2003 TRAIL BOSS
SERVICE MANUAL
PN 9918061
PN 9918061
Printed in USA
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2003 TRAIL BOSS 330
SERVICE MANUAL
Foreword
This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle
are from the operator’s perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar
with service procedures before starting the work. Certain procedures require the use of special tools. Use
only the proper tools as specified.
This manual includes procedures for maintenance operations, component identification and unit repair, along
with service specifications for 2003 Polaris Trail Boss ATVs.Comments or suggestions about this manualmay
be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.
2003 Trail Boss 330 ATV Service Manual (PN 9918061)
ECopyright 2002 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of
publication. Due to constant improcvements in the design and quality of production components, some minor descrepancies may result
between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended
for reference use only. No liability can be accepted for ommisions or inaccuracies. Any reprinting or reuse of the depictions and/or
procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
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UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
Throughout these instructions, important information is brought to your attention by the following symbols:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
DANGER
Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person
inspecting or servicing the ATV.
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or
person inspecting or servicing the ATV.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property
damage.
NOTE:
A NOTE provides key information to clarify instructions.
Trademarks
Polaris acknowledges the following products mentioned in this manual:
FLEXLOC, Registered Trademark of SPS Technologies
Loctite, Registered Trademark of the Loctite Corporation
STA-BIL, Registered Trademark of Gold Eagle
FOX, Registered Trademark of Fox Shox
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Ammco, Registered Trademark of Ammco Tools, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
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CHAPTER INDEX
CHAPTER 1
GENERAL
CHAPTER 2
CHAPTER 3
CHAPTER 4
CHAPTER 5
CHAPTER 6
CHAPTER 7
CHAPTER 8
CHAPTER 9
CHAPTER 10
MAINTENANCE
ENGINE
FUEL SYSTEM
BODY/SUSPENSION
PVT SYSTEM
FINAL DRIVE
TRANSMISSION
BRAKES
ELECTRICAL
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GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION/
MAINTENANCE
1
2003 Model Identification . . . . . . . . . . . . . . . . . . 1.2
Serial Number Location . . . . . . . . . . . . . . . . . . . 1.2
2003 Trailboss Model . . . . . . . . . . . . . . . . . . . . . 1.3
Replacement Keys . . . . . . . . . . . . . . . . . . . . . . . 1.4
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . 1.5
Specifications - 2003 Trail Boss 330 . . . . . . . . 1.6-1.7
Publication Numbers . . . . . . . . . . . . . . . . . . . . . 1.8
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Standard Torque Specifications . . . . . . . . . . . . 1.8
Tap Drill Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . 1.9
Unit of Measure Conversion Table . . . . . . . . . . 1.10
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . 1.11
1.1
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GENERAL INFORMATION
MODEL IDENTIFICATION
The machine model number must be used with any correspondence regarding warranty or service.
Machine Model Number Identification
A 0 3 C A 3 2 A A
Emissions &
Model Option
Year Designation
Basic Chassis
Designation
Engine Designation
ENGINE DESIGNATION NUMBERS
32 ES32PFE10 . . . . . . . . . . . . Single, Air Cooled, SOHC 4 Stroke, Electric Start
VIN IDENTIFICATION
World Mfg. ID
Vehicle Descriptor
Vehicle Identifier
1
4
2
3
4
5
6
3
7
8
9 10 11 12 13 14 15 16 17
2
A
*
3
P
0
0
0
0
0
0
X
A
A
A
Model
Year
Emissions
Engine
Powertrain
* This could be either
a number or a letter
Body Style
Individual Serial No.
Plant No.
Check Digit
ENGINE SERIAL NUMBER LOCATION
Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This
information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional
number is stamped on the center top of crankcase beneath the cylinder coolant elbow.
UNIT MODEL NUMBER AND SERIAL NUMBER LOCATION
The machine model number and serial numberare
important for vehicle identification. The machine
serial number is stamped on the lower left side of
the frame tube.(B)
A
Front
The transmission I.D. number is located
on top of the transmission, right side of
machine.
TRANSMISSION I.D. NUMBER
LOCATION
1.2
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GENERAL INFORMATION
2003 TRAILBOSS MODEL
2003 TRAILBOSS 330
1.3
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GENERAL INFORMATION
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, ignition switch
replacement is required.
Series #
Part Number
4010278
4010278
4010321
4010321
4010321
4010321
4110141
4110148
4010278
4010278
20
21
22
23
27
28
31
32
67
68
31XX
Key Series
Number
1.4
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GENERAL INFORMATION
MACHINE DIMENSIONS
46 in
117 cm
FRONT
46 in
117 cm
75 in
191 cm
34 in
86 cm
SIDE
49.5 in
126 cm
1.5
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GENERAL INFORMATION
MODEL: . . . . . . . . . . 2003 TRAIL BOSS 330
MODEL NUMBER: . A03CA32
ENGINE MODEL: . . ES32PFE10
JETTING CHART
CARBURETION
AMBIENT TEMPERATURE
Type . . . . . . . . . . . . . . . . BST 34 Mikuni
Main Jet . . . . . . . . . . . . 122.5
Pilot Jet . . . . . . . . . . . . . 42.5
Jet Needle . . . . . . . . . . . 4HB48--2
Needle Jet . . . . . . . . . . . P-0M
Pilot Screw . . . . . . . . . . 2 Turns Out
Pilot Air Jet . . . . . . . . . . 160
Altitude
Below 40LF
Below 5LC
+40EF to +80EF
+5EC to +26EC
0-1800
Meters
(Feet)
117.5
120
122.5
115
(0-6000)
above 1800
(above 6000)
Valve Seat . . . . . . . . . . . 1.5
Fuel Octane (R+M/2) . 87 Non-Oxygenated or
89 Oxygenated
CLUTCH CHART
CLUTCH
Type . . . . . . . . . . . . . . . . . . . . PVT
Belt . . . . . . . . . . . . . . . . . . . . . 3211077
Belt Width (Projected) . . . . . 1.1882 (30.18mm)
Side Angle (Overall) . . . . . . 26L
Shift
Drive Clutch
Driven Clutch
Driven
Helix
Altitude
Weight
Spring
Spring
Meters
(Feet)
0-1800
20--40
20--38
Blue/Grey
Black
2+2
2+2
(0-6000)
1800-3700
(6000-12000)
Blue/Grey
Black
* 40E helix, black driven spring
Outside Circumference . . . . 40.86 M.122
Center Distance . . . . . . . . . . 10M.122 (254.5mm)
Clutch Offset . . . . . . . . . . . . 0.52 (12.7mm)
Drive Spring . . . . . . . . . . . . . Grey
Driven Spring . . . . . . . . . . . . Black
Driven Helix . . . . . . . . . . . . . 2+2
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle, Single Cyl.
Displacement . . . . . . . . . . . . . . . 329 cc
Bore . . . . . . . . . . . . . . . . . . . . . . . 3.0912 (78.5mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.6792 (68mm)
Valve Clearance In & Ex . . . . . . 0.006 M 0.00082 (0.15 M 0.02 mm) BTDC on compression
Cooling . . . . . . . . . . . . . . . . . . . . Air with fan assisted oil cooler
Lubrication Type . . . . . . . . . . . . Wet Sump
Piston Marking . . . . . . . . . . . . . . None
Operating RPMM200 . . . . . . . . . 6300 RPM
Idle RPM M 50 (lights off) . . . . . 1300 RPM
Compression Ratio . . . . . . . . . . 9.2:1
Compression Pressure . . . . . . . 70--90 PSI
1.6
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GENERAL INFORMATION
MODEL: . . . . . . . . . . . . 2003 TRAIL BOSS 330
MODEL NUMBER: . . . A03CA32
ENGINE MODEL: . . . . ES32PFE10
ELECTRICAL
FLUID
Capacity
Type
Flywheel I.D. . . . . . . None
Fuel Tank . . . . . . . . . . 3.25 gals. (12.30 L)
Transmission . . . . . . . 11.3 oz. (335 ml) PPS*
Engine Oil . . . . . . . . . 1.5 qts (1.4 L) PP4*
Brake (Hand) . . . . . . . . . . . . . . . . . . . . . Dot 3
Brake (Foot) . . . . . . . . . . . . . . . . . . . . . . Dot 3
CDI Part Number . . . 4010697
Alternator Output . . . 210 watts
Ignition Timing . . . . . 30LM2L BTDC@5000RPM
Spark Plug / Gap . . . NGK BKR6E / 0.0362 (0.9 mm)
Lights: Head . . . . . . (2) Dual Beam 30/30 watts
Tail . . . . . . . . 8.26 watts
Brake . . . . . . 26.9 watts
Indicator . . . 1.0 watts
Electric Start . . . . . . . Standard
Electronic Speedo . . N/A
Polaris Lubricants
*PP6 Polaris Premium 60/40 Antifreeze/Coolant
*PPS Polaris Premium Synthetic Gear Case Oil
*PP4 Polaris 0W--40 Synthetic Engine Lubricant
*PDD Premium Demand Drive Hub Fluid
SUSPENSION / CHASSIS
DRIVE TRAIN
Body Style . . . . . . . . Gen IV
Chain Type . . . . . . . . . 520 O-Ring
Gear Reduction-Rev . 3.05/1
Front Suspension . . MacPherson Strut
Tow Capacity . . . . . . 850 lbs. (385.9 kg)
Turning Radius . . . . . 752 (191 cm)
Toe Out . . . . . . . . . . . 1/82-1/42 (3-6.35 mm)
Ground Clearance . . 5.52 (13.97 cm)
Front Vertical Travel 6.72 (17.02 cm)
Rear Suspension . . . Progressive Rate Swing Arm
Rear Travel . . . . . . . . 9.02 (22.86 cm)
Rear Shock . . . . . . . . 22 Gas Charged Twin Tube
Shock Adjustment . . Cam
Gear Reduction-High 2.68/1
Final Drive Ratio . . . . 11/40 78P
Brake (Hand) . . . . . . . Single Lever, Hyd. Disc
Brake ( Auxiliary Foot) Hydraulic
TIRES
LOAD CAPACITY
Front Rack (Accy) . . . . 75 lbs. (34 kg)
Rear Rack (Std) . . . . . . 125 lbs. (57 kg)
Tire Size - Front . . . . 23 x 7 - 10
Tire Size - Rear . . . . 22 x 11 - 10
Tire Pressure - F/R . 4/3 lbs.
Tongue Weight . . . . . . . 85 lbs. (14 kg)
Tow Hitch . . . . . . . . . . . Std
Total Width . . . . . . . . 462 (117 cm)
Total Length . . . . . . . 752 (191 cm)
Total Height . . . . . . . . 462 (117 cm)
Wheel Base . . . . . . . 49.52 (125.73 cm)
Weight - Dry . . . . . . . 505 lbs. (230 kg)
OPTIONAL SUSPENSION SPRINGS
SPRING TYPE
SOFT
STANDARD
FIRM
Rear Compression Spring
7041518-067
7041303-067
N / A
N / A
130 --165 lb/in.
250 lb/in.
Front Strut Spring
7041850-067
7041375-067
64 - 113 lb/in.
41 lb/in.
1.7
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GENERAL INFORMATION
PUBLICATION NUMBERS
Year
Model
Model No.
Owner’s
Manual PN
Parts Parts
Manual PN Micro Fiche PN
NOTE: When ordering service parts be sure to use the correct parts manual.
PAINT CODES
PAINTED PART
COLOR
DESCRIPTION
DITZLER
NUMBER
POLARIS
NUMBER
Springs
Rims
Silver
Bright White
Black
-- --
P-385
P-133
P-067
P-067
2185
9440
9440
Rack(s)
Frame
Black
FRAME COLOR - P067 Medium Gloss Black 9440 / 8520147.
Order direct from Midwest Industrial Coatings 952--252--2000 See Quick Reference Manual for ordering info.
STANDARD TORQUE SPECIFICATIONS
The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF
FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering,
suspension, and engine sections.
Bolt Size Threads/In
Grade 2
Grade 5
Grade 8
Torque in. lbs. (Nm)
#10
#10
-
-
24 . . . . . . . . . . . . . . 27 (3.1) . . . . . . . . . . . . . . . . 43 (5.0) . . . . . . . . . . . . . . 60 (6.9)
32 . . . . . . . . . . . . . . 31 (3.6) . . . . . . . . . . . . . . . . 49 (5.6) . . . . . . . . . . . . . . 68 (7.8)
Torque ft. lbs. (Nm)*
1/4
1/4
5/16
5/16
3/8
-
-
-
-
-
-
-
-
-
-
20 . . . . . . . . . . . . . . 5 (7) . . . . . . . . . . . . . . . . . . 8 (11) . . . . . . . . . . . . . . . . 12 (16)
28 . . . . . . . . . . . . . . 6 (8) . . . . . . . . . . . . . . . . . . 10 (14) . . . . . . . . . . . . . . 14 (19)
18 . . . . . . . . . . . . . . 11 (15) . . . . . . . . . . . . . . . . 17 (23) . . . . . . . . . . . . . . 25 (35)
24 . . . . . . . . . . . . . . 12 (16) . . . . . . . . . . . . . . . . 19 (26) . . . . . . . . . . . . . . 29 (40)
16 . . . . . . . . . . . . . . 20 (27) . . . . . . . . . . . . . . . . 30 (40) . . . . . . . . . . . . . . 45 (62)
24 . . . . . . . . . . . . . . 23 (32) . . . . . . . . . . . . . . . . 35 (48) . . . . . . . . . . . . . . 50 (69)
14 . . . . . . . . . . . . . . 30 (40) . . . . . . . . . . . . . . . . 50 (69) . . . . . . . . . . . . . . 70 (97)
20 . . . . . . . . . . . . . . 35 (48) . . . . . . . . . . . . . . . . 55 (76) . . . . . . . . . . . . . . 80 (110)
13 . . . . . . . . . . . . . . 50 (69) . . . . . . . . . . . . . . . . 75 (104) . . . . . . . . . . . . . 110 (152)
20 . . . . . . . . . . . . . . 55 (76) . . . . . . . . . . . . . . . . 90 (124) . . . . . . . . . . . . . 120 (166)
3/8
7/16
7/16
1/2
1/2
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.
1.8
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GENERAL INFORMATION
SAE TAP DRILL SIZES
DECIMAL EQUIVALENTS
1/64 . . . . . . . . . . . . . . . . .0156
1/32 . . . . . . . . . . . .0312 . . . 1 mm = .0394N
3/64 . . . . . . . . . . . . . . . . .0469
1/16 . . . . . . . . . . . .0625
Thread Size/Drill Size Thread Size/Drill Size
#0-80
#1-64
#1-72
#2-56
#2-64
#3-48
#3-56
#4-40
#4-48
#5-40
#5-44
#6-32
#6-40
#8-32
#8-36
#10-24
#10-32
#12-24
#12-28
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
3/64
53
53
51
50
5/64
45
43
42
38
37
36
33
29
29
24
21
17
4.6mm
7
1/2-13
1/2-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
27/64
29/64
31/64
33/64
17/32
37/64
21/32
11/16
49/64
13/16
7/8
5/64 . . . . . . . . . . . . . . . . .0781 . . . 2 mm = .0787N
3/32 . . . . . . . . . . . .0938
7/64
. . . . . . . . . . . . . . .1094 . . . 3 mm = .1181N
1/8. . . . .1250
9/64 . . . . . . . . . . . . . . . . .1406
5/32 . . . . . . . . . . . .1563 . . . 4 mm = .1575N
11/64 . . . . . . . . . . . . . . . .1719
3/16 . . . . . . . . . . . .1875 . . . 5 mm = .1969N
13/64 . . . . . . . . . . . . . . . .2031
7/32 . . . . . . . . . . . .2188
15/64 . . . . . . . . . . . . . . . .2344 . . . 6 mm = .2362N
1/4 . . . . .25
17/64 . . . . . . . . . . . . . . . .2656 . . . 7 mm = .2756N
9/32 . . . . . . . . . . . .2813
19/64 . . . . . . . . . . . . . . . .2969
5/16 . . . . . . . . . . . .3125 . . . 8 mm = .3150N
21/64 . . . . . . . . . . . . . . . .3281
11/32 . . . . . . . . . . .3438 . . . 9 mm = .3543N
23/64 . . . . . . . . . . . . . . . .3594
3/8 . . . . .375
25/64 . . . . . . . . . . . . . . . .3906 . . . 10 mm = .3937N
13/32 . . . . . . . . . .4063
27/64 . . . . . . . . . . . . . . . .4219 . . . 11 mm = .4331N
7/16 . . . . . . . . . . . .4375
29/64 . . . . . . . . . . . . . . . .4531
15/32 . . . . . . . . . .4688 . . . 12 mm = .4724N
31/64 . . . . . . . . . . . . . . . .4844
1/2 . . . . .5 . . . . . . . . . . . . . . 13 mm = .5118
33/64 . . . . . . . . . . . . . . . .5156
17/32 . . . . . . . . . .5313
35/64 . . . . . . . . . . . . . . . .5469 . . . 14 mm = .5512N
9/16 . . . . . . . . . . . .5625
7/8-14
1-8
1-12
59/64
63/64
1 3/64
1 7/64
1 11/64
1 11/32
1 27/64
1 9/16
1 43/64
1 25/32
1 59/64
2 1/32
2 1/4
1 1/8-7
1 1/8-12
1 1/4-7
1 1/4-12
1 1/2-6
1 1/2-12
1 3/4-5
1 3/4-12
2-4 1/2
2-12
3
F
I
O
Q
U
25/64
2 1/4-4 1/2
2 1/2-4
2 3/4-4
3-4
2 1/2
2 3/4
37/64 . . . . . . . . . . . . . . . .5781 . . . 15 mm = .5906N
19/32 . . . . . . . . . .5938
39/64 . . . . . . . . . . . . . . . .6094
5/8 . . . . .625 . . . . . . . . . . . . 16 mm = .6299N
41/64 . . . . . . . . . . . . . . . .6406
21/32 . . . . . . . . . .6563 . . . 17 mm = .6693N
43/64 . . . . . . . . . . . . . . .6719
11/16 . . . . . . . . . . .6875
METRIC TAP DRILL SIZES
Tap Size
Drill Size
Decimal
Equiva-
lent
Nearest
Fraction
45/64 . . . . . . . . . . . . . . . .7031 . . . 18 mm = .7087N
23/32 . . . . . . . . . .7188
47/64 . . . . . . . . . . . . . . . .7344 . . . 19 mm = .7480N
3/4 . . . . .75
49/64 . . . . . . . . . . . . . . . .7656
25/32 . . . . . . . . . .7813 . . . 20 mm = .7874N
51/64 . . . . . . . . . . . . . . . .7969
13/16 . . . . . . . . . .8125 . . . 21 mm = .8268N
53/64 . . . . . . . . . . . . . . . .8281
27/32 . . . . . . . . . .8438
55/64 . . . . . . . . . . . . . . . .8594 . . . 22 mm = .8661N
7/8 . . . . .875
57/64 . . . . . . . . . . . . . . . .8906 . . . 23 mm = .9055N
29/32 . . . . . . . . . .9063
59/64 . . . . . . . . . . . . . . .9219
15/16 . . . . . . . . . .9375 . . . 24 mm = .9449N
61/64 . . . . . . . . . . . . . . . .9531
31/32 . . . . . . . . . .9688 . . . 25 mm = .9843
63/64 . . . . . . . . . . . . . . . .9844
3 x .50
3 x .60
4 x .70
4 x .75
5 x .80
5 x .90
6 x 1.00
7 x 1.00
8 x 1.00
8 x 1.25
9 x 1.00
9 x 1.25
10 x 1.25
10 x 1.50
11 x 1.50
12 x 1.50
12 x 1.75
#39
3/32
#30
1/8
#19
#20
#9
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
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
16/64
J
17/64
5/16
5/16
11/32
R
3/8
13/32
13/32
13/32
13/32
1 . . . . . 1.0
1.9
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GENERAL INFORMATION
CONVERSION TABLE
Unit of Measure
Multiplied by
Converts to
= in. lbs.
ft. lbs.
x 12
in. lbs.
x .0833
x 1.356
x .0115
x .7376
x 7.233
= ft. lbs.
ft. lbs.
= Nm
in. lbs.
= kg-m
Nm
= ft.lbs.
kg-m
= ft. lbs.
kg-m
x 86.796
x 10
= in. lbs.
kg-m
= Nm
in.
x 25.4
=mm
mm
x .03937
x 2.54
= in.
in.
= cm
mile (mi.)
x 1.6
= km
km
x .6214
x 28.35
x 29.57
x .03381
x 0.035
x .454
= mile (mi.)
Ounces (oz)
Fluid Ounces (fl. oz.)
Cubic Centimeters (cc)
Grams (g)
= Grams (g)
= Cubic Centimeters (cc)
= Fluid Ounces (fl. oz.)
= Ounces (oz)
= kg
lb.
kg
x 2.2046
x 16.387
x 0.061
x 0.568
x 1.76
= lb.
Cubic inches (cu in)
Cubic centimeters (cc)
Imperial pints (Imp pt)
Liters (l)
= Cubic centimeters (cc)
= Cubic inches (cu in)
= Liters (l)
= Imperial pints (Imp pt)
= Liters (l)
Imperial quarts (Imp qt)
Liters (l)
x 1.137
x 0.88
= Imperial quarts (Imp qt)
= US quarts (US qt)
= Imperial quarts (Imp qt)
= Liters (l)
Imperial quarts (Imp qt)
US quarts (US qt)
US quarts (US qt)
Liters (l)
x 1.201
x 0.833
x 0.946
x 1.057
x 3.785
x 0.264
= US quarts (US qt)
=Liters (l)
US gallons (US gal)
Liters (l)
= US gallons (US gal)
= Kilopascals (kPa)
= Pounds - force per square inch (psi)
= Kilograms - force per square cm
= Kilopascals (kPa)
= Cylinder Volume
Pounds - force per square inch (psi) x 6.895
Kilopascals (kPa)
x 0.145
x 0.01
x 98.1
Kilopascals (kPa)
Kilograms - force per square cm
ꢀ ꢁꢂꢃꢄꢅ x R2 x H (height)
LC to LF: 9 (LC + 40) T 5 - 40 = LF
LF to LC: 5 (LF + 40) T 9 - 40 = LC
1.10
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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 = 3/8N 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.
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.
2
kg/cm : 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/in 2 : Pounds per square inch.
Left or Right Side: Always referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the
windings. Mechanical energy is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040N.
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch System)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
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.
1.11
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GENERAL INFORMATION
NOTES
1.12
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MAINTENANCE
CHAPTER 2
MAINTENANCE
Periodic Maintenance Chart . . . . . . . . . . . . . . . 2.2-2.3
Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . 2.3
Recommended Maintenance Products . . . . . . 2.4
Lubricant and Maintenance Quick Reference 2.5-2.6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
Transmission Lubrication . . . . . . . . . . . . . . . . . . 2.8
Transmission Linkage Adjustment . . . . . . . . . . 2.9
Throttle Operation / Choke Adjustment . . . . . . 2.10
Carburetor Adjustments . . . . . . . . . . . . . . . . . . . 2.10-2.11
ETC Switch Adjustment . . . . . . . . . . . . . . . . . . . 2.11
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . 2.13
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . 2.13-2.14
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14-2.15
Oil Cooler Maintenance . . . . . . . . . . . . . . . . . . . 2.15
Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Air Box Sediment Tube Service . . . . . . . . . . . . 2.16
Breather Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
Recoil Housing/PVT Drying . . . . . . . . . . . . . . . . 2.16-2.17
Oil Level/Change/Filter . . . . . . . . . . . . . . . . . . . . 2.17-2.18
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . 2.19-2.20
Steering and Toe Alignment . . . . . . . . . . . . . . . 2.20-2.22
Exhaust System Maintenance . . . . . . . . . . . . . 2.22
Brake System Service . . . . . . . . . . . . . . . . . . . . 2.23-2.24
Drive Chain and Sprocket Service . . . . . . . . . . 2.24-2.26
Suspension Service / Controls . . . . . . . . . . . . . 2.26-2.27
Wheel Removal / Installation . . . . . . . . . . . . . . . 2.27
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
2
2.1
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MAINTENANCE
PERIODIC MAINTENANCE CHART
Inspection, adjustment and lubrication intervals of important components is listed in the following chart.
Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 mph.
Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for
replacement parts. Always use genuine Polaris parts.
H = CAUTION: Due to the nature of these adjustments, it is recommended that service be performed by
an authorized Polaris dealer.
"
= Vehicles subjected to severe use (operation in wet or dusty areas, low speed heavy load operation,
prolonged idle) should be inspected and serviced more frequently. For engine oil, short trip cold
weather riding also constitutes severe use. Pay special attention to oil level. A rise in oil level in cold weather
can indicate moisture collecting in the oil tank. Change oil immediately if oil level begins to rise.
E =
Emission Control System Service (California).
Frequency
(Whichever comes first)
Item
Hours
Calendar
Miles
(Km)
Remarks
Engine Oil - Level/Change
Oil Filter
100 hrs
6 months
6 months
Daily
1000 (1600)
1000 (1600)
Check Level Daily; Break In service at 1 month
Replace with oil change
E"
E
100 hrs
Daily
Air Filter - Foam Pre-Cleaner
Air Filter - Main Element
Inspect-Clean & oil more often in dirty conditions.
Inspect - Replace if necessary
E"
Weekly
Weekly
E"
"
Air Box Sediment Tube
Engine Breather Filter
Oil Tank Vent Hose
Valve Clearance
-
Daily
Drain deposits whenever visible
Inspect and replace if necessary
Inspect hose routing /hose condition
Inspect/Adjust
"
20 hrs
100 hrs
100 hrs
Monthly
12 months
12 months
200 (320)
"
1000 (1600)
1000 (1600)
EH
Idle Speed
As required
As required
Adjust
E
H
Throttle Cable / ETC Switch
Choke (Enricher) Cable
Carburetor Float Bowl
50 hrs
50 hrs
50 hrs
6 months
6 months
6 months
6 months
12 months
500 (800)
500 (800)
500 (800)
500 (800)
1000 (1600)
Inspect -Adjust, Lubricate, Replace if necessary
Inspect -Adjust, Lubricate, Replace if necessary
Drain bowl periodically and prior to storage
Inspect all ducts for proper sealing/air leaks
Carburetor Air Intake Ducts/Flange 50 hrs
Fuel System
100 hrs
Check for leaks at tank cap, lines, fuel valve, filter,
pump & carburetor. Replace lines every 2 years.
EH
Fuel Filter
100 hrs
12 months
1000 (1600)
1000 (1600)
Replace filter annually
EH
Coolant/Level Inspection
Daily
Daily
Replace engine coolant every 2 years
Coolant Strength / Pressure Test
System
100 hrs
6 months
Inspect strength seasonally; Pressure test sys-
tem annually
Radiator
100 hrs
100 hrs
100 hrs
Weekly
100 hrs
12 months
12 months
12 months
Weekly
1000 (1600)
1000 (1600)
1000 (1600)
Inspect / Clean external surface
Cooling System Hoses
Engine Mounts
Inspect
Inspect
Drain Recoil Housing
Exhaust Muffler / Pipe
More often if operating in wet environment
12 months
1000 (1600)
ELECTRICAL
12 months
Spark Plug
100 hrs
1000 (1600)
Inspect - Replace if necessary
E
Wiring
100 hrs
100 hrs
20 hrs
12 months
12 months
Monthly
1000 (1600)
1000 (1600)
200 (320)
Inspect for abrasion, routing, security
Inspect
Ignition Timing
Battery
Check terminals; Clean; Check fluid level
Adjust if Necessary
Headlight Aim
Headlamp Inspection
As required
Daily
As required
Daily
Check operation daily; Apply Nyogelt Grease
to connector when lamp is replaced
Tail Lamp Inspection
Daily
Daily
Check Operation Daily; Apply Nyogelt Grease
to socket when lamp is replaced
2.2
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MAINTENANCE
PERIODIC MAINTENANCE CHART, CONT.
CHASSIS
Frequency
(Whichever comes first)
Item
Hours
Calendar
Miles
(Km)
Remarks
"
"
"
H
General Lubrication
50 hrs
3 months
6 months
12 months
12 months
12 months
500 (800)
500 (800)
1000 (1600)
Lubricate All Fittings, Pivots, Cables, Etc.
Check monthly
Front Hubs/Fluid Check
Front Hubs/Fluid Change
Front Wheel Bearings (2x4)
50 hrs
100 hrs
Annually
Annually
Check monthly
Inspect and replace if necessary
H
Front Hub Spindle Nut Torque
(AWD Models)
Inspect Torque and Locking Fastener and re-
place if necessary
Drive Belt
50 hrs
6 months
12 months
Monthly
500 (800)
1000 (1600)
250 (400)
500 (800)
500 (800)
Inspect - Adjust, Replace if Necessary
Inspect, Clean
Clutches (Drive And Driven)
Transmission Oil Level
Shift Linkage
100 hrs
25 hrs
"
Inspect Monthly; Change Annually
Inspect,Lubricate, Adjust
Inspect Daily, Lubricate
50 hrs
6 months
6 months
As required
H
H
Steering
50 hrs
Toe Adjustment
As required
Periodic Inspection, Adjust When Parts are Re-
placed
"
"
"
Rear Axle
50 hrs
6 months
6 months
6 months
6 months
Pre-ride
24 months
Pre-ride
Pre-ride
Monthly
500 (800)
500 (800)
500 (800)
500 (800)
Inspect Bearings, Grease Fitting
Inspect - Lubricate
Front Suspension
Rear Suspension
Drive Chain
50 hrs
50 hrs
Inspect - Lubricate
50 hrs
Inspect Daily, Adjust and Lubricate if Needed
Inspect Daily, Pre-Ride Inspection Item
Change Every Two Years
Tires
Pre-ride
200 hrs
Pre-ride
Pre-ride
10 hrs
H
"
"
H
Brake Fluid
2000 (3200)
100 (160)
Brake Fluid Level
Brake Lever Travel
Brake Pad Wear
Auxiliary Brake Adjustment
Output Shaft Bearing
Brake System
Inspect Daily, Pre-Ride Inspection Item
Inspect Daily, Pre-Ride Inspection Item
Inspect Periodically
As required
Monthly
Pre-ride
Pre-ride
Pre-ride
As required
Monthly
Inspect Deflection Daily; Adjust
Grease Monthly
Pre-ride
Pre-ride
Pre-ride
Pre-Ride Inspection Item
Wheels
Pre-Ride Inspection Item
Frame Nuts, Bolts, Fasteners
Pre-Ride Inspection Item
PRE-RIDE / DAILY INSPECTION
Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
G
G
G
G
G
G
G
G
G
G
G
G
Tires - check condition and pressures
Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank
All brakes - check operation and adjustment (includes auxiliary brake)
Throttle - check for free operation and closing
Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
Engine stop switch - check for proper function
Wheels - check for tightness of wheel nuts and axle nuts; be sure axle nuts are secured by cotter pins
Drive chain - condition and slack; refer to drive chain adjustment
Air cleaner element - check for dirt; 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 - check for proper level at the recovery bottle
2.3
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MAINTENANCE
POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS
Part No.
Description
Engine Lubricant
2870584
Loctitet 680-Retaining Compound (10
ml.)
2870587
Loctitet 518 Gasket Eliminator / Flange
Sealant (50 ml.) (10 Count)
2870791
2871281
Fogging Oil (12 oz. Aerosol)
Engine Oil (Quart) Premium 4 Synthetic
0W--40 (4--Cycle) (12 Count)
2872113
2871326
Disk Brake Quiet (12 oz.) (12 Count)
Premium Carbon Clean (12 oz.) (12
Count)
2871844
2871567
Engine Oil (Gallon) Premium 4 Synthetic
0W--40 (4--Cycle) (4 Count)
2870652
2871957
Fuel Stabilizer (16 oz.) (12 Count)
Engine Oil (16 Gallon) Premium 4
Synthetic 0W--40 (4--Cycle)
Black RTV Silicone Sealer (3 oz. tube)
(12 Count)
Gearcase / Transmission Lubricants
2873603
Premium Synthetic Gearcase Lubricant (1
Gal.) (4 Count)
2871958
Black RTV Silicone Sealer (11 oz.
cartridge) (12 Count)
2873602
2871653
2871653
Premium Synthetic Gearcase Lubricant
(12 oz. bottle) (12 Count)
2870990
2872113
DOT3 Brake Fluid (12 Count)
Disc Brake Quiet, Aerosol, (9 oz.) (12
Count)
Premium Front Gearcase Fluid (8 oz.) (12
Count)
2871557
2872893
Crankcase Sealant, 3-Bond 1215 (5oz.)
Engine Degreaser (12oz.) (12 Count)
Premium Front Gearcase Fluid (2.5 Gal)
(2 Count)
2870465
2871654
Oil Pump for 1 Gallon Jug
NOTE: The number count indicated by each part
number in the table above indicates the number of
units that are shipped with each order.
Premium Drive Hub Fluid (8 oz.) (12
Count)
2872277
2871653
Premium Drive Hub Fluid (2.5 gal.) (2
Count)
NOTE: Each item can be purchased separately at
your local Polaris dealer.
Angle Drive Fluid (8 oz.)
Grease / Specialized Lubricants
2871322
2871423
Premium All Season Grease (3 oz.
cartridge) (24 Count)
Premium All Season Grease (14 oz.
cartridge) (10 Count)
2871460
2871515
2871551
2871312
2871329
Starter Drive Grease (12 Count)
Premium U-Joint Lube (3 oz.) (24 Count)
Premium U-Joint Lube (14 oz.) (10 Count)
Grease Gun Kit
Dielectric Grease (Nyogelt)
Coolant
2871323
2871534
60/40 Coolant (Gallon) (6 Count)
60/40 Coolant (Quart) (12 Count)
Additives / Sealants / Thread Locking Agents /
Misc.
2870585
2871956
Loctitet Primer N, Aerosol, 25 g
Loctitet Thread Sealant 565 (50 ml.) (6
Count)
2871949
2871950
2871951
2871952
2871953
2871954
Loctitet Threadlock 242 (50 ml.) (10
Count)
Loctitet Threadlock 242 (6 ml.) (12
Count)
Loctitet Threadlock 262 (50 ml.) (10
Count)
Loctitet Threadlock 262 (6 ml.) (12
Count)
Loctitet Threadlock 271 (6 ml.) (12
Count)
Loctitet Threadlock 271 (36 ml.) (6
Count)
2.4
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MAINTENANCE
RECOMMENDED MAINTENANCE PRODUCTS - QUICK
REFERENCE
Item
Type
Notes
See
Pages
Engine Oil
Polaris Premium 4
Synthetic, 0W--40
Add to proper level on dipstick.
2.17-2.18
Transmission
Brake Fluid
Polaris Synthetic Gear
Case Lubricant
Refer to procedures outlined later in this
chapter.
2.8
Polaris DOT 3 Brake Fluid Fill to indicated level inside reservoir.
2.23
MAINTENANCE QUICK REFERENCE
Ill.
#
Item
Lube Rec.
Method
Frequency*
1
Engine Oil
Polaris 0W--40
Synthetic
Add oil to proper level.
Change after 1st month, 6 months or 100
hours thereafter; Change more often (25-50
hours) in extremely dirty conditions, or short
trip cold weather operation.
2
3
4
Transmission Polaris Synthet- Add lube to FULL level on dip-
Change annually ©
ic Gear Case
Lubricant
stick.
Brake Fluid
Drive Chain
Polaris DOT 3
Brake Fluid
Fill master cylinder reservoir to in- As required. Change fluid every 2 years.
dicated level inside reservoir. See
Page 2.23.
Polaris Chain
Lube or O-Ring ers.
chain lube
Apply to chain link plates and roll- As required*
Transmission
Dipstick
Dipstick
Operatin
Range
ull
1. Engine Oil
2. Transmission
Parking Brake Lock
Reservoir
3. Brake Fluid
4. Rear Drive Chain
2.5
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MAINTENANCE
MAINTENANCE QUICK REFERENCE CONT’D
8. Rear Axle Bearings
7. Tie Rod End
9. Swing Arm
Bushings
5. Front
Wheel
Bearings
6. Ball Joint
Ill.
#
Item
Lube Rec.
Method
Frequency*
5
6
7
8
9
Front Wheel Bear-
ings
Sealed; Replace
Inspect and replace bearings if necessary
Annually ©
Ball Joint
Polaris All Season
Grease¢
Locate grease fitting on back side of struts and
grease with grease gun.
Semi-annually
¡
Tie Rod Ends
Polaris All Season
Grease¢
Lift boot. Clean away dirt and grease. Apply fresh
grease by hand and reassemble.
Semi-annually
¡
Rear Axle Bearings Polaris All Season
Grease¢
Locate grease fitting on eccentric and grease with
grease gun.
Semi-annually
¡
Swing Arm Bush-
ings
Polaris All Season
Grease¢
Locate grease fitting on swing arm and grease with
grease gun.
Semi-annually
¡
* More often under severe use, such as operated in water or under severe loads.
¡
©
Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
¢ Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or
Mobilegrease Special
2.6
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MAINTENANCE
SPECIAL TOOLS
PART NUMBER
PA--44689
2870872
TOOL DESCRIPTION
Valve Clutch Adjuster
CHAPTER TOOL USED IN
2
2, 5
2,10
3
Shock Spanner Wrench
Tachometer
8712100DX or 8712500
2200634
Valve Seat Reconditioning Kit
Piston Support Block
2870390
3
2870159
Flywheel Puller
3
2871293
Slotted Nut Socket
3
PV--43527
2872314
OIl Filter Wrench
3
Carburetor Float Adjustment Tool
Mity Vact Pressure Test Tool
Ball Joint Replacement Tool
Shock Absorber Spring Compression Tool
Strut Rod Wrench
4
2870975
4, 9
5
2870871
2870623
5
2871572
5
2871573
LH Strut Spring Compressor
RH Strut Spring Compressor
Clutch Puller
5
2871574
5
2870506
6
9314177
Clutch Holding Wrench
Clutch Holding Fixture
Drive Clutch Spider Removal and Install Tool
Clutch Offset Alignment Tool
Driven Clutch Puller
6
2871358
6
2870341
6
2870654
6
2870913
6
2870910
Roller Pin Tool
6
2871226
Clutch Bushing Replacement Tool Kit
Piston Pin Puller
6
2870386
6
8700220
Clutch Compression Tool
10” Center Distance Tool
Fluket77 Digital Multimeter
Timing Light
6
2871710
8
PV--43568
2870630
10
10
10
10
2870836
Battery Hydrometer
8712100 or 8712500
Tachometer
NOTE: Polaris dealers can order the tools listed above through the SPX Service Tools catalog.
2.7
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MAINTENANCE
TRANSMISSION LUBRICATION TRANSMISSION FLUID
CHANGE/TORQUE STOP
ADJUSTMENT
The transmission lubricant level should be checked
and changed in accordance with the maintenance
schedule.
1. Remove skid plate (if necessary).
G
G
G
Be sure vehicle is level before
proceeding.
2. Place a drain pan beneath the transmission oil
drain plug area.
Check vent hose to be sure it is
routed properly and unobstructed.
3. Loosen jam nut (A).
Follow instructions on following
4. Turn adjuster bolt (B) in to allow the removal of
drain plug.
pages
transmission lubricant.
to
check
/
change
5. Remove the drain plug and wipe the magneticend
clean to remove accumulated metallic filings.
TRANSMISSION SPECIFICATIONS
6. After the oil has drained completely, install a new
sealing washer and install the drain plug. Torque
to 14 ft. lbs. (19.3 Nm).
Specified Lubricant:
Polaris Premium Synthetic Gearcase Lubricant
7. Turn adjuster bolt (B) out until it touches the
frame, and then an additional 1/2 turn.
(PN 2871477) (Gallon) (PN 2871478) (12 oz.)
Capacity: 11.3 oz. (335 ml)
Drain Plug / Fill Plug Torque:
PVT Cover
Drain Plug
B
14 ft. lbs. (19.4 Nm)
Transmission
Dipstick
A
Forward
8. Tighten the jam nut securely while holding the
adjuster bolt.
9. Add the proper lubricant through the dipstick hole
until the oil level is between the upper and lower
limits. Do not overfill.
To check the level:
1. Remove dipstick and wipe clean.
10. Check for leaks.
2. Reinstall dipstick completely, remove and check
the level. Add the proper lubricant as required to
bring level into operating range as shown.
11. Reinstall skid plate if removed in Step 1.
Full
Operating
Range
2.8
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MAINTENANCE
TRANSMISSION GEARSHIFT
LINKAGE ADJUSTMENT/
INSPECTION
SHIFT LINKAGE
ADJUSTMENT
1. Inspect shift linkage tie rod ends, clevis and pivot
bushings and replace if worn or damaged.
Linkage rod will rotate
1/8 -1/4 turn if rod ends
are tightened properly.
2. Place gear selector in neutral.
3. Loosen rod end adjuster jam nuts (A) on both
ends of linkage rod. NOTE: The jam nut closest
to the knurled end is Left Hand thread.
Parallel
Incorrectly Tightened
Jam Nut
Correctly Tightened
Jam Nut
Jam Nuts (A)
G
G
If shifting problems are encountered,
the transmission linkage may require
adjustment.
Linkage Rod
Ill. 1
Visually check for contact of shift
lever to shifter opening in the front
fender. Ensure shift linkage or shift
lever is not contacting the frame or
exhaust components.
4. Turn linkage rod (A) to shorten or lengthen rod
until the shift lever is centered on hole in the fender.
G
G
G
Tighten shift linkage rod end jam nuts
properly after adjustment.
You
should be able to rotate the linkage
rod between 1/8 and 1/4 turn after
both jam nuts are tight.
The transmission shift linkage
should be periodically inspected for
wear and parts replaced as required
to remove excess play from shift
linkage.
Refer to Transmission chapter for
more information.
A
NOTE: The rod end must be held when tightening the
jam nut to prevent damage to the rod end.
5. Hold rod end parallel to mounting surface and
tighten jam nuts securely.
2.9
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MAINTENANCE
THROTTLE OPERATION - ALL
MODELS
PILOT SCREW (IDLE
MIXTURE) ADJUSTMENT
Check for smooth throttle opening and closing in all
handlebar positions. Throttle lever operation should
be smooth and lever must return freely without
binding.
NOTE: These procedures are intended as reference
only. Actual final settings may be different depending
on the atmospheric conditions in your area.
1. 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.
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.
FRONT
(Engine)
CHOKE (ENRICHER)
ADJUSTMENT
Pilot Screw
Pilot Screw Adjustment:
2.0 Turns
2. 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).
3. Start engine and warm it up to operating
temperature (about 10 minutes).
Boot
4. Set idle speed to 1300 RPM. Always check
throttle cable freeplay after adjusting idle speed
and adjust if necessary.
If the choke knob does not stay out when pulled,
adjust the choke tension by tightening the tensioner
located under the rubber boot between the choke
knob and nut. Firmly grasp the rubber boot and
tighten until the choke slides freely but stays out when
pulled.
5. Slowly turn mixture screw clockwise using the
pilot screw wrench until engine begins to miss.
6. Slowly turn mixture screw counterclockwise until
idle speed increases to maximum RPM.
Continue turning counterclockwise until idle RPM
begins to drop.
Verify free play of 1/16--3/16” (1.6--4.76 mm) and
smooth operation of choke cable.
7. Center the pilot screw between the points in Step
5 and 6.
If smooth choke operation is not obtainable, inspect
choke cable for kinks or sharp bends in routing.
8. Re adjust idle speed if not within specification.
2.10
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MAINTENANCE
3. Tighten locknut and slide boots over cable
adjuster until they touch at the middle point of the
adjuster.
IDLE SPEED ADJUSTMENT
1. Start engine and warm it up thoroughly.
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.
CV Carburetor
THROTTLE OPERATION
To remove the ETC cover:
1. Use a medium flat blade screwdriver and insert
blade into the pockets of the cover starting on the
#1 position.
Idle Screw
Idle Speed:
2
3
1
4
1300 M 100 RPM
2. Adjust idle speed by turning the idle adjustment
screw in (clockwise) to increase or out
(counterclockwise) to decrease RPM. (Refer to
Ill. at right).
6
NOTE: Adjusting the idle speed affects throttle cable
freeplay and electronic throttle control (ETC)
adjustment. Always check throttle cable freeplay
after adjusting idle speed and adjust if necessary.
5
2. Twist screwdriver slightly while lifting on the cover
to release snap.
ELECTRONIC THROTTLE
CONTROL (ETC SWITCH)/
THROTTLE CABLE
3. Repeat procedure at the other five locations as
shown. NOTE: Do not attempt to remove cover
until all latch points are released.
Check for smooth throttle opening and closing in all
handlebar positions. Throttle lever operation should
be smooth and lever must return freely without
binding. Replace the throttle cable if worn, kinked, or
damaged.
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 1/16N - 1/8N
freeplay is achieved at the thumb lever. After
making any adjustment, “flip” the lever slightly to
confirm adjustment.
Lock-
nut
Boot
Boot
Adjuster
Sleeve
NOTE: When replacing the cover, check for correct
placement of cover O-ring.
Direction
of travel
1/16N - 1/8N
Freeplay
2.11
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MAINTENANCE
FUEL SYSTEM
VENT LINES
1. Check fuel tank, oil tank, carburetor, battery and
transmission vent lines for signs of wear,
deterioration, damage or leakage. Replace every
two years.
WARNING
Gasoline is extremely flammable and explosive
under certain conditions.
2. Be sure vent lines are routed properly and
secured with cable ties. CAUTION: Make sure
lines are not kinked or pinched.
G
Always stop the engine and refuel
outdoors or in a well ventilated area.
G
Do not smoke or allow open flames
or sparks in or near the area where
refueling is performed or where
gasoline is stored.
FUEL FILTER
The fuel filter should be replaced in accordance with
the Periodic Maintenance Chart.
G
G
Do not overfill the tank. Do not fill the
tank neck.
1. Shut off fuel supply at fuel valve.
2. Remove line clamps at both ends of the filter.
3. Remove fuel lines from filter.
If you get gasoline in your eyes or if
you swallow gasoline, seek medical
attention immediately.
4. Install new filter and clamps onto fuel lines with
arrow pointed in direction of fuel flow.
G
G
If you spill gasoline on your skin or
clothing, immediately wash it off with
soap and water and change clothing.
Never start the engine or let it run in
an enclosed area. Engine exhaust
fumes are poisonous and can result
loss of consciousness or death in a
short time.
Arrow Indicates Direction
of Flow
G
Never drain the float bowl when the
engine is hot. Severe burns may
result.
To Carburetor
FUEL LINES
5. Install clamps on fuel line.
6. Turn fuel valve ON.
Fuel Lines
7. Start engine and inspect for leaks.
Pulse Line
CARBURETOR DRAINING
The carburetor float bowl should be drained
periodically to remove moisture or sediment from the
bowl, or before extended periods of storage.
Fuel Pump
Fuel Filter
Ill.1
1. Check fuel lines for signs of wear, deterioration,
damage or leakage. Replace if necessary.
2. Be sure fuel lines are routed properly and secured
with cable ties. CAUTION: Make sure lines are
not kinked or pinched.
Drain tube
attached
here
3. Replace all fuel lines every two years.
Drain Screw
2.12
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MAINTENANCE
NOTE: The bowl drain screw is located on the bottom
left side of the float bowl.
Cylinder Compression
Standard 70--90 PSI
1. Turn fuel valve to the off position.
2. Place a clean container beneath the bowl drain
spigot or bowl drain hose.
Cylinder Leakage
Service Limit: 10 %
(Inspect for cause if leakage exceeds 10%)
RES
OFF
ENGINE MOUNTS
Inspect rubber engine mounts for cracks or damage.
ON
ENGINE FASTENER TORQUE
Fuel Valve
Check engine fasteners and ensure they are tight.
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.
BATTERY MAINTENANCE
6. Turn fuel valve to “ON”.
7. Start machine and check for leaks.
WARNING
NOTE: If there is a tube attached, it must be
reattached as this will effect engine performance.
Battery electrolyte is poisonous. It contains
sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing. Anti-
dote:
COMPRESSION TEST
NOTE: This Polaris 4-Stroke engine is equipped with
an automatic decompressor. Compression readings
will vary in proportion to cranking speed during the
test. Average compression (measured) is about
70--90 psi during a compression test.
External: Flush with water.
Internal: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten
egg, or vegetable oil. Call physician im-
mediately.
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.
Eyes: Flush with water for 15 minutes and
get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc. away. Venti-
late when charging or using in an enclosed
space. Always shield eyes when working
near batteries. KEEP OUT OF REACH OF
CHILDREN.
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).
NOTE: All 2003 Trail Boss ATV batteries are
Maintenance--Free design and construction. All
Maintenance--Free batteries are fully charged and
tested at the factory before installation. Expected
shelf life is 6--8 months depending on storage
conditions. As a general rule before placing the
battery into service, check the battery condition
and charge accordingly .
2.13
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MAINTENANCE
Maintenance--Free batteries are permanently
sealed at the time of manufacture. The use of
lead--calcium and AGM technology instead of
lead--antimony allows the battery acid to be fully
absorbed. For this reason, a Maintenance--Free
battery case is dark and the cell caps are not
removable, since there is no need to check
electrolyte level.
SPARK PLUG
1. Remove spark plug high tension lead. Clean plug
area so no dirt and debris can fall into engine
when plug is removed.
2. Remove spark plug.
3. Inspect electrodes for wear and carbon buildup.
Look for a sharp outer edge with no rounding or
erosion of the electrodes.
4. Clean with electrical contact cleaner or a glass
bead spark plug cleaner only. CAUTION: A wire
brush or coated abrasive should not be used.
5. Measure gap with a wire gauge. Refer to
specifications for proper spark plug type and gap.
Adjust gap if necessary by bending the side
electrode carefully.
NEVER attempt to add electrolyte or water to a
Maintenance--Free battery. Doing so will damage
the case and shorten the life of the battery. Refer
to the Battery Maintenance Video (PN 9917987) for
proper instruction on servicing Maintenance--Free
batteries.
The battery is located under the left rear fender.
B
A
Spark Plug Gap
.036N (.9 mm)
6. If necessary, replace spark plug with proper type.
CAUTION: Severe engine damage may occur if
the incorrect spark plug is used.
Battery
7. Apply a small amount of anti-seize compound to
the spark plug threads.
8. Install spark plug and torque to 14 ft. lbs.
To remove the battery:
1. Disconnect holder strap (A) and remove cover
(B).
Recommended Spark Plug:
NGK BKR6E
2. Disconnect battery negative (-) (black) cable first,
followed by the positive (+) (red) cable.
CAUTION
Spark Plug Torque: 14 Ft. Lbs. (19 Nm)
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.
IGNITION TIMING
Refer to Electrical chapter for ignition timing
procedure.
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.
Ignition Timing:
30LM2L BTDC@5000RPM
6. Coat terminals and bolt threads with Dielectric
Grease (PN 2871329).
7. Reinstall battery cover and holder strap.
2.14
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MAINTENANCE
ENGINE-TO-FRAME GROUND
AIR FILTER/PRE-FILTER
SERVICE
Inspect engine-to-frame ground cable connection. Be
sure it is clean and tight.
It is recommended that the air filter and pre filter be
replaced annually. When riding in extremely dusty
conditions, replacement is required more often.
Engine Ground Strap
The pre filter should be cleaned before each ride using
the following procedure:
1. Lift up on the rear of the seat.
2. Pull the seat back and free of the tabs. NOTE:
When reinstalling seat, make sure the slots in the
seat engage the tabs in the fuel tank.
3. Remove clips from air box cover (A) and remove
cover. Inspect the gasket (E). It should adhere
tightly to the cover and seal all the way around.
4. Loosen clamp and remove air filter assembly (B &
C).
C
A
MAIN AIR FILTER CLEANING
B
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.
E
G
Never immerse the filter in water
since dirt can be transferred to the
clean air side of the filter.
G
If compressed air is used never
exceed a pressure of 40 PSI. Always
use a dispersion type nozzle to
prevent filter damage and clean from
the inside to the outside.
Cleaning:
G
Replace the air filter every 50 hours,
and possibly more often in very dirty
conditions.
5. Slip the pre-filter element (C) off of main element.
Clean the pre filter with high flash point solvent,
followed by hot soapy water.
6. Rinse and dry thoroughly.
7. Inspect element for tears or damage.
8. Apply foam filter oil or clean engine oil and
squeeze until excess oil is removed.
9. Inspect main filter and replace if necessary. If the
filter has been soaked with fuel or oil it must be
replaced.
Installation:
10. Reinstall pre-filter element over main filter. Be
sure the element covers entire surface of main
filter without folds, creases, or gaps.
11. Reinstall filter on main filter mount. Place filter
clamp over the assembly and tighten.
2.15
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MAINTENANCE
NOTE: Apply a small amount of general purpose
grease to the sealing edges of the filter before
reinstalling.
Filter Clamp
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.
ILL.1
1. Remove drain plug from end of sediment tube.
2. Drain tube.
Proper Filter Placement
Main Filter
3. Reinstall drain plug.
RECOIL HOUSING
Filter Support
Air Box
0
Drain the housing periodically to
remove moisture.
Crankcase Drain
Ill.3
Front
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.
Recoil Drain
Drain the recoil housing after
1. Install air box cover and secure with clips.
0
operating the ATV in very wet
conditions. This should also be done
before storing the ATV. The drain
screw is located at the bottom of the
recoil housing. Remove the screw
with a 10mm wrench. Reinstall
screw once housing has been
drained.
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.
0
CAUTION: Make sure the manual
start handle is fully seated on the
recoil housing, especially when
travelling in wet areas. If it is not
sealed properly, water may enter the
recoil
housing
and
damage
components.
2.16
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MAINTENANCE
sealed properly, water may enter the
recoil housing and damage
components.
ENGINE OIL LEVEL
To check the oil level:
G
G
G
G
Water will enter the recoil housing if
the starter handle is disengaged
from the rope guide when under
water.
1. Set machine on a level surface.
2. Start and run engine for 20-30 seconds. This will
return oil to its true level in the engine sump.
3. Stop engine, remove dipstick and wipe dry with a
clean cloth.
After travelling in wet areas, the
recoil housing and starter should
always be drained completely by
removing the recoil.
4. Reinstall dipstick, screwing into place.
5. The dipstick must be screwed completely in to
ensure accurate measurement.
Do not open the crankcase drain
unless the engine has ingested
water. Some engine oil will be lost if
crankcase drain is opened.
6. Remove dipstick and check to see that the oil
level is in the normal range. The oil should be
between the top of the bottom crosshatched area
and the bottom of the top crosshatched area. Add
oil as indicated by the level on the dipstick. Do not
overfill.
If recoil handle seal has been
damaged, the handle assembly
should be replaced.
PVT DRAIN PLUG & DRYING
Normal Oil Operating
Range is between crosshatch.
NOTE: If operating the ATV in or through water, be
sure to check the PVT cover and other components
for water ingestion. The ATV should be checked
immediately.
1. To release any water that maybe trapped in the
PVT cover, simply remove the PVT drain plug and
O--ring located on the bottom of the PVT cover
and let the water drain out. The PVT drain plug is
shown below.
Crosshatch Areas of Dipstick
NOTE: Do not fill the over the normal oil operating
range. Filling over the normal operating range could
cause a mist of oil to enter the air box.
NOTE: Rising oil level between checks in cool
weather driving, can indicate moisture collecting inthe
oil reservoir. If the oil level is over the full mark,
change the oil.
PVT Drain Plug & O--ring
Ill.3
Recommended Engine Oil:
2. To further expel water from the cover and to dry
out the PVT system, shift the transmission to
neutral and rev engine slightly to expel the
moisture and air-dry the belt and clutches. Allow
engine RPM to settle to idle speed, shift
transmission to lowest available range and test
for belt slippage. Operate ATV in lowest available
range for a short period of time until PVT system
is dry.
Polaris Premium 4 All Season
Synthetic, 0W-40 (PN 2871281)
Ambient Temperature Range:
-40L F to 120L F
2.17
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MAINTENANCE
8. The oil filter is located on the right side of the
machine. Place shop towels beneath oil filter.
Using an oil filter wrench, turn filter
counterclockwise to remove.
OIL AND FILTER CHANGE
1. Place vehicle on a level surface.
2. Clean area around drain plug at bottom of oil pan.
3. Run engine two to three minutes until warm. Stop
engine.
4. Place a drain pan beneath oil pan and remove
drain plug from under the crankcase. CAUTION:
Oil may be hot. Do not allow hot oil to come into
contact with skin as serious burns may result.
5. Allow oil to drain completely.
NOTE: It is not necessary to drain the oil from the oil
cooler, unless contaminants, water, or debris are
found in the crankcase oil.
6. Replace sealing washer (A) on drain plug. NOTE:
The sealing surfaces on drain plug and oil tank
should be clean and free of burrs, nicks or
scratches.
9. Using a clean dry cloth, clean filter sealing surface
on crankcase.
10. Lubricate O-ring on new filter with a film of engine
oil. Check to make sure the O-ring is in good
condition.
7. Reinstall drain plug and torque to 14 ft. lbs. (19
Nm).
11. Install new filter and turn by hand until filter gasket
contacts the sealing surface, then turn and
additional 1/2 turn.
NOTE: The sealing surfaces on the drain plug and
crankcase should be clean and free of burrs, nicks or
scratches.
12. Remove dipstick and fill tank with 2 quarts (1.9 l)
of Polaris Premium 4 Synthetic Oil (PN 2871281).
13. Place gear selector in neutral and set parking
brake.
14. Start the engine and let it idle for one to two
minutes. Stop the engine and inspect for leaks.
15. Re-check the oil level on the dipstick and add oil
as necessary to bring the level to the upper mark
on the dipstick.
Drain plug located under the engine.
Crankcase Drain
16. Dispose of used filter and oil properly.
Crankcase Drain Plug Torque:
14 ft. lbs. (19 Nm)
Oil Filter Torque:
Turn by hand until filter gasket
contacts sealing surface, then
turn an additional 1/2 turn
Oil Filter Wrench:
(PV--43527)
Engine Sump Drain Plug - Bottom View
2.18
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MAINTENANCE
VALVE CLEARANCE
Inspect and adjust valve clearance while the engine
is cold and the piston positioned at Top Dead Center
(TDC) on compression stroke.
1. Remove the seat.
2. Remove body panels and fuel tank as necessary
to gain access to valve cover.
3. Remove the spark plug high tension lead and
remove the spark plug. CAUTION: Place a clean
shop towel into the spark plug cavity to prevent
dirt from entering.
4. Remove plastic valve plugs.
330 Valve Plugs
INTAKE VALVE CLEARANCE
ADJUSTMENT
1. Insert a .006N (.15mm) feeler gauge between end
of intake valve stem and clearance adjuster
screw.
2. Using Valve/Clutch Adjuster (PA--44689), loosen
adjuster lock nut and turn adjusting knob until
there is a slight drag on the feeler gauge.
330 Engine
5. Remove timing inspection plug from recoil
housing.
CAUTION: Failure to position the crankshaft at TDC
on compression stroke will result in improper valve
adjustment.
6. Rotate engine slowly with recoil rope, watching
the intake valve(s) open and close.
NOTE: Observe the intake valve closing and then
start to open, continue to rotate until the “T” aligns with
pointer. The camshaft lobes should be pointing
downward.
3. Hold adjuster screw and tighten adjuster lock nut
securely.
7. Verify accurate TDC positioning by observing the
“T” mark aligned with the pointer in the timing
inspection hole. In this position there should be
clearance on all valves.
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until
clearance is correct with locknut secured.
INTAKE VALVE CLEARANCE:
EXHAUST VALVE
CLEARANCE ADJUSTMENT
0.006M0.0008I (0.15M0.02 mm)
BTDC on compression
NOTE: The exhaust valve is adjusted thesame asthe
intake valve.
2.19
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MAINTENANCE
1. Insert .006N feeler gauge between end of exhaust
valve stem and adjuster screw.
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.
EXHAUST VALVE CLEARANCE:
0.006M0.0008I (0.15M0.02 mm)
BTDC on compression
TIE ROD END / STEERING
INSPECTION
2. Loosen locknut and turn adjuster screw until there
is a slight drag on feeler gauge.
To check for play in the tie rod end, grasp the steering
tie rod, pull in all directions feeling for movement.
3. When clearance is correct, hold adjuster screw
and tighten locknut securely
G
Repeat inspection for inner tie rod
end (on steering post).
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until
clearance is correct with locknut secured.
G
Replace
any
worn
steering
components. Steering should move
freely through entire range of travel
without binding.
6. Inspect o-rings on the plastic valve plugs, replace
if damaged. Securely fasten valve plugs.
7. Reinstall fuel tank and any body panels that were
removed to gain access.
STEERING
The steering components should be checked
periodically for loose fasteners, worn tie rod ends, and
damage. Also check to make sure all cotter pins are
in place. If cotter pins are removed, they must not be
re-used. Always use new cotter pins.
Replace any worn or damaged steering components.
Steering should move freely through entire range of
travel without binding. Check routing of all cables,
hoses, and wiring to be sure the steering mechanism
is not restricted or limited. NOTE: Whenever steering
components are replaced, check front end alignment.
Use only genuine Polaris parts.
G
Elevate front end of machine so front
wheels are off the ground. Check for
any looseness in front hub / wheel
assembly by grasping the tire firmly
at top and bottom first, and then at
front and rear. Try to move the wheel
and hub by pushing inward and
pulling outward.
WARNING
NOTE: Due to the critical nature of the procedures
outlined in this chapter, Polaris recommends steering
component repair and adjustment be performed by an
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
2.20
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MAINTENANCE
G
G
If abnormal movement is detected,
inspect the hub and wheel assembly
to determine the cause.
WHEEL ALIGNMENT
METHOD 2: CHALK
Refer to the Body/Steering or Final
Drive chapter for more information.
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 “frog” can be used as an indicator of
whether the handlebars are straight. The frog
should always point straight back from the
steering post.
CAMBER AND CASTER
The camber and caster are non-adjustable.
WHEEL ALIGNMENT METHOD:
STRAIGHTEDGE OR STRING
3. Place a chalk mark on the center line of the front
tires approximately 10N (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.
Be sure to keep handlebars centered. See notes
below.
4. Measure the distance between the marks and
record the measurement. Call this measurement
“A”.
NOTE: String should just touch side sur-
face of rear tire on each side of machine.
5. Rotate the tires 180L 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 1/8N to 1/4N (.3 to .6 cm)
toe out. This means the measurement at the front
of the tire (A) is 1/8N to 1/4N (.3 to .6 cm) wider than
the measurement at the rear (B).
Rear rim
measure-
Measure
from string
ment should
to rim at
front and
rear of rim.
be 1/16N to
1/8N (.2 to .3
cm) more
than front rim
measure-
ment.
Chalk L
Measure
“A”
Measurement “B”
used as an indicator of whether the handle-
bars are straight. The frog should always
point straight back from the steering post.
2.21
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MAINTENANCE
TOE ALIGNMENT
ADJUSTMENT
EXHAUST CLEANING
WARNING
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.
G Do not perform clean out immediately
after the engine has been run, as the ex-
haust system becomes very hot. Serious
burns could result from contact with ex-
haust 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.
G To reduce fire hazard, make sure that
there are no combustible materials in the
area when purging the spark arrestor.
G Wear eye protection.
G Do not stand behind or in front of the ve-
hicle while purging the carbon from the
spark arrestor.
To adjust toe alignment:
G
G
G
Hold tie rod end to keep it from
rotating.
G Never run the engine in an enclosed
area. Exhaust contains poisonous car-
bon monoxide gas.
Loosen jam nuts at both end of the tie
rod.
G Do not go under the machine while it is
inclined. Set the hand brake and block
the wheels to prevent roll back.
Shorten or lengthen the tie rod until
alignment is as required to achieve
the proper toe setting. Method 1
(1/16N to 1/8N) or Method 2 (1/8N to
1/4N).
Failure to heed these warnings could result in
serious personal injury or death.
G
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 may not be immediately
apparent if done incorrectly. See
illustration.
The exhaust pipe must be periodically purged of
accumulated carbon as follows:
1. Remove the clean out plugs located on the
bottom of the muffler as shown in illustration 1.
Hold
Rod End
Clean Out Plug
Ill.1
Jam Nut
Correctly
Tightened
Jam Nut
2. Place the transmission in neutral and start the
engine. Purge accumulated carbon from the
system by momentarily revving the engine
several times.
3. If some carbon is expelled, cover the exhaust
outlet and rap on the pipe around the clean out
plugs while revving the engine several more
times.
4. If particles are still suspected to be in the muffler,
back the machine onto an incline so the rear of the
machine is one foot higher than the front. Set the
hand brake and block the wheels. Make sure the
machine is in neutral and repeat Steps 2 and 3.
SEE WARNING ABOVE
2.22
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MAINTENANCE
5. If particles are still suspected to be in the muffler,
drive the machine onto the incline so the front of
the machine is one foot higher than the rear. Set
the hand brake and block the wheels. Make sure
the machine is in neutral and repeat Steps 2 and
3. SEE PREVIOUS WARNING
BRAKE PAD INSPECTION
6. Repeat Steps 2 through 5 until no more particles
are expelled when the engine is revved.
7. Stop the engine and allow the arrestor to cool.
8. Reinstall the clean out plugs.
3/64N
(.1cm)
Minimum
Thickness
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.
Pads should be changed when friction material is
worn to 3/64N(.1 cm), or about the thickness of a dime.
G
Keep fluid level in the master cylinder
reservoir to the indicated level inside
reservoir.
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.
G
Use Polaris DOT 3 Brake Fluid (PN
2870990).
Sight
Glass
Parking Brake
Lock
AUXILIARY BRAKE
ADJUSTMENT (HYDRAULIC)
Use the following procedure to inspect the hydraulic
auxiliary (foot) brake system and adjust or bleed if
necessary:
First, check foot brake effectiveness by applying 50lb.
(approx.) downward force on the pedal. The top of the
pedal should be at least 1 inch, (25.4mm) above the
surface of the footrest.
Rear Master Cylinder Reservoir
1/8, to 1/4,
Free Play
1N or greater
Max
Min
Floorboard
G
G
Check brake system for fluid leaks,
excessive travel or spongy feel.
Check friction pads for wear,
damage or looseness.
G
G
Check surface condition of the disc.
Inspect thickness of brake pad
friction material.
2.23
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MAINTENANCE
If less than one inch, two things must be examined:
To check for wear, pull outward on the chain as
shown. Replace sprocket if chain movement exceeds
1/4N (.6 cm).
Free Play:
Free play of the brake pedal should be 1/8 - 1/4
inch (3.2 - 6.35 mm).
DRIVE CHAIN INSPECTION
If free play is excessive, inspect pedal, linkage, and
master cylinder for wear or damage and replace any
parts as needed.
The chain must be replaced when it reaches 3%
elongation.
1. Stretch the chain tightly in a straight line.
Bleeding:
2. Measure a length of twenty pitches (pins) from pin
center to pin center, and compare to the
specification. Replace the chain if the length
exceeds the wear limit.
If free play is correct and brake pedal travel is still
excessive, air may be trapped somewhere in the
system. Bleed the hydraulic auxiliary brake system in
a conventional manner, following the procedure
outlined in Brake Chapter 9.
3. When replacing or reinstalling drive chain, install
the closed end of the splice link clipas shown, with
the closed end leading in forward operation.
DRIVE CHAIN AND
SPROCKET INSPECTION
Polaris ATV drive chains are equipped with O-ring
sealed permanently greased pins and rollers. The
sprockets and outer rollers require periodic
lubrication. Lubricate the chain with Polaris O-Ring
Chain Lubricant (PN 2872073).
Proper
Splicelink Clip
Opening
Position
Inspect the drive chain for missing or damaged
O-Rings, link plates, or rollers. Do not wash the chain
with a high pressure washer, gasoline or solvents; do
not use a wire brush to clean the chain as damage to
the O-Rings may occur. Clean chain with hot soapy
water and a soft bristled nylon brush.
Drive Chain Wear Limit--20 Pitch Length:
Std: 12.5N (32 cm)
Wear Limit: 12.875N (32.7 cm)
Never allow battery acid to contact the drive chain.
DRIVE CHAIN ADJUSTMENT,
CONCENTRIC SWINGARM
CAUTION: Never adjust or operate the vehicle
with the rear drive chain too loose or too tight as
severe damage to the transmission and drive
components can result.
Break-In: It is extremely important to maintain proper
chain tension to ensure the best possible chain life.
There is a chain break-in period of approximately 100
miles or two (2) tanks of fuel. During this time chain
tension should be watched very closely and loads to
the chain should be kept light.
Service Limit:
1/4N (6mm)
Drive Chain Lubricant:
Checking Deflection: Inspect chain deflection by
slowly moving the ATV forward so any slack that may
have previously been on the under part of the chain
is now on the top side of the chain. The bottom part
of the chain should be taught during inspection.
Measure the chain deflection as shown in the
diagram. Deflection should be approximately 3/8
in. (10 mm).
Polaris O-Ring Chain Lubricant
(PN 2872073)
SPROCKET INSPECTION
Inspect the sprocket for worn, broken or bent teeth.
2.24
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MAINTENANCE
After inspection, again slowly move the ATV forward
until all the chain slack is on the top side of the chain
and inspect the deflection. Repeat this procedure
several times to check different spots on the chain.
Loosen Eccentric
clamp bolts (Step 2)
The chain is correctly adjusted when the tightest
portion of the chain itself has approximately 3/8 in.,
(10 mm) of deflection. It’s a common characteristic of
any chain to have one or more tight spots in the chain.
Therefore, it is extremely important to check chain
deflection in several areas of the chain to ensure
deflection is correct at the tightest point.
Loosen (2) caliper
mounting bracket
bolts (Step 3)
4. Insert a pin punch through the sprocket hub and
into the eccentric axle housing.
5. Move the ATV forward or back to move the
eccentric housing and adjust to the proper tension
(Approximately: 3/8” , or 10 mm)
Pin Punch
6. Tighten the eccentric clamp bolts to specification.
Eccentric Clamp With Hitch
3/8N (10 mm) Deflection
ADJUSTMENT PROCEDURE -
CONCENTRIC SWINGARM
1. Loosen chain guide.
Torque the nut
2. Loosen the two (2) eccentric clamp bolts.
3. Loosen caliper mounting bracket bolts located
under the axle.
WITH TRAILER HITCH - 45 ft. lbs. (61 Nm)
See illustration for bolt locations.
2.25
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MAINTENANCE
CAUTION: DO NOT OVER-TIGHTEN ECCENTRIC
CLAMP BOLTS. PRE-MATURE BEARING
FAILURE MAY RESULT.
Loosen
Eccentric Clamp Without Hitch
Tighten
SUSPENSION SPRING
PRELOAD ADJUSTMENT
Torque the nut
WITHOUT TRAILER HITCH - 30 ft. lbs. (41 Nm)
Operator weight and vehicle loading affect
suspensionspringpreloadrequirements.Adjustas
necessary to avoid bottoming of the shocks.
7. Tighten caliper mounting bracket bolts 10-12 ft.
lbs. (14 - 17 Nm)
FRONT SUSPENSION
Caliper Mount Bracket
Compress and release front suspension. Damping
should be smooth throughout the range of travel.
Check all front suspension components for wear or
damage.
Inspect front strut cartridges for leakage.
REAR SUSPENSION
Compress and release rear suspension. Damping
should be smooth throughout the range of travel.
10-12 ft. lbs
Rea
Adjus
8. Remove pin punch.
9. Roll ATV forward checking chain tension at the
same point in several places around the chain.
The chain is adjusted correctly when the
tightest portion of the chain has
approximately 3/8 in. (10 mm) of deflection.
10. Position chain guide to allow 1/8” (3.175 mm),
clearance and tighten retaining bolt to 5 ft.lbs (7
Nm).
G
G
Check
all
rear
suspension
components for wear or damage.
The chain can also be adjusted by loosening the rear
eccentric housing as described previously and using
a 2 1/2” (63.5 mm) wrench on the flats of the eccentric.
Turn the eccentric with the wrench until chain tension
is to specification.
Inspect shock for leakage.
Shock Spanner Wrench
(PN 2870872)
2.26
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MAINTENANCE
4. Remove the wheel nuts and remove the wheel.
CONTROLS
Check controls for proper operation, positioning
and adjustment.
Tapered nuts - install with
tapered side against wheel
G
Brake control and switch must be
positioned to allow brake lever to
travel throughout entire range
without contacting switch body.
WHEELS
Flange Nuts:
Flat side against wheel
Inspect all wheels for runout or damage. Check wheel
nuts and ensure they are tight. Do not over tighten the
wheel nuts.
WHEEL INSTALLATION
1. With the transmission in gear and the parking
brake locked, place the wheel in the correct
position on the wheel hub. Be sure the valve stem
is toward the outside and rotation arrows on the
tire point toward forward rotation.
WHEEL, HUB, AND SPINDLE
TORQUE TABLE
Item
Specification
20 Ft. Lbs. (27 Nm)
50 Ft. Lbs. (68 Nm)
40 Ft Lbs. (54Nm)
80 Ft. Lbs. (108 Nm)
2. Attach the wheel nuts and finger tighten them.
3. Lower the vehicle to the ground.
Front Wheel Nuts
Rear Wheel Nuts
Front Spindle Nut
Rear Hub Retaining Nut
4. Securely tighten the wheel nuts to the proper
torque listed in the table above.
CAUTION:
If wheels are improperly installed it could affect
vehicle handling and tire wear. On vehicles with
tapered rear wheel nuts, make sure tapered end of nut
goes into taper on wheel.
WHEEL REMOVAL FRONT OR
REAR
1. Stop the engine, place the transmission in gear
and lock the parking brake.
2. Loosen the wheel nuts slightly.
3. Elevate the side of the vehicle by placing a
suitable stand under the footrest frame.
2.27
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MAINTENANCE
TIRE PRESSURE
FRAME, NUTS, BOLTS,
FASTENERS
Tire Pressure Inspection (PSI - Cold)
Periodically inspect the tightness of all fasteners in
accordance with the maintenance schedule. Check
that all cotter pins are in place. Refer to specific
fastener torques listed in each chapter.
Front
Rear
4
3
TIRE INSPECTION
WARNING
Operating an ATV with worn tires will increase
the possibility of the vehicle skidding and pos-
sible loss of control.
Worn tires can cause an accident.
Always replace tires when the tread depth
measures 1/8N (.3 cm) or less.
CAUTION:
G
Maintain proper tire pressure. Refer
to the warning tire pressure decal
applied to the vehicle.
G
G
G
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.
Tire Tread Depth
Always replace tires when tread depth is worn to
1/8N (3 mm) or less.
Tread
8I (3 mm)
2.28
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ENGINE
CHAPTER 3
ENGINE
Engine Service Data . . . . . . . . . . . . . . . . . . . . . . . . . 3.2-3.3
Special Tools and Torque Specifications . . . . . . . . 3.4
Torque Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Piston Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . 3.6
Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6-3.7
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7-3.8
Lubrication/Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8-3.9
Engine Exploded View . . . . . . . . . . . . . . . . . . . . . . . 3.10
Engine Top End Disassembly . . . . . . . . . . . . . . . . . 3.11-3.18
Valve/ Valve Seat Service . . . . . . . . . . . . . . . . . . . . 3.18-3.22
Engine Bottom End Disassembly . . . . . . . . . . . . . . 3.22-3.32
Crankcase & Bearing Assembly . . . . . . . . . . . . . . . 3.32
Crankshaft End Play Inspection . . . . . . . . . . . . . . . 3.32-3.33
Engine Assembly/Inspection . . . . . . . . . . . . . . . . . . 3.33-3.42
Recoil Disassembly/Inspection/Reassembly . . . . 3.42-3.44
Spark Plug Fouling Checklist . . . . . . . . . . . . . . . . . . 3.45
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45-3.46
3
3.1
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ENGINE
ES32PFE10 ENGINE SERVICE DATA
Cylinder Head / Valve
Rocker arm ID
ES32PFE10
.8669-.8678N (22.020-22.041 mm)
.8656-.8661N (21.987-22.0 mm)
.0008-.0021N (.020-.054 mm)
.0039N (.10 mm)
Rocker Arm
Rocker shaft OD
Rocker shaft Oil Clearance
Std
Limit
Std
Camshaft
Cam lobe height
In
1.3001--1.3041N (33.023-33.123 mm)
1.2883N (32.723 mm)
Limit
Std
Ex
1.3007-1.3047N (33.039-33.139 mm)
1.2889N (32.739 mm)
Limit
Mag
PTO
Mag
PTO
Std
Camshaft journal OD
1.4935-1.4941N (37.935-37.950 mm)
1.4935-1.4941N (37.935-37.950 mm)
1.4963-1.4970N (38.005-38.025 mm)
1.4963-1.4970N (38.005-38.025 mm)
.0022-.0035N (.055-.090 mm)
.0039N (.10 mm)
Camshaft journal bore ID
Camshaft Oil clearance
Limit
Cylinder Head
Valve Seat
Surface warpage limit
Standard height
.0020N (.05 mm)
2.908N (73.8 mm)
Contacting width
In
Std
.039N (1.0 mm)
Limit
Std
.055N (1.4 mm)
Ex
.059N (1.5 mm)
Limit
.071N (1.8 mm)
Valve Guide
Valve
Inner diameter
.2362-.2367N (6.000-6.012 mm)
.681-.689N (17.3-17.5 mm)
.039N (1.0 mm)
Protrusion above head
Margin thickness
In
Std
Limit
Std
Limit
In
.032N (0.8 mm)
Ex
.047N (1.2 mm)
.032N (0.8 mm)
Valve
Stem diameter
.2343-.2348N (5.950-5.965 mm)
.2341-.2346N (5.945-5.960 mm)
0.0014-0.0024N (0.035-0.062mm)
0.0016-0.0026N (0.040-0.067mm)
.0059N (0.15 mm)
Ex
Stem oil clearance
Std
In
Ex
Limit
Overall length
Free length
Squareness
In
3.979N (101.0 mm)
Ex
3.987N (101.2 mm)
Std
Limit
1.673N (42.5 mm)
-- -- --
0.075N (1.9 mm)
3.2
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ENGINE
ES32PFE10 ENGINE SERVICE
DATA
Cylinder / Piston / Connecting Rod
ES32PFE10
Cylinder
Surface warpage limit (mating with cylinder .0020N (0.050 mm)
head)
Cylinder bore
Taper limit
Std
3.0906-3.0913N (78.50-78.520 mm)
.0020N (0.050 mm)
Out of round limit
Piston clearance
.0020N (0.050 mm)
Std
.0015-.0032N (0.038-0.082 mm)
Limit .004N (0.11 mm)
Boring limit
.0020N (0.5 mm)
Piston
Outer diameter
Std
3.0881-3.0891N (78.438-78.462 mm)
.0098N (.25 mm) 3.0980-3.0989N (78.688-78.712 mm)
OS
.0197N (.50 mm) 3.1078-3.1087N (78.938-78.962 mm)
OS
Standard inner diameter of piston pin bore
Outer diameter
.7095-.7097N (18.007-18.013 mm)
.7092--.7095N (18.001-18.007 mm)
0.0-.0005N (0.0-0.012 mm)
Piston Pin
Standard clearance-piston pin to pin bore
Degree of fit
Piston pin must be a push (by hand) fit at 68L
F (20L C)
To
Std
.0079-.0118N (0.20-0.30 mm)
Limit .039N (1.0 mm)
Second
ring
Std
.0138-.0197N (0.35-0.50 mm)
Limit .039N (1.0 mm)
Std
.0079-.0236N (0.20-0.60 mm)
Limit .059N (1.5 mm)
Standard clearance -
piston ring to ring groove
To
Std
.0014-.0030N (0.035-0.075 mm)
Limit .0059N (0.15 mm)
Second
ring
Std
.0010-.0026N (0.025-0.065 mm)
Limit .0059N (0.15 mm)
Connecting Rod
Connecting rod small end ID
.7095-.7101N (18.007-18.023 mm)
0.0-.0009N (0.0-0.022 mm)
Limit .0012N (0.03 mm)
Connecting rod small end radial
clearance
Std
Connecting rod big end side clear-
ance
Std
.0028-.0118N (0.07-0.30 mm)
Limit .0138N (0.35 mm)
clearance
Std
0.0007-0.0021N (0.019-0.053 mm)
Limit 0.0026N (0.065 mm)
0.0024N (0.060 mm)
Crankshaft
Crankshaft runout limit (PTO end)
Crankshaft end play
0.002-0.008N (0.05-0.20 mm)
KEY - Std: Standard; OS: Oversize; ID: InnerDiameter;
OD: Outer Diameter; Mag: Magneto Side; PTO: Power
Take Off Side
3.3
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ENGINE
Oil Line Fitting
20 (27 Nm)
SPECIAL TOOLS
Oil Pump Cov-
er
6mm
4-5 (5-7 Nm)
PART NUMBER
TOOL
DESCRIPTION
Oil Relief Valve
Plug
14mm
14.5-16.5 (20-23 Nm)
2200634
2870390
Valve Seat
Reconditioning Kit
Recoil Housing
Rocker Cover
6mm
6mm
5-6.5 (7-9 Nm)
7-8 (9-11 Nm)
39-44 (53-59)
Piston Support
Block
2870159
2871293
Flywheel Puller
Slotted Nut Socket
Oil Filter Wrench
Rocker Cover
Block Plug
28mm
PV--43527
Rocker Adjus-
ter Screw Lock
Nut
6mm
6-7 (8-10 Nm)
TORQUE SPECIFICATIONS
Stator Plate
Starter Motor
Spark Plug
6mm
6mm
5-6.5 (7-9 Nm)
5-6.5 (7-9 Nm)
9-11 (12-15 Nm)
ENGINE TORQUE SPECIFICATIONS
Fastener
Size
330
ES32PFE10
Ft. Lbs. (Nm)
14mm
ENGINE FASTENER TORQUE
PATTERNS
Camshaft
Chain Tension-
er Lever
6mm
6mm
5-6.5 (7-9 Nm)
5-6.5 (7-9 Nm)
8--10 (11--14 Nm)
Camshaft
Chain Tension-
er
Tighten cylinder head, cylinder base, and crankcase
fasteners in 3 steps following the sequence outlined
below.
Camshaft
Chain Tension-
er Cap
11mm
3
2
5
Camshaft
Sprocket
10mm
8mm
25-29 (34-40 Nm)
12-14 (16-20 Nm)
29-33 (39-45 Nm)
6mm
6
1
4
Carburetor
Adaptor
Cylinder Head
Cylinder Base
Connecting
Rod
8.5mm
Crankcase
8mm
14-15 (19-21 Nm)
35-51 (47-69 Nm)
Crankshaft
Slotted Nut
(Drive Sprock-
et)
28mm
9
5
7
11
10
1
Cylinder Base
Bolts
6mm
5-7 (7-9 Nm)
3
2
Cylinder Head
Bolts
10mm
Refer to Engine
Assembly for torque pro-
cedure
8
4
Drive Clutch
Bolt
7/16 - 20
40 (55 Nm)
Flywheel
16mm
58-72 (78-98 Nm)
20 (27 Nm)
6
Oil Hose Fit-
tings
1/2 & 9/16
Crankcase
Oil Delivery Pi-
pe
12mm
14mm
20mm
11-15 (15-21 Nm)
14-17 (19-23 Nm)
36-43 (49-59 Nm)
Oil Drain Bolt
(Crankcase)
Oil Filter Pipe
Fitting (Con-
nector)
3.4
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ENGINE
The following components require engine
removal for service:
PISTON IDENTIFICATION
The piston may have an identification mark or the
piston may not have an identification mark for
piston placement. If the piston has an identification
mark, follow the directions for piston placement
below. If the piston does not have an identification
mark, the direction for placement of the piston does
not matter.
G
G
G
G
G
Camshaft
Connecting Rod
Crankshaft
Crankshaft Main Bearings
Crankcase
Note the directional and identification marks when
viewing the pistons from the top. The letter “F”, “ !
”, “ "” or : must always be toward the flywheel side
of the engine. The other numbers are used for
identification as to diameter, length and design. Four
stroke engine rings are rectangular profile. The
numbers or letters on all rings (except oil control rings)
must be positioned upward. See text for oil control
ring upper rail installation. Use the information below
to identify pistons and rings.
ENGINE REMOVAL
1. Clean work area.
2. Thoroughly clean the ATV engine and chassis.
3. Disconnect battery negative (-) cable.
4. Remove the following parts as required.
G
G
Seat
Left and Right Side Covers (Refer to
Chapter 5)
Engine
Model No.
Oversize
Available*
(mm)
Standard
Piston
Identification
G
Fuel Tank Cover / Front Cab (Refer to
Chapter 5)
G
Fuel Tank (Refer to Chapter 4)
ES32PFE
.25
.50
None
5. Disconnect spark plug high tension lead.
6. Disconnect all electrical wires from the engine.
7. Remove springs from exhaust pipe and remove
pipe.
*Pistons and rings marked 25 are .25mm (.010I)
oversized. Pistons and rings marked 50 are .50mm
(.020I) oversized
8. Drain engine oil.
9. Remove airbox.
10. Remove carburetor. Insert a shop towel into the
carburetor flange to prevent dirt from entering the
intake port.
ACCESSIBLE COMPONENTS
The following components can be serviced or
removed with the engine installed in the frame:
11. Loosen auxiliary brake master cylinder mount if
necessary for clearance.
12. Refer to PVT System Chapter 6 to remove outer
clutch cover, drive belt, drive clutch, driven clutch,
and inner cover.
G
G
G
G
G
G
G
G
G
Flywheel
Alternator/Stator
Starter Motor/Starter Drive
Cylinder Head
Cylinder
13. Starter motor. Note ground cable location. Mark
positive (+) cable mounting angle and remove
cable.
14. Remove transmission linkage rod(s) from gear
selector and secure out of the way.
Piston/RIngs
15. Remove engine to chassis ground cable.
Oil pump
16. Remove all engine mount nuts and / or engine
mount plates.
Rocker Arms
17. Remove engine through right side of frame.
Cam Chain and Sprockets
3.5
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ENGINE
ENGINE INSTALLATION
NOTES
CYLINDER HONE
SELECTION/HONING
PROCEDURE
After the engine is installed in the frame, review this
checklist and perform all steps that apply.
CAUTION:
General Items
A hone which will straighten as well as remove
material from the cylinder is very important. Using a
common spring loaded glaze breaker for honing is not
advised for nicasil cylinders. Polaris recommends
using a rigid hone or arbor honing machine.
G
Install
components using new gaskets,
seals, and fasteners where
applicable.
previously
removed
G
Perform regular checks on fluid
levels, controls, and all important
areas on the vehicle as outlined in
the daily pre-ride inspection checklist
(refer to Chapter 2).
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.
PVT System
HONING TO DEGLAZE
G
G
G
Adjust center distance of drive and
driven clutch. (Chapter 6)
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:
Adjust clutch offset, alignment, and
belt deflection. (Chapter 6)
Clean clutch sheaves thoroughly and
inspect inlet and outlet ducts for
proper routing and sealing. (Chapter
6)
G
Use a motor speed of approximately
300-500 RPM, run the hone in and
out of the cylinder rapidly until cutting
tension decreases. Remember to
keep the hone drive shaft centered
(or cylinder centered on arbor) and to
bring the stones approximately 1/2N
(1.3 cm) above and below the bore at
the end of each stroke.
Transmission
G
Inspect transmission operation and
adjust linkage if necessary. Refer to
Chapter 2 and Chapter 8.
Exhaust
G
Replace exhaust gaskets.
Seal
connections with high temp silicone
sealant.
G
G
Release the hone at regular intervals
and inspect the bore to determine if
it has been sufficiently deglazed, and
to check for correct cross--hatch.
NOTE: Do not allow cylinder to
heat up during honing.
G
Check to be sure all springs are in
good condition.
Engine Break In Period
After honing has been completed,
inspect cylinder for thinning or
peeling.
4 Cycle Engine Break-In Period is defined as the first
10 hours of engine operation or 2 full tanks of fuel.
G
Use only Polaris Premium 4 All
Season Synthetic Oil, or API certified
“SH” oil.
IMPORTANT: Clean the Cylinder After Honing
It is very important that the cylinder be thoroughly
cleaned after honing to remove all grit material. Wash
the cylinder in a solvent, then in hot, soapy water. Use
electrical contact cleaner if necessary to clean these
areas. Rinse thoroughly, dry with compressed air,
and oil the bore immediately with Polaris 4 Cycle
Lubricant to prevent the formation of surface rust.
G
G
Use fuel with a minimum octane of 87
(R+M)/2 method.
Change break-in oil and filter at 20
hours or 500 miles, whichever
comes first.
3.6
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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.
rough or sharp edges. Apply a slight
chamfer to all ports to remove sharp
edges or burrs, paying particular
attention to the corners of the intake
and exhaust ports.
IMPORTANT: Clean the Cylinder After Honing
It is very important that the cylinder be thoroughly
cleaned after honing to remove all grit material. Wash
the cylinder in a solvent, then in hot, soapy water. Use
electrical contact cleaner if necessary to clean these
areas. Rinse thoroughly, dry with compressed air,
and oil the bore immediately with Polaris 4 Cycle
Lubricant to prevent the formation of surface rust.
EXAMPLE OF CROSS HATCH PATTERN
HONING TO OVERSIZE
ENGINE LUBRICATION -
ES32PF10
If cylinder wear or damage is excessive, it will be
necessary to oversize the cylinder using a new
oversize piston and rings. This may be accomplished
by either boring the cylinder and then finish honing to
the final bore size, or by rough honing followed by
finish honing.
Oil Type . . . . . Polaris Premium 0--40W Synthetic
(PN 2871281)
Capacity . . . . . Approximately 2 U.S. Quarts (1.9 l)
Filter . . . . . . . . . . . . . . . PN 3084963
For oversize honing always wet hone using honing oil
and a coarse roughing stone. Measure the piston (see
piston measurement) and rough hone to the size of the
piston. Always leave .002 - .003N (.05 - .07 mm) for
finish honing. Refer to piston-to-cylinder clearance
specifications on Page 3.2 before honing. Complete the
sizing with fine grit stones to provide the proper
cross-hatch finish and required piston clearance.
OIl Filter Wrench . . . PV--43527
Drain Plug/
Screen Fitting . . . . . . 14 ft. lbs. (19 Nm)
Oil Pressure
Specification
(ES32PF10) . . . . . . . . . 71-99 PSI @ 3000 RPM,
Polaris 0W--40 Synthetic
(Oil temp at 122_F 50_C)
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:
OIL PRESSURE TEST
ES32PF10
G
Use a motor speed of approximately
300-500 RPM, run the hone in and
out of the cylinder rapidly until cutting
tension decreases. Remember to
keep the hone drive shaft centered
(or cylinder centered on arbor) and to
bring the stone approximately 1/2N
(1.3 cm) beyond the bore at the end
of each stroke.
WARNING: Oil temperature and pressure can cause
serious injury and damage. Wear the proper safety
gear when performing these procedures.
1. Remove lower blind plug behind oil filter on
crankcase.
2. Insert a 1/8” NPT oil pressure gauge adaptor into
the crankcase and attach gauge.
G
Release the hone at regular intervals
and inspect the bore to determine if
it has been cleared, and to check
piston fit. NOTE: Do not allow
cylinder to heat up during honing.
The thinner areas of the liner around
the ports will expand causing an
uneven bore.
G
After honing has been completed
inspect all port opening areas for
3.7
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ENGINE
3. Start engine and allow it to reach operating
temperature while monitoring gauge indicator.
NOTE: Use Polaris Premium 0--40W Synthetic
Engine Lubricant (PN 2871281).
ES32PF10
Oil Pressure at 3000 RPM (Engine Hot):
Standard: 71-99 PSI
Minimum: 20 PSI at idle
OIL COOLER ASSEMBLY
Top Bracket
Screws
Fan Motor
To Engine
Shroud
Thermistor
Inlet Hose
Oil Cooler
Hose Clamps
Rubber
Mounts
Lower Bracket
U--Clips
3.8
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ENGINE
OIL FLOW DIAGRAM - ES32PF
Chain Room
Small End
Bearing
Piston
Rocker Arm /
Rocker Shaft /
Sprocket /
Chain
Oil Jet
Cylinder Sleeve
Main Bearing
(Fixed)
Connecting Rod
Indirect
Lubrication
Cam Shaft
Journal
Cam Shaft
Journal
Through Front Right
Cylinder Head Bolt
Passage
Cam Lobe
Large End
Bearing
Oil Passage In
Cylinder
Crank Pin
Crankcase
Oil Passage
Oil Hoses
Crankcase
Oil Passage
Crankshaft
In
Out
Bypass
Oil Filter
Pressure Relief
Oil Pump
Engine Sump
Crankcase
Oil Passage
Oil Pickup
Screen
Crankcase
Oil Passage
3.9
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ENGINE
ES32PFE ENGINE EXPLODED VIEW
Cylinder/
Cylinder Head
Crankcase
ES32PF
Valve Train
Crankshaft
and Piston
3.10
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ENGINE
5. Remove cam chain tensioner plug, sealing
washer, spring and pin. CAUTION: The plug is
under spring tension. Maintain inward pressure
while removing.
ENGINE REMOVAL
REFER TO PAGE 3.5 - 3.6 FOR ENGINE
REMOVAL / INSTALLATION NOTES.
6. Remove the two 6x25 mm cam chain tensioner
flange bolts.
7. Tap lightly on tensioner body with a soft face
hammer and remove tensioner.
CAM CHAIN TENSIONER
REMOVAL
1. Remove ignition timing inspection plug from recoil
housing.
To position crankshaft at Top Dead Center (TDC)
on compression stroke:
2. Rotate engine slowly in the direction of rotation
watching intake valves open and start to close.
3. Continue to rotate engine slowly, watching
camshaft sprocket marks and the mark in the
timing inspection hole.
Single TDC Mark Aligned
TDC Mark
CAM CHAIN TENSIONER
INSPECTION
Rotation
1. Pull cam chain tensioner plunger outward to the
end of its travel. Inspect teeth on ratchet pawl (A)
and plunger teeth (B) for wear or damage.
Do Not Use
Advance Marks
4. Align single (TDC) mark on flywheel with
projection in inspection hole, and the cam
sprocket pin (facing upward) aligned with the
camshaft to crankshaft center line. NOTE: The
sprocket marks align with gasket surface and the
cam lobes should be pointing down and valves
should have clearance at this point.
B
A
2. Push ratchet pawl and hold it. The plunger should
move smoothly in and out of the tensioner body.
3. Release ratchet pawl and push inward onplunger.
It should remain locked in position and not move
inward.
Sprocket marks
align with gasket
surface
3.11
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ENGINE
4. Measure free length of tensioner spring. Replace
spring if excessively worn.
4. Remove cylinder block plug using a 14 mm hex
head wrench.
Cylinder block
plug
Tensioner Spring Free Length:
5. Measure O.D. of rocker shaft. Inspect it for wear
or damage. Compare to specifications.
2.06N (5.23 cm) Std.
1.92N (4.88 cm) Limit
5. Replace entire tensioner assembly if any part is
worn or damaged.
ROCKER ARM/SHAFT
INSPECTION
1. Remove rocker cover.
2. Mark or tag rocker arms to keep them in order for
assembly.
Wave
washer
Rocker Shaft O.D.:
.8656-.8661I (21.987-22.0 mm)
Inspect surface
of followers
6. Measure I.D. of each rocker arm and compare to
specifications.
PTO
3. Inspect each rocker arm cam follower surface. If
there is any damage or uneven wear, replace the
rocker arm. NOTE: Always inspect camshaft
lobe if rocker arms are worn or damaged.
3.12
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ENGINE
CAMSHAFT REMOVAL
1. Remove cam shaft end plug (A).
A
Rocker Arm & Support I.D.:
.8669-.8678I (22.020-22.041 mm)
2. Remove camshaft sprocket flange bolt and
washer.
7. Measure I.D. of both rocker arm shaft support
areas and visually inspect surface. Compare to
specifications.
3. Place a clean shop towel in the area below cam
chain sprocket.
Rocker Shaft Oil Clearance:
Std: .0008-.0021I (.020-.054 mm)
Limit: .0039I (.10 mm)
8. Inspect rocker adjuster screws for wear, pitting, or
damage to threads of the adjuster or locknut.
Replace all worn or damaged parts. NOTE: The
end of the adjuster screw is hardened and cannot
be ground or re-faced.
4. Remove sprocket from camshaft and chain.
5. Secure cam chain with a wire to prevent it from
falling into the crankcase.
3.13
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ENGINE
CAMSHAFT REMOVAL CONT’D
6. Inspect cam sprocket teeth for wear or damage.
Replace if necessary.
Lobe
Inspect for Areas of
Tooth Wear or Damage
2. Remove release lever shaft and return spring
(spacer).
3. Inspect shaft for wear or galling.
7. Remove camshaft.
Return spring (spacer)
4. Inspect lobe on end of release lever shaft for wear
and replace if necessary.
AUTOMATIC COMPRESSION
RELEASE INSTALLATION
1. Slide spring onto shaft.
2. Apply engine oil to release lever shaft.
CAMSHAFT INSPECTION
1. Visually inspect each cam lobe for wear, chafing
Dowel pin
Release lever
AUTOMATIC COMPRESSION
RELEASE REMOVAL/
INSPECTION
Lubrication holes
Lobe height
NOTE:
The automatic compression release
mechanism can be inspected and serviced without
removing the camshaft from the cylinder head.
Cam Lobe Height
1. Check release lever shaft for smooth operation
throughout the entire range of rotation.
Intake
Std: 1.3001-1.3041I (33.023-33.123 mm)
Limit: 1.2883I (32.723 mm)
Exhaust
Std: 1.3007-1.3047I (33.039-33.139 mm)
Limit: 1.2889I (32.739 mm)
3.14
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ENGINE
2. Thoroughly clean the cam shaft, making sure the
oil feed holes are not obstructed.
CYLINDER HEAD REMOVAL
3. Measure height of each cam lobe using a
micrometer. Compare to specifications.
1. Loosen each of the four cylinder head bolts
evenly 1/8 turn each time in a cross pattern until
loose.
4. Measure camshaft journal outside diameter
(O.D.)
Journal O.D.
A
Journal
2. Remove bolts (A) and tap cylinder head lightly
with a plastic hammer until loose. CAUTION:
Tap only in reinforced areas or on thick parts of
cylinder head casting to avoid damaging casting.
Camshaft Journal O.D.:
Mag & PTO End: 1.4935-1.4941I
(37.935-37.950 mm)
3. Remove cylinder head and head gasket.
5. Measure ID of camshaft journal bore.
Camshaft Journal I.D.:
Mag & PTO End: 1.4963-1.4970I
(38.005-38.025 mm)
6. Calculate oil clearance by subtracting journal OD
from journal bore ID. Compare to specifications.
Camshaft Oil Clearance:
Std: .0022-.0035I (.055-.090 mm)
Limit: .0039I (.10 mm)
CYLINDER HEAD
INSPECTION
Replace camshaft if damaged or if any part is worn
past the service limit.
1. Thoroughly clean cylinder head surface to
remove all traces of gasket material and carbon.
CAUTION: Use care not to damage sealing
surface.
Replace cylinder head if camshaft journal bore is
damaged or worn excessively.
3.15
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ENGINE
2. Remove spring retainer and spring.
CYLINDER HEAD WARPAGE
1. Lay a straight edge across the surface of the
cylinder. head at several different points and
measure warpage by inserting a feeler gauge
between the straight edge and the cylinder head
surface. If warpage exceeds the service limit,
replace the cylinder head.
A
NOTE: The valve springs should be positioned with
the tightly wound coils against the cylinder head on
progressively wound springs (A).
3. Push valve out, keeping it in order for reassembly
in the same guide.
4. Measure free length of spring with a Vernier
caliper, Ill.1. Check spring for squareness as
shown in Ill.2.
Replace spring if either measurement is out of
specification.
Compare to specifications.
Cylinder Head Warpage Limit:
.002” (.05mm)
CYLINDER HEAD
DISASSEMBLY
Valve Spring
Free Length
WARNING: Wear eye protection or a face shield
during cylinder head disassembly and reassembly.
NOTE: Keep all parts in order with respect to their
location in the cylinder head.
Ill.1
1. Using a valve spring compressor, compress the
valve spring and remove the split keeper. NOTE:
To prevent loss of tension, do not compress the
valve spring more than necessary.
Coil Fatigue/
Squareness
Ill.2
Valve Spring Length:
Std: 1.673I (42.5 mm)
Squareness:
.075I (1.9 mm)
3.16
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ENGINE
5. Remove valve seals. CAUTION: Replace seals
whenever the cylinder head is disassembled.
Hardened, cracked or worn valve seals will cause
excessive oil consumption and carbon buildup.
A
B
4. Inspect split keeper groove for wear or flaring of
the keeper seat area (B). NOTE: The valves
cannot be re-faced or end ground. They must be
replaced if worn, bent, or damaged.
5. Measure diameter of valve stem with
a
micrometer in three places and in two different
directions (six measurements total). Compare to
specifications.
VALVE INSPECTION
1. Remove all carbon from valve with a soft wire
wheel.
Measure valve stem in
several places.
2. Check valve face for runout, pitting, and burnt
spots. To check for bent valve stems, mount
valve in a drill or use “V” blocks and a dial
indicator.
Valve Stem Diameter:
Intake: .2343-.2348I (5.950-5.965 mm)
Exhaust: .2341-.2346I (5.945-5.960 mm)
6. Measure valve guide inside diameter at the top
middle and end of the guide using a small hole
gauge and a micrometer. Measure in two
directions, front to back and side to side.
3. Check end of valve stem for flaring, pitting, wear
or damage (A).
3.17
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ENGINE
VALVE SEAT
RECONDITIONING
Valve Seat Inspection
Inspect valve seat in cylinder head for pitting, burnt
spots, roughness, and uneven surface. If any of the
above conditions exist, the valve seat must be
reconditioned. See Valve Seat Reconditioning, Page
3.19--3.21. If the valve seat is cracked the cylinder
head must be replaced.
7. Subtract valve stem measurement to obtain stem
to guide clearance. NOTE: Be sure to measure
each guide and valve combination individually.
8. Replace valve and/or guide if clearance is
excessive. Compare to specifications.
Too
Wide
Too
Narrow
Good
Uneven
Valve Guide I.D.:
.2362-.2367I (6.0-6.012 mm)
Cylinder Head Reconditioning
NOTE: If valve guides are replaced, valve seats must
be reconditioned. Refer to Valve Seat Reconditioning
for procedure.
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).
COMBUSTION CHAMBER
Clean all accumulated carbon deposits from
combustion chamber and valve seat area with a soft
wire brush.
CAUTION: Wear eye protection when performing
cylinder head service. Valve guide replacement will
require heating of the cylinder head. Wear gloves to
prevent burns.
Valve Guide Removal/Installation
1. Remove all carbon deposits from the combustion
chamber, valve seat and valve guide area before
attempting to remove valve guides. CAUTION:
Carbon deposits are extremely abrasive and may
damage the valve guide bore when guides are
removed.
2. Place new valve guides in a freezer for at least 15
minutes while heating cylinder head.
3. Heat cylinder head in an oven or use a hot plate to
bring cylinder head temperature to 212L F (100L
C). CAUTION: Do not use a torch to heat
cylinder head or warpage may result from uneven
heating. Head temperature can be checked with
a pyrometer or a welding temperature stick.
3.18
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ENGINE
4. Follow the manufacturers instructions provided
with the valve seat cutters in the Valve Seat
Reconditioning Kit (PN 2200634). Abrasive stone
seat reconditioning equipment can also be used.
Keep valves in order with their respective seat.
Reaming The Valve Guide
9. Allow cylinder head to cool to room temperature.
Apply cutting oil to the reamer. Guides should be
reamed from the valve spring side of the cylinder
head. Ream each guide to size by turning the
reamer clockwise continually. Continue to rotate
reamer clockwise during removal of the tool.
NOTE: Valve seat width and point of contact on the
valve face is very important for proper sealing. The
valve must contact the valve seat over the entire
circumference of the seat, and the seat must be the
proper width all the way around. If the seat is uneven,
compression leakage will result. If the seat is too
wide, seat pressure is reduced, causing carbon
accumulation and possible compression loss. If the
seat is too narrow, heat transfer from valve to seat is
reduced and the valve may overheat and warp,
resulting in burnt valves.
5. Once thoroughly heated, place cylinder head on
blocks of wood which will allow the old guides to
be removed.
6. Using valve guide driver, drive guides out of the
cylinder head from the combustion chamber side.
Be careful not to damage guide bore or valve seat
when removing guides.
10. Clean guides thoroughly with hot soapy water and
a nylon brush. Rinse and dry with compressed
air. Apply clean engine oil to guides.
7. Place cylinder head on cylinder head table.
NOTE: Be sure cylinder head is still at 212L F
(100L C) before installing new guides.
8. Place a new guide in the valve guide installation
tool and press guide in to proper depth. Check
height of each guide above the cylinder head (A).
Refer to specifications.
VALVE SEAT
RECONDITIONING
1. Install pilot into valve guide.
NOTE: The guide can also be driven in to the
proper depth. Inspect the guide closely for cracks
or damage if a driver is used.
A
Valve Guide Installed Height
2. Apply cutting oil to valve seat and cutter.
Valve Guide Height:
.681-.689I (17.3-17.5 mm)
3.19
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ENGINE
VALVE SEAT RECONDITIONING CONT’D
6. Insert valve into guide and tap valve lightly into
place a few times.
3. Place 46L cutter on the pilot and make a light cut.
7. Remove valve and check where the Prussian
Bluet or black marker indicates seat contact on
the valve face. The valve seat should contact the
middle of the valve face or slightly above, and
must be the proper width (A).
(B)
(A)
4. Inspect the cut area of the seat.
G
G
G
If the contact area is less than 75%
of the circumference of the seat,
rotate the pilot 180L and make
another light cut.
Proper Seat Contact On Valve Face
G
G
If the indicated seat contact is at the
top edge of the valve face and
contacts the margin area(B) it is too
high on the valve face. Use the 30L
cutter to lower the valve seat.
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 too low use the 60L or 75L cutter to
raise the seat. When contact area is
centered on the valve face, measure
seat width.
G
G
If the seat is too wide or uneven, use
both top and bottom cutters to
narrow the seat.
G
If the contact area of the initial cut is
greater than 75%, continue to cut the
seat until all pits are removed and a
new seat surface is evident. NOTE:
Remove only the amount of material
necessary to repair the seat surface.
If the seat is too narrow, widen using
the 45L cutter and re-check contact
point on the valve face and seat width
after each cut.
5. To check the contact area of the seat on the valve
face, apply a thin coating of Prussian Bluetpaste
to the valve seat. If using an interference angle
(46L) apply black marker to the entire valve face
(A).
Bottom - 60L or 75L
Seat - 45L or 46L
Top - 30L
(A)
3.20
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ENGINE
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.
12. Clean cylinder head, valves, and camshaft oil
supply passage (A) thoroughly.
A
Seat
Width
Valve Seat Width:
13. Spray electrical contact cleaner into oil passage
and dry using compressed air.
Intake Std: .039I (1.0 mm)
Limit: .055I (1.4 mm)
Exhaust Std: .059I (1.4 mm)
Limit: .071I (1.8 mm)
CYLINDER HEAD ASSEMBLY
CAUTION: Wear eye protection during assembly.
8. Clean all filings from the area with hot soapy
water, rinse, and dry with compressed air.
NOTE: Assemble the valves one at a time to maintain
proper order.
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.
1. Install new valve seals on valve guides.
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.
2. Apply engine oil to valve guides and seats.
3. Coat valve stem with molybdenum disulfide
grease.
4. Install valve carefully with a rotating motion to
avoid damaging valve seal.
11. Rotate the valve rapidly back and forth until the
cut sounds smooth. Lift the valve slightly off of the
seat, rotate 1/4 turn, and repeat the lapping
process. Do this four to five times until the valve is
fully seated, and repeat process for the other
valve.
3.21
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ENGINE
CYLINDER HEAD ASSEMBLY CONT’D
ENGINE BOTTOM END
DISASSEMBLY
5. Dip valve spring and retainer in clean engine oil
and install spring with closely spaced coils toward
the cylinder head.
Cylinder Removal
Follow engine disassembly procedures to remove
valve cover, camshaft and rocker arms, and cylinder
head.
Closely spaced
coils toward
cylinder head
1. Remove cam chain guide at front of cylinder.
2. Remove the two 6 mm cylinder base bolts.
6. Place retainer on spring and install valve spring
compressor. Compress spring only enough to
allow split keeper installation to prevent loss of
spring tension. Install split keepers with the gap
even on both sides.
3. Tap cylinder lightly with a plastic hammer in the
reinforced areas only until loose.
A
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
4. Rock cylinder forward and backward and lift it
from the crankcase, supporting piston and
connecting rod. Support piston with Piston
Support Block (PN 2870390) (A).
1. Clean and dry the combustion chamber area.
2. Pour a small amount of clean solvent into the
intake port and check for leakage around each
intake valve. The valve seats should hold fluid
with no seepage.
5. Remove dowel pins from crankcase.
3. Repeat for exhaust valves by pouring fluid into
exhaust port.
3.22
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ENGINE
5. Remove the top rail first followed by the bottom
rail.
PISTON REMOVAL
6. Remove the expander.
1. Remove circlip. Note that opening for circlip
access is on the intake side.
CYLINDER INSPECTION
1. Remove all gasket material from the cylinder
sealing surfaces.
2. Inspect the top of the cylinder for warpage using a
straight edge and feeler gauge.
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.
Cylinder Warpage:
3. Remove top compression ring.
.0020N (.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 (1/2N down from top,
in the middle, and 1/2N up from bottom).
1/2N Down From Top of Cylinder
Y
X
*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.
Y
X
*By hand: Placing both thumbs as shown, spread the
ring open and push up on the opposite side. Do not
scratch the ring lands.
Y
X
4. Repeat procedure for second ring.
The oil control ring is a three piece design consisting
of a top and bottom steel rail and a center expander
section.
1/2N Up From Bottom
3.23
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ENGINE
CYLINDER INSPECTION CONT’D
3. Measure piston pin bore.
5. Record measurements. If cylinder is tapered or
out of round beyond .002, the cylinder must be
re-bored oversize, or replaced.
Cylinder Taper
Limit: .002 Max.
Cylinder Out of Round
Limit: .002 Max.
Standard Bore Size:
3.0906-3.0913I (78.50-78.520 mm)
Piston Pin Bore:
PISTON INSPECTION
1. Measure piston outside diameter at a point 5 mm
up from the bottom of the piston at a right angle to
the direction of the piston pin.
.7095-.7097I (18.007-18.013 mm)
4. Measure piston pin O.D. Replace piston and/or
piston pin if out of tolerance.
5 mm
Piston
Piston Pin
Piston Pin Measurement Locations
2. Subtract this measurement from the maximum
cylinder measurement obtained in Step 5.
Piston Pin O.D.
Piston to Cylinder Clearance
.7092-.7095I (18.001-18.007 mm)
Std: .0015-.0032I (.038-.082 mm)
Limit: .004I (.11 mm)
Piston O.D.:
Std: 3.0881-3.0891I (78.438-77.462 mm)
3.24
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ENGINE
5. Measure connecting rod small end ID.
PISTON RING INSTALLED
GAP
1. Place each piston ring inside cylinder using piston
to push ring squarely into place as shown.
Piston ring end gap installed
Feeler Gauge
Cylinde
5-50mm
Connecting Rod Small End I.D.
.7095-.7101I (18.007-18.023 mm)
2. Measure installed gap with a feeler gauge at both
the top and bottom of the cylinder.
6. Measure piston ring to groove clearance by
placing the ring in the ring land and measuring
with a thickness gauge. Replace piston and rings
if ring-to-groove clearance exceeds service
limits.
NOTE: A difference in end gap indicates cylinder
taper. The cylinder should be measured for
excessive taper and out of round.
3. If the bottom installed gap measurement exceeds
the service limit, replace the rings.
Ring to groove clearance
NOTE: Always check piston ring installed gap after
re-boring a cylinder or when installing new rings. A
re-bored cylinder should always be scrubbed
thoroughly with hot soapy water, rinsed, and dried
completely. Wipe cylinder bore with an oil rag
immediately to remove residue and prevent rust.
Piston
Ring
Piston Ring Installed Gap
Feeler Gauge
Top Ring
Std: .0079-.0138I (.20-.36 mm)
Limit: .039I (1.0 mm)
Second Ring
Std: .0138-.0197I (.35-.50 mm)
Limit: .039I (1.0 mm)
Oil Ring
Piston Ring-to-Groove Clearance
Std: .0079-.0276I (.20-.70 mm)
Limit: .059I (1.5 mm)
Top Ring Std: .0014-.0030I (.035-.075 mm)
Limit: .0059I (.15 mm)
Second Ring Std: .0010-.0026I (.025-.065
mm)
Limit: .0059I (.15 mm)
CRANKCASE DISASSEMBLY
NOTE: The recoil starter, starter motor, starter drive,
flywheel, stator, cam chain and sprockets can be
serviced with the engine in the frame.
3.25
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ENGINE
STARTER DRIVE
REMOVAL/INSPECTION
Starter Drive Bushing Clearance:
Std: .0015N-.004N (.038-.102 mm)
Service Limit:
008N (.203 mm)
1. Remove recoil housing bolts and remove
housing.
6. Inspect gear teeth on starter drive. Replace
starter drive if gear teeth are cracked, worn, or
broken.
FLYWHEEL/STATOR
REMOVAL/INSPECTION
1. Remove flywheel nut and washer.
2. Remove starter drive assembly. Note the thrust
washer located at the rear of the drive
mechanism.
3. Inspect the thrust washer for wear or damage and
replace if necessary.
4. Measure the OD of the starter drive shaft on both
ends and record.
Std. Bushing ID:
.4735N-.4740N (11.11-12.04 mm)
2. Install Flywheel Puller (PN 2871043) and remove
flywheel. CAUTION: Do not thread the puller
bolts into the flywheel more than 1/4N or stator
coils may be damaged.
Std. Shaft OD:
.470N-.472N (11.93-11.99 mm)
3. Mark or note position of stator plate on crankcase.
5. Measure the ID of the bushing in the recoil
housing (A) and in the crankcase and record.
Measure in two directions 90L apart to determine
if bushing is out of round. Calculate bushing
clearance. Replace bushing if clearance exceeds
the service limit.
A
4. Remove bolts and carefully remove stator
assembly, being careful not to damagecrankshaft
bushing on stator plate.
3.26
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