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Polaris A07TH50AU User's Manual

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12. 2007 SPORTSMAN 500 EFI ADC GEARCASE
13. 2 IBI T 2007 SPORTSMAN X2 500 EFI QUAD RH DIAGNOSTIC ONT ERON
14. PO SPORT SMA 3 mc 1 OFF SPEEDO DIAG ACCESSORIES HEADLIGHT GY TO BN W 24 200 SPORTSMAN 500 EFI X2 CAN UPPER f oo QN T
15. 007 SPORTSMAN 500 EFI DELUXE ER i OFF RIES HEADLIGHT BN WH 24 2007 SPORTSMAN 5 JELU RH UPPER rio SENSOR p POD ACC BN TO 8180120 _ ATV_OT_SPORTSMAN_500_EF 1 DELUXE MODEL NO AOTMH50AQ AF in HEADLIG
16. HOLIMS 8304 1N391 113112541 15 SUNG xis 401 20 T31NI jar Mvua Ne OT vu ou 945 tar SIHIN 3015 HOT 18500 1 wesa egon T TA un 169110 N d 1081502 Wad 541 2018 H9IH SERIES NO O 2 HOLIMS NOILINDI 1 2 8255 91 13 88 118 Nd a D mm EE 8255 9 im JONVYO 18 EN p Na HW JONYY 2 1H91T1I V
17. RISMAN 450 LH HEADLIGHT RH HEADLIGHT UPPER r ATV_07_SPORTSMAN_450 MODEL NO A07MH46AA AD AF LN FADLIGHT A O H PAGE 1 2 a WHEEL SPEED o E SIGNAL SENSOR stator WIRES ARE REPRESENTED BY Y SEE SHEET 2 SOLID OR DASHED LINES 1 SIMPLIFY TRACING IN DIAGRAM K FUEL SENDER iL Een SEES D PUR W BRN 4
18. 07 SPRBTSMA RACE SEL GNOS OF ES HEADLIG GY TO BN WH 24 O 0 SPORTSMAN 500 BASE LH RH UPPER f ON E b TD AC GY TO GROUND NO CONNECTION ATV 0T SPORTSMAN 500 EFI 8ASE MODEL NO AOTMHSOAX AY AZ HEADLIGHT HEADLIGHT HEADLIGHT RED 5 x Lm Ys WHEEL SPEED E aa E de WORK ae aie AND 8 1e o10N PAGE 1 OF 2 SENSOR y U LIGHT i HUB C 3 STATOR SWITCH co
19. 2007 SPORTSMAN 450 WIRE DIAGRAM
20. x ACCESSORIES A EE 5 5 7 3 SPEEDO neum 5 er Meiner ote jeran on gao 1 HORN ATV_0T_SPORTSMAN 500_EF1_INTL MODEL NO A0TMH50FA Bio HEADLIGHT HEADLIGHT HEADLIGHT E J EMT on y id LOCATED SWITCH gt gt n WHEEL SPEED HIGH BEAN HIGH BEAN ON RUNNING INSIDE POD OF F B SENSOR kr mel en E E 49 PAGE 1 OF 2 6 a Li pis v i FUEL PUMP STATOR 1 D CDE F WIRES ARE REPRESENTED BY IN FUEL
21. xx A INO 408484418 404 JUV SLYVd 1291A983S 110N m A 49V18 181504 119 0192042 5 10d f l 391195 0 1H91 TIVI H3 8 1980 98 3018 WAG 0 WNIT 3181503 11 1092022 S Y 10d 2 HSA 14 NISL 2 421145 0441 q IHS 4 1HS S 121146 311 1H911 9NI LNOYd H1 8 JLIBM Q3H 58 9 NAS O 1181504 11 1712042 5 10d 01 121145 21 9 H 1 8299 Z 79 011414251 ON 18 4 YJyNLIVINNYN 69 GE 121145 NMOUG TWNDIS NUNL HH 02 MOYE Cg 519 3714845 5 2 99 z 321145 038 3018 2 lVNOIS INOUJ HY 02
22. WIRE DIAGRAM 2007 SPORTSMAN ACTIVE DESCENT CONTROL ADC WIRE DIAGRAM
23. WD 5
24. WMd HOLIMS YIMOd IN391I 1131INI Sdl NS CONI MS amy 5 5 lt 100 15 ep adie 407 mS 41083105 1 op 541 3015 13834310 320 HH 3INI j 2f SLHOM pzp 305 oar y er p sal 3015 o p 0921107 N d 10 02 opp 981 3019 HTH LVLS Nyder 121145 21 891 8055 21 034 78 did Tad 3 sd 3916 H9 1041007 a nd a y B 321145 NMOUG ANNOYS A MOYE cg s MP c 5 l NOLLIN9 oy 54 H9 121145 034 N3349 11 g 03345 02 384 1389 11 29 FI zm cem g 2 41145 3 0444 02 18 ues Y 2 43145 v 03345 02 1L HM QU 08 lE D 5 43404 MS S31808 5320Y 121145 311HM 39NYWO 21 311 HM 61 UN m 2 121145 Sdl 02 19Nv 80 81 SO TAS eS AN311V8 1 3 108 07 yov 18 Ti LOHd LIVE 7 7 sel 305 c 5 121145 MO113 038 0 JVO3TQNVYH Ho 9 M01134 Q3U 9 mm 321145 3016 1H911430M H 9 9 anono A x Poorer O 321145 3018 1H91 DINOM 8 3118 Ivg Mi 15 4 6 TT TTT 2010 5 t 121
25. ADAPTOR cM UC oe dag OT LESS DROS 21 SCREW 1 4 20 X 3 4 HXHDCP 7 26 Dre ED 2 25 24 PLATE BRAKE VALVE BLK VALVE REDUCING BRAKE 2 BLOCK DISI BRAKE LONG PISION 2 INE BRAKE REAR 000 INTL 20 INE BRAKE REAR SERVICE 800 INTL d BOLT BANJO DE PDT 8 BOLT DOUBLE BANJO TOMM X 25 DOLI BANJO IOMM X 1 25 66 2 INE BRAKE J B P VALVE NPI 2 OS RC RM P SED 2 4 ASM RESERVOIR REAR BRAKE 2 2 ASM M CYL FOOT 3 47 3 10 LONG 999 ol NTL 0 DERE OURO qu 24 J BOLT BANJO 10MM X 1 00 SWITCH PRESSURE BRAKE MIO X 1 25 1 INE BRAKE HAND J B 6 INE BRAKE FRO FLUID BRAKE DOT4 4 ASM MASTER CYLINDER HB 11 16 3 ASM CALIPER 1 74 9 2 ASM CALIPER BRAKE 1 1 4 LH 9 ASM CALIPER 165YPAD 2 ITEM ARI NAME 017 11 2 500 EFI INTERNATIONAL QUADRICYCLE Exploded View FROM FOOT M C TO REAR AUX TO PROP VALVE TO FRONT CALIPER RIGHT CALIPER Hand Brake Supply Foot Brake Supply N av J O 2 lt gt N
26. 2007 SPORTSMAN 500 EFI STANDARD WIRE DIAGRAM
27. ES 1 II MIN WIRE DIAGRAM
28. S 10 44 STARTER LOCKOUT TROUBLESHOOTING EFI MODELS 10 44 STARTER LOCKOUT TROUBLESHOOTING SPORTSMAN 450 10 44 STARTER LOCKOUT DIAGRAM 10 45 STARTER LOCKOUT DIAGRAM SPORTSMAN 450 10 45 STARTER MOTOR REMOVAL 10 46 BRUSH INSPECTION REPLACEMENT 10 46 ARMATURE TESTIN creed erent ss AOSD iuto Dc e 10 47 STARTER HEASSEMBLY 022 reader Eon dioe eS ROBUR S S A 10 48 STARTER SOLENOIB BENGH TEST lt x eR Ges br RE ETE ELS 10 48 SIARTER EXPLODED VIEW 4 5 4 65 89 d OER ou Gee eee ip Eee mici Em 10 48 STARTER DRIVE eo LE ls Sete Sca Ron nd de qs PINION GEAR ANTI KICK OUT SHOE GARTER SPRING REPLACEMENT 10 49 STARTER SYSTEM TESTING FLOW BASIC WINGH WIRING ESS Gita ac AES PRE WIRED MODES vsu e eee REI RR geet eed 10 51 TROUBLESHOOTING DIAGRAMS POWER ON ERI Ag eu OE A cand RAE f 10 52 START CIRCUIT EFE oe mc ex mer ea bese M aree 10 52 IGNITION Oe EPI s nur SOS tect Us et eR eo Qt 10 53 RUE PUMP SER
29. 3 34 CRANKSHAFT 3 35 CRANKCASE BEARING 3 36 PUMP SHAFT OIL SEAL WATER PUMP MECHANICAL SEAL REMOVAL 3 36 CRANKCASE INSPECTION qo SSE es pt 3 36 BEARING INSTALLATION 2 33 2 come yh cae ea ath Bee ee aaa e Desa 3 37 END PLAY 3 37 CRANKSHAFT END PLAY 3 37 COUNTER BALANCER SHAFT END PLAY ADJUSTMENT 3 38 OIL PUMP SHAFT END PLAY 3 39 ENGINE REASSENMBISY ER UR ARE RERO RE ade A Ra dat E eee es PUMP SHAFT OIL SEAL 3 40 CRANKSHAFT COUNTER BALANCE OIL PUMP INSTALLATION 3 40 CRANKCASE ASSEMBLY 2 522 5554 a Ree ROC eek 3 41 WATER PUMP MECHANICAL SEAL INSTALLATION 3 41 WATER PUMP MECHANICAL SEAL REMOVAL ENGINE INSTALLED 3 41 ONE WAY VALVE 3 42 CAM CHAIN DRIVE SPROCKET 3 43 TENSIONER BLADE INSTALELATION 3 253 Sees vated sere 3 43 PIST
30. am dt 6 3 PVT SEALING AND DUCTING 6 3 DRIVE GEUTGH EXPEODED VIEW s s o ntt ca pue Rin p ec RED ee 6 3 ENGINE BRAKING SYSTEM EBS EXPLODED 6 4 EBS DRIVEN CLUTCH EXPLODED VIEW oe Eb ERE EET pies 6 5 PVT SV OVEN PP 6 6 PVT OPERATION OVERVIEWS 3 e OSEE UP ger aes 6 6 DRIVE CLUTCH OPERATION a d es SORES SS SSE ele 6 6 DRIVEN CLUTCH OPERATION 53522 ei bau ee es 6 6 2 476 anata ede ie NIS Pap ena 6 7 PVT 6 7 DRIVE CLUTCH SPRING ie s hes cyan otic cit cle n 6 8 OPTKONAL SHIET WEIGHT od eR Rd ul Eon io 6 9 DRYING wd e 6 10 PV DISASSEMBLY serie ME RE eee hee Rue baee Re iad 6 10 eite eee E excom Eae quie cs mr ers 6 11 DRIVE BELT HEMOVALEJINSPEGTION Doe 6 12 DRIVE BELT INSTALLATION aieo s ete 6 13 CLUTGHALIGNMENT retoque tase Git eene Sb 6 14 COUTE ME ui M Mid 6 14
31. 1 2 VEHICLE IDENTIFICATION NUMBER 1 2 TRANSMISSION 1D LOCATION vto REPRE RE acus Pe erdt eee 1 2 ENGINE AND MACHINE SERIAL 5 1 2 PUBLICATIONS uis 1 3 PAINT Ez id Beene Bete 1 3 REPLACEMENT KEYS 5545 bd oae e dee og 1 3 SPORTSMAN DELUXE AND STANDARD MODEL COMPONENT COMPARISON 1 4 SPORTSMAN X2 DELUXE AND STANDARD MODEL COMPONENT COMPARISON1 5 2007 SPORTONIAN 4S0 tete opu ire dee Ma A pub suiit 1 6 MODEL NUMBER A07MH46AA AZ Ee ree ERR 1 6 2007 9R ORUTOSIVIAN SO0U E toe 1 8 MODEL NUMBER 07 5 AY AZ A07MN50AQ AF AO7MH50FC 1 8 2007 SPORTSIVIAN X 2 900 E TII cut ie ens ee dob gie deve 1 10 MODEL NUMBER A07TH50AU AZ 7 AQ 7 50 1 10 MISC NUMBERS CHART Sira das co god i s Robe od ar OR ku Ton 1 12 STANDARD TORQUE SPECIFICATIONS droite bl tts eo bp cs 1 12 SAE TAP DRILL SIZES casei teeta ees 1 13 METRIC TAP DRIED SIZE Siete 1 13 DECIMAL EQUIVAIENTS vae bete EP PORE
32. gt Iu 59 6 mn pg 98 RD WH 7 AWD ON OFF SWITCH ON OFF D 81 06 WH 1 LOCATED ON RIGHT HANDLEBAR 66 Me i REED 3 0 on bue ld SWITCH SSCB matote nc EEEE GI D Bl G 2 1 L i 0 E 4 7 1 c P R D LOCATED BELOW HANDL 64 RD BK 48 BN 60 06 BK INDICATOR E 1 e 146 08 36 YE 1 DERE 10 RD WH TIIE LOLs Ii CES Y 101 RD Lobo rid m Oc gt EETLCI Met T 14 GY WH ou res ort ow Don Oo ovo lt E Su E OE ERES L E Our NTO OOO B 4 163 06 ae EL TSF gt NOTRE JE C SSCB E EYIN nt 2 gt sl EV A BV 4 DIAGNOSTIC a 0 Fi 2 Py 43 RD BK 2 EE zi Ot RD WH RD YE RD WH RD WH RD BK B B B B 8 TP20 SEE PAGE 2 OF 2 FOR SPECIFICATIONS 59 SPLICE SPLICE SPLICE SPLICE 3 SPLICE 1 SPLICE SPLICE SPLICE SPLICE SPLICE 2 SPLICE 3 SPLICE 4 A 06 un C Wu DT E 4 B 132 YE E 06 06 5 DB WH DG 1 ACH BU SPLICE SPLICE Mog ee OG WH DB DB RD SPLICE 1 SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE 2 43 SPLICE 5
33. EH50PL Flow Diagram nternal passage to camshaft front left head bolt Oil Filter feed to filter From filter to crankshaft Bottom fitting is oil le Way Mave Oil Tank bai exhaust or return fitting is to tank feed or intake from bottom of tank EH50PL Oil Flow Chart Top of Oil Tank Union Fitting Lower Oil Tank Crankcase Oil Pump Oll Strainer Oil Gallery Scavenging u creen Fitting Union Fitting Bottom of Tank Upper Crankcase Crankcase oprocket Oise Sun ferae y Bearing Cam Shaft Hocker Arm Cylinder Sleeve Journal Rocker Shaft Prevents oil from Feed draining into crankcase with engine off Indirect Main Bearing Lubrication One Way Valve Delivery Pipe 4 Cam Shaft Journal il Fil Crank Pin Through Oylinder Stud Front Left Crankcase Oil Gallery Large End Bearing 1 N Oil Jet Crankshaft Delivery Pipe Delivery Pipe 3 12 EH50PL Engine Exploded Views Cylinder Crankcase Cylinder Head Crankshaft and Piston Valvetrain 3 13 ENGINE DISASSEMBLY Cam Chain Tensioner ROCKER ARM CAMSHAFT Removal 1 Remove ignition timing inspection plug from recoil housing TDC Mark Hotation To position crankshaft at Top Dead Center TDC on compression stroke 2 Rota
34. 10 34 DIFFERENTIAL SOLENOID csse iege 10 36 Ww TEST EPI Er 10 36 BEDA GEMENS Jpn TEPORE 10 36 10 1 ELECTRICAL miei ce PTT eRe ke HIGH BEAM HEADLIGHT BULB 10 36 HEADLIGHT HOUSING 10 37 HIGH BEAM HEADLIGHT 10 38 LOWER HEADLAMP REMOVAL 10 38 LOW BEAM HEADLIGHT 10 39 SWITCH 4 1 10 39 WORK LIGHT SWIT OR uA I 10 40 BRAKE LIGHT WORK LIGHT REPLACEMENT 10 40 BRAKE LIGHT SWITCH TESI ad ian acetate 10 41 SPEED SED SO imd deiade dedu ew SRL EU DRE TES HNOS p PT TETTE 10 42 credas Rer tatis puduit luas 10 42 FUE SENDER SISE Rega a e ma atn e adeat du Ferd aft TESTING qc TII 10 42 ACCES SONY POWER Ro aba vo t WIRE CONNECTIONS pte seat ote ae x ER EE ERU AE UE Mp Ma tos uses gst 10 43 SL AED Y STE a nee pene ee ee Cuba tora CSR a d ode S TROUBLESHOOTING deant Ake be eee 10 44 VOLTAGE DROP TEST
35. 2 3 MAINTENANCE CHART KEY tical sede ew e posed d os acutae 2 3 PERIODIC MAINTENANCE CHART EORR eee cen 2 4 EUBRIOATIONJZ FLUIDS Res E SOC e Ec OPERE 2 7 SPORTSMAN COMPONENT 5 2 7 SPORTSMAN X2 COMPONENT 5 2 8 POLARIS LUBRICANTS MAINTENANCE AND SERVICE PRODUCTS 2 9 POLARIS LUBRICANT SYMBOL 2 10 FRE RIDES DAILY INSPECTION sepeser ut dta D 2 10 LUBRICATION 2 11 FRONT GEARCASE 2 12 TRANSMISSION 2 13 ADC DIFFERENTIAL HYDRAULIC CIRCUIT FLUID 2 14 VERIGUEINGPEGION RA adero coiere dodo cs Y os ce eos 2 14 SHIFT EINE ROD INSPECTION iua quta oo baat EE ess 2 14 THROTTEEJNSPEGTION uti don tentis mcr reeled A peat bad alec eee 2 15 THROTTLE CABLE ELECTRONIC THROTTLE CONTROL ADJUSTMENT 2 15 PUBL SOT BM ces oer tere a C dee dt me ee Bates dre poire e Lc 2 16 FOUE LEINE SEA aE oe SE 2 16 VEIN CINE Sr eer os ace aia GSE E 2 16 eh ot ier aN I
36. 110 152 12 BI BB iex hi OE EXC s 90 124 120 166 Metric 6x1 0 72 78 In 108 Bx1 25 14 18 ft Ibs 10 1 25 26 30 ft Ibs convert ft lbs to Nm multiply foot pounds by 1 382 convert Nm to ft Ibs multiply Nm by 7376 SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section 1 12 GENERAL INFORMATION SAE Tap Drill Sizes Decimal Equivalents 1 64 0156 0394 0 80 1 2 13 27 64 3 64 Ms Por EE s 41 64 1 2 20 29 64 0625 5 64 0781 2 0787 2 ala 0938 2 56 9 16 18 33 64 MEME RN 1094 3 1181 2 64 5 8 11 17 32 1 8 1250 id 5 321 1563 4 mm 1575 3 56 3 4 10 21 32 TOA Lust irte eR RES 11719 4 40 3 4 16 11 16 MTS 1875 5mm 1969 2031 4 48 718 9 49 64 7 321 2188 5 40 7 8 14 13 16 2344 6mm 2362 idus s He 17 64 tees 2656 7mm 2756 6 32 1 12 59 64 9 32 2813 6 40 1 1 8 7 63 64 19 64 2969 5 16 3125 8mm 3150 056 Lue MM 3281 8 36 1 1 4 7 1 7 64 Te cers sarees 3438 9 mm 3543 10 24 1 1 4 12 1 11 64 23 64 3594 3 8 375 10 32 PEU DB 3906 10 mm 3937 12 24 1 1 2 2 1 27 64
37. 4 10 EFI Priming Starting Procedure 4 11 Electrical Service Notes 10 4 Electrical Service Notes 10 4 Electrical Special Tools 413224 EX 10 3 Electronic Control 4 12 Elelctrical Troubleshooting Diagrams 10 52 Engine Diagnostic Codes 4 24 Engine Disassembly 3 14 Engine Exploded Views 3 13 Engine Installation Notes 3 0 Engine Inspection 1 uei mr DES ERR RS 2 25 Engine ReassembLy dee Ero 3 40 E sibe RenioVal iu estais wert eek tfe tes 3 8 ENGINE Service Data 5 er ws 3 4 Engine Temperature Sensor 4 22 Engine Temperature Sensor Replacement 4 22 Engine Temperature Sensor Test 4 22 Engine Fastener Torque Patterns 3 3 Engine Lubrication Requirements 3 11 Engine Oil and Filter 2 23 Engine Pump Priming 2 22 Engine Torque Specifications 3 3 Engine Valve Clearance Adjustment 2 25 IX 2 ETC Test isto Pb tope 10 27 ETC Switch Operation 10 27 F Fan Control Circuit Operation 10 25 Fa
38. i i FAR STAT a FAR The Power Distribution Module integrates these electronic features found on Polaris 500 and 500 X2 EFI ATVs rectifier regulator main solid state circuit breaker SSCB output accessory power output ignition relay output fan relay controller ECM relay output ECM cluster memory power light output starter lockout active descent control ADC and differential solenoid drive X2 ONLY There are no service parts in the PDM If the PDM fails it must be replaced Following are overviews of the various PDM circuits and how they function Regulator The rectifier converts the output of the 3 phase alternator and applies it to the battery and the PDM loads The regulator monitors the battery voltage and shuts off the rectifier when full charge exists on the battery SCR s are used to connect and disconnect the alternator from the battery to achieve regulation of the battery voltage The regulator shuts off current on the pin if the battery exceeds the over voltage threshold The regulator will not turn on unless there exists battery voltage in excess of the minimum battery voltage requirement Therefore do not attempt to charge dead batteries using the vehicle s charging system 10 5 ELECTRICAL Battery Protected Output The battery protected output BAT PROT provides solid state circuit breaker SSCB outputs and enables most of the functions on the PDM The BAT PROT output must
39. 6 32 STANDARD DRIVEN CLUTCH acd deo bun tea 6 33 DISA SSE MBE bas ku add em niei E bb s Stab s bir oa ni 6 33 INSPECTION dete oo Sae arabe trends 6 33 POSEN BEN WDE MOLEC 6 34 PVT TROUBLESHOOTING 35 68 4t ida dit ads t o edes 6 35 OVERHEATING esase aS Ru S RERUM abate eS 6 35 PROBLEM CAUSE AND REMEDY 6 36 6 1 CLUTCH SYSTEM SPECIAL TOOLS AND Component Fastener Torques SPECIFICATIONS Drive Clutch Retaining Bol 40 Driven Clutch Retaining Bolt Clutch Holding Wrench Drive Clutch Spider Removal amp Install Tool UU Driven Clutch Puller 2870913 Roller Pin Tool 2870910 PVT Inner Cover Bolts a Drive Clutch Spider EBS 00 271 Clutch Nut Drive Clutch Cover Plate 90 Clutch Bushing Replacement 2871226 Tool Clutch Bushing Replacement 2871025 Tool Kit Clutch Compression Tool PS 45909 Extensions 6 2 CLUTCH SYSTEM PVT EXPLODED VIEWS PVT Sealing And Ducting Components Clutch Inlet Duct Transmission Cover Seal Inner Seal Cover Seal Retainer Bracket Deluxe Models NON EBS Standard Models 6 3 CLUTCH SYSTEM Driven Clutch Exploded Views Standard and Deluxe Secondary Stationary Sheave Moveable Inner Sheave Inner Spring
40. HEADLIGHT ey o VY dio SWITCH 10 MODEL NO BNE A E LEFT J LOCATED INSIDE POD inercia POD ACC 6 TO GROUND NO CONNECTION WI ATV 0T SPTSMN X2 500 EFI 0UAD MODEL NO AOTMN5OEA UPPER HEADLIGHT HEADLIGHT FROM RON TURN TUR Sa POWER POD ACC 2 v gt HEADLIGHT RUNNING RUNNING dE 1 1 OFF 9 22 PAGE 1 OF 2 LIGHT LIGHT B U AWD 70 WIRES ARE REPRESENTED BY FUEL PUMP 5 3 I 23 i ABC DEF SOLID OR DASHED LINES TO 00 OAS L SESI EF Rp 0 IN FUEL TANK 679 m CLITA SIMPLIFY TRACING IN DIAGRAM ite O TA 5 ues 22 e FH Li e lt 5 OLO 2 CO e N 1 5 es Tm OER O FUEL uj sr gt don oue ocor GAUGE H STATOR LOCATED UNDER RECOIL mpi py canc Werde SENDER ng E T GY TRANS SWITCH r BOD i Sa E Er ou EE SE jeg SPUC m RESISTOR MODULE B6 BEIGE TAN ENGINE GROUND FULL 90 SPLIC oe 1 5K BLACK pu i ale 20 AN T Ton RESISTANCE 5 DARE BLUE T ades s T holga 1E UE VE CHASSIS G TF ae lt gt e 101 CBA di SPEED RD YE DG SA i es 85 5
41. replace bearings if worn Brake disc warped or excessively worn Educate operator Brake disc misaligned or Inspect and repair as loose necessary If noise does not change when brake is applied check other sources Inspect and repair as necessary Change to a softer or harder pad if available Brake Bleeding Fluid Change NOTE When bleeding the brakes or replacing the fluid always start with the caliper farthest from the master cylinder Noise is from other source chain axle hub disc or wheel Wrong pad for conditions CAUTION Always wear safety glasses during these procedures Brake fluid will damage finished surfaces Do notallow brake fluid to come in contact with finished surfaces NOTE Do not remove brake lever when reservoir fluid level is low This procedure should be used to change fluid or bleed brakes during regular maintenance 1 Clean reservoir cover thoroughly 2 Remove screws cover and diaphragm C from reservoir 9 7 BRAKES 3 Inspect vent slots A in cover and remove any debris or 6 Slowly pump the brake lever until pressure builds and blockage holds Sight Glass 7 While maintaining lever pressure open bleeder screw Close bleeder screw and release brake lever NOTE Do not release lever before bleeder screw is tight or air may be drawn into caliper 6 Repeat procedure until clean fluid appears in bleeder hose and al
42. 11 4 Steering Post Assembly 5 20 Steering Post 1 5 20 Steering Torque Values 2 2 Steering Inspection 2 26 Storage Compartment Latch Operation 2 33 Strut Assembly Puente 5 21 Strut Cartridge Replacement Front 5 20 Suspension Inspection 2 3 Thermostat Installation 3 50 06 ASSES el eu AD se NP a Md 2515 Throttle Position 4 20 Throttle Position Sensor Initialization 4 21 Throttle Position Sensor Replacement 4 21 Throttle Linkage Inspection 2 15 Tie Rod Inspection teen toed hse dake 2 27 Trail Boss Emissions System 11 5 SENS 8 1 Transmission I D Information 1 2 Transmission Mounts Exploded View 4 2 Transmission Disassembly 8 9 Transmission Exploded View 6 7 Transmission Fluid Check Change 2 13 Transmission Install 8 5 Transmission Output Shaft Backlash Procedure 8 15 Transmission 9 14 Transmission Removal 8 3 Transmission
43. NT TE G Vl 089 AZARD HAZARD SWITCH 7 5 84 n FLASHER RESISTANCE BETWEEN PINS RD STARTER gA m PINS RESISTANCE BATTERY HA 6 GAUGE MOTOR On WG G 200007 m E 15 V FUNCTION PIN LEFT 1 3 0002 IO E 20 C 37 3KQ x51 FLASI F ZEN ial lt gt a Ni RC un e en 4 5 0 po 00 C 2 1K x51 RH TUR T d _ LICENSE 7 Y EUE CRANK 5 6 3001 2 5 ND f ATO RIGHT TURN 1 o FU W IGNITION AIR GND 0 LEFT TURN INDICATOR PANEL E oe PLATE f N LOCATED AHEAD OF LEFT REAR WHEEL E COOLANT 1 __ SIGNA SIGNAL LH TAILLIGHT LH TURN SIGNAI RH TAILLIGHT RH TURN SIGNAI U INJECTOR COIL TEMP INTAKE Ww d WD 9
44. Eos d todos four ea 9 24 REAR BRAKE DISGO sad aueh rd ada Sos d s acid OW A ewe aur ut qoae ud qas 9 25 INSPECTION S aet ut US aree podus ee 9 25 HEAR MASTER CYLINDER ates cx betes UR ESSA EE e Rc 9 26 AS EXPLODED VIEW irati Dus owas teh E ESE 9 26 OVERVIEW usitata heb E err d s mt 9 27 X2 REAR MASTER CYLINDER REMOVAL AND INSTALLATION 9 27 SPORTSMAN REAR MASTER CYLINDER REMOVAL INSTALLATION 9 28 PEDAL REMOVAL AND INSTALLATION 9 29 TROUBLE SHOO eS ENE Roe e RC 9 29 BRAKES SOUE A Dess pasto V I esce dt de 9 29 POOR BRAKE PERFORMANCE ne 22402 de dae eee a 9 29 FEVER VIBRATION scs tts td sectors e 9 29 CALIPER OVERHEATS BRAKES 9 29 BRAKES aise ee s 9 29 9 1 BRAKES SPECIFICATIONS Torque Table TORQUE SPECIFICATIONS Sportsman and X2 Front Rear Caliper Mounting Bolts Handlebar Master Cylinder Clamp Bolts 25 in lbs Hand Master Cylinder Reservoir Cover Screws 7 11 165 Brake Line Banjo Bolt 15 0 a O 19 M O Brake Switch Caliper Mounting Bolts Sportsman Caliper Slide Pins Rear Master Cylinder to Fr
45. La 1 N Lau 7 N 4 x gt Ou lt gt Ou Q co gt a an Lc Lc CES CLE l mes w gt Ow gt lt gt lt gt 41 lt gt aw ea ea QE a 1 lt L gt oo oo TE her cr lt caa pa ee Ow a EGO o zu 5 Or e xL n Liu Lid LL lt gt Cc E ua gt gt Ou gt Lil c UN AN NOTES A Q 500 EFI INTERNATIONAL QUADRICYCLE 500 EFI INTERNATIONAL QUADRICYCLE STEERING POST AND LOCK Steering Assembly Exploded View The 500 EFI International Quadricycle Sportsman is equipped with a steering locking mechanism to prevent theft or unauthorized use Steering post removal may be required for lock service or repair Lock System Item Number Description 11 Lock Collar 12 Lock Set 13 Bolt Lock Set 14 Bolt s Lock Collar 15 Nut s Lock Collar 2006 Polaris Sales Inc lt 21 11 4 500 EFI INTERNATIONAL QUADRICYCLE 500 EFI QUADRICYCLE EMISSIONS SYSTEM Overview 500 EFI Quadricycle model ATVs are equipped with an emissions system from the factory The emission system is designed to meet the various international emissions standards The emissions system co
46. 10 38 Hydraulic Brake System Operation Overview 9 6 I HE 55 10 28 Ignition System Troubleshooting 10 31 Instrument Cluster Speedometer Overview 10 13 Instrument Cluster Diagnostic Mode 10 14 Instrument Cluster Overview 10 13 Instrument Cluster Setting New Service Interval 10 16 K Keys Replacement s ence 1 3 L Low Beam Headlight Adjustment 10 39 Low Maintenance Battery Charging 10 61 Low Maintenance Battery 10 61 Lower Headlamp Housing Removal 10 39 Lower Headlamp Removal 10 38 Lubricants Fluids Polaris Brand Part Numbers 2 9 Lubricants Fluids Polaris Brand Symbol Identification Chart 2 10 M Maintenance Chart 2 4 Maintenance Schedule 2 38 Maintenance General Information 23 SENIOR Seis Cos eA 4 18 Mikuni Jet Part Numbers 4 32 Mise Fables ko Ero nS bowed asa 1 12 Mod RR E T TT TC EE TQUE TINTE 17 Model Number Information 1 2 Needle Seat Leakage Test 4 42 O Or Plow Chait ba idiot eee ae ae ee aes 3917 Oil Flow Overview 3 11 Oil Pressure Test Bnoine 3 11 Oil P
47. 2 reat 6Y GRAY T T lt gt lt gt 2 5 ae 8 xt WH SPLICE 2 SPLICE p U L5 77 2o 2 06 DARK GREEN a gt Zu SPLICE Ea d FRI 7 TP20 ese co Ze f 06 ORANGE NC SE we RRNA 0 08 HS am eo amp P K SWITCH NORMALLY CLOSED R uu m H Lu 8 EI Ey R RED NO prem AXE T N EC ABE NR HE E VIOLET PURPLE SWITCH NORMALLY OPEN je Sr Ego lt lt HARNESS 2410752 04 dior EZ BSS I5 NORMAL OPERATION 15 OPE UNDER THROTTLE TWO WIRE COLORS ARE SHOWN S ISOS E cim RCUIT IF CLOSED ASSEMBLY COVER WITH MAIN TRACE COLORS AC A Ai ADJUSTMENT IS REQUIRED EXAMPLE RD YE RED WITH co YELLOW TRACE gt e Ent lt 57 BK i SWITCH Nees 4 WH DG H 904 4 1 3 gt 38 RD WH d AWD AWD ON TURF 04 87 gen meu 3 BK 2 il Y 2 n Ms SPLIC LOCATED ON RIGHT HANDLEBAR 14 6 l7 SN 00 84 RD 22 0 88 YE 1 ow f 55 RE EE d 30 10 8 Vr 2 NUES 4 8 YE 06 i n LOCATED BELON EBD RD BK SENSOR J Pm Vee PIN AY 80 gt 81 2 AM Vout PIN JAS
48. SPECIFICATIONS Special Tools Torque Specifications PART NUMBER TOOL DESCRIPTION Valve Seat Reconditioni TORQUE SPECIFICATIONS 2200634 EH50PLE 2870390 Piston Support Block Ft Lbs Nm 2871043 Flywheel Puller d 6 5 11 9 15 Nm Crankshaft Water Pump 965 79Nm 5131135 Water Pump Install Kit 5 6 5 7 9 E65 75 m 2870569 Crankshaft Truing Stand 6mm 5 65 7 9 Nm 2870975 MID Va us il PV 43527 Filter Wrench 11mm 14 19 20 25 Nm 12 14 16 20 Nm amm 14 15 19 21 Nm Tighten cylinder head cylinder base and crankcase fasteners in 28mm 35 51 47 69 Nm 3 steps following the sequence outlined Engine Fastener Torque Patterns Cam Chain Drive oprocket Cylinder Base Bolts 10mm 45 2 61 67 Nm Cylinder Head Bolts 11mm Foo to SIE agi 6mm Assembly for torque procedure Drive Clutch Bolt 7 16 20 40 55 Nm lywheel 58 72 78 98 Nm Oil Delivery Pipe 11 15 15 21 Nm Oil Drain Bolt 14mm 14 17 19 23 Nm Crankcase Oil Filter Pipe Fitting 36 43 49 59 Nm Oil Hose Fitting 1 8 Pipe 6 5 11 9 15 Nm Tead Hard Metal Oil Line 11 16 p E 15 21 Banjo Fitting Lm Ls Oil Pump 5 6 5 78 5 Rocker Adjuster screw 6mm 6 7 10 Water Pump Impeller 6mm 5 6 5 7 9 Nm Nut Water Pump Housing 6mm 5 6 5 7 9 Nm Cover 5 65 7 9 Nm 5 65 7 9 Nm park Plug 9 11 12 15 Nm Temi 28321 85 3Nm Cylinder Head
49. TTD 2 3 300 0 RA PRIM 20 C 550MQ 54 00 C 2 454 O 1 3 600 2 AC X 41 SEC 20 C 5 5KQ 5 TONG FLASH F e m 5 52 2 52 5777 5 3004120 ES COOLANT iC 37 0210 HIM A m 1s 2 E 5 WU LICENSE CRANK uf ant 30041 20 C H W a SENSOR az GND LEFT TURN INDICATOR PANEL RIGHT TURN LH TAILLIGHT LH TURN SIGNAL RH TAILLIGHT RH TURN SIGNAI PLATE UR POSSITIO 4 6 600 22 4Q LOCATED AHEAD OF ae WHEEL py 6 GAUGE ET INTAKE HAZARD SIGNA SIGNAL R 5 ALL OTHER COMBINATIONS OPEN BATTERY LAMP SENSO WD 13
50. UU Fuel Filter Service In line filter replacement is recommended every 2 years of operation or more frequently under extremely dusty dirty conditions Use only the specified filter and install it according to the directional arrows DO NOT use an aftermarket filter as operating performance and safety can be affected Fuel Filter Replacement 1 Relieve system pressure through the test valve in the fuel rail before servicing Loosen clamps and slide hose off the filter ends 3 Install new filter with arrow pointing to the fuel line connected to the injector rail and reinstall the clamps NOTE When replacing the fuel filter wet the interior of the new filter with gasoline before installation to ensure high pump pressure doesn t tear the filtering material 4 16 FUEL INJECTOR General Information The fuel injector mounts into the intake manifold and the fuel rail attaches at the top end Replaceable O Rings on both ends of the injector prevent external fuel leakage and also insulate it from heat and vibration When the key switch is on the fuel rail is pressurized and voltage is present at the injector At the proper instant the ECM completes the ground circuit energizing the injector The valve needle in the injector is opened electromagnetically and the pressure in the fuel rail forces fuel down through the inside The director plate at the tip of the injector contains a series of calibrated open
51. 10 61 LOW MAINTENANCE BATTERY CHARGING 10 61 LOW MAINTENANCE BATTERY OCV OPEN CIRCUIT VOLTAGE TEST 10 62 LOW MAINTENANCE BATTERY LOAD TEST 10 62 LOW MAINTENANCE BATTERY CHARGING PROCEDURE 10 62 10 2 ELECTRICAL Ignition System Basic Electrical omponents GENERAL INFORMATION Special Tools Table 10 1 PART NUMBER TOOL DESCRIPTION Fluke 77 Digital 2870630 Timing Light 28 0836 Battery Hydrometer 2460761 Hall Sensor Probe Harness 2871745 Static Timing Light Harness Battery to uA Cable ir Starter N S Negative Cable Starter as Cables 10 3 ELECTRICAL Electrical Service Notes Keep the following notes in mind when diagnosing an electrical problem 10 4 Refer to wiring diagram for stator and electrical component resistance specifications When measuring resistance of a component that has a resistance value under 10 Ohms remember to subtract meter lead resistance from the reading Connect the leads together and record the resistance The resistance of the component is equal to tested value minus the lead resistance Become familiar with the operation of your meter Be sure leads are in the proper jack for the test being performed i e 10 for current readings Refer to the Owner s 1 included with your meter for more information
52. 10 16 FEI DIAGNOSTIC MOD Eis Rol S CR eng CR OO ed 10 17 SPEEDOMETER REMOVAL vue LEE RARE ESAE RED REI 10 18 SPEEDOMETER 10 18 ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING 10 19 TEST 1 NOALL WHEEL DRIVE 41 ode sow ike once a mE IS 10 19 TEST 2 SPEEDOMETER DISPLAY oe PE i 10 20 TESIT 3 NOREVERSESPBEED LIMIT 241351 tied eee oe tel Reel cs t 10 20 TEST 4 NO AWD SAFETY 10 21 TEST 5 REVERSE SPEED LIMITER ACTIVATED IN FORWARD GEAR 10 22 TEST 6 WHEEL SPEED SENSOR E eR IER E IRE s 10 22 TEST 7 FUEL GAUGE DISPLAY NOT 10 23 TEST 8 SHIFT INDICATOR NOT WORKING 10 23 ACTIVE DESCENT CONTROL ADC 10 24 OPERATION OVERVIEW a Rated donus 10 24 DIAGNOSING SYSTEM 5 10 24 ALL WHEEL DRIVE AWD 10 24 OPERATION OVERVIEW 10 24 DIAGNOSING SYSTEM 5 10 24 COOLING SYSTEM COMPONENTS 10 25 FAN CONTROL CIRCUIT OPERATION 10 25
53. 5 lt o 5 3 24 Unit of Measure Converts to ft Ibs in Ibs in 108 ft Ibs ibs Nn s on bs on zin bs on nie mi km 5214 mile EE Grams 0 2 Z A 5 mm in 2 3 2 3 O Fluid Ounces fl oz Cubic Centimeters cc Grams g Ounces oz bk Tm ug mT 82006 0 imperial pints pt quarts US quarts US at Imperial quarts Imp at US gallons US gal Liters I pes 0 0 0 0 00 Kilopascals kPa Pounds force per square inch psi Kilopascals kPa Kilograms force per square cm Kilograms force per square cm Kilopascals kPa T 3 14 xR x H height Cylinder Volume to F 9 40 5 40 F F to C 5 40 9 40 i GENERAL INFORMATION Glossary Of Terms ABDC After bottom dead center Alternating current voltage ADC Active Descent Control Alternator Electrical generator producing voltage alternating current ATDC After top dead center BBDC Before bottom dead center BDC Bottom dead center BTDC Before top dead center CC Cubic centimeters Center Distance Distance between center of crankshaft and center of driven clutch shaft Chain Pitch Distance between chain link pins No 35 3 8 or 1 Polaris measures chain length in number of pitches Crankshaft Run Out Run out or bend of crankshaf
54. n pus OD ENS ee Ke ps eSI evo ome CD lt o opm ceo gt gt Ie lt gt lt lt eS per lt gt x peser gt oO lt S ux OD ex OO SP rel LC LD LO lt lt pepe Li 5 gt 11 c 2 gt 2 gt gt Lu Lu uu S iul 2 p I co gt On 1 lt gt gt gt e a e Lu ac Co eu Set gt 2 gt gt gt 1 gt c Ss 2 N 9 1 4 n Fy Fs CJ Cy M oO O Ou AM gt e c c c 5
55. Cooling System WARNING Never remove radiator cap when engine is warm or hot The cooling system is under pressure and serious burns may result Allow the engine and cooling system to cool before servicing Thermostat Water Pump Cylinder Head Cylinder Upper Hose Radiator Filler Neck Lower Hose Overflow Bottle System Pressure Test 1 Remove radiator cap cover located in storage box 2 Remove recovery bottle hose from coolant filler 3 Connect a Mity Vac PN 2870975 to radiator and pressurize system to 10 PSI 68 9 kpa The system must retain 10 Ibs of pressure for five minutes or longer If pressure loss is evident within five minutes check radiator all cooling system hoses and clamps or water pump seal Radiator Cap Pressure Test 1 Remove radiator cap and test using cap tester commercially available 2 radiator cap relief pressure 15 13 16 89 6 kpa amp Xx A ral f i E 1 A o T CES ta VA NR Bottom Radiator Left Side View Radiator Front View 3 7 RECOMMENDED COOLANT Use only high quality antifreeze coolant mixed with distilled water in a 50 50 or 60 40 ratio depending on freeze protection required in your area CAUTION Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow
56. 2 17 4 46 Fuel Gauge Sender Installation 4 47 Fuel Gauge Sender Removal 4 46 Fuel Injection Component Locations 4 9 Fuel Injection Exploded View 4 8 Fuel Injection Service Notes 4 7 Fuel Injection Special Tools 4 5 INC bbe de tele ped 4 16 Pael Level Vest vents oe otra Son ESS 4 43 Fuel Pressure Regulator o ss savin IEEE REIS 4 15 Fuel Pump Tank Assembly 4 13 Pump 4 45 Fuel Semdet redo Soter aur SEES 10 42 Fuel System Special Tools 4 32 Fuel System EFI Circuit Diagrams 4 26 Fuel System Inspection 2 16 Tank EO6 QOL 4 10 Fuel Tank Fuel Delivery System 4 44 G Gear Position Indicator Switch Test 10 26 Gearcase ADC Hydraulic Fluid Change 2 14 Gearcase Front Capacity and Fluid Type 7 2 Glossary of Tems E 1 15 Handlebar Block Installation Procedure 5 16 Headlamp Switch 222222222222 27 2 10 39 Headlight Housing Replacement 10 37 Headlight Pod Exploded View 5 15 High Beam Bulb Replacement 10 36 High Beam Headlight Adjustment
57. 7 Install the rollers and roll cage into the ring gear Insert the rollers as the roll cage is installed MERI p 7 17 FINAL DRIVE 8 Install the ring gear and roll cage assembly into the gearcase housing 9 Install the armature plate on top of the roll cage ring gear assembly Be sure that the armature plate tabs are fully engaged into the roll cage assembly NOTE Verify armature plate tabs are placed into the slots on roll cage See Photo Below M i f T E f LI 10 Install the cover plate assembly with new o ring onto main gearcase NOTE Verify the square O ring arrow is placed flat on the cover surface If the O ring is twisted fluid leakage may occur 7 18 11 Torque the cover plate bolts to specification Output Cover Bolt Torque 14 ft Ibs 19 Nm 12 Lay gearcase on the side with the output cover facing up Setting Ring Gear Backlash NOTE Ring gear backlash is set at the factory No adjustment is required unless the front cover is replaced or the back lash pad screw is removed 1 The backlash screw has locking agent that holds it into place Use a heat gun to lightly heat up the locking agent on the screw FINAL DRIVE 2 Using a 3 32 hex wrench turn the back lash screw out 3 4 turns Re apply Loctite 262 onto the bottom screw threads 3 Turn the screw in until
58. varstu riaki 5 18 Active Descent Control ADC Coil 10 24 Active Descent Control Gearcase 1 22 ADC Gearcase Piston Service 7 27 ADC Gearcase Disassembly Inspection 7 22 ADC reservoir level inspection 2 18 AIR Piter 5 eats 2 20 Alignment WBeel 2425 ya test bas 2 27 Wheel Drive AWD Coil 10 24 All Wheel Drive and Speedometer Troubleshooting Tests 10 19 Alternator Ignition Components 10 29 Alternator Output Test 10 32 Cleaning and Storage 2 36 Ball Joint Replacement Front 5 19 Battery Activation Conventional 10 57 Battery Charging Procedure Low Maintenance 10 62 battery Load Test ios tese Ut deed 10 60 Battery Load Test Low Maintenance 10 62 Battery Off Season Storage 10 59 Battery Off Season Storage Low Maintenance 10 59 Battery Open Circuit Voltage Low Maintenance 10 62 Battery Removal Inspection Conventional 10 58 Battery Specific Gravity Tes Conventional 10 59 Battery Terminals Bolts 10 58 Battery Installation 10 58 Battery Maintenance secus iR dou 2 18 Body and Steering
59. 5 IC S gt If 1 gt WIRE DIAGRAM INTENTIONAL BLANK PAGE WD 2 2007 5 2 WIRE DIAGRAM
60. Recoil Assembly CAUTION Be sure to wear a face shield and eye protection when performing this procedure 1 Place spring in housing with the end positioned so spring spirals inward in a counterclockwise direction See photo at right 2 Hold spring in place and cut retaining wire To reinstall an old spring 1 Hook outer tab in place in recoil housing and wind spring in a counterclockwise direction one coil at a time while holding the installed coils in place 2 Lubricate the spring with light lubricant such as Premium Season Grease PN 2871423 To complete recoil assembly 1 Route rope through guide bushing in recoil housing and into reel Tie a secure knot in end of the rope 2 Windrope counterclockwise onto the reel as viewed from ratchet side of reel 3 Lock rope into notch on outer edge of reel Apply a small amount of grease or equivalent to the center 3 52 post of the housing and the bushing 5 Install reel into housing making sure the spring drive tab on the reel engages the spring and the reel is fully seated in the housing 6 Apply downward pressure on the reel and rotate counterclockwise approximately 6 7 turns to pre wind the spring Continue rotating counterclockwise until rope on outer edge aligns with rope guide bushing 7 Release rope from notch and allow reel to rewind completely If more pre wind is required place rope in notch and add additional turns of p
61. 1 Layastraight edge across the surface of the cylinder head at several different points and measure warpage by inserting a feeler gauge between the straight edge and the cylinder head surface If warpage exceeds the service limit replace the cylinder head Cylinder Head Disassembly WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly NOTE Keep all parts in order with respect to their location in the cylinder head 1 Using a valve spring compressor A compress the valve springs and remove the split keeper NOTE To prevent loss of tension do not compress the valve spring more than necessary 2 Remove spring retainer and spring NOTE The valve springs should be positioned with the tightly wound coils against the cylinder head on progressively wound springs A 3 Push valve out keeping it in order for reassembly in the same guide 3 21 4 Measurefree length of spring with a Vernier caliper Check spring for squareness Compare to specifications Replace spring if either measurement is out of specification 5 Remove valve seals CAUTION Replace seals whenever the cylinder head is disassembled Hardened cracked or worn valve seals will cause excessive oil consumption and carbon buildup Valve Inspection 1 Remove all carbon from valve with a soft wire wheel 2 Check valve face for runout pitting and
62. MAINTENANCE Suspension Spring Preload Adjustment Center Spring Adjustment Ring Shock Spanner Wrench PN 2871095 Operator weight and vehicle loading affect suspension spring preload requirements Adjust as necessary using the spanner wrench 2 to turn the adjustment cam 1 Front Suspension Compress and release front suspension Damping should be smooth throughout the range of travel Check all front suspension components for wear or damage Inspect front strut cartridges for leakage CV Shaft Boot Inspection Inspect the CV shaft boots in the front and rear of the ATV for damage tears wear or leaking grease If the rubber boot exhibits any of these symptoms replace the boot Refer to Chapter 7 for CV boot replacement Controls gaa 4 x Check controls for proper operation adjustment positioning and Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body Throttle assembly Align clamp edge with knurl Align throttle control assembly clamp with knurl on handlebar Wheels Inspect all wheels for runout or damage Check wheel nuts and ensure they are tight Do not over tighten the wheel nuts A WARNING Operating an ATV with worn tires will increase the possibility of the vehicle skidding and possible loss of control Worn tires can cause an accident Always replace tires when
63. RELAY stays activated until the input goes high The RELAY output current is monitored by the 10 6 micro controller If the over current threshold is exceeded for the pre programmed delay time the output current will shut off Exceeding the power switch maximum current limit shuts down the output immediately Cycling the EFI via the key run switches will reset the output if RUN is active Note If RUN is not active the micro controller powers down therefore the maximum current limit will be the only overload protection active until the EFI input disables the RELAY Fuel Pump Relay The fuel pump circuit utilizes a and a smart high side power switch output The FUEL PUMP output is enabled when RUN is activated and FUEL is low If the maximum output current threshold is exceeded the output current will be reduced until the relay thermally shuts down It will automatically turn back on when it has cooled based on thermal recovery Repeated cycles will cause the short circuit limit to turn off repeatedly until the overload has been removed Active Descent Control An IPS is provided for current flow to the hub coil The PDM receives inputs from the TPS to determine throttle open closed and the Speed Sensor signal to determine vehicle speed ECM Memory The MEM output is a current limited high side power switch for the ECM and cluster This output is enabled whenever battery po
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65. 2 28 Exhaust Pipe Do not E clean out immediately after the engine has been run as the exhaust system becomes very hot Serious burns could result from contact with exhaust components To reduce fire hazard make sure that there are no combustible materials in the area when purging the spark arrestor Wear eye protection Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Do not go under the machine while it is inclined Set the hand brake and block the wheels to prevent roll back Failure to heed these warnings could result in serious personal injury or death The exhaust pipe must be periodically purged of accumulated carbon as follows 1 Remove the clean out plugs located on the bottom of the muffler Clean Out Plug 2 Place the transmission in Park and start the engine Purge accumulated carbon from the system by momentarily revving the engine several times MAINTENANCE 3 If some carbon is expelled cover the exhaust outlet and lightly tap on the pipe around the clean out plugs with a rubber mallet while revving the engine several more times If particles are still suspected to be in the muffler back the machine onto an incline so the rear of the machine is one foot higher than the front Set the hand brake and block the wheels Make sure the machi
66. M E MGR 6 E120 DG S888 559 ca oo ce See 218 ap z LOW t ud 19 YE 50 MOD M lt exco coco COCOLMLO 22 VT 2 T OH 76 RD YE e T 529 oe PUD NE TTT NEE L_ ofF S ore 0 16 RD YE 328 24 DG L oH 92 RD WH 26 B OFF 22 54 27 06 EE OFF 29 06 7 s3 WH 32 B OFF aL u 90 RD BK x n B oOoo oo 0 o oo o oooo o ooo o RUN Orr ON d Le N OFF H L ce 00 B SPEEDO _ mf103 61 06 M REVERSE lt OVERRIDE OVERRIDE NT Lg GY WH _ op 1 13 WH 138 DB WH J1 BKH l LOCATED IN FRONT P OF FUEL TANK 07 p 06 DB RD QU 04 08 06 30 06 03 DB WH 2 C BRAKE LIGHT SENSOR un CLOSED WITH a HAND BRAKE APPLIED E ai SHLD2 1 edo sog a 20 2 E c ER T MW TT acts E 11 e 09 52 ds e 2 eie e gt FF EE 0 3g i 2 lt 5 FUSIBLE LINK P N S m H SOLE O aS ME A 9 0 2202607 DB p tHe SOLENGID 99 Sa ds CASI RAM s EI TT GROUND GROUND EN a p J p 22 EA JJ 2 9 RESISTANCE BETWEEN PINS 4 ans RD STARTE
67. N pion Ring Piston Ring Installed Gap Std 0079 36 mm Limit L 0 mm econd Std 0079 0138 2 20 36 mm Limit 039 1 0 Cil Rin Std 0079 0276 20 70 Limit 059 1 5 mm 2 Measure installed gap with a feeler gauge at both top and bottom of the cylinder NOTE A difference in end gap indicates cylinder taper The cylinder should be measured for excessive taper and out of round 3 the bottom installed gap measurement exceeds the service limit replace the rings If ring gap is below specified limit file ring ends until gap is within specified range NOTE Always check piston ring installed gap after re boring a cylinder or when installing new rings A re bored cylinder should always be scrubbed thoroughly with hot soapy water rinsed and dried completely Wipe cylinder bore with an oil rag immediately to remove residue and prevent rust Crankcase Disassembly NOTE The recoil starter starter motor starter drive flywheel stator cam chain and sprockets can be serviced with th engine in the frame Starter Drive Removal Inspection 5 Measure the ID of the bushing in the recoil housing A and in the crankcase and record Measure in two directions 90 oil housing bolts and housing apart to determine if bushing is out of round Calculate AN di ce bushing clearance Replace bushing if clearance exceeds service lim
68. hime E eer aon ER 4 44 EET IP acts cages bet a ee RS EU md tread ados t 4 45 FUEL PUMP TESTING x ua atomes te a a Roe ar SSE en 4 45 FUEL TUMFPABISASSEMBLY eadar deae m T Ee tO eC e Eee bue exe 4 45 FUEL PUMP INSPECTION AND REASSEMBLY 4 46 FUEL FILTER REPLACEMENT st reper ORE dp RR bn pot so sce ss ar Sis 4 46 FUEL GAUGE SENDING 4 46 SENDING UNIT REMOVAL 222 me SER iw dt Roe E 4 46 TESTINO SESE EELS obtenta ur poseer 4 47 SENDING 4 47 jEBHOUBEESFHOPO LIN aee aen E RED E URN Ret eode acide ax teo atas 4 47 FUEL STARVATION LEAN 4 47 4 31 CARBURETOR SPORTSMAN 450 GENERAL INFORMATION AND SPECIFICATIONS Special Tools TOOL PART SMEER DESCRIPTION Mity Vac Pressure Test 2870975 Carburetor Float I Adjustment Tool A WARNING Gasoline is extremely flammable and explosive under certain conditions Always stop the engine and refuel outdoors or in a well ventilated area Do not overfill the tank The tank is at full capacity when the fuel reaches the bottom of the filler neck Leave room for expansion of fuel Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can
69. 5 Place the piston in the piston cavity aligning the pins with the pin bosses Using the casting and piston marks as a guide as shown will aid pin alignment 7 28 6 Place ADC Piston Tool PA 48542 on top of the piston and verify alignment of the sight hole circled and piston mark with the casting marks Support the case and press the piston down evenly The piston is fully seated and located in the pin bosses when the piston surface is just below the cavity edge E 7 Repeat procedure for the other gearcase half NOTE Verify that the o rings are seated properly and that no o ring shavings exist outside of the piston area which is an indication of damage during installation Assembly 1 Thoroughly clean the gearcase components before beginning reassembly 2 Install a new seal in the main gearcase halve 3 Install the input shaft assembly Install the pinion gear bearing assembly 1 Install a new seal and o ring the input shaft cover 2 prior to reassembly FINAL DRIVE 5 Install the eccentric cam assembly 1 7 Install the input shaft cover assembly bolts and bracket Torque to specification F Input Cover Bolt Torque 7 11 ft Ibs 9 4 14 9 Nm 7 29 FINAL DRIVE 8 Install a new seal 1 in the outer cover plate assembly Install a new o ring on the backlash pad 2 stem NOTE Ring gear backlash 2 is set at the fa
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71. NOTE The rod pin position in relation to the dial indicator position tells you what action is required to straighten the shaft HIGH 004 1 mm SUPPORT CRANKSHAFT HERE 1 Tocorrect a situation like the one shown in the illustration strike the shaft at point A with a brass hammer HIGH 002 05 mm 005 13 2 To correct a situation like the one shown in the illustration squeeze the crankshaft at points A Use tool from alignment kit HIGH 002 05 mm HIGH 005 13 mm A 3 Ifthe crank rod location is 180 from the dial indicator opposite that shown above it will be necessary to spread the crankshaft at position A as shown in the illustration at right When rebuilding and straightening a crankshaft runout must be as close to zero as possible NOTE Maximum allowable runout is 0024 Engine Lubrication EH 50PL Oil Type Polaris Premium 4 Synthetic PN 2871281 or API certified SH 0 40W oil Capacity Approximately 2 U S Quarts 1 91 Filter Wrench PV 43527 Drain Plug Screen Fitting 14 ft Ibs 19 Nm If fitting is removed follow oil pump priming procedure Pressure Specification 20 PSI 5500 RPM Polaris OW 40 Synthetic Engine Hot Pressure Test EH 50PL 1 Remove blind plug on front left cylinder head Insert a 1 8 NPT oil pressure gauge adaptor into the cylinder head and attach the gauge
72. T25 Torx 42 52 in lbs 4 75 5 88 Nm 6 28 STANDARD DRIVE CLUTCH Drive Clutch Disassembly 1 Using a permanent marker mark the cover spider and moveable and stationary sheaves for reference as the previous X s may not have been in alignment before disassembly 2 Remove cover bolts evenly in a cross pattern and remove cover plate 3 Inspect cover bushing A The outer cover bushing is manufactured with a Teflon M coating Wearis determined by the amount of Teflon M remaining on the bushing Cover Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replacement in this chapter 4 Inspect area on shaft where bushing rides for wear galling nicks or scratches Replace clutch assembly if worn or damaged 5 Remove and inspect spring See Drive Clutch Spring Specifications for spring inspection CLUTCH SYSTEM Spider Removal 2 Inspect the Teflon M coating on the moveable sheave bushing 1 Remove the limiter nut using the Clutch Spider Nut Socket PN 2870338 Install clutch in holding fixture and loosen the spider counterclockwise using Clutch Spider Install Tool PN 2870341 Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing Clutch HoldingFixture PN 2871358 replacement in this chapter Spider Removal Tool PN 2870341 3
73. adi oan ERU Ra 10 53 doas ue tico dob dero 10 54 CHARGING epee ees qst 10 54 AEE WHEEL DRIVE NERVIS B eR tots ban 10 55 TRANSMISSION SWITCH EFI EE 10 55 REVERSE OVERRIDE FERESTE oto serat obo eeu NL 10 56 DIFFERENTIAL SOLENOID X2 duce deor ee a elo Ca eo cente d e 10 56 S sex hr d du d tutu fun Eus EN pU BATTERY IDENTIFICATION ne tius sta ea Rt s t ORI SSIES genu do a 10 57 BATTERY ACTIVATION 2 piii erdt bon Kee eR at eite i bae sto i eee eee 10 57 TERMINAL PREPARATION lt lt n pe eet tats ws 10 58 BATTERY REMOVALS tuat 10 58 BATTERY INSTALLATION ed epe mb sor es 10 58 OFF SEASON STORAGE rx iate e RR Exe Deque Dresd etes Bor ned 10 59 LOW MAINTENANCE BATTERY OFF SEASON STORAGE 10 59 BATTERY TESTING os uis ie irs o Rma Etpe f ates se 10 59 CONVENTIONAL BATTERY OCV OPEN CIRCUIT VOLTAGE TEST 10 59 CONVENTIONAL BATTERY SPECIFIC GRAVITY 10 59 BATTERY LOAD TE Salsa Am sequo deo sy ae ee aie 10 60 CHARGING PROCEDURE 4 m reb b derer Ce 10 60 LOW MAINTENANCE BATTERY
74. 123 02 5 JuVg310NvH H1 3 02 JONYYO AYY9 0 E 221145 038 123 02 IE 321148 311887038 2 02 JLIHM Q3Y 20 J Z 8255 92 123 02 7 24 121145 38 02 3 10 2 40123741 1303 123 21 5 121145 NMOUB d 02 NOXE 00 6 43134003345 121145 311HM 3018 02 2 1 2 8255 2 8 NOXE 66 11 13130003345 123 02 3LIHMDIOV TG l 121145 311887038 1 02 311847038 86 121145 3018 TWNOIS INOUJ H3 21 1018 0 121145 02 9 8 138 16 1 8255 6 123 02 2V18 80113A 60 l 121145 01134 038 d 9 111 038 96 2 1148 21 123 02 80 E 121145 NMOS s 9 MOU 56 9 8255 123 02 y2v18 AV49 10 I 321148 01134 038 9 111 038 76 y 2 6 123 02 038 3018 90 IE 121145 311887038 Y 9 3L1HM 038 6 ov 9 123 02 4 3118 0 l 121145 311887038 J YVGIIONVH H1 9 311847038 26 9 ov 8 123 02 39NY30 3018 70 121145 02 9 1083105 6 ov 123 02 3018 0 1 uvg310NVH H1 1 011189 8 42 18 38 06 1102 NOILINOI 123 21 3L1HM N3385 20 U3MOd MS 93190853227 301 148 0 9 TLIHM ONYYO 69 121145 038 123 02 aay 10 0123092 OL 80121 02 10079 40102 ddy YOLIANNOD OL ALIAV YOLIINNOD 10079 40102 ddy i v 11071 NOIIVNINS3I 38 31071 NOLIVNINS3I 381M CON 13004 1437006 2X NNS 14S LO ALY 3 WIRE DIAGRAM YNO Idd 005 CX 4046 1006
75. 25 gt 59 GY m 98 AWD ON OFF SWITCH 8 co o ON OFF D 81 06 WH LOCATED ON RIGHT HANDLEBAR 62 WH o TJ BK 2 gt h ret IGNI SWIT p 01 GY BK 5 ION SWITCH f f SSCB E O P 38 ow Pj 4 JI K d Si i 55 m p qs f 64 RD B 115 LOCATED BELOW HANDLEBARS 48 BN i 60 06 8 lian 136 YE e L nu 01 RD Ezz D 39 DB WH eaa annaa rci Ec COCA coco coo aac 14 GY WH CORRER See waaa cun TERR mee is farum LII 06 Pu EIN E eie o cereo 5925050500 f DDOD Sore ORS Gals eo PORT xem seni 1 V SSCB TA 31 RD YE d v 1 ES S e 2 H JR E ej T i pa s S 1 T 2 D W BD WH 3 99 8 R RD YE RD WH R E RD BK BK B BR l al 88 YE SPLICE SPLICE SPLICE 3 SPLICE SPLICE 2 SPLICE SPLICE SPLICE 1 SPLICE 2 SPLICE 3 SPLICE 4 9 RDID6 33 YE 132 YE 06 06 OG W DB DB W 06 VT E SPLICE SPLICE LEFT HANDLEBAR SPLICE 1 SPLICE 2 SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE 2 3 SWITCH ASSEMBLY m o 1 11 E 1 B ili com 1 19 YE
76. 3 Start engine and allow it to reach operating temperature monitoring gauge indicator NOTE Use only Polaris Premium 4 Synthetic Engine Lubricant PN 2871281 Pressure at 5500 RPM Engine Hot Standard 20 PSI Minimum 12 PSI Oil Pump Priming Procedure See Oil Pump Priming Procedure on page 2 25 Cil Flow EH50PL The following chart describes the flow of oil through the EH50PL engine Beginning at the oil tank the oil flows through a screen fitting in the bottom of the tank and into the oil supply hose The feed side of the oil pump draws oil through the hose and into the crankcase oil gallery and then pumps the oil through another passage to the one way valve When the engine is off the one way valve closes to prevent oil in the tank from draining into the crankcase The oil is pumped through a delivery pipe to the oil filter If the oil filter is obstructed a bypass valve contained in the filter allows oil to bypass the filter element At this point the oil is diverted in two directions Oil is supplied to the camshaft through the left front cylinder stud and an oil passage in the head enters the camshaft through the PTO L Journal The camshaft journals cam lobes and rocker arms are lubricated through holes in the camshaft The oil lubricates the cam chain and sprocket and drains to the sump The other oil path from the filter leads through a delivery pipe to the crankcase main oil galler
77. 4063 12 28 1 3 4 5 19 16 PTOA etic sida tate ete E 4219 11 mm 2 4331 4375 1 4 20 1 3 4 12 1 43 64 29 64 4531 1 4 28 2 4 1 2 1 25 32 4688 12 4724 5 16 18 2 42 1 59 64 SWORE LRA 4844 5 16 24 214412 21 32 3 8 16 2 1 2 4 21 4 e 5313 3 8 24 2 3 4 4 2 1 2 OO OF 5469 14 mm 5512 9 16 5625 7 16 14 3 4 2 3 4 E er 5781 15 mm 5906 7 16 20 19 32 5938 39 64 6094 58 625 16mmz 6299 Metric Tap Drill Sizes a 6406 Decimal Nearest rd eue fact at 6563 17 mm 6693 Tap Size 43 64 6719 Equivalent Fraction 6875 3x 50 45 64 7031 18 mm 7087 3 60 188 pie 47 64 222 7344 19 mm 7480 E 75 4x 75 49 64 7656 580 ERAS 7813 20 7874 7969 90 13 16 deer coiere 8125 24 mm 8268 6x1 00 53 64 8281 8438 i 55 64 8594 22 mm 8661 8x1 00 7 8 875 8 1 25 57 64 8906 23 mm 9055 29 32 9063 9x1 00 59 64 9219 9 1 25 9375 24 9449 10 1 25 9531 9688 25 9843 63 64 9844 11 1 50 1 0 12 1 50 12 1 75 1 13 GENERAL INFORMATION
78. Check connectors for moisture wire color matching or corrosion Test the ignition switch engine stop Brown for operation Does it have spark Verify that 12 VDC power is getting to the ECM Refer to the wiring schematic for meter connec tions and specifications Compare results to the specifications on the exploded views Are all within specifications Inspect battery fusible link con nectors wiring and grounds Replace the componer if a wiring problem cannot be found Check coil and connections between ECM and coil i Replace coil if failed mount using an ohmmeter Is there continuity No Repair wire connections Yes Disconnect and check the coil Resistance val ues should be Primary Side Coil terminal to terminal 5 Ohms Secondary Side High Tension Wire to High Ten sion Wire Cap installed 11 2000 Cap removed 55000 Are these values within specs If all of the above tests are within specifications and all switches grounds connections and wire color coding have been inspected perform voltage output tests on following page or replace the ECM 10 30 ELECTRICAL Crankshaft Position Sensor Gap Ignition Output Test Using Gap Tester Measure trigger coil gap with a feeler gauge The gap should be Re connect all wires Disconnect spark plug wire from the spark 0 4 1 2 mm 0 015 047 in plug Connect gap tester lead to engine ground and the other to
79. ELECTRONIC FUEL INJECTION General Information The Electronic Fuel Injection EFI system 15 a complete engine fuel and ignition management design This system contains the following principal components Fuel Pump Fuel Rail Fuel Line s Fuel Filter s Fuel Injector Pressure Regulator Throttle Body Intake Manifold Engine Control Module ECM Ignition Coils ngine Coolant Temperature Sensor ECT Throttle Position Sensor TPS Crankshaft Position Sensor CPS Manifold Absolute Pressure Sensor MAP Idle Air Control IAC Intake Air Temperature Sensor IAT Wire Harness Assembly Check Engine Light MIL Efi Operation Overview The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions The ignition and injection functions are electronically controlled monitored and continually corrected during operation to maintain peak performance The central component of the system is the Visteon Engine Control Module ECM which manages system operation determining the best combination of fuel mixture and ignition timing for the current operating conditions An in tank electric fuel pump is used to move fuel from the tank through the fuel line and in line fuel filter The in tank fuel pressure regulator maintains a system operating pressure of 39 E and returns any excess fuel to the tank At the engine fuel is ed through the fuel rail and into the injector which injects i
80. Ignition timing misadjusted Low oil level Spark plug incorrect heat range Faulty hot light circuit stuck closed or not Thermostat completely opening Temperature Too Low Thermostat stuck open Leak at Water Pump Weep Hole Faulty water pump mechanical seal coolant leak e Faulty pump shaft oil seal oil leak FUEL SYSTEM CHAPTER 4 FUEL SYSTEM ELECTRONIC FUEL INJECTION 4 3 4 30 CARBURETOR SPORTSMAN 450 4 31 4 47 4 1 FUEL SYSTEM 4 2 FUEL INJECTION CHAPTER 4 FUEL INJECTION SPECIAL TOOLS ec iet stereo ERR EP UE downs 4 5 PART NUMBERS 5 4 5 EFI SERVICE 4 7 GENERAL SERVICE 4 7 EFI SYSTEM EXPLODED 4 8 EELS VOTE cresta 4 9 COMPONENT LOCATIONS IDENTIFICATION lese hn nn iB 4 9 SUN P 4 10 EXPEODED VIEW 125545 5 DAS SEE 4 10 ELECTRONIC FUEL 4 10 GENERAL 4 10 EFI OPERATION OVERVIEW 255
81. Retaining Ring Pull Shaft to Remove from CV Joint 7 Remove small clamp and boot from driveshaft NOTE If the ATV has been operated with a damaged boot the CV joint grease may be contaminated Inspect the grease carefully for contamination and clean the joint thoroughly if necessary Front drive axle CV boot replacement requires 3 5 oz of grease CV Joint Grease 3 5 oz Refertoparts manualforbootkit CV Boot Clamp Pliers Earless Type PN 8700226 Boot replacement with complete CV joint cleaning requires the entire 3 5 oz of grease 8 Before installing the new boot remove all grease from the boot area and shaft NOTE It is very important to use the correct type and quantity of grease Use only the grease contained in the boot kit DO NOT use a substitute grease and DO NOT overfill or under fill the CV joint 9 Slide the new clamp and boot small end first over the splined shaft then slide tap the CV joint into the splines of the axle 10 Add grease through large end of boot 11 Install a new boot onto the axle shaft and fill the CV joint and boot with the correct type and amount of grease 12 While pulling out on the CV shaft fully extend the CV joint 7 and slide a straight O ring pick or a small slotted screw driver between the small end of the boot and the shaft This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life Before
82. Symptoms Hard start or no start bog backfire popping through intake exhaust hesitation detonation low pou spark plug erosion engine runs hot surging high idle idle speed erratic No fuel in tank Restricted tank vent or routed improperly Fuel lines or fuel injectors restricted Fuel filter plugged e Fuel pump inoperative Air leak in system Intake air leak throttle shaft intake boot gasket grommet Throttle stop screw tampering replace throttle body Failed Sensor or disconnected wiring RICH MIXTURE Fouls spark plugs black sooty exhaust smoke rough idle poor fuel economy engine runs rough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug TPS setting incorrect e Injector failure Failed Sensor or disconnected wiring Throttle stop screw tampering replace throttle body POOR IDLE Symptom Idle Too High If greater than 1300 RPM when engine is warm Throttle stop screw tampering replace throttle body Throttle cable sticking improperly adjusted routed incorrectly Failed Sensor or disconnected wiring AC stuck or inoperative ntake air leak Symptom Idle Too Low if less than 900 RPM when engine is warm Plugged air filter Leaking injector rich condition Belt dragging Throttle stop screw
83. Voltage amperage and resistance values included in this manual are obtained with a Fluke 77 Digital Multimeter 43568 This meter is used for when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multimeter reading K M etc and the position of the decimal point For resistance readings isolate the component to be tested Disconnect it from the wiring harness or power supply Troubleshooting No Spark Weak or Intermittent Spark Spark plug gap incorrect Fouled spark plug Faulty pars plug cap or poor connection to high tension Related wiring loose disconnected shorted or corroded Engine stop switch or ignition switch faulty ETC switch misadjusted or faulty Wire harness or connections wet corroded or broken Poor ignition coil ground Incorrect wiring after repair inspect color coding in connectors etc Faulty ignition coil windings measure resistance of primary and secondary Sheared flywheel key Flywheel Loose or damaged Excessive crankshaft runout should not exceed 0024 Faulty ECM Faulty CPS Low Battery ELECTRICAL POWER DISTRIBUTION MODULES PDM Sportsman EFI Overview Power Distribution Module PDM am a E Fr a i PDM Located Inside Front Grill Cover SPORTSMAN 500 EFI X2 hon SPORTSMAN 500 EFI BUT i CONST PRI Li gir La EDU
84. deputato phe B ceu n dtu e ete ab aes 9 2 COMPONENT SERVIGE EIMIDS acc p e ehe etd det 9 2 BRAKE SYSTEM EXPLODED VIEWS SSS SERS atau e ta tert n 9 3 X2 SYSTEM COMPONENT EXPLODED VIEW 9 3 SPORTSMAN SYSTEM COMPONENT EXPLODED VIEW 9 4 BRAKE CALIPER EXPLODED VIEWS 9 5 SPORTSMAN AND X2 FRONT CALIPER 5 9 5 X2 REAR CALIPER ASSEMBLY ssn 9 5 SPORTSMAN REAR CALIPER 5 9 6 AY DRAULIC BRAKE SYSTEM cx ga 3 vao x HERE E IE EEG died Een xd 9 6 OPERATION OVERVIEW ux ee uA d e ueni b met ert atiis 9 6 BRAKE NOISE TROUBLESHOOTING 9 7 BRAKE BLEEDING FLUID 97 FRONT MAS TER GYEINDER apex Eu Boe d d Re a e ar 9 9 REMOVALS cutus uetus aa e BET AE it dg ate de speci RN 9 9 SRS NE Ned 9 9 magia Sous bias otek eee be ae eS 9 10 2 lesa eae Oe St iet 9 10 cis RONAS icri eise edo ideae quar en cu aria esu tera eae 9 11 BRAKE BURNISHING PROCEDURE ste Eph Che ite es 9 12 FR
85. silicone sealant to outside edge of inner cover to engine seal to ensure a water tight fit between the seal and the cover on engine side Surfaces must be clean to ensure adhesion of silicone sealant 4 Reinstall cover and tighten rear cover bolts just enough to hold it in place 5 Fit lip of inner cover seal A to engine Install seal retainer plate and tighten screws securely 6 Torque rear inner cover bolts B to specification Foam Seal 10 Remove inner cover retaining bolts at rear of cover 11 Remove cover along with foam seal on back of cover or shaft Seal Outer Edge To Cover w silicone sealant Inner Cover Bolt Torque B 12 ft Ibs 16 6 Nm 6 11 CLUTCH SYSTEM 7 Install clutch offset spacer s on transmission input shaft Offset Spacer 6 8 Clean splines inside driven clutch and on the transmission input shaft 9 Apply a light film of grease to the splines on the shaft 10 Install the driven clutch washer lock washer and retaining bolt Torque to specification Driven Clutch Retaining Bolt Torque 17 ft 105 23 5 Nm 11 Clean end of taper on crankshaft and the taper bore inside drive clutch 12 Install drive clutch and torque retaining bolt to specification Drive Clutch Retaining Bolt Torque 40 ft Ibs 55 Nm 13 Reinstall drive belt noting direction of rotation If a new belt is installed install so numbers can be easily read
86. turn the starter must be removed for static testing and inspection 10 50 ELECTRICAL BASIC WINCH WIRING Pre wired Models NIRE S0L D IFT TRACING ARE REPRESENTED 1 OR DASHED LINES TO N DIAGRAM COLOR CODE BLK BLACK BROWN GREEN PUR PURPLE ME ENGINE GROUND BLU BLUE e GRY GRAY 6 2 CHASSIS OR ORANGE 5 YELLOW c RED WHITE TWO COLOR WIRES ARE SHOWN WITH TRACE COLORS EXAMPLE HED WITH YELLOW RACER SWITCH WORMALLY CLOSED SWITCH NORMALLY OPER RN v BATTERY BLU E 1 3 BLK 12 POWER BLK BLU 40 C BLA R OPEN T 44 0 541 4 0 51 00 t cen POWER BLU R 40 Lo PS 1 BLK R OPEN Ty g ers 5 Et BLK POWER BLU BRN BLA R xm Ti ma 10 51 ELECTRICAL TROUBLESHOOTING DIAGRAMS Power On EFI Ignition Switch Red White Splice 3 Splice 1 To ECU Pin 34 To ECU Pin 33 4 To ECU Pin 12 Brown Splice 4 Splice 2 SSCB 2 SSCB 1 on f F Protected et ES Battery Output O Or TA on 2 uum Y a a 121 Fusible Link Ur pp Rinvarsm Crenrrida Protected Battery Output Red White Splice 1 Starter Solano
87. 10 Remove carburetor Insert a shop towel into the carburetor flange to prevent dirt from entering the intake port 11 Remove center chain guard on chain drive AWD models 12 Remove center drive and driven sprocket bolts and remove chain and sprockets as an assembly 13 Refer to PVT System to remove outer clutch cover drive belt drive clutch driven clutch and inner cover 14 Starter motor Note ground cable location Mark positive cable mounting angle and remove cable 15 Remove transmission linkage rod s from gear selector and secure out of the way 16 Disconnect coolant temperature sensor wire 17 Remove engine to chassis ground cable 18 Removeall engine mount nuts and or engine mount plates 19 Remove engine through right side of frame Engine Installation Notes After the engine is installed in the frame review this checklist and perform all steps that apply General Items 1 Install previously removed components using new gaskets seals and fasteners where applicable 2 Perform regular checks on fluid levels controls and all important areas on the vehicle as outlined in the daily pre ride inspection checklist refer to Chapter 2 or the Owner s Safety and Maintenance Manual PVT System 1 Adjustcenter distance of drive and driven clutch Chapter 6 2 Adjust clutch offset alignment and belt deflection Chapter 6 3 Clean clutch sheaves thoroughly and inspe
88. EBS DRIVE CLUTCH SERVICE 3 c ex ete aee me ds 6 15 DRIVE CLUTCH DISASSEMBDLUY s iriure dee ee gee ee ee de hasc 6 15 SPRIDER REMOVAL ru std RSS SENS SS OES 6 15 BUTTON TO TOWER CLEARANCE 6 17 SHIFT WEIGHT INSPECTION s i uirtute d t HE REP aed ae aes Y Ser RS Ree 6 17 DRIVE GEUTCHJINSPEGTION 555545 desto Xo eid e Rte 6 17 MOVEABLE SHEAVE BUSHING INSPECTION 6 18 DRIVE CLUTCH BUSHING SERVICE EE o etie 6 18 ONE WAY CLUTCH INSPECTION DRIVE CLUTCH 6 20 DRIVE CLUTCR UREASSEMBLY 34 24 chewed hae setae het ey tei 6 20 EBS DRIVEN CLUTCH SERVICE 52 3 4 2 8 92 4 doe od wind oe oes utes 6 22 DRIVEN GEUT CH DISASSEMBLY tale es ae iis 6 22 DRIVEN CLUTCH BUSHING REMOVAL INSTALLATION 6 24 EBS DRIVEN CLUTCH REASSEMBLY 2 o Rx LE ERE eyed ieee nes 6 25 STANDARD DRIVE CLUTCH icy 6 28 DRIVE CLUTCH DISASSEMBLY ici eese oat pee use dn 6 28 SPIDER REMOVAL sano cs siete ce ox ose UE ET SEEM her San Oe 6 29 BUTTON TO TOWER CLEARANCE 6 30 SHIFT WEIGHT INSPECTION cete S deb Oca reo e Rt bs 6 30 DRIVE CLUTCH REASSEMBL Y INS 6 31 SHEAVE BUSHING
89. GENERAL INFORMATION Publications Table 1 1 Publications Owner s Parts Parts A07MN50A Deluxe Sportsman 500 EFI AO7MHSOA Standard 9920364 9920365 N A 07 50 Standard Intl 50 Deluxe 2007 Sportsman X2 500 EFI 07 5 Standard 9920632 9920902 2007 Sportsman 450 EFI A07MH46A 9920629 9920557 3007 PB9Hsman 42 300 EET AO7MH46E 9920650 9920899 N A Quadricycle Paint Codes Table 1 2 Paint Codes COLOR DITZLER POLARIS Pyne DESCRIPTION NUMBER NUMBER Sportsman Frame Replacement Keys Replacement keys can be made from the original key Phoenix excluded To identify which series the key is take the first two digits on the original key and refer to the chart to the right for the proper part number Should both keys become lost ignition switch replacement is required Table 1 3 Key Numbers Key Cover opi 4010078 PN 5433534 4010278 4010321 4010321 4010321 E Me Key Series 4110141 Number 4110148 4010276 1 3 GENERAL INFORMATION Sportsman Deluxe and Standard Model Component Comparison For Model Year 2007 a Sportsman Deluxe and Standard model were offered Use the following table as a guide SPORTSMAN DELUXE MODEL Item Location SPORTSMAN STANDARD MODEL Deluxe Model Pictured 1 4 GENERAL INFORMATION Sportsman X2 Deluxe and Standard Model Component Comparison For Mod
90. ISWITCHED POWER POD ACC BN TO BK RD 11 2 12 4 Q ATV OT SPORTSMAN 500 EFI X2 MODEL NO AOTMNSOAF AQ AU AZ pl HEADLIGHT HEADLIGHT iE 1 s UEM TO GROUND NO CONNECTION E TE p pr PAGE 1 OF 2 A m ge WORK S S _ 9 LOW i U LIGHT WIRES ARE REPRESENTED BY FUEL PUMP i SPEED SWITCH uds non SOLID OR DASHED LINES TO Bh y i SEES 222415 e SIMPLIFY TRACING IN DIAGRAM A 3 ae E NEST 54 gt a o PARK FUEL x f im gt T i F 9 AR IM STATOR LOCATED UNDER RECOIL z H5 f 1 T3 TRANS SWITCH ER LOI d Boo WIRE COLOR TEGE f ence EMPTY 50 STATOR ABE l LISS RESISTOR MODULE 20 ECE AN V ENGINE GROUND FULL 90 Q m Ty _ ES EN RESISTANCE 5 LAY o SE 8 LIGHT BLUE co aS o nu AT TU T A eu a OT CHASSIS GROUND 288 7 2 J Ts zi B BROW 9 0 Of 0 mr lt 9 e a aa 00 0 E eee 6 LIGHT GREE ii Lo P zo o zc 9 06 DARK GREE a EINE Pun 2 em P20 dee 06 ORANGE NC Orie 055 Be Bau Se 2 No 7 PIN SWITCH NORMALLY CLOSED pem
91. Illustration 3 NOTE If the float 15 past parallel with the mating surface the carburetor has been tilted back too far and the float tongue is likely compressing the needle valve pin Mity Vac PN 2870975 3 Measure the height from the float bowl mating surface to the top of step of the float as shown in Illustration 2 Both sides of float should be parallel to each other The measurement should be made at the mid point on top of the 4 42 CARBURETOR SPORTSMAN 450 Fuel Level Test A fuel level test can be performed on some models if the drain hose fitting is accessible Be sure to re attach the bowl drain hose after performing the test A fuel level test allows you to observe the height of the fuel in the float bowl without removing the carburetor The fuel level can be observed with the engine either running or shut off however engine must run briefly to allow fuel level to stabilize 1 Attacha clear line to drain fitting Be sure line fits tightly on fitting Position hose along side of carburetor as shown Surface 2 Open bowl drain screw by turning counterclockwise approximately two turns Start and run engine for 3 to 5 seconds to allow fuel level to stabilize in the line If level is out of specification remove carburetor and inspect inlet needle and seat float height passages etc NOTE If a line was removed to perform this procedure it must be replaced 4 43 CARBURETOR S
92. Push Instrument Cluster Outward NOTE Do not remove the rubber grommet in the pod Only remove the rubber grommet if necessary The bezel is a snap on assembly and is a serviceable part 10 18 Speedometer Installation 1 Sprayasoap and water mixture onto the outer surface area of the instrument cluster This will help the instrument cluster slide into the pod assembly more easily 1 43 DE E P 1 E d y f 2 Be sure the rubber grommet inside the pod is fully installed and that the indexing key is in the headlight pod keyway a fu cluster into the pod assembly Twist the instrument cluster gently in a clockwise motion to properly seat the instrument cluster into the pod assembly Apply pressure on the bezel while pressing down on the instrument cluster NOTE Do not allow alcohol or petroleum products to come in contact with the instrument cluster lens ELECTRICAL ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING TEST 1 No Wheel Drive TEST 1 NO ALL WHEEL DRIVE START HERE CHECK SPEEDOMETER PERFORM TEST 2 KEY SWITCH ON TRANSMISSION IN GEAR AWD SWITCH ON ON HUB COIL LEAVE IT CONNECTED x MEASURE FOR 12V FROM NBROWN WHITE TO TH COIL BODY GROUND LEAVE AWD SWITCH ON TUR
93. Rear Brake Pad Thickness Service Limit 180 4 6 mm X2 Pad Installation 4 Slowly pump the brake lever until pressure has been built up Maintain at least 1 2 12 7 mm of brake fluid in the 1 Lubricate mounting bracket pins with a light film of reservoir to prevent air from entering brake system Polaris Premium Season Grease PN 2871423 and install rubber dust boots 5 Install the adjuster screw and turn clockwise until the stationary pad contacts the disc then back off 1 2 turn counterclockwise 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other 6 Verify fluid level in reservoir is up to the MAX line inside reservoir and install reservoir cap A WARNING 7 Install wheel s and torque wheel nut s If brake pads are contaminated with grease oil or liquid soaked do not use the pads Use only new clean pads 8 It is recommended that a burnishing procedure performed after installation of new brake pads to extend service life and reduce noise 9 18 5 Sportsman Rear Pad Removal NOTE When removing caliper be careful not to damage brake line Support caliper so as not to kink 1 Support the machine Remove the rear tire or bend brake line 2 Remove the slide pin clips from the slide bolt 5 Push caliper pistons into caliper bore slowly with pads installed 6 Remove the caliper sl
94. Requirement 6 gal US 22 7 liters Wheels Brakes 87 Octane minimum LL MEN Table 1 12 Sportsman 500 EFI Clutching Weight No Operating RPM 6000 RPM Adjustment Ignition System DC CDI Ignition Meters 0 1800 10 Blu Green White Yel EBS PAESE Feet 0 6000 5630710 7041157 7041635 5131674 Ignition Timing 13 3 BTDC 1150 RPM 1800 3700 10 RH Blu Green White Yel EBS Spark plug Gap BKROE 035 in 0 9 mm 6000 12000 5630709 7041157 7041635 5131674 Battery Amp Hr Lead Acid 30 Amp Hr Circuit Breakers Fan 12 amp Switched Power 10 amp Fuel Pump 10 amp ECU 15 amp Ignition Coil 10 amp Accessory Power 10 amp Lights 20 Amp Starting Electric Recoil Instrument Cluster Analog Speedo w LCD 1 9 GENERAL INFORMATION 2007 SPORTSMAN X 2 500 EFI Model Number A07TH50AU AZ AO7TN50AF AO7TH50EA Standard Models Deluxe Model Intl Quadricycle Engine Model 5 Table 1 13 Sportsman 2 500 General Specifications Category Dimension Capacity SS in Z36 cm Height 48 in 122 cm Body Style Spirit Hitch Tongue Capacity 120 Ibs 54 4 kg Rear box capacity and tongue weight not to exceed 400 Ibs 181kg 1 10 Table 1 14 Sportsman X2 500 EFI Compression Pressure 60 90 psi W Compression Release Cooling System Capacity Exhaust System single Pipe USFS Approved Fuel System Oil Requirements Capacity Polaris
95. SSCB 2 O ON Fusible Link i 2 Resare Dpr kia Handlebar SSCB 1 10 52 ELECTRICAL Ignition Coil EFI Ignition Col Driver SSCB 2 Fuel Pump EFI Brown Splice 84 Brown Splice 2 SSCB 2 High Side Driver 10 53 ELECTRICAL Fan EFI SSCB 1 K High Side Driver Fan Control Brown Splice 4 Brown 3 Stator Bicwn Splice Brown SSCB 1 Speedometer To Starter 10 54 ELECTRICAL Wheel Drive EFI From Stop Switch Splice 1 Right Hand Handlebar Speedometer Transmission Switch EFI Transmission Connector Speedometer Neutral Fark E ivl at F NEC ME EN E J 2 LIE Resistor Module 10 55 ELECTRICAL Reverse Override EFI Neutral Clutch Switch S Ti M Ignition Switch Speedometer Differential Solenoid X2 DIFFERENTIAL SOLENOID 149 BL righ Gee i Ball MLE B PONDE WIDE dd wil TUA OM NIAE 8 if SPEED 4 eon Dy 10 56 E
96. To install the screen simply press the tabs on the screen back into the mounting grommets Be sure the screen is securely in place 9 11 BODY STEERING SUSPENSION Sportsman Body Assembly Exploded View Rear Cab Assembl Pull UP on rear of seat and back to disengage tabs at amp of seat iS s 18 N eat 1 p Storage Frame Side Cover Support Front Cab gt Shields 5 12 BODY STEERING SUSPENSION X2 Body Assembly Exploded View Rear Cab Assembly ines Footwell RH Rear Cab Footwell Support Front Cab Assembly Front Cab 5 13 BODY STEERING SUSPENSION Body Rack Exploded Views Rack Rails Lo lt lt c Rear Rack Sportsman Only WL Rear Rack Support Rack Rails Box Assembly Front Brush Guard i L e 4 2 Radiator Shield Grill Radiator Screen E t Front Bumper 5 14 BODY STEERING SUSPENSION Headlight Pod Exploded View amp gt Worklight Instrument m i Cluster Ki T r 5 ake pu Clean knurling when repositioning andlebars Wheel Speed Sensor Sportsman C AN X2 Speed Sensor Located on Transmission Disassembly Assembly Remove two side Phillips screws A bottom of pod onto handlebar and secure to brackets Remove one rear Phill
97. idm gemere Da icon Fw ced s FUEL STARVATION CEAN MIXTURE sae 4 23 EFI DIAGNOSTICS USING BLINK 5 BEINISGODES OPERATION vs sedeat duae pet utate thet og dubbio 4 24 TROUBLESHOOTING DIAGRAMS 5 etta icti a ep en i ciens EFFCIRGUIT POWER 4 26 EFI CIRCUIT CRANK POSITION SENSOR 4 26 EFECIRCULT PUMP Cer uS abs 4 27 EFI CIRCUIT IGNITION COIL etie smi dur atri ereer 4 27 EFLCIRCUIT IDLE AIR CONTROL esas ted uer ens Pus Mo eed 4 28 EFI CIRCUIT THROTTLE POSITION SENSOR 4 28 EFI CIRCUIT MANIFOLD ABSOLUTE PRESSURE 5 5 4 29 EFI CIRCUIT ENGINE COOLANT 4 29 EFI CIRCUIT AIR TEMPERATURE SENSOR 53 creda aed d ate 4 30 EFI CIRCUIT MALFUNCTION INDICATOR 4 30 4 4 FUEL INJECTION SPECIAL TOOLS Fuel Pressure Tester PU 43506 inti IMPORTANT The EFI fuel system remains under high Part Numbers Descriptions even when the engine is not running efore attempting to service part of the fuel Table 4 1 system the pressure must be relieved The pressure adapter has an integrated relief valve Connect to the PART 2 TOOL DESCRIPTION test valve and rel
98. ignition coil primary wire leading from coil Crank engine and check output Spark should jump a 1 4 6mm gap Reconnect coil wire Interrup Table 10 1 CONNECT GAP TESTER White Blue spark jumps 1 4 6mm gap CPS Spark Gap Spark plug lead and Output Test ground Crankshaft Position Sensor Gap 0 4 1 2 mm 0 015 047 in Ignition Troubleshooting No Spark Weak or Intermittent Spark e Spark plug gap incorrect Fouled spark plug Faulty ien plug cap or poor connection to high tension lead Related wiring loose disconnected shorted or corroded Engine Stop switch or ignition switch faulty ETC switch misadjusted or faulty Wire harness or connections wet corroded Poor coil ground e g coil mount loose corroded Incorrect wiring inspect color coding in connectors etc Faulty ignition coil winding measure resistance of primary and secondary Sheared flywheel key Flywheel loose or damaged Faulty ECU 10 31 ELECTRICAL CHARGING SYSTEM Current Draw Key Off CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running Damage will occur to electrical components Connect an ammeter in series with the negative battery cable Check for current draw with the key off If the draw is excessive loads should be disconnected from the system one by one until the draw is eliminated Check component wir
99. 10 02 NMOUG 1211465 JONVYO 8 FONVUO E 121145 2 18 38 ovi 02 yov 18 03u 0 121145 3399 J Yvg310NYH HJ 9 1189 02 121145 2 ovi 02 yov 18 038 6c g 1H911Qv3H 3iddf NVOJTQNYH 8 MOT TSA 6 321145 13101 JYYINI 02 131014 2 310008 840151534 3 HOLIMS SNYUL 8 1301 9 121145 13101 4431 INY 1002 02 13101A g FINGOW 80151538 F HOLIMS SNYUL 8 38 ONY HO L 121145 2 18 38 NOIO3 NI 1313 81 32v 18 03U g 1102 gnH 9 43134043365 02 3L IH NMOSG 9 2 121145 p 121145 NMOUG 9 121145 NMOUG I HOLIMS NOILINOI 02 NMOUG s 2 121145 38 2 8255 02 5 51145 T 43134043345 02 FLT HM y 2 8 123 0241 yov 1g 2 HOLIMS SNVUL I 43134043365 02 0138 NMONUH LG 23 0241 JLIHM g 130 2 43134043345 02 FLIHM LAIOIAN 2 24 321145 123 02 39NY3O 62 121145 39NYNO 1 2 4255 8 FONVUO C 405835 dY 3 02 92 g 24 8255 321145 311HM Q3U 9 3L IH Gad 0 2 di 3 02 3359 12 gt 321145 AOI 121145 038 2 60 121145 2 14 IG 02 yov 18 92 2 2 121145 8 43134043365 2 NMOUG 80 21150809716 m 3 0241 N39 v2 121145 MOT13A 43134043365 7 138 NO1134 LO H J1 LSON9YIQ LY 123 0241 MO1134 3 2ILSONOVIQ 043345 9 43134043345 2 3018 90 T 123 02 13101 22 2 21150 9 10 043345 43134043345 2 N33U9 0 ee IS 23 02 NMOUG 121145 2v 18 y 4313
100. 2 Pull the seat back and free of the tabs NOTE When reinstalling seat make sure the slots in the seat engage the tabs in the fuel tank 3 Remove clips A from air box cover and remove cover Inspect the gasket It should adhere tightly to the cover and seal all the way around MAINTENANCE 4 Loosen clamp and remove air filter assembly Carb Boot Cleaning 5 Slip the pre filter element off of main element Clean the pre filter with high flash point solvent followed by hot soapy water 6 Rinseand dry thoroughly 7 Inspect element for tears or damage 8 Apply foam filter oil or clean engine oil and squeeze until excess oil is removed 9 Inspect main filter and replace if necessary If the filter has been soaked with fuel or oil it must be replaced Installation 10 Reinstall pre filter element over main filter Be sure the element covers entire surface of main filter without folds creases or gaps 11 Reinstall filter on main filter mount Place filter clamp over the assembly and tighten NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling Filter Clamp Proper Filter Placement Main Filter Filter Support Air Box NOTE The air filter should rest on the filter support Proper placement of the air filter is important to prevent rattles and air leaks See Illustration above 12 Install air box cover and secure with clips
101. 21 Nm 3 Remove the two bolts that secure the rear master cylinder to brake mount plate Replace parts as needed 2 T 4 install the rear brake master cylinder mount the master cylinder to the mount plate and torque bolts to specification Flare Stye Brake Line Torque 12 15 ft Ibs 16 20 Nm gt T 6 Perform brake bleeding procedures as outlined in this Master Cylinder to Frame Bolt Torque chapter 8 ft lbs 11 Nm A SPORTSMAN A Brake Reservoir B Rear Foot Brake Line C Rear Master Cylinder D Master Cylinder Bolts E Bushing Washer G Cotter Pin H Foot Pedal I Mount Plate Bolts J Mount Plate K Spring 9 28 5 Pedal Removal and Installation TROUBLESHOOTING Brakes Squeal Dirty contaminated friction pads Improper alignment e Worn disc e Worn disc splines Poor Brake Performance Air in system Water in system brake fluid contaminated e Caliper disc misaligned 1 2 the footwell to gain access to rear master Caliper dirty or damaged cylinder 2 Remove the cotter key Brake line damaged or lining ruptured e Worn disc and or friction pads 3 Remove the washers bushings and tension spring P ncorrectly adjusted lever 4 Reverse the steps for installation use a new cotter key during installation Incorrectly adjusted stationary pad Worn or damaged master cylinder or components
102. 4 10 INITIAL PRIMING STARTING 4 11 FUELLINES D nue eui c a ME 4 11 QUICK CONNECT 4 11 ELECTRONIC CONTROL MODULE 4 12 OPERATION OVERVIEW 425 East cctv BRE ERU RERUM EE nee 4 12 ECM REPLACEMENT bb ear ee ode le ilt eae 4 12 22 5 EE oed REA a e od 4 12 FUEL PUMP 5 5 4 13 OPERATION 7 TESTING 1233 ee EXE Ee RR Be LR cR ER usd 4 13 FUEL TPUNP TESTz i EAS Sere Sechs esitare 4 13 FUEL PUMP TANK ASSEMBLY REPLACEMENT 4 14 FUEL PRESSURE 4 15 GENERAL 4 15 FUEL 5 4 16 GENERAL 4 16 FUELINJECTOR sisi dese SUE RASER AEA 4 16 GENERAL 4 16 CRANKSHAFT POSITION SENSOR 8 4 17 GENERAL INFORMATION rns 4 17 MANIFOLD AIR
103. 5 25 REMOVAL INSTALLATION 5 om eoe e Eee ot Ge tee edam 5 26 SEAT ASSEMBLY 3552 xXx ERE RR ets Sd cba d Rud d EERE 5 28 EXPLODED VIEWS RU eee ae tenet 5 28 X2 SEAT OPERATION CONFIGURING CARGO BOX FOR PASSENGER RIDING 5 29 DRIVER SEAT BACKREST REMOVAL INSTALLATION 5 30 PASSENGER SEAT BACKREST REMOVAL 5 30 5 1 BODY STEERING SUSPENSION GENERAL INFORMATION Torque Specifications Table 5 1 BEEF JE Front A Arm Attaching Bolt Front A Arm Ball Joint Stud Nut Handlebar Adjuster Block 11 13 15 18 Master Cylinder Clamp Bolt 45 55 5 2 6 3 Rear Shock Bolt Upper Rear Shock Bolt Lower Rear Wheel Hub Nut 80 108 Upper Stabilizer Support Nuts Upper Control Arm Mounting Bolt Lower Wheel Bearing Carrier Bolt Strut Rod Retaining Nut Top pw NOTE Refer to exploded views throughout this Strut Casting Pinch Bolt Tie Rod End Jam Nut Tie Rod End Castle Nut Tie Rod End Attaching Bolt chapter for identification components 5 2 location of Special Tools Table 5 2 PART NUMBER DESCRIPTION 2870871 Ball Joint Replacement Tool 2870872 Shock Spanner Wrench 2870623 Shock Absorber d Compression 2871572 Strut Rod Wrench 2871573 LH Strut Spring Compressor Fox Shock IFP Depth Tool Decal Replacement 2871351 Flame Treating Decal Area Plastic polyethylene material mus
104. 6 ft Ibs 8 Nm 5 Torque bolts evenly to specification Stator Plate Bolt Torque 5 6 5 ft 105 7 9 Nm 3 Install the spring new sealing washer and tensioner plug Tensioner Plug Torque 17 ft Ibs 23 Nm 6 Seal stator wire grommet with Crankcase Sealant PN 2871557 or equivalent sealer 4 Slowly rotate engine two to three revolutions and re check Flywheel cam timing 1 Install flywheel washer and nut Torque flywheel to specification Stator Flywheel and Starter Drive Installation Flywheel Nut Torque NOTE The stator flywheel starter drive and recoil can 58 72 ft 105 78 98 Nm be assembled with the engine in the frame Stator Starter Drive 1 Apply a light film of grease to the crankshaft seal Apply molybdenum disulfide grease or assembly lubricant to the crankshaft bushing 2 Install a new O Ring in the oil passage recess in the crankcase i 1 Be sure the washer is positioned on the back of the drive 3 49 gear Apply Starter Drive Grease to Bushing 2 Apply starter drive grease to the drive bushing in the crankcase and all moving surfaces of the starter drive mechanism Install the starter drive 3 Install recoil housing gasket and recoil housing Starter Drive Grease PN 2871460 Rocker Shaft Rocker Arm Assembly Installation 1 Assemble rocker arms rocker shaft and shaft supports Install and tighten rocker arm shaft locatin
105. 64 d 1304 cl 2 5 45 7S 12 02 82 421146 49 4 2 541 24 Ld d t 391 145 JLI HM GQd3 0 121145 124 0c 92 x 29 144 52 8 9313 145 9 Nod 0441 vd l 43114 345 10 24 00 9 t 45 9 9y 0c 22 e 5 k dS 50 7 12 V k c y 04 84114 0044145 0 6 003 0c 6 2 84111 0441445 20 8t 003 0c 8 9 8411 3345 5 2 SEES ERI e VE NO 02 d3 10 2 121145 23 02 9 N 2 66 11 1145 34 02 G 3 2 8255 82 3 V 16 2 40123 13 52 124 3 9 6 8414 5 2 2 56 41114 5 c 124 04 76 0 6 6 12 02 60 2 2 321145 123 0d 80 9 GOSS Nod 04 0 3 0 y 6 12 90 68 9 123 G0 q 88 9 g 123 VO 7 18 JA 04 0 7 98 24 9 20 59 24 02 0 3 dd t A f P giie 1 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI INTERNATIONAL WIRE DIAGRAM
106. Allow engine RPM to settle to idle speed shift transmission to lowest available range and test for belt slippage Repeat as needed Operate ATV in lowest available range for a short period of time until PVT system is dry PVT Drain Plug amp O Ring 6 10 PVT Disassembly NOTE Some fasteners and procedures will vary Refer to the appropriate parts manual for proper fasteners and fastener placement 1 Remove seat Remove or loosen cab and footwell fasteners as necessary to gain access to PVT outer cover 3 Remove PVT air outlet duct hose Remove outer PVT cover screws 5 Mark the drive belt direction of rotation and remove drive belt See the DRIVE BELT REMOVAL procedure later in this chapter 6 Remove drive clutch retaining bolt and remove drive clutch using puller Drive Clutch Puller Clutch Holding Wrench PN 2870506 PN 9314177 7 Remove driven clutch retaining bolt and driven clutch Use puller if necessary Driven Clutch Puller PN 2870913 CLUTCH SYSTEM 8 Remove driven clutch offset spacers from the transmission PVT Installation input shaft NOTE Remember to keep spacers in order for proper clutch offset on reassembly 1 Inspect PVT inner cover to engine seal Replace if cracked or damaged Align the alignment mark on the Offset Spacer cover with mark on engine seal Seal This Edge To Place a new seal on transmission input shaft 3 Apply
107. Button To Tower Clearance Inspection 2 Inspect the weight pivot bore and pivot bolts for wear or galling If weights or bolts are worn or broken replace in 1 Inspect for any clearance between spider button to tower sets of three with new bolts If clearance exists replace all buttons and inspect surface of towers See Spider Removal procedure NOTE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly See roller inspection see Roller Pin and Thrust Washer Inspection WARNING The clutch assembly is a precisely balanced unit Never replace parts with used parts from another clutch assembly Al PVT maintenance or repairs should be performed only by a certified Polaris Master Service Dealer MSD technician who has received the proper training and understands the procedures outlined in this manual Because of the critical nature and precision balance incorporated into the PVT system it is absolutely essential that no attempt at disassembly or repair be made without factory authorized special tools and service procedures Button to Tower Clearance 000 001 2 Inspect sheave surfaces Replace the entire clutch as an assembly if worn damaged or cracked Shift Weight Inspection 1 If clutch is not disassembled inspect as shown using a clutch holding tool to compress the moveable sheave The Drive Clutch In spection contact surface of the weight should be smooth and
108. ETC Switch Composite Throttle Housing ETC switch contacts are closed in a fault condition throttle cable slack Switch contacts are open during normal operation UNDER THAT ILE ASSEMBLY COVER sn _ HORMAL 15 CLOSED ADJUSTMENT 15 REQUIRED Cu Te i m IE ll p i Bm ISWITCH TS AWD Ujj T x T ON OF LOCATED ON RIGHT HANDLEBAR 10 27 ELECTRICAL IGNITION SYSTEM Overview The Sportsman has incorporated into it s design a DC CDI ignition system The DC ignition system relies on battery power for ignition EFI Instead of generating DC voltage via flywheel magnetic induction a 12 volt DC current is supplied directly from the battery to At the DC current is supplied to the ignition coil for the initial ignition charge A small A C signal from the CPS helps the ECM pre determine Top Dead Center TDC which in turn signals the ECM to release the electrical charge collapsing the coil field for ignition based on the ECM timing map CDI A 12 volt DC current is supplied directly from the battery to the CDI At the CDI a current is supplied to the coil for the initial ignition charge small A C signal from the stator pulse coil triggers the CDI to fire the coil DC ignition systems have the ability to ignite with as little as 6 volts of power Some of the advantages of DC ign
109. F3 YE BK IS SE Ses ae TE E 195 9 FAN ON TEMP RISING E3 138 vE BK gt gt gt EE E i aem AWD 215 102 HOT LIGHT gt ees ec E Dan Boe r 6 i ON OFF BOTH LAM FAN SHOULD BE ON WITH eo RU d SWITCH A THERMISTOR LEADS UNPLUGGED OR SHORTED TOT on o cy oru REN A d ke s W FACH OTHER tye f i H Y ON OFF RD YE 06 POWER SPLICE SPLICE 2 SPLICE SPLIC 2 LOCATED ON RIGHT HANDLEBAR L POINT i 3 BN B SPLICE 1 SPLICE 4 SPL SPLICE 2 6 SPLICE ri 1 x Wu R NIA IGNITION SWITCH 64 OG WH 2 e START FIO 2 1 lt ACC tl 60 OG WH SSSS oman manan corm a rn rn a E RD WH Cr gt En 32 RDIBKAO LOCATED BELOW TE TON PNM E OMEN V HEAD LAMPS 64 OG WH DEDE TRIES FOG WOW ELA ES LUN ACC 2 i 8 93 06 WH E a dj LOCATED BELOW HANDLEBARS j EFT HAND SWITCH ASS 13 DG 39 BN 43 RD WH C ri Cp 9 S Wick 1 LuLlos yE 01 BK SEE SHEET 2 lt L LOW 84 RD YE lt E are 22 4 24 RD WH cotta OFF Lo 25 25 BNE SPEEDO 23 1 E 2 0 DIAGNOSTIC ie OFF Co T L 32 RD BK 9 Li A OFF al p C zt OFF RU M
110. Idle Air Stepper Motor 1 E idie Air Stepper Motor 2 Air Stepper Motor 4 idie Air Stepper Motor 3 Red Black Splice 1 R High Side Driver EFI CIRCUIT Throttle Position Sensor Violat Splice Sensor Ground Throttle Position Signal Orange Splice 2 5 Volt Reference 4 28 FUEL INJECTION EFI CIRCUIT Manifold Absolute Pressure Sensor Violel Splice Sensor Ground Orange Splice 2 5 Volt Reference Engine Coolant Temp Signal sensor Ground Violet Splice 4 29 FUEL INJECTION EFI CIRCUIT Air Temperature Sensor Sensor Ground Violet Splice EFI CIRCUIT Malfunction Indicator Light Malfunction Indicator Lamp Driver 4 30 CARBURETOR SPORTSMAN 450 CHAPTER 4 CARBURETOR SPORTSMAN 450 GENERAL INFORMATION AND SPECIFICATIONS 4 32 SPECIAL VOGELS 35 E SAE ee CEE 4 32 tae 4 32 MIKUNLJET PART NUMBERS 23222549402 e err d eme e bx qas 4 32 CARBURETOR SPECIFICATIONS bd domui PES es 4 32 CARBUBE MONG s ES ec e Rf S a US dua 4 33 BST 34 CARBURETOR EXPLODED VIEW 1 2 4 33 BST 34 CARBURETOR EXPLODED VIEW 2 2 4 34 CV CARBURETOR SYSTEM 4 35 CARBURETOR
111. Inspect all rollers bushings and roller pins by pulling a flat metal rod across the roller Turn roller with your finger If you notice resistance galling or flat spots replace rollers pins and thrust washers in sets of three Also inspect to see if roller and bushing are separating Bushing must fit tightly in roller Use the Roller Pin Tool PN 2870910 to To maintain proper clutch balance and belt to sheave replace rollers and pins Take care not to damage roller clearance be sure to reinstall original quantity and thickness washers under the spider e installation NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly Be sure to note the number and thickness of these washers X 6 29 CLUTCH SYSTEM 4 Rubber backed buttons and should be used in all Shift Weight Inspection clutches if the hollow roller pin is changed to a solid roller pin NOTE The rubber side of the button is positioned toward the solid roller pin It is recommended to switch all buttons to the rubber version during service if needed Button To Tower Clearance Inspection 1 Inspect for any clearance between spider button to tower If clearance exists replace all buttons and inspect surface of towers See Spider Removal procedure Button to Tower Clearance 000 001 2 Inspect sheave surfaces Replace the entire
112. Inspect roll cage sliding surface 2 This surface must be MT clean and free of nicks burrs or scratches Remove and inspect the H springs 4 Replace any components as required 10 Thoroughly clean all parts 11 Inspect the rollers 1 for nicks scratches and flat spots Inspect the roll cage 2 for damage or cracks The rollers must slide up and down freely within the roller cage surfaces Inspect the ring gear 3 for consistent wear patterns Surfaces should be free of nicks or burrs 13 Inspect the armature plate for a consistent wear pattern Uneven wear of the armature plate indicates a warped plate which may cause intermittent operation NOTE See Front Gearcase Diagnosis page 7 19 7 25 FINAL DRIVE 14 Inspect the magnetic coil 1 in the outer cover plate 16 Inspect the magnetic coil 1 and bushing in the input cover assembly Inspect the backlash pad 2 for excessive wear plate assembly Replace the input cover seal NOTE See FRONT GEARCASE DIAGNOSIS in this chapter NOTE Ring gear backlash 2 is set at the factory No adjustment is required unless the front cover is replaced or the back lash pad screw is removed See the FRONT GEARCASE ASSEMBLY in this chapter for details on backlash setting 4 mnm Toa T Lar duet 5 LES EM 1 17 Remove the splined armature plate 1 15 Remove bolts retaining the input shaft cover and pinio
113. Inverting the clutch while initially tightening the spider will help position the washers Spider Torque 200 ft Ibs 271 Nm Cover Screw Torque 90 in Ibs 10 4 Nm 6 21 CLUTCH SYSTEM EBS DRIVEN CLUTCH SERVICE Driven Clutch Disassembly 1 Remove driven clutch from the transmission input shaft Do not attempt disassembly of the driven clutch from the outside snap ring The driven clutch must be disassembled from the helix side Do not disassemble from this side 2 It1s important to mark the position of the shaft cam cover and sheave before disassembly or use the X s on components for reference This will aid in reassembly and helps to maintain clutch balance after reassembly 3 Remove the four torx screws that secure the cam assembly helix using a T25 torx regem Place clutch into Clutch Compression Tool PN 8700220 Using Compression Extensions PN PS 45909 Press down on top of the spider assembly compressing the spider onto the shaft Remove snap ring A and slowly release the assembly Press down on spider Remove the spider assembly spring B and spacer washer NOTE Spring is compression only and has no torsional wind CLUTCH SYSTEM 6 Remove the inside spider plate D and spider dampener 10 Pull out the clutch roller pins L and rollers M E Inspect the spider dampener E for wear and replaced if needed 7 Remove
114. Rear Drive CV Shafts Right Side View Front Prop Shaft Between Transmission and Front Gearcase Front Drive CV Shafts Auxiliary Brake 2 8 MAINTENANCE Polaris Lubricants Maintenance and Service Table 2 1 Products 5 PART Coolant NUMBER DESCRIPTION Additives Sealants Thread Locking Agents Misc x Eene SURIBORHE 2874275 Loctite Primer Aerosol OW 40 4 cycle 12 count 2871956 Loctite M Thread Sealant 565 2871844 Engine Oil Gallon Premium Synthetic 50 ml 6 count OW 40 4 cycle 4 count 2871950 Loctite M Threadlock 242 Engine Oil 16 Gallon Premium 4 6 ml 12 count 2871567 Synthetic 40 4 cycle Loctite 1M Threadlock 262 EC 2871951 Gearcase Transmission Lubricants 50 ml 10 count 2876251 Demand Drive LT Premium Hub Fluid Loctite Threadlock 271 6 ml 12 count 2871557 3 Bond 1215 Sealant 5 oz 3234438 Polaris ADC Hydraulic Fluid Premium Carbon Clean 12 oz 12 count Premium Synthetic AGL Gearcase Lube 2870652 Fuel Stabilizer 16 oz 12 count 12 oz bottle 12 count Premium Synthetic AGL Gearcase Lube Black Silicone Sealer 3 oz tube 12 count Black RTV Silicone Sealer 2911226 11 oz cartridge 12 count 1 Gal bottle 4 count Premium ATV Angle Drive Fluid 2870990 DOT 3 Brake Fluid 12 count 2871557 Crankcase Sealant 3 Bond 1215 5 oz 2870791 Fogging Oil 12 oz
115. Storage Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components With a few precautions your ATV can be cleaned much like an automobile Washing the ATV The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last tRinse with water frequently and dry with a chamois to prevent water spots NOTE If warning and safety labels are damaged contact your a Polaris dealer for free replacement Polaris does not recommend the use of a high pressure type car wash system for washing the ATV If a high pressure system is used exercise extreme care to avoid water damage to the wheel bearings transmission seals body panels brakes and warning labels NOTE Grease all zerk fittings immediately after washing and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system Waxing the ATV Your ATV can be waxed with any non abrasive automotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish Polaris offers a detailing kit for ATVs CAUTION Certain products including insect repellents and chemicals will damage plastic surfaces Use caution when using these products near plastic surfaces Storage Tips See Page 2 9 for the part numbers of Polaris
116. T 4 121145 311887038 Q 311HM 38 27 321145 NMOS 229 009 1H9110Y3H 9 g 16 1 HOLIMS 9 213 3 8255 8 N338U9 311HM I 121145 NMOUG H1 8 d T 1 8255 E 123 02 131014 07 1211 13 1H9110V3H HU 8 1 1 121145 311HM 3018 2 1255 02 3079 6 24 121145 MOU 1H9110V3H HY 8 d 2 121145 311HM 3018 72 123 02 3119 8 2 121145 NMOUB z 1H9110Y3H H1 8 9 06 1 121145 2011117038 9 2 8255 9 WO179K 7034 1 121146 80089 15 2 02 d 6r 121145 HOWL 2 8255 7 N01134 9 121145 NMOS 1 8255 2 d 97 121145 HOWL d NOLVIS 7 ct 2 121145 MO 0 YJHSY14 QUVIVH 8 d 17 121145 NMOUB 0 501115 7 0 31000N YOLSIS3Y 0 HOLIMS SNVHI 8 3349 97 24 9955 j 401115 N0113A T 121145 13101 Sm 02 13101 24 8255 401115 25 121145 13101 2 NOSN3S dVN 02 131014 vy G 321145 12 9 4 24 8256 2 1102 NOILINO 8 1 32114 2 pv 9 39 40 0 2 121145 038 911800910 02 03 2 321145 4 02 62 I 121145 0 9115009910 02 NMOUG 121145 8 NOXE 82 121145 4ov18 038 6 ov 02 y2v18 039 0r 321145 8 MOUS 12 121145 X2v18 038 2 02 2 18 39 6 121145 H9 8 MOUS 92 121145 131014 JYYINI YIY 02 131014 at 121145 a 10 9 G2 5 121145 1 1 1091009 02 1301 16 121145 3389 189 8 3389 72 121145 Xo
117. VALVE GLEARANCE 2 23 centert iT naa RO ES Doa esed St 2 25 INTAKE VALVE CLEARANCE ADJUSTMENT 2 26 EXHAUST VALVE CLEARANCE ADJUSTMENT 2 26 o 2 26 TIE ROD END STEERING INSPECTION 2 27 CAMBERAND CASTER 39 235 i943 4584s tC Re wat x Edd Ova 2 27 WHEELALIGNMEN etes td dade frere Pace Pc SESE SEDs 2 27 TOE ALIGNMENT 2 28 Sasa oc eot ep neces 2 28 BRAKE SYSTEM INSPECTION hia urbs GR 2 29 BRAKE PAD INSPEGIION SEA SSE HEU ate X Ha 2 30 HOSE FITTING INSPEC HON nte ea ERES ERR DERI ED 2 30 2 1 MAINTENANCE 2 2 AUXILIARY BRAKE TESTIN iux dits dote Xx et Se E Sea todo Ced 2 30 AUXILIARY BRAKE ADJUSTMENT HYDRAULIC 2 30 SUSPENSION SPRING PRELOAD ADJUSTMENT 2 31 FRONT SUSPENSIONS 520954 3 mov dos recte so dois 2 31 GV SHAFT BOOT INSPECTION hurt e ees 2 31 CONT OS eise pascere ud eva ede AG D iD ders 2 31 2 31 WHEEL SPINDLE TORQUE TABLE 2 32 WHEEL RE
118. and install assembly into sheave 6 Install left hand thread nut C onto puller rod and hand tighten against installation tool 7 Turn clutch sheave counterclockwise making sure bushing is drawn straight into bore Continue until bushing is seated 8 Remove nut C from puller rod and set aside Remove installation tool and clutch sheave from puller EBS DRIVEN CLUTCH REASSEMBLY 1 Press a new bearing onto the output shaft using a press 2 Install the shaft bearing into the outer sheave 6 25 CLUTCH SYSTEM 3 Install the small and large retaining rings into the outer 5 Install the roller onto the roller pin B Both Sides sheave above the bearing 6 Install the roller pin into sheave assembly Both sides The flat side of the roller pin faces downward when the shaft side 15 laying flat on the bench 4 Line up the X on the moveable sheave with the X on the stationary sheave or use the marks previously used Put the sheaves together 7 Install the spring pins C to secure the roller pins Install until flush with sheave surface 6 26 CLUTCH SYSTEM 8 Install the spacer washer 12 Install the spider assembly onto the shaft with the retaining j ring on top ofthe spider NOTE Use marks previously made to align the skip tooth spider or use the X on top of the spider and align it with the skip tooth on the shaft EUN TE M
119. body Clean Components 9 14 5 Inspection 1 Inspect caliper body for nicks scratches or wear Measure bore size and compare to specifications Replace if damage is evident or if worn beyond service limit Front Caliper Piston Bore I D Service Limit 1 193 30 30 mm 2 Inspect piston for nicks scratches wear or damage Measure diameter and replace if damaged or worn beyond service limit 3 Inspect the brake disc and pads as outlined for brake pad replacement in this section See BRAKE PAD INSPECTION earlier in this chapter Reassembly 1 Install new caliper seals A in the caliper body B Be sure groove 15 clean and free of residue or brakes may drag upon assembly 2 Coat piston with clean Polaris DOT approved Brake Fluid C Install piston D with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 3 Lubricate the mounting bracket pins with Polaris Premium All Season Grease PN 2871423 and install the rubber dust seal boots 9 15 BRAKES 4 Compress the mounting bracket and make sure the dust 6 Install brake line and torque the banjo bolt to specification seals are fully seated Install the brake pads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease 7 Install the adjuster screw and turn until stationary pad contacts disc then
120. ica TO ER 2 5 2 25 2 00 1 75 1 50 COMPRESSED SPRING LENGTH INCHES 125 1 19 The drive clutch spring has two primary functions 1 Controls clutch engagement RPM The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM 2 Controls the rate at which the drive belt moves upward in the drive clutch sheaves This is referred to as drive clutch upshift The drive clutch spring is one of the most critical components of the PVT system It 1s also one of the easiest to service Due to the severe stress the coil spring is subject to during operation it should always be inspected for tolerance limits during any clutch diagnosis or repair There are other components which control upshift but the spring is one of the primary components in insuring d performance It is very important that the spring is of correct design and is in good condition CAUTION Never shim a drive clutch spring to increase its compression rate This may result in complete stacking of the coils and subsequent clutch component failure 6 8 Measuring Spring Length With the spring resting on a flat surface measure its free length from the outer coil surfaces as shown Refer to the spring specification chart for specific free length measurements and tolerances Also check to see that spring coils are parallel to one another Distortion of the spring indicates stress fatigue requirin
121. interference and or damage Set up the TPS Test Adapter Harness 2201519 Verify that the 9 volt battery is new Figure 2 TPS T PENNE 2201519 dapter ould Read 1 10 1 14 vde i if H y HE Black Proba VIC EEH Red Probe n 1 a n Nm 500 EFI engines Apply RED meter lead to the R port and BLACK meter lead to the port of TPS Tester Harness to obtain correct reading NOTE Applies to 500 EFI ONLY Attach the RED meter lead to the R port and BLACK meter lead to the Y port of the TPS Tester Harness 2201519 verify the voltage output of the TPS reads 1 10 1 14 vdc f it does not read 1 10 1 14 vdc loosen the screws holding the TPS to the throttle body Rotate TPS until voltmeter reads 1 10 1 14 vdc Retighten TPS mounting screws to specification and verify the voltage did not change TPS Retaining Screws 17 7 in 105 2 0 5 Nm 4 21 FUEL INJECTION ENGINE TEMPERATURE SENSOR General Information Mounted on the cylinder the engine temperature sensor measures coolant temperature The engine temperature sensor is a Negative Temperature Coefficient NTC type sensor as the temperature increases the resistance decreases Engine Coolant Temperature Sensor ECT Coolant passes through the cylinder and by the sensor probe varying a resistance reading which is
122. uec i SCB Tene Nm Ta S M z KC Es n J 5 _ N F m w 4 M 4 M 4 4 PAEFEBEIIAG Sep 4 5 2 20 uA c EE ia TA at F Rc NOUO D ETT RD WH RD YE RD RD RD BK BK EN B BN BN de wi m vo mer 33 SPLICE 4 SPLICE SP SPLICE 4 SPLICE 2 SPLICE SPLICE SPLICE 4 SPLICE 2 SPLICE 3 SPLICE 88 YE CAUTION DO NOT POWER WITH 12 VOLT 59 4 FOR MORE THAN SECOND E M LOCATED ON REAR DIFFERENTIAL 132 YE GN RD OG OG OG W DB DB WH DG YE SPLICE SPLICE VT G W 4 SPLIC SPLICE SPLICE 2 SPLICE SPLICE SPLICE SPLICE SPLICE 2 3 SPLICE SPLICE SPLICE EFT HANDLEBAR areal 1 g 1 M 1 1 1 1 SWITCH ASSEMBLY xx JN UR T pM S Lui SE HIGH 6 D 120 06 Coe 25 SSS Co ASA SR gt gt gt SNES 9595 Bas Te Br W a 119 YE eS moon Lomo T 0 a LOW H ATE cor oo aon coco lt t 16 RDIYE v e 21 92 4 OFF F aa 54 BN 131 BK 2 ON 3 e Li 3 90 RD BK RUNI L4 ogl w 0N OFF RUN OFF L 100 BN 000000990 00009 CU SPEEDO a103 61 06 REVERSE 0 E OVERRIDE OVERRIDE Oy J LOCATED IN FRONT L OF FUEL TANK QU Pas 5 1130 06 D 94 R
123. 038 3018 29 19 c amp 121145 NMOWG 2 1H911 ONINNNY 1NOUJ HY 8 MOUS 19 1 0266 121145 311HM 02 121145 311HM 039 1H911 ONINNAY 1NOUJ HY 8 311 HA 038 09 4 31714 41544211 121145 NMOUG 81 NMOUG G9 Y3MOd MS 53190553997 121145 31IHM 39NYHO 9 JLIHM 39NV3SJO 61 HOLIMS 1N3911131NI dI HOLIMS SNYUI y 121145 02 NMOUG T 2 121145 JONVYO 3 4 02 T 1 2 0255 1 121145 39NYUO 02 9 121145 21 9 11083105 0 1116 11 2 YALUVLS GR Cis ton 1 29 121146 ANNOYS 390 02 91 19 gt 321145 3 VNOIS H1 9 118 GL o 2 09 121145 039 18015 NUNL HY 9 rl Sau a 121145 81 02 AY311Y8 1083105 60 UTD 66 121145 10104 NV 9 E1 3018 H9 ee ae 8 121145 2 VIG 9 JONVYO 85 121145 MOT 2 HY Q Zi er 121145 011347033 8 011347038 16 G 121145 2 1H911 ONINNNY INOUJ H1 8 11 AMOWAIN e S41 305 MI SB 121145 3018 11 H3 9 3018 11 9G 7 ds dwnd 1313 Q 01 108180 z 121145 91 02 J 41 6 13 QUVZVH 9 039 1 2 8255 dwnd 1302 8 69 e NO G 301148 NA 1067 g 76 121145 N0113 1H9110V3H Q 89 N QUVZVH HOLIMS QUVZVH Q 039 3018 11 7 121145 NMONO 5 121145 NMOWG 9 NONE 19 fld
124. 12 80V 12 50V 12 50V 12 20V 12 20V 12 0V 75 Charged 50 25 0 Charged less than 12 0V less than 11 9V Measurement at 80 F NOTE Subtract 01 from the specific gravity reading at 402 F 10 62 At least 20 hours Low Maintenance Battery Load Test AX CAUTION To prevent shock or component damage remove spark plug high tension leads and connect securely to engine ground before proceeding NOTE This test can only be performed on machines with electric starters Test cannot be performed with an engine or starting system that is not working properly A battery may indicate a full charge condition in the OCV test and the specific gravity test but still may not have the storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is encountered To perform this test 1 Hooka multitester to the battery in the same manner as was done in the OCV test The reading should be 12 8 volts or greater 2 Engage the starter and observe the battery voltage while cranking the engine Continue the test for 15 seconds 3 During cranking the observed voltage should not drop below 9 5 volts 4 f the beginning voltage is 12 8 volts or higher and the cranking voltage drops below 9 5 volts during the test replace the battery Low Maintenance Battery Charging Procedure 1 Remove the battery from
125. 3211456 39NVUO HY 9 JONVUO 99 dO 39Vd 121145 JY 123 02 n 121145 YOY 3 HOLIMS NOILINSI 02 yov 18 cg AM NER ES 101538802 OL EO123NNOO NONI 19090 40105 101518802 OL 80123NNOO onyo 40105 D Nl uM dM O 2 3igYI NOTLYNINGSL HIM TiBYI NOIIVNIWU3I JUIN CX 53 004 NVANSLEOdS LOOC WD 12 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI X2 QUADRICYCLE WIRE DIAGRAM
126. 4 NO AWD HUB SAFETY LIMIT NOTE IF THE AWD ICON DOES NOT COME ON OR IF 12 VOC IS NOT REGISTERING AND AWD IS ENGAGING ABOVE 3100 RPM IT MAY MECHANICAL PROBLEM START HERE 5 SPEEDO FUNCTIONING x CORRECTLY CHECK SPEEDO ATV IN NEUTRAL TOGGLE TO TACHOMETER SETTING amp REV ENGINE HOLD UNTIL DISPLAY STABILIZES TEST NO 2 DOES IT APPEAR _ ACCURATE RESTART ENGINE IDLING MEASURE AC VOLTAGE BETWEEN PIN 7 AND TURN KEY SWITCH OFF 1 RAISE ATY WHEELS OFF GROUND AND REMOVE 16 PIN SUPPORT IN SAFE MANNER CONNECTOR FROM BACK OF 2 MONITOR VOLTAGE AT HUB COIL INSTRUMENT CONNECTOR BETWEEN BROWN AWHITE CLUSTER AND GROUND Y SPEEDOMETER CHECK CHARGING SYSTEM STATOR REGULATOR AND WIRING 16 Pin Connector TURN AWD OFF START THE ENGINE REV AND HOLD THE N 1 300 OG 450 12Vdc Constant 9 DB NH Engine Overheat Switch RPM S ABOVE 3100 2 RD WH 12Vdc Switched 10 OPEN TURIN AWD ON 3 GOG Mode Override Button 11 Malfunction Indicator DOES FRONT 4 BK ignition Kil 12 VT WH Fuel Gauge 5 DG Factory Use 13 OPEN 6 DB Factory Use 14 WH Gear Signal 7 RPM 15 8 BH Ground 16 BWH AWD Control INSPECT FOR SHORT CIRCUITS TO GROUND DISCONNECT CONNECTOR amp MEASURE BETWEEN HUB COIL BROWNAVHT amp GRO
127. Aerosol 2873602 2873603 2876160 32 oz 12 count Premium ATV Angle Drive Fluid 2 5 Gal 2 count Oil Pump for 1 Gallon Jug 2872216 2870465 Grease Specialized Lubricants Premium Season Grease 2871322 3 oz cartridge 24 count Premium Season Grease 14 oz cartridge 10 count 2871460 Starter Drive Grease 12 count Premium U Joint Lube 3 oz 24 Count Premium U Joint Lube 14 oz 10 count 2871329 Dielectric Grease Nyogel M 2871423 2 9 MAINTENANCE Polaris Lubricant Symbol Identification NOTE The symbols used are for quick reference in identifying which lubricant grease to use on each component Polaris DOT Brake Fluid Gearcase Lube Polaris X Hydraulic Fluid Polaris Synthetic Polaris 60 40 0W 40 Coolant Polaris ATV Angle Drive Fluid cm Polaris U Joint Lube Polaris Demand Drive LT Hub Fluid GREASE Polaris All Season Grease 2 10 Polaris Synthetic AGL Pre ride Daily Inspection Perform the following pre ride inspection daily and when servicing the vehicle at each scheduled maintenance Verify seat lock out operation Verify box lock out operation Tires check condition and pressures Fuel and oil tanks fill both tanks to their proper level Do not overfill oil tank All brakes check operation and adjustment includes auxiliary brake Throttle check for free operation Headl
128. 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 1 Remove drain plug from end of sediment tube 2 Drain tube 3 Reinstall drain plug Sediment Tube Drain Plug NOTE The sediment tube will require more frequent service if the vehicle is operated in wet conditions or at high throttle openings for extended periods 2 21 MAINTENANCE 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 In line breather filters can be installed either direction Typical Breather Filter Location In Line Breather Filter Location A Breather Hose 1 Be sure breather line is routed properly and secured in place CAUTION Make sure lines are not kinked or pinched NOTE In line breather filter service is extended when the foam air box pre filter is in place and maintained properly Never operate the engine without the pre filter 2 22 Recoil Housing Drain the housing periodically to remove moisture 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 bottom of the recoil housing Remove the screw with a 10 mm wrench Reinstall screw once housing has b
129. C O 5 aS 145 TW LY me GND PIN BY E L marta boot SEn Net MET Net 1 1 1 JUUUUUL ee 555 DIFFERENTIAL SOLENOID BSS messe Ses pacc ZS 143 08 NOTE POWERED TO UNLOCK mam 55 STRIS 255058 HERES 35279 FISEER 28s g2 Cui up o e E 7 ES xir X NA MS 4 EN C y WER W Vy bf BHO Mou SM BI OM hg toe ut sto RD WH RD YE R W DB RD RD RD RD BK BN LOCATED ON REAR DIFFERENTIAL SEE PAGE OF 2 FOR SPECIFICATIONS SPLICE SPLICE SPLICE 3 SPLICE SPLICEs1 SPLICE 2 SPLICE SPLICE SPLICE 2 SPLICE 3 SPLICE 4 INDICATOR PANEL _ oi 156 0 0 115 BN NMONS zT h Ls Bp eal lg 2 E64 BN GN RD BU OG DB W YE _ SPLICE V DB BN m LEFT HANDLEBAR HORN SPLICE SPLICE SPLICE 2 SPLICE SPLICE 2 SPLICE SPLICE SPLICE S EVERSE SWITCH ASSEMBLY E ER 15 RD 2 78 E 4 PES LIES gt gt gt SSS Donn Doran c RDINH i n a DE ET Los IM 5i D EAE TU 21 BN 5 HIGH 32 DB RD xS GTO 22 VT Cre y RO NN 23 YE 7
130. E pe r o um wu Lie lt gt CO 3 3 NI t H C z D eo Lu CO k HE HE HE xd Co C2 Q Lil a m 22 2 fia Lad a co pon j Ix i 4 i gt o 9215 n 1 gt C2 T 2 IS lt Es a lt 2 ANS V m ee P Ico gt E 1 iA Liu Lo gt pies Te 51 a gt me c K sm gt p L3 Ll cr o Ie gt S lt gt lt lt lt gt 92 X lt gt e lt TE lt lt e N lt e e e ex Lu Li coc gt Li b Lo a Lit ti 1 D U T 9
131. Electronic Throttle Control ETC Switch Adjustment 1 Slide boot off throttle cable adjuster and jam nut 2 Place shift selector in neutral and set parking brake 3 Loosen lock nut on in line cable adjuster Ill 1 Adjuster Sleeve q ock Nut 4 Turn adjuster until specified freeplay is achieved at thumb lever see illustration After making adjustments quickly actuate the thumb lever several times and reverify freeplay 1 16 1 8 Freeplay Throttle Freeplay 0625 1250 1 58 3 17mm 5 Tighten lock nut securely and slide boot completely in place to ensure a water resistant seal 6 Turnhandlebars 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 2 15 MAINTENANCE Fuel System Fuel Lines EFI Example A WARNING Gasoline is extremely flammable and explosive under certain conditions components are under high pressure Verify system pressure has been relieved before disassembly Never drain the fuel system when the engine is hot Severe burns may result Do not overfill the tank The tank is at full capacity when the fuel reaches the bottom of the filler neck Leave room for expansion of fuel Never start the engine or let it run in an enclosed 1 Check fuel lines for signs of wear deterioration damage area Gasoline power
132. FAN_STAT will go low only when the fan is off For overloads the FAN_STAT will go low after the pre programmed delay time For an open fan condition the micro controller will wait the programmed open fan delay time and then indicate a fan fault The FAN_STAT output is current limited Accessory Power The ACC_PWR switch uses a smart high side power switch It is enabled when the RUN input is activated and disabled when it s removed If the output current exceeds the short circuit limit the output current will be reduced until the ACC_PWR thermally shuts down ACC_PWR will automatically turn back on when it has cooled based on thermal recovery Repeated cycles will cause the short circuit limit to turn off repeatedly until the overload has been removed Ignition Relay Output The IGNITION relay uses a smart high side power switch The IGNITION relay output is enabled when the RUN input is activated and disabled when it s removed If the maximum output current threshold is exceeded the output current will be reduced until the IGNITION circuit thermally shuts down IGNITION will automatically turn back on when it has cooled based on thermal recovery Repeated cycles will cause the short circuit limit to turn off repeatedly until the overload has been removed ECM Relay Output The ECM_RELAY is a smart high side power switch The ECM_RELAY relay output is enabled when the RUN input is activated and KAP EFI input is low Once enabled
133. H Needle Bearing Q Retaining Ring Sprocket R Ball bearing GENERAL INFORMATION 6 Inspect the shift drum for any damage or wear Inspect the NOTE To ease assembly use a plastic tie strap to hold splines of the shift drum Replace O rings onthe end of shift forks D and the shift drum C together during the shift drum and lubricate them before assembly assembly 7 Stretch the silent chain on a flat surface and measure the length of 8 pitches in a minimum of three places on the chain Replace the chain if the measurement is longer than 3 0904 7 8496 cm 9 With the gearcase on it s side hold the gear cluster assembly and output assembly together Carefully install each shaft into their respective recess in the gearcase p d Silent Chain Length 3 0904 7 8496 cm 8 The shift drum C reverse shaft D input shaft E and output gear assembly must be installed at the same time to properly align all components NU 10 With all of the components in the correct positions install the 4 output gear assembly screws Apply LoctiteTM 262 PN 2871952 to the threads of the screws Torque the screws to 8 12 ft lbs 11 17 Nm NOTE If the transmission is in locked in Park place the transmission in Neutral GENERAL INFORMATION 11 Install the oil deflector shield into the gearcase Apply 14 Lift the leg of the spring up and over the rear pin The LoctiteTM 242 to the threads of the
134. Inspection 2 29 Brakes Operation Overview 9 6 Brakes Troubleshooting 9 20 C Cam Chain Removal 3 14 Cam Chain Tensioner Inspection 3 14 Removal essendo tot o a E ELE 3 16 TININ od Ser Am 3 46 Carburetor BST34 Exploded View 4 33 Carburetor Jeune stele puta ae iro ee aane as 4 32 Carburetor Operation osse utr x Ree CC 4 35 Carouretor Velit po SUR AC MGR 4 35 Carburetor Air Fuel Ratio 4 38 Carburetor Assembly 4 41 Carburetor Choke System 4 36 Carburetor Cleaning ieu vsu RN ETT A EE a 4 40 Carburetor Disassembly 4 39 Carburetor Float Adjustment 4 42 Carburetor Float 4 37 Carburetor Idle System es yant Vas SER 4 36 Carburetor Inspection 225524545254 4 41 Carburetor Jet Needless e ES 4 39 Carburetor Main System 4 37 Carburetor Needle Jet aen 4 39 Carburetor V ius eti or d SIRE Rok 4 35 Carburetor PIOCSCI W La doc ee es 4 38 Carburetor Throttle Opening vs Fuel Flow 4 39 Cargo Box Removal and Installation 5 26 Chaine PrOCeQUEIe sse
135. Install rear carriers and hubs Torque lower carrier bolts to 50 ft Ibs 71 Nm Torque all other control arm bolts and remaining carrier bolts to 35 ft Ibs 50 Nm Install the rear hubs rear brake disc and brake caliper Refer to Chapters 5 and 9 for procedures and torque specifications 10 Install PVT system Refer to Chapter 6 PVT section for procedures and torque specifications 8 5 GENERAL INFORMATION 11 Once the PVT system is installed Tighten all remaining transmission mounting bolts to 40 ft Ibs 57Nm See page 8 2 for transmission bolt placement 12 Install transmission vent line Be sure vent line is not kinked or pinched 13 Install seat both side panels both rear cab quarter panels and both footwells See Chapter 5 14 Reconnect the differential speed sensor and gear selection switch connectors to the transmission 15 Reconnect the shift rod Torque to standard specification 16 Install the rear w heel nuts and torque to specification Lum Rear Wheel Nut Torque Refer to Chapter 2 17 With the ATV on level ground add Polaris AGL Gearcase Lubricant to the proper level See Chapter 2 for proper fill procedures and Torque Specifications Polaris AGL Gearcase Lubricant EN 2873602 12 oz PN 2873603 Gallon 8 6 Troubleshooting Checklist Check the following items when shifting difficulty is encountered speed adjustment e Transmission oil type qu
136. LEFT HANDLEBAR i m m i nas 1 Cl al PAL 1 1 3 R REVERSE SWITCH ASSEMBLY A SS VE ZI N an d AN IE To Em e is sae ceee 28 Ei qu ill il aal mw d UM 59 Ba5 E Ss a DAP s OVERRIDE 21 E Sas 5859 Haase Eum Sam oo EDD 5222 TOPAN 1 1 2 pn MES L 44 06 m 5 92 RD WH 26 B A 119 YE 21 DG E LOW k 5 8 DK E OBE 06 0 3 01 JAJKO 31 WH OFF RUN 32 00 RD BK A DG 000000 909 56 BU 3 jos o UI 144 GY RD 103 01 06 0000000000 0000900 LEES EST E 143 RD YE 7N HORN nic 14 G Bd 19 ET BK 1 09 Y 8 B 01 G 06 DB 04 D 03 D 05 D 02 D 01 8 o 2 RD YE 1 Y i ES 2 130 06 NES x i i H aes 2 Iu ii a c0 S e EU did coe x OG y 2 P20 oe ER im a a n Es a me Boe 1 E 1 dii 0 Du SNC du es IDLO H o O O zz Ilo lt x H m gt es fu E a 0 FUSIBLE 8 5 SIARI 00 Anes Em em 2 0 2202114 BLU n H2 SOLENOID d Sea cadi E gt B gt HIE 51 Ges 2 CASE FRAME 0 JE ZY t GROUND GROUND RD 6 GAUGE
137. MAP sensor sends a negative pressure reading indicating that the engine is on the intake stroke Once this has been learned the ECM will then monitor the MAP sensor and cease the initial start up program Map Sensor Test MAP sensors are a non serviceable item If it is faulty it must be replaced This sensor requires a 5 Vdc input to operate therefore the MAP sensor should only be tested usine Polaris Diagnostic Software dealer only Refer to the EFI Diagnostic Software Manual for more information Map Sensor Replacement 1 Disconnect sensor from engine harness Using a suitable tool remove the retaining screw and replace the sensor using a light coating of soapy water on the grommet to aid installation NOTE Replacement MAP sensors may have an o ring installed that must be removed prior to installing the grommet 3 Install the sensor as shown in Figure 1 inserting it with a twisting motion to properly seat the grommet Verify that the connector centerline is aligned with the throttle body centerline 4 Install the retaining bracket NOTE Do not allow the retaining bracket to contact the MAP body Torque retaining screw to specification MAP Retaining Screw 29 in Ibs 3 3 Nm FUEL INJECTION INTAKE AIR TEMPERATURE SENSOR IAT Operation Overview The intake air temperature sensor LAT is used to indicate charge air temperatures to the ECM Mounted on the rear of the air box
138. OW 40 2 qt 1 9 ltr Fuel System Electronic Fuel Injection EFI Fuel Pump in tank assembly 25L per hr at 39 psi Fuel Filter s 10 micron in line 30 micron in tank not replaceable ELT EFI Controller Visteon VP5U1U 12A650 AA Fuel Capacity Requirement 6 gal US 22 7 liters 87 Octane minimum or 89 Oxygenated LET EMI Circuit Breakers Fan 12 amp Switched Power 10 amp Fuel Pump 10 amp ECU 15 amp Ignition Coil 10 amp Accessory Power 10 amp Lights 20 Amp GENERAL INFORMATION Table 1 15 Sportsman X2 500 EFI Transmission Type Transmission Capacity Front Gearcase Capacity CH Front Gearcase Capacity ADC Gear Ratio Low Rev High Front Drive Clutch Type PVT w EBS Belt 3211113 Steering Suspension A arm MacPherson Strut Front Travel 8 2 in 20 8 cm Front Suspension Shock Rear Suspension Shock Progressive Rate Independent Coil over shock Rear Travel 8 75 1n 22 2 cm Ground Clearance 11 in 28 cm Shock Preload Adjustment Front Non Adjustable Front Rear Rear Ratchet Style Std 82 1n 208 cm unlocked Toe Out 0 1 16 in 0 159 mm Wheels Brakes Wheel Size Pattern Front Steel 12x6 4 156 Wheel Size Pattern Rear Steel 12x8 4 156 Recommended Air Pressure Front amp Rear 5 psi Table 1 16 Sportsman X2 500 EFI Turning Radius Altitude Shift Drive Driven Helix Weight Clutch Clutch No Spring Spring Adjustment Meters 0 1800 10 WH Blu G
139. Offset IMPORTANT Inspect clutch alignment and center distance before adjusting offset Offset is correct when rear of tool contacts rear of inner sheave with driven clutch pushed completely inward spacers installed if required on shaft and bolt torqued to specification Spacer Washer PN 7556401 1 Install alignment tool as shown Remember to measure above and below the shaft centerlines 2 Adjust offset by adding or removing spacer washers between back of driven clutch and spacer CLUTCH SYSTEM EBS DRIVE CLUTCH SERVICE 5 Remove and inspect spring See Drive Clutch Spring Specifications for spring inspection Drive Clutch Disassembly 1 Using a permanent marker mark the cover spider and moveable and stationary sheaves for reference as the cast in X s may not have been in alignment before disassembly Spider Removal 1 Remove the limiter nut using the Clutch Spider Nut Socket PN 2870338 Install clutch in holding fixture and loosen the spider counterclockwise using Clutch Spider Install Tool PN 2870341 2 Remove cover bolts evenly in a cross pattern and remove cover plate 3 Inspect cover bushing A The outer cover bushing is manufactured with a Teflon M coating Wear is determined by the amount of Teflon M remaining on the bushing Clutch Holding Fixture PN 2871358 Spider Removal Tool PN 2870341 Cover Bushing Inspection Replace the cover bushing if m
140. PTO End 1 4963 1 4970 38 005 38 025 mm Calculate oil clearance by subtracting journal OD from journal bore ID Compare to specifications Camshaft Oil Clearance Std 0022 0035 055 090 mm Limit 0039 10 mm NOTE Replace camshaft if damaged or if any part is worn past the service limit NOTE Replace cylinder head if camshaft journal bore is damaged or worn excessively Cylinder Head Removal 1 2 Remove the two 6mm flange bolts A from cylinder head See next exploded view on next page Loosen each of the four cylinder head bolts B evenly 1 8 turn each time in a criss cross pattern until loose Remove bolts B and tap cylinder head lightly with a plastic hammer until loose CAUTION Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging the thread Remove cylinder head and head gasket 3 19 Cylinder Head Exploded View EH50PL EHSOPL A 1 n r x Y ie Y k amp x x 4 5 1 te B x B 11 4 ET EL ss E NM Lu oleae j E 3 20 Cylinder Head Inspection 1 Thoroughly clean cylinder head A surface to remove all traces of gasket material and carbon CAUTION Use care not to damage sealing surface Cylinder Head Warp Limit 002 05 mm
141. REMOVAL ASE TA Dac EC Ere dh ere nea 8 3 TRANSMISSION REMOVAL dts sss Ret Devo eie p eo rto 8 3 TRANSMISSION 8 5 TROUBLESHOOTING CHEGHRLIST cede 8 6 TRANSMISSION SERVIO E 6422 70 01 Ba Er OR Bea c oe 8 7 EXPLODED VIEW 8 7 TRANSMISSION DISASSEMBLY 8 9 TRANSMISSION ASSEMBLY nd meses RE REVERSE 8 14 TRANSMISSION FRONT OUTPUT SHAFT BACKLASH PROCEDURE 8 15 8 1 GENERAL INFORMATION TRANSMISSION GENERAL Mounting Exploded View 9 2 Torque Specifications COMPONENT FT LBS IN LBS Transmission Case Bolts 25 30 Bell Crank Nut 12 18 Transmission Fill Drain Plug 20 25 36 43 17 26 29 36 Trans Mounting Bolts 20 30 11 17 2 3 6 11 17 Ha 33 39 11 17 11 17 Gear Sector Cover Oil Deflector Screws Snorkel Torx Screw Bearing Cover Carrier Cover Shift Fort Retainer Screws Park Plate Special Tools TOOL DESCRIPTION 2871695 Part of 2871702 Kit Backlash Setting Tool 2871698 Part of 2871702 Kit 192 Output Seal river 2871699 Part of 2871702 Kit Rear Driveshaft Seal Guide 2871282 Bearing Seal Driver 50 mm Lubrication Refer to Chapter 2 for transmission lubricant
142. Removal and Inspection 3 35 Current Draw Key Off Test 10 32 Boot Inspection wa vt om dro Or bor Rte 2 31 Boot Replacement ed aerei eat vagues 7 4 CV Carburetor System Function 4 35 Cylinder Head Removal 3 19 Cylinder Head Torque Procedure 3 45 Cylinder Honing rescatar E eso ha Probe ees 3 0 Cylinder Installation 3 44 Cylinder REMOVAL 5 05 ba 3 27 D Decal Replacement sats SSS eSATA 3 2 Di snosttC Ode Sus ies loses ASRS 10 17 Diagnostic Mode EFI System 10 17 Differential Solenoid ew doe a 10 36 Drive Belt Installation 6 13 Drive Belt Removal Inspection 6 12 Drive Clutch Sprints 3 22 vu dp Ee 6 8 Drive Clutch Weights ER RE ed 6 9 Drive Clutch Operation ess SARS knees 6 6 Drive Clutch Standard Service 6 28 Drive Shaft Boot Inspection 7 4 Driven Clutch Operation 6 6 Driven Clutch Standard Service 6 34 E EBS Drive Clutch Service ad welah abot 6 15 EBS Driven Clutch Service 6 22 EBS Exploded View aos 449 RE X 6 4 6 5 EBS Driven Clutch Operation 6 7 EFI Operation Overview
143. Removed From Engine 3 Turn the camshaft until the actuator ball is in the lowest position and install the release lever shaft If Camshaft Is Installed In The Engine 4 Use a small magnet to draw the actuator ball outward or rotate the engine until the cam lobes face upward and install release lever shaft Position camshaft as shown at bottom of illustration at right Place arm of spring under stop pin as shown and push release lever inward until fully seated Do not pre wind the spring one full turn or the compression release will not disengage when the engine starts Check operation of mechanism as outlined in Step 1 of Removal above NOTE When shaft is properly installed actuator ball will be held in the out position It is important to note that spring pressure is very light 3 18 Camshaft Inspection l Visually inspect each cam lobe for wear chafing or damage Thoroughly clean the cam shaft making sure the oil feed holes are not obstructed Cam Lobe Height Intake amp Exhaust Std 1 2884 102924 32 726 32 826 mm Limit 1 2766 32 426 mm 3 Measure height of each cam lobe using micrometer Compare to specifications Journal O D Journal Camshaft Journal O D Mag amp PTO End 1 4935 1 4941 37 935 37 950 mm 4 Measure camshaft journal outside diameter O D 5 Measure ID of camshaft journal bore Camshaft Journal I D Mag amp
144. SOR dva end eeu ibat inch a atti e 2 17 COMPRESSION TEST cuneta 2 17 ENGINE MODBNITES 5225525955 oai Nee test tod des 2 17 SPARR PEU aenaran ccc PHP 2 18 ACTIVE DESCENT CONTROL ADC RESERVOIR 2 18 BATTERY MAINTENANCE 2 2 18 LIQUID COOLING SYSTEM OVERVIEW 2 19 COOLANT STRENGTH 22 Se 2 19 COOLING SYSTEN HOSES 5505 ki ode br Ee ete ee Rer 2 19 RADIATOR GRILL SCREEN CEES 2 19 COOLING SYSTEM PRESSURE TEST nii Erie ga abc 2 20 COOLANT LEVELINSPEC TION PP ee EDAD hun 2 20 RADIATOR COOLANT 2 20 AIFCEIETER PHE FIETER SERVICE e seio ius Deo te rode 2 20 AIR BOX SEDIMENT TUBE 22 22 3 gee ee DES EB ee oes 2 21 BREATHER FILTER INSPECTION is co cei cede pate er cde d caw see eed 2 22 BREATHER HOSE ced tod ea o ds dia 2 22 RECOIL THIOUSING2 ao TANI Ima 2 22 ENGINE OIL EEVEL etd bad 2 23 OIL AND FILTER CHANGE ntact ein De pot tee 2 23 OIL POMP PRIMING PROCEDURE temet ct REPRE ERR ER 2 25
145. Subtract the thickness of the existing shim from the result of Step 8 to determine if a different shim is required The result must be within the specified range listed Crankshaft End Play 008 016 02 04 cm Counter Balancer Shaft End Play Adjustment 7 Subtract the thickness of the straightedge from the measurement obtained in Step 4 and record Mag Case Depth 8 Add readings recorded in Step 3 and Step 5 and record below Total Case Width 12 Make sure all bearings are firmly seated in the crankcase 13 Measure the width of the counter balancer shaft at the bearing seats with a dial caliper or micrometer and record reading 9 Measure the width of the crankshaft at the bearing seats with a micrometer or dial caliper and record Crankshaft Width 3 38 14 Measure the distance from crankcase mating surface to the balance shaft bearing using a dial caliper and a straight edge Subtract the thickness of the straightedge and record 15 Measure the distance from the PTO crankcase mating surface to the bearing using the same method outlined in Step 1 2 and 3 16 Add the readings obtained in Step 3 and Step 4 17 Subtract the counter balancer shaft width measured in Step 2 from the figure obtained in Step 5 18 Subtract the thickness of the existing shim from the result of Step 6 to determine if a different shim is needed The result must be within the speci
146. Test 1 Remove the headlight pod cover 4 Install the harness assembly into the headlight assembly 2 Set meter to DC Volts and probe the head lamp plug wires Turn the headlight harness clockwise to secure the head Brown and Yellow at back of connector for 12 Volts lamp into place 3 Turn ignition and headlight on If there is no power continue with checks to the harness Lower Head Lamp Housing Removal if required 5 Remove the screw that secures the lower head lamp Brown Im Upper Headlamp Plug Wires Yellow Lower Headlamp Plug Wires 6 Pull head lamp out of the locking tab 10 39 ELECTRICAL Work Light Switch Brake Light Work Light Replacement Remove the headlight pod cover to locate the switch wires The The brake light A and the work light B are both located in the switch A snaps out by pushing in on the tabs on both sides of rear tail lamp housing the switch 1 X2 Open the tailgate and remove the 2 torx head screws A securing the rear taillights on each side of the cargo box as illustrated below e Check for continuity between the switch contacts _ Place meter leads between two contacts with switch in ON position Probe the worklight plug wires at back of vehicle there should be at least 12V at the plug Check for 12 volt power at the blue wire A CAUTION Use caution when disconnecting the smaller light bulb Follow th
147. an ohmmeter or voltmeter If the ECT circuit is open the engine Hot light and fan will both come on With engine at an ambient temperature of 68 F 209 disconnect lead and measure the resistance of sensor between the two ECT terminals and compare to the specification listed 1 With the engine and temperature sensor at room temperature 68 F 20 C disconnect the harness connector 2 With the meter in the ohms mode place the meter leads onto the sensor contacts 3 Use the Temperature Resistance table to determine if the sensor needs to be replaced Table 10 1 68 F 20 C 37 3k O 5 GEAR POSITION INDICATOR SWITCH Test Diagram NOTE Also see INSTRUMENT CLUSTER TROUBLESHOOTING for gear switch resistance High POW RE Ves Park High Range Low Range Neutral Reverse Park White Blue Blue Red 212 F 100 C 2 1 k O 5 NOTE If the coolant temperature sensor or circuit malfunctions the radiator fan will default to ON NOTE The fan may not function or operation may be delayed if coolant level is low or if air is trapped in the cooling system Be sure cooling system is full and purged of air Refer to Maintenance Chapter 2 for cooling system information 10 26 o PO PARK ELECTRICAL ELECTRONIC THROTTLE CONTROL ETC SWITCH Operation Overview The Electronic Throttle Control ETC system is designed to stop t
148. and oil seal with a light film of grease and install housing aligning marks 4 Install O Ring on other end of field magnet casing Make sure it is in good condition and not twisted on the case 5 Align casing marks and install housing pushing back brushes while installing shaft in bushing 6 Reinstall starter motor housing bolts Make sure O Rings are in good condition and seated in groove Align brush plate and install cover and screws rwr Weight Spring 8 Install the starter onto the engine case Hand tighten the starter bolt Torque bolt to 9 ft Ibs 12 Nm Return Spring Starter Solenoid Bench Test To measure the resistance of the pull in coil connect one meter lead to the solenoid lead wire and the other to ground The resistance should be 3 7 ohms 5 Refer to Electric Starter System Testing in this section to further test the solenoid 10 48 ELECTRICAL STARTER DRIVE Pinion Gear Anti Kick Out Shoe Garter Spring Replacement If the garter spring is damaged the overrun clutch may fail to return properly Use either of the following methods to remove and install a new garter spring Gear Assembly Thrust Washer Bushing Retaining Ring Thrust Washer Stopper Cover Spring A B C D 1 Screw overrun clutch to engaged position on pinion shaft assembly Use small piece of wire with end bent in a hook and pick the old spring out
149. and reduce heat dissipation resulting in possible engine damage Polaris Premium 60 40 Antifreeze Coolant is recommended for use in all cooling systems and comes pre mixed ready to use Accessible Components The following components can be serviced or removed with the engine installed in the frame Flywheel e Alternator Stator e Starter Motor Starter Drive Cylinder Head e Cylinder e Piston RIngs Camshaft e Rocker Arms e Cam Chain and Sprockets e Water Pump Water Pump Mechanical Seal The following components require engine removal for service Oil pump Pump Drive Gear Counterbalance Shaft or Bearing s Connecting Rod e Crankshaft e Crankshaft Main Bearings Crankcase may be necessary to loosen engine mounts and move engine slightly to access water pump Use the Water Pump Mechanical Seal Puller IE 28 2105 to replace mechanical seal with engine in frame 3 8 Engine Removal TYPICAL Clean work area Thoroughly clean the ATV engine and chassis Disconnect battery negative cable pe Remove the following parts as required e and Right Side Covers Refer to Chapter 5 Fuel Tank Cover Front Cab Refer to Chapter 5 Fuel Tank Refer to Chapter 4 5 Disconnect spark plug high tension lead 6 Remove springs from exhaust pipe and remove pipe 7 Drain coolant and engine oil 8 Remove air pre cleaner and duct 9 Remove airbox
150. approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible NOTE It is important that the height of both marks be equally positioned in order to get an accurate measurement 4 Measure the distance between the marks and record measurement Call this measurement 5 Rotate the tires 180 by moving vehicle forward or backward Position chalk marks facing rearward even with the hub axle centerline 6 Again measure the distance between the marks and record Replace any worn steering components Steering should Call this measurement Subtract measurement move freely through entire range of travel without from measurement A difference between binding PES measurements and is vehicle toe alignment Elevate front end of machine so front wheels are off the The recommended vehicle toe tolerance is 1 8 to 1 4 3 ground Check for any looseness in front hub wheel to 6 cm toe out This means the measurement at the front assembly by grasping the tire firmly at top and bottom first id hen at font and rear Try to wheel of the tire A is 1 8 to 1 4 3 to 6 cm wider than and hub by pushing inward and pulling outward measurement at the rear B If abnormal movement is detected inspect the hub and wheel assembly to determine the cause possible loose wheel nuts or loose front hub components
151. be routed only to the vehicle key run switch for proper power up sequence BAT PROT is enabled when the key run switch connects the BAT PROT output to loads must include RUN input This causes the micro controller to power up and energize BAT_PROT When RUN input goes high the micro controller will remain until RUN input goes low by disconnection of the BAT_PROT via the key switch or on off switch The BAT_PROT output is protected from overloads and short circuits If this occurs the output turns off Once tripped the SSCBs can be reset by removing the overload or cycling the key run switches The SSCBs will trip again if the issue causing the overload is not removed Fan Relay Controller The FAN relay is a smart high side power switch The FAN controller requires the RUN input to be active and then is enabled by the FAN_ON signal The FAN output current is monitored by the micro controller If the over current limit is exceeded for the amount of delay time programmed the output will shut off If the maximum current limit is exceeded the current will shut off immediately The micro controller disables the FAN output for a pre programmed amount of time then resets the FAN relay This will continue until the issue causing the fault has been removed When the FAN relay is off the micro controller also monitors the output to see if the fan has been disconnected Fan Status The FAN_STAT output is control by the micro controller
152. be worn or damaged 6 Remove ratchet pawl with spring and inspect Replace spring or ratchet pawl if worn broken or damaged NOTE Long arm of spring engages reel Short end against pawl 7 Hold reel firmly in housing Pull rope handle until 12 18 30 46cm of rope is exposed and hold reel in place 8 Place rope in notch on outer edge of reel Release tension 1 Remove bolts and recoil from the engine on hub and allow reel to unwind approximately 6 7 turns Pull recoil rope if applicable so it is extended until spring tension is released approximately 12 18 30 46cm Check handle c ring for proper tension and the handle for cracks or damage which may allow water or dirt to enter the recoil housing through the rope 3 Remove handle from the rope and allow spring tension on recoil to relax NOTE The handle must seal tightly on the recoil housing to prevent water from entering 4 Remove center bolt from recoil friction plate A 9 Slowly and carefully remove reel from recoil housing making sure the spring remains in the housing Inspect the reel hub and bushing A for wear 10 Unwind rope and inspect for cuts or abrasions 11 Inspect drive tab on hub return spring for damage To remove hub return spring hold outer coils in place with one hand and slowly remove spring one coil at a time from the inside out 12 Pull knot out of recoil reel Untie knot Remove rope from reel 3 51
153. cap Inner splash cap vent hole must be clear and open 2 Hill 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 and inspect for signs of trapped air in system Radiator Coolant Level Inspection NOTE This procedure is only required if the cooling system has been drained for maintenance and or repair However if the recovery bottle has run dry or if overheating 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 severe burns The engine must be cool before removing the pressure cap 2 20 NOTE Use of a non standard pressure cap will not allow the recovery system to function properly Remove Radiator Cap To access the radiator pressure cap 1 Open the front cargo storage 2 Remove the inside cover over the radiator cap Air Filter Pre Filter Service It is recommended that the air filter and pre filter be replaced annually When riding in extremely dusty conditions replacement is required more often The pre filter should be cleaned before each ride using the following procedure 1 Lift up on the rear of the seat
154. cause loss of consciousness and death in a short time Never drain the float bowl when the engine is hot Severe burns may result Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored If you get gasoline in your eyes or if you should swallow gasoline seek medical attention immediately If you spill gasoline on your skin or clothing immediately wash with soap and water and change clothing NOTE It is strongly recommended that Polaris Carbon Clean be added regularly as directed to the fuel systems of all Polaris ATVs Carbon Clean stabilizes the fuel preventing clogging of the small passages and orifices common to ATV carburetors and ensures constant performance reliability and easier starting 4 32 Carburetor Jetting IMPORTANT The following guidelines must be followed when establishing a main jet setting 1 Select the lowest anticipated temperature and altitude at which the machine will be operated 2 Select the correct main jet according to the engines fuel performance requirements A main jet that is too small will cause a lean operating condition resulting in serious engine damage Select the correct main jet carefully for elevation and temperature according to the charts in the Specifications section or in the Owner s Safety and Maintenance Manual for each particular model Mikuni Jet Part Numbers Main Jets Jet Number Part Num
155. clean any residue 2 14 VEHICLE INSPECTION Shift Link Rod Inspection NOTE Shift rod is preset at time of manufacturer 1 Inspect shift link tie rod ends and replace if worn or damaged Lubricate pivot points with a light aerosol lubricant or grease if desired 2006 Polaris Sales Inc Shifter i5 amp S IMS Aus s NNUS Shift Link Rod MAINTENANCE Throttle Inspection Check for smooth throttle opening and closing in all handlebar positions Throttle lever operation should be smooth and lever must return freely without binding Place the gear selector in Park 2 Set parking brake 3 Start the engine and let it idle 4 Turn handlebars from full right to full left If idle speed increases at any point in the turning range inspect throttle cable routing and condition Adjust cable tension as needed until lock to lock turning can be accomplished with no rise in engine rpm 5 Replace the throttle cable if worn kinked or damaged 9 8 2 5 Sequence 1 Usea medium flat blade screwdriver and insert blade into the pocket of the cover starting on the 1 position 2 Twist screwdriver slightly while lifting on the cover to release snap 3 Repeat procedure at the other five locations as shown NOTE Do not attempt to remove cover until all latch points are released Throttle Cable
156. clutch as an assembly if worn damaged or cracked 6 30 1 2 If clutch is not disassembled inspect as shown using clutch holding tool to compress the moveable sheave The contact surface of the weight should be smooth and free of dents or gall marks Remove shift weight bolts and weights Inspect the weight pivot bore and pivot bolts for wear or galling If weights or bolts are worn or broken replace in sets of three with new bolts NOTE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly See roller inspection see Roller Pin and Thrust Washer Inspection A WARNING The clutch assembly is a precisely balanced unit Never replace parts with used parts from another clutch assembly Al PVT maintenance or repairs should be performed only by a certified Polaris Master Service Dealer MSD technician who has received the proper training and understands the procedures outlined in this manual Because of the critical nature and precision balance incorporated into the PVT system it is absolutely essential that no attempt at disassembly or repair be made without factory authorized special tools and service procedures CLUTCH SYSTEM Sheave Bushing Inspection Inspect the Teflon coating on the sheave bushings and cover bushing Inspect BOTH sheaves for signs of wear grooving or cracking Clean sheave surfaces with a 3M pad if needed Cover Shea
157. ee FE COLOR LEGEN 07 SPORTSMAN 500 EFI ADC BG BEIGE TAN B BLAC WIRE TERMINATION TABLE ou m B LIGHT BLUE CCT COLOR GAUGE FROM CONNECTOR CAVITY CONNECTOR CAVITY 5 DB DARK BLUE 2 33 BROW 18 TRANS SWITCH C BROWN SPLICE ABE ABE BROW 59 GRAY 2 EIC amp AWD SWITCH GRAY SPLICE 1 GY GRAY 62 WHITE 2 SSCB 1 WHITE SPLICE i PrepegA G LIGHT GREEN 63 WHITE 2 RESISTOR MODULE WHITE SPLICE DG DARK GREEN 82 GREEN RED 2 SPEED 1 LT GREEN RED SPLICE sel OG ORANGE 98 RED WHITE 2 ETC amp AWD SWITCH RED WHITE SPLICE 1 5 PINK 14 WHITE 2 SPEEDOMETER 14 HITE SPLICE E m TTE RD RED l6 BROWN WHITE 2 SPEEDOMETER l6 HUB COIL VI VIOLET PURPLE GRAY 2 SSCB GRAY SPLICE WHITE 4 VIOLET 2 ECU 2 SSCB 1 D 00 o YELLOW BLACK RED 18 SSCB HUB COIL A 20 O4 TWO WIRE COLORS ARE SHOWN 45 GREEN RED 2 SPEED 2 LT GREEN RED SPLICE La WITH MAIN TRACE COLORS 46 LT GREEN RED 2 SSCB 2 LT GREEN RED SPLICE 07 EXAMPLE RD YE RED WITH 48 BROWN 18 UB COIL D BROWN SPLICE 4 YELLOW TRACE 50 GRAY 2 UB COII GRAY SPLICE P NORMAL OPERATION IS OPEN UNDER THROTTLE CIRCUIT IF CLOSED ASSEMBLY COVER ADJUSTMENT 15 REQUIRED EE ETE P SWITCH OMNE 59 GY E 98 RD WH j AWD ON OFF l O W ON OFF D 62 WH u 22 L
158. flat washer large phenolic washer two small phenolic washers and O Ring from brush terminal Inspect the O Ring and replace if damaged 3 Remove brush plate and brushes Measure length of brushes and replace if worn past the service limit Replace springs if they are discolored or have inadequate tension NOTE The electrical input post must stay with the field coil housing ELECTRICAL 4 Inspect surface of commutator for wear or discoloration See Steps 3 6 of Armature Testing Brush Inspection l Measure length of each carbon brush Replace brush assembly when worn to 5 16 8 mm orless The brushes must slide freely in their holders Brush Length Limit 5 16 8 mm Brush Replacement l Install a new carbon brush assembly in the brush housing NOTE Be sure that the terminal bolt insulating washer is properly seated in the housing and the tab on the brush plate engages the notch in the brush plate housing Place a wrap of electrical tape on the threads of the terminal bolt to prevent O Ring damage during reinstallation Install the O Ring over the bolt Make sure the O ring is fully seated Remove the electrical tape and reinstall the two small phenolic washers the large phenolic washer flat washer and nut Armature Testing 1 Remove armature from starter casing NOTE Note order of shims on drive end for reassembly 2 4 Inspect surface of commutator
159. fluid A NOTE To speed up the brake bleeding procedure the master cylinder can be purged of air before brake line is attached Fill with DOT approved brake fluid and pump lever slowly two to three times with finger over the outlet end to purge master cylinder of air 4 Follow proper bleeding procedures Check all connections for leaks and repair if necessary 9 10 FRONT BRAKES Pad Removal 1 Elevate and support the of the ATV Ak CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur 2 Remove the wheel 3 Loosen pad adjuster screw 2 3 turns 5 5 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Front Brake Pad Thickness Service Limit Remove excess fluid from reservoir as required 180 4 6 mm 6 Pushmounting bracket inward and slip outer brake pad past Assembly edge Remove inner pad y 3 MES 1 Lubricate mounting bracket pins with a light film of Polaris Premium Season Grease PN 2871423 install rubber dust boots 5 gt NA Ten Exo EC 7 Measure the thickness of the pad material Replace pads if worn beyond the service limit P 9 11 BRAKES 2 Co
160. gas tank vent lines use tape to secure the vent line in place See Pic 1 5 Reconnect the negative battery cable Test the sender for proper operation FUEL PRESSURE REGULATOR General Information The fuel pressure regulator maintains the required operating system pressure of 39 psi 3psi A rubber fiber diaphragm divides the regulator into two separate sections the fuel chamber and the pressure regulating chamber The pressure regulating spring presses against the valve holder part of the diaphragm pressing the valve against the valve seat The combination of atmospheric pressure and regulating spring tension equals the desired operating pressure Any time the fuel pressure against the bottom of the diaphragm exceeds the desired top pressure the valve opens relieving the excess pressure returning the excess fuel back to the tank Fuel Pressure Regulator Test Refer to the FUEL PUMP TEST procedure Fuel Pressure Regulator Replacement The regulator is a sealed non serviceable assembly If it is faulty the pump assembly must be replaced Refer to the Fuel Pump Tank Assembly Replacement procedure 4 15 FUEL INJECTION FUEL FILTERS General Information NOTE All EFI units utilize quick connect fuel lines EFI Engines use a non serviceable high volume high pressure 30 micron internal fuel pump filter and a replaceable 10 micron in line fuel filter Only the 10 micron filter is replaceable L3 X
161. guide can also be driven in to the proper depth Inspect the guide closely for cracks or damage if a driver is used e Guide u Allow cylinder head to cool to room temperature Apply cutting oil to the reamer Guides should be reamed from the valve spring side of the cylinder head Ream each guide to size by turning the reamer clockwise continually Continue to rotate reamer clockwise during removal of the tool Clean guides thoroughly with hot soapy water and a nylon brush Rinse and dry with compressed air Apply clean engine oil to guides Install pilot into valve guide 8 9 10 12 Apply cutting oil to valve seat and cutter Place 46 cutter on the pilot and make a light cut Inspect the cut area of the seat e f the contact area is less than 75 of the circumference of the seat rotate the pilot 180 and make another light cut e If the cutter now contacts the uncut portion of the seat check the pilot Look for burrs nicks or runout If the pilot is bent it must be replaced If the contact area of the cutter is in the same place the valve guide is distorted from improper installation and must be replaced Be sure the cylinder head is at the proper temperature and replace the guide If the contact area of the initial cut is greater than 75 continue to cut the seat until all pits are removed and a new seat surface is evident NOTE Remove only the amount of material necessary
162. hub coil The instrument cluster senses grounding at pin 16 AWD icon should turn on at the instrument cluster e System must be grounded to operate Diagnosing System Failures Verify the AWD switch is functional Verify the AWD hub coil is functional Test the AWD hub coil using an ohm meter AWD Hub Coil Resistance 24 x 596 Verify the wiring harness wiring connectors connector pins and grounds are undamaged clean and connect properly Verify continuity of wire connections with a known good volt ohm meter IMPORTANT Verify all wires and wiring connections have been tested properly with a known good volt ohm meter before suspecting a component failure 80 of all electrical issues are caused by bad failed connections and grounds ELECTRICAL COOLING SYSTEM COMPONENTS Fan Control Circuit Operation Power is supplied to the fan via the Orange Black wire when the relay is ON The ground path for the fan motor is through the Brown harness wire Refer to RELAYS later in this chapter for more information on fan functions AX CAUTION Keep hands away from fan blades during operation Serious personal injury could result NOTE The fan may not function or operation may be delayed if coolant level is low or if air is trapped in the cooling system Be sure cooling system is full and purged of air Refer to Maintenance Chapter 2 for cooling system information Fan Control Bypass
163. if fluid looks dark or contaminated Drain the Recoil Housing Remove the recoil housing drain plug and drain any moisture Storage Kits Polaris offers storage kits for ATVs See a Polaris dealer or visit www purepolaris com ie the Engine 2 operly store engine use Polaris Fogging Oil according to the directions ou choose not to use Polaris Fogging Oil perform the follo owing procedure Support the front end of the machine so the engine is level or tilted slightly rearward 2 Treat the fuel system with Polaris Carbon Clean according to the directions 3 Remove the spark plug and add 2 3 tablespoons of Premium 4 Synthetic OW 40 engine oil To access the plug hole use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Note Do this carefully If you miss the plug hole oil will drain from the spark plug cavity into the hole at the front of the cylinder head and appear to be an oil leak Install the spark plug and pull the engine over slowly with the recoil starter Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 4 Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug MAINTENANCE 5 Turn the engine over several times with the recoil only to ensure coverage of piston rings cylinder walls and crankshaft bearings 6 IfPolaris fuel syste
164. in R ED _ NO DE CTTT VIOLET PURPLE SWITCH NORMALLY OPEN le ee HE a HARNESS 2410613 07 EET EM qe A aes NORMAL OPERATION IS OPE UNDER THROTTLE S Y Y ZI gt CIRC TWO WIRE COLORS ARE SHOWN cO EG CIRCUIT IF CLOSED ASSEMBLY COVER WITH MAIN TRACE COLORS EO MARNE ADJUSTMENT 15 REQUIRED lt EXAMPLE RD YE RED WITH m eT YELLOW TRACE ape e ETC 5 BK gt 5 D 58 BH 142 RD WH O sis 141 WH DG4 9 dp p p 71 99 GY g 98 RD WH 7 i L Wb AND ON TURF EE 8 J F 81 _06 WH f 62 WH i LOCATED ON RIGHT HANDLEBAR 09 YE BK 1 GY BK 122 WIRD ET WITCH Te an Er 93 RD WHNG p GNI 10 SWITCH eu 90 RD BK O Fd SSCB E E DE G at 88 YE j qn 0 si e OF E 115 BN F LOCATED BELOW HANDLEBARS 64 RD BK 129 6 T 48 BN 41 BK RD im SPEED 43 DB 80 RD WH 2e 5 5 60 06 BK Ee 81 BN 2 06 WH E 145 GN RDO PJ m bo HHH 0 1 Tu EES 3 RD 225555 225225 Lal a 39 DB WH GE cg eae IRE amann cocamaaaooaaga cadaamaaacogata MUR bo es eS 2 2 Z ae s
165. it is lightly seated then turn the screw out 1 4 turn 4 Setthe gearcase upright Rotate the input shaft at least 4 times rotation This ensures the ring gear completes one full 5 If a tight spot is felt during rotation loosen backlash screw another 1 8 turn Perform the step 16 again Repeat this procedure until the pinion shaft rotates smoothly 4 times 1 revolution of ring gear Front Gearcase Diagnosis e Symptom AWD Will Not Engage 1 Check the gearcase coil resistance To test the gearcase coil resistance use the coil harness Grey amp Brown White NOTE To test the gearcase coil resistance use the coil harness The gearcase coil should measure between 22 8 ohms and 25 2 ohms Front Gearcase Coil Resistance 24 10 2 Check the minimum battery voltage at Grey amp Brown White wires that feed the hub coil wires There should be a minimum of 11 80 12 0 Volts present for proper operation AWD Coil Applied Battery Voltage 11 80 12 0 Vdc 3 Inspect the armature plate for a consistent wear pattern There should be two distinct wear bands one band inside the other If only one band of wear is present or if there is wear between the two bands inspect the coil area as indicated in Step 4 A band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation Armature Plate Check for Wear Bands 7 19 FINAL DRIVE 4 Che
166. level surface with the headlight approximately 25 7 6 m from a wall 84 25 7 6 m Lamp Center Height ae fo 2 5 1 cm 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall in Step 2 NOTE Rider weight must be included on the seat On machines with separate low beam lights the drop should be 8 20 3 25 from the center of the low beam lamp 5 Adjust beam to desired position Lower Headlamp Removal Installation 1 Turn the back of the head lamp harness in counter clockwise direction to loosen ELECTRICAL 2 Pullthe harness assembly out from the headlight assembly Low Beam Headlight Adjustment 1 The low beam can be adjusted slightly upward or downward ET an zu o T 3 Remove the lamp and replace with a new head lamp NOTE Do not touch the new lamp with bare fingers Hold the plastic part 1 of the lamp Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp ETT 2 Loosen the phillips screw located at rear of head lamp 3 Tilt the head lamp upward or downward 4 Tighten the screw Headlamp Switch
167. may dislodge and leak d iei ic e d um Cylinder Compression 1 Locate filter at the front of the NOTE Remove tandard 60 90 PSI access panels if necessary Remove fuel lines from filter 3 Install new filter onto fuel lines with arrow pointed in Service Limit 10 direction of fuel flow Inspect for cause if leakage exceeds 10 Cylinder Leakage Install clamps on fuel line if required 5 Turn ignition to Engine Mounts 6 Start engine and inspect for leaks Inspect rubber engine mounts A for cracks or damage Check engine fasteners and ensure they are tight f aX 4 on M vs 7 Me 2 17 MAINTENANCE 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 Spark Plug Gap jm 036 0 9 mm 6 7 8 2 18 If necessary replace spark plug with proper type CAUTION Severe e
168. of its channel Slide it off the end of the shaft Slide the new spring over the overrun clutch and into the spring groove Make sure that the spring 15 positioned between the shoe alignment pins and the back flange of the anti kick out shoes 2 Remove the retaining ring thrust washer spring retainers and clutch return spring Screw the overrun clutch off the end of the pinion shaft Remove the old spring and install a new one Lightly grease the pinion shaft and reinstall the clutch spring retainers end washer and lock ring in the reverse order Make sure the end washer is positioned properly so that it will hold the lock ring in its groove 10 49 ELECTRICAL STARTER SYSTEM TESTING FLOW CHART Condition Starter fails to turn motor NOTE Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system A digital multitester must be used for this test This flow chart assumes that the starter lockout system is functional With the tester on the VDC position place the tester s black lead on the battery negative and the red lead on the battery positive Reading should be 12 4 V D C or greater Remove battery and properly service Install fully charged shop battery to continue test Check voltage on both sides of circuit Disconnect coil engagement wire from the starter Oitag breaker ignition switch engine stop switch solenoid Connect tester black wire to battery ground Con
169. pump shaft for wear 3 34 Oil Pump Assembly 1 Clean and dry all parts thoroughly Apply clean engine oil to all parts Do not use gasket sealer on the pump body mating surfaces or oil passages will become plugged Install pump shaft and scavenge rotor drive pin 27543 Install outer scavenge rotor inner scavenge rotor and scavenge casing Install outer feed rotor and inner feed rotor drive pin Install inner feed rotor and feed chamber cover with screw Tighten screw securely Install screen on pump body Install oil pump on crankcase and torque bolts to 6 ft Ibs 8 Nm Cil eat ibs Nm Torque Counter Balancer Shaft Removal Inspection 1 Remove the shim washer A from the counter balancer shaft 2 Note the alignment dots on the balancer and crankshaft marks must aligned during reassembly 3 Turn shaft until balancer counter weights clear crankshaft and remove the balancer shaft from the crankcase dis Inspect the balancer drive gear and pump shaft drive gear 5 Replace the shaft if gear teeth are abnormally worn or damaged 6 Inspect the balancer shaft bearings NOTE Due to extremely close tolerances and minimal wear the balancer shaft ball bearings must be inspected visually and by feel Look for signs of discoloration scoring or galling Turn the inner race of each bearing The bearings should turn sm
170. rubber seal and allow contaminants to enter the connector Never attempt to service any fuel system component while engine 15 running or ignition switch 15 turned to on USE CARE when removing or installing the ECM connector as well as all other harness connections on the ATV Dirt even in small quantities can cause significant problems Clean connectors thoroughly before opening to prevent dirt from entering Properly connect and disconnect the ECM harness to minimize damage to the connector pins and locking mechanism Do not use compressed air if the EFI system is open Cover any parts removed and wrap any open Joints with plastic if they will remain open for any length of time New parts should be removed from their protective packaging just prior to installation Although every precaution has been taken to prevent water intrusion failure avoid direct water or spray contact with system components Do not disconnect or reconnect the wiring harness connector to the control unit or any individual components with the ignition on This can send a damaging voltage spike through the ECM Do not allow the battery cables to touch opposing terminals When connecting battery cables attach the positive cable to positive battery terminal first followed by negative cable to negative battery terminal Never start the engine when the cables are loose or poorly connected to the battery terminals Never disconn
171. tampering replace throttle body Failed Sensor or disconnected wiring Symptom Erratic Idle Throttle cable incorrectly adjusted Air Leaks dirty injector TPS damaged or adjusted Tight valves Belt dragging Dirty air cleaner Engine worn Spark Plug fouled Throttle stop screw tampering replace throttle body Failed Sensor or disconnected wiring 4 23 FUEL INJECTION EFI DIAGNOSTICS USING BLINK NOTE To clear codes manually disconnect the CODES A Am positive battery lead for 20 seconds Blink Codes Operation 7 To enable blink codes turn ignition from OFF to 3 times leaving it 3rd time within 5 seconds Any blink codes that are stored in the ECM will display one at a time in numerical order The word WAIT will appear on the LCD display and the Malfunction Indicator Light MIL or Check Engine light will begin to flash Read and record the number of flashes of the MIL light code 12 indicates the beginning of the diagnostic sequence A code 61 will flash after all codes have been transmitted Malfunction Indicator Light MIL Diagnostic Example BC 12 Sequence Begin BC 42 Trouble Code 45 Trouble Code EC 51 Trouble Code BC Sequence 4 24 FUEL INJECTION Table 4 1 DIAGNOSTIC BLINK CODES CHART CODE ON ggg 7 TPS Circuit Sensor High
172. the to prevent damage from leaking or spilled acid during charging 2 Charge the battery with a variable rate charging output Charge as needed to raise the specific gravity to 1 270 or greater 3 Install battery in vehicle with positive terminal toward front Coat threads of battery bolt with a corrosion resistant Nyogel Grease PN 2871329 4 Route cables so they are tucked away in front and behind battery 5 Connect battery cables A WARNING To avoid the possibility of sparks and explosion connect positive red cable first and negative black cable last 6 Install cover on the battery and attach hold down strap 500 EFI INTERNATIONAL QUADRICYCLE 500 EFI INTERNATIONAL QUADRICYCLE BRAKE 11 2 OVERVIEW rage doe S EA Es 11 2 EXPLODED VIEW ETE Pa C E 11 3 500 EFI INTERNATIONAL QUADRICYCLE STEERING POST AND LOCK 11 4 STEERING ASSEMBLY EXPLODED 11 4 500 EFI QUADRICYCLE EMISSIONS 5 19 MAE be 11 5 S00 QUADRHICYODLE ELEGTRIGAL ens 11 6 TURN HAZARD SIGNAL 11 6 NOTE This chapter illustrates components that are unique to the Sportsman 500 EFI International and Quadricycle models Except where noted any se
173. the E clip F washer G and the clutch rollers H Inspect the rollers for wear replace if worn 11 Press the shaft and bearing out of the outer sheave using a press 8 Remove the clutch assembly from the holding tool Remove the large outer retaining ring I and the inner retaining ring J 9v c um dior 9 Press out the spring pins in the inner sheave 6 23 CLUTCH SYSTEM 12 Inspect the bearing for wear Spin the bearing if the Table 6 1 bearing does not spin smoothly replace as needed To remove the bearing simply press the bearing from the shaft ITEM 13 Inspect the bearing for wear Spin the bearing if the bearing does not spin smoothly replace as needed B 1 Bushing ee ae remove the bearing simply press the bearing from shaft NENNEN Piston Pin Puller 2870386 NOTE Bushings are installed at the factory using 609 In order to remove bushings it will be necessary to apply heat evenly to the area around each bushing Clean all residual Loctite from bushing bore prior to installing new bushing Driven Clutch Bushing Removal Install main puller adapter Item 8 onto puller Install adapter reducer Item 9 Inspect Sheave Surface 3 Using ahand held propane torch apply heat around outside of bushing until tiny smoke tailings appear 14 Inspect the cam assembly helix bushing for wear If the 4 Flip sheave over so
174. the tread depth measures 1 8 3 cm or less Inspect all wheels for runout or damage Check wheel nuts and ensure they are tight Do not over tighten the wheel nuts 2 31 MAINTENANCE Wheel Hub And Spindle Wheel Installation Torque Table 1 With the transmission in Park and the parking brake Specificati locked place the wheel in the correct position on the wheel poetae hub Be sure the valve stem is toward the outside and oteel Front Wheel Nuts 27 Ft Lbs 37 Nm rotation arrows on the tire point toward forward rotation 2 Attach the wheel nuts and fi tighten them Steel Rear Wheel Nuts 27 Ft Lbs 37Nm M E MR NN 3 Lower the vehicle to the ground Aluminum 90 Ft Lbs 122 Nm 4 Securely tighten the wheel nuts to the proper torque listed Front Wheel Nuts in the table Aluminum Rear Wheel Nuts 90 Ft Lbs 122 Nm Front Hub Retaining Nut 70 ft Ibs 90 Nm Rear Hub Retaining Nut 80 Ft Lbs 108 Nm Wheel Removal Front or Rear Front amp Rear Wheels Front amp Rear Wheel Nuts 4 See table Below Front Hub Nut 70 ft 105 95 Nm 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 80 ft Ibs 108 Nm 1 Stop the engine place the transmission in Park and lock Tire Pressure the parking brake 2 Loosen the wheel nuts slightly Elevate side of
175. the vehicle by placing a suitable A CAUTION stand under the footrest frame Maintain proper tire pressure Refer to the warning tire pressure decal applied to the vehicle Tire Pressure Inspection PSI Cold 3 Remove the wheel nuts and remove the wheel 2 32 MAINTENANCE Tire Inspection e Improper inflation affect maneuverability When replacing a tire always use original equipment size and type The use of non standard size or type tires may affect ATV handling Tire Tread Depth Always replace tires when tread depth is worn to 1 8 or less 3 mm Tread Depth 1 8 3 mm 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 torque of all fasteners in accordance with the maintenance schedule Check that all cotter pins are in place Refer to specific fastener torques listed in each chapter Storage Compartments The storage compartments are easily accessible To open the front compartment turn the latch handle to the horizontal position on both sides To close the storage compartment turn the latch handles just past the vertical position Use the arrow located on top of the latch as a reference 2 33 MAIN
176. tutae dct pes be ent rs 3 11 PUMP PRIMING PROCEDURE vertiba niti Vere be beers xs 3 11 OSES CAESARS SANS quta SS ER EE HE ee 3 11 EHSOPL OIEFEOWDIAGRAM 33 3 2 eS S eek ESI 3 12 EH50PL ENGINE EXPLODED 5 3 13 ENGINE DISASSEMBLY 31s beatin wi sis deae cs ER e arque wa dete ane 3 14 CAM CHAIN TENSIONER ROCKER ARM CAMSHAFT REMOVAL 3 14 CAM CHAIN TENSIONER 3 14 ROCKER ARM SHAFT 3 15 CAMSHAFT REMOVA 3 b LAE he ete See ee mene 3 3 16 AUTOMATIC COMPRESSION RELEASE REMOVAL INSPECTION 3 17 AUTOMATIC COMPRESSION RELEASE 3 18 CAMSHAFT INSPECTION utto eeu ibd Gate el oe P Hr Dna io 3 18 CYLINDER HEAD REMOVAL od Ree eee E 3 19 CYLINDER HEAD EXPLODED VIEW 3 20 CYLINDER HEAD INSPEGTION editae dites EE terea tac a es 3 21 CYLINDER HEAD WARP EC PE scs 3 21 CYLINDER HEAD DISASSEMBLY sss 3 21 VALVE INSPECTION are SSR A 3 22 COMBUSTION 4 3 23
177. ty es M eet Oe ey eB 7 22 ADG COIL TES GING dct d arce ee de de ok Dee a 7 23 ADC DIFFERENTIAL HYDRAULIC CIRCUIT 7 23 DISASSEMBLY INSBEEGTIOGON 2233 NO Et ce RUE ed 7 24 ADC GEARCASE PISTON REPLACEMENT PROCEDURE 7 28 POSSE NIB Ye eo sein P as dais 7 30 REAR HUB MAMMA 7 33 REMOVALS EET 7 33 DISASSEMBLY eh E Ee A rat EASES SAS De 7 34 iere zzi RT TET ETT eats St ne Oe ts et i Mae eae 7 35 INSTALLATION a ahi ie hee ld ep Be 1 35 REAR DRIVE CV 5 7 36 REMOVE Tn DPI Pm 7 36 SERVICE tk Sa om SS 7 37 CV BOOT REPLACEMENT px Eum oe Sate e oar 7 38 INSTALLATION seo a irri testi ite fus e 7 39 DRIVE SHAFT AND CV JOINT 5 7 40 7 1 FINAL DRIVE SPECIFICATIONS Gearcase Fluid Capacity ome un FR Aluminum Wheel Nu 3E _ 9 39 Demand Drive LT Premium Hub Fluid 8 97 oz 265 ml Centralized Hilliard Demand Drive LT w ADC Premium Hub Fluid Deluxe Models 9 3 oz 275 ml ADC Gearcase Polaris ADC or AW ISO 10 Pump Rese
178. type and capacity Gear Selector Removal l Disconnect linkage rod from gear selector handle Remove two bolts attaching gear selector mount to machine frame Lift gear selector out of mounting bracket and away from frame GENERAL INFORMATION Transmission Removal 1 Place vehicle in Raise securely support rear of at the frame Remove both rear wheels Drain transmission lubricant if required Remove seat both side panels both rear cab quarter panels and both footwells See Chapter 5 Disconnect the differential speed sensor and gear selection switch connectors from the transmission Disconnect transmission vent line C Remove PVT outer cover drive and driven clutches and the inner PVT cover refer to Clutch Removal in Chapter 6 Remove both rear drive shafts Brake caliper removal is required Do not let calipers hang by the brake line See Chapters 7 and 9 Remove both upper shock absorber mounting bolts and swing shocks away from the transmission 10 Remove the torsion bar mountings from the control arms 8 3 GENERAL INFORMATION 14 Remove the middle transmission support bracket K 11 Remove all fasteners X attaching the torsion mount and completely from the completely remove the mount Z from the ATV 12 Remove both upper control arms I Refer to Chapter 7 for more details 15 Remove the rear transmi
179. use both top and lapping tool or a section of fuel line connected to the valve bottom cutters to narrow the seat stem the seat is too narrow widen using the 45 cutter 17 Rotate the valve rapidly back and forth until the cut sounds and re check contact point on the valve face and smooth Lift the valve slightly off of the seat rotate 1 4 turn seat width after each cut and repeat the lapping process Do this four to five times until the valve is fully seated and repeat process for the Valve Seat Width PIDE Intake Std 028 7 mm Limit Exhaust Std 1 0 mm Limit 071 1 8 mm 18 Clean cylinder head valves and camshaft oil supply passage A thoroughly 19 If oil passage blind plug was removed apply Crankcase Sealant PN 2871557 or equivalent sealer to the threads Bottom 60 or 759 Seat 45 or 460 and install torquing to 8 ft Ibs 11 Nm CAUTION Do not allow sealant to enter oil passage 20 Spray electrical contact cleaner into oil passage and dry using compressed air 3 25 Cylinder Head Assembly CAUTION Wear eye protection during assembly NOTE Assemble the valves one at a time to maintain proper order Install new valve seals on valve guides Apply engine oil to valve guides and seats Coat valve stem with molybdenum disulfide grease pe Dg Install valve carefully with a rotating motion to avoid damaging valve seal 5 D
180. valves Intake Valve Clearance Adjustment 1 Inserta 006 15mm feeler gauge between end of intake valve stem and clearance adjuster screw 2 Usinga l0 mm wrench and a screwdriver loosen adjuster lock nut and turn adjusting screw until there is a slight drag on the feeler gauge 3 Hold adjuster screw and tighten adjuster lock nut securely Re check the valve clearance 5 Repeat adjustment procedure if necessary until clearance is correct with locknut secured 6 Repeat this step for the other intake valve INTAKE VALVE CLEARANCE 006 15 mm Exhaust Valve Clearance zia NOTE The exhaust valves share a common rocker arm and must be adjusted using two feeler gauges 2 26 1 Insert a 006 15mm feeler gauge between end of exhaust valve stem and adjuster screw s 2 Loosen locknut s and turn adjuster screw s until there is a slight drag feeler gauge s The Valve Clutch Adjuster Tool PA 44689 can be used to adjust the engines valves NOTE Both feeler gauges should remain inserted during adjustment of each valve EXHAUST VALVE CLEARANCE 006 15 3 When clearance is correct hold adjuster screw and tighten locknut securely 4 Re check the valve clearance 5 Repeat adjustment procedure if necessary until clearance is correct with locknut secured Steering The steering components should be checked periodically for loose fasteners worn tie rod ends and damage Als
181. winter months electrolyte will freeze at higher temperatures as the battery discharges chart below indicates freezing points by specific gravity Battery Testing Whenever a service complaint is related to either the starting or charging systems the battery should be checked first Following are three tests which can easily be made on a battery to determine its condition OCV Test Specific Gravity Test and Load Test Conventional Battery OCV Open Circuit Voltage Test Battery voltage should be checked with a digital multitester Readings of 12 6 volts or less require further battery testing and charging See charts and Load Test below NOTE Lead acid batteries should be kept at or near a full charge as possible Electrolyte level should be kept between the low and full marks If the battery is stored or used in a partially charged condition or with low electrolyte levels hard crystal sulfation will form on the plates reducing the efficiency and service life of the battery Conventional Battery Specific Gravity Test A tool such as a Battery Hydrometer PN 2870836 can be used to measure electrolyte strength or specific gravity As the battery goes through the charge discharge cycle the electrolyte goes from a heavy more acidic state at full charge to a light more water state when discharged hydrometer can measure state of charge and differences between cells in a multi 10 59 ELECTRICAL cell b
182. 0 14 Instrument Cluster Diagnostic Mode NOTE This gauge features auto shut off protection if the voltage on the DC bus is excessive This is usually the result of an open battery condition and the gauge is designed to survive such an event NOTE If the gauge will not indicate what gear it is in and will not allow AWD operation AWD can still be enabled by holding in the mode override button NOTE As long as you are in the diagnostic mode the wrench icon will remain lit NOTE Any movement of the tires will trigger the speedometer out of the diagnostic mode and into standard display mode NOTE To leave the diagnostic mode turn the key switch off and on 1 Turn key switch off and wait 10 seconds Set the park brake and shift the transmission to neutral 3 Hold the mode reverse override button as you turn the key switch on 4 Release the switch as soon as the display is activated Use the mode reverse override button to toggle through the diagnostic screens NOTE The initial screen display refers to the software version installed on your ATV This information is only displayed briefly Screen 1 The first screen indicates battery voltage Refer to S 70 Tach Trip AA ELECTRICAL Screen 2 Tachometer Ill 3 indicates engine rpm NOTE 10 20 Variance from these reading is within normal parameters 74 POLARIS Tach Trip Odo 23 Ohms in Park Z
183. 003345 8 69 121145 M 18H9130V3H H1 8 I SLANI 2 5 121145 NMOUG 2 TWNOIS NUML INOUI HU 8 NOXE 85 2 121145 NMOXG 2 did 130 8 01 121145 038 3018 13NVd YOLYDIGNI 8 34 3018 16 7 24 825 dWnd 130 8 69 121145 3018 13874 NOIV2IQNI 9 1018 9G J HOLIMS NOILINOI y YYg310NYH H1 9 99 121145 3018 11 VGITONVH H1 8 3119 11 56 ve 121145 NMOUG 121145 NMOUG 9 19 1062 YOH H1 9 38 AVU9 T I 121145 NMOS JILSONDVIG 003345 02 99 2 121145 01134 013 9 VGVIONVH H 8 N03134 03U 2 121145 0 NOSN3S dVN 02 39Nv90 69 121145 038 3018 q uV8310NVH H1 8 34 3018 26 121145 X2v18 5 8255 9 79 21145 3018 YVGIIONVH H1 8 3119 321145 118 310008 80151538 02 9 121145 2 1102 02 19 06 121145 2 8255 02 29 8255 1083105 1j 8 6r 121145 311847038 121145 JLIHM Q3Y 9 1033 19 c amp 121145 NMOUG 1 1102 ANH 8 NOXE 87 8255 g YOLOW NY 9 y2Y18 39NY 30 09 121145 M3 d 1H9110V3H 83440 8 Ly 3 HOLIMS 9 213 121145 789 02 9 6 121145 033 N3389 17 2 8255 02 Q35 N33899 11 9r 121145 NMOUE g HOLIMS 9 213 02 d 85 gt 121145 033 N3389 11 2 2 13345 02 Q3 N3389 11 i 121145 JOYE Y HOLIMS 9 213 02 d 16 7 1 8255 1102 9 038 32v18 7 31000N 40151538 y HOLIMS SNYYL Q 18 96 1 8255 d 1083105 4319 8 1018 3 80151538 g HOLIMS 8
184. 02 62 g Z 4311 041345 2 2 YOSNIS 123 02 92 4 2 42 2 41 G 23 02 LZ g E C 3921145 3 434 0 19 5 5 ND 02 94 02 60 9 41 145 02 90 5 123 yz L 44 145 2 10 H LY 123 0241 9 145 02 9 A 9 123 02 22 2 G 41 145 2 GO y 23 02 2 02 70 9 02 6 23 02 6 02 20 8 23 02 8 2 02 0 ve 123 02 02 00 E 23 02 9 66 23 02 2 52 1 02 y 9 2 123 8 8 96 6 321145 4 02 2 9 t 123 9 0 9 6 1 82 123 02 60 6 32 12 02 90 16 9 8256 123 02 10 j 9 y 123 02 90 9 69 123 02 SO 9 9 123 02 yo 2 402 9 19 23 02 0 55 99 LINO 123 8 20 59 S 03 2 10 A ddd JCE 5 dd WIRE DIAGRAM 2007 SPORTSMAN 500 EFI DELUXE WIRE DIAGRAM
185. 1 13 CONVERSION TABLE aaa rn 1 14 GLOSSAR VOR TERMS SL Reese ieee 1 15 GENERAL INFORMATION MODEL NUMBER INFORMATION Model Number The machine model number must be used with any correspondence regarding warranty or service Machine Model Number ldentiticaton Pa Eu 50 AU Emissions amp Year Desig Basic Model Option Designation Engine Designation Engine Designation Numbers EHS0PLE Single Cylinder Liquid Cooled 4 Stroke Electric Start Vehicle Identification Number VIN World ui Vehicle Descriptor Vehicle Identifier 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4XA IMN 50A 7 P 0 0 0 0 0 0 Model Engine Vear Individual Serial Number Body Style Emissions ant No l Powertrain i This could be either Check Digit a number or a letter Transmission l d Location The transmission I D number is located on top of the transmission snorkel right side of machine Engine And Machine Serial Numbers The machine model number and serial number are important for vehicle identification Be sure to refer to the engine model number and serial number whenever 2 about an engine This information be found on sticker applied to top side of the crankcase A An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow The machine serial number is stamped on the lower left side of the frame tube B 1 2
186. 14 Only replace PVT outer cover rubber gasket if it is damaged Place the gasket with the narrow side out C Towards Outside Cover PVT Cover Gasket 15 Reinstall PVT outer cover and secure with screws Torque to specification 16 Reinstall cab footwell assembly panel and seat 6 12 Drive Belt Removal Inspection Remove outer PVT cover as described in PVT Disassembly 2 Mark drive belt direction of rotation so that it can be installed in the same direction The belt is normally positioned so part numbers are easily read 3 To remove drive belt apply brake pull upward and rearward on belt while turning the back moveable driven sheave clockwise to open driven clutch sheaves Pull out and down on belt to slip over the driven clutch outer sheave 4 Measure belt width and replace if worn Generally belts should be replaced if clutches can no longer be adjusted to provide proper belt deflection NOTE If the top edges are trimmed on some drive belts it will be necessary to project the side profiles in order to measure from corner to corner 5 Place a straight edge on each side of the drive belt Place another straight edge on top of belt CLUTCH SYSTEM 6 Measure the distance where the side straight edges intersect the top as shown in the illustration Projected Belt Width 10 Belt Width Wear Limit 1 125 2 86 cm Inspect belt for loose cords missing cogs cr
187. 145 NMOUG V UOLON NY 9 MOYE 1 LIB va 110 121145 MOT134 038 2 HY 8 01134 038 21 121145 3016 HOLIMS LHOI1 8 ing n 2 121145 NMOUG 2 1303 8 MOUS 01 HSAT4 SE Wage 0241 HS 20 1HS 1 2 8255 Y 1313 8 3389 038 69 121145 9 1102 BMH 02 0 121145 1134 38 HOLIMS 0 WHOM 8 01134 38 99 0266 y QION310S 4314 91 FLTHM 39NYUO 6r 121145 NMOUG 121145 9 MOUS 19 3291148 NMOUG 0 1102 91 NMOUG 9 5 121145 2ILSONOVIQ 043345 02 MOUS 99 321145 418 33849 11 2 8255 02 038 N3349 11 9r 2 121145 NOSN3S dYN 02 JONYYO 9 121145 11 3 2 13145 02 0138 N33849 11 121145 1 38 1 Goss 9 yov 18 038 79 T 1 8255 v 1102 81 038 J2V18 T 121145 3LIHM Y FINGOW 501515384 02 9 1 8255 g QION310S 4 14 81 3118 121145 3LIHM 5 amp Goss 02 JLIHM 29 121145 3LIHM IIY 5 HOLIMS 213 81 31 HM Q38 ev 121145 E 121145 311HM Q3U 9 3L IHN Q38 9 0 HOLIMS 213 J OSs T N3389 3L1HM Goss g YOLOW NY 4 9 NOV 18 39NY3O 09 0 14 8255 E 123 2 13101A 0 J HOLIMS OMY 213 121145 02 hvu 6G 121145 3IIHM 3018 0 2 4255 2 311 4 3018 6c 121145 NMOUG g HOLIMS OMY 213 02 MOYE 85 121145 3L1IHM 3n18 E 123 2 311 4 30118 8 2 121145 X
188. 15 18 Nm 5 Install the rear bolts and tighten evenly Evenly torque the 2 rear bolts to specification NOTE There will be a slight gap on the backside of the blocks after the procedure is performed 5 16 BODY STEERING SUSPENSION Steering A arm Exploded View 30 ft Ibs 41 Nm Steering Post a Wa 25 30ft Ibs ze 4 35 41 d e 1130 8 1 41 Nm MI NN T Steering Post Arm 4 2 M il EF E as b ES Ew Y Es Na P m eS QA te m 25 ft lbs 35 A 40 45 ft lbs 54 61 Nm e E AC 12 14 165 17 19 Nm amp Always use new cotter pins upon XsslvLEoctiteX949 o boltibreads 2 reassembly Install with open end FEM 1 Always use new bolts toward rear of machine upon reassembly NOTE To avoid damage to tie rods and other steering components be sure to install tie rod end bolts in the proper direction The steering post arm bolt B points up the rod end bolts A point down Verify inner rod ends are placed between the steering post arms 9 17 BODY STEERING SUSPENSION A Arm Replacement Apply Loctite 242 to the bolt threads me MIN ML LL Bolt 30 ft Ibs 41 Nm e i ek b M CoA ushing Ball Joint Stud ES j i A A Arm Tube e 8 ft lbs 11 Nm io A arm Shaft N EC et J 8 3 8 TM 25 ft lbs 35 Nm C
189. 16 PIN DOWEL 3 16 X 1 0 PLUG FLANGE 3 4 10 TORQUE 20 29 5 COMPRESSION SPRING RETAINING RING WASHER CUP RINGS RETAIN Wo SHIM 2 049 1 53 DOG ENGAGEMENT TORSION SPA ING FORK SHIFT SIDE GEAR 367 SUBASSEMBLT SPRUCHET CARRIER 39T SIDE GEAR 467 DISCONNECT SUBASSEMBLT SHAFT PLANET PIN DOWEL Id X 45 COVER CARRIER SCREW CAP HH 5 18 24 x 1 50 TORQUE 23 31 FT LBS SOLENOID TORQUE 23 27 5 WASHER FENDER 296 amp 1 00 BEARING PLAIN PLAIN HEARING 40 x 44 5 BEARING PLAIN 4d X 44 3 15 BEARING NEEDLE 25 X 29 X 19 LOCKOUT RING 4041 Transmission Disassembly 15 2 ES Place transmission in the Neutral gear before disassembly Drain and properly dispose of transmission oil See Chapter 2 Remove bellcrank nut 1 and remove bellcrank 2 Remove the c clip 3 that holds the gear selector switch 4 onto the shaft and remove the selector switch Remove the sector cover bolts 5 and remove the sector cover 6 Removal can be aided by using your thumbs to press down on the shafts and pulling up the cover with your fingers GENERAL INFORMATION 6 Remove the compression spring 7 7 Remove the detent star 8 Note how the detent star fits onto the splined shaft and the raised edge facing outward for reassembly 8 Remove the lockout disc 9 Note the raised edge facing outwar
190. 2 Elevate and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure 3 Remove wheel nuts and wheels Remove cotter pin A from ball joint castle nut B 5 Remove castle nut B and separate A arm C from ball joint stud 6 Remove screws D and ball joint retaining plate E 7 Use the Ball Joint Replacement Tool PN 2870871 remove ball joint F from strut housing Refer to photos 8 Install puller guide G with extension cap H 9 Apply grease to extension cap and threads of puller bolt to ease removal 10 Thread bolt J with nut I onto ball joint stud as shown 11 Apply heat to ease removal 12 Hold bolt J and turn nut I clockwise until ball joint is removed from strut housing 13 To install new ball joint Remove extension cap and attach puller guide using short bolts provided in the kit 14 Remove extension cap and attach puller guide using short bolts provided in the kit 15 Insert new ball joint K into driver 16 Slide ball joint driver assembly into guide 17 Apply heat to ease installation 18 Drive new joint into strut housing until fully seated 19 Apply Loctite 242 PN 2871949 to threads of retaining plate screws or install new screws with pre applied locking agent Torque screws to specification Retaining Screw T
191. 2608 remove roll pin from prop shaft at rear of housing front only or A CAUTION transmission output shaft rear only Slide prop shaft back and away from housing then pull sharply forward to remove from transmission shaft Always wear eye protection when working with spring tensioned components 2 For installation reverse the removal procedure a 1 Remove internal or external snap ring from all bearing caps NOTE If removing rear propshaft loosening and or removal of rear gearcase mounting bolts may be required to gain necessary clearance for propshaft removal NOTE If yoke or bearing is removed cross bearing must be replaced Note orientation of grease fitting if equipped and mark inner and outer yoke for correct re positioning during installation 2 Support inner yoke as shown and drive outer yoke down bearing cap out with a soft face hammer UI ID DANN DEG c OO REDECHECIMEESEENUSEI X a7 Ped IS 7 7 7 FINAL DRIVE 3 Support U joint in vise as shown drive inner yoke down Assembly to remove remaining bearing ca 1 Install new bearing caps in yoke by hand Carefully install U joint cross with grease fitting properly positioned inward toward center of shaft Take care not to dislodge needle bearings upon installation of cross joint Tighten vise to force bearing caps in 2 Using a suitable ar
192. 2v18 v HOLIMS ONY 213 02 NOVI 121145 M01134 03U 5 2 8255 9 01134 0138 1 FINGOW 80151538 HOLIMS 8 0138 3018 9G 121145 MO113A y 2 8255 9 3 FINGOW 80151538 g HOLIMS SNVUL 8 3018 3L1HM 5 121145 MOT1134 g HOIVIS MOTTA Ge 121145 g JVg3TQNYH H1 02 76 121145 NMOYE 0 YOLYLS y s 121145 NMOUG HT 8 MOYE pu f 2 8255 3 HOLVIS 1 MOTTA 121145 NMOUG y 1H9110YJH 51440 8 MOYE 2 H 2 8255 y YOLYLS y MOT13A dE 2 121145 NMOUG Y IHO11QV3H 8 MOYE 121145 2 14 Y JV8B310NYH H7 2 42714 2 121145 NMOUG Y H9 1 10V 3H H1 8 MOYE 0G 121145 HOSN3S I1HO11 9 JONVUO 0 lt 121145 ANNOYS 35 2 02 MOUS 6r 121145 1 8255 7 62 3 vt 321145 NMOUG N 8255 2 MOUS gy 121145 NMOUG 1H91 DINOM H7 8 92 121145 NMOUG 92 004 LHS QV3H 9 321145 NMOUG LHOT IYUOM HY 8 MOUS 12 0 31000N 80151538 0 HOLIMS SNYUL 8 11 3389 T 121145 NMOUG HY 8 MOUS 92 321145 13101 41 02 13101A 121145 NMOUG 121145 9 MOUS p 121145 137014 2 405 25 dV 02 13101 121145 3399 g IH911QV3H HY 8 1189 2 0985 2 1102 NOTLINS 8 yov 19 01 121145 2399 g 1H9110Y3H H7 9 3399 2 121145 38 v 2I LSONDV IC 02 2 1ON310S 29715 Y HOLIMS NOILINSI g Q38 311HM 22 121145 NMOUG 0 21150 9
193. 3 21 Specification Cylinder Taper 3 20 Specification Cylinder Warp 3 28 Specification Differential Solenoid Resistance 10 36 10 42 Specification Differential Solenoid Torque 10 36 10 42 Specification Drill and Sizes 1 13 Specification Flywheel Nut Torque 3 40 Specification Fuel Pump Pressure 4 13 Specification Oil and Filter 2 23 Specification Oil Pip Bolt Torque 3 50 Specification Oil Pump Bolt Torque 3 34 Specification Oil Pump Shaft Endplay 3 30 Specification One Way Valve Spring Length 3 32 Specification Piston to Cylinder Clearance 3 20 Specification PVT Center to Center Distance 6 13 Specification PVT Component Torque Table 6 2 Specification PVT Drive Belt Width 6 13 Specification Rocker Arm and Shaft 3 15 Specification Rocker Shaft Bolt Torque 3 50 Specification Spark Plug Gap 2 18 Specification Speed Sensor Bolt Torque 10 42 Specification Tensioner Blade Bolt Torque 3 43 Specification Transmission Silent Chain Length 8 17 Specification Valve Clearance 2 26 3 26 Specification Valve Guide Height 3 23 Specification Valve Stem and Guide 2222 Specifications Bod
194. 3 Brake Fluid ene on As required change fluid every 2 years to indicated level re Polaris All Season Grease Locate fitting and grease Semi annually Rear A Arm Polaris Season Grease Locate fitting and grease Semi annually 0 Front Propshaft Polaris U Joint Grease Locate fitting and grease Semi annually More often under severe use such as operated in water under severe loads Semi annually or 50 hours of operation refer to Maintenance Schedule for additional information More often under severe conditions operating in water or hauling heavy loads 2 Annually or 100 hours of operation refer to Maintenance Schedule for additional information More often under severe conditions operating in water or hauling heavy loads 3 Grease conforming to NLGI No 2 such as Polaris Premium Season Grease Superlube M or Mobilegrease Special 2 11 MAINTENANCE Front Gearcase Lubrication The front gearcase lubricant level should be checked and changed in accordance with the maintenance schedule Be sure vehicle is level before proceeding and in PARK Check vent hose to be sure it is routed properly and unobstructed The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid FRONT GEARCASE Nx Fill Plug 41 8 10 ft Ibs e 2 L 11 14 Nm 40 Drain Plug Ha 11 165 15 Nm Specified Lubricant Demand Drive LT P
195. 3H H1 9 J349 2 121145 111014 4431 1 1002 02 13101 19 1083105 1915 NOILINO 9 038 31 1HM 22 121145 40123781 1304 9 5 1 121145 39NY30 HI 9 JONVYO 2 19114 y 121145 NMOWG 9 121145 1 uvg310NYH 9 3349 02 1 121145 MOTIJA 1 H1 9 201134 6 8 2 3101008 80151534 3 HOLIMS SNY3I g 13101 g 2 NYYD 85 23 0241 2 lt d 31000N 840151538 1 HOLIMS SNYUI 8 039 7 39 1 YNYYO LG 23 0241 d 1102 8H 9 93138003348 02 31IHM NMOUG 9 0 321145 NMOWG 2 4 YOLYOIONI 02 2 121145 59 02 JONVYO 62 f 321145 T 1313003145 02 JLIHM NOSN3S dV 75 23 02 92 121145 NMOWG 1067 JIV Ml 9 2 Sdl 9 23 02 N3349 12 d 1304 2 13130003345 02 311HM L3101A 2 121145 JY8 23 02 42 18 92 21145 N01134 039 31914 3583211 91 01134 413 G2 d 2 255 4 121145 311HN 38 9 39 0 9 1 LSONDV IC 97 23 0241 N33J9 2 121145 2v18 03u 1 121145 039 02 ay 60 ILSONDVIQ Ly 21 0241 401134 24 321145 8 43134003345 02 80 121145 131014 T 23 02 31017 22 321145 HOV 4113 043345 02 033 80113A 10 121146 7 23 02 NMOUG 2 21150 9 10 043345 9 43134003345 02 318 90 02 2 21150 9 10 043345 43134043345 02 N3349 60 2 4431 1091009 6C 3 02 501134 6 321145 2 18 y 1313
196. 4 BODY STEERING SUSPENSION Foot Well Removal Installation X2 Foot Well Removal Installation 1 Remove the four plastic inserts A that secure the wheel 1 Remove the four plastic inserts A that secure the wheel well to the front and rear cabs See PLASTIC INSERT well to the front and rear cabs See PLASTIC INSERT REMOVAL INSTALLATION for help REMOVAL INSTALLATION for help 2 Remove the four screws B from the bottom of the foot 2 Remove the six screws B from the bottom of the foot well well Remove the footwell Remove the footwell NI c cu m s 3 Reverse the removal procedures to install the foot well Be 3 Reverse the removal procedures to install the foot well Be sure to properly align the cab ends into the foot wells upon sure to properly align the cab ends into the foot wells upon reassembly reassembly 9 9 BODY STEERING SUSPENSION Front Storage Removal 2 Remove the four bolts that secure the storage rack to the frame Front Storage 3 Remove the two T25 screws that secure the storage box to the front fender well areas each side 1 Remove the front radiator cap cover A by lifting upward on the cover 4 Removethe two T25 screws that secure the outside of the storage box to the front fenders each side T 25 Screws 5 6 BODY STEERING SUSPENSION Winch Install
197. 4043365 2 42718 70 2 dW3l 1 1002 6c 123 02 M01134 6 g JVg31Q0NYH H1 S 43134043345 2 0 2 JYYINI 8 1 02 JLIHM YNId 9 gt 121145 JLIHM QIY 2 43134043345 Z 3LIHM Q38 20 5 121145 311HN Q3U 38 02 3L IHM 38 1 2 121145 039 43134043365 2 10 2 121145 T 123 02 NMOUG 9 121145 NMOUG 7 JVOJTQNVH HI 2 MOUS 00 5 121145 038 3 02 139 N 2 4255 2 1043105 18 15 8 NOUS 6 1 2 8255 82 123 02 3L IHMAVUO y 121145 3LIHM Q3U 1 HOLIMS 213 2 3LIHM Q38 8 2 193 1313 G2 123 8 JLIHM 4304 MS 53190553207 20V 404 IH9IQV3H 9 3L 39 0 6 11100031345 121145 3IIHA 3018 02 JLIHM 3018 2 121145 N01134 03U 2 IH9L TII VI H7 8 M01134 03U 9 81138N00114S 02 1LLHMZ OV 18 p 301145 NMOUOG 5 2 121145 NMOUG 9 B 1 8255 6 3 02 32V 18 80 113A 60 121145 MO1134 03U 05 35 IVS 9 MOTIGA 0138 y 2 121145 A 123 02 NMOUG 90 121145 311 4 034 g HOLIMS NOILINOI 9 3L1HM Q38 C 5 t GOSS 123 02 YOVIE AVES 10 121145 31IHM Q3U 5 JV8B3TQNYH H7 9 3L IHM Q38 26 y ov 6 123 02 0138 3n 18 90 1 JVg310NVH H1 0 HOLIMS NOILINSI 8 42 18 438 0 T 9 123 02 60 MS 53150593207 121145 3LIHM 39NVUO 9 JLIHM JONYYO 69 4 ov 8 123 02 JONVYO an 1g 70 0 HOLIMS NOILINSI T 2 8255 9 MOT TSA 99 ov 1 02 11 4 3016 0 121145 JLIHM 39NYY0 v 825 9 JLIHM JONYYO 19 1102 123 91 3L IHA N3349 20
198. 5 BN gt a OFF o E US _ SPEEDO o UR E REVERSE oe le si OVERRIDE gt pud 0 SERVER S COQ D CO L STA LOCATED IN FRONT OF FUEL TANK Ol E mm FUSIBLE LINK SOLENOI P N S 2202601 T RN GRY Pes 1182 06 eo 134 RD YE BK 6 GAUGE 25 RD SOLENOID e lt gt BATTERY BRAKE LAMP SWITCH E zu RD aa CLOSED WITH HAND BRAKE APPLIED 6 GAUGE V 9 OM us NM VS GROUND GROUND LOCATED BEHIND BATTERY 5 6 GAUGE LH WORKL GHT RH IGHT RH IGH WD 3 WIRE DIAGRAM z II 4 I 8 lt EIRE lt 2 1 lt a az gt ex c SE E ex Lo Lo 2 e U a E D 1 e 05 e 1 1 e n P eu lt gt 1 m ex se Ea CIAO C2 C2 2 e 2 lt gt e v 22 lt gt gt ce Er it I 1 co Lit 3 is
199. 8 Retaining Ring 29 Pinion Gear Assembly 3 me TI 31 Drain Plug 3 2 7 21 N FINAL DRIVE Operation Engaging Front Gearcase Active Descent Control ADC is controlled by the ECU and will not enable until the following conditions are met Vehicle speed is below 15 Mph 24Kph Throttle Position Sensor TPS is at idle position The AWD switch is switched to AWD Once the conditions are met for engagement ADC remains engaged as long as the conditions are met With the AWD switch off the vehicle drives only the rear wheels 2 wheel drive When the AWD switch is ON the magnetic coils are active the AWD coil indexes the clutch mechanism so that both front axles will engage when there is a loss of rear wheel traction In addition to the rear wheel engine braking the ADC coil provides front wheel engine braking at speeds less than 15 Mph 24Kph with the TPS at idle position ADC Engagement When the AWD switch is activated a 12 Vdc current is present at the input shaft coil 1 Operation is controlled by the ECU grounding and ungrounding the coil The coil s magnetic field attracts a splined armature plate 2 on the pinion input shaft 4 The energized splined armature plate attracts the unsplined eccentric cam 3 which begins to turn with the input shaft The eccentric cam drives a hydraulic piston pump assembly 5 The pressure created by the pum
200. 800334 02 y2v18 70 2 HIV at 3 02 I HINT d Q JVg31QNVH H1 931300322145 02 39NV30 0 121145 311 HM 38 3 02 038 L 121145 311HM Q3U 2 1313003345 02 311 HN au 20 2 1211465 23 02 9 24 0255 4313 003345 02 13 10 121145 138 23 02 13 121145 NMOWG d YYgJ10NYH H1 02 00 1 2 8255 92 23 02 7 N 24 0255 2 1083105 18415 9 g 66 2 0123781 1313 G2 23 g THM 2 321145 311 HN Q3U 1 HOLIMS 213 02 86 6 41118003345 121145 311HM 3018 02 JLIHM 3N18 2 2 121145 NMOWG 1 YJHSV14 QUVZVH 9 g 16 1 41114043345 23 02 2 18 5 321145 M01134 033 2 LHOITTIVL 9 96 0 7 121145 5 2 121145 9 56 1 8255 6 23 02 2 18 1134 60 121145 N01134 038 Jyv49 1003 9 2 121165 2 23 02 oud 80 5 121145 JLIHM QJY HOLIMS NOILINOI 9 6 9 8255 23 02 2V18 AV89 10 321145 311HM Q3U 3 YYgJ10NYH H1 9 26 y 0 6 23 02 038 3018 90 G 121145 NNOUE TWNOIS NUAL INOUJ HJ 02 16 ov 9 23 02 YNI 4 3118 c0 1 JVO310NYH HT q H LIMS NOILINOI 9 06 9 ov 8 23 02 JONVYO INIG 70 YIMOd MS S3180 5322V 121145 311HM 39NV3O 9 69 0 23 02 311HM 3018 0 j HOLIMS NOILINOI 1 2 4255 9 99 192 NOILIN I 53 Q JLIHI N3339 20 121145 31 HM 39NV3O y 1 9966 9 19 1 121145 038 23 02 039 10 7 40 Z ALIAYD 80124 09 OL ALIAYD YOLOIANNOD j9nv9 118 ALIAYO YOLOANNOD OL ALIAVO YOLIANNOD
201. 8255 78 ES y 30 9 5 2 28 1 gt Ig 2 e C gt gt 531 pr 21145 39 9 2 5 02 c 21 91 0I x 1015 HOIH c 2 Li al dau 1 9 9 4 121145 3118 9 3015 5 _ 121145 101164 Q V1 209 3 121145 9 3 301v 1093 rar 3 O x 121145 2 9 al Hd Mi 121145 3 9 L 1 eu 2 321145 j 1304 9 01 1 2 4255 dWNd 13043 9 69 21145 1 HOLIMS 1H9 9 99 9 19 2 45 99 2 0c 69 32 S 4255 9 y 9 j 02 9 9 02 29 i 4 32 KIER 9 9 09 02 65 8 21 213 02 96 21 3 02 16 4 491 9 96 3 S q 2 02 1 g 21 9 21145 02 g uvg3 02 321 148 9 Z 8255 9 1 LH9 9 b 21145 1134 2 8255 9 lt H9 Iddh 25 121145 9 MOIVIS y 1H9110V3H HY 9 G t 121145 g q HOLVIS ve 1H9110V3H HI 9 06 2 8255 2 S tt 089 15 2 02 2 8255 Y 801715 y 2 lt 2 97 121145 M HVEIIANVH gt 22 9 LV 121145 NIS 1H911 3 3 0 15153 2 1101 02 9 84 8c 3 2 02 yy 8 ug 12 2 8255 2 8 g ug 92 4 3 V 02 y 9 N 32 1 02 y g 9 31409 4 9 13389 2 02 6 1 82 9 035 31 2 2 02 8 321148 3 9 2 2 02 8 02 gt gi 9 lt g J 8 6 2 121145 7 9 3 J 9 9 g j 9 L pt 12117 g 8 g 9 S 02 9 2 95 123 0241 Z 4 19 02 LS 123 0241 y S 2 y 0 2 321145 39 23
202. 97 265 ml 9 3 275 ml Platform Fuji Single Cylinder Transmission Type Engine Model Number 5 210 SERES CO Engine Displacement 499cc Number of Cylinders 1 Front Gearcase Capacity ADC Bore amp Stroke mm 92 75 mm Gear Ratio Low Rev 50 90 psi W Compression Release Front Drive PVT Standard Models PVT w EBS Deluxe Models 3211113 EBS 3211077 Non EBS Engine Idle Speed 1100 200 RPM Engine Max Operating Rpm 6000 Rpm 200 Rpm Cooling System Capacity Liquid 2 5 qt 2 4 ltr Overheat Warning HOT on Instrument Cluster Steerin g Su spen sion Lubricati ized Dry S IHRE IC UU STE Front Suspension Shock Oil Requirements Capacity Polaris OW 40 2 qt 1 9 ltr Front Travel Exhaust System Single Pipe USFS Approved Rear Suspension Shock Fuel System S Q e g C E v 3 A arm MacPherson Strut 8 2 in 20 8 cm Progressive Rate Independent Coil over shock 9 5 in 24 13 cm 11 in 27 94 cm Fuel Filter s 10 micron in line Shock Preload Adjustment Front Non Adjustable 30 micron in tank not replaceable Front Rear Rear Ratchet Style Std 65 in 165 10 cm unloaded 0 1 16 in 0 159 mm Fuel System Electronic Fuel Injection EFI Rear Travel Fuel Pump in tank assembly 25L per hr at 39 psi Ground Clearance Fuel Injector s Visteon Turning Radius EFI Controller Visteon VP5U1U 12A650 AA z Fuel Capacity
203. A Measurement Check for Loose Wheel or Hub Refer to the Body Steering Chapter 5 or Final Drive Chapter 7 for service procedures Wheel Toe Out A B 1 8 1 4 3 to 6 cm Camber and Caster The camber and caster are non adjustable 2 27 MAINTENANCE Toe Alignment Adjustment If toe alignment is incorrect measure the distance between vehicle center and each wheel This will tell you which tie rod needs adjusting NOTE Be sure handlebars are straight ahead before determining which tie rod s need adjustment 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 Incorrectly Tightened Jam Nut Correctly Tightened Jam Nut IIl 2 To adjust toe alignment Hold tie rod end to keep it from rotating Loosen jam nuts at both end of the tie rod e Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in Method 1 or Method 2 IMPORTANT When tightening the tie rod end jam nuts the rod ends must be held parallel to prevent rod end damage and premature wear Damage may not be immediately apparent if done incorrectly See illustration 2 After alignment is complete torque jam nuts to specification Tie Rod Jam Nut Torque 12 14 ft Ibs 16 19 Nm
204. A Tach Screen 3 AWD diagnostic screen This screen indicates whether or not current is flowing through the AWD coil on models with switchable AWD 158 Ohms in Neutral Screen 4 Gear Circuit Diagnostic 75 Ohms in Reverse This screen displays the resistance value in ohms being read at the gear switch input of the gauge 10 15 ELECTRICAL POLARIS POLARIS 628 Ohms in High 5 Programmable Service Interval The purpose of the programmable service interval 1s to provide the consumer and dealer with a convenient reminder for routine maintenance When the ATV leaves the factory this feature 1s set at 50 hours Once the service interval mode 1s set with the hours when service is due the hours of actual engine operation are subtracted from the set hours until O 1s reached When the counter reaches 0 the wrench icon will flash quickly for 10 seconds each time the vehicle 1s started as a reminder that the periodic maintenance is due r EM 10 16 Setting A New Service Interval 1 While in the service interval mode press and hold the mode override button until the wrench icon flashes When it begins to flash release the button 2 The setting will increase by one hour each time the button is pressed Pressing and holding the button will allow the numbers to escalate much faster 3 When the desired time increment is displayed release the button and wai
205. AC Voltage Start the engine and let it idle 3 While holding the at a specified RPM separately measure the voltage across each leg of the stator by connecting meter leads to the wires leading from the alternator Y1 to Y2 Y1 to Y3 Y2 to 4 Refer to the table below for approximate Voltage AC readings according to RPM Test each leg at the specified RPM in the table Example The alternator voltage output reading should be no less than 30 40 Vac above 2000 RPM between each NOTE If one or more of the stator leg output AC voltage varies significantly from the specified value the stator may need to be replaced 10 33 ELECTRICAL Charging System Testing Diagrams Whenever charging system problems are suspected proceed with the following system check after verifying that all wires are in good condition connected and not kinked or pinched SPORTSMAN 500 500 X2 EFI T L 55 SPORTSMAN 450 LIR POTE RD 1 10 34 Using multitester set on D C volts mea sure the battery open circuit voltage See earlier test It should be 12 4 volts or more Is it Yes Meter Setting Volts With the transmission in Park start the en gine and increase RPM to between 3000 and 4000 Read battery voltage with the multi tester Readings should increase to between 130 and 14 8 V D C Are they gt Ye
206. Cylinder Base Pattern Crankcase Pattern 3 3 Engine Service Data Head Valve WIL Rocker arm ID arm 10 8669 8678 22 020 22 041 Rocker shaft Roker sna OD 8656 8661 21 987 22 0 mm Rocker shaft Hein GC NNI Clearance 0008 0021 020 054 mm Limit 0039 10 mm M EE M 7 Camshaft journal OD 1 4935 1 4941 37 935 37 950 mm 1 4935 1 4941 37 935 37 950 mm Camshaft journal bore ID 4963 1 4970 38 005 38 025 mm 1 4963 1 4970 38 005 38 025 mm Camshaft Oil clearance 022 0035 055 090 mm Cylinder Head Surface warpage limit 0020 05 Standard Height 3 870 98 3 Nr Valve Seat Contacting width In Std Std 039 m 0 mm Limit 1 1 8 mm Valve Guide Inner diameter 2362 2367 6 0 6 012 mm Protrusion above head 689 709 17 5 18 0 mm Valve Margin Thickness In 039 1 0 mm 031 8 mm 047 1 2 mm Valve Stem diameter 2343 2348 E 950 5 965 mm Stem Oil Clearance Std 0014 0024 5 035 062 mm LET 0016 0026 040 067 mm 08 16 Overall length 3 976 101 0 3 984 101 2 Valve Spring Overall Length Std 1 654 42 0 mm Limit 1 575 40 0 mm Squareness 075 1 9 mm 3 4 Engine Service Data Cylinder Pisto
207. D YE E BRAKE LAMP SWITCH CLOSED WITH HAND BRAKE APPLIED n Of 0 n E L 2 1 35 T a zu gt gt gt Top m eal TS ays TP20 c AZ ee zio iE b is G9 g t 1 2IN amp Bea ea ius START 0 Eus Se FUSIBLE LINK SOLENOID 02 LIA 2202610 BLK SOL i 5 eds 0 TA gt Ld RD 6 GAU Y 1 L PS 000 8 N 7 d RESISTANCE BETWEEN PINS OLIO RD STARTER A FRAME O _ 9 O PINS RESISTANCE Le MOTOR S W GROUND GROUND 120 020 C NI f NY 300 1 20 20 C 37 3KQE54 ad 2 3 30002 1 20 PRIM 20 C 5504 54 100 C 2 Lam Lal 2 l 3 600 42 40 P 0 N SEC 20 C 5 KOE 7 EN 300 4120 L COOLANT MAP _ E CRANK 5 6 300 x1 20 m TEMP SENSOR AIR LH WORKL IGHT RH WORKLIGHT F POSSITION gt 0 82 40 LOCATED AHEAD OF LEFT REAR WHEEL BK 6 GAUGE MT INTAKE WU n E 9 INJEC OR d C f C WK IL 2 SENSOR ALL OTHER COMBINATIONS OPEN v TA WD 11 WIRE DIAGRAM
208. ECTRICAL TEST 2 No Speedometer Display TEST 2 NO SPEEDOMETER AND OR ODOMETER DISPLAY Note Before starting diagnosis turn off speedometer and wait 10 seconds then turn on again to see problem clears START HERE KEY amp STOP POINTER MOVE WIRING TEST 3 No Reverse Speed Limit TEST 3 NO REVERSE SPEED LIMIT VEHICLE EXCEEDS 7 9 MPH IN REVERSE START HERE CHECK IS THE SPEEDO SPEEDOMETER READ OUT OK PERFORM TEST 2 A D C Power B Signal Cc Ground CHECK FOR MINIMUM ON PIN B TO SPEEDO AT BACK OF SPEEDO CHECK FOR 10 12 VDC ON FIN A TO PIN ON THE 3 PIN CON REPLACE SPEEDO 16 Pin Connector 1 RD 500 06 450 12Vdc Constant 2 RD WH 12Wdc Switched J GYiOG ModelOverride Button 4 BK Ignition Kill 5 DG Factory Use Factory Use INSPECT WIRING AND ECM TEST TRANSMISSION SHIFT INTO REVERSE IS REVERSE INDICA TOR ON WIRING TURN KEY SWITCH OFF REMOVE 18 PIN PLUG FROM BACK OF SPEEDOMETER HEAD 10 20 SHIFT SWITCH AND JUMPER TO PIN 4 BLACK TO PIN 8 BROWN DOES 9 DB WH Engine Overheat Switch 10 OPEN 11 Malfunction Indicator 12 VTMHM Fuel Gauge 13 OPEN 14 WH Gear Signal 15 OPEN 16 BHAWH AVID Control Measure Harness Side Y REPLACE SPEEDO x ENGINE STOP ELECTRICAL TEST 4 No AWD Hub Safety Limit TEST
209. FAN CONTROL BYPASS TEST x rit proe RC EORR Rb Sate te 10 25 FAN MOTOR CURRENT DRAW 5 10 25 COOLANT TEMPERATURE SENSOR 10 26 GEAR POSITION INDICATOR 10 26 TEST DIAGRAM ouis ra xs SU Bn ol SY EMEN REN 10 26 ELECTRONIC THROTTLE CONTROL ETC 10 27 OPERATION OVERVIEW id rd are esas pode 10 27 ETC TESI Bae aa E AAAI 10 27 IGNITION 5 5 10 28 OVER VIEW user ee ch en fru nic Mte Cain tes SE M e UE 10 28 COMPONENTS OF EFI ALTERNATOR AND CDI IGNITION SYSTEM 10 29 EFI IGNITION SYSTEM TESTING FLOW CHART 10 30 CRANKSHAFT POSITION SENSOR 10 31 IGNITION 10 31 IGNITION OUTPUT TEST USING GAP 5 10 31 CHARGING 5 10 32 CURRENT DRAW KEY ORE eb pastes anne E SURE ar CENSO e s 10 32 BREAK EVEN dr astute mE EM EXER CE sis 10 32 ALTERNATOR OUTPUT TEST zo pL Uie x bees SiR 10 32 CHARGING SYSTEM TESTING DIAGRAMS
210. FOR PROPER OPERATION REFER TO TEST ON PAGE 10 40 IS IT OK SENDEH CLEAN CONNECTOR TERMINALS CHECK RELATED WIRING TEST 8 Shift Indicator Not Working TEST 8 SHIFT INDICATOR NOT WORKING TRANSMISSION SWITCH Ta B la Operation Instrument cluster sends a signal through the White wire to the resistor module This signal completes it s path on the wire through the transmission switch Depending on the transmission switch position the Instrument cluster interprets the resistance reading and displays the corre Blu hit spending shift position in the LCD panel Vi Wh Bm Wht 1 Testing Use the diagram provided to test the continuity loop at each of the shift points with a multi meter NOTE The Instrument cluster contains this diagnostic feature 16 Pin Connector RD 500 OG 450 12Vdc Constant 9 DR WH Engine Overheal Switch RDANH 12Vdc Switched 10 OPEN GYlOG ModelOverride Button 11 BKAWH Malfunction Indicator BK Ignition Kill 12 Fuel Gauge FRE acum DG Factory Use 13 OPEN RESISTOR M DE Factory Use 14 WH Gear Signal LOCATED BELOW E YERD RPM 15 da BH Ground 16 BHAWH AWD Control C 2 BI 1 B n ELECTRICAL ACTIVE DESCENT CONTROL ADC COIL Operation Overview AWD switch must ON e on 55 1 c
211. H output hub Inspect the bearing and 9 Inspect roll cage B sliding surface This surface must be contact surfaces of the output hub for signs of wear or clean and free of nicks burrs or scratches Inspect the H damage Replace component if found to be worn or springs but do not remove them from the roll cage damaged H Spring E P z 1 En s N d w j E 10 Inspect the armature plate for a consistent wear pattern 7 Thoroughly clean all parts Inspect the bearing surfaces of Uneven wear of the armature plate indicates a warped the output hub Inspect the rollers A for nicks scratches plate which may cause intermittent operation and flat spots Inspect the roll cage B for damage or p cracks The rollers must slide up and down freely within NOTE See FRONT GEARCASE DIAGNOSIS later the roller cage surfaces in this chapter for more details 8 Inspect the ring gear C for consistent wear patterns The surfaces should be free of nicks or burrs 7 15 FINAL DRIVE 11 Inspect the magnetic coil A in the outer cover plate 13 Remove the snap ring retaining the input shaft assembly assembly Inspect the backlash pad B for excessive wear I 14 Remove the input shaft assembly Inspect the pinion gear NOTE See FRONT GEARCASE DI AGNOSIS later C for chipped broken or missing teeth Inspect the input in this chapter for more details
212. HL r 1 anm ar Y Preload Adjustment Cam Tx ga ifa NESS Tay d LS SS SY cn UN 2 Ma ue e P E JULI E INTE dA a En Rear Shock Bushings GER Control Arm Pivot Bracket A Arm Shaft Lower Control Arm 5 418 Grease Zerk 5 23 BODY STEERING SUSPENSION X2 Torsion Bar Exploded View Linkage Bushing CRUS Stabilizer Bar a Pd 9 54 Stabilizer Bushing id Pd i lt 4 Bushing oe E a 2 Torsion Mount Linkage Asm i 5 24 BODY STEERING SUSPENSION X2 CARGO BOX Exploded View r3 ds e ve 3 ao 2 Bad 2 A N N NN gt N gt BODY STEERING SUSPENSION Removal Installation IMPORTANT Before attempting to remove the cargo box be sure that the cargo box is not set up for 2 UP riding The passenger backrest should be face down in the cargo box and the driver seat backrest should be locked into position 1 Open the tailgate and remove the 2 torx head screws securing the rear taillights on each side of the cargo box as illustrated below 5 26 Disconnect the two wire harnesses connected to each of the taillights AX CAUTION Use caution when disconnecting the smaller light bulb Follow the procedure below to keep from dam
213. HT HEADLIGHT HEADLIGHT mI POWER IN PIN A 1 GY TO GROUND NO CONNECTION oz I a Eom WORK if Hi f 08 AMON PAGE 1 OF 2 LIGHT L iim m FUEL PUMP sh 8 SWITCH DIE EN 7 COL X COLL DEE 5 COMMON PIN C INO WIRES ARE REPRESENTED BY LIN FUEL v zs ce amp BREE SOLID OR DASHED LINES TO n 22 9 SIMPLIFY TRACING IN DIAGRAM R m Sz S gt PME nu 4 i n 1 SPEEDO DIAGNOSTIC P E 1 9 GAUGE STATOR LOCATED UNDER RECOIL SP D f GN SANE uic ws LOCATED INSIDE POD EU Boas lt gt RANS SWITCH SEND RD Sr e Lc Ez ms STATOR SPLICE m S ERE UE RESISTOR MODULE x nes V T 4H j g RESISTANCE 51 5 XE g 5 2s T d LOCATED BELOW HEAD LAMP LN E ENGINE GROUND jet i oe d t 2 il a fas ii 1 bu BLIE C CHASSIS GROUND ABE PHH n HH TOY S _ 588 Eu BEI MN 2E Tag fo 0 55 ae 258 GN LIGHT GREEN _ o dud 03 SST 8 G DARK GREEN NC SWITCH NORMALLY CLOSED lt 120 04 TT Lah ig YS 06 ORANGE NO SWITCH NORMALLY OPEN ELE d dad 2S5 aS as pug 57 PIN M
214. Hook up an ohm meter to the fuel sender harness wire B and wire C 4 With the sender float in the empty position the meter should read 5 ohms 5 Slowly tilt invert the tank so that gravity moves the sender float to the full position the meter should now read 90 ohms Fuel Sender Empty 6 Q 5 Half 57 5 Full 900 t 5 6 Ifthe readings are not between 5 ohms and 90 ohms or if the reading is erratic or LCD display sticks check the following before replacing the tank assembly Speed Sensor Test Using Special Tools Loose float Static Timing Light Harness Float contact with tank PN 2871745 Bent Float Rod Hall Sensor Probe Harness recom PN 2460761 If none of the conditions exists the sender assembly is faulty Fuel tank assembly replacement is required on EFI models as Replacement the sender assembly is not serviceable 1 Remove the sensor retaining using a suitable tool Coat o ring of new sensor with anti seize compound or sealant 3 Push new sensor into gearcase housing Install bolt and tighten to specification opeed Sensor Bolt Torque 8 12 ft Ibs 11 17 Nm 10 42 ELECTRICAL ACCESSORY POWER NOTE Refer to the accessory instructions for accessory hook up and installation Wire Connections i Winch Installation The Sportsman models have the main winch cables routed and installed from the factory This enables quick installation Refer to Chapte
215. I ned eae a aa ee a HARNESS 2410769 03 F 5288 tise T WH WH YELLOW NS P zm 2 cu ORMAL OPERATION IS OPE UNDER THROTTLE TWO WIRE COLORS ARE SHOWN lt SE CIRCUIT F CLOSED ASSEMBLY COVER WITH MAIN TRACE COLORS Ams EG as aaa ADJUSTMENT 15 REQUIRED Mariner Mn rz Sige es es ETC 51 BK H gt SWITCH iW 58 BN co Essa ae C 5 _ r 59 01 m 98 RDN B AWD ON OFF SWITCH 1 o W ON OFF D L LOCATED ON RIGHT HANDLEBAR 22 gt a IGNITION SWITCH 4 HIE POSEE SANG 115 f BELO acces _ 7 36 Y ES 10 RON 1 101 RD Ill C Sa eu Lore een mex ease xps 52 6 PIED gt SAFE LELLES 552 SSCB T Wr EU WW CX A 72 C 27 TNT PN mn m 5 V x ET SK M 43 RD DK RD W RD YE RD W RD W RD BK BK B BR BN B GY SEE PAGE 2 OF 2 FOR SPECIFICATIONS 33 E SPLICE 1 SPLICE 2 SPLICE 3 SPLICE 1 1 SPLICE 2 SPLICE SPLICE SPLICE 1 SPLICE 2 SPLICE 3 SPLICE SPLICI 69 R GR 146 GN RD 133 YE 3 YE 06 DB W DG YT E SPLICE SPLICE SPLICE 1 SPLICE 2 SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE 2 3 HANDLEBAR In Inl mi ral il Imi Ge iCal Inl RD
216. ING The gases given off by a battery are explosive Any spark or open flame near a battery can cause an explosion which will spray battery acid on anyone close to it Should there be contact with battery acid wash the affected area with large quantities of cool water and seek immediate medical attention To ensure maximum service life and performance from a new battery perform the following steps NOTE Do not service the battery unless it will be put into regular service within 30 days After initial service add only distilled water to the battery Never add electrolyte after a battery has been in service NOTE New Battery Battery must be fully charged before use or battery life will be significantly reduced 10 30 of the battery s full potential To activate a new battery 1 Remove vent plug from vent fitting Remove cell caps Fill battery with electrolyte to upper level marks on case 3 Set battery aside to allow for acid absorption and stabilization for 30 minutes 10 57 ELECTRICAL 4 Add electrolyte to bring level back to upper level mark case NOTE This is the last time that electrolyte should be added the level becomes low after this point add only distilled water 5 Charge battery at 1 10 of its amp hour rating Examples 1 10 of 9 amp battery 2 9 amp 1 10 of 14 amp battery 1 4 amp 1 10 of 18 amp battery 1 8 amp recommended charging rates 6 Check specific gravity of each cell
217. L ABCDEF WIRES ARE REPRESENTED BY LIN FUE i LL BLEC PIN rct A COIL ALII aye SOLID OR DASHED LINES TO tot LT S r g0 SIMPLIFY TRACING IN DIAGRAM TAAL 35 m A 125 p GAUGE B j 1 SPEEDO DIAGNOSTIC 8 88 58 oo meret SENDER L5 STATOR LOCATED UNDER RECOIL EE 2 LOCATED INSIDE POD lt RANS SWITCH STATOR an E WIRE COLOR LEGEID M LOCATED ON RIGHT FRONT BRAKE mim eager RESISTOR MODULE 86 BEIGE TAN FULL 900 LI m hn ME Gu e RESISTANCE 5 E Ua ENGINE GROUND TE E LOCATED BELOW HEAD LAMP B DARK BLUE SENSOR LP pollen eu aS amp C CHASSIS GROUND Y Y 1 222 m 2 B d t 475 a E WHT V QUT PIN B ire T 8 6 NC SWITCH NORMALLY CLOSED ze 20 04 i amp TUE dn 06 NO SWITCH NORMALLY OPEN 30 05 ENS ms 7 OS Ee 150 of 55 Ba V HARNESS 241086102 m PEOR 08 TTE CIA S NORMAL OPERATION IS OPE UNDER THROTTLE HIRE COLORS ARE SHOWA oe re Zim SO CIRCUIT IF CLOSED ASSEMBLY COVER E RD YE RED WITH ma DG RD dM ADJUSTMENT 15 REQUIRED OW TRACE Aca o Onm COLO ST DQ acc i et s s 215 51 BK SWITCH NP 58 BN co 3
218. L HY 21 JONVYO 99 WIYL 391148 0241 OHS 20 1HS 24 121145 01134 013 134 038 9 N03134 038 8 qus ol gare 5 21 121145 21 91 H 1 8255 2 aay 79 _ c 5 f 11 pt 321145 NMOUg NNO INYA e MOUS 8 a4 eL oo T 121145 438 3018 43 9 12 QUVZVH 8 03 0L 121145 038 N3389 11 g 3345 02 38 3349 11 28 O 321145 3016 J Y3HSY14 QUVZVH 9 69 g 28 1345 1145 02 oud ig IN C G 121145 NMOUG 2 1H911 ONINNNY INO HY 8 89 2 03345 y 3345 02 31 1HN 038 09 2 24 121145 2011317038 1H911 ONINNAY HY 8 19 HIMOA 318055322Y 121145 311 FONVYO 9 311HN 39NV3O 6l i 1 121145 NMOS 1H9110V3H 3941 9 99 2 121145 541 02 3980 81 Sal 3015 121145 3018 11 1 Y3HSY14 QUVZVH 8 9 121145 21 91 AN3LIV8 0103105 071 92 18 m 5 6 121145 NMOUG 1052 YOH 8 79 3140552222 92V 404 1 9114 3 9 3L LHN 04 30 9L cin 8 J3HSV14 QUVZVH HOLIMS QYYZYH 8 38 9 118 1 915 NUNL HI 8 3119 51 vayam FT t 109 O 121145 3018 11 HOLIMS QUVZVH 8 29 32 14 3018 16 HY 8 038 3018 7 VHA TTT 2 109 121145 NMOUG 2 31V1d 3543211 8 19 121145 NMOUG NOLON 9 el 1019 121145 01134 03 dNV1 31914 3543211 8 0 09 I 121145 01134 038 g LHOITTIVL HY g 134 038 21 pact 121145 M3 01 33130
219. LEL Starter Lockout Diagram Sportsman 450 y Jt Bt d Af mm B B 4 10 45 ELECTRICAL Starter Motor Removal Disassembly NOTE Use electrical contact cleaner to clean starter motor parts Some solvents may leave a residue or damage internal parts and insulation 1 Remove the starter from the engine 2 Remove the two bolts washers and sealing O Rings Inspect O Rings and replace if damaged NOTE Note the alignment marks on both ends of the starter motor casing These marks must align during reassembly 3 Remove the rear brush housing assembly holding the front housing and armature assembly together 4 Remove the shims from the armature shaft and inspect the 10 46 O rings located on the armature housing LE a NOTE shims must reassembly reinstalled during Brush Inspection Replacement Ak CAUTION Some cleaning solvents may damage the insulation in the starter Care should be exercised when selecting an appropriate solvent If the commutator needs cleaning use only electrical contact cleaner 1 Measure resistance between starter input terminal and insulated brushes The reading should be 3 ohms or less Measure the resistance between the cable terminal and brush housing Make sure the brush is not touching the case The reading should be infinite 2 Removenut
220. LLAR SHIFT PLATE PARK 2 FACE BEARING BALL 6203 X 40 12 SEAL QUAL LIP 25 47 HEARING BALL 6203 C3 25 3 32 X 5 SILENT CHAIN 28P amp AQ 901 COMPRESSION FORK SHIFT COMPRESSION SPRING 82 0 2 000 RAIL SHIFT SHAFT TORSION SPRING CHAIN TENSIONER 3HOE CHAIN TENSIONER SHIFT SEAR SECTOR SHAFT SHIFT O RING Dld PAWL DETENT SPRING COMPRESSION COVER SECTOR GEAR MACH HELLERANK SHIFT DRUM HUT LOCK HEA FLANGE MYLAN 5716 24 TORQUE 12 18 FT LAS QTY a qx DESCRIPTION BEAR SPUR 36T DPIB PAIA4 3 HAZ RIGHT SHAFT LABEL TRANS POS 909 EFI GEAR SPUR 367 DPIB PAI4 3 8 RIGHT SHAFT LABEL TRANS POS 400 EFI GEAR SPUR 32T DPIB PAI4 5 SHAFT INPUT 42T 1 4 5 HAZI LEFT INPUT DFIG PAI4 5 LEFT INPUT 357 DFIG P l4 5 HAZ LEFT RIGHT SWITCH ROTARY amp PIN ITW RING RETAINING BASIC EST GEAR SECTOR 6T SENSOR SPEED STAR DETEMT O RING 12 GEAR SNORKEL BEARING BALL S007 C3 35 amp 14 RING RETAINING BASIC EXT 422 0 TUBE SNORKEL MACH SCREW TORX PAN HD 174 20 TORQUE 4 12 FT LB3 SHIM 1 180 995 RING RETAIN SEAL TRIPLE LIP 25 5 80 I TUBE VENT 90 174 LINE CAP VENT PLUG 3
221. MOVAL FRONT OR 2 32 WHEEL INSTALLATION a ote trout 2 32 TIRE PRESSURE ua d eto tee d Mad 2 32 TREINSPECTION s cone aetatis SINT SERA 2 33 FRAME NUTS BOLIS FASTENERS sala de 2 33 STORAGE 5 2 33 WINCH OPERATION IF EQUIPPED 2 34 CEEANINGS SIORAGE ed ce nausea eda IAS 2 36 MAINTENANCE SCHEDULE lt lt ces ERE eee ee 2 38 MAINTENANCE MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more fre
222. MPH and Kilometers Per Hour KPH C The Rider Information Center performs a number of functions See Illustration 2 1 Odometer Tachometer Trip meter Hour Meter Clock Odometer records the miles traveled by ATV Tachometer displays engine RPM This feature will also display with the vehicle in motion NOTE Small RPM fluctuations from day to day are normal because of changes in humidity temperature and elevation Trip meter records the miles traveled by the ATV if reset before each trip or total miles to 999 reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour meter logs the total hours the engine has been in operation Clock displays hours and minutes 2 Programmable Service Interval Diagnostic Mode Service Interval The purpose of the programmable service interval is to provide the consumer and the dealer with a convenient way to schedule routine maintenance When the ATV leaves the factory this feature 1s set at 50 hours When the first 50 hours of engine operation are finished the wrench icon will flash for 10 seconds each time the 15 started as a reminder that ATV maintenance 1s due NOTE To reset the Service Interval follow the directions for 2207
223. N KEY SWITCH OFF DISCONNECT 16 PIN CONNECTOR FROM CLUSTER TURN KEY SWITCH ON CHECK FOR 12V FROM BRNAWHITE TO GROUND TURN KEY SWITCH OFF RECONNECT CLUSTER LEAVE HEADLIGHT POD DISASSEMBLED SHIFT TO LOW OR HIGH LEAVE AWD ON NOT AN INSTRUMENT N CLUSTER PROBLEM CHECK AWD SWITCH AND WIRING WIRING PROBLEM Mote AWD icon comes on instru ment cluster is O K Proceed to me chanical tests in Service Manual Check the AWD icon on instrument clus ter to verify its operation The AWD switch is directly powered by switched 12 volts red white The gear switch only interfaces with the instrument clus ter To enable AWD the cluster must be displaying low or high gear or reverse gear with the override button pushed in 16 Pin Connector 9 DBEJWH Engine Overheat Switch 10 OPEN 11 Malfunction Indicator 12 Fuel Gauge 13 OPEN 14 WH Gear Signal 15 OPEN 16 BH WH AWD Control 1 RD 500 OG 450 12Vdc Constant 2 RD AWH 12Vdc Switched 3 GY OG ModelOverride Button 4 BK Ignition 5 DG Factory Use 6 DB Factory Use YEIRD RPM BH Ground the battery or other DC DOW source backwards will fail the AWD control and the instrument cluster If the key switch and the AWD switch are turned on REPLACE INSTRUMENT CLUSTER PROCEED TO MECHANICAL AWC COMPONENTS IF AWD PROBLEM PERSISTS 10 19 EL
224. NEW SERVICE INTERVAL later in this chapter 3 Check Engine Warning Indicator The word HOT will display alpha numerically when the engine 15 overheating Do not continue to operate the if this warning appears Refer to Chapter 3 COOLING SYSTEM TROUBLESHOOTING for help with diagnosis of overheating 10 13 ELECTRICAL 4 High Low Battery Voltage This warning usually indicates that the 15 being at an RPM too low to keep battery charged A low battery warning may also occur under normal operation if the machine is at idle and high electrical load lights cooling fan accessories is applied Driving at a higher RPM or connecting a battery charger will usually clear the warning 5 Engine Hour Display Indicator Displays number of hours of engine operation 6 AWD Indicator lluminates when the electrical portion of the AWD system is enabled 7 Gear Indicator e Specifies what position the shift lever and transmission in This area 15 blank if a fault occurs 8 Mode Indicator ndicates which modes are being utilized 9 Fuel Gauge The segments of the fuel gauge indicate the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated related icons will flash FUEL will display in the LCD and the speedometer needle will blink If riding be sure to refuel immediately 5 00 oO Blink When Low On Fuel 1
225. NOS 1090 9 YO 109 ddi 3161 NOILIVNIWHS3I 3M jidvi 391 4OSHNLOY 13009 1437006 NN 130257 LO ALY WIRE DIAGRAM X 159 006 NVINSLHOdS 1002 WD 10 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI X2 WIRE DIAGRAM
226. NS RESISTANCE 6 GAUGE MOTOR d 120 020 C 2 90 120 T 2 3 001 20 5 2 OHMS I3 60052 40 20 C 37 3KQ 51 ae ay 4 5 0 21 100 C 2 x51 CR p 00 2 5 U Li LOCATED AHEAD OF LEFT REAR WHEEL IGNITION COOLANT AIR W H H Wi e OSSITIO 4 6 600 2 4 LUGA L EAR 6 GAUG 2 WD 7 WIRE DIAGRAM 3XVHg V 9988 ane 1151107 N c
227. Nm E 5 mU d Gc eo All Bleed Screws 25 30 in lbs 2 80 3 40 Nm 9 3 BRAKES Sportsman System Component Exploded View 3 Flare Style Fittings 12 15 ft lbs 2 16 21 Nm Bleed Screws 25 30 tan ar in lbs 2 80 3 40 Nm le bs S 92 2 Screws 7 in Ibs 0 79 m 9 4 Apply Pipe Sealant To Threads 5 BRAKE CALIPER EXPLODED VIEWS Sportsman and X2 Front Caliper Assembly A Apply Polaris DOT approved Brake Fluid to Component mg Apply Polaris Purpose Grease A Socket Set Screw B Bleeder Screw C Caliper Asm D Boot E Square O rings F Piston G Caliper Mount H Brake PAds X2 Rear Caliper Assembly A A Socket Set Screw B Bleeder Screw C Caliper Asm LI Apply Polaris DOT approved D Boot Brake Fluid to Component E Caliper Seals Piston G Caliper Mount H Brake Pads 9 5 BRAKES Sportsman Rear Caliper Assembly L1 Apply Polaris DOT approved Brake fluid to component 30 35 ft Ibs 41 48 Nm H HYDRAULIC BRAKE SYSTEM Operation Overview Compensating port compensates for temperature changes by allowing fluid back to master cylinder Must be clear to allow proper diaphragm movement T D Move Brake Pad 20 The Polaris disc brake system consists following components or assemblies brake lever maste
228. OCATED ON RIGHT HANDLEBAR u 5 pue 40 VT E C rt SSCB a SET E E Gl EH Hoe ei J 33 BN e C O NEU 29 GY MN un 144 BK RD n E REV E Q 4 IRANS SWITC U RESISTOR MODUL RESISTANCE 5 LOCATED BELON HERD AMP U U Aim gt S C SSCB i CI D E E 3 63 WH B lt MV O 2 JSTOR O MI NI P SUV 46 GN RD MM ELA LJ 30 HM ALTERNATOR INPUTS CO BATT COL 2 f 3 PHASE PROTECT GROUND f A COIL 3 REGULATOR C JI qo PROCESO DOO DRIVER Voo aos HIGH SIDE IPS o BATT PROT HIGH SIDE IPS e ECU RELAY M JI A ACC PWR HIGH SIDE IPS em 5 DIFF SOL KAP JZ TET 1ps AP IGNITION O FUEL CONTROL sive Ho FUEL PUMP Ac a 2 0 FAN STAT S E 5 FAN e CONTROL 5 5 T HIGH SIDE IPS ce FA e SAS dt PDM CONTROL gt lt 2 co EC TRUE RT e IDLE Ji D CIRCUIT i co NS aJ gt SPEED a FWBD CONTROL Dee ae ECU MEMORY TRANS od sive 65 LIGHTS J2 F INTERLOCK ea ING d 1 GH SIDE He FWBD LOW SIDE 2 N STARTER s m NE E LT GREEN RED ED WHITI WHITI BROWN GRAY IPS INTELLIGENT POWER SWITCH S
229. ON 5 11 RADIATOR SCREEN REMOVAL Eres Doi soe eee at it 5 11 SPORTSMAN BODY ASSEMBLY EXPLODED 5 12 Ke BODY ASSEMBLY EXPLODED VIEW 52 exceso SSE YAS ee 5 13 BODY RAGKEXPLEODED VIEWS eee eur Rn ee oe es 5 14 HEADLIGHT POD EXPLODED VIEW pz VER ASSIS SS 5 15 rd de ay a ee B dei dg 5 16 HANDLEBAR BLOCK INSTALLATION PROCEDURE 5 16 STEERING A ARM EXPLODED VIEW 5 17 AARM REPLACEMENT 5 18 BALL JOINT 5 19 STEERING POSITEMONAL epa pint dd eis Sota ee oe 5 20 gt TEERING POST ASSEMBLY baba ER i tient dee ether on a bees bee Gard MA 5 20 SU OPE NOON CLP 5 20 FRONT STRUT CARTRIDGE REPLACEMENT 5 20 STRUT ASSEMBLY abra soho coke atte red 5 21 SPORTSMAN REAR SUSPENSION 5 22 X2 REAR SUSPENSION EXPLODED 5 23 A2 TORSION BAR EXPLODED VIEW 5 24 Ke CARGO x84 qus caro 5 25 EAP LOD ED VIEW velata
230. ON RING INSTALLATION s ned sit ee Chee eee 3 43 PISTON INSTALLATION aye E EURO ci Sese aros 3 44 CYLINDER INSTALLATION 025 2rd hg ed eee ts ey s 3 44 CYLINDER HEAD INSTALLATION 3 45 CAM CHAIN CAMSHAFT 3 45 CAMSRAR TIMING oiu en deas eU PR AEQ AC atten RC meat ede sec 3 46 CAMSHAFT TIMING euo o ln ow Chu ds rg diet eae eee 3 48 CAM CHAIN TENSIONER 3 49 STATOR FLYWHEEL AND STARTER DRIVE 3 49 ROCKER SHAFT ROCKER ARM ASSEMBLY 3 50 THERMOSTAT INSTALLATION Asas EN 3 50 E Di ca 3 50 RECOIL 5 3 51 RECOIL ASSEMBLY octo audito mta Ee sc Pak 3 52 TROUBLESHOOTING 3 8 ake argo Rb oa RW paced o fo onde dos SPARK PLUG FOULING uad rir eee eb egestas eae ee e 3 53 ei mcm 3 59 COOLING SYS TEN a io muera 3 54 3 2
231. ONT BRAKE DISGO SNS m ode Deb ee V ace BERN qr ain o Rug e 9 12 Shey bud EIN IEE A 9 12 REMOVAL REPLAGEMENT AA eek eee eund 9 13 PRON ICAI Bil terriere ara ac ob doe ooo enc d n tert Loop att 9 14 REMOVALS Sade aa Ge d dd ose aaa ddr 9 14 INSPEC TON MUERE 9 15 HEASSEMBLEY SSNS SSS bou aa door tate 9 15 INSTALLATION 5 Ca RESETS TREE SRS ieee 9 16 REAR BRAKE PFAD Yuste De awe a po de 9 17 Ae PAESBENONVAL Ss hE LE LR dh s d ben ete Pc diem diua BE cR SEARS Qul Ae DPADINSLDAEEATION 2 9 18 SPORTSMAN REAR PAD 9 19 SPORTSMAN REAR PAD 9 20 BRAKE BURNISHING PROCEDURE m Rhe ne 9 20 REAR CALIPER urea Euro Eae Iesu aded usd alos uiuis fp ds 9 21 REMOVAL a er ea DEES eer eet ee eee ene at me eee a eee a e 9 21 seen oe 9 22 DEASSEMBIEY us CONS mos ote eek ESE 9 22 SPORTSMAN REAR CALIPER Sass 8404600044046 sev Ose et ak dew en eee 9 23 REMOVAL AND INSPECTION 21 d rico tik Gace Valer ee DIENEN xc 9 23 ASOENBLDY
232. POLARIS The Way Out wy lead i s es re pur m role woe ELIT d AS r ese P 1 3 D z rJ H na TT i n 1 Uy 1 oum MI 3 7597 fi p D a ee 4 Ese LIE 7 2v EU 4 19 em E E E ir me Nu v B E M Ma E mw l 1 i 3 a a I E P ndi Pr 421 4 zi TECUM WORK TO MAKE IT BRETT ERR 2 7 ERE 06 p Vo a Vi ee Mur j 4 a z r f 4 aa 77 L Foi 3 y 1 a i A vg X i p af T i je 1 T E 4 2007 SPORTSMAN 450 500 500 X2 EFI SERVICE MANUAL FOREWORD This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference All references to left and right side of the vehicle are from the operator s perspective when seated in a normal riding position Some procedures outlined in this manual require a sound knowledge of mechanical theor
233. PORTSMAN 450 FUEL TANK FUEL DELIVERY SYSTEM Fuel System Exploded View ck Gas Cap E Vent Line Fuel Valve 18 24 in lbs ts Fuel Sender FUEL FLOW Carbu is Vent Garburetor Located Above Oil Tank 4 44 CARBURETOR SPORTSMAN 450 FUEL PUMP Fuel Pump Testing 1 2 d 4 S 7 B Fuel Pump Assembly Diaphragm Gasket Set ecrew and Washer Assembly Screw and Washer Assembly Screw and Washer Assembly Pressure Regulator Fuel Inlet Fuel Outlet This ATV is equipped with a pressure regulated fuel pump 1 3 PSI The pump is located under the left front fender of the machine To test the fuel pump 1 Turn fuel off 2 Disconnect impulse line from pump 3 Connect Mity Vac PN 2870975 to the impulse line fitting on the pump Impulse Line a aM 4 Apply 5 inches Hg vacuum to the pump fitting The diaphragm should hold vacuum indefinitely If fuel is present in the impulse line or vacuum chamber of the Pump the diaphragm is ruptured The pump diaphragms must e replaced Fuel Pump Disassembly Remove the screws from the pump assembly NOTE Mark the location of the 2 longer screws for reassembly 2 Remove the diaphragm cover gasket diaphragm and valve body gasket 3 Remove the outlet check valve cover diaphragm and gasket 4 45 CARBURETOR SPORTSMAN 450 Fuel Pump Inspection and Reassembl
234. PRESSURE SENSOR 4 18 OPERATION OVERVIEW 4 18 MAP SENSOR TESI zie ane seta uat ee dest aee eee 4 18 MAP SENSOR 4 18 INTAKE AIR TEMPERATURE SENSOR 4 19 OPERATION OVERVIEW 4 19 INTAKE AIR TEMPERATURE SENSOR 5 4 19 INTAKE AIR TEMPERATURE SENSOR 4 19 IDLE AIR CONTROL arc tate aaaea 4 19 GENERAL 4 19 THROTTLE POSITION SENSOR 4 20 OPERATION OVERVIEW ea Iaceo ra ub prb 4 20 THROTTLE POSITION SENSOR 5 4 20 THROTTLE POSITION SENSOR 4 21 THROTTLE POSITION SENSOR TPS 4 21 ENGINE TEMPERATURE SENSOR 00ccceceeeccueceeeeueeeees 4 22 GENERAL INFORMATION 24 45272 2 53 uuu RP tree San 4 22 ENGINE TEMPERATURE SENSOR 4 22 ENGINE TEMPERATURE SENSOR REPLACEMENT 4 22 4 3 FUEL INJECTION FUEL SYSTEM TROUBLESHOOTING
235. Pin connector from speedometer 2 Connect wires from test light to sensor 3 Pin connector as shown at right using the Hall Sensor Probe Harness PN 2460761 or jumper leads d Elevate end of vehicle sensor is located at until the tires are free to rotate um ft ur uno r r um 4 Slowly turn the applicable wheel while observing the test light 5 If light flashes sensor is sure connections Static Timing Light are good and 9 volt battery is in good condition 2871745 WHEEL SPEED STMSOR 10 22 ELECTRICAL TEST 7 Fuel Gauge Display Not Working TEST 7 FUEL GAUGE DISPLAY NOT WORKING 16 Pin Connector 1 RD 800 OG 450 12Vdc Constant 8 DB WH Engine Overheat Switch 2 RDAWH 12Wdc Switched 10 OPEN F CHECK J3 GYlOG ModelOverride Button 11 BEH Malfunction Indicator INSTRUMENT N SPEEDOMETER LI Gauge nd PERFORM TEST 2 6 DB Factory Use 14 WH Gear Signal T YERD RPM 15 E BH Grourd 18 BNANH Control START HERE TURN KEY SWITCH OFF GAIN ACCESS TO FUEL SENDER WIRING CHECK FOR CONTINUITY ON REPAIR GAIN ACCESS N PURPLE WHT WIRES AS BACK OF GAUGE URPLEANVH REQUIRED WIRES FIXED BUT CHECK CONNECTION CHECK FOR CONTINUITY AND PROBLEM REMAINS FROM BRN TO GROUND Qe AT GAUGE PIN 12 TEST ARE WIRES OK DOES FUEL INDICATOR WORK TEST SENDER
236. R B c5 Or L PINS RESISTANCE BATTERY e 6 GAUGE MOTOR mE 20 020 C NI 2 2 00120 2 T Y L4 T V 2 3 3001 20 V UU 3 5900 2740 0 20 C 37 00 55 OHMS 4 5 90 120 4 8 d TY s Erg NS Ul CRANK 5 6 90 120 2 METERS IGNITION AIR 1 WO I POSSITION 1 6 600 x2 40 LOCATED AHEAD OF LEFT REAR WHEEL gy 6 GAUGE COOLANT LH TAILLIGHT LH WORKLIGHT RH INJECTOR Ed IAC c COIL TEMP SENSOR INTAKE WIRE DIAGRAM HOLIMS 410 VI31NI Sd 151107 T PUE m 3211 H amp
237. RT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage NOTE NOTE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL Loctite Registered Trademark of the Loctite Corporation Nyogel Trademark of Wm Nye Co Fluke Registered Trademark of John Fluke Mfg Co Mity Vac Registered Trademark of Neward Enterprises Inc Torx Registered Trademark of Textron Hilliard Trademark of the Hilliard Corporation Warn Trademark of Warn Industries some Polaris factory publications can be downloaded from www polarisindustires com purchased from www purepolaris com or by contacting the nearest Polaris dealer GENERAL MAINTENENCE ENGINE FUEL SYSTEM BODY SUSPENSION CLUTCH TRANSMISSION FINAL DRIVE BRAKES ELECTRICAL INTERNATIONAL a H a A 5 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION MODEL NUMBER 1 2 MODEL NUMBETL cct S Oe et esr E vet 1 2 ENGINE DESIGNATION 5
238. Retainer Compression Spring Spring Retainer Retaining Ring STANDARD NON EBS DELUXE EBS Torx Screw 11 Moveable Sheave Cam Assembly T c 12 Roller Pin Retaining Ring EX h c 13 Spring Pin E clip 2 14 Stationary Sheave Washer ziz YR 7 15 Bearing Outer Spider WA PT 17 Retaining Ring Spring B ey 18 Inner Spider Plate 2 3 4 5 6 Roller 16 Retaining Ring 8 9 Shaft E 19 Spider Dampener 10 Thrust Washer 20 Clutch Roller CLUTCH SYSTEM Engine Braking System EBS Exploded View Shift Weights Roller Bushing Assembly Torque 200 ft Ibs Spacer Clutch Rollers Spider Lock Nut Bushing Cover Coil Spring Bearing Retaining Rings One Way Clutch Drive Drive Belt Cam Assembly Spider Assembly Spring Clutch Shaft Spacer Washer 6 5 CLUTCH SYSTEM PVT SYSTEM PVT Operation Overview A WARNING All PVT maintenance or repairs should be performed only by a certified Polaris Master Service Dealer MSD technician who has received the proper training and understands the procedures outlined in this manual Because of the critical nature and precision balance incorporated into the PVT components it is absolutely essential that no disassembly or repair be made without factory authorized special tools and service procedures The Polaris Variable Transmissi
239. Roll Cage Output Hubs VERGO 4x4 Engagement When the AWD switch 1s activated a 12 Vdc current charges the central coil creating a magnetic field This magnetic field attracts an armature plate keyed to a roller cage that contains 14 rollers and roller cam The difference in rpm between the input shaft and front axles forces the rollers up the external cam rollers engage or wedge themselves between the pinion gear and output hubs that link both front axles resulting in true all wheel drive 7 12 Rollers Ring Gear CAUTION If the rear wheels are spinning release the throttle before turning the AWD switch on If AWD is engaged while the wheels are spinning severe drive shaft and clutch damage could result Disengagement As the front and rear wheels gain equal traction rotating very close to the same speed the transmission shaft overdrives the front gearcase input The rollers are forced outward disengaging the AWD The vehicle is now back to rear wheel drive until the next loss of rear wheel traction Gearcase Removal 1 Stopengine place machine in Park and set parking brake 2 Loosen left front wheel nuts slightly 3 Elevate the machine until the front wheels are off the ground and support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure Wear eye protection when
240. S SPORTSMAN Component Locations Instrument Cluster AWD Switch Deluxe s FEES Brake Fluid Reservoir Work ee Light Control Hun Switch Reverse Ovarride Thrattla Front Storage Compartment Iqnition Ke amp Rack 9 y p uu a iM rr bre x J Hear Storage Compartment Sportsman Only Front Gearcase BehindRadato ing Uo jl PVT Cover Drain Transmission Tren PR in Mutter S Hight Side View a o M SENT i i zd _ LU _ a 2 3 um Front Drive Shafts A Front Prop Shaft Tm M e Between Transmssion m l ill 1 vie eM 2 7 MAINTENANCE SPORTSMAN X2 Component locations Brake Fluid Reservoir Worklight Instrument Cluster AWD Turf Switch Speedometer Brake Diagnostic Light Control Port under access panel amp Run Switch Heverse Throttle Override Front Storage Front Demand e E Drive Unit IE Tam m Rear Dump Passenger Area Behind Radiator Battery Under Tank Qs es Gear Shifter Gas Cap Muffler Transmission yg 2 FE 1 EX Tir
241. Seat Reconditioning Kit PN 2200634 Abrasive stone seat reconditioning equipment can also be used Keep all valves in order with their respective seat Uneven Good Too Narrow Wide NOTE Valve seat width and point of contact on the valve face is very important for proper sealing The valve must contact the valve seat over the entire circumference of the seat and the seat must be the proper width all the way around If the seat is uneven compression leakage will result If the seat is too wide seat pressure is reduced causing carbon accumulation and possible compression loss If the seat is too narrow heat transfer from valve to seat is reduced and the valve may overheat and warp resulting in burnt valves 1 When thoroughly heated place cylinder head on blocks of wood which will allow the old guides to be removed 2 Using valve guide driver drive guides out of the cylinder head from the combustion chamber side Be careful not to damage guide bore or valve seat when removing guides 3 23 Reaming 3 24 Place cylinder head on cylinder head table NOTE Be sure cylinder head is still at 212 F 100 C before installing new guides Y Valve Guide Installed Height Valve Guide Height 689 709 17 5 18 0 mm Place a new guide in the valve guide installation tool and press guide in to proper depth Check height of each guide above the cylinder head A NOTE The
242. Special Tools 8 3 Troubleshooting Diagrams Elelctrical 10 52 Troubleshooting EFI Circuit Diagrams 4 26 Troubleshooting Engine 3 53 U U joint Disassembly and Assembly FE V Valve Clearance Adjustment 2 26 3 26 Valve Seat Reconditioning 3 23 Vehicle Identification Number VIN 1 2 Voltage Drop Test visit otek aan Ss 10 44 W Warn Winch Operation 2 34 Water Pump Seal Installation 3 4 ERR oe oes 2 27 Wheels Removal 522222522255 edv 2 32 Wheels Tire Pressure 2 32 Wheels Torque 2 32 Wire Diagram Winch 10 51 Wire Diagrams Electrical 10 52 Work Light SWITCH aieo Quod ww eene 10 40 X 252 Ocal DISassembly 5 30 IX 5 IX 6 WD 1
243. System Voltage High Air Temp Sensor IAT Low Voltage Air Temp Sensor IAT High Voltage Engine Temperature Sensor Circuit ECT Low Voltage LE d Engine Temperature Sensor Circuit ECT High Voltage 3 3 CPS Circuit Fault Barometric Pressure Sensor MAP Circuit Low Input Barometric Pressure Sensor MAP Circuit High Input IAC Short to Ground Injector 1 Open Load Short Circuit to Ground ESSE Injector 1 Short Circuit to Battery Diagnostic Lamp Open Load 51 Diagnostic Lamp Short Circuit to Ground 5 5 6 Fuel Pump Short Circuit to Battery Cooling Fan Open Load Short Circuit to Ground 58 Cooling Fan Short Circuit to Battery END SEQUENCE 2 1 1 1 1 2 2 4 5 6 7 7 1 5 5 6 9 9 1 Open Load 4 25 FUEL INJECTION TROUBLESHOOTING DIAGRAMS EFI CIRCUIT Power On Ignition Switch Red White Splice Red White Splice 1 To ECLI Pin 34 To ECU Pin 33 1 SoCB 2 Splice 82 Protected Battery Output 5 0 Fusible Link or Roverse Override Handlebar EFI CIRCUIT Crank Position Sensor Position Sense 4 26 FUEL INJECTION EFI CIRCUIT Fuel Pump Brown Splice 4 Brown Splice 2 G SSCB 82 P High Side Driver EFI CIRCUIT Ignition Coil Ignition Coil Driver ole m H 4 27 FUEL INJECTION EFI CIRCUIT Idle Air Control
244. T 4 AS SS Align Marks 13 Place the clutch into Clutch Compression Tool PN 8700220 Using Compression Extensions PN PS 45909 Press down on the top of the spider assembly pushing the spider onto the shaft 10 Install the clutch rollers D onto each side of the outside spider Install the washers E and E clips F to secure the rollers Spin the roller the rollers should spin freely 11 Install the spider dampener G inside the outer spider and 14 Slowly compress the spider into place If the spider appears install the inside spider plate H to bind while compressing stop and make sure the skip tooth on the shaft and the spider are aligned Once the spider passes the retaining ring notch on the shaft install the retaining ring A Outer Spider 6 27 CLUTCH SYSTEM 15 Install the cam assembly helix over the shaft Line up the X on the cam X on spider and X on the stationary sheave or use the marks previously made before disassembly NOTE If the cam assembly helix is difficult to install be sure the sheaves are aligned To align the sheaves place the clutch assembly on a flat surface with the cam assembly helix side down Press down on the moveable sheave belt face with both hands and the helix will release Press Down to Loosen Helix E 4 16 Usea T25 torx to install the four torx screws and torque to specification C e x
245. TANK v N GD 7 Bn RV SOLID OR DASHED LINES TO t 7 8 r FO SIMPLIFY TRACING IN DIAGRAM ar 1 a JW I 2 FUEL Id T ieee ms w STATOR LOCATED UNDER RECOIL R o ERE A ene 5 Lh rere RANS SWITCH La a 2 COLO LES STATOR g WIRE COLOR LEGE prr LOCATED ON RIGHT FRONT BRAKE 1 RESISTOR MODULE an ENGINE GROUND FULL 90 0 oe 2 LOCATED BELOW HEAD LAMP BU LIGHT BLUE N 2 e Jul Te A m C CHASSIS GROUND T I oeque da 8 a S VY as oum gt Z3 WE cH 50 V OUT PIN B iic ae 15 E Sz 2 5 IDEE De AV 06 NC 55 30 05 lt gt E aT Ne SWITCH NORMALLY CLOSED ong I Se COMMON PIN C in n TT PP NO T 160 08 E cou ea d SWITCH NORMALLY OPEN 2 UNE 11083 ORMAL OPERATION 15 OPE UNDER THROTTLE 1 HARNESS 2410830 03 enel ens S cou CIRCUIT IF CLOSED ASSEMBLY COVER TWO WIRE COLORS ARE SHOWN E ez ADJUSTMENT IS REQUIRED WITH MAIN TRACE COLORS E es woke Ss EXAMPLE RD YE RED WITH gt x om NN CES YELLOW TRACE SRS 55555555 m lanes o pr 22222222 57 gt 1 A 58 BN
246. TENANCE Winch Operation If Equipped This information is for Sportsman models equipped with a winch in the front Winch Handlebar Controls The winch is located in the front bumper area 2 34 The mini rocker IN OUT control controls the direction of the cable for the winch IN pulls the cable into the winch and OUT feeds the cable out of the winch OUT IE fig IN Winch Control The winch control located on the side of the winch gives the Operator easy access to switch between ENGAGED and FREESPOOL When the winch is ENGAGED the winch only allows the cable to be pulled IN or released OUT via the mini rocker switch on the handlebar When the winch is FREESPOOL the winch allows the cable to be pulled out freely NOTE The switch on the handlebar does not have to be in the OUT position Winch Wire Locations The winch wires can be located under the front cab area Locate the wires remove the cap and hook up to winch the Blue and MAINTENANCE Yellow 6 Ga wires to the winch Refer to the installation The Orange White wires are located under the front cover instructions for more details under headlight E The Orange White wires supply the control power to the winch Winch Connector Winch Connecting Locate the Red wire 6 Ga with the yellow crimp cover is located in the rear fender area The red wire connects to the battery 2 35 MAINTENANCE ATV Cleaning amp
247. Test 1 Disconnect harness from coolant temperature sensor on engine 2 Withthe ATV in Park and with the parking brake on turn the ignition key and engine stop switch ON The fan should start running 3 Ifthe fan does not run or runs slowly check the fan motor wiring ground motor condition for proper operation refer to FAN MOTOR CURRENT DRAW in this section Repair or replace as necessary If the fan runs with the sensor harness disconnected but will not turn on when the engine is hot check the coolant temperature sensor and connector terminals Fan Motor Current Draw Test A current draw test will provide a good indication of fan motor condition A worn or damaged fan motor will draw more current which causes a reduction in blade speed and reduced cooling Fan Ammeter OG Black Connect Between 1 Disconnect the harness from the coolant sensor Connect a DC ammeter in between the fan switch harness wires as shown 3 sure fan blade is free to rotate 4 Turn ignition key and engine stop switch to ON position Read the current draw on ammeter with fan running 5 If the fan motor draws more than 10 Amps replace the motor Fan Motor Current Draw Should Be Less Than 10 Amps NOTE This fan motor current draw specification only applies to Sportsman EFI models 10 25 ELECTRICAL Coolant Temperature Sensor The coolant temperature sensor can be tested using
248. Torque Values 3 2 Body Assembly Exploded View 25 12 5 3 Body Rack Exploded View 5 14 brake Bleeding a iudei aL 33V ES 9 7 Brake Burnishing Procedure 9 12 Brake Caliper Exploded View 9 5 Brake Caliper Removal 9 21 9 23 Brake Caliper Assembly 9 24 Brake Caliper Prone 4 v0 03 9 14 Brake DISC Front aive RE iene arbem iras 9 12 Brake DISC Inspection 9 25 Brake Light Work Light Switch Replacement 10 40 Brake Light 5 10 41 Brake Noise Troubleshooting 9 7 Brake Pad Install 9 20 Brake Pad Removal 9 19 Brake Pad Rear Xon fX A eho ay 9 17 Brake Pad Removal and Installation 9 10 Brake System Components Std Sportsman 9 4 Brake System Components X2 9 3 Brake System Exploded View International 11 3 Brake System Exploded Views 9 3 Brake System Overview International 11 2 Brake Master Cylinder Removal 9 9 Brake Rear Auxiliary Brake 9 28 Brake Rear Auxiliary Master Cylinder 9 26 Brake Torque Specifications 9 2 Brakes
249. UND 15 THE REPLACE AWD ICON SPEEDOMETER N MECHANICAL PROBLEM REPAIR HUB COIL WIRING 10 21 ELECTRICAL TEST 5 Reverse Speed Limiter Activated In Forward Gear TEST 5 REVERSE SPEED LIMITER ACTIVATED IN FORWARD GEAR Engine loses spark when vehicle speed is above 7 9 mph START HERE 16 Pin Connector RD 500 OG 450 12Vdc Constant 8 DB WH Engine Overheat Switch RDIMH 12V dc Switched 10 GTIOG ModelrOverride Button 11 EAMH Malfunction indicater lgnitian 12 Fuel Gauge DG Factory Use 13 OPEN DB Factory Use 14 WH Gear Signal YEIRD RPM 15 OPEN BH Ground 16 Control f CHECK NST HUMEN I SPEEDOMETER CLUSTER FUNC ups TION OK PERFORM TEST 2 1 2 3 4 6 8 CHECK FUEL 4 SHIFT TOLOW OR IGNITION SYSTEMS HIGH GEARS Y DOES GEAR INDICATOR ep Ca GILY TURN KEY SWITCH OFF REMOVE PLUG FROM BACK OF PROBLEM INSTRUMENT CLUSTER REMAINS RESTART ATV AND TEST DAIVE REPLACE SPEEDOMETER TEST TRANSMISSION SWITCH CHECK RELATED WIRING NOTE OVERRIDE SWITCH PLAYS ROLE IN HEVERSE GEAR OLITPLIT TEST 6 Wheel Speed Sensor TEST 6 WHEEL SPEED SENSOR Tools Required Static Timing Light Harness 2871 745 Sensor Probe Harness PN 2480761 or equiva lent jumper wires P E a aha Whee speed e 1 Disconnect 3
250. US vc EL AT 2 0255 121145 3118 3018 02 11 4 3016 6C g AT 8 MOUS HOLVNESLL TV 72 123 121145 3118 3018 02 3LIHM 3018 ge 1 121145 JA 1H9110YJH HY Q 0113 26 9 2 4255 121145 01134 13 9 11 03 2 121145 g LH9110V3H HY 8 MONG 321145 HOVI y 2 928 y TIJA 2 121145 g y H9110Y3H HT 8 MOUS 0 321145 HOV g NOLVIS y NOT13A 121145 g ANNOYS NYU 2 6r 391148 NMOUG 0 401715 7 121146 g 1 9285 2 MOUS 8 2 8255 YOLVIS 7 NO1134 PE 321145 MOTTI g 1H9110Y3H 93441 8 NO113A LY 240255 01 15 7 JA 26 q FINGOW 40151538 0 HOLIMS SNVUL 8 LIHM NI9 321145 3119 2 y3HSV14 QUVZVH g 1016 121145 131014 Sdl 02 131010 3 8 121145 2 1004 9 TONVYO 0 121145 13101A 2 NOSN3S 02 13101A T 321145 3119 16 INOUJ HJ 02 3016 62 d 2 8255 2 1102 NOILINOI Q y2v18 03J ty 121145 1VNOIS HI g 92 321145 138 y 31 ISONOYIQ 02 039 T 121145 NMOYG gt 16 NUAL HY g 12 8 121145 NMOWG 1 D1 ISONOYIQ 02 NMOU E 4 121145 HY Q NOUO 92 121145 ovi 02 42 18 138 0r y 121145 NMOWG 121145 9 NOE G2 121145 X2v18 038 2 ovi 02 yov 18 038 6C 121145 1H9110V3H HY 3349 72 21145 131014 02 131014 at 121145 d 1H9110V
251. UTPUT O 9 5 Am _ Rep Short circuit Limit 26 Amp Typical limit to cause repetitive thermal cycling ACC PWR OUTPUT 9 5 Ame Mecmm mesawt _ Rep Short circuit Limit 26 Amp Typical limit to cause repetitive thermal cycling FUEL PUMP OUTPUT 10 75 Aw Messen Rep Short circuit Limit 26 Amp Typical limit to cause repetitive thermal cycling FAN RELAY CONTROLLER Fan Load Open Fan Load Open Delay M Time delay after detection of open fan load Time FAN output will remain on Fan Stall On Time after current limit exceeded Time FAN output will remain off after current limit Fan Stall Time mI en seer reu exceeded FAN STAT on during this time 10 8 ELECTRICAL CHARACTERISTIC UNIT NOTE ECM MEM OUTPUT constant power for ECM and Instrument Cluster MEM Circuit Limit 02 12 Amp Current capability of the output REVERSE POLARITY PROTECTION Battery Reverse Current 182 mA Max reverse leakage current when connected in reverse 2 Mm ss va DIFFERENTIAL SOLENOID DRIVER X2 ONLY Pull in Current Max pull in current when solenoid is energized Hold Current Pf 2 Max holding current when solenoid is energized TURF MODE Input 16 V Input voltage range p 1 ME BEES Resistance to ground on input pin Max SPEED input to prevent solenoid Speed Limit dif
252. VALVE SEAT 3 23 CYLINDER HEAD ASSEMBLY Pu ac ma S RR eR 3 26 VALVE SEAEINGCTEST use ONERE EINE EAR EEG S Red eut 3 26 VALVE CLEARANCE ADJUSTMENT 3 26 CYLINDER PISTON REMOVAL AND 3 27 PISTON REMOVALS Betas Basis USE Det qe 3 28 CYEINDEBRJANSPECTIGOI s Sess anal od oth pc mb acsi ye dots etes 3 28 PISTONSTOSCYEINDBER CLEARANCE 52252 oe cy tug 3 29 PISTON ARODINSPEGTION icon perite dido cn ote exce o xc a 3 29 PISTON RINGINSTALLED GAP d 3 30 CRANKCASE 3 30 STARTER DRIVE 3 31 FLYWHEEL STATOR 3 31 CHAIN TENSIONER 3 32 ONE VALVE REMOVAL 3 32 CRANKCASE 3 33 3 1 OIL PUMP 3 33 OIL PUMP ASSEMBEY lt earl s deca ds 3 34 COUNTER BALANCER SHAFT
253. VENTING S oe sce e e a eese iret 4 35 MIKUNI CV CARB OPERATION 4 35 STARTER SYSTEM CHOKE OR 4 36 PILOT IDEE AND SLOW SYSTEM 4 eR RR De pose Ree Eon SOR ERE Re RO es 4 36 MAIN SYSTEM 245 0 cic td cage shaded pended ig 4 37 POAT SY SEM rare tte ta hd te e Meets 4 37 FILO SCREW acetate auem ee ates t e ee 4 38 AlRN VPUEL MIXTURE SA ee eee eas 4 38 JETTEBBEE ras ied Our ean ete NE EA Bhat d hat 4 39 NEEDLE VET x eine o ee Serge e SESS fica Seles qute he ee 4 39 THROTTEE OPENING Vo FUEL FLOW er sait ve 4 39 CARBURETOR DISASSEMBLY 4 39 CARBURETOR CLEANING 25 8 SSeS 4 40 CARBURETOR INSPECTION 22 gt heb dea 4 41 CARBURETOR ASSEMBLY emda asa ean Ce antigen a 4 41 FLOAT HEIGHT 4 42 NEEDLE AND SEAT LEAKAGE TEST a ro DIO eL Ee 4 42 FUEL LEVEL TEST a teca ab dal ences erae 4 43 FUEL TANK FUEL DELIVERY SYSTEM th rac Pw eae ex ds 4 44 FUEL SYSTEM EXPLODED VIEW
254. WH E SWITCH ASSEMBLY 25 L HI HIGH 21 Di 5555 aS 222 za eo i 522 22 VT I Lo a LOW 1 FS m Soe ices pu RSS EEE OSs Sen ier 23 YE cule 1 16 RDIVE TENE 228 T T 24 DG I OFF m OFF d L4 crr 92 RD VH 7 je 05 a g i 9 06 TUM u E 90 RD BK ofr U 1 ECU OFF RUN OFF ON 00 0 0 000990009000 0 s s ig PEED app 61 06 REVERSE 14 GY WI OVERRIDE OVERRIDE J 138 AT ii BKH 3 40 Y 49 YE BK LOCATED IN FRONT 08 Bi Moe QU d 06 DBIRD RT 5 130 06 2 05 DBIPK J ydo gt 94 RD YE t Ll BRAKE LIGHT SENSOR CLOSED WITH 4 HAND BRAKE APPLIED a Cf Lr LE 5 e Bs 2 m cC o on se ep 5 D e gt E pm H AES Net HH z Er 060 Li gt F 3 in Or SMD Wa a SES i E j START 69 d A 3 FUSIBLE LINK PIN S SOLENOID pee 3 9 2202607 08 142 SOLENOI o e T RL CASE FRAME 0 Pees R GROUND GROUND TE 02 27 312 059 E 1 RESISTANCE BETWEEN RD STARTER if CN 6 G G G f PI
255. XE EMPTY 5 OHMS JEL EP REV z WIRE 626 ENGINE GROUND LOCATED ON RIGHT FRONT BRAKE Ve i al mon Ox F ON co ON gt HALL J F PARK 3 i CHASSIS GROUND NEL eoo T BLUE 57 CHAS m Lil 6 EL FARE TRANSMISSION DB BLUE P il WHT y OUT PIN e YE E SWITCH B ROW HAY D r 04 DB WHr 9001 45 0 a 83 06 5 z 2 00 02 GAT HARNESS 2410795 03 os 61 06 D To e rud DER 5 O To M 51 VT WHH 120 04 03 B lt min RESISTOR MODULE 06 DARK GREEN SENDER T T T X HN WORK 53 0G WH YE BKC 3 LOCATED UNDER SEAT 06 ORANGE co ea co com 06 E733 pe PUB m 38 YE BK m lt P PINK Co 2 lo 017 415 YE p 96 06 e 62 WH 55 RD RED BN WHH 160 H08 26 06 KLA B85 RDI YE P d VT VIOLET PURPLE E WH WHITE J z EL CN ES Bs co E t YELLOW DN MAS TWO WIRE COLORS ARE SHOWN al E SK WITH MAIN TRACE COLORS be X 7 EXAMPLE RD YE RED WITH e 620 GHM YELLOW TRACE UNDER THROTTLE NORMAL OPERATION IS OPEN ASSEMBLY COVER CIRCUIT IF CLOSED pas 7 ADJUSTMENT IS REQUIRED a o e FTC 4 BN WH E THERMISTOR RESIST FAN HOT LAMP h44 GY 68 gt SWITCH F CONTROL m 12 BN co T 25 ROOM TEMPERATURE 5 mi Y
256. able to be pushed down into and between the sheaves 4 Install clutch cover temporarily Verify engine is in PARK Start engine and raise engine RPM enough to engage the clutch rotating the belt and seating it in the clutches Remove clutch cover and verify belt is seated properly before final cover installation 6 13 CLUTCH SYSTEM Clutch Alignment 1 Remove belt and install the Clutch Offset Alignment Tool PN 2872292 as shown Offset Alignment Tool PN 2872292 1 8 07 1 10 3 2mm 0 1 6 2 With tool touching rear of driven clutch inner sheave the distance at point A should be 1 8 NOTE If the distance is greater than 1 8 or less than 1 16 clutch alignment must be adjusted as follows 3 Remove drive and driven clutch See DIASSEMBLY at the beginning of the chapter Remove PVT inner cover 5 Loosenall engine mounts Move front of engine to the right or left slightly until alignment 15 correct 6 Tighten engine mounts and verify alignment is correct 6 14 7 Measure belt deflection and measure offset both above and below shaft centerlines Adjust if necessary Measure Above and Below Centerline NOTE On some models minor adjustments can be made by adding shims between the frame and front lower left engine mount to increase the distance at point A If a shim is present it can be removed to decrease the distance at point A Shim Kit PN 2200126 Clutch
257. ables so they are tucked away in front and behind battery Low Maintenance Battery Check NOTE All Low Maintenance batteries are fully charged and tested at the factory before installation Expected shelf life varies on storage conditions As a general rule before placing the battery into service check the battery condition and charge accordingly 1 Check the date label on the side of the battery to calculate when to check voltage The battery should be checked every 3 months 2 Check the voltage with a voltmeter or multimeter fully charged battery should be 12 8 V or higher 3 Ifthe voltage is below 12 8 V the battery will need to be recharged STEP 2 Check with volimeter or multimeter Fully charged is 12 8 or higher date label fo calculate when chock voltage voltage is below 12 8 volts a refresh charge may be niquired NEW BATTERIES Batteries must be fully charged before use or battery life can be reduced by 10 3046 of full potential Charge battery for 3 5 hours using a variable rate charger Do not use the alternator to charge a new battery A high rate battery charger can cause battery damage Low Maintenance batteries are permanently sealed at the time of manufacture The use of lead calcium and AGM technology instead of lead antimony allows the battery acid to be fully absorbed For this reason a Low Maintenance battery case is dark and the cell caps are not removable si
258. abrasion and leaks Tighten any loose fittings and replace any worn or damaged parts Auxiliary Brake Testing The auxiliary brake should be checked for proper function mel d 5 Auxiliary Brake 1 Support the rear wheels off the ground 2 30 2 While turning the rear wheels by hand apply the auxiliary 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 Foot Brake Pedal Full Height Full Engagement Floor Board Surface Auxiliary Brake Adjustment Hydraulic Use the following procedure to inspect the hydraulic auxiliary foot brake system and adjust or bleed if necessary First check foot brake effectiveness by applying 50 Ib approx downward force on the pedal The top of the pedal be at least 1 inch 25 4mm above surface of ootrest 1 8 to 1 4 Free Play greater Floorboard If less than one inch two things must be examined Free Play Foot Brake Freeplay 1 8 1 4 inch 3 2 6 35 mm If free play is excessive inspect pedal linkage and master cylinder for wear or damage and replace any parts as needed Bleeding If free play 15 correct and brake pedal travel 15 still excessive air may be trapped somewhere in the system Bleed the hydraulic auxiliary brake system in a conventional manner following the procedure outlined in Brake Chapter 9
259. acement the pad contact surface Replace disc if worn beyond service limit NOTE To reduce the possibility of warping try removing the brake disc mounting bolts before applying heat to the bolts 1 Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent Brake Disc Thickness Service Limit 140 3 556 mm 2 Remove bolts and disc 3 Clean mating surface of disc and hub 4 Install disc on hub 5 Install new bolts and tighten to specification T 3 Mount dial indicator as shown to measure disc runout Slowly rotate the disc and read total runout on the dial Brake Disc Bolt Torque indicator Replace the disc if runout exceeds specifications 18 ft Ibs 24 Nm A CAUTION Always use new brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal Brake Disc Runout Service Limit 010 254 mm 9 13 BRAKES FRONT CALIPER 3 Remove mounting bracket pin assembly and dust boot Removal CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur 1 Loosen and remove brake line to caliper Place a container under caliper to catch fluid draining from brake line 4 Remove piston dust seals and piston seals 5 Clean the caliper body piston and retaining bracket with brake cleaner or alcohol NOTE Be sure to clean seal grooves in caliper
260. acks abrasions thin spots or excessive wear Replace if necessary Inspect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt Hour glassing occurs when the drive train does not move and the drive clutch engages the belt continuously in one spot Measure belt length with a tape measure around the outer circumference of the belt Belts which measure longer than nominal length may require driven shimming or engine adjustment for a longer center distance to obtain proper belt deflection Belts which measure shorter than nominal length may require driven shimming or a shorter center distance Remember proper belt deflection 15 the desired goal not a specific center distance Replace belt if worn past the service limit Belts with thin spots burn marks etc should be replaced to eliminate noise vibration or erratic PVT operation See Troubleshooting Chart at the end of this chapter for possible causes lt lt Distance gt Clutch Center Distance 10 1 05 254 2 51 3mm Belt Nominal Length 40 875 3 16 103 8 48 cm DRIVE BELT INSTALLATION NOTE Be sure to position belt so part number is easily read Verify new belt is seated properly in the clutches before operating the ATV 1 Loop belt over drive and over top of driven sheave 2 While pushing down on top of belt turn the back or moveable driven sheave clockwise 3 The belt then should be
261. aging the connector Damaging a connector may require wire harness replacement 4 Carefully pull out the red locking tab on the connector Once the red tab is pulled out press in on the black tab and pull out to disconnect harness Black Tab BODY STEERING SUSPENSION 6 Lift up firmly in the cargo box release lever on either side Remove the four bolts attaching the rear of the cargo box to the frame There are two on each side Support the cargo box and remove the clip and pin holding the gas shock t o the cargo box 9 Carefully remove the cargo box from the E 1 4 e E dim 10 Reverse removal steps to reinstall cargo box Refer to the standard fastener torque values in Chapter 1 during assembly See Standard Torque Specifications on page 1 12 5 27 BODY STEERING SUSPENSION X2 SEAT ASSEMBLY Exploded Views 5 28 BODY STEERING SUSPENSION X2 Seat Operation Configuring Cargo Box 4 Fold the driver seat backrest down into place to serve as For Passenger Riding passenger seat bottom Passenger Backrest Unlatch the driver seat backrest by turning the engagement knobs on each side the directions shown below Driver Seat Backrest Passenger Seat Bottom 5 the latch on the passenger backrest to set the proper 2 While pulling the backrest towards the front of the ATV backrest height
262. ality e Drive belt deflection e Worn broken or damaged internal transmission components GENERAL INFORMATION TRANSMISSION SERVICE Exploded View THREAD LOCKING AGENT FOR ALL LBS FASTENERS 29 THREAD LOCKING AGENT FOR INCH LBS FASTENERS 8 7 GENERAL INFORMATION 8 8 ND OUR m qm rm m m AIT DESCRIPTIGN SCREW TAPPING HEX WASHER TORQUE 22 27 FT LBS SEAL TRIPLE LIP 40 X 76 X COVER LH MACH HEARING BALL GOIO C3 Bu ID CHAIN SILENT IT WIDE X 1 0 X Shp CASE RH MACH BEARING BALL 5204 C3 X 47 14 SPROCKET 8T DEFLECTOR OIL SCREW TAPPING TORK 8 328 90 TORSUE 20 30 IN LBS GEAR OUTPUT BIT RING RING RR Teoo 118 SCREW TAPPING HEX 1 4 20 UNC X TORQUE 8 12 FI LBs COVER BEARING CENTER DRIVE RING RETAINING SHIM 1 100 X 1 385 HEARING BALL 6207 FINIH aT CENTER DRIVE RING RETAINING SHH 75 WASHER THRUST 1 270 f 199 X D55 HEARING WEEDLE SPLIT CAGE 22 X 26 x l WASHER 290 X 050 L P ENGAGEMENT Dou B PACE RING RETAINING BASIC EAT 938 WASHER THRUST 39D f 899 X SPROCKET 38T B FACE SHAFT REVERSE 26T SEAR 33 B FALE CO
263. ame Bolts n NOTE Refer to tightening procedures in this chapter Some special procedures are used when torquing certain bolts and fasteners Component Service Limits FRONT BRAKE CALIPER Sportsman and X2 STANDARD SERVICE LIMIT Brake Pad Thickness 298 7 6 mm 180 4 6 mm Brake Disc Thickness 150 165 3 81 4 19 mm 140 3 556 mm Brake Disc Thickness Variance 00 0 002 051 mm Brake Disc Runout EE 010 254 mm REAR BRAKE CALIPER X2 ONLY STANDARD SERVICE LIMIT Brake Pad Thickness 298 7 6 mm 180 4 6 mm Brake Disc Thickness 180 195 4 57 4 95 mm 170 4 318 mm Brake Disc Thickness Variance ue 002 051 mm Brake Disc Runout 0107 254 mm REAR BRAKE CALIPER Sportsman ONLY STANDARD SERVICE LIMIT Brake Pad Thickness 318 7 6 mm 180 4 6 mm Brake Disc Thickness 150 165 3 81 4 19 mm 140 3 56 mm Brake Disc Thickness Variance 0027 051 mm Brake Disc EE 010 254 mm 9 2 5 BRAKE SYSTEM EXPLODED VIEWS X2 System Component Exploded View 1 Master Cylinder Cover Screws 7 1 165 0 79 Nm 2 Banjo Style Fitting 15 ft lbs 21 Nm 3 Flare Style Fittings 12 15 ft Ibs 16 21 Nm 4 Brake Switch 12 15 ft Ibs 16 21 Nm Apply Pipe Sealant to Threads 5 Dual Input Master Cylinder and Bleed Screw 25 30 in Ibs 2 8 3 4 Nm 6 Front and Rear Caliper Bleed Screws 36 60 in 165 4 07 6 78
264. artial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture This causes the boiling temperature of the brake fluid to drop which can lead to brake fade and the possible loss of control Brake Noise Troubleshooting Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise squeal caused by vibration If cleaning does not reduce the occurrence of brake noise a product such as Permatex Disc Brake Quiet can be applied to the back of the pads Follow directions on the package This will keep pads in contact with caliper piston s to reduce the chance of squeaks caused by dirt or dust BRAKE NOISE TROUBLESHOOTING POSSIBLE CAUSE REMEDY Spray disc and pads with CRC Brake Kleen or equivalent non flammable aerosol brake cleaner Remove pads and or disc hub to clean imbedded material from disc or pads Pad s dragging on disc noise or premature pad wear Insufficient lever or pedal Master cylinder reservoir Check brake fluid level overfilled adjust as needed Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston s not returning Dirt dust or imbedded material on pads or disc Clean piston s seal BRAKES BRAKE NOISE TROUBLESHOOTING POSSIBLE CAUSE REMEDY Operator error riding the brake park brake applied Loose wheel hub or bearings
265. ase mating surface and install the shift drum shaft Be sure to install the lockout disc H the cover Install and tighten the 22 screws in a criss cross and detent star J with the raised edge facing outward pattern to evenly secure the cover Torque the screws to 25 30 ft Ibs 36 43 Nm NOTE Case halve mating may be difficult due to tensioner installation Release tension to aid installation 19 Install the detent pawl I onto the shift shaft Install the detent star J Install a new O ring onto the shift shaft Apply a small amount of grease onto the O rings and end of the shift drum 16 Place a small amount of grease PN 2871551 into the pocket before installing the sector gear gt 17 Install the shift gear 16T G on the shift drum shaft Install the sector gear F in the bushing pocket on the left side Aligning the timing marks on the gears 21 Apply Crankcase Sealant 3 Bond PN 2871557 onto the cover and case mating surfaces 8 19 GENERAL INFORMATION 22 Install the bellcrank onto the shift shaft Note the key splined on the bellcrank and shaft Install the nut Torque the nut to 12 18 ft Ibs 16 26 Nm 23 Install the transmission switch and secure the switch with the retaining ring 8 20 5 9 5 SPECIFICATIONS pu FE EUR 9 2 TORQUE TABLE itunes
266. ates crankshaft position from the time interval between the consecutive pulses Synchronization of the CPS ECM and MAP sensor takes place during the first two 2 revolutions each time the engine is started Once the engine is started the ECM monitors the MAP sensor for the engine intake stroke The CPS must be properly connected at all times If the sensor fails or becomes disconnected for any reason the engine will quit operating Crankshaft Position Sensor Test The crankshaft position sensor is a sealed non serviceable assembly If fault code diagnosis indicates a problem within this area test and correct as follows 1 Disconnect main harness connector ECM Connect an ohmmeter between the pin terminals A resistance value of 1850 20 at room temperature 202 C 68 F should be obtained If resistance is correct check the mounting air gap toothed ring gear damage runout etc and flywheel key Crankshaft Position Sensor Resistance 1850 20 20 68 4 17 FUEL INJECTION 3 Disconnect crankshaft sensor connector from wiring harness Test resistance between the terminals A reading of 1850 20 at room temperature 202 682 F should again be obtained NOTE If the resistance reading is incorrect remove the screws securing the sensor to the mounting bracket and replace the sensor If the resistance in step 2 was incorrect but the resistance of the sensor alone was correct test the
267. ation Area 6 Remove the front headlights C or simply disconnect the electric connector D before removing the front plastic 5 Remove the front cover piece by lifting up on sides of the bumper two locking tabs as shown Pull the tabs out of the notches and lift up on the cover piece C Pull On m Ne 7 Remove the remaining bolts and screws that secure the front bumper section to the frame To install the front cover place top lip of the cover into and lift up to remove 2 Press Tabs 9 7 BODY STEERING SUSPENSION Front Storage Installation 8 Install the front radiator cap cover 25 Screw A 14 ft llbs 19 Nm C 10 in lbs 1 13 Nm B 10 in lbs 1 13 Nm D 24 in lbs 2 7 Nm Place the front storage rack onto the frame Install the four bolts A into the inside of the compartment hand tight 3 Install the four screws and washers B T 25 under the fender area 2 each side 4 Install the four screws C T 25 into the front fender area 127 Screw of the storage box 2 each side 36 16 4 Nm 18 in lbs 2 Nm 5 Install two screws D into the rear area of the cab if removed 6 Install the two plastic inserts E into the front cab if removed Remove the six A T27 screws and two bolts B that secure the rear rack to the rear cab and frame Lift the rear rack from the ATV Remove the two rack spacers C 7 T
268. attery Readings of 1 270 or greater should be observed in a fully charged battery Differences of more than 025 between the lowest and highest cell readings indicate a need to replace the battery TATE OF NVENTIONAL poss Low MAINTENANCE 12 40V 12 50V 12 10V 12 20V 50 Charged 11 90V 12 0V Table 10 2 SPECIFIC GRAVITY LEAD ACID 1 210 1 160 1 120 Charged Low MAINTENANCE 1 275 1 225 1 175 1 135 STATE OF CHARGE Charged Charged a 188 Measurement at 80 F NOTE Subtract 01 from the specific gravity reading at 40 F 10 60 Battery Load Test AX CAUTION To prevent shock or component damage remove spark plug high tension leads and connect securely to engine ground before proceeding NOTE This test can only be performed on machines with electric starters This test cannot be performed with an engine or starting system that is not working properly A battery may indicate a full charge condition in the OCV test and the specific gravity test but still may not have the storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is encountered To perform this test hook a multitester to the battery in the same manner as was done in the OCV test The reading should be 12 6 volts or greater Engage the starter and observe the ba
269. b from housing 6 Remove the head lamp and replace with a new head lamp NOTE Do not touch the lamp with bare fingers Hold the plastic part 1 of the lamp Oil from your skin leaves residue causing hot spot that will shorten the life of the lamp ae 3 a4 EL 27 3 b une dile 7 Install the new head lamp and harness assembly into the headlight assembly Turn the headlight harness clockwise to secure the head lamp into place 5 Pull the headlight housing up to release from the locking tabs Headlight Housing Relacement 1 Remove three Phillips screws on the headlight pod 2 Disconnect instrument cluster harness and work light switch B 6 adjusting knob up to remove from the locking tabs 7 Carefully pull the assembly up and out of pod 10 37 ELECTRICAL 8 steps to install the new housing and reassemble the pod 5 1 8 13 NOTE he distance from the head lamp parting line to the end of the adjustment knob stop is 5 1 8 13 cm See illustration 9 Adjust the headlight aim by turning the adjusting knob High Beam Headlight Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob located on the bottom right side of the headlight pod Raise Headlight Turn knob counter counterclockwise Lower Headlight Turn knob clockwise 10 38 1 Place the vehicle on a
270. back off 1 2 turn Installation 5 Install caliper on hub strut and torque mounting bolts to specification 15 ft Ibs 21 Nm 6 Perform brake bleeding procedure as outlined earlier in this chapter 9 Install wheels and torque wheel nuts to specification Refer to Chapter 2 Brake Caliper Mounting Bolt Torque 18 ft lbs 24 Nm 9 16 5 REAR BRAKE PAD X2 Pad Removal 1 Hlevate and support the rear of the 2 Remove the rear wheel 3 Loosen pad adjuster screw 2 3 turns 4 Remove the two caliper mounting bolts and lift caliper off the brake disc NOTE When removing caliper be careful not to damage brake line Support caliper so as not to kink or bend brake line 7 Remove the inner brake pad 5 Push caliper piston into the caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 6 Pushcaliper mounting bracket inward and slip outer brake pad past the edge to remove 8 Clean caliper with brake cleaner or alcohol 9 17 BRAKES 9 Measure the thickness of the pad material Replace pads if 3 Install caliper and torque the mounting bolts to worn beyond the service limit specification Measure e Thickness Ch m
271. ber Pilot Jets Jet Number Part Number 3131537 25 3131538 132 5 3131536 27 5 3131539 135 3131535 30 3131540 137 5 3131534 32 5 3131541 140 3131522 35 3131542 142 5 3131523 37 5 3131543 145 3131524 40 3131544 147 5 3131525 42 5 3131545 152 5 3131526 47 5 3131546 155 3131527 50 3131547 157 5 3131528 52 5 3131548 160 3131529 55 3131549 162 5 3131530 57 5 3131550 165 3131531 60 3131551 167 5 3131532 65 3131552 170 3131533 70 3131553 Carburetor Specifications Fuel System Carburetor Mikuni BST 34mm 167 5 Pilot Air Jet Float Height 13mm 1 51 0 40 Fuel Delivery Fuel Capacity Requirement Main Jet Fuel Pump 4 25 gal US 19 9 liters 87 Octane minimum or 89 Oxygenated CARBURETOR SPORTSMAN 450 CARBURETION BST 34 Carburetor Exploded View 1 of 2 Table 4 1 Carburetor Components REFERENCE DESCRIPTION REFERENCE DESCRIPTION gg mm EE COO _ b emen _ E Mmm E em pem CE 4 33 CARBURETOR SPORTSMAN 450 BST 34 Carburetor Exploded View 2 of 2 Table 4 2 Carburetor Components REFERENCE DESCRIPTION REFERENCE DESCRIPTION e meme es NS RS Needle Valve Retaining Plate BO 4 34 CARBURETOR SPORTSMAN 450 CV Carburetor System Function Carburetor Venting The carburetor float bowl vent lines supply atmospheric Carburetor Component Fu
272. between the pump terminals replace the fuel pump tank assembly NOTE If the voltage is below 7Vdc test the battery ignition switch wiring harness and ECM 4 If voltage at the plug was good and there was continuity across the pump terminals reconnect the plug to the pump making sure you have good clean connections Turn on the key switch and listen for the pump to activate NOTE If the pump starts repeat steps 1 and 2 to verify correct pressure NOTE If the pump still does not operate check for correct ECM operation by plugging in a known good ECM NOTE If the pump still does not operate replace the pump tank assembly Fuel Pump Tank Assembly Replacement NOTE All EFI units utilize quick connect fuel lines A WARNING Always wear safety goggles when working with high pressure or flammable fluids Failure to do so could result in serious injury or complications NOTE The fuel pump cannot be replaced as an individual part the entire fuel pump and fuel tank is replaced as an assembly Refer to your parts book for the proper part number 1 Disconnect the negative battery cable 2 Remove the side panels and front cab assembly Refer to COVER PANEL REMOVAL in Chapter 5 for details 4 14 3 Removethe clamps on the PVT intake duct and remove the PVT duct 4 Remove the gas tank cover vent hoses Be sure to properly route the vent hoses upon reassembly 5 With all the body panels remov
273. bor fully seat bearing cap in one side Continually check for free movement of bearing cross as bearing caps using a suitable arbor fully seat bearing cap in one side Continually check for free movement of bearing cross as bearing caps are assembled are assembled 3 Install snap ring to contain bearing cap just installed Repeat procedure for other side 7 8 FINAL DRIVE 4 Install snap ring to contain bearing cap just installed Repeat procedure for other side 5 Install snap ring to contain bearing cap just installed Repeat procedure for other side 6 Seatall bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown 7 When installation is complete yokes must pivot freely in all directions without binding If the joint is stiff or binding tap the yoke lightly to center the joint until it pivots freely in all directions 7 9 FINAL DRIVE DRIVE AXLE EXPLODED VIEWS Drive Shafts and Propshafts NOTE Refer to your parts manual for the proper replacement parts Drive Axle Components Inner CV Joint Circlip Inner Boot Circlip Outer Boot Outer CV Joint Circlip Drive Boot Replacement Kits Clamp 3 5 oz grease Boot p az fi ue v Outer Clamp NOM S 5 Er pA Prop Shaft Components tene Prop Shaft Cross amp Bearing pe eh Lem e 7E 74 A Zz Yok
274. burnt spots To check for bent valve stems mount valve in a drill or use V blocks and use a dial indicator 3 Checkendof valve stem for flaring pitting wear or damage A 4 Inspect split keeper groove for wear or flaring of the keeper 3 22 seat area B NOTE The valves cannot be re faced or end ground Valves must be replaced if worn bent or damaged Measure valve stem in several places Valve Stem Diameter Intake 2343 2348 5 950 5 965 mm Exhaust 2341 2346 5 945 5 960 mm 5 Measure diameter of valve stem with a micrometer in three places and in two different directions six measurements total Compare to specifications uide I D 2362 6 0 6 012 mm Valve 6 Measure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer Measure in two directions front to back and side to side Subtract valve stem measurement to obtain stem to guide clearance NOTE Be sure to measure each guide and valve combination individually 8 Replace valve and or guide if clearance is excessive Compare to specifications NOTE If valve guides are replaced valve seats must be reconditioned Refer to Valve Seat Reconditioning for procedure Clean all accumulated carbon deposits from combustion chamber and valve seat area with a soft wire brush Valve Seat ReconditionING Valve Seat Inspection Inspect valve seat in cylin
275. bushing faces downward and install bushing is worn or the shaft does not fit snug into the onto puller bushing replace the cam assembly cover 5 Install bushing tool Item 2 EBS Driven Clutch Outer Bushing Removal Bushing Tool 2 ami Nut C Adapter Reducer 9 Main Adapter 8 DRIVEN CLUTCH BUSHING REMOVAL INSTALLATION 6 Install left hand nut C and spacer onto puller rod and tighten by hand Turn puller barrel for further tension if NOTE Special Tool Required EBS CLUTCH BUSHING REMOVAL AND INSTALLATION 7 Turn clutch sheave counterclockwise until bushing is Table 6 1 removed and sheave comes free 8 Remove nut C left hand thread from puller rod and set ITEM PART DESCRIPTION PART aside 9 Remove adapters from puller NL LL ii iiid 10 Remove bushing and removal tool from adapters Discard C 1 EBS Puller Nut 5132501 bushing Ln EBS Main Adapter 5132029 EBS Bushing Removal 5132008 Tool Instructions 6 24 CLUTCH SYSTEM Driven Clutch Bushing Installation Install puller adapter Item 10 onto puller 2 Install adapter Item 9 onto puller EBS Driven Clutch OuterBushing Installation Nut C Bushing Bushing Puller Adapter 10 3 Apply 609 evenly to bushing bore inside moveable sheave Install sheave face down on puller 5 Install new bushing on installation tool Item 2
276. ck Make sure lines are not kinked or pinched f you get gasoline in your eyes or if you swallow gasoline seek medical attention immediately If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time Never drain the system when the engine is hot Severe burns may result 2 16 MAINTENANCE Fuel Filter Compression Test The fuel filter should be replaced in accordance with the NOTE 450 500 4 Stroke engines are equipped with an Periodic Maintenance Chart automatic decompressor Compression readings will vary in proportion to cranking speed during the test Average compression measured is about 60 90 psi during a compression test Smooth idle generally indicates good compression Low engine compression 15 rarely a factor running condition problems above idle speed Abnormally high compression can be caused by a decompressor malfunction or worn or damaged exhaust cam lobes Inspect camshaft and automatic decompression mechanism if compression is abnormally high A cylinder leakage test is the best indication of engine condition on models with automatic decompression Follow manufacturer s instructions to perform a cylinder leakage test Never use high pressure leakage testers as crankshaft seals
277. ck to make sure coil is seated in the U shaped insert Gearcase Installation that is pressed into the gearcase cover The top of the coil should be seated below the U shaped insert The U shaped 1 Toinstall gearcase reverse removal procedures Use new insert controls the pole gap If the top of the coil is above roll pin in front prop shaft the surface of the U shaped insert it raises the armature 2 Torque mounting bolts in skid plate to 30 ft Ibs 41 Nm plate thereby increasing pole gap If the pole gap increases the coil will not be strong enough to engage the n AWD system If this is the cause order a new Cover Plate i Assembly Cutaway View of Gearcase Cover U Shaped Insert 5 Inspect the rollers for nicks scratches and flat spots Also inspect the roll cage for cracks and ensure the rollers are able to slide up and down and in and out freely within the roll cage sliding surfaces New Roll Pin B Rollers P 3 Add the proper lubricant to the front gearcase Check drain plug for proper torque Refer to Chapter 2 for fluid fill and change information 7 20 FINAL DRIVE GEARCASE ACTIVE DESCENT CONTROL DELUXE MODELS 5 I Gear Case 1 Z2 13 Clutch Assembly RH 2 15 Reservoir 2 j Roll Cage Assembly 36 _ 1 7727 Pinion Cover T 2
278. ckshifting CLUTCH SYSTEM EBS Clutch Operation This EBS driven clutch provides the same engine braking abilities as the EBS drive clutch One Way Clutch Downhill Belt Rotation When the ATV is moving the drivetrain turns in the direction of engine rotation as the clutches belt and one way clutches at the same speed When the drivetrain rotational speed exceeds the one way clutch rotation see exploded view of drive clutch the one way clutch locks to the clutch shaft and engine braking occurs Essentially the driven clutch has become the driving clutch The spider assembly with the two rollers fixed to the transmission shaft rotates in the pockets of the sheave allowing the stationary sheave to rotate with the moveable sheave as the rollers move to the other side of the ramp providing instant EBS Engine braking EBS continues until the drive clutch speed exceeds the one way clutch speed or until the throttle is applied and the engine reaches clutch engagement speed AX CAUTION Driven clutches must be disassembled from the helix end to reduce spring pressure Review all information below before proceeding PVT Maintenance Inspection Under normal operation the PVT system will provide years of trouble free operation Periodic inspection ed maintenance is required to keep the system operating at peak performance The following list of items should be inspected and maintained to ensure maximum performanc
279. ct inlet and outlet ducts for proper routing and sealing Chapter 6 Transmission 1 Inspect transmission operation and adjust linkage if necessary Refer to Chapter 2 and Chapter 8 Exhaust 1 Replace exhaust gaskets Seal connections with high temp silicone sealant if required 2 Check to be sure all springs are in good condition Bleed Cooling System 1 Remove radiator cap and slowly add coolant to top of filler neck Fill coolant reservoir tank to full mark 3 Install radiator cap and squeeze coolant lines to force air out of system 4 Again remove radiator cap and slowly add coolant to top of fill neck 5 Start engine and observe coolant level in the radiator Allow air to purge and top off as necessary Reinstall radiator cap and bring engine to operating temp Check level in reservoir tank after engine is cool and add coolant if necessary Engine Break In Period 4 Cycle Engine Break In Period is defined as the first 10 hours of engine operation or 2 full tanks of fuel 1 Use only Polaris Premium 4 Season synthetic oil or certified oil Never substitute or mix oil brands Serious engine damage can result Use fuel with a minimum octane of 87 R M 2 method 3 Change break in oil and filter at 20 hours or 500 miles whichever comes first Cylinder Hone Selection Honing Procedure Selecting a hone which will straighten as well as remove material from the cylinder is very importan
280. ct shift weight kit to match engine application Replace spring refer to proper installation location a Disassemble drive clutch inspect shift weights for Engine RPM below specified operating range although engine is properly tuned shift weight too heavy wear and free operation Replace belt a Replace ramp buttons b Inspect movable sheave for excessive bushing Replace the clutch Install correct recommended spring rate Drive clutch shift weights incorrect for application too light Erratic engine operating RPM during acceleration or load variations 1 1 1 1 1 1 1 1 2 J 9 aE pel S B OS lt lt lt lt dic G lt z 2E JE g EF S al e 5 amp lt ga lt Em un AB 0 Q z 5 5 2 5 x 5 cL d 5 lt ga 5 ge JE De 5 8 2 E 3 S o S ps z e za z 1 O ua un un 3 z ga 5 C un gt 5 0a da Install correct recommended shift weights Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring Engine RPM above Drive clutch binding specified operating range Disassemble clean and inspect driven clutch noting worn sheave bushing and ramp buttons and helix COREE suadent Dukes sene Clean sheaves with denatured alcoho
281. ctory No adjustment is required unless the front cover is replaced or the back lash pad screw is removed 9 Install the roll cage and rollers into the ring gear Insert the rollers as the roll cage is installed 7 30 10 Install the clutch pack 1 spacer 2 and ring gear 3 NOTE Align locating pins holes for installation arrow 11 Install the armature plate Verify the armature plate tabs align with tab recesses in the roll cage FINAL DRIVE 12 Install new cover o ring 1 on the cover plate assembly 14 Place cover assembly on Install bolts arrows retaining the outer cover plate assembly and torque to specification Ua da er 13 Install the remaining output clutch assembly NOTE Align locating pins holes for installation 15 Install a new passage o ring dotted circle on the gearcase and install the piston pump assembly Torque the screws to specification Pump Assembly Screw Torque 17 23 in Ibs 1 9 2 5 Nm NOTE See Gearcase Installation on page 7 20 Properly route and install the ADC reservoir and line 7 31 FINAL DRIVE RE AR H U B 8 Remove hub nut domed washer and flat washer Removal 1 Place the in Park and lock the parking brake Remove rear hub cap 9 Remove hub Remove cotter pin A Loosen the hub retaining nut B Loosen the wheel nuts C Safely support the rear of the ATV Remove whee
282. cu utate dur det oak 10 60 Charging System Break Even Test 10 32 Charging System Flow Chart 10 30 10 34 CHOKES Stell atoque gap Sh EE eb 4 36 C Tute ANS MMe TIE o sos aede dosi e dada boc 6 14 C itc aos eoa e er decet 6 14 Clutch Troubleshooting 6 36 Clutclung Chart ier be ehem ed 1 6 1 8 1 10 Component Locations 2 8 Component Locations Sportsman 2 7 Compression Test iu a Ses a 27 Controls Inspection 2 31 Conversion Table sois 1 14 Coolant Senser Test 10 26 Coolant Level Inspection 2 20 Coolant Recommended 3 8 Cooling System Pressure 3 7 Cooling System Specifications 3 6 Cooling System Maintenance 2 19 Counter Balancer Endplay Adjustment 3 38 Counter Balancer Removal and Inspection 3 34 Crankcase Breather Filter Service 2 22 Crankcase Separation 3 33 Crankshaft Endplay Adjustment 3 37 Crankshaft Position Sensor 4 17 IX 1 Crankshaft Position Sensor Gap 10 31 Crankshaft Straightening 3 10 Crankshaft
283. d hold it up while rotating the engine to avoid damage to the chain drive sprocket teeth or tensioner blade 15 Tighten the cylinder bolts in three steps in a criss cross pattern and torque to specifications 16 Install the two 6 mm bolts and torque to specifications Cylinder Bolt Torque 10 mm 46 ft Ibs En Nm 6 mm 6 ft 155 8 Nm Cylinder Head Installation Clean the gasket surfaces on the cylinder head and cylinder Remove all traces of old gasket material efer to disassembly photos 1 Install the cam chain tensioner guide Be sure bottom end of guide is located properly in crankcase Install the two dowel pins and a new cylinder head gasket 3 Place the cylinder head on the cylinder Apply a film of engine oil to the cylinder head bolt threads and washers and hand tighten the bolts The following procedure must be used to torque the cylinder head properly Torque all bolts evenly in a criss cross pattern Torque bolts to 22 ft Ibs 30 Nm Torque bolts to 51 ft Ibs 70 Nm Loosen bolts evenly 180 1 2 turn Loosen bolts again another 180 1 2 turn Torque bolts to 11 ft Ibs 15 Nm From this point tighten bolts evenly 90 1 4 turn Finally tighten another 90 1 4 turn Install two 6 mm bolts and torque to 6 ft Ibs 8 Nm Guide in recess Cam Chain Camshaft Installation Install the cam chain over the crankshaft A CAUTION Serious engine dama
284. d for reassembly 9 Remove the shift shaft 10 and the shift gears 11 12 NOTE Note the timing marks on the shift gears 12 13 for reassembly 8 9 GENERAL INFORMATION 10 Remove all cover bolts Using suitable pry tools remove the cover using the designated pry points Tap cover with soft face hammer to remove The pry points are indicated by the white arrows in the photo below Pry points CAUTION Do not pry on case half sealing surfaces Use only the designated pry points on the transmission 11 Note location of chain tensioner cam 17 If fully extended chain is worn beyond service limit Replace chain and chain tensioner shoe 8 10 12 Remove the cam chain tensioner spring 14 Slide the cam chain tensioner shoe 15 pins 16 and cam chain tensioner cam 17 from the assembly 13 Remove the differential gear 18 and chain by gently prying underneath or tapping the differential gear from the opposite side until it tips toward the output gear 19 The differential gear 15 connected to the shift fork and must slide backwards to clear the fork arms once the chain is removed 14 Remove the T20 screws that secure the oil deflector 20 with a T20 hex socket or driver V 15 Remove 27 screws that secure the output gear 21 with a T27 hex socket or driver 3 i a Pu ae j ra 4 VM a Eo yw 21 4 Di LOS 16 Remo
285. dd 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 and Filter Change Oil Filter Torque Turn by hand until filter gasket contacts sealing surface then turn an additional 1 2 turn Oil Filter Wrench PV 43527 Oil Tank Screen Fitting Torque 25 ft Ib 34Nm Recommended Engine Oil Polaris Premium 4 Season Synthetic 0W 40 A WARNING Personal injury can occur when handling used oil Hot oil can cause burns or skin damage NOTICE Care must be taken to ensure that the fluids are contained Be prepared to collect the fluid with suitable containers before opening any compartment or disassembly of any component containing fluids Place vehicle on a level surface Clean area around drain plug A at bottom of oil tank 2 3 Runengine two to three minutes until engine is warm 4 After two or three minutes stop the engine 2 23 MAINTENANCE 5 pan beneath oil tank and remove the drain plug A CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as serious burns may result 6 Allow oil to drain completely 7 Replace sealing washer B on drain plug A NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burr
286. dealer only or limited testing may be done manually using the procedures provided 80 of all EFI problems are caused by wiring harness connections Follow a common sense approach when diagnosing a potential EFI issue 1 Disconnect the harness at the suspected sensor connector 2 Inspect the connector ends for damage or contamination If damaged repair if contaminated clean Reconnect and check function 3 If the problem persists perform a sensor bench test according to the specific sensor requirements 4 sensor bench tests pass disconnect the connector at the ECM and perform a continuity check between the sensor connector and the appropriate pin at the ECM connector all connections for that sensor Wiring resistance should be less than five 5 ohms 5 Ifthe resistance is high or open a wiring harness inspection is dictated including a thorough inspection of the ECM connector for contamination or damage 6 If the sensor passes and the wiring passes inspection and reconnecting the ECM does not resolve the issue then at that point a known good ECM from another 500 EFI ATV could be connected and tested for problem resolution For the purpose of troubleshooting difficult running issues a known good ECM from a same model Polaris 500 ATV EFI system may be used without damaging system or engine components Do not use dielectric grease on sealed connectors connectors with a rubber grommet as it may displace the
287. der head for pitting burnt spots roughness and uneven surface If any of the above conditions exist the valve seat must be reconditioned f the valve seat is cracked the cylinder head must be replaced Cylinder Head Reconditioning NOTE Servicing the valve guides and valve seats requires special tools and a thorough knowledge of reconditioning techniques Follow the instructions provided in the cylinder head service tool kit CAUTION Wear eye protection when performing cylinder head service Valve guide replacement will require heating of the cylinder head Wear gloves to prevent burns Valve Guide Removal Installation 1 Remove all carbon deposits from the combustion chamber valve seat and valve guide area before attempting to remove valve guides CAUTION Carbon deposits are extremely abrasive and may damage the valve guide bore when guides are removed 2 Place new valve guides in a freezer for at least 15 minutes while heating cylinder head ENGINE 3 Heat cylinder head in an oven or use a hot plate to bring cylinder head temperature to 212 F 100 C CAUTION Do not use a torch to heat cylinder head or warpage result from uneven heating Head temperature can be checked with a pyrometer or a welding temperature stick Wear the appropriate safety equipment for working with heated metal Follow the manufacturers instructions provided with the valve seat cutters in the Valve
288. desired by the passenger lift up on the passenger backrest loop that is face down in the cargo box Driver Seat Backrest 3 Lift the passenger backrest up and into place then lay driver seat backrest down into place 5 29 BODY STEERING SUSPENSION Driver Seat Backrest Removal Installation 1 Configure the seating for 2 UP riding With the passenger seat bottom in place remove the two screws retaining the seat bottom 2 Remove the two pivot pins holding the seat bottom to the frame and then lift up on the seat bottom to remove 3 For installation reverse the removal steps Passenger Seat Backrest Removal Installation 1 Configure the seating for 2 UP riding Lift up on the latch for the passenger backrest and lift the backrest to the full up position Lift up on the latch for the passenger seat bottom and lock it in the upright position as shown below Remove the two pivot pins holding the backrest to the frame Lift up on the backrest latch and tilt the backrest in towards the cargo box and lift up to remove it For installation reverse the removal steps CLUTCH SYSTEM CHAPTER 6 CLUTCH SYSTEM SPECIAL TOOLS AND 5 6 2 SPECIAL TOOLS actuum Sg Soe Se 6 2 COMPONENT FASTENER TORQUES hrec RR sees 6 2 PYT EXP ODED VIEWS S vids i qot
289. di ra peces edd dedo ira ae he args de 7 6 ASSEMBLY Ere ees ba BSS GAS aks wee Tes a ew 7 6 PROP SHAFT FRONT OR 7 7 REMOVAL AND 7 7 7 7 DISASSEMBIEY ia atsan 7 7 ASSEMBLE eae es Bees e 7 8 DRIVE AXLE EXPLODED 5 7 10 DRIVE SHAFTS AND PROPSHAFTS 7 10 FRONT GEARCASE CENTRALIZED HILLIARD STANDARD MODELS 7 11 EXPLODED VIEW STANDARD 7 11 OPERATION x E EE 7 12 GEARCASE REMOVAL 2214 555 ake Adda 7 12 DISASSEMBLY INSPECTION SORGE E RI de Sle ee 7 13 REASSEMBLY 7 17 SETTING RING GEAR 000 eee Rh 7 18 FRONT GEARCASE 5 7 19 GEARGASE INSTALLATION SUED OARS d VEI ewe 7 20 FRONT GEARCASE ACTIVE DESCENT CONTROL DELUXE MODELS 7 21 ADC GEARCASE EXPLODED VIEW DELUXE MODELS 7 21 OPERATION SESS ater oS
290. dition Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California Bi Have an authorized Polaris dealer perform these services 2 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Calendar Miles Km Fuel system 100 H 12M 620 Check for leaks at tank cap lines fuel valve filter 1000 pump carburetor replace lines every two years Fuel Filter 100 H 2M Radiator if applicable 2 2 2 2 2 12 1000 Replace yearly 620 1000 Inspect clean external surfaces 1000 Inspect replace as needed im 00 tease to connectors subjected to water mud et Clutches drive 100H 12 620 and driven M 1000 Inspect clean replace worn parts Front wheel 1000 L bearings 100 H 1600 Inspect replace as needed 1240 Brake fluid 200 H 2000 Change every two years opark arrestor 300 H 36M 1 Clean out 3000 m loeadustment Inspect periodically adjust when parts are replaced Inspect daily adjust as needed N O LN Auxiliary brake jHeadigntam Adjust as needed Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California Have an authorized Polaris dealer perform these services 2 6 MAINTENANCE LUBRICATION FLUID
291. drive Faulty starter drive gears or starter motor gear e Faulty flywheel gear or loose flywheel VOLTAGE DROP TEST The Voltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection will appear as a high voltage reading Voltage shown on the meter when testing connections should not exceed 1 VDC connection or component To perform the test place the meter on DC volts and place the meter leads across the connection to be tested Refer to the chart on 1 47 to perform voltage drop tests on the starter system Voltage should not exceed 1 DC volts per connection 10 44 Starter Lockout Troubleshooting EFI Models The starter lockout is controlled by the PDM Pin C on SSCB 1 of the senses the transmission signal and determines if the switch is in Neutral or Park When the conditions are met the will activate SSCB 2 Pin N to ground the starter solenoid Pin G on SSCB 2 of the PDM senses when the brake is applied and activates SSCB 2 pin N to ground the solenoid The will allow starting in Neutral or Park without the brake applied Applying the brake overrides this system and allows starting regardless of transmission shift position Items to check when diagnosing a no start condition are Transmission switch for proper function Starter solenoid for proper funct
292. e Front Gearcase Yoke Prop to Transmission Yoke Prop to T 1551 Prop Shaft oke Prop to Transmission 7 10 FINAL DRIVE FRONT GEARCASE CENTRALIZED HILLIARD STANDARD MODELS Exploded View Standard Models Description oy Description _ e Oil Seal 3 1 Input Cover Plate Asm Retaining Ring Bearing Pinion Gear Asm 3 Pinion Bushing 0 9 Magnetic Dain Plug 1 pisa Z2 me N 5 7 11 FINAL DRIVE Operation Engaging front gearcase The AWD switch may be turned on or off while the vehicle is moving AWD will not enable until the engine rpm is below 3100 RPM Once enabled the AWD remains engaged while the front gearcase is moving and will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where the front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest With the AWD switch off the vehicle drives only the rear wheels 2 wheel drive When the AWD switch is activated it engages the hilliard locking both front axles into all wheel drive when there is a loss of rear wheel traction Armature Plate
293. e and service life of PVT components Referto the troubleshooting checklist at the end of this chapter for more information 1 Drive to Driven Clutch Offset Belt Width See Clutch Alignment on page 6 14 2 Drive and Driven Clutch Rollers and Bushings Drive Clutch Shift Weights and Pins Drive Clutch Spider Rollers and Roller Pins Drive and Driven Clutch Springs See Drive Clutch Inspection on page 6 17 3 Sheave Faces Clean and inspect for wear 4 PVTSystem Sealing Refer to appropriate illustrations and photos The PVT system is air cooled by fins on the drive clutch stationary sheave The fins create a low pressure area in the crankcase casting drawing air into the system through an intake duct The opening for this intake duct is located at a high point on the vehicle location varies by model The intake duct draws fresh air through a vented cover connecting air ducts as well as the inner and outer covers must be properly sealed to ensure clean air 15 being used for cooling the PVT system This also will prevent water and other contaminants from entering the PVT area A sealed PVT is especially critical on units subjected to frequent water forging 6 7 CLUTCH SYSTEM Drive Clutch Spring T 280 FULL A r D TANUL 26 240 FORCE POUNDS ITO 200 160 FH ion d 1182 er E
294. e and slide lower control arm bushings into place securing corner housing 3 Install and torque both lower control arm bolts Upper Control Arm Bolt Torque 35 ft Ibs 48 Nm 7 34 FINAL DRIVE Removal Lower Control Arm Bolt Torque 50 ft Ibs 68 Nm 1 Remove rear hub see REAR HUB REMOVAL 2 Remove upper carrier bolt Tip hub outward and remove shaft from carrier 4 Lift bearing carrier until top aligns with upper control arm Install and torque upper control arm bolt and torque to specification 5 Pull drive shaft outward and install hub onto driveshaft splines 6 Install cone washers with domed side facing outward 7 Install retainer nut wheel and wheel nuts 8 Remove jackstand and torque axle nut and wheel nuts to specification 3 Pull sharply outward to remove shaft from transmission Install a new lock ring upon assembly Wheel Nut Torque See Torque Table on page 7 2 Hub Nut Torque 80 ft Ibs 109 Nm Lock Ring 9 Install a new cotter pin Tighten nut slightly to align holes if required 7 35 FINAL DRIVE Service 3 snap ring using a snap ring pliers or small needle nose pliers Tap CV housing off shaft with a soft faced 1 Remove clamps from rubber boot s using the CV Boot hammer while holding snap ring open Clamp Pliers PN 8700226 A CV housing 0 shaft 4 Place a new snap ring in the groove
295. e doque D odd 6 6 PVT Overheating 6 36 PVT Special Toolsi eae ees CESS 6 2 PVT Torgu Specs sus 6 2 PVT Troubleshooting Chart 6 37 PVT Button to Tower Clearance 6 17 6 30 PVT Clutch 6 14 PVT Clutch Offset 6 14 PVT Drive Belt Installation 6 13 PVT Drive Belt Removal Inspection 6 12 PVT Drive Clutch Disassembly 6 15 6 28 PVT Drive Clutch Exploded View 6 3 PVT Drive Clutch Reassembly 6 20 6 32 PVT Drive Clutch Spider Removal 6 15 6 29 PVT Driven Clutch Bushing Service 6 24 PVT Driven Clutch Disassembly 6 22 PVT Driven Clutch Reassembly 0 25 EBS Clutch Operation 6 7 PVT EBS Drive Clutch Bushing Service 6 18 6 31 PVT EBS Drive Clutch Cover Bushing Remove Install 6 19 6 32 PVT Moveable Sheave Inspection 6 18 6 31 R Radiator Cap Pressure Test 3 7 Radiator Screen Removal 5 11 Rear Cab Removal Installation 5 10 Rear Master Cylinder Exploded View 9 26 Rear Rack Removal Installation 5 8 Rear Storage Removal Insta
296. e has greater control over fuel flow Medium Large Clearance One half Full Throttle Throttle Closed Throttle Carburetor Disassembly Mikuni CV Use the following disassembly assembly and inspection techniques to service a CV carburetor 1 Remove carburetor diaphragm chamber cover with a ratchet style screwdriver DO NOT use an impact driver to remove the screws or carburetor may be permanently damaged K 2 Remove float bowl Remove the float pin screw The float 4 39 CARBURETOR SPORTSMAN 450 3 and float pin can be removed Support Here 1 LT tad Remove inlet needle seat retaining screw along with plate and carefully remove needle seat NOTE Do not use a pliers to remove the seat or permanent damage may occur 4 Remove the pilot mixture screw spring flat washer and 4 40 O Ring If an anti tamper plug is installed over the pilot screw cavity it must be removed for access O Ring Washer Spring Pilot Screw NOTE The starter jet is removable Upon disassembly place the parts in a container for safe keeping Pilot Screw Starter Jet Carburetor Cleaning A WARNING Protect eyes from contact with cleaner Take appropriate safety measures during these procedures Safety glasses and chemical resistant gloves are required Should you get cleaner in your eyes or if you swallow cleaner seek medical attention immed
297. e needle The middle to upper portion of the needle contacts the needle jet and is the most likely wear point If jet needle shows signs of wear replace both the needle and needle jet to prevent a rich condition TIP A worn needle jet is difficult to spot To check slide a slightly larger new jet needle into the needle jet and hold it to a light source Light will be visible between the needle and needle jet if it is worn Needle Jet Jet Needle Inspect this area Inspect the inlet needle tapered surface for any sign of wear or damage Be sure the spring loaded pin is free moving and returns freely when pushed The inlet needle and seat should be pressure tested after assembly Good Condition Worn Deposits Wear areas Needle Carburetor Assembly Inspect the diaphragm A for holes deterioration or damage Make sure the diaphragm is pliable but not swollen The Replace parts in proper order The spring seat B is stepped and must be placed on TOP of Clip C Spacer washer D must be installed below the E Clip Refer to parts manual for more information Be sure the tab E on outer edge of diaphragm 15 positioned properly in the carburetor body Pilot Screw Install the pilot mixture screw spring washer and O ring as an assembly Lubricate the O Ring with oil or light grease before installation CAUTION Do not damage the O ring during installation Turn the screw in until it lightly con
298. e procedures to keep from damaging the connector Damaging a connector may require wire harness replacement Worklight Connector Wires 10 40 ELECTRICAL 3 X2andSportsman Carefully pull out the red locking tab on the connector 4 X2 and Sportsman Once the red tab is pulled out press in on the black tab and pull out to disconnect harness Black Tab Red Tab Se 7 y 2 5 X2 and Sportsman Disconnect the two wire harnesses connected to each of the taillights Twist bulb housing to remove from lamp assembly and replace bulb T Install E Brake Light Switch Test 1 Remove the front cover Brake Lamp Switch Brake Switch Location Disconnect wire harness from switch 3 Connect an ohmmeter across switch contacts Reading should be infinite 00 4 Apply brake at handlebar lever and check for continuity between switch contacts Replace switch if there is no continuity or greater than 5 ohms resistance when the brake is applied with slight pressure 10 41 ELECTRICAL SPEED SENSOR FUEL SENDER Testing Testing Using the special tools listed test the speed sensor according to 1 Drain fuel tank and remove it from the tester instructions Remove sensor and inspect the o ring 2 Setthe fuel tank on a flat surface seal for damage or wear and replace as required Replacement 3 of sensor is required as it is not serviceable
299. e sai xus quo Na 1904 2 Y HOLIMS QuVzVH 5 121145 3018 11 Q 3118 11 26 1 121145 NMOWG 21150 9 10 043345 02 NOYE 99 2 121145 405835 02 JONVYO 59 OLLINSI or 2 321145 3018 11 1 y3HSV13 QUVZVH 9 3119 11 T 121145 2v18 03H 9 4 8255 9 79 gp HB 1 121145 N0113A 01 13130003345 Q 201134 6r 21145 311 110008 40151534 02 9 08 5 121145 034 3018 UIHSV14 QUVZYH 8 033 3018 8 121145 NMOWG 1 9110 3 81440 g MOUS 29 99V NM 121145 038 3018 13 4 9 038 3018 1 321145 121145 JLIHM QJY 9 19 og 08 5 321145 3119 TANVd HOIV2IQNI 9 ing OSS g NV4 9 09 121145 311 39NV3O 1981 20v AZI 9 31 1HM 39NV3O T 3 HOLIMS 213 1102 02 6G 1069 1108 7 7 sel 3015 1057 NYOH JuVg310NVH H1 8 1 32114 d HOLIMS OMY 213 02 MOUS 95 m uu 121145 01134 138 9 uVg310NVH H Q 34 038 tr 121145 y HOLIMS 213 02 1 13 E 5 121145 038 3018 q UVGIIONVH H 9 038 3018 T 1 31 00 80151538 v HOLIMS SNVUL g 39 3018 T m zs 2 0 121145 1018 2 uvgi110NVH HI 9 3118 lv J JINGOW 80151534 8 HOLIMS SNVUI 9 3018 311HM GG ER 3599 6 dd a 3 HOLIMS NOILINOI 9 N3389 N01134 OF 5350148 121145 NMOUG j MO
300. e sender out of the tank Lift the sender out at an angle so the float will more easily come out of the fuel tank Testing Refer to Chapter 10 for fuel gauge sending unit troubleshooting Sending Unit Installation 1 Reinstall the fuel sender with a new gasket using care not to bend or damage the float arm 2 Install the 5 screws and torque the screws to specification Reconnect the sender and route the harness properly sending Unit Screw Torque 18 24 in Ibs 2 3 Nm in criss cross pattern 3 Reinstall the PVT intake duct gas tank vent line front cab assembly and side panels NOTE Properly route the gas tank vent line use tape to secure the vent line in place See Pic 1 4 Reconnect the negative battery cable Test the sender for proper operation TROUBLESHOOTING FUEL STARVATION LEAN MIXTURE Symptoms Hard start or no start bog backfire popping through intake exhaust hesitation detonation low spark plug erosion engine runs hot surging high idle idle speed erratic No fuel in tank e Restricted tank vent or routed improperly Fuel lines or fuel valve restricted Fuel filter plugged Carburetor vent line s restricted Plugged or restricted inlet needle and seat screen or inlet passage Clogged jets or passages Float stuck holding inlet needle closed or inlet needle stuck Float level too low Intake air leak throttle shaft intake ducts airbox or air cl
301. e threaded rod into the crankshaft until the threads are engaged a minimum of one inch 25 4mm 2 Install the collar washer and nut onto the threaded rod Hold the crankshaft and tighten the nut to draw the crankshaft into the main bearings until fully seated Loosen the nut and remove the threaded rod from the crankshaft If removal is difficult install two nuts on the end of the threaded rod and tighten against each other 3 Install the proper shim on the magneto end of the crankshaft 4 Place the balancer shaft in the PTO crankcase aligning timing marks on the crankshaft and balancer gears Install the proper shim washer on the shaft 5 Inspect the oil pump sealing surface on the crankcase Apply a light film of engine oil to the surface and install the oil pump NOTE Do not use gasket sealer on the pump mating surfaces NOTE After engine is assembled and machine is readied for field operation oil pump MUST be primed Follow oil pump priming procedure Oil Pump Bolt Torque 6 ft Ibs 8 Nm 6 Align the drive gear with the drive pin on the pump shaft and install the gear Be sure the gear is fully seated and properly engaged 7 Install the proper shim washer on the pump shaft Assembly 1 Apply Crankcase Sealant PN 2871557 to crankcase mating surfaces Be sure the alignment pins are in place 2 Setthe crankcase in position carefully to avoid damaging
302. e to equalize in the CV boot in the position that the joint will spend most of its life Before you remove your instrument be sure the small end of the boot is in its correct location on the axle 2 Apply anti seize compound to splines of shaft 3 Install a new lock ring and install the shaft 4 Lift bearing carrier into place and install bolt to upper control arm Torque bolt to specification Install the small clamp on the boot supplied with boot service kit IF JOINT WAS CLEANED add the recommended amount of grease to the joint in addition to the grease pack supplied with boot kit Joint Capacity 50 grams Joint Capacity 50 grams Boot Capacity 30 Grams Boot Capacity 50 grams Outboard 80g Tota Inboard 100g Total 5 Install hub flat washer domed washer domed side out 30g PN AMEN a 20g PN 1350047 and nut Torque center hub nut to specification Install new cotter pin and hub cap Hub Nut Torque Inboard Joint 50g if boot 15 replaced only Another 50g 100 total if joint is cleaned 80 ft Ibs 109 Nm 7 38 FINAL DRIVE 6 Install rear wheel and torque wheel nuts to specification 80 ft Ibs 109 Nm Refer to Page 7 2 for Wheel Nut Torque 7 Grease all fittings thoroughly with Premium U Joint Lubricant PN 2871551 Drive Shaft and CV Joint Handling Tips Care should be exercised during driveshaft removal or when servicing CV joints Drivesha
303. eal Guide PN 2871699 to install the seals into the gearcases See illustration 1 to identify seals for replacement E 4 Install 2 new O rings onto the snorkel tube Apply a white lithium grease onto the O rings and threads of the snorkel tube LH Gearcase 5 Install snorkel shaft assembly into gearcase Install Cover Seals i snorkel shaft assembly in until second O ring is contacting the gearcase but is still visible Gearcase Seal 2 Reverse the disassembly procedure for the assembly of the snorkel shaft assembly 8 14 GENERAL INFORMATION 6 Install the output gear assembly Be sure to properly mesh Check the output shaft gear backlash again by feel If the snorkel shaft bevel gear with the output bevel gear n 12 MU 4 Install 4 torx screws 2 to secure output gear 8th notch assembly into place Torque screws to 8 12 ft lbs 11 17 Nm NOTICE It is important to set zero lash between the output gear and the snorkel shaft gear If there is binding or excess lash tighten or loosen the snorkel shaft until there is Zero lash Transmission Front Output Shaft Backlash Procedure and Reassembly 1 The following steps must be performed to obtain proper front output gear backlash adjustment Upon completion of Step 6 make sure the snorkel gear and output bevel ao are lightly seated or meshing so there is zero lash Do not overtighten Gears
304. eaner cover Jet needle position incorrect Incorrect pilot screw adjustment RICH MIXTURE Symptoms Fouls spark plugs black sooty exhaust smoke rough idle poor fuel economy engine runs rough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Electric choke inoperative Incorrect pilot air fuel screw adjustment Faulty inlet needle and seat Faulty inlet needle seat O Ring Float level too high Poor fuel quality old fuel Loose jets e jet needle needle jet or other carburetor parts Dirty carburetor air bleed passages or jets 4 47 CARBURETOR SPORTSMAN 450 POOR IDLE Idle Too High Idle adjusted improperly idle mixture screw damage oticky vacuum slide Throttle cable sticking improperly adjusted routed incorrectly Choke cable sticking improperly adjusted routed incorrectly Plugged or restricted idle jet Idle Too Low Choke cable bending or incorrectly adjusted Idle speed set incorrectly Idle mixture screw misadjusted or damaged Belt dragging Ignition timing incorrect Worn jet needle needle jet Plugged or restricted idle jet Erratic Idle Choke cable bending or incorrectly adjusted Throttle cable incorrectly adjusted Air leaks dirty carburetor passages pilot circuit Pilot mixture screw damaged adjusted incorrectly Tight valves Ignition timing incorrect Bel
305. ease the pressure Polaris Polaris EFI Diagnostic PU 47063 ooftware Digital Wrench Fuel Pressure ELT 43506 Test Kit Fuel Pressure mu Test Valve Kit wi 7 2201519 Throttle Position Sensor Tester 2 igi ter _ Digital Wrench icio ME es ias SmartLink Kit e Gasoline is extremely flammable and explosive Test Valve under certain conditions e EFI components are under high pressure Verify system pressure has been relieved before disassembly e Never drain the fuel system when the engine is hot Severe burns may result e Do not overfill the tank The tank is at full capacity when the fuel reaches the bottom of the filler neck Leave room for expansion of fuel e Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are oisonous and can cause loss of consciousness death in a short time Polaris EFI Diagnostic Software e Do not smoke or allow open flames or sparks in Digital Wrench PU 47063 or near the area where refueling is performed or h linn d This dealer only software installs on laptop computers equipped Tere Mta Store with CD drive and serial port connection and is designed to e f you get gasoline in your eyes or if you should replace multiple shop tools often used to test EFI components swallow gasoline seek medical attention It also includes step by step diagnostic procedures to aid immediately technician repair and tro
306. ect battery while engine is running Never use a quick start battery charger to start the engine e Always unplug ECM from the wire harness before performing any welding on 4 7 FUEL INJECTION EFI SYSTEM EXPLODED VIEW 4 8 Electronic Control Module Manifold Absolute Pressure Sensor MAP Intake Air Temperature Sensor IAT Idle Air Control Crankshaft Position Sensor CPS inside cover Fuel Injector Fuel Rail Fuel Filter s Fuel Pump Tank Assy IAC 10 Engine Coolant Temperature Sensor ECT 11 Throttle Position Sensor TPS LH side of Throttle body 12 Throttle Body FUEL INJECTION EFI SYSTEM 7 Fuel Rail Component Locations Identification 1 Electronic Control Module ECM 2 Manifold Absolute Pressure Sensor MAP 1 7 9 Fuel Pump Regulator Gauge Sender Assembly located In tank as an assembly 11 Throttle Body 12 Wire Harness Assembly 13 Engine Coolant Temperature Sensor ECT 6 Fuel Injector 4 9 FUEL INJECTION FUEL TANK Exploded View 2 lank Vent In Out ank Assembly 5 Seat Foam Lines 8 Fuel Filter Fuel Flow Fuel Tank Pos 77 Fuel Filter Pressure Regulator 30 micron Unit External Fuel Filter 10 micron Fuel Supply Rail component located in fuel tank 4 10
307. ect of FAN J2 E Fuel pump control input J2 G High side drive for vehicle lights J2 H Input from stator coil winding 2 J2 J Input from stator coil winding 3 Low side starter solenoid connection J2 P IPS to power the ignition output 10 7 ELECTRICAL CHARACTERISTIC PARAMETER UNIT Ambient temperatures at which module Operating Temperature erating Temperature 40 to 55 e should emai within specified limits Ambient temperatures which should Storage Temperature 50 to 85 have no adverse effects on module operation CHARACTERISTIC NOTE PUE Battery Voltage PDM functions will operate over this range REGULATOR Regulator Output 25 32 Ade Max total DC amperage available from regulator Battery voltage that will cause Over Voltage Threshold vee the regulator to temporarily turn off Min voltage required on RUN for Minimum Battery Voltage 2 Jove regulator to begin operation Resistance between alternator signal and ground Alternator Coil 1 Resistance o f om Only on this designated alternator signal BAT PROT OUTPUT Um 30 Current level that will cause turn off after delay Time Delay 06 Sec Time above limit until SSCB trips ECM RELAY OUTPUT Nemo 30 Amp Current level that will cause turn off after delay Overload Delay 106 Sec Time above limit until ECM Relay trips IGNITION RELAY O
308. ecting an open or shorted thermistor A thermistor fault will cause the engine hot indicator and FAN output to activate Accessory Power The PWR switch uses a smart high side power switch It is enabled when the RUN input is activated and disabled when it s removed If the output current exceeds the short circuit limit the output current will be reduced until the ACC PWR CONNECTOR 1 PIN SIGNAL NAME thermally shuts down PWR will automatically turn back on when it has cooled based on thermal recovery Once tripped this output will remain off until the key switch is cycled on and off again Lights Output The LIGHTS output uses a smart high side power switch The LIGHTS relay output is enabled when the RUN input is activated and disabled when its removed If the maximum output current threshold is exceeded the output current will be reduced until the LIGHTS circuit thermally shuts down Once tripped this output will remain off until the key switch is cycled on and off again HOT Indicator Output The HOT Indicator output uses a low side power switch smart FET that indicates when the thermistor input exceeds the values programmed in the PDM It also indicates a stalled or open fan condition The output is protected against shorts to battery over load over voltage and over temperature conditions Starter Lockout Starter Lockout monitors the brake input and transmission signal to determine if t
309. ector as it is a sealed connector Install the upper left retaining screw spacer and screws Tighten screws to 10 in Ibs 1 1 Nm ECM Service Never attempt to disassemble the ECM It is sealed to prevent damage to internal Warranty is void if case 15 opened or tampered with in any way operating and control functions within the ECM are pre set No internal servicing or readjustment may be performed If a 2 is encountered and you determine the to be aulty contact the Polaris Service Department for specific handling instructions Do not replace the ECM without factory authorization The relationship between the ECM and the throttle position sensor 5 is very critical to proper system operation If the TPS is faulty or the mounting position of the TPS is altered the TPS must be re initialized For the purpose of troubleshooting a known good ECM from a same model Polaris 500 ATV EFI may be used without system or engine component damage FUEL INJECTION FUEL PUMP ASSEMBLY Operation Testing NOTE All EFI units utilize quick connect fuel lines An electric fuel pump assembly is used to transfer fuel to the EFI system from inside the fuel tank This assembly includes the fuel pump regulator and fuel gauge sender The pump is rated for a minimum output of 25 liters per hour at 39 psi and has a non serviceable internal 30 micron filter In addition the pump has a replaceable 10 micron filte
310. ed View A Master Cylinder Bolts B Rear Brake Line C Rear Master Cylinder D Bushing s E Washer s Cotter Pin G Foot Pedal H Spring I Front Brake Line J Banjo Fitting 9 26 5 Overview Polaris disc brake systems are light weight low maintenance and perform well in the conditions ATV s routinely encounter However there are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life Perform a brake burnishing procedure after installing new pads to maximize service life Optional pads are available to suit conditions in your area Select a pad to fit riding style and environment Do not over fill the master cylinder fluid reservoir Make sure the brake lever and pedal returns freely and completely Adjust stop pin on caliper if applicable after pad service Check and adjust master cylinder reservoir fluid level after pad service Make sure atmospheric vent on reservoir is unobstructed Test for brake drag after any brake system service and investigate cause 1f brake drag is evident Make sure caliper moves freely on guide pins where applicable e Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely CAUTION Use only DOT approved brake fluid as an assembly aid for all procedures described in this chapt
311. ed and changed in accordance with the maintenance schedule To check the level 1 Besure vehicle is level before proceeding 2 Clean around fill plug area 3 Remove fill plug located on the left side of the 4 Fluid should be filled to bottom of fill plug hole threads Add the proper lubricant as required to bring level into operating range as shown s Oil Fill Level Bottom Fill Plug Hole Threads 5 Install the check plug and torque it to specification To change lubricant 1 Place a drain pan beneath the transmission oil drain plug area 2 Clean around the drain plug and remove the drain plug and wipe the magnetic end clean to remove all accumulated metallic filings A E 3 After the oil has drained completely install a new sealing washer if installed and install the drain plug Torque to specification 4 Add the proper lubricant through the fill plug hole until the oil level is to the bottom of the fill plug hole threads Do not overfill Oil Fill Level Bottom Fill Plug Hole Threads 5 Check for leaks 2 13 MAINTENANCE ADC Differential Hydraulic Circuit Fluid Change 1 Make sure vehicle is parked on flat ground and allowed to sit at least 30 minutes prior to bleeding hydraulic circuit 2 Thoroughly clean area around and on remote reservoir and bleeder valves 3 Remove reservoir cap and diaphragm assembly Make sure hyd
312. ed engine exhaust fumes are or leakage Replace if necessary poisonous and can cause loss of consciousness 2 Be sure fuel lines are routed properly the connectors and death in a short time latched and lines secured with cable ties Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored If you get gasoline in your eyes or if you should swallow gasoline seek medical attention immediately 3 f you spill gasoline on your skin or clothing immediately wash with soap and water and change NOTE See Chapter 4 for fuel line routing diagram clothing Always stop the engine and refuel outdoors or in Vent Lines a well ventilated area Keep away from open flames Check tue Wek olik k alt d fuel tank oil tank crankcase carburetor battery and electrical components when removing fuel transmission vent lines for signs of wear deterioration damage filter or leakage Replace every two years CAUTION Make sure lines are not kinked or pinched Replace all fuel lines every two years Be sure vent lines are routed properly and secured with cable e Always stop the engine and refuel outdoors orina well proper ventilated area Do not smoke or allow open flames or sparks in or near where refueling performed or where gasoline CAUTION 15 Stored e Do not overfill the tank Do not fill the tank ne
313. ed from the front of the ATV and the gas tank exposed disconnect the pump wiring harness A WARNING Wear safety goggles while performing this procedure failure to do so could result in serious injuries 6 Relieve the fuel pressure at the fuel test valve FUEL INJECTION 7 Loosen the fuel tank hose and pull the fuel line from tank NOTE A small amount of fuel may come out of the fuel line or tank Plug the fuel line and tank inlet or use a shop towel during removal Fuel Line CAUTION Check the fuel test valve for any possible fuel seepage after performing any tests or procedures Fuelis extremely flammable and may cause severe burns injury or death Do not use any device that produces a flame or electrical devices that may spark around fuel or fuel vapors 8 Remove the air box cover and remove the two gas tank mounting bolts at the rear of the gas tank Remove 9 Carefully pull the fuel tank out of the frame Keep the fuel tank horizontal during removal this will keep the fuel in the tank from spilling out the top inlet Fuel Tank Installation 1 Reinstall the tank assembly Reconnect the sender wiring harness and route the harness properly Install the fuel line s and verify they are secure 3 Reinstall the two fuel tank mounting bolts at back of tank Reinstall the PVT intake duct gas tank vent line front cab assembly and side panels NOTE Properly route the
314. een drained e CAUTION Make sure the manual start handle B is fully seated on the recoil housing especially when travelling in wet areas If it is not sealed properly water may enter the recoil housing and damage components Water will enter the recoil housing if the starter handle B is disengaged from the rope guide when under water After travelling in wet areas the recoil housing and starter should always be drained completely by removing the recoil Do not open the crankcase drain unless the engine has ingested water Some engine oil will be lost if crankcase drain is opened If recoil handle B seal has been damaged the handle should be replaced MAINTENANCE Engine Oil Level The oil tank 15 located on left side of the vehicle To check the oil level 1 Setmachine on a level surface 2 Clean the area around the dip stick 3 Start and run engine for 20 30 seconds This will return oil to its true level in the oil tank 4 Stopengine remove dipstick A and wipe dry with a clean cloth 5 Reinstall dipstick screw the dipstick into place NOTE The dipstick must be screwed completely in to ensure accurate measurement ADD 8 OZ NoRMAL FULL A Maintain Oil Level In Normal range ocrew Dipstick in completely to check 6 Remove dipstick and check to see that the oil level is in the normal range The oil should be between the top line and the bottom line on the dipstick A
315. eeze and distilled water will provide the optimum cooling corrosion protection and antifreeze protection Do not use tap water straight antifreeze or straight water in the system Tap water contains minerals and impurities which build up in the system e Straight water or antifreeze may cause the system to 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 in 105 4 Nm Radiator Grill Screen 1 Check radiator A air passages for restrictions or damage Check and clean the radiator screen B Carefully straighten any bent radiator fins 3 Remove any obstructions with compressed air or low pressure water 2 19 MAINTENANCE Cooling System Pressure Test Refer to Chapter 3 for pressure test procedure Coolant Level Inspection The recovery bottle located on the left side of the machine must be maintained between the minimum and maximum levels indicated on the recovery bottle Hecovery 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
316. eight of the clip CARBURETOR SPORTSMAN 450 Jet Needle The jet needle has five adjustment grooves cut into the upper portion and is tapered from approximately the middle of the needle to the lower end The top is fixed to the center of the throttle valve by the needle clip and the tapered end extends into the needle jet Fuel flows through the space between the needle jet and jet needle This space does not vary until the throttle reaches the 1 4 open point At that time the tapered portion of the needle begins to move out of the jet affecting fuel flow as the opening enlarges If the needle clip is changed from the standard position to a lower groove the needle taper starts coming out of the jet sooner resulting in a richer mixture Moving the clip higher produces a leaner mixture If the taper is worn due to vibration fuel flow may be significantly affected Jet Needle Position Hicher Needle Jet The needle jet works in conjunction with the jet needle to regulate fuel flow rate An air bleed opening in the side of the needle jet brings in air measured by the air jet This air initiates the mixing and atomizing process inside the needle jet Needle Jet H 1 T Main Jet NE Throttle Opening vs Fuel Flow In a full throttle condition the cross sectioned area between the jet needle and the needle jet 15 larger than the cross sectioned area of the main jet The main jet therefor
317. el Year 2007 an X2 Deluxe and Standard model were offered Use the following table as a guide X2 DELUXE MODEL Item Location X2 STANDARD MODEL Standard Model Pictured 1 5 GENERAL INFORMATION 2007 SPORTSMAN 450 Model Number A07MH46AA AZ Engine Model EH46PLE Table 1 4 Sportsman 450 General Specifications Category Dimension Capacity Length 83 in 211 cm Height 48 122 cm Wheel Base 50 5 11 128 3 cm Body Style Spirit Hitch Tongue Capacity 120 Ibs 54 4 kg Table 1 5 Sportsman 450 Compression Pressure 50 90 psi W Compression Release Oil Requirements Capacity Exhaust System Single Pipe USFS Approved Fuel System Mikuni BST 34mm Float Height 13mm 1 51 0 40 Fuel Delivery Fuel Pump Fuel Capacity Requirement 4 25 gal US 19 9 liters 87 Octane minimum or 89 Oxygenated Alternator Output 260 3000 RPM Voltage Regulator 3 phase PDM 1 50 Grill Brake Tail Worklight 2 x 37 watts 26 0 watts 8 26 watts 13 watts Indicator watt Operating RPM 6000 RPM DC CDI Ignition 30 22BTDC 5000 RPM BKR6E 035 in 0 9 mm Ignition System Ignition Timing Spark plug Gap Battery Amp Hr Maintenance Free 12 Amp Hr Circuit Protection Solid State PDM ga co ua GENERAL INFORMATION Table 1 6 Sportsman 450 Transmission Type Drumshift H L N R P Transmission Capacity 32 oz 948 m
318. el rail mounting screws doubler plate and carefully loosen pull the rail away from the injector 6 Reverse the procedures to install the new injector and reassemble Use new O rings any time an injector is removed new replacement injectors include new O rings Lubricate the upper O ring lightly with soapy water to aid installation The lower O ring should remain dry Torque the fuel rail mounting screws to 5 7 ft Ibs 6 9 Nm Then install the doubler plate and torque to 8 9 5 ft Ibs 11 13 Nm Fuel Rail Mounting Screws 5 7 ft Ibs 6 9 Nm Doubler Plate Screws 8 9 5 ft Ibs 11 13 Nm CRANKSHAFT POSITION SENSOR CPS General Information The engine speed sensor is essential to engine operation constantly monitoring the rotational speed RPM of the crankshaft Interrup CPS e Es i Y s j j ferromagnetic 36 1 ring gear 15 cast onto flywheel The inductive crankshaft sensor 15 mounted 0 4 1 2 mm 0 015 047 in away from this ring gear During rotation an AC pulse is created within the sensor for each passing tooth The tooth gap creates an interrupt input signal corresponding to specific crankshaft position for PTO cylinder This signal serves as a reference for the control of ignition timing by the ECM Crankshaft Position Sensor Air Gap 0 4 1 2 mm 0 015 047 in Within one 1 revolution at start up the ECM calcul
319. eme _ 4 Visually inspect PTFE thrustwasher for damage Measure 1 f Instructions 9915111 the thickness and compare to specification Replace if worn or damaged Shaft Diameter Standard 1 3745 1 375 Service Limit 1 3730 PTFE Washer Thickness Standard 030 76mm Service Limit 025 64mm 6 18 CLUTCH SYSTEM NOTE Bushings are installed at the factory using Drive Clutch Bushing Installation Loctite V 609 In order to remove bushings it will be necessary to apply heat evenly to the area around each bushing Clean all residual Loctite from Puller Tool Side toward sheave 1 Place main adapter Item 8 on puller bushing bore prior to installing new bushing CAUTION Clutch components will be hot In order to avoid serious burns wear insulated gloves during the removal process Drive Clutch Bushing Removal 1 Remove clutch as outlined previously in this chapter Install handle end of Piston Pin Puller PN 2870386 securely into bench vise and lightly grease puller threads 3 Remove nut from puller rod and set aside Install puller adapter Item 10 from kit PN 2871226 2 Apply Loctite 609 evenly to bushing bore inside moveable sheave 5 Install main adapter Item D onto puller ub 3 Set bushing place on sheave Puller Tool A B Nn 4 Insert installation puller tool Item A B with side CA toward p down into cente
320. er to prevent brake system contamination DO NOT USE LUBRICANTS OF ANY KIND FOR ASSEMBLY AS THEIR USE CAN CAUSE RUBBER COMPONENTS TO SWELL X2 Rear Master Cylinder Removal and Installation Put acm 1 Remove the RH footwell to gain access to the rear master cylinder 2 If required remove the rear brake line from the master cylinder Use a suitable container to catch the brake fluid Dispose of brake fluid properly Brake Fluid Reservoir a Sr Frame Brake Mount mu Spring y j _ m E Brake Lever E 3 Remove the two bolts that secure the rear master cylinder to the frame Replace parts as needed 4 To install the rear master cylinder mount the master cylinder to the frame and torque bolts to specification Master Cylinder to Frame Bolt Torque 8 ft lbs 11 Nm 5 Reinstall the brake line and torque the banjo bolt to specification Banjo Bolt Torque 15 ft lbs 21 Nm 6 Perform brake bleeding procedures as outlined in this chapter 9 27 BRAKES Sportsman Rear Master Cylinder Removal 5 Reinstall the brake line and torque the banjo bolt to Installation specification depending on the style of fitting 1 Remove the RH footwell to gain access to the rear master cylinder T 2 Remove rear brake lines from the master cylinder Use a suitable container to catch the brake fluid Dispose of Banjo Bolt Torque brake fluid properly 15 ft Ibs
321. es which should Storage Temperature 50 to 85 have no adverse effects on module operation CHARACTERISTIC Pay Battery Voltage pepe functions will operate over this range E over this range REGULATOR Regulator Output Output 18 Ade Max total DC Max total DC amperage available from regulator available from Max total DC amperage available from regulator Min voltage required on RUN for Minimum Battery Voltage O O regulator to begin operation Resistance between alternator signal and ground Alternator Coil 1 Resistance 14 7k 15 2k Only on this designated alternator signal _ PROT OUTPUT Output Current Amp Nominal Continuous output current o 9 20 Amp Current level that will cause turn off after delay Time Dela 100 150 mSec Time above limit until SSCB trips y Voltage 5 5 Vdc Min Battery voltage for BAT_PROT to remain on 8 ACC_PWR pep Dems ns Current above which the output will shut off after Initial peak short circuit current limit above which the device Peak Current Hardware EFIE will current limit then quickly shut down Power Off Delay Delay after run switch is turned off LIGHTS OUTPUT Output Current 18 Amp MAX Continuous Current p Current Limit 40 65 65 Amp Current limit above which device will shut down within thermal shutdown time Rep E Circuit 060 Current level that will cause turn off and on afte
322. esistance 3 Lubricate the mounting bracket pins with Polaris Premium Season Grease PN 2871423 and install the rubber 2 Inspect piston for nicks scratches wear or damage dust seal boots Measure diameter and replace if damaged or worn beyond service limit 3 Inspect the brake disc and pads as outlined for brake pad replacement in this section See BRAKE PAD INSPECTION earlier in this chapter 9 22 5 4 Compress mounting bracket and make sure dust 4 Remove the slide bolt snap rings A the slide pins B the seals are fully seated Install the brake pads Clean the disc bracket pad C and the brake pads D and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease Caliper 5 Remove the anvil bolts and separate caliper halves and remove pistons with piston pliers SPORTSMAN REAR CALIPER Removal and Inspection Caliper 1 Clean caliper area before removal Using a flare nut wrench remove hand brake inner and auxiliary brake outer lines arrows Place a container to catch brake fluid draining from brake lines Seal 3 Pistons amp O ring E Anvil Bolts 6 Remove seals and O rings Clean the O ring grooves 7 Clean disc caliper body and pistons with brake cleaner or alcohol 8 Remove the slide bolt bushings Inspect the bushings and O rings and replace if necessary 3 Remove the two caliper mounting bol
323. essure the use of filters and the detergent additives in the gasoline Symptoms that could be caused by dirty clogged injectors include rough idle hesitation stumble during acceleration or triggering of fault codes related to fuel delivery Injector clogging is usually caused by a buildup of deposits on the director plate restricting the flow of fuel resulting in a poor spray pattern Some contributing factors to injector clogging include dirty air filters higher than normal operating temperatures short operating intervals and dirty incorrect or poor quality fuel Cleaning of clogged injectors is not recommended they should be replaced Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem Fuel Injector Resistance Test If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem Check as follows Using an ohmmeter test for continuity by placing the test leads on each pin of the injector Resistance specification is 12 00 0 40 20 C 68 F Injector Resistance Specification 12 00 0 40 20 C 68 F Fuel Injector Replacement 1 Engine must be cool Depressurize fuel system through test valve in fuel rail Remove the front fender assembly and fuel tank 3 Thoroughly clean the area around and including the throttle body manifold and the injectors Disconnect the fuel injector harness 5 Remove the fu
324. esult Repeat this procedure 10 times Caliper Mount Bolt Torque 18 ft lbs 24 Nm 9 20 BRAKES X2 REAR CALIPER 6 Remove piston dust seals and piston seals Removal CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur 1 Clean caliper area before removal 2 Placeacontainer below the caliper to catch brake fluid that will drain from the brake line Remove brake line from caliper 4 pU f 4 T S 7 Clean the caliper body piston and retaining bracket with brake cleaner or alcohol NOTE Be sure to clean seal grooves in caliper body Clean Components 3 Remove the two caliper mounting bolts and the caliper 4 Loosen the adjuster screw and remove the brake pads 5 Remove mounting bracket pin assembly and dust boot 9 21 BRAKES Inspection Reassembly 1 Inspect caliper body for nicks scratches or wear Measure 1 Install new caliper seals A in the caliper body B Be bore size and compare to specifications Replace if damage sure groove is clean and free of residue or brakes may drag is evident or if worn beyond service limit upon assembl A 2 Coat piston with clean Polaris DOT approved Brake a n mm Fluid C Install piston D with a twisting motion while J pushing inward Piston should slide in and out of bore smoothly with light r
325. face injury Transmission Snorkel Shaft Removal 27 Remove snorkel lock screw located inside the gearcase Use a T27 hex socket or driver 28 Mark the snorkel tube and case with a white pen or marker Towards Inside This is used to ease reassembly of the gearcase of Case 25 Remove the retaining ring 6 and then washer 7 gear 8 and split bearing 9 from the reverse shaft 8 12 GENERAL INFORMATION 29 Use a 2 3 8 wrench to loosen and remove the front drive 30 If needed remove the seal from the front of the snorkel shaft snorkel tube 11 tube Remove the snap ring 12 F 3 Remove the second snap ring 13 and spacer 14 from the snorkel shaft NOTE Shim may or may not be present Depending on input shaft tolerance A O ring B Seal C Retaining Ring D Retaining Ring E Spacer F Ball Bearing G Snorkel tube H Retaining Ring Ball Bearing J Snorkel Shaft 32 To remove the snorkel shaft from the snorkel tube use a press to press the snorkel shaft out 8 13 GENERAL INFORMATION 33 To remove the remaining bearing on the snorkel shaft 15 3 Inspect the output gear assembly 1 replace bearings if remove the retaining ring and press the bearing off needed Inspect the 91T gear for nics chips or abnormal worn teeth Transmission Assembly 1 Install all new seals in the gearcases Use the Rear Output Seal Driver PN 2871698 and Rear Driveshaft S
326. ferential solenoid engagement STARTER LOCKOUT TRANS Park Limits 032 Voltage range to enable STARTER output TRANS Neutral Limits 1 83 2 53 Voltage range to enable STARTER output BRAKE Input 0 Input voltage range 10 9 ELECTRICAL Sportsman 450 Overview Power Distribution Module PDM DAD V C T A ACE AC RA Nd TT Located Inside Front Grill Cover COIL1 O 2 Y 3 Phase Regulator Regulator a Control Circuit Breaker Control Starter Low Side Temperature Switch INDICATOR Controller E High Side x7 F LEES O FAN Control Circuit The Power Distribution Module PDM integrates these electronic features found on the Sportsman 450 rectifier regulator solid state circuit breaker output starter lockout output and engine temperature controller There are no service parts in the PDM If the PDM fails it must be replaced Following are overviews of the various PDM circuits and how they function EEF Switch RELAY 20 PWR Regulator The rectifier converts the output of the 3 phase alternator COIL 1 2 3 and applies it to the battery and the PDM loads The regulator monitors the battery voltage and shuts off the rectifier when full charge exists on the battery SCR s are used to connect and disconnect the alternator from the bat
327. fied range listed at below Counter Balance Shaft End Play 008 016 02 04 cm Oil Pump Shaft End Play Adjustment 1 Make sure the pump shaft bearing is firmly seated in the Magneto side crankcase 2 Measure the distance from the magneto crankcase mating surface to the bearing using a dial caliper and a straight edge Subtract the thickness of the straightedge and record Install the gear on the oil pump and measure the width of the pump and gear Subtract this measurement from the measurement recorded in Step 2 Subtract the thickness of the existing shim from the result of Step 3 to determine if a different shim is needed See Shaft End Play Spec Oil Pump Shaft End Play 008 016 02 04 cm 3 39 ENGINE REASSEMBLY Pump Shaft Oil Seal Installation 1 Install the seal from the outside of the crankcase water pump side with the spring facing inward toward the pump shaft bearing 2 Drive or press the seal into place using a 25 mm 985 seal driver until flush with the outer edge of the seal bore 3 Lubricate the seal lip with grease 3 40 Crankshaft Counter Balance Oil Pump Installation Lubricate all bearings with clean engine oil before assembly Use the Crankshaft Water Pump Installation Kit PN 2871283 to prevent damage to the crankshaft and main bearings during installation 1 Install the crankshaft into the PTO side crankcase Screw th
328. for efficient engagement Continuous operation at the point of engagement engagement initial vehicle movement increases PVT temperatures and component wear Towing Pushing at low RPM low Use Low Range only ground speed Plowing snow dirt etc utility Use Low Range only Shift the transmission to Low Range carefully use fast aggressive throttle application to engage clutch Warning Excessive throttle may cause loss of control and vehicle overturn Stuck in mud or snow Climbing over large objects from Shift the transmission to Low Range carefully use fast aggressive throttle application to a stopped position engage clutch Warning Excessive throttle may cause loss of control and vehicle overturn Shift the transmission to neutral Using the throttle vary the engine rpm from idle to 3 4 throttle Belt slippage from water or snow Engage transmission in the lowest possible range and test for belt slippage Repeat several times ingestion into the PVT system as required During this procedure the throttle should not be held at the full position for more than 10 seconds PVT seals should be inspected for damage if repeated leaking occurs Clutch malfunction 2 of clutch components should be performed certified Polaris MSD 6 36 CLUTCH SYSTEM Problem Cause and Remedy Chart Table 6 2 Problem Cause and Remedy SITUATION POSSIBLE CAUSE REMEDY ing Replace with recommended spring Install corre
329. free of dents or gall marks Remove shift weight bolts and NOTE Remove cover spring and spider following weights instructions for drive clutch removal then proceed as follows 1 Remove moveable sheave spacer sleeve 1 and the thrust washer 2 Visually inspect the washer for damage Measure the thickness and compare to specification Replace if worn or damaged Broken Worn Good Thrust Washer Thickness Standard 030 76mm Service Limit 025 64mm 6 17 CLUTCH SYSTEM 2 Lift one way clutch 3 and thrustwasher 4 off shaft Moveable Sheave Bushing Inspection Replace as an assembly if worn damaged or if problems were noted Inspect the Teflon coating arrow on the moveable sheave bushing Inspect BOTH sheaves for signs of wear grooving or cracking De glaze surfaces with a 3M pad if needed __ 3 Inspect surface of shaft for pitting grooves or damage Measure the outside diameter and compare to specifications Replace the drive clutch assembly if shaft is worn or damaged Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replacement in this chapter Drive Clutch Bushing Service NOTE Special Tool Required EBS CLUTCH BUSHING REMOVAL AND INSTALLATION Table 6 1 Special Tools SEI A 1 main adaper 513209 Bushing Replacement Ki 2871226 _ Pixon Pin Par m
330. ft Continue rotating until the remaining portion of mechanical seal has been removed from the cases Ill 6 Pump shaft oil seal can also be replaced at this time if necessary 7 Water Pump Install Kit PN 5131135 is required to install the new mechanical seal This tool is available separately and it is also included in the Crankshaft Water Pump Seal Installation Kit PN 2871283 One Way Valve Installation Install the one way valve plunger spring and plug using a new sealing washer One Way Valve Plug Torque 16 ft Ibs 22 Nm Cam Chain Drive Sprocket Installation Install the Woodruff key drive sprocket and slotted nut Tighten the nut to the specified torque Tighten Slotted Nut Torque 35 51 ft Ibs 47 69 Nm Tensioner Blade Installation 1 Install the tensioner blade and tighten the mounting bolt to specified torque Tensioner Blade Mounting Bolt Torque 6 ft Ibs 8 Nm Piston Ring Installation NOTE Apply clean engine oil to all ring surfaces and ring lands Always check piston ring installed gap before rings are installed on piston If the piston has been in service clean any accumulated carbon from the ring grooves and oil control ring holes 1 Place the oil control ring expander in oil ring groove with the end gap facing forward The expander has no up or down marking and can be installed either way The ends should butt squarely together and must no
331. ft components are precision parts Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life The complete driveshaft and joint should be handled by getting hold of the interconnecting shaft to avoid disassembly or potential damage to the driveshaft joints Over angling of joints beyond their capacity could result in boot or joint damage Make sure surface ground areas and splines of shaft are protected during handling to avoid damage Do not allow boots to come into contact with sharp edges or hot engine and exhaust components The driveshaft is not to be used as a lever arm to position other suspension components Never use a hammer or sharp tools to remove or to install boot clamps Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned Refer to text for grease capacity of CV joints and CV joint boots 7 39 FINAL DRIVE NOTES 7 40 GENERAL INFORMATION CHAPTER 8 GENERAL INFORMATION TRANSMISSION 8 2 MOUNTING EXPLODED VIEW itte det b pcd SR ES ANE aS oc gs 8 2 TORQUE SPECIFICATIONS su 45 stc nud ard gata eee ESTE ete t 8 3 SPECIAL TOOES cire tite cn eae notru Pos ie Poster s Ges E eis d e 8 3 ge pe Ell C LT 8 3 GEAR SEMECTOR
332. g Installation 4 Measure the distance from the PTO crankcase mating surface to main bearing using dial caliper and NOTE To ease bearing installation warm the straight edge crankcase until hot to the touch Place the bearings in a freezer Install the bearings so the numbers are visible 2 Drive or press new bearings into the crankcases using the proper driver AX CAUTION Press only on outer race of bearing to prevent bearing damage 70 mm 2 755 driver For crankshaft main bearings e 46 mm 1 810 For counter balancer bearings 5 28 mm 1 100 For pump shaft bearing measurement obtained in Step 2 and record End Play Inspection Adjustment Before reassembling the crankcase the following steps should be performed to determine the amount of crankshaft counter balancer shaft and pump shaft end play Excessive end play ma cause engine noise at idle and slow speeds Too little play will load bearings which may lead to premature bearing ailure Crankshaft End Play Adjustment 3 Make sure all bearings are firmly seated in the both Mag and PTO crankcase PTO Case Depth 3 37 6 Measure distance from Magneto mating 10 Subtract the Crankshaft Width measured in Step 7 from the surface to the main bearing using the same method and Total Case Width recorded in Step 6 and record below record Total End Play 11
333. g bolt 3 Apply starter drive grease to the cam lobes and cam follower surfaces 4 Rotate the engine until the cam lobes are pointing downward 5 Be sure the dowel pins are in place and install the rocker shaft assembly 6 Applya light film of engine oil to the threads of the bolts and tighten evenly Rocker Shaft Support Tower Bolt Torque 9 ft Ibs 12 Nm Rocker Shaft Locating Bolt Torque 6 ft 155 8 Nm 7 Adjust valves according to the valve adjustment procedure found in Chapter 2 Maintenance 8 Apply clean engine oil liberally to the valve springs cam chain rocker arms and camshaft 9 Place a new rocker cover gasket the cylinder head and 3 50 install the cover and bolts Rocker Cover Bolt Torque 6 ft Ibs 8 Nm Thermostat Installation Install the thermostat with one of the air bleed holes next to the upper thermostat cover hole as shown Cil Pipes Install the oil pipes with new sealing washers Tighten all bolts evenly to specified torque Cil Pipe Bolt Torque 20 ft Ibs 27 Nm RECOIL 5 Inspect plate for wear or damage Inspect plate friction spring for wear damage and proper tension The spring Recoil Disassembly Inspection should fit tightly on friction plate CAUTION The recoil is under spring tension A face shield and eye protection is required during this procedure Replace any parts found to
334. g replacement Table 6 1 Primary Clutch Springs Table 6 2 Secondary Clutch Springs PART DESCRIPTION CLUTCH SYSTEM Optional Shift Weights Shown below are optional shift weights which may be used in the PVT system These shift weights have many different factors designed into them for controlling engagement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough understanding the effects they have on belt to sheave clearance clutch balance engagement and shifting characteristics PN NLA PN 5630279 PN NLA PN 5630509 50 gr 43 gr 53 gr 55 PN 5630709 5630710 44 gr 47gr PN 5631214 5631215 PN 5631216 PN 5631698 PN 5631700 94 gr 56 gr 58 gr 60 gr 62 gr 6 9 CLUTCH SYSTEM PVT Drying IMPORTANT If operating the ATV through water be sure to check the PVT cover and other components for water ingestion The ATV should be checked immediately Refer to Owner s Manual for Safe Riding Tips PVT Drain Plug To drain any water that may be trapped inside the PVT cover simply remove the PVT drain plug and O ring located on the bottom of the PVT cover and let the water drain out The drain plug is shown below To further expel water in the PVT cover and to dry out the system shift the transmission to neutral and rev engine slightly to expel the moisture This will also air dry the belt and clutches
335. ge hold in the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set KM z Kilometers EFI Diagnostic Mode NOTE The EFI diagnostic mode is intended to quickly view fault codes stored in the EFI module Polaris dealers are equipped with the proper diagnostic tools to further diagnose the blink codes To recall blink codes fail codes from the ECM 1 Verify the ATV key switch is off and the transmission is in park 2 Turn the key switch ON and OFF 3 times within 5 seconds and leave the key switch in the ON position on the third 3 The word Wait will appear the ECM is now searching for blink codes READ AND RECORD THE NUMBER OF FLASHES OF THE Check Engine LIGHT Codes 12 and 61 indicate the beginning and end of the check sequence NOTE The check engine icon mil will flash the codes during this mode Record the flash sequences POLARIS 71 7 71 Tach Trip Odo 4 The word End will display after all of the codes have been displayed Bog 10 17 ELECTRICAL Speedometer Removal 1 Remove the three screws that secure the headlight pod cover and disconnect the wire connectors from the instrument cluster 2 Push the instrument cluster out from backside of pod while securely holding the pod xe Instrument Bezel Rubber Mount
336. ge may result if the camshaft is not properly timed to the crankshaft 3 45 IMPORTANT CAMSHAFT TIMING NOTE In order to 4 Loop cam chain on cam sprocket with the dots time the camshaft to the crankshaft the piston must be the sprocket facing outward and the alignment pin notch facing directly upward precisely located at Top Dead Center TDC Camshaft Timing 5 Before positioning the EE on the camshaft check the TY position of the cam sprocket alignment pin When the cam 2871460 to the camshaft main journals and cam lobes is positioned properly the cam sprocket alignment pin A Lubricate automatic compression release mechanism with is directly in line with the crankshaft camshaft centerline clean engine oil B 2 Install the camshaft with the lobes facing downward and the sprocket alignment pin facing upward 1 Apply Polaris Premium Starter Drive Grease PN 3 Disconnect the wire from the cam chain and rotate the engine to align the single TDC timing mark Top Dead Center on the flywheel with the notch in the timing m inspection window Be sure to use the single TDC mark AR Sey when installing the cam Do not use the advance marks See Set illustration Single TDC Mark Aligned ie ap 3 46 6 10 Install sprocket on camshaft Apply Loctite 242 PN 2871949 to the cam sprocket bolts and torque to s
337. gularities reinforced areas YE a 3 Tap lightly on balancer gear with a brass drift through the hole in the crankcase if necessary to ensure the balancer shaft stays in the PTO side crankcase Watch the gap along the crankcase mating surface and separate the crankcase evenly It may also be necessary to tap the oil pump shaft lightly to separate the crankcase A CAUTION Do not strike the oil pump shaft at an angle or the shaft may bend causing irreparable damage Tap only ightly on the pump shaft if necessary 4 Remove the Mag RH crankcase from the PTO case 6 Remove the three screws and strainer screen from pump 7 Clean screen thoroughly Pump Removal Inspection 6 Remove pump body screw and feed chamber cover 1 Remove pump shaft bearing A and thrust washer from pump shaft 2 Remove 2 bolts holding pump drive gear C 3 33 9 Measure pump end clearance using feeler gauge and straight edge Pump End Clearance Std 001 003 0254 0762 mm Wear Limit 004 1016 mm 10 Measure clearance between outer feed rotor and pump body with a feeler gauge Rotor Tip Clearance Std 005 127 mm Wear Limit 008 2032 mm 11 Measure rotor tip clearance with a feeler gauge 12 Remove inner and outer feed rotor and pump chamber body 13 Repeat measurements for scavenge rotor 14 Remove inner and outer scavenge rotor and inspect
338. he STARTER output FET will enable a ground path for the starter solenoid The output is enabled if either the BRAKE input is high or the TRANS signal voltage indicates PARK or NEUTRAL TRANS voltage is based on a 5Vdc power supply with a 220 ohm with 24 ohm for park and 160 ohm for neutral RUN input must be enabled for the starter lockout to function This output is overload and short circuit protected by the BAT PROT output on the high side Reverse Polarity Protection The reverse polarity protection circuit is in series with the battery positive input of the PDM It allows forward current to flow with little voltage drop When the battery terminals are connected in reverse the protection switch is forced off interrupting any current flow other than 2mA of bias current DESCRIPTION Ips Intelligent Power Switch starter output provides ground path when active Brake input for starter lockout Active high J1 C RUN PDM enable input Connected to BAT_PROT via ignition and run J1 D Engine hot signal Provides a ground path for the hot indicator lamp J1 J COIL 3 Alternator coil input JI K COIL 2 Alternator coil input COIL 1 Alternator coil input w resistance to ground GND 10 11 ELECTRICAL CHARACTERISTIC PARAMETER UNIT NOTE Ambient temperatures at which module Operating Temperature erating Temperature 40 to 55 should within specified limits Ambient temperatur
339. he engine of an ATV in the event of a mechanical problem with the throttle mechanism The ETC switch is mounted independently of the throttle actuator lever inside the throttle block assembly This is a normally closed switch and is held in the open position contacts are separated as shown below by throttle cable tension The contacts are open during normal operation regardless of throttle lever position In the event of a mechanical problem in the throttle mechanism cable tension is lost the switch contacts close connecting the black wire to ground which prevents ignition spark This is the same as turning the key or engine stop switch OFF NOTE Test the ETC switch at the harness connector ETC will not activate unless there is throttle plate movement off of zero detected by the ECM Adjust throttle cable freeplay ETC switch and make sure throttle mechanism is functioning properly before testing the switch Refer to Maintenance Chapter 2 for cable adjustment procedure ETC Test 1 Remove throttle block cover by carefully releasing all tabs around edge of cover Place transmission in neutral and apply parking brake 3 Start engine and open throttle lever slightly until engine RPM is just above idle speed 4 Hold throttle cable with fingers at point as shown below and release throttle lever If the ETC system is functioning properly the engine will lose spark and stop Electronic Throttle Control
340. he issue causing the overload is not removed Engine Temperature Controller The engine temperature controller has several features and two outputs HOT INDICATOR and FAN The engine hot output is low and sinks the indicator signal to ground The fan output is active high and sources battery power to turn on the fan The controller s primary function is to control the fan motor The fan motor is turned on and off at pre set resistances as determined by the engine temperature thermistor The FAN output is protected against short circuit and overload If the fan current exceeds the overload limit longer than the time allowed for inrush the fan will shut off and the HOT INDICATOR will turn on After a delay the FAN output will then reset itself and turn on again If the overload persists the controller will cycle the FAN output on and off at set interval until the overload is removed If the maximum temperature of the switching device is exceeded the fan output will turn off The fan will cycle on and off as previously described until the device temperature drops The FAN output driver also monitors to see if the fan is connected during ON state only If the FAN output is open circuit upon power up the engine temperature controller will activate the hot indicator If the engine temperature exceeds the engine hot thermistor limit or detects a fan overload condition the hot indicator will activate The controller also contains provisions for det
341. hing bore in cover Working from inside of cover insert new bushing and bushing installation tool into center of clutch cover 3 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 4 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 5 Turn clutch cover counterclockwise on puller rod until bushing is seated 6 Remove nut from puller rod Take installation tool and clutch cover off rod 6 32 Drive Clutch Reassembly NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly The Teflon bushings are self lubricating Do not apply oil or grease to the bushings Reassemble drive clutch in the following sequence Be sure the X or the marks that were made earlier are aligned during each phase of assembly A X7 or the marks that were made earlier on cover on spider making sure spacer washers are installed underneath spider and positioned properly in recess C X7 or the marks that were made earlier under weight 1 Install moveable sheave onto fixed sheave Install spider spacers Use same quantity and thickness as were removed 3 Compress spider buttons for each tower and install spider towers on the moveable sheave Verify that the alignment marks on spider align with the marks that were made on the moveable sheave 4 Torque spider to specificatio
342. iately Carburetor cleaners can be extremely caustic Extended periods of soaking can loosen the adhesive sealer on the passage drill way plugs Do not soak rubber or plastic components such as the vacuum slide diaphragm needle seat screen or O Rings in caustic cleaning solutions Damage may occur Do not use agitator type carburetor cleaning equipment Rubber parts must be cleaned with mild detergent and hot water only Thoroughly clean the carburetor body jets and all passages with carburetor cleaner or electrical contact cleaner If the carburetor is extremely dirty or contaminated with fuel residue and varnish soak for short periods only in carburetor cleaner and rinse in hot water Replace the jets if they have a buildup of fuel residue or bacterial growth that cannot be removed Even a small amount of residue will reduce the flow characteristics of the jet Verify all passages and jets are unobstructed by spraying electrical contact cleaner through the passages CAUTION Do not use wire or welding tip cleaners as the orifice size may be altered Use low pressure air to dry carburetor body and all components CARBURETOR SPORTSMAN 450 diaphragm should fit properly in the carburetor body Replace Carburetor Inspection pro diaphragm assembly if diaphragm is damaged 1 Inspect jet needle and needle jet for wear Look for discoloration shiny spots or an area that looks different than the rest of th
343. ide pins and remove the brake pads from the caliper 4 we ub o 2 ow 3 Loosen the slide pins with a hex wrench Clean the caliper with brake cleaner or alcohol 8 Measure the thickness of the pad material Replace pads 1f worn beyond the service limit Measure m Thickness lt 2 Er 1 lt lt 5 In mm Hear Brake Pad Thickness Service Limit 180 4 6 mm 9 19 BRAKES Sportsman Rear Pad Installation 4 Install the slide bolt snap ring Torque the slide pin to specification 1 Install new brake pads in caliper body Install Pads WARNING If the brake pads are contaminated with grease oil or liquid soaked do not use the pads use only new clean pads 5 Slowly pump the brake lever until pressure has been built Install and tighten the slide pin with a hex wrench up Maintain at least 1 2 12 7 mm of brake fluid in the 3 Install caliper and torque the mounting bolts to reservoir to prevent air from entering the master cylinder specification 6 It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Brake Burnishing Procedure Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Allow pads and disc to cool sufficiently during the procedure Do not allow pads or disc to become hot or warping may r
344. ight Taillight Brakelight check operation of all indicator lights and switches Engine stop switch check for proper function Wheels check for loose wheel nuts and axle nuts check to be sure axle nuts are secured by cotter pins Air cleaner element check for dirt or water clean or replace Steering check for free operation noting any unusual looseness in any area Loose parts visually inspect vehicle for any damaged or loose nuts bolts or fasteners Engine coolant check for proper level at the recovery bottle ADC Fluid Level check for proper level MAINTENANCE Lubrication Components 1 Engine Oil 2 Transmission Fluid 4 Rear Gearcase oy 2 3 Front Gearcase ape Gearease F ia Fluid Reservoir 11 OEA 8 p 5 Brake Fluid Cs Change after Ist month months or 100 after Ist month 6 months or 100 7 Paine Oil Polaris OW 40 Check dipstick and add to hours thereafter Change more often 25 50 proper level hours in extremely dirty conditions or short trip cold weather operation 2 Transmission Add lube to bottom fill hole Change annually Gearcase Lube B Front Gearcase e LI Drain completely Add lube to Gearcase Change annually ADC Fluid Polaris ADC Hydraulic specified quantity ADC Change fluid every 2 years spem ATV Angle Drive Fluid Change annually specified quantity Brake Fluid Polaris Dot
345. il it comes free Lift sheave off puller 10 Remove nut from puller rod and set aside 11 Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard 6 31 CLUTCH SYSTEM Drive Clutch Bushing Installation 1 Place main adapter on puller Apply Loctite 609 evenly to bushing bore inside moveable sheave 3 Set bushing in place on sheave Insert installation puller tool into center of bushing 5 With towers pointing upward slide sheave bushing and tool onto puller rod 6 Install nut on puller rod and hand tighten Turn barrel to apply additional tension if needed 7 Turn sheave counterclockwise making sure bushing 15 drawn straight into bore Continue until bushing is seated 8 Remove nut from puller rod and set aside 9 Remove sheave from puller 10 Remove installation tool Cover Bushing Removal 1 Install main adapter on puller Install adapter reducer 3 From outside of clutch cover insert removal tool into cover bushing With inside of cover toward vise slide cover onto puller 5 Install nut onto puller rod and hand tighten Turn puller barrel to increase tension as needed 6 Turn clutch cover counterclockwise on puller rod until bushing 15 removed and cover comes free 7 Remove nut from puller rod and set aside 8 Remove bushing and bushing removal tool from puller Discard bushing Cover Bushing Installation 1 Apply Loctite 609 evenly to bus
346. ing C 7Z gt F a 4 TP el 1 CA RAE ES gt p Ne E 5 t Vae 3 Remove the inner spring retainer F from the inner sheave X and inspect for signs of wear 6 34 CLUTCH SYSTEM 4 Inspect the rollers in the stationary sheave for signs of wear Assembly 1 Install inner spring retainer 1f removed 2 Install the inner sheave onto the outer sheave NOTE Verify X marks on each side of sheaves are aligned upon reassembly of sheaves NOTE Rollers and helix are non serviceable items Replacement of clutch assembly is required if damaged beyond usable condition 5 Inspect the bushings inside the moveable sheave If replacement is required use Bushing Removal Kit PN 2871226 following the instructions 3 Install the compression spring Install the outer retainer on top of spring Using special tool PN 8700220 compress the outer retainer onto the shaft and install the snap ring CAUTION Wear eye protection when working with spring tensioned components to avoid serious injury Sheave Bushing Inspection Replace bushing if more brass than Teflon is visible on the bushing Do not clean bushings 6 35 CLUTCH SYSTEM TROUBLESHOOTING Overheating General Range Operation Guidelines LOW RANGE Heavy pulling basic operational speeds less IMPORTANT During routine maintenance MPH riding th
347. ing as well as the component for partial shorts to ground to eliminate the draw Current Draw Inspection key off Current Draw Key Off Maximum of 01 DCA 10 mA Break Even Test Do not connect or disconnect the battery cable or ammeter with the engine running Damage will occur to electrical components The break even point of the charging system is the point at which the alternator overcomes all system loads lights etc and begins to charge the battery Depending on battery condition and system load the break even point may vary slightly The battery should be fully charged before performing this test Never start the engine with an ammeter connected in series Damage to the meter or meter fuse will result Do not run test for extended period of time Do not run test with high amperage accessories 10 32 Connect a tachometer to the engine Using an inductive amperage metering device set to DC amps connect to the negative battery cable 3 With engine off and the key kill switch and lights in the ON position the ammeter should read negative amps battery discharge Reverse meter lead if a positive reading is indicated Ne 4 Shift transmission into Park and start the engine With the engine running at idle observe meter readings 5 Increase engine RPM while observing ammeter and tachometer 6 Note RPM at which the battery starts to charge ammeter indication 15 positive 7 With ligh
348. ings which directs the fuel into the intake port in a cone shaped spray pattern The injector is opened and closed once every other crankshaft revolution The total amount of fuel needed for one firing is injected during each opening The amount of fuel injected is controlled by the ECM and determined by the length of time the valve needle is held open also referred to as the injection duration or pulse width It may vary in length from 1 5 8 milliseconds depending on the speed and load requirements of the engine Fuel Injector Service Injector problems typically fall into three general categories electrical dirty clogged or leakage An electrical problem usually causes the injector to stop functioning NOTE Do not apply voltage directly to the fuel injector s Excessive voltage will burn out the injector s Do not ground the injector with the ignition on Injector will open turn on if relay is energized If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem Check as follows Injector leakage is very unlikely but in rare instances it can be internal past the tip of the valve needle or external weeping around the injector body The loss of system pressure from the leakage can cause hot restart problems and longer cranking times FUEL INJECTION Injector problems due to dirt or clogging are unlikely due to the design of the injectors the high fuel pr
349. ion Brake switch for proper function Wire harness loose connections pins including the PDM leading to and from these components Proper ground to frame Should all these items be found in working order the PDM may be at fault Starter Lockout Troubleshooting Sportsman 450 The starter lockout is controlled by the PDM Pin G on SSCB 1 of the senses the transmission signal and determines if the switch is in Neutral or Park When the conditions are met the PDM will activate Pin A to ground the starter solenoid Pin H on SSCB 1 ofthe PDM senses when the brake is applied and activates to ground the starter solenoid The PDM will allow starting in Neutral or Park without the brake applied Applying the brake overrides this system and allows starting regardless of transmission shift position Items to check when diagnosing a no start condition are Transmission switch for proper function Starter solenoid for proper function Brake switch for proper function Wire harness loose connections pins including the PDM leading to and from these components Proper ground to frame Should all these items be found in working order the PDM may be at fault ELECTRICAL Starter Lockout Diagram EFI i i 1 SSCB HE TOU af 5 F td En f mF E i 6
350. ip valve spring and retainer in clean engine oil and install spring with closely spaced coils toward the cylinder head 7 2 6 Place retainer on springs and install valve spring compressor Compress spring only enough to allow split keeper installation and prevent loss of spring tension Install split keepers with the gap even on both sides 7 Repeat procedure for remaining valve 8 When all valves are installed tap lightly with soft faced hammer on the end of the valves to seat the split keepers 3 26 Valve Sealing Test 1 Clean and dry the combustion chamber area Pour a small amount of clean high flash point solvent into the intake port and check for leakage around each intake valve The valve seats should hold fluid with no seepage 3 Repeat for exhaust valves by pouring fluid into exhaust port Valve Clearance Adjustment e NOTE The valves share a common rocker arm and must be adjusted using two feeler gauges 1 Insert 006 feeler gauge s between end of exhaust valve stem and adjuster screw s 2 Loosen locknut s and turn adjuster screw s until there is a slight drag on feeler gauge s The Valve Clutch Adjuster Tool PA 44689 can be used to adjust the 500 engines valves NOTE Both feeler gauges should remain inserted during adjustment of each valve VALVE CLEARANCE 006 15 mm 3 When clearance 15 correct hold adjuster screw and tighten locknut securely 4 Re check the valve clea
351. ips screw B nstall key switch choke cable and headlight Lift top half of pod Connect 12Vdc power outlet where applicable Disconnect instrument cluster wire connectors Connect headlight Disconnect work light switch connector Connect instrument cluster connectors to instrument Disconnect 12Vdc power plug G cluster Disconnect headlight harness Install top of pod onto bottom half making sure interlocking tabs mate properly Remove ignition switch C and choke cable D nstall two side Phillips screws Remove headlight F with adjuster nstall one rear Phillips screw Remove two screws securing bottom half of pod E To adjust headlight refer to procedure outlined in Chapter 2 5 15 BODY STEERING SUSPENSION STEERING Handlebar Block Installation Procedure Clean knurling when repositioning handlebars afe NN E Ac 1 The pin A on the bottom side of the top handlebar block faces down and to the front of ATV 2 The bottom handle bar block has a side with 3 holes the side with 3 holes faces up and to the front of the 3 Align the pin A in the top block with the middle hole B in the bottom block for proper installation The pin and middle hole B should face the front of the 4 Install the pin side bolts first and evenly tighten bolts down Evenly torque the 2 front bolts to specification Handle Bar Bolt Torque 11 13 ft lbs
352. is the brain or central processing computer of the entire EFI fuel ignition management system During operation sensors continuously gather data which is relayed through the wiring harness to input circuits within the ECM Signals to the ECM include ignition on off crankshaft position and speed RPM throttle position engine coolant temperature air temperature intake manifold air pressure and battery voltage The ECM compares the input signals to the programmed maps in its memory and determines the appropriate fuel and spark requirements for the immediate operating conditions The ECM then sends output signals to set the injector duration and ignition ming During operation the ECM continually performs a diagnostic check of itself each of the sensors and system performance If a fault 1s detected the ECM turns on the Malfunction Indicator Light MIL Check Engine Light on the speedometer and stores the fault code in its fault memory A technician access the stored fault codes manually using a blink code diagnosis flashed out through the instrument a or using the Digital Wrench Diagnostic Software The ECM requires a minimum of 7 0 volts to operate The memory in the ECM is operational the moment the battery cables are connected Depending on the significance or severity of the fault normal operation may continue or a Fail Safe operation may be initiated In the event a Fail Safe mode occurs a base fueling
353. it 1 Remove rec 6 Inspect gear teeth on starter drive Replace starter drive if gear teeth are cracked worn or broken Flywheel Stator Removal Inspection 1 Remove flywheel nut and washer 2 Install Flywheel Puller PN 2871043 and remove flywheel CAUTION 257 25 Do thread the puller bolts into the flywheel more 2 Remove starter drive assembly Note the thrust washer than 1 4 or stator coils may be damaged located at the rear of the drive mechanism 3 Inspect the thrust washer for wear or damage and replace 3 Mark or note position of stator plate on crankcase if necessary 4 Remove bolts and carefully remove stator assembly being careful not to damage crankshaft bushing on stator plate 5 Replace crankshaft seal A Std Bushing ID 4735 4740 11 11 12 04 mm Std Shaft OD 470 472 11 93 11 99 mm Starter Drive Bushing Clearance Std 0015 004 038 102 mm Service Limit 008 203 mm 4 Measure the OD of the starter drive shaft on both ends and record 3 31 7 Remove large sealing O Ring from outer edge of stator section of chain Replace if worn past service limit plate Chain Service Limit 5 407 13 7 cm 4 Using the special socket remove the crankshaft slotted nut NOTE The crankshaft slotted nut is a left hand thread 5 Remove cam chain drive sprocket and woodruff key from crankshaft 6 Inspec
354. ition are e Stronger more consistent spark at low rpm for better performance Easier starts Fault detection by the ECM EFT NOTE Do not remove wiring harness while the key switch is on or while the engine is running Damage to electronic components may occur SPORTSMAN 500 500 X2 EFI 4 e SPORTSMAN 450 10 28 ELECTRICAL Components of EFI Alternator and DC CDI Ignition System Refer To Wiring Diagrams For Specified Resistance Hegulator Rectifier and 12vdc power supply to coil Coll operation controlled by ECM Resistor Cap Ignition Stator Connector and Harness Crank Position Sensor and Harness Crank Position Sensor Interrupt signal missing tooth Battery Charging Coils Flywheel 10 29 ELECTRICAL EFI Ignition System Testing Flow Chart Whenever troubleshooting an electrical problem first check all connections to be sure the pins are not damaged or loose backed out that the connectors are clean and fit together tight Also be sure that colors match when wires are connected Use the following as a guide for troubleshooting Condition No Spark or intermittent spark Replace Spark Plug Disconnect the black wire at the ignition switch to isolate the the kill and ETC system n s n Verify the system has a good ground L Yes switch speed limiter circuit and re lated wiring for shorts to ground
355. ize ID Inner Diameter OD Outer Diameter Mag Magneto Side PTO Power Take Off 3 5 GENERAL ENGINE SERVICE Cooling System Specifications Sensor 18 5 ft Ibs Piston Identification The piston may have an identification mark or the piston may not have an identification mark for piston placement If the piston has an identification mark follow the directions for piston placement below If the piston does not have an identification mark the direction for placement of the piston does not matter Note the directional and identification marks when viewing the pistons from the top The letter 4 gt must always be toward the flywheel side of the engine The other numbers are used for identification as to diameter length and design Four stroke engine rings are rectangular profile See text for oil control ring upper rail installation Use the information below to identify pistons and rings Engine Oversize Piston Standard Model No Available mm Length Piston THERMISTOR READING DURING OPERATION Identification EH50PLE 25 72 mm C Condition Approx Temperature Min Max 373 392k0 68 20 C 50 EHA2PLE 25 66 mm 50 oystem 2 25 Quarts Pistons and rings marked 25 equal 25mm 010 oversized 2 may Pistons and rings marked 50 equal 50mm 020 oversized Radiator Cap Relief 13 PSI 89 6 kpa Pressure 3 6
356. l Front Gearcase Capacity 8 97 265 ml Gear Ratio Low Rev High Front Drive A arm MacPherson Strut 8 2 in 20 8 cm Rear Suspension Shock Progressive Rate Independent w 2 Coil over shock 9 5 in 24 13 cm 11 in 27 94 cm Ground Clearance Shock Preload Adjustment Front Non Adjustable Front Rear Rear Ratchet Style Std Turning Radius 65 in 165 10 cm unloaded Wheel Tire Size Pattern Rear Recommended Air Pressure Front amp Rear 5 psi Table 1 7 Sportsman 450 Jetting AMBIENT TEMPERATURE Altitude Below 40 F 40 to 80 Below 5 5 to 28 C Meters 0 1800 1800 3700 Table 1 8 Sportsman 450 Clutching Shift Driven 0 1800 10WH BluGrey Black 407 0 6000 5630710 7042202 7041782 2 2 Meters 5131446 Feet 1800 3700 20 40 Blu Grey Black 2 2 2 6000 12000 5631356 7042202 7041782 21 5131446 1 GENERAL INFORMATION 2007 SPORTSMAN 500 EFI Model Number A07MH50AX AY AZ AQ AO7MN50AL AF AO7MH50FC Standard Models Deluxe Models International Engine Model 5 Table 1 9 Sportsman 500 General Specifications Category Dimension Capacity Height 48 in 122 cm 11 25 in 28 6 cm Body Style Spirit Hitch Tongue Capacity 120 Ibs 54 4 kg 1 8 GENERAL INFORMATION Table 1 10 Sportsman 500 EFI Table 1 11 Sportsman 500 EFI Drumshift H L N R P 32 oz 948 ml 8
357. l air has been purged Add fluid as necessary to maintain level in reservoir If changing fluid remove old fluid from reservoir with a A CAUTION Mity Vac pump PN 2870975 or similar tool we 4 Maintain least 1 2 1 27 cm of brake fluid in the reservoir to prevent air from entering the master cylinder Fill Line 9 Tighten bleeder screw securely and remove bleeder hose Torque the bleeder screw to specification Bleeder Screw Torque 25 30 in Ibs 2 80 3 40 Nm 10 Repeat procedure Steps 5 9 for the remaining caliper s Begin bleeding procedure with the caliper that is farthest from the master cylinder Install a box end wrench on caliper bleeder screw Attach a clean clear hose to fitting and place the other end in a clean container Be sure the hose fits tightly on fitting 11 Add Polaris DOT approved Brake Fluid to MAX level inside reservoir NOTE Fluid may be forced from supply port B when brake lever is pumped Place diaphragm C in reservoir to prevent spills Do not install cover See Illustration above 9 8 5 12 Install diaphragm sight glass cap and screws 15 Field test machine at low speed before putting into service Check for proper braking action and lever reserve With lever firmly applied lever reserve should be no less than 1 2 1 3 cm from handlebar 16 Check brake system for fluid leaks and inspect all hoses and lines for wear o
358. l nuts and wheel po Oy Remove rear brake caliper and safely suspend caliper from the frame with a piece of wire 7 32 FINAL DRIVE 11 Remove both lower control arm bolts 2 From the back side tap on the outer bearing race with a drift punch in the reliefs as shown or press out using a hydraulic press 12 Remove bearing carrier NOTE Drive bearing out evenly by tapping on outer Disassembly race only Once bearing is at bottom of casting support casting on outer edges so bearing can be 1 Remove outer snap ring removed 3 Inspect bearing NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 4 Inspect bearing housing for wear or damage Replace housing if damaged 7 33 FINAL DRIVE Assembly 3 Press bearing into place until outer race bottoms on housing 1 Support bottom of bearing carrier housing 2 Start bearing in housing CAUTION Use an arbor press only on the outer race to avoid bearing damage 4 Install snap ring into groove Installation Insert bearing carrier on drive shaft 2 Align bottom of carrier housing and lower control arm Greas
359. l or brake Bag cleaner install new belt Replace belt Driven clutch binding Harsh drive clutch engagement Perform belt sheave clearance adjustment with shim washers beneath spider Drive belt turns over Belt slippage due to water oil grease etc rubbing on cover Seal PVT system ducts Clutches or weight being applied to cover while in operation I sees ES Qj S Oj 9 OQ lt x 2 Q B o O EA z 5 xj A 5 2 le 0 9 Sle G Oj SES lt Su E 2 ees a Ee 2 qe Bs O EI 5 PVT cover overheating melting Remove weight Inform operator Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance leaking Find leak and repair as necessary Instruct operator on guidelines for operation in wet Water Ingestion terrain as outlined in Owner s Safety and Maintenance Replace belt Inspect and seal PVT system Belt contaminated with oil or grease Inspect and clean 6 37 Belt Slipping ot C dE A MESE me xm ER E E el x quU S 3 101 ga 5 ga 5 5 3 aol Sj S lt c gt CLUTCH SYSTEM Tab
360. l will not pass through fuel valve Fuel pump inoperative restricted Tank vent plugged Carb starter circuit Engine flooded Low compression high cylinder leakage No spark Spark plug fouled Engine Does Not Turn Over Dead battery Starter motor does not turn e Engine seized rusted or mechanical failure Engine Runs But Will Not Idle Restricted carburetor pilot system Carburetor misadjusted Choke not adjusted properly Low compression Crankcase breather restricted Engine Idles But Will Not Rev Up Spark plug fouled weak spark Broken throttle cable Obstruction in air intake Air box removed reinstall all intake components Incorrect or restricted carburetor jetting ETC switch limiting speed Reverse speed limiter limiting speed Carburetor vacuum slide damaged Incorrect ignition timing Restricted exhaust system sticking diaphragm 3 53 Engine Has Low Power Spark plug fouled Cylinder piston ring or valve wear or damage check compression PVT not operating properly Restricted exhaust muffler e Carburetor slide damaged vacuum sticking diaphragm Dirty carburetor Piston Failure Scoring Lack of lubrication Dirt entering engine through cracks in air filter or ducts Engine oil dirty or contaminated Excessive Smoke and Carbon Buildup Excessive piston to cylinder clearance e Wet sumping e Worn rings piston or cylinder e Worn
361. le 6 2 Problem Cause and Remedy Abuse continued throttle application when Caution operator to operate machine within vehicle is stationary excess load guidelines Belt burnt thin spots Vehicle operated with park brake on Inspect brake system Instruct firm effective use of throttle for efficient Slow easy clutch engagement engagement Belt worn or separated thin spots loose belt P P Replace belt PVT noise Broken or worn clutch components cover utehe Inspect and repair as necessary E TSBs be Replace belt Refer to belt burnt troubleshooting and ngagemen 4 erraticor jerk instruct operator Drive clutch bushings stick Inspect and repair clutches 6 38 FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIFICATIONS sss ee 72 TOROUE TABLE oin ur d Mnt 7 2 SEE CIAL oy Gi es WI kG RSE 7 2 GEARGCGASE FEUID 7 GAPAGIIY 13422259952 hay od PR Mud unt 7 2 FRONT DRIVE AXLE REMOVAL e sese me rote ta tora MEM d M ped as a 7 2 x aie era leuc Reni Red E 7 4 FRONT DRIVE SHAFT CV 7 4 INSPECTION MENDES 7 4 RBEPEAGEMIENTI dt auct t olive aa ac o t s atenta Bete 7 4 FRONT HUB 7 6 DISASSEMBIEY
362. lean battery cables and terminals with a stiff wire brush Corrosion can be removed using a solution of one cup water and one tablespoon baking soda Rinse well with clean water and dry thoroughly 2 Route the cables correctly 3 Reinstall battery attaching positive red cable first and then the negative black cable Coat terminals and bolt threads with Nyogel Grease PN 2871329 ELECTRICAL 4 Install clear battery vent tube from vehicle to battery vent WARNING Vent tube must be free from obstructions and kinks and securely installed If not battery gases could accumulate and cause an explosion The vent tube should be routed away from frame and body to prevent contact with Route the cables correctly 5 Reinstall the holder strap Off Season Storage To prevent battery damage during extended periods of non use the following basic battery maintenance items must be performed Remove the battery from the machine and wash the case and battery tray with a mild solution of baking soda and water Rinse with lots of fresh water after cleaning NOTE Do not get any of the baking soda into the battery or the acid will be neutralized Using a wire brush or knife remove any corrosion from the cables and terminals Make sure that the electrolyte is at the proper level Add distilled water if necessary Charge at a rate no greater than 1 10 of the battery s amp hr capacity until the electr
363. llation 5 11 Rear Suspension Assembly 25 22 2 23 Recoil Housing Draining Inspection 2 22 Recoil Reasseumbly vcs cee inie HERR RA Rendons 3 92 Removal nr RO 3 51 5 Shift Linkage Inspection 2 14 Side Panel Removal RD RR E rS 5 4 Solenoid Differential 10 36 Spark Plug Inspection Replacement 2 18 Special Tools Body amp Steering 2 IX 3 Special ES OS 4 5 Special Tools BHEID 5 4 o 3 3 Special Tools Final Drive 2 Special Tools Speed Sensor 10 42 Specificaiton Stator Plate Bolt Torque 3 40 Specification Brake Disc Service Limit 9 25 Specification Brake Disc Thickness 9 25 Specification Brake Pad Thickness 9 19 Specification Cam Chain Stretch 3 32 Specification Cam Chain Tensioner Spring 3 15 Specification Camshaft Lobe Height 3 18 Specification Crankcase Bolt Torque 3 41 Specification Crankshaft Slotted Nut Torque 3 43 Specification Cylinder Compression 2 17 Specification Cylinder Head Torque Procedure 3 45 Specification Cylinder Head Warp
364. low these steps to check reference voltage Harness Test Insert black voltmeter probe into the test port Connect the red meter probe into the port and verify the voltage is 4 99 5 01 vdc If this reading is low verify the 9 volt battery is good or try a new 9 volt battery Throttle Position Sensor Replacement NOTE The correct position of the TPS is established and set at the factory If the TPS 15 repositioned replaced or loosened it must be recalibrated cc 1 Remove LH side panel assembly Disconnect sensor from the engine harness 3 Loosen and rotate the throttle body B to gain access to the retaining screws if required 4 Remove the retaining screws and replace the sensor but do not tighten the screws at this point 5 Referto 5 Initialization for setting the TPS voltage Throttle Position Sensor Tps Initialization The correct position of the throttle body idle stop is established and set at the factory Do not loosen the throttle body idle stop or alter the stop position in any fashion If the stop is repositioned the entire throttle body assembly must be replaced Establishing a TPS setting This step is crucial as it sets TPS position using the fixed physical stop Open and close throttle plate a couple of times to ensure full throttle closing Do not snap closed as this could cause unnecessary throttle plate to throttle body
365. m Decreased performance may be encountered with inadequate bleed of the hydraulic circuit 5 Begin the bleeding process by filling reservoir to line with clean Polaris ADC oil AW ISO 10 hydraulic fluid equivalent 6 Locate bleeder valves found on either side of differential and remove the protective caps 7 Turn bleeder valves counter clockwise to loosen Loosen bleeder screw slowly allowing oil and any trapped air to flow out of fitting IMPORTANT Do not allow hydraulic fluid in reservoir to drain below minimum fill line Close bleeder valve before oil level falls below minimum fill line Refilling empty reservoir will result in air pockets becoming trapped NOTE If empty reservoir is encountered filling of fluid is still possible Verify air is not trapped before proceeding with step 7 8 Continue steps 6 8 on both sides in sequence until no air bubbles are seen when bleeding occurs 9 Re torque both bleeder valves to specification and reinstall cover caps Bleeder Valve Torque 80 in Ibs 9 Nm 10 Fill reservoir with to a level midway between and MIN fill lines Verify no debris is found in reservoir oil 11 Replace reservoir cap securely and wipe clean any residue Disassembly Inspection 1 Drain and properly dispose of used oil Remove any metal particles from the drain plug magnet 2 Remove the piston pump assembly from the gearcase NOTE Pist
366. m additive is not used fuel tank and fuel lines should be completely drained of gasoline Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant Follow lubrication guidelines in the maintenance section of the service or owner s manual to completely grease and lubricate the entire vehicle with Polaris Premium Season Grease Storage Tips Battery Storage Remove the battery from the vehicle and ensure that it s fully charged before placing it in storage See Chapter 10 for instructions Engine Anti Freeze Test coolant strength and change if necessary Coolant should be replaced every two years Storage Area Covers Set the tire pressure and safely support the ATV with the tires 1 2 offthe ground Be sure the storage area is well ventilated and cover the machine with a genuine Polaris ATV cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Transporting the ATV Follow these procedures when transporting the vehicle 1 Turn off the engine and remove the key to prevent loss during transporting 2 Always place the transmission in park and lock the parking brake 3 Turn the fuel valve off Be sure the fuel cap oil cap and seat are installed correctly 5 Always the frame of the to the transporting unit securely using suitable straps or rope 2 37 MAINTENANCE Maintena
367. main harness circuit between the sensor connector terminals and the corresponding pin terminals in the main connector Correct any observed problem reconnect the sensor and perform step 2 again Crankshaft Position Sensor Replacement 1 Remove the footwell and rear body panel to gain access to the recoil cover 2 Disconnect sensor harness connector 3 Using an 8 mm socket remove the recoil cover retaining bolts A mallet or soft hammer may be required to loosen the cover for removal 4 Remove the retainer screws securing the sensor 5 Install the new sensor routing the harness wire through the top of the case housing as was previously installed 6 Set the air gap of the new sensor to the specified distance away from the ring gear Torque the retaining screws to specification and reverily air gap CPS Retaining Screws 26 34 in Ibs 2 9 3 92 Nm 4 18 MANIFOLD AIR PRESSURE SENSOR MAP Operation Overview Mounted on the throttle body intake the manifold air pressure sensor MAP measures air passing and provides the ECM with the manifold pressure during engine operation This allows the ECM to adjust the fueling according to actual engine load as well as identify which stroke is the intake stroke The MAP sensor also provides the ECM with the ability to compensate for high altitude operation without any recalibration During initial start up the ECM is in a waste spark waste fuel mode until the
368. mpress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other 5 Install the adjuster screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn counterclockwise A WARNING If pads are contaminated with grease oil or liquid soaked do not use the pads Use only new clean pads 3 Install caliper on hub strut and torque mounting bolts 18 165 25 Nm 4 Slowly pump the brake lever until pressure has been built up Maintain at least 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the brake system 9 12 6 Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap 7 Install wheels and torque wheel nuts It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise NOTE Front Wheel Nut Torque Refer to Chapter 2 Brake Burnishing Procedure Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Allow pads and disc to cool sufficiently during the procedure Do not allow pads or disc to become hot or warping may result Repeat this procedure 10 times FRONT BRAKE DISC Inspection 1 Visually inspect the brake disc for nicks scratches or damage 5 2 Measure disc thickness at eight different points around Removal Repl
369. mproper clearance between lever and switch Lever Vibration Disc damaged Disc worn runout or thickness variance exceeds service limit Caliper Overheats Brakes Drag Compensating port plugged Pad clearance set incorrectly Auxiliary brake pedal incorrectly adjusted Brake lever or pedal binding or unable to return fully Parking brake left on Residue build up under caliper seals Operator riding brakes Brakes Lock Alignment of caliper to disc 9 29 BRAKES NOTES 9 30 ELECTRICAL CHAPTER 10 ELECTRICAL GENERAL 10 3 SPEGIAL TOOLS Sass AS Ese vica e RE E Een edic Aso he edes 10 3 IGNITION SYSTEM BASIC ELECTRICAL COMPONENTS 10 3 ELECTRICAL SERVICE NOTES 522 Eb REED ERRASSE 10 4 TROUBLESHOOTING 22 eek ss 10 4 POWER DISTRIBUTION MODULES 10 5 SPORTSMAN EFI OVERVIEW i aude eO does koe Ve E ERR UE CUN 10 5 SPORTSMAN 450 10 10 INSTRUMENT CLUSTER 10 13 OVERVIEWS Sie ae tears eta chat tong be iced ae een Bee 10 13 INSTRUMENT CLUSTER DIAGNOSTIC 10 14 SETTING A NEW SERVICE INTERVAL
370. n Connecting Rod Piston Connecting Rod EH50PLE Surface warpage limit mating with cylinder 0020 0 05 mm head Cylinder bore Std 3 6221 3 6228 92 00 92 02 mm Taper limit 0020 0 05 mm Out of round limit 0020 0 05 mm Piston clearance 0006 0018 0 015 0 045 mm Limit 0024 0 060 mm l OOOO Limit 020 5 mm Piston Outer diameter co ores 3 6204 3 6215 91 970 91 985mm 0098 25 mm OS 3 6304 3 6310 92 21 92 23 mm 5 3 6403 3 6407 92 46 92 47 mm 9055 9057 23 0 23 006 Piston Pin 9053 9055 22 994 23 0 mm 0002 0003 004 008 mm Piston Pin must be a push by hand fit at 68 F 20 Piston Ring Piston Ring Installed Top ring Std 0079 0138 20 36 mm Limit 039 1 0 mm Second Sid 0079 0138 20 36 mm 039 1 0 mm Oil ring Std 0079 0276 0 20 0 70 Limit 059 1 5 mm Piston Ring Standardclearance ring Std 0016 0031 0 040 080 mm to ring ee 0059 15 mm Second Std 0012 0028 0 030 0 070 mm m 3 m 3 i Limit 0059 15 mm e Connecting rod small end radial 0003 0010 007 026 mm clearance 0020 05 mm Connecting rod big end side 0039 0256 1 65 mm clearance 0315 80 mm Connecting rod big end radial 0004 0015 011 038 mm clearance 0020 05 mm Crankshaft Crankshaft runout limit 0024 06 mm KEY Std Standard OS Overs
371. n gear assembly E 1 18 Remove eccentric cam assembly Inspect cam 1 and bushing 2 for wear or damage Replace component as required 7 26 FINAL DRIVE 19 Remove the snap ring retaining the input shaft assembly ADC Gearcase Piston Replacement ec A CAUTION This repair procedure involves the use of compressed air Safety glasses or a face shield are required 1 Place ADC Piston Tool PA 48542 on top of the piston Using moderate hand pressure hold the tool on top of the piston while using compressed air at the gearcase passage circled to force piston up and out of the case See photo 0 20 Remove input shaft assembly Inspect the pinion gear E 1 1 for chipped broken or missing teeth Inspect the input AU 7 shaft bearing 2 for signs of wear Replace the input shaft cover O ring 3 prior to reassembly m j gt A j i i l a ADC Piston Tool 48542 2 Repeat procedure for other piston See photo 7 3 Remove discard inner and outer o rings from piston assembly NOTE Never re use o rings Always replace with new 7 27 FINAL DRIVE 4 Coat new piston and o rings with a moderate amount of white lithium grease or assembly lube Coat the edges of the piston cavities Install the inner and outer piston o rings
372. n Control Circuit Operation Testing 10 25 Fan Motor Current Draw 10 25 Final Drive Torque Specifications 2 Flywheel Stator Removal 3 31 Foot Well Removal Installation 5 5 Front Cab Removal Installation 5 9 Front Cover Removal Installation 5 4 Front Drive Axle Installation 7 4 Front Drive Axle Removal 7 2 Front Gearcase Back Lash Pad Adjustment 7 18 Front Gearcase Coil Resistance 7 14 7 23 Front Gearcase Lubrication 2 12 Front Gearcase Active Descent Control Exploded View 7 21 Front Gearcase Diagnoses 7 19 Front Gearcase Disassembly Inspection 7 13 Front Gearcase Exploded View 7 11 Front Gearcase Installation 7 20 Front Gearcase Operation 7 11 Front Gearcase Reassembly 1 29 Front Gearcase Reassembly Inspection TA Front Gearcase Removal 7 12 Front Hub Assembly occ stock e sens RES 7 6 Front Hub Disassembly 7 6 Front Storage Installation 5 8 Front Storage Removal 5 6 Duel Dr Pos Sane ein Keele toa tone eae acd 4 16 Fuel Filter Replacement
373. n three different levels 1 2 down from top in the middle and 1 2 up from bottom Piston Pin Bore 5 Record measurements If cylinder is tapered or out of round beyond 002 the cylinder must be re bored oversize or im Piston Pin Bore Cylinder Taper 9055 9057 23 0 23 006 mm Limit 002 Max Cylinder Out of Round Limit 002 1 Measure piston pin bore Standard Bore Size 3 6221 3 6228 92 00 92 012 mm Piston to Cylinder Clearance Piston Piston Pin Measurement Locations Piston Pin O D 9053 9055 22 994 23 0 mm Piston Pin 1 Measure piston outside diameter at a point 40 mm down from the top of the piston at a right angle to the direction of the piston pin 3 29 2 Measure piston pin O D Replace piston and or piston if out of tolerance 3 Measure connecting rod small end ID Feeler Gauge Piston Ring to Groove Clearance Top Ring Std 0016 0031 Tenes a mm Limit 0059 15 m Second Ring Std 0012 0028 030 070 mm Limit 0059 1 m 4 Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge Replace piston and rings if ring to groove clearance exceeds service limits 3 30 Piston Ring Installed Gap 1 Place each piston ring inside cylinder using piston to push ring squarely into place as shown at right Mii Cylinder 1 25 50 mm
374. n using the holding fixture and spider tool Torque with smooth motion to avoid damage to the stationary sheave CLUTCH SYSTEM 8 Reinstall cover aligning bosses on the tower and cover Torque cover bolts evenly to specification Spacer Washers Verify spider spacer washers are fully seated in the recessed area of the spider Any misalignment will alter clutch balance Inverting the clutch while initially tightening the spider will help position the washers 2 Install limiter nut on top of spider using the Clutch Spider Nut Socket PN 2870338 Torque to specification 6 Reinstall shift weights using new lock nuts on the bolts 7 Reinstall clutch spring Engine Rotation Nut on trailing s 6 33 CLUTCH SYSTEM STANDARD DRIVEN CLUTCH 3 Separate the clutch sheaves by pulling upward while rotating the inner sheave Disassembly 1 Using special tool PN 8700220 apply and hold downward pressure on the outer spring retainer and remove the snap ring Inspection 1 Inspect both the inner and outer sheave surfaces Replace the entire clutch assembly if worn damaged or cracked 2 Inspect the inner sheave helix E and spring retainer for signs of wear CAUTION Wear eye protection when working with spring tensioned components to avoid serious injury 2 With snap ring removed and spring pressure relieved remove the outer retainer B and spr
375. nce Schedule Hours Miles Service Performed Serviced By 2 38 3 ENGINE SPECIFICATIONS tug ees pea RUP EORR CU SL pe 3 3 TORQUE SPECIFICATIONS cio Js toL EaR et IE ESA 3 3 DE Diele nena hw eec ue a a a 3 9 ENGINE FASTENER TORQUE PATTERNS 2 m RR 3 9 ENGINE SERVICE DATOS epus eost tae sr eet sir 3 4 ENGINE SERVICE dria esate Exe qune pU pti 3 5 GENERAL ENGINE SERVICE i ur EE She t i atto seu eR SES RR 3 6 PISTON IDENTIFICATION bees 3 6 COOLING SYSTEM 6 3 6 COOLING So EM start oh tate RU ES E re 3 7 AGOCESSIBEE COMPONENTS 34 3 cl v E eres as 3 8 ENGINE REMOVAL 14 3 8 ENGINE INSTALLATION NOTES 3 9 CYLINDER HONE SELECTION HONING 3 9 HONING TO OVERSIZE Na decade eet ebbe e t Cte 3 9 CLEANING THE CYLINDER AFTER HONING 3 10 CRANKSHAFT STRAIGHTENING 5 ha ttn 3 10 ENGINE LUBRICATION EhB 5OPLI iet etta Y aat etre ee mto PEL 3 11 OIL PRESSURE TESTA ERSP Caes
376. nce there 15 no need to check electrolyte level NEVER attempt to add electrolyte or water to a Low Maintenance battery Doing so will damage the case and shorten the life of the battery Refer to the Battery Activation and Maintenance Video PN 9917987 for proper instruction on servicing Low Maintenance batteries NOTE New Batteries Batteries must be fully charged before use or battery life will be reduced by 10 3096 of full potential Charge battery for 3 5 hours at a current equivalent of 1 10 of the battery s rated amp hour capacity Do not use the alternator to charge a new battery Refer to Battery Activation and Maintenance video PN 9917987 NEVER attempt to add electrolyte or water to a Low Maintenance battery Doing so will damage the case and shorten the life of the battery Refer to the Battery Maintenance Video PN 9917987 for proper instruction on servicing Low Maintenance batteries TO SERVICE A LOW MAINTENANCE BATTERY 1 Remove battery from the vehicle Test battery with a voltage meter or load tester to determine battery condition This will determine the length of time required to charge the battery to full capacity Refer to capacity table 3 Charge battery using a variable rate charger Low Maintenance Battery Charging If battery voltage is 12 8 V or less the battery may need recharging When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constan
377. nction pressure to the float bowl The lines must be free of kinks i restrictions and be properly routed This allows fuel to flow in Main System Components the proper amount and prevents contaminants from entering the carburetor Float X Inlet Pipe Maintains All systems System Needle and specified fuel All throttle Mikuni CV Carb Operation Level Seat Float level in float ranges Control Float Pin shamber The constant velocity carburetor incorporates a mechanically operated throttle plate and a vacuum controlled slide valve carburetor float vacuum slide The venturi cross sectional area in the carburetor bore is increased or decreased automatically by the vacuum slide which moves according to the amount of negative Passages in All systems pressure less than atmospheric present in the venturi All throttle A diaphragm attached to the top of the vacuum slide is sealed to the slide and to the carburetor body forming two chambers The chamber above the diaphragm is connected to the venturi area by a drilled orifice in the center of the vacuum slide The chamber below the diaphragm is vented to atmospheric pressure by a passage on the air box side of the carburetor A spring Starter Choke Lever Supplies All throttle installed in the center of the vacuum slide dampens the slide Choke Cable Plunger additional fuel ranges movement and assists the return of the slide Enrichment Return Spring Jair mi
378. ne is in Park and repeat Steps 2 and 3 SEE WARNING If particles are still suspected to be in muffler drive the machine onto the incline so the front of the machine is one foot higher than the rear Set the hand brake and block the wheels Make sure the machine is in Park and repeat Steps 2 and 3 SEE WARNING Repeat steps 2 through 5 until no more particles are expelled when the engine is revved Stop the engine and allow the arrestor to cool Reinstall the clean out plugs Brake System Inspection The following checks are recommended to keep the brake system in good operating condition Service life of brake system components depends on operating conditions Inspect brakes in accordance with the maintenance schedule and before each ride Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir e Use Polaris DOT 3 Brake Fluid e m F Sight Glass e Use Polaris DOT 3 Brake Fluid Check brake for excessive travel or spongy feel Check brake system for fluid leaks Check friction pads for wear damage or looseness Check surface condition of the disc 2 29 MAINTENANCE Brake Pad Inspection Pads should be changed when the friction material is worn to 180 4 6 mm or about the thickness of a dime 180 4 6 mm Minimum Thickness Hose Fitting Inspection Check brake system hoses and fittings for cracks deterioration
379. nect red tester lead to harness wire at No 2 on both sides d be same e ignition switch engine stop solenoid Turn on ignition switch Tester should x read battery voltage switch must be on Replace component if failed Test starter solenoid coil by connecting an ohmmeter between the solenoid wire and the solenoid mounting plate Check solenoid ground path by Yes measuring resistance between mounting plate and battery negative terminal Voltage Drop There should be no continuity Testing Reconnect the solenoid Connect the tester black Clean the battery to solenoid cable ends lead to the battery positive and the red lead to the or replace cable solenoid end of battery to solenoid wire Depress starter button Reading should be less tha V D C Yes Connect the black tester lead to solenoid end of battery to solenoid cable Connect red tester lead to solenoid end of solenoid to starter cable Replace the starter solenoid Depress starter button Reading should be less tha V D C Yes Connect the black tester lead to the solenoid end of the solenoid to starter cable Connect the red tester lead to the starter end of the same cable Depress the starter button The reading should be less than 1 V D C Yes If all of these indicate a good condition yet the starter still fails to Clean the solenoid to starter cable ends or replace the cable
380. ng the battery into service check the battery condition and charge accordingly MAINTENANCE New Batteries Batteries must be fully charged before use or battery life can be reduced by 10 30 of full potential Charge battery for 3 5 hours at a current equivalent of 1 10 of the battery s rated amp hour capacity i e 12amp hr x 10 1 2 amp charg ing Do not use the alternator to charge a new bat tery Liquid Cooling System Overview The engine coolant level is 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 coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator 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 some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels often during the break in period Overheating of engine could occur if air is not fully purged from system Polaris 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 Antifreeze Hydrometer e 50 50 or 60 40 mixture of antifr
381. ngine damage may occur if the incorrect spark plug is used Apply a small amount of anti seize compound to the spark plug threads Install spark plug and torque to specification Recommended Spark Plu Refer to the Specifications page in Chapter 1 for spark plug type Spark Plug Torque 14 Ft Lbs 19 Nm Active Descent Control ADC Reservoir Level The Active Descent Control reservoir DELUXE Models Only is located by the radiator fill cap Check the level and verify it is between the and MIN lines Add only Polaris ADC fluid when required Battery Maintenance Complete battery servicing information for both conventinoal nd sealed batteries can be found in Chapter 10 of this manual 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 immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN NOTE Expected battery shelf life is 6 8 months depending on storage conditions As a general rule before placi
382. nnecting rod both ends balancer drive gear and crankshaft main bearing area Cm 5 Install the piston on the connecting rod with the arrow mark facing the magneto RH end of the crankshaft The piston pin should be a push fit in the piston Install the other with gap facing up down tang outward See Caution with Step 3 above Push the piston pin in both directions to make sure the clips are properly seated in the groove 3 44 Cylinder Installation 7 Place dowel pins in and install a new cylinder base gasket Position the Piston Support Block PN 2870390 A beneath the piston skirt to support the piston during cylinder installation Make sure the oil control ring upper rail tab is positioned properly in the notch of the piston Verify all ring end gaps are correctly located 10 Apply clean engine oil liberally to the cylinder bore and tapered area of the sleeve Install the cylinder with a slight rocking motion until the rings are captive in the sleeve METUO E es 11 Remove the ring compressor and support block 12 Push the cylinder downward until fully seated on the base gasket 13 Apply a light film of oil to the threads and flange surface of the cylinder mounting bolts 14 Install all four bolts finger tight Rotate the engine and position the piston at NOTE If cam chain is installe
383. nsists of Air Valve Filter B Air Valve Assembly one way operation C Tubing D Air Injection Tube E Catalyst The emissions system utilizes an air valve filter A one way air valve system B and vacuum to help reduce emissions The air valve assembly B contains a vacuum shutoff When engine RPM drops quickly or is at high RPM ilic air valve closes During idle through mid range RPM the air valve is open and air is drawn into the from the PVT intake duct The air valve assembly B opens and closes based on the vacuum pressure connected to the air duct The exhaust pipe creates a vacuum after each engine exhaust pulse The air valve B opens and closes based on this engine pulse Fresh air then travels through the air injection tubes C and D and into the exhaust This air oxygen enters the exhaust pipe and mixes with the exhaust gases from the engine reducing emissions The air and exhaust gas mixture then passes through the silencer E which contains a catalyst This catalyst also reduces emissions by interacting with the exhaust as it passes through the silencer NOTE No maintenance or service of the catalyst 1s required 2008 Polaris Sales Inc 11 5 500 EFI INTERNATIONAL QUADRICYCLE 500 INTERNATIONAL 8 QUADRICYCLE ELECTRICAL Turn Hazard Signal Diagram MOTE Switched a Dun ding Provided On ECL Pin 312 di he MO 11 6 A Arm
384. nternal pre programmed maps to determine the required fuel and ignition settings for the amount of engine load Throttle Position Sensor Test The throttle position sensor TPS is a non serviceable item If it is faulty it must be replaced It can be tested using the following method Using an ohmmeter 1 With the test leads connected and the meter set to the ohms scale observe the reading at the following pin locations of the TPS Table 4 1 5 Resistance Readings Throttle Position Uu sateen 4 20 Using TPS Test Adapter Harness 2201519 Set up the TPS Test Harness 2201519 according to the instructions Verify that the 9 volt battery is new Figure Tester 2201519 Use NEW OV battery Tester 2201519 No Jumps in read out 70 99 Black Probe Red Probe amp WN Black Y Pink Figure 2 Red Connect the test leads connected as shown in Figure 2 and the meter set to the scale move the throttle open and closed slowly while reading the display The voltage should increase smoothly with no jumps decreases when the throttle is applied f the TPS does not function correctly replace it FUEL INJECTION Tps Tester Correct Reference Voltage A 5 volt reference voltage signal from the test harness is required for the TPS test to be accurate Refer to the instructions rovided with the TPS Test Adapter Harness 2201519 or ol
385. nto the intake port The ECM controls the amount of fuel by varying the length of time that the injectors are on This can range from 1 5 8 0 milliseconds depending on fuel requirements The controlled injection of the fuel occurs every other crankshaft revolution or once for each 4 stroke cycle The total amount of fuel needed for one firing of a cylinder is injected during each cycle When the intake valve opens the fuel air mixture is drawn into the combustion chamber ignited and burned The ECM controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for air temperature manifold absolute pressure engine temperature engine speed RPM and throttle position load These primary signals are compared to the programming in the ECM computer chip and the ECM adjusts the fuel delivery and ignition timing to match the values During the ECM has ability to re adjust temporarily providing compensation for changes in overall engine condition and operating environment so it will be able to maintain the ideal air fuel ratio During certain operating periods such as cold starts warm up acceleration etc a richer air fuel ratio is automatically calculated by the ECM FUEL INJECTION Initial Priming Starting Procedure NOTE The Injection system must be purged of all air prior to the initial start up and or any time the system has been disassembled If the EFI s
386. o 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 A WARNING Due to the critical nature of the procedures outlined in this chapter Polaris recommends steering component repair and adjustment be performed by an authorized MSD certified technician when replacing worn or damaged steering parts Use only genuine Polaris replacement parts MAINTENANCE Tie Rod End Steering Inspection Wheel Alignment To check for play in the tie rod end grasp the steering 1 Place machine on a smooth level surface tie rod pull in all directions feeling for movement 2 Set handlebars in a straight ahead position and secure Repeat inspection for inner tie rod end on steering post handlebars in this position NOTE The steering arm center CFR section be used as an indicator of whether HE ET handlebars straight The center section should always point straight back from the steering post 3 Place a chalk mark on the center line of the front tires
387. of the CV joint inner 2 Photo below is shown without shaft for clarity hub with tabs facing the shaft as shown Wipe grease away from recess in CV joint inner hub to locate snap ring 7 36 Refit CV joint on interconnecting shaft by tapping with a plastic hammer on the joint housing Take care not to damage threads on the outboard CV joint The joint is fully assembled when the snap ring is located in the groove on the interconnecting shaft Install and tighten large boot clamp with boot clamp pliers Remove excess grease from the CV joint s external surfaces and position joint boot over housing making sure boot is seated in groove Position clamp over boot end and make sure clamp tabs are located in slots NOTE Before tightening boot clamp on inboard joint make sure any air pressure which may have built up in joint boot has been released The air should be released after the plunging joint has been centered properly Tighten boot clamp using boot clamp pliers Open snap ring and pull joint away 3 VU est FINAL DRIVE CV Boot Replacement 1 Remove CV joint from end of shaft 2 Remove boot from shaft NOTE When replacing a damaged boot check the grease for contamination by rubbing it between two fingers A gritty feeling indicates contamination If the grease is not contaminated the boot can be replaced without cleaning the CV joint Use the recommended amount of grease for b
388. of the fuel pump and circuitry may be conducted CAUTION Check the fuel test valve for any possible fuel seepage after performing any tests or procedures Fuel is extremely flammable and may cause severe burns injury or death Do not use any device that produces a flame or electrical devices that may spark around fuel or fuel vapors 1 Insert the fuel test valve adapter PU 47476 Connect the pressure hose of the Polaris pressure tester PN PU 43506 to the test valve Route the clear hose into a portable gasoline container or the equipment fuel tank 2 Turn the key switch to activate the pump and check the system pressure on the gauge If system pressure of 39 psi 3 16 observed the ignition switch ECM fuel pump and pressure regulator are working properly Turn the key switch off and depress the valve button on the tester to relieve the system pressure Fuel Pump Pressure 39 psi 3 NOTE If the pressure is too high or too low replace the fuel pump assembly 4 13 FUEL INJECTION 3 If the pump did not activate Step 2 disconnect the plug from the fuel pump Connect a DC voltmeter across terminals and in the plug turn on the key switch and observe if a minimum of 7 volts is present If voltage is between 7 and 14 turn key switch off and connect an ohmmeter between the terminals and on the pump to check for continuity NOTE If there was no continuity
389. olyte s specific gravity reaches 1 270 or greater Store the battery either in the machine with the cables disconnected or store in a cool place NOTE Recharge to full capacity every 30 to 60 days during a non use period If the battery is stored during the winter months electrolyte will freeze at higher temperatures as the battery discharges The chart below indicates freezing points by specific gravity Table 10 1 ELECTROLYTE FREEZING POINTS PECIFI RAVITY OF SPECIFIC G FREEZING POINT ELECTROLYTE Low Maintenance Battery Off Season Storage Battery voltage should be checked with a digital multitester Readings of 12 8 volts or less require further battery testing and charging See charts and Load Test Remove the battery from the machine and wash the case and battery tray with a mild solution of baking soda and water Rinse with lots of fresh water after cleaning Using a wire brush or knife remove any corrosion from the cables and terminals Make sure that the electrolyte is at the proper level eis at a rate no greater than 1 10 of the battery s amp hr capacity until the electrolyte s specific gravity reaches 1 270 or greater e Store the battery either in the machine with the cables disconnected or store in a cool place NOTE Stored batteries lose their charge at the rate of 1 per day Recharge to full capacity every 30 to 60 days during a non use period If the battery is stored during the
390. on PVT consists of three major assemblies 1 The Drive Clutch 2 The Driven Clutch and 3 The Drive Belt The internal components of the drive clutch and driven clutch control engagement initial vehicle movement clutch upshift and backshift During the development of a Polaris ATV the PVT system is matched first to the engine power curve then to average riding conditions and the vehicle s intended usage Therefore modifications or variations of components at random are never recommended Proper clutch setup and careful inspection of existing components must be the primary objective when troubleshooting and tuning Drive Clutch Operation Drive clutches primarily sense engine RPM The two major components which control its shifting function are the shift weights and the coil spring Whenever engine RPM is increased centrifugal force is created causing the shift weights to push against rollers on the moveable sheave which is held open by coil spring preload When this force becomes higher than the preload in the spring the outer sheave moves inward and contacts the drive belt This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotates the driven clutch At lower RPM the drive belt rotates low in the drive clutch sheaves As engine RPM increases centrifugal force causes the drive belt to be forced upward on drive clutch sheaves 6 6 Driven Clutch Operation Driven clutches
391. on pump assembly is a non serviceable item and should not be disassembled Replace as an assembly if found to be damaged or non working 3 Remove bolts arrows retaining the outer cover plate assembly 7 23 FINAL DRIVE 4 Remove the outer cover plate assembly Remove and 6 Remove the armature plate Inspect the armature plate for inspect the cover o ring 1 Inspect thrust bearing 2 for wear distortion or other damage Replace component as wear Replace items as required required it Thrust bearing 2 located between p 7 Remove the spacer Inspect for signs of wear or damage output assemblies is pressed into the clutch pack Replace component as required and is not removable NOTE locating pins arrow are for spacer 5 Removethe output clutch assemblies Inspect the bearings installation Note for reassembly contact surfaces and splines of the output clutch for signs p of wear or damage Visually inspect clutch plate area If plates are steel on steel orif the friction material is worn the assembly should be replaced NOTE Excessive debris in the oil and or noise coming from the front drive on deceleration with ADC active are key indicators of clutch pack failure Replace clutch as an assembly if found to be worn or damaged NOTE Locating pins holes circle aid installation Note for reassembly 7 24 FINAL DRIVE 8 Remove the ring gear 1 and spacer 2 12
392. on the coil shaft bearing D for signs of wear Replace the input shaft NOTE The backlash for the centralized hilliard is set 2 at the factory adjustment is required unless front cover needs to be replaced or the back lash C pad screw is removed See the FRONT GEARCASE D ASSEMBLY procedure later in this chapter for details on backlash setting 12 Remove bolts retaining the input shaft cover and pinion 15 Inspect the input shaft bushing NET 16 Thoroughly clean the gearcase components before beginning reassembly 7 16 FINAL DRIVE Reassembly Inspection 5 Install the LH output hub A into the gearcase housing 1 Replace all O rings seals and worn components 6 Install the RH output hub B into the output cover The 2 Press the pinion shaft seal into the pinion cover until the output hub should spin freely seal 15 flush with the sealing surface 3 Inspect bearings on output and pinion shafts To replace press new bearing on to shaft NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement side to side 4 Install input shaft bearing snap ring and input cover with new o ring Torque bolts to specification
393. onsisting of a top and necessary heat the crown of the piston slightly with a bottom steel rail and a center expander section The top rail has propane torch a locating tab on the end which fits into a notch A in the upper il 2 Remove top compression ring oil ring land of the piston 3 Repeat procedure for second ring 4 Remove the top rail first followed by the bottom rail 5 Remove the expander Cylinder Inspection 1 Remove all gasket material from the cylinder sealing surfaces Do not apply heat to the piston rings The ring may lose radial tension 2 Inspect the top of the cylinder for warpage using a straight Using a piston ring pliers Carefully expand ring and lift it off edge and feeler gauge the piston Cylinder Warp Limit CAUTION 002 05 mm Do not expand the ring more than necessary to remove it from the piston or the ring may break 3 28 3 Inspect cylinder for wear scratches damage 2 Subtract this measurement from the maximum cylinder measurement obtained in Step 5 above 1 2 Down From Top of Cylinder Piston to Cylinder Clearance Std 0006 0018 015 045 mm Piston O D Std 3 6204 3 6215 91 970 91 985 mm Piston Rod Inspection 1 2 Up From Bottom 4 Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge Measure in two different directions front to back and side to side o
394. ontrols power to ADC hub coil for operation e pin C on SSCB 1 senses the gear signal indicating the transmission 15 engaged and is not in Park or Neutral PDM pin K on SSCB 72 senses the speed sensor signal for determining if vehicle speed is below 15 Mph ECU pin 21 sends a signal to pin D on SSCB 1 to determine TPS position and will cancel ADC operation if TPS moves off idle position System must be grounded to operate Diagnosing System Failures Verify the AWD switch is functional Verify the ADC hub coil is functional Test the ADC hub coil using an ohm meter ADC Hub Coil Resistance 12945 Verify the TPS is functioning correctly Test Digital Wrench Diagnostic Software Dealer Only Verify the wiring harness wiring connectors connector pins grounds and PDM ECU pin locations are undamaged clean and connect properly Verify continuity of wire connections with a known good volt ohm meter IMPORTANT Verify all wires and wiring connections have been tested properly with a known good volt ohm meter before suspecting a component failure 80 of all electrical issues are caused by bad failed connections and grounds NOTE Refer to the ADC subsystem diagram located in Wire Diagrams at the end of this chapter 10 24 ALL WHEEL DRIVE AWD COIL Operation Overview e AWD switch must be ON 12Vdc power is present at the ADC
395. oot replacement only see below Proceed to Boot Installation 3 Thoroughly clean and dry the CV joint and inspect ball tracks and cages for wear cracks or other damage NOTE Shiny areas in ball tracks and on the cage spheres are normal not replace CV joints because parts have polished surfaces Replace CV joint only if components are cracked broken worn or otherwise unserviceable 4 Add the recommended amount of grease for CV joint cleaning to the joint as shown below Be sure grease penetrates all parts of the joint 5 Refit CV joint on interconnecting shaft by tapping with a plastic hammer on the joint housing Take care not to damage threads on the outboard CV joint The joint is fully assembled when the snap ring is located in the groove on the interconnecting shaft 6 Add grease through large end of boot 7 Install a new boot onto the axle shaft and fill the CV joint and boot with the correct type and amount of grease 7 37 FINAL DRIVE 9 10 Be sure to use only the Constant Velocity Joint grease NOTE CV Joint Grease Capacity Outboard Joint 30g if boot is replaced only Another 50g 80 total if joint is cleaned While pulling out on the CV shaft fully extend the CV joint INSTALLATION and slide a straight O ring pick or a small slotted screw driver between small end of the boot and the shaft This 1 Slide shaft assembly into bearing carrier hub will allow the air pressur
396. oothly and quietly The outer race of each bearing should fit tightly in the crankcase The inner race should be firm with minimal side to side movement and no detectable up and down movement Crankshaft Removal Inspection PIK KAA a k 4 a 7 Remove the shim washer A from the crankshaft 8 Support the PTO side crankcase and crankshaft press the crankshaft out Be careful not to damage the crankcase mating surface or connecting rod 9 Use a feeler gauge to measure the connecting rod big end side clearance Connecting Rod Big End Side Clearance Std 0039 0256 1 65 mm Limit 0315 80 mm 10 Place the crankshaft in a truing stand or V blocks and measure the runout on both ends with a dial indicator Max Runout 0024 06 mm 11 Measure the connecting rod big end radial clearance Big End Radial Clearance Std 0004 0015 011 038 mm Limit 0020 05 mm 12 Inspect the crankshaft main bearing journals for scoring and abnormal wear 3 35 Crankcase Bearing Inspection 1 Remove the seal from the PTO side crankcase Inspect the crankshaft main bearings balancer shaft bearings and pump shaft bearing NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel Look for signs of discoloration scoring or galling Turn the inner race of each bearing The bearings should turn smoothly and quietly The
397. or wear or damage Compare to specifications 5 Replace entire tensioner assembly if any part is worn or damaged 4 Measure free length of tensioner spring Replace spring if excessively worn Compare to specifications Rocker Arm Shaft Inspection m 1 m L Wem Er i 1 Mark or tag rocker arms to keep them order for assembly 3 15 4 Measure I D of each rocker arm and compare to 3 Loosen three camshaft sprocket bolts specifications 4 Remove camshaft end cap and O Ring Rocker Shaft Oil Clearance Std 0008 0021 020 054 mm Limit 0039 10 mm 5 Measure I D of both rocker arm shaft supports and visually inspect surface Compare to specifications 6 Subtract rocker shaft O D from rocker arm amp shaft support I D This is the oil clearance Compare to specifications 7 Inspect rocker adjuster screws for wear pitting or damage to threads of the adjuster or locknut Replace all worn or damaged parts NOTE The end of the adjuster screw 1s hardened and cannot be ground or re faced 5 Inspect camshaft end cap thrust face for wear Replace if Camshaft Removal worn or damaged 6 Place a clean shop towel in the area below cam chain l Remove thermostat housing sprocket and remove sprocket retaining bolts 2 m camshaft sprocket TUER COVer 7 Slide camshaft inward to allow removal of cam sprocket and remo
398. ore brass than Teflon is visible on the bushing Refer to bushing replacement in this chapter 4 Inspect area on shaft where bushing rides for wear galling nicks or scratches Replace clutch assembly if worn or damaged 6 15 CLUTCH SYSTEM NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly Be sure to note the number and thickness of these washers To maintain proper clutch balance and belt to sheave clearance be sure to reinstall original quantity and thickness washers 2 Inspect the coating on the moveable sheave bushing 6 16 3 Inspectall rollers bushings and roller pins by pulling a flat metal rod across the roller Turn roller with your finger If you notice resistance galling or flat spots replace rollers pins and thrust washers in sets of three Also inspect to see if roller and bushing are separating Bushing must fit tightly in roller Use the Roller Pin Tool PN 2870910 to replace rollers and pins Take care not to damage roller bushing or bearing surface of the new pin during installation 4 Rubber backed buttons can and should be used in all ATV clutches if the hollow roller pin is changed to a solid roller pin NOTE Rubber side of the button is positioned toward the solid roller pin It is recommended to switch all buttons to the rubber version during service if needed CLUTCH SYSTEM
399. orque 8 ft Ibs 11 Nm 20 Install A arm on ball joint and torque castle nut to specification Castle Nut Torque 25 ft Ibs 35 Nm 2 Reinstall cotter pin with open ends toward rear of machine 5 19 BODY STEERING SUSPENSION Steering Post Removal pa ue up s Remove the front cab Remove the handle bar pod Remove the handle bar Remove the fuel tank bracket assembly Remove the steering tie rod ends from the steering bracket Note the orientation of the fasteners and bracket on the steering assembly Remove the steering post nut at the mount plate Remove the top steering bracket Remove the steering post Steering Post Assembly 5 20 12 ft lbs 16 Nm Hand tighten steering post slotted nut A Align the cotter pin hole on the steering post slotted nut A Install the cotter pin B Bend both ends of the cotter pin around the slotted nut A in opposite directions Check the steering the handle bars must move freely and easily from full left to full right without binding SUSPENSION Front Strut Cartridge Replacement NOTE Refer to illustration on following page 1 Hold strut rod and remove top nut Remove upper strut pivot assembly Strut Rod Wrench PN 2871572 Strut Spring Compressor Tools PN 2871573 and PN 2871574 3 Compress spring using any commercially available spring compressor tool and remove the spacer nut Remove coil spring and collapse str
400. orque all bolts and screws according to the illustration 5 8 BODY STEERING SUSPENSION Place spacers on frame Install rear rack onto rear frame and cab Install the two bolts B and six A T 27 screws Torque the bolts A to 18 in Ibs 2 Nm and six T 27 screws to 36 in lbs 4 Nm Refer to the illustration for torque values Front Cab Fender Removal Installation 1 Follow the FRONT RACK BUMPER REMOVAL section to begin removal of the front cab rack and bumper Remove the plastic inserts A that secure the front cab to the upper strut support 3 Remove the two screws B that secure the front cab to the frame in the fuel tank mount area 4 Remove the side panels D refer to the SIDE PANEL REMOVAL section 5 Remove the plastic inserts E that secure the front of the foot wells to the front cab 6 Remove the fuel cap and place a clean lint free shop towel into the tank neck to keep any debris from falling into the tank 7 The front cab should now slide back over the fuel tank and fuel tank neck NOTE When removing the front cab use caution so the plastic cab does not scratch or get caught on other components 6 Reverse the removal steps for installation Torque two front cab to frame screws to specification Cab to Frame Screws 24 in lbs 2 7 Nm 5 9 BODY STEERING SUSPENSION Sportsman Rear Cab Fender Removal 4 Disconnect the rear lights by p
401. otter Pin Install New Elevate and safely support vehicle with weight removed from front wheel s Remove cotter pin from ball joint stud at wheel end of A arm and loosen nut until it is flush with end of stud Using a soft face hammer tap nut to loosen A arm from bolt Remove nut and A arm from hub strut assembly Loosen two bolts on A arm tube by alternating each about 1 3 of the way until A arm can be removed Examine A arm shaft Replace if worn Discard hardware Insert A arm shaft into new A arm Install CV joint shields Install new A arm assembly onto vehicle frame Torque new bolts to specification A Arm Bolt Torque 30 ft Ibs 41 4 Nm The locking features on the existing bolts were destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation oe ay 4L qon S 9 Attach A arm to hub strut assembly Tighten ball joint nut to specification If cotter pin holes are not aligned tighten nut slightly to align Install a new cotter pin with open ends toward rear of machine Bend both ends in opposite directions around nut Ball Joint Nut Torque 25 ft Ibs 85 Nm Upon A arm installation completion test vehicle at low speeds before putting into regular service 5 18 BODY STEERING SUSPENSION Ball Joint Replacement NOTE Refer to the illustration on the previous page for this procedure 1 Loosen front wheel nuts slightly
402. outer race of each bearing should fit tightly in the crankcase The inner race should be firm with minimal side to side movement and no detectable up and down movement 3 Support the crankcase and drive or press the main bearings out of each crankcase 4 Toremove balancer shaft bearings and pump shaft bearing use a blind hole bearing puller NOTE Bearings are stressed during the removal process and should not be re used 3 36 Pump Shaft Oil Seal Water Pump Mechanical Seal Removal Engine Disassembled NOTE The water pump mechanical seal can be removed without removing the engine Refer to Water Pump Mechanical Seal Installation Replace the pump shaft seal and water pump mechanical seal whenever the crankcase is disassembled 1 Remove the pump shaft bearing from the Magneto right hand side crankcase 2 Pryoutthe oil seal noting the direction of installation with the spring side facing IN toward inside of case 3 Drive the water pump mechanical seal out of the crankcase from inside to outside Note The new mechanical seal must be installed after the crankcases are assembled using a special tool See Mechanical Seal Installation Crankcase Inspection 1 Remove all traces of gasket sealer from the crankcase mating surfaces Inspect the surfaces closely for nicks burrs or damage 2 Check the oil pump and oil passage mating surfaces to be sure they are clean and not damaged Bearin
403. p assembly forces hydraulic fluid through passages to the piston assemblies 6 located in each case half Hydraulic pressure forces the piston assemblies inward to compress the splined clutch packs 7 forming a dynamic coupling to each front drive axle resulting in true all wheel EBS operation upon deceleration Disengagement Current to the ADC coil 15 turned off by the ECU anytime the following conditions are met Throttle Position Sensor TPS moves off idle position The AWD switch is switched to OFF Vehicle speed is above 15 Mph 24Kph Hydraulic pressure stops and the pistons release disengaging the ADC function The vehicle returns to rear wheel drive until the next deceleration FINAL DRIVE ADC Coil Testing Refer to the following tests in Chapter 10 See ALL WHEEL DRIVE AWD COIL on page 10 24 See ACTIVE DESCENT CONTROL ADC COIL on page 10 24 ADC Differential Hydraulic Circuit Bleeding 1 Make sure vehicle is parked on flat ground and allowed to sit at least 30 minutes prior to bleeding hydraulic circuit 2 Thoroughly clean area around and on remote reservoir and hydraulic bleeders 3 Remove reservoir cap and diaphragm assembly Make sure hydraulic oil inside reservoir is free of debris If any debris is found use clean rag or suction device to remove from the reservoir NOTE Debris in reservoir may block porting and produce inadequate bleeding of the syste
404. pecification Cam Sprocket Bolt Torque 6 ft Ibs 8 Nm Single TDC Mark Aligned Verify TDC mark in timing inspection hole and alignment pin is directly in line with crankshaft to camshaft centerline Refer to illustration Apply Crankcase Sealant PN 2871557 to the camshaft end cap and install using a new O Ring Check all cam timing marks to verify proper cam timing and install the cam chain tensioner body with a new gasket After tensioner installation rotate engine at least two revolutions and re check marks timing 3 47 CAMSHAFT TIMING NF Crankshaft to Camshaft Centreline Dots gt c D lt x O O Q Single Mark Aligned gt O C Es Rotation Do Not Use Advance Marks 3 48 Cam Chain Tensioner Installation 3 Apply 3 Bond 1215 PN 2871557 or an equivalent sealer to the stator plate 1 Release the ratchet pawl A and push the tensioner 2 plunger B all the way into the tensioner body outer surface and install a new O Ring f p 2 i y oc A 3 4 Install stator plate being careful not to damage seal Align timing reference marks on the plate and crankcase bolts Be sure the plate is fully seated NOTE This is a static timing mark Strobe timing should Tensioner Bolt Torque be performed after start up
405. peed rises and this increases negative pressure in the venturi Consequently the vacuum slide 2 moves upward The fuel in float chamber 3 is metered by main jet 4 and metered fuel enters needle jet 5 in which it mixes with the air admitted through main air jet 6 to form an emulsion The emulsified fuel then passes through the clearance between needle jet 5 and jet needle 7 and is discharged into the venturi Mixture proportioning is accomplished in needle jet 5 the clearance through which the emulsified fuel must flow is determined ultimately by throttle position and vacuum slide height Float System Fuel enters the float chamber 3 by means of the inlet pipe and passage through a screen on the back of the inlet needle seat 4 and around the inlet needle 2 As the fuel fills the float chamber the float 1 rises and forces the inlet needle against the seat shutting off the orifice in the seat When fuel level is up in float chamber floats are up and needle valve remains pushed up aeainst valve seat Under this condition no fuel enters the float chamber As the fuel level falls floats go down and needle valve unseats itself to allow fuel into the chamber In this manner the needle valve releases and shuts off fuel alternately to maintain a constant fuel level inside the float chamber 4 37 CARBURETOR SPORTSMAN 450 Pilot Screw The pilot system supplies fuel during engine operation with the
406. per mount Inspection 1 Visually inspect disc for scoring scratches or gouges Replace the disc if any deep scratches are evident 2 Useamicrometer and measure disc thickness at 8 different points around perimeter of disc Replace disc if worn beyond service limit Slide Pin Torque 30 35 ft lbs 41 48 Nm 4 Install caliper and torque mounting bolts to specification 30 35 ft Ibs 1 Disc Thickness Bc n a r EL s EP f 7 62 5 y TI 4 M 2 ON e i P 7 Brake Disc Thickness Service Limit 170 4 318 mm Brake Disc Thickness Variance Caliper Mounting Bolt Torque Service Limit 002 051 mm 16 18 ft lbs 22 24 Nm Between Measurements 5 Install brake line and tighten securely with a line wrench 3 Mount dial indicator and measure disc runout Replace the Torque the brake lines to the proper torque specification disc if runout exceeds specifications 6 Follow bleeding procedure outlined in the BLEEDING PROCEDURE in this chapter E NY 7 Field test unit for proper braking action before putting into j In mm service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when lever is released If the brake Brake Disc Runout drags re check assembly and installation Service Limit 010 254 mm 9 25 BRAKES REAR MASTER CYLINDER X2 Explod
407. ponents Check regulator rectifier connections and ground battery connections and connecting wires or replace faulty wiring or components 10 35 ELECTRICAL DIFFERENTIAL SOLENOID LIGHTING Testing High Beam Headlight Bulb Replacement Disconnect from the wire harness Using a digital ohmmeter test the solenoid at the connector leads and compare to the specification Replacement of solenoid is required as it is not serviceable a CAUTION Do not service while headlight is hot Serious burns may result Protect lamp during install Differential Solenoid Resistance Remove three Phillips screws on the headlight pod 1 45 5 2 Lift pod cover up Disconnect instrument cluster harness A and work light NOTE See Trouble Shooting Diagrams in this iiid 8 chapter for a Differential Solenoid system break out Replacement 1 Remove the solenoid using a suitable tool Coat threads of new solenoid with anti seize compound or sealant 3 Thread new solenoid into gearcase housing Tighten to specification Differential Solenoid Torque 23 27 ft Ibs 31 37 Nm 10 36 ELECTRICAL 4 Turn the headlight lamp socket counter clockwise and 3 Unplug head lamp harness C remove ie cB T i m 4 Remove O Ring D from headlight pivot pins Both Sides F d fi i 5 Carefully remove head lamp bul
408. por vr ridin T o DL 5 ion gv R H Handlebar ain ELECTRICAL BATTERY Battery Identification NOTE It is important to identify what type of battery you have installed in your ATV Different types of batteries require different service procedures Proper servicing and upkeep of your battery is very important for maintaining long battery life Your ATV may have a Conventional Battery or a Sealed Low Maintenance Battery To identify which type of battery your ATV has refer to the illustration below and follow the correct service and charging procedures that follow in the manual Conventional Battery Removable Caps Top View Electrolyte Level j Indicator gg Removable Top View No Electrolyte Level Indicator Battery Activation 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 immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN A WARN
409. positive side of the differential solenoid is current limited via PWR To active the solenoid driver the MODE input must be high and the SPEED input must read less than the solenoid speed limit Once enabled the driver provides an initial pull in current for a pre determined time and then lowers to a hold current until the TURF MODE input goes low or the TRANS input is in Park or Neutral and the SPEED is less than the solenoid speed limit ELECTRICAL CONNECTOR 1 PIN SIGNAL NAME DESCRIPTION Ips Intelligent Power Switch J1 B Unused J1 C TRANS Input signal from the transmission IDLE Input signal for Active Descent Control ADC High side enable to control differential solenoid Uses SPEED and TRANS signals to determine differential solenoid operation X2 Only FAN_ON Relay input to control operation of the fan J1 E X2 Only TURF_MODE KAP_EFI Relay input to control operation of the ECM relay J1 J X2 Only DIFF_SOL IPS that provides power to the differential solenoid IPS that operates the fan TEN JI R Unused RELAY IPS to the power the ECM relay output CONNECTOR 2 PIN SIGNAL DESCRIPTION Ips Intelligent Power Switch COIL 1 Input from stator coil winding 1 15k resistance to ground Run input signal Battery voltage when J2 C MEM Used to provide the instrument cluster constant power for memory FAN STAT Open collector output Pulsed low upon overload or disconn
410. primarily sense torque opening and closing according to the forces applied to it from the drive belt and the transmission input shaft If the torque resistance at the transmission input shaft is greater than the load from the drive belt the drive belt is kept at the outer diameter of the driven clutch sheaves As engine RPM and horsepower increase the load from the drive belt increases resulting in the belt rotating up toward the outer diameter of the drive clutch sheaves and downward into the sheaves of the driven clutch This action which increases the driven clutch speed is called upshifting Should the throttle setting remain the same and the vehicle is subjected to a heavier load the drive belt rotates back up toward the outer diameter of the driven clutch and downward into the Sheaves of the drive clutch This action which decreases the driven clutch speed is called backshifting In situations where loads vary such as uphill and downhill and throttle settings are constant the drive and driven clutches are continually shifting to maintain optimum engine RPM At full throttle a perfectly matched PVT system should hold engine RPM at the peak of the power curve This RPM should be maintained during clutch upshift and backshift In this respect the PVT system is similar to a power governor Rather than vary throttle position as a conventional governor does the PVT system changes engine load requirements by either upshifting or ba
411. products CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period 2 36 Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime Don t use harsh detergents or high pressure washers Some detergents deteriorate rubber parts Use dish soap type cleaners only High pressure washers may force water past seals Stabilize the Fuel Fill the fuel tank Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon clean will also reduce the possibility of bacterial growth in the fuel system Allow 15 20 minutes of operation for the stabilizer to disperse through the fuel in the tank and EFI sytem carburetor Turn the fuel valve off and drain the carburetor bowl 450 only Oil and Filter Warm the engine and change the oil and filter Follow the procedure in this chapter for proper oil change Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Breather Filter Inspect and clean or replace the breather filter Fluid Levels Inspect the following fluid levels and change if necessary front gearcase transmission brake fluid change every two years or as required
412. quently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Maintenance Chart Key The following symbols denote potential items to be aware of during maintenance m CAUTION Due to the nature of these adjustments it is recommended this service be performed by authorized Polaris dealer gt SEVERE USE ITEM If vehicle is subjected to severe use decrease interval by 50 Severe Use is defined as frequent vehicle immersion in mud water or sand racing or race style high rpm use prolonged low speed heavy load operation or extended idle More preventative maintenance is required under these conditions Fluid changes cable and chassis lubrication are required more frequently For engine oil short trip cold weather riding also constitutes severe use Pay special attention to oil level A rising oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil imme diately and monitor level If oil level begins to rise discontinue use and de
413. r 2 for more information on winch installation and operation Accessory Power Wires The accessory power leads for all accessories are located under the front cover The wires are 12 Volt wires and are Orange White in color To locate the wires remove the front cover The wires will be located in the main wire loom on the right side If you have trouble locating the Orange White wires remove the left side panel and search under the front fender area Accessory Wires Located in Pod Located in Lower LI 10 43 ELECTRICAL STARTER SYSTEM Troubleshooting Starter Motor Does Not Run Battery discharged Low specific gravity Loose or faulty battery cables or corroded connections see Voltage Drop Tests Related wiring loose disconnected or corroded Poor ground connections at battery cable starter motor or starter solenoid see Voltage Drop Tests Faulty key switch Faulty kill switch Faulty starter solenoid or starter motor Engine problem seized or binding Can engine be rotated easily with recoil starter Starter lockout malfunction Starter Motor Turns Over Slowly Battery discharged low specific gravity Excessive circuit resistance poor connections see Voltage Drop Test below Engine problem seized or binding Can engine be rotated easily Faulty or worn brushes in starter motor Starter Motor Turns Engine Does Not Rotate Faulty starter
414. r abrasion Replace hose if wear or abrasion is found FRONT MASTER CYLINDER Removal Master Cylinder Cap Sight Glass Screws 1 Clean master cylinder and reservoir assembly Make sure you have a clean work area to disassemble brake Diaphragm components 2 Remove master cylinder from handlebars 13 Wiggle and press down on the cap to be sure it fits evenly and snug Ay CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 3 While holding upright continue to remove master cylinder Cover the brake line to avoid spillage when removing the brake line banjo bolt Installation 1 Install master cylinder on handlebars Torque mounting bolts to specification Torque the inner bolt first as indicated in the illustration below 14 Torque the screw to specification 7 10 165 79 Nm lt uL E 25 in Ibs 3 Nm 7 in Ibs 0 Torque inner Bolt First Torque Inner Bolt First Master Cylinder Mount Bolt Torque Master Cylinder Cover Screw Torque 25 in Ibs 3 Nm 7 in lbs 0 79 Nm Torque Inner Bolt First 9 9 BRAKES 2 Place new sealing washers on each side of banjo fitting on the brake line and torque banjo bolt to specification n to 15 ft Ibs 21 Nm Sealing Washer Banjo Banjo Bolt Torque 15 ft lbs 21 Nm 3 Hill reservoir with DOT approved brake
415. r attached to the pump outlet which is located under the strut mount Fuel pump replaceable picture for reference only Regulator Fuel Pump Internal 30 Micron Strainer Bottom Fuel Gauge Sender When the key switch is turned to ON the ECM activates the fuel pump which pressurizes the system for start up The ECM switches off the pump preventing the continued delivery of fuel in these instances If key switch is not promptly turned to the start position f the engine fails to start or If the engine is stopped with the key switch on as in the case of an accident In these situations the check engine light will go on but will turn off after 4 cranking revolutions if system function is OK Once the engine is running the fuel pump remains on NOTE FUEL GAUGE SENDER TEST To test fuel gauge sender function refer to Chapter 10 in this service manual FUEL PUMP TEST NOTE The fuel pump tank assembly is a non serviceable assembly and must be replaced if determined to be faulty If a fuel delivery problem is suspected make certain the filters are not plugged that the pump is being activated through the ECM all electrical connections are properly secured the fuses are good and a minimum of 7 0 volts is being supplied If during starting the battery voltage drops below 7 0 volts a reduction of fuel pressure may occur resulting in a lean starting condition lf required testing
416. r cylinder hydraulic hose brake calipers slave cylinder brake pads and brake discs which are secured to the drive line 9 6 16 18 ft Ibs A 22 24 Nm J 25 30 in Ibs 2 80 3 40 Nm A Anvil Bolts B Bleed Screws C Washers D O rings E Rear Housing F Seals G Piston H Slide Pins I Bushings J Seal K Bracket L Pad M Front Housing N Retaining Clips When the hand activated brake lever A is applied it contacts piston B within the master cylinder As the master cylinder piston moves inward it closes a small opening compensating port C within the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the piston D located 1n the brake caliper moves outward and applies pressure to the brake pad This pad contacts the brake disc and moves the caliper in its floating bracket pulling the stationary side pad into the brake disc The resulting friction reduces brake disc and vehicle speed As the lever pressure is increased the braking affect 1s also increased The friction applied to the brake pads will cause the pads to wear As these pads wear the piston within the caliper moves further outward and becomes self adjusting Fluid from the reservoir fills the additional area created when the caliper piston moves outward Brake fluid level is critical to proper system operation Too little fluid will allow air to enter the system and cause
417. r delay STARTER OUTPUT TRANS Park Voltage Current capability of the output Neutral Voltage Current capability of the output REVERSE POLARITY PROTECTION Battery Reverse Current 18 2 mA Max reverse leakage current when connected in reverse Reverse Bias Voltage ETETE Absolute maximum reverse voltage before device breakdown 10 12 ELECTRICAL INSTRUMENT CLUSTER Overview A Needle also flashes during warning condition B Speedometer in MPH KPH ILL 1 ILL 2 Introduction Refer To Illustration 1 The Polaris ATV Instrument Cluster is powered by battery voltage 12 VDC and requires inputs from the engine RPM transmission gear and transmission speed sensor for proper operation Two harnesses plug into the cluster head one from the transmission speed sensor and one from the vehicle main harness A non serviceable internal memory battery maintains odometer and hour meter data when the machine is not running The illumination lamp inside the gauge 15 non serviceable and is designed to last for the life of the unit A The speedometer needle indicates speed from an electronic wheel speed sensor located on the transmission and the needle also flashes during a warning condition The speedometer needle indicates speed in MPH and KPH NOTE A flashing needle could indicate a hot engine low battery warning or the No 10 Pin could be grounded B The speedometer features numbers in Mile Per Hour
418. r of bushing NOTE 800 EFI Clutch Use Bushing Tool 47336 5 With towers pointing upward slide sheave bushing and tool onto puller rod 6 Install nut on puller rod and hand tighten Turn barrel to apply additional tension if needed 7 Turn sheave counterclockwise making sure bushing is drawn straight into bore Continue until bushing is seated Puller 8 Remove nut from puller rod and set aside adapter 10 9 Remove sheave from puller Adapter D N 10 Remove installation tool 6 With towers pointing toward the vise slide sheave onto puller rod 7 Install removal tool Item A B into center of sheave with A side toward sheave NOTE Smooth One way Clutch Use Bushing Tool PA 47336 8 Install nut C onto end of puller rod and hand tighten Turn puller barrel to increase tension on sheave if needed Using a hand held propane torch apply heat around outside of bushing until tiny smoke tailings appear 9 Turn sheave counterclockwise on puller rod until it comes free Lift sheave off puller 10 Remove nut from puller rod and set aside 11 Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard 6 19 CLUTCH SYSTEM Cover Bushing Removal Install main adapter Item 8 on puller Removal Tool 3 Main Adapter 8 Install adapter reducer Item 9 3 From outside of clutch cover insert removal tool Item 3 into cover bushing With in
419. rance 5 Repeat adjustment procedure if necessary until clearance is correct with locknut secured Cylinder Piston Removal and Inspection 4 Remove the two 6 mm cylinder base bolts NOTE Follow engine disassembly procedures to remove valve cover camshaft and rocker arms and cylinder head 5 Loosen each of the four large cylinder base bolts 1 4 turn at a time in a criss cross pattern until loose and remove bolts 1 Remove chain guide at front of cylinder NOTE The bolts are inside the water jacket EEr F d i Tap cylinder lightly with a plastic hammer in the reinforced 2 Loosen all four oil pipe banjo bolts and then remove the areas only until loose 1 igh li hers R the pipes bolts and eight sealing washers Remove the pipes 7 Rock cylinder forward and backward and lift it from the crankcase supporting piston and connecting rod Support piston with Piston Support Block PN 2870390 8 Remove dowel pins from crankcase 3 Loosen hose clamps and remove coolant inlet hose 3 27 Piston Removal By hand Placing both thumbs as shown spread the ring open and push up opposite side Do not scratch the ring lands 1 Remove circlip Note piston directional arrow pointing toward the right Mag side of engine 1 Remove piston circlip and push piston pin out of piston If The oil control ring is a three piece design c
420. raulic oil inside reservoir is free of debris If any debris is found use clean rag or suction device to remove from the reservoir NOTE Debris in reservoir may block porting and produce inadequate bleeding of the system Decreased performance may be encountered with inadequate bleed of the hydraulic circuit 5 Begin the bleeding process by filling reservoir to line with clean Polaris ADC hyrdraulic fluid AW ISO 10 hydraulic fluid equivalent 6 Locate bleeder valves found on either side of differential and remove the protective caps 7 Turn bleeder valves counter clockwise to loosen Loosen bleeder screw slowly allowing oil and any trapped air to flow out of fitting IMPORTANT Do not allow hydraulic fluid in reservoir to drain below minimum fill line Close bleeder valve before oil level falls below minimum fill line Refilling empty reservoir will result in air pockets becoming trapped NOTE If empty reservoir is encountered filling of fluid is still possible Verify air is not trapped before proceeding with step 7 8 Continue steps 6 8 on both sides in sequence until clean fluid is seen when bleeding occurs 9 Re torque both bleeder valves to specification and reinstall cover caps Bleeder Valve Torque 80 in Ibs 9 Nm 10 Fill reservoir with to a level midway between and MIN fill lines Verify no debris is found in reservoir oil 11 Replace reservoir cap securely and wipe
421. re wind 8 Install ratchet pawl and return spring with long leg of spring engaged in reel 9 Reinstall friction plate NOTE The friction plate must be positioned with both end tabs of the friction spring opposite the ratchet pawl 10 Torque friction plate retaining bolt to 5 6 ft Ibs 7 9 Nm 11 Reinstall recoil housing using a new gasket Seal stator wire harness grommet with RTV silicone TROUBLESHOOTING Spark Plug Fouling opark plug cap loose or faulty Choke cable adjustment or plunger cable sticking Foreign material on choke plunger seat or plunger Incorrect spark plug heat range or gap Carburetor inlet needle and seat worn Jet needle and or needle jet worn or improperly adjusted Excessive carburetor vibration loose or missing needle jet locating pins Loose jets in carburetor or calibration incorrect for altitude temperature Incorrect float level setting PVT system calibrated incorrectly or components worn or mis adjuste Fuel quality poor old or octane too high Low compression Restricted exhaust Weak ignition loose coil ground faulty coil stator or ETC switch ETC switch mis adjusted Restricted air filter main or pre cleaner or breather system Improperly assembled air intake system Restricted engine breather system Oil contaminated with fuel Restricted oil tank vent Engine Engine Turns Over But Fails to Start No fuel Dirt in fuel line or filter Fue
422. reen White Yel EBS Feet 0 6000 5630710 7041157 7041635 5131674 1800 3700 10 RH Blu Green White Yel EBS 6000 12000 5630709 7041157 7041635 5131674 GENERAL INFORMATION MISC NUMBERS CHARTS Standard Torque Specifications The following torque specifications are to be used as a general guideline There are exceptions in the steering suspension and engine areas Always consult the exploded views in each manual section for torque values of fasteners before using standard torque Bolt Size Threads In Grade 2 Grade 5 Grade 8 Torque lbs Nm 10 2 3 1 O 60 6 9 10 32 21 6 49 5 68 7 8 Torque ft Ibs Nm 14 A SON 11 12 06 14 28 BIB 14 18 516 1 MG TTT Geel 25 35 516 24 19 26 3554553 TOT 29 40 38 18 20 27 30 40 45 62 38 BO 23 32 Spates 35 48 50 69 716 14 50 69 70 97 716 MUiseriuexawerex qe MB On TDI sac xsesiesres BO 110 12 1 SO BB FS OOM
423. relayed to the ECM This signal is processed by the ECM compared to it s programming for determining the fuel and ignition requirements during operation The ECM also uses this signal to determine when to activate the fan during operation If for any reason the engine temperature sensor circuit is interrupted the fan will default to ON 4 22 Engine Temperature Sensor Test Polaris dealers can test the sensor by using the Polaris Digital Wrench M Software dealer only Refer to the Digital Wrench M Software Manual for more information To measure the sensor using an ohmmeter place the tester leads on each terminal an read the resistance with the sensor at an ambient temperature of 68 F 20 C Table 4 1 Resistance Readings RESISTANCE 37 3 39 2 kQ TEMPERATURE F C 68 F 20 C Engine Temperature Sensor Replacement 1 Disconnect sensor from engine harness Using a wrench remove and replace the sensor applying a light coating of thread sealant to aid installation 3 Torque the sensor to specification ETS Installation Torque 18 5 ft Ibs 25 Nm FUEL INJECTION FUEL SYSTEM TROUBLESHOOTING FUEL STARVATION LEAN MIXTURE The correct position of the throttle body idle stop is established and setat the factory Do not loosen the throttle body idle stop or alter the stop position in any fashion If the stop is repositioned the entire throttle body assembly must be replaced
424. remium Hub Fluid PN 2876251 CH Gearcase Capacity 8 97 oz 265 ml ADC Gearcase Capacity 9 3 oz 275 ml Fill Plug Torque 8 10 ft Ibs 11 14 Nm Drain Plug Torque 11 ft lbs 15 Nm To Check the Lubricant Level The front and rear gearcase lubricant level cannot be checked with a dipstick The gearcase must be drained and re filled with the proper amount of lubricant or be filled to the bottom of the fill plug hole threads Refer to procedures 2 12 To Change Gearcase Lubricant V e NN Drain Plug 1 Remove gearcase drain plug A located on the bottom of the gearcase and drain oil The drain plug is accessible through the skid plate Catch and discard used oil properly 2 Clean and reinstall drain plug A using a new sealing washer B Torque to specification 3 Remove fill plug Inspect the O ring P Fill with the recommended fluid amount or to the bottom of the fill plug hole threads See Illustration below Front Gearcase Fill Demand Drive LT Premium Hub Fluid Install torque fill plug and check for leaks A MAINTENANCE Transmission Lubrication Transmission Specified Lubricant Polaris AGL Gearcase Lubricant Gallon PN 2873603 12 oz PN 2873602 Transmission Capacity 32 oz 948 ml Transmission Drain Fill Plug Torque 20 25 ft lbs 27 34 Nm The transmission lubricant level should be check
425. removing and installing bearings and seals 4 Remove left wheel nuts and wheel FINAL DRIVE 5 Remove cotter pin lower ball joint nut and A arm from 8 Remove bolts securing the bottom of housing to the skid ball joint plate frame Bolts and fluid drain plug are accessible f through skid plate a 4 6 Pull the hub and strut assembly out and pull the drive shaft out of the hub 9 Remove vent line 10 Remove the front gearcase from left side of frame pulling both the remaining CV shaft and propshaft from the gearcase Replace the circlips on the CV shaft ends prior to reassembly 7 Remove the roller pin from the front prop shaft Use the Roller Pin Removal Tool PN 2872608 R A Bolt emove 4 Bolts Disassembly Inspection 1 Drain and properly dispose of used oil Remove any metal particles from the drain plug magnet 7 13 FINAL DRIVE 2 Remove bolts retaining the outer cover plate assembly 3 Remove the outer cover plate assembly NOTE Thrust bearing located between two output hubs is pressed into assembly 7 14 4 Remove the armature plate and RH output hub assembly from the outer cover plate Inspect the bearing and contact surfaces of the output hub for signs of wear or damage Replace component if found to be worn or damaged Armature Plate FINAL DRIVE 6 Remove the L
426. ressure on the side cutters to lift up on the insert DO NOT apply too much pressure on the side cutters or damage to the insert will occur The inside insert A should be flush with the top of the outside insert B 2 Next use the diagonal side cutters under outside insert B to completely remove the assembly NOTE The inside insert will still be installed in the outside insert NOTE The inside insert A will still be installed in the outside insert B 5 3 BODY STEERING SUSPENSION BODY 3 Reinstall the side panel by reversing the removal procedure EK ul 2 271 Side Panel Removal 27 Side panel removal is quick and easy use following instructions for removal and installation 1 Remove seat by releasing the latch and lifting up on the seat AN if j O HE MEE Fg gl Front Cover Removal Installation 1 Open the front storage compartment Pull up and outward on the front cover to remove the cover 2 Grasp the rear of the side panel near the rear cab With firm motion pull the panel outward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it from the 3 install the front cover insert the tabs of the front cover into the inserts of the cab Make sure the tabs are aligned with the slots Then press the rear tabs into the slots 9
427. rough rough terrain swamps mountains whenever PVT system overheating is evident it s low ground speeds important to check the inlet and outlet ducting for obstructions Obstructions to air flow through the ducts will increase PVT system operating temperatures The ATV should be operated in low range when pulling or plowing heavy loads or if extended low speed operation is anticipated HIGH RANGE High ground speeds speeds above 7 MPH Table 6 1 Cause and Remedy DIAGNOSIS OF CLUTCH DRIVE BELT amp COVER RELATED ISSUES POSSIBLE CAUSES SOLUTIONS WHAT TO DO Loading the into a pickup or PEN tall trailer when in high range Shift transmission to low range during loading of the ATV to prevent belt burning Starting out going up a steep When starting out on an incline use low range or dismount the ATV after first applying the park brake and perform the K turn Driving at low RPM or low ground speed at approximately 3 7 MPH Drive at higher speed or use Low Range The use of Low Range is highly recommended for cooler PVT operating temperatures and longer component life Insufficient warm up of ATVs exposed to low ambient temperatures Warm engine at least 5 min then with transmission in neutral advance throttle to 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow and easy clutch Fast effective use of the throttle
428. roximately 300 500 RPM run the hone in and out of the cylinder rapidly until cutting tension decreases Remember to keep the hone drive shaft centered or cylinder centered on arbor and to bring the stones approximately 1 2 1 3 cm above and below the bore at the end of each stroke Release the hone at regular intervals and inspect the bore to determine if it has been cleared and to check piston fit NOTE Do not allow cylinder to heat up during honing The thinner areas of the Mel around the ports will expand causing uneven ore After honing has been completed inspect all port opening areas for rough or sharp edges Apply a slight chamfer to all ports to remove sharp edges or burrs paying particular attention to the corners of the intake and exhaust ports Cleaning the Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material Wash the cylinder in a solvent then in hot soapy water Pay close attention to areas where the cylinder sleeve meets the alumina casting transfer port area Use electrical contact cleaner if necessary to clean these areas Rinse thoroughly dry with compressed air and oil the bore immediately with Polaris 2 Cycle Lubricant 3 10 Crankshaft Straightening Lubricate the bearings and clamp the crankshaft securely in the Crankshaft Truing Stand PN 2870569 Refer to illustrations below Crankshaft Truing Stand PN 2870569
429. rvicing of these components or other components on can be done using this service manual s procedures and illustrations 11 1 500 EFI INTERNATIONAL QUADRICYCLE 500 EFI INTERNATIONAL QUADRICYCLE BRAKE SYSTEM Overview The Sportsman International Quadricycle brake system consists of a complete hydraulic brake system All wheel braking is integrated into the foot brake and hand brake systems and allows 4 wheel braking from either control separately or at the same time When the foot brake is applied all brake calipers are active as braking pressure is routed from the foot brake master cylinder through the proportioning valve and distribution block exiting one line to the front calipers while the other line exits the proportioning valve and feeds the outer line of the rear calipers When the hand brake 15 applied all brake calipers are active as braking pressure is routed from the hand brake master cylinder through the distribution block exiting one line to the front calipers while the other line feeds the inner line of the rear calipers
430. rvoir Hydraulic Fluid Standard Gearcase Screws FRO NT DRIVE AXLE Lower Hub Carrier Bolts Lower Hub Carrier Bolts Upper Hub Carrier Bolts ADC Pump Screws 17 23 1 9 2 5 ADC Cover Screws 9 4 14 9 ADC Bleed Valves 80 IMPORTANT Verify which type of wheel is Safely lift and support the front of the ATV equipped with aluminum or steel when torquing Ay CAUTION wheel nuts Special Tools Serious injury could occur if machine tips or falls n i 7 Remove the two brake caliper attaching bolts 2872608 Roller Pin Removal Tool 8700226 CV Boot Clamp Pliers Centralized Hilliard Standard Models Set the ATV in park Remove hub dust cap Remove cotter pin Loosen the hub retaining nut Loosen but do not remove the wheel nuts ge Ss 2870772 1 3 4 Straight Wrench PA 48542 ADC Gearcase Piston Installation Tool CAUTION Do not hang the caliper by the brake line Use wire to hang the caliper to prevent possible damage to the brake line 7 2 FINAL DRIVE 8 Remove hub 10 Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly 9 Remove cotter pin and nut from lower A arm ball joint Remove lower A arm from ball joint 11 Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly 7 3 FINAL DRIVE Installation 1 Install new spring ring on drive
431. s Meter Setting DC Amps Perform system Break Even Amperage test Yes Does charging occur as specified No Ohm stator wires bad replace stator good continue with alternator output test Meter Setting Volts Disconnect the wires from the regulator rectifier Using a multitester perform an Alternator Output AC Volt test gt is output 30 40V AC above 2000 RPM on each leg Yes Meter Setting DC Volta Reconnect the alternator wires Note Red wire must be connected to harness Battery Voltage must be present on red wire terminal on harness side of voltage regulator connector Is it Yes If all of the previous tests indicate a good condition but the charging voltage does not rise above battery voltage at the connector or wire harness replace the volt age regulator PDM ELECTRICAL Remove the battery and properly ser vice Reinstall the fully charged battery or a fully charged shop battery Check Key off Current Draw Check for owner modification and discuss operating habits The battery will continually discharge if operated below the Break Even RPM Con tinued problems would call for battery inspection Inspect the wiring harness be tween the panel and the stator for damage If no damage is found remove the recoil and flywheel Inspect the flywheel magnets sta tor coils and stator wire harness for damage Repair or replace any damaged com
432. s nicks or scratches 8 Reinstall the drain plug A and torque it to specification Oil Tank Drain Plug Torque 14 ft Ibs 19 Nm Crankcase Drain Plug Torque 14 ft Ibs 19 Nm 9 Loosen clamp D 10 Remove oil hose E from screen fitting C on bottom of oll tank 11 Remove screen fitting C and clean the screen 12 Apply Loctite thread sealant 505 or an equivalent pipe thread sealant or PTFE sealant tape to clean oil free threads of fitting C 13 Install screen fitting C and rotate a minimum of 2 1 2 turns clockwise into the tank threads Then rotate the screen fitting clockwise until the nipple of the screen fitting aligns with the reference marking on the tank CAUTION Maximum torque for the screen fitting is 25 ft lb 34Nm do not over tighten NOTE Maximum torque for the screen fitting is 25 ft lb 34Nm do not over tighten 2 24 14 Install oil hose E on fitting C and re install clamp D 15 Place shop towels beneath oil filter Use Oil Filter Wrench PV 43527 turn filter counterclockwise to remove Oil Filter 16 Using a clean dry cloth clean filter sealing surface on the crankcase 17 Lubricate the o ring on new filter with a thin film of engine oil Check to make sure the O ring is in good condition 18 Install the new filter and turn it by hand until the filter gasket contacts the sealing surface then turn an additional 1 2 of a turn 19 Approxima
433. screws Torque the tensioner cam will lift the shoe and tension chain screws to 16 30 in Ibs 2 3 6 Nm Tensioner Assembly Top View Spring Leg Tensioner Mar 1 gt x 77 m d I v ps d 12 Install rear drive differential and drive chain following these precautions e The case half rear output seal should be removed prior to installation of the differential as seal damage can occur with seal installed due to the angle of entry Install the differential sliding geardog onto the shift fork arms at the same time the silent chain is installed Lock Cam The differential gear bearing may be lightly into place The case half seal can be installed once the f EN assembly is in place View From Left Side of Transmission lt A Forward Lift Spring Over Rear Hook Spring Leg Under Cam Mounting Pin 13 Tensioner Installation NOTE Case halve mating may be difficult due to tensioner installation Release tension to aid installation Place the tensioner cam on the front spacer and tensioner shoe on the rear spacer Insert pins through the cam and through the shoe Place the spring over the front pin and hook the spring leg under the cam 8 18 GENERAL INFORMATION 15 Apply a continuous bead of Crankcase Sealant 3 Bond 18 Install the O ring if not yet done and lockout disc H onto PN 2871557 to the LH gearc
434. shaft Apply an anti seize compound to splines Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft with rubber faced hammer Install drive shaft in strut 3 Install lower ball joint torque nut to specification and install new cotter pin Ball Joint Retaining Nut Torque 25 ft Ibs 34 5 Nm 4 Install hub and tighten hub nut to specification Front Hub Retaining Nut Torque 70 ft Ibs 95 Nm 7 4 DRIVE SHAFT BOOT Inspection Check the front and rear driveshaft CV boots for any tears or leaking grease If the driveshaft boot loses all of the grease CV joint failure will occur PENTA x r B Replacement 1 Remove wheel brake caliper and wheel hub Refer to FRONT DRIVE AXLE REMOVAL earlier in this chapter for procedure 2 Remove cotter pin and castle nut from A arm ball joint FINAL DRIVE 3 Disconnect A arm from ball joint using a tie rod fork lt T Slide strut off end of drive shaft and tie it up out of the way of the shaft Remove clamps from rubber boot using the proper boot clamp pliers Remove the large end of the boot from the joint slide the boot back and separate the wheel spindle and joint assembly from the axle shaft by pulling the shaft sharply outward away from the CV joint It may be necessary to tap the CV joint assembly outward with a soft faced hammer
435. should rotate freely without binding Before turning the snorkel tube look down into the gearcase at the snorkel lock screw hole opening Photo 2 to reference your starting point Next slowly rotate the snorkel tube counterclockwise Photo 3 counting the number of notches passing through the thread hole as you rotate the tube Rotate the snorkel tube to the 7th notch from seated position Photo 1 amp 2 using a 2 3 8 wrench 8 15 GENERAL INFORMATION 8 16 shaft assembly Once the gear backlash is found to install the snorkel lock 4 Assemble the input shaft assembly if previously screw you may have to rotate the snorkel tube clockwise disassembled or counterclockwise slightly This will allow the lock screw A Ball Bearing Input Shaft Assembly to thread itself into one of the slots of the snorkel tube See B Input Shaft illustration below to secure the snorkel tube C Silent Chain Screw Fits in Slots of Snorkel Tube 2 4 5 Assemble reverse shaft assembly if previously disassembled REVERSE SHAFT 8 12 ft lb 11 17 With the snorkel shaft assembly in place remove the 4 Torx screws from the output shaft assembly Remove the output Towards Inside of Case A Ball Bearing J Washer B Engagement Dog K retaining Ring C Retaining Ring L Engagement Dog D Washer M Washer E Gear N Needle Bearing F Needle Bearing O Gear G Reverse Shaft P Washer
436. side of cover toward vise slide cover onto puller 5 Install nut onto puller rod and hand tighten Turn puller barrel to increase tension as needed 6 Turn clutch cover counterclockwise on puller rod until bushing is removed and cover comes free 7 Remove nut from puller rod and set aside 8 Remove bushing and bushing removal tool from puller Discard bushing Cover Bushing Installation 1 Apply Loctite 609 evenly to bushing bore in cover Working from inside of cover insert new bushing and bushing installation tool into center of clutch cover 3 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 4 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 5 Turn clutch cover counterclockwise on puller rod until bushing is seated 6 Remove nut from puller rod Take installation tool and clutch cover off rod 6 20 One Way Clutch Inspection Drive Clutch 1 Rotate one way clutch clockwise as viewed from cover plate side The clutch should rotate on the shaft with only slight amount of drag Verify there is no binding or rough spots When rotated counterclockwise the clutch should lock to the shaft without slipping If problems are noted in either direction continue with disassembly Drive Clutch Reassembly NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembl
437. ssion support brackets L completely from the a 68 74 1 E XN 13 Remove all lower transmission mounting fasteners J from each side 16 Lift and remove transmission out right side of frame while pulling the output shaft from the propshaft yoke 8 4 Transmission Installation 1 Apply Polaris Premium All Season Grease PN 2871423 to splines of front output shaft install new O ring in prop shaft With the help of an assistant rotate transmission into place from the right side of the frame aligning the forward transmission bracket into the rear engine mounting holes while ensuring that the output shaft and propshaft align and slide together Loosely install lower transmission mounting fasteners and forward engine mounting nuts Install the rear support bracket middle support bracket and torsion bar support bracket Torque all lower bracket bolts to 40 ft lbs 57Nm Torque all upper rear and middle support bracket bolts circled to 17 ft Ibs 24 Nm gt GENERAL INFORMATION Install the upper control arms Refer to Chapter 5 for procedures and torque specifications Reconnect the torsion bar to both lower control arms Torque to 17 ft Ibs 24 Nm Install both upper shock absorber mounts and torque to 30 ft Ibs 43 Nm Apply anti seize to splines of rear drive shafts and insert drive shafts into carriers and transmission
438. t Using a common spring loaded finger type glaze breaker for honing is never advised Polaris recommends using a rigid hone or arbor honing machine which also has the capability of oversizing Cylinders may be wet or dry honed E upon the hone manufacturers recommendations Wet honing removes more material faster and leaves a more distinct pattern in the bore NOTE See next page for more information on honing Honing To Oversize If cylinder wear or damage is excessive it will be necessary to oversize the cylinder using a new oversize piston and rings This may be accomplished by either boring the cylinder and then finish honing to the final bore size or by rough honing followed by finish honing For oversize honing always wet hone using honing oil and a coarse roughing stone Measure the piston see piston measurement and rough hone to the size of the piston Always leave 002 003 05 07 mm for finish honing Refer to piston to cylinder clearance specifications before honing Complete the sizing with fine grit stones to provide the proper cross hatch finish and required piston clearance SS EXAMPLE OF CROSS HATCH PATTERN finished cylinder should have cross hatch pattern to ensure piston ring seating and to aid in the retention of the fuel oil mixture during initial break in Hone cylinder according to hone manufacturer s instructions or these guidelines Use a motor speed of app
439. t be flame treated prior to installing a decal to ensure good adhesion The flame treatin procedure can often be mes to reduce or eliminate the whitis stress marks that are sometimes left after a fender or cab is bent flexed or damaged A WARNING The following procedure involves the use of an open flame Wear the appropriate safety equipment at all times Perform this procedure in a well ventilated area away from gasoline or other flammable materials Verify the area to be flame treated is clean and free of gasoline or flammable residue 1 Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appears slightly glossy This should occur after just a few seconds of flame treating Do not hold the torch too close to the surface Keep the torch moving to prevent damage 2 Apply the decal BODY STEERING SUSPENSION Plastic Insert Removal Installation 3 Toinstall the inserts press outside insert B into the hole Press inside insert A until it snaps into place Some Polaris ATVs use a two piece plastic insert in place of a metal screw plastic inserts simple to remove and install NOTE The outside insert B should be flush surface after installation 1 Useaa pair of diagonal side cutters to lift the plastic insert A until you feel some slight pressure or lift the insert approximately 1 4 6 35 mm Apply just enough p
440. t current charger use the following guidelines for recharging NOTE Always verify battery condition before and 1 2 hours after the end of charging A WARNING An overheated battery could explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging 10 61 ELECTRICAL Table 10 1 LOW MAINTENANCE BATTERY CHARGING REFERENCE TABLE STATE OF VOLTAGE ACTION None check voltage at 3 mos after manufacture date May need slight charge Needs Charge CHARGE TIME None d Required 3 6 Hours 75 100 12 5 12 8 V 50 75 12 0 12 5 V 25 50 11 5 12 0 V 0 25 90 11 5 V orless Low Maintenance Battery OCV Open Circuit Voltage Test 5 11 Hours At least 13 hours verify state of charge Needs Charge Needs Charge Battery voltage should be checked with a digital multitester Readings of 12 8 volts or less require further battery testing and charging See charts and Load Test NOTE Lead acid batteries should be kept at or near a full charge as possible If the battery is stored or used in a partially charged condition or with low electrolyte levels hard crystal sulfation will form on the plates reducing the efficiency and service life of the battery NOTE Use a voltmeter or multimeter to test battery voltage Table 10 1 OPEN CIRCUIT VOLTAGE CHARGE BATTERY BATTERY
441. t dragging Dirty air cleaner Engine worn Spark plug fouled Idle speed set incorrectly speed limiter Worn jet needle needle jet Plugged or restricted idle jet 4 48 BODY STEERING SUSPENSION CHAPTER 5 BODY STEERING SUSPENSION GENERAL INFORMATION 35 dO eeu E E SRS 5 2 TORQUE SPECIFICATIONS su u saree ae a eae ee eee Meee OSS 5 2 SPECIAL TOOLS iau otio eat quere ues taedia 5 2 DECAL REFLACEMEN T sii artt deste quai d decade e dosi d 5 2 PLASTIC INSERT REMOVAL 5 3 BODY guc eee eee 5 4 SIDE PANEL REMOVAL 25482 6 5 etu petet Ue e pr aec acido e 5 4 FRONT COVER REMOVAL 5 4 FOOT WELL REMOVAL 5 5 X2 FOOT WELL REMOVAL 5 5 FRONT STORAGE REMOVAL ea due e nea sec oc end gs 5 6 FRONT STORAGE INSTALLATION 5 8 SPORTSMAN REAR RACK REMOVAL INSTALLATION 5 8 FRONT CAB FENDER REMOVAL INSTALLATION 5 9 SPORTSMAN REAR CAB FENDER REMOVAL INSTALLATION 5 10 X2 REAR QUARTER PANEL REMOVAL INSTALLATION 5 10 SPORTSMAN REAR STORAGE REMOVAL INSTALLATI
442. t for the wrench to stop flashing When the wrench stops blinking your service hours are set NOTE If you scroll past the intended number hold the button down until the count turns over to 0 You can then reset the number Turn Service Interval OFF 1 If the service interval is enabled functioning on your ATV and you wish to turn it off toggle to the service interval mode 2 Press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center The service interval is now OFF To enable turn on the service interval mode repeat the steps above in Setting Service Interval After Countdown Change Service Interval Time If you would like to change the service interval time example change the interval from 50 hrs to 55 hrs Follow the steps below 1 While in the service interval mode press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center 2 Wait 5 seconds and then press the mode button in until the wrench icon flashes 3 Press the mode button again to set the desired service increment 4 Release the button and wait for the wrench icon to stop flashing The new service interval is now set ELECTRICAL Screen 6 Miles Kilometers The display in the trip meter and odometer can be changed to display either kilometers or miles The current display mode will be shown as KM or MP To chan
443. t measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase Measure at various points especially at PTO DCV Direct current voltage Electrical Open Open circuit An electrical circuit which isn t complete Electrical Short Short circuit An electrical circuit which is completed before the current reaches the intended load i e a bare wire touching the chassis Engagement RPM Engine RPM at which the drive clutch engages to make contact with the drive belt ft Foot feet Ft Ib Foot Pound force of one pound at the end of a lever one foot in length applied in a rotational direction g Gram Unit of weight in the metric system gal Gallon ID Inside diameter in Inch inches Inch Pound In 16 12 in Ibs 1 ft Ib kg cm Kilograms per square centimeter kg m Kilogram meters Kilogram meter A force of one kilogram at the end of a lever one meter in length applied in a rotational direction l or ltr Liter Left Side Always referred to based on normal operating position of the driver m Meter meters Mag Magneto Magnetic Induction As a conductor coil is moved through a magnetic field a voltage will be generated in the windings Mechanical energy is converted to electrical energy in the stator mi Mile miles mm Millimeter Unit of length in the metric system 1mm approximately 040 Nm Newton meters OD Outside diameter Ohm The
444. t overlap 2 Install the oil ring top rail NOTE The top rail has a locating tab to prevent rotation The tab must be positioned in the notch on the side of the piston as shown A 3 Install the bottom rail with the gap at least 30 from the end of the expander on the side opposite the top rail gap See ILL 1 4 Install the second ring with R mark facing up Position the end gap toward the rear intake side of the piston 5 Install the top ring chrome faced with the R mark facing up and the end gap facing forward toward the exhaust See ILL 1 6 Check to make sure the rings rotate freely in the groove when compressed Ring Profile EDAM 3 43 Piston Installation 1 Clean the gasket surfaces on the cylinder and crankcase Remove all traces of old gasket material 2 Make sure the cylinder mounting bolt holes are clean and free of debris Tang Outward 3 Install a new circlip on one side of the piston with the end gap facing up or down and tang outward Circlips become deformed during the removal process Do not re use old circlips Do not compress the new clip more than necessary upon installation to prevent loss of radial tension Severe engine damage may result if circlips are re used or deformed during installation Apply clean engine oil to the piston rings ring lands piston pin bore piston pin and piston skirt Lubricate the co
445. t sprocket teeth for wear or damage 7 Inspect woodruff key for wear 8 Replace any worn or damaged parts One Way Valve Removal The one way valve prevents oil from draining out of the oil tank and into the crankcase when the engine is off It must be clean and have adequate spring pressure in order to seal properly Cam Chain Tensioner Blade 1 Remove bolt securing tensioner blade to crankcase A 1 Remove cap bolt A sealing washer B spring C and one way valve D from PTO side crankcase 2 Inspect free length of spring and check coils for distortion One Way Valve Spring Free Length Std 1 450 3 68 cm 2 Remove blade and inspect for cracks wear or damage 3 Inspect valve for wear 4 Check seat area for nicks or foreign material that may prevent proper sealing of valve 20 Pitch Section 3 Remove cam chain B Inspect chain for worn or missing rollers or damage Stretch chain tight on a flat surface and apply a 10 Ib 4 53 kg load Measure length of a 20 pitch 3 32 3 Inspect drive gear teeth for cracks damage or excessive wear 1 Remove flange bolts 10 from magneto side crankcase 4 Remove three oil pump retaining bolts and pump evenly in a criss cross pattern 5 Inspect mating surface of crankcase and oil pump Check 2 Separate crankcase by tapping with a soft faced hammer in for nicks burrs or surface irre
446. table is used to determine the injector pulse width This strategy will not compensate for engine temperature intake air temperature or altitude change but instead operates based on the latest valid information taken from those sensors To prevent engine over speed and possible failure an RPM lim ting feature is programmed into the ECM If the maximum RPM limit 7000 is exceeded the ECM will suppress the ignition signal or injection signal This process repeats itself in rapid succession limiting operation to the preset maximum 4 12 Sportsman 500 EFI RPM Limit This EFI system utilizes 2 methods Hard Limit Ignition suppression occurs when RPM peaks rapidly e High 7000 RPM Returns 6900 RPM Soft Limit Injector suppression occurs when RPM reaches peak gradually High 7000 RPM e Returns 6900 RPM RPM limits may vary slightly under operating conditions ECM Replacement 1 Remove the 2 retaining screws holding the ECM NOTE Retain upper left spacer located behind the ECM for re installation 2 Withthe ignition turned off disconnect the wire harness by pulling the black slider away from the ECM Once the slider is fully extended pull the connector from the ECM using great care not to damage the harness connector or locking mechanism NOTE Should the black slider become broken replacement parts are available 3 Toinstall reverse the procedures DO NOT apply dielectric grease to the conn
447. tacts the seat Back out the specified number of turns NOTE The final pilot idle mixture must be adjusted with 4 41 CARBURETOR SPORTSMAN 450 the engine running Refer to Page 2 10 float using Float Adjustment Tool PN 2872314 or a vernier caliper When measuring the height be sure the Pilot Screw Base Setting inlet needle valve spring is not compressed Set at Factory Factory Specification 2 5 Turns Out Float Bowl Height 13 14 mm 4 Ifadjustment is necessary bend the tongue slightly Be sure Float Height Adjustment float measurement is even on left and right side 1 Illustration 1 Place the throttle side of the carburetor on Float arms even a level surface to remove weight from float arm In this position the float tongue will rest slightly outward Needle and Seat Leakage Test ees vi e 1 Install the float bowl Invert the carburetor and install a 2 Illustration 2 With the carburetor still resting on the level Mity Vac PN 2870975 to the fuel inlet fitting Apply surface use one hand to slightly tilt the carburetor back 5 PSI Pressure inlet fitting The needle and seat should The float will then fall into the correct position with the hold piece indefinitely If not inspect needle and seat float tongue resting lightly on the inlet needle valve pin and seat O ring without compressing the spring The bottom of the float should be parallel with the float bowl mating surface
448. te engine slowly in the direction of rotation watching intake valves open and start to close 3 Continue to rotate engine slowly watching camshaft sprocket marks and the mark in the timing inspection hole 4 Align single TDC mark on flywheel with projection in inspection hole and the cam sprocket pin facing upward aligned with the camshaft to crankshaft center line 3 14 NOTE The cam lobe should be pointing down and valves should have clearance at this point 5 Remove cam chain tensioner plug sealing washer and spring CAUTION The plug is under spring tension Maintain inward pressure while removing 6 Remove the two 6x25 mm cam chain tensioner flange bolts 7 lightly on tensioner body with a soft face hammer to loosen and remove tensioner Cam Chain Tensioner Inspection 1 Pull cam chain tensioner plunger outward to the end of its travel Inspect teeth on ratchet pawl A and plunger teeth B for wear or damage 2 Push ratchet pawl and hold it The plunger should move 2 Inspect each rocker arm cam follower surface If there is smoothly in and out of the tensioner body any damage or uneven wear replace the rocker arm 3 Release ratchet pawl and push inward on plunger It should NOTE Always inspect camshaft lobe if rocker arms are remain locked in position and not move inward worn or damaged 3 Measure O D of rocker shaft Inspect it f
449. tely 1 cup of engine oil will remain in the crankcase To drain remove drain plug found on lower right side of crankcase Engine Sump Engine Sump Drain Plug Bottom View NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 20 Reinstall drain plug and torque to specification 21 Remove dipstick and fill tank with 2 quarts 1 9 L of Polaris Premium 4 Synthetic Oil 22 Place gear selector in Park and set parking brake NOTE Clamp or pinch off the vent line 2 from the oil tank as shown in the Oil Pump Priming Procedure for the 450 500 engine MAINTENANCE 23 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 24 Dispose of used filter and oil properly Oil Pump Priming Procedure NOTE This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected 1 Clamp or pinch off vent line A approximately 2 from oil tank to avoid the end of oil tank vent fitting and the vent line s pressure relief slit To Air Box 1 Slit Pinch Off Vent Hose Oil Tank Run engine at IDLE for 10 20 seconds 3 Remove the vent line clamp The oil pump will now be properly primed and ready for field operation Note f the system is primed properly you should hear some air release If you do not the sys
450. tem has not primed Repeat the process if necessary Oil Lines To Engine Valve Clearance Inspect and adjust valve clearance while the engine is cold and the piston positioned at Top Dead Center TDC on compression stroke 1 Remove the seat 2 Remove body panels and fuel tank as necessary to gain access to valve cover 3 Remove the spark plug high tension lead and remove the spark plug CAUTION Place a clean shop towel into the spark plug cavity to prevent dirt from entering 4 Remove 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 adjustment Sprocket alignment pin facing up bi Crankshaft to Camshaft Centerline 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 upward directly in line with the crankshaft to camshaft center line as shown The camshaft lobes should be pointing downward 2 25 MAINTENANCE 7 Verify accurate TDC positioning by observing the mark aligned with the pointer in the timing inspection hole In this position there should be clearance on all
451. ter pump shaft Pump shaft replacement requires engine removal and crankcase separation Use caution while performing this procedure Make sure that the puller is parallel to the shaft at all times Do not place side loads on the water pump shaft or strike the puller or shaft in any way 1 Afterthe coolant has been drained remove the water pump cover impeller and the sealing washer Ill 1 Sealing Washer Sealing Washer Copper or Aluminium Coolant Drain Mechanical Seal 3 41 2 Slide main puller body over the outer portion of mechanical seal as shown in Ill 2 and turn T Handle clockwise until it contacts water pump shaft Continue rotating until outer portion of mechanical seal is separated from the metal seal body T Handle Main Puller Body 3 Insert the puller legs between the water pump drive shaft and the remaining portion of the mechanical seal Attach the puller legs to the main puller body 3 Position the split 90 to opening on main puller body 4 Ensure that the split between the puller legs are fully supported by the main body of the tool 4 Hex Socket WS must grasp inside of mechanical seal 3 42 5 Tighten the hex socket screws on the puller legs sufficiently so the lip of the puller legs will grasp the mechanical seal 5 Main Puller Body 6 Turn the puller T Handle clockwise until it contacts the water pump sha
452. termine cause E Emission Control System Service California NOTE Inspection may reveal the need for replacement parts Always use genuine Polaris parts A WARNING Improperly performing the procedures marked with could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 2 3 MAINTENANCE Periodic Maintenance Chart Maintenance Interva comes first Miles teering Pre Hide Forss rede Tires 2 re Hide Brake watever eRe Brake lever trave 7 Make adjustments as needed Lj reu lox pramefasenes Engine oil level Pre Ride Bii odi RN Ni NUN LL Dump Box Operation ide 7 ver Verify Box is latched 0 Box Is latcheo pre filter omy clean often E box sediment tube EET Drain deposits when visible years peadamptallamp lamp Day 1 operation apply dielectric grease replacing Inspect replace as needed main element housing Weekly rain water as needed check o ten I operating in wet conditions Brake pad wear 10 H Monthly 100 Inspect periodically sey 29H 125 200 aan gearcase ol EI H Monthly 155 250 Inspect level change yearly Middle gearcase oil i uc Monthly 155 250 Inspect le
453. tery to achieve regulation of the battery voltage The regulator shuts off current the BAT pin if the batter exceeds the over voltage threshold A high voltage transient will cause the regulator to turn off for a short period of time If there truly is an open battery condition then the regulator will remain off as the minimum battery requirement will not be met The regulator will not turn on unless there exists battery voltage in excess of the minimum battery voltage requirement Therefore do not attempt to charge dead batteries using the vehicle s charging system NOTE COIL 1 has a resistance to ground Battery Protected Output The battery protected output PROT provides solid state circuit breaker SSCB outputs and enables most of the functions on The PROT output must be routed only to the vehicle key run switch for proper power up sequence BAT PROT is enabled when the key run switch connects the PROT output to loads must include RUN input When RUN input goes high 10 10 ELECTRICAL the micro controller will remain ON until RUN input goes low by disconnection of the BAT PROT via the key switch or on off switch It will remain ON for 5 seconds before turning off The BAT PROT output is protected from overloads and short circuits If this occurs the output turns off Once tripped the SSCBs can bereset by removing the overload or cycling the key run switches The SSCBs will trip again if t
454. the IAC is disconnected or inoperative it will remain at it s last operated position Idle Air Control Test The 15 a non serviceable item If it is faulty it must be replaced It can be bench tested using the following method 1 With the test leads connected and the meter set to the ohms scale observe the reading at the following pin locations of the IAC amp bj 6 irr 2 _ 1 If any of the readings are out of specification replace the IAC Idle Air Control Replacement 1 Disconnect the from the engine harness Using a suitable tool remove the retaining screws and replace the sensor 3 Torque the retaining screws to IAC Retaining Screws 17 7 in 105 2 0 5 Nm 4 19 FUEL INJECTION THROTTLE POSITION SENSOR TPS Operation Overview The throttle position sensor TPS mounted to the throttle body is used to indicate throttle plate angle to the ECM The correct position of the throttle body idle stop is established and setat the factory Do not loosen the throttle body idle stop or alter the stop position in any fashion If the stop is repositioned the entire throttle body assembly must be replaced Mounted on the throttle body and operated directly off the end of the throttle shaft the TPS works like a rheostat varying the voltage signal to the ECM in direct correlation to the angle of the throttle plate This signal is processed by the ECM and compared to the i
455. the IAT sends a varying voltage signal to the ECM direct correlation to the ambient air temperature This signal is processed by the ECM and compared to the internal pre programmed maps to determine the required fuel and ignition settings for the amount of engine load Intake Air Temperature Sensor Test The IAT sensor is a non serviceable item If it is faulty it must be replaced It can be tested using the following method With the test leads connected and the meter set to the ohms scale observe the reading at room temperature 20 C 68 F The reading should be IAT Resistance 2 45 0 240 New 2 45 0 360 Used If the sensor does not read correctly replace it Intake Air Temperature Sensor Replacement 1 Disconnect engine harness from sensor Using a suitable tool remove the sensor from the grommet 3 Lightly coat the grommet with soapy water and install a new sensor using a twisting motion to properly seat the sensor in the grommet 4 Re connect the harness IDLE AIR CONTROL IAC General Information The Idle Air Control LAC is used to stabilize the idle quality of the engine at cold start up and after warm up operations Mounted on the throttle body the IAC contains 1 stepper motor which receives varying voltage signal pulses from the ECM These pulses determine the IAC plunger setting thereby controlling the amount of air bypassing the closed throttle bod for idle control If
456. the brakes to feel spongy Too much fluid could cause brakes to drag due to fluid expansion Located within the master cylinder is the compensating port C which is opened and closed by the master cylinder piston assembly The port is open when the lever is released and the master cylinder piston is outward As the temperature within the hydraulic system changes this port compensates for fluid expansion heated fluid or contraction cooled fluid Durin system service be sure this port is open Due to the Bid temperatures created within the system during heavy braking it is very important that the master cylinder reservoir has adequate space to allow for fluid expansion Never overfill the reservoir Fill to 1 4 5 16 64 80 cm from top of the cylinder This system also incorporates a diaphragm as part of cover gasket and a vent port F located between the gasket and the cover The combination diaphragm and vent allow for the air above the fluid to equalize pressure as the fluid expands or contracts Make sure the vent is open and allowed to function If the reservoir 15 over filled or the diaphragm vent is plugged the expanding fluid may build pressure in the brake system leading to brake fail When servicing Polaris ATV brake systems use only Polaris DOT approved brake fluid A WARNING Once a bottle is opened use what is necessary and discard the rest in accordance with local laws Do not store or use a p
457. the pump shaft seal and install the magneto end crankshaft installation tool follow instructions provided with the Crankshaft Water Pump Installation Kit PN 2871283 Draw the crankcase halves together by tightening the nut on the tool and tapping lightly in the pump shaft area with a soft faced hammer to maintain alignment Continually check alignment of the cases during installation closing the gap equally until the surfaces are tightly seated 3 Remove the tool Install the crankcase flange bolts and tighten in 3 steps following the pattern to specified torque Crankcase Bolt Torque 14 ft Ibs 19 Nm Crankcase Sealant PN 2871557 Water Pump Mechanical Seal Installation 5 Clean the seal cavity to remove all traces of old sealer Place a new mechanical seal in the seal drive collar and install on the pump shaft Screw the guide onto the end of the pump shaft 8 Installthe washer and nut and tighten to draw seal into place until fully seated 9 Remove the guide adaptor using the additional nut as a jam nut if necessary Water Pump Mechanical Seal Removal Engine Installed Water Pump Mechanical Seal Puller PN 2872105 Replacement T Handle PN 2872106 This tool allows a technician to replace the mechanical water pump seal on EH50PL engines without removing the engine and splitting the cases CAUTION Improper or careless use of this tool or procedure can result in a bent wa
458. throttle valve closed or slightly opened The fuel air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet CAUTION The pilot screw is calibrated at the factory to meet EPA CARB regulations for air quality standards andis sealed with a brass plug to prevent tampering Removal of the tamper proof plug is not permitted For service purposes cleaning of the pilot circuit can be done only by a certified repair shop to ensure air quality standards are not exceeded 4 T ik 1 j E Pilot Screw Location Brass Plug Installed Brass Plug Removed 4 38 Air Fuel Mixture Ratio E Clip Position vs Fuel Flow Fuel flow 15 50 75 100 Throttle Valve Opening A carburetor with a slide type throttle valve is also called a variable venturi type carburetor In this type of carburetor the needle jet and jet needle serve to control proper air fuel mixture ratio at the medium throttle valve opening between 1 4 and 3 4 opening Having the proper needle jet and jet needle has a major impact on engine performance at partial load The jet needle tapers off at one end and the clearance between jet needle and the needle jet increases as the throttle valve opening gets wider The m n mixture ratio is controlled by the height of the E clip inserted into one of the five slots provided in the head of the jet needle The previous chart shows the variation of fuel flow based on the h
459. to repair the seat surface To check the contact area of the seat on the valve face apply a thin coating of Prussian Blue paste to the valve seat If using an interference angle 469 apply black permanent marker to the entire valve face A Insert valve into guide and tap valve lightly into place a few times 13 Remove valve and check where Prussian Blue NOTE When using an interference angle the seat indicates seat contact on the valve face The valve seat contact point on the valve will be very narrow and is should contact the middle of the valve face or slightly normal condition Look for an even and continuous above and must be the proper width contact point on the black marker all the way around the valve face e If the indicated seat contact is at the top edge of the valve face and contacts the margin area B it is 14 Clean all filings from the area with hot soapy water rinse too high on the valve face Use the 30 cutter to and dry with compressed air lower the valve seat 15 Lubricate the valve guides with clean engine oil and apply If too low use the 60 or 75 cutter to raise the oil or water based lapping compound to the face of the seat When contact area is centered on the valve valve Lapping is not required with an interference angle face measure seat width 16 Insert the valve into its respective guide and lap using a f the seat is too wide or uneven
460. ts and other electrical loads off the break even point should occur at approximately 1500 RPM or lower 8 With the engine running turn the lights on and engage parking brake lock to keep brake light on 9 Repeat test observing ammeter and tachometer With lights on charging should occur at or below 2000 RPM Alternator Output Test Three tests can be performed using a multimeter to determine the condition of the stator alternator STATOR LOCATED QM RIGHT SIDE OF CRANK ELECTRICAL TEST 1 Resistance Value of Each Stator Leg 1 Measure the resistance value of each of the three stator legs Y1 to Y2 Y1 to and Y2 to Y3 Each should measure 0 19 t 15 Table 10 2 CONNECT METER READING IN OHM WIRES To G IN OHMS Charge Coil Y1 to Y2 0 43 15 Charge Coil 0 43 15 Charge Coil Y2 to Y3 0 43 1590 Y Y2 or Y3 to 2 Charge Coil Open Infinity NOTE If there are any significant variations in ohm s readings between the three legs it is an indication that one of the three stator legs maybe weak or failed TEST 2 Resistance Value of Stator Leg to Ground 1 Measure the resistance value of each of the stator legs to ground Y1 to Ground Y2 to Ground Y3 to Ground NOTE Any measurement other than Infinity open will indicate a failed or shorted stator leg TEST 3 Measure AC Voltage Output of Each Stator Leg at Charging RPM 1 Setthe selector dial to measure
461. ts and the caliper ho mm O ring Bushing 9 23 BRAKES 9 Measure the inside diameter of the rear caliper The caliper body is a 2 step piston The rear step is measured as well as the outside step 941 23 88 mm 1 5 in 38 1 mm Rear Caliper Piston Bore I D Inner Bore Service Limit 94 23 88 mm Outer Bore Service Limit 1 5 38 1 mm 10 Inspect caliper piston bore for scratches severe corrosion or galling and replace if necessary Inspect 11 Inspect surface of caliper piston for nicks scratches or damage and replace if necessary 9 24 Assembly Install new O rings in the slide bolt bushing holes Be sure O ring and seal grooves are thoroughly cleaned of all residue or piston may bind in bore Apply brake fluid to piston seals and install carefully with a twisting motion to ease assembly until fully seated Seals 2 Carefully assemble caliper body making sure O rings are properly positioned in groove Tighten the caliper anvil bolts and then torque the anvil bolts evenly to specification Sr 16 18 ftlbs 22 24 Caliper Anvil Bolt Torque 16 18 ft Ibs 22 24 Nm 3 Install brake pads in caliper body with friction material facing each other Install the slide pins and the slide pin retaining rings Torque the slide pins to specification 5 NOTE The slide pins should be torqued when REAR BRAKE DISC installed on cali
462. ttery voltage while cranking the engine Continue the test for 15 seconds During cranking the observed voltage should not drop below 9 5 volts If the beginning voltage is 12 6 volts or higher and the cranking voltage drops below 9 5 volts during the test replace the battery Charging Procedure 1 Remove the battery from the to prevent damage from leaking or spilled acid during charging 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific gravity to 1 270 or greater 3 Install battery in vehicle with positive terminal toward the front Coat threads of battery bolt with a corrosion resistant dielectric grease PN 2871329 4 Connect battery cables A WARNING To avoid the possibility of explosion connect positive red cable first and negative black cable last 5 After connecting the battery cables install the cover on the battery and attach the hold down strap ELECTRICAL 6 Install clear battery vent tube from vehicle to battery vent WARNING Vent tube must be free from obstructions and kinks and securely installed If not battery gases could accumulate and cause an explosion Vent should be routed away from frame and body to prevent contact with electrolyte Avoid skin contact with electrolyte as severe burns could result If electrolyte contacts the vehicle frame corrosion will occur 7 Route c
463. ubleshooting e f you spill gasoline on your skin or clothing immediately wash with soap and water and change clothing e Always stop the engine and refuel outdoors or in a well ventilated area 4 5 FUEL INJECTION Digital Wrench SmartLink Module Kit PU 47471 Available to Polaris dealers through our tool supplier SPX 1 800 328 6657 This module kit contains the necessary cables and hardware to communicate between the vehicle ECM and the Digital Wrench diagnostic software Polaris dealers can also order separately SmartLink Module PU 47468 Vehicle Interface Cable PU 47469 and PC Interface Cable PU 47470 For use on all 15 pin connector based Polaris EFI systems Connect io Vehicia Diagnostic Connector barca Cable PU 47469 Lirras Bor dim Darras bar Ber locam han Sims LED Lice ani eri pp edges PU 47468 Seral inberface Cape PU 47470 Connect t Dipi Viranch PC Throttle Position Sensor Tester 2201519 This tester allows the use of a digital multi meter to test TPS function as well perform initialization procedures Polaris Dealers can order special tools from SPX 4 6 FUEL INJECTION EFI SERVICE NOTES General Service Information e For more convenient and accurate testing of EFI components it is recommended dealers utilize the Polaris Diagnostic Software
464. uel air ratio 555 P IRR ES TON f Note Diagrams for explanation of theory only and are true representations of Mikini BST carburetor Starter System Choke or Enrichment When the choke cable 1 is activated the starter plunger 5 is lifted off the seat Fuel is drawn into the starter circuit from the float chamber 2 through the starter jet 3 Starter jet meters this fuel which then flows into starter pipe 4 and mixes with the air 7 coming from the float chamber The mixture rich in fuel content reaches starter plunger and mixes again with the air coming through a assage 8 extending from underneath the diaphragm The rich uel air mixture for starting is discharged through starter outlet 6 in the main bore 4 36 Pilot Idle and Slow System This system supplies fuel during engine operation with throttle valve closed Doi slightly opened The fuel from float chamber 2 15 metered by pilot jet 3 where it mixes with air coming in through pilot air jet 4 The mixture then goes up through pilot passage to pilot screw 5 A part of the mixture is discharged into the main bore out of bypass ports 6 The remainder is then metered by pilot screw and discharged into the main bore through pilot outlet 7 CARBURETOR SPORTSMAN 450 Main System As throttle valve 1 is opened engine s
465. ulling the locks on each side Installation and removing the connectors Lift the rear cab from the frame 1 Follow the REAR RACK REMOVAL procedure to remove the rear rack 2 Removethe three screws A T 25 that secure the rear cab to the storage container 5 Reverse the removal steps for installation X2 Rear Quarter Panel Removal Installation Remove the seat Remove the plastic inserts circled that secure the quarter panel to the rear footwell See PLASTIC INSERT REMOVAL INSTALLATION for information 3 Remove the ten plastic inserts that secure the rear cab to the frame and plastic 3 Reverse the removal procedures to install the quarter panels Verify panels are properly aligned to the footwell end upon reassembly 5 10 BODY STEERING SUSPENSION Sportsman Rear Storage Removal Installation 1 Follow the REAR RACK REMOVAL and REAR CAB REMOVAL procedure to remove the rear storage compartment After the rear cab is removed the storage compartment comes out Remove the two plastic inserts that hold the rear storage compartment in place For installation reverse the removal steps Torque the three T 25 screws that hold the rear storage to the rear cab to specification Radiator Screen Removal 1 Pull out slightly on top of radiator screen 2 With the top free pull out on the bottom of the screen to 3 remove the screen
466. ump Priming Procedure Oil Pump Shaft Endplay Adjustment 3 39 Oil Pump Removal and Inspection 3 33 P Paint Codes oa bur er e n 1 3 Passenger Seat Operation 5 29 450 500 EFI Overview 10 5 450 Connector Pin Table 10 11 X2 EFI Connector Pin Table 10 7 Pilot Syse co but ER ee e us 4 36 Piston Identification 3 6 Piston Removal d REPE Heese 3 28 Piston Ring Installation 3 30 3 43 BIS Here econ 5 3 Power Distribution Module 10 5 Preside Bee Hb 2 10 Propshatt ater UE e Publication Numbers 1 3 PNCSESASSEIIDIU 205 x kaos 6 11 PVT Disassemply aito bane tico bo ore 6 10 PVT Drive Clutch 6 6 PVT Drive Clutch Shift Weights 6 9 PVT Drive Clutch Specifications 6 8 PVT Driven Clutch 6 6 ea a dd oe RU A orte t nis 6 10 X EROS a 6 3 PVT Maintenance Inspection 6 7 PVT Operation 23951 tars wae e
467. unit of electrical resistance opposing current flow oz Ounce ounces PDM Power Distribution Module Piston Clearance Total distance between piston and cylinder wall psi Pounds per square inch PTO Power take off qt Quart quarts RPM Revolutions per minute Regulator Voltage regulator Regulates battery charging system output at approx 14 5 DCV as engine RPM increases Resistance In the mechanical sense friction or load In the electrical sense ohms Both result in energy conversion to heat Right Side Always referred to based on normal operating position of the driver RPM Revolutions per minute Seized Piston Galling of the sides of a piston Usually there is a transfer of aluminum from the piston onto the cylinder wall Possible causes 1 improper lubrication 2 excessive temperatures 3 insufficient piston clearance 4 stuck piston rings Stator Plate The plate mounted under the flywheel supporting the battery charging coils TDC Top dead center Piston s most outward travel from crankshaft Volt The unit of measure for electrical pressure of electromotive force Measured by a voltmeter in parallel with the circuit Watt Unit of electrical power Watts amperes x volts WOT Wide open throttle 1 15 GENERAL INFORMATION NOTES MAINTENANCE CHAPTER 2 MAINTENANCE MAINTENANCE c Ediz EATUR DERE ROCHE SEE OG SOURCE IOS Se 2 3 PERIODIC MAINTENANCE
468. ut cartridge Remove two pinch bolts from strut casting Remove strut cartridge Install cartridge until bottomed in strut casting Install pinch bolts with wire clamp s Torque pinch bolts to specification Pinch Bolt Torque 15 ft 105 21 Nm 9 Reassemble spring and top pivot assembly Be sure all parts are installed properly and seated fully 10 Torque strut rod nut to specification Do not over torque the nut Strut Rod Nut Torque 15 ft Ibs 21 Nm BODY STEERING SUSPENSION Strut Assembly Nut 15 ft Ibs 21 Nm CB P alld Strut Bumper Spacer Rubber md m trut Washers Upper Pivot Ball 18 ft lbs 25 Nm 5 21 BODY STEERING SUSPENSION Sportsman Rear Suspension Assembly 17 ft lbs 24 Nm 30 ft lbs 41 Nm Orientate Bushings Rear Correctly 5 22 BODY STEERING SUSPENSION X2 Rear Suspension Exploded View NT Mta e giu alius MR JU MM Ie za 22 UE z Ix Era AUTE pU E M st lr B EM E X PLNS a dr M E tte Ro Rear Compression Spring a zm so 7 M TE ap EN PEST ust L iR EM E MH WEIL Fa i pu Il 250 BEGESS EI
469. v18 038 40123741 130j 8 121145 13389 1H9 8 3389 2 121145 121145 NMOYE 9 MOY 1083105 1915 d HOLIN 8 038 311HM az 2 121145 038 2 8299 02 JY T 121145 1980 189 8 ONY YO 12 121145 033 3018 3 IWNOIS INOU HY 8 038 3018 T 121145 N3189 uv 8 1389 02 2 85 123 0241 z 121145 M1 1 8 6 JNVU2 19 123 0241 31000N 40151538 3 8 3101 9 c amp 121145 NMOUG 2 H911 ONINNAY HT 8 0 g 31nd0N 80151538 8 038 39NV3O 1 2 121145 0 123 02 3980 62 8 1102 91 5 02 3L IHM NNOUG 9 80515 dY 9G 123 02 Id 82 1 121145 NMOUE 2 0 02 O4 2 41 t6 123 02 1189 12 321145 311HM a 5 02 y 5 121145 X2v1g 123 02 42 18 92 HOLIMS SNYUL 43139003145 02 2 121145 01134 438 1H911 ONINNAY INOI H1 81 11 038 8 dWid 130 21 93138003348 02 31IHM L3101A Z 9 21150991 97 123 0241 3399 72 321145 3 2 8255 21 3980 H JT LSONOVIQ E 123 0241 N0113A g 2 8255 2 121145 31IHN 038 3 311 HA 038 0 121145 11101 123 02 131014 22 121145 02 038 60 391145 y 123 02 24 321145 8 02 MOU 80 2 221145 INOUJ H3 21 02 21145 HOWL 02 030 N0113A 10 2 dN3L 1 1002 6c 123 02 6 JILSONDVIG 0033dS 9 02 3119 90 2 JIVINI BLY m 123 02 8 2 2115009910 043365 02 3389 0 121145 311HI 038 T 123 02 1 121145 X2v18 y 02 yov 18 70 24 3121145
470. valve guides or seals e Restricted breather e Air filter dirty or contaminated Low Compression e Decompressor stuck e Cylinder head gasket leak e No valve clearance or incorrectly adjusted e Cylinder or piston worn Piston rings worn leaking broken or sticking Bent valve or stuck valve Valve spring broken or weak Valve not seating properly bent or carbon accumulated on sealing surface e Rocker arm sticking Backfiring ETC or speed limiter system malfunction Fouled spark plug or incorrect plug or plug gap Carburetion faulty lean condition e Exhaust system air leaks 3 54 gnition system faulty opark plug cap cracked broken Ignition coil faulty mE Ignition or kill switch circuit faulty Ignition timing incorrect heared flywheel key Poor connections in ignition system e System wiring wet Valve sticking Air leaks in intake e Lean condition Cooling System Overheating Low coolant level Air in cooling system e Wrong type of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins or restriction to air flow passages blocked in radiator lines pump or water jacket Lean mixture restricted jets vents fuel pump or fuel valve Fuel pump output weak Restricted radiator internally or cooling fins e Water pump failure Cooling system restriction Cooling fan inoperative or turning too slowly perform current draw test
471. ve Bushing Inspection Replace bushing if more brass than Teflon is visible on the bushing Do not clean bushings Drive Clutch Bushing Service NOTE Special Tool Required CLUTCH BUSHING REMOVAL AND INSTALLATION KIT ITEM PART DESCRIPTION PART e Bushing Replacement Kit 2871025 2870386 Piston Pin Puller NOTE Bushings are installed at the factory using Loctite V 609 In order to remove bushings it will be necessary to apply heat evenly to the area around each bushing Clean all residual Loctite from bushing bore prior to installing new bushing CAUTION Clutch components will be hot In order to avoid serious burns wear insulated gloves during the removal process Drive Clutch Bushing Removal Remove clutch as outlined previously in this chapter Install handle end of Piston Pin Puller PN 2870386 securely into bench vise and lightly grease puller threads Remove nut from puller rod and set aside Install puller adapter Item 10 from kit PN 2871226 Install main adapter onto puller p With towers pointing toward vise slide sheave onto puller rod a Install removal tool into center of sheave 6 Install nut onto end of puller rod and hand tighten Turn puller barrel to increase tension on sheave if needed Using a hand held propane torch apply heat around outside of bushing until tiny smoke tailings appear 9 Turn sheave counterclockwise on puller rod unt
472. ve sprocket from camshaft and chain 3 16 8 Secure cam chain with wire to prevent it from falling into the crankcase Inspect for Areas of Tooth Wear or Damage 9 Inspect cam sprocket teeth for wear or damage Replace if necessary Decompressor Shaft Decompressor Ball Retainer Sleeve 10 Slide camshaft out the PTO side of the cylinder head Automatic Compression Release Removal Inspection NOTE The automatic compression release mechanism can be inspected and serviced without removing the camshaft from the cylinder head The actuator ball C in the camshaft is not replaceable Replace the camshaft as an assembly if the actuator ball is worn or damaged 1 Check release lever shaft A for smooth operation throughout the entire range of rotation The spring B should hold the shaft weight against the stop pin In this position the actuator ball C will be held outward in the compression release mode 2 Removerelease lever shaft and return spring 3 Inspect shaft for wear or galling 4 Inspect lobe on end of release lever shaft and actuator ball for wear and replace if necessary 3 17 Automatic Compression Release Installation Slide spring onto shaft 2 Apply engine oil to release lever shaft The actuator ball must be held outward to allow installation of the release lever shaft Stop Pin d If Camshaft Is
473. ve the shift drum 22 from the gearcase by moving the drum up and to the right to clear the shift shaft oL j T N 4 i M ALI E 1 A j a b i 4 1 ik 1 E Tu 1 i 1 i 17 Remove the output gear 21 and gear cluster assembly from the gearcase by pulling both assemblies straight up Place the gear cluster assembly on a clean surface for inspection GENERAL INFORMATION Gear Cluster Disassembly 18 19 20 21 Needle Bearing 2 33T Gear 3 Retaining Ring Engagement Dog 1 Bearing Remove the bearing from the reverse shaft using a bearing puller Slide the engagement dog 1 off of the reverse shaft Remove the retaining ring and washer from the reverse shaft Remove the bearing from the input shaft using a bearing puller Remove the 33T gear 3 and needle bearing 2 from the reverse shaft 8 11 GENERAL INFORMATION 22 The reverse shaft should slide out of the silent chain 4 to 26 To disassemble the shift fork rail remove the snap ring 10 separate the assembly from the end of the shift rail on either side 23 Remove the rest of the bearings from the shafts Use caution when disassembling the shift rail The 24 Remove the engagement dog 5 from the reverse shaft compressed springs on the shift rail may pop off causing REVERSE SHAFT eye or
474. vel change yearly ear gearcase a 4 equipped EI H Monthly 155 250 Inspect level change yearly Transmission ol 25 Monthly 155 250 Inspect level change yearly Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California Have an authorized Polaris dealer perform these services 2 4 Periodic Maintenance Chart Item Maintenance Interval Hemarks whichever comes first Calendar Miles KM Monthly 155 250 Inspect replace if necessary 155 250 Perform a break in oil change at one month enera 50 H 310 500 ubricate all grease fittings pivots lubrication cables etc 50 H 310 500 nspect lubricate adjust OM Engine breather filter if equipped SN H Engine oil change 25 break in 50 H 310 500 Lubricate Cable nspect adjust lubricate replace i 1M 3M V 6M 50H 6M 310 600 Lubricate 6M 6M 6M 310 500 Switch necessary Air intake ducts 50 H 310 500 nspect ducts tor proper sealing alr flange leaks 50 H 6M 310 00 nspect adjust replace as needed a 2 50 H 310 500 2 pplicable pressure test system yearly Engine oil change 100 H 620 1000 Perform a break in oil change at 25 hours one month Oil filter change 100 H 620 1000 Replace with oil change Oil tank vent hose 100 H 18M 62000000 Inspect routing con
475. wer is connected to the PDM Reverse Polarity Protection The reverse polarity protection circuit if in series with the battery positive input of the PDM It allows forward current to flow with little voltage drop When the battery terminals are connected in reverse the protection switch is forced off interrupting any current flow other than 2mA of bias current Light Output The LIGHTS switch uses a smart side power switch The LIGHTS output is enabled when the RUN input goes high and disabled when it 1s low If the output current exceeds the short circuit limit the output current will be reduced until the device thermally shuts down It will automatically turn back on when it has cooled based on thermal hysteresis Repeated cycles will use the repetitive short circuit limit to turn off until the overload has been removed Starter Lockout The starter lockout uses a low side drive FET to connect the ground side of the starter solenoid when the lockout is enabled To enable the lockout the brake switch must be pulled high or the transmission must be in Park or Neutral The starter solenoid positive side must be connected to BAT PROT as the lockout relies on the current limit of PROT Differential Solenoid X2 ONLY The differential solenoid driver provides a current regulated low side drive for the solenoid coil The low side driver sinks current from the inductive load that is sourced internally via the ACC PWR output The
476. with a hydrometer to assure each has a reading of 1 270 or higher excludes low maintenance batteries Terminal Preparation Use Polaris corrosion resistant Nyogel grease PN 2871329 on battery bolts and terminals when installing a battery This will help to prevent corrosion and maintain good electrical connection See BATTERY INSTALLATION Battery Removal SPORTSMAN The battery is located under the seat X2 The battery is located under fuel tank and can be accessed 10 58 Inspect the battery fluid level When the battery fluid nears the lower level remove the battery and fill with distilled water only to the upper level line To remove the battery Maintain between _ upper and lower level marks Disconnect holder strap and remove covers Disconnect battery negative black cable first followed by the positive red cable me CAUTION Whenever removing or reinstalling the battery disconnect the negative black cable first and reinstall the negative cable last 3 Remove the battery 4 Remove the filler caps and add distilled water only as needed to bring each cell to the proper level Do not overfill the battery NOTE Refill using only distilled water Tap water contains minerals which are harmful to a battery NOTE Do not allow cleaning solution or tap water inside the battery Battery life may be reduced 5 Reinstall the battery caps Battery Installation 1 C
477. worn or damaged Replace if excessively Using a digital multitester measure the resistance between each of the commutator segments The reading should be 3 ohms or less Measure the resistance between each commutator segment and the armature shaft The reading should be infinite no continuity Check commutator bars for discoloration Bars discolored in pairs indicate shorted coils requiring replacement of the starter motor Place armature in a growler Turn growler on and position a hacksaw blade or feeler gauge lengthwise 1 8 3 cm above armature coil laminates Rotate armature 360 If hacksaw blade is drawn to armature on any pole the armature is shorted and must be replaced 10 47 ELECTRICAL Starter Reassembly Starter Exploded View starter Motor Exploded View Hear Brkt Assy CAUTION Use care when handling starter housing Do not drop or strike the housing as magnet damage is possible If magnets are damaged starter must be replaced 1 Inspect permanent magnets in starter housing Make sure they are not cracked or separated from housing Place armature in field magnet casing 2 Place shims on drive end of armature shaft with phenolic washer outermost on shaft Engage tabs of stationary washer in drive end housing holding it in place with a light film of grease 3 Install case sealing O Ring Make sure O Ring is in good condition and not twisted on the case Lubricate needle bearing
478. xture Greatest Carb Passages necessary for effect at low 5 Low Pressure iaphragm From Venturi Starter Jet cold starting throttle Atmospheric Pressure lt lt x 4 Hu 91 T A j Vacuum Ez Side Pilot Idle Pilot Jet Primarily system Passage ways supplies fuel at to 1 4 Pilot Mixture idle and low throttle throttle positions Minimal effect after 1 2 throttle Ring By pass Ports Behind TRAN Pez 2 a Throttle Plate A SAAT i 5 Pi E GFE rd Pilot Air Jet Pilot 2 p AY Venturi Outlet Throttle hi VEDY 4 Air Flow lt F Low pressure Needle Vacuum Slide Throttle When the throttle plate is opi and engine speed begins to Plate increase the pressure in the venturi and therefore the chamber above the diaphragm becomes significantly lower than atmospheric Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward raising the slide against spring pressure 4 35 CARBURETOR SPORTSMAN 450 When the pressure above and below the diaphragm are nearly equal the slide moves downward under spring pressure Raising or lowering the slide increases or decreases the cross sectional area in the venturi and therefore the air velocity in the venturi is kept relatively constant This provides improved fuel atomization and optimum f
479. y 1 Inspect inlet and outlet check valves for cracks warping or damage Inspect the diaphragms for cracks holes or swelling 3 Tocleanthe valves or pump body remove the set screw and washer Remove the valve assembly and wash with soap and water NOTE Carburetor cleaner may used to clean the pump body when the check valves are removed CAUTION Carburetor cleaners are caustic and should not be used to clean non metal parts of the fuel pump Avoid breathing of vapors 4 Carefully remove all traces of old gaskets and check surfaces for damage Replace diaphragms and gaskets as a set 5 Reassemble the pump in reverse order of disassembly Tighten all screws evenly Fuel Filter Replacement 1 Loosen the filter clamps and remove filter 2 Install new filter onto fuel lines and install clamps 4 46 FUEL GAUGE SENDING UNIT Sending Unit Removal 1 Disconnect the negative battery cable Remove the side panels and front cab assembly Refer to Chapter 5 for details 3 Remove the gas tank cover vent hose Be sure to properly route the vent hose upon reassembly 4 Removethe clamps on the PVT intake duct and remove the PVT duct 7 5 With all the body panels removed from the front of the and the gas tank exposed disconnect the fuel sender wiring harness CARBURETOR SPORTSMAN 450 Remove the 5 screws that secure the fuel sender to the tank 7 Slowly lift th
480. y The Teflon bushings are self lubricating AX CAUTION Do not apply oil or grease to the bushings 1 Reassemble drive clutch in the following sequence Be sure the X or the marks that were made earlier are aligned during each phase of assembly A X7 or the marks that were made earlier on cover B X on spider making sure spacer washers are installed underneath spider and positioned properly in recess CLUTCH SYSTEM C X or the marks that were made earlier under weight 6 Install limiter nut on top of spider using the Clutch Spider Nut Socket PN 2870338 Torque to specification Reinstall shift weights using new lock nuts on the bolts Engine Rotation Install moveable sheave onto fixed sheave 3 Install spider spacers Use same quantity and thickness as were removed 4 Compress spider buttons for each tower and install spider making sure that X or the marks that were made earlier on spider aligns with X or the marks that were made earlier on the moveable sheave 5 Torque spider to specification using the holding fixture and spider tool Torque with smooth motion to avoid damage to the stationary sheave 8 Reinstall cover aligning bosses the tower and cover Torque cover bolts evenly to specification Spacer Washers Verify spider spacer washers are fully seated in the recessed area of the spider Any misalignment will alter clutch balance
481. y tool use and procedures in order to perform the work safely and correctly Technicians should read the text and be familiar wit 1 pedo before starting the work Certain procedures require the use of special tools Use only the proper ools as specified Comments or suggestions about this manual may be directed to Service Publications Dept Polaris Sales Inc 2100 Hwy 55 Medina Minnesota 55340 2007 Sportsman 450 500 EFI 500 X2 EFI Service Manual PN 9920560 Copyright 2006 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant E in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual important information is brought to your attention by the following symbols A WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator bystander or person s inspecting or servicing the vehicle CAUTION SAFETY ALE
482. y which leads to the stator plate oil passage Here it passes through the slotted friction bearing located in the stator plate into the crankshaft An oil seal on the stator plate prevents oil from entering the stator flywheel area Oil travels through the crankshaft to the crank pin lubricating the connecting rod large end bearing directly Oil also passes through an oil jet drilled orifice in the end of the crank pin to the PTO end main bearings and counterbalancer gears Residual oil from the lubrication of the crankshaft and connecting rod indirectly lubricates the cylinder wall piston rings connecting rod small end bearing piston pin oil water pump drive gears cam chain and drive sprocket and Magneto end crankshaft main bearing The one way valve is located on the front left PTO side of the crankcase The valve prevents oil in the tank from draining into the engine sump when the engine is off The valve mechanism consists of a plunger return spring guide plug and sealing washer When the engine is running oil pressure lifts the plunger off the seat allowing oil flow When the engine is off spring pressure forces the plunger against the oil passage seat preventing oil flow from the tank to the sump The one way valve requires very little maintenance If engine oil drains into the sump when the engine is off inspect the valve sealing surface for debris or damage Inspect the return spring for distortion or damage 3 11
483. y and Steering Torque Values 5 2 Specifications Brake Component Service Limits 92 Specifications Brake Component Torque Values 9 2 Specifications Engine Fastener Torque 3 3 Specifications Engine Service Data 3 4 Specifications Final Drive Torque Values T2 Specifications Front Gearcase Lubrication Type Capacity 7 2 Specifications Piston 3 29 Specifications Power Distribution Module 10 10 Specifications Standard Torque Values 1 312 Specifications Vehicle 1 6 1 8 1 10 deer ahs s Pas 10 42 Speedometer Installation 10 18 Speedometer Removal 10 18 4 Speedometer Troubleshooting Tests 10 19 Starter Armature Testing 10 47 Starter Assembly Exploded View 10 48 Starter Brush Inspection Replacement 10 46 Slater DEVe Sero EO DU dede 10 49 Starter Drive Removal 3 31 Starter Lockout Troubleshooting 10 44 Starter Motor Dissassembly Replacement 10 46 Starter Reassembly Installation 10 48 Starter System Flow 10 50 Steering A Arm Exploded View 5 17 Steering Lock Exploded View
484. you remove your instrument be sure the small end of the boot is in its correct location on the axle CARE MUST BE TAKEN TO AVOID DAMAGE TO THE NEWLY INSTALLED BOOT 7 9 FINAL DRIVE 13 Install the small clamp on the boot Front Shaft FRONT HUB Disassembly 1 Remove outer snap ring 2 From the back side tap on the outer bearing race with a drift 7 6 punch in the reliefs as shown NOTE Drive bearing out evenly by tapping on outer race only Once bearing is at bottom of casting support casting on outer edges so bearing can be removed 3 Inspect the bearing NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 4 Inspect bearing housing for scratches wear or damage Replace housing if damaged Assembly 1 Support bottom of hubstrut housing Start bearing in housing 3 Press bearing into place until outer race bottoms on housing CAUTION When using an arbor press be sure to press only on the outer race to avoid bearing damage 4 Install snap ring into groove FINAL DRIVE PROP SHAFT FRONT OR REAR U JOINT Removal and Installation Disassembly 1 Using Roll Pin Removal Tool PN 287
485. ystem is completely empty of fuel or has been disassembled and repaired 1 Cycle the key switch from OFF to 6 times waiting for approximately 3 seconds at and 5 seconds at OFF in sequence to allow the fuel pump to cycle and shut down 2 step 1 is completed turn the key switch to START until the engine starts or 5 seconds has passed 3 If the engine failed to start repeat step 1 for 2 more cycles and attempt to start the engine If the engine fails to start a problem may still exist and should be diagnosed NOTE Accurate testing of EFI components is recommended utilizing the Polaris Diagnostic Software dealer only FUEL LINES Quick Connect Removal Installation CAUTION Verify fuel system has been depressurized before performing this procedure Sportsman 500 EFI models use quick connect fuel lines Refer to the steps for fuel line removal installation l Thoroughly clean the connector Place a shop towel around the fuel line to catch any dripping fuel Squeeze the connector tabs together and push the locking tab out Pull out on the fuel line for removal To install the line verify the connector and nipple are clean and free of debris Snap the fuel line back over the nipple verify the connector tabs snap back into place Squeeze Connector Tabs 4 11 FUEL INJECTION ELECTRONIC CONTROL MODULE ECM Operation Overview The ECM

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