08 Sportman 500

2008 SPORTSMAN 500 EFI / X2 / TOURING / 500 H.O.
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 theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with
service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper
tools as specified.
Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100
Hwy 55 Medina Minnesota 55340.
2008 Sportsman 500 EFI / X2 / Touring / 500 H.O. Service Manual PN 9921315
© Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements 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:
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 ALERT 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. F. 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 1
MAINTENANCE 2
ENGINE 3
FUEL SYSTEM 4
BODY / SUSPENSION 5
CLUTCH 6
TRANSMISSION 7
FINAL DRIVE 8
BRAKES 9
ELECTRICAL 10
INTERNATIONAL 11
NOTES
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
1
MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
TRANSMISSION I.D. LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE AND MACHINE SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
2008 SPORTSMAN 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MODEL NUMBER: A08MH50AX, AZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2008 SPORTSMAN 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
MODEL NUMBER: A08MN50AF, AN, AQ, AS, AX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
2008 SPORTSMAN X-2 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
MODEL NUMBER: A08TN50AX, AZ / A08TN50EA . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
2008 SPORTSMAN TOURING 500 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
MODEL NUMBER: A08DN50AF, AS, AZ / A08DN50EA. . . . . . . . . . . . . . . . . . . . . . . . 1.10
MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
1.1
GENERAL INFORMATION
MODEL NUMBER INFORMATION

Model Number
The machine model number must be used with any correspondence regarding warranty or service.
A 08 MN 50 AX
Engine Designation Numbers

EH50PLE - Single Cylinder, Liquid Cooled,4 Stroke, Electric Start
Vehicle Identification Number (VIN)

World
Mfg. ID
Vehicle Descriptor Vehicle Identifier
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A M N 5 0 A * 8 P 0 0 0 0 0 0
}
Transmission I.d. Location

Body Style
Engine
Powertrain
Emissions
Model
Year
Check Digit }
Plant No
Individual Serial Number
The transmission I.D.number is located on top of

the transmission snorkel, right side of machine.
* This could be either
a number or a letter
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 corresponding about an engine. This information can be found on the sticker applied to the 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
GENERAL INFORMATION
Publications
Table 1-1: Publications

1
Owner's Parts
Year Model Model No.
Manual PN Manual PN
2008 Sportsman 500 A08MH50A 9921161 9921555
2008 Sportsman 500 EFI A08MN50A 9921477 9921355
2008 Sportsman X2 500 EFI A08TN50A 9921436 9921437
Sportsman Touring 500 EFI A08DN50A
2008 Touring Quadricycle A08DN50E 9921436 9921437
X2 Quadricycle A08TN50E
Paint Codes
Table 1-2: Paint Codes

COLOR DITZLER POLARIS
PAINTED PART
DESCRIPTION NUMBER NUMBER
Sportsman Frame Black 9440 P-067
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

Series # Part Number Key Cover
PN 5433534
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
1.3
GENERAL INFORMATION
2008 SPORTSMAN 500

Model Number: A08MH50AX, AZ
Engine Model: EH50PLE
Table 1-4: Sportsman 500 General

Specifications
Category Dimension / Capacity
Length 83 in./211 cm
Width 48 in./122 cm
Height 48 in./122 cm
Wheel Base 50.5 in./128.3 cm
Ground Clearance 11 in./27.94 cm
Dry Weight 715 lbs./324 kg
Gross Vehicle Weight 1210 lbs./549 kg
Front Rack/Box Capacity 90 lbs./40.8 kg
Rear Rack Capacity 180 lbs./81.6 kg
Towing Capacity 1225 lbs./555.6 kg
Body Style Spirit
Hitch Tongue Capacity 120 lbs./54.4 kg
Rear rack capacity and tongue weight
not to exceed 180 lbs./82 kg
1.4
GENERAL INFORMATION
Table 1-5: Sportsman 500 Table 1-6: Sportsman 500
ENGINE Drivetrain 1
Platform Fuji Single Cylinder Transmission Type Drumshift - H/L/N/R/P
Engine Model Number EH50PLE Transmission Capacity 32 oz. / 948 ml
Engine Displacement 499cc Front Gearcase Capacity 8.97 oz. / 265 ml
Number of Cylinders 1 Gear Ratio : Low 23.91:1

Rev 16.30:1
Bore & Stroke (mm) 92 x 75 mm High 10.49:1
Compression Ratio 10.2:1 Front Drive 3.82:1
Compression Pressure 50-90 psi W/Compression Release Clutch Type PVT Non-EBS
Engine Idle Speed 1100 ± 50 RPM Belt 3211077
Engine Max Operating Rpm 6000 Rpm ± 200 Rpm Steering / Suspension
Cooling System / Capacity Liquid - 2.7 qt / 2.5 ltr Front Suspension / Shock A-arm / MacPherson Strut
Overheat Warning HOT on Instrument Cluster Front Travel 8.2 in. / 20.8 cm
Lubrication Pressurized Dry Sump Rear Suspension / Shock Progressive Rate Independent -
Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 ltr w/ 2" Coil-over shock
Exhaust System Single Pipe USFS Approved Rear Travel 9.5 in. / 24.13 cm
Fuel System Ground Clearance 11 in. / 27.94 cm
Carburetor Mikuni BST 40mm Shock Preload Adjustment Front -Non Adjustable.
Front / Rear Rear - Ratchet Style- Std.
Main Jet 155
Turning Radius 65 in./165.10 cm unloaded
Pilot Jet 40
Toe Out 0-1/16 in / .0 - .159 mm
Jet Needle / Clip Position 6MGH1-94-3
Needle Jet X-6M
Wheels / Brakes
Pilot Screw 2 Turns Out (initial) Wheel / Tire Size / Pattern - Front Steel 25x8 - 12 / 4-156
Pilot Air Jet 160 Wheel / Tire Size / Pattern - Rear Steel 25x11 - 12 / 4-156
Float Height 14.7mm ± 1 (.58 ± 0.40") Recommended Air Pressure Front & Rear - 5 psi
Fuel Delivery Fuel Pump Brake - Front Dual Hydraulic Disc
Fuel Capacity / Requirement 4.25 gal US / 19.9 liters Brake - Rear Single Hydraulic Disc
87 Octane (minimum) Brake Fluid DOT - approved only
or 89 Oxygenated
Electrical Table 1-7: Sportsman 500 Jetting
Alternator Output 260 w @ 3000 RPM
AMBIENT TEMPERATURE
Voltage Regulator 3-phase - PDM Altitude Below 40 ° F +40 to +80 ° F
Lights : Pod 50 watts Below 5 ° C +5 to +28 ° C
Grill 2 x 37 watts Meters 0-1800
(Feet) (0-6000)
160 155
Brake 26.9 watts
1800-3700
Tail 8.26 watts (6000-12000)
152.5 147.5
Worklight 13 watts
Indicator 1 watt Table 1-8: A08MH50A Clutching
Operating RPM 6000 RPM
Drive Driven
Shift Driven-
Ignition System DC/CDI Ignition Altitude Clutch Clutch
Weight Helix
Spring Spring
Ignition Timing 30°± 2° BTDC @ 5000 RPM
41-37°
Spark plug / Gap BKR6E / .035 in. / 0.9 mm 0-1800 10 WH Blu/Grn Black
(0-6000) (5630710) (7041157) (7041782) 2+2
Meters (5132344)
Battery / Amp Hr Maintenance-Free / 12 Amp Hr.
(Feet)
Circuit Protection Solid State - PDM 41-37°
1800-3700 10 RH Blu/Grn Black
(6000-12000) (5630709 (7041157) (7041782) 2+2
Starting Electric / Recoil (5132344)
Instrument Cluster Analog Speedo w/ LCD
1.5
GENERAL INFORMATION
2008 SPORTSMAN 500 EFI

Model Number: A08MN50AF, AN, AQ, AS, AX
Table 1-9: Sportsman 500 EFI General

Specifications
Width 48 in./122 cm
Wheel Base 50.5 in./128.3 cm
Ground Clearance 11.25 in./28.6 cm
Rear Rack Capacity 180 lbs./81.6 kg
Body Style Spirit
1.6
GENERAL INFORMATION
Table 1-10: Sportsman 500 EFI Table 1-11: Sportsman 500 EFI
ENGINE Drivetrain 1
Platform Fuji Single Cylinder Transmission Type Drumshift - H/L/N/R/P
Engine Displacement 499cc Front Gearcase Capacity- CH 8.97 / 265 ml
Number of Cylinders 1 Front Gearcase Capacity- ADC 9.3 / 275 ml
Bore & Stroke (mm) 92 x 75 mm Gear Ratio : Low 23.91:1

Rev 21.74:1
Compression Ratio 10.2:1 High 10.57:1
Compression Pressure 50-90 psi W/Compression Release Front Drive 3.82:1
Engine Idle Speed 1100 ± 200 RPM Clutch Type PVT (Standard Models)
PVT w/EBS (Deluxe Models)
Engine Max Operating Rpm 6000 Rpm ± 200 Rpm
Belt 3211113 EBS
Cooling System / Capacity Liquid - 2.7 qt / 2.5 ltr
3211077 Non-EBS
Overheat Warning HOT on Instrument Cluster
Steering / Suspension
Lubrication Pressurized Dry Sump
Front Suspension / Shock A-arm / MacPherson Strut
Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 ltr
Front Travel 8.2 in. / 20.8 cm
Exhaust System Single Pipe USFS Approved
Rear Suspension / Shock Progressive Rate Independent -
Fuel System Coil - over shock
Fuel System Electronic Fuel Injection (EFI) Rear Travel 9.5 in. / 24.13 cm
Fuel Pump (in tank assembly) 25L per hr. at 39 psi Ground Clearance 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.
Fuel Injector(s) Visteon Turning Radius 65 in./165.10 cm unloaded
EFI Controller Visteon Toe Out 0-1/16 in / .0 - .159 mm
Fuel Capacity / Requirement 4.13 gal US / 15.63 liters Wheels / Brakes
87 Octane (minimum)
or 89 Oxygenated Wheel/Tire Size / Pattern - Front 26 x 8 - 12 / 4-156
Electrical Wheel/Tire Size / Pattern - Rear 26 x 11 - 12 / 4-156
Alternator Output 350 w @ 6000 RPM Recommended Air Pressure Front & Rear - 5 psi
Lights : Pod 50 watts Brake - Front Dual Hydraulic Disc
Grill 2 x 37 watts Brake - Rear Single Hydraulic Disc
Brake 2 x 8.26 watts Brake Fluid DOT - approved only
Tail 2 x 26.9 watts

Worklight 2 x 13 watts
Table 1-12: A08MN50A Clutching
Indicator 1 watt Altitude Shift Drive Driven Helix*
Weight Clutch Clutch *No
Operating RPM 6000 RPM Spring Spring Adjustment
Ignition System DC/CDI Ignition Meters 0-1800 10 WH Blu/Green Red EBS

(Feet) (0-6000) (5630710) (7041157) (3234451) (3234356)
Ignition Timing 13°± 3 BTDC @ 1150 RPM
1800-3700 10 RH Blu/Green Red EBS
Spark plug / Gap BKR6E / .035 in. / 0.9 mm (6000-12000) (5630709) (7041157) (3234451) (3234356)
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
1.7
GENERAL INFORMATION
2008 SPORTSMAN X-2 500 EFI

Model Number: A08TN50AX, AZ / A08TN50EA
(Intl’ Quadricycle)
Table 1-13: Sportsman X-2 500 EFI General

Specifications
Width 48 in./122 cm
Wheel Base 57 in./145 cm
Ground Clearance 11 in./28 cm
Rear Box Capacity 400 lbs./81.6 kg
Body Style Spirit
Rear box capacity and tongue weight
not to exceed 400 lbs./181kg
1.8
GENERAL INFORMATION
Table 1-14: Sportsman X2 500 EFI Table 1-15: Sportsman X2 500 EFI
ENGINE Drivetrain 1
Platform Fuji Single Cylinder Transmission Type Drumshift - H/L/N/Rev/Park

Rev 21.74:1
Engine Idle Speed 1150 ± 50 RPM Clutch Type PVT w/EBS
Engine Max Operating Rpm 6000 Rpm ± 200 Rpm Belt 3211113
Cooling System / Capacity Liquid - 2.7 qt / 2.5 ltr Steering / Suspension
Overheat Warning HOT on Instrument Cluster Front Suspension / Shock A-arm / MacPherson Strut
Lubrication Pressurized Dry Sump Front Travel 8.2 in. / 20.8 cm
Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 ltr Rear Suspension / Shock Progressive Rate Independent -
Exhaust System Single Pipe USFS Approved Coil - over shock
Fuel System Rear Travel 8.75 in. / 22.2 cm

Ground Clearance 11 in. / 28 cm
Fuel System Electronic Fuel Injection (EFI)
Shock Preload Adjustment Front -Non Adjustable.
Fuel Pump (in tank assembly) 25L per hr. at 39 psi
Fuel Filter(s) 30 micron in tank - (not replaceable)
Turning Radius 82 in./208 cm unlocked
Fuel Injector(s) Visteon
Toe Out 0-1/16 in / .0 - .159 mm
EFI Controller Visteon
Wheels / Brakes
Fuel Capacity / Requirement 6 gal US / 22.7 liters
87 Octane (minimum) Wheel Size / Pattern - Front Steel 12x6 / 4-156
or 89 Oxygenated Wheel Size / Pattern - Rear Steel 12x8 / 4-156
Electrical Front Tire Size 25x8-12
Alternator Output 350 w @ 6000 RPM Rear Tire Size 25x11-12
Lights : Pod 50 watts Recommended Air Pressure Front & Rear - 5 psi
Grill 2 x 37 watts Brake - Front Dual Hydraulic Disc
Brake 2 x 8.26 watts Brake - Rear Dual Hydraulic Disc
Tail 2 x 26.9 watts
Worklight 2 x 13 watts Table 1-16: A08TN50A Clutching
Indicator 1 watt
Altitude Shift Drive Driven Helix*
Operating RPM 6000 RPM Weight Clutch Clutch *No
Spring Spring Adjustment
Ignition System DC/CDI Ignition
Meters 0-1800 10 WH Blu/Green White/Yel EBS
Ignition Timing 10°± 1 BTDC @ 1150 RPM (Feet) (0-6000) (5630710) (7041157) (7041635) (5131674)
Spark plug / Gap BKR6E / .035 in. / 0.9 mm 1800-3700 10 RH Blu/Green White/Yel EBS
(6000-12000) (5630709) (7041157) (7041635) (5131674)
Lights 20 Amp
1.9
GENERAL INFORMATION
2008 SPORTSMAN TOURING 500 EFI

Model Number: A08DN50AF, AS, AZ / A08DN50EA
(Intl’ Quadricycle)
Table 1-17: Sportsman Touring 500 EFI

General Specifications
Width 48 in./122 cm
Wheel Base 57 in./145 cm
Ground Clearance 11 in./28 cm
Rear Rack Capacity 180 lbs./82 kg
Body Style Spirit
1.10
GENERAL INFORMATION
Table 1-18: Sportsman Touring 500 EFI Table 1-19: Sportsman Touring 500 EFI
ENGINE Drivetrain 1
Platform Fuji Single Cylinder Transmission Type Drumshift - H/L/N/Rev/Park

Rev 21.74:1
Engine Idle Speed 1150 ± 50 RPM Clutch Type PVT w/EBS
Engine Max Operating Rpm 6000 Rpm ± 200 Rpm Belt 3211113
Cooling System / Capacity Liquid - 2.7 qt / 2.5 ltr Steering / Suspension
Overheat Warning HOT on Instrument Cluster Front Suspension / Shock A-arm / MacPherson Strut
Lubrication Pressurized Dry Sump Front Travel 8.2 in. / 20.8 cm
Oil Requirements / Capacity Polaris 0W-40 2 qt. / 1.9 ltr Rear Suspension / Shock Progressive Rate Independent -
Exhaust System Single Pipe USFS Approved Coil - over shock
Fuel System Rear Travel 8.75 in. / 22.2 cm

Ground Clearance 11 in. / 28 cm
Fuel System Electronic Fuel Injection (EFI)
Shock Preload Adjustment Front -Non Adjustable.
Fuel Pump (in tank assembly) 25L per hr. at 39 psi
Fuel Filter(s) 30 micron in tank - (not replaceable)
Turning Radius 82 in./208 cm unlocked
Fuel Injector(s) Visteon
Toe Out 0-1/16 in / .0 - .159 mm
EFI Controller Visteon
Wheels / Brakes
Fuel Capacity / Requirement 6 gal US / 22.7 liters
87 Octane (minimum) Wheel Size / Pattern - Front Steel 12x6 / 4-156
or 89 Oxygenated Wheel Size / Pattern - Rear Steel 12x8 / 4-156
Electrical Front Tire Size 25x8-12
Alternator Output 350 w @ 6000 RPM Rear Tire Size 25x11-12
Lights : Pod 50 watts Recommended Air Pressure Front & Rear - 5 psi
Grill 2 x 37 watts Brake - Front Dual Hydraulic Disc
Brake 2 x 8.26 watts Brake - Rear Dual Hydraulic Disc
Tail 2 x 26.9 watts
Worklight 2 x 13 watts Table 1-20: A08DN50A Clutching
Indicator 1 watt
Altitude Shift Drive Driven Helix*
Operating RPM 6000 RPM Weight Clutch Clutch *No
Spring Spring Adjustment
Ignition System DC/CDI Ignition
Meters 0-1800 10 WH Blu/Green White/Yel EBS
Ignition Timing 10°± 1 BTDC @ 1150 RPM (Feet) (0-6000) (5630710) (7041157) (7041635) (5131674)
Spark plug / Gap BKR6E / .035 in. / 0.9 mm 1800-3700 10 RH Blu/Green White/Yel EBS
(6000-12000) (5630709) (7041157) (7041635) (5131674)
Lights 20 Amp
1.11
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.
1.12
GENERAL INFORMATION
SAE Tap Drill Sizes Decimal Equivalents
Thread Size/ Drill Size Thread Size / Drill Size 1/64 .................
1/32 . . . . . . . . . . . . .
.0156
.0312 . . 1 mm= .0394"
1
#0-80 3/64 1/2-13 27/64 3/64 ................. .0469
#1-64 53 1/2-20 29/64 1/16 . . . . . . . . . . . . . .0625
#1-72 53 9/16-12 31/64 5/64 ................. .0781 . . 2 mm = .0787"
3/32 . . . . . . . . . . . . . .0938
#2-56 51 9/16-18 33/64 7/64 ................. .1094 . . 3 mm =.1181"
#2-64 50 5/8-11 17/32 1/8 . . . . . . . . .1250
#3-48 5/64 5/8-18 37/64 9/64 ................. .1406
5/32 . . . . . . . . . . . . . .1563 . . 4 mm = .1575"
#3-56 45 3/4-10 21/32 11/64 ................. .1719
#4-40 43 3/4-16 11/16 3/16 . . . . . . . . . . . . . .1875 . . 5mm= .1969"
13/64 ................. .2031
#4-48 42 7/8-9 49/64
7/32 . . . . . . . . . . . . . .2188
#5-40 38 7/8-14 13/16 15/64 ................. .2344 . . 6 mm = .2362"
#5-44 37 1-8 7/8 1/4 . . . . . . . . .25
17/64 ................. .2656 . . 7 mm = .2756"
#6-32 36 1-12 59/64 9/32 . . . . . . . . . . . . . .2813
#6-40 33 1 1/8-7 63/64 19/64 ................. .2969
#8-32 29 1 1/8-12 1 3/64 5/16 . . . . . . . . . . . . . .3125 . . 8mm= .3150"
21/64 ................. .3281
#8-36 29 1 1/4-7 1 7/64 11/32 . . . . . . . . . . . . .3438 . . 9 mm = .3543"
#10-24 24 1 1/4-12 1 11/64 23/64 ................. .3594
#10-32 21 1 1/2-6 1 11/32 3/8 . . . . . . . . .375
25/64 ................. .3906 . . 10 mm = .3937"
#12-24 17 1 1/2-12 1 27/64 13/32 . . . . . . . . . . . . .4063
#12-28 4.6mm 1 3/4-5 1 9/16 27/64 ................. .4219 . . 11 mm =.4331"
1/4-20 7 1 3/4-12 1 43/64 7/16 . . . . . . . . . . . . . .4375
29/64 ................. .4531
1/4-28 3 2-4 1/2 1 25/32 15/32 . . . . . . . . . . . . .4688 . . 12 mm = .4724"
5/16-18 F 2-12 1 59/64 31/64 ................. .4844
1/2 . . . . . . . . .5. . . . ....... 13mm = .5118"
5/16-24 I 2 1/4-4 1/2 2 1/32
33/64 ................. .5156
3/8-16 O 2 1/2-4 2 1/4 17/32 . . . . . . . . . . . . .5313
3/8-24 Q 2 3/4-4 2 1/2 35/64 ................. .5469 . . 14 mm = .5512"
9/16 . . . . . . . . . . . . . .5625
7/16-14 U 3-4 2 3/4 37/64 ................. .5781 . . 15 mm = .5906"
7/16-20 25/64 19/32 . . . . . . . . . . . . .5938
39/64 ................. .6094
Metric Tap Drill Sizes 41/64
5/8 . . . . . . . . .625. .
.................
.......
.6406
16mm=. 6299"
21/32 . . . . . . . . . . . . .6563 . . 17 mm =.6693"

Tap Size Drill Size Decimal Nearest 43/64 ................. .6719
Equivalent Fraction
11/16 . . . . . . . . . . . . .6875
3x.50 #39 0.0995 3/32 45/64 ................. .7031 . . 18 mm = .7087"
3x.60 3/32 0.0937 3/32 23/32 . . . . . . . . . . . . .7188
47/64 ................. .7344 . . 19 mm = .7480"
4x.70 #30 0.1285 1/8
3/4 . . . . . . . . .75
4x.75 1/8 0.125 1/8 49/64 ................. .7656
5x.80 #19 0.166 11/64 25/32 . . . . . . . . . . . . .7813 . . 20 mm = .7874"
51/64 ................. .7969
5x.90 #20 0.161 5/32 13/16 . . . . . . . . . . . . .8125 . . 21 mm =.8268"
6x1.00 #9 0.196 13/64 53/64 ................. .8281
7x1.00 16/64 0.234 15/64 27/32 . . . . . . . . . . . . .8438
55/64 ................. .8594 . . 22 mm = .8661"
8x1.00 J 0.277 9/32 7/8 . . . . . . . . .875
8x1.25 17/64 0.265 17/64 57/64 ................. .8906 . . 23 mm = .9055"
9x1.00 5/16 0.3125 5/16 29/32 . . . . . . . . . . . . .9063
59/64 ................. .9219
9x1.25 5/16 0.3125 5/16 15/16 . . . . . . . . . . . . .9375 . . 24 mm = .9449"
10x1.25 11/32 0.3437 11/32 61/64 ................. .9531
31/32 . . . . . . . . . . . . .9688 . . 25 mm = .9843"
10x1.50 R 0.339 11/32 63/64 ................. .9844
11x1.50 3/8 0.375 3/8 1. . . . . . . . . . 1.0
12x1.50 13/32 0.406 13/32
12x1.75 13/32 0.406 13/32
1.13
GENERAL INFORMATION
Conversion Table
Unit of Measure Multiplied by Converts to

ft. lbs. x 12 = in. lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.356 = Nm
in. lbs. x .0115 = kg-m
Nm x .7376 = ft. lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 = in. lbs.
kg-m x 10 = Nm
in. x 25.4 =mm
mm x .03937 = in.
in. x 2.54 = cm
mile (mi.) x 1.6 = km
km x .6214 = mile (mi.)
Ounces (oz.) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x 0.035 = Ounces (oz.)
lb. x .454 = kg
kg x 2.2046 = lb.
Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in)
Imperial pints (Imp pt.) x 0.568 = Liters (l)
Liters (l) x 1.76 = Imperial pints (Imp pt.)
Imperial quarts (Imp qt.) x 1.137 = Liters (l)
Liters (l) x 0.88 = Imperial quarts (Imp qt.)
Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.)
US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.)
US quarts (US qt.) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt.)
US gallons (US gal) x 3.785 =Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x 0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)
π(3.14)xR x H (height)
2
= Cylinder Volume
°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F

°F to °C: 5 (°F + 40) ÷ 9 - 40 = °C
1.14
GENERAL INFORMATION
Glossary Of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
1
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 cm). Polaris measures chain length in number of pitches.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between
centers on V blocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage.
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. lb. / Foot Pound: A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/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 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
1.16
MAINTENANCE
CHAPTER 2
MAINTENANCE
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2
LUBRICATION / FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
SPORTSMAN COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
SPORTSMAN X2-TOURING COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . 2.8
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . . 2.9
POLARIS LUBRICANT SYMBOL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
LUBRICATION COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
ADC DIFFERENTIAL HYDRAULIC CIRCUIT FLUID CHANGE. . . . . . . . . . . . . . . . . . . 2.14
VEHICLE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
SHIFT LINK ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
THROTTLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL ADJUSTMENT . . . . . . . 2.15
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
CHOKE (ENRICHER) ADJUSTMENT - (500 CARB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
ACTIVE DESCENT CONTROL (ADC) RESERVOIR LEVEL. . . . . . . . . . . . . . . . . . . . . 2.18
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
LIQUID COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
RADIATOR/GRILL SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
RADIATOR COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
AIR FILTER/PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
AIR BOX SEDIMENT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
BREATHER FILTER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
BREATHER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
RECOIL HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
OIL PUMP PRIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
INTAKE VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
EXHAUST VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
TIE ROD END/STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
TOE ALIGNMENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
BRAKE SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
2.1
MAINTENANCE
HOSE/FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
AUXILIARY BRAKE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
AUXILIARY BRAKE ADJUSTMENT (HYDRAULIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
SUSPENSION SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
FRONT SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
WHEEL REMOVAL FRONT OR REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
STORAGE COMPARTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
WINCH OPERATION (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
ATV CLEANING & STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36
SPORTSMAN 500 CARBURETED MAINTENENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
CHOKE (ENRICHER) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
PILOT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
PILOT SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39
IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40
CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.41
2.2
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.
2
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately
10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the
oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to
rise, discontinue use and determine the cause or see your dealer.
Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:
= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.
= SEVERE USE ITEM --If vehicle is subjected to severe use, decrease interval by 50%
(Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm
use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is required
under these conditions. Fluid changes, cable 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 determine cause.)
E= Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
WARNING
Improperly performing the procedures marked with

a could result in component failure and lead to
serious injury or death. Have an authorized Polaris
dealer perform these services.
2.3
MAINTENANCE
Item Maintenance Interval Remarks
(whichever comes first)
Hours Calendar Miles
(KM)
Steering - Pre-Ride -
Front-suspension - Pre-Ride -
Rear-suspension - Pre-Ride -
Tires - Pre-Ride -
ADC fluid level - Pre-Ride -
Brake fluid level - Pre-Ride - Make adjustments as needed.
Brake lever travel - Pre-Ride -
Brake systems - Pre-Ride -
Wheels /fasteners - Pre-Ride -
Frame fasteners - Pre-Ride -
Engine oil level - Pre-Ride -
E
Passenger Seat Lock Out - Pre-Ride - Verify Seat is secured
Dump Box Operation - Pre-Ride - Verify Box is latched
Air filter, pre-filter - Daily - Inspect; clean often
E
Air box sediment tube - Daily - Drain deposits when visible
E
Check level daily, change coolant every 2
Coolant - Daily -
years
Check operation; apply dielectric grease if
Headlamp/tail lamp - Daily -
replacing
Air filter, - Weekly - Inspect; replace as needed
E main element
Drain water as needed, check often if
Recoil housing - Weekly -
operating in wet conditions
Brake pad wear 10 H Monthly 60 (100) Inspect periodically

Battery 20 H Monthly 125 (200) Check terminals; clean; test
Front gearcase oil (if
equipped)
25 H Monthly 155 (250) Inspect level; change yearly
Middle gearcase oil (if

equipped)
Rear gearcase oil
(if equipped)
Transmission oil 25 H 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
MAINTENANCE
(KM)

E
Engine breather
filter (if equipped)
25 H Monthly 155 (250) Inspect; replace if necessary 2
Engine oil change
25 H 1M 155 (250)
Perform a break-in oil change at one
E (break-in) month
General Lubricate all grease fittings, pivots,
lubrication
50 H 3M 310 (500)
cables, etc.
Shift Linkage 50 H 6M 310 (500) Inspect, lubricate, adjust
Steering 50 H 6M 310 (500) Lubricate
Front suspension 50 H 6M 310 (500) Lubricate
Rear suspension 50 H 6M 310 (500) Lubricate
Throttle Cable/ETC Inspect; adjust; lubricate; replace if
50 H 6M 310 (500)
E Switch necessary
Air intake ducts/ Inspect ducts for proper sealing/air
E 50 H 6M 310 (500)
flange leaks
Drive belt 50 H 6M 310 (500) Inspect; adjust; replace as needed
Cooling system Inspect coolant strength seasonally;
50 H 6M 310 (500)
(if applicable) pressure test system yearly
Engine oil change
100 H 6M 620 (1000)
Perform a break-in oil change at 25
E hours/one month
Oil filter change 100 H 6M 620 (1000) Replace with oil change
E
Oil tank vent hose 100 H 12 M 620 (1000) Inspect routing, condition
E
Valve clearance 100 H 12 M 620 (1000) Inspect; adjust
E
2.5
MAINTENANCE
(Km)
620 Check for leaks at tank cap, lines, fuel valve, filter,
Fuel system 100 H 12M
E (1000) pump, carburetor; replace lines every two years
620
Fuel Filter 100 H 12M Replace yearly
E (1000)
Radiator 620
(if applicable) 100 H 12M
(1000)
Inspect; clean external surfaces
Cooling hoses 620
(if applicable) 100 H 12M
(1000)
Inspect for leaks
620
Engine mounts 100 H 12M
(1000)
Inspect
Exhaust muffler / 620
100 H 12M Inspect
pipe (1000)
620
Spark plug 100 H 12M Inspect; replace as needed
E (1000)
620
Ignition Timing 100 H 12M Inspect
E (1000)
620 Inspect for wear, routing, security; apply dielectric
Wiring 100 H 12M
(1000) grease to connectors subjected to water, mud, etc.
Clutches (drive 620
100 H 12M Inspect; clean; replace worn parts
and driven) (1000)
Front wheel 1000
100 H 12M Inspect; replace as needed
bearings (1600)
1240
Brake fluid 200 H 24M Change every two years
(2000)
1860
Spark arrestor 300 H 36M Clean out
(3000)
Toe adjustment - Inspect periodically; adjust when parts are replaced
Auxiliary brake - Inspect daily; adjust as needed

Headlight aim - Adjust as needed
2.6
MAINTENANCE
LUBRICATION / FLUIDS
SPORTSMAN Component Locations
(Deluxe)
Choke - 500 Carburetor
(Sportsman Only)
2.7
MAINTENANCE
SPORTSMAN X2-Touring Component locations
Instrument Cluster AWDSwitch
(Sportsman X2 Shown) Brake Fluid Reservoir Worklight (Speedometer)
Brake Lever
Diagnostic Light Control

Port (under access panel) & Run Switch
Reverse Throttle
Override Differential Lock Switch
Front Storage Ignition/Key
Compartment
& Rack
Front Demand
Drive Unit X2 Rear Dump Box / Passenger Area
(Behind Radiator)
Battery (Under Tank)

Oil Dipstick
PVT Cover
Gear Shifter Gas Cap
Muffler
Transmission
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
PART
DESCRIPTION
Table 2-1: NUMBER
Coolant
PART
DESCRIPTION
2
2871323 60/40 Coolant (Gallon) (6 count)
NUMBER
2871534 60/40 Coolant (Quart) (12 count)
Engine Lubricant
Additives / Sealants / Thread Locking Agents / Misc.
2870791 Fogging Oil (12 oz. Aerosol)
2874275 Loctite™ Primer N, Aerosol
Engine Oil (Quart) Premium Synthetic
2876244
2W-50 (4-cycle) (12 count) Loctite™ Thread Sealant 565
2871956
Engine Oil (Gallon) Premium Synthetic (50 ml.) (6 count)
2876245
2W-50 (4-cycle) (4 count) Loctite™ Threadlock 242
2871950
Gearcase / Transmission Lubricants (6 ml.) (12 count)
2876251 Demand Drive LT Premium Hub Fluid Loctite™ Threadlock 262
2871951
2867144 Polaris ADC Hydraulic Fluid (50 ml.) (10 count)
Premium Synthetic AGL Gearcase Lube Loctite™ Threadlock 271
2873602 2871953
(12 oz. bottle) (12 count) (6 ml.) (12 count)
Premium Synthetic AGL Gearcase Lube 3-Bond 1215 Sealant
2873603 2871557
(1 Gal. bottle) (4 count) (5 oz.)
Premium ATV Angle Drive Fluid Premium Carbon Clean
2876160 2871326
(32 oz.) (12 count) (12 oz.) (12 count)
Premium ATV Angle Drive Fluid 2870652 Fuel Stabilizer (16 oz.) (12 count)
2872276
(2.5 Gal.) (2 count)
Black RTV Silicone Sealer
2870465 Oil Pump for 1 Gallon Jug 2871957
(3 oz. tube ) (12 count)
Grease / Specialized Lubricants Black RTV Silicone Sealer
Premium All Season Grease 2871958
2871322 (11 oz. cartridge) (12 count)
(3 oz. cartridge) (24 count) 2872189 DOT 4 Brake Fluid (12 count)
Premium All Season Grease 2871557 Crankcase Sealant, 3 Bond 1215 (5 oz.)
2871423
(14 oz. cartridge) (10 count)
2871460 Starter Drive Grease (12 count)
Premium U-Joint Lube
2871515
(3 oz.) (24 Count)
Premium U-Joint Lube
2871551
(14 oz.) (10 count)
2871312 Grease Gun Kit
2871329 Dielectric Grease (Nyogel™)
2.9
MAINTENANCE
Polaris Lubricant Symbol Identification Pre-ride / Daily Inspection
NOTE: The symbols used are for quick reference in identifying Perform the following pre-ride inspection daily, and when
which lubricant/grease to use on each component. 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;
Polaris DOT 4 Do not overfill oil tank
Brake Fluid Polaris Synthetic AGL
Gearcase Lube • All brakes - check operation and adjustment (includes
auxiliary brake)
Polaris ADC
Hydraulic Fluid • Throttle -check for free operation
• Headlight/Taillight/Brakelight - check operation of all
indicator lights and switches
Polaris Synthetic • Engine stop switch - check for proper function

Polaris 60/40
2W/50 Coolant • 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
Polaris ATV Angle Polaris Demand Drive
Drive Fluid LT Hub Fluid • Loose parts - visually inspect vehicle for any damaged
or loose nuts, bolts or fasteners
• Engine coolant - check for proper level at the recovery
bottle
Polaris U-Joint Lube Polaris All
Season Grease • ADC Fluid Level - check for proper level
2.10
MAINTENANCE
Lubrication Components
1. Engine Oil 2. Transmission Fluid
2
5. Front A-Arm
3. Front Gearcase
4. Brake Fluid
7. Front Propshaft
6. Rear A-Arm
# ITEM LUBE METHOD FREQUENCY*

Change after 1st month, 6 months, or 100
Check dipstick and add to hours thereafter; Change more often (25-50
1. Engine Oil Polaris 2W/50
proper level. hours) in extremely dirty conditions, or short
trip cold weather operation.
Polaris AGL Synthetic
2. Transmission Add lube to bottom fill hole. Change annually o
Gearcase Lube
Demand Drive LT Gearcase - Change annually o
3A. Front Gearcase Drain completely. Add lube to
Premium
3B. ADC Fluid specified quantity. ADC - Change fluid every 2 years
Polaris ADC Hydraulic
Fill master cylinder reservoir
4. Brake Fluid Polaris DOT 4 Brake Fluid As required, change fluid every 2 years
to indicated level
5. Front A-Arm Polaris All Season Grease Locate fitting and grease. Semi-annually n
6. Rear A-Arm Polaris All Season Grease Locate fitting and grease Semi-annually n
7. Front Propshaft Polaris U-Joint Greasep Locate fitting and grease. Semi-annually n
* More often under severe use, such as operated in water or under severe loads.
1 Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
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 All Season Grease, Conoco Superlube M or
Mobilegrease Special
2.11
MAINTENANCE
Front Gearcase Lubrication To Change Gearcase Lubricant:
The front gearcase lubricant level should be checked and

changed in accordance with the maintenance schedule. Verify
gearcase type to ensure proper fill level amount.
• 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
Drain Plug
1. Remove gearcase drain plug (A) located on the bottom of

the gearcase and drain oil. (The drain plug is accessible
Fill Plug through the skid plate.) Catch and discard used oil
8-10 ft.lbs. properly.
(11-14 Nm) 2. Clean and reinstall drain plug (A) using a new sealing
washer (B). Torque to specification.
Drain Plug
11 ft.lbs. (15 Nm)
Fill Plug
Specified Lubricant:
Demand Drive LT Premium Hub Fluid
(PN 2876251) Left Side View
CH Gearcase Capacity: 8.97 oz. (265 ml.)

3. Remove fill plug. Inspect the O-ring.
ADC Gearcase Capacity: 9.3 oz. (275 ml.)
4. Fill with the recommended fluid amount or to the bottom
of the fill plug hole threads. (See Illustration below).
Front Gearcase
=T
Fill Plug Torque: 8-10 ft.lbs. (11-14 Nm)
Drain Plug Torque: 11 ft.lbs. (15 Nm)

Fill -
To Check the Lubricant Level: Demand Drive LT
The front and rear gearcase lubricant level cannot be checked Premium
with a dipstick. The gearcase must be drained and re-filled with Hub Fluid
the proper amount of lubricant or be filled to the bottom of the
fill plug hole threads. Refer to procedures.
5. Install / torque fill plug and check for leaks.
2.12
MAINTENANCE
Transmission Lubrication 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
2
Transmission - Specified Lubricant: metallic filings.
Polaris AGL Gearcase Lubricant
(Gallon - PN 2873603) (12 oz. - PN 2873602)
Transmission - Capacity:
32 oz. (948 ml)
=T
Transmission Drain / Fill Plug Torque:
20-25 ft.lbs. (27-34 Nm)
The transmission lubricant level should be checked and changed
in accordance with the maintenance schedule. Drain Plug
To check the level:
3. After the oil has drained completely, install a new sealing
1. Be sure vehicle is level before proceeding washer (if installed) and install the drain plug. Torque to
2. Clean around fill plug area. specification.
3. Remove fill plug located on the left side of the ATV. 4. Add the proper lubricant through the fill plug hole until the
4. Fluid should be filled to bottom of fill plug hole threads. oil level is to the bottom of the fill plug hole threads. Do
Add the proper lubricant as required to bring level into not overfill.
operating range as shown.
Oil Fill Plug

Oil Fill Plug
Oil Fill Level-

Oil Fill Level- Bottom Fill Plug
Bottom Fill Plug Hole Threads
Hole Threads
5. Check for leaks.
5. Install the check plug and torque it to specification
2.13
MAINTENANCE
ADC Differential Hydraulic Circuit Fluid VEHICLE INSPECTION
Change
1. Make sure vehicle is parked on flat ground and allowed to
Shift Link Rod Inspection
sit at least 30 minutes prior to bleeding hydraulic circuit. NOTE: Shift rod is preset at time of manufacturer.
2. Thoroughly clean area around and on remote reservoir and
bleeder valves. 1. Inspect shift link tie rod ends and replace if worn or
3. Remove reservoir cap and diaphragm assembly. damaged. Lubricate pivot points with a light aerosol
4. Make sure hydraulic oil inside reservoir is free of debris. lubricant or grease if desired.
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. Shift Mount
5. Begin the bleeding process by filling reservoir to ‘MAX’

line with clean Polaris ADC hyrdraulic fluid.
6. Locate bleeder valves found on either side of differential
and remove the protective caps. Shifter
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 Shift Link Rod
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.
=T
Bleeder Valve Torque:
80 in. lbs. (9 Nm)
10. Fill reservoir with to a level midway between ‘MAX’ and

‘MIN’ fill lines. Verify no debris is found in reservoir oil.
11. Replace reservoir cap securely and wipe clean any residue.
2.14
MAINTENANCE
Throttle Inspection Throttle Cable / Electronic Throttle Control
(ETC Switch) Adjustment
Check for smooth throttle opening and closing in all handlebar
positions. Throttle lever operation should be smooth and lever 1. Slide boot off throttle cable adjuster and jam nut.
must return freely without binding. 2. Place shift selector in neutral and set parking brake.
1. Place the gear selector in Park. 3. Loosen lock nut on in-line cable adjuster (Ill. 1).
2.
3.
Set parking brake.
Start the engine and let it idle. Boot
2
4. Turn handlebars from full right to full left. If idle speed Boot
Adjuster Sleeve Lock Nut
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.
2
3
1
4. Turn adjuster until specified freeplay is achieved at thumb

6 lever. (see illustration). After making adjustments, quickly
5
4 actuate the thumb lever several times and reverify freeplay.
ETC Cover
Removal Sequence
III. 1
To remove the ETC cover:

1. Use a 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 Direction of Travel
release snap.
1/16-1/8” Freeplay
3. Repeat procedure at the other five locations as shown.
NOTE: Do not attempt to remove cover until all latch
points are released.
= In. / mm.
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. Turn handlebars from left to right through the entire turning
range. If idle speed increases, check for proper cable
routing. If cable is routed properly and in good condition,
repeat adjustment procedure
2.15
MAINTENANCE
Fuel System Fuel Lines
EFI Example
WARNING
* Gasoline is extremely flammable and explosive

under certain conditions.
* EFI 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 powered 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 the lines secured with cable ties.
* Do not smoke or allow open flames or sparks in
or near the area where refueling is performed or CAUTION
where gasoline is stored.
* If you get gasoline in your eyes or if you should
swallow gasoline, seek medical attention Make sure lines are not kinked or pinched
immediately. 3. Replace all fuel lines every two years.
* If 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
and electrical components when removing fuel Check fuel tank, oil tank, crankcase, carburetor, battery and
transmission vent lines for signs of wear, deterioration, damage
filter. or leakage. Replace every two years.
• Always stop the engine and refuel outdoors or in a well Be sure vent lines are routed properly and secured with cable
ventilated area. ties.
• Do not smoke or allow open flames or sparks in or near

the area where refueling is performed or where gasoline CAUTION
is stored.
• Do not overfill the tank. Do not fill the tank neck. Make sure lines are not kinked or pinched
• If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately.
• If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water and change
clothing.
• 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: 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
EFI Example during a compression test.
2
Smooth idle generally indicates good compression. Low engine
compression is rarely a factor in running condition problems
above idle speed. Abnormally high compression can be caused
by a decompressor malfunction, or worn or damaged exhaust
cam lobes. Inspect camshaft and automatic decompression
mechanism if compression is abnormally high.
A cylinder leakage test is the best indication of engine condition
on models with automatic decompression. Follow
manufacturer’s instructions to perform a cylinder leakage test.
(Never use high pressure leakage testers as crankshaft seals may
dislodge and leak).
1. Locate filter at the front of the ATV. NOTE: Remove Cylinder Compression
Standard 60-90 PSI
access panels if necessary.
2. Remove fuel lines from filter. Cylinder Leakage
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%)
4. Install clamps on fuel line (if required).
5. Turn ignition to “ON”.
Engine Mounts
6. Start engine and inspect for leaks.
Inspect rubber engine mounts (A) for cracks or damage. Check
Choke (Enricher) Adjustment - (500 Carb) engine fasteners and ensure they are tight.
Verify free-play and smooth operation of the choke cable.

Adjustments to the choke can be made by turning the cable A
adjustment in or out to gain the desired cable free-play.
= In. / mm.
Choke Cable Freeplay: 1/16 - 3/16" (1.6 - 4.76mm)
2.17
MAINTENANCE
Spark Plug Active Descent Control (ADC) Reservoir
Level
1. Remove spark plug high tension lead. Clean plug area so
no dirt and debris can fall into engine when plug is The Active Descent Control reservoir (Equipped Models Only)
removed. is located by the radiator fill cap. Check the level and verify it
2. Remove spark plug. is between the ‘MAX’ and ‘MIN’ lines. Add only Polaris ADC
fluid when required.
3. Inspect electrodes for wear and carbon buildup. Look for a
sharp outer edge with no rounding or erosion of the
electrodes.
4. Clean with electrical contact cleaner or a glass bead spark

plug cleaner only. CAUTION: A wire brush or coated
abrasive should not be used.
5. Measure gap with a wire gauge. Refer to specifications for
Battery Maintenance
proper spark plug type and gap. Adjust gap if necessary by Complete battery servicing information for both conventinoal
bending the side electrode carefully. and sealed batteries can be found in Chapter 10 of this
manual.
Spark Plug Gap
WARNING
Battery electrolyte is poisonous. It contains sulfuric

acid. Serious burns can result from contact with
skin, eyes or clothing. Antidote:
.036” (0.9 mm) External: Flush with water.
Internal: Drink large quantities of water or milk.

6. If necessary, replace spark plug with proper type. Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.
CAUTION
Eyes: Flush with water for 15 minutes and get
prompt medical attention.
Severe engine damage may occur if the incorrect
spark plug is used. Batteries produce explosive gases. Keep sparks,
flame, cigarettes, etc. away. Ventilate when
7. Apply a small amount of anti-seize compound to the spark charging or using in an enclosed space. Always
plug threads. shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
8. Install spark plug and torque to specification.
NOTE: Expected battery shelf life is 6-8 months
depending on storage conditions. As a general rule
=T before placing the battery into service, check the
battery condition and charge accordingly.
Recommended Spark Plug
Refer to the Specifications page in
Chapter 1 for spark plug type.
Spark Plug Torque: 14 Ft. Lbs. (19 Nm)
2.18
MAINTENANCE
New Batteries: Batteries must be fully charged Cooling System Hoses
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. 2
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 1. Inspect all hoses for cracks, deterioration, abrasion or
temperature decreases the contracting (cooled) coolant is drawn leaks. Replace if necessary.
back up from the tank past the pressure cap and into the radiator. 2. Check tightness of all hose clamps.
Some coolant level drop on new machines is normal as the
system is purging itself of trapped air. Observe coolant levels CAUTION
often during the break-in period.
Overheating of engine could occur if air is not fully purged from Do not over-tighten hose clamps at radiator,
system. or radiator fitting may distort,
Polaris Premium 60/40 is already premixed and ready to use. Do causing a restriction to coolant flow.
not dilute with water. Radiator hose clamp torque is 36 in. lbs. (4 Nm).
Coolant Strength / Type

Radiator/Grill Screen
Test the strength of the coolant using an antifreeze hydrometer.
Antifreeze Hydrometer
• A 50/50 or 60/40 mixture of antifreeze and distilled

water will provide the optimum cooling, corrosion
protection, and antifreeze protection.
1. Check radiator (A) air passages for restrictions or damage.
• Do not use tap water, straight antifreeze, or straight Check and clean the radiator screen (B).
water in the system. Tap water contains minerals and
impurities which build up in the system. 2. Carefully straighten any bent radiator fins.
3. Remove any obstructions with compressed air or low
• Straight water or antifreeze may cause the system to
freeze, corrode, or overheat. pressure water.
Polaris 60/40 Anti-Freeze/ Coolant

(PN 2871323)
2.19
MAINTENANCE
Cooling System Pressure Test NOTE: Use of a non-standard pressure cap will not
allow the recovery system to function properly.
Refer to Chapter 3 for pressure test procedure.
Coolant Level Inspection

Remove
The recovery bottle, located on the left side of the machine, must Cover
be maintained between the minimum and maximum levels
indicated on the recovery bottle.
Recovery Bottle
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.
With the engine at operating temperature, the coolant level The pre filter should be inspected before each ride, and if
should be between the upper and lower marks on the coolant required, cleaned using the following procedure:
reservoir. If not:
1. Lift up on the rear of the seat.
1. Remove reservoir cap. Inner splash cap vent hole must be 2. Pull the seat back and free of the tabs.
clear and open.
NOTE: When reinstalling seat, make sure the slots
2. Fill reservoir to upper mark with Polaris Premium 60/40
in the seat engage the tabs in the fuel tank.
Anti Freeze / Coolant or 50/50 or 60/40 mixture of
antifreeze and distilled water as required for freeze 3. Remove clips (A) from air box cover and remove cover.
protection in your area. Inspect the gasket. It should adhere tightly to the cover and
3. Reinstall cap. seal all the way around.
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. A
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.
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
MAINTENANCE
4. Loosen clamp and remove air filter assembly.
Proper Filter Placement Main Filter
Cover
2
Filter Support
Pre-Filter
Gasket Air Box
Main Element
Carb Boot Front
Cleaning: NOTE: The air filter should rest on the filter support.
5. Slip the pre-filter element off of main element. Clean the Proper placement of the air filter is important to prevent
pre filter with hot, soapy water. rattles and air leaks. See Illustration above.
6. Rinse and dry thoroughly. 11. Install air box cover and secure with clips.
7. Inspect element for tears or damage.
8. Inspect main filter and replace if necessary. If the filter has Air Box Sediment Tube
been soaked with fuel or oil it must be replaced.
Periodically check the air box drain tube located toward the rear
Installation: of the machine. Drain whenever deposits are visible in the clear
9. Reinstall pre-filter element over main filter. Be sure the tube.
element covers entire surface of main filter without folds, 1. Remove drain plug from end of sediment tube.
creases, or gaps. 2. Drain tube.
10. Reinstall filter on main filter mount. Place filter clamp over 3. Reinstall drain plug.
the assembly and tighten.
NOTE: Apply a small amount of general purpose grease
to the sealing edges of the filter before reinstalling.
Filter Clamp
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 Recoil Housing
Four-cycle ATV engines are equipped with a breather filter. The
in-line filter is similar in appearance to a fuel filter, and is visible
on the left side (Location A).
In-line breather filters can be installed in either direction. B
Typical Breather Filter Location
Recoil Drain
• Drain the housing periodically to remove moisture.

• Drain the recoil housing after operating the ATV in very
In-Line Breather Filter wet conditions. This should also be done before storing
Location A 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 been drained.
Breather Hose
• CAUTION: Make sure the manual start handle (B) is
1. Be sure breather line is routed properly and secured in fully seated on the recoil housing, especially when
travelling in wet areas. If it is not sealed properly, water
place. CAUTION: Make sure lines are not kinked or may enter the recoil housing and damage components.
pinched.
• Water will enter the recoil housing if the starter handle
NOTE: In-line breather filter service life is extended (B) is disengaged from the rope guide when under
when the foam air box pre-filter is in place and water.
maintained properly. Never operate the engine without • After travelling in wet areas the recoil housing and
the pre-filter. 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.
2.22
MAINTENANCE
Engine Oil Level Oil and Filter Change
Oil Filter Torque:

Turn by hand until filter gasket
2
contacts sealing surface, then
turn an additional 1/2 turn
Oil Filter Wrench:

(PV-43527)
Oil Tank Screen Fitting Torque:

25 ft-lb (34Nm)
A Recommended Engine Oil:
Polaris Premium 4 All Season

Synthetic, 2W-50
The oil tank is located on the left side of the vehicle. To check
the oil level:
1. Set machine on a level surface.
2. Clean the area around the dip stick. WARNING
3. Start and run engine for 20-30 seconds. This will return oil
to its true level in the oil tank. Personal injury can occur when handling used
oil. Hot oil can cause burns or skin damage.
4. Stop engine, remove dipstick (A) and wipe dry with a clean
cloth. NOTICE: Care must be taken to ensure that the fluids are
5. Reinstall dipstick, screw the dipstick into place. contained. Be prepared to collect the fluid with suitable
containers before opening any compartment or disassembly of
NOTE: The dipstick must be screwed completely in to any component containing fluids.
ensure accurate measurement.
1. Place vehicle on a level surface.
2. Clean area around drain plug (A) at bottom of oil tank.
ADD 8 OZ. NORMAL FULL 3. Run engine two to three minutes until the engine is warm.
4. After two or three minutes stop the engine.
5. Place a drain pan beneath oil tank and remove the drain plug
Maintain Oil Level In Normal range (A). CAUTION: Oil may be hot. Do not allow hot oil to
Screw Dipstick in completely to check come into contact with skin as serious burns may result.
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
D
the bottom line on the dipstick. Add oil as indicated by the
level on the dipstick. Do not overfill.
B
NOTE: Rising oil level between checks in cool weather
driving, can indicate moisture collecting in the oil A E
reservoir. If the oil level is over the full mark, change the
oil. C
Reference mark
6. Allow oil to drain completely.

7. Replace sealing washer (B) on drain plug (A).
2.23
MAINTENANCE
NOTE: The sealing surfaces on the drain plug and 16. Using a clean dry cloth, clean filter sealing surface on the
the oil tank should be clean and free of burrs, nicks crankcase.
or scratches. 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.
8. Reinstall the drain plug (A) and torque it to specification.
18. Install the new filter and turn it by hand until the filter
gasket contacts the sealing surface, then turn an additional
=T 1/2 of a turn.
19. Approximately 1 cup of engine oil will remain in the
Oil Tank Drain Plug Torque: crankcase. To drain, remove drain plug found on lower right
14 ft. lbs. (19 Nm) side of crankcase.
Crankcase Drain Plug Torque: Engine Sump

14 ft. lbs. (19 Nm) Drain
9. Loosen clamp (D).

10. Remove oil hose (E) from screen fitting (C) on bottom of
oil 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 Engine Sump Drain Plug- Bottom View
(clockwise) into the tank threads. Then rotate the screen
fitting clockwise until the nipple of the screen fitting aligns NOTE: The sealing surfaces on the drain plug and
with the reference marking on the tank. crankcase should be clean and free of burrs, nicks or
scratches.
CAUTION
20. Reinstall drain plug and torque to specification.
Maximum torque for the screen fitting 21. Remove dipstick and fill tank with 2 quarts (1.9 L) of
is 25 ft-lb (34Nm), do not over tighten. Polaris Premium 4 Synthetic Oil.
22. Place gear selector in Park and set parking brake.
NOTE: Maximum torque for the screen fitting is 25
NOTE: Clamp or pinch off the vent line 2” from the oil
ft-lb (34Nm), do not over tighten.
tank as shown in the Oil Pump Priming Procedure.
14. Install oil hose (E) on fitting (C) and re-install clamp (D). 23. Re-check the oil level on the dipstick and add oil as
15. Place shop towels beneath oil filter. Use Oil Filter Wrench necessary to bring the level to the upper mark on the
(PV-43527), turn filter counterclockwise to remove. dipstick.
24. Dispose of used filter and oil properly.
Oil Filter
2.24
MAINTENANCE
Oil Pump Priming Procedure Valve Clearance
NOTE: This priming procedure must be performed Inspect and adjust valve clearance while the engine is cold and
whenever the oil hose connection between the oil the piston positioned at Top Dead Center (TDC) on compression
tank and pump inlet has been disconnected. stroke.
1. Remove the seat.
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
2. Remove body panels and fuel tank as necessary to gain
access to valve cover. 2
line’s pressure relief slit 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.
Slit
CAUTION
(A) Failure to position the crankshaft at TDC on
compression stroke will result in improper valve
adjustment.
2. Run engine at IDLE for 10-15 seconds.

Sprocket alignment pin facing up
3. Remove the vent line clamp. The oil pump will now be
properly primed and ready for field operation. Note: If the
system is primed properly you should hear some air release.
If you do not, the system has not primed. Repeat the process
if necessary.
(A) Vent Hose to Air Box
Oil Lines Crankshaft-to-Camshaft Centerline

To Engine
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 “T” 1. Insert a .006" (.15mm) feeler gauge between end of
mark aligned with the pointer in the timing inspection hole. exhaust valve stem and adjuster screw(s).
In this position there should be clearance on all valves. 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 engines valves.
NOTE: Both feeler gauges should remain inserted
during adjustment of each valve.
EXHAUST VALVE CLEARANCE

.006” (.15 mm)
3. When clearance is correct, hold adjuster screw and tighten

locknut securely.
Intake Valve Clearance Adjustment 4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until clearance is
1. Insert a .006" (.15mm) feeler gauge between end of intake correct with locknut secured.
valve stem and clearance adjuster screw.
2. Using a 10 mm wrench and a screwdriver, loosen adjuster Steering
lock nut and turn adjusting screw until there is a slight drag
on the feeler gauge. The steering components should be checked periodically for
3. Hold adjuster screw and tighten adjuster lock nut securely. loose fasteners, worn tie rod ends, and damage. Also check to
make sure all cotter pins are in place. If cotter pins are removed,
4. Re-check the valve clearance. they must not be re-used. Always use new cotter pins.
5. Repeat adjustment procedure if necessary until clearance is Replace any worn or damaged steering components. Steering
correct with locknut secured. should move freely through entire range of travel without
6. Repeat this step for the other intake valve. 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
INTAKE VALVE CLEARANCE alignment. Use only genuine Polaris parts.
.006” (.15 mm)
WARNING
Exhaust Valve Clearance Adjustment 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.
Feeler gauge for both valves
NOTE: The exhaust valves share a common rocker

arm, and must be adjusted using two feeler gauges.
2.26
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
section can be used as an indicator of whether the
handlebars are straight. The center section should always
point straight back from the steering post. 2
3. Place a chalk mark on the center line of the front tires
approximately 10" (25.4 cm) from the floor or as close to
the hub/axle center line as possible. NOTE: It is important
that the height of both marks be equally positioned in order
to get an accurate measurement.
4. Measure the distance between the marks and record the
measurement. Call this measurement “A”.
5. Rotate the tires 180o by moving vehicle forward or
backward. Position chalk marks facing rearward, even with
the hub/axle centerline.
6. Again measure the distance between the marks and record.
• Replace any worn steering components. Steering should Call this measurement “B”. Subtract measurement “B”
move freely through entire range of travel without from measurement “A”. The difference between
binding.
measurements “A” and “B” is the 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, and then at front and rear. Try to move the wheel of the tire (A) is 1/8" to 1/4" (.3 to .6 cm) wider than the
and hub by pushing inward and pulling outward. measurement at the rear (B)
• If abnormal movement is detected, inspect the hub and III. 1
wheel assembly to determine the cause ( possible loose
wheel nuts or loose front hub components).
Chalk Line
Measurement
“A” Measurement “B”
Check for Loose Wheel or Hub

= In. / mm.
• 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 Exhaust Pipe
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
WARNING
before determining which tie rod(s) need adjustment.
• Do not perform clean out immediately after the
engine has been run, as the exhaust system
CAUTION becomes very hot. Serious burns could result
from contact with exhaust components.
During tie rod adjustment, it is very important that the • To reduce fire hazard, make sure that there are no
following precautions be taken when tightening tie combustible materials in the area when purging
the spark arrestor.
rod end jam nuts. If the rod end is positioned
incorrectly it will not pivot, and may break • Wear eye protection.
• Do not stand behind or in front of the vehicle
while purging the carbon from the spark arrestor.
Hold
Rod End • 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:
Correctly Incorrectly 1. Remove the clean out plugs located on the bottom of the
Tightened Tightened muffler.
Jam Nut Jam Nut
III. 2
To adjust toe alignment:

• Hold tie rod end to keep it from rotating.
• Loosen jam nuts at both end of the tie rod.
Clean Out Plug
• Shorten or lengthen the tie rod until alignment is as III. 1
required to achieve the proper toe setting as specified.
2. Place the transmission in Park and start the engine. Purge
• IMPORTANT: When tightening the tie rod end jam accumulated carbon from the system by momentarily
nuts, the rod ends must be held parallel to prevent rod
end damage and premature wear. Damage may not be revving the engine several times.
immediately apparent if done incorrectly. See
illustration 2.
• After alignment is complete, torque jam nuts to
specification.
=T
Tie Rod Jam Nut Torque:
12-14 ft. lbs. (16-19 Nm)
2.28
MAINTENANCE
3. If some carbon is expelled, cover the exhaust outlet and Brake System Inspection
lightly tap on the pipe around the clean out plugs with a
rubber mallet while revving the engine several more times. 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. 2
• Use Polaris DOT 4 Brake Fluid
Sight Glass
4. If particles are still suspected to be in the muffler, back the

machine onto an incline so the rear of the machine is one
foot higher than the front. Set the hand brake and block the
wheels. Make sure the machine is in Park and repeat Steps
2 and 3. SEE WARNING
5. If particles are still suspected to be in the muffler, drive the Parking Lock Brake
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
• Use Polaris DOT 4 Brake Fluid
2 and 3. SEE WARNING
1 ft.
6. Repeat steps 2 through 5 until no more particles are

expelled when the engine is revved.
7. Stop the engine and allow the arrestor to cool. • Check brake for excessive travel or spongy feel.
8. Reinstall the clean out plugs. • 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 Auxiliary Brake Testing
Pads should be changed when the friction material is worn to The auxiliary brake should be checked for proper function.
.180” / 4.6 mm, or about the thickness of a dime.
Auxiliary Brake
.180” / 4.6 mm,

Minimum Thickness
= In. / mm. 1.
2.
Support the rear wheels off the ground.
While turning the rear wheels by hand, apply the auxiliary
foot brake. This brake should not stop the wheels from
Brake Pad Service Limit: turning until the lever is half way between its rest position
.180" (4.6 mm) and bottoming on the footrest.
Auxiliary Foot Brake Pedal
Hose/Fitting Inspection
Full Height Full
Check brake system hoses and fittings for cracks, deterioration, Engagement
abrasion, and leaks.Tighten any loose fittings and replace any
worn or damaged parts.
Floor
Board Surface
2.30
MAINTENANCE
Auxiliary Brake Adjustment (Hydraulic) Suspension Spring
Preload Adjustment
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 lb. (approx.) Center Spring
downward force on the pedal. The top of the pedal should be at Adjustment Ring
least 1 inch, (25.4mm) above the surface of the footrest.
1
2
2
1/8, to 1/4, 1” or
50 lbs greater
Free Play
Floorboard
Shock Spanner Wrench
(PN 2871095)
If less than one inch, two things must be examined: Operator weight and vehicle loading affect suspension spring
preload requirements. Adjust as necessary, using the spanner
Free Play: wrench (2) to turn the adjustment cam (1).
Front Suspension
= In. / mm.
Compress and release front suspension. Damping
Foot Brake Freeplay: should be smooth throughout the range of travel.
1/8 - 1/4" (3.2 - 6.35 mm) Check all front suspension components for wear or damage.
If free play is excessive, inspect pedal, linkage, and master Inspect front strut cartridges for leakage.
cylinder for wear or damage and replace any parts as needed.
CV Shaft Boot Inspection
Bleeding:
If free play is correct and brake pedal travel is still excessive, air Inspect the CV shaft boots in the front and rear of the ATV for
may be trapped somewhere in the system. Bleed the hydraulic damage, tears, wear, or leaking grease. If the rubber boot
auxiliary brake system in a conventional manner, following the exhibits any of these symptoms, replace the boot. Refer to
procedure outlined in Brake Chapter 9. Chapter 7 for CV boot replacement.
Inspect Boots
2.31
MAINTENANCE
Controls Wheel, Hub, And Spindle
Torque Table
Item Specification
Steel - Front Wheel Nuts 27 Ft. Lbs. (37 Nm)
Steel - Rear Wheel Nuts 27 Ft. Lbs. (37Nm)
Aluminum
90 Ft. Lbs. (122 Nm)
Front Wheel Nuts
Aluminum
90 Ft. Lbs. (122 Nm)
Rear Wheel Nuts
Front Hub Retaining Nut 60 ft.lbs. (81 Nm)
Rear Hub Retaining Nut 80 Ft. Lbs. (109 Nm)
Check controls for proper operation, positioning and
adjustment. Wheel Removal Front or Rear
Brake control and switch must be positioned to allow brake Front & Rear Wheels
lever to travel throughout entire range without contacting switch
body. Front & Rear
Throttle Wheel Nuts (4)
assembly See table Below
clamp
Front Hub Nut

60 ft. lbs. (81 Nm)
Rear Hub Nut

80 ft. lbs. (109 Nm)
Align clamp
edge with
knurl
1. Stop the engine, place the transmission in Park and lock the
parking brake.
Align throttle control assembly clamp with knurl on handlebar. 2. Loosen the wheel nuts slightly.
Wheels • Elevate the side of the vehicle by placing a suitable

stand under the footrest frame.
Inspect all wheels for runout or damage. Check wheel nuts and
ensure they are tight. Do not over tighten the wheel nuts.
WARNING
Operating an ATV with worn tires will increase the

possibility of the vehicle skidding and possible loss
of control.
Worn tires can cause an accident.
Always replace tires when the tread depth

measures 1/8” (.3 cm) or less.
3. Remove the wheel nuts and remove the wheel.
Inspect all wheels for runout or damage. Check wheel nuts and
ensure they are tight. Do not over tighten the wheel nuts.
2.32
MAINTENANCE
Wheel Installation Tire Inspection
1. With the transmission in Park and the parking brake • Improper tire inflation may affect ATV
locked, place the wheel in the correct position on the wheel maneuverability.
hub. Be sure the valve stem is toward the outside and • When replacing a tire always use original equipment
rotation arrows on the tire point toward forward rotation. size and type.
2.
3.
Attach the wheel nuts and finger tighten them.
Lower the vehicle to the ground.
• The use of non-standard size or type tires may affect
ATV handling.
2
4. Securely tighten the wheel nuts to the proper torque listed
Tire Tread Depth
in the table.
Always replace tires when tread depth is worn to 1/8" (3 mm)
Steel Wheel Aluminium Wheel or less.
Tread
Depth 1/8” (3 mm)
CAUTION
WARNING
If wheels are improperly installed it could affect
vehicle handling and tire wear. On vehicles with Operating an ATV with worn tires will increase the
tapered rear wheel nuts, make sure tapered end of possibility of the vehicle skidding easily with
nut goes into taper on wheel. possible loss of control.
Tire Pressure Worn tires can cause an accident.
Always replace tires when the tread depth

CAUTION measures 1/8” (.3 cm) or less.
Maintain proper tire pressure. Refer to the warning tire Frame, Nuts, Bolts, Fasteners
pressure decal applied to the vehicle.
Periodically inspect the torque of all fasteners in accordance
with the maintenance schedule. Check that all cotter pins are in
Tire Pressure Inspection (PSI - Cold) place. Refer to specific fastener torques listed in each chapter.
Front Rear
5 5
2.33
MAINTENANCE
Storage Compartments Winch Operation (If Equipped)
The storage compartments are easily accessible. To open the This information is for Sportsman models equipped with a
front compartment turn the latch handle to the horizontal winch in the front.
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.
Unlatch
Winch Handlebar Controls

The winch is located in the front bumper area.
Latch
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.
2.34
MAINTENANCE
Winch Control
The winch control located on the side of the winch gives the Winch Connecting
operator easy access to switch between ENGAGED and Splash Guard for Contactor mount Harness
FREESPOOL.
When the winch is ENGAGED, the winch only allows the cable
2
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.
LFREESPOOL
Right Side Front Fender
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.
ENGAGE
Winch Connecting Wire
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
Yellow (6 Ga.) wires to the winch. Refer to the installation
instructions for more details.
Winch Connector
The Orange/White wires are located under the front cover

(under headlight pod). The Orange/White wires supply the
control power to the winch.
2.35
MAINTENANCE
ATV Cleaning & Storage Oil and Filter
Warm the engine and change the oil and filter. Follow the
Cleaning the ATV
procedure in this chapter for proper oil change.
Keeping your ATV clean will not only improve its appearance Air Filter / Air Box
but it can also extend the life of various components. With a few
precautions, your ATV can be cleaned much like an automobile. Inspect and clean or replace the pre-cleaner and air filter. Clean
the air box and drain the sediment tube.
Washing the ATV
Breather Filter
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 Inspect and clean or replace the breather filter.
washing mitten, cleaning the upper body first and the lower parts
last. Rinse with water frequently and dry with a chamois to Fluid Levels
prevent water spots. NOTE: If warning and safety labels are Inspect the following fluid levels and change if necessary: front
damaged, contact your a Polaris dealer for free replacement. gearcase; transmission; brake fluid (change every two years or
Polaris does not recommend the use of a high pressure type car as required if fluid looks dark or contaminated).
wash system for washing the ATV. If a high pressure system is Drain the Recoil Housing
used, exercise extreme care to avoid water damage to the wheel
bearings, transmission seals, body panels, brakes and warning Remove the recoil housing drain plug and drain any moisture.
labels. NOTE: Grease all zerk fittings immediately after
Storage Kits
washing, and allow the vehicle to run for a while to evaporate
any water that may have entered the engine or exhaust system. Polaris offers storage kits for ATVs. See a Polaris dealer or visit
www.purepolaris.com.
Waxing the ATV
Fog the Engine
Your ATV can be waxed with any non-abrasive automotive
paste wax. Avoid the use of harsh cleaners since they can scratch To properly store the engine, use Polaris Fogging Oil according
the body finish. Polaris offers a detailing kit for ATVs. to the directions.
If you choose not to use Polaris Fogging Oil, perform the
CAUTION following procedure:
1. Support the front end of the machine so the engine is level
Certain products, including insect repellents and or tilted slightly rearward.
chemicals, will damage plastic surfaces. Use caution 2. Treat the fuel system with Polaris Carbon Clean according
when using these products near plastic surfaces. to the directions. If Polaris fuel system additive is not used,
fuel tank, and fuel lines should be completely drained of
Storage Tips gasoline
See Page 2.9 for the part numbers of Polaris products. 3. Remove the spark plug and add 2-3 tablespoons of
Synthetic 2W-50 engine oil. To access the plug hole, use a
CAUTION 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
Starting the engine during the storage period will
spark plug cavity into the hole at the front of the cylinder
disturb the protective film created by fogging and
head, and appear to be an oil leak. Install the spark plug
damage could occur. Never start the engine during
and pull the engine over slowly with the recoil starter. Oil
the storage period.
will be forced in and around the piston rings and ring lands,
Clean the Exterior coating the cylinder with a protective film of fresh oil.
4. Apply dielectric grease to the inside of the spark plug cap
Make necessary repairs and then clean the ATV thoroughly with
mild soap and warm water to remove all dirt and grime. Don’t and install the cap onto the plug.
use harsh detergents or high pressure washers. Some detergents 5. Turn the engine over several times with the recoil only to
deteriorate rubber parts. Use dish soap type cleaners only. High ensure coverage of piston rings, cylinder walls and
pressure washers may force water past seals. crankshaft bearings.
Stabilize the Fuel 6. .
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 (500 Carb only).
2.36
MAINTENANCE
Lubricate Transporting the ATV
Inspect all cables and lubricate with Polaris Cable Lubricant. Follow these procedures when transporting the vehicle.
Follow lubrication guidelines in the maintenance section of the 1. Turn off the engine and remove the key to prevent loss
service or owner’s manual to completely grease and lubricate during transporting.
the entire vehicle with Polaris Premium All Season Grease.
2. Always place the transmission in park and lock the parking
2
Storage Tips brake.
Battery Storage 3. Turn the fuel valve off.
Remove the battery from the vehicle and ensure that it’s fully 4. Be sure the fuel cap, oil cap and seat are installed correctly.
charged before placing it in storage. See Chapter 10 for 5. Always tie the frame of the ATV to the transporting unit
instructions. securely using suitable straps or rope.
Engine Anti-Freeze
Test engine 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” off the 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.
2.37
MAINTENANCE
SPORTSMAN 500 CARBURETED

MAINTENENCE
Choke (Enricher) Adjustment
Pilot Screw Location
Brass Plug Installed

Boot
If the choke knob does not stay out when pulled, adjust
the choke tension by tightening (clockwise) the jam nut
under the rubber boot between the choke knob and nut.
Firmly grasp the rubber boot and tighten until the choke
slides freely but stays out when pulled.
Brass Plug Removed
Pilot Screw
The pilot system supplies fuel during engine operation
with the throttle valve closed or slightly opened. The fuel/
air mixture is metered by pilot screw and discharged into
the main bore through the pilot outlet.
CAUTION
The pilot screw is calibrated at the factory to meet

EPA / CARB regulations for air quality standards
and is sealed with a brass plug to prevent tamper-
ing. Removal of the tamper proof plug is not permit-
ted. 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.
2.38
MAINTENANCE
Pilot Screw Adjustment necessary.
5. Slowly turn mixture screw clockwise using the pilot
screw wrench until engine begins to miss.
6. Slowly turn mixture screw counterclockwise until idle
speed increases to maximum RPM. Continue turning
counterclockwise until idle RPM begins to drop.
2
7. Center the pilot screw between the points in Step 5
FRONT
(Engine) and 6.
8. Re adjust idle speed if not within specification.
Idle Speed Adjustment

Pilot Screw
CV Carburetor
Idle Screw
1. Start engine and warm it up thoroughly.

1. Start engine and warm it up to operating temperature 2. Adjust idle speed by turning the idle adjustment
(about 10 minutes). screw in (clockwise) to increase or out
2. Turn pilot screw in (clockwise) until lightly seated. (counterclockwise) to decrease RPM. (Refer to Ill. at
Turn screw out the specified number of turns. NOTE: right).
Do not tighten the pilot screw forcefully against the NOTE: Adjusting the idle speed affects throttle cable
seat or the screw and/or seat will be permanently freeplay and electronic throttle control (ETC) adjustment.
damaged. Always check throttle cable freeplay after adjusting idle
speed and adjust if necessary.
Pilot screws are calibrated at the factory. Each
carburetor has a slightly different pilot screw Idle speed:
setting. The specifications below are the “base”
recommended setting, and may require 1100 +/- 200 RPM
additional tuning to achieve the desired results.
_______________________
Pilot Screw Adjustment:

Sportsman 500 - 2 Turns Out
3. Connect an accurate tachometer that will read in

increments of + or - 50 RPM such as the PET
2100DX (PN 8712100DX) or the PET 2500 (PN
8712500).
4. Set idle speed to 1200 RPM. Always check throttle
cable freeplay after adjusting idle speed and adjust if
2.39
MAINTENANCE
Fuel Filter 3. Turn drain screw out two turns and allow fuel in the
float bowl and fuel line to drain completely.
The fuel filter should be replaced in accordance with the
Periodic Maintenance Chart or whenever sediment is 4. Inspect the drained fuel for water or sediment.
visible in the filter. 5. Tighten drain screw.
Arrow Indicates Direction of Flow 6. Turn fuel valve to “ON”.
7. Start machine and check for leaks.
NOTE: All tubes attached to the carburetor must be
check for pinching or blockage, as this will effect engine
performance
To Carburetor
Drain tube
attached
here
Drain Screw
Fuel valve Located at bottom

of tank / Left Side Panel
1. Shut off fuel supply at fuel valve.
2. Remove seat and locate filter on right side of atv.
NOTE: Remove side panel if necessary.
3. Remove line clamps at both ends of the filter.
4. Remove fuel lines from filter.
5. Install new filter and clamps onto fuel lines with arrow
pointed in direction of fuel flow.
6. Install clamps on fuel line.
7. Turn fuel valve “ON”.
8. Start engine and inspect for leaks.
Carburetor Draining
The carburetor float bowl should be drained periodically
to remove moisture or sediment from the bowl, or before
extended periods of storage.
NOTE: The bowl drain screw is located on the bottom
left side of the float bowl.
1. Turn fuel valve to the OFF position.
2. Place a clean container beneath the bowl drain spigot
or bowl drain hose.
2.40
MAINTENANCE
Maintenance Schedule
Service Date Hours / Miles Service Performed Serviced By:
2.41
MAINTENANCE
Maintenance Schedule
Service Date Hours / Miles Service Performed Serviced By:
2.42
ENGINE
CHAPTER 3
ENGINE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE FASTENER TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
ENGINE REMOVAL (TYPICAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
CYLINDER HONE SELECTION/ HONING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . 3.9
HONING TO OVERSIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
CRANKSHAFT STRAIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE LUBRICATION- EH 50PL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
OIL PRESSURE TEST - EH 50PL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
OIL PUMP PRIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
OIL FLOW - EH50PL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
EH50PL OIL FLOW DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
EH50PL ENGINE EXPLODED VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
ENGINE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
CAM CHAIN TENSIONER/ROCKER ARM/ CAMSHAFT REMOVAL . . . . . . . . . . . . . . 3.14
CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
ROCKER ARM/SHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
AUTOMATIC COMPRESSION RELEASE REMOVAL/INSPECTION . . . . . . . . . . . . . . 3.17
AUTOMATIC COMPRESSION RELEASE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 3.18
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
CYLINDER HEAD EXPLODED VIEW, EH50PL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
CYLINDER HEAD WARP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
COMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
CYLINDER/PISTON REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
PISTON/ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
STARTER DRIVE REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
FLYWHEEL/STATOR REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CAM CHAIN/TENSIONER BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
ONE WAY VALVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
3.1
ENGINE
OIL PUMP REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
COUNTER BALANCER SHAFT REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . 3.34
CRANKSHAFT REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
CRANKCASE BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
PUMP SHAFT OIL SEAL/WATER PUMP MECHANICAL SEAL REMOVAL. . . . . . . . . 3.36
CRANKCASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
BEARING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
END PLAY INSPECTION/ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
CRANKSHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
COUNTER BALANCER SHAFT END PLAY ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . 3.38
OIL PUMP SHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
PUMP SHAFT OIL SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
CRANKSHAFT/COUNTER BALANCE/OIL PUMP INSTALLATION . . . . . . . . . . . . . . . 3.40
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
WATER PUMP MECHANICAL SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
WATER PUMP MECHANICAL SEAL REMOVAL - ENGINE INSTALLED . . . . . . . . . . 3.41
ONE WAY VALVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
CAM CHAIN DRIVE SPROCKET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
TENSIONER BLADE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
CAM CHAIN/CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
STATOR, FLYWHEEL AND STARTER DRIVE INSTALLATION. . . . . . . . . . . . . . . . . . 3.49
ROCKER SHAFT/ROCKER ARM ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . 3.50
THERMOSTAT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
OIL PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
RECOIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
RECOIL DISASSEMBLY/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
RECOIL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
SPARK PLUG FOULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
3.2
ENGINE
SPECIFICATIONS Special Tools
Torque Specifications PART NUMBER TOOL DESCRIPTION

Valve Seat Reconditioning
TORQUE SPECIFICATIONS 2200634
Kit
Fastener Size EH50PLE 2870390 Piston Support Block
Ft. Lbs. (Nm) 2871043 Flywheel Puller
Blind Plug (Oil 1/8 PT 6.5-11 (9-15 Nm) Crankshaft/Water Pump
Pressure) (28tpi) 2871283
Seal Install Kit
3
Camshaft Sprocket 6mm 5-6.5 (7-9 Nm) 5131135 Water Pump Install Kit
Camshaft Chain 6mm 5-6.5 (7-9 Nm) 2870569 Crankshaft Truing Stand
Tensioner Lever
Mity Vac™ Pressure Test
Camshaft Chain 6mm 5-6.5 (7-9 Nm) 2870975
Tool
Tensioner
PV-43527 OIl Filter Wrench
Camshaft Chain 11mm 14-19 (20-25 Nm)
Tensioner Cap
Engine Fastener Torque Patterns
Carburetor Adaptor 8mm 12-14 (16-20 Nm)
Crankcase 8mm 14-15 (19-21 Nm) Tighten cylinder head, cylinder base, and crankcase fasteners in
Crankshaft Slotted Nut 28mm 35-51 (47-69 Nm) 3 steps following the sequence outlined.
(Cam Chain Drive
6mm
Sprocket) 2
3
Cylinder Base Bolts 10mm 45-49 (61-67 Nm) 5
6mm 6-8 (9-11 Nm)
Cylinder Head Bolts 11mm Refer to Engine
6
6mm Assembly for torque
1 4
procedure
Drive Clutch Bolt 7/16 - 20 40 (55 Nm)
Cylinder Head
Flywheel 16mm 58-72 (78-98 Nm)
Cylinder Base
Oil Delivery Pipe 12mm 11-15 (15-21 Nm) Pattern
Oil Drain Bolt 14mm 14-17 (19-23 Nm)
(Crankcase) 7 5 9 10
Oil Filter Pipe Fitting 20mm 36-43 (49-59 Nm)
Oil Hose Fitting 1/8 Pipe 6.5-11 (9-15 Nm)
3 1
Thread
8
Hard Metal Oil Line N/A 11-16 ft.lbs. (15-21
Banjo Fitting Nm) 2
Oil Pump 6mm 5-6.5 (7-9 Nm) 6
Oil Pump Case Screw 5mm 1.5-2 (2-3 Nm) 4
One Way Valve 11mm 14-19 (20-25 Nm)
Recoil Housing 6mm 5-6.5 (7-9 Nm)
Rocker Cover 6mm 7-8 (9-11 Nm) Crankcase
Rocker Support 8mm 8-10 (11-13 Nm) Pattern
Rocker Adjuster Screw 6mm 6-7 (8-10 Nm)
Water Pump Impeller 6mm 5-6.5 (7-9 Nm)
Nut
Water Pump Housing 6mm 5-6.5 (7-9 Nm)
Cover
Stator Plate 6mm 5-6.5 (7-9 Nm)
Starter Motor 6mm 5-6.5 (7-9 Nm)
Spark Plug 14mm 9-11 (12-15 Nm)
Thermistor -- 26 ± 2.1 (35 ± 3 Nm)
3.3
ENGINE
Engine Service Data
Cylinder Head / Valve EH50PLE
Rocker Arm Rocker arm ID .8669-.8678" (22.020-22.041 mm)
Rocker shaft OD .8656-.8661" (21.987-22.0 mm)
Rocker shaft Oil Clearance Std .0008-.0021" (.020-.054 mm)
Limit .0039" (.10 mm)
Camshaft Cam lobe height In Std 1.2884-1.2924” (32.726-32.826 mm)
Limit 1.2766" (32.426 mm)
Ex Std 1.2884-1.2924” (32.726-32.826 mm)
Limit 1.2766" (32.426 mm)
Camshaft journal OD Mag 1.4935-1.4941” (37.935-37.950 mm)
PTO 1.4935-1.4941” (37.935-37.950 mm)
Camshaft journal bore ID Mag 1.4963-1.4970” (38.005-38.025 mm)
PTO 1.4963-1.4970” (38.005-38.025 mm)
Camshaft Oil clearance Std .022-.0035”(.055-.090 mm)
Limit .0039" (.10 mm)
Cylinder Head Surface warpage limit .0020" (.05 mm)
Standard Height 3.870" (98.3 mm)
Valve Seat Contacting width In Std .028" (.7 mm)
Limit .055" (1.4 mm)
Ex Std .039" (1.0 mm)
Limit .071" (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 Std .039" (1.0 mm)
Limit .031" (.8 mm)
Ex Std .047" (1.2 mm)
Limit .031" (.8 mm)
Valve Stem diameter In .2343-.2348" (5.950-5.965 mm)
Ex .2341-.2346" (5.945-5.960 mm)
Stem Oil Clearance Std In .0014-.0024" (.035-.062 mm)
Ex .0016-.0026" (.040-.067 mm)
Limit .0059" (.15 mm)
Overall length In 3.976" (101.0 mm)
Ex 3.984" (101.2 mm)
Valve Spring Overall Length Std 1.654" (42.0 mm)
Limit 1.575" (40.0 mm)
Squareness .075” (1.9 mm)
3.4
ENGINE
Engine Service Data
Cylinder / Piston / Connecting Rod EH50PLE
Cylinder 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)
3
Piston clearance Std .0006-.0018" (0.015-0.045 mm)
Limit .0024” (0.060 mm)
Boring Limit .020” (.5 mm)
Piston Outer diameter Std 3.6204-3.6215” (91.970-91.985mm)
.0098" (.25 mm) OS 3.6304-3.6310” (92.21-92.23 mm)
.0197" (.50 mm) OS 3.6403-3.6407” (92.46-92.47 mm)
Standard inner diameter of piston pin bore .9055-.9057” (23.0-23.006 mm)
Piston Pin Outer diameter .9053-.9055” (22.994-23.0 mm)
Standard clearance-piston pin to pin bore .0002-.0003” (.004-.008 mm)
Degree of fit Piston Pin must be a push (by hand) fit at 68o F (20o
Piston Ring Piston Ring Installed Top ring Std .0079-.0138" (.20-.36 mm)
gap
Limit .039” (1.0 mm)
Second Std .0079-.0138" (.20-.36 mm)
ring
Limit .039” (1.0 mm)
Oil ring Std .0079-.0276" (0.20-0.70 mm)
Limit .059" (1.5 mm)
Piston Ring Standard clearance - Top ring Std .0016-.0031" (0.040.-080 mm)
piston ring to ring
Limit .0059" (.15 mm)
groove
Second Std .0012-.0028" (0.030-0.070 mm)
ring
Limit .0059" (.15 mm)
Connecting Connecting rod small end ID .9058- .9063” (23.007 - 23.020 mm)
Rod
Connecting rod small end radial Std .0003-.0010” (.007-.026 mm)
clearance
Limit .0020 (.05 mm)
Connecting rod big end side Std .0039-.0256” (.1-.65 mm)
clearance
Limit .0315” (.80 mm)
Connecting rod big end radial Std .0004-.0015” (.011-.038 mm)
clearance
Limit .0020” (.05 mm)
Crankshaft Crankshaft runout limit .0024” (.06 mm)
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off.
3.5
ENGINE
GENERAL ENGINE SERVICE Cooling System Specifications
Sensor
Piston Identification 18.5 + ft. lbs.
The piston may have an identification mark or the piston may (25 Nm)
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 “F”, “J ”,“ X” or : must always
be toward the flywheel side of the engine. The other numbers are
used for identification as to diameter, length and design. Four
stroke engine rings are rectangular profile. 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 Approx. Reading
.50 Condition Temperature
(Min-Max)
EH42PLE .25 66 mm B
.50 Temperature 37.3 - 39.2 k Ω 68° F (20° C)
System 2.25 Quarts
*Pistons and rings marked 25 equal .25mm (.010”) oversized
Capacity (2.13L)
*Pistons and rings marked 50 equal .50mm (.020”) oversized Radiator Cap
Relief 13 PSI (89.6 kpa)
Pressure
3.6
ENGINE
Cooling System System Pressure Test
1. Remove radiator cap cover located in storage box.
2. Remove recovery bottle hose from coolant filler.
WARNING 3. Connect a Mity Vac™ (PN 2870975) to radiator and
pressurize system to 10 PSI (68.9 kpa). The system must
Never remove radiator cap when engine is warm or hot. retain 10 lbs of pressure for five minutes or longer. If
The cooling system is under pressure and serious burns pressure loss is evident within five minutes, check radiator,
may result. Allow the engine and cooling system to cool all cooling system hoses and clamps, or water pump seal.
before servicing.
Radiator Cap Pressure Test
3
1. Remove radiator cap and test using a cap tester
FLOW (commercially available).
Radiator 2. The radiator cap relief pressure is 13 lbs (89.6 kpa).
Thermostat Water Pump
Cylinder
Cylinder
Head
Upper Hose
Radiator
Fan
Top
Bottom
Filler Neck Radiator

Lower Hose
Left Side
View
Radiator
Front
Overflow Bottle View
3.7
ENGINE
RECOMMENDED COOLANT Engine Removal (TYPICAL)
Use only high quality antifreeze/coolant mixed with distilled 1. Clean work area.
water in a 50/50 or 60/40 ratio, depending on freeze protection
required in your area.. 2. Thoroughly clean the ATV engine and chassis.
3. Disconnect battery negative(-) cable.
CAUTION 4. Remove the following parts as required.
• Seat
Using tap water in the cooling system will lead to a
buildup of deposits which may restrict coolant flow • Left and Right Side Covers (Refer to Chapter 5)
and reduce heat dissipation, resulting in possible • Fuel Tank Cover / Front Cab (Refer to Chapter 5)
engine damage. Polaris Premium 60/40 Antifreeze/
Coolant is recommended for use in all cooling • Fuel Tank (Refer to Chapter 4)
systems, and comes pre-mixed, ready to use. 5. Disconnect spark plug high tension lead.
6. Remove springs from exhaust pipe and remove pipe.
Accessible Components
7. Drain coolant and engine oil.
The following components can be serviced or removed with the 8. Remove air pre-cleaner and duct.
engine installed in the frame:
9. Remove airbox.
• Flywheel 10. Remove carburetor. Insert a shop towel into the carburetor
• Alternator/Stator flange to prevent dirt from entering the intake port.
11. Remove center chain guard on chain drive AWD models.
• Starter Motor/Starter Drive
12. Remove center drive and driven sprocket bolts and remove
• Cylinder Head chain and sprockets as an assembly.
13. Refer to PVT System to remove outer clutch cover, drive
• Cylinder
belt, drive clutch, driven clutch, and inner cover.
• Piston/RIngs 14. Starter motor. Note ground cable location. Mark positive
• Camshaft (+) cable mounting angle and remove cable.
15. Remove transmission linkage rod(s) from gear selector and
• Rocker Arms secure out of the way.
• Cam Chain and Sprockets 16. Disconnect coolant temperature sensor wire.
• Water Pump / Water Pump Mechanical Seal* 17. Remove engine to chassis ground cable.
18. Remove all engine mount nuts and / or engine mount plates.
The following components require engine removal for
service: 19. Remove engine through right side of frame.
• Oil pump / Oil Pump Drive Gear

• Counterbalance Shaft or Bearing(s)
• Connecting Rod
• Crankshaft
• Crankshaft Main Bearings
• Crankcase
*It may be necessary to loosen engine mounts and move
engine slightly to access water pump. Use the Water
Pump Mechanical Seal Puller (PN 2872105) to replace
mechanical seal with engine in frame.
3.8
ENGINE
Engine Installation Notes Cylinder Hone Selection/ Honing Procedure
After the engine is installed in the frame, review this checklist
and perform all steps that apply.
CAUTION
General Items
1. Install previously removed components using new gaskets, Selecting a hone which will straighten as well as
seals, and fasteners where applicable. remove material from the cylinder is very important.
2. Perform regular checks on fluid levels, controls, and all Using a common spring loaded finger type glaze
important areas on the vehicle as outlined in the daily pre- breaker for honing is never advised. Polaris
ride inspection checklist (refer to Chapter 2 or the Owner’s recommends using a rigid hone or arbor honing
3
Safety and Maintenance Manual). machine which also has the capability of oversizing.
PVT System Cylinders may be wet or dry honed depending upon the
hone manufacturer’s recommendations. Wet honing
1. Adjust center distance of drive and driven clutch. (Chapter removes more material faster and leaves a more distinct
6) pattern in the bore.
2. Adjust clutch offset, alignment, and belt deflection. NOTE: See next page for more information on honing.
(Chapter 6)
3. Clean clutch sheaves thoroughly and inspect inlet and Honing To Oversize
outlet ducts for proper routing and sealing. (Chapter 6)
Transmission CAUTION
1. Inspect transmission operation and adjust linkage if
necessary. Refer to Chapter 2 and Chapter 8. If cylinder wear or damage is excessive, it will be
Exhaust necessary to oversize the cylinder using a new oversize
piston and rings. This may be accomplished by either
1. Replace exhaust gaskets. Seal connections with high temp
boring the cylinder and then finish honing to the final bore
silicone sealant if required.
size, or by rough honing followed by finish honing.
2. Check to be sure all springs are in good condition.
Bleed Cooling System
CAUTION
1. Remove radiator cap and slowly add coolant to top of filler
neck.
2. Fill coolant reservoir tank to full mark. For oversize honing, always wet hone using honing oil
and a coarse roughing stone. Measure the piston (see
3. Install radiator cap and squeeze coolant lines to force air out
piston measurement) and rough hone to the size of the
of system.
piston. Always leave .002 - .003" (.05 - .07 mm) for finish
4. Again remove radiator cap and slowly add coolant to top honing. Refer to piston-to-cylinder clearance
of fill neck. specifications before honing. Complete the sizing with
5. Start engine and observe coolant level in the radiator. Allow fine grit stones to provide the proper cross-hatch finish
air to purge and top off as necessary. Reinstall radiator cap and required piston clearance.
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 All Season synthetic oil, or
API certified “SH” oil.Never substitute or mix oil brands.
Serious engine damage can result.
2. 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.
EXAMPLE OF CROSS HATCH PATTERN
3.9
ENGINE
A finished cylinder should have a cross-hatch pattern to ensure Crankshaft Straightening
piston ring seating and to aid in the retention of the fuel/oil
mixture during initial break in. Hone cylinder according to hone Lubricate the bearings and clamp the crankshaft securely in the
manufacturer’s instructions, or these guidelines: Crankshaft Truing Stand (PN 2870569). Refer to the
illustrations below.
• Use a motor speed of approximately 300-500
RPM, run the hone in and out of the cylinder
rapidly until cutting tension decreases. Remember
to keep the hone drive shaft centered (or cylinder Crankshaft Truing Stand
centered on arbor) and to bring the stones
approximately 1/2” (1.3 cm) above and below the (PN 2870569)
bore at the end of each stroke.
• Release the hone at regular intervals and inspect NOTE: The rod pin position in relation to the dial
the bore to determine if it has been cleared, and to indicator position tells you what action is required to
check piston fit. NOTE: Do not allow cylinder to
heat up during honing. The thinner areas of the straighten the shaft.
liner around the ports will expand causing uneven HIGH .004 (.1 mm)
bore.
• After honing has been completed inspect all port A HIGH .004 (.1 mm)
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 B
solvent, then in hot, soapy water. Pay close attention to areas
where the cylinder sleeve meets the aluminum casting (transfer
port area). Use electrical contact cleaner if necessary to clean SUPPORT CRANKSHAFT HERE
these areas. Rinse thoroughly, dry with compressed air, and oil
the bore immediately with Polaris 4 Cycle Lubricant. 1. To correct a situation like the one shown in the illustration,
strike the shaft at point A with a brass hammer.
HIGH .002 (.05 mm)
HIGH .005 (.13 mm)
A A
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)
A A HIGH .005 (.13 mm)
3.10
ENGINE
3.If the crank rod pin location is 180o from the dial indicator Oil Flow - EH50PL
(opposite that shown above), it will be necessary to spread
the crankshaft at position A as shown in the illustration at The following chart describes the flow of oil through the
EH50PL engine. Beginning at the oil tank, the oil flows through
right. When rebuilding and straightening a crankshaft, a screen fitting in the bottom of the tank and into the oil supply
runout must be as close to zero as possible. hose. The feed side of the oil pump draws oil through the hose
and into the crankcase oil gallery, and then pumps the oil
NOTE: Maximum allowable runout is .0024”. 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
Engine Lubrication- EH 50PL 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
Oil Type:Polaris Premium 4 Synthetic or API certified “SH” element.
2W-50 oil
Capacity:. . . . . . . . Approximately 2 U.S. Quarts (1.9 l)
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. Oil enters the camshaft through the PTO (L)
3
Filter Wrench . . . . (PV-43527) journal. The camshaft journals, cam lobes, and rocker arms are
*Drain Plug / Screen Fitting...14 ft. lbs. (19 Nm) (If fitting is lubricated through holes in the camshaft. The oil lubricates the
removed, follow oil pump priming procedure). cam chain and sprocket and drains to the sump.
*Oil Pressure Specification...20 PSI @ 5500 RPM, Polaris The other oil path from the filter leads through a delivery pipe
2W-50 Synthetic (Engine Hot) to the crankcase main oil gallery, 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
Oil Pressure Test - EH 50PL stator plate prevents oil from entering the stator/flywheel area.
Oil travels through the crankshaft to the crank pin, lubricating
1. Remove blind plug on front left cylinder head. the connecting rod large end bearing directly. Oil also passes
2. Insert a 1/8 NPT oil pressure gauge adaptor into the cylinder through an oil jet (drilled orifice) in the end of the crank pin to
the PTO end main bearings and counterbalancer gears.
head and attach the gauge.
Residual oil from the lubrication of the crankshaft and
3. Start engine and allow it to reach operating temperature, connecting rod indirectly lubricates the cylinder wall, piston,
monitoring gauge indicator. rings, connecting rod small end bearing, piston pin, oil/water
pump drive gears, cam chain and drive sprocket, and Magneto
NOTE: Use only Polaris Premium 4 Synthetic Engine end crankshaft main bearing.
Lubricant (PN 2871281). 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
Oil Pressure at 5500 RPM (Engine Hot): consists of a plunger, return spring, guide plug, and sealing
Standard: 20 PSI washer. When the engine is running, oil pressure lifts the
Minimum: 12 PSI 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
Oil Pump Priming Procedure the sump when the engine is off, inspect the valve sealing
surface for debris or damage. Inspect the return spring for
See “Oil Pump Priming Procedure” on page 2.25. distortion or damage.
3.11
ENGINE
EH50PL Oil Flow Diagram
Internal passage to
camshaft (front left
head bolt)
Vent Hose
Oil Filter
Oil feed to filter
From filter to
crankshaft
One way valve

Bottom fitting is oil
Oil Tank exhaust or return Top fitting is oil
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
Oil Hose Oil Strainer
Oil Gallery (Scavenging)
Screen Fitting
Union Fitting
(Bottom of Tank)
(Upper)
Crankcase
Oil Hose
Crankcase Sprocket
Chain Room Chain Small End
Oil Gallery Bearing
Cam Shaft Rocker Arm Cylinder Sleeve

Oil Pump
(Feed) Journal Rocker Shaft
Prevents oil from
draining into
crankcase with
engine off Indirect Main Bearing
One Way Valve Lubrication (PTO)
Cam Lobe
Delivery Pipe Large End

Bearing
Cam Shaft Oil
Metal
Journal Jet
Oil Filter Crank Pin
Bypass Through Cylinder
Stud Front Left
Crankshaft
Delivery Pipe
Crankcase
Delivery Pipe Oil Gallery
3.12
ENGINE
EH50PL Engine Exploded Views
Crankcase Cylinder/
Cylinder Head
Crankshaft
Valvetrain
and Piston
3.13
ENGINE
ENGINE DISASSEMBLY NOTE: The cam lobe should be pointing down and
valves should have clearance at this point.
Cam Chain Tensioner/ROCKER ARM/
CAMSHAFT Removal
1. Remove ignition timing inspection plug from recoil
housing.
TDC “T” Mark
Rotation Advance Marks

5. Remove cam chain tensioner plug, sealing washer, and
spring.
CAUTION
To position crankshaft at Top Dead Center (TDC) on
compression stroke:
The plug is under spring tension. Maintain inward
2. Rotate engine slowly in the direction of rotation watching pressure while removing.
intake valves open and start to close.
3. Continue to rotate engine slowly, watching camshaft 6. Remove the two 6x25 mm cam chain tensioner flange
sprocket marks and the mark in the timing inspection hole. bolts.
7. Tap 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.
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.
A B
3.14
ENGINE
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 for wear or damage.

Compare to specifications.
Tensioner Spring Free Length:
2.02” (5.13 cm) Rocker Shaft O.D.:
Limit 1.92 (4.88cm)
.8656 - .8661 (21.987-22.0 mm)
4. Measure free length of tensioner spring. Replace spring if

excessively worn. Compare to specifications.
5. Replace entire tensioner assembly if any part is worn or
damaged.
Rocker Arm/Shaft Inspection
Rocker Arm & Support I.D.:

.8669 - .8678 (22.020-22.041 mm)
1. Mark or tag rocker arms to keep them in order for

assembly.
3.15
ENGINE
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 & 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 is
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
1. Remove thermostat housing. sprocket and remove sprocket retaining bolts.
2. Remove camshaft sprocket inspection cover. 7. Slide camshaft inward to allow removal of cam sprocket
and remove sprocket from camshaft and chain.
3.16
ENGINE
8. Secure cam chain with a wire to prevent it from falling into Automatic Compression Release Removal/
the crankcase. Inspection
NOTE: The automatic compression release mechanism can
Sprocket Teeth 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.
C
3
A
Inspect for Areas of Tooth

Wear or Damage
9. Inspect cam sprocket teeth for wear or damage. Replace if B
necessary.
Decompressor Shaft 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. Remove release lever shaft and return spring.
3. Inspect shaft for wear or galling.
4. Inspect lobe on end of release lever shaft and actuator ball
Decompressor Ball for wear and replace if necessary.
Retainer Sleeve
10. Slide camshaft out the PTO side of the cylinder head.
3.17
ENGINE
Automatic Compression Release Installation Camshaft Inspection
1. Slide spring onto shaft. 1. Visually inspect each cam lobe for wear, chafing or
2. Apply engine oil to release lever shaft. damage.
2. Thoroughly clean the cam shaft, making sure the oil feed
The actuator ball must be held outward to allow installation
of the release lever shaft. holes are not obstructed.
Stop Pin
Spring in relaxed position
Lubrication holes
Lobe Height
Cam Lobe Height (Intake & Exhaust)

Std: 1.2884-102924” (32.726-32.826 mm)
Limit: 1.2766” (32.426 mm)
If Camshaft Is 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.
5. Position camshaft as shown at bottom of illustration at
right.
6. 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
ENGINE
3. Measure height of each cam lobe using a micrometer. Cylinder Head Removal
Compare to specifications.
Journal O.D 1. Remove the two 6mm flange bolts (A) from cylinder head.
See next exploded view on next page.
2. Loosen each of the four cylinder head bolts (B) evenly 1/8
turn each time in a criss-cross pattern until loose.
3
B
Journal
Camshaft Journal O.D.:

Mag & PTO End: 1.4935-1.4941”
(37.935- 37.950 mm)
4. Measure camshaft journal outside diameter (O.D.)

3. Remove bolts (B) and tap cylinder head lightly with a
5. Measure ID of camshaft journal bore.
plastic hammer until loose. CAUTION: Tap only in
reinforced areas or on thick parts of cylinder head casting
Camshaft Journal I.D.: to avoid damaging the thread.
Mag & PTO End: 1.4963-1.4970” 4. Remove cylinder head and head gasket.
(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.
3.19
ENGINE
Cylinder Head Exploded View, EH50PL
EH50PL
3.20
ENGINE
Cylinder Head Inspection 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.
A
3
(A)
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

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.
Cylinder Head Warp Limit:

.002” (.05 mm)
2. Remove spring retainer and spring.
1. Lay a straight edge across the surface of the cylinder head NOTE: The valve springs should be positioned with the
at several different points and measure warpage by tightly wound coils against the cylinder head on
inserting a feeler gauge between the straight edge and the progressively wound springs (A).
cylinder head surface. If warpage exceeds the service limit, 3. Push valve out, keeping it in order for reassembly in the
replace the cylinder head. same guide.
3.21
ENGINE
4. Measure free length of spring with a Vernier caliper. Check seat area (B). NOTE: The valves cannot be re-faced or end
spring for squareness. Compare to specifications. Replace ground. Valves must be replaced if worn, bent, or damaged.
spring if either measurement is out of specification 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.
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.
Valve Guide I.D.:

.2362-.2367” (6.0-6.012 mm)
6. Measure valve guide inside diameter at the top middle and

end of the guide using a small hole gauge and a micrometer.
Measure in two directions, front to back and side to side.
2. Check valve face for runout, pitting, and burnt spots. To
7. Subtract valve stem measurement to obtain stem to guide
check for bent valve stems, mount valve in a drill or use “V”
clearance.
blocks and use a dial indicator.
NOTE: Be sure to measure each guide and valve
A 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.
B
3. Check end of valve stem for flaring, pitting, wear or damage

(A).
4. Inspect split keeper groove for wear or flaring of the keeper
3.22
ENGINE
Combustion Chamber 3. Heat cylinder head in an oven or use a hot plate to bring
cylinder head temperature to 212o F (100o C).
CAUTION
Do not use a torch to heat cylinder head or warpage may

result from uneven heating. Head temperature can be
checked with a pyrometer or a welding temperature
stick. Wear the appropriate safety equipment for
working with heated metal.
Follow the manufacturers instructions provided in the

Valve Seat Reconditioning Kit. Abrasive stone seat
3
reconditioning equipment can also be used. Keep all
valves in order with their respective seat.
Clean all accumulated carbon deposits from combustion

chamber and valve seat area with a soft wire brush.
Valve Seat Reconditioning

Valve Seat Inspection Too Uneven Good Too
Inspect valve seat in cylinder head for pitting, burnt spots, Wide Narrow
roughness, and an uneven surface. If any of the above
conditions exist, the valve seat must be reconditioned. If NOTE: Valve seat width and point of contact on the
the valve seat is cracked the cylinder head must be
replaced. valve face is very important for proper sealing. The valve
Cylinder Head Reconditioning must contact the valve seat over the entire
circumference of the seat, and the seat must be the
NOTE: Servicing the valve guides and valve seats proper width all the way around. If the seat is uneven,
requires special tools and a thorough knowledge of compression leakage will result. If the seat is too wide,
reconditioning techniques. Follow the instructions seat pressure is reduced, causing carbon accumulation
provided in the cylinder head service tool kit. Only use and possible compression loss. If the seat is too narrow,
service kits designed specifically for ATV engines. heat transfer from valve to seat is reduced and the valve
may overheat and warp, resulting in burnt valves.
CAUTION 4. When thoroughly heated, place cylinder head on blocks of
wood which will allow the old guides to be removed.
Wear eye protection when performing cylinder head 5. Using valve guide driver, drive guides out of the cylinder
service. Valve guide replacement will require heating of head from the combustion chamber side. Be careful not to
the cylinder head. Wear gloves to prevent burns. damage guide bore or valve seat when removing guides.
Valve Guide Removal/Installation
1. Remove all carbon deposits from the combustion chamber,
valve seat and valve guide area before attempting to
remove valve guides.
CAUTION
Carbon deposits are extremely abrasive and may

damage the valve guide bore when guides are removed.
2. Place new valve guides in a freezer for at least 15 minutes

while heating cylinder head.
3.23
ENGINE
6. Place cylinder head on cylinder head table. NOTE: Be sure 11. Apply cutting oil to valve seat and cutter.
cylinder head is still at 212o F (100o C) before installing
new guides.
Valve Guide Installed Height
12. Place 46o cutter on the pilot and make a light cut.
Valve Guide Height: 13. Inspect the cut area of the seat.
.689-.709” (17.5-18.0 mm)
• If the contact area is less than 75% of the
circumference of the seat, rotate the pilot 180o and
7. Place a new guide in the valve guide installation tool and make another light cut.
press guide in to proper depth. Check height of each guide
• If the cutter now contacts the uncut portion of the
above the cylinder head (A). NOTE: The guide can also be seat, check the pilot. Look for burrs, nicks, or
driven in to the proper depth. Inspect the guide closely for runout. If the pilot is bent it must be replaced.
cracks or damage if a driver is used.
• If the contact area of the cutter is in the same
Reaming The Valve Guide place, the valve guide is distorted from improper
installation and must be replaced. Be sure the
cylinder head is at the proper temperature and
replace the guide.
• If the contact area of the initial cut is greater than
75%, continue to cut the seat until all pits are
removed and a new seat surface is evident.
NOTE: Remove only the amount of material
necessary to repair the seat surface.
(A)
8. 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 14. To check the contact area of the seat on the valve face, apply
to rotate reamer clockwise during removal of the tool. a thin coating of Prussian Blue™ paste to the valve seat. If
9. Clean guides thoroughly with hot soapy water and a nylon using an interference angle (46o) apply black permanent
brush. Rinse and dry with compressed air. Apply clean marker to the entire valve face (A).
engine oil to guides. 15. Insert valve into guide and tap valve lightly into place a few
10. Install pilot into valve guide. times.
3.24
ENGINE
16. Remove valve and check where the 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 a
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.
• If the indicated seat contact is at the top edge of
the valve face and contacts the margin area(B) it is 17. Clean all filings from the area with hot soapy water, rinse,
too high on the valve face. Use the 30o cutter to and dry with compressed air.
lower the valve seat.
18. Lubricate the valve guides with clean engine oil, and apply
• If too low use the 60o or 75o 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.
• If the seat is too wide or uneven, use both top and
19. Insert the valve into its respective guide and lap using a
lapping tool or a section of fuel line connected to the valve
3
bottom cutters to narrow the seat. stem.
20. Rotate the valve rapidly back and forth until the cut sounds
• If the seat is too narrow, widen using the 45o cutter
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: other valve(s).
Intake Std: .028” (.7 mm) A

Limit: .055” (1.4 mm)
Exhaust Std: .039” (1.0 mm)
Limit: .071” (1.8 mm)
Seat
Width
21. Clean cylinder head, valves, and camshaft oil supply

passage (A) thoroughly.
22. If oil passage blind plug was removed, apply Crankcase
Sealant (PN 2871557) or equivalent sealer to the threads
Bottom - 60o or 75o Seat - 45o or 46o and install, torquing to 8 ft. lbs. (11 Nm).
Top - 30o
CAUTION
Do not allow sealant to enter oil passage.
23. Spray electrical contact cleaner into oil passage and dry
using compressed air.
3.25
ENGINE
Cylinder Head Assembly Valve Sealing Test
1. Clean and dry the combustion chamber area.
CAUTION 2. Pour a small amount of clean, high flash point solvent into
the intake port and check for leakage around each intake
Wear eye protection during assembly. valve. The valve seats should hold fluid with no seepage.
3. Repeat for exhaust valves by pouring fluid into exhaust
NOTE: Assemble the valves one at a time to maintain port.
proper order.
Valve Clearance Adjustment
1. Install new valve seals on valve guides. Feeler gauge for both valves
2. Apply engine oil to valve guides and seats.
3. Coat valve stem with molybdenum disulfide grease. NOTE: The valves share a common rocker arm, and
4. Install valve carefully with a rotating motion to avoid must be adjusted using two feeler gauges.
damaging valve seal. 1. Insert .006 feeler gauge(s) between end of exhaust valve
5. Dip valve spring and retainer in clean engine oil and install stem and adjuster screw(s).
spring with closely spaced coils toward the cylinder head. 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 is correct, hold adjuster screw and tighten

locknut securely
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until clearance is
6. Place retainer on springs and install valve spring correct with locknut secured.
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
ENGINE
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 cam chain guide at front of cylinder. NOTE: The bolts are inside the water jacket.
6. 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.
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
ENGINE
Piston Removal *By hand: Placing both thumbs as shown, spread the ring open
and push up on the opposite side. Do not scratch the ring lands.
1. Remove circlip. Note piston directional arrow pointing

toward the right (Mag) side of engine. 3. Repeat procedure for second ring.
1. Remove piston circlip and push piston pin out of piston. If The oil control ring is a three piece design consisting 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
oil ring land of the piston.
2. Remove top compression 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.
CAUTION
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
ENGINE
3. Inspect cylinder for wear, scratches, or damage. 2. Subtract this measurement from the maximum cylinder
measurement obtained in Step 5 above.
1/2” Down From Top of Cylinder
Y Piston to Cylinder Clearance

X
Std: .0006- .0018” (.015- .045 mm)
Piston O.D.:
Y
X Std: 3.6204- 3.6215” (91.970-91.985 mm)
X
Y
Piston/Rod Inspection
3
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, on 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
replaced.
Piston Pin Bore:
Cylinder Taper .9055-.9057” (23.0-23.006 mm)
Limit: .002 Max.
Cylinder Out of Round
Limit: .002 Max. 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.

40 mm
.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
ENGINE
Piston Ring Installed Gap
1. Place each piston ring inside cylinder using piston to push
ring squarely into place as shown at right.
Feeler Gauge
Cylinder 25-50 mm
2. Measure piston pin O.D. Replace piston and/or piston pin

if out of tolerance.
3. Measure connecting rod small end ID. Piston Ring
Piston
Piston Ring Installed Gap
Ring
Top Ring
Std: .0079- .0138” (.20- .36 mm)
Limit: .039” (1.0 mm)
Second Ring
Std: .0079- .0138” (.20- .36 mm)
Limit: .039” (1.0 mm)
Oil Ring
Feeler Gauge Std: .0079- .0276” (.20- .70 mm)
Limit: .059” (1.5 mm)
2. Measure installed gap with a feeler gauge at both the top

and bottom of the cylinder.
Piston Ring-to-Groove Clearance NOTE: A difference in end gap indicates cylinder taper.
Top Ring Std: .0016-.0031” (.040-.080 mm) The cylinder should be measured for excessive taper
Limit: .0059” (15 mm) and out of round
Second Ring Std: .0012-.0028” (.030-.070 mm)
Limit: .0059” (15 mm)
3. If the bottom installed gap measurement exceeds the
service limit, replace the rings. If ring gap is below
4. Measure piston ring to groove clearance by placing the ring specified limit, file ring ends until gap is within specified
in the ring land and measuring with a thickness gauge. range.
Replace piston and rings if ring-to-groove clearance
exceeds service limits 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 the engine
in the frame.
3.30
ENGINE
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 90o
1. Remove recoil housing bolts and remove housing. apart to determine if bushing is out of round. Calculate
bushing clearance. Replace bushing if clearance exceeds
the service limit.
6. Inspect gear teeth on starter drive. Replace starter drive if
gear teeth are cracked, worn, or broken.
Flywheel/Stator Removal/Inspection
3
1. Remove flywheel nut and washer.
2. Install Flywheel Puller (PN 2871043) and remove
flywheel.
CAUTION
Do not 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).
A
A
Std. Bushing ID:

.4735”-.4740” (11.11-12.04 mm) 6. Remove oil passage O-Ring (B).
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
ENGINE
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. Inspect 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). A
B
D C
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:

2. Remove blade and inspect for cracks, wear, or damage.
Std: 1.450” (3.68 cm)
B
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 lb. (4.53 kg) load. Measure length of a 20 pitch
3.32
ENGINE
Crankcase Separation 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 irregularities.
reinforced areas.
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.
CAUTION
Do not strike the oil pump shaft at an angle or the

shaft may bend, causing irreparable damage. Tap
only lightly 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.
Oil Pump Removal/Inspection
8. Remove pump body screw and feed chamber cover.
C A
B
1. Remove pump shaft bearing (A) and thrust washer (B)
from pump shaft.
2. Remove (2) bolts holding pump drive gear (C).
3.33
ENGINE
9. Measure pump end clearance using a feeler gauge and Oil Pump Assembly
straight edge.
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.
2. Install pump shaft and scavenge rotor drive pin.
3. Install outer scavenge rotor, inner scavenge rotor, and
scavenge casing.
4. Install outer feed rotor and inner feed rotor drive pin.
5. Install inner feed rotor and feed chamber cover with screw.
6. Tighten screw securely.
7. Install screen on pump body.
8. Install oil pump on crankcase and torque bolts to 6 ft. lbs.
(8 Nm).
Oil Pump Attaching Bolt Torque:

6 ft. lbs. (8 Nm)
Pump End Clearance:
Std: .001 -.003 (.0254-.0762 mm)
Counter Balancer Shaft Removal/Inspection
Wear Limit: .004 (.1016 mm)
1. Remove the shim washer (A) from the counter balancer
shaft.
10. Measure clearance between outer feed rotor and pump body
with a feeler gauge.
A
2. Note the alignment dots on the balancer and crankshaft

gears, the marks must be aligned during reassembly.
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 pump
shaft for wear.
3.34
ENGINE
3. Turn the shaft until balancer counter weights clear the 8. Support the PTO side crankcase and crankshaft; press the
crankshaft and remove the balancer shaft from the crankshaft out. Be careful not to damage the crankcase
crankcase. mating surface or connecting rod.
4. Inspect the balancer drive gear and pump shaft drive gear. 9. Use a feeler gauge to measure the connecting rod big end
side clearance.
5. Replace the shaft if gear teeth are abnormally worn or
damaged.
Connecting Rod Big End Side Clearance:
6. Inspect the balancer shaft bearings.
Std: .0039-.0256” (.1-.65 mm)
NOTE: Due to extremely close tolerances and minimal Limit: .0315” (.80 mm)
wear, the balancer shaft ball bearings must be inspected
visually and by feel. Look for signs of discoloration,
10. Place the crankshaft in a truing stand or V-blocks and
scoring or galling. Turn the inner race of each bearing.
measure the runout on both ends with a dial indicator.
The bearings should turn smoothly 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 Max Runout: .0024” (.06 mm)
movement and no detectable up and down movement.
11. Measure the connecting rod big end radial clearance.
Crankshaft Removal/Inspection
A 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.
7. Remove the shim washer (A) from the crankshaft.
3.35
ENGINE
Crankcase Bearing Inspection 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 seal from the PTO side crankcase.

2. 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. 1. Remove the pump shaft bearing from the Magneto (right
Turn the inner race of each bearing. The bearings should hand) side crankcase.
turn smoothly and quietly. The outer race of each bearing 2. Pry out the oil seal, noting the direction of installation with
should fit tightly in the crankcase. The inner race should the spring side facing IN (toward inside of case).
be firm with minimal side to side movement and no 3. Drive the water pump mechanical seal out of the crankcase
detectable up and down movement. from inside to outside. Note: The new mechanical seal must
3. Support the crankcase and drive or press the main bearings be installed after the crankcases are assembled, using a
out of each crankcase. special tool. See Mechanical Seal Installation.
4. To remove balancer shaft bearings and pump shaft bearing
use a blind hole bearing puller. Crankcase Inspection
NOTE: Bearings are stressed during the removal 1. Remove all traces of gasket sealer from the crankcase
process and should not be re-used! 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.
3.36
ENGINE
Bearing Installation 4. Measure the distance from the PTO crankcase mating
surface to the main bearing using a dial caliper and a
NOTE: To ease bearing installation, warm the straight edge.
crankcase until hot to the touch. Place the bearings in a
freezer.
1. Install the bearings so the numbers are visible.
2. Drive or press new bearings into the crankcases, using the
proper driver.
CAUTION
Press only on outer race of bearing 3

to prevent bearing damage
• 70 mm (2.755") driver- For crankshaft main

bearings.
• 46 mm (1.810") For counter balancer bearings.
5. Subtract the thickness of the straightedge from the
• 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 may
cause engine noise at idle and slow speeds. Too little play will
side load the bearings which may lead to premature bearing
failure.
Crankshaft End Play Adjustment

3. Make sure all bearings are firmly seated in the both Mag
and PTO crankcase.
PTO Case Depth_________________________
3.37
ENGINE
6. Measure the distance from the Magneto crankcase 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. 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 the 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
ENGINE
14. Measure the distance from the Mag crankcase mating 3. Install the gear on the oil pump and measure the width of
surface to the balance shaft bearing using a dial caliper and the pump and gear. Subtract this measurement from the
a straight edge. Subtract the thickness of the straightedge measurement recorded in Step 2.
and record. 4. Subtract the thickness of the existing shim from the result
15. Measure the distance from the PTO crankcase mating of Step 3 to determine if a different shim is needed. See
surface to the bearing using the same method outlined in Shaft End Play Spec.
Step 1, 2, and-3.
16. Add the readings obtained in Step 3 and Step 4. Oil Pump Shaft End Play:
17. Subtract the counter balancer shaft width measured in Step .008”-.016” (.02-.04 cm)
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
3
result must be within the specified 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.
3.39
ENGINE
ENGINE REASSEMBLY Crankshaft/Counter Balance/Oil Pump
Installation
Pump Shaft Oil Seal 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
the 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
1. Install the seal from the outside of the crankcase (water crankshaft.
pump side) with the spring facing inward, toward the pump 4. Place the balancer shaft in the PTO crankcase aligning the
shaft bearing. timing marks on the crankshaft and balancer gears. Install
2. Drive or press the seal into place using a 25 mm (.985") seal the proper shim washer on the shaft.
driver, until flush with the outer edge of the seal bore.
5. Inspect the oil pump sealing surface on the crankcase.
3. Lubricate the seal lip with grease. 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. lbs. (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.
3.40
ENGINE
Crankcase Assembly Water Pump Mechanical Seal Removal -
Engine Installed
1. Apply Crankcase Sealant (PN 2871557) to the crankcase
mating surfaces. Be sure the alignment pins are in place.
2. Set the crankcase in position carefully to avoid damaging Water Pump Mechanical Seal
the pump shaft seal, and install the magneto end crankshaft Puller: (PN 2872105)
installation tool (follow instructions provided with the Replacement T-Handle:
Crankshaft/Water Pump Installation Kit (PN 2871283). (PN 2872106)
Draw the crankcase halves together by tightening the nut
on the tool and tapping lightly in the pump shaft area with This tool allows a technician to replace the mechanical
3
a soft faced hammer to maintain alignment. Continually water pump seal on EH50PL engines without removing
check alignment of the cases during installation, closing the the engine and splitting the cases.
gap equally until the surfaces are tightly seated.
3. Remove the tool. CAUTION
4. Install the crankcase flange bolts and tighten in 3 steps
following the pattern to specified torque. Improper or careless use of this tool or procedure
can result in a bent water pump shaft.Pump shaft
Crankcase Bolt Torque: replacement requires engine removal and
crankcase separation. Use caution while performing
14 ft. lbs. (19 Nm) 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
Crankcase Sealant: any way.
(PN 2871557)
1. After the coolant has been drained, remove the water pump
cover, impeller and the sealing washer. (Ill. 1).
Water Pump Mechanical Seal Installation Sealing Washer
5. Clean the seal cavity to remove all traces of old sealer.
Sealing Washer
6. Place a new mechanical seal in the seal drive collar, and
(Copper or Aluminium)
install on the pump shaft.
7. Screw the guide onto the end of the pump shaft. Oil
8. Install the washer and nut and tighten to draw seal into place Coolant Drain Seal
until fully seated. Bolt
9. Remove the guide adaptor using the additional nut as a jam
nut if necessary.
Impeller
Mechanical Seal
III. 1
3.41
ENGINE
2. Slide the main puller body over the outer portion of the 5. Tighten the hex socket screws on the puller legs sufficiently
mechanical seal as shown in Ill. 2 and turn T-Handle so the lip of the puller legs will grasp the mechanical seal.
clockwise until it contacts water pump shaft. Continue Ill. 5.
rotating until outer portion of mechanical seal is separated
from the metal seal body.
T-Handle
T-Handle
Main Puller Body
III. 5
Main Puller Body 6. Turn the puller T-Handle clockwise until it contacts the
water pump shaft. Continue rotating until the remaining
III. 2 portion of mechanical seal has been removed from the
cases. Ill. 6 Pump shaft oil seal can also be replaced at this
3. Insert the puller legs between the water pump drive shaft
time if necessary.
and the remaining portion of the mechanical seal. Attach
the puller legs to the main puller body. Ill. 3 7. The 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
Main puller
body Pump Seal Installation Kit (PN 2871283).
One Way Valve Installation

Install the one way valve plunger, spring, and plug using a
new sealing washer.
Position the split One Way Valve Plug Torque:

90o to opening 16 ft. lbs. (22 Nm)
on main puller
body
III.3
4. Ensure that the split between the puller legs are fully
supported by the main body of the tool (Ill 4).
Hex Socket Screws
Puller Legs
Lip must grasp inside of

III. 4 mechanical seal
3.42
ENGINE
Cam Chain Drive Sprocket Installation NOTE: The top rail has a locating tab to prevent
rotation. The tab must be positioned in the notch on the
1. Install the Woodruff key, drive sprocket, and slotted nut. side of the piston as shown (A).
Tighten the nut to the specified torque.
B
Tighten
3. Install the bottom rail with the gap at least 30o from the end
of the expander on the side opposite the top rail gap.(See
Slotted Nut Torque:
ILL. 1).
35-51 ft. lbs. (47-69 Nm) 4. Install the second ring with the “R” mark facing up.
Position the end gap toward the rear (intake) side of the
piston.
Tensioner Blade Installation 5. Install the top ring (chrome faced) with the “R” mark facing
1. Install the tensioner blade and tighten the mounting bolt to up and the end gap facing forward (toward the exhaust).
specified torque. (See ILL. 1).
6. Check to make sure the rings rotate freely in the groove
Tensioner Blade Mounting Bolt Torque: when compressed.
Ring Profile
6 ft. lbs. (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 Top
service clean any accumulated carbon from the ring Mark- up
grooves and oil control ring holes.
1. Place the oil control ring expander in oil ring groove with
the end gap facing forward. The expander has no up or
down marking and can be installed either way. The ends
should butt squarely together and must not overlap.
2. Install the oil ring top rail.
Second
Mark- up
ILL. 1
3.43
ENGINE
Piston Installation Cylinder Installation
1. Clean the gasket surfaces on the cylinder and crankcase. 7. Place the dowel pins in the crankcase and install a new
Remove all traces of old gasket material. cylinder base gasket.
2. Make sure the cylinder mounting bolt holes are clean and 8. Position the Piston Support Block (PN 2870390) (A)
free of debris. beneath the piston skirt to support the piston during
cylinder installation.
Tang Outward
A
3. Install a new circlip on one side of the piston with the end 9. Apply clean engine oil to a ring compressor and install the
gap facing up or down, and tang outward. compressor following manufacturers instructions.
CAUTION
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.
4. Apply clean engine oil to the piston rings, ring lands, piston
pin bore, piston pin, and piston skirt. Lubricate the
connecting rod (both ends), balancer drive gear, and
crankshaft main bearing area.
CAUTION
Make sure the oil control ring upper rail tab is

positioned properly in the notch of the piston. Verify
Mag
all ring end gaps are correctly located.
or :
5. Install the piston on the connecting rod with the arrow or :

mark facing the magneto (RH) end of the crankshaft. The
piston pin should be a push fit in the piston.
6. Install the other circlip with the gap facing up or down and
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
ENGINE
10. Apply clean engine oil liberally to the cylinder bore and The following procedure must be used to torque the
tapered area of the sleeve. Install the cylinder with a slight cylinder head properly:
rocking motion until the rings are captive in the sleeve.
Torque all bolts evenly in a criss- cross pattern
*Torque bolts to 22 ft. lbs. (30 Nm)
*Loosen bolts evenly 180o (1/2 turn)
*Loosen bolts again another 180o (1/2 turn)
*From this point, tighten bolts evenly 90o (1/4 turn)
3
*Finally, tighten another 90o (1/4 turn)
*Install two 6 mm bolts and torque to 6 ft. lbs. (8 Nm)
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 BDC.
Guide in
NOTE: If cam chain is installed, hold it up while rotating recess
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. lbs. (62 Nm)
6 mm - 6 ft. lbs. (8 Nm)
Cylinder Head Installation

Clean the gasket surfaces on the cylinder head and
cylinder. Remove all traces of old gasket material.
Refer to disassembly photos.
1. Install the cam chain tensioner guide. Be sure bottom end
of guide is located properly in crankcase.
2. 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 Cam Chain/Camshaft Installation
hand tighten the bolts. Install the cam chain over the crankshaft.
CAUTION
Serious engine damage may result if the camshaft

is not properly timed to the crankshaft.
3.45
ENGINE
IMPORTANT CAMSHAFT TIMING NOTE: In order to 4. Loop the cam chain on the cam sprocket with the dots on
time the camshaft to the crankshaft, the piston must be the sprocket facing outward and the alignment pin notch
precisely located at Top Dead Center (TDC).
facing directly upward.
Camshaft Timing
A
5. Before positioning the sprocket on the camshaft, check the

1. Apply Polaris Premium Starter Drive Grease (PN 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. B
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 A
inspection window. Be sure to use the single TDC mark
when installing the cam. Do not use the advance marks. See
illustration.
Single (TDC)
Mark Aligned
3.46
ENGINE
6. Install the sprocket on the camshaft. Apply Loctite™ 242
(PN 2871949) to the cam sprocket bolts and torque to
specification.
Cam Sprocket Bolt Torque:

6 ft. lbs. (8 Nm)
Single (TDC)
Mark Aligned
7. Verify TDC mark in timing inspection hole and alignment

pin is directly in line with crankshaft to camshaft centerline.
Refer to illustration.
8. Apply Crankcase Sealant (PN 2871557) to the camshaft
end cap and install using a new O-Ring.
9. Check all cam timing marks to verify proper cam timing,
and install the cam chain tensioner body with a new gasket.
10. After tensioner installation, rotate engine at least two
revolutions and re-check marks/timing.
3.47
ENGINE
CAMSHAFT TIMING
Crankshaft to Camshaft Centreline
Dots
Sprocket Alignment Pin
Single TDC Mark Aligned
TDC Mark
Rotation
Do Not Use
Advance Marks
3.48
ENGINE
Cam Chain Tensioner Installation 3. Apply 3 Bond 1215 (PN 2871557) or an equivalent sealer
to the stator plate outer surface and install a new O-Ring.
1. Release the ratchet pawl (A) and push the tensioner
plunger (B) all the way into the tensioner body.
3
B
A
4. Install the stator plate being careful not to damage the seal.
2. Install the tensioner body with a new gasket and tighten the 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.
6 ft. lbs. (8 Nm) 5. Torque bolts evenly to specification.
Stator Plate Bolt Torque:

3. Install the spring, new sealing washer, and tensioner plug.
5-6.5 ft. lbs. (7-9 Nm)
Tensioner Plug Torque:
17 ft. lbs. (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. lbs. (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.
1. Be sure the washer is positioned on the back of the drive
3.49
ENGINE
gear. install the cover and bolts.
Apply Starter Drive
Grease to Bushing Rocker Cover Bolt Torque:
6 ft. lbs. (8 Nm)
Thermostat Installation
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:

Install the thermostat with one of the air bleed holes
(PN 2871460) positioned next to the upper thermostat cover bolt hole as
shown.
Rocker Shaft/Rocker Arm Assembly Oil Pipes

Installation
Install the oil pipes with new sealing washers. Tighten all
1. Assemble rocker arms, rocker shaft, and shaft supports. bolts evenly to specified torque.
2. Install and tighten rocker arm shaft locating bolt.
3. Apply starter drive grease to the cam lobes and cam Oil Pipe Bolt Torque:
follower surfaces.
20 ft. lbs. (27 Nm)
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. Apply a light film of engine oil to the threads of the bolts
and tighten evenly.
Rocker Shaft Support Tower Bolt Torque:

9 ft. lbs. (12 Nm)
Rocker Shaft Locating Bolt Torque:

6 ft. lbs. (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 on the cylinder head and
3.50
ENGINE
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.
3
Replace any parts found to 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
2. Pull recoil rope (if applicable) so it is extended until spring tension is released.
approximately 12-18" (30-46cm). Check handle c-ring for
A
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
ENGINE
Recoil Assembly post of the housing and the bushing.
CAUTION
Be sure to wear a face shield and eye protection

when performing this procedure.
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
To install a new spring:
notch and add additional turns of pre-wind.
1. Place spring in housing with the end positioned so the
8. Install ratchet pawl and return spring, with long leg of
spring spirals inward in a counterclockwise direction. See
spring engaged in reel.
photo at right.
2. Hold spring in place and cut retaining wire. 9. Reinstall friction plate.
NOTE: The friction plate must be positioned with both
To reinstall an old spring: end tabs of the friction spring opposite the ratchet pawl.
1. Hook outer tab in place in recoil housing and wind spring
in a counterclockwise direction one coil at a time while 10. Torque friction plate retaining bolt to 5-6 ft. lbs. (7-9 Nm).
holding the installed coils in place. 11. Reinstall recoil housing using a new gasket. Seal stator wire
2. Lubricate the spring with light lubricant such as Premium harness grommet with RTV silicone.
All 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. Wind rope counterclockwise onto the reel, as viewed from
ratchet side of reel.
3. Lock rope into notch on outer edge of reel.
4. Apply a small amount of grease or equivalent to the center
3.52
ENGINE
TROUBLESHOOTING Engine Does Not Turn Over
• Dead battery
Spark Plug Fouling
• Starter motor does not turn
• Spark plug cap loose or faulty
• Engine seized, rusted, or mechanical failure
• Choke cable adjustment or plunger/cable sticking
Engine Runs But Will Not Idle
• Foreign material on choke plunger seat or plunger
• Restricted carburetor pilot system
• Incorrect spark plug heat range or gap
• Carburetor misadjusted
3
• Carburetor inlet needle and seat worn
• Choke not adjusted properly
• Jet needle and/or needle jet worn or improperly
adjusted • Low compression
• Excessive carburetor vibration (loose or missing • Crankcase breather restricted
needle jet locating pins)
Engine Idles But Will Not Rev Up
• Loose jets in carburetor or calibration incorrect for
altitude/temperature • Spark plug fouled/weak spark
• Incorrect float level setting • Broken throttle cable
• PVT system calibrated incorrectly or components • Obstruction in air intake
worn or mis-adjusted
• Air box removed (reinstall all intake components)
• Fuel quality poor (old) or octane too high
• Incorrect or restricted carburetor jetting
• Low compression
• ETC switch limiting speed
• Restricted exhaust
• Reverse speed limiter limiting speed
• Weak ignition (loose coil ground, faulty coil, stator,
or ETC switch) • Carburetor vacuum slide sticking/diaphragm
damaged
• ETC switch mis-adjusted
• Incorrect ignition timing
• Restricted air filter (main or pre-cleaner) or
breather system • Restricted exhaust 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
• Fuel 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)
3.53
ENGINE
Engine Has Low Power • Ignition system faulty:
Spark plug cap cracked/broken
• Spark plug fouled Ignition coil faulty
Ignition or kill switch circuit faulty
• Cylinder, piston, ring, or valve wear or damage Ignition timing incorrect
(check compression) Sheared flywheel key
• PVT not operating properly • Poor connections in ignition system
• Restricted exhaust muffler • System wiring wet
• Carburetor vacuum slide sticking/diaphragm • Valve sticking
damaged
• Air leaks in intake
• Dirty carburetor
• Lean condition
Piston Failure - Scoring
• Lack of lubrication Cooling System
• Dirt entering engine through cracks in air filter or Overheating
ducts
• Low coolant level
• Engine oil dirty or contaminated
• Air in cooling system
Excessive Smoke and Carbon Buildup
• Wrong type of coolant
• Excessive piston-to-cylinder clearance
• Faulty pressure cap or system leaks
• Wet sumping
• Restricted system (mud or debris in radiator fins or
• Worn rings, piston, or cylinder restriction to air flow, passages blocked in radiator,
lines, pump, or water jacket)
• Worn valve guides or seals
• Lean mixture (restricted jets, vents, fuel pump or
• Restricted breather fuel valve)
• Air filter dirty or contaminated • Fuel pump output weak
Low Compression • Restricted radiator (internally or cooling fins)
• Decompressor stuck • Water pump failure
• Cylinder head gasket leak • Cooling system restriction
• No valve clearance or incorrectly adjusted • Cooling fan inoperative or turning too slowly
(perform current draw test)
• Cylinder or piston worn
• Ignition timing misadjusted
• Piston rings worn, leaking, broken, or sticking
• Low oil level
• Bent valve or stuck valve
• Spark plug incorrect heat range
• Valve spring broken or weak
• Faulty hot light circuit
• Valve not seating properly (bent or carbon
accumulated on sealing surface) • Thermostat stuck closed or not opening
completely
• Rocker arm sticking
• Possible loose or missing diverter inside radiator
Backfiring
Temperature Too Low
• ETC or speed limiter system malfunction
• Thermostat stuck open
• Fouled spark plug or incorrect plug or plug gap
Leak at Water Pump Weep Hole
• Carburetion faulty - lean condition
• Faulty water pump mechanical seal (coolant leak)
• Exhaust system air leaks
• Faulty pump shaft oil seal (oil leak)
3.54
FUEL SYSTEM
CHAPTER 4
FUEL SYSTEM
ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 - 4.30
CARBURETOR (SPORTSMAN 500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31 - 4.47
4.1
FUEL SYSTEM
4.2
FUEL INJECTION
CHAPTER 4
FUEL INJECTION
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
PART NUMBERS / DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
EFI SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
EFI SYSTEM EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
EFI SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
COMPONENT LOCATIONS/IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
EFI OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
INITIAL PRIMING / STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
4
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
QUICK CONNECT REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
ELECTRONIC CONTROL UNIT (ECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
ECU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
FUEL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
OPERATION / TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
FUEL PUMP / TANK ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
FUEL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL INJECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
MANIFOLD AIR PRESSURE SENSOR (MAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
MAP SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
MAP SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
INTAKE AIR TEMPERATURE SENSOR (IAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
INTAKE AIR TEMPERATURE SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
INTAKE AIR TEMPERATURE SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 4.17
IDLE AIR CONTROL (IAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
THROTTLE POSITION SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
THROTTLE POSITION SENSOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
THROTTLE POSITION SENSOR (TPS) INITIALIZATION. . . . . . . . . . . . . . . . . . . . . . . 4.20
ENGINE TEMPERATURE SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
ENGINE TEMPERATURE SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
ENGINE TEMPERATURE SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
FUEL SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
FUEL STARVATION / LEAN MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
EFI DIAGNOSTICS USING ‘BLINK CODES’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
BLINK CODES - OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
TROUBLESHOOTING DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
EFI CIRCUIT - POWER ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
EFI CIRCUIT - CRANK POSITION SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
EFI CIRCUIT - FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
EFI CIRCUIT - IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
EFI CIRCUIT - IDLE AIR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26
EFI CIRCUIT - THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26
EFI CIRCUIT - MANIFOLD ABSOLUTE PRESSURE SENSOR . . . . . . . . . . . . . . . . . . 4.27
EFI CIRCUIT - ENGINE COOLANT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27
EFI CIRCUIT - AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28
EFI CIRCUIT - MALFUNCTION INDICATOR LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28
4.3
FUEL INJECTION
SPECIAL TOOLS Fuel Pressure Tester - PU-43506
Part Numbers / Descriptions IMPORTANT: The EFI fuel system remains under high
pressure, even when the engine is not running.
Before attempting to service any 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 NUMBER TOOL DESCRIPTION test valve and release the pressure.
Polaris EFI Diagnostic
PU-47063 Software
(Digital Wrench™)
Fuel Pressure
PU-43506
Test Kit
Fuel Pressure
PU-47476
Test Valve Kit
Throttle Position Sensor
2201519
Tester
Fuel Pressure Tester -
Digital Wrench™ PU-43506
PU-47471
SmartLink Kit
Fuel Pressure Test Valve - PU-47476

WARNING
• Gasoline is extremely flammable and explosive Test Valve

under certain conditions.
• EFI 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
area. Gasoline powered engine exhaust fumes are
poisonous and can cause loss of consciousness
and death in a short time. Polaris EFI Diagnostic Software
• Do not smoke or allow open flames or sparks in Digital Wrench™ - PU-47063
or near the area where refueling is performed or
This dealer-only software installs on laptop computers equipped
where gasoline is stored. with a CD drive and serial port connection, and is designed to
• If 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
technician repair and troubleshooting.
immediately.
• If you spill gasoline on your skin or clothing,
immediately wash with soap and water and change
clothing.
• Always stop the engine and refuel outdoors or in
a well ventilated area.
4.4
FUEL INJECTION
Digital Wrench™ SmartLink Unit Kit - PU-47471
Available to Polaris dealers through our tool supplier, SPX (1-800-328-6657) This kit contains the necessary cables and hardware
to communicate between the vehicle ECU 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.
PU-47469
4
PU-47468
PU-47470
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.
4.5
FUEL INJECTION
EFI SERVICE NOTES
General Service Information
• For more convenient and accurate testing of EFI components, it is recommended dealers utilize the
Polaris Diagnostic Software (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. If the sensor bench tests pass, disconnect the connector at the ECU and perform a continuity check between the sensor
connector and the appropriate pin at the ECU connector (all connections for that sensor). Wiring resistance should be
less than five (5) ohms.
5. If the resistance is high (or open), a wiring harness inspection is dictated (including a thorough inspection of the ECU
connector for contamination or damage).
6. If the sensor passes and the wiring passes inspection, and reconnecting the ECU does not resolve the issue, then at that
point a known-good ECU (from another 500 EFI ATV) could be connected and tested for problem resolution.
• For the purpose of troubleshooting difficult running issues, a known-good ECU 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 rubber seal and allow contaminants to enter the connector.
• Never attempt to service any fuel system component while engine is running or ignition switch is
turned to "on".
• USE CARE when removing or installing the ECU 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 ECU 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 ECU.
• 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 disconnect battery while engine is running.
• Never use a quick-start battery charger to start the engine.
• Always unplug ECU from the wire harness before performing any welding on the ATV.
4.6
FUEL INJECTION
EFI SYSTEM EXPLODED VIEW
1. Electronic Control Unit (ECU)

2. Manifold Absolute Pressure Sensor (MAP)
3. Intake Air Temperature Sensor (IAT)
4. Idle Air Control (IAC) 1
5. Crankshaft Position Sensor (CPS - inside cover)
6. Fuel Injector
7. Fuel Rail
8. Fuel Filter(s)
9. Fuel Pump/Tank Assy.
10. Engine Coolant Temperature Sensor (ECT)
11. Throttle Position Sensor (TPS) LH side of Throttle body
12. Throttle Body
3
4
7
9
2
4
12 11 6
10
4.7
FUEL INJECTION
EFI SYSTEM 7. Fuel Rail
Component Locations/Identification 7 2
1. Electronic Control Unit (ECU)
6
9 & 10
8. Fuel Filter (located in tank as an assembly - see item #9)
9. Fuel Pump / Regulator / Gauge Sender Assembly
(located In tank as an assembly)
2. Manifold Absolute Pressure Sensor (MAP) 2
9 & 10
10. Throttle Position Sensor (TPS)
3. Intake Air Temperature Sensor (IAT) 2
10 11
9 & 10
11. Throttle Body
12. Wire Harness Assembly
4. Idle Air Control (IAC) 13. Engine Coolant Temperature Sensor (ECT)
11
5. Crankshaft Position Sensor (CPS) - inside recoil cover
9 & 10
6. Fuel Injector
4.8
FUEL INJECTION
FUEL TANK ELECTRONIC FUEL INJECTION
Exploded View General Information
The Electronic Fuel Injection (EFI) system is a complete engine
fuel and ignition management design. This system contains the
1 following principal components:
• Fuel Pump
2 • Fuel Rail
• Fuel Line(s)
• Fuel Filter(s)
4 • Fuel Injector
3 • Pressure Regulator
• Throttle Body / lntake Manifold
• Engine Control Unit (ECU)
• Ignition Coils
• Engine Coolant Temperature Sensor (ECT)
• Throttle Position Sensor (TPS)
5
7
•
•
•
Crankshaft Position Sensor (CPS)
Manifold Absolute Pressure Sensor (MAP)
Idle Air Control (IAC)
4
• Intake Air Temperature Sensor (IAT)
• Wire Harness Assembly
• Check Engine Light (MIL)
EFI Operation Overview

6 8
The EFI system is designed to provide peak engine performance
with optimum fuel efficiency and lowest possible emissions.
1. Cap 2. Tank Vent In/Out 3. Tank Mount 4. Fuel Pump/ The ignition and injection functions are electronically
Tank Assembly 5. Seat Foam 6. Protective Foil 7. Fuel controlled, monitored and continually corrected during
Lines 8. Fuel Filter operation to maintain peak performance.
The central component of the system is the Visteon Engine
Control Unit (ECU) which manages system operation,
Fuel Flow determining the best combination of fuel mixture and ignition
timing for the current operating conditions.
Fuel Tank 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
psi and returns any excess fuel to the tank. At the engine, fuel is
fed through the fuel rail and into the injector, which injects into
the intake port. The ECU controls the amount of fuel by varying
* Fuel Filter the length of time that the injectors are "on." This can range from
* Fuel Pump / 1.5-8.0 milliseconds depending on fuel requirements. The
Pressure Regulator (30 micron) controlled injection of the fuel occurs every other crankshaft
Unit 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 ECU 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 ECU computer
chip, and the ECU adjusts the fuel delivery and ignition timing
to match the values.
During operation the ECU has the ability to re-adjust
Fuel Supply Rail Injectors temporarily, providing compensation for changes in overall
engine condition and operating environment, so it will be able
to maintain the ideal air/fuel ratio.
* component located in fuel tank and is non-serviceable During certain operating periods such as cold starts, warm up,
acceleration, etc., a richer air/fuel ratio is automatically
calculated by the ECU.
4.9
FUEL INJECTION
Initial Priming / Starting Procedure FUEL LINES
NOTE: The Injection system must be purged of all
Quick Connect Removal/Installation
air prior to the initial start up, and/or any time the
system has been disassembled.
CAUTION
If the EFI system is completely empty of fuel or has been
disassembled and repaired:
Verify fuel system has been depressurized before
1. Cycle the key switch from “OFF” to “ON” 6 times, performing this procedure.
waiting for approximately 3 seconds at “ON” and 5
seconds at “OFF” in sequence to allow the fuel pump to Sportsman 500 EFI models use quick connect fuel lines. Refer
cycle and shut down. to the steps for fuel line removal / installation:
2. Once step 1 is completed, turn the key switch to “START”
1. Thoroughly clean the connector. Place a shop towel
until the engine starts or 5 seconds has passed.
around the fuel line to catch any dripping fuel. Squeeze the
3. If the engine failed to start, repeat step 1 for 2 more cycles connector tabs together and push the locking tab out.
and attempt to start the engine. 2. Pull out on the fuel line for removal.
If the engine fails to start, a problem may still exist, and should 3. To install the line, verify the connector and nipple are clean
be diagnosed. and free of debris.
4. Snap the fuel line back over the nipple, verify the connector
NOTE: Accurate testing of EFI components is
tabs snap back into place.
recommended utilizing the Polaris Diagnostic
Software (dealer only).
Squeeze Connector Tabs
4.10
FUEL INJECTION
ELECTRONIC CONTROL UNIT (ECU) Sportsman 500 EFI RPM Limit:
This EFI system utilizes 2 methods -
Operation Overview
“Hard” Limit - Ignition suppression occurs when RPM peaks
The ECU is the brain or central processing computer of the rapidly:
entire EFI fuel/ignition management system. During operation,
sensors continuously gather data which is relayed through the • High: 7000 RPM
wiring harness to input circuits within the ECU. Signals to the
ECU include: ignition (on/off), crankshaft position and speed • Returns: 6900 RPM
(RPM), throttle position, engine coolant temperature, air
temperature, intake manifold air pressure and battery voltage.
“Soft” Limit - Injector suppression occurs when RPM reaches
The ECU compares the input signals to the programmed maps peak gradually:
in its memory and determines the appropriate fuel and spark
requirements for the immediate operating conditions. The ECU • High: 7000 RPM
then sends output signals to set the injector duration and ignition
timing. • Returns: 6900 RPM
4
RPM limits may vary slightly under operating conditions.
ECU Replacement
1. Remove the 2 retaining screws holding the ECU. NOTE:
Retain upper-left spacer located behind the ECU for re-
installation.
2. With the ignition turned off, disconnect the wire harness by
ECU pulling the black slider away from the ECU. Once the slider
is fully extended, pull the connector from the ECU, using
great care not to damage the harness connector or locking
mechanism. NOTE: Should the black slider become
broken, replacement parts are available.
During operation, the ECU continually performs a diagnostic 3. To install, reverse the procedures, DO NOT apply dielectric
check of itself, each of the sensors, and system performance. If grease to the connector, as it is a sealed connector. Install
a fault is detected, the ECU turns on the Malfunction Indicator the upper-left retaining screw spacer and screws. Tighten
Light (MIL) (Check Engine Light) on the speedometer and
stores the fault code in its fault memory. A technician can screws to 10 in. lbs. (1.1 Nm).
access the stored fault codes manually using a “blink code”
diagnosis flashed out through the instrument cluster or using the
Digital Wrench Diagnostic Software. The ECU requires a ECU Service
minimum of 7.0 volts to operate. The memory in the ECU is
operational the moment the battery cables are connected. Never attempt to disassemble the ECU. It is sealed to prevent
Depending on the significance or severity of the fault, normal damage to internal components. Warranty is void if the case is
operation may continue, or a "Fail-Safe" operation may be opened or tampered with in any way.
initiated. In the event a “Fail-Safe” mode occurs, a base fueling
table is used to determine the injector pulse width. This strategy All operating and control functions within the ECU are pre-set.
will not compensate for engine temperature, intake air No internal servicing or readjustment may be performed. If a
temperature, or altitude change, but instead operates based on problem is encountered, and you determine the ECU to be
the latest valid information taken from those sensors. faulty, contact the Polaris Service Department for specific
handling instructions. Do not replace the ECU without factory
To prevent engine over-speed and possible failure, an RPM- authorization.
limiting feature is programmed into the ECU. If the maximum
RPM limit (7000) is exceeded, the ECU will suppress the The relationship between the ECU and the throttle position
ignition signal or injection signal. This process repeats itself in sensor (TPS) is very critical to proper system operation. If the
rapid succession, limiting operation to the preset maximum. 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 ECU from a
same-model Polaris 500 ATV EFI may be used without system
or engine component damage.
4.11
FUEL INJECTION
FUEL PUMP ASSEMBLY electrical connections are properly secured, the
fuses are good, and a minimum of 7.0 volts is being
Operation / Testing supplied. If during starting, the battery voltage drops
below 7.0 volts, a reduction of fuel pressure may
NOTE: All EFI units utilize quick connect fuel lines. occur resulting in a lean starting condition. If
required, testing of the fuel pump and circuitry may
An electric fuel pump assembly is used to transfer fuel to the EFI be conducted.
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. CAUTION
Fuel pump not
replaceable, picture Check the fuel test valve for any possible fuel
for reference only.
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
Regulator
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)
Fuel Pump to the test valve. Route the clear hose into a portable
gasoline container or the equipment fuel tank.
Internal 30 Micron
Strainer (Bottom)
Fuel Gauge
Sender
When the key switch is turned to "ON", the ECU activates the
fuel pump, which pressurizes the system for start-up.
The ECU switches off the pump preventing the continued 2. Turn on the key switch to activate the pump and check the
delivery of fuel in these instances: system pressure on the gauge. If system pressure of 39 psi
± 3 is observed, the ignition switch, ECU, fuel pump, and
• If the key switch is not promptly turned to the "start" pressure regulator are working properly. Turn the key
position.
switch “off” and depress the valve button on the tester to
• If the engine fails to start, or relieve the system pressure.
• If the engine is stopped with the key switch "on" (as in
the case of an accident) Fuel Pump Pressure - 39 psi ± 3
In these situations, the “check engine” light will go on, but will
turn off after 4 cranking revolutions if system function is OK. NOTE: If the pressure is too high or too low, replace
Once the engine is running, the fuel pump remains on.
the fuel pump assembly.
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 ECU, all
4.12
FUEL INJECTION
3. If the pump did not activate (Step 2), disconnect the plug 3. Remove the clamps on the PVT intake duct and remove the
from the fuel pump. Connect a DC voltmeter across PVT duct.
terminals “A” and “C” 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 “A” and “C”' on the pump
to check for continuity.
NOTE: If there was no continuity 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 ECU.
4. If voltage at the plug was good, and there was continuity

across the pump terminals, reconnect the plug to the pump,
4
making sure you have good, clean connections. Turn on the
key switch and listen for the pump to activate. 4. Remove the gas tank cover vent hoses. Be sure to properly
NOTE: If the pump starts, repeat steps 1 and 2 to route the vent hoses upon reassembly.
verify correct pressure.
NOTE: If the pump still does not operate, check for

correct ECU operation by plugging in a known-good
ECU.
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.
WARNING 5. With all the body panels removed from the front of the ATV
and the gas tank exposed, disconnect the pump wiring
Always wear safety goggles when working with harness.
high pressure or flammable fluids. Failure to do so
could result in serious injury or complications. WARNING
NOTE: The fuel pump cannot be replaced as an Wear safety goggles while performing this
individual part, the entire fuel pump and fuel tank is procedure, failure to do so could result in serious
replaced as an assembly. Refer to your parts book injuries.
for the proper part number.
6. Relieve the fuel pressure.
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.
4.13
FUEL INJECTION
7. Loosen the fuel tank hose and pull the fuel line from the Fuel Tank Installation
tank.
1. Reinstall the tank assembly.
NOTE: A small amount of fuel may come out of the
2. Reconnect the sender wiring harness and route the harness
fuel line or tank. Plug the fuel line and tank inlet or
properly. Install the fuel line(s) and verify they are secure.
use a shop towel during removal.
3. Reinstall the two fuel tank mounting bolts at back of tank.
Fuel Line 4. Reinstall the PVT intake duct, gas tank vent line, front cab
assembly, and side panels.
NOTE: Properly route the 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 Pump 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
CAUTION 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.
Check the fuel test valve for any possible fuel
seepage after performing any tests or procedures. Fuel Pressure Regulator Test
Fuel is extremely flammable and may cause severe
Refer to the “FUEL PUMP TEST” procedure.
burns, injury, or death. Do not use any device that
produces a flame or electrical devices that may Fuel Pressure Regulator Replacement
spark around fuel or fuel vapors.
The regulator is a sealed, non-serviceable assembly. If it is
faulty, the pump assembly must be replaced. Refer to the Fuel
8. Remove the air box cover and remove the two gas tank Pump/Tank Assembly Replacement procedure.
mounting bolts at the rear of the gas tank.
FUEL FILTER
General Information
NOTE: All EFI units utilize quick connect fuel lines.
All EFI Engines use a non-serviceable, high-volume, high-

pressure, 30-micron internal fuel pump filter. The filter is
located inside the tank as part of the fuel pump assembly.
Fuel Filter Service

The in-tank filter is non-serviceable. Tank flushing to remove
sediments may temporarily restore fuel flow, but is not a
recommended service procedure.
Fuel Filter Replacement

9. Carefully pull the fuel tank out of the frame. Keep the fuel NOTE: Tank replacment is required.
tank horizontal during removal, this will keep the fuel in the
tank from spilling out the top inlet.
4.14
FUEL INJECTION
FUEL INJECTOR Injector problems due to dirt or clogging are unlikely due to the
design of the injectors, the high fuel pressure, the use of filters
and the detergent additives in the gasoline. Symptoms that could
General Information be caused by dirty/clogged injectors include rough idle,
hesitation/stumble during acceleration, or triggering of fault
The fuel injector mounts into the intake manifold, and the fuel codes related to fuel delivery. Injector clogging is usually caused
rail attaches at the top end. Replaceable O-Rings on both ends by a buildup of deposits on the director plate, restricting the flow
of the injector prevent external fuel leakage and also insulate it of fuel, resulting in a poor spray pattern. Some contributing
from heat and vibration. 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:
Injector
• Using an ohmmeter, test for continuity by placing the
test leads on each pin of the injector. 4
Injector • Resistance specification is 12.0Ω ±0.4Ω (20°C, 68°F)
Injector Resistance Specification:

12.0Ω ±0.4Ω (20°C, 68°F)
When the key switch is on, the fuel rail is pressurized, and
voltage is present at the injector. At the proper instant, the ECU
completes the ground circuit, energizing the injector. The valve Fuel Injector Replacement
needle in the injector is opened electromagnetically, and the
pressure in the fuel rail forces fuel down through the inside. The 1. Engine must be cool. Depressurize fuel system through
“director plate” at the tip of the injector contains a series of test valve in fuel rail.
calibrated openings which directs the fuel into the intake port in
a cone-shaped spray pattern. 2. Remove the front fender assembly and fuel tank.
3. Thoroughly clean the area around and including the throttle
The injector is opened and closed once every other crankshaft
revolution. The total amount of fuel needed for one firing is body/manifold and the injectors.
injected during each opening. The amount of fuel injected is 4. Disconnect the fuel injector harness.
controlled by the ECU and determined by the length of time the
valve needle is held open, also referred to as the “injection 5. Remove the fuel rail mounting screws, doubler plate and
duration” or “pulse width”. It may vary in length from 1.5-8 carefully loosen / pull the rail away from the injector.
milliseconds depending on the speed and load requirements of
the engine. 6. Reverse the procedures to install the new injector and
reassemble. Use new O-rings any time an injector is
Fuel Injector Service removed (new replacement injectors include new O-rings).
Lubricate the upper O-ring lightly with soapy water to aid
Injector problems typically fall into three general categories- installation. The lower O-ring should remain dry. Torque
electrical, dirty/clogged, or leakage. An electrical problem
usually causes the injector to stop functioning. the fuel rail mounting screws to 5~7 ft. lbs. (6-9 Nm). Then
install the doubler plate and torque to 8~9.5 ft. lbs. (11-13
NOTE: Do not apply voltage directly to the fuel Nm).
injector(s). Excessive voltage will burn out the
injector(s). Do not ground the injector with the
ignition “on”. lnjector will open/turn on if relay is =T
energized.
Fuel Rail Mounting Screws:
If an injector is not operating, it can indicate either a bad injector, 5~7 ft. lbs. (6-9 Nm)
or a wiring/electrical connection problem. Check as follows:
Injector leakage is very unlikely, but in rare instances it can be Doubler Plate Screws
internal (past the tip of the valve needle), or external (weeping 8~9.5 ft. lbs. (11-13 Nm)
around the injector body). The loss of system pressure from the
leakage can cause hot restart problems and longer cranking
times.
4.15
FUEL INJECTION
CRANKSHAFT POSITION SENSOR 3. Disconnect crankshaft sensor connector from wiring
(CPS) harness. Test resistance between the terminals. A reading
of 185Ω ± 20% at room temperature (20°C, 68° F)
General Information should again be obtained.
NOTE: If the resistance reading is incorrect, remove
The engine speed sensor is essential to engine operation, the screws securing the sensor to the mounting
constantly monitoring the rotational speed (RPM) of the
crankshaft. bracket and replace the sensor. If the resistance in
step 2 was incorrect, but the resistance of the
sensor alone was correct, test the main harness
Interrupt
circuit between the sensor connector terminals and
the corresponding pin terminals in the main
connector. Correct any observed problem,
CPS reconnect the sensor, and perform step 2 again.
Crankshaft Position Sensor Replacement

1. Remove the RH 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.
A ferromagnetic 36-1 ring gear is cast onto the flywheel. The
inductive crankshaft sensor is mounted 0.4 - 1.2 mm (0.015 - 4. Remove the retainer screws securing the sensor.
.047 in.) away from this ring gear. During rotation, an AC pulse 5. Install the new sensor, routing the harness wire through the
is created within the sensor for each passing tooth. The tooth
gap creates an “interrupt” input signal, corresponding to specific top of the case housing as was previously installed.
crankshaft position for PTO cylinder. This signal serves as a 6. Set the air gap of the new sensor to the specified distance
reference for the control of ignition timing by the ECU.
away from the ring gear. Torque the retaining screws to
specification and reverify air gap.
Crankshaft Position Sensor Air Gap: 0.4 - 1.2 mm (0.015 - .047 in.)
0.4 - 1.2 mm (0.015 - .047 in.)
Within one (1) revolution at start-up, the ECU calculates

crankshaft position from the time interval between the
consecutive pulses. Synchronization of the CPS, ECU and MAP
sensor takes place during the first two (2) revolutions each time
the engine is started. Once the engine is started, the ECU
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
= In. / mm.
area, test and correct as follows:
1. Disconnect main harness connector from ECU. CPS Air Gap:
2. Connect an ohmmeter between the pin terminals. A 0.4 - 1.2 mm (0.015 - .047 in.)
resistance value of 185Ω ± 20% at room temperature (20°
C, 68° F) should be obtained. If resistance is correct, check
=T
the mounting, air gap, toothed ring gear (damage, runout,
etc.), and flywheel key.
CPS Retaining Screws:
26-34 in. lbs. (2.9-3.92 Nm)
Crankshaft Position Sensor Resistance:
185Ω ± 20% @ (20° C , 68° F)
4.16
FUEL INJECTION
MANIFOLD AIR PRESSURE SENSOR INTAKE AIR TEMPERATURE SENSOR
(MAP) (IAT)
Operation Overview Operation Overview
Mounted on the throttle body intake, the manifold air pressure The intake air temperature sensor (IAT) is used to indicate
sensor (MAP) measures air passing and provides the ECU with charge air temperatures to the ECU.
the manifold pressure during engine operation. This allows the
ECU to adjust the fueling according to actual engine load as well Mounted on the rear of the air box, the IAT sends a varying
as identify which stroke is the intake stroke. The MAP sensor voltage signal to the ECU in direct correlation to the ambient air
also provides the ECU with the ability to compensate for high temperature. This signal is processed by the ECU and compared
altitude operation without any recalibration. to the internal pre-programmed maps to determine the required
fuel and ignition settings for the amount of engine load.
During initial start-up, the ECU is in a “waste spark - waste fuel”
mode until the MAP sensor sends a negative pressure reading,
indicating that the engine is on the intake stroke. Once this has Intake Air Temperature Sensor Test
been ‘learned’, the ECU will then monitor the MAP sensor and
cease the initial start-up program. The IAT sensor is a non-serviceable item. If it is faulty, it must
4
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).
Do not allow bracket to contact MAP
• The reading should be:
IAT Resistance:
2.45±0.24Ω (New)
2.45±0.36Ω (Used)
Map Sensor Test
MAP sensors are a non-serviceable item. If it is faulty, it must • If the sensor does not read correctly, replace it.
be replaced. This sensor requires a 5 Vdc input to operate,
therefore the MAP sensor should only be tested using Polaris
Diagnostic Software (dealer only). Refer to the EFI Diagnostic Intake Air Temperature Sensor Replacement
Software Manual for more information.
1. Disconnect engine harness from sensor.
Map Sensor Replacement 2. Using a suitable tool, remove the sensor from the grommet.
3. Lightly coat the grommet with soapy water and install a
1. Disconnect sensor from engine harness. new sensor, using a twisting motion to properly seat the
2. Using a suitable tool, remove the retaining screw and sensor in the grommet.
replace the sensor, using a light coating of soapy water on
4. Re-connect the harness.
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 the
retaining screw to specification.
=T
MAP Retaining Screw:
29 in. lbs. (3.3 Nm)
4.17
FUEL INJECTION
IDLE AIR CONTROL (IAC) THROTTLE POSITION SENSOR (TPS)

General Information Operation Overview
The Idle Air Control (IAC) is used to stabilize the idle quality The throttle position sensor (TPS), mounted to the throttle body,
of the engine at cold start-up and after warm-up operations. is used to indicate throttle plate angle to the ECU.
Mounted on the throttle body, the IAC contains 1 stepper motor
which receives varying voltage signal pulses from the ECU. The correct position of the throttle body idle
These pulses determine the IAC plunger setting, thereby
controlling the amount of air bypassing the closed throttle body stop is established and set at the factory. Do not
for idle control. If the IAC is disconnected or inoperative, it will loosen the throttle body idle stop or alter the
remain at it’s last operated position. stop position in any fashion. If the stop is
repositioned, the entire throttle body assembly
Idle Air Control Test must be replaced.
The IAC is a non-serviceable item. If it is faulty, it must be
replaced. It can be ‘bench tested’ using the following method: Mounted on the throttle body and operated directly off the end
of the throttle shaft, the TPS works like a rheostat, varying the
1. With the test leads connected and the meter set to the ohms voltage signal to the ECU in direct correlation to the angle of the
scale, observe the reading at the following pin locations of throttle plate. This signal is processed by the ECU and
the IAC: compared to the internal 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:
1. If any of the readings are out of specification, replace the
IAC.
Idle Air Control Replacement

1 2 3
1. Disconnect the IAC from the engine harness.
2. Using a suitable tool, remove the retaining screws and
replace the sensor.
3. Torque the retaining screws to specification.
Table 4-1: TPS Resistance Readings
Pin Throttle Position Resistance
d-GND ----- ∞
c-d Closed 4KΩ (reference)
c-d Open 820Ω (reference)
c-e ----- 4kΩ − 6kΩ
=T
IAC Retaining Screws:
17.7 in. lbs. (2 ± 0.5 Nm)
4.18
FUEL INJECTION
Using TPS Test Adapter Harness 2201519- TPS Tester - Correct Reference Voltage
• Set up the TPS Test Harness 2201519 according to the A 5 volt reference voltage signal from the test harness is
instructions. Verify that the 9 volt battery is new. Figure required for the TPS test to be accurate. Refer to the instructions
2 provided with the TPS Test Adapter Harness (2201519) or
follow these steps to check reference voltage.
Tester 2201519
• Harness Test: Insert black voltmeter probe into the
“Bk” test port.
• Connect the red meter probe into the “R” port and
Use NEW verify the voltage is 4.99-5.01 vdc. If this reading is
9V battery low, verify the 9 volt battery is good or try a new 9 volt
battery.
4
Tester 2201519 No “Jumps” in read out
• Connect the test leads connected as shown in Figure 2

and the meter set to the “vdc” scale, move the throttle
open and closed slowly while reading the display. The
voltage should increase smoothly with no “jumps” or
decreases when the throttle is applied.
Throttle Position Sensor Replacement
• If the TPS does not function correctly, replace it.
NOTE: The correct position of the TPS is established and set at
the factory. If the TPS is repositioned, replaced or loosened it
must be recalibrated.
1. Remove the LH side panel assembly.

2. Disconnect sensor from the engine harness.
3. Loosen and rotate the throttle body (B) to gain access to the
retaining screws (if required).
4.19
FUEL INJECTION
4. Remove the retaining screws and replace the sensor, but do ENGINE TEMPERATURE SENSOR
not tighten the screws at this point.
5. Refer to “TPS Initialization” for setting the TPS voltage. General Information
Mounted on the cylinder, the engine temperature sensor
Throttle Position Sensor (Tps) Initialization measures coolant temperature. The engine temperature sensor
is a Negative Temperature Coefficient (NTC) type sensor, as the
temperature increases the resistance decreases.
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 the

TPS position using the fixed physical stop.
• Open and close throttle plate a couple of times to ensure Engine Coolant Temperature Sensor (ECT)
full throttle closing. Do not snap closed, as this could
cause unnecessary throttle plate to throttle body
interference and/or damage. Coolant passes through the cylinder and by the sensor probe,
varying a resistance reading which is relayed to the ECU. This
• Set up the TPS Test Adapter Harness 2201519. Verify signal is processed by the ECU and compared to it's
that the 9 volt battery is new. Figure 2. programming for determining the fuel and ignition
requirements during operation. The ECU also uses this signal to
TPS Tester Adapter determine when to activate the fan during operation. If for any
Harness- 2201519 Should Read: 1.10 - 1.14 vdc reason the engine temperature sensor circuit is interrupted, the
fan will default to “ON”.
1.12v
Fig. 2
500 EFI engines - Apply RED meter lead to the “R”

port and BLACK meter lead to the “Y” 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.
• If 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.
=T
TPS Retaining Screws:
17.7 in. lbs. (2 ± 0.5 Nm)
4.20
FUEL INJECTION
Engine Temperature Sensor Test FUEL SYSTEM TROUBLESHOOTING
Polaris dealers can test the sensor by using the Polaris Digital
Wrench™ Software (dealer only). Refer to the Digital FUEL STARVATION / LEAN MIXTURE
Wrench™ Software Manual for more information.
To measure the sensor using an ohmmeter, place the tester leads The correct position of the throttle body idle
on each terminal an read the resistance with the sensor at an stop is established and set at the factory. Do not
ambient temperature of 68°F (20°C). loosen the throttle body idle stop or alter the
stop position in any fashion. If the stop is
Table 4-1: Resistance Readings repositioned, the entire throttle body assembly
must be replaced.
TEMPERATURE °F (°C) RESISTANCE
Symptoms: Hard start or no start, bog, backfire, popping
68 °F (20 °C) 37.3 - 39.2 k Ω through intake / exhaust, hesitation, detonation, low power,
spark plug erosion, engine runs hot, surging, high idle, idle
speed erratic.
Engine Temperature Sensor Replacement
1. Disconnect sensor from engine harness.
• No fuel in tank 4
2. Using a wrench, remove and replace the sensor, applying • Restricted tank vent, or routed improperly
a light coating of thread sealant to aid installation. • Fuel lines or fuel injectors restricted
3. Torque the sensor to specification.
• Fuel filter plugged
=T • Fuel pump inoperative

• Air leak in system
ETS Installation Torque:
18.5 ft. lbs. (25 Nm) • Intake air leak (throttle shaft, intake boot, gasket or
grommet)
• Throttle stop screw tampering - replace throttle body
• Failed Sensor or disconnected wiring
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
• Poor fuel quality (old fuel)
• Fouled spark plug
• TPS setting incorrect
• Injector failure
4.21
FUEL INJECTION
POOR IDLE
Symptom: Idle Too High (If greater than 1300 RPM when
engine is warm)
• Throttle cable sticking, improperly adjusted, routed
incorrectly
• IAC stuck or inoperative
• Intake air leak
Symptom: Idle Too Low (if less than 900 RPM when engine is
warm)
• Plugged air filter
• Leaking injector (rich condition)
• Belt dragging
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
4.22
FUEL INJECTION
EFI DIAGNOSTICS USING ‘BLINK NOTE: To clear codes manually, disconnect the
CODES’ positive battery lead for 20 seconds.
Blink Codes - Operation

ON
To enable the blink codes, turn the ignition from “OFF” to
“ON” 3 times, leaving it 'on' the 3rd time, within 5 seconds.
Any “blink codes” that are stored in the ECU 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. A 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
Sequence Begin
4
Trouble Code
Trouble Code
Trouble Code
Sequence End
Table 4-1: DIAGNOSTIC “BLINK CODES” CHART

BLINK NAME MIL LIGHT
21 Loss of Synchronization Yes
22 TPS Circuit: Sensor Low Yes
22 TPS Circuit: Sensor High Yes
25 Transmission Input - Invalid Gear Yes
26 Vehicle Speed Sensor - Implausible Yes
31 System Voltage Low Yes
31 System Voltage High Yes
41 Air Temp Sensor (IAT): Low Voltage Yes
41 Air Temp Sensor (IAT): High Voltage Yes
42 Engine Temperature Sensor Circuit (ECT): Low Voltage Yes
42 Engine Temperature Sensor Circuit (ECT): High Voltage Yes
44 CPS Circuit Fault Yes
45 Barometric Pressure Sensor: MAP Circuit Low Input Yes
46 Barometric Pressure Sensor: MAP Circuit High Input Yes
47 IAC: Open Load Yes
47 IAC: Short to Ground Yes
51 Injector 1: Open Load / Short Circuit to Ground Yes
51 Injector 1: Short Circuit to Battery Yes
55 Diagnostic Lamp: Open Load Yes
55 Diagnostic Lamp: Short Circuit to Ground Yes
55 Diagnostic Lamp: Short Circuit To Battery Yes
56 Fuel Pump: Open Load / Short Circuit to Ground Yes
56 Fuel Pump: Short Circuit to Battery Yes
61 END SEQUENCE --
4.23
FUEL INJECTION
TROUBLESHOOTING DIAGRAMS
EFI CIRCUIT - Power On
EFI CIRCUIT - Crank Position Sensor
4.24
FUEL INJECTION
EFI CIRCUIT - Fuel Pump
EFI CIRCUIT - Ignition Coil
4.25
FUEL INJECTION
EFI CIRCUIT - Idle Air Control
EFI CIRCUIT - Throttle Position Sensor
4.26
FUEL INJECTION
EFI CIRCUIT - Manifold Absolute Pressure Sensor
EFI CIRCUIT - Engine Coolant Temperature
4.27
FUEL INJECTION
EFI CIRCUIT - Air Temperature Sensor
EFI CIRCUIT - Malfunction Indicator Light
4.28
CARBURETOR - SPORTSMAN 500
CHAPTER 4
GENERAL INFORMATION AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
CARBURETOR JETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
MIKUNI JET PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
CARBURETOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
CARBURETION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.33
BST 40 CARBURETOR EXPLODED VIEW 1 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.33
BST 40 CARBURETOR EXPLODED VIEW 2 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.34
CV CARBURETOR SYSTEM FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
4
CARBURETOR VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
MIKUNI CV CARB OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
STARTER SYSTEM (CHOKE OR ENRICHMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.36
PILOT (IDLE AND SLOW) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.36
MAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.37
FLOAT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.37
PILOT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.38
AIR/FUEL MIXTURE RATIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.38
JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.39
NEEDLE JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.39
THROTTLE OPENING VS. FUEL FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.39
CARBURETOR DISASSEMBLY – MIKUNI CV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.39
CARBURETOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40
CARBURETOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.41
CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.41
FLOAT HEIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.42
NEEDLE AND SEAT LEAKAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.42
FUEL LEVEL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.43
FUEL TANK/FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.44
FUEL SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.44
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.45
FUEL PUMP TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.45
FUEL PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.45
FUEL PUMP INSPECTION AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.46
FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.46
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.46
SENDING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.46
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.47
SENDING UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.47
FUEL STARVATION/LEAN MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.47
4.31
GENERAL INFORMATION AND Carburetor Jetting
SPECIFICATIONS IMPORTANT: The following guidelines must be followed
when establishing a main jet setting:
Special Tools
1. Select the lowest anticipated temperature and altitude at
TOOL which the machine will be operated.
PART NUMBER
DESCRIPTION 2. Select the correct main jet according to the engines fuel/
performance requirements.
2870975 Mity VacTM Pressure Test
Tool CAUTION
Carburetor Float
2872314 A main jet that is too small will cause a lean
Adjustment Tool
operating condition resulting in serious engine
damage. Select the correct main jet carefully for
elevation and temperature according to the charts in
WARNING the Specifications section or in the Owner’s Safety
and Maintenance Manual for each particular model.
Gasoline is extremely flammable and explosive
under certain conditions. Mikuni Jet Part Numbers
Always stop the engine and refuel outdoors Main Jets Pilot Jets
or in a well ventilated area. Jet Number Part Number Jet Number Part Number
130 3131537 25 3131538
Do not overfill the tank. The tank is at full 132.5 3131536 27.5 3131539
135 3131535 30 3131540
capacity when the fuel reaches the bottom of 137.5 3131534 32.5 3131541
the filler neck. Leave room for expansion of 140 3131522 35 3131542
fuel. 142.5 3131523 37.5 3131543
145 3131524 40 3131544
147.5 3131525 42.5 3131545
Never start the engine or let it run in an 152.5 3131526 47.5 3131546
enclosed area. Gasoline powered engine 155 3131527 50 3131547
157.5 3131528 52.5 3131548
exhaust fumes are poisonous and can cause 160 3131529 55 3131549
loss of consciousness and death in a short 162.5 3131530 57.5 3131550
time. 165 3131531 60 3131551
167.5 3131532 65 3131552
170 3131533 70 3131553
Never drain the float bowl when the engine is
hot. Severe burns may result. Carburetor Specifications
Do not smoke or allow open flames or sparks
Fuel System
in or near the area where refueling is
Carburetor Mikuni BST 40mm
performed or where gasoline is stored.
Main Jet 155
If you get gasoline in your eyes or if you Pilot Jet 40
should swallow gasoline, seek medical Jet Needle / Clip Position 6MGH1-94-3
attention immediately. Needle Jet P-6M (829)
Pilot Screw 2 Turns Out (initial)
If you spill gasoline on your skin or clothing,
immediately wash with soap and water and Pilot Air Jet 160
change clothing. Float Height 14.7mm ± 1 (.58 ± 0.40")
NOTE: It is strongly recommended that Polaris Carbon Fuel Delivery Fuel Pump
Clean be added regularly as directed to the fuel systems Fuel Capacity / Requirement 4.25 gal US / 19.9 liters
of all Polaris ATVs. Carbon Clean stabilizes the fuel, 87 Octane (minimum)
or 89 Oxygenated
preventing clogging of the small passages and orifices
common to ATV carburetors, and ensures constant
performance, reliability and easier starting.
4.32
CARBURETION
BST 40 Carburetor Exploded View 1 of 2
A
G
H
4
C
N
M
P L
D
J
E
F
Table 4-1: Carburetor Components

REFERENCE DESCRIPTION REFERENCE DESCRIPTION
A Jet Needle J Throttle Control Cover Plate
B Diaphragm Assembly K Carburetor Body
C Needle Jet L Enrichment Plunger
D Jet Block Assembly M Enrichment Spring
E Washer N Cable guide
F Main jet P Pilot Air Jet
G Cover
H Spring
4.33
BST 40 Carburetor Exploded View 2 of 2
A D
B F
C
E
J
K
Table 4-2: Carburetor Components

REFERENCE DESCRIPTION REFERENCE DESCRIPTION
A Throttle Plate Shaft Retaining Components J Float Bowl O Ring
B Pilot Jet K Float Bowl
C Needle Valve Assembly L Float Bowl Drain Screw
D Throttle Plate M Throttle Shaft
E Idle RPM Speed Adjustment Screw N Throttle Shaft Return Spring
F Spring
G Needle Valve Retaining Plate
H Floats
4.34
CV Carburetor System Function Carburetor Venting
The carburetor float bowl vent lines supply atmospheric
Carburetor Component Function pressure to the float bowl. The lines must be free of kinks,
Main Main Main restrictions and be properly routed. This allows fuel to flow in
System the proper amount and prevents contaminants from entering the
Components Function Affect carburetor.
Float Inlet Pipe, Maintains All systems
System Needle and specified fuel All throttle Mikuni CV Carb Operation
(Level Seat, Float, level in float ranges
The constant velocity carburetor incorporates a mechanically
Control) Float Pin chamber operated throttle plate and a vacuum controlled slide valve
(carburetor float (vacuum slide). The venturi cross–sectional area in the
bowl) carburetor bore is increased or decreased automatically by the
vacuum slide, which moves according to the amount of negative
Venting Passages in Supplies All systems pressure (less than atmospheric) present in the venturi.
Carburetor, Vent atmospheric All throttle A diaphragm attached to the top of the vacuum slide is sealed to
lines pressure to float ranges the slide and to the carburetor body forming two chambers. The
4
to frame chamber 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, air mixture Greatest
Carb Passages necessary for effect at low Diaphragm
Low Pressure
(Starter Jet, cold starting throttle From Venturi
Starter Bleed settings and
Pipe) idle Atmospheric
Pressure
Pilot (Idle Pilot Jet/ Primarily Mainly idle Atmospheric

Air inlet
System) Passage-ways, supplies fuel at to 1/4
Pilot–Mixture idle and low throttle
Screw with throttle positions Minimal
Spring Washer effect after Vacuum
Slide
and Sealing O– 1/2 throttle
Ring, By-pass Throttle Plate
Ports (Behind
Throttle Plate),
Pilot Air Jet, Pilot Venturi
Outlet, Throttle
Plate
Main Main Jet, Main Supplies fuel at 1/4 to full
System Air Jet, Main Air mid–range and throttle
Passage, high throttle
Needle Jet, Jet settings. = Air Flow = Low pressure
Needle, Vacuum
Slide, Throttle When the throttle plate is opened and engine speed begins to
Plate increase, the pressure in the venturi (and therefore in the
chamber above the diaphragm) becomes significantly lower
than atmospheric. Atmospheric pressure in the chamber below
the diaphragm forces the diaphragm upward, raising the slide
against spring pressure.
4.35
When the pressure above and below the diaphragm are nearly Pilot (Idle and Slow) System
equal, the slide moves downward under spring pressure. Raising
or lowering the slide increases or decreases the cross sectional This system supplies fuel during engine operation with throttle
area in the venturi, and therefore the air velocity in the venturi valve closed (1) or slightly opened. The fuel from float chamber
is kept relatively constant. This provides improved fuel (2) is metered by pilot jet (3) where it mixes with air coming in
atomization and optimum fuel/air ratio. 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).
5
2
Note: Diagrams are for explanation of theory only, and are not true 3
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.
8
5 1
7 6
2
3
Fuel is drawn into the starter circuit from the float chamber (2)
through the starter jet (3). Starter jet meters this fuel, which then
flows into starter pipe (4) and mixes with the air (7) coming from
the float chamber. The mixture, rich in fuel content, reaches
starter plunger and mixes again with the air coming through a
passage (8) extending from underneath the diaphragm. The rich
fuel/air mixture for starting is discharged through starter outlet
(6) in the main bore.
4.36
Main System Float System
As throttle valve (1) is opened, engine speed rises, and this Fuel enters the float chamber (3) by means of the inlet pipe and
increases negative pressure in the venturi. Consequently the passage, through a screen on the back of the inlet needle seat (4),
vacuum slide (2) moves upward. The fuel in float chamber (3) and around the inlet needle (2). As the fuel fills the float
is metered by main jet (4), and the metered fuel enters needle jet chamber, the float (1) rises and forces the inlet needle against the
(5), in which it mixes with the air admitted through main air jet seat, shutting off the orifice in the seat. When fuel level is up in
(6) to form an emulsion. The emulsified fuel then passes through float chamber, floats are up and needle valve remains pushed up
the clearance between needle jet (5) and jet needle (7), and is against valve seat. Under this condition, no fuel enters the float
discharged into the venturi (A). Mixture proportioning is chamber. As the fuel level falls, floats go down and needle valve
accomplished in needle jet (5); the clearance through which the unseats itself to allow fuel into the chamber. In this manner, the
emulsified fuel must flow is determined ultimately by throttle needle valve releases and shuts off fuel alternately to maintain
position and vacuum slide height. a constant fuel level inside the float chamber.
4
2
Inlet
Pipe
A
6
3
1
5 3
4 4 2
4.37
Pilot Screw Air/Fuel Mixture Ratio
The pilot system supplies fuel during engine operation with the E-Clip Position vs. Fuel Flow
throttle valve closed or slightly opened. The fuel/air mixture is
metered by pilot screw and discharged into the main bore 2
through the pilot outlet. 3
4
CAUTION
4
The pilot screw is calibrated at the factory to meet
EPA / CARB regulations for air quality standards
and is sealed with a brass plug to prevent tampering. 3
Removal of the tamper proof plug is not permitted.
For service purposes, cleaning of the pilot circuit can 2
be done only by a certified repair shop to ensure air
quality standards are not exceeded.
15 50 75 100%
Throttle Valve Opening
Pilot Screw Location
A carburetor with a slide type throttle valve is also called a
variable venturi type carburetor. In this type of carburetor, the
needle jet and jet needle serve to control proper air/fuel mixture
ratio at the medium throttle valve opening (between 1/4 and 3/
4 opening).
Having the proper needle jet and jet needle has a major impact
on engine performance at partial load. The jet needle tapers off
Brass Plug Installed at one end and the clearance between the jet needle and the
needle jet increases as the throttle valve opening gets wider. The
air/fuel mixture ratio is controlled by the height of the “E” clip
inserted into one of the five slots provided in the head of the jet
needle. The previous chart shows the variation of fuel flow
based on the height of the “E” clip.
Brass Plug Removed
4.38
Jet Needle Throttle Opening vs. Fuel Flow
The jet needle has five adjustment grooves cut into the upper In a full throttle condition the cross sectioned area between the
portion, and is tapered from approximately the middle of the jet needle and the needle jet is larger than the cross sectioned
needle to the lower end. The top is fixed to the center of the area of the main jet. The main jet therefore has greater control
throttle valve by the needle clip, and the tapered end extends into over fuel flow.
the needle jet. Fuel flows through the space between the needle
jet and jet needle. This space does not vary until the throttle Small Medium Large
reaches the 1/4 open point. At that time the tapered portion of the Clearance Clearance Clearance
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
Leaner
Position#
4
Richer
Closed One-half Full

Throttle Throttle 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
Needle Jet damaged.
The needle jet works in conjunction with the jet needle to
regulate fuel flow rate. An air bleed opening in the side of the
needle jet brings in air measured by the air jet. This air initiates
the mixing and atomizing process inside the needle jet.
Needle Jet
Main Jet
2. Remove float bowl. Remove the float pin screw. The float
4.39
and float pin can be removed. NOTE: The starter jet is removable. Upon disassembly,
place the parts in a container for safe keeping.
3. Remove inlet needle seat retaining screw along with plate,

and carefully remove needle seat. NOTE: Do not use a
pliers to remove the seat or permanent damage may occur. Carburetor Cleaning
WARNING
Protect eyes from contact with cleaner. Take

appropriate safety measures during these
procedures. Safety glasses and chemical resistant
gloves are required. Should you get cleaner in your
eyes or if you swallow cleaner, seek medical
attention immediately.
Carburetor cleaners can be extremely caustic.
Extended periods of soaking can loosen the
adhesive sealer on the passage drill-way plugs. Do
Remove Screw not soak rubber or plastic components (such as the
vacuum slide diaphragm, needle seat screen, or O-
Rings in caustic cleaning solutions. Damage may
4. Remove the pilot mixture screw, spring, flat washer, and occur. Do not use agitator-type carburetor cleaning
O–Ring. If an anti–tamper plug is installed over the pilot equipment. Rubber parts must be cleaned with mild
screw cavity, it must be removed for access. detergent and hot water only.
1. Thoroughly clean the carburetor body, jets, and all

passages with carburetor cleaner or electrical contact
cleaner.
O-Ring
2. If the carburetor is extremely dirty or contaminated with
Washer fuel residue and varnish, soak for short periods only in
Spring carburetor cleaner, and rinse in hot water.
3. Replace the jets if they have a buildup of fuel residue or
bacterial growth that cannot be removed. Even a small
Pilot Screw amount of residue will reduce the flow characteristics of the
jet.
4. Verify all passages and jets are unobstructed by spraying
electrical contact cleaner through the passages.
CAUTION: Do not use wire or welding tip cleaners as the
orifice size may be altered.
5. Use low pressure air to dry carburetor body and all
components.
4.40
Carburetor Inspection diaphragm should fit properly in the carburetor body. Replace
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 the needle. The middle to upper portion of
the needle contacts the needle jet and is the most likely
wear point. If jet needle shows signs of wear replace both
the needle and needle jet to prevent a rich condition. TIP:
A worn needle jet is difficult to spot. To check, slide a
slightly larger new jet needle into the needle jet and hold it
to a light source. Light will be visible between the needle
and needle jet if it is worn.
Needle Jet
4
Jet Needle
Inspect this
area
2. Inspect the inlet needle tapered surface for any sign of wear 1. Replace parts in proper order. The spring seat (B) is
or damage. Be sure the spring loaded pin is free moving and stepped and must be placed on TOP of “E” Clip (C).
returns freely when pushed. The inlet needle and seat Spacer washer (D) must be installed below the E–Clip.
should be pressure tested after assembly. Refer to parts manual for more information.
2. Be sure the tab (E) on outer edge of diaphragm is positioned
Good Condition Worn, Deposits properly in the carburetor body.
Seat FRONT
(Engine)
Wear areas
Pilot Screw
Needle
3. Install the pilot mixture screw, spring, washer, and O–ring
as an assembly. Lubricate the O–Ring with oil or light
grease before installation. CAUTION: Do not damage the
O–ring during installation. Turn the screw in until it lightly
contacts the seat. Back out the specified number of turns.
NOTE: The final pilot (idle) mixture must be adjusted with
the engine running. Refer to Page 2.10.
Carburetor Assembly Pilot Screw Base Setting

(Set at Factory)
Inspect the diaphragm (A) for holes, deterioration, or damage.
Make sure the diaphragm is pliable but not swollen. The Factory Specification: 2 Turns Out
4.41
Float Height Adjustment float measurement is even on left and right side.
1. Illustration 1: Place the throttle side of the carburetor on

a level surface to remove weight from float arm. In this
position, the float tongue will rest slightly outward.
Needle and Seat Leakage Test

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 to inlet fitting. The needle and seat should
The float will then fall into the correct position, with the hold pressure 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.
Illustration 3: NOTE: If the float is past parallel with the
mating surface, the carburetor has been tilted back too far
and the float tongue is likely compressing the needle valve
pin.
Float parallel with float Mity VacTM (PN 2870975)

bowl mating surface
3. Measure the height from the float bowl mating surface to

the top of step of the float as shown in Illustration 2. Both
sides of float should be parallel to each other. The
measurement should be made at the mid–point on top of the
float using Float Adjustment Tool (PN 2872314) or a
vernier caliper. When measuring the height, be sure the
inlet needle valve spring is not compressed.
Float Bowl Height: 13-14 mm
4. If adjustment is necessary, bend the tongue slightly. Be sure
4.42
Fuel Level Test
A fuel level test can be performed on some models if the drain
hose fitting is accessible. Be sure to re–attach the bowl drain
hose after performing the test. A fuel level test allows you to
observe the height of the fuel in the float bowl without removing
the carburetor. The fuel level can be observed with the engine
either running or shut off, however, engine must run briefly to
allow fuel level to stabilize.
1. Attach a clear line to drain fitting. Be sure line fits tightly
on fitting. Position hose along side of carburetor as shown.
4
1.5 mm
.060 in. Bowl Mating
Surface
2. Open bowl drain screw by turning counterclockwise

approximately two turns. Start and run engine for 3 to 5
seconds to allow fuel level to stabilize in the line. If level
is out of specification, remove carburetor and inspect inlet
needle and seat, float height, passages, etc.
NOTE: If a line was removed to perform this procedure,
it must be replaced.
4.43
FUEL TANK/FUEL DELIVERY SYSTEM
Fuel System Exploded View
4.44
FUEL PUMP 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.
Fuel Pump Testing
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.
4
Impulse Line
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
be replaced.
Fuel Pump Disassembly

1. 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
Fuel Pump Inspection and Reassembly FUEL GAUGE SENDING UNIT
1. Inspect inlet and outlet check valves for cracks, warping or
Sending Unit Removal
damage.
2. Inspect the diaphragms for cracks, holes or swelling. 1. Disconnect the negative battery cable.
3. To clean the valves or pump body, remove the set screw and 2. Remove the side panels and front cab assembly. Refer to
washer. Remove the valve assembly and wash with soap Chapter 5 for details.
and water. 3. Remove the gas tank cover vent hose. Be sure to properly
NOTE: Carburetor cleaner may used to clean the route the vent hose upon reassembly.
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 the

surfaces for damage. Replace diaphragms and gaskets as a
set.
5. Reassemble the pump in reverse order of disassembly.
Tighten all screws evenly.
4. Remove the clamps on the PVT intake duct and remove the
Fuel Filter Replacement PVT duct.
1. Loosen the filter clamps and remove filter.
Typical Filter
Location
5. With all the body panels removed from the front of the ATV
2. Install new filter onto fuel lines and install clamps.
and the gas tank exposed, disconnect the fuel sender wiring
harness.
4.46
6. Remove the 5 screws that secure the fuel sender to the tank. TROUBLESHOOTING
FUEL STARVATION/LEAN MIXTURE
Symptoms: Hard start or no start, bog, backfire, popping
through intake / exhaust, hesitation, detonation, low power,
spark plug erosion, engine runs hot, surging, high idle, idle
speed erratic.
• No fuel in tank
• Restricted tank vent, or routed improperly
• Fuel lines or fuel valve restricted
• Fuel filter plugged
• Carburetor vent line(s) restricted
7. Slowly lift the sender out of the tank. Lift the sender out at
an angle, so the float will more easily come out of the fuel
• Plugged or restricted inlet needle and seat screen
or inlet passage 4
tank. • 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 cleaner 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)
Testing
• Air filter dirty/plugged
Refer to Chapter 10 for fuel gauge sending unit troubleshooting.
• Electric choke inoperative
Sending Unit Installation • Incorrect pilot air/fuel screw adjustment
1. Reinstall the fuel sender with a new gasket, using care not • Faulty inlet needle and seat
to bend or damage the float arm.
2. Install the 5 screws and torque the screws to specification. • Faulty inlet needle seat O-Ring
Reconnect the sender and route the harness properly. • Float level too high
• Poor fuel quality (old fuel)
=T
• Loose jets
Sending Unit Screw Torque: • Worn jet needle/needle jet or other carburetor
18--24 in.lbs. (2--3 Nm) in criss-cross pattern parts
• Dirty carburetor (air bleed passages or jets)
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.
4.47
POOR IDLE
Idle Too High
• Idle adjusted improperly/idle mixture screw
damaged
• Sticky 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
Erratic Idle
• Choke cable bending or incorrectly adjusted
• Throttle cable incorrectly adjusted
• Air leaks, dirty carburetor passages (pilot circuit)
• Pilot mixture screw damaged or adjusted
incorrectly
• Tight valves
• Ignition timing incorrect
• Belt dragging
• Dirty air cleaner
• Engine worn
• Spark plug fouled
• Idle speed set incorrectly (speed limiter)
• Worn jet needle/needle jet
4.48
BODY / STEERING / SUSPENSION
CHAPTER 5
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
DECAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
PLASTIC INSERT REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
SIDE PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
FRONT COVER REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
FOOT WELL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
X2-TOURING FOOT WELL REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 5.5
FRONT STORAGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
FRONT STORAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
SPORTSMAN REAR RACK REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 5.8
FRONT CAB/FENDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5
SPORTSMAN REAR CAB / FENDER REMOVAL / INSTALLATION. . . . . . . . . . . . . . . 5.10
X2-TOURING REAR QUARTER PANEL REMOVAL / INSTALLATION . . . . . . . . . . . . 5.10
SPORTSMAN REAR STORAGE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . 5.11
RADIATOR SCREEN REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
SPORTSMAN BODY ASSEMBLY EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
X2-TOURING BODY ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
TOURING BODY/RACK ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . 5.14
BODY / RACK EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
TOURING BODY/SEAT ASSEMBLY EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . 5.16
HEADLIGHT POD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
HANDLEBAR BLOCK INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
STEERING / A-ARM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
A-ARM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
BALL JOINT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
STEERING POST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
STEERING POST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
FRONT STRUT CARTRIDGE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
STRUT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
SPORTSMAN REAR SUSPENSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
X2-TOURING REAR SUSPENSION EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . 5.25
X2-TOURING TORSION BAR EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
X2 CARGO BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
X2 SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30
EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30
X2 SEAT OPERATION - CONFIGURING CARGO BOX FOR PASSENGER RIDING . 5.31
X2 DRIVER SEAT BACKREST REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . 5.32
X2 PASSENGER SEAT BACKREST REMOVAL / INSTALLATION . . . . . . . . . . . . . . . 5.32
5.1
GENERAL INFORMATION Special Tools
Torque Specifications Table 5-2:
Table 5-1: PART NUMBER DESCRIPTION
FT.LBS.
2870871 Ball Joint Replacement Tool
COMPONENT NM
(IN.LBS.) 2870872 Shock Spanner Wrench
Front Hub Nut 60 81 Shock Absorber Spring Compression
2870623
Front A-Arm Attaching Bolt 37 50 Tool
Front A-Arm Ball Joint Stud Nut 30 41 2871572 Strut Rod Wrench
Handlebar Adjuster Block 14 23 2871573 LH Strut Spring Compressor

Master Cylinder Clamp Bolt (45-55) 5.2-6.3 2871574 RH Strut Spring Compressor
Rear Shock Bolt (Upper) 30 41
Decal Replacement
Rear Shock Bolt (Lower) 30 41
Flame Treating Decal Area
Rear Wheel Hub Nut 80 109
Plastic polyethylene material must be “flame treated" prior to
Upper Stabilizer Support Nuts 17 27 installing a decal to ensure good adhesion. The flame treating
procedure can often be used to reduce or eliminate the whitish
Upper Control Arm Mounting Bolt 37 50 stress marks that are sometimes left after a fender or cab is bent,
flexed, or damaged.
Lower Wheel Bearing Carrier Bolt 37 50
Strut Rod Retaining Nut (Top) 15 21
WARNING
Strut Casting Pinch Bolt 17 27
Tie Rod End Jam Nut 12 17 The following procedure involves the use of an
open flame. Wear the appropriate safety equipment
Tie Rod End Castle Nut 45 61 at all times. Perform this procedure in a well
Tie Rod End Attaching Bolt 24 33 ventilated area, away from gasoline or other
flammable materials. Verify the area to be flame
Upper Shock Mounting Bolt 37 50
treated is clean and free of gasoline or flammable
Lower Shock Mounting Bolt 37 50 residue.
NOTE: Refer to exploded views throughout this 1. Pass the flame tip of a propane torch back and forth quickly
chapter for identification and location of over the area where the decal is to be applied until the
components. 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.
5.2
Plastic Insert Removal / Installation 3. To install the inserts, press outside insert (B) into the hole.
Press inside insert (A) until it snaps into place.
Some Polaris ATVs use a two piece plastic insert in place of a
metal screw. The plastic inserts are simple to remove and install. NOTE: The outside insert (B) should be flush
surface after installation.
1. Use a pair of diagonal side cutters to lift the plastic insert
(A) until you feel some slight pressure or lift the insert
approximately 1/4" (6.35 mm). Apply just enough
pressure on the side cutters to lift up on the insert. DO
NOT apply too much pressure on the side cutters, or
damage to the insert will occur.
5
The inside insert (A) should be flush with the top of the outside
insert (B).
A
2. Next, use the diagonal side cutters under outside insert (B)
to completely remove the assembly. NOTE: The inside B
insert (A) will still be installed in the outside insert (B).
NOTE: The inside insert (A) will still be installed in

the outside insert (B).
5.3
BODY 3. Reinstall the side panel by reversing the removal procedure.
Step 3
Side Panel Removal
Side panel removal is quick and easy, use the following
instructions for removal and installation.
1. Remove seat by releasing the latch (if equipped) and lifting
up on the seat. (X2 seats do not have a latch system.)
Step 1
Front Cover Removal / Installation

1. Open the front storage compartment
2. 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 a
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 ATV.
Step 2
3. To 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.
5.4
Foot Well Removal / Installation X2-Touring 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.
5
18 in.lbs. (
A A
A A
B
B
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.
5.5
Front Storage Removal 2. Remove the four bolts that secure the storage rack to the
frame.
Front Storage
Remove Bolts
3. Remove the two (T25) screws that secure the storage box
to the front fender well areas (each side).
Remove Bolts
T-25 Screws
1. Remove the front radiator cap cover (A) by lifting upward

on the cover.
A
4. Remove the two (T25) screws that secure the outside of the
storage box to the front fenders (each side).
T-25 Screws
5.6
Winch Installation 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.
D
C
Pull Out to Remove

7. Remove the remaining bolts and screws that secure the
front bumper section to the frame.
5
To install the front cover place top lip of the cover into and lift
up to remove.
1. Place Lip In Groove

Groove
Lip
2. Press in Tabs
5.7
Front Storage Installation 8. Install the front radiator cap cover (E) .
A Front Storage
B E
C inserts Sportsman Rear Rack Removal / Installation
C
B A B
A
A C
D
T-25 Screw A
A. 14 ft.lbs. (19 Nm) C. 10 in.lbs. (1.13 Nm) B
B. 10 in.lbs. (1.13 Nm) D. 24 in.lbs (2.7 Nm)
1. Place the front storage rack onto the frame.

2. 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 C
fender area (2 each side).
4. Install the four screws (C) (T-25) into the front fender area T-27 Screw
of the storage box (2 each side).
A. 36 in.lbs. (4 Nm) B. 18 in.lbs. ( 2 Nm)
5. Install the 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). 1. Remove the six (A) T27 screws and two bolts (B) that
7. Torque all bolts and screws according to the illustration. secure the rear rack to the rear cab and frame.
2. Lift the rear rack from the ATV. Remove the two rack
spacers (C).
5.8
3. Place spacers on frame. 3. Remove the two screws (B) that secure the front cab to the
frame in the fuel tank mount area.
4. Install rear rack onto rear frame and cab.

5. Install the two bolts (B) and six (A) T-27 screws. Torque 4. Remove the side panels (D), refer to the “SIDE PANEL
the bolts (A) to 18 in.lbs. (2 Nm) and six T-27 screws to 36 REMOVAL” section.
in.lbs. (4 Nm). Refer to the illustration for torque values.
5
5. Remove the plastic inserts (E) that secure the front of the
foot wells to the front cab.
Front Cab/Fender Removal/Installation
1. Follow the “FRONT RACK / BUMPER REMOVAL”
section to begin removal of the front cab, rack, and D
bumper.
2. Remove the plastic inserts (A) that secure the front cab to
the upper strut support.
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.
A 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.
8. Reverse the removal steps for installation. Torque two

front cab to frame screws to specification.
=T
Cab to Frame Screws
24 in.lbs. (2.7 Nm)
5.9
Sportsman Rear Cab / Fender Removal / X2-Touring Rear Quarter Panel Removal /
Installation Installation
1. Follow the “REAR RACK REMOVAL” procedure to 1. Remove the seat.
remove the rear rack. 2. Remove the plastic inserts (circled) that secure the quarter
2. Remove the plastic inserts that secure the rear cab to the panel to the rear footwell. (See “PLASTIC INSERT
frame and plastic. REMOVAL / INSTALLATION” for information).
3. Reverse the removal procedures to install the quarter

panels. Verify panels are properly aligned to the footwell
Remove plastic dart inserts. end upon reassembly.
3. Disconnect the rear lights by pulling the locks on each side

and removing the connectors. Lift the rear cab from the
frame.
Remove Connectors
Lock
4. Reverse the removal steps for installation.
5.10
Sportsman Rear Storage Removal / Radiator Screen Removal
Installation
1. Pull out slightly on the top of the radiator screen.
1. Follow the “REAR RACK REMOVAL” and “REAR 2. With the top free, pull out on the bottom of the screen to
CAB REMOVAL” procedure to remove the rear storage remove the screen.
compartment. After the rear cab is removed the storage 3. To install the screen, simply press the tabs on the screen
compartment comes out. back into the mounting grommets. Be sure the screen is
2. Remove the two plastic inserts that hold the rear storage securely in place.
compartment in place.
3. For installation, reverse the removal steps.
5.11
Sportsman Body Assembly Exploded View
Rear Cab Assembly Pull UP on rear of seat and
back to disengage tabs at front
of seat.
Seat Latch
Rear Cab Wheelwell
Storage
Frame
Front Cab Assembly

Side Cover
Frame
Front Cover
Front Brush Guard
Support
Front Cab
Splash Shields
5.12
X2-Touring Body Assembly Exploded View
Rear Cab Assembly
Footwell
RH Rear Cab
Footwell Support Frame 5
Front Cab Assembly

Side Cover
Frame
Front Cover
Front Brush Guard
Support
Front Cab
Splash Shields
5.13
Touring Body/Rack Assembly Exploded View
Hand Rails
Rear Rack
Rear Rack Support
Footwell and Auxiliary

Foot Rests
5.14
Body / Rack Exploded Views
Rack Rails
Sportsman Only
Rear Rack
Rear Rack Support
5
Rack Rails
Frame
Box Assembly
Cover
Front Brush Guard
Panel
Radiator Shield Grill

Radiator Screen
Front Bumper
5.15
Touring Body/Seat Assembly Exploded View
Upper Seat
Upper Support Lower Seat
Rear Seat Support
Latch Assembly
Base and Pin Latch
5.16
Headlight Pod Exploded View
Worklight Switch
A
Instrument
Cluster F
A
ETC
Brake
Clean knurling when

repositioning handlebars
G
5
D
C
E
Wheel Speed Sensor - Sportsman
C (X2 Speed Sensor Located on Transmission)
Disassembly Assembly
• Remove two side Phillips screws (A) • Install bottom of pod onto handlebar and secure to
brackets
• Remove one rear Phillips screw (B)
• Install 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)
• Install two side Phillips screws
• Remove headlight (F) with adjuster
• Install one rear Phillips screw
• Remove two screws securing bottom half of pod (E)
• To adjust headlight, refer to procedure outlined in
Chapter 2
5.17
STEERING
Handlebar Block Installation Procedure
Clean knurling when

repositioning handlebars
B
1. The pin (A) on the bottom side of the top handlebar block faces down and to the front of the 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 ATV.
3. Align the pin (A) in the top block with the middle hole (B) in the bottom block for proper installation. The pin (A) and middle
hole (B) should face the front of the ATV.
4. Install the pin side bolts first and evenly tighten the bolts down. Evenly torque the 2 front bolts to specification.
=T
Handle Bar Bolt Torque
14 ft.lbs.(19 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.
5.18
Steering / A-arm Exploded View
1 30 ft.lbs. (41 Nm)
Steering Post
25-30 ft.lbs.
(35-41 Nm)
1 30 ft.lbs. (41 Nm)
3 Steering Post Arm
5
8 ft.lbs. (11 Nm)
B
A
25 ft.lbs. (35 Nm)
40-45 ft.lbs. (54-61 Nm) 12-14 ft.lbs. (17-19 Nm)
1 Always use new bolts

upon reassembly.
2 Always use new cotter pins upon
reassembly. Install with open end 3 Apply Loctite™ 242 to bolt threads.
toward rear of machine.
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.
5.19
A-Arm Replacement
Vehicle Frame Bolt - 30 ft.lbs. (41 Nm)

Apply Loctite™ 242
to the bolt threads.
Bushing Ball Joint Stud
30 ft.lbs. (41 Nm) A-Arm Tube 8 ft.lbs. (11 Nm)

A-arm Shaft
25 ft.lbs. (35 Nm)

Cotter Pin - (Install New)
1. Elevate and safely support vehicle with weight removed from front wheel(s).
2. Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud.
3. Using a soft face hammer, tap nut to loosen A-arm from bolt. Remove nut and A-arm from hub strut assembly.
4. Loosen two bolts on A-arm tube by alternating each about 1/3 of the way until A-arm can be removed.
5. Examine A-arm shaft. Replace if worn. Discard hardware.
6. Insert A-arm shaft into new A-arm.
7. Install CV joint shields.
8. Install new A-arm assembly onto vehicle frame. Torque new bolts to specification.
=T
A-Arm Bolt Torque: 37 ft. lbs. (50 Nm)
WARNING
The locking features on the existing bolts were

destroyed during removal. DO NOT reuse old
bolts. Serious injury or death could result if
fasteners come loose during operation.
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.
=T
Ball Joint Nut Torque: 30 ft. lbs. (41 Nm)
WARNING
Upon A-arm installation completion, test vehicle at

low speeds before putting into regular service.
5.20
Ball Joint Replacement 8. Install puller guide (G) with extension cap (H).
9. Apply grease to extension cap and threads of puller bolt to
NOTE: Refer to the illustration on the previous page
ease removal.
for this procedure.
10. Thread bolt (J) with nut (I) onto ball joint stud as shown.
1. Loosen front wheel nuts slightly. 11. Apply heat to ease removal.
2. Elevate and safely support machine under footrest/frame 12. Hold bolt (J) and turn nut (I) clockwise until ball joint is
area. removed from strut housing.
CAUTION
K
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.
F 5
L
E 13. To install a new ball joint, Remove extension cap and
B attach puller guide using short bolts provided in the kit.
14. Remove extension cap and attach puller guide using short
A bolts provided in the kit.
D 15. Insert new ball joint (K) into driver (L).
4. Remove cotter pin (A) from ball joint castle nut (B). 16. Slide ball joint/driver assembly into guide.
5. Remove castle nut (B) and separate A-arm (C) from ball 17. Apply heat to ease installation.
joint stud. 18. Drive new joint into strut housing until fully seated.
6. Remove screws (D) and ball joint retaining plate (E). 19. Apply Loctite™ 242 (PN 2871949) to threads of retaining
7. Use the Ball Joint Replacement Tool (PN 2870871), plate screws or install new screws with pre-applied locking
remove ball joint (F) from strut housing. Refer to photos. agent. Torque screws to specification.
=T
G
H Retaining Screw Torque: 8 ft. lbs. (11 Nm)
20. Install A-arm on ball joint and torque castle nut to

I
specification.
J
=T
Castle Nut Torque: 30 ft. lbs. (41 Nm)
21. Reinstall cotter pin with open ends toward rear of machine.
5.21
Steering Post Removal SUSPENSION
1. Remove the front cab.
Front Strut Cartridge Replacement
2. Remove the handle bar pod.
3. Remove the handle bar. NOTE: Refer to illustration on following page.
4. Remove the fuel tank bracket assembly.
1. Hold strut rod and remove top nut.
5. Remove the steering tie rod ends from the steering bracket.
2. Remove upper strut pivot assembly.
Note the orientation of the fasteners and bracket on the
steering assembly.
6. Remove the steering post nuts at the mount plate.
Strut Rod Wrench:
(PN 2871572)
7. Remove the top steering bracket. Strut Spring Compressor Tools:
8. Remove the steering post. (PN 2871573) and (PN 2871574)
Steering Post Assembly 3. Compress spring using any commercially available spring
compressor tool and remove the spacer nut.
4. Remove coil spring and collapse strut cartridge.
5. Remove two pinch bolts from strut casting.
6. Remove strut cartridge.
7. Install cartridge until bottomed in strut casting.
8. Install pinch bolts with wire clamp(s). Torque pinch bolts
to specification.
17 ft.lbs. (23 Nm)
=T
Pinch Bolt Torque:
17 ft. lbs. (23 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.
NOTE: Steering post bearing is shown in exploded =T

view form. This bearing is attached to the post using
a radial riveting method and is a non-serviceable item.
Steering post relacement is required in the event of a Strut Rod Nut Torque:
bearing failure. 15 ft. lbs. (21 Nm)
1. Install the steering post.

2. Install the steering post nuts at the mount plate.
3. Install the top steering bracket.
4. Torque all fasteners to specification.
5. Install the steering tie rod ends from the steering bracket,
noting the orientation of the fasteners and bracket on the
steering assembly.
6. Install the fuel tank bracket, handle bar and pod. Torque
fasteners to specification.
7. Check the steering, the handle bars must move freely and
easily from full left to full right without binding.
8. Install front cab.
5.22
Strut Assembly
Nut - 15 ft.lbs. (21 Nm)
Strut Bumper
Spacer Rubber
Washer
Strut
Upper Pivot Ball
Spacer Nut
Clamp
Lower Pivot Ball Washer
17 ft.lbs. (23 Nm)
5
Spring Retainer
17 ft.lbs. (23 Nm)
Bolts
Spring
Brake Caliper
Hubstrut Bearing
Retaining Ring
5.23
Sportsman Rear Suspension Assembly
17 ft.lbs. (24 Nm)
Stabilizer Bar
1
37 ft.lbs. (50 Nm)
37 ft.lbs. (50 Nm)
37 ft.lbs. (50 Nm)
37 ft.lbs. (50 Nm)
Upper Control Arm Bushings
37 ft.lbs.
(50 Nm) Rear Shock
Lower Control Arm
37 ft.lbs. (50 Nm)
Orientate Bushings Rear Front

1 Correctly
Bushing Orientation
5.24
X2-Touring Rear Suspension Exploded View
Rear Compression Spring
Preload Adjustment Cam
Rear Shock
5
Bushings
Control Arm Pivot Bracket
Upper Control Arm
Boot Shield
A-Arm Shaft
Lower Control Arm

Wheel Bearing Carrier
Grease Zerk
5.25
X2-Touring Torsion Bar Exploded View
Linkage Bushing Stabilizer Bar
Stabilizer Bushing
Bushing
Torsion Mount
Linkage Asm.
5.26
X2 CARGO BOX
Exploded View
5.27
Removal / Installation 3. Disconnect the two wire harnesses connected to each of
the taillights.
IMPORTANT: Before attempting to remove the cargo
box, verify 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 (A)
securing the rear taillights on each side of the cargo box as
illustrated below.
CAUTION
Use caution when disconnecting the smaller light

bulb. Follow the procedure below to keep from
damaging the connector. Damaging a connector
may require wire harness replacement.
2. Remove the taillight assembly from the cargo box. 4. Carefully pull out the red locking tab on the connector.
5. Once the red tab is pulled out, press in on the black tab and
pull out to disconnect harness.
Black Tab
Red Tab
5.28
6. Lift up firmly in the cargo box release lever on either side 9. Carefully remove the cargo box from the ATV.
of the ATV.
10. Reverse the removal steps to reinstall the cargo box. Refer
to the standard fastener torque values in Chapter 1 during
7. Remove the four bolts attaching the rear of the cargo box assembly.
to the frame. There are two on each side.
See “Standard Torque Specifications” on page 1.12.

8. Support the cargo box and remove the clip and pin holding
the gas shock to the cargo box.
Clip Pin
5.29
X2 SEAT ASSEMBLY
Exploded Views
5.30
X2 Seat Operation - Configuring Cargo Box 4. Fold the driver seat backrest down into place to serve as the
For Passenger Riding passenger seat bottom.
Passenger Backrest
1. Unlatch the driver seat backrest by turning the engagement
knobs on each side in the directions shown below.
A
B
Driver Seat Backrest / Passenger Seat Bottom

5. Lift the latch on the passenger backrest to set the proper
backrest height desired by the passenger.
5
2. While pulling the backrest towards the front of the ATV,
lift up on the passenger backrest loop that is face down in
the cargo box.
Driver Seat Backrest
Passenger Backrest
3. Lift the passenger backrest up and into place, then lay the
driver seat backrest down into place
A
B
5.31
X2 Driver Seat Backrest Removal / X2 Passenger Seat Backrest Removal /
Installation Installation
1. Configure the seating for 2-UP riding. With the passenger 1. Configure the seating for 2-UP riding. Lift up on the latch
seat bottom in place, remove the two screws retaining the for the passenger backrest and lift the backrest to the full
seat bottom. up position.
2. Lift up on the latch for the passenger seat bottom and lock
it in the upright position as shown below.
2. Remove the two pivot pins holding the seat bottom to the
frame and then lift up on the seat bottom to remove.
5.32
3. Remove the two screws retaining the passenger backrest.
4. Remove the two pivot pins holding the backrest to the

frame.
5. Lift up on the backrest latch and tilt the backrest in towards

the cargo box and lift up to remove it.
5.33
NOTES
5.34
CLUTCH SYSTEM
CHAPTER 6
CLUTCH SYSTEM
SPECIAL TOOLS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SERVICE NOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
COMPONENT FASTENER TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT EXPLODED VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
PVT SEALING AND DUCTING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
DRIVE CLUTCH EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
DRIVEN CLUTCH EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
ENGINE BRAKING SYSTEM (EBS) EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
PVT OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
DRIVEN CLUTCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
EBS CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
PVT MAINTENANCE / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
DRIVE CLUTCH SPRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
OPTIONAL SHIFT WEIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
PVT DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
PVT DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
PVT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
6
DRIVE BELT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
DRIVE BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
CLUTCH ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
CLUTCH OFFSET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
EBS DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
DRIVE CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
BUTTON TO TOWER CLEARANCE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
SHIFT WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
DRIVE CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
MOVEABLE SHEAVE BUSHING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
DRIVE CLUTCH BUSHING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
ONE-WAY CLUTCH INSPECTION (DRIVE CLUTCH) . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
DRIVE CLUTCH REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
EBS DRIVEN CLUTCH SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
DRIVEN CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
DRIVEN CLUTCH BUSHING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 6.24
EBS DRIVEN CLUTCH REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25
STANDARD DRIVE CLUTCH - 500 CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28
DRIVE CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28
SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.29
BUTTON TO TOWER CLEARANCE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.30
SHIFT WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.30
SHEAVE / BUSHING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.31
DRIVE CLUTCH BUSHING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.31
DRIVE CLUTCH REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.32
STANDARD DRIVEN CLUTCH - 500 CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . 6.34
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.34
CLUTCH DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.34
BUSHING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.35
MOVEABLE SHEAVE - BUSHING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.36
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.37
PVT TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.39
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.39
PROBLEM, CAUSE AND REMEDY CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.40
6.1
CLUTCH SYSTEM
SPECIAL TOOLS AND Component Fastener Torques
SPECIFICATIONS
FT.LBS.
Special Tools COMPONENT NM
(IN.LBS.)
Drive Clutch Retaining Bolt 40 54

TOOL DESCRIPTION PART NUMBER
Driven Clutch Retaining
17 23
Clutch Puller 2870506 Bolt
Clutch Holding Wrench 9314177 PVT Inner Cover Bolts 12 16
Clutch Holding Fixture 2871358 Drive Clutch Spider EBS

200 271
Clutch
Spider Nut Socket 2870338
Drive Clutch Spider Lock
15 20.3
Drive Clutch Spider Removal Nut
2870341
& Install Tool Drive Clutch Cover Plate (90) 10
Driven Clutch Puller 2870913
Roller Pin Tool 2870910
Clutch Bushing Replacement

2871226
Tool Kit
Piston Pin Puller 2870386
EBS Clutch Alignment Tool 2872292
EBS Bushing Replacement Kit 2201379
Clutch Compression Tool 8700220
Clutch Bushing Replacement

2871025
Tool Kit
Clutch Compression Tool

PS-45909
Extensions
Service Note
• Upon installation of a drive clutch, ALWAYS use a
NEW drive clutch bolt. The old drive clutch bolt has
been weakened by the removal process and will not
provide a true clamp load during the torque procedure.
6.2
CLUTCH SYSTEM
PVT EXPLODED VIEWS
PVT Sealing And Ducting Components
Clutch Inlet Duct
Transmission Cover Seal

Inner Clutch Cover
Clamps
Boot Duct
Clutch Cover Seal
Inner Seal Cover
Seal Retainer Bracket
6
Clutch Cover
Drive Clutch Exploded Views
EBS
One Way Clutch
NON-EBS
6.3
CLUTCH SYSTEM
Driven Clutch Exploded Views
NON EBS
EBS
1. Torx Screw 11. Moveable Sheave

2. Cam Assembly 12. Roller Pin
3. Retaining Ring 13. Spring Pin
4. E-clip 14. Stationary Sheave
5. Washer 15. Bearing
6. Roller 16. Retaining Ring
7. Outer Spider 17. Retaining Ring
8. Spring 18. Inner Spider Plate
9. Shaft 19. Spider Dampener
10. Thrust Washer 20. Clutch Roller
6.4
CLUTCH SYSTEM
Engine Braking System (EBS) Exploded View
One Way Clutch Drive

Washer
Washer Drive Belt
Shift Weights Cam Assembly

Roller/Bushing Retaining Ring
Assembly - Torque
200 ft.lbs.
Spacer
Clutch Rollers
Spider Assembly
Spider Lock Nut
Bushing Cover Compression Spring
6
Clutch Shaft
Coil Spring
Spacer Washer
Bearing
Sheaves
Retaining Rings
6.5
CLUTCH SYSTEM
PVT SYSTEM Driven Clutch Operation
Driven clutches primarily sense torque, opening and closing
PVT Operation Overview 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
WARNING belt, the drive belt is kept at the outer diameter of the driven
clutch sheaves.
All PVT maintenance or repairs should be
performed only by a certified Polaris Master Service As engine RPM and horsepower increase, the load from the
Dealer (MSD) technician who has received the drive belt increases, resulting in the belt rotating up toward the
proper training and understands the procedures outer diameter of the drive clutch sheaves and downward into
outlined in this manual. Because of the critical the sheaves of the driven clutch. This action, which increases
the driven clutch speed, is called upshifting.
nature and precision balance incorporated into the
PVT components, it is absolutely essential that no Should the throttle setting remain the same and the vehicle is
disassembly or repair be made without factory subjected to a heavier load, the drive belt rotates back up toward
authorized special tools and service procedures. the outer diameter of the driven clutch and downward into the
sheaves of the drive clutch. This action, which decreases the
The Polaris Variable Transmission (PVT) consists of three driven clutch speed, is called backshifting.
major assemblies: 1) The Drive Clutch; 2) The Driven Clutch;
and 3) The Drive Belt. The internal components of the drive In situations where loads vary (such as uphill and downhill) and
clutch and driven clutch control engagement (initial vehicle throttle settings are constant, the drive and driven clutches are
movement), clutch upshift and backshift. During the continually shifting to maintain optimum engine RPM. At full
development of a Polaris ATV, the PVT system is matched first throttle a perfectly matched PVT system should hold engine
to the engine power curve; then to average riding conditions and RPM at the peak of the power curve. This RPM should be
the vehicle's intended usage. Therefore, modifications or maintained during clutch upshift and backshift. In this respect,
variations of components at random are never recommended. the PVT system is similar to a power governor. Rather than vary
Proper clutch setup and careful inspection of existing throttle position, as a conventional governor does, the PVT
components must be the primary objective when system changes engine load requirements by either upshifting or
troubleshooting and tuning. backshifting.
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
CLUTCH SYSTEM
EBS Clutch Operation PVT Maintenance / Inspection
This EBS driven clutch provides the same engine braking Under normal operation the PVT system will provide years of
abilities as the EBS drive clutch. trouble free operation. Periodic inspection and maintenance is
required to keep the system operating at peak performance. The
following list of items should be inspected and maintained to
One-Way Clutch ensure maximum performance and service life of PVT
components. Refer to 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.

Drive Clutch
Assembly 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.
Driven
See “Drive Clutch Inspection” on page 6.17.
Downhill Belt
Rotation 3. Sheave Faces. Clean and inspect for wear.
4. PVT System 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
6
Drive cover. All connecting air ducts, as well as the inner and
outer covers, must be properly sealed to ensure clean air is
being used for cooling the PVT system. This also will
prevent water and other contaminants from entering the
When the ATV is moving the drivetrain turns in the direction of PVT area. A sealed PVT is especially critical on units
engine rotation as the clutches, belt, and one-way clutches at the subjected to frequent water forging.
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.
CAUTION
Driven clutches must be disassembled from the

helix end to reduce spring pressure. Review all
information before disassembly.
6.7
CLUTCH SYSTEM
Drive Clutch Spring 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, requiring replacement.
Table 6-1: Primary Clutch Springs

COLOR FREE LENGTH
PART # WIRE DIA.
CODE ± .125”
7041021 Plain .157” 4.38”

The drive clutch spring has two primary functions:
7041022 Black .140” 4.25”
1. Controls clutch engagement RPM. The springs which
7041063 Purple .168” 4.37”
have a higher rate when the clutch is in neutral will
increase clutch engagement RPM. 7041132 White .177” 2.92”
2. Controls the rate at which the drive belt moves upward
7041168 Green .177” 3.05”
in the drive clutch sheaves. This is referred to as drive
clutch upshift. 7041157 Blue/Green .177” 2.53”
The drive clutch spring is one of the most critical components

of the PVT system. It is also one of the easiest to service. Due Table 6-2: Secondary Clutch Springs
to the severe stress the coil spring is subject to during operation,
it should always be inspected for tolerance limits during any PART # DESCRIPTION
clutch diagnosis or repair.
3234199 White
There are other components which control upshift, but the
spring is one of the primary components in insuring optimum
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
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.
- NLA - - NLA -
698
6.9
CLUTCH SYSTEM
PVT Drying PVT Disassembly
IMPORTANT: If operating the ATV through water, be NOTE: Always replace the old drive clutch bolt with
sure to check the PVT cover and other ATV a new bolt upon reassembly, as the torque load
components for water ingestion. The ATV should be
checked immediately. Refer to Owner's Manual for properties are destroyed upon removal.
Safe Riding Tips.
1. Remove seat.
2. Remove or loosen cab and footwell fasteners as necessary
PVT Drain Plug to gain access to PVT outer cover.
3. Remove PVT air outlet duct hose.
4. 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.
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 PVT
drain plug is shown below.
To further expel water in the PVT cover and to dry out the PVT
system, shift the transmission to neutral and rev engine slightly
to expel the moisture. This will also air-dry the belt and clutches.
Allow engine RPM to settle to idle speed, shift transmission to
lowest available range and test for belt slippage. Repeat as
needed. Operate ATV in lowest available range for a short Drive Clutch Puller: (PN 2870506)
period of time until PVT system is dry.
Clutch Holding Wrench: (PN 9314177)
7. Remove driven clutch retaining bolt and driven clutch. Use

puller if necessary.
PVT Drain Plug & O-Ring
Driven Clutch Puller: (PN 2870913)
6.10
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
cover with the mark on the engine seal.
Offset Spacer
Seal This Edge To Cover On Engine
9. Remove cover screws and retainer plate.

2. Place a new seal on transmission input shaft.
Inner Cover 3. Apply RTV silicone sealant to outside edge of inner cover-
to-engine seal, to ensure a water tight fit between the seal
Retainer 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. 6
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
B
10. Remove inner cover retaining bolts at rear of cover. C
11. Remove cover along with foam seal on back of cover or
shaft. A
Seal Outer Edge To Cover

w/ RTV silicone sealant
=T
Inner Cover Bolt Torque (B):
12 ft. lbs. (16.6 Nm)
6.11
CLUTCH SYSTEM
7. Install clutch offset spacer(s) on transmission input shaft. Drive Belt Removal / Inspection
1. Remove outer PVT cover as described in PVT
Offset Spacer 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.
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.
=T
Driven Clutch Retaining Bolt Torque:
17 ft. lbs. (23.5 Nm)
11. Clean end of taper on crankshaft and the taper bore inside
drive clutch.
12. Install a NEW drive clutch bolt and torque retaining bolt
to specification.
=T
Drive Clutch Retaining Bolt Torque:
40 ft. lbs. (55 Nm)
ALWAYS USE A NEW BOLT UPON INSTALLATION
13. Reinstall drive belt noting direction of rotation. If a new 4. Measure belt width and replace if worn. Generally, belts
belt is installed, install so numbers can be easily read. should be replaced if clutches can no longer be adjusted to
14. Only replace PVT outer cover rubber gasket if it is provide proper belt deflection.
damaged. Place the gasket with the narrow side out (C). NOTE: If the top edges are trimmed on some drive
belts, it will be necessary to project the side profiles
Towards Outside Cover 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.
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
CLUTCH SYSTEM
6. Measure the distance where the side straight edges intersect DRIVE BELT INSTALLATION
the top, as shown in the illustration.
NOTE: Be sure to position belt so part number is easily
read. Verify new belt is seated properly in the clutches
Projected Belt Width 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.
Belt Width:
Wear Limit 1.125" (2.86 cm)
7. Inspect belt for loose cords, missing cogs, cracks,

abrasions, thin spots, or excessive wear. Replace if
necessary.
8. 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.
6
9. Measure belt length with a tape measure around the outer
3. The belt then should be able to be pushed down into and
circumference of the belt. Belts which measure longer than
between the sheaves.
nominal length may require driven shimming or engine
adjustment for a longer center distance to obtain proper belt 4. Install clutch cover temporarily. Verify engine is in PARK.
deflection. Belts which measure shorter than nominal Start engine and raise engine RPM enough to engage the
length may require driven shimming or a shorter center clutch, rotating the belt and seating it in the clutches.
distance. Remember, proper belt deflection is the desired Remove clutch cover and verify belt is seated properly
goal - not a specific center distance. before final cover installation.
10. 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.
Center
Distance
Clutch Center Distance:

10.05 ± .05" (254 ± 2.51mm)
6.13
CLUTCH SYSTEM
Clutch Alignment 7. Measure belt deflection and measure offset both above and
below shaft centerlines. Adjust if necessary.
1. Remove belt and install the Clutch Offset Alignment Tool
as shown. Center Line
B
Offset Alignment
Tool
Measure Above and Below Centerline

A 1/8” + 0 / -1/16
(3.2mm + 0 / - 1.6)
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 Offset
2. With tool touching rear of driven clutch inner sheave, the
IMPORTANT: Inspect clutch alignment and center
distance at point “A” should be 1/8”. distance before adjusting offset.
NOTE: If the distance is greater than 1/8, or less
than 1/16,, clutch alignment must be adjusted as Offset is correct when rear of tool contacts rear of inner sheave
with driven clutch pushed completely inward, spacers installed
follows: (if required) on shaft and bolt torqued to specification.
3. Remove drive and driven clutch. See “PVT
DIASSEMBLY” at the beginning of the chapter. Spacer Washer (PN 7556401)
4. Remove PVT inner cover.
5. Loosen all engine mounts. Move front of engine to the right 1. Install alignment tool as shown. Remember to measure
or left slightly until alignment is correct. above and below the shaft centerlines.
6. Tighten engine mounts and verify alignment is correct. 2. Adjust offset by adding or removing spacer washers
between back of driven clutch and spacer.
6.14
CLUTCH SYSTEM
EBS DRIVE CLUTCH SERVICE 5. Remove and inspect spring. See “Drive Clutch Spring
Specifications” for spring inspection.
Drive Clutch Disassembly
Inspect Shaft
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).
6
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™ coating. Wear is determined
by the amount of Teflon™ remaining on the bushing.
Clutch Holding Fixture: (PN 2871358)

Spider Removal Tool: (PN 2870341)
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.
6.15
CLUTCH SYSTEM
NOTE: It is important that the same number and 3. Inspect all rollers, bushings and roller pins by pulling a flat
thickness of washers are reinstalled beneath the metal rod across the roller. Turn roller with your finger. If
spider during assembly. Be sure to note the number you notice resistance, galling, or flat spots, replace rollers,
and thickness of these washers. pins and thrust washers in sets of three. Also inspect to see
if roller and bushing are separating. Bushing must fit
To maintain proper clutch balance and belt-to-sheave
clearance, be sure to reinstall original quantity and tightly in roller. Use the Roller Pin Tool (PN 2870910) to
thickness washers replace rollers and pins. Take care not to damage roller
bushing or bearing surface of the new pin during
installation.
2. Inspect the Teflon™ coating on the moveable sheave

bushing.
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).
Moveable Sheave Bushing Inspection:

brass than Teflon™ is visible
on the bushing. Refer to bushing
6.16
CLUTCH SYSTEM
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
NOTE: A damaged shift weight is usually caused by
of towers. See “Spider Removal” procedure.
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!
performed only by a certified Polaris Master Service
Dealer (MSD) technician who has received the
proper training and understands the procedures
Button to Tower Clearance: .000-.001 outlined in this manual.
Because of the critical nature and precision
2. Inspect sheave surfaces. Replace the entire clutch as an balance incorporated into the PVT system, it is
assembly if worn, damaged or cracked. absolutely essential that no attempt at
disassembly or repair be made without factory
authorized special tools and service
Shift Weight Inspection
procedures.
1. If clutch is not disassembled, inspect as shown, using a 6
clutch holding tool to compress the moveable sheave. The Drive Clutch Inspection
contact surface of the weight should be smooth and 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.
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.
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

ITEM QTY PART DESCRIPTION PART #
A, B 1 EBS Puller Tool 5132027

C 1 EBS Puller Nut 5132501
= In. / mm. D 1 EBS Main Adapter 5132029
E 1 EBS Bushing Removal 5132028
Shaft Diameter:
Standard: 1.3745 - 1.375 (34.91 - 34.92mm) -- 1 Bushing Replacement Kit 2871226
Service Limit: 1.3730” (34.87mm) -- 1 Piston Pin Puller 2870386
4. Visually inspect PTFE thrustwasher for damage. Measure -- 1 Instructions 9915111
the thickness and compare to specification. Replace if
worn or damaged
= In. / mm.
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™ 609. In order to remove bushings it will be
1. Place main adapter (Item 8) on puller.
necessary to apply heat evenly to the area around
each bushing. Clean all residual Loctite™ from Puller Tool (A,B) Side Nut (C)
“A” toward sheave
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.
Bushing Piston Pin Puller
Drive Clutch Bushing Removal
1. Remove clutch as outlined previously in this chapter.
2. Install handle end of Piston Pin Puller (PN 2870386) Main Adapter (8)
securely into bench vise and lightly grease puller threads.
3. Remove nut from puller rod and set aside.
4. 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.
3. Set bushing in place on sheave.
Puller Tool (A,B) Nut (C) 4. Insert installation puller tool (Item A/B) with “A” side
Side “A” toward down, into center of bushing. NOTE: 800 EFI Clutch -
sheave
6
Use Bushing Tool PA-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.
Main 10. Remove installation tool.
Adapter (D) Piston Pin
Puller
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.
11. Pull bushing removal tool and adapter from puller rod.
Remove bushing from tool and discard.
6.19
CLUTCH SYSTEM
Cover Bushing Removal One-Way Clutch Inspection (Drive Clutch)
1. Install main adapter (Item 8) on puller. 1. Rotate one-way clutch clockwise (as viewed from the
cover plate side). The clutch should rotate on the shaft
Removal Tool (3) with only slight amount of drag. Verify there is no binding
Nut (C) or rough spots. When rotated counterclockwise, the clutch
should lock to the shaft without slipping. If problems are
noted in either direction, continue with disassembly.
Adapter Reducer (9)
Piston Pin Pulle

Main Adapter (8)
2. Install adapter reducer (Item 9).

3. From outside of clutch cover, insert removal tool (Item 3)
into cover bushing.
4. 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 is removed and cover comes free. Drive Clutch Reassembly
NOTE: It is important that the same number and
8. Remove bushing and bushing removal tool from puller.
thickness of washers are reinstalled beneath the
Discard bushing.
spider during assembly. The Teflon bushings are
Cover Bushing Installation self-lubricating.
1. Apply Loctite™ 609 evenly to bushing bore in cover.

2. Working from inside of cover, insert new bushing and CAUTION
bushing installation tool into center of clutch cover.
3. With main adapter on puller, insert cover onto puller rod, Do not apply oil or grease to the bushings.
placing outside of cover toward vise.
4. Install nut on rod and hand tighten. Turn puller barrel to 1. Reassemble drive clutch in the following sequence. Be
apply more tension if needed. sure the “X”, or the marks that were made earlier, are
5. Turn clutch cover counterclockwise on puller rod until aligned during each phase of assembly.
bushing is seated.
A) “X”, or the marks that were made earlier on cover
6. Remove nut from puller rod. Take installation tool and
clutch cover off rod. B) “X” on spider, making sure spacer washers are installed
underneath spider and positioned properly in recess
6.20
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.
=T
Spider Nut Torque:
15 ft. lbs. (20 Nm)
7. Reinstall clutch spring.
Engine
Rotation
2. 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
5.
earlier on the moveable sheave.
Torque spider to specification using the holding fixture and
Nut on trailing side 6
spider tool. Torque with smooth motion to avoid damage
8. Reinstall cover, aligning bosses on the tower and cover.
to the stationary sheave.
Torque cover bolts evenly to specification.
Spacer Washers
CAUTION
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.
=T
Spider Torque: =T
200 ft. lbs. (271 Nm)
Cover Screw Torque:
90 in. lbs. (10.4 Nm)
6.21
CLUTCH SYSTEM
EBS DRIVEN CLUTCH SERVICE 4. Place the clutch into Clutch Compression Tool PN
8700220. Using Compression Extensions PN PS-45909,
Driven Clutch Disassembly Press down on top of the spider assembly, compressing the
spider onto the shaft. Remove snap ring (A) and slowly
1. Remove driven clutch from the transmission input shaft. release the assembly.
Do not attempt disassembly of the driven clutch from the Press down on spider
outside snap ring. The driven clutch must be disassembled
from the helix side.
5. Remove the spider assembly, spring (B), and spacer washer

Do not disassemble from this side
(C). NOTE: Spring is compression only and has no
2. It is important to mark the position of the shaft, cam cover, torsional wind
and sheave before disassembly or use the “X’s” on the
components for reference. This will aid in reassembly and
helps to maintain clutch balance after reassembly. B
3. Remove the four torx screws that secure the cam assembly
(helix) using a T25 torx.
6.22
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.
D K
E
M L
7. Remove the E-clip (F), washer (G), and the clutch rollers
(H). Inspect the rollers for wear replace if worn.
H G
F
K
11. Press the shaft and bearing out of the outer sheave using a
press.
6
8. Remove the clutch assembly from the holding tool.
Remove the large outer retaining ring (I) and the inner
retaining ring (J).
Press Shaft & Bearing Out
9. Press out the spring pins (K) in the inner sheave.
Inspect Bearing
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 QTY PART DESCRIPTION PART #
13. Inspect the bearing for wear. Spin the bearing, if the
-- 1 Bushing Replacement Kit 2871226
bearing does not spin smoothly replace as needed. To
remove the bearing, simply press the bearing from the shaft. -- 1 Piston Pin Puller 2870386
-- 1 Instructions 9915111
NOTE: Bushings are installed at the factory using

necessary to apply heat evenly to the area around
each bushing. Clean all residual Loctite™ from
Driven Clutch Bushing Removal

1. Install main puller adapter (Item 8) onto puller.
2. Install adapter reducer (Item 9).
Inspect Sheave Surface 3. Using a hand 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 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).
Inspect Bushing
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 needed.
BUSHING REMOVAL AND INSTALLATION
7. Turn clutch sheave counterclockwise until bushing is
removed and sheave comes free.
Table 6-1:
8. Remove nut (C) (left hand thread) from puller rod and set
ITEM QTY PART DESCRIPTION PART # aside.
9. Remove adapters from puller.
A, B 1 EBS Puller Tool 5132027 10. Remove bushing and removal tool from adapters. Discard
C 1 EBS Puller Nut 5132501 bushing.
D 1 EBS Main Adapter 5132029
EBS Bushing Removal
E 1 5132028
Tool Instructions
6.24
CLUTCH SYSTEM
Driven Clutch Bushing Installation EBS DRIVEN CLUTCH REASSEMBLY
1. Install puller adapter (Item 10) onto puller. 1. Press a new bearing onto the output shaft using a press.
2. Install adapter (Item 9) onto puller.
2. Install the shaft/bearing into the outer sheave.
3. Apply Loctite™ 609 evenly to bushing bore inside

moveable sheave.
4. Install sheave face down on puller.
5. Install new bushing on installation tool (Item 2) and install
6.
assembly into sheave.
Install left hand thread nut (C) onto puller rod and hand
6
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.
9. Remove installation tool and clutch sheave from puller.
6.25
CLUTCH SYSTEM
3. Install the small and large retaining rings into the outer 5. Install the roller (A) onto the roller pin (B). (Both Sides).
sheave above the bearing.
6. Install the roller pin into the sheave assembly. (Both sides).
The flat side of the roller pin faces downward when the
shaft side is laying flat on the bench.
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.
Align “X’s”
Flat Side Down
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
ring on top of the spider. NOTE: Use the marks previously
Install Spacer Washer 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.
Align Marks
9. Install the spring over the shaft (arrow). 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.
Press Down on Spider
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
Outer Spider
D spider passes the retaining ring notch on the shaft, install
E F the retaining ring (A).
H A
6.27
CLUTCH SYSTEM
15. Install the cam assembly (helix) over the shaft. Line up the STANDARD DRIVE CLUTCH - 500
“X” on the cam, “X” on spider, and “X” on the stationary CARBURETOR
sheave or use the marks previously made before
disassembly. NOTE: If the cam assembly (helix) is Drive Clutch Disassembly
difficult to install, be sure the sheaves are aligned. To align
the sheaves place the clutch assembly on a flat surface with 1. Using a permanent marker, mark the cover, spider, and
the cam assembly (helix) side down. Press down on the moveable and stationary sheaves for reference, as the
moveable sheave belt face with both hands and the helix previous “X's” may not have been in alignment before
will release. disassembly.
2. Remove cover bolts evenly in a cross pattern and remove
Press Down to Loosen Helix cover plate.
3. Inspect cover bushing (A). The outer cover bushing is
manufactured with a Teflon™ coating. Wear is determined
by the amount of Teflon™ remaining on the bushing.
16. Use a T25 torx to install the four torx screws and torque to
specification.
Cover Bushing Inspection:

brass than Teflon™ is visible on
the bushing. Refer to bushing
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.
=T Inspect Shaft
T25 Torx:
42-52 in. lbs. (4.75 - 5.88 Nm)
6.28
CLUTCH SYSTEM
Spider Removal 2. Inspect the Teflon™ 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.

brass than Teflon™ is visible
on the bushing. Refer to bushing
Clutch Holding Fixture: PN 2871358
Spider Removal Tool: PN 2870341
6
3. Inspect all rollers, bushings and roller pins by pulling a flat
metal rod across the roller. Turn roller with your finger. If
NOTE: It is important that the same number and
you notice resistance, galling, or flat spots, replace rollers,
thickness of washers are reinstalled beneath the
pins and thrust washers in sets of three. Also inspect to see
spider during assembly. Be sure to note the number
if roller and bushing are separating. Bushing must fit
and thickness of these washers.
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 bushing or bearing surface of the new pin during
thickness washers under the spider assembly.
installation.
6.29
CLUTCH SYSTEM
4. Rubber backed buttons can and should be used in all ATV Shift Weight Inspection
clutches if the hollow roller pin is changed to a solid roller
pin. 1. If clutch is not disassembled, inspect as shown, using a
clutch holding tool to compress the moveable sheave. The
NOTE: The rubber side of the button is positioned
contact surface of the weight should be smooth and free of
toward the solid roller pin. It is recommended to
dents or gall marks. Remove shift weight bolts and
switch all buttons to the rubber version during
weights.
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.
2. 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”.
WARNING
The clutch assembly is a precisely balanced unit.

Never replace parts with used parts from another
Button to Tower Clearance: .000-.001 clutch assembly!
performed only by a certified Polaris Master Service
2. Inspect sheave surfaces. Replace the entire clutch as an Dealer (MSD) technician who has received the
assembly if worn, damaged or cracked. 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.
6.30
CLUTCH SYSTEM
Sheave / Bushing Inspection NOTE: Bushings are installed at the factory using
Inspect the Teflon™ coating on the sheave bushings and cover
bushing. Inspect BOTH sheaves for signs of wear, grooving or necessary to apply heat evenly to the area around
cracking. Clean sheave surfaces with a 3M™ pad if needed. each bushing. Clean all residual Loctite™ from
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.
2. Install handle end of Piston Pin Puller (PN 2870386)
securely into bench vise and lightly grease puller threads.
Cover / Sheave Bushing Inspection: 3. Remove nut from puller rod and set aside.
Replace bushing if more brass than Teflon™ is 4. Install puller adapter (Item 10 from kit PN 2871226).
visible on the bushing. Do not clean bushings. 5. Install main adapter onto puller.
6. With towers pointing toward the vise, slide sheave onto
puller rod.
Drive Clutch Bushing Service
7. Install removal tool into center of sheave.
NOTE: Special Tool Required: CLUTCH BUSHING
REMOVAL AND INSTALLATION KIT
8. Install nut onto end of puller rod and hand tighten. Turn
puller barrel to increase tension on sheave if needed. Using
6
a hand held propane torch, apply heat around outside of
ITEM QTY PART DESCRIPTION PART # bushing until tiny smoke tailings appear.
9. Turn sheave counterclockwise on puller rod until it comes
-- 1 Bushing Replacement Kit 2871025 free. Lift sheave off puller.
-- 1 Piston Pin Puller 2870386 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 Drive Clutch Reassembly
1. Place main adapter on puller. NOTE: It is important that the same number and
2. Apply Loctite™ 609 evenly to bushing bore inside thickness of washers are reinstalled beneath the
moveable sheave. spider during assembly. The Teflon bushings are
3. Set bushing in place on sheave. self-lubricating. Do not apply oil or grease to the
4. Insert installation puller tool into center of bushing. bushings.
5. With towers pointing upward, slide sheave, bushing and
Reassemble drive clutch in the following sequence. Be sure the
tool onto puller rod. “X”, or the marks that were made earlier, are aligned during
6. Install nut on puller rod and hand tighten. Turn barrel to each phase of assembly.
apply additional tension if needed.
A) “X”, or the marks that were made earlier on cover
7. Turn sheave counterclockwise, making sure bushing is
drawn straight into bore. Continue until bushing is seated. B) “X” on spider, making sure spacer washers are installed
underneath spider and positioned properly in recess
9. Remove sheave from puller. C) “X”, or the marks that were made earlier under weight
10. Remove installation tool.
Cover Bushing Removal

1. Install main adapter on puller.
2. Install adapter reducer.
3. From outside of clutch cover, insert removal tool into cover
bushing.
4. 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 is removed and cover comes free.
8. Remove bushing and bushing removal tool from puller.
Discard bushing.
Cover Bushing Installation 1. Install moveable sheave onto fixed sheave.

2. Install spider spacers. Use same quantity and thickness as
1. Apply Loctite™ 609 evenly to bushing bore in cover. were removed.
2. Working from inside of cover, insert new bushing and 3. Compress spider buttons for each tower and install spider
bushing installation tool into center of clutch cover. towers on the moveable sheave. Verify that the alignment
3. With main adapter on puller, insert cover onto puller rod, marks on spider align with the marks that were made on the
placing outside of cover toward vise. moveable sheave.
4. Install nut on rod and hand tighten. Turn puller barrel to 4. Torque spider to specification using the holding fixture and
apply more tension if needed. spider tool. Torque with smooth motion to avoid damage
5. Turn clutch cover counterclockwise on puller rod until to the stationary sheave.
bushing is seated.
6. Remove nut from puller rod. Take installation tool and
clutch cover off rod.
6.32
CLUTCH SYSTEM
8. Reinstall cover, aligning bosses on the tower and cover.
Torque cover bolts evenly to specification.
Spacer Washers
=T
Spider Torque:
200 ft. lbs. (271 Nm)
CAUTION
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
6
spider will help position the washers.
5. Install limiter nut on top of spider using the Clutch Spider
Nut Socket (PN 2870338). Torque to specification.
=T
=T
Cover Screw Torque:
Spider Limiter Nut Torque: 90 in. lbs. (10.4 Nm)
15 ft. lbs. (20 Nm)
6. Reinstall shift weights using new lock nuts on the bolts.

7. Reinstall clutch spring.
Engine
Rotation
Nut on trailing side
6.33
CLUTCH SYSTEM
STANDARD DRIVEN CLUTCH - 500
CARBURETOR
Exploded View
DRIVEN CLUTCH
Button Ramp
Inner Sheave
Stationary Ramp
Clutch Spring
Outer Sheave
Spacer Shims
Moveable Bearing
Driven Clutch Bolt
Clutch Disassembly / Inspection 3. Note the location of the spring and remove helix.
4. Note the location of the spring in the moveable sheave, and
1. Apply and hold downward pressure on the helix, or place
remove the spring.
driven clutch in the Clutch Compression Tool
(PN 8700220).
CAUTION
Wear eye protection when removing snap ring to

prevent serious personal injury.
2. Remove snap ring retainer.
5. Check alignment of tabs on spring. Replace the spring if

tabs are misaligned or the spring coils are distorted.
6.34
CLUTCH SYSTEM
6. Inspect ramp buttons in the moveable sheave and replace 8. Inspect the Teflon™ coating on the moveable sheave
if worn. bushing.
Inspect bushing for wear
NOTE: The ramp buttons are secured by Torx™

screws (T20). Use heat to loosen screw locking Moveable Sheave Bushing Inspection:
agent prior to removal.
7. Remove moveable sheave and note the number of spacer Replace the bushing if more brass than
washers. One spacer must remain between the sheaves Teflon™ is visible on the bushing. Refer
when adjusting belt deflection. to bushing replacement in this chapter.
Belt deflection
adjustment washers 9. Inspect driven clutch faces for wear or damage.
10. Clean and inspect splines on helix and transmission input
shaft.
6
11. Lube splines with a light film of grease. Do not lubricate
the bushings!
Bushing Service
Bushings are installed at the factory using Loctite™. In order
to remove the bushing it will be necessary to apply heat. A press
can be used to remove and install some of the bushings. Be sure
to support the sheave or cover as close as possible to the bushing
bore when using a press.
1. Remove ramp buttons from moveable sheave.

2. Install Main Puller Adapter (#8) (PN 5020632) onto the
Piston Pin Puller (PN 2870386).
Main Puller Adaptor (#8)
Used to adjust
belt tension. One must Adapter
always be installed.
Piston Pin Puller Reducer (#9)
(PN 2870386)
6.35
CLUTCH SYSTEM
3. Insert Adapter Reducer (#9) (PN 5010279) onto the puller, 6. Install sheave onto puller.
sliding it inside the main adapter. 7. Install nut onto puller rod and tighten by hand. Turn puller
barrel for further tension if needed.
removed. Repeat Steps 5 - 8 for other bushing.
4. Using an appropriate heat gun, apply heat directly on

bushing until tiny smoke tailings appear.
CAUTION
Clutch components will be hot! In order to avoid 10. Remove adapters from puller.
serious burns, wear heat resistant insulated 11. Remove bushing and removal tool from adapters. Discard
gloves for the rest of the removal process. bushing.
Moveable Sheave - Bushing Installation

1. Working from the top, insert Puller Adapter (#10)
(PN 5020633) onto the puller.
Clutch Bushing Number Two Puller

Removal Tool (#5) Adapter (#10)
Piston Pin Puller
(PN 2870386)
5. Working from the top, install Driven Clutch Bushing
Removal Tool (#5) (PN 5020631) into the center of clutch 2. Start new bushing evenly in moveable sheave. Apply
sheave with smaller diameter toward bushing to be Loctite™ 680 (PN 2870584) to the back side of new
removed. See illustration. bushing.
6.36
CLUTCH SYSTEM
3. Install sheave onto puller with new bushing upward as Clutch Assembly
shown. Install Puller Adapter (#10) (PN 5020633).
4. Install nut onto puller rod and hand tighten against

installation tool.

seated.
Moveable Spring
Example: Helix Sheave Tension
2 - 1 Heavy
Spring/ 2 - 2
Position 1 - 1
2 - 3
1 - 2
1 - 3 Soft
Refer to General Information Chapter 1 for
driven clutch spring color and production setting.
6. Remove nut from puller rod and set aside. 1. Install moveable sheave with spacer washers. Important:
At least one spacer washer must be installed. Teflon™
7. Remove installation tool and clutch sheave from puller.
6
bushings are self-lubricating. Do not apply oil or grease to
the bushings.
2. Install spring, inserting spring tab into proper hole in
moveable sheave.
3. Insert spring tab into proper hole in helix. See “Clutch
Chart” of the specifications page in Chapter 1.
The driven clutch, helix/moveable assembly has several

different spring locations which affect clutch shifting and
RPMs. The greatest amount of spring tension will raise engine
RPMs during clutch upshift and allow quicker backshift or
downshift when pulling or negotiating a hill, for example. The
least amount of tension will create a slower downshift and a
harder upshift.
8. Repeat installation procedure for other moveable bushing.
9. Reinstall ramp buttons and screws with locking agent on

the threads. Tighten securely.
Driven Spring
Driven Clutch
6.37
CLUTCH SYSTEM
4. Line up boss spline and push helix down until it engages
the splines 1/2" to 3/4".
5. While holding downward pressure on helix, wind

moveable sheave counterclockwise approximately 1/3 turn
(120°).
6. Push helix into place and install snap ring.
6.38
CLUTCH SYSTEM
PVT TROUBLESHOOTING
General Range Operation Guidelines
Overheating
LOW RANGE: Heavy pulling, basic operational speeds less
IMPORTANT: During routine maintenance or than 7 MPH, riding through rough terrain (swamps, mountains,
whenever PVT system overheating is evident, it's etc..), low ground speeds.
important to check the inlet and outlet ducting for
obstructions. Obstructions to air flow through the
ducts will significantly increase PVT system
operating temperatures. The ATV should be operated
in low range when pulling or plowing heavy loads, or HIGH RANGE: High ground speeds, speeds above 7 MPH.
if extended low speed operation is anticipated.
Table 6-1: Cause and Remedy

DIAGNOSIS OF CLUTCH DRIVE BELT & COVER RELATED ISSUES:
POSSIBLE CAUSES SOLUTIONS/WHAT TO DO
Loading the ATV into a pickup or

Shift transmission to low range during loading of the ATV to prevent belt burning.
tall trailer when in high range.
Starting out going up a steep When starting out on an incline, use low range, or dismount the ATV after first applying the park
incline. brake and perform the “K” turn.
Driving at low RPM or low
Drive at higher speed or use Low Range. The use of Low Range is highly recommended for
ground speed (at approximately
cooler PVT operating temperatures and longer component life.
3-7 MPH).
Insufficient warm-up of ATVs
exposed to low ambient
Warm engine at least 5 min., then with transmission in neutral, advance throttle to 1/8 throttle 6
in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning.
temperatures.
Slow and easy clutch Fast, effective use of the throttle 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.
use.
Shift the transmission to Low Range, carefully use fast, aggressive throttle application to engage
Stuck in mud or snow.
clutch. Warning: Excessive throttle may cause loss of control and vehicle overturn.
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.
Inspection/repair of clutch components should be performed by a certified Polaris MSD
Clutch malfunction.
technician.
6.39
CLUTCH SYSTEM
Problem, Cause and Remedy Chart
Table 6-2: Problem, Cause and Remedy

SITUATION POSSIBLE CAUSE REMEDY
Engine RPM below -Wrong or broken drive clutch spring. -Replace with recommended spring.
specified operating range -Install correct shift weight kit to match engine
-Drive clutch shift weight too heavy.
although engine is application.
properly tuned. -Driven clutch spring broken or installed wrong . -Replace spring; refer to proper installation location
a. Disassemble drive clutch; inspect shift weights for
-Drive clutch binding. wear and free operation.
Erratic engine operating -Belt worn unevenly - thin/burnt spots Replace belt
RPM during acceleration
or load variations. a. Replace ramp buttons.
-Driven clutch malfunction. b. Inspect movable sheave for excessive bushing
-Sheave face grooved. -Replace the clutch.

-Incorrect drive clutch spring (too high spring
-Install correct recommended spring.
rate).
-Drive clutch shift weights incorrect for
-Install correct recommended shift weights.
application (too light)
Engine RPM above -Disassemble and clean clutch, inspecting shift

-Drive clutch binding. weights and rollers. Reassemble without the spring
specified operating range.
-Disassemble, clean, and inspect driven clutch, noting
-Driven clutch binding. worn sheave bushing and ramp buttons and helix
-Clean sheaves with denatured alcohol or brake

-Converter sheaves greasy; belt slippage.
cleaner, install new belt.
-Drive belt worn too narrow. -Replace belt.
Harsh drive clutch
engagement. -Perform belt/sheave clearance adjustment with shim
-Excessive belt/sheave clearance with new belt.
washers beneath spider.
-Wrong belt for application. -Replace with correct belt.
Drive belt turns over -Clutch alignment out of spec. -Adjust alignment offset.
-Engine mount broken or loose -Inspect/adjust or replace.
-Plugged air intake or outlet -Clear obstruction.
-Belt slippage due to water, oil, grease, etc., -Inspect system. Clean , repair or replace as necessary.
rubbing on cover Seal PVT system ducts.
PVT cover overheating
-Clutches or weight being applied to cover while
(melting) Remove weight. Inform operator.
in operation
-Instruct operator on guidelines for operation in wet
-Use of High vs. low range terrain as outlined in Owner's Safety and Maintenance
-Cover seals or ducts leaking -Find leak and repair as necessary.

Water Ingestion -Instruct operator on guidelines for operation in wet
-Operator error terrain as outlined in Owner's Safety and Maintenance
-Belt worn out -Replace belt.

Belt Slipping -Water ingestion -Inspect and seal PVT system.
-Belt contaminated with oil or grease -Inspect and clean.
6.40
CLUTCH SYSTEM
Table 6-2: Problem, Cause and Remedy
SITUATION POSSIBLE CAUSE REMEDY
-Abuse (continued throttle application when -Caution operator to operate machine within
vehicle is stationary, excess load) guidelines.
-Vehicle operated with park brake on. Inspect brake
Belt burnt, thin spots -Dragging brake
system.
-Instruct firm, effective use of throttle for efficient
-Slow, easy clutch engagement
engagement.
-Belt worn or separated, thin spots, loose
-Replace belt.
belt
PVT noise
-Broken or worn clutch components, cover
-Inspect and repair as necessary.
hitting clutches
-Replace belt. Refer to belt burnt troubleshooting and
Engagement -Thin spots on belt, worn belt
instruct operator.
erratic or “jerks”
-Drive clutch bushings stick -Inspect and repair clutches.
6.41
CLUTCH SYSTEM
NOTES
6.42
FINAL DRIVE
CHAPTER 7
FINAL DRIVE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
GEARCASE FLUID / CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
FRONT HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
FRONT DRIVE SHAFT (CV) SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
CV JOINT/BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
PROP SHAFT - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
U-JOINT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
DRIVE AXLE EXPLODED VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
DRIVE SHAFTS AND PROPSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
FRONT GEARCASE - CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
7
REASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
SETTING RING GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
FRONT GEARCASE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
FRONT GEARCASE - ACTIVE DESCENT CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
ADC GEARCASE EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
ADC COIL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
ADC DIFFERENTIAL HYDRAULIC CIRCUIT BLEEDING . . . . . . . . . . . . . . . . . . . . . . . 7.23
DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
ADC GEARCASE PISTON REPLACEMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . 7.27
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
REAR HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34
REAR DRIVE (CV) SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
CV BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
DRIVE SHAFT AND CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
7.1
FINAL DRIVE
SPECIFICATIONS Gearcase Fluid / Capacity
Torque Table GEARCASE DESCRIPTION
Demand Drive LT
FT.LBS. Centralized Hilliard
COMPONENT NM Premium Hub Fluid
(IN.LBS.) (500 Carburetor)
8.97 oz. (265 ml)
F/R Steel Wheel Nuts 30 41 Centralized Hilliard Demand Drive LT
F/R Aluminum Wheel Nuts 90 122 w/ ADC Premium Hub Fluid
(All EFI) 9.3 oz. (275 ml)
Front Hub Nut 60 81
Rear Hub Nut 80 109 ADC Gearcase Polaris ADC
Pump Reservoir Hydraulic Fluid
Front Gearcase Mount Bolts 30 41
Standard Gearcase Screws 14 19 FRONT HUB
Lower Hub Carrier Bolts 37 50
Disassembly
Upper Hub Carrier Bolts 37 50
NOTE: Follow steps 1-10 for wheel/hub removal in
ADC Pump Screws (17-23) 1.9 - 2.5 ‘Front Drive Shaft (CV) Service / Removal’
ADC Cover Screws 7 - 11 9.4 - 14.9 1. Remove outer snap ring.
ADC Bleed Valves (80) 9
IMPORTANT: Verify which type of wheel ATV is

equipped with (aluminum or steel) when torquing
wheel nuts.
Special Tools
PART NUMBER TOOL DESCRIPTION
2872608 Roller Pin Removal Tool

8700226 CV Boot Clamp Pliers
2870772 1 3/4” Straight Wrench
ADC Gearcase Piston
PA-48542
Installation Tool
2. From the back side, tap on the outer bearing race with a drift
punch in the reliefs as shown.
7.2
FINAL DRIVE
NOTE: Drive bearing out evenly by tapping on outer FRONT DRIVE SHAFT (CV) SERVICE
race only. Once bearing is at bottom of casting,
support casting on outer edges so bearing can be Removal
removed.
3. Inspect the bearing. 1. Set the ATV in park. Remove hub dust cap.
NOTE: Due to extremely close tolerances and 2. Remove cotter pin.

minimal wear, the bearings must be inspected 3. Loosen the hub retaining nut.
visually, and by feel. While rotating bearings by 4. Loosen - but do not remove - the wheel nuts.
hand, inspect for rough spots, discoloration, or 5. Safely lift and support the front of the ATV.
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement CAUTION
and minimal movement sideways between inner and
outer race.
Serious injury could occur if machine tips or falls.
4. Inspect bearing housing for scratches, wear or damage.
Replace housing if damaged. 6. Remove wheel.
7. Remove the two brake caliper attaching bolts.
Assembly
1. Support bottom of hubstrut housing.
2. 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.

NOTE: Follow steps 2-6 for wheel/hub installation in 7
‘Front Drive Shaft (CV) Service / Installation’
CAUTION
Do not hang the caliper by the brake line. Use wire

to hang the caliper to prevent possible damage to
the brake line.
8. Remove hub.
7.3
FINAL DRIVE
9. Remove cotter pin and nut from lower A-arm ball joint. Installation
Remove lower A-arm from ball joint.
1. Install new spring ring on drive 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.
2. Install drive shaft in strut.
3. Install lower ball joint, torque nut to specification and
install new cotter pin.
=T
Ball Joint Retaining Nut Torque:
30 ft. lbs. (41 Nm)
10. Pull strut assembly out while pivoting front drive shaft
downward until it clears strut assembly.
4. Install hub and tighten hub nut to specification.
=T
11. Pull strut assembly out while pivoting front drive shaft
downward until it clears strut assembly. Front Hub Retaining Nut Torque:
60 ft. lbs. (81 Nm)
5. Install brake caliper and tighten bolts to specification. refer

to Chapter 9.
6. Install wheel.
7.4
FINAL DRIVE
Inspection 2. Remove cotter pin and castle nut from A-arm ball joint.
NOTE: The following procedure applies to BOTH

inner and outer CV joints.
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.
3. Disconnect A-arm from ball joint using a tie rod fork.
CV Joint/Boot Replacement
NOTE: When replacing a damaged boot, check the
grease for contamination by rubbing it between two
fingers. A gritty feeling indicates contamination. If
the grease is not contaminated, the boot can be
replaced without cleaning the CV joint. Use the
recommended amount of grease for boot 7
replacement only (see illustration).
NOTE: Use only the Constant Velocity Joint grease
supplied with boot service kit. IF CV JOINT WAS 4. Slide strut off end of drive shaft and tie it up out of the way
CLEANED, add the recommended amount of grease of the shaft. Remove entire CV shaft if required.
to the joint in addition to the grease pack supplied
5. Remove clamps from rubber boot(s) using the proper boot
with boot kit (see illustration).
clamp pliers.
1. Remove wheel, brake caliper, and wheel hub. Refer to
“FRONT DRIVE AXLE REMOVAL” earlier in this
chapter for procedure.
7.5
FINAL DRIVE
6. Remove the large end of the boot from the CV joint, slide 11. Remove excess grease from the CV joint's external surfaces
the boot back and separate the spindle/CV joint assembly and position the large boot joint over the CV housing,
from the axle shaft by pulling the shaft sharply outward, making sure boot is seated in groove. Position clamp over
away from the CV joint. It may be necessary to tap the boot end and make sure clamp tabs are located in slots
CV joint assembly outward with a soft-faced hammer. 12. Install and tighten large boot clamp with boot clamp pliers.
13. Remove excess grease from the CV shaft’s external
Retaining Ring surfaces and position the small boot joint over the CV shaft,
making sure boot is seated in the shaft groove. While
pulling out on the CV shaft, fully extend the CV joint and
slide a straight O-ring pick or a small slotted screw driver
between the small end of the boot and the shaft. This will
allow the air pressure to equalize in the CV boot in the
position that the joint will spend most of its life. Position
the small clamp over boot end and make sure clamp tabs
are located in slots.
Pull Shaft to Remove from

CV Joint
7. Remove small clamp and boot from driveshaft.

8. Before installing the new boot, remove all grease from the
boot area and shaft. Slide the new clamp and boot (small
end first) over the splined shaft.
9. Refit CV joint on the interconnecting shaft by tapping with
a soft-faced hammer on the joint housing. Take care not to
damage threads on an outboard CV joint. The joint is fully
assembled when the compression ring is seated in the
groove on the CV joint. 14. Install and tighten small boot clamp with boot clamp pliers
10. Add remaining grease through large end of boot.
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.
Joint Capacity -
50 grams Joint Capacity - 50
grams
Boot Capacity -
30 Grams Boot Capacity - 50
grams
Outboard - 80g Total Inboard - 100g Total
7.6
FINAL DRIVE
PROP SHAFT - FRONT U-JOINT
Removal and Installation Disassembly
1. Using Roll Pin Removal Tool (PN 2872608), remove the
roll pin from prop shaft at rear of housing (front only) or CAUTION
transmission output shaft (rear only). Slide prop shaft back
and away from housing, then pull sharply forward to Always wear eye protection when working with
remove from transmission shaft. spring-tensioned components
2. For installation, reverse the removal procedure. Use anti-
seize compound on the splines. 1. Remove internal or external snap ring from all bearing
caps.
NOTE: If removing rear of propshaft, loosening and/

NOTE: If yoke or bearing is removed, cross bearing
or removal of rear gearcase mounting bolts may be
required to gain necessary clearance for propshaft
removal.
must be replaced. Note orientation of grease fitting
(if equipped) and mark inner and outer yoke for 7
correct re-positioning during installation.
2. Support inner yoke as shown and drive outer yoke down
(bearing cap out) with a soft face hammer.
7.7
FINAL DRIVE
3. Support U-joint in vise as shown and 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.
4. Force U-joint cross to one side and lift out of inner yoke.
2. Using a suitable arbor, fully seat bearing cap in one side.

Continually check for free movement of bearing cross as
bearing caps using a suitable arbor, fully seat bearing cap
in one side. Continually check for free movement of
bearing cross as bearing caps are assembled. are assembled.
3. Install snap ring to contain bearing cap just installed.

Repeat procedure for other side.
7.8
FINAL DRIVE

6. Seat all 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 Propshaft
NOTE: Refer to your parts manual for the proper replacement parts.
Compression Drive Axle Components Compression

Ring
Inner CV Joint Ring Inner Boot
Outer Boot Outer CV Joint
Compression Ring
Clamps
Drive Boot Replacement Kits
Clamp 3.5 oz. grease
Boot
Outer Clamp
Propshaft Assy.
Prop Shaft Components O-Ring
Prop Shaft
Cross & Bearing Kit
Yoke, Front Gearcase Yoke, Prop to Transmission
7.10
FINAL DRIVE
FRONT GEARCASE - CENTRALIZED HILLIARD
Exploded View
12 13
10 11
14
15
16 17
18
16
6 19
8 1
7
9
6 20
10
5
4
2 21
22
1
7
Ref. # Description Qty Ref. # Description Qty
1 Bolt 8 12 Vent Tube 1
2 Oil Seal 1 13 Plug 1
3 Input Cover Plate Asm. 1 14 Gearcase Sub Asm. 1
4 O-Ring 1 15 Ring Gear / Clutch Housing 1
5 Retaining Ring 1 16 Output Hub Asm. 2
6 Bearing 3 17 Roll Cage Asm. 1
7 Pinion Gear Asm. 1 18 Armature Plate 1
8 Pinion Bushing 1 19 Output Cover Asm. 1
9 Magnetic Drain Plug 1 20 Connector Asm. 1
10 Oil Seal 2 21 Thrust Button Asm. 1
11 Plug Cap 1 22 Set Screw 1
7.11
FINAL DRIVE
Operation
Rollers
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 Ring Gear
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 Roll Cage

spinning may cause severe drive shaft and
gearcase damage. Always switch to AWD while the
rear wheels have traction or are at rest.
CAUTION
With the AWD switch off the vehicle drives only the rear wheels
(2 wheel drive). When the AWD switch is activated it engages If the rear wheels are spinning, release the throttle
the hilliard, locking both front axles into all wheel drive when before turning the AWD switch on. If AWD is
there is a loss of rear wheel traction. engaged while the wheels are spinning, severe
drive shaft and clutch damage could result.
Roll Cage Output Hubs Armature Plate 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. Stop engine, 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.
Ring Gear Magnetic Coil
CAUTION
4x4 Engagement: When the AWD switch is activated, a 12 Serious injury may result if machine tips or falls. Be
Vdc current charges the central coil, creating a magnetic field.
This magnetic field attracts an armature plate keyed to a roller sure machine is secure before beginning this
cage that contains 14 rollers and roller cam. The difference in service procedure. Wear eye protection when
rpm between the input shaft and front axles forces the rollers up removing and installing bearings and seals.
the external cam. The rollers engage, or “wedge” themselves
between the pinion gear and output hubs that link both front 4. Remove left wheel nuts and wheel.
axles, resulting in true all wheel drive.
7.12
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
through the skid plate.
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.
Front Gearcase Removal
7. Remove the roller pin from the front prop shaft. Use the
Roller Pin Removal Tool (PN 2872608).
Remove 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. 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
Output Hub Assembly Armature Plate
3. Remove the outer cover plate assembly.

Thrust Bearing
5. Remove the roll cage assembly, rollers, and ring gear.
NOTE: Thrust bearing located between the two

output hubs is pressed into assembly.
7.14
FINAL DRIVE
6. Remove the LH 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.
B H-Spring
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
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
A C B
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.
A
B 14. Remove the input shaft assembly. Inspect the pinion gear
NOTE: See “FRONT GEARCASE DIAGNOSIS” later (C) for chipped, broken, or missing teeth. Inspect the input
in this chapter for more details on the coil. shaft bearing (D) for signs of wear. Replace the input shaft
cover O-ring prior to reassembly.
NOTE: The backlash for the centralized hilliard is set
at the factory. No adjustment is required, unless the
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 the bolts retaining the input shaft cover and pinion
gear assembly.
15. Inspect the input shaft bushing.
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.
The output hub should spin freely.
1. Replace all O-rings, seals, and worn components.
A
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 is flush with the sealing surface.
3. Inspect bearings on output and pinion shafts. To replace,

press new bearing on to shaft.
C B
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 B
quietly, with no detectable up and down movement
and minimal movement side to side.
7
4. Install input shaft, bearing, snap ring, and input cover with
new o-ring. Torque bolts to specification.
7. Install the rollers and roll cage into the ring gear. Insert the
rollers as the roll cage is installed.
=T
Input Cover Bolt Torque
14 ft. lbs. (19 Nm)
7.17
FINAL DRIVE
8. Install the ring gear and roll cage assembly into the 11. Torque the cover plate bolts to specification.
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)
14 ft.lbs. (19 Nm)
=T
Output Cover Bolt Torque
14 ft. lbs. (19 Nm)
12. Lay the gearcase on the side with the output cover facing up.
10. Install the cover plate assembly with new o-ring onto the Setting Ring Gear Backlash
main gearcase.
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.
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
FINAL DRIVE
2. Using a 3/32 hex wrench, turn the back-lash screw out 3-4 NOTE: To test the gearcase coil resistance, use the
turns. Re-apply Loctite 262™ onto the bottom screw coil harness. The gearcase coil should measure
threads. between 22.8 ohms and 25.2 ohms.
3. Turn the screw in until it is lightly seated, then turn the

screw out 1/4 turn. Front Gearcase Coil Resistance:
4. Set the gearcase upright. Rotate the input shaft at least 4 24 Ω ±10%
times. This ensures the ring gear completes one full
rotation. 2. Check the minimum battery voltage at the Grey & 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
7
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.
5. If a tight spot is felt during rotation, loosen the backlash

Armature Plate
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

• Symptom: AWD Will Not Engage
1. Check the gearcase coil resistance. To test the gearcase
coil resistance, use the coil harness (Grey & Brown/
White).
Check for Wear Bands
7.19
FINAL DRIVE
4. Check to make sure the 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. To install 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.lbs. (41 Nm).
plate, thereby increasing pole gap. If the pole gap
increases the coil will not be strong enough to engage the
30ft.lbs. (41 Nm)
AWD system. If this is the cause order a new Cover Plate
Assembly.
Cutaway View of Gearcase Cover
Coil
U-Shaped Insert
=T
Gearcase Mounting Bolt Torque:
5. Inspect the rollers for nicks, scratches, and flat spots. Also 30ft.lbs. (41 Nm)
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
Rollers
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
FRONT GEARCASE - ACTIVE DESCENT CONTROL
ADC Gearcase Exploded View
Ref. # Description Qty Ref. # Description Qty

1 O-ring 2 17 Roll Cage Assembly 1
2 1/4" Tubing 1 18 8-32 x 3/8" Screws 4
3 1/4-20 Screws 5 19 Spacer, Gear 1
4 Armature Plate 1 20 Pump Assembly 1
5 Clutch Assy - LH Exploded View 1 21 Wire Connector 1
6 Vent 1 22 O-ring, Outer 2
7 Cap, Bleed Screw 2 23 O-ring, Inner 2
8 Spacer, Clutch Basket 1 24 Bleeder Valve 2
9 Cover Assembly 1 25 Cam Assembly 1
10 Cover Bracket 1 26 Armature Plate 1
11 Gear Case Sub-Assembly 1 27 Pinion Cover Assembly 1
12 Hose Clamp 2 28 Retaining Ring 1
13 Clutch Assembly - RH 2 29 Pinion Gear Assembly 1
14 Plastic Clip 2 30 Fill Plug 1
15 Reservoir 1 31 Drain Plug 1
16 Ring Gear 1 32 Piston Assembly 2
33 1/4-20 Screws 3
7.21
FINAL DRIVE
Operation ADC Engagement: When the AWD switch is set to ‘4x4/
ADC’, a 12 Vdc current is present at the input shaft coil (1).
Engaging Front Gearcase: Active Descent Control (ADC) is Operation is controlled by the ECU grounding and ungrounding
controlled by the ECU and will not enable until the following the coil. The coil’s magnetic field attracts a splined armature
conditions are met: plate (2) on the pinion (input) shaft (4). The energized splined
armature plate attracts the unsplined eccentric cam (3), which
• Vehicle speed is below 15 Mph (24Kph) begins to turn with the input shaft. The eccentric cam drives a
hydraulic piston/pump assembly (5). The pressure created by
• Throttle Position Sensor (TPS) is at idle position the pump assembly forces hydraulic fluid through passages to
the piston assemblies (6) located in each case half. Hydraulic
• The AWD switch is switched to ‘4x4/ADC’ pressure forces the piston assemblies inward to compress the
splined clutch packs (7) forming a dynamic coupling to each
Once the conditions are met for engagement, ADC remains front drive axle, resulting in true all-wheel EBS operation upon
engaged as long as the conditions are met. deceleration.
With the AWD switch set to ‘2x4’, the vehicle drives only the Disengagement: Current to the ADC coil is turned off by the
rear wheels (2 wheel drive). When the AWD switch is set to ECU anytime the following conditions are met:
‘4x4’ the magnetic coils are active, the AWD coil indexes the
clutch mechanism so that both front axles will engage when • Throttle Position Sensor (TPS) moves off idle position
there is a loss of rear wheel traction. In addition to the rear wheel
engine braking, the ADC coil provides front wheel engine • The AWD switch is switched to ‘4x4’ or ‘2x4’
braking at speeds less than 15 Mph (24Kph) with the TPS at idle
position. • 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.
2
3
4
7.22
FINAL DRIVE
ADC Coil Testing Disassembly / Inspection
Refer to the following tests in Chapter 10: 1. Drain and properly dispose of used oil. Remove any metal
particles from the drain plug magnet.
See “ALL WHEEL DRIVE (AWD) COIL” on page 10.19.
2. Remove the piston pump assembly from the gearcase.
See “ACTIVE DESCENT CONTROL (ADC) COIL” on
page 10.19.
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.
4. 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 system.
Decreased performance may be encountered with NOTE: Piston pump assembly is a non-serviceable
inadequate bleed of the hydraulic circuit. item and should not be disassembled. Replace as an
5. Begin the bleeding process by filling reservoir to ‘MAX’ assembly if found to be damaged or non-working.
line with clean Polaris ADC oil . (AW ISO 10 hydraulic 3. Remove bolts (arrows) retaining the outer cover plate
fluid equivalent). assembly.
6. Locate bleeder valves found on either side of differential
and remove the protective caps.
7. Turn bleeder valves counter-clockwise to loosen. Loosen
7
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.
=T
Bleeder Valve Torque:
80 in. lbs. (9 Nm)
10. Fill reservoir with to a level midway between ‘MAX’ and

‘MIN’ fill lines. Verify no debris is found in reservoir oil.
11. Replace reservoir cap securely and wipe clean any residue.
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.
NOTE: Thrust bearing (2) located between the two 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. Remove the output clutch assemblies. Inspect the bearings, installation. Note for reassembly.
contact surfaces and splines of the output clutch for signs
of wear or damage. Visually inspect the clutch plate area.
If plates are steel-on-steel, or if 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. Inspect roll cage sliding surface (2). This surface must be
clean and free of nicks, burrs or scratches. Remove and
inspect the H-springs (4). Replace any components as
required.
1 2 4
2
9. Remove and inspect the bearing surfaces of the output hub.

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 13. Inspect the armature plate for a consistent wear pattern.
must slide up and down freely within the roller cage Uneven wear of the armature plate indicates a warped
surfaces. Inspect the ring gear (3) for consistent wear plate, which may cause intermittent operation.
patterns. Surfaces should be free of nicks or burrs.
NOTE: See “Front Gearcase Diagnosis” on
page 7.19.
1 3 2
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.
1 2
NOTE: See “FRONT GEARCASE DIAGNOSIS” in this 17. Remove the splined armature plate (1).
chapter.
NOTE: Ring gear backlash (2) is set at the factory.
No adjustment is required, unless the front cover is
See the “FRONT GEARCASE ASSEMBLY” in this
chapter for details on backlash setting. 1
15. Remove the bolts retaining the input shaft cover and pinion
gear assembly.
18. Remove the eccentric cam assembly. Inspect the 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
Procedure
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)
AIR
20. Remove the input shaft assembly. Inspect the pinion gear
(1) for chipped, broken, or missing teeth. Inspect the input
shaft bearing (2) for signs of wear. Replace the input shaft
cover O-ring (3) prior to reassembly.
1 3
ADC Piston Tool
2 PA-48542
2. Repeat procedure for the other piston. (See photo) 7
21. Inspect the input shaft bushing. Replace case if worn.

AIR
PA-48542
3. Remove and discard the inner and outer o-rings from the
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 6. Place ADC Piston Tool PA-48542 on top of the piston and
white lithium grease or assembly lube. Coat the edges of the verify alignment of the sight hole (circled) and piston mark
piston cavities. Install the inner and outer piston o-rings. with the casting marks. Support the case and press the
piston down evenly. The piston is fully seated and located
Outer in the pin bosses when the piston surface is just below the
cavity edge.
Inner
5. Place the piston in the piston cavity, aligning the pins with
the pin bosses. Using the casting and piston marks as a Tool PA-48542
guide as shown will aid pin alignment.
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.
7.28
FINAL DRIVE
Assembly 5. Install the eccentric cam assembly (1).
1. Thoroughly clean the gearcase components before

beginning reassembly. 1
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.
2
1
6. Install the splined armature plate (1).
4. Install the snap ring retaining the input shaft assembly. 1
7
7. Install the input shaft cover assembly, bolts and bracket.
Torque to specification.
=T
Input Cover Bolt Torque:
7-11 ft. lbs. (9.4-14.9 Nm)
7.29
FINAL DRIVE
8. Install a new seal (1) in the outer cover plate assembly. 10. Install the clutch pack (1), spacer (2) and ring gear (3).
Install a new o-ring on the backlash pad (2) stem . NOTE: Align locating pins / holes for installation.
1 2
3
2
1
NOTE: Ring gear backlash (2) is set at the factory. NOTE: Align locating pins / holes for installation
No adjustment is required, unless the front cover is (arrow).
9. Install the roll cage and rollers into the ring gear. Insert the
rollers as the roll cage is installed.
11. Install the armature plate. Verify the armature plate tabs
align with tab recesses in the roll cage.
7.30
FINAL DRIVE
12. Install new cover o-ring (1) on the cover plate assembly 14. Place cover assembly on Install bolts (arrows) retaining the
and a new passage o-ring (2) on the gear case. outer cover plate assembly and torque to specification.
13. Install the remaining output clutch assembly.

NOTE: Align locating pins / holes for installation. =T
Input Cover Bolt Torque:
7-11 ft. lbs. (9.4-14.9 Nm)
15. Install a new passage o-ring (dotted circle) onto the

gearcase before installing the piston pump assembly.
Torque the screws to specification.
=T
Pump Assembly Screw Torque:
17-23 in. lbs. (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
REAR HUB 8. Remove hub nut, domed washer and flat washer.
Removal
1. Place the ATV in Park and lock the parking brake.
Remove rear hub cap.
9. Remove hub.
B
C
2. Remove cotter pin (A).

3. Loosen the hub retaining nut (B).
4. Loosen the wheel nuts (C).
5. Safely support the rear of the ATV.
6. Remove wheel nuts and wheel.
7. Remove the rear brake caliper and safely suspend the
caliper from the frame with a piece of wire.
10. Remove upper control arm bolt as shown.
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
quietly, with no detectable up and down movement
and minimal movement sideways between inner and 7
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
1. Insert bearing carrier on drive shaft.
2. Align bottom of carrier housing and lower control arm.
Grease and slide lower control arm bushings into place,
securing corner housing.
3. Install and torque both lower control arm bolts.
=T
Upper Control Arm Bolt Torque:
37 ft. lbs. (50 Nm)
7.34
FINAL DRIVE
REAR DRIVE (CV) SHAFT SERVICE
=T
Removal
Lower Control Arm Bolt Torque:
37 ft. lbs. (50 Nm) 1. Remove rear hub, see “REAR HUB REMOVAL”.
2. Remove upper carrier bolt. Tip hub outward and remove
4. Lift bearing carrier until top aligns with upper control arm. shaft from carrier.
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 compression ring upon assembly.
Pull outward sharply to remove

from transmission
7
=T
Wheel Nut Torque:
See “Torque Table” on page 7.2.
=T
Rear Hub Nut Torque:
80 ft. lbs. (109 Nm) Compression Ring
9. Install a new cotter pin. Tighten nut slightly to align holes

if required.
7.35
FINAL DRIVE
Service 4. Refit CV joint on interconnecting shaft by tapping with a
soft-faced hammer on the joint housing. Take care not to
NOTE: The following procedure applies to BOTH damage threads on the outboard CV joint. The joint is fully
inner and outer CV joints. assembled when the compression ring is seated in the
1. Remove clamps from rubber boot(s) using a CV Boot groove on the CV joint.
Clamp Pliers (A) and slide back boot.
Tap joint onto shaft
5. Remove excess grease from the CV joint's external surfaces

2. Tap CV housing off shaft with a soft faced hammer. and position the large boot joint over the CV housing,
making sure boot is seated in groove. Position clamp over
boot end and make sure clamp tabs are located in slots.
6. Install and tighten large boot clamp with boot clamp pliers.
surfaces and position the small boot joint over the CV shaft,
making sure boot is seated in the shaft groove. While
pulling out on the CV shaft, fully extend the CV joint and
slide a straight O-ring pick or a small slotted screw driver
between the small end of the boot and the shaft. This will
allow the air pressure to equalize in the CV boot in the
position that the joint will spend most of its life. Position
the small clamp over boot end and make sure clamp tabs
are located in slots.
NOTE: Release any air pressure which may have
built up inside the boot has been released. The air
should be released after the joint has been centered
Tap CV housing off shaft
properly.
3. Place a new compression ring in the groove of the CV shaft. 8. Tighten small boot clamp using boot clamp pliers.
7.36
FINAL DRIVE
CV Boot Replacement boot end and make sure clamp tabs are located in slots.
9. Install and tighten large boot clamp with boot clamp pliers.
1. Remove CV joint from end of shaft.
2. Remove boot from shaft. surfaces and position the small boot joint over the CV shaft,
NOTE: When replacing a damaged boot, check the making sure boot is seated in the shaft groove. While
grease for contamination by rubbing it between two pulling out on the CV shaft, fully extend the CV joint and
fingers. A gritty feeling indicates contamination. If slide a straight O-ring pick or a small slotted screw driver
the grease is not contaminated, the boot can be between the small end of the boot and the shaft. This will
replaced without cleaning the CV joint. Use the allow the air pressure to equalize in the CV boot in the
recommended amount of grease for boot position that the joint will spend most of its life. Position
replacement only (see illustration). Proceed to step the small clamp over boot end and make sure clamp tabs
#5. are located in slots.
NOTE: Use only the Constant Velocity Joint grease
supplied with boot service kit. IF CV JOINT WAS
CLEANED, add the recommended amount of grease
to the joint in addition to the grease pack supplied
with boot kit.
3. Thoroughly clean and dry the CV joint and inspect ball
tracks and cages for wear, cracks or other damage.
NOTE: Shiny areas in ball tracks and on the cage
spheres are normal. Do not replace CV joints
because parts have polished surfaces. Replace CV
joint only if components are cracked, broken, worn
or otherwise unserviceable.
11. Install the small clamp on the boot.
NOTE: CV Joint Grease Capacity:
Joint Capacity -
50 grams Joint Capacity - 50
grams
7
Boot Capacity -
30 Grams Boot Capacity - 50
grams
4. Add the recommended amount of grease for CV joint Outboard - 80g Total Inboard - 100g Total
cleaning to the joint. Be sure grease penetrates all parts of
the joint.
5. Slide a new CV boot onto the shaft. Do not install the boot
clamps at this time. CV Joint Grease:
6. Refit CV joint on the interconnecting shaft by tapping with 30g PN 1350046 50g PN 1350047
a soft-faced hammer on the joint housing. Take care not to
damage threads on the outboard CV joint. The joint is fully
assembled when the compression ring is seated in the Outboard Joint - 30g if boot is replaced only. Another 50g (80
groove on the CV joint. total) if joint is cleaned.
7. Add remaining grease through large end of boot. Inboard Joint - 50g if boot is replaced only. Another 50g (100
8. Remove excess grease from the CV joint's external surfaces total) if joint is cleaned.
and position the large boot joint over the CV housing,
making sure boot is seated in groove. Position clamp over
7.37
FINAL DRIVE
INSTALLATION 6. Install rear wheel and torque wheel nuts to specification.
1. Slide shaft assembly into bearing carrier hub. 80 ft.lbs. (109 Nm)
Refer to Page 7.2 for Wheel Nut Torque.

2. Apply anti-seize compound to splines of shaft.
3. Install a new compression ring and install the shaft. 7. Grease all fittings thoroughly with Premium U-Joint
4. Lift bearing carrier into place and install bolt to upper Lubricant (PN 2871551).
control arm. Torque bolt to specification.
Drive Shaft and CV Joint Handling Tips
Care should be exercised during driveshaft removal or when
servicing CV joints. Driveshaft components are precision parts.
Cleanliness and following these instructions is very important to

ensure proper shaft function and a normal service life.
• The complete driveshaft and joint should be handled by

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.
=T • The driveshaft is not to be used as a lever arm to

position other suspension components.
Upper Hub Carrier Bolt Torque: • Never use a hammer or sharp tools to remove or to
37 ft. lbs. (50 Nm) install boot clamps.
5. Install hub, flat washer, domed washer (domed side out) • Be sure joints are thoroughly clean and that the proper
amount and type of grease is used to refill when joint
and nut. Torque center hub nut to specification. Install new boots are replaced and when joints are cleaned. Refer
cotter pin and hub cap. to text for grease capacity of CV joints and CV joint
boots.
=T
Rear Hub Nut Torque:
80 ft. lbs. (109 Nm)
7.38
TRANSMISSION
CHAPTER 8
TRANSMISSION
TRANSMISSION - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
MOUNTING EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
GEAR SELECTOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
TROUBLESHOOTING CHECKLIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
TRANSMISSION SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
X2 - TOURING EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
500 CARBURETED EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
TRANSMISSION FRONT OUTPUT SHAFT BACKLASH PROCEDURE . . . . . . . . . . . 8.17
8.1
TRANSMISSION
TRANSMISSION - GENERAL
Mounting Exploded View
x1
x1
x2
x4
x4
x1
x2
x3
8.2
TRANSMISSION
Torque Specifications Transmission Removal
1. Place vehicle in “park”. Raise and securely support rear of
COMPONENT FT. LBS. NM ATV at the frame. Remove both rear wheels.
(IN.LBS.) 2. Drain transmission lubricant (if required).
Transmission Case Bolts 25-30 36-43 3. Remove seat, both side panels, both rear cab quarter panels
and both footwells as required. See Chapter 5.
Bell Crank Nut 12-18 17-26
4. Disconnect the differential, speed sensor and gear selection
Transmission Fill/Drain Plug 20-25 29-36 switch connectors from the transmission (as required
Trans. Mounting Bolts 40 57 depending on model).
5. Disconnect transmission vent line (A).
Gear Sector Cover 8-12 11-17
Oil Deflector Screws (20-30) 2-3.6
Snorkel Torx Screw 8-12 11-17
Bearing Cover 8-12 11-17
Carrier Cover 23-27 33-39 A
Shift Fort Retainer Screws 8-12 11-17
Park Plate 8-12 11-17
Special Tools
TOOL
PART NUMBER
DESCRIPTION 6. Disconnect shift rod end (B) from transmission bellcrank
2871695 (Part of 2871702 Kit) Backlash Setting Tool (C).
Rear Output Seal

2871698 (Part of 2871702 Kit)
Driver B
Rear Driveshaft Seal C
2871699 (Part of 2871702 Kit)
Guide
Bearing Seal Driver
2871282
(50 mm)
8
Lubrication
Refer to Chapter 2 for transmission lubricant type and capacity.
Gear Selector Removal

1. Disconnect linkage rod from gear selector handle.
7. Remove PVT outer cover, drive and driven clutches, and
2. Remove two bolts attaching gear selector mount to machine
the inner PVT cover. (refer to Clutch Removal in Chapter
frame.
6).
3. Lift gear selector out of mounting bracket and away from
8. Remove both rear drive shafts. Brake caliper removal is
frame.
required. Do not let calipers hang by the brake line. See
Chapters 7 and 9.
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
TRANSMISSION
11. Remove all fasteners (X) attaching the torsion mount, and 14. Remove the middle transmission support bracket (K)
completely remove the mount (Z) from the ATV. completely from the ATV.
X
K
X
X
Z X
12. Remove both upper control arms (I). Refer to Chapter 7 for
more details. 15. Remove the rear transmission support brackets (L)
completely from the ATV.
H
L
I
13. Remove all lower transmission mounting fasteners (J) from

each side.
J 16. Lift and remove transmission out right side of frame while
pulling the output shaft from the propshaft yoke.
8.4
TRANSMISSION
Transmission Installation 5. Install the upper control arms. Refer to Chapter 5 for
procedures and torque specifications.
1. Apply Polaris Premium All Season Grease (PN 2871423)
6. Reconnect the torsion bar to both lower control arms.
to splines of front output shaft ,install new O–ring in prop
Torque to 17 ft.lbs. (24 Nm).
shaft.
7. Install both upper shock absorber mounts and torque to 30
2. With the help of an assistant, rotate transmission into place
ft.lbs. (43 Nm).
from the right side of the frame, aligning the forward
transmission bracket into the rear engine mounting holes 8. Apply anti-seize to splines of rear drive shafts and insert
while ensuring that the output shaft and propshaft align and drive shafts into carriers and transmission. Install rear
slide together. carriers and hubs.
Torque lower carrier bolts to 50 ft.lbs. (71 Nm). Torque all
3. Loosely install lower transmission mounting fasteners and
other control arm bolts and remaining carrier bolts to 35
forward engine mounting nuts.
ft.lbs. (50 Nm).
Apply anti-seize to splines
4. Install the rear support bracket, middle support bracket and 9. Install the rear hubs, rear brake disc and brake caliper. Refer
torsion bar support bracket. Torque all lower bracket bolts to Chapters 5 and 9 for procedures and torque
to 40 ft.lbs. (57Nm). Torque all upper rear and middle specifications.
support bracket bolts (circled) to 17 ft.lbs. (24 Nm).
10. Install PVT system. Refer to Chapter 6 PVT section for

procedures and torque specifications.
8.5
TRANSMISSION
11. Once the PVT system is installed. Tighten all remaining Troubleshooting Checklist
transmission mounting bolts to 40 ft.lbs. (57Nm). See page
8.2 for transmission bolt placement. Check the following items when shifting difficulty is
encountered.
12. Install transmission vent line. Be sure vent line is not kinked
or pinched. • Idle speed adjustment
13. Install seat, both side panels, both rear cab quarter panels • Transmission oil type/quality
and both footwells. See Chapter 5.
• Drive belt deflection
14. Reconnect the differential, speed sensor and gear selection
switch connectors to the transmission. • *Worn, broken or damaged internal transmission
components
15. Reconnect the shift rod. Torque to standard specification.
16. Install the rear wheel nuts and torque to specification.
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

(PN 2873602) (12 oz.)
(PN 2873603) (Gallon)
8.6
TRANSMISSION
TRANSMISSION SERVICE
X2 - Touring Exploded View
262 = THREAD LOCKING AGENT FOR ALL ‘FT. LBS.’ FASTENERS
242 = THREAD LOCKING AGENT FOR ‘INCH LBS. ‘ FASTENERS
8.7
TRANSMISSION
262
242
262
262
262
262
8.8
TRANSMISSION
500 Carbureted Exploded View
8.9
TRANSMISSION
8.10
TRANSMISSION
Transmission Disassembly 6. Remove the compression spring (7).
1. Place the transmission in the Neutral gear before

disassembly.
2. Drain and properly dispose of transmission oil. See Chapter
2.
3. Remove the bellcrank nut (1) and remove the bellcrank (2).
4. Remove the c-clip (3) that holds the gear selector switch (4)
onto the shaft and remove the selector switch.
3 4
2
1
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
outward 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)
5. Remove the sector cover bolts (5) and remove the sector for reassembly.
cover (6). Removal can be aided by using your thumbs to
press down on the shafts and pulling up the cover with your 12
fingers. 13
7
11
5 6
10
8
9
8
8.11
TRANSMISSION
10. Remove all cover bolts. Using suitable pry tools, remove 12. Remove the cam chain tensioner spring (14). Slide the cam
the cover using the designated pry points. Tap cover with chain tensioner shoe (15), pins (16), and cam chain
soft face hammer to remove. The pry points are indicated tensioner cam (17) from the assembly.
by the white arrows in the photo below.
Pry points
17
16 16
14 15
13. Remove the differential gear (18) and chain by gently

CAUTION prying underneath or tapping the differential gear from the
opposite side until it tips toward the output gear (19). X2
Do not pry on case half sealing surfaces. Use and Touring -The differential gear is connected to the shift
only the designated pry points on the fork and must slide backwards to clear the fork arms once
transmission. the chain is removed.
18
19
14. Remove the T20 screws that secure the oil deflector (20)
with a T20 hex socket or driver.
11. Note location of chain tensioner cam (17). If fully extended,
chain is worn beyond service limit. Replace chain and chain 20
tensioner shoe.
8.12
TRANSMISSION
15. Remove the T27 screws that secure the output gear (21)
with a T27 hex socket or driver.
21
Gear Cluster Disassembly

16. Remove the shift drum (22) from the gearcase by moving
the drum up and to the right to clear the shift shaft.
22
Reverse
Shaft
Needle
Bearing (2)
33T Gear (3)
Washer
Retaining Ring
8
17. Remove the output gear (21) and gear cluster assembly
from the gearcase by pulling both assemblies straight up. Engagement Bearing
Place the gear cluster assembly on a clean surface for Dog (1)
inspection. Input Shaft
Bearing
Bearing
21
18. Remove the bearing from the reverse shaft using a bearing
puller. Slide the engagement dog (1) off of the reverse shaft.
19. Remove the retaining ring and washer from the reverse
shaft.
20. Remove the bearing from the input shaft using a bearing
puller.
21. Remove the 33T gear (3) and needle bearing (2) from the
reverse shaft.
8.13
TRANSMISSION
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.
10
4
10
CAUTION
23. Remove the rest of the bearings from the shafts. Use caution when disassembling the shift rail.
24. Remove the engagement dog (5) from the reverse shaft. The compressed springs on the shift rail
REVERSE SHAFT may pop off causing eye or face injury.
Transmission Snorkel Shaft Removal

27. Remove the snorkel lock screw located inside the gearcase.
Use a T27 hex socket or driver.
5
9
8
6 7
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.
8.14
TRANSMISSION
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).
12
11
31. Remove the second snap ring (13) and spacer (14) from the
Front Drive Snorkel Assembly
snorkel shaft.
NOTE: Shim may or may not be present. Depending on
input shaft tolerance.
13
14
A. O-ring
B. Seal
C. Retaining Ring
D. Retaining Ring
E. Spacer
J
F. Ball Bearing
G. Snorkel tube
H. Retaining Ring
I. Ball Bearing
J. Snorkel Shaft
I 32. To remove the snorkel shaft from the snorkel tube, use a
press to press the snorkel shaft out.
8
H
G
A
CD
B
E
A
8.15
TRANSMISSION
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.
15
Transmission Assembly
1. Install all new seals in the gearcases. Use the Rear Output 1
Seal Driver (PN 2871698) and Rear Driveshaft Seal Guide
(PN 2871699) to install the seals into the gearcases. See
illustration 1 to identify seals for replacement.
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 the snorkel shaft assembly into the gearcase. Install
Cover Seals the snorkel shaft assembly in until the second O-ring is
contacting the gearcase, but is still visible.
Gearcase Seal
ILL 1
2. Reverse the disassembly procedure for the assembly of the
snorkel shaft assembly.
8.16
TRANSMISSION
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. the output shaft lash appears to be too tight, rotate the
snorkel shaft counterclockwise to the next notch (or
Install the 4 torx screws (2) to secure the 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.
Notches
2 Count 7 notches of snorkel tube through

lock screw hole.
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 gear are lightly seated or meshing so
there is ‘zero’ lash. Do not overtighten. Gears should 2
rotate freely without binding.
• Before turning the snorkel tube, look down into the
gearcase at the snorkel lock screw hole opening (Photo Rotate snorkel counterclockwise 7 notches
8
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 & 2) using
a 2 3/8” wrench.
8.17
TRANSMISSION
2. 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
A
B
5. Assemble the reverse shaft assembly if previously

disassembled.
REVERSE SHAFT
Q
R
8-12 ft-lb. (11-17) Nm P
O
N
M L
K
J
I
H
G F
E
3. With the snorkel shaft assembly in place, remove the 4 Torx D
screws from the output shaft assembly. Remove the output C
shaft assembly.
B
A
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
H. Needle Bearing Q. Retaining Ring
I. Sprocket R. Ball bearing
8.18
TRANSMISSION
6. Inspect the shift drum for any damage or wear. Inspect the 9. With the gearcase on it’s side, hold the gear cluster
splines of the shift drum. Replace the O-rings on the end of assembly and output assembly together. Carefully install
the shift drum and lubricate them before assembly. each shaft into their respective recess in the gearcase.
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 10. With all of the components in the correct positions install
3.0904” (7.8496 cm). the 4 output gear assembly screws. Apply Loctite™ 262
(PN 2871952) to the threads of the screws. Torque the
Silent Chain Length: screws to 8-12 ft.lbs. (11-17 Nm). NOTE: If the
transmission is in locked in Park, place the transmission in
3.0904” (7.8496 cm) Neutral.
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.
E
8
11. Install the oil deflector shield into the gearcase. Apply
Loctite™ 242 to the threads of the screws. Torque the
D
screws to 16-30 in.lbs. (2-3.6 Nm).
NOTE: To ease assembly use a plastic tie strap to hold

the shift forks (D) and the shift drum (C) together during
assembly.
C
8.19
TRANSMISSION
12. Install the rear drive differential and drive chain, following
these precautions:
Tensioner Assembly - Top View
• 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.
• X2 and Touring - Install the differential sliding Forward
geardog onto the shift fork arms at the same time the
silent chain is installed.
• The differential gear bearing may be lightly tapped into
place. The case half seal can be installed once the Spring Leg
assembly is in place. Tensioner
Lock Cam
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 the pins through the cam and through the shoe.
• Place the spring over the front pin and hook the spring
leg under the cam.
• Lift the leg of the spring up and over the rear pin. 14. Apply a continuous bead of Crankcase Sealant (3-Bond)
The tensioner cam will lift the shoe and tension (PN 2871557) to the LH gearcase mating surface and install
chain. the cover. Install and tighten the 22 screws in a criss cross
pattern to evenly secure the cover. Torque the screws to 25-
View From Left Side of Transmission 30 ft.lbs. (36-43 Nm).
NOTE: Case-halve mating may be difficult due to tensioner
Forward installation. Release tension to aid installation.
25-30 ft-lb. (36-43 Nm)
Lift Spring Over Rear

Hook Spring Leg Under Cam Mounting Pin
8.20
TRANSMISSION
15. Place generous amounts of grease (PN 2871551) into the 18. Install the detent pawl (I) onto the shift shaft. Install the
pocket before installing the sector gear and other detent star (J). Install a new O-ring onto the shift shaft.
components. Apply a small amount of grease onto the O-rings and end
of the shift drum.
16. Install the shift gear (16T) (G) on the shift drum shaft.
Install the sector gear (F) in the bushing pocket on the left 19. Install the compression spring (K).
side. Aligning the timing marks on the gears.
G
H
Timing marks
17. Install the O-ring (if not yet done) and lockout disc (H) onto 20. Apply Crankcase Sealant (3-Bond) (PN 2871557) onto the
8
the shift drum shaft. Be sure to install the lockout disc (H) cover and case mating surfaces.
and detent star (J) with the raised edge facing outward.
21. 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.lbs. (16-26 Nm).
22. Install the transmission switch and secure the switch with
the retaining ring.
8.21
TRANSMISSION
NOTES
8.22
BRAKES
CHAPTER 9
BRAKES
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
COMPONENT SERVICE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
BRAKE SYSTEM EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
X2, TOURING SYSTEM COMPONENT EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . 9.3
SPORTSMAN SYSTEM COMPONENT EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . 9.4
BRAKE CALIPER EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
SPORTSMAN AND X2, TOURING FRONT CALIPER ASSEMBLY . . . . . . . . . . . . . . . . 9.5
X2, TOURING REAR CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
SPORTSMAN REAR CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
BRAKE BLEEDING / FLUID CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
FRONT MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
FRONT BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
FRONT CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
REAR BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
X2, TOURING PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
X2, TOURING PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
SPORTSMAN REAR PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
SPORTSMAN REAR PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
X2, TOURING REAR CALIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
SPORTSMAN REAR CALIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
REMOVAL AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
REAR MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
X2, TOURING EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
X2, TOURING REAR MASTER CYLINDER REMOVAL AND INSTALLATION . . . . . . . 9.27
SPORTSMAN REAR MASTER CYLINDER REMOVAL / INSTALLATION . . . . . . . . . . 9.28
PEDAL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
9.1
BRAKES
SPECIFICATIONS
Torque Table
TORQUE SPECIFICATIONS (Sportsman and X2, Touring)

ITEM TORQUE FT.LBS. (IN.LBS.) TORQUE NM
Front / Rear Caliper Mounting Bolts 18 24

Handlebar Master Cylinder Clamp Bolts (25 in.lbs.) 3.0
Hand Master Cylinder Reservoir Cover Screws (7 in.lbs.) 0.79
Brake Line Banjo Bolt 15.0 21
Brake Line Flared Fittings 12-15 16-21
18.0 Front 24 Front
Brake Disc Bolts Front / Rear
27 Rear 37 Rear
Brake Switch 12-15 16-21
Caliper Mounting Bolts 18.0 24
Sportsman Caliper Slide Pins 30-35 41-48
Rear Master Cylinder-to-Frame Bolts 8 11
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, Touring)

ITEM 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 -- .002” / .051 mm
Brake Disc Runout -- .010 / .254 mm
REAR BRAKE CALIPER (X2, Touring ONLY)


Brake Disc Runout -- .010” / .254 mm
REAR BRAKE CALIPER (Sportsman ONLY)


Brake Disc Runout -- .010” / .254 mm
9.2
BRAKES
BRAKE SYSTEM EXPLODED VIEWS
X2, Touring System Component Exploded View
1) Master Cylinder Cover Screws: 7 in.lbs. (0.79 Nm)
2) Banjo Style Fitting: 15 ft.lbs. (21 Nm)
3) Flare Style Fittings: 12-15 ft.lbs. (16-21 Nm)
4) Brake Switch: 12-15 ft.lbs. (16-21 Nm) *Apply Pipe Sealant to Threads
5) Dual Input Master Cylinder and Bleed Screw: 25-30 in. lbs. (2.8-3.4 Nm)
6) Front and Rear Caliper Bleed Screws: 36-60 in. lbs. (4.07-6.78 Nm)
2
1
3
4
2
9
3
3
2
*All Bleed Screws: 25-30 in.lbs. (2.80-3.40 Nm)
9.3
9.4
BRAKES
All Banjo Style All Flare Style

Fittings: 15 ft.lbs. Fittings: 12-15 ft.lbs.
(21 Nm) (16-21 Nm)
All Bleed Screws: 25-30

in.lbs. (2.80-3.40 Nm)
2 Screws - 7 in.lbs. (0.79 m)
Sportsman System Component Exploded View
Apply Pipe Sealant

To Threads
BRAKES
BRAKE CALIPER EXPLODED VIEWS
Sportsman and X2, Touring Front Caliper Assembly
A Apply Polaris DOT approved

3 Brake Fluid to Component
Apply Polaris All

Purpose Grease
B 3
E
G
H
C
A. Socket Set Screw

B. Bleeder Screw D
C. Caliper Asm.
D. Boot F
E. Square O-rings
F. Piston
G. Caliper Mount
H. Brake PAds
X2, Touring Rear Caliper Assembly

A A. Socket Set Screw
B. Bleeder Screw
C.Caliper Asm
Apply Polaris DOT-approved D. Boot
3 Brake Fluid to Component E. Caliper Seals
F. Piston
G. Caliper Mount
H. Brake Pads
9
E G
B
D
3 F
9.5
BRAKES
Sportsman Rear Caliper Assembly
16-18 ft.lbs. A
(22-24 Nm)
C
Apply Polaris DOT approved Brake fluid D
3 to component. E
30-35 ft.lbs. 3G B
(41-48 Nm) H 25-30 in lbs.
(2.80-3.40 Nm)
I
A. Anvil Bolts
K F B. Bleed Screws
3 C. Washers
D. O-rings
E. Rear Housing
F. Seals
G. Piston
M J H. Slide Pins
I. Bushings
J. Seal
K. Bracket
L. Pad
M.Front Housing
N. Retaining Clips
N L
HYDRAULIC BRAKE SYSTEM 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
Operation Overview port C) within the cylinder and starts to build pressure within the
brake system. As the pressure within the system is increased,
Must be clear to Compensating port the piston (D) located in the brake caliper moves outward and
allow proper E compensates for
temperature changes by
applies pressure to the brake pad. This pad contacts the brake
disc and moves the caliper in its floating bracket, pulling the
diaphragm
movement allowing fluid back to stationary side pad into the brake disc. The resulting friction
master cylinder reduces brake disc and vehicle speed. As the lever pressure is
increased, the braking affect is also increased.
The friction applied to the brake pads will cause the pads to
F C wear. As these pads wear, the piston within the caliper moves
further outward and becomes self adjusting. Fluid from the
reservoir fills the additional area created when the caliper piston
moves outward.
Brake fluid level is critical to proper system operation. Too little
fluid will allow air to enter the system and cause the brakes to
A B 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
D master cylinder piston is outward. As the temperature within the
Move Brake Pad hydraulic system changes, this port compensates for fluid
expansion (heated fluid) or contraction (cooled fluid). During
system service, be sure this port is open. Due to the high
temperatures created within the system during heavy braking, it
is very important that the master cylinder reservoir has adequate
The Polaris disc brake system consists of the following space to allow for fluid expansion. Never overfill the
components or assemblies: brake lever; master cylinder; reservoir! Fill to 1/4, - 5/16, (.64 - .80 cm) from top of the
hydraulic hose; brake calipers (slave cylinder); brake pads; and cylinder.
brake discs, which are secured to the drive line.
9.6
BRAKES
This system also incorporates a diaphragm (E) as part of the BRAKE NOISE TROUBLESHOOTING
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 POSSIBLE CAUSE REMEDY
contracts. Make sure the vent is open and allowed to function.
If the reservoir is over filled or the diaphragm vent is plugged the Operator error (riding the
expanding fluid may build pressure in the brake system leading brake / park brake Educate operator
to brake fail
applied)
When servicing Polaris ATV brake systems, use only Polaris
DOT-approved brake fluid. Tighten wheel, hub nuts or
Loose wheel hub or bearings
replace bearings if worn
Brake disc warped or
WARNING excessively worn
Replace disc
Once a bottle is opened, use what is necessary and Brake disc misaligned or Inspect and repair as
discard the rest in accordance with local laws. Do loose necessary
not store or use a partial bottle of brake fluid. Brake If noise does not change when
fluid is hygroscopic, meaning it rapidly absorbs Noise is from other source
brake is applied check other
moisture. This causes the boiling temperature of (chain, axle, hub, disc or
sources. Inspect and repair as
the brake fluid to drop, which can lead to brake fade wheel)
necessary
and the possible loss of control.
Wrong pad for Change to a softer or harder
conditions pad (if available)
Brake Noise Troubleshooting
Dirt or dust buildup on the brake pads and disc is the most Brake Bleeding / Fluid Change
common cause of brake noise (squeal caused by vibration). If
cleaning does not reduce the occurrence of brake noise, a NOTE: When bleeding the brakes or replacing the
product such as Permatex™ Disc Brake Quiet can be applied to fluid, always start with the caliper farthest from the
the back of the pads. Follow directions on the package. This will
keep pads in contact with caliper piston(s) to reduce the chance master cylinder.
of squeaks caused by dirt or dust.
BRAKE NOISE TROUBLESHOOTING CAUTION
POSSIBLE CAUSE REMEDY Always wear safety glasses during these

procedures. Brake fluid will damage finished
Spray disc and pads with CRC surfaces. Do not allow brake fluid to come in contact
Brake Kleen™ or equivalent with finished surfaces.
Dirt, dust, or imbedded non-flammable aerosol brake
material on pads or disc cleaner. Remove pads and/or NOTE: Do not remove brake lever when reservoir
disc hub to clean imbedded fluid level is low.
9
material from disc or pads.
This procedure should be used to change fluid or bleed brakes
Pad(s) dragging on disc (noise during regular maintenance.
Adjust pad stop
or premature pad wear)
1. Clean reservoir cover thoroughly.
Insufficient lever or pedal
Set to proper level
clearance 2. Remove screws, cover and diaphragm (C) from reservoir.
Master cylinder reservoir Check brake fluid level,
overfilled adjust as needed
Master cylinder
compensating port
restricted, Master cylinder
Clean piston(s) seal
piston not returning
completely, Caliper piston(s)
not returning
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.
C Sight Glass
7. While maintaining lever pressure, open bleeder screw.
Close bleeder screw and release brake lever.
D
NOTE: Do not release lever before bleeder screw is
A
B tight or air may be drawn into caliper.
8. Repeat procedure until clean fluid appears in bleeder hose

and all air has been purged. Add fluid as necessary to
maintain level in reservoir.
4. If changing fluid, remove old fluid from reservoir with a CAUTION

Mity Vac™ pump (PN 2870975) or similar tool.
Maintain at 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.
=T
Bleeder Screw Torque:
25-30 in.lbs. (2.80-3.40 Nm)
10. Repeat procedure Steps 5-9 for the remaining caliper(s).

5. Begin bleeding procedure with the caliper that is farthest
from the master cylinder. Install a box end wrench on 11. Add Polaris DOT-approved Brake Fluid to MAX level
caliper bleeder screw. Attach a clean, clear hose to fitting inside reservoir.
and place the other end in a clean container. Be sure the
hose fits tightly on fitting.
Bleeder Screw
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
BRAKES
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
Master Cylinder Cap 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 or abrasion. Replace hose if wear or abrasion
Sight Glass
is found.
FRONT MASTER CYLINDER

Cap Screws
Removal
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. 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
Cap Must be Even
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 in.lbs. (.79 Nm)
25 in.lbs. (3 Nm)
7 in.lbs. (0.79 Nm)
Torque inner Bolt First
Torque Inner
Bolt First
=T
=T
Master Cylinder Mount Bolt Torque:
Master Cylinder Cover Screw Torque: 25 in. lbs. (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 FRONT BRAKES
the brake line and torque banjo bolt to specification.
Torque to 15 ft.lbs. (21 Nm) Pad Removal
Sealing Washer 1. Elevate and support the of the ATV.
CAUTION
Banjo Bolt
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.
Brake Line
=T
Banjo Bolt Torque:
15 ft.lbs. (21 Nm)
3. Fill reservoir with DOT-approved brake fluid.
4. Remove caliper from mounting bracket.
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
BRAKES
5. Push caliper piston into caliper bore slowly using a C-
clamp or locking pliers with pads installed.
Measure Pad
NOTE: Brake fluid will be forced through

= In. / mm.
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. Push mounting bracket inward and slip outer brake pad past
Assembly
edge. Remove inner pad.
1. Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease (PN 2871423), and
install rubber dust boots.
7. Measure the thickness of the pad material. Replace pads if

worn beyond the service limit.
9
9.11
BRAKES
2. Compress mounting bracket and make sure dust boots are 5. Install the adjuster screw and turn clockwise until
fully seated. Install pads with friction material facing each stationary pad contacts disc, then back off 1/2 turn
other. (counterclockwise).
6. Verify fluid level in reservoir is up to MAX line inside

WARNING reservoir and install reservoir cap.
If pads are contaminated with grease, oil, or liquid 7. Install wheels and torque wheel nuts. It is required that a
soaked do not use the pads. Use only new clean pads. burnishing procedure be performed after installation of new
brake pads to extend service life and reduce noise.
3. Install caliper on hub strut, and torque mounting bolts.
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.
18 ft.lbs. FRONT BRAKE DISC

(25 Nm)
Inspection
1. Visually inspect the brake disc for nicks, scratches, or
damage.
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
BRAKES
2. Measure the disc thickness at eight different points around Removal / Replacement
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.
= In. / mm.
Brake Disc Thickness:

Service Limit: .140” / 3.556 mm 2. Remove bolts and disc.
3. Clean mating surface of disc and hub.
= In. / mm. 4. Install disc on hub.
5. Install new bolts and tighten to specification.

Brake Disc Thickness Variance Service Limit:
.002” (.051 mm) between measurements.
=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. Front - 18 ft.lbs. (24 Nm)
Rear - 27 ft.lbs. (37 Nm)
CAUTION
Always use new brake disc mounting bolts. The 9

bolts have a pre-applied locking agent which is
destroyed upon removal.
= In. / mm.
Brake Disc Runout Service Limit:

.010” / .254 mm
9.13
BRAKES
FRONT CALIPER 3. Remove mounting bracket, pin assembly and dust boot.
Removal
CAUTION

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

body.
Clean Components
2. Push upper pad retainer pin inward and slip brake pads past
edge. Loosen pad adjuster.
9.14
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 assembly.
C
B
2. Coat piston with clean Polaris DOT-approved Brake Fluid

= In. / mm. (C). Install piston (D) with a twisting motion while pushing
inward. Piston should slide in and out of bore smoothly,
with light resistance.
Front Caliper Piston Bore I.D.:
Service Limit: 1.193” (30.30 mm) 3. Lubricate the mounting bracket pins with Polaris Premium
All 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.
9.15
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
=T
remove any dirt, oil or grease.
Brake Line Banjo Bolt Torque:
15 ft.lbs. (21 Nm)
7. Install the adjuster screw and turn until stationary pad

contacts disc, then back off 1/2 turn.
Installation
5. Install caliper on hub strut, and torque mounting bolts to
specification.
15 ft.lbs. (21 Nm)
8. Perform brake bleeding procedure as outlined earlier in this
chapter.
9. Install wheels and torque wheel nuts to specification. Refer

to Chapter 2.
18 ft.lbs.
(24 Nm)
=T
Brake Caliper Mounting Bolt Torque:
18 ft.lbs. (24 Nm)
9.16
BRAKES
REAR BRAKE PAD 5. Push caliper piston into the caliper bore slowly using a C-
clamp or locking pliers with pads installed.
X2, Touring Pad Removal
1. Elevate and support the rear of the ATV.
2. Remove the rear wheel
3. Loosen pad adjuster screw 2-3 turns.
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. Push caliper mounting bracket inward and slip outer brake

pad past the edge to remove.
4. Remove the two caliper mounting bolts and lift caliper off
the brake disc.
7. Remove the inner brake pad.
NOTE: When removing caliper, be careful not to

9
damage brake line. Support caliper so as not to kink
or bend brake line.
8. Clean the 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
Thickness
= In. / mm.
=T
Rear Brake Pad Thickness
Service Limit: .180” (4.6 mm) Caliper Mount Bolt Torque:
18 ft.lbs. (24 Nm)
X2, Touring 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 the brake system.
Polaris Premium All 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.
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. 8. It is recommended that a burnishing procedure be
Use only new clean pads. performed after installation of new brake pads to extend
service life and reduce noise.
9.18
BRAKES
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 slide pins and remove the brake pads
from the caliper.
3. Loosen the slide pins with a hex wrench. Remove Rear Pads
7. Clean the caliper with brake cleaner or alcohol.

8. Measure the thickness of the pad material. Replace pads if
worn beyond the service limit.
Measure
Thickness
9
4. Remove caliper mounting bolts and lift caliper off of disc.
= In. / mm.
Rear 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
30-35 ft.lbs.
(41-48 Nm)
WARNING =T
If the brake pads are contaminated with grease, Caliper Slide Bolt Torque:
oil, or liquid soaked do not use the pads, 30-35 ft.lbs. (41-48Nm)
use only new clean pads.
5. Slowly pump the brake lever until pressure has been built
2. 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 result. Repeat this procedure 10
times.
18 ft.lbs. (24 Nm)
=T
Caliper Mount Bolt Torque:
18 ft.lbs. (24 Nm)
9.20
BRAKES
X2, TOURING REAR CALIPER 6. Remove piston, dust seals and piston seals.
Removal
CAUTION

1. Clean caliper area before removal.
2. Place a container below the caliper to catch brake fluid that

will drain from the brake line. Remove brake line from
caliper
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 assembly.
C
B
2. Coat piston with clean Polaris DOT-approved Brake

= In. / mm. Fluid (C). Install piston (D) with a twisting motion while
pushing inward. Piston should slide in and out of bore
smoothly, with light resistance.
Rear Caliper Piston Bore I.D.
Service Limit: 1.193” (30.30 mm) 3. Lubricate the mounting bracket pins with Polaris Premium
All 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
BRAKES
4. Compress the mounting bracket and make sure the 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 C
B
A
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.
2. 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
Pistons & O-ring
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. 9
3. Remove the two caliper mounting bolts and the caliper. O-ring
Bushing
9.23
BRAKES
9. Measure the inside diameter of the rear caliper. The caliper Assembly
body is a 2-step piston. The rear step is measured as well
as the outside step. 1. 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
.94in. (23.88) mm)
1.5 in. (38.1 mm)
= In. / mm.
Rear Caliper Piston Bore I.D. 2. Carefully assemble caliper body, making sure O-rings are
Inner Bore Service Limit: .94” (23.88 mm) properly positioned in groove. Tighten the caliper anvil
Outer Bore Service Limit: 1.5” (38.1 mm) bolts and then torque the anvil bolts evenly to specification.
10. Inspect caliper piston bore for scratches, severe corrosion, 16-18 ft.lbs. (22-24
or galling and replace if necessary.
Inspect
=T
11. Inspect surface of caliper piston for nicks, scratches, or Caliper Anvil Bolt Torque:
damage and replace if necessary. 16-18 ft.lbs. (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.
9.24
BRAKES
NOTE: The slide pins should be torqued when REAR BRAKE DISC
installed on caliper mount.
Inspection
1. Visually inspect disc for scoring, scratches, or gouges.
Replace the disc if any deep scratches are evident.
2. Use a micrometer and measure disc thickness at 8 different

points around perimeter of disc. Replace disc if worn
beyond service limit.
=T
Slide Pin Torque:
30-35 ft.lbs. (41-48 Nm)
4. Install caliper and torque mounting bolts to specification.
30-35 ft.lbs.
(41-48 Nm) Disc Thickness
18 ft.lbs.
= In. / mm.
(24 Nm)
Brake Disc Thickness:
Service Limit: .170” (4.318 mm)
= In. / mm.
9
=T
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.
7. Field test unit for proper braking action before putting into
= 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, Touring Exploded View
J I
A
H
F E
D A. Master Cylinder Bolts

B. Rear Brake Line
C. Rear Master Cylinder
D D. Bushing(s)
E. Washer(s)
F. Cotter Pin
G. Foot Pedal
H. Spring
G I. Front Brake Line
E J. Banjo Fitting
9.26
BRAKES
Overview 2. If required, remove the rear brake line from the master
cylinder. Use a suitable container to catch the brake fluid.
Polaris disc brake systems are light weight, low maintenance Dispose of brake fluid properly.
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 Brake Fluid Reservoir
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.
Rear Brake Line Front Brake Line
• 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 Frame
service.
• Check and adjust master cylinder reservoir fluid level
after pad service.
Rear Brake MC
• Make sure atmospheric vent on reservoir is
unobstructed. Brake Mount
• Test for brake drag after any brake system service and
investigate cause if brake drag is evident. Spring
• Make sure caliper moves freely on guide pins (where
applicable). Brake Lever
• Inspect caliper piston seals for foreign material that

could prevent caliper pistons from returning freely. 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
CAUTION cylinder to the frame and torque bolts to specification.
Use only DOT-approved brake fluid as an assembly

aid for all procedures described in this chapter to
=T
prevent brake system contamination.
Master Cylinder to Frame Bolt Torque:
DO NOT USE LUBRICANTS OF ANY KIND FOR
8 ft.lbs. (11 Nm)
ASSEMBLY, AS THEIR USE CAN CAUSE
RUBBER COMPONENTS TO SWELL. 5. Reinstall the brake line and torque the banjo bolt to
specification.
X2, Touring Rear Master Cylinder Removal
and Installation
=T
9
Banjo Bolt Torque:
15 ft.lbs. (21 Nm)
6. Perform brake bleeding procedures as outlined in this

chapter.
1. Remove the RH footwell to gain access to the rear master

cylinder.
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 the 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.lbs. (21 Nm)
3. Remove the two bolts that secure the rear master cylinder
to the brake mount plate. Replace parts as needed.
=T
4. To 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.lbs. (16-20 Nm)
=T
6. Perform brake bleeding procedures as outlined in this
Master Cylinder to Frame Bolt Torque: chapter.
8 ft.lbs. (11 Nm)
A SPORTSMAN
B
J
C
15 ft.lbs.
(21 Nm)
A. Brake Reservoir
B. Rear Foot Brake Line
C. Rear Master Cylinder
D D. Master Cylinder Bolts
E. Bushing
K F. Washer
I G. Cotter Pin
H. Foot Pedal
I. Mount Plate Bolts
J. Mount Plate
F K. Spring
G E H
9.28
BRAKES
Pedal Removal and Installation TROUBLESHOOTING
Brakes Squeal
• Dirty/contaminated friction pads
• Improper alignment
• Worn disc
• Worn disc splines
X2, Touring Shown
Poor Brake Performance
• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
1. Remove the RH footwell to gain access to the rear master • Caliper dirty or damaged
cylinder.
2. Remove the cotter key. • Brake line damaged or lining ruptured
• Worn disc and/or friction pads
3. Remove the washers, bushings, and tension spring.
• Incorrectly 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
• Improper 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
9
• 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 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
IGNITION SYSTEM / BASIC ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . 10.3
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
POWER DISTRIBUTION MODULE (PDM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
SPORTSMAN 500 CARBURETED OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
INSTRUMENT CLUSTER DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
SETTING A NEW SERVICE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
EFI DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
SPEEDOMETER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
SPEEDOMETER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING . . . . . . . . . . . . . . 10.14
TEST 1 - NO ALL WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
TEST 2 - NO SPEEDOMETER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
TEST 3 - NO REVERSE SPEED LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
TEST 4 - NO AWD HUB SAFETY LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
TEST 5 - REVERSE SPEED LIMITER ACTIVATED IN FORWARD GEAR . . . . . . . . 10.17
TEST 6 - WHEEL SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
TEST 7 - FUEL GAUGE DISPLAY NOT WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
TEST 8 - SHIFT INDICATOR NOT WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
ACTIVE DESCENT CONTROL (ADC) COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
OPERATION OVERVIEW - EFI ONLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
DIAGNOSING SYSTEM FAILURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
ALL WHEEL DRIVE (AWD) COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
DIAGNOSING SYSTEM FAILURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
COOLING SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
FAN CONTROL CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
FAN CONTROL BYPASS TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
FAN MOTOR CURRENT DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
GEAR POSITION INDICATOR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
TEST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 10.22
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
ETC TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
COMPONENTS OF ALTERNATOR AND DC / CDI IGNITION SYSTEM . . . . . . . . . . 10.24
EFI IGNITION SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
10
CRANKSHAFT POSITION SENSOR GAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
IGNITION TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
IGNITION OUTPUT TEST USING GAP TESTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
BREAK EVEN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
ALTERNATOR OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
CHARGING SYSTEM TESTING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
OPERATION - EFI MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
FUSES/CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
OPERATION - EFI MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
10.1
ELECTRICAL
DIFFERENTIAL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
OVERVIEW - X2 AND TOURING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
DIFFERENTIAL SOLENOID DIAGRAM - X2 AND TOURING . . . . . . . . . . . . . . . . . . . 10.33
LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
HIGH BEAM HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
HEADLIGHT HOUSING RELACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
HIGH BEAM HEADLIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
LOWER HEADLAMP REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
LOW BEAM HEADLIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
HEADLAMP SWITCH TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
WORK LIGHT / DIFFERENTIAL LOCKOUT SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . 10.37
BRAKE LIGHT / WORK LIGHT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
BRAKE LIGHT SWITCH TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
ACCESSORY POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
WIRE CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
STARTER LOCKOUT TROUBLESHOOTING- EFI MODELS . . . . . . . . . . . . . . . . . . . 10.42
STARTER LOCKOUT TROUBLESHOOTING- SPORTSMAN 500 CARBURETED . . 10.42
STARTER LOCKOUT DIAGRAM- EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.43
STARTER LOCKOUT DIAGRAM- SPORTSMAN 500 CARBURETED . . . . . . . . . . . . 10.43
STARTER MOTOR REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
BRUSH INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
ARMATURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.45
STARTER REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46
STARTER SOLENOID BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46
STARTER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46
STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47
PINION GEAR - ANTI-KICK OUT SHOE, GARTER SPRING REPLACEMENT . . . . . 10.47
STARTER SYSTEM TESTING FLOW CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48
BASIC WINCH WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.49
PRE-WIRED MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.49
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50
BATTERY IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50
BATTERY ACTIVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50
TERMINAL PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.51
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.51
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.51
OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.52
LOW MAINTENANCE BATTERY OFF-SEASON STORAGE . . . . . . . . . . . . . . . . . . . 10.52
BATTERY TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.52
CONVENTIONAL BATTERY OCV - OPEN CIRCUIT VOLTAGE TEST . . . . . . . . . . . 10.52
CONVENTIONAL BATTERY SPECIFIC GRAVITY TEST . . . . . . . . . . . . . . . . . . . . . . 10.52
BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.53
CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.53
LOW MAINTENANCE BATTERY CHECK: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54
LOW MAINTENANCE BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54
LOW MAINTENANCE BATTERY - OCV- OPEN CIRCUIT VOLTAGE TEST . . . . . . . 10.55
LOW MAINTENANCE BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.55
LOW MAINTENANCE BATTERY CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . 10.55
TROUBLESHOOTING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.56
ALL WHEEL DRIVE - EFI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.56
FUEL PUMP AND IGNITION COIL - EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.56
REVERSE OVERRIDE - EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.57
FAN CONTROL - EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.57
10.2
ELECTRICAL
Ignition System / Basic Electrical
Components
GENERAL INFORMATION
Special Tools
Table 10-1:
PART NUMBER TOOL DESCRIPTION
Fluke™ 77 Digital
PV-43568
Multimeter
2870630 Timing Light
2870836 Battery Hydrometer
(500 Carbureted)
2460761 Hall Sensor Probe Harness
2871745 Static Timing Light Harness
10
10.3
ELECTRICAL
Electrical Service Notes Troubleshooting
Keep the following notes in mind when diagnosing an electrical No Spark, Weak or Intermittent Spark
problem:
• Spark plug gap incorrect
• Refer to wiring diagram for stator and electrical
component resistance specifications. • Fouled spark plug
• When measuring resistance of a component that has a • Faulty spark plug cap or poor connection to high
resistance value under 10 Ohms, remember to subtract tension lead
meter lead resistance from the reading. Connect the
leads together and record the resistance. The resistance • Related wiring loose, disconnected, shorted or corroded
of the component is equal to tested value minus the lead
resistance. • Engine stop switch or ignition switch faulty
• Become familiar with the operation of your meter. Be • ETC switch misadjusted or faulty
sure leads are in the proper jack for the test being
performed (i.e. 10Ajack for current readings). Refer to • Wire harness or connections wet, corroded or broken
the Owner’s manual included with your meter for more
information. • Poor ignition coil ground
• Voltage, amperage, and resistance values included in • Incorrect wiring after repair (inspect color coding in
this manual are obtained with a Fluke™ 77 Digital connectors, etc.)
Multimeter (PV-43568). This meter is used for when
diagnosing electrical problems. Readings obtained with • Faulty ignition coil windings (measure resistance of
other meters may differ. primary and secondary)
• Pay attention to the prefix on the multimeter reading (K, • Sheared flywheel key
M, etc.) and the position of the decimal point.
• Flywheel Loose or damaged
• For resistance readings, isolate the component to be
tested. Disconnect it from the wiring harness or power • Excessive crankshaft runout - should not exceed .0024”
supply.
• Faulty ECU
• Faulty CPS
• Low Battery
10.4
ELECTRICAL
POWER DISTRIBUTION MODULE (PDM)
Sportsman 500 Carbureted Overview
The Power Distribution Module (PDM) integrates these electronic features found on the Sportsman 500 Carbureted model; 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:
10
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 battery to achieve regulation of the battery voltage. The regulator shuts off current on 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.
10.5
ELECTRICAL
Battery Protected Output Accessory Power:
The battery protected output (BAT_PROT) provides solid- The ACC_PWR switch uses a smart high-side power switch. It
state-circuit-breaker (SSCB) outputs and enables most of the is enabled when the RUN input is activated and disabled when
functions on the PDM. The BAT_PROT output must be routed it's removed. If the output current exceeds the short-circuit limit,
only to the vehicle key/run switch for proper power up sequence. the output current will be reduced until the ACC_PWR
BAT_PROT is enabled when the key/run switch connects the thermally shuts down. ACC_PWR will automatically turn back
BAT_PROT output to loads (must include RUN input). When on when it has cooled, based on thermal recovery. Once tripped,
RUN input goes high, the micro-controller will remain 'ON' this output will remain off until the key switch is cycled on and
until RUN input goes low by disconnection of the BAT_PROT off again.
via the key switch or on/off switch. It will remain 'ON' for 5
seconds before turning off The BAT_PROT output is protected Lights Output
from overloads and short circuits. If this occurs, the output turns
off. Once tripped, the SSCBs can be reset by removing the The LIGHTS output uses a smart high-side power switch. The
overload or cycling the key/run switches. The SSCBs will trip LIGHTS relay output is enabled when the RUN input is
again if the issue causing the overload is not removed. activated and disabled when it's removed. If the maximum
output current threshold is exceeded, the output current will be
Engine Temperature Controller reduced until the LIGHTS circuit thermally shuts down. Once
tripped, this output will remain off until the key switch is cycled
The engine temperature controller has several features and two on and off again.
outputs: HOT INDICATOR and FAN. The engine hot output is
low and sinks the indicator signal to ground. The fan output is HOT Indicator Output
active high and sources battery power to turn on the fan. The
controller's primary function is to control the fan motor. The fan The HOT Indicator output uses a low-side power switch 'smart
motor is turned on and off at pre-set resistances as determined FET' that indicates when the thermistor input exceeds the values
by the engine temperature thermistor. The FAN output is programmed in the PDM. It also indicates a stalled or open fan
protected against short circuit and overload. If the fan current condition. The output is protected against shorts to battery, over-
exceeds the overload limit longer than the time allowed for load, over-voltage and over-temperature conditions.
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 Starter Lockout
on again. If the overload persists, the controller will cycle the
FAN output on and off at set interval until the overload is Starter Lockout monitors the brake input and transmission
removed. If the maximum temperature of the switching device signal to determine if the STARTER output FET will enable a
is exceeded the fan output will turn off. The fan will cycle on and ground path for the starter solenoid. The output is enabled if
off as previously described until the device temperature drops. either the BRAKE input is high or the TRANS signal voltage
The FAN output driver also monitors to see if the fan is indicates PARK or NEUTRAL. TRANS voltage is based on a
connected during 'ON' state only. If the FAN output is open 5Vdc power supply with a 220-ohm with 24-ohm for park and
circuit upon power up, the engine temperature controller will 160-ohm for neutral. RUN input must be enabled for the starter
activate the hot indicator. If the engine temperature exceeds the lockout to function. This output is overload and short circuit
engine hot thermistor limit, or detects a fan overload condition, protected by the BAT-PROT output on the high side.
the hot indicator will activate. The controller also contains
provisions for detecting an open or shorted thermistor. A Reverse Polarity Protection
thermistor fault will cause the engine hot indicator and FAN
output to activate. 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.
CONNECTOR 1 - PIN # SIGNAL NAME DESCRIPTION - IPS = Intelligent Power Switch

J1-A STARTER Starter output provides ground path when active.
J1-B BRAKE Brake input for starter lockout. Active high.
J1-C RUN PDM enable input. Connected to BAT_PROT via ignition and run
J1-D HOT_INDICATOR Engine hot signal. Provides a ground path for the hot indicator
J1-E THERM_RTN Thermistor ground
J1-F THERM Thermistor input
J1-G TRANS Transmission signal voltage input for starter lockout
J1-H LIGHTS Powers vehicle lighting
J1-J COIL 3 Alternator coil input
J1-K COIL 2 Alternator coil input
J1-L COIL 1 Alternator coil input w/resistance to ground
J1-M BAT+ Battery Positive
J1-N ACC_PWR Battery Ground
10.6
ELECTRICAL
CONNECTOR 1 - PIN # SIGNAL NAME DESCRIPTION - IPS = Intelligent Power Switch

J1-P GND Cathode side of AWD circuit
J1-R BAT_PROT SSCB output provides battery power to loads
J1-S FAN Relay control input to enable operation of the fan
CHARACTERISTIC PARAMETER UNIT NOTE
Operating Temperature -40 to +55 °C Ambient temperatures at which module
should remain within specified limits
Storage Temperature -50 to +85 °C Ambient temperatures which should have no
adverse effects on module operation
CHARACTERISTIC MIN TYP MAX UNIT NOTE

Battery Voltage 7 14.4 16 Vdc PDM functions will operate over this range
Batt. Quiescent Current 2 mA Min. draw from battery with key off
REGULATOR
Regulator Voltage 14.1 14.4 14.8 Vdc
Regulator Output 18 Adc Max. total DC amperage available from regulator
Minimum Battery Voltage 2 Vdc Min. voltage required on RUN for
regulator to begin operation
Alternator Coil 1 Resistance 14.7k 15k 15.2k Ohm Resistance between alternator signal and ground
Only on this designated alternator signal
BAT_PROT OUTPUT
Output Current 8 Amp Nominal Continuous output current
Limit 9 11 20 Amp Current level that will cause turn off after delay
Time Delay 100 150 mSec Time above limit until SSCB trips
Voltage 5.5 Vdc Min Battery voltage for BAT_PROT to remain on
ACC_PWR OUTPUT
Output Current 10 25 Amp Max. continuous current
Nominal Current 26 Amp Current above which the output will shut off after
15 - 25 seconds
Overload Current 13 16 19 Amp Current above which the output will shut off after
1.5 - 2.5 seconds
Peak Current - Hardware 31 50 65 Amp Initial peak short circuit current limit above which the device
will current limit then quickly shut down
Power Off Delay 7 10 13 Sec Delay after run switch is turned off
LIGHTS OUTPUT
Output Current 18 Amp MAX Continuous Current
Current Limit 40 65 65 Amp Current limit above which device will shut down within
thermal shutdown time
Repetitive Short Circuit
Limit 65 Amp Current level that will cause turn off and on after delay
10
Inrush Time 50 100 500 mSec Inrush time delay
STARTER OUTPUT
Current 6 Amp Current capability of the STARTER output
TRANS
Park Voltage 118 490 870 mVdc Current capability of the output
Neutral Voltage 1.73 2.11 2.48 Vdc Current capability of the output
REVERSE POLARITY PROTECTION
Battery Reverse Current 1.8 2 mA Max reverse leakage current when connected in reverse
Reverse Bias Voltage 2 -55 Vdc Absolute maximum reverse voltage before device breakdown.
10.7
ELECTRICAL
INSTRUMENT CLUSTER Introduction
Overview Refer To Illustration 1:
(A) Needle (also flashes during warning condition) The Polaris ATV Instrument Cluster is powered by battery
voltage (12 VDC) and requires inputs from the engine RPM,
(B) Speedometer transmission gear, and transmission speed sensor for proper
in MPH/KPH 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 is 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 (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 the ATV.
(C) Rider Information Center ILL. 1 • 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
4 1 9
5 2 • Trip meter - records the miles traveled by the ATV if
reset before each trip or total miles to 999. To reset the
trip meter, select the trip meter mode. Press and hold
the mode button (override button) until the total
3 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.
6
• Clock - displays hours and minutes.
2. Programmable Service Interval / Diagnostic Mode
7 9 8 ILL. 2 • 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 is 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 ATV is started as a
reminder that ATV maintenance is due. NOTE: To
reset the Service Interval, follow the directions for
“SETTING NEW SERVICE INTERVAL” later in this
chapter.
3. Check Engine Warning Indicator
• The word HOT will display alpha numerically when the

engine is overheating. Do not continue to operate the
ATV if this warning appears. Refer to Chapter 3
“COOLING SYSTEM TROUBLESHOOTING” for
help with diagnosis of overheating.
10.8
ELECTRICAL
4. High/Low Battery Voltage Instrument Cluster Diagnostic Mode
• This warning usually indicates that the ATV is being NOTE: This gauge features auto shut-off protection
operated at an RPM too low to keep the battery if the voltage on the DC bus is excessive. This is
charged. A low battery warning may also occur under
normal operation if the machine is at idle and high usually the result of an open battery condition, and
electrical load (lights, cooling fan, accessories) is the gauge is designed to survive such an event.
applied. Driving at a higher RPM or connecting a
battery charger will usually clear the warning.
NOTE: If the gauge will not indicate what gear it is in
5. Engine Hour Display Indicator and will not allow AWD operation, AWD can still be
enabled by holding in the mode/override button.
• Displays number of hours of engine operation.
NOTE: As long as you are in the diagnostic mode,
6. AWD Indicator
the wrench icon will remain lit.
• Illuminates when the electrical portion of the AWD
system is enabled. NOTE: Any movement of the tires will trigger the
speedometer out of the diagnostic mode and into
7. Gear Indicator standard display mode.
• Specifies what position the shift lever and transmission NOTE: To leave the diagnostic mode, turn the key
are in. This area is blank if a fault occurs.
switch off and on.
8. Mode Indicator
1. Turn the key switch off and wait 10 seconds.
• Indicates which modes are being utilized. 2. Set the park brake and shift the transmission to neutral.
9. Fuel Gauge 3. Hold the mode/reverse override button as you turn the key
switch on.
• The segments of the fuel gauge indicate the level of fuel 4. Release the switch as soon as the display is activated.
in the fuel tank. When the last segment clears, a low
fuel warning is activated. All related icons will flash,
“FUEL” will display in the LCD, and the speedometer Use the mode/reverse override button to toggle through the
needle will blink. If riding, be sure to refuel diagnostic screens.
immediately.
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 Ill.

2.
Blink When Low On Fuel
Ill. 2
10
10.9
ELECTRICAL
Screen 2: Tachometer (Ill. 3) indicates engine rpm. Screen 4: Gear Circuit Diagnostic
This screen displays the resistance value (in ohms) being read at
the gear switch input of the gauge.
NOTE: 10-20% Variance from these reading is within

normal parameters.
Ill.3
Screen 3: AWD diagnostic screen. This screen indicates

whether or not current is flowing through the AWD coil on
models with switchable AWD.
23 Ohms in Park
AWD Off
158 Ohms in Neutral
AWD On
75 Ohms in Reverse
10.10
ELECTRICAL
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 wait 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
297 Ohms in Low 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”.
628 Ohms in High Change Service Interval Time:
If you would like to change the service interval time, (for

5. Programmable Service Interval: example change the interval from 50 hrs. to 55 hrs.). Follow the
steps below:
The purpose of the programmable service interval is to provide
the consumer and dealer with a convenient reminder for routine 1. While in the service interval mode, press and hold the
maintenance. When the ATV leaves the factory, this feature is mode button for approximately 7 seconds until the word
set at 50 hours. OFF appears in the Rider Information Center.
2. Wait 5 seconds and then press the mode button in until the
Once the service interval mode is set with the hours when wrench icon flashes.
service is due, the hours of actual engine operation are
subtracted from the set hours until 0 is reached. When the 3. Press the mode button again to set the desired service
counter reaches 0, the wrench icon will flash quickly for 10 increment.
seconds each time the vehicle is started as a reminder that the 4. Release the button and wait for the wrench icon to stop
periodic maintenance is due.
flashing. The new service interval is now set.
10
Set at 50 hours from factory.
10.11
ELECTRICAL
Screen 6: Miles/Kilometers: 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
The display in the trip meter and odometer can be changed to turn.
display either kilometers or miles. The current display mode
will be shown as “KM” or “MP”. To change, 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.
ON
3. The word “Wait” will appear, the ECU is now searching for
blink codes. READ AND RECORD THE NUMBER OF
MP = Miles FLASHES OF THE ‘MIL’ (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.
KM = Kilometers
EFI Diagnostic Mode

NOTE: The EFI diagnostic mode is intended to
quickly view fault codes stored in the EFI unit.
Polaris dealers are equipped with the proper 4. The word “End” will display after all of the codes have been
diagnostic tools to further diagnose the blink codes. displayed.
To recall blink codes (fail codes) from the ECU:
1. Verify the ATV key switch is off and the transmission is in

park.
10.12
ELECTRICAL
Speedometer Removal Speedometer Installation
1. Remove the three screws that secure the headlight pod 1. Spray a soap and water mixture onto the outer surface area
cover and disconnect the wire connectors from the of the instrument cluster. This will help the instrument
instrument cluster. cluster slide into the pod assembly more easily.
2. Be sure the rubber grommet inside the pod is fully installed

and that the indexing key is in the headlight pod keyway.
2. Push the instrument cluster out from the backside of the
pod, while securely holding the pod.
Align
3. Hold the pod assembly securely and insert the instrument

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.
Bezel
Instrument Bezel
Rubber Mount
Pod
10
Push Instrument
Cluster Outward
NOTE: Do not remove the rubber grommet in the NOTE: Do not allow alcohol or petroleum products
pod. Only remove the rubber grommet if necessary. to come in contact with the instrument cluster lens.
The bezel is a snap-on assembly and is a serviceable
part.
10.13
ELECTRICAL
ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING
TEST 1 - No All Wheel Drive
10.14
ELECTRICAL
TEST 2 - No Speedometer Display
TEST 3 - No Reverse Speed Limit
10
10.15
ELECTRICAL
TEST 4 - No AWD Hub Safety Limit
10.16
ELECTRICAL
TEST 5 - Reverse Speed Limiter Activated In Forward Gear
TEST 6 - Wheel Speed Sensor
10
10.17
ELECTRICAL
TEST 7 - Fuel Gauge Display Not Working
TEST 8 - Shift Indicator Not Working
10.18
ELECTRICAL
ACTIVE DESCENT CONTROL (ADC) ALL WHEEL DRIVE (AWD) COIL
COIL
Operation Overview
Operation Overview - EFI Only
• Switch must be set to ‘4x4’ or ‘4x4/ADC’. 12Vdc
• RH Switch must be set to ‘4x4/ADC’. power is present at the AWD hub coil.
• Pin #5 on the ECU controls the power to the ADC hub • The instrument cluster senses grounding at pin #16.
coil for operation. AWD icon should turn on at the instrument cluster.
• Pin #26 on the ECU controls the ground to the ADC • System must be grounded to operate.
hub coil for operation.
Diagnosing System Failures
• ECU senses the gear signal indicating the transmission
is engaged and is not in Park or Neutral. • Verify the AWD switch is functional.
• ECU senses the speed sensor signal for determining if • Verify the AWD hub coil is functional. Test the AWD
vehicle speed is below 15 Mph (24 Kph). ADC will hub coil using an ohm meter.
cancel if speed is above 15 Mph (24 Kph).
• ECU determines if the TPS position is at ‘idle’ and will
cancel ADC operation if TPS moves off ‘idle’ position. EFI Shown
• 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:

12 Ω ± 5%
AWD Hub Coil Resistance:
• Verify the TPS is functioning correctly. Test using 24 Ω ± 5%
Digital Wrench Diagnostic Software. (Dealer Only)
• Verify the wiring harness, wiring, connectors, • Verify the wiring harness, wiring, connectors,
connector pins, grounds and ECU pin locations are connector pins and grounds are undamaged, clean and
undamaged, clean and connect properly. connect properly.
• Verify continuity of wire connections with a known • Verify continuity of wire connections with a known
good volt/ohm meter. good volt/ohm meter.
IMPORTANT: Verify all wires and wiring connections IMPORTANT: Verify all wires and wiring connections
have been tested properly with a known good volt/ have been tested properly with a known good volt/
ohm meter before suspecting a component failure. ohm meter before suspecting a component failure.
80% of all electrical issues are caused by bad/failed 80% of all electrical issues are caused by bad/failed
connections and grounds. connections and grounds.
NOTE: Refer to the ADC subsystem diagram located
in ‘Wire Diagrams’ at the end of this chapter.
10
10.19
ELECTRICAL
COOLING SYSTEM COMPONENTS Fan Motor Current Draw Test
A current draw test will provide a good indication of fan motor
Fan Control Circuit Operation condition. A worn or damaged fan motor will draw more
current, which causes a reduction in blade speed and reduced
Power is supplied to the fan via the Orange/Black wire when the cooling.
relay is ON. The ground path for the fan motor is through the
Brown harness wire. Refer to “RELAYS” later in this chapter Fan
for more information on fan functions.
OG/
CAUTION OG/
Brn
Keep hands away from fan blades during operation. Connect Ammeter
Serious personal injury could result. Between OG/Black
NOTE: The fan may not function or operation may Fan

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 Test

1. Disconnect harness from coolant temperature sensor on
engine.
2. With the ATV in “Park” and with the parking brake on, turn 1. Disconnect the harness from the coolant sensor.
the ignition key (and engine stop switch) “ON”. The fan 2. Connect a DC ammeter in between the fan switch harness
should start running. wires as shown.
3. If the fan does not run or runs slowly, check the fan motor 3. Be sure fan blade is free to rotate.
wiring, ground, motor condition for proper operation (refer 4. Turn ignition key and engine stop switch to ON" position.
to “FAN MOTOR CURRENT DRAW” in this section). Read the current draw on ammeter with fan running.
Repair or replace as necessary. If the fan runs with the 5. If the fan motor draws more than 10 Amps, replace the
sensor harness disconnected, but will not turn on when the motor.
engine is hot, check the coolant temperature sensor and
connector terminals.
Fan Motor Current Draw:
Should Be Less Than 10 Amps
NOTE: This fan motor current draw specification

only applies to Sportsman EFI models.
10.20
ELECTRICAL
Coolant Temperature Sensor GEAR POSITION INDICATOR SWITCH
The coolant temperature sensor can be tested using an ohmmeter
or voltmeter. Test Diagram
NOTE: Also see “INSTRUMENT CLUSTER
If the ECT circuit is open the engine Hot light and fan will both TROUBLESHOOTING” for gear switch resistance.
come on. With engine at an ambient temperature of 68°F
(20°C), disconnect lead and measure the resistance of sensor
between the two ECT terminals and compare to the specification TRANSMISSION SWITCH
High/Low/Neutral/Reverse/Park
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.
High Range
Low Range
Neutral
Reverse
Park
Green/White Brown/Red
Violet (purple) White/Blue
Orange/Red Blue/Red
Table 10-1:
TEMPERATURE °F (°C) RESISTANCE
68 °F (20 °C) 37.3 k Ω ± 5%

212 °F (100 °C) 2.1 k Ω ± 5%
NOTE: If the coolant temperature sensor or circuit

10
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.
10.21
ELECTRICAL
ELECTRONIC THROTTLE CONTROL 4. Hold throttle cable with fingers at point “A” as shown
(ETC) SWITCH below and release throttle lever. If the ETC system is
functioning properly, the engine will lose spark and stop.
Operation Overview
The Electronic Throttle Control (ETC) system is designed to
stop the 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
ECU. 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.
2. Place transmission in neutral and apply parking brake.
3. Start engine and open throttle lever slightly until engine
RPM is just above idle speed.
10.22
ELECTRICAL
IGNITION SYSTEM initial ignition charge. A small A/C signal from the stator pulse
coil triggers the CDI to fire the coil.
Overview DC/ignition systems have the ability to ignite with as little as 6
volts of power.
The Sportsman has incorporated into it's design a DC/ CDI
ignition system. The DC/ ignition system relies on battery Some of the advantages of DC ignition are:
power for ignition.
• Stronger, more consistent spark at low rpm for better
EFI - Instead of generating DC voltage via flywheel magnetic performance
induction, a 12 Vdc current is supplied from the Ignition/Fuel
Pump Relay to the Ignition coil. At the ECU, a small A/C signal • Easier starts
from the CPS helps the ECU pre-determine Top Dead Center
(TDC), which in turn signals the ECU to release the electrical • Fault detection by the ECU (EFI)
charge collapsing the coil field for ignition (based on the ECU
timing map). NOTE: Do not remove wiring harness while the key
switch is on or while the engine is running. Damage
CDI- A 12 volt DC current is supplied directly from the battery to electronic components may occur!
to the CDI. At the CDI, a current is supplied to the coil for the
SPORTSMAN 500 / 500 X2 and TOURING EFI
SPORTSMAN 500
Carbureted
10
10.23
ELECTRICAL
Components of Alternator and DC / CDI Ignition System
Sportsman 500 Carbureted
EFI Models
10.24
ELECTRICAL
EFI Ignition System Testing Flow Chart
10
10.25
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
the ignition coil primary wire leading from the coil. Crank
engine and check output. Spark should jump a 1/4" (6mm) gap.
Interrupt Reconnect coil wire.
Table 10-1:
CPS
CONNECT GAP
TEST READING
TESTER TO:
White/Blue spark
Spark Gap Spark plug lead and
jumps 1/4" (6mm)
Output Test ground
gap
Crankshaft Position Sensor Gap:

0.4 - 1.2 mm (0.015 - .047 in.)
Ignition Troubleshooting
No Spark, Weak, or Intermittent Spark
• Spark plug gap incorrect

• Fouled spark plug
• Faulty spark plug cap or poor connection to high
tension lead
• Related wiring loose, disconnected, shorted, or
corroded
• Engine Stop switch or ignition switch faulty
• ETC switch misadjusted or faulty
• Wire harness or connections wet, corroded
• Poor ignition coil ground (e.g. coil mount loose or
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
10.26
ELECTRICAL
CHARGING SYSTEM Break Even Test
Current Draw - Key Off

CAUTION
CAUTION Do not connect or disconnect the battery cable or

ammeter with the engine running. Damage will
Do not connect or disconnect the battery cable or occur to electrical components.
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
Connect an ammeter in series with the negative battery cable. condition and system load, the break even point may vary
Check for current draw with the key off. If the draw is excessive,
slightly. The battery should be fully charged before performing
loads should be disconnected from the system one by one until this test.
the draw is eliminated. Check component wiring as well as the
component for partial shorts to ground to eliminate the draw.
Current Draw Inspection (key off) WARNING
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.
1. Connect a tachometer to the engine.

2. Using an inductive amperage metering device, (set to DC
YB30L-B 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
Current Draw - Key Off: (battery discharge). Reverse meter lead if a positive
Maximum of .01 DCA (10 mA) reading is indicated.
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 is positive).
7. With lights 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.
10
10.27
ELECTRICAL
Alternator Output Test TEST 1: Resistance Value of Each Stator Leg
Three tests can be performed using a multimeter to determine 1. Measure the resistance value of each of the three stator
the condition of the stator (alternator). legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3. Each should
measure 0.19 Ω ± 15 %.
Table 10-2:
CONNECT METER
TEST READING IN OHMS
WIRES TO:
Charge Coil Y1 to Y2 0.43 Ω ± 15%

Y1, Y2, or Y3 to
Charge Coil Open (Infinity)
Ground
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. Set the selector dial to measure AC Voltage.

2. Start the engine and let it idle.
3. While holding the ATV at a specified RPM, separately
measure the voltage across each “leg” of the stator by
connecting the meter leads to the wires leading from the
alternator (Y1 to Y2, Y1 to Y3, Y2 to Y3).
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 'leg'.
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.
10.28
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 and TOURING EFI
SPORTSMAN 500 Carbureted
10
10.29
ELECTRICAL
(PDM)
10.30
ELECTRICAL
RELAYS ECU RELAY
Operation - EFI Models COLOR FUNCTION
The relays, located next to the ECU, assist with component KEY-ON Battery power supply, switched
operation such as the fan, fuel pump, etc. Red/White on by the key and LH control switches,
enables power to relay.
The fan relay, controlled by the ECU, operates the fan.
Relay “ON” command. The ECU supplies a
The ECU relay, controlled by the key switch, operates the ECU Gray/Black ground which closes the relay, supplying
power to run the fuel pump, injectors, etc.
The Ignition Coil and Fuel Pump relay, controlled by the ECU,
turns on power for components such as the fuel pump, injectors, Fused 15-amp, unswitched battery power
etc. Red
IN supply for EFI component operation.
The differential relay, controlled by the AWD switch and ECU, EFI power output. 'ON' when ECU sends a
operates the differential solenoid.
signal on the GRY/W wire, closing the
Red/Black
relay. Supplies 15-amp power for ECU-
operation of EFI components.
IGNITION COIL/FUEL PUMP RELAY

COLOR FUNCTION
KEY-ON Battery power supply, switched

Red/White on by the key and LH control switches,
Relay “ON” command. The ECU supplies a
Gray/White ground which closes the relay, supplying
power to run the fuel pump, injectors, etc.
Fused 20-amp, switched battery power IN
Red/White
supply for EFI component operation.
Power output. 'ON' when ECU sends a
signal on the GRY/W wire, closing the
Red/Dark Green
relay. Supplies power for ECU-controlled
FAN RELAY operation of EFI components.
COLOR FUNCTION
NOTE: See “Differential Solenoid Diagram - X2 and
Fused 10-amp, unswitched FAN power Touring” on page 10.33.
Red
supply.
Fan 'ON' Command. Ground is supplied by
Yellow /Black
the ECU, closing the relay to turn on the fan.
KEY-ON Battery power supply, switched
Red / White on by the key and LH control switches, 10
Fan battery power supply, switched on by
Orange / Black
the ECU, enables power to Fan.
10.31
ELECTRICAL
FUSES/CIRCUIT BREAKER DIFFERENTIAL SOLENOID
Operation - EFI Models Overview - X2 and Touring
The fuse panel, located next to the ECU, assists with component The differential solenoid, located on the transmission, is
protection such as the Instrument Cluster/ECU, EFI system, activated by a switch on the headlight pod. The solenoid moves
Chassis Power and Accessories. a fork inside the transmission, which unlocks the rear
differential allowing only one drive wheel to be powered.
A 10-amp circuit breaker protects the fan circuit.
Anytime the ADC/4x4 on the right-hand control is swtiched to
‘2x4’, this feature is available. Anytime the ADC/4x4 switch is
activated away from ‘2x4’, the differential solenoid is disabled
regardless of the pod-mounted switch position and the
differential remains locked.
Testing
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.
Differential Solenoid Resistance:

1.45 Ω ± 5 %
NOTE: See “Trouble Shooting Diagrams” in this

chapter for a Differential Solenoid system break-out.
10.32
ELECTRICAL
Replacement
1. Remove the solenoid using a suitable tool.
2. Coat threads of new solenoid with anti-seize compound or sealant.
3. Thread new solenoid into gearcase housing. Tighten to specification.
=T
Differential Solenoid Torque
23-27 ft. lbs. (31-37 Nm)
Differential Solenoid Diagram - X2 and Touring
10
10.33
ELECTRICAL
LIGHTING 4. Turn the headlight lamp socket counter-clockwise and
remove.
High Beam Headlight Bulb Replacement
Turn Harness Assembly
Remove 3 Screws
Loosen Tighten
5. Carefully remove head lamp bulb 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 a residue, causing a hot spot that will
shorten the life of the lamp.
CAUTION
Do not service while headlight is hot. Serious burns

may result. Protect lamp during install.
1. Remove three Phillips screws on the headlight pod.

2. Lift pod cover up. 7. Install the new head lamp and harness assembly into the
3. Disconnect instrument cluster harness (A), differential headlight assembly. Turn the headlight harness clockwise
switch and work light switch (B) if equipped . to secure the head lamp into place.
Headlight Housing Relacement

A B 1. Remove three Phillips screws on the headlight pod.
2. Disconnect instrument cluster harness (A), differential
switch and work light switch (B) if equipped.
A B
10.34
ELECTRICAL
3. Unplug head lamp harness (C). 8. Reverse the steps to install the new housing and reassemble
the pod.
4. Remove O-Ring (D) from headlight pivot pins. (Both 5 1/8” (13 cm)
Sides)
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.

D
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
5. Pull the headlight housing up to release from the locking

tabs.
Pull Upward
10
6. Lift the adjusting knob up to remove from the locking tabs.

7. Carefully pull the assembly up and out of pod.
10.35
ELECTRICAL
1. Place the vehicle on a level surface with the headlight 2. Pull the harness assembly out from the headlight assembly.
approximately 25' (7.6 m) from a wall.
25’ (7.6 m)
Lamp Center Height
2” (5.1 cm)
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
2. Measure the distance from the floor to the center of the skin leaves a residue, causing a hot spot that will
headlight and make a mark on the wall at the same height. shorten the life of the lamp.
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 cm) in 25' from the center of
the low beam lamp.
4. Install the harness assembly into the headlight assembly.
5. Adjust beam to desired position. Turn the headlight harness clockwise to secure the head
lamp into place.
Lower Headlamp Removal / Installation
Lower Head Lamp Housing Removal (if required)
5. Remove the screw that secures the lower head lamp.
Turn Harness Assembly
Remove Screw
Remove Install
1. Turn the back of the head lamp harness in a counter-

clockwise direction to loosen.
6. Pull the head lamp out of the locking tab.
10.36
ELECTRICAL
Low Beam Headlight Adjustment Work Light / Differential Lockout Switch
1. The low beam can be adjusted slightly upward or Remove the headlight pod cover to locate the switch wires. The
downward. switch (A) snaps out by pushing in on the tabs on both sides of
the switch.
Loosen Screw A
Work Light Shown
2. Loosen the phillips screw located at the rear of the head

lamp. Squeeze Tabs - Push Through
3. Tilt the head lamp upward or downward. Pod To Remove
4. Tighten the screw.
Headlamp Switch Test

1. Remove the headlight pod cover.
2. Set meter to DC Volts and probe the head lamp plug wires
(Brown and Yellow) at back of connector for 12 Volts.
3. Turn ignition and headlight on. If there is no power,
continue with checks to the harness and PDM.
Brown • Check for continuity between the switch contacts -

Place meter leads between two contacts with switch in
ON position.
Yellow • Probe the worklight plug wires at back of vehicle, there
Upper Headlamp Plug Wires should be at least 12V at the plug with the key ‘ON’.
• Check for 12 volt power at the wire.
Lower Headlamp Plug Wires
Brown
Test
Green
10
Worklight / Differential Lockout Connector Wires
10.37
ELECTRICAL
Brake Light / Work Light Replacement 3. X2, Touring and Sportsman - Carefully pull out the red
locking tab on the connector.
The brake light (A) and the work light (B) are both located in the
rear tail lamp housing.
1. X2 only - 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.
4. X2, Touring and Sportsman - Once the red tab is pulled

out, press in on the black tab and pull out to disconnect
harness.
Black Tab
2. X2 only - Remove the taillight assembly from the cargo Red Tab
box.
5. X2, Touring and Sportsman - Disconnect the two wire

harnesses connected to each of the taillights. Twist bulb
housing to remove from lamp assembly and replace bulb.
CAUTION
Use caution when disconnecting the smaller light

Install Remove
bulb. Follow the procedures to keep from damaging
the connector. Damaging a connector may require
wire harness replacement.
10.38
ELECTRICAL
Brake Light Switch Test SPEED SENSOR
1. Remove the front cover.
Testing
Using the special tools listed, test the speed sensor according to
the tester instructions. Remove sensor and inspect the o-ring
seal for damage or wear and replace as required. Replacement
of sensor is required as it is not serviceable.
Brake Lamp Switch
Brake Switch
Location
2. Disconnect wire harness from switch.

3. Connect an ohmmeter across switch contacts. Reading Speed Sensor
should be infinite (∞). Test Using Special Tools:
4. Apply brake at handlebar lever and check for continuity
between switch contacts. Replace switch if there is no Static Timing Light Harness
continuity or greater than .5 ohms resistance when the brake PN 2871745
is applied with slight pressure. Hall Sensor Probe Harness
PN 2460761
Replacement
1. Remove the sensor retaining using a suitable tool.
2. Coat o-ring of new sensor with anti-seize compound or
sealant.
3. Push new sensor into gearcase housing. Install bolt and 10
tighten to specification.
=T
Speed Sensor Bolt Torque
8-12 ft. lbs. (11-17 Nm)
10.39
ELECTRICAL
FUEL SENDER ACCESSORY POWER
Testing Wire Connections
1. Drain the fuel tank and remove it from the ATV. Winch Installation
2. Set the fuel tank on a flat surface.
The Sportsman models have the main winch cables routed and
3. Hook up an ohm meter to the fuel sender harness wire (B) installed from the factory. This enables quick installation.
and wire (C).
4. With the sender float in the empty position, the meter Refer to Chapter 2 for more information on winch installation
should read 5 ohms. and operation.
5. Slowly tilt invert the tank so that gravity moves the sender Accessory Power Wires
float to the full position, the meter should now read 90
ohms. 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.
Fuel Sender
If you have trouble locating the Orange / White wires remove
the left side panel and search under the front fender area.
Empty: 6 Ω ± 5%
Half: 57 Ω ± 5%
Full: 90 Ω ± 5%
6. If the 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.
• Loose float
• Float contact with tank
• Bent Float Rod
If none of the conditions exists, the sender assembly is faulty.
NOTE: **In the event of a failure, fuel tank assembly

replacement is required on ALL models, as the
sender assembly or pump assembly is not
serviceable.
10.40
ELECTRICAL
NOTE: Refer to the accessory instructions for STARTER SYSTEM
accessory hook-up and installation.
Troubleshooting
Orange/White
Wires Located Starter Motor Does Not Run
In This Area
• 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
Orange/White Wires
Starter Motor Turns Over Slowly
• Battery discharged - low specific gravity

• Excessive circuit resistance - poor connections (see
Voltage Drop Test below)
• Engine problem - seized or binding (Can engine be
rotated easily?)
• Faulty or worn brushes in starter motor
Starter Motor Turns - Engine Does Not Rotate
• Faulty starter drive

Accessory Wires • Faulty starter drive gears or starter motor gear
Located in Pod • Faulty flywheel gear or loose flywheel
Located in Lower VOLTAGE DROP TEST

Head Lamp Area
The Voltage Drop Test is used to test for bad connections. When
performing the test, you are testing the amount of voltage drop
through the connection. A poor or corroded connection will
appear as a high voltage reading. Voltage shown on the meter
when testing connections should not exceed .1 VDC per
connection or component.
To perform the test, place the meter on DC volts and place the
10
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
10.41
ELECTRICAL
Starter Lockout Troubleshooting- EFI Models
The starter lockout is controlled by the ECU. Pin #52 of the ECU senses the transmission signal and determines if the switch is in
Neutral or Park. When the conditions are met, the ECU will activate SSCB #2 Pin 'N' to ground the starter solenoid.
Pin #35 of the ECU senses when the brake is applied and activates Pin #2 pin to ground the solenoid. The ECU 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 ECU) leading to and from these components
• Proper ground to frame
• Proper voltage to solenoid
Should all these items be found in working order, the ECU may be at fault.
Starter Lockout Troubleshooting- Sportsman 500 Carbureted

The starter lockout is controlled by the PDM. Pin 'G' on SSCB #1 of the PDM 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 of the PDM senses when the brake is applied and activates pin ‘A’ 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.
10.42
ELECTRICAL
Starter Lockout Diagram- EFI
Starter Lockout Diagram- Sportsman 500 Carbureted
10
10.43
ELECTRICAL
Starter Motor Removal / Disassembly O-rings located on the armature housing.
NOTE: Use electrical contact cleaner to clean starter

O-Rings
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.
Shims
NOTE: The shims must be reinstalled during

reassembly.
Brush Inspection / Replacement
CAUTION
NOTE: Note the alignment marks on both ends of
the starter motor casing. These marks must align Some cleaning solvents may damage the insulation
during reassembly. in the starter. Care should be exercised when
selecting an appropriate solvent. If the commutator
3. Remove the rear brush housing assembly, holding the front needs cleaning use only electrical contact cleaner.
housing and armature assembly together.
1. Measure resistance between starter input terminal and
insulated brushes. The reading should be .3 ohms or less.
O-Rings
Measure the resistance between the cable terminal and
brush housing. Make sure the brush is not touching the
case. The reading should be infinite.
4. Remove the shims from the armature shaft and inspect the
2. Remove nut, 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.
10.44
ELECTRICAL
4. Inspect surface of commutator for wear or discoloration. Armature Testing
See Steps 3-6 of ‘Armature Testing’.
1. Remove armature from starter casing.
Brush Inspection NOTE: Note order of shims on drive end for reassembly.
1. Measure length of each carbon brush. Replace brush 2. Inspect surface of commutator. Replace if excessively
assembly when worn to 5/16” (8 mm) or less. The brushes worn or damaged.
must slide freely in their holders. 3. Using a digital multitester, measure the resistance between
each of the commutator segments. The reading should be
Brush Length .3 ohms or less.
Limit 5/16” (8 mm)
Brush Replacement
1. 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.
4. Measure the resistance between each commutator segment

and the armature shaft. The reading should be infinite (no
continuity).
2. Place a wrap of electrical tape on the threads of the terminal

bolt to prevent O-Ring damage during reinstallation.
3. Install the O-Ring over the bolt. Make sure the O-ring is
fully seated.
4. Remove the electrical tape and reinstall the two small
phenolic washers, the large phenolic washer, flat washer,
and nut.
10
5. Check commutator bars for discoloration. Bars discolored
in pairs indicate shorted coils, requiring replacement of the
starter motor.
6. Place armature in a growler. Turn growler on and position
a hacksaw blade or feeler gauge lengthwise 1/8” (.3 cm)
above armature coil laminates. Rotate armature 360°. If
hacksaw blade is drawn to armature on any pole, the
armature is shorted and must be replaced.
10.45
ELECTRICAL
Starter Reassembly Starter Exploded View
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 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.
7. Align brush plate and install cover and screws.
8. Install the starter onto the engine case. Hand tighten the
starter bolt. Torque the bolt to 9 ft.lbs. (12 Nm).
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.
10.46
ELECTRICAL
STARTER DRIVE
Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement
If the garter spring is damaged, the overrun clutch may fail to return properly. Use either of the following methods to remove and
install a new garter spring:
H
G
A F
D
A. Gear Assembly E
B. Thrust Washer C
C. Bushing
D. Retaining Ring
E. Thrust Washer
F. Stopper
G. Cover
H. Spring
1. Screw the overrun clutch out to the engaged position on the pinion shaft assembly. Use a small piece of wire with the end bent
in a hook and pick the old spring out of its channel. Slide it off the end of the shaft. Slide the new spring over the overrun
clutch and into the spring groove. Make sure that the spring is positioned between the shoe alignment pins and the back flange
of the anti kick-out shoes.
2. Remove the retaining ring, thrust washer, spring retainers and clutch return spring. Screw the overrun clutch off the end of the
pinion shaft. Remove the old spring and install a new one. Lightly grease the pinion shaft and reinstall the clutch, spring,
retainers, end washer and lock ring in the reverse order. Make sure the end washer is positioned properly so that it will hold
the lock ring in its groove.
10
10.47
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 Remove battery and properly service. Install
No fully charged shop battery to continue test.
be 12.4 V D. C. or greater.
Yes
Disconnect coil engagement wire from the starter Check voltage on both sides of circuit
solenoid. Connect tester black wire to battery breaker, ignition switch/engine stop switch.
ground. Connect red tester lead to harness wire at The voltage on both sides should be the same.
No NOTE: The ignition switch and engine stop
solenoid. Turn on ignition switch. Tester should
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 No Clean the battery-to-solenoid cable ends
lead to the battery positive and the red lead to the or replace the cable.
solenoid end of the battery-to-solenoid wire.
Depress starter button. Reading should be less than
.1 V D.C.
Yes
Connect the black tester lead to solenoid end of

battery-to-solenoid cable. Connect red tester lead No
to solenoid end of solenoid-to-starter cable. Replace the starter solenoid.
Depress starter button. Reading should be less than
.1 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. No Clean the solenoid-to-starter cable ends or
Depress the starter button. The reading should be replace the cable.
less than .1 V D.C.
Yes
If all of these indicate a good condition, yet the starter still fails to
turn, the starter must be removed for static testing and inspection.
10.48
ELECTRICAL
BASIC WINCH WIRING
Pre-wired Models
10
10.49
ELECTRICAL
BATTERY Battery Activation
Battery Identification
WARNING
NOTE: It is important to identify what type of battery
you have installed in your ATV. Different types of Battery electrolyte is poisonous. It contains sulfuric
batteries require different service procedures. acid. Serious burns can result from contact with
Proper servicing and upkeep of your battery is very skin, eyes or clothing. Antidote:
important for maintaining long battery life.
External: Flush with water.
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 Internal: Drink large quantities of water or milk.
service and charging procedures that follow in the manual. Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.
Conventional Battery
Eyes: Flush with water for 15 minutes and get
Removable prompt medical attention.
Caps
Batteries produce explosive gases. Keep sparks,
flame, cigarettes, etc. away. Ventilate when
charging or using in an enclosed space. Always
Top View shield eyes when working near batteries. KEEP
OUT OF REACH OF CHILDREN.
Electrolyte Level
Indicator WARNING
The gases given off by a battery are explosive. Any

spark or open flame near a battery can cause an
explosion which will spray battery acid on anyone
close to it. Should there be contact with battery
acid, wash the affected area with large quantities of
cool water and seek immediate medical attention.
Sealed Low Maintenance Battery 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

No Caps (Non- put into regular service within 30 days. After initial
Removable) service, add only distilled water to the battery.
Never add electrolyte after a battery has been in
service.
Top View
NOTE: New Battery: Battery must be fully charged
before use or battery life will be significantly
No Electrolyte reduced 10-30% of the battery's full potential.
Level Indicator
To activate a new battery:
1. Remove vent plug from vent fitting. Remove cell caps.

2. Fill battery with electrolyte to upper level marks on case.
3. Set battery aside to allow for acid absorption and
stabilization for 30 minutes.
10.50
ELECTRICAL
4. Add electrolyte to bring level back to upper level mark on Inspect the battery fluid level. When the battery fluid nears the
case. lower level, remove the battery and fill with distilled water only
to the upper level line. To remove the battery:
NOTE: This is the last time that electrolyte should
be added. If the level becomes low after this point,
add only distilled water.
5. Charge battery at 1/10 of its amp/hour rating. Examples:

Maintain
1/10 of 9 amp battery = .9 amp; 1/10 of 14 amp battery = between
1.4 amp; 1/10 of 18 amp battery = 1.8 amp (recommended upper and
charging rates). lower level
6. Check specific gravity of each cell with a hydrometer to marks
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”.
1. Disconnect holder strap and remove covers.
Battery Removal 2. Disconnect battery negative (-) (black) cable first, followed
by the positive (+) (red) cable.
SPORTSMAN - The battery is located under the seat.
CAUTION
X2 and Touring - The battery is located under fuel tank and can
be accessed by removing the right hand side panel.
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
BATTERY 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
10
1. Clean battery cables and terminals with a stiff wire brush.
Corrosion can be removed using a solution of one cup
water and one tablespoon baking soda. Rinse well with
clean water and dry thoroughly.
2. Route the cables correctly.
3. Reinstall battery, attaching positive (+) (red) cable first and
then the negative (-) (black) cable. Coat terminals and bolt
threads with Nyogel Grease (PN 2871329).
10.51
ELECTRICAL
4. Install clear battery vent tube from vehicle to battery vent. Low Maintenance Battery Off-Season
Storage
WARNING
Battery voltage should be checked with a digital multitester.
Readings of 12.8 volts or less require further battery testing and
Vent tube must be free from obstructions and kinks and charging. See charts and Load Test.
securely installed. If not, battery gases could accumulate
and cause an explosion. The vent tube should be routed • Remove the battery from the machine and wash the
case and battery tray with a mild solution of baking
away from frame and body to prevent contact with Route soda and water. Rinse with lots of fresh water after
the cables correctly. cleaning.
5. Reinstall the holder strap. • Using a wire brush or knife, remove any corrosion from
the cables and terminals.
Off Season Storage • Make sure that the electrolyte is at the proper level.
To prevent battery damage during extended periods of non-use, • Charge at a rate no greater than 1/10 of the battery's
the following basic battery maintenance items must be amp/hr capacity until the electrolyte's specific gravity
reaches 1.270 or greater.
performed:
• Store the battery either in the machine with the cables
• Remove the battery from the machine and wash the disconnected, or store in a cool place.
case and battery tray with a mild solution of baking
soda and water. Rinse with lots of fresh water after NOTE: Stored batteries lose their charge at the rate
cleaning. NOTE: Do not get any of the baking soda
into the battery or the acid will be neutralized. of 1% per day. Recharge to full capacity every 30 to
60 days during a non-use period. If the battery is
• Using a wire brush or knife, remove any corrosion from stored during the winter months, electrolyte will
the cables and terminals.
freeze at higher temperatures as the battery
• Make sure that the electrolyte is at the proper level. discharges. The chart below indicates freezing
Add distilled water if necessary. points by specific gravity.
• Charge at a rate no greater than 1/10 of the battery's
amp/hr capacity until the electrolyte's specific gravity Battery Testing
reaches 1.270 or greater.
Whenever a service complaint is related to either the starting or
• Store the battery either in the machine with the cables charging systems, the battery should be checked first.
disconnected, or store in a cool place.
NOTE: Recharge to full capacity every 30 to 60 days Following are three tests which can easily be made on a battery
to determine its condition: OCV Test, Specific Gravity Test and
during a non-use period. If the battery is stored Load Test.
during the winter months, electrolyte will freeze at
higher temperatures as the battery discharges. The Conventional Battery OCV - Open Circuit
chart below indicates freezing points by specific Voltage Test
gravity.
Battery voltage should be checked with a digital multitester.
Table 10-1: ELECTROLYTE FREEZING POINTS Readings of 12.6 volts or less require further battery testing and
charging. See charts and Load Test below.
SPECIFIC GRAVITY OF
FREEZING POINT NOTE: Lead-acid batteries should be kept at or near
ELECTROLYTE
a full charge as possible. Electrolyte level should be
1.265 -75° F kept between the low and full marks. If the battery is
1.225 -35° F stored or used in a partially charged condition, or
with low electrolyte levels, hard crystal sulfation will
1.200 -17° F form on the plates, reducing the efficiency and
1.150 +5° F service life of the battery.
1.100 +18° F
1.050 +27° F
10.52
ELECTRICAL
Conventional Battery Specific Gravity Test Battery Load 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
CAUTION
goes from a heavy (more acidic) state at full charge to a light
(more water) state when discharged. The hydrometer can To prevent shock or component damage, remove
measure state of charge and differences between cells in a multi- spark plug high tension leads and connect securely
cell battery. Readings of 1.270 or greater should be observed in to engine ground before proceeding.
a fully charged battery. Differences of more than .025 between
the lowest and highest cell readings indicate a need to replace
the battery. 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

Battery Hydrometer (PN 2870836) and the specific gravity test, but still may not have the storage
capacity necessary to properly function in the electrical system.
For this reason, a battery capacity or load test should be
conducted whenever poor battery performance is encountered.
To perform this test, hook a multitester to the battery in the same
manner as was done in the OCV test. The reading should be 12.6
volts or greater. Engage the starter and observe the battery
voltage while cranking the engine. Continue the test for 15
seconds. During cranking the observed voltage should not drop
below 9.5 volts. If the beginning voltage is 12.6 volts or higher
and the cranking voltage drops below 9.5 volts during the test,
replace the battery.
Table 10-1: OPEN CIRCUIT VOLTAGE
Charging Procedure
STATE OF CONVENTIONAL
LOW MAINTENANCE
CHARGE LEAD - ACID 1. Remove the battery from the ATV to prevent damage from
100% 12.60V 12.70V leaking or spilled acid during charging.
2. Charge the battery with a charging output no larger than 1/
Charged 12.40V 12.50V
10 of the battery's amp/hr rating. Charge as needed to raise
75% Charged 12.10V 12.20V the specific gravity to 1.270 or greater.
50% Charged 11.90V 12.0V 3. Install battery in vehicle with positive terminal toward the
25% Charged less than 11.80V Less than 11.90V front. Coat threads of battery bolt with a corrosion resistant
0% Charged - - dielectric grease (PN 2871329).
4. Connect battery cables.
Table 10-2: SPECIFIC GRAVITY
WARNING
STATE OF CONVENTIONAL LOW
CHARGE* LEAD - ACID MAINTENANCE
To avoid the possibility of explosion, connect
100% 1.265 1.275 positive (red) cable first and negative (black) cable
10
Charged 1.210 1.225 last.
75% Charged 1.160 1.175
5. After connecting the battery cables, install the cover on the
50% Charged 1.120 1.135
battery and attach the hold down strap.
25% Charged less than 1.100 Less than 1.115
0% Charged - -
* Measurement at 80° F
NOTE: Subtract .01 from the specific gravity reading

at 40° F
10.53
ELECTRICAL
6. Install clear battery vent tube from vehicle to battery vent. Low Maintenance batteries are permanently sealed at the time of
manufacture. The use of lead-calcium and AGM technology
WARNING instead of lead-antimony allows the battery acid to be fully
absorbed. For this reason, a Low Maintenance battery case is
dark and the cell caps are not removable, since there is no need
Vent tube must be free from obstructions and kinks to check electrolyte level.
and securely installed. If not, battery gases could
NEVER attempt to add electrolyte or water to a Low
accumulate and cause an explosion. Vent should Maintenance battery. Doing so will damage the case and shorten
be routed away from frame and body to prevent the life of the battery.
contact with electrolyte. Avoid skin contact with
electrolyte, as severe burns could result. If NOTE: New Batteries: Batteries must be fully
electrolyte contacts the vehicle frame, corrosion will charged before use or battery life will be reduced by
occur. 10-30% of full potential. Charge battery for 3-5 hours
at a current equivalent of 1/10 of the battery's rated
7. Route cables so they are tucked away in front and behind amp/hour capacity. Do not use the alternator to
battery. charge a new battery.
Low Maintenance Battery Check: NEVER attempt to add electrolyte or water to a Low
Maintenance battery. Doing so will damage the case and shorten
NOTE: All Low Maintenance batteries are fully the life of the battery.
charged and tested at the factory before installation.
TO SERVICE A LOW MAINTENANCE BATTERY:
Expected shelf life varies on storage conditions. As
a general rule before placing the battery into service, 1. Remove battery from the vehicle.
check the battery condition and charge accordingly. 2. Test battery with a voltage meter or load tester to determine
battery condition. This will determine the length of time
1. Check the date label on the side of the battery to calculate
required to charge the battery to full capacity. Refer to
when to check voltage. The battery should be checked
capacity table.
every 3 months.
2. Check the voltage with a voltmeter or multimeter. A fully 3. Charge battery using a variable rate charger.
charged battery should be 12.8 V or higher.
3. If the voltage is below 12.8 V, the battery will need to be
Low Maintenance Battery Charging
recharged. 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 constant current charger, use the following guidelines for
recharging.
NOTE: Always verify battery condition before and 1-

2 hours after the end of charging.
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.
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 using a variable rate charger. Do
not use the alternator to charge a new battery. A high rate battery
charger can cause battery damage.
10.54
ELECTRICAL
Table 10-1: LOW MAINTENANCE BATTERY Low Maintenance Battery Load Test
CHARGING REFERENCE TABLE
STATE OF CHARGE CAUTION
VOLTAGE ACTION
CHARGE TIME
None, check To prevent shock or component damage, remove
voltage at 3 mos. None spark plug high tension leads and connect securely
100% 12.8-13 V to engine ground before proceeding.
after manufacture Required
date
NOTE: This test can only be performed on machines
May need slight
75-100% 12.5-12.8 V 3-6 Hours with electric starters. Test cannot be performed with
charge
an engine or starting system that is not working
50-75% 12.0-12.5 V Needs Charge 5-11 Hours properly.
At least 13
25-50% 11.5-12.0 V Needs Charge hours, verify A battery may indicate a full charge condition in the OCV test
state of charge and the specific gravity test, but still may not have the storage
capacity necessary to properly function in the electrical system.
At least 20 For this reason, a battery capacity or load test should be
0-25% 11.5 V or less Needs Charge
hours conducted whenever poor battery performance is encountered.
To perform this test:
Low Maintenance Battery - OCV- Open
Circuit Voltage Test 1. Hook a multitester to the battery in the same manner as was
done in the OCV test. The reading should be 12.8 volts or
Battery voltage should be checked with a digital multitester. greater.
Readings of 12.8 volts or less require further battery testing and 2. Engage the starter and observe the battery voltage while
charging. See charts and Load Test. cranking the engine. Continue the test for 15 seconds.
NOTE: Lead-acid batteries should be kept at or near 3. During cranking the observed voltage should not drop
a full charge as possible. If the battery is stored or below 9.5 volts.
used in a partially charged condition, or with low 4. If the beginning voltage is 12.8 volts or higher and the
electrolyte levels, hard crystal sulfation will form on cranking voltage drops below 9.5 volts during the test,
the plates, reducing the efficiency and service life of replace the battery.
the battery.
Low Maintenance Battery Charging
NOTE: Use a voltmeter or multimeter to test battery Procedure
voltage.
1. Remove the battery from the ATV to prevent damage from
Table 10-1: OPEN CIRCUIT VOLTAGE leaking or spilled acid during charging.
2. Charge the battery with a variable rate charging output.
STATE OF LOW MAINTENANCE CONVENTIONAL Charge as needed to raise the specific gravity to 1.270 or
CHARGE BATTERY BATTERY greater.
100 % 13.0V 12.70V 3. Install battery in vehicle with positive terminal toward the
75% Charged 12.80V 12.50V front. Coat threads of battery bolt with a corrosion resistant
50% 12.50V 12.20V Nyogel Grease (PN 2871329).
25% 12.20V 12.0V 4. Route cables so they are tucked away in front and behind
10
battery.
0% Charged less than 12.0V less than 11.9V
5. Connect battery cables.
* Measurement at 80° F
WARNING
NOTE: Subtract .01 from the specific gravity reading
at 40° F. 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.
10.55
ELECTRICAL
TROUBLESHOOTING DIAGRAMS
All Wheel Drive - EFI
Fuel Pump and Ignition Coil - EFI
10.56
ELECTRICAL
Reverse Override - EFI
Fan Control - EFI
10
10.57
ELECTRICAL
NOTES
10.58
500 EFI X2 / TOURING QUADRICYCLE
CHAPTER 11
500 EFI X2 / TOURING QUADRICYCLE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 11.2
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
500 EFI X2 / TOURING QUADRICYCLE STEERING POST AND LOCK. . . . . . . . . . . . 11.4
STEERING ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
500 EFI QUADRICYCLE EMISSIONS SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
500 QUADRICYCLE ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
TURN / HAZARD SIGNAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
NOTE: This chapter illustrates components that are unique to the

Sportsman 500 EFI Quadricycle models (International).
Except where noted, any servicing of these components or other components
on the ATV can be done using this service manual’s procedures and illustrations.
11
11.1
500 EFI X2 / TOURING QUADRICYCLE BRAKE SYSTEM
Overview
The Sportsman 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 is 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.
11
11.2
Exploded View
Hand Brake Supply
Foot Brake Supply
11
11.3
500 EFI X2 / TOURING QUADRICYCLE STEERING POST AND LOCK
Steering Assembly Exploded View
The 500 EFI 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
11
11.4
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 consists of:
• A. 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, the 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 is required.
E
A
D C 11
Air Flow
11.5
500 QUADRICYCLE ELECTRICAL
Turn / Hazard Signal Diagram
11.6
A Brake, Rear Auxiliary Master Cylinder . . . . . . . . . . . . . 9.26
A-Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
Active Descent Control (ADC) Coil . . . . . . . . . . . . . . 10.19
Brake, Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 9.2
Brakes, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 IX
Brakes, Operation Overview . . . . . . . . . . . . . . . . . . . . . . . 9.6
Active Descent Control Gearcase . . . . . . . . . . . . . . . . . . 7.22
Brakes, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
ADC Gearcase Piston Service . . . . . . . . . . . . . . . . . . . . 7.27
ADC Gearcase, Disassembly / Inspection . . . . . . . . . . . 7.23 C
ADC reservoir level inspection . . . . . . . . . . . . . . . . . . . 2.18 Cam Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Air Filter, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 Cam Chain Tensioner, Inspection . . . . . . . . . . . . . . . . . . 3.14
Alignment, Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 Camshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
All Wheel Drive (AWD) Coil . . . . . . . . . . . . . . . . . . . 10.19 Camshaft Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
All Wheel Drive and Speedometer Troubleshooting Tests . . Carburetor (BST34) Exploded View . . . . . . . . . . . . . . . . 4.33
10.14 Carburetor Jetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
Alternator / Ignition Components . . . . . . . . . . . . . . . . . 10.24 Carburetor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . 10.28 Carburetor Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
ATV Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . . 2.36 Carburetor, Air/Fuel Ratio . . . . . . . . . . . . . . . . . . . . . . . 4.38
B Carburetor, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.41
Carburetor, Choke System . . . . . . . . . . . . . . . . . . . . . . . 4.36
Ball Joint Replacement, Front . . . . . . . . . . . . . . . . . . . . 5.21
Battery Activation, Conventional . . . . . . . . . . . . . . . . . 10.50 Carburetor, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40
Battery Charging Procedure, Low Maintenance . . . . . 10.55 Carburetor, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 4.39
Carburetor, Float Adjustment . . . . . . . . . . . . . . . . . . . . . 4.42
Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.53
Carburetor, Float System . . . . . . . . . . . . . . . . . . . . . . . . . 4.37
Battery Load Test, Low Maintenance . . . . . . . . . . . . . 10.55
Carburetor, Idle System . . . . . . . . . . . . . . . . . . . . . . . . . .4.36
Battery Off Season Storage . . . . . . . . . . . . . . . . . . . . . 10.52
Carburetor, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.41
Battery Off Season Storage, Low Maintenance . . . . . . 10.52
Carburetor, Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.39
Battery Open Circuit Voltage (OCV), Low Maintenance . . .
Carburetor, Main System . . . . . . . . . . . . . . . . . . . . . . . . 4.37
10.55
Battery Removal / Inspection, Conventional . . . . . . . . 10.51 Carburetor, Needle Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.39
Carburetor, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
Battery Specific Gravity Tes, Conventional . . . . . . . . . 10.53
Carburetor, Pilot Screw . . . . . . . . . . . . . . . . . . . . . . . . . .4.38
Battery Terminals/Bolts . . . . . . . . . . . . . . . . . . . . . . . . 10.51
Carburetor, Throttle Opening vs. Fuel Flow . . . . . . . . . . 4.39
Battery, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.51
Cargo Box, Removal and Installation . . . . . . . . . . . . . . . 5.28
Battery, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.53
Body and Steering Torque Values . . . . . . . . . . . . . . . . . . 5.2
Charging System - Break Even Test . . . . . . . . . . . . . . . 10.27
Body Assembly Exploded View . . . . . 5.12, 5.13, 5.14, 5.16
Charging System Flow Chart . . . . . . . . . . . . . . 10.25, 10.29
Body Rack Exploded View . . . . . . . . . . . . . . . . . . . . . . 5.15
Choke System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.36
Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
Brake Burnishing Procedure . . . . . . . . . . . . . . . . . . . . . . 9.12
Clutch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
Brake Caliper Exploded View . . . . . . . . . . . . . . . . . . . . . 9.5
Clutch Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
Brake Caliper Removal, Rear . . . . . . . . . . . . . . . . 9.21, 9.23
Clutch, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 6.39
Brake Caliper, Assembly . . . . . . . . . . . . . . . . . . . . . . . . 9.24
Clutching Chart . . . . . . . . . . . . . . . . . . . . .1.4, 1.6, 1.8, 1.10
Brake Caliper, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Brake Disc, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
Component Locations, Sportsman . . . . . . . . . . . . . . . . . . 2.7
Brake Disc, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
Brake Light / Work Light Switch Replacement . . . . . . 10.38
Controls, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
Brake Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
Brake Noise Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 9.7
Coolant Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
Brake Pad Install, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
Coolant, Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.20
Brake Pad Removal, Rear . . . . . . . . . . . . . . . . . . . . . . . . 9.19
Coolant, Recommended Ratio . . . . . . . . . . . . . . . . . . . . . . 3.8
Brake Pad, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
Brake Pad, Removal and Installation . . . . . . . . . . . . . . . 9.10 Cooling System Pressure Test . . . . . . . . . . . . . . . . . . . . . . 3.7
Brake System Components, Std, Sportsman . . . . . . . . . . 9.4 Cooling System Specifications . . . . . . . . . . . . . . . . . . . . . 3.6
Brake System Components, X2 . . . . . . . . . . . . . . . . . . . . 9.3 Cooling System, Maintenance . . . . . . . . . . . . . . . . . . . . . 2.19
Counter Balancer Endplay Adjustment . . . . . . . . . . . . . . 3.38
Brake System Exploded View, International . . . . . . . . . 11.3
Counter Balancer, Removal and Inspection . . . . . . . . . .3.34
Brake System Exploded Views . . . . . . . . . . . . . . . . . . . . 9.3
Crankcase Breather Filter, Service . . . . . . . . . . . . . . . . . 2.22
Brake System Overview, International . . . . . . . . . . . . . . 11.2
Crankcase Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
Brake, Master Cylinder Removal . . . . . . . . . . . . . . . . . . . 9.9
Crankshaft Endplay Adjustment . . . . . . . . . . . . . . . . . . . 3.37
Brake, Rear Auxiliary Brake . . . . . . . . . . . . . . . . . . . . . 9.28
IX.1
Crankshaft Position Sensor (CPS) . . . . . . . . . . . . . . . . . .4.16 Engine Temperature Sensor Replacement . . . . . . . . . . . 4.21
Crankshaft Position Sensor Gap . . . . . . . . . . . . . . . . . .10.26 Engine Temperature Sensor Test . . . . . . . . . . . . . . . . . . 4.21
Crankshaft Straightening . . . . . . . . . . . . . . . . . . . . . . . . .3.10 Engine, Fastener Torque Patterns . . . . . . . . . . . . . . . . . . 3.3
Crankshaft, Removal and Inspection . . . . . . . . . . . . . . . .3.35 Engine, Lubrication Requirements . . . . . . . . . . . . . . . . 3.11
Current Draw - Key Off Test . . . . . . . . . . . . . . . . . . . .10.27 Engine, Oil and Filter Change . . . . . . . . . . . . . . . . . . . . 2.23
CV Boot, Front Replacement . . . . . . . . . . . . . . . . . . . . . .7.5 Engine, Oil Pump Priming . . . . . . . . . . . . . . . . . . . . . . . 2.25
CV Boot, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31 Engine, Torque Specifications . . . . . . . . . . . . . . . . . . . . . 3.3
CV Boot, Rear Replacement . . . . . . . . . . . . . . . . . . . . . .7.37 Engine, Valve Clearance / Adjustment . . . . . . . . . . . . . 2.25
CV Carburetor System Function . . . . . . . . . . . . . . . . . . .4.35 ETC Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . .3.19 ETC Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Cylinder Head Torque Procedure . . . . . . . . . . . . . . . . . .3.45 F
Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9
Fan Control Circuit Operation . . . . . . . . . . . . . . . . . . . 10.20
Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44
Fan Control Circuit Operation / Testing . . . . . . . . . . . 10.20
Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27
Fan Motor Current Draw . . . . . . . . . . . . . . . . . . . . . . . 10.20
D Final Drive Torque Specifications . . . . . . . . . . . . . . . . . . 7.2
Decal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 Flywheel / Stator Removal . . . . . . . . . . . . . . . . . . . . . . . 3.31
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.12 Foot Well Removal / Installation . . . . . . . . . . . . . . . . . . . 5.5
Diagnostic Mode, EFI System . . . . . . . . . . . . . . . . . . .10.12 Front Cab Removal / Installation . . . . . . . . . . . . . . . . . . . 5.9
Differential Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . .10.32 Front Cover Removal / Installation . . . . . . . . . . . . . . . . . 5.4
Drive Belt, Installation . . . . . . . . . . . . . . . . . . . . . . . . . .6.13 Front Drive Axle Installation . . . . . . . . . . . . . . . . . . . . . . 7.4
Drive Belt, Removal/Inspection . . . . . . . . . . . . . . . . . . .6.12 Front Drive Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Drive Clutch Service, EBS . . . . . . . . . . . . . . . . . . . . . . .6.15 Front Gearcase - Back Lash Pad Adjustment . . . . . . . . 7.18
Drive Clutch Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8 Front Gearcase Coil Resistance . . . . . . . . . . . . . . .7.14, 7.23
Drive Clutch Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.9 Front Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . 2.12
Drive Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . . .6.6 Front Gearcase, Active Descent Control Exploded View 7.21
Drive Clutch, Standard . . . . . . . . . . . . . . . . . . . . . . . . . .6.28 Front Gearcase, Diagnoses . . . . . . . . . . . . . . . . . . . . . . . 7.19
Drive Shaft Boot Inspection . . . . . . . . . . . . . . . . . . . . . . .7.5 Front Gearcase, Disassembly / Inspection . . . . . . . . . . . 7.13
Driven Clutch Service, EBS . . . . . . . . . . . . . . . . . . . . . .6.22 Front Gearcase, Exploded View . . . . . . . . . . . . . . . . . . 7.11
Driven Clutch, Assembly . . . . . . . . . . . . . . . . . . . . . . . .6.37 Front Gearcase, Installation . . . . . . . . . . . . . . . . . . . . . . 7.20
Driven Clutch, Bushing Service . . . . . . . . . . . . . . . . . . .6.35 Front Gearcase, Operation . . . . . . . . . . . . . . . . . . . . . . . 7.11
Driven Clutch, Disassembly / Inspection . . . . . . . . . . . .6.34 Front Gearcase, Reassembly . . . . . . . . . . . . . . . . . . . . . 7.29
Driven Clutch, Exploded View . . . . . . . . . . . . . . . . . . . .6.34 Front Gearcase, Reassembly / Inspection . . . . . . . . . . . 7.17
Driven Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . .6.6 Front Gearcase, Removal . . . . . . . . . . . . . . . . . . . . . . . . 7.12
Driven Clutch, Standard . . . . . . . . . . . . . . . . . . . . . . . . .6.34 Front Hub, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
E Front Hub, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Front Storage Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
EBS Drive Clutch Service . . . . . . . . . . . . . . . . . . . . . . . .6.15
Front Storage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
EBS Driven Clutch Service . . . . . . . . . . . . . . . . . . . . . . .6.22
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
EBS Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . 6.4, 6.5
Fuel Filter, Replacement . . . . . . . . . . . . . . . . . . . .2.17, 4.46
EBS, Driven Clutch Operation . . . . . . . . . . . . . . . . . . . . .6.7
Fuel Gauge Sender, Installation . . . . . . . . . . . . . . . . . . . 4.47
EFI Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . .4.9
Fuel Gauge Sender, Removal . . . . . . . . . . . . . . . . . . . . . 4.46
EFI Priming / Starting Procedure . . . . . . . . . . . . . . . . . .4.10
Fuel Injection, Component Locations . . . . . . . . . . . . . . . 4.8
Electrical Service Notes . . . . . . . . . . . . . . . . . . . . . . . . .10.4
Fuel Injection, Exploded View . . . . . . . . . . . . . . . . . . . . 4.7
Electrical, Service Notes . . . . . . . . . . . . . . . . . . . . . . . . .10.4
Fuel Injection, Service Notes . . . . . . . . . . . . . . . . . . . . . . 4.6
Electrical, Special Tools . . . . . . . . . . . . . . . . . . . . . . . . .10.3
Fuel Injection, Special Tools . . . . . . . . . . . . . . . . . . . . . . 4.4
Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . .4.11
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Elelctrical, Troubleshooting Diagrams . . . . . . . . . . . . .10.56
Fuel Level Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.43
Engine Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . .4.23
Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14 Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Engine Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . .3.13 Fuel Pump / Tank Assembly . . . . . . . . . . . . . . . . . . . . . 4.12
Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . .3.9 Fuel Pump, Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.45
Fuel Sender Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
Engine Oil, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
Fuel System Special Tools . . . . . . . . . . . . . . . . . . . . . . . 4.32
Engine Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40
Fuel System, EFI Circuit Diagrams . . . . . . . . . . . . . . . . 4.24
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8
Fuel System, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
Engine Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4
Fuel Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Engine Temperature Sensor . . . . . . . . . . . . . . . . . . . . . .4.20
IX.2
Fuel Tank/Fuel Delivery System . . . . . . . . . . . . . . . . . . 4.44 P
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
G
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Passenger Seat, Operation . . . . . . . . . . . . . . . . . . . . . . . . 5.31
IX
Gear Position Indicator Switch Test . . . . . . . . . . . . . . . 10.21 PDM, 450 Connector Pin Table . . . . . . . . . . . . . . . . . . . 10.6
Gearcase, ADC Hydraulic Fluid Change . . . . . . . . . . . . 2.14 PDM, 500 Carbureted Overview . . . . . . . . . . . . . . . . . . . 10.5
Gearcase, Front Capacity and Fluid Type . . . . . . . . . . . . 7.2 Pilot System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.36
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 Piston Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
H Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . 3.30, 3.43
Handlebar Block Installation Procedure . . . . . . . . . . . . . 5.18
Headlamp Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 10.37 Plastic Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Headlight Housing Replacement . . . . . . . . . . . . . . . . . 10.34 Pre-ride Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
Headlight Pod Exploded View . . . . . . . . . . . . . . . . . . . . 5.17 Propshaft, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
High Beam Bulb Replacement . . . . . . . . . . . . . . . . . . . 10.34 Publication Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
High Beam Headlight Adjustment . . . . . . . . . . . . . . . . 10.35 PVT Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
Hydraulic Brake System Operation Overview . . . . . . . . . 9.6 PVT Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
PVT Drive Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . 6.6
I PVT Drive Clutch Shift Weights . . . . . . . . . . . . . . . . . . . 6.9
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23 PVT Drive Clutch Specifications . . . . . . . . . . . . . . . . . . . 6.8
Ignition System Troubleshooting . . . . . . . . . . . . . . . . . 10.26 PVT Driven Clutch Operation . . . . . . . . . . . . . . . . . . . . . . 6.6
Instrument Cluster (Speedometer) Overview . . . . . . . . . 10.8 PVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
Instrument Cluster Diagnostic Mode . . . . . . . . . . . . . . . 10.9 PVT Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Instrument Cluster Overview . . . . . . . . . . . . . . . . . . . . . 10.8 PVT Maintenance / Inspection . . . . . . . . . . . . . . . . . . . . . 6.7
Instrument Cluster, Setting New Service Interval . . . . 10.11 PVT Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
K PVT Overheating Chart . . . . . . . . . . . . . . . . . . . . . . . . . .6.39
Keys, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 PVT Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT Torque Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
L PVT Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . 6.40
Low Beam Headlight Adjustment . . . . . . . . . . . . . . . . 10.37 PVT, Button to Tower Clearance . . . . . . . . . . . . . 6.17, 6.30
Low Maintenance Battery Charging . . . . . . . . . . . . . . . 10.54 PVT, Clutch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
Low Maintenance Battery Info . . . . . . . . . . . . . . . . . . . 10.54 PVT, Clutch Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
Lower Headlamp Housing Removal . . . . . . . . . . . . . . 10.36 PVT, Drive Belt Installation . . . . . . . . . . . . . . . . . . . . . . 6.13
Lower Headlamp Removal . . . . . . . . . . . . . . . . . . . . . . 10.36 PVT, Drive Belt Removal/Inspection . . . . . . . . . . . . . . . 6.12
Lubricants/Fluids, Polaris Brand Part Numbers . . . . . . . . 2.9 PVT, Drive Clutch Disassembly . . . . . . . . . . . . . . 6.15, 6.28
Lubricants/Fluids, Polaris Brand Symbol Identification Chart PVT, Drive Clutch Exploded View . . . . . . . . . . . . . . . . . . 6.3
2.10 PVT, Drive Clutch Reassembly . . . . . . . . . . . . . . 6.20, 6.32
M PVT, Drive Clutch Spider Removal . . . . . . . . . . . 6.15, 6.29
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 PVT, Driven Clutch Bushing Service . . . . . . . . . . . . . . . 6.24
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . 2.41, 2.42 PVT, Driven Clutch Disassembly . . . . . . . . . . . . . . . . . . 6.22
Maintenance, General Information . . . . . . . . . . . . . . . . . . 2.3 PVT, Driven Clutch Reassembly . . . . . . . . . . . . . . . . . . 6.25
MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17 PVT, EBS Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . 6.7
Mikuni Jet Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . 4.32 PVT, EBS Drive Clutch Bushing Service . . . . . . . 6.18, 6.31
Misc. Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 PVT, EBS Drive Clutch Cover Bushing Remove/Install 6.19,
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 6.32
Model Number Information . . . . . . . . . . . . . . . . . . . . . . . 1.2 PVT, Moveable Sheave Inspection . . . . . . . . . . . . 6.18, 6.31
N R
Needle and Seat, Leakage Test . . . . . . . . . . . . . . . . . . . . 4.42 Radiator Cap Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . 3.7
O Radiator Screen Removal . . . . . . . . . . . . . . . . . . . . . . . . 5.11
Rear Cab Removal / Installation . . . . . . . . . . . . . . . . . . . 5.10
Oil Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
Rear Master Cylinder, Exploded View . . . . . . . . . . . . . . 9.26
Oil Flow, Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Rear Rack Removal / Installation . . . . . . . . . . . . . . . . . . . 5.8
Oil Pressure Test, Engine . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Rear Storage Removal / Installation . . . . . . . . . . . . . . . . 5.11
Oil Pump Priming Procedure . . . . . . . . . . . . . . . . . . . . . 3.11
Rear Suspension Assembly . . . . . . . . . . . . . . . . . . 5.24, 5.25
Oil Pump Shaft Endplay Adjustment . . . . . . . . . . . . . . . 3.39
Recoil Housing, Draining / Inspection . . . . . . . . . . . . . . 2.22
Oil Pump, Removal and Inspection . . . . . . . . . . . . . . . . 3.33
Recoil, Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
Recoil, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
IX.3
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.31 Specifications, Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
S Specifications, Power Distribution Module . . . . . . . . . . 10.5
Specifications, Standard Torque Values . . . . . . . . . . . . 1.12
Shift Linkage Inspection . . . . . . . . . . . . . . . . . . . . . . . . .2.14
Specifications, Vehicle . . . . . . . . . . . . . . . 1.4, 1.6, 1.8, 1.10
Side Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4
Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
Solenoid, Differential . . . . . . . . . . . . . . . . . . . . . . . . . .10.32
Speedometer Installation . . . . . . . . . . . . . . . . . . . . . . . 10.13
Spark Plug, Inspection / Replacement . . . . . . . . . . . . . . .2.18
Speedometer Removal . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
Special Tools, Body & Steering . . . . . . . . . . . . . . . . . . . .5.2
Speedometer Troubleshooting Tests . . . . . . . . . . . . . . 10.14
Special Tools, EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4
Starter Armature Testing . . . . . . . . . . . . . . . . . . . . . . . 10.45
Special Tools, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3
Starter Assembly Exploded View . . . . . . . . . . . . . . . . 10.46
Special Tools, Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .7.2
Starter Brush Inspection / Replacement . . . . . . . . . . . . 10.44
Special Tools, Speed Sensor . . . . . . . . . . . . . . . . . . . . .10.39
Starter Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47
Specificaiton, Stator Plate Bolt Torque . . . . . . . . . . . . . .3.49
Starter Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
Specification, Brake Disc Service Limit . . . . . . . . . . . . .9.25
Starter Lockout, Troubleshooting . . . . . . . . . . . . . . . . 10.42
Specification, Brake Disc Thickness . . . . . . . . . . . . . . . .9.25
Starter Motor Dissassembly / Replacement . . . . . . . . . 10.44
Specification, Brake Pad Thickness . . . . . . . . . . . . . . . .9.19
Starter Reassembly / Installation . . . . . . . . . . . . . . . . . 10.46
Specification, Cam Chain Stretch . . . . . . . . . . . . . . . . . .3.32
Starter System Flow Chart . . . . . . . . . . . . . . . . . . . . . . 10.48
Specification, Cam Chain Tensioner Spring . . . . . . . . . .3.15
Steering A-Arm Exploded View . . . . . . . . . . . . . . . . . . 5.19
Specification, Camshaft Lobe Height . . . . . . . . . . . . . . .3.18
Steering Lock, Exploded View . . . . . . . . . . . . . . . . . . . 11.4
Specification, Crankcase Bolt Torque . . . . . . . . . . . . . . .3.41
Steering Post Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
Specification, Crankshaft Slotted Nut Torque . . . . . . . .3.43
Steering Post Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
Specification, Cylinder Compression . . . . . . . . . . . . . . .2.17
Steering Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Specification, Cylinder Head Torque Procedure . . . . . . .3.45
Steering, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
Specification, Cylinder Head Warp . . . . . . . . . . . . . . . . .3.21
Storage Compartment, Latch Operation . . . . . . . . . . . . 2.34
Specification, Cylinder Taper . . . . . . . . . . . . . . . . . . . . .3.29
Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
Specification, Cylinder Warp . . . . . . . . . . . . . . . . . . . . .3.28
Strut Cartridge Replacement, Front . . . . . . . . . . . . . . . . 5.22
Specification, Differential Solenoid Resistance 10.32, 10.39
Suspension, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
Specification, Differential Solenoid Torque . . . 10.33, 10.39
Specification, Drill and Tap Sizes . . . . . . . . . . . . . . . . . .1.13 T
Specification, Flywheel Nut Torque . . . . . . . . . . . . . . . .3.49 Thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
Specification, Fuel Pump Pressure . . . . . . . . . . . . . . . . .4.12 Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Specification, Oil and Filter . . . . . . . . . . . . . . . . . . . . . .2.23 Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
Specification, Oil Pip Bolt Torque . . . . . . . . . . . . . . . . .3.50 Throttle Position Sensor Initialization . . . . . . . . . . . . . . 4.20
Specification, Oil Pump Bolt Torque . . . . . . . . . . . . . . .3.34 Throttle Position Sensor Replacement . . . . . . . . . . . . . . 4.19
Specification, Oil Pump Shaft Endplay . . . . . . . . . . . . . .3.39 Throttle, Linkage Inspection . . . . . . . . . . . . . . . . . . . . . 2.15
Specification, One Way Valve Spring Length . . . . . . . .3.32 Tie Rod, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Specification, Piston to Cylinder Clearance . . . . . . . . . .3.29 Trail Boss Emissions System . . . . . . . . . . . . . . . . . . . . . 11.5
Specification, PVT Center-to-Center Distance . . . . . . . .6.13 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Specification, PVT Component Torque Table . . . . . . . . .6.2 Transmission I.D. Information . . . . . . . . . . . . . . . . . . . . . 1.2
Specification, PVT Drive Belt Width . . . . . . . . . . . . . . .6.13 Transmission Mounts, Exploded View . . . . . . . . . . . . . . 8.2
Specification, Rocker Arm and Shaft . . . . . . . . . . . . . . .3.15 Transmission, 500 Carbureted Exploded View . . . . . . . . 8.9
Specification, Rocker Shaft Bolt Torque . . . . . . . . . . . .3.50 Transmission, Disassembly . . . . . . . . . . . . . . . . . . . . . . 8.11
Specification, Spark Plug Gap . . . . . . . . . . . . . . . . . . . .2.18 Transmission, Exploded View . . . . . . . . . . . . . . . . . . . . . 8.7
Specification, Speed Sensor Bolt Torque . . . . . . . . . . .10.39 Transmission, Fluid Check / Change . . . . . . . . . . . . . . . 2.13
Specification, Tensioner Blade Bolt Torque . . . . . . . . . .3.43 Transmission, Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Specification, Transmission Silent Chain Length . . . . . .8.19 Transmission, Output Shaft Backlash Procedure . . . . . . 8.17
Specification, Valve Clearance . . . . . . . . . . . . . . . 2.26, 3.26 Transmission, Reassembly . . . . . . . . . . . . . . . . . . . . . . . 8.16
Specification, Valve Guide Height . . . . . . . . . . . . . . . . .3.23 Transmission, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Specification, Valve Stem and Guide . . . . . . . . . . . . . . .3.22 Transmission, Special Tools . . . . . . . . . . . . . . . . . . . . . . 8.3
Specifications, Body and Steering Torque Values . . . . . .5.2 Troubleshooting Diagrams, Elelctrical . . . . . . . . . . . . 10.56
Specifications, Brake Component Service Limits . . . . . . .9.2 Troubleshooting, EFI Circuit Diagrams . . . . . . . . . . . . . 4.24
Specifications, Brake Component Torque Values . . . . . .9.2 Troubleshooting, Engine . . . . . . . . . . . . . . . . . . . . . . . . 3.53
Specifications, Engine Fastener Torque . . . . . . . . . . . . . .3.3 U
Specifications, Engine Service Data . . . . . . . . . . . . . . . . .3.4
U-joint, Disassembly and Assembly . . . . . . . . . . . . . . . . 7.7
Specifications, Final Drive Torque Values . . . . . . . . . . . .7.2
Specifications, Front Gearcase Lubrication Type/Capacity 7.2
IX.4
V
Valve Clearance Adjustment . . . . . . . . . . . . . . . . 2.26, 3.26
Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . . . . 3.23
IX
Vehicle Identification Number (VIN) . . . . . . . . . . . . . . . 1.2
Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
W
Warn Winch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
Water Pump Seal, Installation . . . . . . . . . . . . . . . . . . . . 3.41
Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Wheels, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
Wheels, Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
Wheels, Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
Wire Diagram, Winch Basic . . . . . . . . . . . . . . . . . . . . . 10.49
Wire Diagrams, Electrical . . . . . . . . . . . . . . . . . . . . . . 10.56
Work Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
X
X2, Seat Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32
IX.5
PAGE INTENTIONALLY BLANK
IX.6
WIRE DIAGRAM
2008 SPORTSMAN 500 CARBURETED
WD-1
WIRE DIAGRAM
WD-2
WIRE DIAGRAM
2008 SPORTSMAN 500 EFI
WD-3
WIRE DIAGRAM
WD-4
WIRE DIAGRAM
2008 SPORTSMAN 500 X2 and TOURING EFI
WD-5
WIRE DIAGRAM
WD-6
WIRE DIAGRAM
2008 SPORTSMAN 500 X2 QUADRICYCLE EFI
WD-7
WIRE DIAGRAM
WD-8

08 Sportman 500

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2008 SPORTSMAN 500 EFI / X2 / TOURING / 500 H.O.

NOTE provides key information by clarifying instructions.

MODEL NUMBER INFORMATION

Engine Designation Numbers

Vehicle Identification Number (VIN)

Transmission I.d. Location

The transmission I.D.number is located on top of

Engine And Machine Serial Numbers

Table 1-1: Publications

Table 1-2: Paint Codes

Table 1-3: Key Numbers

2008 SPORTSMAN 500

Table 1-4: Sportsman 500 General

Engine Model Number EH50PLE Transmission Capacity 32 oz. / 948 ml

Engine Displacement 499cc Front Gearcase Capacity 8.97 oz. / 265 ml

Number of Cylinders 1 Gear Ratio : Low 23.91:1

Fuel System Ground Clearance 11 in. / 27.94 cm

Fuel Delivery Fuel Pump Brake - Front Dual Hydraulic Disc

Instrument Cluster Analog Speedo w/ LCD

2008 SPORTSMAN 500 EFI

Table 1-9: Sportsman 500 EFI General

Engine Model Number EH50PLE Transmission Capacity 32 oz. / 948 ml

Engine Displacement 499cc Front Gearcase Capacity- CH 8.97 / 265 ml

Number of Cylinders 1 Front Gearcase Capacity- ADC 9.3 / 275 ml

Bore & Stroke (mm) 92 x 75 mm Gear Ratio : Low 23.91:1

Electrical Wheel/Tire Size / Pattern - Rear 26 x 11 - 12 / 4-156

Lights : Pod 50 watts Brake - Front Dual Hydraulic Disc

Grill 2 x 37 watts Brake - Rear Single Hydraulic Disc

Brake 2 x 8.26 watts Brake Fluid DOT - approved only

Tail 2 x 26.9 watts

Ignition System DC/CDI Ignition Meters 0-1800 10 WH Blu/Green Red EBS

2008 SPORTSMAN X-2 500 EFI

Engine Model: EH50PLE

Table 1-13: Sportsman X-2 500 EFI General

Engine Model Number EH50PLE Transmission Capacity 32 oz. / 948 ml

Engine Displacement 499cc Front Gearcase Capacity- CH 8.97 / 265 ml

Number of Cylinders 1 Front Gearcase Capacity- ADC 9.3 / 275 ml

Bore & Stroke (mm) 92 x 75 mm Gear Ratio : Low 23.91:1

Fuel System Rear Travel 8.75 in. / 22.2 cm

2008 SPORTSMAN TOURING 500 EFI

Engine Model: EH50PLE

Table 1-17: Sportsman Touring 500 EFI

Engine Model Number EH50PLE Transmission Capacity 32 oz. / 948 ml

Engine Displacement 499cc Front Gearcase Capacity- CH 8.97 / 265 ml

Number of Cylinders 1 Front Gearcase Capacity- ADC 9.3 / 275 ml

Bore & Stroke (mm) 92 x 75 mm Gear Ratio : Low 23.91:1

Fuel System Rear Travel 8.75 in. / 22.2 cm

21/32 . . . . . . . . . . . . .6563 . . 17 mm =.6693"

Unit of Measure Multiplied by Converts to

°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F

Maintenance Chart Key

Improperly performing the procedures marked with

 Middle gearcase oil (if

 Transmission oil 25 H Monthly 155 (250) Inspect level; change yearly

Choke - 500 Carburetor

Diagnostic Light Control

Battery (Under Tank)

Gear Shifter Gas Cap

Rear Drive CV Shafts

Middle gearcase oil (if

Transmission oil 25 H Monthly 155 (250) Inspect level; change yearly