Home

9915083 1999-2000 Vol. III ATV Service Manual Chapter

1. Airbox Retainer se IND WOR HSH N Airbox Main Filter Neck Polaris Sales Inc J 4 99 MAINTENANCE Air Cleaner 2 Cycle Dual Stage Air Cleaner 300 Style The primary pre cleaner foam boot is designed to re move the majority of dust particles before they reach the secondary dry filter element Primary Pre cleaner Foam Boot Inspect the primary air cleaner boot in accordance with the maintenance schedule 1 2 Remove the seat Remove the primary air filter box Remove the yellow pre cleaner foam boot held in place by a gray collar from the air box Do not re move the collar Carefully wash the foam bootin soapy water and dry it thoroughly Replace the pre filter if the element is torn or damaged Apply 1 to 2 teaspoons 2 cycle injection oil to the foam pre filter Squeeze filter gently to distribute oil evenly over entire filter Squeeze out the excess into an absorbant cloth Reinstall the foam boot onto the air filter box Reinstall the primary air filter box removed in step 2 NOTE There will be some resistance Be sure the black rubber sealing ring is securely positioned over the main filter neck CAUTION When installing the primary air filter box be sure the gray foam collar B is below the air intake opening of the air box intake duct A Improper installa tion will restrict airflow to the engine possibly resulting in a rich mixture and poor runni
2. Method Frequency 1 Front Gearcase Oil GL5 80 90 Weight Gear Lube Add to bottom of fill plug threads See page NO TAG Change annually 2 U Joint Rear Prop Shaft Front Shaft Ride Models Premium U Joint Grease Locate Fittings and Grease Semi annuallyj 3 Yoke Rear Prop Shaft Shaft Ride Models Premium U Joint Grease Locate Fittings and Grease Semi annuallyj 4 U Joints Front Prop Shaft Premium U Joint Grease Locate Fittings and Grease Semi annuallyj 5 Propshaft Yoke Premium U Joint Grease Locate fittings and grease 3 pumps maximum Annually 6 Transmission Synthetic Transmission Lubricant Add to proper level on dipstick Approx 20 oz at change Approx 32 oz initial fill after disassembly Inspect Monthly Change annually More often under severe use such as wet or dusty conditions ii 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 4 99 Polaris Sales Inc NOTE 7NO TAG Upper Con trol MAINTENANCE Lubrication Chart Shaft Drive Models On Shaft Drive models lubricate these areas in addition to applicable
3. S Fasten the strap around the axle and rear bumper tube Tighten until a straight line A can be drawn from the axle to the transmission output shaft intersecting the swing arm pivot S If the chain needs adjustment use the following procedure tandard Swingarm Drive Chain Adjustment 1 4 6 cm Deflection IMPORTANT On models with standard swingarm non concentric suspension must be compressed as shown to check drive chain tension Ul 4 Rear Drive Chain Tension Adjustment Standard Swingarm 1 Loosen chain guard 2 Loosen two eccentric locking bolts Rear Drive Chain Adjustment 3 Insert a pin punch through the sprocket hub and into Step 3 the eccentric axle housing A ep 4 Roll the vehicle ahead or back to adjust chain slack Ka to 1 4 inch 6mm in the center of the chain as shown li above 5 Tighten the nut side of eccentric pinch bolts to 60 ft Ibs 83 Nm while holding the bolt with a wrench Verify proper chain deflection measurement after Step 2 Loosen pinch bolts are tight and readjust if necessary Step 5 Torque nut side of pinch bolts 6 Reinstall chain guard where applicable 7 Adjust stone guard to allow 1 8 clearance between sprocket and guide Polaris Sales Inc 26 4 99 MAINTENANCE Drive Chain Drive Chain Adjustment Concentric Swingarm caution Never adjust or operate the vehicle with the rear drive chain too l
4. 4 Remove the wheel nuts and remove the wheel 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 2 Attach the wheel nuts and finger tighten them Lower the vehicle to the ground 4 Securely tighten the wheel nuts to the proper torque listed in the table above wo 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 Flange Nuts Flat side against wheel Tapered nuts install with tapered side against wheel 4 99 2 Polaris Sales Inc MAINTENANCE Chassis Maintenance Tire Pressure Tire Pressure Inspection PSI Cold 1999 Model Front Center All Models Except Listed Below aS en a a nn Sportsman Models 5 5 Independent Rear Suspension Tire Inspection CAUTION S Maintain proper tire pressure Refer to the warning tire pressure decal applied to the vehicle S Improper tire inflation may affect ATV maneuverability Tread Depth 1 81 3 mm S When replacing a tire always use original equipment size and type S The use of non standard size or type tires may affect ATV handling Tire Tread Depth Alwaysreplacetireswhentread dep
5. CV Carburetor 4 Cycle Engines Idle Screw VM Carburetor 2 Cycle Engines Polaris Sales Inc 2 2 4 99 MAINTENANCE Carburetor Adjustments Throttle Cable Electronic Throttle Control ETC Switch Adjustment 1 Slide boot off throttle cable adjuster and jam nut Adjuster Lock Boot Sleeve nut 2 Place shift selector in neutral and set parking brake 3 Start engine and set idle to specified RPM NOTE Be sure the engine is at operating temperature See Idle Speed Adjustment 4 Loosen lock nut on in line cable adjuster Ill 1 5 Turn cable adjuster out until engine RPM begins to increase 6 Turn cable adjuster back in until throttle lever has 1 16 16 cm of travel before engine RPM increases Ill 2 4 Throttle Cable 2 Adjuster NOTE On models with aluminum throttle block cover is held on by 3 screws see Ill 4 be sure ETC switch plunger is held inward by throttle cable tension Pech Nut 7 Tighten lock nut securely and slide boot completely in place to ensure a water tight seal NOTE On 2 stroke models whenever throttle cable ad justments are made always check oil pump adjustment and re adjust if necessary 8 Turn handlebars from left to right through the entire turning range If idle speed increases check for proper cable routing If cable is routed properly and in good condition repeat adjustment procedure Direction of travel 4 16 1 8 Fre
6. 1 Place gear selector lever in center of travel range as shown at right Be sure the lever does not move from this position Turn linkage rod A to shorten or lengthen rod until end stud B is centered on hole in gear selector arm C Hold rod end parallel to mounting surface and tighten jam nuts securely wy 3 N po Remove Rod End pos Linkage Rod lt Center Lever In Slot 4 99 2 2 Polaris Sales Inc Carburetor Adjustments Throttle Operation All Models Check for smooth throttle opening and closing in all han dlebar positions Throttle lever operation should be smooth and lever must return freely without binding 1 2 3 4 Place the gear selector in neutral Set parking brake Start the engine and let it idle 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 Replace the throttle cable if worn kinked or damaged Choke Enricher Adjustment With the choke control toggle flipped to the full off position the choke plunger must be seated on the fuel passage way in the carburetor If the plunger is not seated on the fuel passage way inside the carburetor not enough cable free play the engine will flood or run too rich causing plug foul ing and poor performance Ill 1 If cable slack is excessive the choke fuel passage will not open far enough which may cau
7. 8 Front Wheel Bear Sealed Replace Inspect and replace bearings if necessary Annually ings Non driving front wheels 9 Front Drive Axle U Polaris U Joint Locate grease fitting and grease with grease gun Semi annually Joints Grease i 10 Ball Joint Polaris All Season Locate grease fitting on back side of struts and Semi annually Grease grease with grease gun i 11 Front A Arm Pivot Polaris All Season Locate grease fitting on pivot shaft and grease with Semi annually Shaft Grease grease gun i 12 Tie Rod Ends Polaris All Season Lift boot Clean away dirt and grease Apply fresh Semi annually Grease grease by hand and reassemble i 13 Counter Balance 10W30 Motor Oil Check level on dipstick and add oil as necessary Change Housing 400L Change annually To change oil see page 2 16 Annually 14 Steering Post Bush All Season Locate fittings on upper and lower steering post and Semi annually ings Grease grease with grease gun i 4 99 O Polaris Sales Inc MAINTENANCE Lubrication 15 Output shaft support rig Ng bearing grease fitting N SAJ Forward o 17 Swing Arm Bushings 17 Center Swing Arm Housing 6x6 19 Rear Strut Stabilizer 6x6 16 Rear Axle Bearing fe PET eee a 15 Transmission Polaris All Season Locate grease fitting on transmission output shaft Semi annually Output Shaft Grease and grease with grease gun i 5 16 Rear and Middle Polaris All Season
8. Check brakes to be sure they are not dragging Read just pedal deflection if necessary MAINTENANCE Auxiliary Brake Mechanical Auxiliary Foot Brake Pedal Full Height Engagement Full 1 2 Height Engagement Flush Floor Ill 1 Board Surface A Side MU Auxiliary Brake Adjustment Type lll 2 A B Side View Auxiliary Brake Adjustment Type Il lll 3 Polaris Sales Inc J 4 99 MAINTENANCE Drive Chain 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 2871079 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 Never allow battery acid to contact the drive chain Sprocket Inspection Inspect the sprocket for worn broken or bent teeth To check for wear pull outward on the chain as shown Re place sprocket if chain movement exceeds 1 4 6 cm Drive Chain Lubricant Polaris O Ring Chain Lubricant PN 2871079 N Service Limit 1 4 6mm Drive Chain Inspection The chain must be replaced when it reaches 3 elonga tion 1 Stre
9. MAINTENANCE Transmission Accessory Dipstick Oil Level View From Front Do not fill to bottom of fill plug threads Oil level should be maintained at the bottom of the fill hole Polaris Sales Inc 2 1 4 99 MAINTENANCE Counter Balancer Counter Balancer Lubrication 400cc Engines The counter balance oil should be checked semi annually especially before off season storage If the machine is used in wet conditions the oil should be checked more frequently If the oil has a milky white or gray appearance it should be changed as soon as possible Failure to properly maintain this important area can result in premature wear or possible failure of the counter balancer components Always use SAE 10W30 oil Procedure for Adding Oil 400 NOTE Check with engine at room temperature Do not overfill If overfilled excess oil will be expelled through the vent hose 1 Remove seat and locate dipstick Remove by loosening with a long handled screwdriver Dipstick 2 Remove dipstick and wipe clean 3 Screw dipstick in fully and remove to check 4 Read level shown on stick 5 Add SAE 10W30 oil with a transmission fluid funnel Recommended oil level The recommended oil level is indicated by the knurled area on the dipstick Capacity after draining is fos i 8 approximately 70 75cc 6 Reinstall dipstick with new sealing o ring Do not over tighten 7 Inspect counter balancer vent line for kinks or
10. Never operate the engine without the pre filter s Breather Hose 1 Besure breather line is routed properly and secured in place CAUTION Make sure lines are not kinked or pinched MAINTENANCE Breather System 4 Strokes Typical Breather Filter Location In Line Breather Filter Location A AK In Line Breather Filter Location B Foam Breather Filter Location C Air Box Polaris Sales Inc 24 4 99 MAINTENANCE Recoil Housing Recoil Housing S Drain the housing periodically to remove moisture S Drain the recoil housing after operating the ATV in very wet conditions This should also be done before storing the ATV The drain screw is located at the bot tom of the recoil housing Remove the screw with a 10mm wrench Reinstall screw once housing has been drained S CAUTION Make sure the manual start handle is ful ly seated on the recoil housing especially when trav elling in wet areas If it is not sealed properly water may enter the recoil housing and damage compo nents S Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water S After travelling in wet areas the recoil housing and starter should always be drained completely by re moving the recoil S Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some en gine oil will be lost if crankcase drain is opened S On
11. obstructions Screw dipstick in completely then Counter Balance Oil Changing Procedure remove to check level 1 Remove seat Locate and remove dipstick Counter Balance Crankcase Drain 2 Remove drain plug and drain oil Catch and discard used oil properly 3 Clean and reinstall drain plug 4 Add SAE 10W30 oil using a transmission fluid funnel The recommended oil level is indicated by the knurled area on the dipstick The dipstick should be screwed in fully to check Do not overfill If overfilled excess oil will be expelled through the vent hose Recoil Drain Pinion Drain 5 Reinstall dipstick 6 Check for leaks 4 99 2 1 Polaris Sales Inc Transmission Gearshift Linkage Adjustment Preliminary Inspection S If shifting problems are encountered the transmis sion linkage can be adjusted on some chain drive models S Refer to the procedures and illustrations on the fol lowing pages to identify the type S 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 S The transmission shift linkage should be periodically inspected for wear and parts replaced as required to remove excess play from shift linkage S Perform torque stop adjustment on models so equipped before adjusting shift linkage S Refer to Transmission chapter for more information Torque Stop Adjustment
12. tric axle housing Drive Chain Adjustment 4 Roll the vehicle ahead or back to adjust chain slack to the proper dimension Correct chain slack adjustment is 1 1 4 to 1 1 2 30 38 mm total at the midpoint 5 Tighten the eccentric locking bolts to 60 ft Ibs 6 Reinstall chain guard NOTE Reposition chain guide to allow 1 8 3 cm clearance be tween sprocket and guide 6x6 Rear Axle Drive Chain Adjustment To adjust the rear axle drive chain on 6x6 models loosen the rear most eccentric and rotate using the same meth od as outlined for the middle axle chain Total slack however should be adjusted to 1 4 1 2 6 13 mm 6x6 Chain Deflection Middle Axle Middle Axle 1 1 4 to 1 1 2 1 1 4 1 1 2 30 38 mm Rear Axle 1 4 1 2 6 13 mm Rear Axle 1 4 1 2 6 13 mm 4 99 26 Polaris Sales Inc Suspension Spring Preload Adjustment Operator weight and vehicle loading affect suspension spring preload requirements Adjust as necessary Front Suspension Compress and release front suspension Damping should be smooth throughout the range of travel Check all front suspension components for wear or dam age Inspect front strut cartridges for leakage Rear Suspension Compress and release rear suspension Damping should be smooth throughout the range of travel Check all rear suspension components for wear or dam age Inspect shock for leakag
13. Adjust the torque stop SPrior to shift linkage adjustment SWhen shifting difficulties are encountered SIf transmission has been removed from the frame NOTE Thetorque stop is located on the bottom left hand side of the transmission where applicable 1 Loosen jam nut A 2 Turn adjuster bolt B out until it touches the frame and then an additional 1 2 turn 3 Tighten the jam nut securely while holding the adjuster bolt MAINTENANCE Transmission Linkage rod will rotate 1 8 1 4 turn if rod ends are tightened properly Correctly Tightened Incorrectly Tightened Jam Nut Jam Nut All models with adjustable linkage KI PVT Cover 1 Forward Polaris Sales Inc 2 1 4 99 MAINTENANCE Transmission Shift Linkage Adjustment High Low Reverse Transmissions Linkage rod adjustment is necessary when symptoms include SNo All Wheel Drive light SNoise on deceleration SInability to engage a gear SExcessive gear clash noise SShift selectors moving out of desired range NOTE When adjusting linkage always adjust both linkage rods where applicable The adjustment of one rod can prevent proper adjustment of the other rod Remove necessary components to gain access to shift linkage rod ends i e exhaust heat shield exhaust pipe etc 1 If model is equipped with a transmission torque stop djust it tlined iously lect adjust it as outlined previously Low Range epee ector 2 Inspect shift linkag
14. Inc 2 3 4 99 MAINTENANCE Electrical Battery Maintenance A WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immedi ately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame ciga rettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN The battery is located under the left rear fender Inspect the battery fluid level When the battery fluid nears the lower level the battery should be removed and distilled water should be added to the upper level line To remove the battery 1 Disconnect holder strap and remove cover 2 Disconnect battery negative black cable first Maintain followed by the positive red cable between upper and lower level A CAUTION marks Whenever removing or reinstalling the battery disconnect the negative black cable first and reinstall the negative cable last 3 Disconnect the vent hose 4 Remove the battery 5 Remove the filler caps and add distilled water only as needed to bring each cell to the proper level Do not overfill the battery A To ref
15. Q SS should just touch NG Q side surface of rear KS NG tire on each side of S KI machine WEY SS oF c2 Measure from string to rim at front and rear of rim Rear rim measure ment should be 1 16 to 1 8 2 to 3 cm more than front rim measure ment NOTE The steering post arm frog can be used as an indicator of whether the handle bars are straight The frog should always point straight back from the steering post Polaris Sales Inc 25 4 99 MAINTENANCE Toe Alignment Method 2 Method 2 Chalk 1 2 Place machine on a smooth level surface Set handlebars in a straight ahead position and secure handlebars in this position NOTE The steering frog can be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post Place a chalk mark on the face of the front tires approximately 10 25 4 cm from the floor as close to the hub axle center line as possible NOTE It is important that both marks be equally positioned from the ground in order to get an accurate measurement Measure the distance between the marks and record the measurement Call this measurement A Chalk Line Measurement A Measurement B Rotate the tires 180 by moving vehicle forward or backward Position chalk marks facing rearward even with the hub axle centerline Again measure the distance between the marks and record C
16. T ro 10 minutes iba 3 Set idle speed to 600 800 RPM Air Screw NOTE Adjusting the air screw may affect idle speed Always check throttle cable freeplay after adjusting idle speed and adjust if necessary 4 Turn the screw in to richen or out to lean the mixture Adjust air screw for best throttle response and smooth idle 5 Re adjust idle speed if necessary 4 99 22 Polaris Sales Inc MAINTENANCE Carburetor Adjustments Pilot Screw Anti Tamper Plug Removal NOTE The pilot screw is pre set at the factory The following adjustment procedure should be used after carbu retor disassembly and cleaning or if the pilot screw is replaced Be sure all engine maintenance items have been performed and are within specifications before adjusting pilot screw Some models have an anti tamper plug cov ering the pilot screw If pilot screw adjustment is required remove it following the procedure outlined below 1 2 3 Remove the carburetor Drain the carburetor bowl and cover all openings to prevent metal shavings from entering Invert the carburetor and carefully drill out the center of the plug with a 1 8 or 5 32 3 or 4mm drill bit Before drilling set a drill stop on the shank of the drill bit to prevent drilling beyond 3 16 CAUTION Be careful not to drill into the pilot screw Drill the plug at slow drill speeds Use a self tapping metal screw and a pliers to remove the plug if it does not rotate out with
17. and allow the arrestor to cool 8 Reinstall the clean out plugs Place the transmission in neutral and start the engine If some carbon is expelled cover the exhaust outlet and If particles are still suspected to be in the muffler back Repeat steps 2 through 5 until no more particles are ex Remove the clean out plugs located on the bottom of the muffler as shown at right Purge accumulated carbon from the system by momen tarily revving the engine several times rap on the pipe around the clean out plugs while revving the engine several more times the machine onto an incline so the rear of the machine is one foot higher than the front Set the parking brake and block the wheels Make sure the machine is in neu tral and repeat steps 2 and 3 WARNING SEE BELOW Clean Out Plugs 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 parking brake Clean Out Plu and block the wheels Make sure the machine is in neu 9 tral and repeat steps 2 and 3 WARNING SEE a BELOW pelled when the engine is revved Clean Out Plugs A WARNING S Do not perform this operation immediately after the engine has been run because the exhaust system becomes very hot S Because of the increased fire hazard make sure that there
18. general lubrication items amp EN 8 Lower Control Arm 8NO TAG Lower Control Arm 10NO TAG Rear 9NO TAG Rear Wheel Hub Anti Bearing Carrier oll Bar lll item Lube Rec Method Frequency 7 Upper Control Arms Polaris All Season Locate fittings and grease Semi annually j Grease 8 Lower Control Arms Polaris All Season Locate fittings and grease Semi annually j Grease 9 Rear Wheel Hub Bearing Carrier Polaris All Season Locate fittings and grease Semi annually j Grease 10 Rear Anti Roll Bar Polaris All Season Locate fittings and grease Semi annually j Grease More often under severe use such as wet or dusty conditions i 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 Polaris Sales Inc 2 4 99 MAINTENANCE Gearcase Lubrication Quick Reference Refer to the following chart and the illustrations on the following pages for gearcase capacity and maintenance procedures 1999 MODEL MODEL GEAR TYPE OIL OIL CHECK METHOD Except where QUANTITY TYPE noted CASE fl oz ml Trail Boss 250 A99AA25CA 16 5 v 1489 py Dipstick Trail Blazer A9IBA25CA ka Ka 11 3 oz 7 335 Dipst
19. level on dip Change annually ic Gear Case stick NOTE See page 2 10 for Lubricant models without a dipstick 3 Brake Fluid Polaris DOT 3 Fill master cylinder reservoir to As required Change fluid every 2 years Brake Fluid 1 4 6 4mm from top or between indicated lines See page 2 57 4 Polaris Chain Apply to chain link plates and As required 7 Lube or O Ring rollers Middle Chain chain lube Transmission Dipstick Dipstick Operating Range Filter 1 E ngine Oil and Filter 4 Cycle Operating Range 2 Transmission Models Equipped With A Dipstick Maximum Master Cylinder Reservoir Minimum 4 Rear Drive Chain 5 Middle Drive Chain 6 Front Drive Chain Polaris Sales Inc 2 4 99 MAINTENANCE Lubrication 11 Front A Arm Pivot Shaft 9 Front Drive Axle U Joint 8 Front Wheel Bearings 2x4 Models 10 Ball Joint 14 Steering Post Bushings i mi boa 13 Counter balance dipstick 12 Tie Rod End 4x4 Models 7 De mand 4 Hubs 4 or 8 O clock position end view 11 Front A Arm Pivot Shaft 10 Ball Joint lll item Lube Rec Method Frequency 7 Demand 4 Hubs Polaris Demand Remove filler hole screw in hubs Rotate wheels to Semi annually All Wheel Drive Drive Hub Fluid or 4 or 8 O clock position If lubricant is not visible add i ATVs ATF Type F until it flows from filler hole Reinstall screw
20. plug 4 Add proper lubricant to bottom of fill hole threads Refer to page 2 10 5 Install fill plug 6 Check for leaks Make sure vent is unobstructed Drain plug Polaris Sales Inc 2 1 4 99 MAINTENANCE Front Gearcase Front Gearcase Lubrication Cont TYPE Il To check the level TYPE Il 1 The Type ll front gearcase lubricant level cannotbe checked with a dipstick or by visual reference Make sure vent is unobstructed The gearcase must be drained and re filled with the proper amount of lubricant Refer to procedure below Fill plug To change lubricant 1 Remove gearcase drain plug located on the bottom and drain oil Catch and discard used oil properly 2 Clean and reinstall drain plug using a new sealing washer Remove fill plug Add proper amount of lubricant Refer to page 2 10 Drain plug Install fill plug O oa A O Check for leaks TYPE Ill To check the level TYPE Ill 1 The Type Ill front gearcase lubricant level cannot be checked with a dipstick or by visual reference The gearcase must be drained and re filled with Make sure vent is unobstructed the proper amount of lubricant Refer to procedure below Fill plug To change lubricant 1 Remove gearcase drain plug located on the bottom and drain oil Catch and discard used oil properly 2 Clean and reinstall drain plug using a new sealing washer Remove fill plug Add proper amount of lubrican
21. the Trail Blazer the recoil handle must be be hind the heat shield for it to seal properly If it is not sealed properly water may enter the recoil housing and damage components 250 300 and 400 Engines Crankcase Drain Recoil Drain Starter Pinion Counter Balance Drain Drain 400s Only 4 Cycle Engines Crankcase Drain Recoil Drain above front propshaft on shaft drive models 4 99 2 4 Polaris Sales Inc Engine Oil Level 4 Stroke The oil tank is located on the left side of the vehicle To check the oil level 1 2 4 Set machine on a level surface Start and run engine for 20 30 seconds This will return oil to its true level in the oil tank About a cup of oil will remain in the crankcase Stop engine remove dipstick and wipe dry with a clean cloth Reinstall dipstick screwing into place NOTE The dipstick must be screwed completely in to en sure accurate measurement 5 Remove dipstick and check to see that the oil level is in the normal range Add oil as indicated by the level on the dipstick Do not overfill NOTE Rising oil level between checks in cool weather driving can indicate moisture collecting in the oil reservoir If the oil level is over the full mark change the oil Oil and Filter Change 4 Stroke 1 2 Place vehicle on a level surface Run engine two to three minutes until warm Stop engine Clean area around drain plug B at
22. the drill bit Turn the screw in until lightly seated Back out the specified number of turns This is the pilot screw base setting Do not tighten the pilot screw forcefully against the seat or the screw and or seat will be permanently damaged Refer to pilot screw adjustment procedure Drill Stop Plug Pilot Screw ee i g Spring Washer KH 3 0 Ring Polaris Sales Inc 22 4 99 MAINTENANCE Carburetor Adjustments Pilot Screw Idle Mixture Adjustment Notes Do not tighten the pilot screw forcefully against the seat or the screw and or seat will be permanently damaged Start engine and warm it up to operating temperature about 10 minutes This is a very important step Pilot Screw Adjustment 425 500 4 Stroke Models 1 Turn pilot screw in clockwise until lightly seated Turn screw out the specified number of turns Pilot Screw Adjustment Refer to Specifications 2 Connect an accurate tachometer that will read in E aa increments of or 50 RPM such as the PET 2100DX P N 8712100DX or the PET 2500 P N 8712500 Pilot Scre 3 Set idle speed to 1200 RPM Always check throttle cable freeplay after adjusting idle speed and adjust if necessary 4 Slowly turn mixture screw clockwise using the pilot screw wrench until RPM begins to decrease by 50 RPM or greater 5 Slowly turn mixture screw counterclockwise until idle speed increases to maximum RPM Continue turning counterclockwise until idl
23. 350047 CV Joint Grease Pack 50g 2871329 Dielectric Grease Nyogelt 2871654 Premium Demand Drive Hub Fluid 12 oz Coolant 2871323 60 40 Coolant Gallon 2871534 60 40 Coolant Quart Additives Sealants Thread Locking Agents Misc 2870585 Loctitet Primer N Aerosol 25g 2871949 Loctitet Threadlock 242 50ml 2871950 Loctitet Threadlock 242 6ml 2871951 Loctitet Threadlock 262 50ml 2871952 Loctitet Threadlock 262 6ml 2871953 Loctitet Threadlock 271 6ml 2871954 Loctitet Threadlock 271 36ml 2870584 Loctitet RC 680 Retaining Compound 10ml 2870587 Loctitet 518 Gasket Eliminator Flange Sealant 50ml 2871326 Premium Carbon Clean 12 oz 2870652 Fuel Stabilizer 16 oz 2871957 Black RTV Silicone Sealer 3 oz tube 2871958 Black RTV Silicone Sealer 11 oz cartridge 8560054 Marine Grade Silicone Sealer 14 oz cartridge 2870990 DOT3 Brake Fluid 2872113 Disc Brake Quiet Aerosol 9 oz 2871557 Crankcase Sealant 3 Bond 1215 4 99 2 Polaris Sales Inc MAINTENANCE Lubrication De ee el Engine Oil Polaris OW 40 Add oil to proper level Change after 1st month 6 months or 100 4 Strokes Synthetic hours thereafter Change more often 25 50 hours in extremely dirty conditions or short trip cold weather operation 2 Transmission Polaris Synthet Add lube to FULL
24. 40 mixture of antifreeze and distilled wa ter will provide the optimum cooling corrosion protec tion and antifreeze protection S Donot use tap water straight antifreeze or straight wa ter in the system Tap water contains minerals and im purities which build up in the system S Straight water or antifreeze may cause the system to Antifreeze Hydrometer freeze corrode or overheat Polaris 60 40 Anti Freeze Coolant PN 2871323 Cooling System Hoses 1 Inspect all hoses for cracks deterioration abrasion or leaks Replace if necessary 2 Check tightness of all hose clamps CAUTION Do not over tighten hose clamps at radiator or radiator fitting may distort causing a restriction to coolant flow Radiator hose clamp torque is 36 inch Ibs Radiator 1 Check radiator air passages for restrictions or damage Carefully straighten any bent radiator fins Remove any obstructions with compressed air or low pressure water Cooling System Pressure Test Refer to page 3 6 for pressure test procedure 4 99 2 3 Polaris Sales Inc Coolant Level Inspection Therecovery bottle locatedontheleftsideofthemachine must be maintained between the minimum and maximum levels indicated on the recovery bottle With the engine at operating temperature the coolant level should be between the upper and lower marks on the coolant reservoir If not 1 Remove reservoir cap Inner splash cap vent hole mus
25. A A Always stop the engine and refuel outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If you get gasoline in your eyes or if you swallow gasoline see your doctor immediately 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 Gasoline powered engine exhaust fumes are poison ous and can cause loss of consciousness and death in a short time Never drain the float bowl when the engine is hot Severe burns may result Fuel Lines 1 3 Check fuel lines for signs of wear deterioration damage or leakage Replace if necessary Be sure fuel lines are routed properly and secured with cable ties CAUTION Make sure lines are not kinked or pinched Replace all fuel lines every two years 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 Be sure vent lines are routed properly and secured with cable ties CAUTION Make sure lines are not kinked or pinched Fuel Filter The fuel filter should be replaced in accordance with the Periodic Maintenance Chart or whenever sediment is vis ible in the filter SON gt NOD O Shu
26. CHAPTER 2 MAINTENANCE Periodic Maintenance Chart Pre Ride Inspection a Recommended Lubricants and Capacities Lubricant and Maintenance Product Numbers Lubrication Chart cece eee ee aes Gearcase Lubrication Quick Reference Front Gearcase Lubrication Rear Gearcase Lubrication Gearcase Trans Lubrication Gearcase Trans Lubrication Shaft Chain Counter Balance Lubrication 400cc engine Gearcase Trams Torque Stop Adjustment Gearcase Trans LInkage Adjustment HLR Carburetor Adjustments a Oil Pump Adjustment Filter 2 stroke Fuel System 0000 cece eens Compression Tests a Battery Maintenance aa Electrical adn akn DA shala Dandan Coolant System Maintenance Air Filter Service 2 Stroke Air Filter Service 4 Stroke Air Box Sediment Tube Service Breather Filter a Recoil Housing 7 2m GENE KE AGANG AGA ede ed Oil Change Filter aa Valve Clearance 4 Stroke Steering and Toe Allignment Front Hub Maintenance AWD Models Brake System Service aa Drive Chain and Sprocket Service Suspension Service nannan annann nan Wheel Removal Installat
27. Clearance Adjustment 1 2 Insert a 006 15mm feeler gauge between end of intake valve stem and clearance adjuster screw Using a 10 mm wrench and a screwdriver loosen adjuster lock nut and turn adjusting screw until there is a slight drag on the feeler gauge Hold adjuster screw and tighten adjuster lock nut securely Re check the valve clearance Repeat adjustment procedure if necessary until clearance is correct with locknut secured Repeat this step for the other intake valve on 4 valve models INTAKE VALVE CLEARANCE 335 425 500 Engines 006 15 mm Exhaust Valve Clearance Adjustment NOTE The exhaust valves on 425 and 500cc share a common rocker arm and must be adjusted using two feel er gauges 1 Insert 006 feeler gauge s between end of exhaust valve stem and adjuster screw s Loosen locknut s and turn adjuster screw s until there is a slight drag on feeler gauge s NOTE Both feeler gauges should remain inserted during adjustment of each valve on 4 valve models EXHAUST VALVE CLEARANCE 335 425 500 Engines 006 15 mm When clearance is correct hold adjuster screw and tighten locknut securely Re check the valve clearance Repeat adjustment procedure if necessary until clearance is correct with locknut secured 4 99 2 5 Polaris Sales Inc Exhaust Valve Clearance Adjustment Cont MAINTENANCE 4 Stroke Engine Maintenance 6 Scrape ga
28. E Recommended Lubricants Recommended Lubricants Quick Reference Lubricants and maintenance product part numbers are listed on page 2 4 Refer to Specifications Chapter 1 for capacity information Type See Chapter Engine Oil Polaris Premium 4 Add to proper level on dipstick 4 Strokes Synthetic OW 40 Engine Injector Oil Polaris Premium TC W3 Add to top of oil reservoir as required 2 Strokes 2 Stroke oil 2 2 2 2 Transmission Polaris Synthetic Gear Refer to procedures outlined later in this Case Lubricant chapter Front Gear Case Premium Front Gearcase Refer to procedures outlined later in this 2 Shaft Drive Fluid or GL5 80 90 Gear chapter Lube Counter Balancer Oil SAE 10W30 Motor Oil Add to proper level on dipstick 400L Engines SG SH Rated Gear Shift Selector Polaris OW 40 Synthetic Oil in selector box should be at the center Box Engine Lubricant or line of the shift selector plungers Do not 10W Motor Oil overfill or the selector may hydro lock Coolant Level Polaris Premium 60 40 Fill reservoir tank to full line Add if neces 2 Pre mixed Antifreeze sary If reservoir was empty or extremely Coolant or a 50 50 mixture low allow engine and cooling system to high quality antifreeze cool completely and check level in radia coolant and distilled water tor Fill to top of filler neck Front Hubs Premium Demand Drive Fill hub at 4 00 or 8 00 position until fluid AWD Models Hub Fluid trickles out Do not
29. Locate grease fitting on eccentric and grease with Semi annually Axle Bearings Grease grease gun i 6x6 17 Swing Arm Polaris All Season Locate grease fitting on swing arm and grease with Semi annually Bushings and Grease grease gun i Center Swing Arm Housing 6x6 Center and Front Grease grease Locate grease fitting on front eccentric side Eccentrics opposite chain and grease Rear Strut 6x6 Polaris All Season Locate fitting on rear strut and grease with grease Semi annually Grease gun i 18 Chain Adjusters Polaris All Season Locate grease fitting on center eccentric and Semi annually 19 More often under severe use such as wet or dusty conditions ji 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 Polaris Sales Inc 2 4 99 MAINTENANCE Lubrication Shaft Drive Models NOTE On Shaft Drive models lubricate these areas in addition to applicable general lubrication items 1 Front Gear Case Fill Plug 2 Rear Prop Shaft Front U Join Shaft Ride Models 3 Rear Prop Shaft Yoke Shaft Ride Models 4 Front Prop Shaft 5 Propshaft Yoke 3 pumps max 6 Transmission Operating Range lll Item Lube Rec
30. O ring on new filter with a film of engine oil Check to make sure the O ring is in good condition Install new filter and turn by hand until filter gasket contacts the sealing surface then turn and additional 1 2 turn Approximately 1 cup of engine oil will remain in the crankcase To drain remove drain plug found on lower right side of crankcase NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 20 21 22 23 24 25 Reinstall drain plug Remove dipstick and fill tank with 2 quarts 1 9 I of Polaris Premium 4 synthetic oil Place gear selector in neutral and set parking brake Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly Oil Tank Drain Plug Torque 14 ft Ibs 19 Nm Crankcase Drain Plug Torque 14 ft Ibs 19 Nm Oil Filter Torque Tum by hand until filter gasket contacts sealing surface then turn an additional 1 2 turn Oil Filter Wrench Snap Ont PN YA997 or 2 1 2 inch Oil Tank Screen Fitting Torque 14 17 ft Ibs 19 Nm Crankcase Drain Starter Engine Sump Drain Plug Bottom View 4 99 2 Polaris Sales Inc Valve Clearance 335 425 500cc Engines Inspect an
31. all this measurement B Subtract measurement B from measurement A The difference between measurements A and B is the vehicle toe alignment The recommended vehicle toe tolerance is 1 8 to 1 4 3 to 6 cm toe out This means the measurement at the front of the tire A is 1 8 to 1 4 3 to 6 cm wider than the measurement at the rear B Toe Alignment Adjustment 7 If toe alignment is incorrect measure the distance between vehicle center and each wheel This will tell you which tie rod needs adjusting NOTE Be sure handlebars are straight ahead before determining which tie rod s need adjustment CAUTION During tie rod adjustment it is very important that the following precautions be taken when tightening tie rod end jam nuts If the rod end is positioned incorrectly it will not pivot and may break To adjust toe alignment S Hold tie rod end to keep it from rotating S Loosen jam nuts at both end of the tie rod S Shorten or lengthen the tie rod until alignment is as re quiredtoachievethepropertoesettingasspecified inMethod1 1 16 to1 8 orMethod2 1 8 to 1 4 When the tie rod end jam nuts are tightened be sure to hold tie rod ends so they are parallel with the steer ing arm or the steering frog respectively to prevent rod end damage 8 After alignment is complete torque jam nuts to 12 14 ft Ibs 1 66 1 93 kg m Correctly Tightened Jam Nut Inco
32. are no combustible materials in the area when purging the spark arrestor S Wear eye protection S Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor S Never run the engine in an enclosed area The exhaust con tains poisonous carbon monoxide gas S Do not go under the machine while it is inclined Failure to heed these warnings could result in serious personal injury or death 4 99 25 Polaris Sales Inc MAINTENANCE Brake System 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 S Keep fluid level in the master cylinder reservoir between Min amp Max lines at all times Use Polaris DOT 3 brake fluid PN 2870990 Check brake system for fluid leaks Hs a Minimum Maximum S S S Check brake for excessive travel or spongy feel S Check friction pads for wear damage and looseness S Check surface condition of the disc S Inspect thickness of brake pad friction material Parking Brake Lock Brake Pad Inspection S Pads should be changed when friction material is worn to 3 64 1 cm or about the thickness of a dime Minimum Thickness Hose Fitting Inspection Check brake system hoses and fittings for cracks deterio ra
33. aris Sales Inc 26 4 99 MAINTENANCE Drive Chain 7 Tighten the eccentric clamp bolts to specification a We Eccentric Clamp With Hitch WITH TRAILER HITCH 40 ft Ibs 55 Nm CAUTION DO NOT OVER TIGHTEN ECCENTRIC CLAMP BOLTS PRE MATURE BEARING FAILURE MAY RESULT Torque the nut WITHOUT TRAILER HITCH 30 ft Ibs 41 Nm 8 Verify chain adjustment is correct after tightening eccentric clamp bolts to specification 9 Tighten caliper mounting bracket bolts 10 12 ft Ibs 14 17 Nm 10 Reinstall chain guard where applicable NOTE Reposition chain guide to allow 1 8 3 cm clearance between sprocket and guide 4 99 26 Polaris Sales Inc MAINTENANCE Drive Chain Center Front Drive Chain Slack Adjustment The center chain should be adjusted before the front chain This adjustment affects the front chain slack Center Front Drive Chain Inspection Adjustment 1 2 Remove center chain guard attaching hardware Press brake pedal downward and remove guard Remove forward chain guard attaching bolts and guard Loosen center chain eccentric clamp bolts A Rotate vehicle forward or rearward until one of sprocket holes aligns with hole provided in eccentric Insert a large punch or screwdriver through sprocket and into eccentric hole Rotate vehicle rearward to tight en chain Chain deflection should be 1 4 1 2 6 13 mm with 18 Ibs 8 18 kg of force at center of chain Tigh
34. ark plug is used Apply a small amount of anti seize compound to the spark plug threads Install spark plug and torque to 14 ft Ibs Ignition Timing Refer to Electrical chapter for ignition timing procedure Engine To Frame Ground Inspect engine to frame ground cable connection Be sure it is clean and tight MAINTENANCE Electrical Recommended Spark Plug Refer to Specifications 14 Ft Lbs 19 Nm Spark Plug Torque omc Jap Spark Plug Gap 024 028 6 7 mm Polaris Sales Inc 2 3 4 99 MAINTENANCE Cooling System Liquid Cooling System Overview Theenginecoolantlevelis controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolantoperating temperatureincreases the expanding heated excess coolantis forced outof theradiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator SSome coolant level drop on new machinesis normalas the system is purging itself of trapped air Observe coolant levels often during the break in period SPolaris Premium 60 40 is already premixed and ready to use Do not dilute with water Coolant Strength Type Test the strength of the coolant using an antifreeze hydrometer S A 50 50 or 60
35. bottom of oil tank Place a drain pan beneath oil tank and remove drain plug CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as serious burns may result Allow oil to drain completely 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 Reinstall drain plug and torque to 14 ft Ibs 1 9 kgm Loosen clamp E or bolt D Remove oil hose from screen fitting C on bottom of oil tank Remove screen fitting C Clean screen thoroughly Apply Loctitet PST 505 or an equivalent pipe thread sealant or PTFE sealant tape to clean oil free threads of fitting Install fitting and torque to 14 17 ft Ibs Install oil hose on fitting and tighten clamp to 25 inch Ibs MAINTENANCE Oil Change 4 Cycle Nat Sh EN a ADD 8 OZ NORMAL D EEEE Maintain Oil Level In Normal Range Screw in completely to check Recommended Engine Oil Polaris Premium 4 All Season Synthetic OW 40 PN 2871281 Ambient Temperature Range 40 F to 120 F Polaris Sales Inc 2 4 4 99 MAINTENANCE 4 Stroke Engine Maintenance Oil and Filter Change Cont 4 Stroke 15 16 17 Place shop towels beneath oil filter Using an oil filter wrench turn filter counterclockwise to remove Using a clean dry cloth clean filter sealing surface on crankcase Lubricate
36. change lubricant 1 2 Remove skid plate if necessary Place a drain pan beneath the transmission oil drain plug area Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings After the oil has drained completely install a new sealing washer and install the drain plug Torque to 14 ft Ibs 1 93 kg m Add the proper lubricant through the dipstick hole un til the oil level is between the upper and lower limits Do not overfill 6 Check for leaks 7 Reinstall skid plate if removed in step 1 Transmission Dipstick Operating Range Operating Range 4 99 2 1 Polaris Sales Inc Transmission Lubrication cont Shaft Chain Models Without Dipstick To 1 To check the level Remove propshaft shield from the right side of the vehicle Remove fill plug and visually inspect the oil level Lev el is correct when it reaches the bottom of the fill hole as shown at right change lubricant Remove propshaft shield from the right side of the vehicle Remove transmission drain plug drain the oil Catch and discard used oil properly Clean and reinstall the drain plug with a new sealing washer Torque to specification Remove fill plug Add Polaris Premium Synthetic Gearcase Lubricant to proper level as described above Check for leaks Reinstall propshaft shield Transmission Fill Plug
37. d 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 rocker cover bolts cover and gasket NOTE It may be necessary to tap cover lightly with a soft faced hammer to loosen it from the cylinder head 5 Remove timing inspection plug from recoil housing CAUTION Failure to position the crankshaft at TDC on compression stroke will result in improper valve adjust ment 6 Rotate engine slowly with recoil rope watching the intake valve s open and close NOTE At this point watch the camshaft sprocket locating pin and slowly rotate engine until locating pin is facing up ward directly in line with the crankshaft to camshaft center line as shown The camshaft lobes should be pointing downward 7 Verify accurate TDC positioning by observing the T mark aligned with the pointer in the timing inspection hole In this position there should be clearance on all valves MAINTENANCE Valve Clearance 4 Cycle Sprocket alignment pin facing up Crankshaft to C amshaft Centerline Polaris Sales Inc J 4 99 MAINTENANCE 4 Stroke Engine Maintenance Intake Valve
38. e Shock Spanner Wrench PN 2870872 Controls Checkcontrolsforproperoperation positioningandad justment Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body MAINTENANCE Chassis Maintenance Rear Spring Adjustment Cam Rear Spring Adjustment Cam Position Master Cylinder and Switch to Provide Clearance Polaris Sales Inc 2 6 4 99 MAINTENANCE Chassis Maintenance Wheels Inspect all wheels for runout or damage Check wheel nuts and ensure they are tight Do not over tighten the wheel nuts Wheel Hub and Spindle Torque Table Rear Wheel Nuts Specification Front Wheel Nuts 15 Ft Lbs 50 Ft Lbs Front Spindle Nut 40 Ft Lbs Rear Hub Retaining Nut 80 Ft Lbs Front Wheel Nuts 15 Ft Lbs 4x4 Rear Wheel Nuts 50 Ft Lbs Chain Drive and Front Spindle Nut Refer to procedure listed in Chapter 7 Chain Shaft Models and Magnum 500 Rear Hub Retaining Nut 80 Ft Lbs Front Wheel Nuts 15 Ft Lbs 4x4 Rear Wheel Nuts 15 Ft Lbs Shaft Drive Front Spindle Nut Refer to procedure listed in Chapter 7 All except Magnum 500 Rear Hub Retaining Nut 100 Ft Lbs 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
39. e RPM begins to drop 6 Center the pilot screw between the points in step 5 and 6 7 Re adjust idle speed if not within specification Pilot Screw Adjustment 335 4 Stroke Models IMPORTANT NOTE Idle speed is specified with the lights OFF On the idle speed will drop between 100 150 RPM when the lights are turned on 1 Remove anti tamper plug and connect an accurate tachometer such as the PET 2100DX P N 8712100DX or the PET 2500 P N 8712500 2 Adjust idle speed using the idle speed screw to about 1600 RPM 3 Turn the pilot screw mixture screw in or out slowly using the pilot screw wrench to obtain the highest idle RPM anu 4 Re adjust idle speed to specified RPM 1300 100 5 Again turn the pilot screw in or out slowly to obtain the highest idle RPM 6 Turn the pilot screw out counterclockwise 1 8 to 1 4 turn 7 Re adjust idle speed to specified RPM 1300 100 4 99 2 2 Polaris Sales Inc Idle Speed Adjustment 1 Start engine and warm it up thoroughly 2 Adjustidle speed by turning the idle adjustment screw in clockwise to increase or out counterclockwise to decrease RPM Refer to Ill at right NOTE Adjusting the idle speed affects throttle cable freeplay and electronic throttle control ETC adjustment Always check throttle cable freeplay after adjusting idle speed and adjust if necessary Idle Speed Refer to Specifications MAINTENANCE Carburetor Adjustments
40. e tie rod ends clevis pins and pivot bushings and replace if worn or damaged Jam Lubricate the tie rod ends with a light aerosol Jam Nut Nut lubricant or grease 3 Loosen all rod end adjuster jam nuts see Ill 1 4 Note orientation of tie rod end studs with stud up or down Remove both rod end studs from transmission bell cranks 5 Be sure idle speed is adjusted properly NOTE Rod end orientation up or down varies by model Note before disassembly NOTE It is important to disconnect both rod ends from the transmission bell cranks If one linkage rod is incor lll 1 rectly adjusted it can affect the adjustment of the other rod Disconnect Low range linkage rod end from pivot arm on Sportsman 500 style linkage 6 Place gear selector in neutral Make sure the transmission bell cranks are engaged in the neutral position detents 4 99 2 Polaris Sales Inc Shift Linkage Adjustment High Low Reverse Cont 7 12 Be sure the shift linkage rod ends are firmly attached to the gear selector slides Adjust the low range inside rod so the rod end is centered on the transmission bell crank or centered on the pivot arm on Sportsman 500 style Install the lock nut to the rod end and torque to 35 in Ibs Rotate the linkage rod clockwise until resistance is felt Mark the rod so revolutions can be easily counted See Ill 3 at right Rotate the linkage rod counterclockwise until the same r
41. ed 2 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 outside to the inside MAINTENANCE Air Cleaner 2 Cycle Polaris Sales Inc 24 4 99 MAINTENANCE Air Cleaner 2 Cycle Main Air Filter Service 400 Style Release seat latch and lift up on the rear of the seat Pull the seat back and free the tab from front cab Remove the two wing nuts and washers securing the air filter access cover Remove the cover Inspect the gasket It should adhere tightly to the cover and seal all the way around Remove the wing nut and washer securing the se cond cover The cover should be straight and not distorted Remove pre filter from main filter and discard the main air filter Carefully wash the pre filter in soapy water and dry it thoroughly Replace the pre filter if the element is torn or damaged Install dry pre filter over new main filter and install NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing Cleaning the Main Filter Important It is advisable to replace the filter when it is dirty How ever in a new filter is not immediately available it is permissible to clean the main filter if you observe the following practices 1 Never immerse the filter in water since dirt can be transferred to the clean air side of the filter In addi tion
42. ely Capacity at change after draining is approximately 20 fl oz 592 ml Middle Angle Drive Complete Assembly is P N 1341239 Rear Angle Drive Complete Assembly is P N 1341246 4 99 2 1 Polaris Sales Inc Front Gearcase Lubrication MAINTENANCE Front Gearcase The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule S Be sure vehicle is level before proceeding S Check vent hose to be sure it is routed properly and unobstructed S Current gearcases in use are shown by illustration Refer to illustrations to determine type and follow instruc tions to check change gearcase lubricant S The correct gearcase lubricant to use is Polaris Premium GL5 80 90 Gear Lube or an equivalent lubricant with a GL5 rating FRONT GEARCASE SPECIFICATIONS Type Il and Ill Specified Lubricant Polaris Front Gearcase Lube PN 2871653 Or API GL5 80 90 Gearlube Capacity Typel amp Il 4 0 Oz 120ml Type Ill 5 0 Oz 150ml Drain Plug Fill Plug Torque 14 ft Ibs 19 4 Nm TYPE To check the level 1 Remove fill check plug 2 Add proper lubricant if necessary until level with bottom of fill hole threads 3 Install fill check plug To change lubricant 1 Remove gearcase drain plug located on the bottom and drain oil Catch and discard used oil properly 2 Clean and reinstall drain plug using a new sealing washer 3 Remove fill
43. eplay Switch Plunger Must Be Held In By Cable Tension Throttle Cable Adjuster Lock Nut Ill 4 4 99 2 2 Polaris Sales Inc Oil Pump Adjustment Procedure 250cc 300cc Engines 1 Before adjusting the oil pump check engine idle RPM and set to specification Adjust if necessary Check and adjust throttle lever free play ETC switch Place gear selector in neutral and apply parking brake Start the engine and let it idle Place very slight pressure on the throttle lever until all freeplay is removed from throttle cable to carburetor to the point where the carb slide is just starting to rise and engine RPM begins to increase Loosen locknut A Turn adjuster B in or out until all freeplay is removed from oil pump cable the point where the oil pump arm C is just starting to move off of its stop NOTE The pump stop keeps the pump arm from rotat ing any farther down than the idle position so no visual alignment of marks is necessary 8 Tighten the locknut MAINTENANCE Oil Pump Adjustment 2 Cycle Engines 250cc 300cc Engine Forward gt Polaris Sales Inc 2 2 4 99 MAINTENANCE Oil Pump Adjustment 2 Cycle Engines Oil Pump Adjustment Procedure 400cc Engines 1 Before adjusting the oil pump check engine idle and adjust to specification if necessary Check and adjust throttle lever free play ETC switch if necessary Place gear selec
44. esistance is felt counting the revolutions as the rod is turned Turn the rod clockwise again one half of the revolutions counted in Step 9 Tighten the rod end jam nuts securely while holding the rod end The jam nuts must be tightened with both front and rear rod ends parallel to each other If jam nuts are properly tightened the rod should rotate freely 1 4 turn without binding Repeat steps 7 10 for the High Reverse rod MAINTENANCE Transmission ont 35 in Ibs Adjust to align linkage rod end studs with holes in bellcrank s V Rotate rod both directions to find points where resistance is felt V Center the rod between the points V Hold rod end parallel to mounting surface and tighten jam nut Parallel Polaris Sales Inc J 4 99 MAINTENANCE Transmission Shift Linkage Adjustment High Reverse Transmissions 1 If model is equipped with a transmission torque stop adjust as outlined previously in Torque Stop Adjustment Inspect shift linkage tie rod ends clevis pins and pivot bushings and replace if worn or damaged Lubricate the tie rod ends with a light aerosol lubricant or grease Place gear selector in neutral Loosen rod end adjuster jam nuts A on both ends of linkage rod Note orientation of tie rod end studs which way the stud goes through the transmission bell crank and gear selector arm Remove rod end from gear selector arm Ill
45. force fluid into hub Brake Fluid Polaris DOT 3 Brake Fluid Fill between Min amp Max indicators on 2 plastic reservoir Cold Weather Kits for 4 Cycle ATVs and 6x6 Oil Tank Cover PN 287187 Engine Heater PN 2871507 Oil Tank Heater PN 2871873 Polaris Sales Inc 2 4 99 MAINTENANCE Maintenance Products Polaris Premium Lubricant and Maintenance Product Part Numbers Part No Description Engine Lubricant 2870791 Fogging Oil 2871281 Engine Oil Quart Premium 4 Synthetic 0 W40 4 Cycle 2871567 Engine Oil 16 Gallon Premium 4 Synthetic 0 W40 4 Cycle 2871098 Premium 2 Cycle Engine Oil Quart 2871097 Premium 2 Cycle Engine Oil Gallon 2871240 Premium 2 Cycle Engine Oil 2 5 Gallon 2871566 Premium 2 Cycle Engine Oil 16 Gallon 2871385 Premium 2 Cycle Engine Oil 30 Gallon 2871240 Premium 2 Cycle Engine Oil 55 Gallon 2871721 Premium Gold 2 Cycle Synthetic Lubricant Gearcase Transmission Lubricants 2871477 Premium Synthetic Gearcase Lubricant 1 Gal 2871478 Premium Synthetic Gearcase Lubricant 12 oz bottle 2870465 Oil Pump for Gearcase Oil 2871653 Premium Front Gearcase Fluid 12 oz Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 0z 2871551 Premium U Joint Lube 14 oz 2871312 Grease Gun Kit 1350046 CV Joint Grease Pack 30g 1
46. ick ml Xplorer 300 A9ICC28CA Trans Trans 20 oz 592 ml Dipstick X press 300 A Trans 20 oz 592 ml Re Dipstick Sportsman 335 A99CH33CA Kag 32 oz 984 PPS Dipstick mla Maa a Front 40z 118 ml 80 90 GL 5 Bottom of fill plug threads Early Type ll Front 40z 118 ml 80 90 GL 5 Drain Refill w proper amount L ate Baka 400 A99BG38CA bi Pes PA Ba eaten Bottomoffill hole fill hole Talore 400 A99CG3ECA ma a ES HA 3 PA Kasi EE 11 3 oz 35 Dipstick ml kakai 500 od E oz 948 ml Bottom of fill hole ll Front 40z 118 ml 80 GL 5 Drain Refill w proper amount Magnum 500 A99CD50AA 13 5 oz 400 Bottom of fill hole ml i ll Front 50z 150 ml 80 90 GL 5 Drain Refill w proper amount Rear O 10 oz 300 ml 80 90 GL 5 Bottom of fill hole Sportsman 500 A9ICH50AA Ka 32 oz 948 PPS Dipstick mba Pa HA Front 40z 118 ml 80 90 GL 5 Bottom of fill plug threads Early Type ll Front 40z 118 ml 80 90 GL 5 Drain Refill w proper amount L ate Big Boss 6x6 A9IAE50AA Trans oZ 20 oz 592 ml ml U Dipstick 3 3 UU ma Front 40z 118 BESE BGC 90 c 5 Bottom a fill plug threads Early Type ll Front 40z 118 ml 80 90 GL 5 Drain Refill w proper amount L ate Approximately 30 ml 30 cc 1 fluid oz PPS Polaris Premium Synthetic G earcase L ubricant i Capacity when disassembled complet
47. ill use only distilled water Tap water contains minerals which are harmful to a battery AN Do not allow cleaning solution or tap water to enter the battery It will shorten the life of the battery 6 Reinstall the battery caps 7 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 8 Reinstall battery attaching positive red cable first and then the negative black cable 9 Reattach vent hose making sure it is properly routed and not kinked or pinched 10 Coat terminals and bolt threads with Polaris dielectric grease 11 Reinstall battery cover and holder strap 4 99 23 Polaris Sales Inc 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 Remove spark plug Inspect electrodes for wear and carbon buildup Look for a sharp outer edge with no rounding or erosion of the electrodes Clean with electrical contact cleaner or a glass bead spark plug cleaner only CAUTION A wire brush or coated abrasive should not be used 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 If necessary replace spark plug with proper type CAUTION Severe engine damage may occur if the incorrect sp
48. ion Tire Inspection 2 0 00 c eee ee 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 re placement parts Always use genuine Polaris parts mCAUTION Due to the nature of these adjustments it is recommended that service be performed by an authorized Polaris dealer p 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 consti tutes severe use Pay special attention to oil level A rise in oil level in cold weather can indicate moisture collect ing in the oil tank Change oil immediately if oil level begins to rise E Emission Control System Service California PERIODIC MAINTENANCE ENGINE Frequency Whichever comes first Calendar Miles Km 100 hrs 1000 1600 Check Level Daily Break In service at 1 month Oil Filter 4 strokes 100 hrs 1000 1600 Replace with oil change Oil Pump Cable 2 strokes 500 800 Inspect Adjust Lubricate Replace if Required Air Filter Foam Pre Cleaner Inspect Clean amp oil more often in dirty condi
49. l cap 2 cycle mod els Remove front cover by placing your fingers under the front of the cover and pulling upward Reinstall oil cap Gen IV Remove the four screws securing front rack Re move front cover by placing your fingers under the front of the cover and pulling upward Gen Ill 4 99 2 Polaris Sales Inc Air Filter Service Trail Blazer Style 1 Release seat latch and lift up on the rear of the seat Pull the seat back and free of the tabs Remove the primary air filter box Remove the yellow pre cleaner foam boot held in place by a gray collar from the air box Do not re move the collar Carefully wash the yellow foam boot in soapy wa ter and dry it Oil the foam boot with engine injection oil 1 to 2 teaspoons Squeeze out the excess into an ab sorbant cloth Reinstall the yellow foam boot onto the air filter box Reinstall the primary air filter box removed in step 2 NOTE There will be some resistance Be sure the black rubber sealing ring is securely positioned over the main filter neck CAUTION When installing the primary air filter box be sure the gray foam collar B is below the intake opening of the air box intake A Improper installation will restrict airflow to the engine possibly resulting in engine damage MAINTENANCE Air Cleaner 2 Cycle Gray Collar Po a see Yellow Boot D Intake Silencer NG
50. lush with upper edge of box Sportsman 500 Make certain foam is flush with front edge of airbox so air cannot enter engine breather fitting hole with out first passing through the foam 335 Tank Foam Correct Position Polaris Sales Inc 24 4 99 MAINTENANCE Air Box Sediment Tube 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 NOTE The sediment tube will require more frequent ser vice if the vehicle is operated in wet conditions or at high throttle openings for extended periods 1 Remove drain plug from end of sediment tube 2 Drain tube 3 Reinstall drain plug _ Sediment Tube 4 99 2 4 Polaris Sales Inc Breather Filter Inspection Four cycle ATV engines are equipped with a breather filter The in line filter is similar in appearance to a fuel filter and is visible on the left side Location A or right side location B of the vehicle Some models have a foam breather filter in the air box location C Some models are equipped with both in line and foam breather filters 1 Inspect the breather filter s for obstruction Replace if necessary In line breather filters should be installed with the arrow pointing toward the engine away from the air box NOTE In line breather filter service life is extended when the foam air box pre filter is in place and maintained prop erly
51. ng Primary Air Filter Box Pre cleaner Boot Main Filter Neck 4 99 2 4 Polaris Sales Inc Air Cleaner Maintenance 300 Style Cont Secondary Main Filter Inspect the secondary filter in accordance with the maintenance schedule Secondary filter removal and installation 1 Remove seat 2 Remove primary air filter box 3 Remove four wing nuts holding cover assembly to secondary air filter housing 4 Remove filter element 5 Inspect gaskets on both sides of filter Replace if required 6 Coat top and bottom gaskets of filter with a gener ous amount of grease 7 Check condition of air box and replace if necessary Inspect air ducts and clamps for proper sealing 8 Install filter into airbox Be sure filter element seats securely 9 Check cover gasket and replace if required Be sure cover is seated properly and wing nuts are fin ger tightened securely 10 Reinstall primary air filter box as per instructions found on previous page 11 Reinstall seat Cleaning the Main Filter Important It is advisable to replace the filter when it is dirty How ever in a new filter is not immediately available it is permissible to clean the main filter if you observe the following practices 1 Never immerse the filter in water since dirt can be transferred to the clean air side of the filter In addi tion the filtering ability of the treated paper element will be significantly reduc
52. ng Procedure To verify oil delivery to engine proceed as follows Premix fuel in tank at a 40 1 fuel oil ratio 2 With the oil reservoir full and the pump bled remove the oil delivery line from the intake manifold 3 Test the oil delivery check valve with a low pressure pump and gauge See Page 3 22 4 Start engine and lift oil pump lever to full open position 5 Oil should pulse from the delivery line every few seconds If it does not suspect one of the following A Oil line or filter plugged B Oil tank vent line restricted C Oil lines leaking or blocked D Faulty oil pump or drive mechanism Polaris Sales Inc 2 4 99 MAINTENANCE Oil Filter 2 Strokes Oil Filter 2 Strokes The oil filter is located in line between the oil tank and the oil pump on all 2 stroke models The in line oil filter is a special type and must not be substituted Replace the oil filter in accordance with the Maintenance Schedule or whenever water or debris has entered the oil tank Do not attempt to clean this filter Oil Filter 1 Remove clamps securing lines to filter 2 Remove lines and replace filter with arrow pointing in direction of oil flow towards pump 3 Reinstall clamps on each line and check for leaks Arrow Indicates Direction of Flow From Tank 4 99 2 3 Polaris Sales Inc MAINTENANCE Fuel System Gasoline is extremely flammable and explosive under certain conditions A A A A A
53. oose or too tight as severe damage to the transmission and drive components can result Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the rear chain At this point the chain should have 3 16 3 8 5 10 mm deflection If the chain needs adjustment use the following procedure Pin Punch aa 3 16 3 8 48 cm 95 cm Deflection Loosen caliper mounting l bracket bolts Step 3 V Adjustment Procedure Concentric Swin garm Rear Axles Tapered Roller Bearings pr Loosen Eccentric N clamp bolts Step 2 1 Loosen chain guard 3 2 Loosen two eccentric clamp bolts 3 Loosen caliper mounting bracket bolts Loosen 2 caliper mounting bracket bolts Step 3 4 99 26 Polaris Sales Inc MAINTENANCE Drive Chain Adjustment Procedure Concentric Swingarm Rear Axles Tapered Roller Bearings Cont 4 Using a 2 1 2 wrench rotate the housing to adjust chain slack to the proper dimension and then pro ceed to Step 7 or follow Steps 5 and 6 for alternate method if 2 i 1 2 wrench is not available wY Sya a wr N a i 1 j Ta NA aA 5 Insert a pin punch through the sprocket hub and into the eccentric axle housing Alternate Adjustment Method Pin Punch Step 5 and 6 6 Roll the vehicle ahead or back to adjust chain slack to the proper dimension Pol
54. rcase viewed Specified Lubricant through the fill plug Hypoid or non hypoid gearlube can 3 be used provided it is API GL5 rated Polaris Front Gearcase Lube PN 2871653 Or API GL5 80 90 Gearlube REAR GEARCASE SPECIFICATIONS 5 Reinstall fill plug Tighten securely 14 ft Ibs 1 93 kgm Capacity 10 0 Oz 300mlI 6 Check for leaks r R Drain P lug Fill P lug Torque 14 ft Ibs 19 4 Nm Polaris Sales Inc 21 4 99 MAINTENANCE Transmission Transmission Lubrication The transmission lubricant level should be checked and changed in accordance with the maintenance schedule S Be sure vehicle is level before proceeding S Check vent hose to be sure it is routed properly and unobstructed S Current gearcases in use are shown by illustration Refer to illustrations and Quick Reference Chart on page 2 10 to determine type Follow instructions on following pages to check change transmission lubricant TRANSMISSION SPECIFICATIONS Specified Lubricant Polaris Premium Synthetic Gearcase Lubricant PN 2871477 Gallon PN 2871478 12 oz Capacity Refer to Quick Reference Chart page 2 10 Drain Plug Fill Plug Torque 14 ft Ibs 19 4 Nm Dipstick Models To check the level 1 2 Remove fill plug dipstick and wipe clean Reinstall dipstick completely remove and check the level Add the proper lubricant as required to bring level into operating range as shown in Ill 1 and Ill 2 To
55. rrectly Tightened Jam Nut 2 5 Polaris Sales Inc Front Hub Fluid Level Inspection AWD Models To check front hub fluid 1 2 5 6 Place vehicle on a level surface Turn wheel until front hub fill check plug is in either the 4 00 or 8 00 position Remove fill check plug Add Polaris Demand Drive Hub Fluid if necessary until fluid trickles out NOTE Do not force the fluid into the hub under pressure or seal damage may occur Reinstall plug Repeat procedure for other hub Front Hub Fluid Change AWD Models 1 2 3 Place a drain pan beneath the hub Remove 3 screws and hub cap Pry equally in notches provided until cap is removed Allow fluid to drain completely Inspect hub cap O rings for nicks cuts or abrasions Replace if necessary Remove check fill plug Reinstall the hub cap NOTE The check fill plug must be removed before reinstalling the hub cap Turn wheel until front hub fill check plug is in either the 4 00 or 8 00 position Add Polaris Demand Drive Hub Fluid until fluid trickles out NOTE Do not force the fluid into the hub under pressure or seal damage may occur Polaris Demand Drive Hub Fluid PN 2871654 8 oz PN 2872277 2 5 gallon MAINTE NANCE Chassis Maintenance Polaris Sales Inc 2 5 4 99 MAINTENANCE Exhaust System Exhaust Pipe The exhaust pipe must be periodically purged of accumu lated carbon as follows 1 7 Stop the engine
56. se cold starting difficulty Also the half choke position used for intermittent applica tions will not function properly 1 2 3 Flip choke toggle to full off position Slide boots C off choke cable adjuster and lock nut Ill 2 Loosen adjustment locknut A on cable sleeve in line adjusters or on carburetor Turn cable sleeve adjusting nut B clockwise on carburetor until 1 4 6 mm or more choke toggle free play is evident Turn cable sleeve adjusting nut counterclockwise until toggle has zero free play then rotate it clockwise until 1 8 1 4 3 6 mm toggle free play is evident Tighten locknut A Slide boots back over cable adjuster sleeve until they touch at the middle point of the sleeve in line adjusters or until seated fully over adjuster Choke Lever Freeplay 1 8 1 4 3 6 cm MAINTENANCE Carburetor Adjustments 1 8 1 4 3 6 cm Choke Toggle Position Freeplay A Adjuster Boot C Sleeve B Locknut Boot C A etm Adjust at cable adjuster or lll 2 Adjust at carburetor Polaris Sales Inc 2 2 4 99 MAINTENANCE Carburetor Adjustments Air Screw Adjustment 2 Stroke Models 1 Turn carburetor air screw in until lightly seated Back screw out the specified number of turns 2 Cycle Engines Air Screw Adjustment 2 Stroke engines Refer to Specifications 2 Warm up the engine to operating temperature about
57. sket surfaces to remove all traces of the old pres gasket CAUTION Use care not to damage the Sealant UP sealing surface of the cover or cylinder head 7 Reinstall the cover using a new gasket 8 Torque cover bolts to 78 in lbs 9 Remove the shop towel from the spark plug cavity 10 Reinstall the spark plug Torque to 14 ft Ibs 19 Nm 11 Reinstall the spark plug high tension lead 12 Reinstall the fuel tank 13 Reinstall the fuel tank shroud 14 Reinstall the left and right body panels Cover Bolt Torque 72 in Ibs Spark Plug Torque 14 ft Ibs Polaris Sales Inc 25 4 99 MAINTENANCE Steering amp Toe Alignment Inspection 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 Due to the critical nature of the procedures outlined in this chapter Polaris recommends steering component re pair and adjustment be performed by an authorized Polaris Dealer Only a qualified technician sho
58. t Refer to page 2 10 Install fill plug O a A O Check for leaks 4 99 2 1 Polaris Sales Inc MAINTENANCE Rear Gearcase Rear Gearcase Lubrication To check the level 1 With machine on level ground remove fill plug from rear gearcase a Photo 1 2 Insert dipstick until it stops squarely against the fill plug gasket surface and then remove it Photo 1 Lubricant level is acceptable if it is within the knurled area on the stick The level can be checked without a dipstick Re fer to Photo 2 below right 3 If level is low add the proper lubricant until level correct on the dipstick or until it is even with the center of the machined drill point inside the gearcase when viewed through the fill plug Hypoid or non hypoid gearlube can be used provided it is API GL5 rated NOTE Do not add lubricant to the bottom of the fill plug threads Tighten securely 14 ft Ibs 1 93 kgm 4 Reinstall fill plug 5 Check for leaks To change the lubricant 1 Remove gearcase drain plug located on the bottom and drain the oil Catch and discard used oil properly Oil Level 2 Clean and reinstall the drain plug with a new sealing washer and tighten securely 14 ft Ibs 1 93 kgm Oil Level 1 5 8 from gasket surface 3 Remove fill plug Ay pared as shown 4 Add 300 ml of GL5 80 90 Weight Gear Lube and in spect level Oil level should be even with the center of the machined drill point inside the gea
59. t 50 hrs 6 months Clutches Drive And Driven 100 hrs 12 months Transmission Oil Level 25 hrs Shift Linkage 50 hrs Shift Selector Box 200 hrs Steering 50 hrs 6 months Toe Adjustment As required As required Rear Axle 50 hrs 6 months Front Suspension 50 hrs 6 months Rear Suspension 50 hrs Drive Chain 50 hrs Tires Pre ride Brake Fluid 200 hrs 24 months Brake Fluid Level Pre ride Pre ride Brake Lever Travel Pre ride Pre ride Brake Pad Wear 10 hrs Monthly Auxiliary Brake Adjustment As required As required e Tires check condition and pressures e Fuel and oil tanks fill both tanks to their proper level Do not overfill 4 stroke oil tank e All brakes check operation and adjustment includes auxiliary brake e Throttle check for free operation and closing e Headlight Taillight Brakelight check operation of all indicator lights and switches e Engine stop switch check for proper function e Wheels check for tightness of wheel nuts and axle nuts check to be sure axle nuts are se cured by cotter pins e Drive chain condition and slack refer to drive chain adjustment e Air cleaner element check for dirt clean or replace e Steering check for free operation noting any unusual looseness in any area e Loose parts visually inspect vehicle for any damaged or loose nuts bolts or fasteners e Engine coolant check for proper level at the recovery bottle Pol aris Sales Inc 4 99 MAINTENANC
60. t be clear and open 2 Fill reservoir to upper mark with Polaris Premium 60 40 Anti Freeze Coolant or 50 50 or 60 40 mixture of antifreeze and distilled water as required for freeze protection in your area 3 Reinstall cap NOTE If overheating is evident allow system to cool completely and check coolant level in the radiator MAINTENANCE Cooling System Gen Il Recovery Bottle Gen Ill Recovery Bottle Recovery Bottle Polaris Sales Inc 2 3 4 99 MAINTENANCE Cooling System Engine Cooling System Radiator Coolant Level Inspection NOTE This procedure is only required if the cooling sys tem has been drained for maintenance and or repair However if the recovery bottle has run dry or if overheat ing is evident the level in the radiator should be inspected and coolant added if necessary A WARNING Never remove the pressure cap when the engine is warm or hot Escaping steam can cause se vere burns The engine must be cool before removing the pressure cap NOTE Use of a non standard pressure cap will not allow the recovery system to function properly To access the radiator pressure cap Gen Il To access the pressure cap remove the access cover on the front of the ATV just below the oil cap Using a flat stubby screwdriver loosen the screw 1 4 turn and pull the cover forward and up to remove Gen Ill To access the pressure cap clean the area around the oil cap and remove the oi
61. t off fuel supply at fuel valve Arrow Indicates Direction Remove line clamps at both ends of the filter of Flow Remove fuel lines from filter Install new filter and clamps onto fuel lines with arrow pointed in direction of fuel flow Install clamps on fuel line To Carburetor Turn fuel valve ON Start engine and inspect for leaks Reinstall fuel tank Polaris Sales Inc 2 3 4 99 MAINTENANCE Carburetor Fuel System Carburetor Draining The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl or before ex tended periods of storage NOTE The bowl drain screw is located on the bottom left side of the float bowl on 4 stroke models A drain plug which also acts as a water sediment trap is located on the bottom of the float bowl on 400cc 2 stroke models 1 Turn fuel valve to the off position 2 Place aclean container beneath the bowl drain spigot or bowl drain hose 3 Turn drain screw out two turns remove drain plug for 2 Strokes and allow fuel in the float bowl and fuel line to drain completely 4 Inspect the drained fuel for water or sediment 5 Tighten drain screw 6 Turn fuel valve to on 7 Start machine and check for leaks 4 Strokes Drain tube attached here ON Fuel Valve 2 Strokes 400cc a Remove Plug Carburetor Bowl 4 99 2 3 Polaris Sales Inc MAINTENANCE Engine Compression Test 2 Stroke 1 Remo
62. tch the chain tightly in a straight line 2 Measure a length of twenty pitches pins from pin center to pin center and compare to the specification Proper Replace the chain if the length exceeds the wear limit Splicelink Clip 3 When replacing or reinstalling drive chain install the Salil closed end of the splice link clip as shown with the osmon Rear Chain closed end leading in forward operation Shown Drive Chain Wear Limit 20 Pitch Length Std 12 5 32 cm Wear Limit 12 875 32 7 cm 4 99 26 Polaris Sales Inc MAINTENANCE Drive Chain Rear Drive Chain Tension Inspection Standard Swingarm Rear drive chain tension must be measured with the swingarm in the position shown below in Ill 1 to ensure accu rate measurement NOTE On models with concentric swingarm all rear chain drive except Xplorer and Xpress 300 chain tension can be measured at any point in the swingarm arc It is not necessary to compress the suspension on concentric models Refer to following page for drive chain adjustment on models with concentric swingarm CAUTION S 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 S Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the rear chain S Collapse the suspension by using an adjustable buckle type trailer tie down
63. ten eccentric clamp bolts to 45 ft Ibs 62 Nm NOTE This does not include nut rolling torque Check chain tension Loosen forward chain eccentric clamp bolt B Install punch as was done previously and adjust chain to 1 4 1 2 6 13 mm with 18 Ibs 8 18 kg force at center of chain Tighten forward eccentric clamp bolt to 45 ft Ibs 62 Nm NOTE This does not include nut rolling torque When this bolt is tightened the chain deflection may change Check deflection and adjust again if needed Center and Front Drive Chain Adjustment 1 4 1 2 6 13 mm with 18 Ibs load 8 18 kg 1 4 1 2 6 13 mm with 18 Ibs load 45 ft Ibs 62Nm z y lroa SL t Pin Punch rs ft Ibs E 62Nm Polaris Sales Inc 26 4 99 MAINTENANCE Drive Chain 6x6 Drive Chain Inspection Adjustment 6x6 CAUTION Never adjust or operate the vehicle with the rear drive chain slack out of the specified range as severe damage to the transmission and drive components can result 6x6 Chain Inspection Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the chain Then pull up and down on the chain Total slack should be as specified below If slack is not within specification adjust the chain 6x6 Middle Axle Chain Adjustment 1 Loosen chain guard 2 Loosen two eccentric locking bolts 3 Insert a pin punch through the sprocket hub and into the eccen BE
64. the filtering ability of the treated paper element will be significantly reduced 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 Access Cover Cover Pro Ftan i 4 99 24 Polaris Sales Inc MAINTENANCE Air Cleaner 4 Cycle Air Filter Service Scrambler 500 Style 1 Remove seat 2 Release clips and remove air box cover Ba Main Filter 3 Loosen clamp and remove filter assembly 4 Remove fabric pre filter from main filter 5 Carefully wash the pre filter in soapy water and dry it thoroughly Replace the pre filter if the element is torn or damaged 6 Replace main filter if dirty 7 Install dry pre filter over new main filter and install 8 Reinstall pre filter in main filter Replace main filter as required Air Filter Service Sportsman 335 500 Magnum 500 Style a 1 Remove seat Pre cleaner 2 Remove spring clamps securing the airbox lid and paa remove lid A Breather Filter Pull foam breather filter out Loosen clamp and remove filter Remove foam pre cleaner from main filter oak w Carefully wash the pre filter in soapy water and dry it thoroughly Replace the pre filter if the element is torn or damaged Install dry pre filter over new main filter and reinstall o IN Push foam breather filter straight down into airbox until f
65. this wornto 1 8 3 mm or less A WARNING Operating an ATV with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control Worn tires can cause an accident Always replace tires when the tread depth measures 1 8 3 cm or less Frame Nuts Bolts Fasteners Periodically inspect the tightness of all fasteners in accor dance with the maintenance schedule Check that all cot ter pins are in place Refer to specific fastener torques listed in each chapter Polaris Sales Inc 2 4 99
66. tion abrasion and leaks Tighten any loose fittings and replace any worn or damaged parts Polaris Sales Inc 25 4 99 MAINTENANCE Auxiliary Brake Hydraulic Auxiliary Brake Adjustment Hydraulic Use the following procedure to inspect the hydraulic auxiliary foot brake system and adjust or bleed if necessary 1 First check foot brake effectiveness by applying a 50 lb approx downward force on the pedal The top of the pedal should be at least 1 25 4mm above the surface of the footrest see Ill 1 If less than one inch two things must be examined Free Play Free play of the brake pedal should be 1 8 1 4 inch 3 2 6 35 mm Free play can be adjusted on some models by altering the length of the pushrod which is connected to the brake pe dal by a clevis Other models are non adjustable type right If free play is excessive on a non adjustable brake inspect pedal linkage and master cylinder for wear or damage and replace any worn parts To adjust the linkage S Remove right hand drive cover to gain access to brake pushrod S Hold clevis A and loosen clevis adjuster lock nut B S To increase free play shorten the pushrod C S To decrease free play lengthen the pushrod C S Hold clevis and tighten lock nut B securely S Reinstall drive cover Bleeding If free play is correct and brake pedal travel is still exces sive air may be trapped somewhere in the system Bleed the hydra
67. tions a Valve Clearance 4 strokes 100 hrs 1000 1600 Inspect Adjust Counter Balancer Fluid 400s 100 hrs 1000 1600 Check Monthly Change Annually Fuel System 100 hrs 12 months 1000 1600 Check for leaks at tank cap lines fuel valve filter pump amp carburetor Replace lines every 2 years Fuel Filter 100 hrs 1000 1600 Replace filter annually Coolant Level Inspection Daily Daily fs Replace engine coolant every 2 years Coolant Strength Pressure Test 100 hrs 6 months 1000 1600 Inspect strength seasonally Pressure test sys System tem annually Headlamp Inspection Daily Daily Check operation daily Apply Polaris Dielectric Grease to connector when lamp is replaced Tail Lamp Inspection Pe ee E Check Operation Daily Apply Polaris Dielectric Grease to socket when lamp is replaced Polaris Sales Inc 2 1 4 99 Engine Oil Level Change MAINTENANCE Periodic Maintenance Chart Cont CHASSIS Frequency Whichever comes first Km place if necessary Periodic Inspection Adjust When Parts are Re placed a a a A QC aa rede a A Pre Ride Daily Inspection Perform the following pre ride inspection daily and when servicing the vehicle at each scheduled maintenance General Lubrication 50 hrs Front Hubs Fluid Check Front Hubs Fluid Change 50 hrs 100 hrs Front Wheel Bearings 2x4 Annually 12 months Front Hub Spindle Nut Torque Annually 12 months AWD Models Drive Bel
68. tor in neutral and apply parking brake Start the engine and let it idle Lift boot A up off adjuster sleeve on cable Remove the oil pump cover Loosen the cable adjuster locknut B Adjust oil pump cable until marks align C when the throttle slide just begins to raise Adjust oil pump cable until marks align when throttle slide just begins to raise and engine speed just begins to increase Tighten jam nuts Reinstall the ETC cover removed in step 1 making sure cover gasket is properly seated If not moisture can enter the ETC and damage the switch Boot Pi tagaan Upper Portion of Bottom Nut ka Lock Nut Marks Must Align When Throttle Begins To Open 4 99 2 Polaris Sales Inc MAINTENANCE Oil Pump Bleeding 2 Cycle Engines Oil Pump Bleeding Procedure Oil Outlet 1 Fill the oil reservoir with Polaris injector oil 2 Loosen the pump bleed screw one full turn Allow Bleed Screw oil to flow from the bleed screw for five to ten seconds Tighten bleed screw CAUTION Never run the engine with the bleed screw loose Loss of oil will cause serious engine damage 3 Start the engine and lift the oil pump lever or reel to its full up open position Allow engine to idle with the lever or wheel in this position for ten to twenty seconds to make sure all air is out of the system Lift Lever 250 300 Oil Pump Bleeding Oil Pump Troubleshooti
69. uld replace worn or damaged steering parts Use only genuine Polaris replacement parts One of two methods can be used to measure toe alignment The string method and the chalk method If adjust ment is required refer to following pages for procedure Tie Rod End Steering Inspection S To check for play in the tie rod end grasp the steering tie rod pull in all directions feeling for movement S Repeat inspection for inner tie rod end on steering post S Replace any worn steering components Steering should move freely through entire range of travel with out binding S 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 S If abnormal movement is detected inspect the hub and wheel assembly to determine the cause loose wheel nuts loose front hub nut 4x4 or spindle nut 2x4 S Refer to the Body Steering or Final Drive chapter for more information Check for Loose Wheel or Hub Camber and Caster The camber and caster are non adjustable 4 99 25 Polaris Sales Inc MAINTENANCE Toe Alignment Method 1 Method 1 Straightedge or String Be sure to keep handlebars centered See note below pan Q gt O ap N po a73 DJ De OS To S AG O 2 NOTE String
70. ulic auxiliary brake system in a conventional manner following the procedure outlined in the Brake chapter 1 8 to 1 4 Free Play 1 or greater pa Adjustable Auxiliary Brake loorboard 4 99 2 Polaris Sales Inc Auxiliary Mechanical Brake System Auxiliary Brake Testing The auxiliary brake should be checked for proper adjust ment 1 Support the rear wheels off the ground 2 While turning the rear wheels by hand apply the auxil iary foot brake This brake should not stop the wheels from turning until the lever is half way between its rest position and bottoming on the footrest Auxiliary Brake Adjustment Mechanical The mechanical auxiliary brake should be adjusted if the brake pedal deflection is under 1 2 1 3 cm or exceeds 3 4 1 9 cm prior to brake activation 1 Place the machine in neutral Stop engine 2 Type l If adjustment is necessary turn adjuster bolt A clockwise until disc rotation becomes difficult Turn adjuster bolt counterclockwise until brake en gagement starts at approximately 1 2 of the total pedal travel See Illustration 1 and 2 Type Il If adjustment is necessary loosen jam nut A and turn adjuster bolt B clockwise until disc rotation becomes difficult Turn adjuster bolt counterclockwise until brake engagement starts at approximately 1 2 of the total pedal travel See Illustration Tighten the lock nut securely See Illustration 1 and 3 3
71. ve spark plug and install compression tester 2 Connect high tension lead to a good ground on engine 3 Open throttle and crank engine until maximum reading is obtained approximately 3 5 revolutions Cylinder Compression 2 Stroke Service Limit 115 PSI Cylinder Compression 4 Stroke Standard See Note Below 50 90 PSI Compression Test 4 Stroke NOTE 4 Stroke engines are equipped with an automatic decompressor Compression readings will vary in pro portion to cranking speed during the test Average compression measured is about 50 90 psi during a compres sion test Smooth idle generally indicates good compression Low engine compression is rarely a factor in running condition problems above idle speed Abnormally high compression can be caused by a decompressor malfunction or worn or damaged exhaust cam lobes Inspect camshaft and automatic decompression mechanism if compres sion is abnormally high Acylinder leakage test is the best indication of engine condition on models with automatic decompression Follow manufacturer s instructions to perform a cylinder leakage test Never use high pressure leakage tester as crank shaft seals may dislodge and leak Cylinder Leakage Service Limit 4 Stroke 10 Inspect for cause if leakage exceeds 10 Engine Mounts Inspect rubber engine mounts A for cracks or damage Fastener Torque Engine Check engine fasteners and ensure they are tight Polaris Sales

9915083 1999-2000 Vol. III ATV Service Manual Chapter

Contents

Download Pdf Manuals

Related Search

Related Contents