PSI. Always use a dispersion type nozzle to prevent filter damage and clean from the inside to the outside. • Replace the air filter every 50 hours, and possibly more often in very dirty conditions. AIR FILTER/PRE-FILTER SERVICE It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty conditions, replacement is required more often. The pre filter should be cleaned before each ride using the following procedure: 1. 3. Inspect the gasket. It should adhere tightly to the cover and seal all the way around. 4. Remove air filter assembly. Cleaning: 5. Slip the pre-filter element off of main element. Clean the pre filter with hot soapy water. 6. Rinse and dry thoroughly. 7. Inspect element for tears or damage. 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. Remove the seat. 2.17 [email protected] MAINTENANCE CVT DRAIN PLUG & DRYING Proper Filter Placement Main Filter Filter Support NOTE: If operating the ATV through water, be sure to check the CVT and other components for water ingestion. The ATV should be checked immediately. 1. To release any water that maybe trapped in the CVT cover, simply remove the CVT drain plug and O-ring located on the bottom of the CVT cover and let the water drain out. 2. To further expel water from the cover and to dry out the CVT 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 CVT system is dry. Air Box III. 3 Rear 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. 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. ENGINE OIL LEVEL To check the oil level: 1. Set machine on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. 4. Start the engine. Allow it to idle for 30 seconds. 5. Turn the engine off. 6. The oil dipstick and fill hole are located behind the recoil on 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. 2.18 [email protected] MAINTENANCE the right side of the ATV. 7. Remove the dipstick and wipe it clean. 8. Reinstall the dipstick completely 9. Remove the dipstick an check the oil level. 10. Add oil as needed to bring the level between the minimum and maximum marks. Do not over fill. 11. Reinstall the dipstick. 6. Clean the area around the drain plug. CAUTION Hot oil may result in serious burns. Do not allow hot oil to contact skin. 7. Place a drain pan under the vehicle. 8. Remove the drain plug. Use a 6mm Allen wrench. 9. Drain the oil. OIL AND FILTER CHANGE 1. Set machine on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. 10. Reinstall the drain plug with a new sealing washer. 11. Torque to 14 ft-lb (19Nm). NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches. 12. Place towels under the oil filter. 13. Using an oil filter wrench, turn the filter counter clockwise to remove it. 4. Start the engine. Allow it to idle for two to three minuets. 5. Turn the engine off. 2.19 [email protected] MAINTENANCE 14. Clean the filter sealing area on the engine. VALVE CLEARANCE ADJUSTMENT 15. Lubricate the filter o-ring. Check to make sure the o-ring is in good condition. 16. Install the new oil filter, After the filter contacts the engine surface turn it 1/2 turn by hand. INTAKE VALVE CLEARANCE 17. Remove the dipstick. 1. Verify cam lobes are pointed down. 2. Insert a .006” (.15 mm) feeler gauge between end of intake valve stem and adjuster screw. 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. 18. Add 0W/50 oil. INTAKE/ EXHAUST VALVE CLEARANCE .006” (.15 mm) EXHAUST VALVE CLEARANCE 1. Verify cam lobes are pointed down. 2. Insert an .006” (.15 mm) feeler gauge between end of exhaust valve stem and adjuster screw. 3. Loosen locknut and turn adjuster screw until there is a slight drag on feeler gauge. 4. When clearance is correct, hold adjuster screw and tighten locknut securely. 5. Re-check the valve clearance. 6. Repeat adjustment procedure if necessary until clearance is correct with locknut secured. 19. Reinstall the dipstick. 20. Start the engine and allow it to idle for two minuets. 21. Turn off the engine. Check for oil leaks. 22. Check the oil level. Add oil as needed to bring the level between the min. and max marks. Do not overfill. STEERING 23. Discard used oil and filter properly. 2.20 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. [email protected] MAINTENANCE 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. first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward. WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris Dealer. Only a qualified technician should replace worn or damaged steering parts. Use only genuine Polaris replacement parts. Check for Loose Wheel or Hub One of two methods can be used to measure toe alignment: The string method and the chalk method. If adjustment is required, refer to following pages for procedure. TIE ROD END/STEERING INSPECTION To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement. • Repeat inspection for inner tie rod end (on steering post). • Replace any worn steering components. Steering should move freely through entire range of travel without binding. • 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 • If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause. CAMBER AND CASTER The camber and caster are non-adjustable. TOE ALIGNMENT 1. Place machine on a smooth level surface. 2. Set handlebars in a straight ahead position and secure handlebars in this position. NOTE: The steering arm can be used as an indicator of 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 180o 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” (.3 to.6 cm) 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 2.21 [email protected] MAINTENANCE may not be immediately incorrectly. See illustration. measurement at the rear (B). apparent if done Hold Rod End Chalk Line Measurement “A” Correctly Tightened Jam Nut Measurement “B” Incorrectly Tightened Jam Nut 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. EXHAUST CLEANING WARNING • 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. 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 reduce fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor. To adjust toe alignment: • Wear eye protection. • Hold tie rod end to keep it from rotating. • Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor. • Loosen jam nuts at both end of the tie rod. • Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting - (1/8” to 1/4”). • Never run the engine in an enclosed area.Exhaust contains poisonous carbon monoxide gas. • Important: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage • 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: 2.22 1. Allow the muffler to cool if hot. 2. Remove the fastener (1) and remove the arrestor from the [email protected] MAINTENANCE • Use Polaris DOT 3 or DOT 4 Brake Fluid end of the muffler. SIGHT GLASS 1 Arrestor 3. 4. Use a non-synthetic brush to clean the arrestor screen. A synthetic brush may melt if components are warm. If necessary, blow debris from the screen with compressed air. • Check brake system for fluid leaks, excessive travel or spongy feel. Inspect the screen for wear and damage. Replace if necessary. • Check surface condition of the disc. 5. Remove and inspect the gasket. Replace if worn or damaged. 6. Reinstall the gasket and arrestor. 7. Use a wire brush to clean the arrestor screen. (NOTE: A synthetic brush may melt if components are warm.) If necessary, blow debris from the screen with compressed air. 8. Reinstall the clean out plug and arrestor. 9. Torque screws to 50 in. lbs. (5.6 Nm). • Check brake pads for wear, damage or looseness. • Inspect thickness of brake pad friction material. BRAKE PAD INSPECTION Front Brake Pads Brake Pad BRAKE SYSTEM INSPECTION The following checks are recommended to keep the brake system in good operating condition. Service life of brake system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride. • Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir. • Check the fluid level “eye”. If it is clear, it is an indication that fluid is needed or the brake pads may be worn, which can reduce the fluid level. Measure Thickness Service Limit - .059” (1.5 mm) Brake pads should be changed when friction material is worn to .59” (1.5 mm). HOSE/FITTING INSPECTION Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks.Tighten any loose fittings and replace any worn or damaged parts. BRAKE FREEPLAY Hand Brake Lever 1. Check the brake lever, and foot brake for loose connections, free play, and damage. 2. Measure the hand brake lever freeplay. Freeplay should be 2.23 [email protected] MAINTENANCE 0.40-0.80 in. (10-20 mm). 3. If excessive free play exists, inspect brake pads, pedal, linkage springs, and hoses for wear or damage and replace any parts as needed. .40” - .80” (10-20 mm) Hand Brake Lever Free Play Rear Foot Brake Rear Brake 4. Check foot brake effectiveness by applying approximately 50 lb. (23 kg) downward force on the pedal. The top of the pedal should travel not more than 1 inch (25.4mm). 50 lbs 1” or greater Floorboard 5. If more than one inch, two things must be examined: • Free play of the brake pedal should be 1/8 - 1/4 inch (3.2 - 6.35 mm). 2.24 • If free play is excessive: Inspect brake pads, pedal, linkage springs, and hoses for wear or damage and replace any parts as needed. SUSPENSION SPRING FRONT / REAR PRELOAD ADJUSTMENT Operator weight and vehicle loading affect suspension spring preload requirements. Using Spanner Wrench (PN 2870872) adjust as necessary to avoid bottoming of the shocks. [email protected] MAINTENANCE FRONT SUSPENSION INSPECTION WHEEL REMOVAL/INSTALL- FRONT OR REAR Compress and release front suspension. Damping should be smooth throughout the range of travel. Wheel Removal Check all front suspension components for wear or damage. 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. REAR SUSPENSION INSPECTION 3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. Compress and release rear suspension. Damping should be smooth throughout the range of travel. 4. Remove the wheel nuts and remove the wheel. • Check all rear suspension components for wear or damage. 1. With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. NOTE:Apply an anti-seize compound on the front wheel spindle before hub/wheel installation. 2. Attach the wheel nuts and finger tighten them. 3. Lower the vehicle to the ground. 4. Securely tighten the wheel nuts to the proper torque listed in the table. Inspect front shocks for leakage. Wheel Installation • Inspect shock for leakage. Shock Spanner Wrench (PN 2870872) CONTROLS Check controls for proper operation, positioning and adjustment. • Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body. WHEELS CAUTION Improperly installed wheels could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end of nut goes into taper on wheel. Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts. WHEEL, HUB, AND SPINDLE TORQUE TABLE Item Specification Front Wheel Nuts 27 Ft. Lbs. (37Nm) Rear Wheel Nuts 27 Ft. Lbs. (37Nm) Hub Retaining Nut 80 Ft. Lbs. (108 Nm) Wheel Wheel Nuts (4) 27 ft. lbs. (37 Nm) Cotter Key Hub Retaining Nut 80 ft. lbs. (108 Nm) 2.25 [email protected] MAINTENANCE WHEEL INSTALLATION Tire Tread Depth 1. With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. Always replace tires when tread depth is worn to 1/8” (3 mm) or less. 2. Attach the wheel nuts and finger tighten them. 3. Lower the vehicle to the ground. 4. Securely tighten the wheel nuts to the proper torque listed in the table. Tread Depth 1/8” (3 mm) CAUTION If wheels are improperly installed it could affect vehicle handling and tire wear. Be sure to properly torque and install all wheel nuts. FRAME, NUTS, BOLTS, FASTENERS TIRE PRESSURE Tire Pressure Inspection (PSI - Cold) Front Rear 4 4 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. CAUTION • Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the vehicle. • Improper tire inflation may affect ATV maneuverability. • When replacing a tire always use original equipment size and type. • The use of non-standard size or type tires may affect ATV handling. 2.26 Periodically inspect the torque 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. [email protected] ENGINE CHAPTER 3 ENGINE TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 ENGINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 ENGINE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 OIL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 PISTON RING IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 3 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 TRANSMISSION INSTALLATION NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16 OIL FLOW / PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16 ENGINE BREATHER / OIL SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16 CAM CHAIN TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16 CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17 ROCKER ARM/SHAFT DISASSEMBLY AND INSPECTION. . . . . . . . . . . . . . . . . . . . . 3.17 CAMSHAFT REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19 CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19 CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19 CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20 COMBUSTION CHAMBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20 CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20 VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21 VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21 CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24 VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24 ENGINE BOTTOM END DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 CAM CHAIN GUIDE AND TESIONER BLADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26 CYLINDER HONE SELECTION/ HONING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . 3.26 HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26 PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27 PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28 FLYWHEEL REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28 STARTER DRIVE CLUTCH REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.29 CAM CHAIN DRIVE SPROCKET REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . 3.29 OIL PUMP INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30 STARTING CLUTCH AND ENGINE BRAKING CLUTCH REMOVAL /INSPECTION . . 3.30 STARTING CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31 CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32 CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32 CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33 CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION. . . . . . . . . . . . . . . . . . . . . . 3.33 CRANKCASE OIL PASSAGES & PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . 3.34 3.1 [email protected] ENGINE CAMSHAFT CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BALANCE SHAFT BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE OIL PICKUP STRAINER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . BEARING /SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . END PLAY INSPECTION/ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COUNTER BALANCER SHAFT END PLAY ADJUST. . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAM CHAIN, OIL PUMP, & TENSIONER BLADE INSTALLATION . . . . . . . . . . . . . . . PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD AND CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFT INSTALLATION & TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROCKER ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34 3.34 3.34 3.34 3.35 3.35 3.36 3.37 3.38 3.39 3.39 3.40 3.40 3.41 3.42 3.42 3.43 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43 SPARK PLUG FOULING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43 ENGINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44 3.2 [email protected] ENGINE TOOLS SPECIAL TOOLS PART NUMBER 2200634 2870390 PA-47308 PA-47457 2871293-B TOOL DESCRIPTION Valve Seat Reconditioning Kit Piston Support Block Flywheel Puller Starting Clutch Holder Crankshaft Slotted Nut Socket TORQUE SPECIFICATIONS ENGINE TORQUE SPECIFICATIONS ENGINE TORQUE SPECIFICATIONS Oil Pressure Blind Plug 1/4 NPT 20-24 (27-33 Nm) Oil Pressure Relief Valve Plug 15-17 (20-23 Nm) 14 mm Recoil Housing 6mm 7-8 (9-11 Nm) Rocker Adjuster Screw 5mm 3.5-5 (5-7 Nm) Rocker Cover 6mm 5-6.5 (7-9 Nm) Rocker Adjuster Screw Lock Nut 5mm 3.7-5.0 (5-7 Nm) 6mm 7-8 (9-11 Nm) 5mm 5-6.5 (7-9 Nm) Starter Motor 6mm 5-6.5 (7-9 Nm) Starting Clutch Cover 8mm 14-15.5 (19-21Nm) Stator Plate to Crankcase Stator to Stator Plate Screws Thread Size ES300PFE010 Ft. Lbs. (Nm) Starting Clutch Nut 16mm 103-118 (140-160 Nm) Camshaft Chain Tensioner Lever 6mm 5-6.5 (7-9 Nm) Spark Plug (New) 12mm 7.5-9 (10-12 Nm) Camshaft Chain Tensioner Body 6mm 6.5-8.0 (9-11 Nm) Spark Plug (Used) 12mm Tighten 30-45 degrees after gasket contact Camshaft Chain Tensioner Cap 8mm 6-7.5 (8-10 Nm) Camshaft Sprocket Cover 6mm 6.5-8.0 (9-11 Nm) Fastener Camshaft Sprocket Bolt 10mm 30-34 (40-46 Nm) Carburetor Adaptor 8mm 12-14 (16-20 Nm) Cylinder Head Bolts 10mm Refer to Torque Procedure Cylinder & Head 6mm Bolts 6mm 5-7 (7-9 Nm) Crankcase 6mm 6.5-8.0 (9-11 Nm) Crankshaft Sprocket Slotted Nut 25mm 34 (46 Nm) Flywheel Nut 16mm 66-81 (90-110 Nm) Oil Drain Bolt (Crankcase) 14mm 13-16 (18-22 Nm) Oil Filter Pipe Fitting (Crankcase) 20mm 9.5-12 (13-16 Nm) 3.3 [email protected] ENGINE TORQUE PATTERNS Tightening method for cylinder head nuts: 1) Apply engine oil to washer and threads of 10mm bolts. 2) Tighten 10mm bolts in pattern below to 18.5 ft. lbs. (25 Nm) 3) Loosen 180 degrees 4) Tighten to 11 ft. lbs. (15 Nm) 5) Tighten 90 degrees 6) Tighten 60 degrees 7) Tighten 6mm head and base bolts to 8 ft. lbs. (11 Nm) Cylinder Head / Cylinder Base 3 2 5 6 1 3.4 4 6 mm [email protected] ENGINE GENERAL ENGINE SERVICE ENGINE EXPLODED VIEW Crankcase Cylinder/ Cylinder Head 6 ft. lbs. 8 ft. lbs. 15 ft. lbs. 15 ft. lbs. SEE PROCEDURE 12-14 ft. lbs. 5.5 ft. lbs. 16 ft. lbs. 5.5 ft. lbs. Crankshaft and Piston Valve Train 3.5 ft. lbs. 7 ft. lbs. 6 ft. lbs. 6 ft. lbs. 34 ft. lbs. 30-34 ft. lbs. 3.5 [email protected] ENGINE ENGINE SERVICE DATA Cylinder Head / Valvetrain Camshaft Lobe Height ES300PFE010 In Std 1.2938-1.2977" (32.863 - 32.963mm) Limit 1.2820" (32.563 mm) Std 1.2938-1.2977" (32.863 - 32.963mm) Limit 1.2820" (32.563 mm) Journal O.D. PTO 1.0998-1.1004" (27.935-27.950mm) Journal O.D. MAG 1.5328-1.5334" (38.935-38.950mm) Journal Bore I.D. PTO 1.1025-1.1033" (28.005-28.025mm) Journal Bore I.D. MAG Std 1.5356-1.5364" (39.005-39.025mm) Limit .0039" (.10mm) Ex Camshaft Journal Oil Clearance Camshaft Chain .0021-.0035" (.055 - .090mm) Install new as a part of any crankshaft removal Cylinder Head Surface Warpage Limit .0020” (.05 mm) Rocker Arm/Shaft Rocker arm ID Rocker shaft OD .8669-.8677" (22.02-22.04 mm) .8656-.8661" (21.987-22.00 mm) Oil Clearance (Limit) .0039" (.10 mm) Valve Clearance Valve Seat Angle Contacting Width In Std .006" (.15 mm) Ex In Std Std .039" (1.0 mm) Limit .055" (1.4 mm) Std .059" (1.5 mm) Ex Valve Stem Diameter Stem Length Margin Valve Guide Valve Spring Limit .070" (1.8 mm) In .2342-.2348" (5.950-5.965 mm) Ex .2340-.2346" (5.945-5.960 mm) Limit In .1921" (4.9 mm) 3.976" (101.0mm) Ex 3.984" (101.2mm) In Limit .031" (.8mm) Ex Limit In .031" (.8mm) .2362-.2367" (6.0-6.012 mm) Ex .2362-.2367" (6.0-6.012 mm) Inner Diameter Stem to Guide Oil Clearance Free Length Squareness .006" (.15 mm) Limit .006" (.15 mm) 1.640" (41.66 mm) 1.377" (35.0 mm) 0.075” (1.9 mm) KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power Take Off 3.6 [email protected] ENGINE ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod Cylinder ES300PFE010 Surface warpage limit (mating with cylinder head) Cylinder bore Std .002” (0.05 mm) Taper or Out-of-Round Limit Limit .002” (0.05 mm) Piston to cylinder clearance Std .0015-.0032" (0.038-0.082 mm) Limit .0043" (0.11 mm) Std 1st O.S. + .0098” (.25 mm) 2nd O.S. + .0197” (.50 mm) 3.0566-3.0575" (77.638-77.662 mm) 1st O.S. .0098" (.25 mm) Oversize 2nd O.S. .0197" (.50 mm) Oversize Boring Limit Piston Piston Pin Piston Ring Outer diameter Pin Bore - Inner Diameter .7089-.7094" (18.007-18.020 mm) Pin outer diameter clearance in piston .00015- .00047” (.004- .012 mm) Degree of fit Push (by hand) fit @ 68o F (20o C) (Standard clearance 0-.0005" (0-.012mm) Piston Ring Installed Gap Top ring Std .008-.0012" (.2-.3 mm) Limit .032" (.8 mm) Second ring Std .018-.019" (.35-.50 mm) Limit .039" (1.0mm) Oil ring Std .0079-.0275" (.2-.7 mm) Limit .059" (1.5 mm) Std .0006-.0029" (.015.-.074 mm) Limit .006" (.15 mm) Piston Ring to Ring Groove Second ring Clearance Std .0009-.0025" (.025-.065 mm) Limit .006" (0.15 mm) Oil ring Std .002-.0057" (.055-.145 mm) Limit N/A Top ring Connecting Rod 3.0590-3.0598" (77.70-77.72 mm) Connecting rod small end ID .7089-.7094" (18.007-18.020 mm) Connecting rod small end radial clearance (to piston pin) Std 0 - .0007" (0 - 0.019 mm) Limit .0011" (.03 mm) Connecting rod big end axial (side) clearance Std Limit Connecting rod big end radial clearance Std Limit .0035-.0196" (.09-.50 mm) .023" (.60 mm) 0.0004-.0014" (.011-0.038 mm) .0019" (.05 mm) 3.7 [email protected] ENGINE Crankshaft / Counter Balancer / Oil Pump Crankshaft Crankshaft End Runout Crankshaft End Play Counter Balancer Counter Balancer Shaft End Play Oil Pump ES300PFE010 Limit 0.0024" (0.06 mm) Std 0.006-.012" (.15 - .30 mm) Limit N/A Std 0.004-.029" (0.1 - .74 mm) Limit N/A Oil Pump Shaft End Play N/A Std 0.0027-.0051" (.070 - .130 mm) Limit N/A Std 0.0047" (.12 mm) Limit N/A Std 0.006 - 008" (.15 - .21 mm) Limit N/A Oil Pump End Clearance Pump Rotor Tip Clearance Pump Feed Rotor to Pump Body Clearance Std Oil Pressure (Polaris 0W-50 @ Normal Operating Temperature @ Idle Speed) Limit Above 9 PSI Below 9 PSI KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power Take Off. 3.8 [email protected] ENGINE OIL FLOW DIAGRAM Rocker Arm Rocker Shaft Valve Springs ES300PFE010 Chain Room Cylinder Head (RH Cam Journal) Camshaft Sprocket & Chain Connecting Rod Small End Piston Skirt / Rings Right Rear Cylinder Bolt Nozzle Counter Balance Gear Connecting Rod Big End Main Bearing Crankshaft MAG SIDE Starting Clutch One Way Clutch Crankcase Oil Passage Oil Cooler / Filter Main Bearing PTO SIDE Crankcase Starting Clutch Oil Passage Stator Plate Crankcase Oil Passage Oil Pressure Inspection & Accy Oil Cooler Fitting Location Oil Pump Crankcase OIL FLOW DIAGRAM KEY Oil Passage Oil Pickup Screen Engine Sump Direct Indirect 3.9 [email protected] ENGINE PISTON IDENTIFICATION • Cylinder Head The piston is identified by the marking ES30A. • Valves Note the directional and identification marks when viewing the pistons from the top. The letters “IN” must always be toward the intake side of the engine. Piston rings must be installed correctly to ensure engine performance. The numbers or letters on all rings (except oil control rings) must be positioned upward. See text for oil control ring upper rail installation. Use the information below to identify pistons and rings. Engine Model No. Oversize Available (mm) Standard Piston Identification ES300PFE010 .25mm .50mm Valve Pocket to Rear (Intake Side) • Carburetor • Piston/RIngs The following components require engine removal for service: • Starting Clutch (transmission removal required) • One-Way Clutch (engine braking) • Crankshaft • Crankshaft Main Bearings • Counter Balance Shaft or Bearings • Crankcase • Transmission NOTE: Crankshaft components are not serviceable. Replace crankshaft as an assembly. PISTON RING IDENTIFICATION The piston ring profile is shown below. Install top and second ring with marking UP. Refer to text for oil control ring installation. Piston Ring Installation Note Profile TOP RING Mark Faces UP Inner Bevel; Barrel Face SECOND RING Mark Faces UP Undercut; Taper Face ACCESSIBLE COMPONENTS The following components can be serviced or removed with the engine installed in the frame: • Flywheel ENGINE SERVICE ENGINE REMOVAL NOTE: The engine removal procedure described below removes the engine and transmission as an assembly, and the engine is then removed from the transmission case. The transmission can be removed separately from the engine (see Transmission Removal procedure in this chapter). 1. Clean work area. 2. Thoroughly clean the ATV engine and chassis. 3. Disconnect battery cables at battery. 4. Drain engine oil. 5. Disconnect spark plug high tension lead. 6. Remove the following parts: • Alternator/Stator • Seat • Starter Motor/Starter Drive • Left and Right Side Covers • Oil pump • Rear cab • Rocker Arms / Rocker Shaft • Camshaft • Cam Chain and Sprockets • Cylinder 3.10 7. Remove CVT cover and both clutches (refer to CVT [email protected] ENGINE Chapter 8) 13. CVT air intake and exhaust ducts 8. Front prop shaft (4x4 models) (Drive pin out at front gearcase, pull shaft back, then forward. Refer to Drive Chapter) 14. Remove carburetor. Insert a clean shop towel into the carburetor flange to prevent dirt from entering the intake port. 15. Remove exhaust head pipe. 16. Starter motor positive (+) and negative (-) cables at starter motor. 9. Remove transmission linkage rod (A) and vent hose (B) 10. Disconnect gear indicator switch harness (at transmission) A B 11. Disconnect speed sensor from transmission (left rear side). 12. Rear fuel tank bracket 3.11 [email protected] ENGINE 17. Recoil housing, flywheel and stator (or if front cab is removed, remove front cab and disconnect wires.) See “Flywheel Removal / Inspection” on page 3.28. for flywheel removal procedure. NOTE: If front cab is already removed, the stator wires can be disconnected. Disregard the steps to remove recoil cover, flywheel, and stator from the engine. 18. 19. 20. 21. Front engine mount Support lower sub-frame with a stable platform jack. Rear lower engine mount Sub frame bolts (2 each side) Rear mount 2 both sides 22. Rear wheel (left side) and brake caliper. Re-install rear wheel after caliper removal. 3.12 23. Top rear shock bolts. 24. Top bolts from sway bar bracket. 25. Lower the jack and pull engine / transmission assembly out the rear. [email protected] ENGINE 26. Support engine and remove (9) transmission-toengine bolts. 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. • Use only Polaris Premium 4 All Season Synthetic Oil, or API certified “SH” oil. • Use fuel with a minimum octane of 87 (R+M)/2 method. • Change break-in oil and filter at 20 hours or 100 miles, whichever comes first. IMPORTANT: DO NOT LIFT ENGINE BY THE STARTING CLUTCH SHAFT! ENGINE INSTALLATION NOTES After the engine is installed in the frame, review this checklist and perform all steps that apply: General Items • Install previously removed components using new gaskets, seals, and fasteners where applicable. • Perform checks on fluid levels, controls, and all important areas on the vehicle as outlined in the daily pre-ride inspection checklist (refer to Chapter 2). CVT System • Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing. • Inspect drive and driven clutch as described in chapter 8. Transmission • Inspect transmission operation. Exhaust • Replace exhaust gaskets. Seal connections if necessary with high temp sealant. • After running the engine, verify all bolted exhaust connections are tight and in good condition. Engine Mount Torque • Inspect all engine mount fasteners and verify they are tightened properly 3.13 [email protected] ENGINE TRANSMISSION REMOVAL NOTE: The transmission can be removed separately from the engine. Follow this procedure if engine removal is not required. 1. Clean work area. 8. Remove transmission linkage rod (A) and vent hose (B) 9. Disconnect gear indicator switch harness (at transmission) 2. Thoroughly clean the ATV engine and chassis. A 3. Disconnect battery cables at battery. 4. Drain transmission oil. 5. Remove the following parts: • Seat • Left and Right Side Covers B • Rear cab 6. Remove CVT cover and both clutches (refer to CVT Chapter 8) 10. Disconnect speed sensor at transmission (left rear side). 11. Rear fuel tank bracket. 12. CVT air inlet duct. 7. Front prop shaft (4x4 models) (Drive pin out at front gearcase, pull shaft back, then forward. Refer to Drive Chapter) 13. Support frame under engine with a stable platform jack. 14. Rear wheels and brake caliper. 3.14 [email protected] ENGINE 15. Remove rear plate (lower control arm bolts) and upper control arm bolts. 16. Remove rear shocks. 22. Loosen, but do not remove the 4 bolts from the rear transmission hanger bracket. 23. Remove (9) transmission-to-engine bolts. 24. Remove the top 2 rear bracket bolts. 25. Carefully lower the transmission jack until rear bracket is clear of frame. 26. Slide transmission to the left until alignment pins in cover are release from engine case. 27. Remove transmission out to the left side. 28. Remove sway bar bracket from transmission. 29. Refer to transmission disassembly in CVT/ Transmission Chapter 8. TRANSMISSION INSTALLATION NOTES 17. Remove rear suspension (both sides) with drive shafts. 18. Rear lower engine mount 19. Sub frame bolts (2 each side) Rear mount 1. Install new gasket on engine 2. Install transmission to engine until alignment pins are engaged, and screw in 4 bolts to hold in place but do not completely tighten at this time. 3. Loosely install upper frame mount bolts and all subframe bolts. 4. Install all remaining transmission-to-engine crankcase bolts and tighten all in 2 steps to specified torque following a cross pattern. 5. Tighten subframe to main frame bolts (4) and rear engine mount bolts. 6. Tighten rear upper bracket bolts. 7. Tighten rear upper bracket bolts. 2 both sides 20. Remove sub frame. 21. Support transmission with another jack. 3.15 [email protected] ENGINE ENGINE LUBRICATION CAM CHAIN TENSIONER REMOVAL Oil Type: . . . . . . . .Polaris Premium 0W-50 Synthetic To position crankshaft at Top Dead Center (TDC) on compression stroke: Capacity (DRY): 1.64-1.95 U.S. Quarts (1.55-1.85 l) Capacity (OIL/FILTER/COOLING BLOCK CHANGE): 1.4-1.7 U.S. Quarts (1.3-1.6 l) Drain Plug:. . . . . .14-18 ft. lbs. (19-24.4 Nm) Oil Pressure Specification: (Using Polaris 0W-50 Synthetic @ Operating Temperature @ Idle) Any pressure reading above 9 PSI. OIL FLOW / PRESSURE TEST 4. Remove the valve cover. 5. Rotate engine in normal direction and watch the intake valve open and begin to close. 6. Continue to rotate engine slowly while watching camshaft sprocket marks and the mark in the timing inspection hole. Single TDC Mark Aligned TDC Mark WARNING Rotation Oil temperature can cause serious injury and damage. Wear the proper safety gear when performing these procedures. NOTE: Due to the engine assembly having a majority of roller bearings, oil pressure readings hot or cold will be very low. Low oil pressure is not an indication of a oil delivery problem. 1. Remove plug from the crankcase. See Page 3.6 2. Insert a 1/4 Pipe Thread oil pressure gauge adaptor into the crankcase and attach an oil pressure gauge. 3. Start engine and allow it to reach operating temperature while monitoring gauge indicator. Any pressure above 9 PSI is an indication of good oil flow. 7. Align single (T) mark on flywheel with in the 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, the cam lobes should be pointing down and the valves should have clearance at this point. ENGINE BREATHER / OIL SEPARATOR Dot The breather / oil separator is located behind the gas tank on the left side. The breather provides ventilation for the valve cover and crankcase through the air box. A FITTING BREATHER Marks Aligned 8. Remove the cam chain tensioner end cap. CAUTION: The plunger is under spring tension. Maintain inward pressure while removing. 9. Remove 2 cam chain tensioner bolts. 3.16 [email protected] ENGINE 10. Tap lightly on tensioner body with a soft face hammer to loosen and remove tensioner if required. ROCKER ARM/SHAFT DISASSEMBLY AND INSPECTION NOTE: Orientation of the components is important for reassembly. Mark all components before disassembly. 1. Remove the valve cover. Be sure engine is positioned at TDC on the compression stroke (there should be clearance on both rocker arm adjusters). CAM CHAIN TENSIONER INSPECTION 1. Pull cam chain tensioner plunger (A) out to the end of its travel and inspect ratchet teeth on plunger and pawl. Inspect spring (B) for wear or damage. A 2. Mark the rocker arms to keep them in order for assembly. 3. Slide the rocker shaft out and be prepared to catch the wave washer (A) positioned on the PTO end of the shaft between the casting and the intake rocker arm. A B 2. Hold the ratchet open and slide the plunger in and out of the tensioner body. The plunger should move smoothly throughout the travel range. 3. Replace entire tensioner assembly if any part is worn or damaged. 4. Inspect each rocker arm cam follower surface. If there is any damage or uneven wear, replace the rocker arm. NOTE: Always replace camshaft if lobe of either rocker arm is worn or damaged. Inspect surface of followers 3.17 [email protected] ENGINE 5. Inspect the rocker arm shaft and the shaft bore in the cylinder head for wear or signs of scoring. 6. Measure I.D. of each rocker arm (A) for out-of-round and visually inspect the I.D. surface. Replace arm if excessive wear is evident. 7. Inspect rocker adjuster screws (B) for wear, pitting, or damage to threads of the adjuster or locknut. Replace all worn or damaged parts. NOTE: The end of the adjuster is hardened and cannot be ground or refaced. 4. If not removing the cylinder for other service, secure the cam chain with a wire to prevent it from falling into the crankcase. 5. Inspect cam sprocket teeth for wear or damage. 8. Measure O.D. of rocker shafts for out-of -round. Inspect them for wear or damage. Replace if excessive wear is evident. NOTE: Orientation of the rocker shafts is important for reassembly. CAMSHAFT REMOVAL AND INSPECTION NOTE: Cam chain tensioner must be removed before performing this procedure. 1. Remove the camshaft end cover. 2. Remove the sprocket bolt. 3. Slip the chain over the sprocket and remove sprocket. 3.18 6. Inspect the automatic compression release mechanism. Replace the cam if parts are worn. Compression Release-one-way operation [email protected] ENGINE CAMSHAFT INSPECTION 1. Thoroughly clean the camshaft. 2. Visually inspect each cam lobe and bearing journal for wear, scoring, or damage. Verify oil delivery passages are clean. 3. Check the automatic decompressor spring legs and replace if broken. Spring preload is very light (about 45 degrees). 4. Measure the height of the cam lobes with a micrometer and compare to specification. Replace cam if worn below minimum height (service limit). 2. Loosen each of the four cylinder head bolts evenly 1/4 turn each time in a cross pattern until loose. 3. Remove bolts (A) and tap the cam support tower with a plastic hammer until loose. Remove. 4. After removing the camshaft and securing the cam chain, tap cylinder head lightly with a plastic hammer until loose. CAUTION: Tap only in reinforced areas or on thick parts of cylinder head casting. 5. Remove cylinder head, gasket, front chain guide and dowel pins. Cam Lobe Height Intake & Exhaust Std: 1.2938”-1.2977 (32.863-32.963 mm) Limit: 1.2820” (32.563 mm) . CYLINDER HEAD REMOVAL NOTE: Cam chain and tensioner must be removed. If no crankshaft service is being performed, secure cam chain with wire to avoid dropping chain into the crankcase. 1. Remove the (two) 6mm screws on the cylinder head and the two on the cylinder base. 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. If there is damage found on the cylinder head combustion chamber, it is recommended the component be replaced. 3.19 [email protected] ENGINE CYLINDER HEAD WARP INSPECTION 1. Lay a straight edge across the surface of the 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. 3. Push valve out, keeping it in order for reassembly in the same guide. 4. Measure free length of the inner and outer springs with a Vernier caliper, Ill.1. Check spring for squareness as shown in Ill.2. Replace spring if measurements are out of specification. A Valve Spring Free Length III.1 Cylinder Head Warp Limit: .002” (.05 mm) Coil fatigue/ Squareness COMBUSTION CHAMBER INSPECTION Clean all accumulated carbon deposits from combustion chamber and valve seat area with a soft wire brush. Inspect the combustion chamber for cracks and/or damage from foreign debris. III.2 CYLINDER HEAD DISASSEMBLY WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly. Cylinder head service should be performed by a technician knowledgeable in cylinder head reconditioning in a properly equipped shop. NOTE: Keep all parts in order with respect to their location in the cylinder head. 1. Using a valve spring compressor, compress the valve springs and remove the split keeper. NOTE: To prevent loss of tension, do not compress the valve spring more than necessary. 2. Remove spring retainer and spring. NOTE: The valve springs should be positioned with the tightly wound coils (A) against the cylinder head. 3.20 5. Remove valve seals. NOTE: Replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup. [email protected] ENGINE VALVE INSPECTION 1. Remove all carbon from valve with a soft wire wheel. 2. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” blocks and use a dial indicator. 3. Check end of valve stem for flaring, pitting, wear or damage (A). A 6. Measure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer. Measure in two directions, front to back and side to side. 7. Subtract valve stem measurement to obtain stem to guide clearance. NOTE: Be sure to measure each guide and valve combination individually. 8. Replace valve and/or guide if clearance is excessive. NOTE: If valve guides are replaced, valve seats must be reconditioned. Refer to Valve Seat Reconditioning for procedure. VALVE SEAT RECONDITIONING B 4. Inspect split keeper groove for wear or flaring of the keeper seat area (B). NOTE: The valves cannot be refaced or end ground. Valves must be replaced if worn, bent, or damaged. 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. If the valve seat is cracked the cylinder head must be replaced. 5. Measure diameter of valve stem with a micrometer in three places and in two different directions (six measurements total). Replace if excessive wear is evident. Measure valve stem in several places Too Wide Uneven Good Too Narrow 3.21 [email protected] ENGINE Cylinder Head Reconditioning 3. Place 46o cutter on the pilot and make a light cut. 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. 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. 1. Install pilot into valve guide. 4. Inspect the cut area of the seat. • If the contact area is less than 75% of the circumference of the seat, rotate the pilot 180o and make another light cut. • 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. • 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. • If the contact area of the initial cut is greater than 75%, continue to cut the seat until all pits are removed and a new seat surface is evident. NOTE: Remove only the amount of material necessary to repair the seat surface. 5. To check the contact area of the seat on the valve face, apply a thin coating of Prussian Blue™ paste to the valve seat. If using an interference angle (46o)apply black marker to the entire valve face (A). (A) 2. Apply cutting oil to valve seat and cutter. 6. Insert valve into guide and tap valve lightly into place a few times. 3.22 [email protected] ENGINE 7. Remove valve and check where the Prussian Blue™ or black marker indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width (A). 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. (B) (A) Seat Width Proper Seat Contact On Valve Face • 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 30o cutter to lower the valve seat. • If too low use the 60o or 75o cutter to raise the seat. When contact area is centered on the valve face, measure seat width. • If the seat is too wide or uneven, use both top and bottom cutters to narrow the seat. • If the seat is too narrow, widen using the 45o cutter and re-check contact point on the valve face and seat width after each cut. Bottom 60o or 75o Seat - 45o or 46o Top - 30o 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. 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. 12. Clean cylinder head, valves, and camshaft oil supply passages thoroughly. 13. Spray electrical contact cleaner into oil passages and dry using compressed air. 3.23 [email protected] ENGINE CYLINDER HEAD ASSEMBLY CAUTION Wear eye protection during assembly. NOTE: Assemble the valves one at a time to maintain proper order. 1. Install new valve seals on valve guides. 6. Place retainer on springs and install valve spring compressor. Compress spring only enough to allow split keeper installation and prevent loss of spring tension. Install split keepers with the gap even on both sides. 7. Repeat procedure for remaining valve. 8. When all valves are installed, tap lightly with soft faced hammer on the end of the valves to seat the Split keepers. VALVE SEALING TEST 1. Clean and dry the combustion chamber area. 2. Pour a small amount of cleaning solvent into each port and check for leakage around each valve. The valve seats should hold fluid with no seepage. 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. 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 3.24 [email protected] ENGINE ENGINE BOTTOM END DISASSEMBLY PISTON REMOVAL Cylinder Removal 1. Remove one circlip. Note valve pocket on intake side of piston for installation. Follow engine disassembly procedures to remove valve cover, camshaft and rocker arms, and cylinder head. 1. Lift to remove cam chain guide at front of cylinder. 2. Remove the two 6 mm cylinder base bolts. 3. Tap cylinder lightly with a plastic hammer in reinforced areas only until loose. 4. Rock cylinder forward and backward and lift it from the crankcase, supporting piston and connecting rod. Support piston with Piston Support Block (PN 2870390). 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 the compression rings, starting with the top ring. *Using a piston ring pliers: Carefully expand ring and lift it off the piston. CAUTION: Do not expand the ring more than the amount necessary to remove it from the piston, or the ring may break. CAM CHAIN GUIDE AND TESIONER BLADE 1. 2. 3. The guide can be removed after cylinder head is removed by pulling it upward out of the channel in the crankcase. Remove blade and inspect. Replace if worn., cracked, or damaged. Tensioner blade removal requires recoil, flywheel, and stator plate removal. Refer to lower end service procedures to access the bolt securing the tensioner blade to the crankcase. *By hand: Placing both thumbs at end gap, carefully spread the ring open and lift ring over piston at the opposite side. Use care to not scratch the ring lands. 4. Repeat procedure for second ring. 5. The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section. Remove the top rail first followed by the bottom rail and expander. 3.25 [email protected] ENGINE CYLINDER INSPECTION CYLINDER HONE 1. Remove all gasket material from the cylinder sealing PROCEDURE surfaces. 2. Inspect the top of the cylinder for warpage using a straight edge and feeler gauge. SELECTION/ HONING 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. 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. Cylinder Warp: .002” (.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 X X X Y HONING TO DEGLAZE A finished cylinder should have a cross-hatch pattern to ensure piston ring seating and to aid in the retention of the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer’s instructions, or these guidelines: • Use a motor speed of approximately 300-500 RPM, run the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered (or cylinder centered on arbor) and to bring the stones approximately 1/2” (1.3 cm) above and below the bore at the end of each stroke. Y • 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. Y • After honing has been completed, THOROUGHLY clean the cylinder to remove all honing residue. IMPORTANT: Clean the Cylinder After Honing 1/2” Up From Bottom 5. Record measurements. If cylinder is tapered or out of round beyond specification, the cylinder must be honed, bored or replaced. Cylinder Taper Limit: .002” (.05 mm) Max. Cylinder Out of Round Limit: .002” (.05 mm) Max. 3.26 Wash the cylinder in a solvent, then in hot, soapy water. Use electrical contact cleaner if necessary to clean areas that cannot be scrubbed. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris 4 Cycle Lubricant to prevent the formation of surface rust. [email protected] ENGINE If cylinder wear or damage is excessive, it will be necessary to replace the cylinder. Hone only enough to deglaze the outer layer of the cylinder bore. 3. Measure piston pin bore. Replace piston if out-ofround Piston Pin Bore 4. Measure piston pin O.D. Replace piston pin if out-ofround. EXAMPLE OF CROSS HATCH PATTERN PISTON INSPECTION 1. Measure piston outside diameter at a point 7 mm up from the bottom of the piston at a right angle to the direction of the piston pin. Piston Pin Measurement Locations 5. Measure connecting rod small end ID. Replace crankshaft if out-of-round. 7mm Piston Piston Pin 2. Subtract this measurement from the maximum cylinder measurement obtained earlier. Piston to Cylinder Clearance Std: .0015- .0032” (0.038- 0.082 mm) Limit: .0043” (.11 mm) 3.27 [email protected] ENGINE 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-togroove clearance exceeds service limits. Piston cylinder should be measured for excessive taper and out of round. 3. If the installed gap measurement exceeds the limit, replace the rings. If using new rings and the measurement is too small, file the ring ends to achieve the proper gap. NOTE: Always check piston ring installed gap after reboring 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. Ring Feeler Gauge FLYWHEEL REMOVAL / INSPECTION CAUTION The crankshaft end contains an oil passage plunge joint (A) as shown below. The plunger must be able to move in and out freely. Avoid damage to the crankshaft end or plunge joint and spring, which can cause loss of oil pressure, resulting in severe engine damage. PISTON RING INSTALLED GAP 1. Place each piston ring inside cylinder using piston to push ring squarely into place as shown. Piston ring installed end gap 1. Remove the recoil housing, recoil hub, and flywheel nut. Feeler Gauge Cylinder 25-50 mm Piston Ring Piston Ring Installed Gap Top Ring Std: .008- .012” (.2- .3 mm) Limit: .032” (0.8 mm) Second Ring Std: .014- .020” (0.35- 0.50 mm) Limit: .039” (1.0 mm) Oil Ring Std: .008- .028” (0.2- 0.7 mm) Limit: .059” (1.5 mm) 2. Measure the gap with a feeler gauge at both the top and bottom of the cylinder. NOTE: Measure at two points in the cylinder A difference in end gap indicates cylinder taper. The 3.28 2. Install Flywheel Puller (PN PA-47308) and remove flywheel. CAUTION: Do not hammer or strike the tool while attached to the crankshaft end. [email protected] ENGINE STARTER DRIVE CLUTCH REMOVAL/ INSPECTION 1. Remove recoil housing bolts and remove housing. 2. Remove the starter drive clutch and washer by pulling the shaft and tilting the gear slightly. 3. Measure the OD of the starter drive shaft on both ends for out-of-round. 4. Measure the ID of the bushings in the recoil housing and in the crankcase (A) in two directions 90o apart to determine if out-of-round. Replace worn bushings. CAM CHAIN DRIVE SPROCKET REMOVAL / INSPECTION 1. Remove recoil housing, flywheel, flywheel key, and stator. 2. Using the Slotted Nut Socket, remove the crankshaft slotted nut by turning it clockwise. NOTE: Slotted nut is left hand thread. A REMOVE Slotted Nut Socket 5. Inspect gear teeth on starter drive. Replace starter drive if gear teeth are cracked, worn, or broken. (PN 2871293-A) 3. Remove cam chain drive sprocket and Woodruff key from crankshaft. 4. Inspect sprocket teeth for wear or damage. Visually inspect for tooth wear or damage 5. Inspect Woodruff key for wear. 3.29 [email protected] ENGINE OIL PUMP INSPECTION / REMOVAL NOTE: Mark the oil pump geroters to keep parts mated for assembly. 1. Remove recoil housing, flywheel, flywheel key, and stator. 2. Use a feeler gauge to check oil pump rotor tip clearance at “A”, and pump body clearance at “B”. Compare to specifications. Replace the oil pump assembly if any parts are damaged, scored, or measure beyond the service limit. A B STARTING CLUTCH AND ENGINE BRAKING CLUTCH REMOVAL /INSPECTION NOTE: The transmission must be removed from the engine to access the starting clutch and one-way engine braking clutch. 1. Inspect the starting clutch drum bearing in the housing. The shaft must turn smoothly (by hand) without binding in the clockwise direction, and should not turn by hand in the counter clockwise direction. Minimal movement in the shaft is NORMAL with engine removed due to the lack of clutch cover bearing support on the free end of the shaft (approximately 0-.060” (0-1.5mm). Press the shaft out of the housing and replace the bearing if worn or rough. DO NOT LIFT ENGINE WITH CLUTCH SHAFT A B 3. Mark the oil pump geroters and shaft and carefully lift the geroters from the housing. 2. Remove all screws from the starting clutch housing. 3. Remove the one-way clutch from the starting clutch drum with a twisting motion. Note direction of installation with flange toward drum for assembly. Inspect Drum For Wear or Damage Flange toward drum 4. Inspect the one-way clutch closely for cracks or damage on the sprag shoes and the cage. 3.30 [email protected] ENGINE 5. Open the staked portion of the nut (A) with a center punch. Inspect the one-way clutch hub surface on the starting clutch (B). The hub must be smooth without any nicks or burrs. Replace the starting clutch assembly if the one-way clutch hub is uneven or damaged 8. Inspect the shoes and springs of the starting clutch. Measure the thickness of the friction material on the shoes as shown, from the bottom of the friction material to the top at the thinnest point. Standard Thickness: .100” (2.54mm) LIMIT: .039” (1.00mm) Inspect entire surface of one-way clutch hub. B A 6. Install the starting clutch holder (PA-47457) onto the starting clutch and engage the tabs (C). C STARTING CLUTCH ASSEMBLY 1. 2. 3. 4. 5. Clean the mating surfaces of the crankcase and clutch starting clutch housing to remove all gasket material. Install the starting clutch on the shaft. Start a NEW stake nut on the shaft. Install the starting clutch holder on the clutch. Torque the nut to specification. Starting Clutch Stake Nut: 103-118 ft. lbs. (140-160 Nm) 7. Remove the nut (counterclockwise). This is a standard thread. 6. Use a center punch or a pin punch to thoroughly stake the nut at the depression in the shaft. 3.31 [email protected] ENGINE 7. If drum bearing was replaced in the starting clutch housing, press the drum/shaft into the housing until fully seated. 8. Clean the inside of the starting clutch drum and lubricate the drum and one-way clutch with engine oil. 9. Install one-way clutch in starting clutch drum with the flanged side toward the hub, using a rotating motion. CRANKCASE DISASSEMBLY NOTE: Engine must be removed from the frame to perform any crankcase or crankshaft removal. NOTE: The starter, starter drive, flywheel, stator, oil pump and transmission can be serviced with the engine in the frame. CRANKCASE SEPARATION Flange side toward hub 10. Install a new housing gasket. 11. Install the drum / housing assembly onto the case, install the housing bolts and torque in two steps using a cross pattern to specification. Starting Clutch Drum Housing: 14-15.5 ft. lbs. (19-21 Nm) 12. CHECK the clutch shaft to be sure it rotates smoothly in the clockwise direction and will not rotate in the counterclockwise direction. If binding is evident, or if the shaft rotates in both directions (without turning the engine over) disassemble and inspect the one-way clutch and hub. 3.32 NOTE: Stator housing, flywheel and gears have are previously removed for this procedure. Use care during the removal process to avoid damage to the cam chain. NOTE: Valvetrain and cylinder removal must be performed prior to this procedure. 1. Remove all bolts and the pressure relief valve (A) from the magneto side crankcase. A 2. Tap carefully on reinforced areas of the cases to separate the halves. Watch the gap along the crankcase mating surface and separate the crankcase evenly. 3. Lift the right case half off of the left, leaving the crankshaft and balance shaft in the left case. [email protected] ENGINE CRANKSHAFT REMOVAL 1. Lift the crankshaft and balance shaft from the left case. 2. Note the number and thickness of any shims installed on either shaft. NOTE: Crankshaft and balance shaft end play must be measured and adjusted with shims if any new components are installed (bearings, crankcase, crankshaft, or balance shaft. See procedure this chapter. visual inspection. 3. The connecting rod utilizes a roller bearing. Clearance can be measured with a dial indicator to check radial clearance. Visually inspect the connecting rod, crank pin, and thrust washers for scoring, damage, excessive wear, or signs of overheating. Check for roughness or noise when rotating the connecting rod on the crank pin. Replace crankshaft if it fails visual inspection, or if any up and down movement is detectable in the connecting rod. Connecting Rod Big End Radial Clearance: CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION 1. Inspect the crankshaft main bearings for wear or damage. .0004-.0014” (.011-.038 mm) LIMIT: .0019” (.05mm) 4. Check connecting rod side clearance with a feeler gauge. 5. Refer to piston inspection in this chapter to inspect the connecting rod small end. Connecting Rod Side Clearance: .0035-.0196” (.09-.50mm) Limit: .023” (.60mm) 6. Clean crankshaft oil passages by running a stream of clean solvent through the crankshaft. Be sure all passages are clear and free of nicks or scratches. NOTE: Due to extremely close tolerances and minimal movement, the ball 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 PTO bearing each bearing should fit tightly on the crankshaft. The outer race should be firm with minimal side to side movement and no detectable up and down movement. The MAG end bearing usually stays in the case. Check the inner race of the MAG bearing in the same manner. 2. Replace the main bearings if the components fail 3.33 [email protected] ENGINE CRANKCASE OIL PASSAGES & PRESSURE RELIEF VALVE 1. Remove the pressure relief valve assembly from the case. 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 balance shaft bearings, use a blind hole bearing puller. NOTE: Bearings are stressed during the removal procedure and should not be re-used. CRANKCASE OIL PICKUP STRAINER INSPECTION 2. Clean all crankcase oil passages with a stream of clean solvent. CAMSHAFT CHAIN 1. Replace the cam chain as part of any crankshaft repair. 2. The cam chain can be removed by removing the engine top end, the recoil assembly, flywheel and flywheel key, stator plate, and slotted nut. 3. Lift the sprocket slightly until chain clears the crankcase to remove. ote: Install new chain as a part of crankshaft repa A 1. Pull the strainer screen (A) from the case carefully and clean or replace it if heavily clogged, or if damaged. BEARING /SEAL INSTALLATION NOTE: To ease crankcase bearing installation, warm the crankcase until hot to the touch. Placing the bearing in a freezer prior to installation will assist the assembly process. 1. Install the 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. 3. Install new seals with the lip facing in. BALANCE SHAFT BEARING INSPECTION NOTE: Replace all seals whenever the crankcase is disassembled. 1. Inspect the balance shaft bearings in the crankcase. NOTE: Due to extremely close tolerances and minimal movement, the bearing must be inspected visually and by feel. Look for signs of discoloration, scoring or galling. 3.34 CAUTION Press only on outer diameter to prevent damage. [email protected] ENGINE END PLAY INSPECTION/ADJUSTMENT 3. Subtract the thickness of the straightedge from the measurement obtained in Step 2 and record. Before reassembling the crankcase, the following steps should be performed to determine the amount of crankshaft, counter balancer shaft, and pump shaft 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. CRANKSHAFT END PLAY ADJUSTMENT NOTE: The method described here is shown with the PTO main bearing on the crankshaft, which is the most common situation. If the bearing is in the case, the procedure is the same, but the photo examples will differ. 1. Make sure all bearings are firmly seated in the crankcase. PTO Case Depth_________________________ 4. Measure the distance from the Magneto crankcase mating surface to the main bearing using the same method and record. 2. Lay a straightedge on the left (PTO) crankcase and measure the distance from the straightedge to the bottom of the main bearing bore (if bearing is still on the crankshaft) or to the bearing race (if the bearing is installed in the case) using a dial caliper. 5. Subtract the thickness of the straightedge from the measurement obtained in Step 4 and record. Mag Case Depth_______________ 3.35 [email protected] ENGINE 6. Add the readings recorded in Step 3 and Step 5 and record below. Total Case Width_________________ 7. Measure the width of the crankshaft at the bearing seats (or to the outside of bearing if bearing is on the crankshaft as shown) with a micrometer or dial caliper and record. COUNTER BALANCER SHAFT END PLAY ADJUST. NOTE: The counterbalance shaft end play measurement procedure is the same as that outlined for the crankshaft. The exception is that measurements are taken to the balance shaft bearings in the case, rather than the crankshaft main bearings, and the width of the balance shaft is measured, not the crankshaft. 1. Make sure the counterbalance shaft bearings are firmly seated in each crankcase. Measure to balance shaft bearing race 2. Crankshaft Width____________ 8. Subtract the Crankshaft Width measured in Step 7 from the Total Case Width recorded in Step 6, and record below. Measure the distance from the Mag crankcase mating surface to the balance shaft bearing using a dial caliper and a straight edge. Subtract the thickness of the straightedge and record. MAG Case Depth_________________________ 3. Measure the distance from the PTO crankcase mating surface to the bearing using the same method outlined for the MAG side. PTO Case Depth_________________________ Total End Play_____________ 4. Measure the width of the counter balancer shaft at the bearing seats with a dial caliper or micrometer, and record reading. 9. Subtract the thickness of the existing shim from the result of Step 8 to determine if a different shim is required. The result must be within the specified range listed below. 5. Add the readings obtained in Step 2 and Step 3. Crankshaft End Play: .006-.012” (.15-.30 mm) 3.36 6. Subtract the counter balancer shaft width measured in Step 4 from the result obtained in Step 5. [email protected] ENGINE 7. Subtract the thickness of the existing shim from the result of Step 6 to determine if a different shim is needed. The result must be within the specified range listed at below. 8. 3. Be sure balance dots on gear teeth are aligned. Add or subtract shims or change shim thickness as required and install them upon assembly. Counter Balance Shaft End Play: .004”-.029” (.1-.74 mm) CRANKCASE REASSEMBLY Crankshaft Installation Lubricate all bearings with clean engine oil before assembly. Be sure crankcase mating surfaces are clean and free from oil or grease. 1. Place the required shims on the crankshaft and balance shaft. 2. Support the PTO side crankcase on blocks. Install the crankshaft and balance shaft in the case, aligning the balance dots on the gears. 4. Apply a thin coat of crankcase sealant to the outer mating surface of the left crankcase. Sealant is not required on the inner mating surfaces (A). A Crankcase Sealant PN 2871557 5. Install the mag side case and tap with a soft faced hammer to seat. 6. Install case screws and torque in a cross pattern to specification. Crankcase Bolt Torque: 6.5-8.0 ft. lbs. (9-11 Nm) 3.37 [email protected] ENGINE CAM CHAIN, OIL PUMP, & TENSIONER BLADE INSTALLATION 1. Install the cam chain over the drive sprocket. 2. Lubricate and install the oil pump geroters, aligning the marks made during disassembly. Clean the marks off the geroters. it with Loctite 242 (blue) before installation. This screw must be sealed 7. Torque the screws to specification. Geroters 3. Install the tensioner blade and tighten the mounting bolt to specified torque. Stator Plate Screw Torque: 6.5-8.0 ft. lbs. (9-11 Nm) 8. Install the flywheel key and flywheel. Flywheel Nut: 67-81 ft. lbs. (90-110 Nm) Recoil Drive Hub: 12-14 ft. lbs. (17-19 Nm) Tensioner Blade Mounting Bolt Torque: 5-6.5 ft. lbs. (7-9 Nm) 4. Install a new O-ring on the stator plate. 5. Lubricate the stator plate seal and bushing with engine oil and install the stator plate. 6. IMPORTANT! Be sure the sealed screw is placed in the hole that aligns with the cam chain cavity or an oil leak may result. If you are installing the old screw seal 3.38 [email protected] ENGINE PISTON RING INSTALLATION NOTE: Apply clean engine oil to all ring surfaces and ring lands. Always check piston ring installed gap before rings are installed on piston. If the piston has been in service, clean any accumulated carbon from the ring grooves and oil control ring holes. 1. Place the oil control ring expander in oil ring groove with the end gap facing forward. The expander has no up or down marking and can be installed either way. The ends should butt squarely together and must not overlap. 2. Install the oil ring top rail with the end gap at least 30o from the end of the expander. 3. Install the bottom rail with the gap at least 30o from the end of the expander on the side opposite the top rail gap. 4. Install the second ring with the mark facing up. The second ring has an undercut with a tapered face. Position the end gap toward the rear (intake) side of the piston. 5. Install the top ring with the marking facing up. The top ring has an inner bevel with a barrel face. Top Ring: Bevel on Inner Edge Install with mark UP piston pin bore, piston pin, and piston skirt. Lubricate the connecting rod (both ends) and crankshaft main bearing area. 3. IMPORTANT- Install the piston on the connecting rod with the valve pocket facing the intake side of engine. The piston pin should be a push fit into the piston. Pocket 4. Install the other circlip with the gap facing up or down. Push the piston pin in both directions to make sure the clips are properly seated in the groove. 5. Lubricate the piston and rings with engine oil and install a ring compressor on the piston assembly. Verify that the ring gaps are 120o - 180o apart from each other before installation. Second Ring Mark Faces UP 6. Verify proper installation of rings by checking to be sure the top and second rings rotate freely in the groove when compressed by hand. PISTON INSTALLATION CAUTION Do not re-use circlips. Circlips become deformed during the removal process. Do not compress the new clip more than necessary to prevent loss of radial tension. Severe engine damage may result if circlips are re-used or deformed during installation. 1. Install a new circlip on one side of the piston with the end gap facing up or down. 2. Apply clean engine oil to the piston rings, ring lands, 3.39 [email protected] ENGINE CYLINDER INSTALLATION NOTE: Clean the gasket surfaces on the crankcase and cylinder. Remove all traces of old gasket material or sealant. The surfaces must be oil-free! 1. Apply a small amount of crankcase sealant at the case parting lines (A). Do not allow sealant to dry. Assemble the top end immediately. 8. Install the cam chain guide and dowel pins into the cylinder. Verify the bottom end of the guide is seated properly in the crankcase. A CYLINDER HEAD AND CAMSHAFT INSTALLATION 2. Install the dowel pin(s). 3. Install a new base gasket onto the mating surface and position the Piston Support Block (PN 2870390) beneath the piston skirt to support the piston during cylinder installation. 4. Apply clean engine oil liberally to the bore and tapered area of the cylinder. Place the cylinder on to the studs. NOTE: Route cam chain through the cylinder chain room and secure it, holding it up to avoid damage to the chain, drive sprocket teeth or tensioner blade. 5. Loop the cam chain through the cylinder chain room and secure with mechanic’s wire. Install cylinder carefully with a front to back rocking motion until rings are fully captive in the sleeve, then remove the compressor and support block. 7. Seat the cylinder firmly onto the base gasket. 6. 3.40 NOTE: Clean the gasket surfaces on the cylinder head and cylinder. Remove all traces of old gasket material. The surfaces must be oil-free! 1. Install the dowel pin(s) and a new cylinder head gasket. 2. Pull the cam chain through the cylinder head chain room and secure with mechanic’s wire. 3. Place the cylinder head on the cylinder. 4. Install the two 6 mm bolts on cylinder base and on the head, but do not tighten. [email protected] ENGINE 5. Lubricate the washers and the threads of the cylinder head bolts and install the bolts with washers. 6. Torque the cylinder head following the procedure and pattern below. timing mark on the flywheel is aligned with the mark in the timing inspection window of the recoil housing. Be sure to use the correct mark when installing the cam. Do not use any advance timing marks. 2. Apply engine oil or starter drive grease (molybdenum disulfide paste) to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil. Starter Drive Grease: Cylinder Head / Cylinder Base (PN 2871460) 3 2 5 6 mm 3. Orient the camshaft with the lobes facing downward, and install the cam into the cylinder head. 6 1 4 Forward • Tighten M10 bolts to 18.5 ft. lbs. (25 Nm) • Loosen 180 degrees • Tighten to 11 ft. lbs. (15 Nm) • Tighten 90 degrees • Tighten 60 degrees • Tighten 6mm head & base bolts to 8 ft.lbs.(11 Nm) CAMSHAFT INSTALLATION & TIMING 4. Disconnect the wire or tie strap securing the cam chain (if used). 5. Be sure the pin on the camshaft is pointing DOWN. CAUTION Serious engine damage will result if the camshaft is not properly timed to the crankshaft. IMPORTANT CAMSHAFT TIMING NOTE: In order to time the camshaft to the crankshaft, the piston must be precisely located at Top Dead Center (TDC). If flywheel key and flywheel are not installed, install them at this time. The recoil housing must also be temporarily installed to use the timing inspection hole. 1. Rotate the crankshaft until the “T” (Top Dead Center) 3.41 [email protected] ENGINE 6. Loop the cam chain over the sprocket and shift the chain on the sprocket until it can be installed onto the camshaft. assembly with a new gasket and tighten the bolts to specification. A B B A Tensioner Bolt Torque: 7. VERIFY the following: 5-6.5 ft. lbs. (7-9 Nm) • “T” Mark on flywheel is aligned with the projection in the timing hole of the recoil housing. • The mark (A) on the camshaft sprocket is aligned with the projection (B) in the camshaft cover window as shown above. 3. Install the pin, spring, and tensioner cap with a new sealing washer. Torque cap to specification. Tensioner Cap Torque: 6-7.5 ft. lbs. (8-10 Nm) 8. Verify all marks are aligned. Install the cam sprocket bolt and torque to specification. Camshaft Sprocket Bolt 35.5-50 ft. lbs. (48-70 Nm) CAM CHAIN TENSIONER INSTALLATION 1. Hold the tensioner ratchet pawl (A) open and push the plunger (B) in to the fully retracted position. A With the plunger retracted, install the tensioner 3.42 ROCKER ARM INSTALLATION 1. Lubricate the rocker arms and shaft with engine oil. Apply a light film of starter grease (moly grease) to the cam follower pad on the rocker arms. Starter Drive Grease: (PN 2871460) B 2. 4. Slowly rotate engine two to three revolutions in the direction of rotation and re-check cam timing. [email protected] ENGINE 2. Slide the shaft through the tower just enough to install the wave washer (A). NOTE: The flats of the wave washer are positioned against the intake rocker arm. STARTER DRIVE ASSEMBLY 1. Be sure the washer is positioned on the back of the drive gear. A Starter Drive Grease: 3. Install the rocker arms in the same position as marked during disassembly. (PN 2871460) 2. Apply Starter Drive Grease (PN 2871460) to the drive bushings in the cases and all moving surfaces of the starter drive gears and install. 3. Install recoil housing and torque bolts to specification. TROUBLESHOOTING SPARK PLUG FOULING TROUBLESHOOTING • Restricted air filter (main or pre-cleaner), or air inlet ducts. • Choke cable adjustment or plunger/cable sticking 4. Turn the engine through several revolutions to be sure parts rotate freely and smoothly. 5. Adjust valve clearance as outlined in the maintenance section. • Foreign material on choke plunger seat or plunger • Incorrect spark plug heat range or gap • Jet needle and/or needle jet worn or improperly adjusted • Excessive carburetor vibration (check all engine and carburetor mounts) • Oil contaminated with fuel • ETC switch mis-adjusted • Low compression • Spark plug cap loose or faulty • Loose jets in carburetor or calibration incorrect for altitude/temperature 3.43 [email protected] ENGINE • Incorrect float level setting • Carburetor inlet needle and seat worn • CVT system calibrated incorrectly or components worn or mis-adjusted • Fuel quality poor (old) • Restricted exhaust • Restricted crankcase breather system • Weak ignition (loose coil ground, faulty coil, stator, engine to chassis ground, or ETC switch) • Improperly assembled air intake system Engine Idles But Will Not Rev Up • Spark plug fouled/weak spark • Broken throttle cable • Obstruction in air intake • Air box removed (reinstall all intake components) • Incorrect or restricted carburetor jetting • ETC switch limiting speed • Reverse speed limiter limiting speed • Carburetor damaged vacuum slide ENGINE Troubleshooting • Incorrect ignition timing Engine Turns Over But Fails to Start • Restricted exhaust system • No fuel • Dirt in fuel line or filter • Fuel will not pass through fuel valve • Fuel pump inoperative/restricted • Fuel tank vent plugged sticking/diaphragm • Camshaft lobes worn • Flywheel key sheared Engine Has Low Power • Spark plug fouled • Carburetor starter circuit restricted • Cylinder, piston, ring, or valve wear or damage (check compression) • Engine flooded • CVT not operating properly • Low compression (high cylinder leakage) • Restricted exhaust muffler • No spark (Spark plug fouled) • Dirty carburetor Engine Does Not Turn Over • Dead battery • Cam lobe worn Piston Failure - Scoring • Starter motor does not turn • Lack of lubrication • Engine seized, rusted, or mechanical failure • Dirt entering engine through cracks in air filter or ducts Engine Runs But Will Not Idle • Engine oil dirty or contaminated • Idle speed set too low • Faulty ETC system Excessive Smoke and Carbon Buildup • Restricted carburetor pilot system • Oil level too high • Carburetor misadjusted • Excessive piston-to-cylinder clearance • Choke not adjusted properly or sticking plunger • Worn rings, piston, or cylinder • Low compression • Worn valves, guides or seals • Crankcase breather restricted • Restricted crankcase vent • Air filter restriction • Air filter dirty or contaminated 3.44 [email protected] ENGINE Low Compression • Decompressor stuck • Cylinder head gasket leak • No valve clearance or incorrectly adjusted • Cylinder or piston worn • Piston rings worn, leaking, broken, or sticking • Bent valve or stuck valve • Valve spring broken or weak • Valve not seating properly (bent or carbon accumulated on valve area) • Rocker arm sticking Backfiring • ETC or speed limiter system malfunction • Fouled spark plug or incorrect plug or plug gap • Carburetion faulty - lean condition • Intake / Exhaust system air leaks • Ignition system faulty: •Spark plug cap cracked/broken •Ignition coil faulty •Ignition or kill switch circuit faulty •Ignition timing incorrect •Sheared flywheel key • Poor connections in ignition system • System wiring wet • Cam lobe worn or Valve sticking • Lean condition 3.45 [email protected] ENGINE NOTES 3.46 [email protected] FUEL SYSTEM / CARBURETION CHAPTER 4 FUEL SYSTEM / CARBURETION SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 CARBURETITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 BST 34 CARBURETOR EXPLODED VIEW 1 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 BST 34 CARBURETOR EXPLODED VIEW 2 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 CARBURETOR VENTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 CARBURETOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 CARBURETOR JETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 MIKUNI JET PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 CV CARBURETOR SYSTEM FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 CARBURETOR VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 MIKUNI CV CARB OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 STARTER SYSTEM (CHOKE OR ENRICHMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 PILOT (IDLE AND SLOW) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 MAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 FLOAT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 PILOT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 AIR/FUEL MIXTURE RATIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 NEEDLE JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 THROTTLE OPENING VS. FUEL FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 CARBURETOR DISASSEMBLY – MIKUNI CV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12 CARBURETOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13 CARBURETOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13 CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14 FLOAT HEIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14 NEEDLE AND SEAT LEAKAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 FUEL LEVEL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16 4 AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17 AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17 FUEL TANK/FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18 FUEL TANK / FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19 4.1 [email protected] FUEL SYSTEM / CARBURETION SPECIAL TOOLS NOTE: It is strongly recommended that Polaris Carbon Clean be added regularly as directed to the fuel systems of all Polaris ATVs. Carbon Clean stabilizes the fuel, preventing clogging of the small passages and orifices common to ATV carburetors, and ensures constant PART NUMBER TOOL DESCRIPTION 2870975 Mity VacTM Pressure Test Tool 2872314 Carburetor Float Adjustment Tool WARNING Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not overfill the tank. The tank is at full capacity when the fuel reaches the bottom of the filler neck. Leave room for expansion of fuel. Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time. Never drain the float bowl when the engine is hot. Severe burns may result. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. If you get gasoline in your eyes or if you should swallow gasoline, seek medical attention immediately. If you spill gasoline on your skin or clothing, immediately wash with soap and water and change clothing. 4.2 performance, reliability and easier starting. [email protected] FUEL SYSTEM / CARBURETION CARBURETITION BST 34 Carburetor Exploded View 1 of 2 A G B H C N M P D L J E F K Table 4-1: Carburetor Components Reference Description Reference Description A Jet Needle J Throttle Control Cover Plate B Diaphragm Assembly K Carburetor Body C Needle Jet L Enrichment Plunger D Jet Block Assembly M Enrichment Spring E Washer N Cable guide F Main jet P Pilot Air Jet G Cover H Spring 4.3 [email protected] FUEL SYSTEM / CARBURETION BST 34 Carburetor Exploded View 2 of 2 M N A D B F C E G H J K L Table 4-2: Carburetor Components Reference 4.4 Description Reference Description A Throttle Plate Shaft Retaining Components J Float Bowl O Ring B Pilot Jet K Float Bowl C Needle Valve Assembly L Float Bowl Drain Screw D Throttle Plate M Throttle Shaft E Idle RPM Speed Adjustment Screw N Throttle Shaft Return Spring F Spring G Needle Valve Retaining Plate H Floats [email protected] FUEL SYSTEM / CARBURETION Carburetor Venting System D B C E A Table 4-3: Carburetor Venting System Reference Description A Check Valve B Hose (Float Bowl Drain) C Hose (Vents) D Tee Fitting E Filter 4.5 [email protected] FUEL SYSTEM / CARBURETION CARBURETOR SPECIFICATIONS CV CARBURETOR SYSTEM FUNCTION Carburetor Component Function 2006 Hawkeye 2x4 / 4x4 (Domestic and International) Altitude Feet (Meters) System Ambient Temperature Below 40F (Below 5C) Above 40F (Above 5C) 0-6000 (0-1800) 152.5 147.5 147.5 142.5 6000-12000 (1800-3700) Float System (Level Control) Venting CARBURETOR JETTING IMPORTANT: The following guidelines must be followed when establishing a main jet setting: 1. Select the lowest anticipated temperature and altitude at which the machine will be operated. 2. Select the correct main jet according to the engines fuel/performance requirements. 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. Jet Number Part Number 130 3130561 132.5 3130562 135 3130563 137.5 3130564 140 3130527 142.5 3130566 145 3130567 147.5 3130568 152.5 3130570 155 3130571 157.5 3130572 160 3131141 162.5 3131142 165 3131143 167.5 3131144 170 3131145 Pilot (Idle System) 4.6 Pilot Jets - BST 34 Jet Number Part Number 25 n/a 27.5 n/a 30 n/a 32.5 n/a 35 n/a 37.5 n/a 40 3130624 42.5 3130526 45 3131397 47.7 3131226 50 3131132 55 n/a 57.5 n/a 60 n/a 65 n/a 70 n/a Inlet Pipe, Needle and Seat, Float, Float Pin Main System Main Function Main Affect Maintains All systems specified fuel All throttle level in float ranges chamber (carburetor float bowl) Passages in Supplies All systems Carburetor, Vent atmospheric All throttle lines pressure to float ranges to frame chamber Starter Choke Lever, (Choke/ Cable, Plunger, Enrichment) Return Spring, Carb Passages (Starter Jet, Starter Bleed Pipe) MIKUNI JET PART NUMBERS Main Jets - BST 34 Main Components Supplies additional fuel air mixture necessary for cold starting Pilot Jet/ Primarily Passage-ways, supplies fuel at Pilot–Mixture idle and low Screw with throttle Spring Washer positions and Sealing O– Ring, By-pass Ports (Behind Throttle Plate), Pilot Air Jet, Pilot Outlet, Throttle Plate Main Jet, Main Supplies fuel at Air Jet, Main Air mid–range and Passage, high throttle Needle Jet, Jet settings. Needle, Vacuum Slide, Throttle Plate All throttle ranges Greatest effect at low throttle settings and idle Mainly idle to 1/4 throttle Minimal effect after 1/2 throttle 1/4 to full throttle [email protected] FUEL SYSTEM / CARBURETION CARBURETOR VENTING The carburetor float bowl vent lines supply atmospheric pressure to the float bowl. The lines must be free of kinks, restrictions and be properly routed. This allows fuel to flow in the proper amount and prevents contaminants from entering the carburetor. MIKUNI CV CARB OPERATION The constant velocity carburetor incorporates a mechanically operated throttle plate and a vacuum controlled slide valve (vacuum slide). The venturi cross–sectional area in the carburetor bore is increased or decreased automatically by the vacuum slide, which moves according to the amount of negative pressure (less than atmospheric) present in the venturi. When the throttle plate is opened and engine speed begins to increase, the pressure in the venturi (and therefore in the chamber above the diaphragm) becomes significantly lower than atmospheric. Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward, raising the slide against spring pressure. When the pressure above and below the diaphragm are nearly equal, the slide moves downward under spring pressure. Raising or lowering the slide increases or decreases the cross sectional area in the venturi, and therefore the air velocity in the venturi is kept relatively constant. This provides improved fuel atomization and optimum fuel/air ratio. A diaphragm attached to the top of the vacuum slide is sealed to the slide and to the carburetor body forming two chambers. The chamber above the diaphragm is connected to the venturi area by a drilled orifice in the center of the vacuum slide. The chamber below the diaphragm is vented to atmospheric pressure by a passage on the air box side of the carburetor. A spring, installed in the center of the vacuum slide, dampens the slide movement and assists the return of the slide. Diaphragm Low Pressure From Venturi Atmospheric Pressure Atmospheric Air inlet Vacuum Slide Note: Diagrams are for explanation of theory only, and are not true representations of Mikini BST carburetor. Throttle Plate Venturi = Air Flow = Low pressure 4.7 [email protected] FUEL SYSTEM / CARBURETION STARTER SYSTEM ENRICHMENT) (CHOKE OR PILOT (IDLE AND SLOW) SYSTEM When the choke cable (1) is activated, the starter plunger (5) is lifted off the seat. 8 5 1 This system supplies fuel during engine operation with throttle valve closed (1) or slightly opened. The fuel from float chamber (2) is metered by pilot jet (3) where it mixes with air coming in through pilot air jet (4). The mixture then goes up through pilot passage to pilot screw (5). A part of the mixture is discharged into the main bore out of bypass ports (6). The remainder is then metered by pilot screw and discharged into the main bore through pilot outlet (7). 6 7 4 4 2 3 Fuel is drawn into the starter circuit from the float chamber (2) through the starter jet (3). Starter jet meters this fuel, which then flows into starter pipe (4) and mixes with the air (7) coming from the float chamber. The mixture, rich in fuel content, reaches starter plunger and mixes again with the air coming through a passage (8) extending from underneath the diaphragm. The rich fuel/ air mixture for starting is discharged through starter outlet (6) in the main bore. 1 6 7 5 2 3 4.8 [email protected] FUEL SYSTEM / CARBURETION MAIN SYSTEM FLOAT SYSTEM As throttle valve (1) is opened, engine speed rises, and this increases negative pressure in the venturi. Consequently the vacuum slide (2) moves upward. The fuel in float chamber (3) is metered by main jet (4), and the metered fuel enters needle jet (5), in which it mixes with the air admitted through main air jet (6) to form an emulsion. The emulsified fuel then passes through the clearance between needle jet (5) and jet needle (7), and is discharged into the venturi (A). Mixture proportioning is accomplished in needle jet (5); the clearance through which the emulsified fuel must flow is determined ultimately by throttle position and vacuum slide height. Fuel enters the float chamber (3) by means of the inlet pipe and passage, through a screen on the back of the inlet needle seat (4), and around the inlet needle (2). As the fuel fills the float chamber, the float (1) rises and forces the inlet needle against the seat, shutting off the orifice in the seat. When fuel level is up in float chamber, floats are up and needle valve remains pushed up against valve seat. Under this condition, no fuel enters the float chamber. As the fuel level falls, floats go down and needle valve unseats itself to allow fuel into the chamber. In this manner, the needle valve releases and shuts off fuel alternately to maintain a constant fuel level inside the float chamber. 1 2 7 A 6 3 5 Inlet Pipe 3 1 4 4 2 4.9 [email protected] FUEL SYSTEM / CARBURETION PILOT SCREW AIR/FUEL MIXTURE RATIO The pilot system supplies fuel during engine operation with the throttle valve closed or slightly opened. The fuel/ air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet. E-Clip Position vs. Fuel Flow 2 3 4 CAUTION 4 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. 3 2 15 50 75 100% Throttle Valve Opening Pilot Screw Location A carburetor with a slide type throttle valve is also called a variable venturi type carburetor. In this type of carburetor, the needle jet and jet needle serve to control proper air/ fuel mixture ratio at the medium throttle valve opening (between 1/4 and 3/4 opening). Brass Plug Installed Brass Plug Removed 4.10 Having the proper needle jet and jet needle has a major impact on engine performance at partial load. The jet needle tapers off at one end and the clearance between the jet needle and the needle jet increases as the throttle valve opening gets wider. The air/fuel mixture ratio is controlled by the height of the “E” clip inserted into one of the five slots provided in the head of the jet needle. The previous chart shows the variation of fuel flow based on the height of the “E” clip. [email protected] FUEL SYSTEM / CARBURETION JET NEEDLE NEEDLE JET The jet needle has five adjustment grooves cut into the upper portion, and is tapered from approximately the middle of the needle to the lower end. The top is fixed to the center of the throttle valve by the needle clip, and the tapered end extends into the needle jet. Fuel flows through the space between the needle jet and jet needle. This space does not vary until the throttle reaches the 1/4 open point. At that time the tapered portion of the needle begins to move out of the jet, affecting fuel flow as the opening enlarges. If the needle clip is changed from the standard position to a lower groove, the needle taper starts coming out of the jet sooner, resulting in a richer mixture. Moving the clip higher produces a leaner mixture. If the taper is worn due to vibration, fuel flow may be significantly affected. The needle jet works in conjunction with the jet needle to regulate fuel flow rate. An air bleed opening in the side of the needle jet brings in air measured by the air jet. This air initiates the mixing and atomizing process inside the needle jet. Needle Jet Main Jet Jet Needle Leaner THROTTLE OPENING VS. FUEL FLOW Position# Richer In a full throttle condition the cross sectioned area between the jet needle and the needle jet is larger than the cross sectioned area of the main jet. The main jet therefore has greater control over fuel flow. Small Clearance Closed Throttle One-half Throttle Medium Clearance Large Clearance Full Throttle 4.11 [email protected] FUEL SYSTEM / CARBURETION CARBURETOR DISASSEMBLY – MIKUNI CV Use the following disassembly, assembly, and inspection techniques to service a CV carburetor. 3. Remove inlet needle seat retaining screw along with plate, and carefully remove needle seat. NOTE: Do not use a pliers to remove the seat or permanent damage may occur. 1. Remove carburetor diaphragm chamber cover with a ratchet style screwdriver. DO NOT use an impact driver to remove the screws or carburetor may be permanently damaged. Remove Screw 4. Remove the pilot mixture screw, spring, flat washer, and O–Ring. If an anti–tamper plug is installed over the pilot screw cavity, it must be removed for access. 2. Remove float bowl. Remove the float pin screw. The float and float pin can be removed. O-Ring Washer Spring Pilot Screw NOTE: The starter jet is removable. Upon disassembly, place the parts in a container for safe keeping. 4.12 [email protected] FUEL SYSTEM / CARBURETION CARBURETOR CLEANING WARNING Protect eyes from contact with cleaner. Take appropriate safety measures during these procedures. Safety glasses and chemical resistant gloves are required. Should you get cleaner in your eyes or if you swallow cleaner, seek medical attention immediately. Carburetor cleaners can be extremely caustic. Extended periods of soaking can loosen the adhesive sealer on the passage drill-way plugs. Do not soak rubber or plastic components (such as the vacuum slide diaphragm, needle seat screen, or O-Rings in caustic cleaning solutions. Irreparable damage may occur. Do not use agitator-type carburetor cleaning equipment. Rubber parts must be cleaned with mild detergent and hot water only. 1. Thoroughly clean the carburetor body, jets, and all passages with carburetor cleaner or electrical contact cleaner. 2. If the carburetor is extremely dirty or contaminated with fuel residue and varnish, soak for short periods only in carburetor cleaner, and rinse in hot water. 3. Replace the jets if they have a buildup of fuel residue or bacterial growth that cannot be removed. Even a small amount of residue will reduce the flow characteristics of the jet. 4. Verify all passages and jets are unobstructed by spraying electrical contact cleaner through the passages. CAUTION: Do not use wire or welding tip cleaners as the orifice size may be altered. 5. Use low pressure air to dry carburetor body and all components. CARBURETOR INSPECTION 1. Inspect jet needle and needle jet for wear. Look for discoloration, shiny spots, or an area that looks different than the rest of the needle. The middle to upper portion of the needle contacts the needle jet and is the most likely wear point. If jet needle shows signs of wear replace both the needle and needle jet to prevent a rich condition. TIP: A worn needle jet is difficult to spot. To check, slide a slightly larger new jet needle into the needle jet and hold it to a light source. Light will be visible between the needle and needle jet if it is worn. Jet Needle Needle Jet Inspect this area 2. Inspect the inlet needle tapered surface for any sign of wear or damage. Be sure the spring loaded pin is free moving and returns freely when pushed. The inlet needle and seat should be pressure tested after assembly. Good Condition Worn, Deposits Seat Wear areas Needle 4.13 [email protected] FUEL SYSTEM / CARBURETION CARBURETOR ASSEMBLY Inspect the diaphragm (A) for holes, deterioration, or damage. Make sure the diaphragm is pliable but not swollen. The diaphragm should fit properly in the carburetor body. Replace diaphragm assembly if diaphragm is damaged. damage the O–ring during installation. Turn the screw in until it lightly contacts the seat. Back out the specified number of turns. NOTE: The final pilot (idle) mixture must be adjusted with the engine running. Refer to Page 2.10. Pilot Screw Base Setting (Set at Factory) Factory Specification: 2.5 Turns Out FLOAT HEIGHT ADJUSTMENT 1. Illustration 1: Place the throttle side of the carburetor on a level surface to remove weight from float arm. In this position, the float tongue will rest slightly outward. 1. Replace parts in proper order. The spring seat (B) is stepped and must be placed on TOP of “E” Clip (C). Spacer washer (D) must be installed below the E–Clip. Refer to parts manual for more information. 2. Be sure the tab (E) on outer edge of diaphragm is positioned properly in the carburetor body. FRONT (Engine) 2. Illustration 2: With the carburetor still resting on the level surface, use one hand to slightly tilt the carburetor back. The float will then fall into the correct position, with the float tongue resting lightly on the inlet needle valve pin without compressing the spring. The bottom of the float should be parallel with the float bowl mating surface. Illustration 3: NOTE: If the float is past parallel with the mating surface, the carburetor has been tilted back too far and the float tongue is likely compressing the needle valve pin. Pilot Screw 3. Install the pilot mixture screw, spring, washer, and O– ring as an assembly. Lubricate the O–Ring with oil or light grease before installation. CAUTION: Do not 4.14 Float parallel with float bowl mating surface [email protected] FUEL SYSTEM / CARBURETION 3. Measure the height from the float bowl mating surface to the top of step of the float as shown in Illustration 2. Both sides of float should be parallel to each other. The measurement should be made at the mid–point on top of the float using Float Adjustment Tool (PN 2872314) or a vernier caliper. When measuring the height, be sure the inlet needle valve spring is not compressed. Float Bowl Height: 13-14 mm 4. If adjustment is necessary, bend the tongue slightly. Be sure float measurement is even on left and right side. FUEL LEVEL TEST A fuel level test can be performed on some models if the drain hose fitting is accessible. Be sure to re–attach the bowl drain hose after performing the test. A fuel level test allows you to observe the height of the fuel in the float bowl without removing the carburetor. The fuel level can be observed with the engine either running or shut off, however, engine must run briefly to allow fuel level to stabilize. 1. Attach a clear line to drain fitting. Be sure line fits tightly on fitting. Position hose along side of carburetor as shown. 1.5 mm .060 in. NEEDLE AND SEAT LEAKAGE TEST 1. Install the float bowl. Invert the carburetor and install a Mity–Vac™ (PN 2870975) to the fuel inlet fitting. Apply 5 PSI pressure to inlet fitting. The needle and seat should hold pressure indefinitely. If not, inspect needle and seat and seat O–ring. Bowl Mating Surface 2. Open bowl drain screw by turning counterclockwise approximately two turns. Start and run engine for 3 to 5 seconds to allow fuel level to stabilize in the line. If level is out of specification, remove carburetor and inspect inlet needle and seat, float height, passages, etc. NOTE: If a line was removed to perform this procedure, it must be replaced. Mity VacTM (PN 2870975) 4.15 [email protected] FUEL SYSTEM / CARBURETION TROUBLESHOOTING POOR IDLE FUEL STARVATION/LEAN MIXTURE Idle Too High Symptoms: Hard start or no start, bog, backfire, popping through intake / exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle speed erratic. • No fuel in tank • Idle adjusted damaged improperly/idle mixture screw • Sticky vacuum slide • Throttle cable sticking, improperly adjusted, routed incorrectly • Restricted tank vent, or routed improperly • Choke cable sticking, improperly adjusted, routed incorrectly • Fuel lines or fuel valve restricted • Plugged or restricted idle jet • Fuel filter plugged Idle Too Low • Carburetor vent line(s) restricted • Choke cable bending or incorrectly adjusted • Plugged or restricted inlet needle and seat screen or inlet passage • Idle speed set incorrectly • Clogged jets or passages • Float stuck, holding inlet needle closed or inlet needle stuck • Idle mixture screw misadjusted or damaged • Belt dragging • Ignition timing incorrect • Float level too low • Worn jet needle/needle jet • Intake air leak ( throttle shaft, intake ducts, airbox or air cleaner cover) • Plugged or restricted idle jet Erratic Idle • Jet needle position incorrect • Choke cable bending or incorrectly adjusted • Incorrect pilot screw adjustment • Throttle cable incorrectly adjusted RICH MIXTURE Symptoms: Fouls spark plugs, black, sooty exhaust smoke, rough idle, poor fuel economy, engine runs rough/ misses, poor performance, bog, engine loads up, backfire. • Air leaks, dirty carburetor passages (pilot circuit) • Pilot mixture incorrectly screw damaged or • Tight valves • Ignition timing incorrect • Air intake restricted (inspect intake duct) • Belt dragging • Air filter dirty/plugged • Dirty air cleaner • Electric choke inoperative • Engine worn • Incorrect pilot air/fuel screw adjustment • Spark plug fouled • Faulty inlet needle and seat • Idle speed set incorrectly (speed limiter) • Faulty inlet needle seat O-Ring • Worn jet needle/needle jet • Float level too high • Plugged or restricted idle jet • Poor fuel quality (old fuel) • Loose jets • Worn jet needle/needle jet or other carburetor parts • Dirty carburetor (air bleed passages or jets) 4.16 adjusted [email protected] FUEL SYSTEM / CARBURETION AIR INTAKE SYSTEM Air Intake System C A D B E F J H G Table 4-4: Air Intake System Reference Description A Pre-Filter B Air Filter C Intake Box Snorkel D Intake Box Cover E Cover Seal F Crankcase Breather Foam G Intake Box Drains H Carburetor Snorkel Reference J Description Crankcase Breather Hose 4.17 [email protected] FUEL SYSTEM / CARBURETION FUEL TANK/FUEL DELIVERY SYSTEM Fuel Tank / Fuel Delivery System A B D C E F N J G K H M L Table 4-5: Fuel Tank / Fuel Delivery System Reference Description Reference Fuel Cap B Fuel Cap O Ring K Fuel Pump C Fuel Level Gauge L Hose (Fuel Pump-To-Carburetor) D Fuel Tank Vent M Hose (Fuel Pump-To-Carburetor Vacuum Impulse) N Fuel Filter (Arrow points in direction of fuel flow to carburetor.) E Fuel Tank Hold-Down Bracket / Pad F Fuel Tank G Fuel Supply Petcock H Hose (Supply Petcock-To-Fuel Pump) 4.18 J Description A Hose (Fuel Tank-To-Supply petcock) [email protected] FUEL SYSTEM / CARBURETION EXHAUST SYSTEM Exhaust System A B C D E F Table 4-6: Exhaust System Reference Description A Tip / Spark Arrestor B Muffler C Pipe Clamp D Gasket E Head Pipe F Flange Gasket 4.19 [email protected] FUEL SYSTEM / CARBURETION NOTES 4.20 [email protected] BODY AND STEERING CHAPTER 5 BODY AND STEERING PLASTIC INSERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 SEAT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 FRONT CAB/FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 FRONT CAB/FENDER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 FRONT CAB/FENDER INSTALATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 REAR CAB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 FOOTWELL REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 BODY RACK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 REAR RACK REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 POD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 POD/KEY SWITCH/CHOKE/SPEEDO CONNECTION REMOVAL/INSTALLATION. . . 5.10 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 HANDLEBAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 HANDLEBAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 STEERING POST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11 STEERING POST BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 STEERING POST INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 5 STEERING / A-ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14 A-ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15 A-ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15 A-ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15 FRONT STRUT CARTRIDGE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16 FRONT STRUT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17 FRONT STRUT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17 BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17 BALL JOINT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18 UPPER AND LOWER REAR CONTROL ARM REMOVAL/INSTALLATION . . . . . . . . . 5.19 5.1 [email protected] BODY AND STEERING PLASTIC INSERT Removal / Installation 3. To install the inserts, press outside insert (B) into the hole. Press inside insert (A) until it snaps into place. NOTE: The outside insert (B) should be flush surface after installation. Some Polaris ATVs use a two piece plastic insert in place of a metal screw. The plastic inserts are simple to remove and install. 1. Use a a pair of diagonal side cutters to lift the plastic insert (A) until you feel some slight pressure or lift the insert approximately 1/4" (6.35 mm). Apply just enough pressure on the side cutters to lift up on the insert. DO NOT apply too much pressure on the side cutters, or damage to the insert will occur. The inside insert (A) should be flush with the top of the outside insert (B). A A B 2. Next, use the diagonal side cutters under outside insert (B) to completely remove the assembly. NOTE: The inside insert (A) will still be installed in the outside insert (B). SEAT B SEAT REMOVAL/INSTALLATION Side panel removal is quick and easy, use the following instructions for removal and installation. 1. NOTE: The inside insert (A) will still be installed in the outside insert (B). 5.2 Remove seat by releasing the latch and lifting up on the [email protected] BODY AND STEERING seat. 2. 3. FRONT CAB/FENDER Grasp the rear of the side panel near the rear cab. With a firm motion, pull the panel outward to disengage the side panel. Pull the panel downward and rearward to remove it from the ATV. Reinstall the side panel by reversing the removal procedure. 5.3 [email protected] BODY AND STEERING FRONT CAB/FENDER REMOVAL For this procedure please refer to the diagram on page 5.3. 1. 2. 3. 4. Remove the seat. Remove the fuel tank cover (4). Remove the side panels (1,3). Remove the plastic rivets on the mud guards (below) and remove them from the front cab assembly. 5. 6. 7. 8. 9. 10. Remove the battery connections (negative first). Remove the battery from the battery compartment. Route the battery cables through the front compartment. Remove the front cab fasteners (8). Remove the plastic rivets from the footwells. Carefully lift off the front cab. FRONT CAB/FENDER INSTALATION For this procedure please refer to the diagram on page 5.3. 1. 2. 3. 4. 5. 6. 7. Carefully place front of the cab onto the frame. Route the battery connections through the cab and into the battery box. Insert the mud guards and plastic rivets. Replace the fuel tank cover (4). Replace the plastic rivets into the footwells. Install the front cab fasteners. Install the battery. 5.4 [email protected] BODY AND STEERING BODY ASSEMBLY 1. Exploded View 2. 3. 4. 5. 6. Follow the procedure to remove the rear rack. See “REAR RACK REMOVAL/INSTALLATION” on page 5.6. Remove the screws (1,19) that secure the rear cab to the frame. Remove the plastic inserts (9) that secure the rear cab to the frame footwells (11,14). Disconnect the rear lights. Lift the rear cab (4) from the frame. Reverse the removal steps for installation. FOOTWELL REMOVAL/INSTALLATION 1. Remove the plastic inserts (A) that secure the wheel well to the front and rear cabs. See “PLASTIC INSERT” on page 5.2. 2. Remove the screws (B) from the bottom of the foot well. Remove the footwell. 3. Reverse the removal procedures to install the foot well. NOTE: Be sure to properly align the cab ends into the footwells upon reassembly. B A REAR CAB REMOVAL/INSTALLATION 5.5 [email protected] BODY AND STEERING BODY RACK EXPLODED VIEW REAR RACK REMOVAL/INSTALLATION 1. 2. 3. Remove the fasteners 2,3,7,9,10 and 11. Remove the rear rack. Replace in reverse order. 5.6 [email protected] BODY AND STEERING POD EXPLODED VIEW 5.7 [email protected] BODY AND STEERING POD/KEY SWITCH/CHOKE/SPEEDO CONNECTION REMOVAL/INSTALLATION 1. 2. 3. 4. 5. 6. Remove the plastic dart clips(1) from the pod (2). Press the center and pull the speedo connection away from the speedo (3). Remove the key switch connection by turning the ignition nut (9) counter clock wise. Remove the choke connection by turing the choke nut (14) counterclockwise. Remove the choke cable (13) from the pod. Replace in reverse order of removal. STEERING HANDLEBAR REMOVAL 1. 2. Remove the handlebar pod. See “POD/KEY SWITCH/CHOKE/SPEEDO CONNECTION REMOVAL/INSTALLATION” on page 5.8. Remove the handlebar block fasteners and (A) the mounting bracket (B). A B 3. Remove the handlebar assembly from the steering post. 5.8 [email protected] BODY AND STEERING HANDLEBAR INSTALLATION 1. 2. Replace the handlebar assembly into the steering post to the desired angle. Place the handlebar block onto the steering post. Make sure that the peg (C) is inserted to the steering post dimple (D). C D 3. Insert the bolts through the top of the handlebar block. 4. Place the mounting bracket (B) onto the bottom of the steering post and install the nuts on the bolts. 5. Evenly torque the two front nuts to 12 ft-lb (16Nm). 6. Torque the rear nuts evenly to 12 ft-lb (16Nm). NOTE: There will be a slight gap on the backside of the blocks after the procedure is performed. 7. Replace the handlebar pod. 5.9 [email protected] BODY AND STEERING STEERING POST REMOVAL 1. 2. 3. 4. 9. Remove the front cab. See “FRONT CAB/FENDER” on page 5.3. Remove the handle bar pod. See “POD/KEY SWITCH/ CHOKE/SPEEDO CONNECTION REMOVAL/ INSTALLATION” on page 5.8. Remove the handle bar. See “HANDLEBAR REMOVAL” on page 5.8. Remove the fuel tank bracket (A). Remove the steering tie rod ends (D) from the steering bracket (E). Note the orentation of the fasteners and bracket on the steering assembly. E D A 10. Remove the steering post bracket (F) at the front gear case (4x4 shown)/plate (2x4). F 5. 6. Turn the fuel valve to the “OFF” position Remove the fuel line (B) from the fuel pump (C). C 11. Remove the top steering bracket (G). G B 7. 8. Remove the vent line from the frame that comes from the top of the fuel tank. Note the vent line routing. Remove the fuel tank from the frame. 12. Remove the steering post. 5.10 [email protected] BODY AND STEERING STEERING POST BEARING REPLACEMENT 5. 1. Remove the steering post. 2. Press out the steering post cotter pin (A). 3. Remove the steering post nut (B), bushing (C). 4. Inspect the bushings 5. Remove and replace the bearing (D). 6. Install the bearing as shown in the image. 7. Torque the steering post nut (B) to 50 ft-lb (68Nm). 8. Install a new cotter pin (A). NOTE: Make sure that the cotter pin is not obstructing steering movement. Place the steering post upper bracket to the frame, torque the upper nuts to 22 ft-lb (30Nm). G C 6. 7. D C 8. Place the tie rod retainer (H) on to a tie rod bolt (I). Insert the tie rod bolts from the bottom of the tie rod, and line up the retainer to the bottom of the tie rods. Torque the tie rod fasteners to 40 ft-lb (54Nm). B A 2x4 4x4 STEERING POST INSTALLATION 1. 2. 3. 4. Insert the steering post assembly into the chassis. Place the lower bracket (F) into the front gear case on the 4x4 units, and into the bracket on the 2x4 units. Apply blue Loctite to the threads of the bracket bolts. Torque the bolts to 19-22 ft-lb (26-30Nm). I F 9. H Replace the fuel tank into the frame. 5.11 [email protected] BODY AND STEERING 10. Make sure that the routing of the vent line is correct. STEERING / A-ARM Exploded View B 11. Place the fuel tank bracket in place. Note to get the routing of the throttle cable and carburetor venting correct. 12. Tighten the fuel tank bracket fasteners. 13. Hook up the fuel line to the fuel pump and move the clamp to the correct area. A NOTE: To avoid damage to tie rods and other steering components, be sure to install tie rod end bolts in the proper direction. The steering post arm bolt (B) points up; the rod end bolts (A) point down. Be sure inner rod ends are placed between the 5.12 [email protected] BODY AND STEERING steering post arms. Replace all cotter pins if removed (4,11). FRONT STRUT CARTRIDGE REPLACEMENT A-ARM A-ARM REMOVAL Refer to drawing on page page 5.12 1. 2. 3. 4. 5. 6. Apply parking brake and loosen the lug nuts. Elevate the front of the machine and secure it with jack stands. Remove the rim from the hub and release the parking brake. Remove the pinch bolt (10) and nut (9) that hold the AArm ball joint (13) to the carrier bearing assembly. Remove the flange bolt (19) and flange nut (3) from the frame. Remove A-Arm. WARNING The locking features on the existing bolts were destroyed during removal. DO NOT reuse old bolts. Serious injury or death could result if fasteners come loose during operation. A-ARM ASSEMBLY Refer to drawing on page page 5.12 1. 2. 3. 4. 5. 6. Assemble A-Arm with all bushings (17), pivot tube (18), ball joint (12,13), and brush guard (15) (if applicable). Place the A-Arm to the frame and insert the flange bolt (19) with the head toward the front of the machine and the flange nut (3) toward the rear. Torque the flange bolt (19) to 40 ft-lbs (54Nm). Insert the ball joint (13) far enough into the carrier bearing assembly so that the pinch bolt (10) can be inserted. Insert the pinch bolt (10) so that the flange head is at the front of the machine and the flange nut (9) is at the rear. Torque the pinch bolt to 20 ft-lbs (27Nm). WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into regular service. 5.13 [email protected] BODY AND STEERING FRONT STRUT REMOVAL Refer to drawing on page page 5.13 1. 2. 3. 4. 5. 6. Remove the wheel on the side of the strut that is to be replaced. Remove the front cab. With an open end wrench hold the shock tower nut (16) and with a socket turn the shock rod. Remove the screw that holds on the brake line to the strut. Remove the carrier bearing assembly fasteners (4,7). Remove the strut from the vehicle. FRONT STRUT INSTALLATION Refer to drawing on page page 5.13 1. 2. 3. 4. 5. 6. Place strut assembly into the frame and insert the strut flange nut (16). Insert the strut into the carrier bearing assembly and insert the fasteners (4,7). Torque the top strut flange nut (16) to 40 ft-lb (54 Nm). Torque the carrier bearing fasteners (7) to 37 ft-lb (50Nm). Replace the torx fastener that holds the brake line in place. Replace front cab. BEARING REPLACEMENT Refer to drawing on page page 5.13 1. 2. 3. 4. 5. 6. 7. Remove the front bearing carrier (1). Remove the snap ring (3) from the bearing carrier. Press out the bearing (2). Press in new bearing. Replace the snap ring Install bearing carrier. Torque the bearing carrier to strut mounting fasteners to 37 ft-lb (50Nm). 5.14 [email protected] BODY AND STEERING BALL JOINT REAR SUSPENSION REPLACEMENT 1 2 1. 2. 3. 4. 5. 6. Remove the A-Arm. See “A-ARM REMOVAL” on page 5.13. Remove the snap ring (1) from the ball joint. Press out the old ball joint (2). Press in new ball joint into A-Arm. Replace the snap ring (1) onto the new ball joint. Assemble the A-Arm, See “A-ARM ASSEMBLY” on page 5.13. 5.15 [email protected] BODY AND STEERING UPPER AND LOWER REAR CONTROL ARM REMOVAL/INSTALLATION Described in this section is for one side of the machine. Duplicate this process for the other side. 1. 2. 3. 4. Raise and secure the rear of the machine. Remove the rear wheel. Remove the rear shock. Remove the Upper Control Arm (UCA) (15) fasteners (1,4,12) from the transmission and bearing carrier. Note the long (12,14) and short (1,3) fasteners and pivot shaft locations. 5. Remove the x short grey bushings (2) and pivot shafts (3,14). 6. Remove the Lower Control Arm (LCA) (11) fasteners (4,5,12) from the frame and bearing carrier. Note the long (5,8) and short (12,14) fasteners and pivot shaft locations. 7. Remove the long grey bushings (9) and pivot shaft (8) from the frame. 8. Remove the short bushings (13) and pivot shaft (14) from the bearing carrier. 9. Remove the LCA (11) from the unit. 10. Replace in reverse order with the following torque values. • LCA to Bearing Carrier 40 ft-lb (54Nm) • LCA to Frame 40 ft-lb (54Nm) • UCA to Bearing Carrier 40 ft-lb (54Nm) • UCA to Transmission 40 ft-lb (54Nm) • Shock Mounts (top and bottom) 40 ft-lb (54Nm) • Wheel Lug Nuts 27 ft-lb (37Nm) 5.16 [email protected] BODY AND STEERING 5.17 [email protected] BODY AND STEERING 5.18 [email protected] BODY AND STEERING 5.19 [email protected] BODY AND STEERING NOTES 5.20 [email protected] BRAKES CHAPTER 6 Brakes SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 BRAKES / TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 BRAKE NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 BRAKE SYSTEM MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 REAR MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 BRAKE BLEEDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 HAND BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10 BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 FRONT CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16 BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16 THICKNESS / RUNOUT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16 WEAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16 REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 FOOT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 FOOT PEDAL REMOVAL / INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 FOOT BRAKE MASTER CYLINDER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . 6.18 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18 6.1 6 [email protected] BRAKES SPECIFICATIONS Brakes / Torque Table 6-1: FRONT BRAKE Item Standard Service Limit Brake Pad Thickness .275” / 7 mm .155” / 3.9 mm Brake Disc Thickness .157” / 4.0 ± 2 mm .140” / 3.55 mm Brake Disc Thickness Variance Between Measurement -- .002” / .051 mm Brake Disc Runout -- .010” / .254 mm Caliper Piston Diameter (Front) 1.250” / 31.75 mm -- Table 6-2: REAR BRAKE Item Standard Service Limit Brake Pad Thickness .275” / 7 mm .155” / 3.9 mm Brake Disc Thickness .157” / 4.0 ± 2 mm .140” / 3.55 mm Brake Disc Thickness Variance Between Measurements -- .002” / .051 mm Brake Disc Runout -- .010” / .254 mm Caliper Piston Diameter (Rear) 1.250” / 31.75 mm -- Table 6-3: TORQUE SPECIFICATIONS Item Torque ft.lbs. (in.lbs.) Torque (Nm) Front / Rear Caliper Mounting Bolts 22 30 Handlebar Master Cylinder Clamp Bolts (70 in.lbs.) 7.9 Hand Master Cylinder Reservoir Cover (7 in.lbs.) .79 Brake Line Banjo Bolt 15 20 Brake Disc Bolts 18 24 Brake Line Flare Fittings 12-15 16-21 Bleeder Screw (36-46 in.lbs.) 4-5 NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures are used when torquing certain bolts and fasteners. Do not re-use fasteners that have pre-applied locking agents. 6.2 [email protected] BRAKES TROUBLESHOOTING Table 6-4: BRAKE NOISE TROUBLESHOOTING Brake Noise Possible Cause Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning does not reduce the occurrence of brake noise, a product such as Permatex™ Disc Brake Quiet or an equivalent can be applied to the back of the pads. Follow directions on the package. This will keep pads in contact with caliper piston(s) to reduce the chance of squeaks caused by dirt or dust. Table 6-4: BRAKE NOISE TROUBLESHOOTING Possible Cause Remedy Noise is from other source (chain, axle, hub, disc or wheel) If noise does not change when brake is applied check other sources. Inspect and repair as necessary Wrong pad for conditions Change to a softer or harder pad (if available) Remedy Dirt, dust, or imbedded material on pads or disc Spray disc and pads with a non-flammable aerosol brake cleaner. Remove pads and/or disc hub to clean imbedded material from disc or pads. Pad(s) dragging on disc (noise or premature pad wear) Adjust pad stop (front calipers) Insufficient lever or pedal clearance Set to proper level Master cylinder reservoir overfilled Check brake fluid level, adjust as needed O-rings worn Rebuild Caliper Master cylinder compensating port restricted, Master cylinder piston not returning completely, Caliper piston(s) not returning Clean piston(s) seal Operator error (riding the brake / park brake applied) Educate operator Loose wheel hub or bearings Tighten wheel nuts or replace bearing if worn Brake disc warped or excessively worn Replace disc Brake disc misaligned or loose Inspect and repair as necessary 6.3 [email protected] BRAKES BRAKE SYSTEM MAIN COMPONENTS System Exploded View 2 screws - 7 in. lbs. (.79Nm ) All Flare Style Fittings: 12-15 ft.lbs. (16-21 Nm) All Bleed Screws: 36-46 in.lbs. (4-5 Nm) Apply a Light Amount of Pipe Sealant to Threads All Banjo Style Fittings: 15 ft.lbs. (20 Nm) 6.4 [email protected] BRAKES BRAKE CALIPER Exploded View A.Bleeder Screw B. Caliper Body C. Internal Caliper Slide Pin O-rings (small) D. Square Seals E. Piston F. Caliper Mount G. Brake Pads H. Internal Caliper Slide Pin O-rings (large) I. Caliper mount O-ring C A B D E H I F G HYDRAULIC BRAKE SYSTEM 6.5 [email protected] BODY AND STEERING Operation Overview Must be clear to allow proper diaphragm movement E C F A Move Brake Pad Compensating port compensates for temperature changes by allowing fluid back to master cylinder B D The Polaris disc brake system consists of the following components or assemblies: hand brake lever; foot brake lever, hand and foot brake master cylinders; hydraulic hoses; brake calipers (slave cylinders); brake pads; and brake discs, which are secured to the drivetrain. When the hand activated brake lever (A) is applied it contacts piston (B) within the master cylinder. As the master cylinder piston moves inward it closes a small opening (compensating port C) within the cylinder and starts to build pressure within the brake system. As the pressure within the system is increased, the piston (D) located in the brake caliper moves outward and applies pressure to the brake pad. This pad contacts the brake disc and moves the caliper in its floating bracket, pulling the stationary side pad into the brake disc. The resulting friction reduces brake disc and vehicle speed. As the lever pressure is increased, the braking affect is also increased. 6.6 The friction applied to the brake pads will cause the pads to wear. As these pads wear, the piston within the caliper moves further outward and becomes self adjusting. Fluid from the reservoir fills the additional area created when the caliper piston moves outward. Brake fluid level is critical to proper system operation. Too little fluid will allow air to enter the system and cause the brakes to feel spongy. Too much fluid could cause brakes to drag due to fluid expansion. Located within the master cylinder is the compensating port (C) which is opened and closed by the master cylinder piston assembly. The port is open when the lever is released and the master cylinder piston is outward. As the temperature within the hydraulic system changes, this port compensates for fluid expansion (heated fluid) or contraction (cooled fluid). During system service, be sure this port is open. Due to the high temperatures created within the system during heavy braking, it is very important that the master cylinder reservoir have adequate space to allow for fluid expansion. Never overfill the reservoir! Fill to 1/4, - 5/16, (.64 - .80 cm) from top of the cylinder. This system also incorporates a diaphragm (E) as part of the cover gasket; and a vent port (F) located between the gasket and the cover. The combination diaphragm and vent allow for the air above the fluid to equalize pressure as the fluid expands or contracts. Make sure the vent is open and allowed to function. If the reservoir is over filled or the diaphragm vent is plugged the expanding fluid may build pressure in the brake system leading to brake fail When servicing Polaris ATV brake systems, use only DOT 3 or DOT 4 Brake Fluid. WARNING Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture. This causes the boiling temperature of the brake fluid to drop, which can lead to brake fade and the possible loss of control. [email protected] BRAKES REAR MASTER CYLINDER • Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely. Operation Overview CAUTION Brake Fluid Reservoir Use only DOT 3 or 4 brake fluid as an assembly aid for all procedures described in this chapter to prevent brake system contamination. DO NOT USE LUBRICANTS OF ANY KIND FOR ASSEMBLY, AS THEIR USE CAN CAUSE RUBBER COMPONENTS TO SWELL. Rear Brake MC Frame Rear Brake Line BRAKE BLEEDING Fluid Change NOTE: When bleeding the brakes or replacing the fluid, always start with the caliper farthest from the master cylinder. Spring CAUTION Brake Mount Always wear safety glasses during these procedures. Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. Brake Lever When the foot activated brake lever is applied it contacts piston of the master cylinder. As the pressure within the system is increased, the piston located in the brake calipers move outward and apply equal pressure to the brake pads. • Perform a brake burnishing procedure after installing new pads to maximize service life. • Optional pads are available to suit conditions in your area. Select a pad to fit riding style and environment. NOTE: Do not move brake lever when reservoir fluid level is low. This procedure should be used to change fluid or bleed brakes during regular maintenance. 1. 2. 3. Clean reservoir cover thoroughly. Remove screws, cover and diaphragm (C) from reservoir. Inspect vent slots (A) in cover and remove any debris or blockage. • Do not over-fill the master cylinder fluid reservoir. • Make sure the brake lever and pedal returns freely and completely. • Adjust stop pin on front caliper after pad service. • Check and adjust master cylinder reservoir fluid level after pad service. • Make sure atmospheric vent on reservoir is unobstructed. • Test for brake drag after any brake system service and investigate cause if brake drag is evident. • Make sure caliper moves freely on guide pins (where applicable). 6.7 [email protected] BODY AND STEERING 4. If changing fluid, remove old fluid from reservoir and lines at the bleeders with a Mity Vac™ pump or similar tool, topping off the reservoir with fresh DOT 3 or DOT 4 fluid as it drains to the MIN reservoir level. DO NOT allow the reservoir to drain completely. Continue this process at each bleeder until the fluid runs clear. C Sight Glass D A MAX Level - Brake B Brake Bleeding 1. Begin bleeding procedure with the caliper that is farthest from the master cylinder. Install a box end wrench on caliper bleeder screw. Attach a clean, clear hose to fitting and place the other end in a container. Be sure the hose fits tightly on fitting. NOTE: Fluid may be forced from supply port (B) if brake lever is pumped. Place diaphragm (C) in reservoir to prevent spills. Do not install cover tight. See Illustration above. 2. Slowly pump brake lever (D) until pressure builds and holds. 3. While maintaining lever pressure, open bleeder screw. Allow lever to relax slowly toward the hand grip while tightening the bleeder screw. Watch for signs of air bubbles in the fluid as the screw is tightened. When no air is present, the bleeding procedure should be complete. 4. Allow lever to return back to it’s normal position once the brake bleeder is securely tightened. NOTE: Do not release lever before bleeder screw is tight or air may be drawn into caliper. 5. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Add fluid as necessary to maintain level in reservoir. CAUTION Maintain at least 1/2, (1.27 cm) of brake fluid in the reservoir to prevent air from entering the master cylinder. 6. 7. 8. 6.8 Tighten bleeder screw securely and remove bleeder hose. Torque the bleeder screw to specification. Repeat procedure for the remaining caliper(s). Add DOT 3 or DOT 4 brake fluid to the MAX level inside reservoir. [email protected] BRAKES 9. Install diaphragm, cover and screws. Align any marks (if present) into the proper holes in the master cylinder. Wiggle and press down on the cap to be sure it fits evenly and snug. Torque the screw to 7 in.lbs. (0.79 Nm). HAND BRAKE MASTER CYLINDER Removal 1. Clean master cylinder and reservoir assembly. Make sure you have a clean work area to disassemble brake components. 2. Remove the banjo bolt that connects the brake line to the master cylinder. Discard the copper washers. CAUTION Cap Must Be Even Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 7 in.lbs. (0.79 Nm) 3. 4. Remove master cylinder clamps from handlebars. Hold brake upright and continue to remove master cylinder. Cover brake line to avoid spilling of fluid. Torque Outer Screw First 10. Field test machine at low speed before putting into service. Check for proper braking action and lever reserve. With lever firmly applied, lever reserve should be no less than 1/ 2”, (1.3 cm) from handlebar. 11. Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasion. Replace hose if wear or abrasion is found. 6.9 [email protected] BODY AND STEERING Installation 2. NOTE: When replacing the brake master cylinder assembly or master cylinder parts, use the correct parts. There are different brake master cylinders for the different Polaris ATV models. Refer to your parts manual or guide for the correct parts. Some master cylinders are not serviceable and are replaced as an assembly. 1. Install master cylinder on handlebars. Torque mounting bolts to 70 in. lbs. (7.9 Nm). Torque the inside bolt first as indicated in the illustration to the right. Place NEW sealing washers on each side of banjo line and torque banjo bolt to specification. Torque to specification (15 ft.lbs.) Sealing Washer Banjo Bolt 7 in.lbs. (.79 Nm) Brake Line Torque Bolt First 3. Fill reservoir with DOT3 or DOT 4 brake fluid. 4. Follow bleeding procedures. Check all connections for leaks and repair if necessary. 70 in.lbs. (7.9 Nm) NOTE: To speed up the brake bleeding procedure, the master cylinder can be purged of air before brake line is attached. Fill with DOT 3 or DOT 4 Brake Fluid and pump lever slowly two to three times with finger over the outlet end to purge master cylinder of air. 6.10 [email protected] BRAKES BRAKE PADS 4. Push mounting bracket inward and slip outer brake pad past edge. Remove inner pad. 5. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. Removal 1. Loosen the wheel nuts. Elevate and support front of machine and remove the tire(s). CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 2. 3. Remove caliper from mounting bracket. Push caliper piston into caliper bore slowly using a Cclamp or locking pliers with pads installed. Measure Pad NOTE: Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. Front Brake Pad Thickness New : .275”/ 7 mm Service Limit: .155” / 3.9 mm 6.11 [email protected] BODY AND STEERING 3. Installation 1. Install caliper on hub strut, and torque mounting bolts. Lubricate mounting bracket pins and external slide pin Oring with a light film of Polaris Premium All Season Grease (PN 2871423). 22 ft.lbs. (30 Nm) 4. 2. Compress mounting bracket. Install pads with friction material facing each other. Slowly pump the brake lever until pressure has been built up. Maintain at least 1/2, (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 5. Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap. 6. Install wheels and torque wheel nuts to specification. NOTE: Front Wheel Nut Torque: Refer to Torque Table at beginning of chapter. FRONT CALIPER Removal CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. WARNING If the brake pads are contaminated with grease, oil, or liquid soaked do not use the pads, use only new clean pads. 6.12 1. Using a line wrench, loosen and remove brake line to caliper. Place a container under caliper to catch fluid [email protected] BRAKES 2. draining from brake line. 3. Push pad retainer pin inward and slip brake pads past the pin edges. A pliers may be used to compress the pad retainer for removal if the pads are too thick. Use caution not to bend or damage the retainer or the brake pad ears. 4. Remove mounting bracket pin assembly . Remove piston using a twisting, pulling motion. Remove the piston square seals using a wooden or plastic pick. Use caution not to scratch or damage the piston or the bore of the caliper. NOTE: Do not use a metal pick or awl to remove the square seals. The use of compressed air may be required to remove the piston. CAUTION Always wear eye protection when using compressed air. 6.13 [email protected] BODY AND STEERING 5. Remove the four (4) O-rings from the caliper body. Note the orientation of the O-rings for reassembly. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTE: Be sure to clean grooves in caliper body. Do not use a petroleum based spray to clean the caliper. Inspection 1. Inspect caliper body for nicks, scratches or wear. Measure bore size and check for out of round. Replace if damage is evident or if worn. 2. Inspect piston for nicks, scratches, wear or damage. Measure diameter and replace if damaged or worn beyond service limit. 3. Inspect the brake disc and pads as outlined for brake pad replacement this section. See “BRAKE PAD INSPECTION” in this chapter. NOTE: O-ring grooves are size-specific Clean Components 6.14 [email protected] BRAKES 4. Reassembly 1. Install new piston square seals (A) in the caliper body (B). Be sure groove is clean and free of residue or brakes may drag upon assembly. Compress the mounting bracket into the caliper and make sure the O-rings are fully seated. Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease. C B A 2. Coat piston with clean Polaris DOT 3 or DOT 4 Brake Fluid (C). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance. 3. Install new slide pin O-rings in the caliper body for the Lubricate the mounting bracket pins with Polaris Premium All Season Grease (PN 2871423), and install.. NOTE: Do not use Polaris Premium All Season Grease (PN 2871423) on the square seals. The petroleum based lubricant will cause the square seals to swell up. Installation 1. Install caliper on hub strut, and torque mounting bolts. 15 ft.lbs. (20 Nm) 22 ft.lbs. (30 Nm) 2. 3. 4. NOTE: O-ring grooves are size-specific Install brake line and tighten securely with a line wrench. Torque the banjo brake lines to the proper torque specification. Perform brake bleeding procedure as outlined earlier in this chapter. Install wheels and torque wheel nuts to specification (See Chapter 2). 6.15 [email protected] BODY AND STEERING BRAKE BURNISHING PROCEDURE 3. Mount dial indicator as shown to measure disc runout. Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if runout exceeds specifications. Overview It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise. Start machine and slowly increase speed to 30 m.p.h.. Gradually apply brakes to stop machine. Allow pads and disc to cool sufficiently after each stop during the procedure. Do not allow pads or disc to become hot or warping may result. Repeat this procedure 10 times. BRAKE DISC Thickness / Runout Inspection 1. 2. Visually inspect the brake disc for nicks, scratches, or damage. Measure the disc thickness at eight different points around the pad contact surface using a 0-1, micrometer. Replace disc if worn beyond service limit. Brake Disc Runout Service Limit: .010” / .254 mm Wear Inspection 1. 2. visually inspect disc for scoring, scratches, or gouges. replace the disc if any deep scratches are evident. use a 0-1” micrometer and measure disc thickness at 8 different points around perimeter of disc. replace disc if worn beyond service limit. BRAKE DISC Brake Disc Thickness: New: .157”(4.0 ± .2mm) Service Limit: .140” / 3.556 mm Disc Thickness 6.16 [email protected] BRAKES 5. Install NEW bolts and tighten to 18 ft.lbs. (24 Nm). Brake Disc Thickness New: .157”(4.0 ± .2mm) Service Limit: .140” (3.556 mm) Brake Disc Thickness Variance Service Limit: .002” (.051 mm) difference between measurements Torque New Bolts: Brake Disc Runout Service Limit: .010” (.254 mm) CAUTION Always use NEW brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. Removal / Replacement NOTE: To reduce the possibility of warping, try removing the brake disc mounting bolts before applying heat to the bolts. 1. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent. FOOT BRAKE Foot Pedal Removal / Install 1. 2. 3. 2. 3. 4. 18 ft.lbs. (24 Nm) Remove the cotter key (A). Remove the washers, bushings, and tension spring and remove the brake lever (F). Reverse the steps for installation, using a new cotter key during installation. Remove bolts and disc. Clean mating surface of disc and hub. Install new disc on hub. 6.17 [email protected] BODY AND STEERING Foot Brake Master Cylinder Removal / Installation • Worn disc and/or friction pads 1. • Incorrectly adjusted stationary pad 2. 3. 4. 5. If necessary, remove the rear brake lines (B) from the master cylinder (C). Use a suitable container to catch the brake fluid. Dispose of brake fluid properly. Remove the two bolts that secure the rear master cylinder to the brake mount plate. Replace parts as needed. To install the rear brake master cylinder, mount the master cylinder to the mount plate and torque bolts to 8 ft.lbs. (11 Nm). Reinstall the brake line and torque the banjo bolt (with new copper washers installed) to 22 ft.lbs. (30 Nm). Torque the flared fitting (if removed) to 12-15 ft.lbs. (1621) Nm. Bleed the master cylinder following the procedure outlined in the brake bleeding section of this manual. • Incorrectly adjusted lever • Worn or damaged master cylinder or components • Improper clearance between lever and switch LEVER VIBRATION • Disc damaged • Disc warp (runout or thickness variance exceeds service limit) CALIPER OVERHEATS (BRAKES DRAG) • Compensating port plugged • Foot brake pedal incorrectly adjusted B • Brake lever or pedal binding or unable to return fully • Parking brake left on C • Residue build up under caliper seals D • Operator riding brakes BRAKES LOCK F A • Alignment of caliper to disc • Compensating port plugged • Parking brake left on TROUBLESHOOTING BRAKE SQUEAL • Dirty/contaminated friction pads • Improper alignment • Worn disc • Worn caliper POOR BRAKE PERFORMANCE • Air in system • Water in system (brake fluid contaminated) • Caliper/disc misaligned • Caliper dirty or damaged • Brake line damaged or lining ruptured 6.18 [email protected] FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 COMPONENT TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 FRONT DRIVE CV SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 CV BOOT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 FRONT HUB BEARING (2X4/4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 FRONT PROP SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 AWD FRONT DRIVE AXLE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 FRONT DRIVE SHAFTS AND PROPSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 FRONT GEARCASE - CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 FRONT GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10 CENTRALIZED HILLIARD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10 ALL WHEEL DRIVE GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15 AWD DIAGNOSTICS: AWD WILL NOT ENGAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 REAR HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20 REAR HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21 7 REAR CV SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22 DRIVE SHAFT AND CV JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22 HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22 REAR CV SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23 CV JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24 CV JOINT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24 REMOVAL AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25 7.1 [email protected] FINAL DRIVE SPECIFICATIONS 5. CAUTION Component Torques IMPORTANT: Verify which type of tire your ATV is equipped with (aluminum or steel wheel) when torquing wheel nuts. Table 7-1: Torque Table Component ft.lbs. (in.lbs.) Nm F/R Steel Wheel Nuts 27 41 F/R Aluminum Wheel Nuts 90 122 Front Hub Nut 80 109 Rear Hub Nut 80 109 Lower Front A-arm 38 51 CAUTION Locking nuts, and bolts with pre-applied locking agent should be replaced if removed. The self-locking properties of the nut or bolt are reduced or destroyed during removal Table 7-2: Special Tools Part Number Tool Description 2872608 Roller Pin Removal Tool 8700226 CV Boot Clamp Pliers -- A- Arm Removal Tool FRONT DRIVE CV SHAFT Removal 1. 2. 3. 4. Remove hub dust caps. Remove cotter pins. Loosen the hub retaining nuts. Loosen - but do not remove - the wheel nuts. 7.2 Safely lift and support the front of the ATV. Serious injury could occur if machine tips or falls. 6. 7. Remove wheels. Remove cotter pin and nut from lower A-arm ball joint. Remove lower A-arm from ball joint using a suitable tool. 8. Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly. (Hub removed for clarity - removal optional) [email protected] FINAL DRIVE 9. Pull sharply or use a pry bar to remove CV shaft from the gearcase. CV BOOT SERVICE Inspection Check the front and rear driveshaft CV boots for signs of cracking, tearing, punctures or leaking grease. If the driveshaft boot loses all of the grease, CV joint failure will occur. Installation 1. 2. 3. 4. Apply an anti-seize compound to all splines. Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft with rubber faced hammer. Install drive shaft into strut housing. Install lower A-arm ball joint. Install cross bolt and torque nut to 38 ft. lbs. (51 Nm) and install new cotter pin. Install hub, washer and nut. Tighten hub nut to specification and install new cotter pin. Disassembly 1. 2. 3. Refer to the “CV SHAFT REMOVAL” section in this chapter for procedures. Remove clamps from rubber boot using the proper boot clamp pliers. Remove the large end of the boot from the CV joint, slide the boot back and separate the wheel spindle and CV joint assembly from the axle shaft by pulling the shaft sharply outward, away from the CV joint. It may be necessary to tap the CV joint assembly outward with a soft faced hammer. Retaining Ring Front Hub Retaining Nut Torque: 80 ft. lbs. (109 Nm) Pull Shaft to Remove from CV Joint 7.3 [email protected] FINAL DRIVE NOTE: If the ATV has been operated with a damaged boot, the CV joint grease may be contaminated. Inspect the grease carefully for contamination, and clean the joint thoroughly if necessary. Front drive axle CV boot replacement requires 4 oz. of grease. 8. While pulling out on the CV shaft, fully extend the CV joint and slide a straight O-ring pick or a small slotted screw driver between the small end of the boot and the shaft. This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life. Before you remove the instrument, verify the small end of the boot is in its correct location on the axle. CARE MUST BE TAKEN TO AVOID DAMAGE TO THE NEWLY INSTALLED BOOT. 9. Install the small clamp on the boot. CV Joint Grease -4 oz. (Refer to parts manual for boot kit) CV Boot Clamp Pliers: Earless Type: (PN 8700226) Boot replacement with complete CV joint cleaning requires the entire 4 oz. of grease. 4. Before installing the new boot, remove all grease from the boot area and shaft. NOTE: It is very important to use the correct type and quantity of grease. Use only the grease contained in the boot kit. DO NOT use a substitute grease and DO NOT overfill or underfill the CV joint. 5. Slide the new clamp and boot (small end first) over the splined shaft, then slide (tap) the CV joint into the splines of the axle. 6. Add grease through large end of boot. 7. Install a new boot onto the axle shaft and fill the CV joint and boot with the correct type and amount of grease. Front Shaft 4 4 7.4 [email protected] FINAL DRIVE FRONT HUB BEARING (2x4/4x4) Installation 1. Removal 1. Remove outer snap ring. 2. 3. Support bottom of hubstrut housing in a press or suitable device. Start bearing in housing. Press bearing into place until outer race bottoms on housing. CAUTION When using an arbor press be sure to press only on the outer race, as bearing damage may occur. 4. Install snap ring into groove. FRONT PROP SHAFT Removal 2. 1. Using Roll Pin Removal Tool (PN 2872608), remove the roll pin from prop shaft at rear of housing. 2. Slide prop shaft back and away from front housing. Pull sharply forward to remove from transmission shaft. From the back side, tap on the outer bearing race with a drift punch in the relief as shown. NOTE: Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed. 3. Discard bearing once removed. NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race. 4. Inspect bearing housing for scratches, wear or damage. Replace housing if damaged. Installation 1. 2. Apply anti-seize compound to all splines. Slide prop shaft back onto the transmission housing, then connect to the front gearcase, verify pin holes are aligned. Using Roll Pin Tool (PN 2872608), install the prop shaft roll pin at rear of housing. 7.5 [email protected] FINAL DRIVE U-JOINT SERVICE 3. Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing ca 4. Force U-joint cross to one side and lift out of inner yoke. Disassembly CAUTION Always wear eye protection! 1. Remove internal or external snap ring from all bearing caps. NOTE: If yoke or bearing is removed, cross bearing must be replaced. Note orientation of grease fitting and mark inner and outer yoke for correct repositioning during installation. 2. Support inner yoke as shown and drive outer yoke down (bearing cap out) with a soft face hammer. 7.6 [email protected] FINAL DRIVE Assembly 1. Repeat procedure for other side. Install new bearing caps in yoke by hand. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft. Take care not to dislodge needle bearings upon installation of cross joint. Tighten vise to force bearing caps in. 5. 6. 2. Using a suitable arbor, fully seat bearing cap in one side. Continually check for free movement of bearing cross as bearing caps. Using a suitable arbor, fully seat bearing cap in one side. Continually check for free movement of bearing cross as bearing caps are assembled. are assembled. 7. 3. 4. Install snap ring to contain bearing cap just installed. Repeat procedure for other side. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown. When installation is complete, yokes must pivot freely in all directions without binding. If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely in all directions. Install snap ring to contain bearing cap just installed. Repeat procedure for other side. Install snap ring to contain bearing cap just installed. 7.7 [email protected] FINAL DRIVE AWD FRONT DRIVE AXLE EXPLODED VIEW Front Drive Shafts and Propshafts NOTE: Refer to your parts manual for the proper replacement parts. Drive Axle Components Outer CV Joint Inner Boot Outer Boot Inner CV Joint Shaft Clamps Drive Boot Replacement Kits Clamp 4 oz. grease Boot 4 oz Outer Clamp Propshaft Assy. Front Prop Shaft Components Cross & Bearing Kit Yoke, Front Gearcase 7.8 Prop Shaft Yoke, Prop to Transmission [email protected] FINAL DRIVE FRONT GEARCASE CENTRALIZED HILLIARD Operation Overview Engaging Front Gearcase: The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains while the front gearcase is moving, it will not disengage until the rear wheels regain traction. Engage the AWD switch before getting into conditions where the front wheel drive may be needed. If the rear wheels are spinning , release the throttle before switching to AWD. CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest. With the AWD switch off the vehicle drives only the rear wheels (2 wheel drive). When the AWD switch is activated it engages the hilliard, locking both front axles into All Wheel Drive. to the output hubs that link both front axles, resulting in True All Wheel Drive. Roller Cage & Bearings Ring Gear Armature Plate CAUTION If the rear wheels are spinning, release the throttle before turning the AWD switch on. If AWD is engaged while the wheels are spinning, severe drive shaft and clutch damage could result. Disengagement: As the front and rear wheels gain traction, their rotational rpms are very close to the same speed. The front wheels ‘overdrive’ the output hubs and the rollers are forced outward, disengaging the AWD. The vehicle is now back to rear wheel drive until the next loss of traction. 4x4 Engagement: When the AWD switch is activated, a 12 VDC current charges the central coil which creates a magnetic field. This magnetic field attracts an armature plate keyed to a roller cage that contains rollers and roller cam. The difference in rotational rpm between the input shaft and front axles forces the rollers up the external cam. The rollers engage themselves 7.9 [email protected] FINAL DRIVE FRONT GEARCASE CENTRALIZED HILLIARD EXPLODED VIEW 7.10 [email protected] FINAL DRIVE ALL WHEEL DRIVE GEARCASE center of the vehicle Removal 1. 2. 3. Stop engine, place machine in gear and set parking brake. Loosen right front wheel nuts slightly. Elevate machine until the front wheels are off the ground and support machine under footrest/frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Wear eye protection when removing and installing bearings and seals. 4. 5. Remove wheel nuts and wheels. To remove the gearcase, the following items must be removed or disconnected so that the steering post brackets can be accessed and the post raised up: * Battery and cables * Seat * Fuel Tank * Front Fender Assy * Side Panels * Head Light Harnesses * AWD Hub Coil Harness * Gearcase vent line 6. Remove the front bumper. (4 Bolts) 7. Remove the front splash guards. (two screws and six slips per side) 8. Remove the center tank cover. (replace gas cap to avoid spills) 9. Remove the front cab by loosening the 4 screws that attach the cab to the frame. Turn the handlebars full left. Rotate and lift the front cab around the steering / components. 10. Remove the fuel tank. (Chapter 4) 11. Remove the steering post brackets from the gearcase mounting flange and bulkhead. Lift the steering post assembly from the front gearcase and move toward the 7.11 [email protected] FINAL DRIVE 12. Remove cotter pin, lower ball joint nut and A-arm from ball joint. 16. Remove bolts securing bottom of housing to frame. Bolts are accessible through the skid plate. Remove vent line. Remove the front gearcase from either side of frame. Front Gearcase Removal Remove 4 Bolts 13. Pull the strut assembly out and pull the drive-shaft out of the hub. (Hubs removed for clarity - removal not required) DISASSEMBLY 1. 2. 14. Pull both driveshafts from the front gearcase. 15. Remove the roller pin from the front prop shaft. Use the Roller Pin Removal Tool (PN 2872608). 7.12 Drain and properly dispose of used oil. Remove any metal particles from the drain plug magnet. Remove bolts and output shaft cover. [email protected] FINAL DRIVE 3. Remove ring gear and roller assembly. 6. Remove the ring gear, roll cage assembly, rollers, and Hsprings from the gearcase. 4. Clean all parts and inspect for wear. Inspect ring gear backlash pad (arrow) for wear or damage. 7. Thoroughly clean all parts. Inspect the rollers (A) for nicks and scratches. The rollers must slide up and down freely within the roller cage surfaces (B). B NOTE: Backlash for the front gearcase is set at the factory. No adjustment can be made. 5. Remove the output hub assembly from the left-hand gearcase half. Inspect surfaces for wear or signs of damage. Replace component if found to worn or damaged. 8. A Inspect the ring gear (C) for consistent wear patterns. The surfaces should be free of nicks and scratches. 7.13 [email protected] FINAL DRIVE 9. Inspect roll cage (B) sliding surface. This surface must be clean and free of nicks, burrs or scratches. Remove and inspect the H-springs. Replace any H-springs that appear damaged or have lost radial tension. 12. Inspect the output hub bearings (arrows). Replace bearings if wear or damage is found. H-Spring B 10. Remove the output hub assembly from the right-hand gearcase half. Inspect surfaces for wear or signs of damage. Replace component if found to worn or damaged. NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement side to side. 13. Inspect the armature plate (E) for a consistent wear pattern. Uneven wear of the armature plate surface (E) indicates a warped plate, which may cause intermittent operation. E 11. Inspect the output hub thrust bearing. Replace if wear or damage is found. E 7.14 [email protected] FINAL DRIVE 14. Inspect the magnetic coil (I) in the output housing. Test the resistance of the coil using an ohmmeter. Replace case half if coil is found to be non-functional or if the coil surface is damaged. 16. Inspect the output shaft bushing (arrow). Replace as needed. Clean the inside surfaces of both gearcase halves. I 17. Remove and replace the O-rings and seals (arrows) from the gearcase halve assemblies. AWD Gearcase Coil Resistance: 21.6 ohms and 23.9 ohms @ 68° F (20° C) NOTE: To test the gearcase coil resistance, use the AWD coil harness. The gearcase coil should measure between 21.6 ohms and 23.9 ohms @ 68° F (20° C). 15. Remove and inspect the input cover (M), bearing (N), and the pinion gear (O). Inspect the pinion gear (O) for chipped, broken, or missing teeth. Replace the input cover O-ring and seal. REASSEMBLY N M 1. 2. 3. Replace all O-rings, seals, and worn components. Press the pinion shaft seal into the pinion cover, until the seal is flush with the sealing surface. Install pinion shaft into the bearing cover, using a small amount of grease on the seal bearing, and input cover with O 7.15 [email protected] FINAL DRIVE new o-ring and torque bolts to 14 ft. lbs (19 Nm). 5. Install the rollers and roll cage into the ring gear. Insert the rollers as the roll cage is installed, installing the lower row first and then the upper row. 6. Install the ring gear over the output hub and into the output cover. Insert the backlash pad (G) and set assembly upright.. 14 ft.lbs. (19 Nm) 4. Install the output hub (A) into the gearcase housing. Apply a small amount of grease to the seal and seal surface as this will aid assembly. The output hub should spin freely. G A 7. Install the armature plate (D) onto the ring gear. Verify the plate tabs are places into the slots on the roller cage. NOTE: Verify backlash plate stays in place. D D 7.16 [email protected] FINAL DRIVE 8. Install the other output hub (B) and thrust bearing (C) into the output case half. Apply a small amount of grease onto the seal surfaces to aid installation. AWD DIAGNOSTICS: AWD Will Not Engage 1. 2. C 9. B Check the gearcase coil resistance. To test the gearcase coil resistance, use the coil harness. The gearcase coil should measure between 21.6 ohms and 23.9 ohms @ 68° F (20° C). Check the minimum battery voltage at the wire that feeds the hub coil wire. There should be a minimum of 11.8012.0 Volts present for proper operation. Install the left-hand output cover onto the right-hand assembly by holding it as shown. Verify the backlash plate thrust bearing and armature plate stay in place during assembly. 3. F Inspect the armature plate for a consistent wear pattern. There should one or two distinct wear bands (one band inside the other). If only one band of wear is present (or if there is wear between the two bands, inspect the coil area as indicated in Step 4. A band with an interrupted wear mark may indicate a warped plate, which may cause intermittent operation. See Illustration 1. Wear Ring on Armature Plate 10. Torque bolts to 14 ft. lbs. (19 Nm). 14 ft.lbs. (19 Nm) Example of Bad Condition (Wear from (Coil on Armature 7.17 [email protected] FINAL DRIVE 4. 30 ft.lbs. (41 Nm). Check to make sure the coil is seated in the U-shaped insert that is pressed into the gearcase cover. The top of the coil should be seated below the U-shaped insert. The U-shaped insert controls the pole gap. If the top of the coil is above the surface of the U-shaped insert it raises the armature plate, thereby increasing pole gap. If the pole gap increases the coil will not be strong enough to engage the AWD system. Side Cutaway View of Gearcase Coil 30 ft.lbs. (41 Nm) 2. U-Shaped Insert 5. Inspect the rollers for nicks and scratches. The rollers must slide up and down and in and out freely within the roll cage sliding surfaces. Rollers INSTALLATION 1. Install gearcase into the frame. Torque mounting bolts to 7.18 Coat splines with anti-seize compound. Install CV shaft into the gearcase. Light tapping may be required to properly seat the splines into the gearcase. [email protected] FINAL DRIVE 3. Pull strut assembly out while pivoting front drive shaft downward until it enters strut assembly. (Hub and brake removed for clarity - removal optional) REAR HUB Removal 1. Place the ATV in Park and lock the parking brake. Remove rear hub cap and loosen wheel nuts. A 4. Install the lower A-arm. Torque nut and bolt to specification. 5. Install the hub and retaining hardware. Torque the hub nut to specification. 6. Install cotter pin. 7. Install the wheel and wheel nuts. 8. Safely lift and lower the front of the ATV. 9. Torque the wheel nuts to specification. 10. Add the proper lubricant to the front gearcase. Check drain plug for proper torque. Refer to Chapter 2 for fluid fill and change information. B 2. 3. 4. 5. 6. 7. C Remove cotter pin (A). Loosen the hub retaining nut (B). Loosen the wheel nuts (C). Safely support the rear of the ATV. Remove wheel nuts and wheel. Remove the rear brake caliper and safely suspend the caliper from the frame with a piece of wire. (Left side only) 7.19 [email protected] FINAL DRIVE 8. Remove hub nut, domed washer and flat washer. 9. Remove hub. 11. Remove both lower control arm bolts. 12. Remove bearing carrier. Disassembly 1. 10. Remove upper control arm bolt as shown. 7.20 Remove outer snap ring. [email protected] FINAL DRIVE 2. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown. 2. Start bearing in housing. 3. Press bearing into place until outer race bottoms on housing. NOTE: Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed. 3. Replace bearing. NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race. 4. Inspect bearing housing for scratches, wear or damage. Replace housing if damaged. Rear Hub Assembly 1. CAUTION Support bottom of bearing carrier housing. Use an arbor press only on the outer race, as bearing damage may occur. 4. Install snap ring into groove. Installation 1. 2. Insert CV shaft into rear hub bearing carrier . Align bottom of carrier housing and lower control arm. Grease and slide lower control arm bushings into place, securing housing. 7.21 [email protected] FINAL DRIVE 3. Install and torque lower control arm bolts. REAR CV SHAFT Removal Lower Control Arm Bolt Torque: 50 ft. lbs. (68 Nm) Upper Control Arm Bolt Torque: 35 ft. lbs. (48 Nm) 4. 5. 6. 7. 8. 9. Lift bearing carrier until top aligns with upper control arm. Install and torque upper control arm bolt and torque to specification. Pull drive shaft outward and install hub onto driveshaft splines. Install cone washers with domed side facing outward. Install retainer nut, wheel and wheel nuts. Remove jackstand and torque axle nut and wheel nuts. Install a new cotter pin. Tighten nut slightly to align holes if required. 1. 2. Remove rear hub; see “REAR HUB REMOVAL”. Tip hub outward and remove shaft from hub. 3. Pry and pull sharply outward to remove shaft from transmission. Install a new lock ring upon assembly. Pull outward sharply to remove from transmission DRIVE SHAFT AND CV JOINT HANDLING TIPS Care should be exercised during driveshaft removal or when servicing CV joints. Driveshaft components are precision parts. Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life. 10. Install hub cap. 7.22 [email protected] FINAL DRIVE • The complete driveshaft / joint should be handled by the interconnecting shaft to avoid disassembly or potential damage to the driveshaft joints. 4. Lift bearing carrier into place and install bolt to upper control arm. Torque bolt to 35 ft. lbs. (48 Nm). 5. Install hub, flat washer, domed washer (domed side out) and nut. Torque center hub nut to 80 ft. lbs. (109 Nm). Install new cotter pin and hub cap. Install rear wheel and torque wheel nuts to specification. • Over-angling of joints beyond their capacity can result in boot or joint damage. • Make sure surface-ground areas and splines of shaft are protected during handling to avoid damage. • Do not allow boots to come into contact with sharp edges or hot engine and exhaust components. • Shafts should never be used as a lever arm to position other suspension components. • Never use a hammer or sharp tools to remove or to install boot clamps. • Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned. Refer to text for grease capacity of CV joints and CV joint boots. REAR CV SHAFT 6. INSTALLATION 1. 80 ft.lbs. (109 Nm) Slide shaft assembly into bearing carrier hub. Refer to specifications for Wheel Nut Torque. 2. 3. Apply anti-seize compound to splines of shaft. Install a new lock ring and install the shaft. 7. Grease all applicable fittings thoroughly with Premium UJoint Lubricant (PN 2871551). 7.23 [email protected] FINAL DRIVE CV JOINT SERVICE hammer while holding snap ring open. Spread ends of snap ring to remove joint from CV Joint Replacement 1. Remove clamps from rubber boot(s) using the CV Boot Clamp Pliers (PN 8700226) (A). A Tap CV housing off shaft 3. Place a new snap ring in the groove of the CV joint inner hub, with tabs facing the shaft as shown. NOTE: Photo below is shown without shaft for clarity. Wipe grease away from recess in CV joint inner hub to locate snap ring Snap Ring Located in recessed area Snap Ring Tabs face shaft 2. Open the snap ring using a snap ring pliers or small needle nose pliers. Tap CV housing off shaft with a soft faced 7.24 [email protected] FINAL DRIVE 4. Refit CV joint on interconnecting shaft by tapping with a plastic hammer on the joint housing. Take care not to damage threads on the outboard CV joint. The joint is fully assembled when the snap ring is located in the groove on the interconnecting shaft. Tap joint onto shaft 5. 6. Removal and Cleaning 1. Remove CV joint from end of shaft. 2. Remove boot from shaft. NOTE: When replacing a damaged boot, check the grease for contamination by rubbing it between two fingers. A gritty feeling indicates contamination. If the grease is not contaminated, the boot can be replaced without cleaning the CV joint. Use the recommended amount of grease for boot replacement only (see below). Proceed to Boot Installation. 3. Thoroughly clean and dry the CV joint and inspect ball tracks and cages for wear, cracks or other damage. NOTE: Shiny areas in ball tracks and on the cage spheres are normal. Do not replace CV joints because parts have polished surfaces. Replace CV joint only if components are cracked, broken, worn or otherwise unserviceable. Install and tighten large boot clamp with boot clamp pliers. Remove excess grease from the CV joint's external surfaces and position joint boot over housing, making sure boot is seated in groove. Position clamp over boot end and make sure clamp tabs are located in slots. Note: Before tightening boot clamp on inboard joint, make sure any air pressure which may have built up in joint boot has been released. The air should be released after the plunging joint has been centered properly. Tighten boot clamp using boot clamp pliers. Open snap ring and pull CV joint away 4. 5. 6. 7. Add the recommended amount of grease for CV joint cleaning to the joint as shown below. Be sure grease penetrates all parts of the joint. Refit CV joint on interconnecting shaft by tapping with a plastic hammer on the joint housing. Take care not to damage threads on the outboard CV joint. The joint is fully assembled when the snap ring is located in the groove on the interconnecting shaft. Add grease through large end of boot. Be sure to use only the Constant Velocity Joint grease supplied with boot service kit. IF CV JOINT WAS CLEANED, add the recommended amount of grease to the joint in addition to the grease pack supplied with boot kit. Install a new boot onto the axle shaft and fill the CV joint and boot with the correct type and amount of grease. 7.25 [email protected] FINAL DRIVE 8. While pulling out on the CV shaft, fully extend the CV joint and slide a straight O-ring pick or a small slotted screw driver between the small end of the boot and the shaft. This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life. Before you remove your instrument, be sure the small end of the boot is in its correct location on the axle. CARE MUST BE TAKEN TO AVOID DAMAGE TO THE NEWLY INSTALLED BOOT. 9. Install the small clamp on the boot. 7.26 [email protected] CVT TRANSMISSION CHAPTER 8 CVT / TRANSMISSION TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 CVT TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 GEAR SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 SHIFT LINKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 GEAR SELECTOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 CVT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 CVT OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 STARTING CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 DRIVEN CLUTCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 ENGINE BRAKING CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 CVT MAINTENANCE/INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 CVT DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 CVT OVERHEATING/DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6 CVT SYSTEM DISASSEMBLY / DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 CVT SYSTEM / DRIVEN CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13 TRANSMISSION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14 TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14 8 8.1 [email protected] CVT TRANSMISSION TORQUE SPECIFICATIONS CVT TORQUE SPECIFICATIONS 96 in. lbs. (10.8 Nm) 185 ft. lbs (250 Nm) Use Clutch Holder PA-47478 14 ft. lbs. (19 Nm) Clamps - 25 in. lbs. 8.2 [email protected] CVT TRANSMISSION GEAR SELECTION SPECIAL TOOLS SHIFT LINKAGE INSPECTION SPECIAL TOOLS NOTE: Shift rod is preset at time of manufacture. 1. Inspect shift linkage rod bushing clips and replace if worn or damaged. Lubrication of rod ends is not required. GEAR SELECTOR REMOVAL 1. Push linkage rod out of bushing clip to remove. 2. Remove bolts attaching gear selector mount to frame. 3. To remove gear selector handle, pry cap off and remove screw. Clutch Compression Tool 8700220 Arm, Clutch Spring Compressor (Use with 8700220) PA-47457-1 Clutch Adaptor PA-47457-2 Spring Retainer Alignment Tool PA-47457-3 Retainer Nut Socket, Driven Clutch PA-46076 Drive Clutch Holder PA-47478 Order tools from SPX Corp. 1-800-328-6657 8.3 [email protected] CVT TRANSMISSION CVT OPERATION CVT OPERATION OVERVIEW WARNING causes the CVT drive clutch mounted on the shaft of the staring clutch hub to rotate at the same RPM. Refer to the ENGINE section for more information. DRIVE CLUTCH OPERATION All CVT maintenance or repairs should be performed only by a certified Polaris Master Service Dealer (MSD) technician who has received the proper training and understands the procedures outlined in this manual. Because of the critical nature and precision balance incorporated into the CVT components, it is absolutely essential that no disassembly or repair be made without factory authorized special tools and service procedures. The CVT drive clutch, mounted on the starting clutch hub shaft, is also RPM sensitive. The drive clutch basic components are the inner (fixed) sheave, the outer (moveable) sheave, the rollers (weights) and the cover plate. The power of the engine is transferred to the wheels through the following components: Starting Clutch, Drive Clutch, Drive Belt, Driven Clutch, Transmission, Drive shaft(s), and Rear Gearcase (and Front Gearcase on 4x4 models). At low RPM, the drive belt is located at the bottom (smallest diameter) of the drive clutch sheaves resulting in a low “gear” ratio. As engine RPM increases, centrifugal force moves the drive clutch shift rollers outward in their respective tracks toward the outside of the drive clutch. This forces the moveable sheave farther inward toward the fixed sheave. The inward movement of the sheave forces the drive belt farther upward in the sheaves toward progressively higher “gear” ratios (larger diameter). During the development of a Polaris ATV, the CVT system is matched first to the engine power curve; then to average riding conditions and the vehicle’s intended usage. Therefore, modifications or variations of components at random are never recommended. The drive clutch begins to rotate when engine RPM reaches engagement speed and the starter clutch engages. DRIVEN CLUTCH OPERATION Proper clutch setup and careful inspection of existing components must be the primary objective when troubleshooting and tuning. The Continuously Variable Transmission (CVT) consists of four major assemblies: 1) Starting Clutch; 2) Drive Clutch; 3) Drive Belt; and 4) Driven Clutch. STARTING CLUTCH OPERATION The starting clutch is located on the left (CVT) side of the engine crankshaft. It is an RPM sensitive clutch that connects the engine crankshaft to the CVT System. When engine RPM is below the factory determined engagement speed of the vehicle, return springs on the staring clutch shoes hold the shoes inward away from the starter clutch hub. When engine RPM is increased, centrifugal force causes the shoes to overcome the return spring force and swing outward. When the shoes contact the surface of the starter clutch hub, the hub rotates at engine speed. This 8.4 The driven clutch is connected to the drive clutch via the drive belt and is mounted on the main gearcase input shaft. The CVT driven clutch consists of a fixed sheave, a moveable sheave with roller tracks, rollers, and a compression style return spring. The driven clutch is primarily torque sensitive, reacting to the forces of engine power and vehicle load to control the upshift and downshift of the CVT system. Engine power is sensed by the driven clutch via the drive belt. Vehicle loads are sensed by the driven clutch through the main gearcase input shaft. If forces on the drive belt (engine power) exceed the forces on the transmission shaft (vehicle loads) the drive clutch sheaves move inward and the belt upward, which forces the sheaves of the driven clutch apart against spring pressure. The drive belt moves downward into the sheaves of the driven clutch to a smaller diameter (higher “gear” ratio), increasing the speed of the driven clutch. This process is called upshifting. [email protected] CVT TRANSMISSION If the torque resistance at the transmission input shaft is greater than the force through the drive belt, the driven clutch spring forces the moveable sheave inward, and the drive belt is forced toward the outer diameter of the sheaves. This action, which decreases the driven clutch speed, is called backshifting. CVT DRYING NOTE: If operating the ATV through water, be sure to check the CVT cover and other ATV components for water ingestion. The ATV should be checked immediately. Refer to Owner’s Manual for Safe Riding Tips. 1. In situations where loads vary (such as uphill and downhill) and throttle settings are constant, the drive and driven clutches upshift or backshift accordingly to maintain optimum engine RPM. At full throttle a perfectly matched CVT maintains engine RPM at the peak of the power curve during upshift and backshift. In this respect, the CVT system is similar to a conventional power governor, but it functions by varying the load rather than by varying throttle position. ENGINE BRAKING CLUTCH To drain any water that may be trapped inside the CVT cover, remove the CVT drain plug located on the bottom of the CVT cover and let the water drain out. (The location of the CVT drain plug is shown on the following page.) NOTE: To further expel water in the CVT cover and to dry out the CVT system, shift the transmission to neutral and rev engine slightly to expel the moisture. This will also 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. Repeat as needed. Operate ATV in lowest available range for a short period of time until CVT system is dry. The engine braking clutch is a one-way clutch located inside the starting clutch hub. This clutch “locks” the starting clutch hub to the crankshaft whenever drive belt (and drive clutch) speeds exceed the engine RPM, such as when travelling down hill with the throttle released, which provides engine braking. Refer to the ENGINE section for more information. CVT MAINTENANCE/INSPECTION Periodic inspection and maintenance is required to keep the system operating at peak performance. The following list of items should be inspected and maintained to ensure maximum performance and service life of CVT components. Refer to the troubleshooting checklist for more information. 1. Drive and Driven Clutch Rollers (Weights), Buttons and Bushings, and Driven Clutch Spring. Inspect for wear. 2. Drive Belt. Inspect condition and width of belt. 3. Sheave Faces. Clean and inspect for wear. 4. CVT System Sealing. The CVT system is air cooled by fins on the drive clutch stationary sheave. The fins create a low pressure area in the CVT area, drawing fresh air into the system through the intake air duct. The opening for this intake duct is located at a high point on the vehicle. All connecting air ducts and the outer cover must be properly sealed to reduce the chance of water ingestion into the CVT area. A sealed CVT is especially critical on units subjected to frequent water forging. 8.5 [email protected] CVT TRANSMISSION Air Intake Duct Drain Plug Location ct Air Intake Duct Air Exhaust Duct Clamps CVT OVERHEATING/DIAGNOSIS During routine maintenance or whenever CVT system overheating is evident, it’s important to check the inlet and outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase CVT system operating temperatures. The ATV should be operated in LOW RANGE (if equipped) when pulling or plowing heavy loads, or if extended low speed operation is anticipated. GENERAL RANGE OPERATION Low Range (if equipped): Heavy pulling, basic operational speeds less than 7 MPH, riding through rough terrain (swamps, mountains, GUIDELINES: etc.), low ground speeds. High Range: High ground speeds, speeds above 7 MPH. Diagnosis of Clutch Drive Belt & Cover Related Issues: Possible Causes 8.6 Solutions/What to do [email protected] CVT TRANSMISSION Loading the ATV into a pickup or tall Shift transmission to low range (if equipped) during loading of the ATV trailer when in high range. to prevent belt burning. Starting out going up a steep incline. When starting out on an incline, use low range (if equipped), or perform the “K” turn to turn around. Warning: Excessive throttle may cause loss of control and vehicle overturn. Driving at low RPM or low ground speed Drive at higher speed or use Low Range. (if equipped) The use of Low (at approximately 3-7 MPH). Range is highly recommended for cooler CVT operating temperatures and longer component life. Insufficient warm-up of ATVs exposed to Warm engine at least 5 min., then with transmission in neutral, advance low ambient temperatures. throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning. Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement. Continuous operation at the point of engagement (initial vehicle movement) increases CVT temperatures and component wear. Towing/Pushing at low RPM/low ground Use Low Range only. (if equipped) speed. Plowing snow, dirt, etc./utility use. Use Low Range only. (if equipped) Stuck in mud or snow. Shift the transmission to Low Range (if equipped), carefully use fast, aggressive throttle application to engage clutch. Warning: Excessive throttle may cause loss of control and vehicle overturn. Climbing over large objects from a Shift the transmission to Low Range (if equipped), carefully use fast, stopped position. aggressive, throttle application to engage clutch. Warning: Excessive throttle may cause loss of control and vehicle overturn. Belt slippage from water or snow Shift the transmission to neutral. Using the throttle, vary engine rpm ingestion into the CVT system. from idle to 3/4 throttle. Engage transmission in the lowest possible range (if equipped) and test for belt slippage Repeat several times as required. During this procedure, the throttle should not be held at the full position. Inspect CVT system for sealing or damage if repeated water ingestion occurs. Clutch malfunction. Inspection/repair of clutch components should be performed by a certified Polaris MSD technician. 8.7 [email protected] CVT TRANSMISSION CVT SYSTEM DISASSEMBLY / DRIVE CLUTCH NOTE: Do not lubricate drive clutch components. 1. Remove seat, left side cover, left foot well, rear rack and rear cab. (Rear tire removal not required but helpful.) 2. Remove all CVT cover screws and CVT cover. NOTE: If tool is not available, use two hands to hold the cam plate and the primary sliding sheave together when removing the primary sliding sheave and the cam plate assembly. This prevents the rollers from falling out of the assembly. 3. Replace cover bearing if worn. Remove the snap ring and draw bearing out with a blind hole puller or slide hammer style puller. NOTE: Do not re-use bearing if removed from cover. 4. Press or drive a new bearing into the cover. Press or drive only on the outer race of bearing. Fit should be snug with no tightness or sticking. Rotate the inner race to be sure it rotates freely without binding after installation. 5. Install the snap ring. Be sure it is fully seated in the groove. Cover Bearing 6. Inspect the CVT cover gasket and replace if damaged. 7. Before removing drive belt, install the tool as shown to prevent drive clutch moveable sheave from moving inward. 8.8 8. Separate driven clutch sheaves and force belt down into the sheaves. Remove belt from driven, then from drive clutch. [email protected] CVT TRANSMISSION 9. Measure belt width and compare to specification. Replace if any area is worn below the minimum width, if belt is unevenly worn (hour glassed) or if damaged. 12. Remove the rollers from the primary sliding sheave. Check the rollers for wear, deep scoring, or flat spots. Remove and inspect the slide bushings and cam plate. Replace any components that found to be worn excessively or appears abnormal. Slide Bushings Rollers 10. Remove the primary sliding sheave and cam plate assembly as one assembly. Inspect the movable sheave for scoring, grooving, or abnormal wear. NOTE: If tool is not installed, be sure to hold cam plate and primary sliding sheave together to prevent rollers from falling out of the assembly. Bushing Cam Plate 13. Note direction of roller thrust surface (wide edge) toward thrust face of sheave. 14. Inspect bushing for wear. 15. When installing cam plate, be sure to align offset hole in cover with threaded hole in sheave. Wide Surface Of Roller Against Thrust Surface Of Roller Track Wide Surface 11. Remove sleeve and fixed sheave. Inspect the cooling fins for damage, the sleeve for wear or rough spots, and the face of the fixed sheave for wear, grooving or rough surface. Bushing Threaded Hole Fixed Sheave Sleeve 8.9 [email protected] CVT TRANSMISSION 16. The clutch sheaves are balanced from the factory. When installing clutch on the vehicle, be sure to align the “X” marks on the sheaves to maintain proper balance. X mark 19. Install the moveable sheave, aligning the “X” mark with the “X” mark on the fixed sheave, engage the splines and install the nut. Do not apply any lubricants to the components. Apply Loctite 242 (Blue) to threads and torque the retaining nut to 185 ft. lbs. (250 Nm). IMPORTANT: Be sure splines of cam plate are fully engaged on shaft spline before tightening the nut! CVT Drive Clutch Nut Torque 185 ft. lbs. (250 Nm) Loctite 242 (Blue) CVT SYSTEM / DRIVEN CLUTCH SERVICE 17. Install the fixed sheave and spacer sleeve. 1. Remove retaining bolt. 2. Pull the clutch off the shaft using flywheel puller as shown. 18. Install the tool in the offset hole of the moveable sheave assembly to hold it together for installation. 3. Remove the puller and place the driven clutch spring side up in the clutch spring compressor 8700220. 4. Install arm PA-47457-1 on the spring compressor. 5. Install adaptor PA-47457-2 on the arm. 6. Remove nut (counterclockwise) using tool PA-46076 or a standard socket. 8.10 [email protected] CVT TRANSMISSION 7. Compress spring enough to remove the chain lock and slowly release spring tension. CAUTION cover for wear. 10. Remove roller pins using a needle-nose pliers and remove top and bottom O-rings. Spring Pressure can cause components to eject suddenly. Use care during removal. NOTE: Use Loctite™ 242 upon reassembly. 8. Measure the free length of spring. Standard free length is 7.52” (191.1mm). Replace spring if length is less than standard or if spring coils are distorted. NOTE “X” MARKS FOR ASSEMBLY Driven Compression Spring Standard Length: 7.52” (191.1 mm) 9. Carefully pry up the roller cover to remove it. Inspect 11. Clean all parts to remove old grease before inspecting the components. 12. Carefully inspect the roller tracks in the hub of the moveable sheave. Replace clutch assembly if tracks are visibly worn. 13. Check the pin holes in the shaft of the fixed sheave. Pins should be a firm fit in the holes. 14. Inspect sheaves for wear, damage, or rough spots. Replace the clutch assembly if sheaves are worn or damaged. 15. Apply a light film of moly grease to seal lips and to the inside of the roller pin hub. Install the moveable sheave over the shaft of the fixed sheave until the sheaves contact each other. 8.11 [email protected] CVT TRANSMISSION 16. Lift the moveable sheave enough to clean all excess grease from the shaft and the sheave faces to prevent belt contamination after assembly. 26. Install tool PA-47457-3 27. Retainer Alignment Tool onto spring retainer. Turn to align flats 17. With sheaves together, rotate the moveable sheave to ALIGN THE “X” MARK of moveable sheave with the “X” mark on fixed sheave. 18. Lubricate the roller pins with grease and install all pins until fully seated. The surface of the pins must be approximately flush with the surface of the roller pin hub. 19. Install new O-rings on top and bottom of roller pin hub. 20. Pack all roller tracks with grease. 21. Install the roller pin sleeve and push it down until fully seated against moveable sheave. 22. Clean the threads of the shaft, and threads of the spring retaining nut to remove all oil or grease. 23. Place the driven clutch assembly in the compressor tool. 24. Install spring. 25. Install spring retainer on spring, visually aligning the flats of the retainer with the flats on the threaded shaft. 8.12 28. Compress the clutch spring slowly, turning the retainer with the tool as required to align the flats. 29. When flats are aligned, fully compress the spring and secure the compressor arm with the chain. 30. Apply Loctite 242 to threads of the nut and the shaft, and install nut hand tight. 31. Release the tool and torque the nut to 45 ft lbs (61 Nm) using the same tools for removal of the nut. Driven Clutch Spring Retainer Nut Torque: 45 ft. lbs. (61 Nm) LoctiteTM 242 (Blue) [email protected] CVT TRANSMISSION TRANSMISSION 18 ft. lbs. (24.5 Nm) 8.13 [email protected] CVT TRANSMISSION TRANSMISSION SERVICE 5. Remove gear position switch and shift bell crank. 1. Drain transmission fluid. 2. Remove Transmission. Refer to the Engine Section for transmission removal procedure. TRANSMISSION DISASSEMBLY 1. Clean the exterior of the transmission. 2. Remove all case screws. 3. Remove the left case from the right. Be sure shafts stay with right case. 6. Remove input shaft, counter shaft, and shift drum as an assembly. 4. Remove output gear and shaft and pull oil deflector from right case. Note orientation for installation later. Oil Deflector 7. Clean all parts. Remove seals from gear case and install new using an appropriate size seal driver. 8. Inspect all bearings, gear teeth, and splines for wear or damage. Inspect gear dogs carefully and replace if the edge of the dog is worn or rounded, chipped, or broken. 9. Inspect the reverse chain for damage. Output Gear Bearings Splines 8.14 Gear Teeth Reverse Chain Engagement Dogs [email protected] CVT TRANSMISSION 10. Gear dogs should be square at the corners. Replace both mating gears if any are rounded. 11. Inspect the shift drum tracks for wear or damage. Inspect shift fork for bending, and the surface for wear, burning, or scoring. 13. Reassemble the drum starting with shaft guide, detent cam (wide flange faces toward the threaded end of drum), the flat washer, and snap ring. 14. Place fork shaft through guide with pointed end as shown. Inspect Shift Fork 12. Inspect the shift fork shaft and all springs. Inspect detent cam and pawl for wear. 8.15 [email protected] CVT TRANSMISSION 15. Slide the spring collar, large diameter spring, shift fork, small spring, and shaft support onto the shaft. The dot on the shaft support faces away from the fork. 17. Assemble the shafts with chain and shift drum and install the assembly into the case. Shaft Support Small Spring Spring Collar Large Spring Fork 18. Install the output gear and oil deflector. Lubricate all components. Oil Deflector DOT 16. Install the detent ratchet with spring. Install the snap ring. 8.16 Output Gear [email protected] CVT TRANSMISSION 19. Apply 3-Bond 1215 sealant evenly to clean and oilfree case sealing surfaces. 20. Install the left case and tap it into place until seated. 21. Install bolts and torque in two steps following a cross pattern to 18 ft. lbs. (24.5 Nm). 22. Install the shift arm (bell crank). 23. Rotate the shafts to be sure they turn smoothly. Verify shifting through all gears while rotating the shafts. 24. Verify drain plug is tight (18 ft. lbs. (24.5 Nm). Fill transmission with specified type and quantity. (Refer to Maintenance Section for procedure). 8.17 [email protected] CVT TRANSMISSION NOTES 8.18 [email protected] ELECTRICAL CHAPTER 9 ELECTRICAL ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 FUSE SPLICE SAVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 FUSIBLE LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 GEAR POSITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 RPM LIMIT MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 INSTRUMENT GAUGE POWER / FWD / NEUTRAL SWITCHES / RPM SIGNAL . . . . . 9.4 VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 AWD CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 ETC / REVERSE RPM CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9 STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10 IGNITION COIL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11 STATOR FUNCTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11 CDI OUTPUT TEST USING PEAK READING ADAPTOR OR A VOLTMETER . . . . . . 9.12 CDI CRANKING OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12 ELECTRONIC THROTTLE CONTROL (ETC) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 9.13 IGNITION SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14 IGNITION SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15 CHARGING SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16 CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17 CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17 ALTERNATOR OUTPUT TEST (AC AMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18 BATTERY IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18 CONVENTIONAL BATTERY ACTIVATION/ SVC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19 BATTERY TERMINALS/TERMINAL BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19 CONVENTIONAL BATTERY INSPECTION/REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 9.20 CONVENTIONAL BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20 CONVENTIONAL BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20 CONVENTIONAL BATTERY OCV - OPEN CIRCUIT VOLTAGE TEST . . . . . . . . . . . . 9.20 CONVENTIONAL BATTERY SPECIFIC GRAVITY TEST . . . . . . . . . . . . . . . . . . . . . . . 9.21 CONVENTIONAL BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21 CONVENTIONAL BATTERY OFF-SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . 9.22 CONVENTIONAL BATTERY CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 9.22 STARTER SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23 STARTER MOTOR EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24 STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25 VOLTAGE DROP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25 STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25 REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25 BRUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26 INSPECTION & REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26 ARMATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28 REASSEMBLY & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28 STARTER SOLENOID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28 BENCH TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28 STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29 PINION GEAR - ANTI-KICK OUT SHOE, GARTER SPRING REPLACEMENT . . . . . . 9.29 9.1 9 [email protected] ELECTRICAL Electrical System FUSE SPLICE SAVER SPECIAL TOOLS The fuse splice saver is near the battery under the front storage compartment. PART NUMBER TOOL DESCRIPTION PV-43568 Fluke™77 Digital Multimeter 2870836 Battery Hydrometer 2870630 Timing Light ELECTRICAL SERVICE NOTES Keep the following notes in mind when diagnosing an electrical problem. • Refer to wiring diagram for stator and electrical component resistance specifications. • When measuring resistance of a component that has a low resistance value (under 10 Ohms), remember to subtract meter lead resistance from the reading. Connect the leads together and record the resistance. The resistance of the component is equal to tested value minus the lead resistance. • Become familiar with the operation of your meter. Be sure leads are in the proper jack for the test being performed (i.e. 10A jack for current readings). Refer to the Owner’s manual included with your meter for more information. • Voltage, amperage, and resistance values included in this manual are obtained with a Fluke™ 77 Digital Multimeter (PV-43568). This meter is acceptable for use when diagnosing electrical problems. Readings obtained with other meters may differ. • Pay attention to the prefix on the multimeter reading (K, M, etc.) and the position of the decimal point. • For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply. 9.2 NOTE: Use only the recommended fuse capacity, as use of a higher amperage fuse to correct blown-fuse situations could lead to electrical component damage. Fusible Link A fusible link is installed on the battery voltage circuit that supplies power to the main 15A fuse. The link is located at the starter motor solenoid + post. Fusible Link PN: 2202607 Always replace a blown fusible link with a new link. Never use a piece of wire or metal in place of the link. [email protected] ELECTRICAL GEAR POSITION SWITCH RPM LIMIT MODES Switch Test Engine RPM is limited when: 1. Locate the gear selector switch on the transmission. Remove the wiring harness connector and insert the two multimeter probes into the switch. 2. Move the gear selector handle to each of the three drive positions (FWD, NEU, or REV). 3. Using an ohmmeter, test for continuity between the switch contacts and connector leads. Replace the switch if no continuity or high resistance is found. • Operator selects reverse gear. The maximum vehicle speed when reverse gear is selected is 6.5 MPH • If the wheel speed sensor malfunctions, the speedometer will limit engine RPM to approximately 3500 RPM when the transmission is in reverse. • Maximum engine RPM is reached. The reverse engine RPM limit can be overridden when the operator presses and holds the override button. On AWD models, the speedometer also limits the maximum engine RPM in which the operator can engage the AWD system. The speedometer will not allow the AWD to engage when the engine RPM is at or above 3100 RPMs. 9.3 [email protected] ELECTRICAL Instrument Gauge Power / FWD / Neutral Switches / RPM Signal The instrument gauge determines engine RPM from the Y/RED AC signal from the voltage regulator. The gauge is powered by switched R/BLK and switched R/WHT battery voltage. Both the key and the RUN switches have to be closed to power-up the gauge. The gear selector switch provides a ground path for the FWD (BLU/RED) or neutral (GRN/WHT) circuits. 9.4 [email protected] ELECTRICAL Vehicle Speed Sensor 3. If voltage is found, test the BRN/RED ground circuit. Verify there is continuity between the circuit and chassis ground. 4. If all circuits function, remove the speed sensor from the transmission. Verify the sensor is not damaged. 5. Back-probe the GRN/RED and BRN/RED wires with the connector still connected to the sensor. Turn the multimeter to measure vDC. Wave a screwdriver back in forth across the face of the sensor while monitoring the multimeter. 6. The multimeter display should flip between a voltage and 0vDC every time the screwdriver blade passes by the sensor face. If this does not occur, replace the sensor. The vehicle speed sensor is mated to the transmission housing and reads the speed of the transmission output gear. The instrument gauge supplies the sensor with battery voltage via the ORANGE circuit, a reference ground via the BRN/ RED circuit and receives a return signal via the GRN/RED circuit. To test the circuit: 1. 2. Turn the ignition key to the ON position and move the RUN/OFF switch to run. Verify there is battery voltage present on the ORANGE circuit. If voltage is not found, inspect the wiring harness, or replace the instrument gauge. 9.5 [email protected] ELECTRICAL AWD Control System The front differential coil is controlled by the speedometer the AWD switch, and the RUN/OFF switch. Battery voltage is supplied to the AWD coil when the operator turns the key switch to RUN, moves the AWD switch to AWD and moves the RUN/OFF switch to RUN. The AWD coil ground circuit is supplied by the instrument gauge. The speedometer will not allow the AWD to engage when the engine RPM is 3100 RPM or higher. 9.6 [email protected] ELECTRICAL ETC / Reverse RPM Control System The instrumentation gauge will signal the CDI controller to limit engine RPM to approximately 3100 RPM (6.5 MPH) whenever the transmission is in reverse gear. If the ETC switch connects to ground, the instrument gauge will shut the engine off. The operator can override the RPM speed limit in reverse, but not the ETC RPM limit, by pressing and holding the reverse override button located on the left handlebar. The reverse override button also serves as the mode switch button for the instrumentation gauge. The mode button toggles between the several function the gauge performs. To rule out engine RPM limiting caused by the CDI or instrument gauge, disconnect the BLACK wire from the CDI controller. 9.7 [email protected] ELECTRICAL Charging System The charging system consists of:. • Stator • Battery • Regulator / Rectifier The regulator / rectifier is responsible for converting AC voltage to DC voltage, and generating the tachometer pulse. 9.8 [email protected] ELECTRICAL Ignition System The ignition system consists of:. • CDI Controller • Battery • Ignition Coil • Stator - Pulse Coil • ETC / Key / Run-Off Switches / Instrument Gauge 9.9 [email protected] ELECTRICAL Starting System The starting system consists of:. • Battery • Key Switch / Run-Off Switch • Solenoid • Brake / Neutral Switches - Diodes • Starter Motor 9.10 [email protected] ELECTRICAL IGNITION COIL TESTING STATOR FUNCTION TEST Three tests can be performed using a multimeter to determine the condition of the stator. Wire Description Resistance Primary Coil (BLK/W to BLK) .21 Ohms Secondary Coil (Black to High Tension lead without cap.) 3.2KOhms TEST 1: Resistance Value of Each Stator Leg 1. Measure the resistance value of each of the three stator legs: W1 to W2, W1 to W3, and W2 to W3. Each should measure 0.314ohms. 2. Measure each of the white wires to ground, the reading should be (O.L.). NOTE: Significant variations in resistance readings between each circuit is an indication that one of the three circuits may be weak or failed. TEST 2: Stator Output. 1. Place the red lead on the tester in the 10A jack. 2. Turn the selector dial to the AC-AMPs position. 3. Start the engine and let it idle (1200 RPM). 4. Separately test each leg of the stator by connecting the meter leads to the wires leading from the alternator (W1 to W2, W1 to W3, W2 to W3). Alternator Current Output Reading should be no less than 8 AMPS. NOTE: Use an inductive amp meter to test stator amperage for engine speeds over 1200 RPM. 9.11 [email protected] ELECTRICAL CDI OUTPUT TEST USING PEAK READING ADAPTOR OR A VOLTMETER Re-connect all CDI wires to stator wires. Disconnect CDI module wire from ignition coil primary terminal. Connect one meter lead to engine ground and the other to the ignition coil primary wire leading from the CDI module. Crank engine and check output of CDI wire to coil. Reconnect CDI wire to the coil. CDI CRANKING OUTPUT TEST The following peak voltage tests will measure the amount of output from each component. A peak reading voltmeter can be used to perform the tests. A variety of peak reading adaptors are commercially available for use with the Fluke™ 77 Digital Multimeter (PV-43568) and other digital VOMs which will allow peak voltage tests to be performed accurately. Follow the directions provided with the adaptor. All measurements are indicated in Volts. Readings obtained without a peak reading adaptor will be significantly different. Disconnect the stator connectors from the CDI module. Test output from the detection and pulse (trigger) coil, and compare to the chart. The following measurements were obtained when cranking the engine with the electric starter, spark plug installed. The starting system must be in good condition and the battery fully charged. Voltage Test Test Connect Meter Wires To: Reading CDI Output W/BLU to Ground 200 - 250 Volts DC 9.12 Connect Reading Meter Wires (With VOM) To: Reading (With Peak Reading Adapter) Pulse Coil W/R and B 0.15 Volts minimum AC @ cranking RPM 5.3 - 5.4 Volts minimum DC @ cranking RPM Ohm Test Connect Meter Wires To: Reading Reading (With Peak Reading Adapter) Pulse Coil W/R and B 520 Ohms n/a W/R to Ground O.L. [email protected] ELECTRICAL ELECTRONIC THROTTLE CONTROL (ETC) SWITCH The Electronic Throttle Control (ETC) switch is designed to close in the event where the throttle cable sticks or breaks. During normal operation, the ETC switch contacts are open (not touching). The contacts will close when slack is present in the cable. IGNITION SYSTEM TESTING Whenever troubleshooting an electrical problem you should first check all terminal connections to be sure they are clean and tight. Also be sure that colors match when wires are connected. Use the following pages as a guide for troubleshooting. The resistance values are also given on the specification pages. Electronic Throttle Control (ETC) Switch NOTE: The throttle cable must have the proper amount of end-play adjustment. A cable that is too tight will cause ETC interruption, resulting in false engine RPM limiting. Electronic Throttle Control Open / Closed Throttle ETC Switch is OPEN. Slack in Cable / Throttle Stuck ETC Switch is CLOSED 9.13 [email protected] ELECTRICAL Condition: No spark or intermittent spark. Verify 12 Volt DC power is present on the wire to CDI. Replace Spark Plug. Disconnect the BLACK wire at the CDI module to isolate the ignition from the over-ride systems, but verify the CDI has a good ground (BROWN) for operation. -Test the ignition switch, engine stop switch, and speed limiter circuit for shorts to ground. - Check connectors for moisture, wire color matching or corrosion. Yes Does it have spark? No Verify that a minimum of 10.5 VDC is getting to the CDI module during cranking. Refer to the wiring schematic for connections and specifications. Compare results to the specifications on the exploded views. Are all within specifications? Inspect battery condition, connectors, wiring and grounds to the component in question. Replace the component if a wiring problem cannot be found. No Yes Check coil ground connection between BROWN and coil mount using an ohmmeter. The coil mount should have good continuity to ground (0-.2 Ω). No Clean coil mounting area. Repair ground wire connections. Yes Disconnect and check the secondary coil. Resistance values should be: Primary Side - Primary Wire Tab to Ground (on coil mount or engine): .21 Ohms Secondary Side High Tension Wire to engine ground- Cap installed - 8,200Ω Cap removed - 3,200Ω No Replace the ignition coil. Are these values within specs? Yes If all of the above tests are within specifications, and all grounds, connections, and wire color coding have been inspected, perform voltage output tests on following page or replace the CDI module. IGNITION SYSTEM TROUBLESHOOTING No Spark, Weak or Intermittent Spark • No12 volt power or ground to CDI • Spark plug gap incorrect 9.14 [email protected] ELECTRICAL • Fouled spark plug • Faulty spark plug cap or poor connection to high tension lead • Related wiring loose, disconnected, shorted, or corroded • Engine Stop switch or ignition switch faulty • ETC switch misadjusted or faulty • Poor ignition coil ground (e.g. corroded) • Faulty stator (measure resistance of all ignition related windings) • Incorrect wiring (inspect color coding in connectors etc) • Faulty ignition coil winding (measure resistance of primary and secondary) • Worn magneto (RH) end Crankshaft bearings • Sheared flywheel key • Flywheel loose or damaged • Excessive crankshaft runout on magneto (RH) end - should not exceed .005” • Faulty CDI module 9.15 [email protected] ELECTRICAL CHARGING SYSTEM TESTING Whenever charging system problems are suspected, proceed with the following system checks: Using a multitester set on D.C. volts, measure the battery open circuit voltage (see procedure later in chapter). It should be 12.4 volts or more. Is it? Remove the battery and properly service. Reinstall the fully charged battery or a fully charged shop battery. No Yes Meter Setting: DC Volts With the transmission in neutral, start the engine and increase RPM to between 3000 and 4000. Read battery voltage with the multitester. Readings should be between 13.0 and 14.6 V D.C. Is it? No Check Key off Current Draw. Refer to Page 9.11. Yes Check for owner modification, and discuss operating habits. The battery will continually discharge if operated below the “Break Even” RPM. Continued problems would call for battery inspection. Meter Setting: DC Amps Perform system “Break Even Amperage” test outlined on Page 9.11. Yes Does charging occur as specified? No Meter Setting: AC Amps Disconnect the wires leading from the regulator/rectifier. Using a multitester, perform an Alternator Output (AC amp) test. See test procedure on Page 9.11 for procedure. No Is output above 5 amps? Yes Inspect the wiring harness between the panel and the stator for damage. If no damage is found, remove the recoil and flywheel. Inspect the flywheel magnets, stator coils and stator wire harness for damage. Repair or replace any damaged components. Meter Setting: DC Volts Reconnect the alternator wires. Note: Red wire must be connected to harness. Battery voltage must be present on red wire terminal on harness side of voltage regulator connector. Is it? Yes If all of the previous tests indicate a good condition, but the charging voltage does not rise above battery voltage at the connector or terminal board, replace the voltage regulator. 9.16 No Check regulator/rectifier connections and ground, battery connections, circuit breaker and connecting wires. Repair or replace faulty wiring or components. [email protected] ELECTRICAL CURRENT DRAW - KEY OFF CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to light bulbs and speed limiter. Connect an ammeter in series with the negative battery cable. Check for current draw with the key off. If the draw is excessive, loads should be disconnected from the system one by one until the draw is eliminated. Check component wiring as well as the component for partial shorts to ground to eliminate the draw. Current Draw - Key Off: Maximum of .02 DCA (20mA) CHARGING SYSTEM “BREAK EVEN” TEST CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running. CAUTION Never use the electric starter with an ammeter connected in series, as damage to the meter or meter fuse may result. Do not run test for extended period of time. Do not run test with high amperage accessories. The “break even” point of the charging system is the point at which the alternator overcomes all system loads (lights, etc.) and begins to charge the battery. Depending on battery condition and system load, the break even point may vary slightly. The battery should be fully charged before performing this test. • Clamp an inductive ammeter or connect an ammeter (set to DC amps) in series between the negative battery cable and terminal. Current Drain Inspection Key Off Less Than 9 mA Do not use electric start. • Connect a tachometer according to manufacturer’s instructions. • With engine off and the RUN/OFF switch in the RUN position, the ammeter should read negative amps (battery discharge). Reverse meter leads if a positive reading is indicated • Shift transmission into neutral and start the engine. • Turn headlight on, and apply the brake light. Increase engine RPM while observing ammeter and tachometer. • Note RPM at which the battery starts to charge (ammeter indication is positive). • With lights and other electrical load off, this should occur at approximately 1500 RPM or lower. • Turn the lights on and lock parking brake to keep brake light on. • Repeat test, observing ammeter and tachometer. With lights on, charging should occur at or below 2000 RPM. 9.17 [email protected] ELECTRICAL ALTERNATOR OUTPUT TEST (AC AMP) ATV has, refer to the illustration below and follow the correct service and charging procedures that follow in the manual. CONVENTIONAL BATTERY This test measures AC amperage from the alternator. Removable Caps CAUTION This test simulates a “full load” on the alternator. Do not perform this test longer than required to obtain a reading or the alternator stator windings may overheat. Do not exceed idle rpm during this test. To Calculate Available Alternator Output I= P E 150 W 12 V = 12.5 Amps Top View Electrolyte Level Indicator I = Current in Amps P = Power in Watts E = Electromotive Force (Volts) Side View Alternator Current Output: Minimum of 8 AC Amps • Maximum alternator output will be indicated on the meter. It is not necessary to increase engine RPM above idle. • Place the red lead on the tester in the 10A jack. • Turn the selector dial to the AC amps (A~) position. • Connect the meter leads to the wires leading from the alternator (see schematic for proper wiring colors). • Start the engine and let it idle. Reading should be a minimum of 8A at idle. BATTERY IDENTIFICATION NOTICE: It is important to identify what type of battery you have installed in your ATV. Different types of batteries require different service procedures. Proper servicing and upkeep of your battery is very important for maintaining long battery life. Your ATV may have a Conventional Battery or a Sealed Low Maintenance Battery. To identify which type of battery your 9.18 [email protected] ELECTRICAL CONVENTIONAL BATTERY ACTIVATION/ SVC NOTE: New Battery: Battery must be fully charged before use or battery life will be significantly reduced 1030% of the battery’s full potential. To ensure maximum service life and performance from a battery, perform the following steps. To activate a new battery: NOTE: This section contains information for both Conventional Lead-Acid batteries and Sealed Low Maintenance batteries. Before service, identify the battery type in the vehicle. Use the section that applies to the battery. 1. Remove vent plug from vent fitting. Remove cell caps. 2. Fill battery with electrolyte to upper level marks on case. 3. Set battery aside to allow for acid absorption and stabilization for 30 minutes. 4. Add electrolyte to bring level back to upper level mark on case. NOTE: This is the last time that electrolyte should be added. If the level becomes low after this point, add only distilled water. 5. Charge battery at 1/10 of its amp/hour rating. Examples: 1/ 10 of 9 amp battery = .9 amp; 1/10 of 14 amp battery = 1.4 amp; 1/10 of 18 amp battery = 1.8 amp (recommended charging rates). 6. Check specific gravity of each cell with a hydrometer to assure each has a reading of 1.270 or higher. 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. BATTERY TERMINALS/ TERMINAL BOLTS Use Polaris corrosion resistant Nyogel™ grease (PN 2871329) on battery bolts. See Battery Installation. 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. WARNING The gases given off by a battery are explosive. Any spark or open flame near a battery can cause an explosion which will spray battery acid on anyone close to it. Should there be contact with battery acid, wash the affected area with large quantities of cool water and seek immediate medical attention. 9.19 [email protected] ELECTRICAL CONVENTIONAL BATTERY INSPECTION/REMOVAL The battery is located in the front rack storage compartment. CONVENTIONAL BATTERY INSTALLATION 1. Clean battery cables and terminals with a stiff wire brush. Corrosion can be removed using a solution of one cup water and one tablespoon baking soda. Rinse well with clean water and dry thoroughly. 2. Route the cables correctly. 3. Reinstall battery, attaching positive (+) (red) cable first and then the negative (-) (black) cable. Coat terminals and bolt threads with Nyogel™ Grease (PN 2871329). 4. Install clear battery vent tube from vehicle to battery vent. WARNING: Vent tube must be free from obstructions and kinks and securely installed. If not, battery gases could accumulate and cause an explosion. The vent tube should be routed away from frame and body to prevent contact with electrolyte. Avoid skin contact with electrolyte, as severe burns could result. If electrolyte contacts the vehicle frame, corrosion will occur. 5. Reinstall the holder strap. Inspect the battery fluid level. When the battery fluid nears the lower level, remove the battery and fill with distilled water only to the upper level line. To remove the battery: Maintain between upper and lower level marks 1. Disconnect holder strap and remove covers. 2. Disconnect battery negative (-) (black) cable first, followed by the positive (+) (red) cable. CAUTION Whenever removing or reinstalling the battery, disconnect the negative (black) cable first and reinstall the negative cable last! 3. Remove the battery. 4. Remove the filler caps and add distilled water only as needed to bring each cell to the proper level. Do not overfill the battery. Refill using only distilled water. Tap water contains minerals which are harmful to a battery. Do not allow cleaning solution or tap water inside the battery. Battery life may be reduced.Reinstall the battery caps. 5. Reinstall the battery caps. 9.20 CONVENTIONAL BATTERY TESTING Whenever a service complaint is related to either the starting or charging systems, the battery should be checked first. Following are three tests which can easily be made on a battery to determine its condition: OCV Test, Specific Gravity Test and Load Test. CONVENTIONAL BATTERY OCV - OPEN CIRCUIT VOLTAGE TEST Battery voltage should be checked with a digital multitester. Readings of 12.6 volts or less require further battery testing and charging. See charts and Load Test on below. NOTE: Lead-acid batteries should be kept at or near a full charge as possible. Electrolyte level should be kept between the low and full marks. If the battery is stored or used in a partially charged condition, or with low electrolyte levels, hard crystal sulfation will form on the plates, reducing the efficiency and service life of the battery. [email protected] ELECTRICAL CONVENTIONAL BATTERY SPECIFIC GRAVITY TEST A tool such as a Battery Hydrometer (PN 2870836) can be used to measure electrolyte strength or specific gravity. As the battery goes through the charge/discharge cycle, the electrolyte goes from a heavy (more acidic) state at full charge to a light (more water) state when discharged. The hydrometer can measure state of charge and differences between cells in a multi-cell battery. Readings of 1.270 or greater should be observed in a fully charged battery. Differences of more than .025 between the lowest and highest cell readings indicate a need to replace the battery. SPECIFIC GRAVITY State of charge* Conventional Lead-acid Low Maintenance Type 100% Charged 1.265 1.275 75% Charged 1.210 1.225 50% Charged 1.160 1.175 25% Charged 1.120 1.135 0% Charged less than 1.100 less than 1.115 * At 80oF NOTE: Subtract .01 from the specific gravity reading at 40o F. Battery Hydrometer (PN 2870836) CONVENTIONAL BATTERY LOAD TEST CAUTION 1.10 1.15 Detail A To prevent shock or component damage, remove spark plug high tension leads and connect securely to engine ground before proceeding. 1.20 1.25 1.30 NOTE: This test can only be performed on machines with electric starters. This test cannot be performed with an engine or starting system that is not working properly. OPEN CIRCUIT VOLTAGE State of charge Conventional Lead-acid Low Maintenance Type 100% Charged 12.60 V 12.70 V 75% Charged 12.40 V 12.50 V 50% Charged 12.10 V 12.20 V 25% Charged 11.90 V 12.0 V 0% Charged less than 11.80 V less than 11.9 V A battery may indicate a full charge condition in the OCV test and the specific gravity test, but still may not have the storage capacity necessary to properly function in the electrical system. For this reason, a battery capacity or load test should be conducted whenever poor battery performance is encountered. To perform this test, hook a multitester to the battery in the same manner as was done in the OCV test. The reading should be 12.6 volts or greater. Engage the starter and observe the battery voltage while cranking the engine. Continue the test for 15 seconds. During cranking the observed voltage should not drop below 9.5 volts. If the beginning voltage is 12.6 volts or higher and the cranking voltage drops below 9.5 volts during the test, replace the battery. 9.21 [email protected] ELECTRICAL CONVENTIONAL BATTERY OFFSEASON STORAGE CONVENTIONAL BATTERY CHARGING PROCEDURE To prevent battery damage during extended periods of nonuse, the following basic battery maintenance items must be performed: 1. Remove the battery from the ATV to prevent damage from leaking or spilled acid during charging. 2. Charge the battery with a charging output no larger than 1/ 10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3. Install battery in vehicle. Coat threads of battery bolt with a corrosion resistant dielectric grease. • Remove the battery from the machine and wash the case and battery tray with a mild solution of baking soda and water. Rinse with lots of fresh water after cleaning.NOTE: Do not get any of the baking soda into the battery or the acid will be neutralized. Dielectric Grease • Using a wire brush or knife, remove any corrosion from the cables and terminals. • Make sure that the electrolyte is at the proper level. Add distilled water if necessary. (PN 2871329) 4. • Charge at a rate no greater than 1/10 of the battery’s amp/hr capacity until the electrolyte’s specific gravity reaches 1.270 or greater. WARNING To avoid the possibility of explosion, connect positive (red) cable first and negative (black) cable last. • Store the battery either in the machine with the cables disconnected, or store in a cool place. NOTE: Stored batteries lose their charge at the rate of up to 1% per day. Recharge to full capacity every 30 to 60 days during a non-use period. If the battery is stored during the winter months, electrolyte will freeze at higher temperatures as the battery discharges. The chart below indicates freezing points by specific gravity. 5. After connecting the battery cables, attach the hold down strap. 6. Install clear battery vent tube from vehicle to battery vent. WARNING: Vent tube must be free from obstructions and kinks and securely installed. If not, battery gases could accumulate and cause an explosion. Vent should be routed away from frame and body to prevent contact with electrolyte. Avoid skin contact with electrolyte, as severe burns could result. If electrolyte contacts the vehicle frame, corrosion will occur. 7. Route cables so they are tucked away in front and behind battery. Electrolyte Freezing Points Specific Gravity of Electrolyte Freezing Point 1.265 -75o F 1.225 -35o F 1.200 -17o F 1.150 +5o F 1.100 +18o F 1.050 +27o F 9.22 Connect battery cables. Do not run the engine with the battery disconnected. Electrical components can become damaged. [email protected] ELECTRICAL STARTER SYSTEM TESTING FLOW CHART Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test. With the tester on the VDC position, place the tesRemove battery and properly service. ter’s black lead on the battery negative and the red Install fully charged shop battery to No lead on the battery positive. continue test. Reading should be 12.4 volts or greater. Yes Disconnect Blue/White engagement wire from the starter solenoid. Connect tester black wire to battery ground. Connect red tester lead to RED/ WHITE harness wire at solenoid.Turn on ignition switch and depress the starter button. Tester should read battery voltage. Yes Voltage Drop Testing No Check voltage on both sides of the fuse, ignition switch/engine stop switch and starter button. The voltage on both sides should be the same. NOTE: The ignition switch and engine stop switch must be on, the starter button depressed. Replace the defective component. Test starter solenoid coil by connecting an ohmmeter between the coil leads Resistance should be 3.7Ω + 1. Check solenoid ground path between the BLUE wire and battery NEG. with transmission in NEUTRAL and the hand brake applied. Set the meter to check continuity of a diode. See Page 9.22 for instructions. Reconnect the solenoid. Connect the tester black lead to the battery positive and the red lead to the solenoid end of the battery-to-solenoid wire. Depress starter button. Reading should be less than .1 V D.C. No Clean the battery-to-solenoid cable ends or replace the cable. Yes Connect the black tester lead to solenoid end of battery-to-solenoid cable. Connect red tester lead to solenoid end of solenoid-to-starter cable. Depress starter button. Reading should be less than .1 V D.C. No Replace the starter solenoid. No Clean the solenoid-to-starter cable ends or replace the cable. Yes Connect the black tester lead to solenoid end of the solenoid-to-starter cable. Connect the red tester lead to the starter end of the same cable. Depress the starter button. Reading should be less than .1 V D.C. Yes If all of these indicate a good condition, yet the starter still fails to turn, the starter must be removed for static testing and inspection. 9.23 [email protected] ELECTRICAL STARTER MOTOR EXPLODED VIEW BRUSH LENGTH SERVICE LIMIT: 5/16″ (8 MM) 9.24 [email protected] ELECTRICAL STARTER SYSTEM Troubleshooting To perform the test, place the meter on DC volts and place the meter leads across the connection to be tested. Refer to the chart on 1.47 to perform voltage drop tests on the starter system. Starter Motor Does Not Run Voltage should not exceed .1 DC volts per connection • Battery discharged. Low specific gravity • Loose or faulty battery cables or corroded connections (see Voltage Drop Tests) • Related wiring loose, disconnected, or corroded • Poor ground connections at battery cable, starter motor or starter solenoid (see Voltage Drop Tests) • Faulty key switch • Faulty kill switch • Faulty starter solenoid or starter motor. • Engine problem - seized or binding (Can engine be rotated easily with recoil starter?) STARTER MOTOR Removal / Disassembly NOTE: Use electrical contact cleaner to clean starter motor parts. Some solvents may leave a residue or damage internal parts and insulation. 1. Remove the starter from the engine. 2. Remove the two bolts, washers, and sealing O-Rings. Inspect O-Rings and replace if damaged. Starter Motor Turns Over Slowly • Battery discharged - low specific gravity • Excessive circuit resistance - poor connections (see Voltage Drop Test below) • Engine problem - seized or binding (Can engine be rotated easily?) • Faulty or worn brushes in starter motor Starter Motor Turns - Engine Does Not Rotate • Faulty starter drive • Faulty starter drive gears or starter motor gear • Faulty flywheel gear or loose flywheel VOLTAGE DROP NOTE: Note the alignment marks on both ends of the starter motor casing. These marks must align during reassembly. Testing The Voltage Drop Test is used to test for bad connections. When performing the test, you are testing the amount of voltage drop through the connection. A poor or corroded connection will appear as a high voltage reading. Voltage shown on the meter when testing connections should not exceed.1 VDC per connection or component. 9.25 [email protected] ELECTRICAL 3. Remove the front bracket assembly and the rear bracket assembly. Remove the shims from the armature shaft and inspect the O-rings located on the armature housing. as necessary. O-Rings Shims 3. NOTE: The shims will be replaced during reassembly. BRUSHES Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate. Slide brush end frame off end of starter. NOTE: The electrical input post must stay with the field coil housing. 4. Measure resistance between ground brush and brush plate. Resistance should be .3 ohms or less. Inspection & Replacement 1. Measure resistance between starter input terminal and insulated brushes. The reading should be .3 ohms or less. Remember to subtract meter lead resistance. Brush Inspection 1. 2. Measure resistance between insulated brush and starter housing. Reading should be infinite. (OL). Inspect insulation on brush wires for damage and repair or replace Measure length of each carbon brush. Replace brush assembly when worn to 5/16” (8 mm) or less. The brushes must slide freely in their holders. Brush Length Limit 5/16” (8 mm) 9.26 [email protected] ELECTRICAL Brush Replacement 1. 2. Remove terminal nut with lock washer, flat washer, large phenolic washer, the small phenolic spacers, and sealing Oring. Inspect O-ring and replace if damaged. 3. Using a digital multitester, measure the resistance between each of the commutator segments. The reading should be .3 ohms or less. 4. Measure the resistance between each commutator segment and the armature shaft. The reading should be infinite (no continuity). 5. Check commutator bars for discoloration. Bars discolored in pairs indicate shorted coils, requiring replacement of the starter motor. 6. Place armature in a growler. Turn growler on and position a hacksaw blade or feeler gauge lengthwise 1/8” (.3 cm) above armature coil laminates. Rotate armature 360°. If hacksaw blade is drawn to armature on any pole, the armature is shorted and must be replaced. Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate. CAUTION Some cleaning solvents may damage the insulation in the starter. Care should be exercised when selecting an appropriate solvent. If the commutator needs cleaning use only electrical contact cleaner. ARMATURE Testing 1. Remove armature from starter casing. Note order of shims on drive end for reassembly. CAUTION Use care when handling starter housing. Do not drop or strike the housing as magnet damage is possible. If magnets are damaged, starter must be replaced. STARTER Reassembly & Installation 1. 2. Install brush plate to field magnet housing aligning index Inspect surface of commutator. Replace if excessively worn or damaged. 9.27 [email protected] ELECTRICAL 9. tab. 2. Install O-ring, two small phenolic spacers, large phenolic washer, flat washer, lock washer, and terminal nut. 3. While holding brush springs away from brushes, push brushes back and hold in place. 4. Slide armature into field magnet housing. Release brushes. 5. Lightly grease the drive roller bearing and reinstall drive end frame on armature. Inspect seal for wear or damage. Replace drive end cap if necessary. Roller Bearing Seal Lightly grease pinion shaft and install pinion, spring stopper, and snap ring. 10. Install the starter onto the engine case. Hand tighten each of the starter bolts. Torque the bottom bolt first to 9 ft.lbs. (12 Nm). Then torque the top bolt to the same specification. NOTE: It is important to tighten the bottom starter bolt first, as the bottom hole acts as a pilot hole to properly align the starter drive (bendix) with the flywheel. This helps to prevent binding and starter damage. STARTER SOLENOID Bench Testing To measure the resistance of the pull-in coil, connect meter leads to the solenoid lead wires. The resistance should be 3.7 ohms. Refer to “Electric Starter System Testing” in this section to further test the solenoid. 6. Be sure wire insulation is in place around positive brush wire and pushed completely into slot on phenolic plate. 7. Using Dielectric Grease (PN 2871329), lubricate brush end bushing and install shims. 8. Align brush plate and install cover and screws. 9.28 [email protected] ELECTRICAL STARTER DRIVE Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement If the garter spring is damaged, the overrun clutch may fail to return properly. Use either of the following methods to remove and install a new garter spring: H G F A D B A. Gear Assembly B. Thrust Washer C. Busing D. Retaining Ring E. Thrust Washer F. Stopper G. Cover H. Spring C E 1. Screw the overrun clutch out to the engaged position on the pinion shaft assembly. Use a small piece of wire with the end bent in a hook and pick the old spring out of its channel. Slide it off the end of the shaft. Slide the new spring over the overrun clutch and into the spring groove. Make sure that the spring is positioned between the shoe alignment pins and the back flange of the anti kick-out shoes. 2. Remove the retaining ring, thrust washer, spring retainers and clutch return spring. Screw the overrun clutch off the end of the pinion shaft. Remove the old spring and install a new one. Lightly grease the pinion shaft and reinstall the clutch, spring, retainers, end washer and lock ring in the reverse order. Make sure the end washer is positioned properly so that it will hold the lock ring in its groove. 9.29 [email protected] ELECTRICAL NOTES 9.30 [email protected] WIRE DIAGRAM 2006 HAWKEYE 2X4/ 4X4 10.1

2006 Hawkeye Chapter 1 - General Information

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