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Polaris Off-Road Coloring Sheets. Send us an e-mail inquiry. Locate the nearest dealer in your area. Polaris Phoenix Owner's Manual. Polaris Predator Service Manual. Polaris Ranger Service Manual. Polaris Sawtooth Owner's Manual. Polaris Sportsman Spare Parts Catalog. Polaris Industries is an American engineering company manufacturing motorcycles, snowmobiles , ATVs and electric cars, headquartered in Midine, Minnesota.
The history of Polaris can be traced from its founding to its founders - Edgar Hettin, his younger brother Allan and his close friend David Johnson. Owwners handlebars can be adjusted for rider preference. Remove snap ring A and slowly Remove driven clutch from the transmission input shaft. This information is for Sportsman models equipped with a winch in the front. All service sportsamn be performed by your authorized Polaris dealer.
Sportsman Touring — Manul the magnetic coil 1 and bushing in the input cover assembly. Engine at operating temperature. Polaris is an American manufacturer of snowmobiles, ATVs and electric vehicles.
Press a new bearing onto the output shaft using a press. Inspect the top of the cylinder B for warp using a straight edge A and feeler gauge C. Pvt Drying Always follow all recommended maintenance procedures.
Do not allow hot oil to come into contact with skin. Install piston D with a twisting motion while pushing inward. A rubber-fiber diaphragm divides the regulator into two separate sections-, the fuel EFI Engines use a non-serviceable, high-volume, high- chamber and the pressure regulating chamber.
Excessive voltage will burn out the injector s. Do not ground the injector s with the Operation Overview ignition on. The throttle position sensor TPS is a non-serviceable item. If it is faulty, it must be replaced. The throttle plate should seal off throttle bore completely.
Establishing correct flow: Now that the zero offset voltage has been set, you can now set the throttle body to the correct air flow Back Air Flow Screw Out Until No value.
This indicates all other components are working properly. Refer to Chapter 10 for ETS testing. Press inside insert A until it snaps into place. Step 3 Side Panel Removal Side panel removal is quick and easy, use the following instructions for removal and installation. Remove seat by releasing the latch and lifting up on the seat. Front Storage Remove Bolts Remove the two T25 screws that secure the storage box to the front fender well areas each side.
Pull the tabs out of the notches and lift up on the cover piece. Remove the two screws B that secure the front cab to the frame in the fuel tank mount area. Install rear rack onto rear frame and cab. Lift the rear cab from the frame.
The bottom handle bar block has a side with 3 holes, the side with 3 holes faces up and to the front of the ATV. Align the pin A in the top block with the middle hole B in the bottom block for proper installation. Ball Joint Stud Bushing 8 ft. Apply grease to extension cap and threads of puller bolt to NOTE: Refer to the illustration on the previous page ease removal.
Front Strut Cartridge Replacement Remove the handle bar pod. NOTE: Refer to illustration on following page. Remove the handle bar. Remove the fuel tank bracket assembly.
Hold strut rod and remove top nut. Remove the steering tie rod ends from the steering bracket. The passenger backrest should be face down in the cargo box and the driver seat backrest should be locked into position.
Reverse the removal steps to reinstall the cargo box. Refer to the standard fastener torque values in Chapter 1 during Remove the four bolts attaching the rear of the cargo box assembly. Passenger Backrest Unlatch the driver seat backrest by turning the engagement knobs on each side in the directions shown below. Configure the seating for 2-UP riding. With the passenger seat bottom in place, remove the two screws retaining the seat bottom.
Torx Screw Moveable Sheave 2. Cam Assembly Roller Pin 3. Retaining Ring Spring Pin 4. E-clip Stationary Sheave 5. Washer Periodic inspection and maintenance is required to keep the system operating at peak performance. Refer to the spring specification chart for specific free length measurements and tolerances. Also check to see that spring coils are parallel to one another.
These shift weights have many different factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding the effects they have on belt to sheave clearance, clutch balance, engagement and shifting characteristics.
The ATV should be fasteners and fastener placement. Replace if proper clutch offset on reassembly. Align the alignment mark on the cover with the mark on the engine seal. Mark drive belt direction of rotation so that it can be installed in the same direction. The belt is normally positioned so part numbers are easily read.
NOTE: Be sure to position belt so part number is easily read. Verify new belt is seated properly in the clutches before operating the ATV. Adjust if necessary. Drive Clutch Disassembly Inspect Shaft Using a permanent marker, mark the cover, spider, and moveable and stationary sheaves for reference, as the cast- in X's may not have been in alignment before disassembly.
Turn roller with your finger. If spider during assembly. Inspect BOTH sheaves for signs of wear, grooving or cracking. In order to remove bushings it will be Place main adapter Item 8 on puller. Rotate one-way clutch clockwise as viewed from the cover plate side. The clutch should rotate on the shaft Removal Tool 3 with only slight amount of drag. Verify there is no binding Nut C or rough spots. Reinstall shift weights using new lock nuts on the bolts. Spider Nut Torque: 15 ft. Remove snap ring A and slowly Remove driven clutch from the transmission input shaft.
Pull out the clutch roller pins L and rollers M. Inspect the spider dampener E for wear and replaced if needed. Remove the E-clip F , washer G , and the clutch rollers H. Inspect the bearing for wear. Spin the bearing, if the bearing does not spin smoothly replace as needed.
To remove the bearing, simply press the bearing from the shaft. Spin the bearing, if the Bushing Replacement Kit bearing does not spin smoothly replace as needed. Press a new bearing onto the output shaft using a press. Install adapter Item 9 onto puller. Both Sides. Install the roller pin into the sheave assembly. Both sides. The flat side of the roller pin faces downward when the shaft side is laying flat on the bench.
Install the spider assembly onto the shaft with the retaining ring on top of the spider. Install the cam assembly helix over the shaft. Replace the entire clutch as an Dealer MSD technician who has received the assembly if worn, damaged or cracked.
Torque cover bolts evenly to specification. Spacer Washers Spider Torque: ft. Any misalignment will alter clutch balance. Disassembly Using special tool PN , apply and hold downward pressure on the outer spring retainer and remove the snap ring A. Inspection Inspect both the inner and outer sheave surfaces. Install inner spring retainer if removed. Install the inner sheave onto the outer sheave. NOTE: Rollers and helix are non-serviceable items.
Page Pvt Troubleshooting During this procedure, the throttle should not be held at the full position for more than 10 seconds. PVT seals should be inspected for damage if repeated leaking occurs. Engine RPM below specified operating range -Install correct shift weight kit to match engine -Drive clutch shift weight too heavy.
Inspect brake Belt burnt, thin spots -Dragging brake system. Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly.
Remove cotter pin and nut from lower A-arm ball joint. Remove lower A-arm from ball joint. Apply an anti-seize Inspection compound to splines. Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft Check the front and rear driveshaft CV boots for any tears or leaking grease. Remove small clamp and boot from driveshaft. Inspect the grease carefully for contamination, and clean the joint thoroughly if necessary. Install the small clamp on the boot. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed.
Slide prop shaft back and away from housing, then pull sharply forward to Always wear eye protection when working with remove from transmission shaft. 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. Repeat procedure for other side. Install snap ring to contain bearing cap just installed. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown.
Description Ref. Gearcase Sub Asm. Once enabled, the AWD Ring Gear remains engaged while the front gearcase is moving and will not disengage until the rear wheels regain traction. Bolts and fluid drain plug are accessible through the skid plate. Pull the hub and strut assembly out and pull the drive-shaft out of the hub. Remove the armature plate and RH output hub assembly from the outer cover plate. Inspect the bearing and contact surfaces of the output hub for signs of wear or damage.
Inspect the bearing and Inspect roll cage B sliding surface. This surface must be contact surfaces of the output hub for signs of wear or clean and free of nicks, burrs or scratches. Inspect the H- damage. Inspect the magnetic coil A in the outer cover plate Remove the snap ring retaining the input shaft assembly. Inspect the backlash pad B for excessive wear. Remove the input shaft assembly. Inspect the pinion gear C for chipped, broken, or missing teeth.
The output hub should spin freely. Replace all O-rings, seals, and worn components. Install the RH output hub B into the output cover. The Press the pinion shaft seal into the pinion cover, until the output hub should spin freely.
Torque the cover plate bolts to specification. Be sure that the armature plate tabs are fully engaged into the roll cage assembly.
The gearcase coil should measure turns. Re-apply Loctite onto the bottom screw threads. The top of the coil To install gearcase, reverse removal procedures. Use new should be seated below the U-shaped insert. The U-shaped roll pin in front prop shaft. Operation is controlled by the ECU grounding and ungrounding the coil. Remove and Remove the armature plate. Inspect the armature plate for inspect the cover o-ring 1. Inspect thrust bearing 2 for wear, distortion or other damage.
Replace component as wear. Replace items as required. Inspect roll cage sliding surface 2. This surface must be clean and free of nicks, burrs or scratches.
Remove and inspect the H-springs 4. Replace any components as required. Remove and inspect the bearing surfaces of the output hub.
Inspect the magnetic coil 1 in the outer cover plate Inspect the magnetic coil 1 and bushing in the input cover assembly. Inspect the backlash pad 2 for excessive wear. Replace the input cover seal. Safety glasses or a face shield are required. Using moderate hand pressure, hold the tool on top of the piston while using compressed air at the gearcase passage circled to force piston up and out of the case. Coat the edges of the verify alignment of the sight hole circled and piston mark piston cavities.
Thoroughly clean the gearcase components before beginning reassembly. Install a new seal in the main gearcase halve. Install the input shaft assembly. Install a new seal and o-ring the input shaft cover 2 prior to reassembly. Install the clutch pack 1 , spacer 2 and ring gear 3. Install a new o-ring on the backlash pad 2 stem. NOTE: Ring gear backlash 2 is set at the factory. Install new cover o-ring 1 on the cover plate assembly Place cover assembly on Install bolts arrows retaining the and a new passage o-ring 2 on the gear case.
Remove rear hub cap. Remove hub. Remove cotter pin A.
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